佛吉亚一般要求中文版64页_V1标准

FIS-S-DSE-5550 Ｆａｕｒｅｃｉａ模具设计通用标准
Summary
1. TOOL FOLLOW-UP: TRIALS & DOCUMENTATIONS (5)
1.1. Pre-study....................................................................................................................................5 1.2. Study...........................................................................................................................................6 1.3. Trials. (6)
1.4. Geometrical tolerance and tool dimensional checking (8)
1.5. Documentations (provided by the tool maker) (11)
1.6. Transport of Tool......................................................................................................................12 2. MATERIALS & FINISHING. (13)
2.1. Material....................................................................................................................................13 2.2. Repair.......................................................................................................................................14 2.3. Finishing.. (14)
3. INJECTION SYSTEM............................................................................................................................16 3.1. Introduction (16)
3.2. Process performance (16)
3.3. Injection system expectations (16)
3.4. Centering ring (reversible) + nozzle inlet (17)
3.5. Hot runner (18)
3.6. Gating systems (21)
3.7. Split line and venting (24)
4. THERMAL CONTROL SYSTEM (25)
4.1. Introduction..............................................................................................................................25 4.2. Expectations.............................................................................................................................25 4.3. Construction.............................................................................................................................25 4.4. Tool insulation..........................................................................................................................31 5. HYDRAULIC CIRCUIT ..........................................................................................................................32 5.1. Introduction..............................................................................................................................32 5.2. Construction.. (32)
5.3. Core sequence marking convention (33)
6. EJECTION (34)
6.1. Introduction (34)
6.2. General construction (34)
7. SLIDERS (42)
7.1. Expectations (42)
7.2. Angled dowel actuated slider..................................................................................................43 7.3. Cylinder actuated slider.. (45)
8. SPLIT FACE, SHUT OFF PLATES and CENTERING PLATES (47)
8.1. Split face...................................................................................................................................47 8.2. Shut off plate............................................................................................................................47 8.3. Centering plates.. (48)
9. INSERTS (50)
9.1. Expectations.............................................................................................................................50 9.2. Construction.............................................................................................................................50 10. LIFTING & HANDLING.......................................................................................................................51 10.1. Lifting....................................................................................................................................51 10.2. Handling.. (52)
10.3. Stability on floor (53)
10.4. Tooling opening assistance (54)
11. MAINTENABILITY (55)
11.1. Wearing parts, protection and servicing elements (55)
