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.

Susanne Schröder will become editor-in-chief of the magazines Kunststoffe and Kunststoffe international on December 1, 2020. Until now she has been editor-in-chief of the trade journal FORM+Werkzeug

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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

Products made from bio-based plastics must undergo the same testing procedures as conventional plastic products to access the market of the European Union (EU). Thereby a health risk for consumers is excluded. Biodegradable or compostable plastics must undergo additional tests.

Biodegradable plastics certified for industrial composting have to meet a fixed limit for heavy metals and other toxic and hazardous substances

Kunststoffe, biobasiert

Verbände, Institutionen, Messen

Kunststoffe, bioabbaubar

Bioplastics Meet All EU Safety Standards

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.

Tool qualification in the test center in Bahlingen, Germany. After that, the tool is ready for the “site acceptance test”, i . e. for the acceptance on site directly at the customer

The Advantages of a Network for Global Qualification for Injection Molding

Spritzgießen

Erstbemusterung, Erstmusterprüfbericht

Qualitätsmanagement

Werkzeugbau

Inline- / Online-Messsysteme

Fast and Effective Start of Production

The Wilhelm Böllhoff GmbH & Co. KG employs Arburg’s ALS host computer system as a uniform MES at locations all over the world. Not only all their injection molding machines are networked with information technology via ALS, but hundreds of machines and turnkey systems for metalworking and assembly, as well. Some 3000 injection molds are also managed. This generates transparency in everything from order planning and process optimization to maintenance.

The process status of every machine can be viewed via the ALS terminal

Böllhoff Uses ALS as a Uniform Global MES for Injection Molding and Metalworking

Spritzgießmaschinen, allgemein

Spritzgießmaschinen

Big Data für die Qualitätssicherung

Industrie 4.0

Industrie 4.0 für die Qualitätssicherung

Energiemanagement

Energieeffizienz

Completely Joined to the Host Computer System

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

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Kameras, intelligente

Fertigungsautomation

Bildverarbeitung

Industrie 4.0 für die Kunststoffverarbeitung

Machine Learning / Künstliche Intelligenz für die spanende Fertigung

Industrie 4.0 für die spanende Fertigung

Datenanalyse

Inline Quality Monitoring and  Data-Based Quality Prediction

Without measurement and testing technology, it would be impossible to ensure consistently high product quality. To tackle such quality assurance tasks, plastics processors can increasingly turn to the blessings of Industry 4.0 and artificial intelligence methods in order to process measurement data more comprehensively, and use the results to improve processes and products.

Digital Data Processing is Breaking New Ground with Connectivity and  Artificial Intelligence

Precision Measurement,  Smart Optimization

Composite materials are often the key to lightweight design for many applications. However, these hybrid materials face a major challenge where recycling is concerned.

The experimental components were manufactured in a fully automated SMC manufacturing cell, developed by Engel, with an Engel v-duo 700 machine and an easix KR35 articulated robot

A Research Project Highlights the Recycling Potential of Lightweight Composites

Composite-Halbzeuge

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Kohlenstofffasern / -matten

Anlagen zur Composite-Herstellung

Spritzprägen

Bruchmechanische Prüfung

Werkstoffprüfung

Verbundwerkstoffe / Werkstoffverbunde

Harzsysteme für Composite-Herstellung

UD-Tapes

Pressen von Kunststoffen

Faserverbundwerkstoffe

Andere Werkstoffe

Zero-Waste Concept for Carbon SMC

The quality of a part design or a strength proof depends to a large extent on how well the material property in question meets the design conditions. For this paper, information about the influences exerted on the strain limits of “microdamage”, as a criterion for mechanical material failure, was compiled from the literature, evaluated and prepared for application as far as possible.

To rule out part failure, it is important to consider strain limits

Strain-Based Design of Plastic Parts

Elastizitätsprüfgeräte

Messgeräte für Kraft, Masse, Dehnung, Druck, Dichte, Viskosität, Drehmoment

Mechanische Messtechnik

Dehnungs- / Drehmomentmessung

Sensoren / Messwertaufnehmer

Produktentwicklung(sprozess)

Influences on Microdamage  Strain Limits

Ceflex and partners PCEP, Petcore Europe, Styrenics Circular Solutions and MORE Recycling team up to understand the reality of today’s collected household packaging waste.

The study aims to understand the reality of today’s collected household packaging waste, in order to help to define and accelerate the development of infrastructure, systems and end market applications required to enable progress in delivering a circular economy.

Infrarottechnik

Elektronik

Study of Plastic Packaging Waste Helps to Deliver a Circular Economy

Recyclates usually show altered properties compared to virgin plastics due to initial processing and influences during the product’s life. This often leads to problems during processing. Especially in melt-expanding processes such as injection stretch blow molding, blow molding, film blow molding or thermoforming a fast incoming goods inspection method for recyclates is important. The Institut für Kunststofftechnik (IKT) at the University of Stuttgart, Germany, has developed a new test method for this purpose.

