operating manual-120321 rgzf-60b tube filling-rigao
TRANSCRIPT
INTERNATIONAL MACHIINE CONCEPTS
IMC-60B Automatic Aluminum Tube
Filling & Sealing Machine
OPERATION
MANUAL
Page 1 of 39
CONTENT
1. Use Instructions
1. Summary 2. Working Principle 3. Technical Parameters 4. Structural Features 5. Equipment Transportation and Installation 6. Safety Notes 7. Operation Procedures 8. Operations of Touch Screen 9. Basic Adjustments 10. Adjustment of Automatic Tube Feeding
System 11. Adjustment of Transmission Part 12. Disassembly and Cleaning 13. Daily Maintenance 14. Common Malfunctions and Troubleshooting
2. Packing List
3. Certification
4. Electric Circuit Diagram (Attachments)
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1. Summary
produced by our company has such features as smooth and flat surface, free of
dead corner, being innoxiously and non-smell, free of pollution, easy cleaning,
and easy maintenance and servicing.
Thanks to the compact structure, simple and convenient operation, the machine is
applicable to the demands of users from the industries such as medicine, food
and daily chemical industry etc. The machine can smoothly and accurately fill
various paste, ointment and viscous fluids etc. materials into the aluminum tube
through the filling system. The operations such as filling, sealing and batch No.
printing (date of manufacturing) etc. for aluminum tubes can be realized through
the folding mechanical hands. The highest production capacity of the machine
can reach 3000 pieces/hour with an error of filling volume not more than ±1%.
2. Working Principle
Put in order the aluminum tubes to be filled on the tube bucket. Through the Thank you for
your using the automatic aluminum tube filling & sealing machine produced by
our company.
With the design, manufacturing, assembly, debugging, as well as main parts and
materials being fully in accordance with GMP requirements, the automatic
aluminum tube filling & sealing machine automatic tube feeding device, they
will be automatically inserted into the cup seats (positioning molds). The cup
seats will rotate with the rotary table so that they will be positioned at different
work stations. Put the ointments for filling into the lockable cone hopper.
Through the plunger type quantitative filling valve directly connecting with the
hopper, they will be accurately and automatically filled into the aluminum tubes
staying at intervals on the work stations of filling. The rotary table will continue
its rotation and rapidly bring the aluminum tubes that have been filled with
ointments to different work stations of sealing. The mechanical hand at each
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work position will instantly seal the tube tail. Different filling volumes can be
achieved through adjusting the filling volume adjusting dial. The sealing
operation of aluminum tubes with different folding forms such as two-side
folding, three-side folding and saddle-shape folding can be finished through
changing different mechanical hands. After the sealing is finished, the
mechanical hand for code printing will automatically print the words such as date
of manufacturing and production batch No. onto the tube tail. Through the
automatic tube discharging structure, the finished tube will be automatically sent
into the tube collecting vessel.
3. Technical Parameters
Filling range: 5-150ml/tube (adjustable)
Filling accuracy: ≤±1%
Production speed: 1800-3000 tubes/hour
Aluminum tube diameter: Φ10- 32mm
Aluminum tube length: 185mm (max. length)
Hopper volume: 40 L
Power supply: 380V/220V (optional)
Air pressure: 0.5-0.7MPa
Machine power: 2 kw
Motor power: 1.1kw
Outline dimensions: 1900(L)×850(W)×1900(H)mm
Machine weight: about 850kg
4. Structural Features
1. Reasonable structure design
The machine has fully embodied the design conception of advancement,
reliability, reasonability of pharmaceutical equipment required by GMP, and
artificial factors have been reduced during the use. Linkage design is adopted for
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the automatic feeding of tubes, the automatic positioning of tube color codes,
filling, sealing, batch No. printing and discharging of finished products so that all
the actions are synchronously completed.
2. The requirements of materials to filling technology have been fully satisfied.
a. The machine has compact structure with short time from filling to sealing.
And complicate sealing forms can be completed.
b. It is guaranteed that there is no pollution during the filling process. The
parts in the machine that contact the materials are all made of 316L
stainless steel materials and complete polishing treatment is carried out on
the contacting surfaces.
c. High filling accuracy. The machine adopts reliable piston type quantitative
filling valve, which is provided with convenient and reliable adjustment of
the filling volume and high filling accuracy.