11.2. Maintenability (55)
目录
模具跟进：　试验及文档前期评审评审试模几何公差和模具尺寸检查证明材料（模具供应商提供）模具运输材料和加工材料维修交模浇注系统概述过程性能注塑系统周期定位圈（正反可换）＋主唧嘴热流道浇口系统分型线和排气温控系统概述预期结构模具隔热液压系统概述结构动作顺序顶出概述常规结构滑块预望机械滑块（斜导柱驱动型滑块）油缸滑块分型面、承压板和耐磨板分型面承压板耐磨板镶块预期结构模具的吊装与搬运吊装搬运稳定放置翘模槽维护与保养耐磨部件，保护和辅助部件
Summary
12. REFERENCES and MARKINGS (56)
12.1. References............................................................................................................................56 12.2. Markings. (57)
13. QUICK CLAMPING SYSTEM...............................................................................................................58 13.1. Expectation and choice.........................................................................................................58 13.2. IMM Tie bars protection.......................................................................................................58 13.3. MAG clamping system..........................................................................................................59 13.4. CRO clamping system..........................................................................................................61 13.5. CLO clamping system.. (62)
14. TOOL LAY OUT (63)
14.1. View from operator side (63)
14.2. View from opposite operator side (63)
14.3. Examples (64)
GLOSSARY
IDS : Injection Data Sheet (Tool Specifications) TFUP : Tool Follow Up OP side : Operator side (machine control side) NOP side : Non operator side (Opposite operator side) SCR
: Standard change request for modification Dev. Pilot : Development Pilot PTE : Process and Tool Engineer POC : Pole of Competence IMM
:
Injection Moulding Machine
参考和标识基准标识快速码模系统目标和选择注塑机大杠的保护ＭＡＧ　码模系统ＣＲＯ码模系统ＣＬＯ码模系统模具的布局操作侧视图非操作侧视图示例相关名词解释模具设计说明书（注塑生产参数表）模具跟踪
操作侧
非操作侧标准修订申请发展策略
模具工艺工程师注射成型机
专家
Purpose and targets
PURPOSE AND TARGETS
DEFINITIONS This document refers to Injection tool design It remains the whole property of FAURECIA.
Any information included in this document is forwarded strictly confidentially to the tool
manufacturer, and shall not be passed on to third persons without prior written agreement of purchasing commodity director.
The The target target target of this document is to obtain an efficient injection tools in the of this document is to obtain an efficient injection tools in the respect of the following Faureci respect of the following Faurecia industrial targets:a industrial targets:a industrial targets:
Easy and reduced maintenance: - Standard structural parts - Maximum interchangeability - Simplified assemblies Integration of the Faurecia IMM/Tool standard interface: - Improved performance (cycle SMED scrap breakdown) - Optimum safety and maximum protection of the tool, accessories and people
Taking advantage of the experience gained: - Tooling being immediately operational on site after reception - Improved product quality - Costs reduction - Energy and material saving - Innovations
The injection tool must comply with the document valid at the time of its launch, unless otherwise expressed.
Upon receipt of a new version, the obsolete version will be archived during 2 years minimum by the whole addressees. (Time being necessary for the manufacture and start in production of a tooling in compliance with the obsolete index).
An update will not be applied to already launch tools. The upgrade of a tool following a document update will be the subject of a special notification. - Any improvement idea can be addressed to Faurecia Injection Pole of Competence. - Any deviation from the Spec. must be approved in writing by Faurecia and reported to POC - Any deviation approval will take place during the pre-study / study reviews using
the tool follow-up document. 目的和目标定义本文件涉及到注塑模具的设计，Ｆａｕｒｅｃｉａ拥有本文件的最终解释权；模具供应商应对本文件的所有信息保密，未经书面许可
不得透漏给第三方。

