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ADVANCEMENTS IN INJECTION MOULDING

ADVANCEMENTS IN INJECTION MOULDING. DHAYA I TRUMAN SALES & MARKETING ENGINEER LARSEN & TOUBRO LIMITED. GENERAL TRENDS IN INDUSTRY (PRODUCT DESIGN & MANUFACTURING ). Weight reduction as industry culture Higher level of functional integration Higher levels of safety

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ADVANCEMENTS IN INJECTION MOULDING

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  1. ADVANCEMENTS IN INJECTION MOULDING DHAYA I TRUMAN SALES & MARKETING ENGINEER LARSEN & TOUBRO LIMITED

  2. GENERAL TRENDS IN INDUSTRY (PRODUCT DESIGN & MANUFACTURING ) • Weight reduction as industry culture • Higher level of functional integration • Higher levels of safety • Economic & Operational efficiency • Evolution of revolutionary processes • Short development / life cycles • Exciting new applications • Technology induced cost efficiency • Built in re-cycle ability

  3. TRENDS - PLASTICS TECHNOLOGY • Optimum utilization of resources( machine / mould) • Reduce scrap / rejects • High precision • increase complexity of molding geometry • Energy efficiency • Optimum Space utilization by process integration • Shorten logistics chain (production cell) • Inj. Moulding going beyond Plastics

  4. WHY NEED FOR ADVANCEMENT? • Requirement for higher productivity • Requirement for better quality • Requirement to mould more intricate parts • Requirement to mould more critical materials • Requirement for stable process • Requirement for special applications • Requirement to make machine trouble free • Lower energy consumption

  5. HIGHER PRODUCTIVITY … • Faster movements • Precise control of position • Good control of speed • Good control of pressure • More parallel operations

  6. FASTER MOVEMENTS … HIGH SPEED 5 POINT TWIN TOGGLE SYSTEM • ROBUST & SWIFT • UNIFORM FORCE DISTRIBUTION • LESS OIL REQUIREMENT • ACCURATE • BETTER MOULD SAFETY • LONG LASTING • LOW ENERGY CONSUMPTION

  7. PRECISE CONTROL OF POSITIONS LINEAR TRANSDUCER

  8. GOOD CONTROL OF SPEED AND PRESSURE … • FAST • ACCURATE • QUICK RESPONSE • RELIABLE • LOW ENERGY CONSUMPTION • MORE PARALLEL OPERATIONS

  9. MORE PARALLEL OPERATIONS …

  10. MORE PARALLEL OPERATIONS … • Ejector operation parallel to mould movement • Hydraulic core operations parallel to mould movement • Dosing parallel to mould movement

  11. MODERN MANAGER’S NEED ON THE MACHINE • Higher productivity • Online Quality Assurance • Less dependency on manpower • Reduced set-up time /Quick Startup • Generate MIS Data (Management Information ) • Downtime logging • Energy Monitoring

  12. PRODUCT QUALITY BY BETTER PROCESS CONTROL • Repeatability • Easy to optimise • Accuracy • Monitoring system

  13. PROCESS MONITORING … PROCESS CAPABILITY - SPC GRAPH

  14. PROCESS START-UP

  15. PROCESS OPTIMIZATION 1)Cleary input as a table 2)All necessary setting parameters for injection with one view 3)Indication of set vs. actual values

  16. AMENDMENT REPORT LOG

  17. LATEST TYPES OF MACHINES • Hydraulic machine with SYDFEE pump • All Electric machines • Hybrid machines

  18. PLC Qsignal Psignal Fixed displacement Pump system

  19. HYDRAULIC MACHINE WITH SYDFEE PUMP

  20. RELIABLE HYDRAULICS • FAST • ACCURATE • QUICK RESPONSE • RELIABLE • LOW ENERGY CONSUMPTION

  21. ADVANTAGES OF SYDFEE PUMP • Close loop for FLOW and PRESSURE • Precise reproduction of set parameters • Energy efficient - Power savings • Faster response - Accurate process control • Switch-over to hold-on based on hydraulic pressure • Simple circuitry • Oil temperature rise minimised

  22. EXCELLENT PLASTICISING UNIT WITH GOOD SCREW DRIVE • HEAVY DUTY • HIGH POWER HYDROMOTOR • HIGHER PLASTICISING CAPACITY • BETTER HOMOGENITY • ACCURATE METERING • CONSISTANCY

