Distributor / authorized representative that deals with supply & delivery of polymer substance press (preforming machines) to industrial enterprises of Russia
Engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), Russia, has been successfully working with a number of Russian industrial enterprises at the local market for more than 20 years. Since the company’s founding, it has acquired immense engineering experience, market reputation, and has realized more than a hundred large-scale projects at the industrial plants in Russia. Our company is continuously in search of new business partners, who consider Russian market investment-attractive and want to boost their sales in the region, as well as expand their field of activities and enter a new international level.Contents:
We are interested in cooperation with the manufacturers of polymer substance press (preforming presses), who are looking for an official and reliable distributor to deal with supply & delivery of their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your preforming presses. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative in Russia, our marketing staff will carry out a market research in order to check the demand for polymer substance presses (preforming presses), will submit a market overview for polymer substance presses that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your preforming presses and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods, for various types of polymer substance presses (preforming machines) in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for preforming presses as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your (preforming presses into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of polymer substance presses (preforming presses). They will also provide necessary training and guidance for the customer’s personnel.
Polymer substance press (preforming machines). A brief description
Designs of the main types of presses. Kinds of drives and their description
A press is a static-action machine, the function of which is to process various materials by pressure. This type of machines can be classified according to the kind of drive they are equipped with:
- Mechanical press (used mainly in the tableting process as well as a part of some designs of automatic presses);
- Hydromechanical press (used widely in the locking assemblies injection-molding machines);
- Hydraulic press (operated actively in the field of such materials as thermosetting plastics and elastomers).
A detailed description of all the three press units will be presented in the following sections.
Mechanical presses. Description
The group of mechanical press machines includes:
- screw presses;
- crank-lever presses;
- eccentric presses;
- rotary presses.
The press machines, equipped with mechanical drive, are used in the process of manufacture of small-sized products. Such production is characterized by high pressing speeds, short holding under pressure and rather low index of force applied by the press. The power of such units can be increased, but it will inevitably lead to increase of the dimensions and metal intensity. In the industrial production, such presses are used as a rule for tableting of the raw materials and as a part of some automatic presses.
Hydromechanical presses. Description
The press machines are equipped with the hydromechanical drive, their construction also provides for a hydraulic cylinder and lever mechanism. Together, these elements enable a movable plate of the press unit to demonstrate higher movement speed with lower force applied at the beginning of the movement and, on the contrary, low speed and higher force applied at the end of the movement.
It should be noted that a hydromechanical press’s increase in power leads also to the increase of its metal intensity. In the industrial production, such presses are used widely in the locking assemblies of injection-molding machines.
Hydraulic presses. Description. Working characteristics
In hydraulic presses, the pressing force value is not dependent on stroke of the press. Moreover, there is no rigid linkage between the hydraulic circuit and the press. The hydraulic presses are mostly used in industries for processing such materials as rubber (elastomer) and thermosetting plastics. The presses of this type can be:
- vertical (the most common kind of the design; the main working cylinder is at the top or at the bottom of the press);
The hydraulic cylinders can be of two types: single-plunger and multiplunger. The press beds can be of column or frame types. Besides, there is an open-side press design. Some hydraulic presses are provided with a pressing out cylinder for removal of the product from the mold.
The main elements of a hydraulic press are press platen. When they are used in frame designs, they are called sliders; when they are used in column designs, they are called crossbars. The press is equipped with two stationary plates and one movable plate. As a rule, the bottom plate is termed as a press table. Usually, the die mold is located on the table (bottom plate) and the second half – on the movable plate.
The hydraulic presses, the cylinder of which is located at the bottom, have two or more openings for processing of rubber in removable die molds. This type of press can be classified according to the control method: automatic, semiautomatic and manual. As regards the method of the plate’s heating, the hydraulic presses are presented as units with steam, electric and induction heating. Physically, such machines can be carousel, rotary and daylight ones.
The hydraulic press structural elements move according to Pascal law: the working fluid is fed under pressure into the cylinder by a hydraulic circuit. This activates the plunger and causes movement of the movable plate. When the press is closing, a certain pressure level or the nominal force of the press Рn occurs. This nominal force is the main parameter of the hydraulic press equipment.
Pn = (p*Dp2/4)*Pf(g)
(p*Dp2/4) is the plunger area;
Dp is the plunger diameter;
Pf is the working fluid pressure.
The basic components of the hydraulic press structure are:
- power cylinder;
- returning and ejection cylinders;
- movable and stationary crossbars and sliders;
- Hydraulic circuit and hydraulic distribution valve.