本文件的目标是为了获得高效的注塑模具以实现以下Ｆａｕｒｅｃｉａ在汽车零部件方面的目标简单和减少维护
尽量采用标准件互换的最大可能性装配简单
标准的模具与Ｆａｕｒｅｃｉａ注塑机接口改进性能（提高生产周期及减少故障）根据已有的经验最大限度的保证模具、人员及设备的安全
保证模具试模一次成功提高产品质量降低成本
节省材料和能源创新
任何改进意见都可以发给弗吉亚注塑方面的专家
任何不符合标准的地方必须有弗吉亚的书面批准并报送弗吉亚专家
任何与合同违背的地方必须在签订前提出并得到批准
注塑模具必须符合此文件的规范要求，除非有其他更新的要求在收到一个新的版本，旧的版本还需要保存至少两年。

（目前所生产制造和开始的模具符合以前的标准）。

更新将不适用于已经制作的模具，标准文件的升级将会将会有一个特殊的通知
利用经验的优势得到好模具
模具跟进：试验和文档　
批准钢料订购
- Steel order approval (Steel certificate) will be cross check with the steel supplier
目标：模具加工前详细结构确认。

1. Tool Follow Up, Trials and documentation
1.2.
Study Target: Validation of the final tool construction details for Machining approval.
Content of the drawings: - View of fixed tool half with IMM tie bars - View of moving half with IMM tie bars - Longitudinal and cross views "assembled tool" - Detailed views with dimension (for ex.: injection) (magnify if necessary) - Section views of the difficult areas as defined by the project (specific CdC)
- Section view of each cooling circuit system (cooling circuit systems in 3D with cavities shape) - Views with dimensions of the ejection system: diameters of nozzles and cold channels, dimensional and size of injection gates, nozzles position…
- A specific view of the tool/injection machine interface (none operator side) including:
- Injection machine tie bars - Lay out of the electric, hydraulic and cooling interface on the NOP side
If the tool drawing is available in 3D format:. CATPart or .CATProduct , all those section views will be carried out with CATIA V5 by Faurecia.
1.3.
Trials 1.3.1. Trials conditions
Several trials must be carried out by the tool maker prior to tool approval: - Usually 3 trials if parts are not grained or not back injected
- Usually 4 trials if parts are grained or back injected Trials must validate: proper function of the tool, part dimensions, part aspect, scrap rate and injection cycle time.
The quantity of produced parts during trials is defined by development and purchasing. The tool maker must carry out an in house trial (trial 0) at his own expense in order to validate the proper function of the tools before the trial 1. The parts produced during this trial 0 must not be used by the project team or given to the
customer for a validation . Nevertheless, the parts must be presented to Faurecia.
T he tool acceptance and trial 5 take place in a Faurecia plant and at the plant expenses. Toolmaker must provide a list of potential trial centers with the main caracteristics of the IMM (valve gate control system, screw diameter, clamping force...) and ancillary equipments (ex: drying bins and dehumidificators , hot runner heating, Thermal control unit, Robots). Faurecia reserves the right to refuse the trial if the conditions of series production are not observed. Refer to the following table for the expected trial condition.
评审
图纸必须包含一下几种视图：
带注塑机大杠的定模侧视图带注塑机大杠的动模侧视图
模具总装的正面视图及侧面视图视图要有有详细的尺寸（如：喷嘴配合尺寸）（如果需要的话要有放大视图）根据工程图要求要剖视图表达模具比较难懂的地方
要有剖视图表达每个水路循环系统（要有３Ｄ视图来表达水路循环系统）
要有视图表达浇注系统的尺寸：喷嘴尺寸和冷流道尺寸，浇口尺寸，喷嘴位置．．．
要有详细的视图表达模具及注塑机接口（包括非操作侧）要表达注塑机大杠要在非操作侧放置电路铭牌，油路铭牌及水路铭牌
传三维图格式：ＣＡＴＰａｒｔ或ＣＡＰＴＰｒｏｄｕｃｔ，所有图都要转成ＣＡＴＩＡ　Ｖ５格式的给弗吉亚
试模
试模情况
在模具验收前模具供应商必须精心不同阶段的试模
不做皮纹或不是后模进胶的模具一般试模三次
皮纹模具或后模进胶模具一般试模四次试模必须验证：模具动作情况，产品尺寸，产品外观，废品率和注塑周期
各试模阶段需要生产的产品数量在模具开发合同里都有规定
在合同规定第一次试模前模具供应商应该自己内部试模一次（Ｔ０试模）以验证模具各方面功能
Ｔ０试模的产品不能被项目团队利用也不能发给客户确认，但是产品必须发给弗吉亚