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21 3 45 6
7
89
10
11
Figure 1 Schematic Figure of Main Machine 1. Electric Box
2. Hopper
3. Frame
5. Main Transmission Haft For Sealing
6. Tube Feeding Part
7. Profiling Lifting Head
8. Mechanical Hand
9. Filling Nozzle
10. Filling Volume Adjusting Hand Wheel
11. Motor
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d. Easy assembly and disassembly of filling assemblies. The bucket valve
body and piston filling head etc. can be rapidly disassembled and it is easy
to carry out cleaning, disinfection and sterilization.
e. During the filling, the filling nozzle can be extended into the tube, so as to
ensure effective filling and prevent the sealing quality from being
influenced as a result of material adhesion on the tube wall.
f. The air blowing device is additionally installed. The filling head adopts the
combined blow-out and cut-out filling mode so as to prevent the sealing
quality and filling volume being influenced as a result of long wire drawn
out by the materials of high viscosity.
3. Multifunctional sealing structure with easy adjustment
The two-side folding, three-side folding and saddle-shape folding etc. different
folding forms of aluminum tubes can be conveniently and accurately adjusted
according to requirements of users.
4. The operating parts of mechanical hand completely adopt fully enclosed ball
bearings, and the upper and lower sliding shafts on the machine table surface
adopt linear bearing and self-lubricating system so as to avoid pollution.
5. The automatic filling & sealing machine adopts frequency conversion step less
speed adjusting system, and the operation implements coordinated linkage
control so as to achieve a higher production speed. The pneumatic control
system is provided with precise filter with stable pressure of certain amount
being maintained.
6. The movement system is allocated with safety clutch, which can effectively
realize protection for fault overload.
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7. Beautiful appearance and easy to be cleaned
With beautiful appearance and compact structure, the machine is elaborately
made by adopting stainless steel polishing, and its table surface is easy to be
cleaned without any dead corner, which are fully in accordance with GMP
requirements for medicine production.
5. Equipment Transportation and Installation
1. Transportation and Placement
It is transported by wood pallet and forklift. Select a flat and dry indoor place,
after the filling & sealing machine is stably placed and unpacked. Adjust the
base bolts to level the main machine. The installation plan is as follows:
Air supply inlet
Tube bucket
Operator
Main machine
Power interface
Power distribution cabinet
Machine bottom corner Cold water inlet Cold water outlet
2. After it is unpacked, please check the followings:
△ Check if the machine is in accordance with your order according to the
instructions.
△ Check if there is any damage or cut that may influence the use caused
during the transportation. If the above problems are found, please
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immediately contact the sales department of our company for a proper
treatment.
3. Installation of tube bucket
Install the tube bucket onto the main machine and adjust the position of the tube
bucket, which shall be kept vertically upward with nuts tightened.
4. Allocation of power supply
The equipment adopts a 3-phase 380V four-line or a 3-phase 220V AC power
supply. The user shall make sure there is reliable grounding when connecting it
with the power supply, so as to guarantee personal security.
5. Allocation of air supply
The equipment adopts an air supply of 0.5-0.7Mpa. The air supply allocated by
the user shall be stable and the air displacement shall be not less than 0.6m3/min
so as to guarantee the reliable operation of cylinder and achieve a precise filling
effect.
6. Safety Notes
1. Before using the machine, please clean the surroundings. There
shall have no dangerous articles or other foreign matters.
2. The machine is provided with protection of safety door. After the
door protection functions, the machine will be stopped when the
door is opened. It is strictly forbidden to operate the machine
without starting the door protection, or else, accidents may take
place.
3. There is high voltage inside the electric control box of the machine.
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Unprofessional or untrained persons are forbidden to open it.
4. Make sure that the machine body is reliably grounded before the
machine is operated
5. The operator shall pay special attention to the parts where safety
warning marks are labeled on the machine body.
6. It is strictly forbidden to open the back cover of casing at the
transmission part when the machine is operated, or else, personal
injury may be caused during the operation.
