Ciject® Injection Equipment Ciject™ Four

CIJECT™ Four- RTM/VRTM Injection Machine

Designed specifically for high volume ‘Direct Infusion’ processes

Based on the proven Ciject metering system, the Ciject Four uses a double pump system to provide optimum output plus a level of process security during the infusion (each pump/mix head can be shut-down and flushed if necessary during the infusion)
The machine is designed for use with multiple In-Mould Pressure Sensors (IMPS)

The specification can be adapted and the control system can be configured to suit the particular parameters of the customer’s process.

The Ciject Four is currently used to manufacture the worlds largest production infused yachts

Features include:

  • General Features
  • Fully enclosed cabinet housing pumping and control systems
  • Fully automatic mixing heads feeding into auto-manifold
  • Skid mounted with castors, fork lift and gantry lift points
  • Resin Inlets with cam-lock IBC connectors, large-bore in-line filters and in-line catalyst/hardener filters for easy cleaning without disconnection
  • Low volume/high velocity mix-head and auto-manifold flush system to ensure simple and quick cleaning with minimum solvent use. 20 Litre non-pressurised solvent tank Pumping System:
  • Purpose designed resin and 316 Stainless Steel catalyst/hardener pumps for high reliability and simple maintenance. Modular for easy removal.
  • Seals designed and tested for service life in excess of 250,000 Kg of resin.
  • Two Independent Pump System - (2 resin & 2 catalyst/hardener) with the option to run independently
  • Mixed output up to 12Kg per min (dependant on resin viscosity) per pump. (note: total output from both pumps will depend on resin viscosity, air supply and downstream pipe-work restrictions)
  • Meter mix from 0.5% to 3.5% resin/catalyst ratio (polyester), 15% to 50% resin/hardener ratio (epoxy)
  • Drive cylinder heating/de-icing system
  • High flow cylinder silencers
  • Recirculation isolation valves to ensure 100% material flow to mixing head during injection
  • Control System:
  • 110-240V Industrial Omron Modular PLC with Integrated 5.7” Colour operator control panel .
  • Alarm beacon mounted on operator control panel
  • 'Uninterruptible’ power supply (UPS) with alarm
  • Intelligent machine program - prevents operator error (e.g. flushing while injecting)
  • Simple selection of infusion settings.
  • 4 input IMPS (Infusion Monitoring Pressure System) with user selectable full PID pressure control
  • Supplied with 4 x IMPS sensors (including 4 x 10m leads as standard)
  • IMPS calibration screen
  • Password protection for configuration and programming screens
  • Programmable input of injection volume, injection pressure, start and end catalyst percentages
  • Machine Operation Log Screen records up to 4000 machine actions
  • Selectable auto/manual flush sequence with adjustable flush alarm to warn operator if flush has not been carried out.
  • Adjustable machine stall warning/alarm
  • Moving average (10 second) and total average flow rates displayed during injection.
  • Automatic recirculation feature with user programmable timers.
  • Recirculation ‘flow test’ function to assist with viscosity/flow rate assessment
  • Monitoring
  • 24v Battery Backed UPS alarm
  • Alarm levels for vacuum
  • Vacuum ‘drop-test’ screen with configurable parameters and Green/Red Pass/Fail display output.
  • Catalyst/hardener check on pre-infusion screen
  • Injection Pause at pre-set level for IBC change
CIJECT™ Four Machine Options
Motorised Catalyst/Hardener Ratio system (MCR)
  • On-screen adjustment of catalyst/ hardener ratios
  • Automatic motorized servo control of catalyst level; linked to recipes.
  • Progressive catalyst injection for automatic control during injection of large components. Allows injection to start at one ratio and progressively increase during the injection to finish at a second ratio.
  • System uses high quality Omron AC servo motor system with digital rotary encoder for continual position monitoring and origin detection.
  • Auto origin function on machine start-up.
  • Radio Frequency Identification System (RFID)
  • RFID mould recognition system enables supervisor to program tag attached to mould. Operator scans tag which sets machine injection parameters. Allows unlimited number of moulds to be identified by the machine. Prevents incorrect injection settings.
  • Tags can be attached to mould, are self powered and are highly resistant to damage.
  • System removes the requirement for an operator to select the correct recipe and allows unlimited numbers of moulds to be instantly recognised by the injection machine.
  • Remote Pendant Operator Screen
  • 5” colour touch screen on 10m armoured pendant cable to enable remote machine operation
  • Includes additional Emergency Stop Button
  • On-board Vacuum System
  • 40m³/hr oil filled rotary vane vacuum pump
  • 2 mbar absolute vacuum level.
  • Mounted to machine skid with appropriate filtration.
  • Provision of a vacuum pump oil fill spout
  • Provision of 1-1/2” ‘Camlock’ vacuum outlet
  • DOL starter unit for start/stop operation of pump linked to screen control.
  • On screen alarms high/low level with adjustable set points
  • Absolute Vacuum level switch with digital display of vacuum level
  • Solid state switching circuitry (SSR’s) for pump operation with electrical overload protection.
  • Easy access front cover
  • In-line Resin Heater
  • Stainless steel in-line fluid heaters with 2KW thermostatically controlled cartridge type elements.
  • Solid State Relay switching reliable operation.
  • Connection to injection machine ‘pump run’ signal to prevent overheating.
  • PID temperature control with over-temperature alarm, adjustable from ambient temperature to 60°C.
  • Dual display output showing actual and pre-set temperature.
  • Note: Machine is rated for maximum material temperature of 80°C
  • Catalyst/Hardener Monitoring System
  • Unique system to monitor catalyst/hardener flow.
  • Alarms to warn of catalyst/hardener over/under pressure with user adjustable setting to warn of irregular flow during recirculation or injection.
  • Catalyst/Hardener and Resin Flow Measurement System
  • A more sophisticated flow sensing system.
  • Sensors available for both resin and catalyst/hardener pump out-puts.
  • Output displayed graphically and numerically on operator screen.
  • Outputs can be data-logged (if SCADA system is specified). *sensors to be specified to suit required mix ratio and output range.
  • SCADA data monitoring option
    To provide hardware/software capability for monitoring and communication to an external data capture system: System to include:
  • Citect run-time software and licence
  • Ethernet connection module Data capture can include:
  • Infusion start time, end time
  • Resin quantity infused (A, B, Total)
  • Resin flow rate (A, B, Total, Moving average)
  • Catalyst/hardener flow (A, B)
  • Catalyst/hardener % (A, B)
  • Vacuum Levels (on-board, external)
  • Resin Temperature
  • Pump temperatures
  • Incoming Air pressure status
  • Analogue IMPS sensor inputs (x 4)
  • Additional thermocouple inputs (x 6)
  • Screen input for event notification
  • Visual on screen representation
  • Historical data trending
  • Export to Microsoft Excel
  • Please Note: Customer to supply suitable PC with Windows 7 or above. (If required, Composite Integration can provide a quotation for a laptop. Please contact Composite Integration Ltd for more details) To facilitate setup the customer will also need to supply a Fixed IP Address and Netmask and Gateway Key
  • Vacuum level Monitoring - 2 inputs
  • Additional PLC Module and connections to enable monitoring of 2 external vacuum levels
  • On-screen display
  • Can be recorded and monitored if SCADA option if specified
  • Thermocouple input module - 6 inputs
  • Additional PLC Module to enable monitoring of up to 6 K type thermocouples
  • On-screen display with graphs
  • Can be recorded and monitored if SCADA option if specified
  • Spares Kit
  • Spares Kit containing all necessary service replacement seals for pumps and injection head
  • How to specify / order

