Susanne Schröder will become editor-in-chief of the magazines Kunststoffe and Kunststoffe international on December 1, 2020. The current editor-in-chief Dr. Karlhorst Klotz will leave the company by mutual agreement.

Werkzeuge für Leichtbauwerkstoffe

Präzisionswerkzeuge

Tiefziehwerkzeug

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Werkzeugüberwachung

Toolmanagement

Werkzeugwechselsysteme, Spritzgieß

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Spritzgießwerkzeuge

Werkzeug- und Formenbau

Modulare Werkzeugsysteme

Absaugungen für Werkzeugmaschinen

Betriebsausrüstung / Betriebsmittel

Absaugvorrichtungen

Fluorkunststoffe

Kunststoff Werkstoffe

Thermoplaste

Werkzeugverwaltungssoftware

Prüfen von Kunststoffen

Messtechnik

Biokunststoffe

Presswerkzeuge, Kunststoff

Werkzeugreinigung, Kunststoffe

Standardkunststoffe

Kunststoffverarbeitung

Lohnfertigung

Technische Kunststoffe

Füllstoffe für Kunststoffe

Kunststoff

Bauwesen

Baustoffe

Kunststoffhandel

Handel

Betriebstechnik für Kunststoffverarbeitung (Peripherie)

Kunststoffverarbeitung: Verfahren

Kunststofffasern

Verstärkungsstoffe

Kunststoff-Recycling

Kunststoff-Aufbereitung

Hochleistungskunststoffe

Qualitätssicherung Kunststoff

Qualitätssicherung

Change in the Chief Editorial Office of Kunststoffe

Hybrid production chains have been increasingly in the spotlight in recent years. This also applies to the combination of conventional manufacturing and additive processes in tool construction. With the example of an injection molding tool, it is shown how mold inserts produced by additive manufacturing can greatly shorten cycle times, and thereby significantly reduce unit costs. The important thing is to find a suitable combination of processes from the variety available.

Additive Manufacturing and Hybrid Molds in Combination with Conventional Machining

Spritzgießen

HSC- / HPC-Bearbeitung

Spanende Verfahren

Werkzeugkonstruktion

Additive Fertigung

Anlagen Additive Fertigung / 3D-Druck, Metall

Anlagen für die Additive Fertigung

The Potential of Redesign and  Part Consolidation

During this year’s pandemic, maintaining supply capability has become a key necessity among processors. Closer involvement of suppliers is only logical in these circumstances. In toolmaking, new challenges are emerging for services related to molds.

The Advantages of a Network for Global Qualification for Injection Molding

Erstbemusterung, Erstmusterprüfbericht

Qualitätsmanagement

Werkzeugbau

Inline- / Online-Messsysteme

Fast and Effective Start of Production

At HRSflow‘s headquarters in San Polo di Piave, Italy, a new production facility for hot runner systems based on lean manufacturing principles was recently completed.

3000 sqm for Lean Manufacturing

Normalien und Heißkanaltechnik

Komponenten für die Kunststoffverarbeitung

HRSflow Expands Headquarter

The signs point to growth: more exhibitors, more internationality and (as far as predictable) more visitors – this is only the second edition, but nevertheless, the Moulding Expo trade show is on its way to establish itself as the leading fair of tool, model and mold making in Europe. Booth bookings from the core area of the industry are over average, which is proof of the acceptance of Messe Stuttgart, Germany. 

Moulding Expo Will Take Place at the End of May, with More than 700 Exhibitors 

Verbände, Institutionen, Messen

Messeveranstalter

"We Want to Be more International" 

Right from start, the goal was to create a trade show "by the industry, for the industry." Mission accomplished: about half of the roughly 700 exhibitors at the second Moulding Expo were from the tool, model and mold making industry. Here is a small selection from the range of topics. 

Mold and Tool Makers Now Have a New Home: Moulding Expo 

Oberflächentechnik

Unmissable 

Some 38 years after it was founded, the tool manufacturer Haidlmair celebrated its first technology open day with an extra special obstacle course. The highlights were the demonstration of a new CNC automation system and an enhancement of an open hot runner nozzle system promising higher productivity chiefly for the production of logistics containers and technical parts. 

Haidlmair Combines the Advantages of Injection Molding and Extrusion in One Tool 

Gate Quality under Control 

The producing industry is increasingly involved in changes due to progressing globalization and derivatization, shorter product lifetimes, and demographic change ¿ with enormous consequences for mold making as well. This is why mold making companies have to continue further development. In actual practice, a so-called 3C approach to "compare, compile, and conduct" has proven effective. 

