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

Spritzgießen

Kunststoffverarbeitung: Verfahren

Schaumspritzgießen

Künstliche Intelligenz für die Qualitätssicherung

Industrie 4.0

Industrie 4.0 für die Qualitätssicherung

Steuern, Regeln

Software

Mehrkomponenten-Spritzgießen

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

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Biokunststoffe

Kunststoff Werkstoffe

Spritzgieß-Sonderverfahren

Nachhaltigkeit

Umweltmanagement

Spritzgießsimulation

Simulation

Schnecken und Plastifiziersysteme

Spritzgießmaschinen

Industrie 4.0 für die Kunststoffverarbeitung

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

Kreislaufwirtschaft

There Is More beyond the Horizon

Guido Frohnhaus has been Managing Director Technology & Engineering at Arburg for a good two years now. The pandemic restrictions meant that he has made very few appearances outside the company so far, but, as he says himself, he spent the time getting to know the in-house processes at all levels and in great detail. In this interview with Kunststoffe, the 52-year-old talks about the course he plans to set and how crucial the high level of in-house manufacturing and programming expertise is for the company’s independence.

16:9

Doriat, Clemens, Dr.

“Gestica Will Be the Fixed Star in the Customer’s Universe”

The digital shadow is the core concept of the Cluster of Excellence “Internet of Production” at RWTH Aachen University. It represents the data trace of an asset to describe its real behavior. In the Plastics Innovation Center 4.0 (PIC 4.0), digital shadows, e.g. the data trace of a sensor, are used to optimize processes taking into account real behavior and to determine simulation quality.

The construction of the PIC 4.0 proceeds and throws its shadow on the Campus Melaten.

Part 7 of the Series: How the Digital Shadow Enlightens Real Processes in the PIC 4.0

Sensorik für Kunststoff-Verarbeitungsmaschinen

Digitaler Zwilling

Out of the Shadow into the Light

The highly diverse offering at K 2019 ranged from ingenious detailed applications to complete solutions that encompass the entire process. In the extrusion sector, the topic of the circular economy was very much in the shadow of developments relating to Industry 4.0.

Size is everything: the largest available pipe die with an adjustable melt gap

New and Further Developments Focus on Quality and Efficiency

Messtechnik

Flachfolienanlagen

Extrusionsanlagen

Blasfolienextrusion

Elektrische / Magnetische Messtechnik

Rohr- und Profilextrusion

Extrusion

Extrusionswerkzeuge

New Dimensions in Extrusion

Innovation management affects many areas, which now increasingly include digital services in addition to classic product and process innovation. Beyond the continuous reassessment of technical setups, a platform is being established for the consistent provision and further development of software services and dedicated analysis algorithms. Thereby, services are being provided to generate new ideas from the application and to facilitate the transfer of technology into industrial practice.

The outer skin of the PIC 4.0 is closing, inside the design of the demonstration cells is in full swing.

Part 8 of the PIC 4.0 Series: Flexible Infrastructures Facilitate Access to Innovative Services

Messdatenerfassung und -verarbeitung

Innovationsmanagement

Produktentwicklung (F+E)

Smart Services

Internet der Dinge

Messdatenerfassung, Software

Softwarearchitektur

Adaptable Structures for  More Innovation

The central control unit of the injection-molding machine is used by the machine operator for control, regulation and optimization of the entire production process. In order to directly integrate external systems as well as proprietary solutions that do not have a standardized interface, Engel uses a technology that is already widespread in day-to-day routine. Via a browser, the new Webviewer can be reliably integrated into the CC300 control panel of the injection-molding machines.

The Webviewer in the machine control system integrates not only ancillary equipment  with web interfaces, but also data from internal and external systems that are accessible via browsers. 

New Webviewer Merges Web and Control Applications

Steuerungen (Hardware und Software)

Automatisierungstechnik

Bedienterminals

Computer Hardware

Central Control Unit Makes Use  of Web Technology

The iSLM web-based platform takes injection molding simulation a big step forward toward sustainability and knowledge management. A discussion.

