IMC System– Improved Mechanical Compensation System — important improvement of the compensation system of isostatic plates by Molde Azul.
Improving the final quality of ceramic products and achieving savings in the pressing process are major objectives of Molde Azul. In 2016 Molde Azul introduced isostatic upper plates, a pressure compensation system through the application of an oil hydraulic system that prevents differences in compaction between punches, thus achieving uniformity of pressing in the different cavities.
Currently, the company goes further in the evolution of this concept with the launch of IMC System, (Improved Mechanical Compensation System), an important improvement in the compensation system for these plates, developed internally by the technical team of Molde Azul.
Hydraulic compensation can have oil leaks in the hydraulic circuit connecting the different cavities, which can cause production stoppages and efficiency losses. The new IMC System improves plate compensation by incorporating a mechanical system into the hydraulic system.
On the other hand, mechanical compensation is a more reliable system with lower maintenance costs, therefore, with this new update it is possible that the mechanical system works and supports greater effort when transmitting the pressure between the different alveoli. For this reason, the durability of IMC System isostatic plates is increased to the point that they can be compared to non-isostatic top plates, without losing the great production benefit of pressure compensation provided by IMC System isostatic top plates.
The new IMC System is composed of the improved hydraulic system and the new mechanical system. The mechanical part is designed to play a major role in pressure compensation. This new design consists of a series of ball joints that limit the movement provided by the hydraulic system, and in turn support the high pressures in which the isostatic plate works.
IMC System upper plates also have the important characteristic of being able to be electropermanent, that is, the fixing system of the upper punches to the upper plate is achieved by applying an electrical impulse. As it is a single impulse, the upper plate does not have to be connected to direct current during the working time, avoiding possible accidents due to loss of current that could cause the demagnetization of the upper punches and their fall (possible damage to operators who work in the press, the mould and the upper punches because of their fall). When you want to change an upper punch or more, the press operator has the option of individually selecting which one or which he wants to change, and apply another electrical impulse to polarize said punch holder and change it in complete safety.
Therefore, the new IMC System allows MOLDE AZUL customers to have important competitive advantages, among which we would highlight:
- Reduction in the number of calibers in production, which translates into greater production of premium quality material.
- Higher and deeper reliefs- which allows our design department a greater creative freedom.
- Greater pressing balance in all mould cavities.
- Reduction of other pressing problems such as tile mismatches
- The maintenance of the plates is comparable to conventional non-isostatic top plates.
- As it is an electropermanent top plate, greater security and protection against accidents caused by loss of electrical current is achieved.
- Versatility when changing the upper punches, since worker can select punches individually to apply the electrical impulse needed to polarize them.
The evolution of this product is the result of the process of innovation and continuous improvement of the R + D + i department of Molde Azul. The company is committed to continuous research in order to improve processes, reduce production costs and offer greater competitive advantages for its customers.