Compare, Compile, Conduct ¿ Further Strategic Development in the Tool and Die Industry 

Industrie 4.0

Maßnahmenmanagement

Benchmarking

Strategie und Organisation

In between Industry 4.0  and Market Intelligence 

At a time of increasing complexity in production, efficient and rapid production and decision-making processes are essential in order to remain competitive. A fundamental requirement for this is complete transparency throughout the entire process chain ¿ including in tool and mold making. One option for creating the necessary infrastructure and transparency for rapid and improved decision-making is to use apps. 

Towards Agility and the Internet of Production with Mobile Applications 

CAD Werkzeug-, Formenbau

ERP-Systeme

Workflow- / Prozessmanagement

Apps in Individual and  Small-Series Production 

Marbling is often a real eye-catcher in plastic components. However, the effect is difficult to create and there are some pitfalls when it comes to reproducibility. Novel nozzles for injection molding machines in combination with a special dosing technology allow marbled molded parts to be produced far more easily in a much more robust process.

A 3D-Printed Nozzle and Modified Dosing Method Deliver Reproducible Marbling  in a Robust Process

Kunststoffe

Photonik

Optik

Farben, flüssig

Additive

Exciting Design instead of  Exciting Manufacturing

At the 2019 K fair, Arburg and Simcon showcased a filling process proceeding in real-time, as a 3D animation, on the display of a machine control panel, for an example of sunglasses, made of PA12. All that was needed to prepare this, was to load the simulation model, as well as the geometry of the part, directly onto the machine controls. This sounds almost too easy to be true. Right?

Interview with Eberhard Duffner and Paul F. Filz by the Magazine Kunststoffe

Doriat, Clemens, Dr.

Spritzgießsimulation

Software

Simulation

Interview

The toolmaker Siebenwurst uses injection molding simulation to optimize part design and production processes in its routine workflows. Among other things, Simcon’s software ensures the quality and dimensional accuracy of the plastic frame for the first series-produced injection molded e-bike.

Controlling Complex Development and Manufacturing Processes, Using Simulation

Composite-Halbzeuge

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Verbundwerkstoffe / Werkstoffverbunde

A Bike Frame from an Injection  Molding Machine

Tool and mold makers are detail oriented and innovative. Prof. Thomas Seul and Fabian Diehr met with some industry players to explore different paths they have taken through the thicket of this industry-jungle they have to deal with.

A Journey through the Landscape of the Tool and Mold Making Industry

Mikrospritzgießen

Mehrkomponenten-Spritzgießen

Innovationsmanagement

Produktentwicklung (F+E)

Projektmanagement

Wirtschaft

Handling, Handhabungstechnik

Automatisierungstechnik

Reinraumsysteme / -technik

Produktmanagement

Trend Setting or Following?

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

Heißkanalsysteme

New Management to Head Barnes Molding Solutions

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

Sensoren / Messwertaufnehmer

Temperiergeräte

Gießanlagen

Temperiertechnik

Normalien für die Kunststofffertigung

Normalien

Kaltkanalsysteme

Exhibitors See Green

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

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. Digital access would allow authorized users to read or enter content, and, if needed, provide important operating instructions and information about the condition of the tool.

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 proven functionality and production capability of an injection molding tool always depends on the accompanying documentation. While the tool is in use, this should be at the user’s fingertips, like the car manual in the glove compartment. Experience teaches us that we will need to consult the manual just when we least expect it.

Predictably, this usually only occurs on the first start-up or recommissioning, or for proof of maintenance. In all cases, it is essential to know where it is stored and to rapidly locate the important content in order to quickly find the desired results and prevent damage to the tool or injuries to people.

A well-designed and maintained tool logbook contains a collection of information that allows users to work safely and correctly with a tool, in a similar way to the instructions for use. The term “instructions for use” is taken from the European standard EN 82079–1, which regulates the preparation of instructions for use. In the best case, the tool logbook contains all information about the entire tool lifecycle.

This includes the basic tool description in the form of technical drawings and/or 3D data, a functional description, information for transport, storage, assembly, installation, commissioning, configuration, operation, maintenance, care, troubleshooting, disposal and other relevant technical data. It is important to know that it is not always necessary to supply a printed copy of the instructions for use, but to provide them entirely or additionally as a file on a storage medium or as web downloads.

The Obligation to Instruct Users Involves Significant Liability

The manufacturer of a tool has an obligation to provide instruction for users. He must meet this by giving them instructions for use. This is therefore a component of the tool, which regulates the use, maintenance and/or servicing, in order to provide safety and safeguard health according to the product safety law (ProdSG). Legally, it should be pointed out here that faulty, incomplete or incomprehensible instructions for use represent a material defect, and can thus lead to a claim for rectification, withdrawal from the purchase contract or reduction of the purchase price.