Fig. 1. The new and fast test method analyzes and identifies the melt extensibility of recyclates prior processing

Incoming Goods Inspection of Recyclates Ensures Reject Minimization

Kunststoff-Rezyklat

Recyclates on the Test Bench

Kistler’s ComoNeo process monitoring system is now much more precise thanks to an envelope curve adapted to the process, and is WLAN-compatible for the first time.

Growing numbers of injection molding professionals seek resource efficiency and high product quality. The solution: the ComoNeo process monitoring system

Werkzeuginnendrucksensoren

Everything under Control

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

Steuern, Regeln

Software

Werkzeugtemperatursensoren

Quality Assurance for Multiple Cavities

NP Germany’s turnkey system around a vertical Arburg injection molding machine takes up a quarter of the production hall.

Benedikt Niglis, head of project (left), and Plant Manager Mario von der Heyde are more than proud of their complex turnkey system

NP Germany: Extraordinary Turnkey System for Automotive Products

Inspektionssysteme

Handling, Handhabungstechnik

Automatisierungstechnik

Linearroboter für die Kunststoffverarbeitung

Knickarmroboter

Montagetechnik

Industrieroboter

Hybrid-Spritzgießen (Metall / Kunststoff)

Dance of the Robots

Pultruded, fiber-reinforced tapes have so far only been tested destructively or optically non-destructively. It would therefore be desirable to have a non-destructive testing method that can detect cracks, inclusions and changes in the impregnation quickly and without contact, i.e. that can detect the complete tape volume in contrast to optical methods. The air-coupled ultrasonic method used in this work meets all these requirements.

Zerstörungsfreie Werkstoffprüfung

Pultrusion

All-embracing Approach of Non-destructive Testing of Thermoplastic CFRP Tapes Using Air-coupled Ultrasound

The occurrence of process-specific defects in the wet filament winding process requires an oversizing of the components which leads to high additional material costs, especially for 700 bar type-IV pressure vessels. This paper presents the development of a quality control together with an image processing algorithm based on an industrial camera with which manufacturing deviations in the cylindrical area of the vessels can be determined.

An industrial camera is used to inspect a pressure vessel for manufacturing deviations during the infeed of fiber slivers.

Bildverarbeitungs-Software

Wickelmaschinen

Faserverarbeitung

Optische Mess- und Prüfverfahren

Use of an industrial camera for quality control in the production of the cylindrical area of type-IV pressure vessels in the wet filament winding process

Qualification and Gauge Management Software for Injection-Molded Thermoplastic  and Thermoset Parts

At the beginning of every quality assurance effort lies the individual measurement value. If this value is measured incorrectly, the collected data is unreliable and has an undesirable effect on all downstream quality management processes. The Kunststoff-Institut Lüdenscheid relies on CAQ AG’s software solutions for gauge and qualification management in order to ensure consistently trained and qualified employees, calibrated test equipment, and valid measurement values right from the very beginning – even in today’s age of working from home and decentralized e-learning.

At the beginning of every quality assurance effort lies the individual measurement value. If this value is measured incorrectly, the collected data is unreliable and has an undesirable effect on all downstream quality management processes. The Kunststoff-Institut Lüdenscheid relies on CAQ AG’s software solutions for gauge and qualification management

When dealing with such an incredibly flexible material such as plastic, one rock-solid factor must never be underestimated: quality. The Kunststoff-Institut für die mittelständische Wirtschaft NRW GmbH (KIMW), Lüdenscheid, Germany, founded in 1988, is an institute made up of absolute plastics technology professionals that is dedicated to research regarding techniques and measures in the field of quality assurance for the plastics industry. The institute is certified according to DIN EN ISO 9001 and has been operating a testing laboratory accredited in accordance with DIN EN ISO/IEC 17025 since 2000, as well as an international round robin test series accredited according to DIN EN ISO/IEC 17043:2010 . The continuous improvement of quality and efficiency in the plastics industry is the clear focus of the institute – especially with regard to injection molded parts made of thermoplastics or thermosets.

Implementing a company-wide quality mindset is the key to securing the future of any organization. Establishing said mindset can, however, only be achieved if every individual employee can join in on the challenge and continuously improve himself via ongoing training measures. At KIMW, 102 experts are devoted to research in materials, process, tooling, surface, process, and testing technology. Among other items of equipment, 12 injection molding machines (eight with insertion and removal automation), a compounding system for new material development, and 108 systems for material, component, and surface testing are at their disposal. For the planning, administration, control, and implementation of its internal qualification measures and the management of its vast array of inspection equipment, KIMW relies on CAQ AG’s CAQ.Net software solutions.

Goodbye, Excel: Enter Dedicated Software Solutions

While Excel spreadsheets were initially sufficient for the small number of employees, handful of gauges, and easily manageable number of training courses, this type of solution soon proved to be outdated for the institute, not least due to its consistent growth in personnel. The risk of incorrect entries, data duplications, or version conflicts had become too great, as had the danger that individual gauges, employees, or training courses could simply be overlooked.