The design of the hydraulic press is characterized by a number of parameters:
- speed of operative parts;
- value of the forces of action upon the material.
In addition to the nominal force, the effective force occurs in the hydraulic press. This force is calculated as follows:
Pe = k*S*Ps
k is the number of the cavities in the mold;
S is the area of projection of the article onto the horizontal plane;
Ps is the specific pressure of pressing, the technological parameter depending on the material
Press parameters determined by the article dimensions and mold
The geometry and dimensions of the future article and, as a consequence, its molds determine the selection of the press equipment. The following parameters are considered: dimensions of the table, slider stroke and maximum distance between the press platen and the slider.
The followings can be referred to the main components of the frame-type press:
- power cylinder;
- movable plate of the press;
- first and second halves of the mold;
- press platen.
The standard of manufacture of press equipment provides for the press platen dimensions and nature of the die stroke.
Thus, the press equipment can be selected subject to availability of the information on the dimensions of the article and mold. The dimensions of the mold shall not exceed those of the press platen.
Structure and assemblies of the press
When selecting the suitable design of the hydraulic cylinder, the structural diagram of the press, working pressure level of the fluid, equipment’s conditions of pressing and operation should be considered. The hydraulic cylinders are divided into two main groups: plunger cylinders (the cylinder body accommodates the plunger) and piston ones. The main elements of the piston cylinder are:
- hydraulic cylinder body;
The piston-type hydraulic cylinders move reciprocally while the design of the plunger-type models should provide for returning hydraulic cylinders.
The hydraulic cylinders are capable of operating under severe conditions. The bodies of such cylinders are manufactured by casting or forging. The hydraulic cylinder workpieces undergo thorough quality control. The forged cylinders are manufactured of carbon or low-allowed steel.
The cylinders can be either blind (rarely) or through. The hydraulic cylinder bottom is manufactured separately and fitted:
- on the thread by means of a shearing ring;
- on bolts;
- be welding;
- by pressing (in rare cases).
The hydraulic cylinder bore is made by:
- machine drilling;
- deep drilling with the help of a special fixture;
- trepan drilling.
The workpiece is bored by a tool that is called a multipoint head. The trepan drilling can be performed through the workpiece. In such cases, the workpiece is first drilled from one side and then from the opposite side with larger diameter. These cylinders are termed as staged ones and used for multipliers and hydraulic boosters.
If the cylinder is to be operated with water or water-based emulsion, its internal surface is chromium-plated to prevent corrosion.
The material for manufacturing of the hydraulic cylinders is selected with regard to the working pressure and plunger movement speed:
- the forged steel cylinders are used in cases when the pressure exceeds 18÷20 MPa and the plunger movement speed is >200 mm/s;
- the cast cylinders made of cast iron or thick-walled pipes are used at the working pressure level of up to 15 MPa and speed is <200 mm/s;
- the cast cylinders with larger diameter made of steel are used if the working pressure level does not exceed 32 MPa.
The geometry and dimensions of the cylinders are determined by GOST 6540-68.
The factors to be taken into account, while designing the hydraulic cylinders, include the nominal force of the press Pn, working fluid pressure level Pf(g) an the maximum allowable value of the cylinder material stretching [σs].
Pn = (p*Dp2/4)*Pg
A guide bush in the hydraulic cylinder is an adjacent part, the main function of which is to prevent the warp of the plunger during the movement. Thus, the guide bush ensures the movement of the plunger from the hydraulic cylinder strictly along the press axis. The bushes are often made of tin bronze or bearing cast iron.
Plungers. Plunger design
The hydraulic cylinder of the press is exposed to the forces created by the pressure of the working substance. This force is transmitted by the movable plate of the press, and as a result the plunger material works in compression. The device for fastening the plunger to the movable plate is determined by the place and method of application of the load.
Most of the designs of the press equipment provide for standard operation with stationary molds, arranged vertically in relation to the press axis. In this case, the plunger is fastened to the movable plate.
Using a threaded flange, a thread is made at the plunger’s end; and the flange is screwed onto the plunger end. The joint is made using bolts and pins.
The plunger is made of carbon or chromium-molybdenum steel or cast iron (rarely due to fragility). The plunger surface is hardened. The plungers are made hollow and can belong to two types:
- Opened outwards;
- Opened inwards.
The plunger and piston are located in the piston cylinder. The cylinder ensures the forward and reverse stroke. In this case, the structure works in compression and stretching, therefore the algorithm of calculation is as follows:
- calculate the structural members with respect to stretching and compression;
- check the transition portion of the plunger at the places of grooves and over the fitting for strength;
- check the plunger for stability.
Then the calculation is performed according to Euler formula.
