樹脂材料の多様化と計量・配合工程に求められる役割

材料・配合条件が複雑な成形現場

近年のプラスチック成形現場では、製品の高付加価値化や軽量化、さらに環境配慮への対応を背景に、使用される樹脂や配合条件がますます高度化、多様化しています。バージン材に加え、マスターバッチや粉砕材、各種添加剤などを組み合わせた複合配合が一般化するなかで、安定した品質をいかに再現するかが、成形工程における重要なテーマとなっています。

成形品質のばらつきや成形不良の要因は、金型や成形条件だけに限られません。材料の計量誤差や配合の不安定さが、品質トラブルの引き金となることもあります。

計量・配合のズレが招く品質とコストへの影響

特に、ポリプロピレン（PP）やポリアミド（PA）といった材料にマスターバッチや粉砕材を配合する場合や、ポリブチレンテレフタレート（PBT）、ポリカーボネート（PC）などのエンジニアリングプラスチックを扱う場合には、わずかな計量ズレや過不足が、

といった、コストと品質の両面で大きな損失につながることがあります。

さらに近年は、サステナビリティや資源有効利用の観点から、「必要な量を、必要な比率て、正確に使い切る」という考え方が、成形工程にも強く求められるようになっています。

材料を余らせない、やり直しを発生させない、不要な再計量や廃棄を出さない。こうしたムダを生まない成形工程を実現するためには、作業者の経験や勘に頼るのではなく、誰が使っても再現性の高い計量・配合の仕組みが欠かせません。

こうした課題に対して、質量式配合装置がどのように役立つのか。使いやすさや安定運転を支える具体的な特長についてご紹介します。

Features of the JCW2-i

1. A weighing system that reduces material waste by approximately 99%!

◆ Supply optimization software

In terms of material mixing, there are many changes in materials, such as in molding with many varieties and small lots.
When the material is finished or just before changing materials, the remaining material in Measuring hopper, charge hopper, and hopper above the molding machine
The large amount of waste of mixed materials was a problem.
The required amount can be measured, making it possible to reduce material waste.

[The mixing device calculates and adjusts the amount of material per batch according to the amount of material used by the molding machine!]

Step 1: Compare the processing capacity of the molding machine and the measuring capacity of the blending equipment.
Step 2: If the computing power is excessive, reduce it to an appropriate value.
Step 3: After charge hopper outputs a request signal, Measuring hopper starts weighing. (This is when "Measuring hopper no standby mode" is selected.)

◆ End warning signal

[After calculating the required amount based on the number of remaining shots, the measuring operation will stop!]

Step 1: Set the number of remaining shots.
Step 2: Calculate the required amount based on the remaining number of shots you set.
Step 3: Calculate the standby amount for the weighing Measuring hopper, charge hopper, and hopper above the molding machine.
Step 4: Subtract the waiting amount from the required amount to calculate the remaining number of weighings.
Step 5: After the remaining number of weighings have been completed, the weighing operation will stop.

2. Achieving a highly accurate supply system by creating a "supply system where the machine thinks"!

When the initial setting of the drop amount is not appropriate or when changing the material, the measurement value variation caused by the error caused by neglecting to change the drop amount has been considered a problem. The JCW2-i's unique control system enables automatic, quick and accurate measurement.

◆ Three-stage supply

[Three-stage supply enables high-speed weighing and shorter supply time compared to conventional two-stage supply.]

Step 1: Change the head amount based on the moving average value of the actual measured head amount.
Step 2: Change the weighing switch value to shorten the overall calculation time so that the medium and small weighings can be calculated within the target weighing time.

Commentator

When raw materials change and their properties change, the JCW2 will measure and supply the optimum amount to suit the material.

This means there's no need to worry about checking the weight or manually changing settings!

3. Easy to use, anyone can operate it!

The interactive settings make it easy for anyone to operate.
The controller can measure and display in increments of 0.1g.

4. Main units and other parts are extremely easy to maintain!

The remaining material is discharged from the bottom of the hopper, and the adhering powder can be brushed off from the top to the bottom.
Yes, that is possible. In addition, Measuring hopper and screw of the main unit can be easily attached and detached.
This contributes to easy maintenance.