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RICH SYSTEM R apid I solation C ooling & H eating

RICH SYSTEM R apid I solation C ooling & H eating. Oct. 2010. -Sales Reference Data-. - Index -. 1. The outline of RICH SYSTEM 2. The principal of steam generation in RICH SYSTEM 3. The configuration of RICH 4. The specification of RICH 5. The additional explanation of RICH SYSTEM

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RICH SYSTEM R apid I solation C ooling & H eating

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  1. RICH SYSTEMRapidIsolationCooling&Heating Oct. 2010 -Sales Reference Data-

  2. - Index - 1.The outlineof RICH SYSTEM 2. The principal of steam generation in RICH SYSTEM 3. The configuration of RICH 4. The specification of RICH 5. The additional explanation of RICH SYSTEM 6. The major sales record & data of RICH 7. Tubing 8. The recommendation of steam(cooling) lines in mold 9. Cycle time reduction of RICH combined with Chiller 10. Energy saving(Patented) 11. The consulting sheet for customers Appendix: CAE data as per tubing size, position and mold material

  3. 1. The outline of RICH SYSTEM • 1.1 The outline • RICH SYSTEM (Rapid Isolation Cooling & Heating) • It is the system to rapidly heat and cool the mold cavity in every cycle by supplying the steam and cooling water each. • The effects • Good surface quality (High glossy, Weld-less, No painting, No scratch) • High productivity(Cycle time reduction) • Microstructure precision molding(Light guide panels of LCD) • The applications • High glossy parts • Weld-less parts • High cycle parts • Parts requiring the improved flow length

  4. 2. The principal of steam generation in RICH SYSTEM Steam pressure: Max 15bar(205℃) • 2.1 The principal of electric steam boiler Tank capacity: 240ℓ <Tank> Saturated steam Pressurevalve & gauge Saturated steam discharge water (Pressure∝ Temperature) Saturated steam: 13bar→ 194℃ Heater165kW = 55kW x 3 When the gauge pressure is 13bar, the temperature of saturated steam is about 194℃ and the latent heat is 468 kcal/kg at this condition. And this steam boiler can be raised the mold temperature faster because it has lots of heat capacity. It is the system to rapidly heat the mold by supplying the saturated steam as turning the valve on/off of which is generated as heating up the water of boiler in the tank.

  5. 3. The configuration of RICH Steam pressure: Max 15bar (205℃) Circuit breaker 300A • 3.1The configuration 13 bar Tank capacity: 240ℓ RICH SYSTEM 3Ph 3W 380V Saturated steam Level sensor MOLD water 25A 25A 25A 25A 25A 25A Purifier Heater165kW = 55kW x 3 20A Feeding pump 32A Manifold Steam Air Water Air supply External type valve (orinternal one) (Mounted on the mold or not) Cooling Tower Cooling pump By-pass line

  6. 3.2 RICH-4 product Rear view Touch screen AIR regulator Front view 1,530 1,450 Power switch 600 Steam/Water/Airsupply (to mold) Water supply line (from cooling tower) Drain line By-pass line Water supply to boiler(from purifier)

  7. 3.3 The relation between IMM sequence and temperature cycle • Temperature control IMM sequence Ejection Cooling Ejection Injection/Holding pressure T2 Temperature(℃) T1 T3 T4 Convert to T1 as soon as opening the mold Higher temperature: 110℃ Lower temperature: 70℃ 110 Temperature cycle Injection signal Holding pressure completion signal RICHIMM IMM RICH 70 Mold opening signal Mold opening signal 0 • 2) Time control After getting the mold opening signal, the mold is heated and cooled by the set values in every cycle as for example heating 5s, cooling 10s & blowing 3s without sensing the temperature. Time(t)

  8. 3.4 The layout of Touch screen • In automatic operation mode, press the “Run” button to run the RICH system. • The heating and cooling operation can be set by temperature or time values. • The manual operation is possible only in the manual operation mode. • The selection between temperature and time setting for heating and cooling operation is only possible after entering the password.