7. Parts that do not conform to the machine performance can’t be
additionally installed and the machine can’t be modified. Otherwise
accidents may take place.
8. In case of emergency, please press the red emergency stop button
and eliminate the malfunction in time. If it is necessary to restart the
machine, make sure that the malfunction has been fully eliminated.
The main drive system of the machine is located at the bottom of the machine table
and is closed by a stainless steel door with a lock. When adjusting the filling volume,
a special person (an operator or a maintenance technician) shall be designated to
carry out the adjustment. Before restarting the machine, make sure that all the doors
are fully closed.
7. Operation Procedures
1. First check if there is any abnormal article on the surface of the
machine.
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2. Check if the aluminum tubes and materials are in good condition.
3. Open the electric control box, switch on the power switch and turn on
the general key switch and main machine switch.
4. Turn on switches for filling, color code, cleaning and tube feeding. If
it is necessary to count, please also turn on the counting switch.
5. If there are heat preservation and stirring systems, please turn on the
heat preservation switch and set the temperature required for heat
preservation on the heat preservation and heating control meter. And
then turn on the stirring switch.
6. Turn on the air pump switch or switch on the air supply. Adjust the
pressure adjusting valve, and make sure the numbers displayed on the
air pressure gauge is the set air pressure (the air pressure value is
generally 0.5-0.7MPa). Press the emergency stop button to reset,
press the inching switch, and then restart the main machine.
7. The machine shall be operated by qualified person after being trained.
Others can’t operate the machine randomly, or else, there may be the
danger of human injury and machine damage.
8. Carry out idle operation for 1-2 minutes every time before filling.
Check the operation status of all parts of the machine, which shall
realize that the working status shall be stable with steady running and
without abnormal noise, the adjusting devices shall function normally
and the instruments and meters shall work reliably.
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VIII. Operations of Touch Screen
1. Turn the combination switch to the position
2. Turn the key clockwise to turn on the power supply. At the time, the
power indicator lamp will be on and the human-machine interface
will be on. The main menu will be displayed (figure 8-1). Click
OPERATION button to enter into the operation window (figure
8-2).
Figure 8-1 Figure 8-2
Click MAIN MENU button to enter into door protection control window.
When the door protection is on, during the normal operation of the
machine, if the door is suddenly opened, the machine will immediately
stop its operation and the touch screen will indicate that the door is not
closed (figure 8-3).
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Figure 8-3 Figure 8-4
Touch NEXT to enter into the window for adjusting coder parameters
(figure 8-4). If the materials are thin with higher viscosity, we can adjust
the parameter values of fill on, fill off and blow on, so as to solve the
problem of wire drawing of filling nozzle. Touch DEBUGGING
OPERATION button on the main menu to enter into the window for
adjusting inching operation (figure 8-5) and carry out manual operation.
Figure 8-5 Figure 8-6
3. When there is any malfunction in the transmission mechanism, the
safety switch at the bottom of the machine will be triggered, and the
overload window will be displayed. Please cut off the power supply
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and eliminate the malfunction before restarting the machine (figure
8-6).
8. Basic Adjustments
1. Install the five mechanical hands according to the dimensions on the
installation figure of saddle-shape folding.
Adjustment of the first mechanical hand
1. Adjust the eccentric shaft on the internal and external mechanical
arms to make the two mechanical arms vertically at the center of the
cup seat (refer to the following figure 1). Adjust the internal and
external mechanical claws to make the interval between the internal
and external mechanical claws at about 0.5mm. (refer to the
following figure 2).
2. Note: The following adjustment is made by referring to the
5mm folding width of finished aluminum tube.
The height of the two mechanical claws shall be the one where they flatten
the tube tail for 25mm (refer to the following figure 4). The insertion board
shall be adjusted to keep a certain distance with the concave and convex
hinges (refer to the arrow indicated in the following figure 3).
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Adjustment of the second mechanical hand
1. Adjust the seat for external mechanical hand to make its bottom
parallel to the bottom of the mechanical arm (refer to the arrow
indicated in the following figure).
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Note: The adjustments shall begin from this position and during the
adjustment, the position shall be guaranteed to be unchanged.
