The GM Diagnostics team were asked to take a look at an issue with a 600t Engel injection moulding machine. After a couple of attempts to resolve an issue with the clamp by other companies, we were asked to get involved.
Our engineers carried out a full strip down of the complete toggle system and that revealed several broken toggle pins and extensive wear to all links and bushes. The customer had been quoted a 16 week lead time to repair and in excess of £70,000.00
However we were able to have all links repaired back to original condition with all new bushes, non bushed parts were bored and bushed back to original specification. Not only that all new toggle pins were manufactured and the machine was fully rebuilt and all tie bars refitted and strain gauged. Our engineers worked hard and they were able to have it all done and back up and running in 7 weeks. And needless to say at a fraction of the cost originally quoted!
What is an Engel Clamp Rebuild?
An Engel clamp rebuild is a crucial process for maintaining the efficiency and performance of injection molding machines. These clamps play a vital role in securely holding the mold halves together during the injection molding process. Over time, due to wear and tear, clamps may lose their effectiveness, leading to decreased productivity, increased downtime, and potential quality issues. Therefore, a meticulous rebuild process is essential to restore the clamp’s functionality and optimize the overall performance of the injection molding machine.
Starting with an Inspection
The first step in an Engel clamp rebuild is a thorough inspection of the existing components. Highly skilled technicians assess the condition of each part, including the clamp housing, platen, tie bars, bolts, and hydraulic cylinders.
Any signs of damage, corrosion, or excessive wear are carefully noted. This evaluation helps in determining the extent of the rebuild required and ensures that no underlying issues are overlooked.
Once the inspection is complete, the disassembly process begins. The old or damaged components are removed, making way for the installation of new parts. It is crucial to source high-quality, genuine Engel replacement parts to guarantee the longevity and reliability of the rebuilt clamp. These parts include seals, bearings, bushings, guide blocks, and hydraulic components, depending on the specific needs of the clamp.
The actual Engel Clamp Rebuild Process
The rebuilding process involves meticulous attention to detail. Each component is cleaned thoroughly to remove dirt, grime, and residue. The mating surfaces are carefully inspected and prepared to ensure a precise fit.
GM Diagnostics Technicians will use specialised tools and equipment to repair or recondition certain parts, such as honing tie bars or resurfacing the platen. Any necessary repairs are made, and all moving parts are lubricated appropriately.
Once the individual components are ready, the reassembly process begins. The new parts are fitted, and adjustments are made to ensure proper alignment and functionality. It is essential to follow the manufacturer’s guidelines and specifications throughout this process to guarantee optimal performance. The hydraulic system is carefully bled to remove any air bubbles, ensuring smooth and efficient operation.
After the Engel Clamp Rebuild
After the clamp is reassembled, a series of tests and inspections are conducted to verify its functionality and performance. Technicians check for proper clamping force, smooth movement, and precise alignment.
They also test the response of the hydraulic system, ensuring that it operates within the specified parameters. These tests may involve operating the clamp at different pressures and speeds to simulate real-world injection molding conditions.
Finally, once the Engel clamp rebuild is complete and the clamp passes all the necessary tests, it is ready to be integrated back into the injection molding machine. The rebuilt clamp restores the machine’s productivity, thus reducing downtime, and ensures consistent product quality. So regular maintenance and periodic inspections are recommended to prevent future issues and maximise the lifespan of the rebuilt clamp.