  9. 4. The specification of RICH

  10. 5. The additional explanation of RICH SYSTEM • 5.1 RICH-II product Rear view of RICH-2 Water supply (from cooling tower) Water supply (to mold) Drain line Water supply to boiler(from purifier) Steam supply By-pass line Water out Angle sheet v/v Steam out From mold Outmanifold Cooling water Air Steam To mold When running the RICH, the saturated steam is full from RICH(boiler) to manifold. RICH SYSTEM In manifold

  11. 5.2 Components in RICH SYSTEM(RICH-II) Shunt Safety valve Air solenoid valve Safety valve Water supply pump to boiler Watertank Drain valve Cooling pump Boiler level sensor

  12. 5.3 Safety devices of electric steam boiler if exceeded the setting pressure • Alarm in touch screen(When exceeded the setting pressure, the heater power is disconnected by SSR.) • Shunt (When exceeded the setting pressure value, the main switch is immediately tripped.) • Safety valve(If exceeded the setting pressure value, the steam pressure is reduced by draining the steam.) Touch screen Shunt (It is worked independently of above touch screen.) Main switchoff Safety valve (It is worked independently of above touch screen.)

  13. 6. The major sales record & data of RICH

  14. 7. Tubing • 7.1 Selection table of main channel size as per sub channel size & number (※ Recommended) • 7.2 Selection of main channel size as per sub channel size & number (※ Sample) • If the size and number of sub channels are Ø8 and 3pcs, the size of main channel should be Ø15. Main channel’s size Subchannels Mainchannel Ø8x3 Ø15 Ensure the sufficient flow rate (Ø15)

  15. 7.3 The selection table of RICH as per sub channel size & number lpm = liter per minute No.= Steam(cooling) channels in mold

  16. 8. The recommendation of steam(cooling) lines in mold • 8.1 Distance between cavity surface and/or steam(cooling) channels and/or temperature sensor (※ Recommended) Cavity surface d 2d 2d Steam(cooling) channels Temperature sensor However, because the above data was not fully calculated the crack and any damage by the strength of mold material, injection pressure and residual stress, it should be thoroughly checked the above data before applying them.

  17. 9. Cycle time reduction of RICH combined with Chiller • 9.1 The configuration of RICH combined with Chiller ○ In this case RICH supplies the steam and air, but the cooling water is supplied by chiller.  The cooling water is supplied by chiller, and the cooling water drained from mold is returned to chiller. (closed loop) Steam drain RICH-2 20RT Water type MOLD When steam valve is ON, steam and air are drained. Steam & air Chiller Cooling water(Min.5℃) SIZE : 120 x 500 x 160 Channel No.: Ø8 x 4 When water valve isON, water is returned. Cooling Tower

  18. 9.2 Test • In case temperature setting of RICHas heating 100℃ & cooling 50℃ • In case temperature setting of RICHas heating 100℃ & cooling 70℃ W/O chiller 50(s) Heat’g(16.5s) Cooling(33s) 50℃ With chiller 50℃ 39.5(s) Heating(17.5s) Cooling(22s) W/O chiller With chiller -10(s) Cycle time21% down W/O chiller 36.3(s) Heat’g(14.6s) Cooling(21.7s) 70℃ 70℃ With chiller 32.2(s) Heating(16s) Cooling(16.2s) W/O chiller With chiller -4.1(s) Cycle time11% down

  19. In case temperature setting of RICHas heating 120℃ & cooling 70℃ • Conclusion • When heating and cooling between temperature band 50℃ by RICH, ‘100 ℃  50 ℃’is more effective than ‘120 ℃  70 ℃’ if using a chiller. • As the temperature band is smaller, the effective of chiller is bigger. So, this chillercan be reduced10 ~ 30%ofcycle time. W/O chiller 45.3(s) Heat’g(22.7s) Cooling(22.6s) 70℃ 70℃ With chiller 43(s) W/O chiller With chiller Heat’g(26s) Cooling(17s) -2.3(s) Cycle time5% down

  20. 9.3 Field TEST • The chiller can be improved the productivity to reduce the cycle time by supplying the constant cooling water with lower temperature, without supplying the water with variable temperature from the cooling tower by a seasonal change. • Alternative to cool down by cooling water of cooling tower and chiller controlled by valve. • Above70℃ it can be cooled downby cooling tower, below 70℃ it can be cooled down by chiller. • By this kind of combination control, the cycle time can be reduced by small sized chiller. Cooling tower Water 70℃ Chiller Water 35℃

  21. 10. Energy saving(Patented) • 10.1 Estimated electricity of RICH in each countries • Korea • Foreign countries

  22. 10.2 Energy saving TEST • The configuration of TEST equipment • TEST condition • Setting temperatureof RICH: Heating100℃, Cooling65℃ • Boiler setting pressure of RICH : 13bar • As running TEST mold withmanifold 3/8” 4EA, 8EA, we measured the heater loading time of boiler in RICH. RICH MOLD Steam Flow control valve Control the steam quantity by using a flow control valve when heating the RICH. Test mold: Manifold 4EA, 8EAeach