Datenbanken

Talking about the Digitalization  of 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

Kameras, intelligente

Fertigungsautomation

Bildverarbeitung

Datenanalyse

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

Smart Factory

Energieeffizienz

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

Spritzgießmaschinen, allgemein

Ressourcenmanagement

Produktion

Compoundieren

Moving with the Times

A consistent flow of data and information is essential for digital solutions and meaningful analytics. The introduction of potential solutions is therefore often associated with high costs for data preparation.

Exemplary information flow across several steps of the value creation process in injection molding(Work-Center-Layer)

Standardization Guarantees High Data Quality for Future Applications

Vernetzung / Cloudlösung für die Kunststoffverarbeitung

IoT-Plattformen für die Kunststoffverarbeitung

To Get the Information Flow in a Row

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

Mikrospritzgießen

Fließpressen

Handling, Handhabungstechnik für die spanende Fertigung

Handling, Handhabungstechnik

Elastomer-Spritzgießen

Linearroboter für die Kunststoffverarbeitung

Industrieroboter

Montagetechnik

Montage-Spritzgießen

Knickarmroboter

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Hybrid-Spritzgießen (Metall / Kunststoff)

Technical Excellence thanks  to Digital Assistance

M-Hub is the first mobile App that helps entrepreneurs to promote their business and find all players in the plastic industry with the tap of a finger.

M-Hub was launched at the K-show 2019. One year after, the app has reached more than 8000 professionals and 1500 companies from more than 80 countries.

The Plastic Industry in Your Hand

The cluster of excellence “Internet of Production” at the RWTH Aachen University conducts research on structures to realize a “Google of Production”. The Plastics Innovation Center 4.0 serves as demonstration platform to present real-world solutions to the industry already today.

The Plastics Innovation Center 4.0 as part of  a network of research facilities at the Campus Melaten, Aachen, focused to production technology

IKV Offers an Application-Oriented Demonstration Platform for Excellent Research

The PIC 4.0 as Part of the Internet  of Production

User-Friendly Data-Exchange in the Digital Engineering

Part 6 of the Series: How a Web-Based Interface Supports Data-Handling

The multitude of software applications often requires the handling of information in different data formats. It is not uncommon for information to be lost in the process, which is why PIC 4.0 is researching methods for implementing continuous simulation chains.

Digital engineering encompasses the complete development chain of a product, from quality requirements to the design of the product and mold, to process simulation and design. The multitude of software applications often requires the handling of information in different data formats. It is not uncommon for information to be lost in the process, which is why PIC 4.0 is researching methods for implementing continuous simulation chains.

In digital engineering, the properties of a product to be developed are simulated and digitally optimized by a digital but physically adequate representation, taking into account the manufacturing process. The consistent use of digital methods and corresponding software (CAx) increases the planning quality along the entire product development and production process [1].

Due to the complex planning and calculation methods in the respective stages of product development (Title figure), many software applications are used. On the one hand, the applications are specialized in the simulation at the respective stage and therefore process specifically provided information. On the other hand, the users are also often specially trained in the use of these programs and their evaluation. As a result, data handling across different formats and planning stages – especially in case of iteration loops across domain boundaries – is often challenging.

Loss of Information by  Software Combination

One use case is the linking of a computational fluid dynamics (CFD) simulation with structural simulation (Fig. 1). Simulation programs specialized in injection molding use STEP files (*.stp, *.step), stereolithography files (*.stl) or a variety of other geometry data in their own and further established formats to generate a calculation mesh suitable for the simulation case. They determine the expected temperature and pressure distribution, provide a filling pattern including the expected defect features (e. g. weld lines) and calculate properties such as shrinkage, warpage, fiber orientation and residual stresses.

The mesh of structure simulation, on the other hand, can be generated differently in terms of shape and granularity of the elements. In order to make comparisons, the meshes must be mapped to each other, e. g. the nodes and edges of the rigid calculation mesh of a filling simulation must be assigned to the more flexible meshes of a structure simulation in order to consider a mechanical load. A loss of information occurs if interpolation is necessary between nodes of one and another mesh, e. g. due to deviating granularity.