模具验收和第５次试模在弗吉亚工厂进行，费用由工厂承担
模具供应商应该提供试模是可能发生的模具问题点及主要的注塑参数（阀针控制系统，
螺钉直径，锁模力…）和辅助设备（如：烘干机和除湿器、热流道加热及控制装
置，机械手等）如果试模时不能满足连续生产的条件，弗吉亚有权否认试模，试模时需要满足下
面表格提到的条件：模具跟进，试验和文档
Risk of issues
Bad conditions
Some circuits are bridged
> 5 circuits / TCU
< 100 L/min
< F OR F > 1.6 x F - Part geometry - Demoulding - Cycle time
- Aspect
1. Tool Follow Up, Trials and documentation
- Validate the colour change capability (if any), conformity of the system will be validated by Faurecia (a number of scraps to each change necessary before having good parts).*
- Track cycle time and scrap rate Note:
Note: Weight monitoring of complete injected part must be done to optimize the holding stage of the injection process. A End of Arm Tooling for the robot (part gripper) must be used for this trial if the plant does not have any, the toolmaker must provide to Faurecia a simple means to carry out cycles automatically . 1.3.4. Trial 3 Target for grained or back injected parts: - Validate the compliance of the modifications and design changes requested by Faurecia after trial 2. - Obtain the graining order approval given by costumer design. Graining order will be transmitted by Faurecia - Track cycle time and scrap rate If no open points are identified during this trial, the graining authorisation is given.
Target in all other cases: - Validate the part aspect (Short shot, jetting, splash mark, burn, sink mark, visible weld line, fragile weld line, flash, bubble, black spot, delamination, ejector mark, orange peel aspect, size and colour and gloss homogeneity ...) - Validate the compliance of the modifications and design changes requested by Faurecia after trial 2. - Validate the IMM/tool interface. (By Faurecia plant representative)
- Check the updated technical and conformity files - Track cycle time and scrap rate If no open points are identified during this trial, the tool transfer is approved.
1.3.5. Trial 4 (grained part or back injected part only) Target: - Validate the part aspect after graining (Short shot, jetting, splash mark, burn, sink mark, visible weld line, fragile weld line, flash, bubble, black spot, delamination, ejector mark, orange peel
aspect, size and colour and gloss homogeneity ...)
- Validate the IMM/tool interface. (By Faurecia plant representative)
- Check the updated technical and conformity files If no open points are identified during this trial, the tool transfer is approved.
1.3.6. Tool acceptance
Target: - Validate the scrap rate and cycle time in the production plant on the production equipment.
- Track cycle time and scrap rate The tool acceptance and trial 5 take place in a Faurecia plant and at the plant expenses.
1.4. Geometrical tolerance and tool dimensional checking
1.4.1. Principle The injection tool must be checked according to the tool checking procedure supplied by Faurecia. 验证更换不同颜色料生产的能力（如果需要），弗吉亚需要验证换色系统（在得到好的制品前每个改动地方都需要切开验证）验证注塑生产周期和废品率
注意：需要验证完整注塑件的重量以调节注塑保压阶段的参数
这次试模需要使用机械手（制品夹具）取件，如果试模工厂没有机械
手，模具供应商需要向弗吉亚提供一个简易的能自动取件的装置；第三次试模
目的是为了做皮纹或采用后模进胶的产品
验证第二次试模后弗吉亚提出的问题点设计更改及执行情况
得到客户设计部门对皮纹样式的认可，皮纹样式将会由弗吉亚提供验证注塑生产周期和废品率
如果这次试模没有发现未关闭的问题点，将被批准做皮纹
目的为了验证其他所有问题点
验证产品外观（打不满，水花，光斑，烧焦，缩痕，外观熔接痕，强度熔接痕，飞边，气泡，黑斑，分层，顶痕，脱伤，尺寸、颜色和外观的一致性…）
验证第二次试模后弗吉亚提出的问题点设计更改及执行情况验证注塑设备／模具接口（由弗吉亚工厂的人员验证）
检查更新后的技术文件及执行情况验证注塑生产周期和废品率如果这次试模没有发现未关闭的问题点，模具将被允许发运。

