Once again, the K 2019 in Düsseldorf, Germany, lived up to its claim to be the leading trade show for plastics technology. At least in the field of injection molding, there were exciting global innovations to see – if you looked closely.

Fig. 1. Smart Operation – the machine is operated with only four buttons (© KraussMaffei)

Injection Molding Trends at K 2019

Spritzgießen

Kunststoffverarbeitung: Verfahren

Schaumspritzgießen

Smart Factory

Energieeffizienz

Mikrospritzgießen

Mehrkomponenten-Spritzgießen

Spritzgießmaschinen, allgemein

Kunststoffverarbeitung: Maschinen und Komponenten

Spritzgießmaschinen

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Fließpressen

Handling, Handhabungstechnik für die spanende Fertigung

Automatisierungstechnik

Handling, Handhabungstechnik

Spritzgieß-Sonderverfahren

Spritzgießsimulation

Software

Simulation

Elastomer-Spritzgießen

Linearroboter für die Kunststoffverarbeitung

Industrieroboter

Montagetechnik

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Montage-Spritzgießen

Knickarmroboter

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Hybrid-Spritzgießen (Metall / Kunststoff)

Ressourcenmanagement

Produktion

Technical Excellence thanks  to Digital Assistance

After a year’s forced break of Fakuma, Wittmann Battenfeld is announcing the new servohydraulic SmartPlus machine as the highlight of this year’s trade show. It is claimed to be characterized by high economic and energy efficiency and repeat accuracy.

The new SmartPlus machine is equipped with the HiQ Flow software and the CMS Light condition monitoring system

Messe Fakuma

kunststoffe-international.com

Spritzprägen

Injection Molding Innovations In-House, Live and in Color

The area of application of cube molds has expanded to take in the production of technical parts. The new Allrounder Cube 1800 from Arburg with a clamping force of 1800 kN is providing the response to this trend. With its compact cube, this machine completes the portfolio of products at the lower end of the range.

At the heart of the cube machine is a compact cube designed by our partner Foboha which can be easily accessed from above. The rotation of the cube is powered servo-electrically and the horizontal movement relies on rack and pinion mechanisms

Arburg Expands Hybrid Cube Series

At Fakuma 2021, Engel is expanding its product range of intelligent assistance systems. The new iQ motion control allows Engel viper series linear robots a reliable early start combined with fully automatically optimized motion planning. Users benefit twofold: from a time-saving in teach-in and shorter production cycles.

iQ motion control operates with automatically optimized motion planning

Folientechnik (IMD, IML, FIM, u.a.)

Medizintechnik

Kreislaufwirtschaft

Optimized Motion Planning for Shorter Cycle Times

iQ motion control from Engel now allows reliable early start combined with fully automatically optimized motion planning. The assistance system has been part of the standard kit of all new Engel viper-type linear robots since October 2021.

If the robot travels into the mold area already during the mold opening movement, this can shorten the cycle time. The effect is particularly large in the case of parts with long cores, such as boxes

16:9

iQ Motion Control Brings the Injection-Molding Machine and Robot Closer together

Steuerungen (Hardware und Software)

A Production Cell with Fluid Movements

Over past months, many in-house workflows and development processes have slowed down and also changed. Nevertheless, time has not stood still, also not in injection molding technology. The debate and development have been shaped by two themes: digitalization and the circular economy. Below are some examples of developments and projects that underpin this trend.

Two displays are seamlessly integrated into the continuously 3D-formed instrument panel

Innovative Injection Molding in Times of Pandemic

Künstliche Intelligenz für die Qualitätssicherung

Industrie 4.0 für die Qualitätssicherung

Steuern, Regeln

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Biokunststoffe

Kunststoff Werkstoffe

Nachhaltigkeit

Umweltmanagement

Schnecken und Plastifiziersysteme

Machine Learning / Künstliche Intelligenz für die spanende Fertigung

Industrie 4.0 für die spanende Fertigung

Kunststoff-Recycling

Kunststoff-Aufbereitung

Lasermarkieren

Oberflächentechnik

Laserbearbeitungen

Inline- / Online-Messsysteme

Qualitätssicherung

Qualitätssicherung Kunststoff

There Is More beyond the Horizon

In the past, relying on vertical injection molding machines instead of traditional horizontal molding machines when it came to the production of 2-component molded parts was a common option for molding small and medium-sized parts but not for large size parts. But when the automotive supplier Eldisy was faced with parts in that segment horizontal injection molding machines proved to be an inaptly alternative as new vertical machine systems proved as more reliable and therefore more productive. In the Bavarian injection molding machine manufacturer LWB-Steinl, the company found a partner to enter this new territory.

A vertical gantry frame machine with two thermoplastic injection units injecting from above proves to be a “gamechanger” for the production of 2-component automotive components at Eldisy in the German Gardelegen.

Eldisy Switches to Vertical Machines for the Production of Large-Size 2-Components

KFZ-Zulieferer

Dienstleistungen

With a System Change  to New Competitiveness

At the Deutsche Kautschuk Tagung (German Rubber Conference), held at the end of June in Nuremberg, Germany, Dr. Boy GmbH & Co. KG presented itself with a liquid silicone application running on a Boy XS.

With this silicone unit as special equipment for the Boy XS the medical syringe plugs were injection molded. 

Boy Presented New LSR Application

At the introductory press conference for K 2022, Dr Thorsten Thümen, Senior Director Technology, outlined the company’s evolving strategic focus.

Senior Director for Technology Dr. Thorsten Thümen announces several premieres at K 2022.