  23. TEST Result • Manifold 4EATEST Mold • Manifold 8EATEST Mold • Conclusion • In case manifold 4EA: The energy is saved 34% without changing the heating time. • In case manifold 8EA: The energy is saved 33% without changing the heating time. 34% saved 33% saved

  24. 10.3 Field TEST

  25. 11. The consulting sheet for customers • 11.1 Customer’s environmental condition

  26. 11.2 Tubing details Standard Option

  27. 11.3The specification of tubing Steam lines Water lines

  28. Clean water supply anddrain lines * RICH BoilerDRAIN  Sewer: The steamdrainis providedwith Φ10 Urethane hose, and the drain temperature is under 90℃. However, if the steam temperature is drained maximum 130℃ as changing internal set values, the drain hose should be changed by different material and the price of it will be charged separately in this case. AIRlines

  29. 11.4 The installation of RICH Layout Tubing Signal d(m) d(m) RICH Purifier d(m) d(m) d(m) d(m) d(m) IMM Customer YUDO Tubing work as per consulting sheet for customers. Interface work between IMM and RICH. Information Measure the distance between equipment in the layout.

  30. 11.5 Overall orderprocess Customer YUDO ● Inform the water quality. Test sample by YUDO if required. ● Check the mold/IMMspecification Optimize the equipment. ● Check the plant layout and surroundings. Reorganize the floor space to install the RICH set. ● Assign the specialist for tubing work. ● Choose the purifier. ● Choose the RICH model. Step1 ● Find the best setup condition by the co-work of customer and our technician. ● Produce the products with high quality and high productivity. ● Present the offer sheet. ● Ship RICH set(RICH, purifier, manifold, tubes). ● Dispatch the service technician. ① Setup the RICH. ② Supervise the tubing work by specialist. ● Trialrunning TEST ● Train the customers using an operation manual. Step 2

  31. Appendix: CAE data as per tubing size, position and mold material • A-1 Heat transfer coefficients • Example (ℓ = 6, 8, 10, 12) • ℓ • ℓ T₁ T₂ Here, Q : amount of heat, t : time, k : heat transferconstant, ℓ: distance, A : cross sectional area, T₁, T₂: temperatures Steam(cooling) channel Cavity surface Heat transfer coefficients  k · A · (T₁- T₂) = constant • The heat transfer coefficients is in inverse proportion to the distance, so the heat transfer coefficients is not efficiently performed if the distance is long.  It causes the electricity price and cycle time to increase.

  32. A-2 The difference of heat transfer time as per mold material and distance by CAE Purpose: When steam(Ø 8) temperature is180℃, test the specimen surface to rise from 50℃ to 100℃ and measure the time of it. Case 2,4 Case 1,3 < Conditions> Initial temperature: 50℃ Surrounding: The specimen is no any contact and natural condition at 25℃. S45C / HP4M S45C / HP4M Test result The heat transfer time as per distance is different, the mold material is also important for heat transfer time. So, the mold material is the important factor of heat transfer.

  33. A-3 The difference of heat transfer time as per mold material CENA-1 and distance by CAE Purpose: When steam(d6,7,8mm)temperature is180 ℃, measure the duration time to rise the mold surface to 100 ℃. < Conditions> Initial temperature: 50℃ Surrounding: The specimen is no any contact and natural condition at 25℃. Mold material: CENA1 8mm 8mm 8mm b b b a a a 8mm 7mm 6mm Case 1 Case 2 Case 3 6, 7, 8mm 16mm

  34. a 100 b Case 1 Case 2 Case 3 a Test result 100 1.84 2.47 b a 100 b In case of same material, heat transfer is different from the distance of steam channels. So, the distance of steam channel and cavity surface should be shorter to increase the heat transfer. 3.19 3.28 2.51 2.81

  35. A-4 The difference of stress as per steam(cooling) lines’ distance by CAE Purpose: When the distance steamchanneland cavity surface is 6, 7, 8mm and applied pressure 400 Kg/cm2, analyze the tensile strength. Case 1 Case 2 Case 3 < Conditions> Mold material: CENA-1 Tensile strength: 1,225 Mpa Pressure: 400 Kg/cm2 Test result 6, 7, 8mm When d is 6mm, max. stress is bigger than other ones. But it is safe because max. stress is smaller than tensile strength(1,225Mpa). 16mm

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