第四次试模（只应用于皮纹件会后模进胶的模具）
目标：
验证做皮纹后的产品外观（打不满，水花，光斑，烧焦，缩痕，外观熔接痕，强度熔接痕，飞边，气泡，黑斑，分层，顶痕，
脱伤，尺寸、颜色和外观的一致性…）
验证注塑设备／模具接口（由弗吉亚工厂的人员验证）
检查更新后的技术文件及执行情况如果这次试模没有发现未关闭的问题点，模具将被允许发运。

　模具接收验证：
目标：
在批量生产厂家的设备上验证废品率和注塑生产周期，
验证注塑生产周期和废品率
模具验收和第５此试模在弗吉亚工厂进行，费用由弗吉亚工厂承担。

几何公差和模具尺寸检查
原则
注塑模具检查必须按照弗吉亚提供的检查步骤执行
模具跟进，　试验和文档
- Reception by the tool maker of the Tool dimensional checking instruction from Faurecia: first part – 1 month - Reception by Faurecia of the measurements results (functional elements + thicknesses): first part
Remark: At each change on tool / part, a tool control must be realized on modified area and the related report sent to program team. This check is composed of: - Location of areas for thicknesses measurements on the part - List of functional elements to be checked (isostatism, holes, process element, end of part, etc…)
- List of each control point for each functional element (from 1 to N points per element) The following table is an estimation of the number of points to be controlled per type of product:
Type of product
Number of
Points (+/-20%)
Type of product
Number of Points
(+/-20%) Top cover 500 Console cover 300 IP main carrier 600 DP main carrier 400 Defroster channel or cover 200 DP top roll or insert 200 Side cover 50 Trunk cover 300 Drive side finisher 100 IP center cover 200 Glove box (outer or inner) 100 Cluster bezel 100 Glove box 300 Center stack 150 Console main carrier 350
Other 200 Max
1.4.
2. Control condition Control of thicknesses must be achieved on a smooth surface (no grain)
Functional elements control must be achieved: - With a CMM (Coordinate Measurement Machine) and a software of surface control (type of Metrolog or PC-DMIS) - In comparison with part CAD data (supplied by FAURECIA) and the injection tool to validate.
1.4.3. Measurement and analysis presentation - Measurements values of thickness must be visualized together with a picture of the part.
-Measurement results of functional elements shall be supplied in an excel sheet with the following information: - Number of measured point (in accordance with the number of the point defined in the Faurecia control range) - Theoretical value X, Y and Z - Measured value X, Y and Z - Real dimension gap of point of surface >> All the results shall be indicated in the vehicle axis system
供应商接收弗吉亚制定的模具尺寸检测说明书：第一个文件－１个月
弗吉亚接收测量结果（功能对象＋厚度）：第一个文件注意：对于每次模具／产品的改动，供应商必须实施关于模具的改动部位以及发送给项目组的相关报告的控制。

检查包括
关于产品厚度的测量区域的定位需要检测的功能对象（ｉｓｏｓｔａｔｉｓｍ、孔、产品末端等）的明细表
每个功能对象的每个控制点的明细表（每个对象的控制点按照从１到Ｎ）
下面的表格是每种产品类型需要测量的控制点数量的估计：仪表板上盖板产品类型点数产品类型点数仪表板骨架除霜风道或盖板仪表板端盖板司机侧饰板手套箱内或外板手套箱本体副仪表板本体副仪表板盖板门饰板本体门上饰板或中饰板行李箱盖板仪表板中央饰板仪表面板中控面板其它控制条件
光滑面（无皮纹）的厚度必须予以控制。

功能对象必须实现控制：
使用ＣＭＭ（坐标测量仪）和曲面控制软件（Ｍｅｔｒｏｌｏｇ
或者ＰＣ－ＤＭＩＳ类型）
对比产品的ＣＡＤ数据（由弗吉亚提供）和注塑模具等效的数据测量和分析的表述
厚度的测量值必须在产品的图片上指示。

测量点的数量（与弗吉亚要求的控制区域定义的点数一致）功能对象的测量结果应该是ｅｘｃｅｌ　表格，内容如下：
理论上的Ｘ、Ｙ和Ｚ值测量出的Ｘ、Ｙ和Ｚ值
曲面上点的实际尺寸差值所有的结果应该以车身坐标系来指示。

