Tool maintenance just got cool… It’s got to be RUD!admin
Mold maintenance, Tool maintenance for longevity and quality output is a no-brainer and yet mold owners and other industry players dealing with heavy tools tend to delay this activity. In spite of the awareness of the importance of maintenance and a detailed maintenance management program in place, a lot of works/ factory managers are unable to follow through due to a number of reasons like,
- Maintenance is time consuming & tool downtime during tight deadlines is not possible
- Maintenance needs resources (A crane, at least 2 operators)
- Cumbersome long processes of dismantling tools & equipment to ensure safety as per the standards prescribed by government bodies like Directorate of Industrial Safety & Health
- Possibility of damage to existing infrastructure while hauling over the tools/dies to the maintenance area
Narrowing down the focus to tools, dies & molds, there is very little information available regarding the correct or proper ways to handle these tools, injection molding dies & molds.
The standard mold is basically a cube with all types of connections to cool and heat areas of the mold and mold tipping. “Inverting” a mold can be very dangerous, if not done the correct way. To start, molds are flipped in order to clean them out and perform maintenance because after injection molding halves are forced to open and close to make thousands of parts, it’s inevitable that plastic and other debris builds up. Without thorough cleaning, molds are extremely liable to produce defective parts, with the formation of bubbles being a common problem that takes place.
To begin the cleaning process, one must first separate the two halves of the mold, which is typically two plates, called platens. Slowly the mold is lifted up until it tips, then pushed until the plates are wall to wall. This process needs to be carried out with extraordinary caution to avoid anyone from getting injured.
Also, If not done the correct way, the mold can pull your entire crane down and can reduce the life of your crane or even destroy it on the spot. When there is a 10-ton crane lifting a 10-ton mold, putting loads of force on the crane, things could go wrong terribly if proper safety precautions are not taken into account.
There are 3 types of ways people clean molds:
- Pneumatic Air Buffers are the most common with around 50 to 60% of the industry utilizing this method.
- Dry Ice Process involves filling up a machine with dry ice then shooting out compressed air at the mold.
- Ultrasonic Cleaning (Bath) is the most effective cleaning method and is essentially a pressure washer that effectively removes all debris.
Negligence in the mold maintenance procedures or improper handling may lead to a hole or two in the mold which ultimately results in getting rid of a very expensive tool.
Identifying these challenges faced by the industry, RUD Group – true to their motto of Tradition in Dynamic Innovation has introduced the Tool Mover to address these common problems and add value to the entire process by optimizing it.
The RUD Tool Mover is popularly known to “Take the strains out of the tasks”; as unmounting heavy tools from injection molding machines or dismantling machine parts weighing a few tonnes with additional resources and a crane, is no longer necessary.
RUD Tool Mover offers a lot of benefits to all the stakeholders (the works/ factory manager, operators, internal workplace safety/ compliance inspectors, finance controller) as it makes handling the tools safer, more efficient and effective in terms of costs & processing. Additionally it provides other advantages such as, like providing the operator a much larger working surface
- Providing the operator a much larger working surface
- Multiple configurations & sizes available – Lower working heights makes it comfortable for the operator
- Mobility of the equipment
RUD’s Tool Mover can be supplied in configurations that suit exact requirements.
For example, the smallest ‘slim version’ can handle weights of up to 10 tonnes on its sturdy 800 mm table surface. The Tool Mover system has been designed for use in the tool and mold making industries, with injection moulding and pressing tools, and with pressing, bending and forming technologies.
Designed to axially rotate tools and machine components weighing up to 64 tonnes, the Tool Mover rotates and turns over even the heaviest loads, reliably and safely – using their center of gravity. The Tool Mover’s work table has a frequency regulated drive to ensure it stops and starts smoothly, without juddering.
It is also fitted with a high-end drive system from the TECDOS range. An Omega Drive at the core of the system also ensures perfect rotation during turnover.
Plugs or cooling hoses that usually have to be dismounted for safety reasons during component maintenance using a crane can simply stay in place when the Tool Mover is used to turn over the components.
Handling, turning and tilting of dies metal molding tools & other heavy toolscan be dangerous without the right equipment, causing risk to operators and damage to expensive tools if they are not turned effectively. The RUD Tool Mover ensures that handling and tilting of heavy and sensitive dies, molds and tools are moved safely and securely, and thus reducing costs and eliminating the possibility of damage to expensive tools or molds. The Tool Mover has been designed with the operator safety as Top Priority.
We would like to quote some of our German colleagues to emphasize on how RUD has revolutionized the maintenance procedures for the modern competitive world today.
“If you’re looking for a win-win situation for everyone involved in maintenance, you can’t do better than Tool Mover,” explains Anne Kühling, product manager in the conveyor and drive division at RUD Ketten Rieger & GmbH und Co KG. “Financial controllers are also pleased, as the machine pays for itself in less than a year. Operational managers and workshop managers also benefit from much shorter maintenance processes and service teams can work more efficiently without risk of injury, thanks to the machine’s ergonomic design.”
The Tool Mover has revolutionized maintenance procedures, enabling operators to work in full compliance with occupational health and safety regulations (such as the German BGV). “Anyone who uses a crane to haul or pull loads across the floor is not only creating a fire hazard but also working in contravention of current standards. For instance, paragraph §37 of the German trade association’s accident prevention regulations for cranes specifically prohibits this,” comments Kühling.
In some cases, users can save a great deal of money by installing a Tool Mover in a workshop instead of investing in an expensive crane system. The Tool Mover can be moved easily with a forklift truck or pallet truck, etc and installed exactly where it is needed. “This gives companies entirely new options for planning production sites. Maintenance procedures and logistics can be completely rethought to benefit from the potential for new hall layouts and innovative handling processes,” explains Anne Kühling
When designing the latest generation of the Tool Mover system, RUD’s engineers reduced the height of the working surface on the smallest model to 595mm. “Enabling users to work as ergonomically as possible was really important to us. This lower working height means that opened tools can be maintained directly on the working table. Operators can also work more comfortably in a natural posture, and there are fewer set-up costs,” says Klaus Pfaffeneder, head of design at RUD (conveyor and drive division).
RUD’s Tool Mover can be supplied in configurations that suit exact requirements. For example, the smallest ‘slim version’ can handle weights of up to 10 tonnes on its sturdy 800mm table surface.
The Tool Mover can also protect existing infrastructure such as the production hall floor, because tools and machine components no longer have to be dragged over to maintenance points.
Available in six standard sizes, the Tool Mover is ideal for a wide range of tool sizes. The smallest version, with a table area of 800mm x 1,300mm (L x W) can handle up to 10 tonnes. In contrast, the THS 64 (the largest standard version) can rotate tools and machine components weighing up to 64 tonnes safely and smoothly on its 3,500mm x 2,500mm table area (L x W).
To know more about the Tool Mover specifications & product features, please log on to RUD India Tool Mover
For more details, we would like to request you email us on email@example.com or call us on (+91) 22 62428500