We look behind the cavity walls and along the data cable at what hot runner technology now offers in terms of mechanical, electronic and digital expertise.

The smart Control monitoring unit permits integrated monitoring of the injection molding production cell, including the mold, hot runner system and all ancillary components. The “Luer connector” application case was on show at K 2022.

16:9

State-of-the-Art Injection Molding Solutions at K 2022: Hot Runner Technology

Spritzgießen

Kunststoffverarbeitung: Verfahren

Doriat, Clemens, Dr.

Mikrospritzgießen

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Normalien und Heißkanaltechnik

Komponenten für die Kunststoffverarbeitung

Mess-, Steuer- und Regelgeräte

Qualitätssicherung

Qualitätssicherung Kunststoff

Temperaturregler

Messtechnik

Sensoren / Messwertaufnehmer

Heißkanalsysteme

Additive Fertigung

Everything under Control

A solution, which is unique in Europe, significantly increases productivity and comprises the production from a 12+12 stack mold with fully automated in-mold labeling and removal with visual 100 % inspection of the parts.

Before relocation to the production site, extensive functional tests and the final trial were carried out at the roth technical center

Fully Automated Production Line with Stack Mold and In-Mold Labeling

Award-Winning Packaging Solution Increases Productivity

Starting with the systematic design of manufacturing processes and the precise simulation of part manufacture, through smart tooling technology and sophisticated melt guidance, to efficient mold temperature control, numerous exhibitors have many innovations in the field of tooling technology on offer at K 2019.The current debates concerning marine pollution as well as anthropogenic climate change and its consequences seem to be having an effect at this world-leading trade show for plastics processing in Düsseldorf, Germany. A number of companies are noting the growing customer interest in sustainable, carbon-neutral and resource-efficient modes of production, and offering products and services intended to satisfy this interest.

Resource-Efficient and Environmentally Friendly Products Are the Trend in  Tooling Technology

Werkzeuginnendrucksensoren

Temperiergeräte

Gießanlagen

Temperiertechnik

Normalien für die Kunststofffertigung

Normalien

Spritzgießsimulation

Software

Simulation

Kaltkanalsysteme

Exhibitors See Green

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

Montagetechnik

Steuern, Regeln

Mehrkomponenten-Spritzgießen

Werkzeugtemperatursensoren

Industrieroboter

Spritzgießmaschinen

Reverse Rotation

A Polish pharmaceutical company is developing inhalation therapy for the treatment of lung disease and the appropriate drug delivery drug. The inhaler has a complex interior and consists of 14 components. In order to be able to produce these with the required precision, Celon Pharma has formed a partnership with the mold making company Glittenberg and its hot runner sister Witosa.

For its complex functional mechanism, the inhaler requires 14 components

Glittenberg Supplies Tools for Vital Medical Devices to Celon Pharma

Medizintechnik

Medizinprodukte

Plastic in the Service of Medicine

Jessica Poliner has been appointed President of Barnes Molding Solutions. She replaces Norbert Scheid, who retired from Barnes Group in December 2020.

Jessica Poliner has been appointed President of Barnes Molding Solutions

Werkzeug- und Formenbau

Dienstleistungen

Werkzeug-, Formen- und Modellbau

New Management to Head Barnes Molding Solutions

The Institute for Plastics Processing (IKV) at RWTH Aachen University is investigating a new control approach for injection molding in which the cavity pressure is controlled by different positions of the hot runner valve pin. The influence on the cavity pressure of different strokes in the holding pressure phase is investigated.

The experimental mold with the cavity of a bicycle saddle has a servo-electrically driven hot runner

20:7

Cavity-Specific Pressure Control to Increase Process Consistency

The Hot Runner Valve Pin  as Actuating Variable

According to the company, the UltraShot Injection System provides part design freedom, while improving part quality and speed of mold qualification.

The UltraShot Injection System filled the entire part where a conventional injection molding process at 2758 bar could not

Husky introduces the UltraShot Injection System

Kunststoffverarbeitung allgemein

Kunststoffverarbeitung

Spritzgießmaschinen, allgemein

Kunststoffverarbeitungsmaschinen

Next Generation Melt Delivery and Control System

Pipette tips feature a challenging wall thickness/length ratio, an inner geometry that is key for analysis results, and a tip opening just a few tenths of a millimeter wide. They have been in extremely high demand during the coronavirus pandemic, which is why the mold construction and hot runner specialist Männer has developed a mold with an innovative cluster concept.

At the Männer test center in Bahlingen, Germany: an injection mold for manufacturing pipette tips, shown here in operation. Automation of the system is currently being set up

Pipette Tips: Männer Presents a Mold with Replaceable Clusters

Maintenance During (Nearly)  Uninterrupted Production

In plastics processing, efficient production methods are required, especially for articles with high volumes and exacting quality requirements, and these must be constantly optimized. The container specialist Walther Faltsysteme has been successfully working together with the Austrian moldmaker Haidlmair for many years.

