2020 CMS "BR5-1512S" Heavy Duty Vacuum Former The BR5 model is a vacuum forming machine that produces top quality parts out of thermoplastic sheets up to 10mm thick. With unmatched quality and reliability, the BR5 will ensure maximum productivity with an easy to use HMI (human machine interface). The BR5 is equipped with multiple solutions for sheet heating, mould changing, sheet management and cooling capabilities Max sheet size mm/in 1.560 X 1.260, 61.4” x 49.6” Maximum lower frame size mm/in 1.500 X 1.200, 59.0”x 47.2” Minimum lower frame size mm/in 500 X 700, 19.6”x 27.5” Max mould height mm/in 600, 23.6” Upper heater power kW 97 Lower heater power kW 97 Vacuum pump rate mc/h 1 X 100 Total power installed kW 220 Compressed air pressure Bar 6 Power supplyV 400 phases 3+N(TT or TN-S)+T Noise level Db(A) Leq 73 AUTOMATIC SHEET LOADER AND PART UNLOADER This system allows the operator to load and unload the sheet material both prior to the thermoform process and following part completion. The auto-center and management function will automatically move the sheet into proper orientation before advancing the sheet into the thermoform station. The loading trolling is controlled with vision and operated using high quality servo motors. Loader Positioning : Left NEW Sheet centering device The automtic sheet centering system mechanically aligns sheets prior to loading to ensure proper orientation in the machine. The Length of the sheet is measured using an optical sensor during the loading process to align the sheet perfectly for the thermoforming process. Access to the loading area is allowed during a work cycle enabling the operator to load and unload without stopping production. PLUG ASSIST Advanced plug assit uses brushless servo motors allowing operator control of feed speed through the control interface. System allows storage of parameters to ensure accurate and repeatable assist. System is equipped with an electromagnetic brake and security system that locks motion of positioning axis in case of ESTOP or powerloss. TOOTHED BLADE – 100% PARAMETER SHEET CLAMPING Optimal clamping is achieved between the plate and frame with a toothed blade and sealing gasket. This system ensures the sheet is completely secured during the thermoforming process. AUTOMATIC ADJUSTMENT OF CLAMP FRAME DIMENSION (LONGITUDINAL BEAMS CENTER DISTANCE AND TELESCOPIC BEAMS) The frame is made of heavy gauge steel to maintain its rigidity. Using brushless servo motors the frame size adjust to the proper dimensions. This system allows for more flexibility with mould design and sheet management. When the sheet thickness varies, no adjustment is required. Servomotors control the clamp frame dimension continuously. The control cycle is automatic and can be saved in programs. AUTOMATIC WINDOW FRAME (REDUCTION STROKES X-1000 MM, Y-500 MM) The automatic window frame allows the flexibility in the thermoforming process. Dimensions are controllable up to 1000mm in X and 500mm in Y. The window plate is made of aluminium and it is complete with copper pipes inserted into the plates for complete thermostatic control. THERMOREGULATOR REDUCTION PLATE Thermoregulator unit controls temperature of Plate up to 95 degree C using water. AUTOMATIC HEATER MOVEMENT BY SERVOMOTOR Heating elements are managed with two servomotors creating a “reciprocating” motion (patented) designed for optimal heat distribution on the entire surface of the sheet. Motors are backed up with a battery set to safely move the heaters into the start position in the event of a power loss. HALOGEN LAMPS (SPEEDIUM) The heaters are equipped with halogen lamps (800/300 W), controlled individually both in percentage and in power, which allow to reduce heating times and to maintain a low temperature while the machine is working; thereby the productivity increases. The heating elements are wired with nickel cables. GLASS-CERAMIC COVER Bottom heater is equipped with glass-ceramic covers. OPTICAL PYROMETER The optical pyrometer controls the sheet temperature. MOULD PLATE The mould plate is equipped to control the temperature of the mould with no. 2 plugs. The movement of the plate is managed with an electronic gantry by means of two servomotors. THERMOREGULATOR BY WATER FOR MOLD Thermoregulator by water with high cooling capacity. Heating power: 9 kW/280°F QUICK MOULD CHANGE SYSTEM The quick mould change system provides the operator a quick and easy way to change the mould to maximize production and minimize change over time. The plate is easily removable by a mechanical lifting system inside the machine structure. Once fully lifted for extraction a trolley is locked into place and the operator can easily slide the mould plate onto the trolley by way of roller bearings on the trolley. Once the mould is removed and a new mould plate is introduced to the machine it is automatically centered. TROLLEY EQUIPPED WITH PNEUMATIC MOULD LIFTING SYSTEM The mould trolley is equipped with a pneumatic system which lifts up the mould by four screws (pneumatically controlled) in order to allow load and removal of trolley by forklift. VACUUM PUMP 165 MC/H CAPACITY The system consists of two oil blade pump (165 mc/h each). Vacuum and vacuum management is equipped with three modes in order to achieve proper cycles and quality. FORMED PART COOLING Centralized Formed Part Cooling Formed part cooling occurs by high capacity and adjustable (in all the directions) draw holes. A big fan installed on the floor supply the air at the draw holes. PYROMETER FOR FORMED PART COOLING CONTROL Positioned