    Machine Item/Option NotesPart/option Number
    Ciject Four Injection Machine
    Polyester version 0.5% - 3.5% ratio rangeXE-4000-01
    Epoxy version 2:1 100:12.5 - 100:50 ratio range XE-4000-02
    Epoxy version 1:1100:25– 100:100 ratio rangeXE-4000-03
    OPTIONS
    Motorised Catalyst Ratio (MCR) x 2
    03
    RFID

    04

    Remote Pendant Screen
    05
    On-Board Vacuum Pump
    06
    High-flow Head option07
    Inline PID Resin Heater
    08
    Catalyst Monitor (x 2)09
    Hardener Monitor (x2)
    Epoxy version
    10
    Resin and Catalyst flow metersPolyester/Vinylester version
    11
    Resin and Hardener flow meters
    Epoxy Version
    12
    SCADA data monitoring
    13
    Vacuum Level Monitoring (x2)

    14
    Thermocouple monitoring module - 6 input
    15
    Additional IMPS input module - 6 input
    16

    Ciject Four: Spares Kits
    Polyester option 0.5% - 3.5% ratio range
    XE-4000-SK-01
    Polyester with High Flow Injection Head option
    XE-4000-SK-02
    Epoxy option 100:12.5 - 100:50 ratio range
    XE-4000-SK-03
    Epoxy with High Flow Injection Head option
    XE-4000-SK-04

    To specify a machine configuration use the machine part number followed by the required option numbers separated by a hyphen.

    e.g. XE-4000-01-09-13 & XE-40000-SK-01 specifies a Ciject Four Polyester with Catalyst Monitoring option and SCADA option plus the appropriate spares kit.