Within the scope of product liability, faulty instructions for use can, in the event of damage or injury, become a considerable financial liability risk for placing the product on the market. In view of the aforementioned legal aspects, it is clear that complete and well prepared tool documentation should form a natural part of an injection molding tool.

With the advances in digitalization of the production process and environment, it is clear that a system that not only contains and digitally implements the content of the conventional tool log should also meet additional functional requirements. The most important thing is that the tool log book must be easy and intuitive to create and maintain. Another goal is to prepare the content such that it is more understandable for the user and more reliable to handle.

With this goal in mind, Werkzeugbau Ruhla GmbH, Seebach, Germany, and the University of Schmalkalden, Germany, set up a research project focused on implementing digital storage solutions in production tools with the aim of audit-proof documentation (ImPro). The requirements described above were transferred to an “ImPro” hardware module (Fig. 1). In the scope of the project, modified hardware with additional functions for use at the injection molding tool was developed. This mini-computer is equipped with a robust housing and plug contacts suitable for service at the high temperatures that are typically found in plastics processing.

In the research project, it was also possible to test the prototype under production conditions. The data stored there cannot be simply retrieved as with USB storage. Access to the data is regulated by a modified role management with access control. All the information are tamper-proofed and automatically stored in an audit-proof way at the tool. The entire life cycle (maintenance reports, error logs, etc.) can be called up at the tool without a network or Internet connection. Besides the technical specifications, aspects such as user-friendly operation, optimized size and low purchasing costs are also taken into account.

Digital Storage Solution, Integrated into the Tool in a Tamper-Proof Way

The digital tool log book is integrated into the tool independently of an electricity supply. The ImPro module’s software operates independently of the particular PC platform or of the user’s device (Windows, Linux, Mac). The hardware uses a specially modified Linux operating system (Linux impro kernel 4.9.82-ti-r102, ImPro-OS), taking into account the following aspects:

<ul><li>Configuration of the hardware components,</li><li> embedded operating system,</li><li>user interface,</li><li>emulation of mass storage,</li><li>monitoring the hardware components (sensor querying, memory),</li><li>monitoring/protection of the data base (tamper protection, versioning/encryption, backup strategy).</li></ul>

The only prerequisites are a USB connection and a web browser (Fig. 2) on the terminal device. Tamper- and audit-proof storage was an key aspect in the implementation of the ImPro module. Both the operator and manufacturer can use it as a basis in case of a warranty claim. This basis is currently not available in practice and consequently leads to resentment in the partnership between the mold maker and injection molding processor.

The content of the ImPro module includes:

<ul><li>A connection diagram for tool temperature control,</li><li>details of the hot-runner system,</li><li> a production flow chart for the tool,</li><li>maintenance schedules and logs,</li><li>assembly videos or assembly and dismantling plans.</li></ul>

An innovative option is thus available for the permanent tamper- and audit-proof storage of the complete documentation, directly in the injection mold under industrial service conditions in an injection molding shop and taking into account the users’ different IT skills.

Videos with Assembly or  Maintenance Instructions

Users and maintenance staff require a thorough understanding of the construction of a tool in order to be able to operate and maintain it correctly. A lack of knowledge – if the documentation is not present or not immediately available – can lead to suboptimal actions in operation and maintenance of the injection mold. This could result in irreparable damage to delicate structures in the tool or, in the worst case, to production downtime.

Besides technical documentation, users can also receive further documents or data, e. g. videos or animations with assembly and/or maintenance instructions. These service options were conceived on the principle of “a picture say more than a thousand words,” to allow an information flow irrespective of the local language. The interactive maintenance process and its documentation by photos and videos can thus be visualized.

A typical view of the ImPro user interface shows the integrated maintenance calendar, alongside a maintenance entry with a modified drawing of the cooling channels and a draft log for maintenance with check list (Fig. 3). In addition to this information, the user interface is also capable of interactively displaying 3D data in STL format (Fig. 4).

Automatic Updating on Product and Tool Modifications

Another interesting feature of the ImPro module is the integrated 3-axis accelerometer, which permits detection of g-forces in all spatial directions (Fig. 5). This permits direct measurement of the tool state, e. g. in the form of a tamper-proof indirect software cycle counter or for detecting a tool crash during transportation. The machine cycle, faults and incorrect or unauthorized use can thus be indirectly recorded and stored.

