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Plate Design For Husky Manifold Systems - V6.0-English PDF
Plate Design For Husky Manifold Systems - V6.0-English PDF
Manifold Systems
6762104-6
Table of Contents
How to Use This Guide 3
Design package 4
Nomenclature 5
General Recommendations 7
Installing Manifold Pocket in Plates 8
Plate Bolts 9
Mold Interfaces 10
Backing Plate Cooling 11
Manifold Plate Cooling 12
Air Lines (if Valve Gate) 13
Cylinder Installation Details 14
Hot Runner Plate Alignment 15
Wire Channels and Electrical 16
Pry Slots and Drainage 21
Lift Taps and Platen Mounting 22
Nameplate 23
Tolerance References 24
UNIFY Specific Requirements 28
Questions 29
2
How to Use This Guide
This guide is designed to help a mold maker integrate a Husky Manifold System
into their plate and mold design. The guide is broken into three main sections:
3
Design Package
The following design items are provided by Husky with all manifold systems
3D Models
2D Print Package
• Plate Installations
• Assembly Electrical
• Gate Detail
4
Nomenclature
Supplied by Husky
Optional item for order:
•Locating Ring
Standard:
• Manifold
• Complete Nozzle Assemblies
• Nameplate
• Design Package
Optional
Option
p items for order:
• Electrical adaptor box
• Electrical Connectors and Wire Clamps
3D Pocket Geometry
Manifold Pocket
M
Manifold Hold
ld Nozzle Bore
N
Down Tap
C
Center Locating
IInsulator Installation
Thermocouple
Clearance Bore
Manifold Alignment
L
Locating Ring
Dowel Installation
Installation
5
Nomenclature
Typical Plate Split Options*
Husky Standard
“L”-Dimension
Cavity Plate
Manifold Plate
Backing Plate
*The remainder
of this guide assumes
Integrated Manifold and Cavity Plate
“Husky Standard”
“ML”-Dimension installation. However,
the basic steps are
unchanged regardless
Manifold/Cavity Plate of plate split option.
Husky calculates and
accounts for thermal
Backing Plate expansion in manifold
and nozzle design
**BL-dimension is to
the bottom of the
Manifold Pocket Spacer Plate nozzle locating bore
“BL”-Dimension
Cavity Plate
Backing Plate
6
General Recommendations
Plate Steel
Stainless steel is the recommended material for plate manufacture.
Recommended plate material properties:
• Minimum Yield Strength 640 Mpa
• Hardness 24-36 HRC
Examples of suitable steels types are listed below:
Manifold Pocket
Husky recommends machining a pocket into the manifold plate for the manifold. The
3D model provided by Husky includes all necessary geometry. A pocket profiled to
match the manifold:
• Allows close positioning of the plate Manifold
Manifold
bolts to the nozzle components, Pocket
minimizing plate deflection
• Provides superior structural support
for the mold and cavities Plate Bolt
Manifold
• Maintains a consistent air gap between Plate
the manifold and manifold pocket to
thermally insulate the manifold
from the surrounding plates
Cavity Numbering
Clear nozzle identification is necessary to ensure the
hot runner properly interfaces with the mold and that
the nozzles are mapped correctly.
7
Installing Manifold Pocket in Plates
Step 1- Adjust Plate Thicknesses
- =
- =
8
Add Plate Bolts
Why good plate bolting is important
The function of the plate bolts is to resist plate separation forces generated under normal
operation. If the forces are not balanced, they can bend (or “bow”) the plates which in certain
situations can cause:
• Premature wear of tightly-toleranced mold and hot runner components
• Leakage in manifold pocket
• Part flash
5mm
minimum
5mm 5mm
minimum minimum
3 Bolts
2 Bolts 4 Bolts
(Preferred)
180° Apart Surrounding
Force Triangle
9
Add Mold Interfaces
Step 1- Add Guide Pin Installations
Guide pins align the hot runner manifold plate to the cavity plate and protect nozzle tips
during lifting and handling (if hot runner built “hot half” style). Husky recommends guide
pin protrusion greater than or equal to 5mm [0.19”] longer than the nozzle length in order
to protect the tips
Interface Tap
10
Add Backing Plate Cooling
Plate cooling circuits maintain a uniform mold plate temperature and match thermal
expansion of the mold plates. To design a uniformly cooled mold, consideration must be
given to the cooling circuit layout, number of channels, lengths, and diameters.
Apply cooling to all drops.