Design of the press bed
The bed function is to provide for fixation and installation of all the press mechanisms in a certain position. Besides, it is a master link, which perceives the nominal pressure of the press. The press weight, vibration and dynamic loads are transmitted to the press foundation.
Depending on the design, the beds can be of:
- column type (have two, four or more columns);
- frame type;
- multiple-arm or double-arm type;
- jaw type.
The most common types of the beds are frame and column beds. The presses can have two or four columns. The frame press beds are made by casting or welding or can be of cast and welded design. The number of arms depends on the press purpose.
A bed of a two-armed frame press or of a four-column press is a closed spatial frame statically indeterminable, which is loaded by non-symmetrically applied forces and momenta. Thus, the press bed, equipped with the front working cylinder and flat static crossbar, is a closed statically indeterminable spatial frame.
The calculation of such a bed is complicated by the presence of stiffeners, holes and other elements on the frame. Thus, the solution of the problem in general terms is impossible. However, taking into account the fact that the most of the products have been made on the presses with static molds, they can be mounted clearly along the vertical axis of the press. In this case, the plates and molds of the press coincide with its geometric axis. When solving this problem, the following assumptions are made:
- The spatial frame is replaced by a flat one;
- The column is rigid with filling in the top and bottom crossbars;
- From the cylinder fitted with a supporting flange, the force is transmitted to the cross-bar as a combination of two forces applied at the centers of supporting half flanges.
In cases when the cylinder supports lean against the bottom, the rated pressure can be considered concentrated or distributed.
- To the bottom cross-bar, the force is transmitted as a load distributed uniformly over the length of 2/3 of the distance between the centers of the columns or width of the press platen.
- The top and bottom crossbars are replaced with bars.
The function of the press column is to connect the top crossbar with the bottom one; besides, the press column serves as a guide for the movable crossbar. The column surface consists of the following elements:
- column thread;
- sealing surface into the crossbar;
- working surface.
The most common material for manufacturing of the column is toughened carbon steel or chromium alloyed steel. The working surface of the column is grounded and chromium plated. The metric, buttress or special buttress thread.
Drives of machines and units for plastics processing
The key unit of the hydraulic system is a pump, which converts the energy of the drive into the energy of the substance flow. Mineral oils (turbine, industrial, spindle and other ones) are used as working fluids in the hydraulic drive systems. While sucking the fluid, the pump imparts some speed to it and feeds the same under pressure to the hydraulic cylinder or hydraulic motor via pipeline.
When selecting the suitable model of the pressure generator, the following factors should be taken into account:
- total energy efficiency;
- controllability and adjustability;
- service life;
- sensitivity to faults;
- noiselessness of operation.
At present, the hydraulic presses are equipped with the following drive types:
- pump-based drive without accumulator;
- individual pump-based drive with accumulator;
- group pump-based drive with accumulator.
Application of pumps in hydraulic presses
The following kinds of pumps are used as parts of individual hydraulic presses:
- gear pumps;
- vane pumps;
- screw pumps;
- radial-piston pumps;
- eccentric piston pumps;
- crank-plunger pumps.
Such mechanism as a pump-based drive with accumulator is used as a part of the group drive.
Selecting the pressure generator, on should consider such parameters as operation conditions, maximum flow rate and working pressure level (fluctuates within the range of 20 to 32 MPa).
Design and operation of various types of pumps, which are used in hydraulic presses
All kinds of the pumps, used in hydraulic presses and in processing of polymer materials, can be related to volumetric pumps or positive displacement ones.
In the positive displacement pumps, the working fluid is displaced from the working and suction chambers as a result of reduction of the volume of the chambers.
In the rotary positive displacement pumps, the fluid is displaced from the working and suction chambers as a result of displacers (gears, vanes, pistons, etc.).
The hydraulic motors convert the work of the fluid flow into the mechanical work of the output shaft (rod). A positive-displacement hydraulic motor is a rotary- or linear-motion motor. Positive-displacement hydraulic motors can be of the following types:
- actuating cylinders, that develop mechanic energy of translation motions;
- hydraulic motors, in which the fluid flow energy is converted into the mechanic energy of the rotational motion of shaft.
Most of the positive displacement rotary pumps and hydraulic motors are inversely mechanical as regards the principle of motion, so that the same units can be used as both pumps and hydraulic motors.
Gearboxes and polymeric equipment
Casting machines, injection molding machines
Extruders, extrusion lines
Gearboxes. Main description
Roll mills, calenders
Upon becoming the official distributer of polymer substance presses (preforming presses), our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (polymer substance press (preforming presses) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!