  23. Metering zone Compersion zone Feed Zone SCREW

  24. Barrier start Barrier end Barrier zone Intake zone eE t hE Barrier screw

  25. Single-flighted screw section Melt film Barrel wall 2-flighted screw section Passive flange Active flange Melt film Barrel wall Passive flange Active flange Melt vortex Solids bed Screw flight Solids bed Melt vortex Screw flight Melting Characteristics of Different Screw Concepts

  26. INTELECT – ELECTRIC MACHINE

  27. M Injection by motor 1 (linear movement) Metering by motor 2 (rotary movement) Injection and metering

  28. High-torque motor Opening and closing movements are powered by high-torque motors

  29. Ejector system

  30. Collision case Protection range Master curve Piston speed 15 mm Offset curve Collision point Kraftverlauf Kolbengeschwindigkeit force travel Mould protection system

  31. ADVANTAGES OF ELECTRIC MACHINE • Short cycle times • High precision/position accuracy • Fast response in acceleration & deceleartion • Torsion free drives/ Mould safety • Reinforced platens/ high performance screws • Parallel motions • Energy efficiency • Low noise level

  32. Mould Movements Metering/ Plasticising Ejectors Nozzle Unit Core Pull Injection MOVEMENTS ON AN INJECTION MOULDING MACHINE

  33. Hydrostatic gear for opening and closing Servomotor Cores Variable capacity pump with central accumulator THE NEW DRIVE CONCEPT: ERGOTECH EL-EXIS S

  34. CUSTOMER BENEFITS: REDUCED ENERGY CONSUMPTION • Electric drive for plasticising (main energy consumer) • Electric drive for mould movement • Reduced supply for pump station(15 kW instead of 45 kW) • Deceleration energy of mould movement used for plastcising

  35. 100 % 90 % 75 % 50 % 50 % Fully Electric Machine Conventional Fast M/C with Constant Delivery Pumps Fast M/C with Constant Delivery Pumps + E-Drive Variable Delivery Pump Hydraulics + Electric Screw Drive ERGOTECH EL-EXIS S ENERGY CONSUMPTION

  36. TYPICAL ADVANTAGES OF DIFFERENT MACHINE CONCEPTS electric drive hydraulic drive - lower energy consumption - higher precision - no oil leckage - lower noice level - higher dynamic - higher performance (injection) - easier for linear movements - one motor for different functions (ejector, cores, ..) - lower installed energy - lower invest - smaller space requirements - integration to modularity - ...

  37. TRENDS – MATERIAL TECHNOLOGY • Property potential of polymers far from being exhausted • Glass and metal substitution at its peak • Polymers competing each other • MIM/CIM gaining grounds • Use of Natural Fibres • Thermosets back on the growth track • Nano technology as a sunrise technology • Easy flow/fast cool properties for moulding efficiency

  38. Stack moulds • Multi axis indexing moulds • Moulds for In-mould labeling and MID • Cavity count at its peak • Complex Hot runner • High mould rigidity TRENDS- MOULD TECHNOLOGY

  39. THIN WALLED TECHNOLOGY • High transparency • Increased impact resistancy • Reduced shot weight • Very low cycle times • High injection speed • Rigid Moulds and platens • Parallel functions ( machine)

  40. THIN WALLED TECHNOLOGY PP (CD-Cover) Cycle time : ca. 5.5s Cavities: 4+4 STACK Machine: Ergotech 300-2300 El-EXIS S • High L/T ratios • Tougher materials • High cavitation • Large volumes • LEAD TO MACHINE COMPLEXITY

  41. TECHNOLOGY LEAPS • Combination of materials • • Metal /plastic/alloys • • Thermoset / thermoplastic / elastomer • Combination of process • • Injection and compression molding • • Injection molding and surface finishing tech • • In mould decoration • Reduction or integration of functions • • Direct compounding • • Online fabrication • Revolutionizing machine design • • All electric/hybrid technologies • • On line assembly/ quality control

  42. TRENDS - NEW APPLICATIONS Stimuli for new applications • New / modified plastics • New / extended processing methods • Fresh potential through new application developments • Economic efficiency / costs • Increasing / charging demands on existing applications

  43. IN-MOULD LABELING TECHNOLOGY

  44. IN-MOULD LABELING WITH PRINTED FILMS HPF / film moulding PC-film

  45. PRACTICAL EXAMPLES OF IN-MOULD DECORATION (IMD)

  46. APPLICATION FOR IN-MOULD DECORATION (IMD) IN “AUTO INDUSTRY”

  47. TYPICAL MID APPLICATIONS

  48. MULTI COLOR / MATERIAL TECHNOLOGY

  49. MULTI- COMPONENT / MULTI- COLOUR PARTS

  50. MULTI COLOR COMPONENTS FOR MOTOR INDUSTRY

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