Sample Layouts
Thermal Gate Examples Valve Gate Examples
Plug
16-Drop
Valve Gate
Acceptable
Locations Ø 6.0-6.5mm
5-7mm 5-7mm [Ø 0.24-0.26]
[0.20-0.28] 5-mm MIN
[0.20-0.28]
[0.20]
5-10mm
[0.20-0.39]
5mm
[0.20]
5-10mm
[0.20-0.39]
5-10mm
[0.20-0.39]
5-10mm 5-10mm
[0.20-0.39] [0.20-0.39]
Section A-A
12
Add Air Lines (if Valve Gate)
Step 1- Add Air Lines for VG Open and Close
A maximum of 36 drops can be on one circuit. Use a balanced design wherever possible
(same distance to each piston)
Air fittings on the Hot Runner should have an internal diameter of no smaller than
9.525mm [3/8”] and no larger than 15.875mm [5/8”]
Drop
Locations
10 ±0.1
[ .394 ±.004 ]
10 ±0.1
[ .394 ±.004 ]
A A B B
AIR CLOSE
CAN MOVE LOCATION
AIR CLOSE
AIR OPEN OF AIR LINES AS LONG
AIR OPEN AS CONNECTED TO
CAN MOVE LOCATION CYLINDER LINES AND
6 MIN
OF AIR LINES AS LONG MINIMUM CLEARANCES
[0.236]
AS CONNECTED TO RESPECTED
CYLINDER LINES AND
0.8 R 1.5
R [ .031 MINIMUM CLEARANCES [ .059] MAX 5 MIN
] MAX RESPECTED [0.197]
5 MIN 5 MIN
0.8 [0.197]
[0.197]
5 MIN
0.8 SHARP [0.197]
SHARP
SECTION B-B
SECTION A-A
EMI Cylinders
0.3 MAX CAN MOVE LOCATION
[ .012 ] X 45° OF AIR LINES AS LONG
3 MIN AS CONNECTED TO
[0.118]
CYLINDER LINES AND
0.8 AIR CLOSE
D 1.6 MINIMUM CLEARANCES
RESPECTED
1.6
0.8 ±0.2
R [ .031 ±.008 ] AIR OPEN
R [ 0.8
.031 ] MAX
SECTION C-C
0.5 MAX SHARP
[ .020 ] X 45°
0.3 MAX 0.8
M8 - 1.25 6H [ .012 ] X 45° R [ .031 ] MAX
16 DP MIN FULL THD
M8-1.25 6H
OR
5/16-18 UNC 2B
[5/16-18 UNC-2B] 1.6 1.6 2X [ 0.1 ±0.1
.004 ±.004 ] X 45°
15° ±2°
0.63 DP MIN FULL THD
0.8 0.65 ±0.1
[ .026 ±.004 ]
C C
2X R [ 0.4 ±0.2
.016 ±.008 ]
1.6
1.6
DETAIL D
14
Add Hot Runner Plate Alignment
The alignment dowel provides precise alignment between the manifold plate and the
backing plate. In doing so, the following are maintained:
Alignment must be
within 0.010mm
[0.0005in] Total Indicator
Run out (T.I.R.)
15
Add Wire Channels and Electrical
Power and thermocouple wires are typically routed to the electrical connectors within
wire grooves, providing the following benefits: Wire Grooves
**
Direct Mounted
16
Add Wire Channels and Electrical
“L”-Dimension
If plate split design is Husky Standard, the
following wire routing is recommended Cavity Plate
Manifold Plate
Backing Plate
Step 3a - Route Wires for Nozzles and any Manifold TCs on Clamp Face of
Manifold Plate
Wire
Channel
Step 4a - Route Wires for Manifold Heaters, Manifold TCs, Sprue Heater,
and Sprue TC on Injection Face of Manifold Plate
Wire
Channel
Chamfer
for Sprue Wires
17
Add Wire Channels and Electrical
“ML”-Dimension
If integrated cavity and manifold
plate, the following wire routing
Manifold/ Cavity Plate
is recommended.
Step 3b - Route Wires for Nozzles and any Manifold TCs on Injection Face
of Manifold Plate
If Husky is
notified wires
will be run
through pocket,
manifold pocket
geometry will
include features
to route wires
out of pocket
ØA
C B
E E
*This feature is for condensation drainage from the Add tap and wire
nozzle bore clamp
18
Add Wire Channels and Electrical
“ML”-Dimension
If integrated cavity and manifold
plate, the following wire routing
Manifold/ Cavity Plate
is recommended.