A visual report can be added with the provided results
1.4.4. Tolerances for Acceptance Tolerances must be according to the following table:
Measures Measures Tolerances (mm)Tolerances (mm)
Dimension (distance between 2 points of 1 element) +/- 0.1 Location (location of a point of a surface or a built axis)
+/- 0.15 Thickness
+0/-0.2
外观检测报告也需要一起提供可以接受的公差
公差必须符合下表的要求
参数
公差
尺寸（两点间的距离）位置（点的位置坐标）产品壁厚
1.5.
Documentations (provided by the tool maker)
1.5.1. Technical file 1.5.1.1. Principle
All technical documents related to the tool must be included into a file called "Technical File". This document must: - Be hand over to the plant before the tool transfer - I nclude an update for each modification of the documents - Be written in a way as simple as possible in order to avoid possible misunderstandings - All documents in english 1.5.1.2. Presentation
The general presentation (binding, binder, file …) is left to the tool manufacturer.
The cover sheet shall include at least the following information: - Name of the tool manufacturer - Supplier’s tool number - FAURECIA Tool number - Description of the injection moulding part(s) - Hot runner system reference - FAURECIA Project code
The file must include a contents table and each page must be numbered. The injection tool drawings size must be standard on the scale 1:1 or 1:2 for large mould
- 2 paper copies - Files 3D on CD
1.5.1.3. Content
- Final drawings of the tool
- CAD of all tool surfaces: split line, cavities surface and including all the machined components (CAD-CAM) of the tool - Drawing of tool footprint on the IMM platens with clamping
- Kinematics scheme and description of auxiliary motions - Drawing of the injection system (forms, types and dimensions) - Hot runner system drawing showing heaters and sensors - Tool cooling circuits scheme (cooling circuits drawing) in core and cavity in 2D & 3D (files
format: CATPart or .CADProduct) and each circuit individually - Cooling table to be filled and provided:
Circuit
number
Length
Ø
Nb of bend 90° Nb of bend 120°
Qty of baffle or cascade
Part surface in front
Flow in L/min under a pressure of 1.5bars
- Electric and hydraulic connection diagrams, core and cavity - Version change procedure if any - Original tool reference compared to its referential and to the vehicle referential system - Instructions for assembly and disassembly of the tool with CAD views if necessary - Preventive maintenance manual - Nomenclature of the parts including at least: - Tooling no. - Drawing no. - Part index 证明材料（模具供应商提供）
技术文件定义
所有关于模具的技术文件必须放在＂技术文件＂的文件夹内
这些技术文件必须满足如下要求
在模具发运前必须把技术文件先发给弗吉亚工厂必须包含所有的模具更改明细文件表述必须言简意赅以避免产生误解
所有的文件必须是英文格式
说明书
通用说明书（要有封面、装订、归档…）由模具供应商提供
通用说明书应该至少包括以下内容模具供应商的名称供应商的模具编号弗吉亚的模具编号
注塑模具零部件的介绍热流道系统相关说明弗吉亚项目代码说明书必须要有目录列表并且每页都要有编码
注塑模具的图纸必须是按照标准时１：１或１：２（对于大型模具）
要提供两份图纸３Ｄ图要刻成光盘
目录
模具的最终图纸
ＣＡＤ里要表示模具所有的外观：分型线、型腔面和所有需要加工的模具零部件（ＣＡＤ－ＣＡＭ）
模具结构图应该表示注塑机参数及装夹位置模具各部件的运动顺序及相关描述图纸要表述注塑系统相关参数
（形状、特征和相关尺寸）热流道图纸要表示出加热部件和温控部件冷却系统的表格必须填好一起提供
模具２Ｄ和３Ｄ图纸
都要有型腔型芯的冷却系统并且每个回路都要单独表示冷却回路编号
长度直径
９０°转折数量
１２０°转
折数量
难冷却或点冷数量
离产品面
得距离
压力为１．５ｂａｒｓ
时的流量（Ｌ／ＭＩＮ）
型腔及型芯侧电路和油路的接线图版本更改流程（如果有的话）
要根据维修保养手册定期检修至少应该包含以下专用名称模具编号
图纸编号以前的模具需要参考此规范的相关说明及
有关运输的有关说明如果需要的话要在ＣＡＤ视图里要有模具
的拆装说明
每个零件钢材根据不一样的受力及不一样的功能来选择
Each element does not withstand the same strain and does not have the same function.
不同钢料的使用情况需要根据下面的对照表执行
Remarks Treatments/ Painting
55HRC
A steel sample plate for the (as follow) graining test. must be delivered to FAURECIA development team 5 weeks after steel order.
draft angle acc. Grain definition
EXAMPLE !
下图所示的钢料样板用于做皮纹测试，必须在钢料订购后五周内交付弗吉亚项目组
项目代码纹理样式返工标识区域产品名称弗吉亚模号产品材料类型标准钢材名称金属的去除使塑料制品的壁厚增加（如图例）。

