Smart assistance systems are paving the way for self-optimizing production. Automatic correction of quality-relevant parameters is already reality for individual phases of the injection molding process. At K 2019, Engel presented the iQ weight control with the example of a recyclate application for the first time.

With the manufacture of thin-walled sample parts, Engel presented the  iQ weight control smart assistance system at K 2019, with a recyclate application for the first time

The iQ weight control Assistance System Ensures Higher Process Stability

Werkzeuginnendrucksensoren

Messtechnik

Sensoren / Messwertaufnehmer

Spritzgießen

Kunststoffverarbeitung: Verfahren

Steuern, Regeln

Software

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Kunststoff-Recycling

Kunststoff-Aufbereitung

Messgeräte für Viskosität

Werkstoffprüfung

Kunststoff-Rezyklat

Kunststoff Werkstoffe

Opening up a Broader Range of Applications for Recyclates

In an online survey, representatives of the plastics industry formulated their expectations toward the Plastics Innovation Center 4.0 (PIC 4.0).

Wordcloud generated from the answers to the open question concerning the most important use cases for PIC 4.0

Part 5 of the Series: Practical Demonstrators for the Plastics Innovation Center 4.0

Industrie 4.0 für die Qualitätssicherung

Messdatenerfassung und -verarbeitung

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Prozessoptimierung

Prozessmanagement

Machine Learning

Datenanalyse

Automatisierungstechnik

Focus on the User Benefit

Phase-unifying cavity pressure control reduces process fluctuations, as shown by the example of post-consumer recyclate processing.

The PCR storage box was very popular with visitors.

16:9

Phase-Unifying Cavity Pressure Control for PCR Processing

Laserbeschriftung

Oberflächentechnik

Laserbearbeitungen

Mess-, Steuer- und Regelgeräte

Qualitätssicherung

Qualitätssicherung Kunststoff

Präzisionswaagen

Mechanische Messtechnik

Precise Process Control with InjectiX

The “HiQ Melt Premium” assistance system is an indicator of melt quality and reduces the reject rate through interaction with the IM machine operator.

Software helps machine operators select the most resource-saving  settings.

Steuerungen (Hardware und Software)

Spritzgießmaschinen

Kunststoffverarbeitung: Maschinen und Komponenten

Mahlen

Resource-Saving  Assistent

Asset administration shells form the basis for interoperable production. In the InterOpera project, four submodels were developed for injection molding.

Asset administration shells attribute asset types (here: injection molding machines) with standardized properties and characterize the instances with specific values.

Big Data

The Interoperable  Injection Molding Production

Engel has used its new “e-connect” strategy to expand its existing customer portal into a scalable digital ecosystem.

Networked into the future with digital solutions from Engel.

Vernetzung / Cloudlösung für die Kunststoffverarbeitung

One Platform for All Injection Molders

A tool logbook on paper is often not to hand just when you need it most. Or it is incomplete, since it is time consuming to keep the information up to date. A cloud-independent, electronic tool log, which is directly integrated into the tool could make all the relevant data available directly.

The installed ImPro module in use on a demonstrator tool under production conditions 

The Electronic Tool Logbook as a Combination of Operating Manual and Check List

Papierlose QM-Dokumentation

Qualitätsmanagement

Dokumentationsmanagement

Werkzeugkonstruktion

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Werkzeugüberwachung

Toolmanagement

Mobile Datenerfassung

Logistik

Lagertechnik

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Werkzeug- und Formenbau

Fernwartung / Ferndiagnose

Instandhaltung

Dokumentenmanagement, CAQ

Data Management at the Tool

Paint bucket or A-pillar finisher? In our thoughts and attribution of value, packaging items and high-tech components often represent opposites. Yet the two can complement one another – when you look at used packaging as a valuable raw material. At the fair, KraussMaffei will be showing the concept for a closed material cycle and is making plastics processing sustainable through this.

First a bucket or another plastic product, then raw material for further processing: the shredded post-industrial material

At the K, KraussMaffei Will Be Showing the Cycle from Product to Upcycling  to a New Product

Messe K-Kunststoffmesse

kunststoffe-international.com

Smart Factory

Energieeffizienz

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

Rückverfolgbarkeit, Traceability

Handling, Handhabungstechnik

Nachhaltigkeit

Umweltmanagement

Zerkleinerungsmaschinen

Greifer für die Kunststofftechnik

Compoundieren

Today Packaging,  Tomorrow Raw Material

The IKV is researching digital solutions for better description and classification of recyclates. The aim is to increase the actual recyclate use rates. Results will be presented at the IKV colloquium in September.

PlasticBOND: Schematic illustration of the platform design to be developed.