2. Adjust the eccentric shaft on the internal and external mechanical
arms to make the two mechanical arms vertically at the center of the
cup seat (refer to the adjustment of the first mechanical hand for
details). Adjust the internal and external mechanical claws to make
the interval between the internal and external mechanical claws at
about 0.5mm. (refer to the above figure).
3. Rock the pulley manually to raise the lifting shaft to the highest
point. Adjust the positions of the insertion board and mechanical
arms according to the following figure. Pay attention to the arrow
direction.
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Note: The steps 1, 2 and 3 shall be synchronously operated.
4. Confirm the height of the rotary table according to the length of
the aluminum tube (4mm is recommended).
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5. Working state: During the operation process of the folding claw at
0-90°, the external mechanical hand will not move. During the
rotating process of the folding claw at 90°-300°, the upper wall of
the external mechanical claw and the inner wall of the folding claw
will make a parallel movement with an interval of 2mm between
them (refer to the following figure 1). At the time, the folding claw
will have a transient pause, and the external mechanical claw will
continue to move. At the same time, the lifting shaft will continue
to descend until the lowest point. From figure 2, we can observe
that there is an interval of 2-3mm between the external mechanical
claw and the folding claw. Only in this way, can it be guaranteed
that the external claw will not block the tail of the aluminum tube
(refer to the following figure 3). The folding claw will continue its
rotation and the external mechanical claw will draw close to the
inside to flatten the tail (refer to the following figure 4). Thus, the
whole folding action is completed. Note: When the lifting
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insertion board descends to the lowest point, the roller shall
keep a certain distance with the mechanical arm. (as shown by
the arrow in figure 2).
Adjustment of the third mechanical hand
1. Please refer to the second mechanical hand for adjustment.
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Adjustment of the fourth mechanical hand
1. Adjust the eccentric shaft on the internal and external mechanical
arms to make the two mechanical arms vertically at the center of the
cup seat (refer to the adjustment of the first mechanical hand
for details). Adjust the internal and external mechanical claws to
make the interval between the internal and external mechanical
claws at about 0.8mm.
2. Adjust the internal and external mechanical claws to make the
internal mechanical claw be about 0.5-1mm lower than the external
mechanical claw (refer to the black arrow indicated in the following
figure 1).
3. Adjust the height of the insertion board. When the insertion board
descends to the lowest point, make the folding shaft at the center of
the internal mechanical claw (refer to the white arrow indicated in
the following figure 2).
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Adjustment of the fifth mechanical hand
1. Adjust the eccentric shaft on the internal and external mechanical
arms to make the two mechanical arms vertically at the center of the
cup seat (refer to the adjustment of the first mechanical hand
for details). The clarity of the printed code granules can be adjusted
by M6 screws on the internal and external mechanical arms.
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9. Adjustment of Automatic Tube Feeding System
923
3
20
6 19
13
15
16
18
17
12
14
218
7
1
5
9
10 11
22
2
4
1
2
3
4
5
6
7
8
Schematic Figure of Tube Feeding Part
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1. Tube bucket 2. Rotary shaft 3. Locking
handle
4. Right fender of
tube bucket 5. Pentagonal nut
6. Handle 7. M8 screw 8. Left support 9. Stainless steel
turning plate
10. Adjustable side
fender
11. Adjustable
fender 12. Joint bearing 13. Pull rod 14. Turning plate
15. Retaining plate
of turning plate
16. Turning plate
base
17. Tube feeding
fender of turning
plate
18. M8 screw 19. Right support
nut 20. Linear bearing
21. Right support 22. SI32*65 cylinder23. Tube fender
support
○1 . Basic adjustment of integral height
Loosen screws 7 and 18, turn handle 6 to adjust the integral height
to the required one, which shall make that the turning plate of the
tube feeding device shall be 10-20mm away from the cup seat at its
bottom when the turning plate turns upwards at an angle of 90°.
○2 . Tube feeding device
Change a suitable turning plate, adjust retaining plate of turning
plate 15 to achieve different heights and adjust turning plate base 16
to achieve different angles.
○3 . Adjustment of height of tube feeding bottom board
According to the height of turning plate, adjust the two screws at
○3 , so as to make the tube feeding bottom board be 3-5mm
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higher than turning plate.