Even when mapping between selected programs and formats using commercially available interface programs, information about the granularity of the output mesh is often lost after interpolation or after rounding of edge lengths in the output mesh. Here, it is necessary to keep track of the output mesh as well as basic mesh information such as the size, order and shape of the elements and the structure of a mesh at the respective stage of development.

Development of a User Interface to Facilitate Data Handling

One solution for a user-friendly data handling is a web-based user interface newly developed as part of the Plastics Innovation Center 4.0 (PIC 4.0) research project. It accesses a database with available simulation files and provides insight into how calculation meshes change in the product development process. In addition, it supports simulation and production processes by generating test plans and automatable optimization routines directly from the application.

For the targeted development of the user interface, a specific use case is considered in which a product for optical applications is to be designed according to defined requirements [3]. This concerns the material selection and the product geometry as well as the manufacturing process. The high requirements on the thermo-optical design of lenses often require a complex development process involving many iterations. Even if the first products have already been produced, the mold geometry often still has to be digitally measured and adapted accordingly. In addition to process simulation in software applications such as Moldex3D, the project focuses also on structure simulation using Ansys or Abaqus to design the optical properties.

From Uploading Geometry Files to Finally Export Machine Settings

The web-based user interface developed in the JavaScript web framework Vue.js (Fig. 2) simplifies the setup of an injection molding simulation in a selected application. It also supports the optimization of setting parameters through the automated evaluation of simulated design of experiments (DoE). The web application guides the operator from the initial upload of several geometry files for part, sprue and cooling channel layout through the entire development process to the export of a machine settings of a desired target machine (module area).

Available models and target applications are displayed in the project preview so that the dataset can be obtained directly via the user interface (simulation setup  download simulation). If a corresponding dataset is not yet available for the requested simulation software, it can be generated via the interface (simulation setup  create simulation). Some basic information about the available datasets is displayed directly in the preview area (part information).

To set up a new simulation project, corresponding files are first uploaded to the user interface via the geometry import and assembled into a simulation project for the target application. For this purpose, the individual geometry data for the component, cooling channel layout or sensor positions are combined in a project file suitable for the target application. After the gathered master data for the simulation project as well as the mesh information have been transferred or manually adapted, the project and geometry files are stored in the object database MinIO of MinIO Inc. (USA). Thereby, they are available for further processing of the parameter and structure optimization in the geometry module of the web application.

Optimization of Quality Models and Neural Networks

As soon as the geometry data is available, a trial plan can be generated via the DoE-module in order to determine and analyze the effects of relevant parameter variations by simulation. For this purpose, the user interface generates a trial plan in the background based on the desired factor combination and simultaneously triggers simulation tasks for the respective trial points. These are sent directly to the selected simulation program via the interface to set up and start simulation of trial points independently of the target application in the user interface.

The corresponding module enables the optimization of the setting parameters and generation of machine-settings on the basis of the simulated test plans. On the one hand, optimization based on quality and process models from statistical analysis is planned, and on the other hand, data-based optimization, e. g. with the aid of neural networks.

In the module for geometry optimization, the automatable iteration of the process and structure simulation is carried out up to the simulated ideal of the component geometry. Each iteration includes both the necessary mapping of the calculation meshes to each other and the storage of the meshes with the relevant mesh information. This ensures that changes in the calculation mesh can be tracked by the mapping and that it is possible to jump to any point in the iteration. The final geometry as well as the recommended process settings are conclusively displayed in the module.

Data Standards Enhance  Individual Workarounds

The web-based user interface is already capable to connect to the Moldex3D simulation environment. Simulation projects can thus also be created and initiated outside the actual simulation application. Due to the modular character of the user interface, the implemented methods can also be individually further developed and reused, for example to send parameter combinations of a simulated test plan directly as an order to the injection molding machine.