At the beginning of 2016, KIMW therefore started searching for a holistic software solution that would manage the institute’s training courses and test equipment in the future. After extensive market research, they found what they were looking for at CAQ AG. The company’s portfolio offers solutions for both areas, which do not function as self-sufficient islands, but are intelligently networked with one another. With the modules for training management and gauge management (Fig. 1), KIMW simultaneously ensures that only persons that have received the latest technical training are allowed to operate the gauges. This is supported by functions such as the qualification matrix. With the matrix, it is possible for all employees at KIMW to find out at any time, down to the individual item of test equipment, who needs which qualifications, who has which qualifications, and for whom which qualifications have expired.

Qualification Matrix and Training Management in One Software

CAQ AG’s Qualify.Net software that is used for this purpose combines qualification matrix, training management, qualification management, and e-learning in one. It offers everything that is needed for planning, managing, controlling, and implementing the various qualification measures at KIMW (Fig. 2). The system thereby supports the fulfillment of documentation requirements according to ISO 9001 and enables the creation of an expressive, easy-to-maintain qualification and training database. Last but not least, thanks to comprehensive e-learning functions, the software also makes it possible to tap the full potential of employees and thus set the course for sustainable corporate success – even in today’s age of working from home and decentralized learning.

While the focus of training management is clearly on people, the topic of gauge management is obviously more technical. Yet the need for software to replace the prevailing Excel spreadsheets arose from a similar motivation. Because, due to the growth at KIMW, in the meantime 774 gauges, 373 test plans, and 49 device managers had to somehow be brought under one hat and all correlations between the entities always kept up to date. Today, KIMW uses CAQ AG’s PMM.Net software solution for its gauge management, gauge monitoring, gauge capability testing, and gauge calibration (Fig. 1).

The Challenge: Managing 774 Gauges and 373 Test Plans

The raison d’être of gauge and test equipment management is actually strikingly obvious: as the only interface between the object that is to be inspected and the resulting measured value, correctly managed test equipment is crucial for monitoring the quality status of products and thus an indispensable precursor for any sustainable quality assurance system.

It is therefore not surprising that, in addition to the seemingly logical necessity of gauge management, numerous standards and legal guidelines also call for a well-functioning and consistently documented gauge management system. Chapter 7.1.5 of ISO 9001, for example, is devoted entirely to the management of an organization’s monitoring and measuring resources. The specifications in this chapter regarding factors such as calibration, adjustment, calibration status, protection, handling, and documentation are intended to ensure the suitability and functionality of test equipment. Furthermore, from a legal point of view, without test equipment management, manufacturers cannot prove in the event of damage that everything possible had actually been done to prevent failure of their product.

Using sophisticated gauge management software means that the requirements of pertinent standards, specifications, and legal frameworks regarding gauge traceability and history can be fulfilled, as all data relevant to a company’s test equipment is stored in the software and is available at any time at the push of a button (Fig. 1). Said data also includes documents such as operating instructions or maintenance certificates. In order to keep an eye on the test equipment itself, functions such as integrated check-out and storage location monitoring via barcodes, QR, and RFID are available. The software can even be connected directly to existing storage systems and conveyor mechanisms on the factory floor via interface technology such as OpenAPI.

The Benefits for KIMW: Efficient Training Management  and Reliable Measurements

With the software solutions for training management and gauge management at its disposal, KIMW now commands state-of-the-art digital tools that significantly assist the institute’s everyday processes. Thanks to their modular design and the easy definition of individual KIMW-specific interfaces, the solutions are both similar in appearance and operation, and – regardless of whether it is training or gauge management – KIMW employees always operate in the same simple and intuitive software environment they are familiar with.

The implementation of CAQ AG’s software solutions led to considerable time savings at KIMW, for example, by eliminating the need to search for specific data. At the same time, potential errors due to redundant data or overlooked inspection equipment, trainings, or employees were eliminated. All of the software-supported measures concerning training and inspection equipment management mean that KIMW can today always blindly trust its measured values (Fig. 3) – for quality, safety, and reliability right from the start.

CAQ AG Factory Systems  

https://www.caq.de

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Fig. 3. View into KIMW’s testing laboratory: The Lüdenscheid-based company devotes itself extensively to research on techniques and measures in the area of quality assurance for the plastics industry   © CAQ/KIMW

Fig. 2. With the matrix in <a href="http://Qualify.Net">Qualify.Net</a>, the qualification status of all employees at KIMW can be precisely determined at any time © CAQ/KIMW

Fig. 1. 774 gauges, 373 test plans, and 49 device managers are managed with the <a href="http://PMM.Net">PMM.Net</a> module © CAQ/KIMW

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<b>Dipl.-Ing. Torsten Urban</b> is the director of training and continuing education at the Kunststoff-Institut Lüdenscheid (KIMW).