Tri-component injection moulding machine in cleanroom design

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Hall 15 | Booth B42 + C58

With a total of 25 exhibits, Engel will show new applications and provide answers to the challenges of the future at the K 2013. Manufacturing cells will combine high levels of process integration, automation and process reliability. On show will be two new injection moulding machines, the e-speed and e-motion 30 TL, the first composite brake pedal produced in a one-shot process and the biggest vertical machine ever presented by Engel at a trade fair.

Also on display will be the e-mac 170/100 injection moulding machine for the production of casings (photos: Engel)

Automotive: composite brake pedal & soft touch applications

Engel and ZF-Friedrichshafen open a new chapter in automotive lightweight design in presenting a stress-resistant plastic brake pedal produced in a one-shot process. The concept for manufacturing a hybrid, organic sheet brake pedal received the Composite Innovations Award in 2011, and since then has been consistently further developed by ZF.

Using a vertical insert 1050H/200 injection moulding machine with an easix multi-axis industrial robot and infrared oven, continuous fibre reinforced thermoplastic semi-finished products (known as ‘organic sheets’) will be heated, preformed in a mould and immediately overmoulded with polyamide (PA). The system produces ready-to-fit components, no cutting is necessary.

In another automotive application, three production processes are combined in a duo 3550/650 pico combi M injection moulding machine to produce dashboards for the Hyundai Kia Automotive Group. In a single process step, the Varysoft process devised by Georg Kaufmann Formenbau, Busslingen, Switzerland, will be used to produce the dashboards from a thermoplastic substrate, a decorative overlay and a layer of polyurethane (PU) foam. The TPE-foils are preheated in an integrated infrared oven. The PU system for this application will be provided by BASF Polyurethanes, while the PU processing system is supplied by Hennecke of St. Augustin in Germany. The integrated production process showcased is automated with a viper 40 double robot and an easix multi-axis robot (for trimming the overlapping foil with an ultrasonic cutting head). To reduce further component weight, MuCell technology is used for the injection moulding of the thermoplastic substrate structure.

V-duo: trade fair premiere with RTM application

The Engel v-duo, the largest vertical machine ever presented at a trade event, will make its trade show debut with another lightweight construction application. A v-duo 700 will produce latch covers for the KTM X-Bow sports car using the RTM process. A number of companies have collaborated to realise this manufacturing cell. Hengersberg-based company Wethje, Germany, is the producer of the components and preforms, while the mould is contributed by Langer, Illmensee, Germany. Hennecke, St. Augustin, Germany is responsible for the HP-RTM system, and the PU-RTM system is provided by BASF Polyurethanes. Finally, KTM Technologies, Salzburg, Austria, is responsible for the component design and the composite-specific construction, including the simulation of the manufacturing process (RTM filling simulation).

A v-duo 700 will produce latch covers for the KTM X-Bow sports car.

Medical: tri-component drip chamber with filter in a single step

A world premiere in the medical section is a drip chamber for blood transfusions, with an integrated filter, that will be produced using an Engel e-victory 310H/80W/50V 160 combi tri-component injection moulding machine in cleanroom design. Each chamber comprises an ABS and a TPE component injection moulded in a single work step. The filter is mounted and joined by means of overmoulding with polypropylene (PP). Conventionally, the two hollow body components are individually injection moulded, the inlay is then fitted and bonded in subsequent process steps. The precision platen parallelism setting on this tie-bar-less injection moulding machine is said to ensure a high level of mould protection. As clamping force builds up, the platen parallelism is automatically adapted to the mould parallelism. Hack Formenbau, Kirchheim, Germany, supplies the mould for this application.

An automated manufacturing cell will produce needle holders for insulin pens

Engel has consistently developed its all-electric e-motion injection moulding series for high performance applications even in the high clamping force ranges. Working with the automation specialist Hekuma, Eching, Germany, and mould manufacturer Braunform, Bahlingen, Germany, the company will feature a highly automated manufacturing cell for making needle holders for insulin pens. The cores of the 96-cavity mould have a diameter of just 0.3mm. To counter deformation of cores effectively, the electric injection unit is equipped with a direct drive. Highly dynamic injection movements and injection speeds of up to 500mm/s can be achieved. A camera-based monitoring system instantly identifies any problems with parts. The showcased all-electric Engel e-motion 440/220 T achieves cycle times of around 5s despite the delicate mould cores.

Packaging: e-speed with up to 800mm/s injection speed

The new e-speed 650 injection moulding machine is said to feature maximum injection speeds with high energy efficiency for wide range of packaging applications. Even with bigger screw diameters from 60mm onwards injection speeds of up to 800mm/s can be achieved, according to Engel. The hybrid machine with the electric clamping unit and hydraulic injection unit has a long opening stroke that enables even large stack moulds to be mounted easily. At the fair, an e-speed 650/90 will produce thin-wall containers in an 8+8-cavity stack mould by StackTeck, Ontario, Canada with a total cycle time of under 4s. The containers will be removed by a robot from Campetella, Montecassiano, Italy.

