Wittmann Battenfeld: Hall 16 | Booth D22
Wittmann Robot Systems: Hall 10 | Booth A4
Wittmann Battenfeld is presenting its range of new developments, with the main focus lying on the machines from the PowerSeries. The company will be exhibiting large-scale machines such as the new MacroPower 1500 and the MacroPower E 450 in a hybrid version, with an electric injection unit and a servo-hydraulic clamping unit. A production cell consisting of two MicroPower 15 machines, representing the smaller compact machines, will demonstrate a state-of-the-art example of “lab on a chip” production for the medical industry.
Hybrid injection moulding machine for high speed IML
Wittmann Battenfeld will present its MacroPower E Hybrid machine combined with a high-speed IML system, which is attuned to the machine. The MacroPower E 450/2250 on display consists of a servo-hydraulic two-platen clamping unit which has been combined with an all-electric injection unit. High injection speeds of up to 450mm/s can be reached. The clamping and nozzle movements are driven by a servo-hydraulic drive, while the ServoPower unit consists of a dynamic servo motor and an electrically adjustable axial piston pump with variable displacement.
The ejection movement is also driven by a servo-electric drive, so that precise settings can be achieved as well as highly dynamic movements, according to the company. This machine reaches Euromap class 60 energy values of 10+ which enable the production of plastic parts with minimal energy consumption. This makes the machine suitable for moulds with high numbers of cavities from the packaging and electronics sectors, as well as for thin-walled, high-precision technical parts.
The functionality of this system will be demonstrated by the production of a 13l bucket with a weight of 450g from PP with IML decoration. For this purpose, a single-cavity mould with 24 cooling circuits from Abate, Italy, will be used.
The IML equipment is a W842 HS top-entry system designed for minimal operation times inside the mould as well as for stacking of the finished buckets. The IML robot takes banderole labels from a vertical label dispenser, which is capable of holding labels ranging from 800 x 200mm to 1000 x 350mm in size, and inserts them into the cavity on the fixed mould half with the help of a dummy core. To minimise the cycle time, removal of the finished buckets and insertion of the labels are carried out simultaneously.
MacroPower 1500: representing the large range
With this model, the company has extended its MacroPower range of large-scale machines to six sizes, ranging from 400 to 1,600t in clamping force. The machine shown at the K, a MacroPower 1500/8800, features the possibility of lateral mould insertion and a 1,600 x 1,250mm diagonal distance between tie-bars. A ground shaft made of polypropylene (PP) from Borealis will be manufactured in a mould supplied by the Austrian mould maker IFW. Its four outlet apertures for pipes branching off are formed with the help of complex core pull technology. The parts are removed and stacked by a W853 Wittmann robot.
Energy efficiency highlight: all-electric machines
The company is also showcasing three injection moulding machines featuring the all-electric, energy-efficient EcoPower which feature a combination of drive technology software with KERS energy recovery technology.
As an optimal combination for longer cycle times, an EcoPower 300/1330, equipped with Airmould gas injection technology, a hockey stick will be manufactured from LGF-PP in a mould supplied by Haidlmair, Austria. With the new nitrogen- and- pressure generator developed in-house, a gas channel with a length of 1,300mm is created inside this moulded part. The part is produced by a partial filling process: first, a piece of sheet supplied by Verstraete, Belgium, is inserted at the end of the flow path; here the gripper is designed for handling the insertion of the sheet as well as parts removal. The cycle time is 105s, cooling time 60s.
In cooperation with mouldmaker Schaumform, Germany, an interior component in structured foam technology will be manufactured. In this application, the company’s Cellmould and BFMold processes are combined to enable the production of light-weight structured foam parts with a high-quality surface. An all-electric EcoPower 240/1330 will be equipped with a mould from Schaumform. The process is being carried out on an all-electric toggle machine for the first time.
On an EcoPower 110/350, LSR penholders will be manufactured in a four-cavity mould supplied by RO-RA. The mould technology allows moulded parts to be manufactured from liquid silicone without sprue, virtually free of ridges and fully automatically. Due to their special design, the penholders adhere automatically by suction to any smooth surface when a light pressure is applied. The penholders are removed, deposited on a conveyor belt and filled automatically by a W818 robot.
Micro injection moulding for medical “lab on a chip”
The company will also showcase a medical technology application consisting of two MicroPower 15/10 machines, where a “lab on a chip” part for analysing blood particles will be manufactured by assembly injection moulding under cleanroom conditions. Both machines are equipped with W8VS2 Scara robots, rotary plates and cleanroom modules.
In a two-cavity mould, the first machine produces the two carrier parts which, following removal, are presented to the inline camera inspection by the W8VS2 Scara robot and then immediately connected with each other on the transfer carriage. The linear axis transports the complete part into the second machine, where the other W8VS2 Scara robot picks up the part and inserts it into the next mould, where the part is overmoulded with TPE.
From robots to drying and temperature control
Wittmann has launched the W842 robot featuring a greater payload and versatility around mid-sized moulding machines of up to 800t clamping force. Due to the rack and pinion drive for the vertical axis, the W842 can handle 25kg of payload. The length of the horizontal axis is variable, and could be executed up to a length of 20m.
The Drymax series will represent the company’s dryer range, including the new Drymax Aton2. A main feature of the new Drymax Aton2 is the thermal energy refeed via the 3-Save Process, taking only what is needed from regeneration energy in order to dry the molecular sieve in the wheel’s segments. Even with this amount of energy, the material drying process air can be heated up to a certain extent.
The company will also present a complete drying battery that consists of a Drymax central dryer and Silmax drying hoppers with an overall volume capacity of 900l. The hoppers are equipped with the so-called SmartFlow functionality which in fact are breath-responsive activated air control flaps. The battery’s hoppers, also breath-responsive, are provided with dry air coming from a Drymax E300-FC central dryer.
The range of temperature control units has also been extended. The new models of the Tempro basic C120 series come in variants in regard to different pumps, and different heating and cooling capacities. With the biggest version of this series, moulds weighing up to 10t can be heated up. The smaller Tempro basic C120 unit has dimensions of just 230 × 690 × 630mm, featuring a delivery rate of up to 200l/min. It comes with a heating capacity of either 12 or 18kW and a pump capacity of 0.75 or 1.5kW. There are many options that can be chosen such as serial interface, external sensor, alarm contact, internal bypass for relieving the pumps, and also manual mould purging. The most powerful model of this series come with either 18, 24 or 46kW of heating capacity. The respective pump capacities range from 200 to 280l/min.