绿色紧凑型高光注塑模具
Eco-friendly compact high gloss injection mold
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注塑模具
3840
2017-08-25
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作品简述
该作品采用新型斜顶定出结构,该结构主要由油缸、推板、拨块和小斜顶组成。推板与拨块固定连接,由油缸驱动推板和拨块,带动小斜顶实现顶出功能。采用此结构替代原有的长斜顶结构,使斜顶杆长度由330-400mm降低至100-120mm,斜顶杆截面积由(10-12)x(20-25)mm变为(6-8)x(25-60)mm,顶出距离由110-130mm降低至40-60mm。采用小斜顶结构,可以比传统的长斜顶结构缩短斜顶长度70%以上,截面尺寸的强度也更好,顶出距离也明显缩短,可以大大减少斜顶断裂风险,提说明 高模具量产时的可靠性。同时减少模具厚度,降低模具材料成本。 同时该模具还应用了急冷急热技术,从而实现产品免喷涂高光效果,省去了后期喷涂环节,避免了对环境的污染, 使首次应用者青岛海信电器股份有限公司废除了原有的喷涂线,实现了真正的绿色生产。
用户价值
该作品于2015年3月23日首次应用在青岛海信电器股份有限公司K550许可65英寸电视前壳模具上,在生产中运行稳定,未出现过斜顶卡死断裂等情况,可靠性远高于常规长斜顶结构模具。
商业表现
截止至2017实际应用 年4月份,该结构模具大范围应用至青岛海信电器有限公司,三星电子和索尼电子电视前壳模具中,共计133套, 实现销售收入1.5亿元。
社会影响
公司通过此产品的应用,提升了在电视前壳模具上的技术实力,扩大了市场份额,提升了公司形象。
流程方法
常规模具斜顶杆长度大,易折断,且模具尺寸大,材料成本高。 实施进度:针对常规模具的以上问题点,优化了模具斜顶顶出机构,用时1个月完成了新结构方案的设计,并通过制作试验模具验证了结构的可靠性,得到了客户的认可,最终于2015年3月23日首次将该结构应用在青岛海信电器股份有限公司K550系列65英寸电视前壳模具上,在生产中运行稳定,新结构可靠。模具厚度减少,节省钢料成本。
项目投入
最终于2015年3月23日首次将该结构应用在青岛海信电器股份有限公司K550系列65英寸电视前壳模具上,在生产中运行稳定,新结构可靠。模具厚度减少,节省钢料成本。
达成情况
该作品于2015年3月23日首次应用在青岛海信电器股份有限公司K550许可65英寸电视前壳模具上,在生产中运行稳定,未出现过斜顶卡死断裂等情况,可靠性远高于常规长斜顶结构模具。截止至2017实际应用 年4月份,该结构模具大范围应用至青岛海信电器有限公司,三星电子和索尼电子电视前壳模具中,共计133套, 实现销售收入1.5亿元。公司通过此产品的应用,提升了在电视前壳模具上的技术实力,扩大了市场份额,提升了公司形象。
Project Description
Out products have pitched roof-like structure which mainly include hydro-cylinders, push pedals, shifting blocks and small pitched roofs. Push pedals and shifting blocks are solidly connected and powered by hydro-cylinders which make the pitched roof stick out at regular intervals. The previous long pitched roofs structure is replaced by newly-designed ones, reducing the ejector robs to 100 to 120 mm from 330 to 400 mm. The sectional area of angle ejector rods is also reduced (6-8) x (25-60) mm from (10-12) x (20-25) mm and the ejection distance to 40 to 60 mm from 110 to 130 mm. Smaller pitched roofs are 70% shorter than the traditional long pitched roofs with stronger sections and shorter projection distance, making pitched roofs less subject to fractures while improving stability. In addition, molds are less thick with lower costs. The snap-chilling and heating technology has avoided the application of high gross materials and environmental footprints. Hisense Electric Co., LTD has given up its spray coating lines, bring the company on a track of green business.
User Value
The product was first used to manufacture the front shell mold of a 65 inch TV set on March 23, 2015. It operated stably with no jams and fractures and is far more stable than its counterparts.
Business Performance
Since April 2017, this mold has been expanded to manufacture 133 front shells of electronic devices and TV sets of Hisense Electric Co., LTD, SUMSUNG and SONY with 150 million in sales value.
Social Impact
The application of this product has made our company more competent in terms of front shell manufacturing of TV sets, grown its market shares and improved company image.
Team Structure
Chief Designer: Wang Jiachang
Flow
With bigger sizes and hinger costs, convention molds have longer ejector robs and are more subject to fractures. Progress: In response to the above mentioned fall backs, the ejector mechanisms have been upgraded and we spent one month designing the new plan. After experiments with sample molds, the stability of the molds have been verified with recognition from our customers. The product was first used to manufacture the front shell mold of a 65 inch TV set on March 23, 2015. It operated stably with no jams and fractures and is far more stable than its counterparts. Molds are less thick with less stell material costs.
Project Investment
The product was first used to manufacture the front shell mold of a 65 inch TV set on March 23, 2015. It operated stably with no jams and fractures and is far more stable than its counterparts. Molds are less thick with less steel material costs.
Project Achievements
The product was first used to manufacture the front shell mold of a 65 inch TV set on March 23, 2015. It operated stably with no jams and fractures and is far more stable than its counterparts. Molds are less thick with less steel material costs.
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