In the following, the PIC 4.0 also focuses on the integration of the potential data standard VMAP, which was developed by industry representatives along the value chain in a research project “Virtual Material Modeling in Manufacturing” completed in 2020 [4, 5]. It is intended to facilitate the consistent exchange of information between applications in digital engineering and thereby further increase the functionality of the user interface. Thereby, information about the calculation mesh might automatically be extracted by the presented user interface without the necessity of application-specific formats or converters. At the same time, a unified data format like VMAP might support automation of a quality-oriented data exchange and comparison between models in digital engineering and high-frequent data from real production processes.

[1] Schumann, M.; Schenk, M.; Schmucker, U.; Saake, G.: Digital Engineering – Herausforderungen, Ziele und Lösungsbeispiele. In: Schenk, M. (Hrsg.): Digitales Engineering und virtuelle Techniken zum Planen, Testen und Betreiben technischer Systeme, 14. IFF-Wissenschaftstage 28.-30.06.2011, pp. 191–200

[2] Balcerowiak, D.: Entwicklung eines geschäumten, thermoplastischen und lokal endlosfaserverstärkten Leichtbauteils sowie Konzipierung der erforderlichen Werkzeugtechnologie und Fertigungszelle mit variantenreicher Produktion. Masterarbeit, RWTH Aachen 2016

[3] Hopmann, C.; Loosen, P.; Stollenwerk, J.; Liu, B.; Gerads, J.; Hofmann, J.: Kunststofflinsen im Laser sind möglich. Gekoppelte Prozess- und thermooptische Auslegung. Plastverarbeiter 72 (2021) 4, pp. 22–25

[4] Fassas, A.; Mokios, G.: Mapping made easy: How the new VMAP interface standard can be utilized in ANSA towards smooth preprocessing. In: N. N. (Hrsg.): NAFEMS World Congress 2019. Québec City, Canada 2019

[5] Liebold, C.; Haufe, A.; Vinot, M.; Holzapfel, M.; Dittmann, J.; Böhler, P.; Fritz, F.; Finckh, H.: Lessons Learned from Developing a Digital Prototype within the ARENA 2036 Environment and Improvements with the new VMAP Standard. In: N. N. (Hrsg.): NAFEMS World Congress 2019. Québec City, Canada 2019

Institut für Kunststoffverarbeitung IKV in Industrie und Handwerk an der RWTH Aachen

https://www.ikv-aachen.de

Ausgabenartikel

Stages of an exemplary product development process for a load-balanced saddle equipped with different tapes

Fig. 1. Linking CFD and structure simulation to get an ideal product design [2] 

Fig. 2. The web-based user interface supports initializing an injection molding process simulation independent from the target application 

Name - Hauptartikel

Univ.-Prof. Dr.-Ing. Christian Hopmann has held the Chair of Plastics Processing as Head oft he Institute for Plastics Processing (IVK) in Industry and Craft at RWTH Aachen University, Germany, since 2011.

Pascal Bibow, M.Sc. RWTH, has been working since September 2016 on intelligent production systems at IKV. Since January 2020, he has been managing director of the Plastics Innovation Center 4.0; <a href="mailto:pascal.bibow@ikv.rwth-aachen.de">pascal.bibow@ikv.rwth-aachen.de</a>

Ben Liu, M.Sc. RWTH, has been working since April 2019 on automated data exchange for targeted analysis with respect to Digital Engineering in injection molding.

The construction of the Plastics Innovation Center 4.0 is funded by the State of North Rhine-Westphalia and by the European Regional Development Fund (ERDF).

In the following article, the authors report about digital shadows from setting up and testing initial PIC 4.0 Testbeds, as well as their storing and processing by smart agents. It will be published in one of the next issues. The previous part has been <a ext="tango:{f0232aa8-a74c-4078-9146-8ea0ebb04235}">published in issue 5/2021</a>.

<a href="http://www.ikv-aachen.de/forschung/efre-pic-40/" target="_blank">www.ikv-aachen.de/forschung/efre-pic-40/</a>