Left: products which are manufactured using the technologies of the Haidlmair Group companies. Right: an application example with folding boxes

Walther Faltsysteme Combines Three Mold Technologies from the Haidlmair Group

Industrie 4.0 für die Qualitätssicherung

Industrie 4.0

Condition Monitoring / Prozessüberwachung

Instandhaltung

Paletten und Behälter

Logistik

Verpackungstechnik

Industrie 4.0 für die Kunststoffverarbeitung

With Broad Sword and Data Collector

The completion of the transaction is subject to customary regulatory approvals and is expected by the second quarter of 2021.

Oerlikon acquires Italian company INglass S.p.A. and its market-leading HRSflow business unit for hot runner system technologies

Oberflächentechnik

Oerlikon Signs Agreement to Purchase INglass

For the further development of the Streamrunner and also for customer demonstration purposes, Hasco hot runner has developed an innovative 32 cavity injection mold tool.

The special feature of the mold is the 32-cavity Hasco Streamrunner

New Design Possibilities in Moldmaking

Aside from offering high mechanical strength, versatility and durability, polymer materials are ideal for applications in the electrical industry because of their ability to isolate electrical current.

For the conduction cooled MicroTCA systems, Harting processes LCP, a material that is flame-resistant, dimensionally stable at high temperatures, chemically resistant, and has only a low thermal expansion

Connectors for Industrial Lifelines: High-Tech Injection Molding at Harting

Hybridtechnik

Polymere, flüssigkristalline

Kunststoff Werkstoffe

Thermoplaste

Stanzen

Verfahren für die spanlose Fertigung

Schneiden

Hybrid-Spritzgießen (Metall / Kunststoff)

Steckverbinder

Elektromechanik

Well-Balanced Hot Runner Technology for LCP Processing

Products intended for use in building services must meet very high quality requirements in terms of both their constituent materials and functionality. A single-cavity mold for a floor grate made by Barku, which appears to be a simple part at first glance, called for a certain level of technical sophistication. This was provided by a moldmaker with the necessary technical understanding and hot-runner manufacturer Witosa who, between them, devised the right solution for what proved nevertheless to be a complex mold.

Sebastian Lotzin, CEO of Barku’s U. S. subsidiary, with floor grate (3250 g) in the 10,000-kN injection molding machine that makes the part

Sequential Injection with a 6-Fold Valve Gate System for a Floor Grate

A Simple Cascade

Under the brand name Monolith, Frankenberg/Germany-based Witosa will present what it calls “a new approach to hot runner technology” at Fakuma.

The tension is rising. The new Monolith nozzle series from Witosa will be unveiled at the trade fair

Messe Fakuma

kunststoffe-international.com

Disruptive Technology Announced

Ewikon will be presenting the second generation of its smart Control system. The previous version has been upgraded with new performance-enhancing features and it can now be fully integrated into networked injection molding production via OPC UA.

Aside from comprehensive collection and logging of all process data related to the hot runner system, communication with the machine, peripherals and higher-level software systems is now also possible and hence the logging and monitoring of all relevant injection molding parameters. A new addition is the optionally integrable virtual rheology function for conducting live simulations of melt flow in the system. It facilitates real-time simulation of the shear rates and residence time in the hot runner system based on the application-specific material and geometry data stored in the system, and also of the hot runner temperatures and injection parameters of the injection molding machine recorded for the current shot. This provides scope for targeted process optimization, especially where shear-sensitive or residence-time-critical materials are processed, and thus guarantees high part quality, according to Ewikon.

The system can be easily integrated into company networks via Ethernet. The browser-based user interface provides user-friendly data visualization and facilitates global availability and secure access via mobile devices without the need for additional software installation. The dashboard features an integrated productivity display that provides information on the current system performance at a glance, along with the most important temperature data of the system components. Smart Control comes in two versions. The “Mold package” system is mold-specific and monitors the injection molding process over the mold’s life cycle. It is supplied as an integral part of a hot half or a drop-in system. The “Machine package” is a versatile system for use in injection molding production cells and is supplied as a compact unit that is mounted directly on the injection molding machine where it can monitor a number of molds used on the machine.

A compact valve gate version has been added to the L2X-Mikro high-performance hot runner system for use in the micro molding sector. This is available exclusively as a 4-drop manifold with screw-in nozzles, whereby the needles are actuated by a compact synchronous plate. As in the open-gating version, the nozzles are direct-heated for high thermal performance and can be individually controlled. This means that the system can be used for processing not only standard resins, but also, without limitation, engineering polymers that have narrow process windows. Shot weights per nozzle start at 0.01 g, with the exact amount depending on the resin.

EWIKON Heißkanalsysteme GmbH  

https://www.ewikon.com

The second generation of the smart Control system can be fully integrated into networked injection molding production via OPC UA

2021-09-03_Werkzeugtechnik_Ewikon

issue 02/2023

issue 01/2023

issue 09/2022

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