○4 . Forward and backward adjustment of tube feeding bottom board
According to the position of turning plate, adjust the two screws at
○4 , so as to make the tube feeding bottom board be 3-5mm away
from the center of turning plate.
○5 . Adjustment of adjustable fender
According to the size of the tube, adjust the height of adjustable
side fenders 10 and adjustable fender 11 and make the height 5mm
higher than that of the tube.
○6 . Adjustment of stainless steel fender
The fender is 5mm higher than the tube and its angle is about
vertical to the tube feeding bottom board.
○7 . Adjustment of tube bucket outlet
Adjust the height of fender 4 to make the outlet be within the height
of 2-4 layers of tubes.
○8 . Adjustment of tube feeding
First lower the fender 4 and block the tube bucket outlet. Unpack
the packaging box for tubes and feed all the tubes in the box onto
the tube bucket. Loosen the locking handle 3 to make the tube
bucket 1 rotate backwards at a certain angle around the rotary shaft
2. Tighten the locking handle 3. Take out the packaging box. After
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the tubes are arranged in order, loosen the locking handle 3 and turn
the tube bucket forward. Tighten the locking handle 3 and open the
fender of tube outlet.
○9 . Adjustment of tube fender support
Turn the rotary table to the work station. Adjust the front and back
tube fender supports to make the tube fender supports keep a
distance of 5mm with the outside wall of the tube.
After the above 9 procedures are completed, manually put the tubes
into the tube feeding bottom board and carry out debugging again.
Before connecting with the air supply to carry out automatic
debugging for tube feeding, make sure that the tubes can be
smoothly inserted into the cup seats.
10. Adjustment of Transmission Part
1. Tension adjustment of transmission triangle belt
Loosen the fastening bolts at the motor base, and adjust the tension
of triangle belt to be appropriate and then tighten the nuts.
2. Tension adjustment of chain
Adjust the position of chain tension wheel to make the chain
tension appropriate.
3. Adjustment of safety clutch
If the spring pressure of safety clutch is too small, the clutch will be
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released and the machine can’t be normally started. Adjust the
adjusting nut for spring of clutch to minimize the spring pressure
which can make the machine normally started. In case of fault
overload, the clutch will be automatically released and the main
machine will stop its operation. The warning lamp will flash to give
indications. At the time, cut off the main power switch, and
eliminate the malfunction immediately. After the malfunction is
eliminated, hold the handle on the pulley and rock the pulley to
reset the clutch, and then restart the main machine according to the
starting procedures.
1、Screw the round nuts in for 8-15mm, with moderate overload
withstanding capacity. 2、When overloading occurs, the output shaft will be separated from the
clutch sprocket wheel, which will contact the switch and the machine will stop its operation.
Figure 10-1
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Schematic Figure of Transmission Part
1.Speedreducer pulley 2.Speed reducer 3. Output shaft 4. Steel ball 5. Clutch sprocket wheel
6. Copper cover 7. Pad 8. Compression spring 9. Pressure cover 10. Round nut
12. Disassembly and Cleaning
The disassembly procedures and cleaning requirements for parts needed to be
cleaned are described in this chapter.
1. Hopper
Loosen the hopper screws on the filling valve body and remove the
hopper. During the first time use, please clean the parts by using
solution made of edible detergent and then flush them with clear
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water, and finally scrub the internal wall with alcohol and make
them dry in the air.
2. Filling nozzle body and filling nozzle
Loosen the fastening screws on the filling head of filling valve
body and remove the air pipe to disassemble the filling head. Then
screw off the filling nozzle to clean the filling nozzle body and
filling nozzle with the cleaning method same as the above.
3. Filling valve body
Loosen the screws connecting the valve body and the cylinder to
separate the valve body from the cylinder. Loosen the rapid
installation ferrule of the valve body and remove the filling valve.
Gently push out the spool shaft, and carry out the cleaning with the
method same as the above.
4. Note: When removing the valve body and spool shaft, please do not
damage the valve spool and collide with the internal cavity of valve.