为了获得认可的尺寸，客户需要考虑在模具上做一个相应的补偿
Development
3. Injection System
3.INJECTION SYSTEM
3.1.
Introduction
3.1.1. Principle The tool maker will propose an injection system which correspond to FAURECIA performance & efficiency
It will be demonstrated by a rheology study or previous experience that will be shown to FAURECIA. In case of complex parts which are injected in FAURECIA production sites, the FAURECIA rheology process department will provide a rheology study & theses studies must be respected. In case of impossibility, other solution will be negotiated.
3.1.2. Validation In all case the definition of the injection system & the risks linked to feeding parts must be clarified at tool pre-study: - Injection gate shape and dimensions (gates must be compatible with the used material) - A cross section of the gate must be presented in order to show the residual gate on the part - The part feeding system and its dimensions including the hotrunner - Any product risk (fragile area, defect risk: weld lines, air traps…)
3.2.
Process performance - System must be adapted to raw material (PP/PE, Styrenic, GF,…) - Homogeneous temperature - Shear rates reduced to avoid material degradation - Shut of pin reactivity < 0.1sec - If product runs with different colours, the hot runner must be prepared in consequence TARGET: 5 scraps maximum when changing colour
3.3.
Injection system expectations
3.3.1.
Product - No generation of traces or distortions / warpage on or of the part (jetting, bubble,…) A thermal or distortion analysis can be requested to validate
- No problem to downstream process (like thermo covering, foaming,…) - No marks on visible or grained area of the part - No risks of visible weld lines, short shot, air traps, over pressures / temperatures areas or other risks of defects of aspect
3.3.2. Process efficiency - Automatic degating is preferred In case of gate cutting necessity, we must be able to cut them simply with snips & no risks for parts or operator - Cold runner as short as possible - Cold runner & sprues must stay on ejector during ejection without deviation for an effortless robot gripping (no wrenching, nor supplementary movement of the robot other than the axis of demoulding)
浇注系统
浇注系统
引言
规范
模具供应商要根据佛吉亚提供的注塑周期和材料性能提供浇注系统方案，以经验和流变学分析为依据提供模流分析报告．
对于复杂零件，佛吉亚相关部门将提供一份流变学报告，而且此报告需模具供应商认可。

如果不可行，需共同协商其它可行方案。

确认
在任何情况下，浇注系统及填充缺陷必须在模具方案评审时确认，具体包含：－浇口形状及直径（浇口必须与注塑材料相匹配）
－必须提供浇口的横截面以显示产品上的残留浇口
－浇注系统尺寸（热流道和冷流道）
－产品填充风险点（薄弱区域，变形，熔接痕，困气）
工艺参数
－热流道系统必须适应于注塑材料（ＰＰ／ＰＥ，ＧＦ…）－温度均匀
－使剪切速率降低到可以避免原料分解的参数－阀针关闭＜０．１秒
－如果产品需要换色，热流道设计必须提前分析目标：换色时最多５件废品
浇注系统期望的目标
产品
－产品无变形翘曲或气痕，流痕…．
可以通过热变形及翘曲的分析报告进行验证
－在外观面或者皮纹面没有明显的痕迹－流动过程没有问题（例如料流流窜，起泡）
－没有明显熔接痕，缺料，困气，压力过大／热点等缺陷或者其他的风险点
效率
优先选用自动断料的浇口如果浇口必须需要切除，我们必须能很容易的将其切下，并且
不会对产品和操作工有损伤
冷流道越短越好
－
在顶出过程中，冷流道和浇口必须停留在拉料杆上无偏离以方便机械手取件。

（没有铲胶，也没有出模方向以外的辅助动作）
3.4.
Centering ring (reversible) + nozzle inlet
- Reversible centering ring for flexibility in clamping system (CRO – CLO – MAG). - To be installed on moving side & fixed side - Radius 20mm in nozzle inlet. - Sprue diameter depends on mould size.
A(mm) B (mm) IMM > 650T 10 10 IMM ≤ 650T
40
20
定位圈（正反可换）＋主唧嘴
正反可换的定位圈可适应在（ＣＲＯ－ＣＬＯ－ＭＡＧ）码模系统中适用灵活。