Kreislaufwirtschaft

Research to Improve Recyclate Use

Time to take stock: in what condition and with what agenda is the industry presenting itself after two-and-a-half years of a difficult climate? We have conducted a survey: insights into the dominant themes of the age.

Preview of K 2022: Kunststoffe Questionnaire on the Situation in Injection Molding Machine Construction

Doriat, Clemens, Dr.

Harsh Realities

Christian Schiller’s goal is to turn the phrase “plastic waste is recyclable material” into reality. His tool of choice: digitalization.

Recycling

Start up

Unternehmen und Unternehmer

Ehrhardt, Melanie

“We See Our Work as Basic  Digitalization“

Part 2 of the series on the Plastics Innovation Center 4.0 (PIC 4.0) at RWTH Aachen describes the procedure by which industrial use cases of a Smart Factory are identified and converted into real testbeds within the PIC 4.0.

The PIC 4.0 extends the infrastructure of the Institute for Plastics Processing in Industry and Craft at RWTH Aachen University

PIC 4.0 Elaborates Holistic Solutions for Industrial Demands

Use Cases of Digitized Plastics Processing

Maintaining competitiveness while producing in Germany requires not only cost-efficient production, but also high-quality products. Vorwerk Elektrowerke is accepting this challenge. In collaboration with the Institute of Product Engineering at the University of Duisburg-Essen, Germany, the company is testing a 100 % inline quality monitoring system as well as a quality prediction using machine learning.

Customers who choose the Kobold VK 200 vacuum cleaner expect top quality. To ensure this, efforts for the introduction of Industry 4.0 measures are taken in the production plant in Wuppertal, Germany

Successfully Managing Digital Transformation with Automation and Artificial Intelligence

Künstliche Intelligenz für die Qualitätssicherung

Mehrkomponenten-Spritzgießen

Kameras, intelligente

Fertigungsautomation

Bildverarbeitung

Machine Learning / Künstliche Intelligenz für die spanende Fertigung

Industrie 4.0 für die spanende Fertigung

Inline- / Online-Messsysteme

Inline Quality Monitoring and  Data-Based Quality Prediction

Because it has not yet been possible to exploit the full potential of digitization in plastics processing, the Institute for Plastics Processing at RWTH Aachen University is building a new application-oriented research infrastructure along the lines of a Smart Factory. Kunststoffe is accompanying the building of the Plastics Innovation Center 4.0 with a series of publications. Part 1 describes the concept and the initial demands on the physical infrastructure.

Visionary overall picture of the expanded IKV in future, supplemented by the Plastics Innovation Center 4.0

The Plastics Innovation Center 4.0 Is under Construction at the Campus Melaten in Aachen, Germany

Central Hub for Digitization  in Plastics Processing

Munich-based mechanical engineering group KraussMaffei is repositioning itself and uniting all divisions under a single brand. At a time of accelerated technological change, the company is increasing its efforts to develop new products for digital solutions and new business models – and that includes plastics recycling.

Everything remains different: Dr. Frank Stieler, CEO of KraussMaffei

KraussMaffei Consolidates Three Divisions and the Previous Group Brands under a Single Brand

Extrusion

Spritzgießmaschinen, allgemein

Ressourcenmanagement

Produktion

Moving with the Times

After the focus was on individual manufacturing and model-supported process set-up in recent years, the Institute for Plastics Processing (IKV) at RWTH Aachen University is linking the two aspects of digitalization and circular economy at K 2022.

After the focus was on individual manufacturing and model-supported process set-up in recent years, the Institute for Plastics Processing (IKV) at RWTH Aachen University is linking the two aspects of digitalization and circular economy at K 2022. The aim is to make the processing of post-consumer recyclates (PCR) reproducible with a digital solution from the field of process control.

Exchanging the material batches (PP Systalen, Duales System Deutschland; color masterbatch: LyondellBasell) changes the part quality as a result of viscosity fluctuations. These changes are identified by means of process indicators and subsequently compensated via the “Injectix” automated process control concept. Injectix combines the phases, regulating the entire injection and holding pressure phase of the injection molding machine (Wittmann Battenfeld) via the cavity pressure (2x pT sensors: Kistler) as controlled variable. This achieves a more robust process control, since no changeover processes occur in the controlled variable. Injectix continually detects process changes during part filling, so that the cavity pressure reference can be adjusted based on live data. After manufacturing, the injection-molded parts are transferred to a quality inspection cell (Kistler), which checks quality parameters such as weight, dimensional accuracy and color quality.

As a demonstrator, a stacking box (mold maker: Kroma International; standards: Hasco) is produced consisting of 100 % PCR. A laser-marked QR code (Datalogic) provides project information and process data.

The QR code on the PCR component provides project information and process data.

2022-10-20 - IKV

kunststoffe.de

issue 03/2025

issue 02/2025

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