The tool velocity (red curve) is shown at the left (Fig. 5), it was registered via the machine control unit and, the velocity calculated with the ImPro module is shown at the right. Depending on the assembly option, the ImPro module can perform an independent position determination in the XYZ direction of the Earth’s gravity and calculate the acceleration vector. The acceleration values can be integrated to convert them to a velocity curve. They are then filtered to obtain a curve comparable to measurement by the machine.

The complete technical documentation of the tool can be extended with a wide range of additional information, such as a detailed connection diagram for temperature control, precise and comprehensive details of the hot-runner system, a production flow chart of the tool, maintenance plans and logs as well as corresponding assembly and disassembly plans and transport instructions. It is certainly also helpful to be able to automatically save the process data of the last machine cycles via the USB interface.

They are then directly available independently of the machine for maintenance, troubleshooting and recommissioning. It is now a thing of the past to search for urgently required information in situations where time is often critical. The same is true of lost, incomplete or outdated documentation, which often generates very high costs as soon as repairs or complex maintenance are required. In this respect, documents are almost automatically updated with a visible history in the event of product and tool modifications.

Components and Integration into the Injection Mold

The ImPro module consists of two hardware components. It centers on a 10 cm x 8.5 cm x 4.3 cm box with three plug connectors on the side and a USB-A port on top (Fig. 1). The electricity supply of the ImPro module can be ensured in three ways, depending on the application. The first option is for operating the module at the injection molding tool (Title figure), using an external 230 V power supply. When the injection-molding machine is in operation, the integrated modified Linux operating system boots up.

The second supply option can be implemented via a coded connecting cable to the operator module of the injection-molding machine. This connection also serves for data transfer from the machine to the ImPro module, which logs on to the machine control unit as a USB storage.

The last variant serves for supply when the tool is decommissioned, e. g. in storage or during transport. In this case, the module can be supplied directly via the USB-A interface. Power management is ensured via an integrated power-path multiplexer and additionally protected against overvoltage by means of other safety mechanisms.

A 1 GHz Cortex-A8 AM335x processor drives the module and is specified for the service temperature range between 0 °C and 85 °C. The operating system is adapted to the IoT (Internet of Things), without any graphical user interface at all, and therefore manages with significantly reduced resources. To allow it to register the operating state even without display and PC, an RGB-LED was integrated into the module, which signals the boot state or activity by changing color. An additional interface can be used to connect an external limit switch contact or inductive proximity sensor to the ImPro module. However, this functionality does need to be preconfigured, depending on the problem.

Summary: Providing Useful Data and Overcoming Language Barriers

The ImPro module can be regarded as electronic tool documentation, a tool log book and a smart tool nameplate. The information stored here may be in the form of images, text, sound or video. The access-protected, browser-based user interface is modular and shows the product to be manufactured on the home page (Fig. 2). Versioning of the stored data prevents the loss of important documents throughout the tool history, which can be made accessible with the necessary authorization.

The performance of correct maintenance and handling is supported by making the necessary documentation permanently available in digital form at the tool and by allowing an interactive sequence of the individual maintenance steps to be called up. Checklists and plans are provided and can be checked off as required. This is intended to support optimum tool quality throughout the lifetime. The different documents can be saved as PDF, CAD, video or image formats in the ImPro module.

At the current state of development of the hardware and valid software, the project partner Werkzeugbau Ruhla, coordinating with the University of Schmalkaden, can equip complex injection-molding tools with the system on customers’ request. The specific content of the unique tools is modified by means of a predefined software backend.

Hochschule Schmalkalden FB Maschinenbau 

Werkzeugbau Ruhla GmbH  

www.ruhla-gmbh.de

Ausgabenartikel

Fig. 5. Comparison of status monitoring at the machine side (left) and tool side (right) and display of the processing of the integrated 3-axis acceleration signal, which can be used as an indirect software cycle counter

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

Fig. 1. The heart of the ImPro module with its diverse integrated functions, sensors and interfaces is a 1 GHz Cortex A8 processor with specially modified Linux operating system Source: University of Schmalkaden; graphic: © Hanser

Fig. 3. User interface showing the integrated maintenance calendar (left), results of the maintenance with inserted pdf (center) and draft of a check list for planned maintenance (right). All content can only be read or captured by authorized persons

Fig. 4. Display of relevant tool data in the user interface, e. g. pdf, 3D-data, maintenance logs or assembly videos

Fig. 2. Start screen of the user interface in the web browser with language selection, short overview of the manufacturer’s tool data, access mask with password control and calendar overview. The illustrated QR code is used to access a video giving a short presentation of the ImPro user interface 