Backing Plate
Step 4b - Route Wires for Manifold Heaters and any Manifold TCs on
Injection Face of Manifold Plate
Wire
Channel
Step 5a – Add Wire Clip Installations (if using Wire Clamps see Step 5b)
Note: Wire clips are available from Husky
3.5 +/- 0.2
B C +/-0.2
14.7 12.7 WIRE
GROOVE +/- 0.2
21.1 19.05 2X R 2.5 +/- 0.2 DEPTH
27.4 25.4
40.1 38.1 R 1.0 +/- 0.5
19
Add Wire Channels and Electrical
Step 5b – Add Wire Clamp Installations (if using Wire Clips see Step 5a)
Clamps should be positioned as close to the nozzle as possible and at every bend and/or
interval of 120mm [4.7”]
Wire clamps for 25.4mm [1.0”] wire groves are available for Husky Manifold Systems
(Suggested quantity: 40 or 2 times the number of drops, whichever is greater)
25.4 ±0.2
[ 1.00 ±.008 ] (TYP)
120
R [ 12.7 ±0.2 [ 4.7 ] MAX
.50 ±.008 ] (TYP)
M6-1.0 6H
A A
12 DP MIN FULL THD
OR
[1/4-20 UNC]
0.5 DP MIN FULL THD
4.6 ±0.2
[ .18 ±.008 ] (TYP)
0.8 ±0.2
R [ .03
6 ±0.2 ±.008 ] (TYP)
[ .24 ±.008 ] (TYP)
±0.2
D [±.008]
(see table in step 1) Thermocouple or
Connector Access
THERMOCOUPLE Hole
OR CONNECTOR
8ACCESS HOLE
heaters and 8 TC’S max
per hole
SECTION A-A 20
[ .8 ] MIN
40
[ 1.6 ] MAX
20
Add Pry Slots and Drainage
Step 1- Add Pry Slots
Pry slots allow easier separation of the plates. Position pry slots between all plate
interfaces, near plate alignment features (guide pins, alignment dowels)
Pry Slot
Drainage Slot
21
Add Lift Taps and Platen Mounting
Step 1- Add Lift Taps
Add sufficient lift taps for handling individual plates as well as the assembly
Lift Taps
Direct Bolting
Clamp Slots
22
Add Nameplate Installation
59 ±0.2
[ 2.32 ±.008 ]
A
1.5 ±0.2
[ .06 ±.008 ]
122 ±0.2
[ 4.80 ±.008 ]
13 ±0.5
4X R [.5
A
±.02 ]
SECTION A-A
23
Tolerance Reference
Refer to 3D model for complete geometry
REFER
REFERTO
TO3D
3DMODEL FORNOMINAL
MODEL FOR NOMINAL
OH +0.03 / -0
[+0.001 / -0]
REFER
REFERTOTO3D
3DMODEL FORNOMINAL
MODEL FOR NOMINAL
OK ±0.2
[±0.008]
REFER TO 3D TO
REFER MODEL FORFOR
3D MODEL NOMINAL
NOMINAL
A +0.02 / -0
[+0.0008 / -0]
3 ±0.2
[ .118 ±.008 ]
R [ 1.5 ±0.2
.059 ±.008 ]
Insulator Type H K
32.01mm 20mm
Small Pitch
[1.26”] [0.78”]
44.01mm 30mm
Standard Pitch
[1.73”] [1.29”]
64.01mm 50mm
Large Pitch
[2.52”] [1.96”]
24
Tolerance Reference
Refer to 3D model for complete geometry
Center Locating Insulator
REFER TO
3D MODEL
FOR
NOMINAL
REFER TO
3D MODEL
FOR
NOMINAL
25
Tolerance Reference
Refer to 3D model for complete geometry
2X M6
2X M6 -x1.0
1.06H
6H
O [ 71.1 ±0.1
2.799 ±.004 ] [1/4-20
12 DP MIN UNC 2B]THD
FULL
OR
[1/4-20 UNC]
7 ±0.5
0.5 DP[MIN
.276FULL
±.020
THD ]
2X [ 42 ±0.1 R [ 0.8
.031 ] MAX
1.654 ±.004 ]
7 +/-0.5
[.276 +/-.020]
LOCATING RING
SPRUE BUSHING
26
Tolerance Reference
Refer to 3D model for complete geometry
Manifold Alignment
Dowel
8 +0.015
0
O
[ .315 +.001
-.000 ]
Manifold Thermocouple
Thru Hole
R [ 1.5
.059 ] MAX
O [ 12.7 ±0.2
.500 ±.008 ]
REFER TO 3D MODEL FOR NOMINAL
B +0.03 / -0
[+0.0001 / -0]
REFER TO 3D MODEL FOR NOMINAL
OA ±0.2
27
UNIFY Specific Requirements
UNIFY simplifies integration into the mold design.
Use this same guide, but only these steps:
1.) Install manifold pocket into plates
2.) Mold interfaces
3.) Manifold plate cooling
4.) Hot Runner plate alignment
5.) Plate bolts (Unique to UNIFY, see requirements below)
6.) Pry slots and drainage
7.) Lift taps and platen mounting
8.) Nameplate
The following are NOT required for UNIFY:
- Backing plate cooling
- Air lines in backing plate
- Air cylinder installation
- Wire channels
Plate Bolt
28
Questions?
Contact your Husky Project Engineer or the general inquiry numbers below
29