on the machine, above the part, the pyrometer takes thermal readings of the thermoformed part and controls the temperature during the cooling process. PROPORTIONAL SYSTEM Both vacuum and air flow functions are controlled by proportional valves. These valves allow for continuous control of pressure and flow rate. The values are saved for future part programming. The pressure chamber for managing pre-stretch is operated by an electro fan and not compressed air. The controllable electro fan allows for better air volume management. SENSOR FOR PRE-STRETCH BUBBLE CONTROL The photocell measures the pre-strech bubble height allowing the controls to automatically optimize airflow. Pre-Stretch optimal height can be fixed at set up and managed automatically by way of the photocell. SHEET SAG CONTROL The pressure system, airflow, optical photocell and heating elements work together to create “Zero Sag” during the heating phase. Zero Sag allows for the highest quality of thermoformed parts. SHEET SAG SAFETY SYSTEM An emergency photocell (laser), fixed on the machine body, ensures the lower heater safety. An emergency photocell, fixed on the movable frame above the transversal bars, ensures the upper heater safety. MACHINE BODY COOLING An automatic exhauster allows the machine frame to be cooled at the same time the mould cooling is in process. In this way machine distortions and mould overheating are avoided. FRONTAL DOORS Frontal doors provide a barrier for protection and also make mold management very easy. The doors are equipped with proximity switches to ensure operator safety during production. SAFETY A laser curtain is installed in front of the machine and is equipped with lateral covers for both laser and operator safety. All other access doors are also equipped with proximity switches for operator safety. PLC AND CONTROL SYSTEM The machine is managed by a PLC controller and touch screen interface. All elements of the Thermo process can be addressed from the control panel. The system allows for heating parameter storage in order to reduce the reoccurence of errors. The storage is possible on both hard disk or USB. Diagnostic features allow operator to see any anomalies in the cycle visually on the control panel. The operator inteface also allows for the operator to run a complete manual cycle. The system allows for online access for trouble shooting by a CMS technician via the 24hr hotlineand comes standard with Industry 4.0 capabilities to ensure proper management visibility into the production process. ELECTRICAL CABINET A separate electrical cabinet in rigid anodized aluminum structure is located beside the machine, dust insulated, in which all the main electrical and electronic parts for the machine control are installed. Protection level: IP 54. An air conditioning system keeps the internal temperature below 35 degrees C (95 degrees F.) The electrical cabinet is located on the right side of the machine with respect to the loading position, unless otherwise noted under the included equipment section. OPC-UA Machine connectivity using Industry 4.0 standard OPC-UA protocol makes it possible to read process parameters, machine status, alarms and productivity values. OPC-UA also allows real-time messages to be sent to operator(s) to optimize production capacity. INSTALLATION DATA All CMS machines adopt the neutral wire connection to avoid any electrocution risk for the operator. Voltage: 480 volts, 3 phases, 60 Hz. (or as specified by the customer). The voltage specified must be within +5% to –5% of the nominal line voltage. The machine is supplied with a UL transformer with the primary voltage as specified by the customer and the secondary voltage of 400 volts, 3 phases. 60 Hz. The machine can be connected (either directly or by means of a transformer) to the TN (TN-C; TN-S) supply systems. If not, the customer shall provide for a secondary, earthed star-to star transformer, placed on line (before) the machine control board. Since the electrical board contains equipment that may generate a continuous component of the fault current, we suggest to use a delayed-action (selective) device type A, or better type B if available, with 0.3 A adjustable differential current, for differential protection (not compulsory for the machine). MACHINE COLORS CMS standard colors: Light Grey RAL 7035 and Dust Grey RAL 7037 MACHINE COMPLYING WITH CE STANDARDS The machine complies with the applicable parts of the following Directives:  Directive 2006/42/CE  Directive 2014/30/EU CMS machines are designed and manufactured in compliance with the European Directives cited in the Conformity Certificate released with the machine documentation. The User’s and Maintenance manual is the cornerstone for all information related to machine use and maintenance, and therefore to the operators’ safety. For this reason, the customer shall acquaint himself with the various chapters (among which Allowed Usage, Residual Risks, etc.) In case of machines bound for the American market please note what follows:  From the electrical point of view the CE adopts the European and international ISO EN 60204-1 regulation, that mostly differs from the corresponding UL, CSA;  From the visual warning point of view, the CE does not accept the usage of warning signs, but the content of the User’s and Maintenance Manual applies. The CE conformity certificate testifies CMS’, the supplier’s, “good faith” to comply with European legally binding laws. Checking the regulations in force in non-European countries is the customer’s liability.