Messe K-Kunststoffmesse

kunststoffe.de

Elektrische Antriebe für Spritzgießmaschinen

Antriebe

Elektrische Antriebe

New High-Speed Machine for the Packaging Market

Industry 4.0, lightweight construction, and combined technology – that is how one could summarize the current trends and challenges that have been the subject of countless injection molding developments during the past years. In their advance releases for the K exhibition, exhibitors clearly indicate that they are continuing along these lines. 

Injection Molding between Industry 4.0, Lightweight Construction, and Combined Technologies 

Verbundwerkstoffe / Werkstoffverbunde

Hybridtechnik

Reinraumsysteme / -technik

Trip to a Known Destination 

The announcements in the field of injection molding give the impression that the developments of recent years are continuing. These include the increasing digitalization of injection molding production, as well as highly integrated production cells that combine very different competencies. The spotlight shines not only on the machinery, but rather on optimum system solutions for integrating molds and individually configured peripheries in the digital and the real world. 

Fakuma 2018: Injection Molding Networked and Integrated 

ERP-Systeme

Treibmittel

Temperiertechnik

The Communicative Machine 

The new Reverse Cube developed by Foboha manufactures various components or multi-component parts from varying materials in one step and assembles individual parts into finished products independently from the cycle time using an integrated handling robot. The automated process improves quality, accelerates cycle times by up to 40 % compared to separate injection molding and assembly processes, and thus enables substantial productivity gains at lower costs.

Two thermally separated cube molds rotate in opposite directions at a 90° angle. Bottom: injection and cooling of component 1 (roller made of PP) and component 2 (female connection made of POM), staggered by 180°

Manufacturing and Installing Multi-Component Parts on a Two-Part Cube Mold

Montage

Werkzeugtemperatursensoren

Messtechnik

Sensoren / Messwertaufnehmer

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

Reverse Rotation

The Reversecube two-part cube mold is used to produce 60 million multicomponent parts per year on one production line and in the same process. The cycle times must be kept very short while at the same time maintaining stable processes and a high part quality. Sensor-based monitoring and automatic process control is therefore deployed in the form of Fillcontrol from Priamus. It consists of hot-runner balancing, viscosity and compression control as well as automatic holding pressure changeover.

The two halves of the Reversecube cube mold, in stacked arrangement, rotate in 90° steps. Bottom: injection and cooling component 1, analogous to the component 2 above, which is offset by 180°

Automating Injection Molding with Process Control – with the Example of a Cube Mold

Werkzeuginnendrucksensoren

Quality Assurance for Multiple Cavities

The aim of the project was clear: a highly automated turnkey system must replace several decentralized, operator-guided machines in order to be able to mass produce enclosures for a vacuum sensor with three inserted pins in a way that is smooth, automated and therefore faster than before in large-scale production, and error-free. The plastics processor Goerlich chose the machine manufacturer Arburg as a partner in its goal of achieving greater production efficiency.

All upstream process steps are integrated in a very small space: after the pins have been  punched out (right), a Scara robot places them in the correct position on a loading plate (left) so that the Multilift V robotic system can pick up 24 pins and insert them into the mold

At Goerlich, a Turnkey Plant Replaces Two Machines with a Vertical Clamping Unit

Automatisierungszellen

A Machine Strategy with  Extra Automation

As an all-inclusive injection molding supplier, the Wittmann Group will also use the Fakuma to showcase its latest innovations in automation and peripherals. In 2019, the Sonic range of robots replaced the high-speed UHS series robots. Sonic robots now come with a new design and are fitted with the latest R9 robot control system.

The Sonic 108 is optimized for fast parts removal in packaging and “pick & place” applications

Extensions to Several Robot Series

“At our trade show presentation this year, we are concentrating on the automation and digitalization of our injection-molding machines,” says Alfred Schiffer, marketing partner at Dr. Boy GmbH & Co. KG, explaining the activities planned for Fakuma. Three of the four applications at its own tradeshow booth – four more can be seen at its partners – are equipped with Dr. Boy’s own LR 5 linear handling unit.

In a fully automated production cell, a Boy 80 E hybrid, in conjunction with a Boy 2C S injection unit, will produce a wine pourer. Besides the energy-efficient servo drive, the hybrid machine is equipped with an optional electromechanical drive for the injection unit (eSP). The rotational and axial movements of the Servo-Plast unit are executed by two servo motors, completely detached from the machine hydraulics. The LR 5 handling unit removes the final two-component part and feeds it to an ultrasound welding unit, where a plastic decanting insert is welded into the pourer.

The biggest of the Boy injection-molding machines, a Boy 125 E with 1250 kN clamping force and only 5.22 m² footprint – demonstrates its effectiveness in producing stacking boxes. The stacking boxes, weighing 77 g, are injection molded in a cycle time of 17 s, and removed by the gripper hand of the LR 5 handling unit and fed to a printer. After marking, the stacking boxes are laid on an integrated conveyor belt.

A Boy 35 E manufactures dental caps from a 2-component liquid silicone. The vertical Boy LR 5 extremely compact telescopic handling unit takes the LSR caps from a four-cavity mold and places them on a conveyor belt. The four tie-bar machine is impressive for its large-dimensioned twin-platen clamping unit and comparatively inexpensive machine-hour rates. The removal handling device of the fourth exhibit, a Boy 25 E, is completely integrated under the safety cover. In the medical application, the side window parts of a respirator mask are removed from the mold by the picker and placed on a small conveyor belt that is also integrated under the safety cover. With a footprint of only 1.9 m², this automated system is among the most compact manufacturing cells at Fakuma 2021.

Dr. Boy GmbH & Co. KG  

https://www.dr-boy.de

On the Boy 35 E, the LR 5 compact telescopic handling system is use for a medical LSR application

2021-09-24 spritzgießen Boy

issue 07/2022

issue 06/2022

issue 05/2022

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