In-mould labelling of packaging containers looks likely to be another hot topic of the show. For this application the hybrid e-duo 5440/700 with a mould by Haidlmair, Nussbach, Austria will demonstrate how the integration of gas injection technology (Engel gasmelt) and in-mould labelling allows highly decorated, high volume packaging parts such as beverage crates and containers. The use of Engel gasmelt also reduces part weight. A viper 60 linear robot is used for the in-mould labelling. IML films will be provided by Viappiani, Milan, Italy while the cooperation partner for the gas injection technology is Bauer Kompressoren, Aix-Les-Bains, France. The e-duo is latest addition to the duo double-platen machine series.

Engel e-duo 5440/700 for in-mould labelling of packaging containers

Teletronics: efficiency and precision for electronics and lifestyle

The highlight of the teletronics area will be the new all-electric and tie-bar-less e-motion 30 TL injection moulding machine, which will be presented for the first time at K 2013. Combining the benefits of tie-bar-less technology and all-electric drive technology, the company is responding to the needs of the electronics industry in the low clamping force segment. Using a 16-cavity mould, 60-pin board-to-board connectors will be produced which requires high precision as the distance between the pins is just 0.5mm. The machine will work with an injection pressure of 3,200bar, injection speed of 800mm/s and an acceleration of more than 40m/s².

A vertical insert 80V/60 rotary rotary table machine proves that not always is an all-electric machine required to manufacture complex, three-dimensional connectors. Pre-assembled punched parts will be inserted into the four-cavity mould provided by Conttek, Pforzheim, Germany before being overmoulded with thermoplastic.

In a third application for the teletronics industry, Engel will combine CRP construction, minimal wall thicknesses and a high gloss finish to produce casings for mobile electronic devices such as tablet PC, smartphone or e-book reader. At the heart of the demonstration will be an e-mac 170/100 injection moulding machine from the all-electric range fitted with a viper 12 linear robot. Pre-formed organic sheets (pressed in advance using variothermal technology) will be inserted into the mould and overmoulded with PC/ABS, again using variothermal technology. This method allows even surfaces and minimal wall thicknesses to be achieved despite the differing contraction levels of CRP and the cladding material. The housing components, which are produced in high gloss piano black, are also provided with a partial PVD coating. Metallisation of the plastic surface serves as electromagnetic shielding. The PVD coating of plastic surfaces is traditionally performed in a separate intermittent process, but here there will be a demonstration of how a high vacuum process can be incorporated inline within the injection moulding cell.

e-mac 170/100 injection moulding machine for the production of casings

Optical parts: multi-layer technology for optical moulded products

Engel will demonstrate how glass can be replaced by lighter polymers in optical applications by means of overmoulding. An e-motion 200/110 T machine with integrated viper 12 robot will firstly produce a pre-moulded part in a mould supplied by Krallmann, Hiddenhausen, Germany. This part will then be recoated with further layers of the same material in a subsequent step. The approach is an improvement on the single-layer process because recoating removes sink marks, thereby achieving higher optical quality with shorter cooling times, and therefore cycle times.

LIM processing: fully automated, reworking-free and low in burrs

An e-victory 200H/80W/120 combi injection moulding machine, automated with a viper 20 linear robot, will show the fully automatic, waste-free and low in burrs processing of liquid silicone. A mould provided by ACH solution, Fischlham, Austria will be used to produce sensor housings for flow measurement with integrated seals. For the first time, iQ weight control software, patented by Engel, is applied in the system which recognises and automatically compensates for fluctuations in melt quantity during the LSR injection process.

Largest viper 120 robot & new control unit CC 300

Engel will be devoting a special exhibition area to automation. In a world premiere, the new viper 120 will be seen in action at a trade fair for the first time. A nominal load-bearing capacity of 120kg and demoulding stroke of 3,000mm and range of 3,550mm makes this the largest linear robot in its class.

Engel’s new CC 300 injection moulding machine control unit

Engel’s new control unit CC 300, featuring a 21? full HD safety glass touch screen, is also set to be unveiled at K show. The increasing degree of process integration and automation is constantly presenting new challenges. The new operating unit allows injection moulding machines and manufacturing cells to be controlled according to tasks such as mould changing, or according to functions such as injecting. The information displayed concentrates on the essential without having to leave out the details at the next level if necessary. The new central operating element, which provides millimetre-precise accuracy and speed-sensitive control for movements, is called e-move. Entire manufacturing cells, including the viper linear robots and easix multi-axis robots, can be controlled and monitored centrally from the injection moulding machine’s control panel.

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