安装在动模以及定模主喷嘴进口半径２０ｍｍ
主喷嘴入口直径取决于模具尺寸截面
偏移
反转位置
材料
注塑机注塑机
3.5.
Hot runner
3.5.1. FAURECIA approved suppliers -RUNIPSYS -SYNVENTIVE -INCOE -HRS - The tool maker must present at least 2 offers from this list. - The toolmaker is the only contact to FAURECIA and he manages relationship with the hot runner supplier.
3.5.2. Hot runner system expectations
3.5.2.1. Generic design - No filter on the hot runner sprue bush
- Screwed or binded nozzles in manifold and the tightness is done mechanically to reduce leak risks - Nozzle, nozzle tip and valve pin are indexed in rotation when necessary (nozzle tip with special shape) - Fitted with guiding columns to guide the system into the tool during the hot runner assembly - The assembly must withstand thermal distortions
- The hot runner must withstand a pressure of 1500 bars - All the materials subject to wear (heating elements, thermocouple and seals) are interchangeable by FAURECIA without machining operation and will be referenced
3.5.2.2. Connections & layout - Hydraulic and electric connections on opposite operator side, protected with protruding plate - All other elements (solenoid valve, pressure limiter and manometer) will be installed on the operator side - Guiding element will be integrated to the hot runner in the following conditions: - Ejection on injection OR - Quantity of nozzle > or equal to 4 AND nozzle length > 250mm - If Ejection is on injection side, the hot runner system must be integrated in a hot half (mounted into the plate)
Electric connections Opposite operator side Operator side Back plate protecting hotrunner connections Filter Solenoid
Oil feeding 热流道
佛吉亚许可的供应商
登莱秀（朗力）圣万提英格斯英柯欧模具厂商必须与上述供应商中的至少两家有供货关系。

－模具厂商是与佛吉亚的唯一联系方，其自行与热流道供应商联系。

热流道系统预期目标
通用设计
－喷嘴与集流板间用螺纹连接，机械紧固，以降低漏胶的风险
喷嘴，喷嘴头和阀针必要时需止转（喷嘴头部有特殊形状时）
－与模具装配时需要导向柱来导向
－系统能承受热变形
－热流道需能承受１５００ｂａｒ的压力
－易损部件（加热丝，热电偶和密封圈）可由佛吉亚自行更换，而不用再行加工
连接和布置
液压系统和电气系统连接在非操作侧，设计保护板
所有其他部件（电磁阀，压力控制器和测压计）安装在操作侧
－以下情况需要考虑设计导向：
顶出和热流道在同一侧或者
喷嘴数量＞＝４并且喷嘴长度＞２５０ｍｍ如果热流道在顶出侧，热流道需要固定在一块模板上（沉入板内）。

操作侧
非操作侧电接口（航空插座）顶板保护热流道接头
油压表进出油嘴电磁阀（螺线管）
Development
3. Injection System
Example:
3.5.2.3. Technical documentation to supply with the hot runner A 3D drawing of hot runner is required under A4 format, with the following details: - The designation of the part - Tool number - The location of different heating zones - The number of different areas regulated with position of thermo-couple - The list of heating elements (diameter, length & power) which equipped heating areas - The direction of the exit of the wires toward the junction box
3.5.2.
4. Sequential gating - If cylinders aren’t in the same axis of the nozzle, there must be enough remaining surface to implement necessary & sufficient die support
- Hydraulic valve are on the tool (as opposite to an IMM) and are operated under 24V/1.5A - Hydraulic filters of 5µm on the hydraulic feeding
- Main supply must be fitted with a manometer - The solenoid valves must be fitted with LED indicating status - Cylinders are oil fed via hard or flexible pipes - Direct access to cylinders after removing back plate only - Position sensor is fitted in each valve pins when we have more than five nozzles - Removal of valve pin within less than 15mn - Valve pin type must be agreed with POC depending on application - Re-centring of valve pin before closing - Valve pin tightness/positions adjustable from cylinder 浇注系统
例如
加热区
热流道技术说明书随热流道系统一起提供
需要一份Ａ４的热流道３Ｄ轴侧图纸，附有以下详细内容：部件的名称模具编号
不同加热区域的位置
由热电偶控制的不同加热区域的数量
加热区各类加热元件的列表（直径、长度和功率）
线路连向接线盒的走线方式顺序阀热流道
如果油缸和喷嘴不同轴，必须有足够的配合面和足够的支撑
油缸
油缸
　液压阀安装在模具上（在注塑机侧），在２４Ｖ／１．５Ａ的状态下工作主供给油路必须配有压力计
电磁阀必须配有ＬＥＤ指示灯油缸通过硬管或者软管进油
只有在去掉支撑板之后才能拆卸油缸当喷嘴数量超过５个，每个阀针需要配有位置检测器
阀针的配合段不超过１５ｍｍ
阀针形式需要由ＰＯＣ许可在合模之前阀针要复位
阀杆与油缸配合安装
排列顺序
顺时针　从内到外。