13. Daily Maintenance
1. Machine body
After work of each shift, the workers shall cut off the power supply,
clean and wipe the filling nozzles, cup seats, rotary table, sealing
and code printing clamp mouths with absorbent cotton dipped into
medicinal alcohol to maintain all parts clean without dusts. Then,
close the reinforced organic glass door.
2. Sealing part
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The roller bearing on the mechanical arm and the radial ball
bearing of supporting clamp rod shall be added with lubricating
grease once every three months.
3. Scale structure
The lubricating grease of the large table column bushing and scale
structure shall be replaced once half a year and they shall be
checked and oiled once a week.
4. Speed reducer
Check once a week. If the oil level is lower than 1/2 of that as
shown on the window, if it is lower than 1/2, please add 30# engine
oil in time.
5. The main drive system, chain and cam plate located at the bottom of
the machine table shall be checked and oiled once a week.
6. If the machine is not used for a long time, before restarting the
machine, please check if the screws of all parts are loose, and
tighten and adjust them if necessary. Check the lubricating
conditions of all transmission parts. After all the inspections are
completed, start the main machine according to the starting
procedures.
7. Please refer to the following figure for the servicing and lubricating
of the machine.
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14. Common Malfunctions and Troubleshooting
Malfunctions Troubleshooting
1. Check if the safety emergency stop switch is locked.
2. Check if the air supply switch is on. The cylinder has no action.
3. Check if the single-direction signal valve is damaged.
1. Check the angle and distance between the photoelectric detector and the aluminum tube.
2. Adjust the sensibility of the photoelectric detector switch to be appropriate.
The code alignment and detection of the aluminum tube are incorrect.
3. Check if the photoelectric detector switch is damaged. If damaged, replace the photoelectric detector switch.
1. Check if the flow control valve is closed.
2. Check if the rotary filling valve is opened.
3. Check if the hopper is provided with sufficient materials.
The filling volume is inaccurate or there is no material discharging.
4. Check if all the connection places are sealed.
1. Check if the installation method of code granules is correct and if they are fastened.
The printed codes are not clear. 2. The code granules are worn. Replace the code granules.
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Pneumatic Drawing:
PLC Wiring:
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Main Circuit Wiring Drawing:
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Packing List of IMC-60B Automatic Aluminum Tube Filling & Sealing Machine
No. Category Name Unit Piece Specification Remark
1 Main machine Set 1
2 Use instructions Copy 1
3 Product certification Copy 1
4 Packing list Copy 1
5
Technical documents Acceptance form of
installation and debuggingCopy 1
6 Cup seat Piece 9
7 Hopper Piece 1
8 Tube bucket Piece 1
9 Plunger pump Piece 1 Purchased by
customer
10 Heating box Piece 1 Purchased by
customer
11 Blender Piece 1
Purchased by
customer
12 Ultrasonic wave Piece 1
Purchased by
customer
13 Toolbox Piece 1
14 Seal ring Set 1
15 Dead wrench Piece 4
16 Flexible wrench Piece 1
17 Slotted screwdriver,
Philips screwdriver Piece
1 for
each
18 Inner hexagon wrench Set 1
19 Code granules Set 1
20
Accessories
Grease gun Piece 1
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Inspector Packer Date of packing
IMC-60B Automatic Aluminum Tube Filling &
Sealing Machine
M a c h i n e m o d e l IMC-60B
M a c h i n e N o .
E x - f a c t o r y d a t e
D a t e o f p u r c h a s i n g
A c c e p t a n c e
s u g g e s t i o n o f u s e r
U n i t s e a l o f u s e r
U s e r ’ s a d d r e s s
R e s p o n s i b l e p e r s o n
o f u s e r
C o n t a c t p h o n e o f
u s e r
P C
S u p p l i e r
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Note: After the product is inspected as qualified, the customer shall fill in
the “acceptance form of RGZF-60B automatic aluminum tube filling &
sealing machine” and send (fax) it back to the customer service center of
our company for record. If it is not sent back, it will be deemed as waiver
of guaranteed maintenance.
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Lobe Pump
Manual Operation
Product Certification
Product name: Automatic aluminum tube filling & sealing machine
Product model: IMC-60B
Ex-factory No.:
The product has been inspected as qualified
And is allowed to leave the factory.
Inspector:
Date of inspection: