Introduction
Forwell has been a pioneer of Quick Mold Change Systems for many years. With over 20 years of experience in developing these systems they can offer you the best for your molding operations. These fully customizable Quick Mold Change Systems drastically minimize setup times, maximize efficiency and increase safety.
Forwell’s Quick Mold Change System can be designed to fit almost any injection molding machine and mold casting machine to allow for quicker mold change times, resulting in shorter machine down time and increased productivity. This system uses a special mold clamp that does not require a cut out on the mold, increasing its application versatility and allowing it to be used with a large number of different molds.
Quick Mold Change Systems can rapidly transform your workshop, allowing for easy changeover for small batches, reduced labor costs and reduced stock holding. Coupling this system with a Mold Cart System will allow for fully automatic mold changing, further increasing the efficiency and productivity of your manufacturing operations.
Mold Cart System Layouts
Forwell can design the most practical and efficient Quick Die Change System according to your plant layout and equipment. To further improve the efficiency of your mold changes, this system can be paired with Forwell’s Mold Cart System to create a fully automatic mold change system for your plastic injection production lines. When establishing a new production facility, please contact Forwell directly to see how beneficial a Quick Mold Change System and Mold Cart System can be for enhancing your productivity. Below you can see the different layout configurations possible when combining Forwell’s Quick Mold Change System with Forwell’s Mold Cart System:
Two Molds on a Moving Car
Mold Cart System with a 2-mold cart for quick and automatic horizontal loading of molds.
Single Mold on a Fixed Cart
Mold Cart System with a single mold for quick and easy loading of molds.
Double Sided Cart Layout
Mold Cart System that loads molds for machines positioned either side of the cart.
Double Sided Cart Layout
Machines are facing the same direction
Parallel Machine Cart Layout
Mold changes are performed using a 2-mold cart that serves two or more injection molding machines that are positioned along one line. This allows for a wide application of quick mold changing.
Mold Loading
Vertical Type
Most of the molds for injection molding and mold casting machines are fitted vertically. FORWELL Q.M.C.S however adopts removable mold changing system that not only saves idle time for enhanced production efficiency but also spurs even rationalized and automated production management.
Horizontal Type
When molds are fitted horizontally, mold changing cart can be used for safe operation, realizing quick mold changing for the entire factory. This increases automation and improves mold delivery and storage rates.
Effects of Introducing QMCS
Before
After
System Selection
There are a number of available options for the Quick Mold Change System so be sure to choose the correct pump model and mold clamps that best suit your injection molding and mold casting operations.
| Ton | Clamp | Pump Model | ||||
|---|---|---|---|---|---|---|
| Moving | PCS | Fixed | PCS | Total | ||
| ~ 150 | TY-2 | 4 | TY-2 | 4 | 16TON | FP6308U-□-□C |
| ~ 250 | TY-4 | 4 | TY-4 | 4 | 32TON | FP1014U-□-□C |
| ~ 350 | TY-6 | 4 | TY-6 | 4 | 48TON | |
| ~ 550 | TY-10 | 4 | TY-10 | 4 | 80TON | |
| ~ 850 | TY-16 | 4 | TY-16 | 4 | 128TON | |
| ~ 1000 | TY-16 | 6 | TY-16 | 6 | 192TON | |
| ~ 1300 | TY-25 | 4 | TY-25 | 4 | 200TON | |
| ~ 1600 | TY-25 | 6 | TY-25 | 6 | 300TON | |
| ~ 2500 | TY-25 | 8 | TY-25 | 8 | 400TON | |
| ~ 3000 | TY-50 | 6 | TY-50 | 6 | 600TON | |
TY Die Clamp
- Quick and easy die changing
- Very high clamping pressure
- High opening and closing speeds
- Easy insertion and removal
- Safer Operations
- Increased productivity
As this lever-type clamp does not require a U-slot on the die shoe it can be used in a wide range of applications. The TY type Die Clamps are machined to fit into the T-slot of the bolster for extra secure positioning. The flange-mount model Die Clamps can be bolted onto the bolster and the automatic slider model Die Clamps makes remote automatic operation possible.
Die Clamp Introduction
All Forwell Quick Mold Change Systems use high quality Die Clamps for very secure clamping, quick mold changing and safer operations. These clamps can fasten Molds whether they are changed vertically or horizontally.
There are also a range of different Die Clamps available to suit your injection molding or mold casting requirements. The TY type Die Clamps are machined to fit into the T-slot of the bolster for extra secure positioning. The flange-mount model Die Clamps can be bolted onto the bolster and the automatic slider model Die Clamps makes remote automatic operation possible.
Clamp Specifications
The following specifications can help you choose the appropriate clamp type in accordance with your injection molding requirements and production situation. Make sure of your production plans and production procedure before choosing your product to be sure of the product that best suits your needs.
| Mold Plate | Mold Change Direction | Clamping type | Characteristics |
|---|---|---|---|
| No Union | Vertically | Moving Clamp | Fixed in with T-slot |
| Union | Vertically | Fixed & Moving Clamp | Clamp fixed or Moving on plate |
| Horizontally | Fixed Clamp | Install roller or sliding rail upon the plate. Use cart or mold exchange table for easy operation and the shortest possible mold changing time. |
TY Clamp Model Specifications
| Model | Unit | TY-1 | TY-2 | TY-4 | TY-6 | TY-10 | TY-16 | TY-25 |
|---|---|---|---|---|---|---|---|---|
| Tons Clamping (at 250Kg/cm2) | tons | 1 | 2 | 4 | 6.3 | 10 | 16 | 25 |
| Full Stroke (X) | mm | 6 | 7 | 7 | 8 | 8 | 7 | 8 |
| Clamping Stroke (Y) | mm | 3 | 2 | 3 | 4 | 3 | 3 | 3 |
| Extra Stroke (Z) | mm | 3 | 5 | 4 | 4 | 5 | 4 | 5 |
| Cylinder Capacity st Full Stroke | cc | 2 | 6.5 | 13.2 | 22.3 | 37 | 61 | 93 |
Clamp Dimensions
For a closer look at the exact dimensions of the TY series die clamps please see the following diagram and table.
| Model | min.E | F | G | J | K | L | max.N | P | R | min.S | PT | min.C | min.A |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| TY-1 | 49.5 | 46 | 20 | 15 | 58 | 73 | 10 | 10 | 34 | 16.5 | 1/8 | 7 | 10 |
| TY-2 | 59 | 63 | 28 | 22 | 85 | 107 | 10 | 12.5 | 48 | 27 | 1/8 | 9.5 | 12.5 |
| TY-4 | 85 | 87 | 40 | 25 | 120 | 145 | 10 | 16 | 12 | 32 | 1/4 | 12 | 15 |
| TY-6 | 94 | 97 | 44 | 29.5 | 133 | 162.5 | 11 | 20 | 12 | 40 | 1/4 | 14 | 19 |
| TY-10 | 105 | 110 | 50 | 28 | 165 | 193 | 11 | 20 | 19 | 53 | 1/4 | 16.5 | 23 |
| TY-16 | 120 | 130 | 60 | 30 | 200 | 230 | 12 | 20 | 25 | 67 | 1/4 | 19 | 27 |
| TY-25 | 133 | 150 | 73 | 30 | 240 | 270 | 13 | 20 | 30 | 81 | 1/4 | 22 | 32 |
| Model | A | B | C | D | Power Unit Models |
|---|---|---|---|---|---|
| TY-1 | 22 | 37 | 16 | 24 | FP6308U-4-4C |
| TY-2 | 22 | 37 | 16 | 24 | |
| TY-4 | 22 | 37 | 16 | 24 | FP1014U-4-4C |
| TY-6 | 28 | 48 | 20 | 28 | |
| TY-10 | 28 | 48 | 20 | 28 | |
| TY-16 | 28 | 48 | 23 | 28 | |
| TY-25 | 36 | 56 | 25 | 28 |
Die shoe thickness (h) available: 25, 30, 35, 40, 45, 50, 55, 60mm.
Before purchasing, please verify if the mold edge thickness (h) and T-slot (A.B.C.D.) have standard or special dimensions.
Control Panel
- Simplifies Operations
- Easy to use
- Multi Language Interface
- Many automatic functions
- Easy status monitoring
Control Panel Introduction
The easy to use control panel offers a simple interface to monitor and control operations of the Quick Mold Change System. The upper half of the screen displays automatic functions while the lower half can be used for operator-controlled functions. This makes this machine easy to control yet still have the functionality needed of a Quick Mold Change System.
Control Panel Layout Example
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Pump Unit
- Very secure and stable clamping
- Pressure can easily be adjusted using an air pressure adjusting valve. Should air pressure become dangerously high, the air pressure will automatically shut off
- Prolonged hydraulic air pressure allows for energy efficient and convenient automated operations
- Hydraulic air pump ensures die clamping even during power cuts or when system pressure drops
Die Clamp Introduction
The hydraulic pump ensures tight and stable die clamping and allows the system to maintain clamping pressure on the mold even when there is a power failure or air pressure drops. The PCB Fine Piercing System uses air-driven hydraulic pumps resulting in very high clamping pressures, high energy efficiency and convenient automated operations. Forwell’s hydraulic pump units also feature an easy to adjust air pressure valve to effectively control the systems air pressure.
Pump Unit Diagram
