Hall 10 | Booth F4
Swiss company Kistler specialises in dynamic measurement technology for pressure, force, torque and acceleration. Kistler’s technology is used to analyse physical processes, control industrial processes and optimise product quality. At K show 2013 it will be presenting a number of upgrades to existing offers, new products and formally announcing developments in its range.
The cavity pressure sensor helps detect filling errors during RTM processing and faciliates the control of cascade filling processes. (photos: Kistler)
Open-top monitoring
The large-scale repeatable production of lightweight structures is a key technology for the future mobility. The repeatable and reliable production of lightweight components and composite structural parts for “future mobility” (including electric, hybrid and lightweight vehicles) is a challenge for process monitoring and quality assurance. Kistler’s new special sensor for resin transfer moulding (RTM) is designed to enable users to optimise processing of crosslinked moulding compounds for lightweight polymer applications in automotive and aeronautical engineering.
Cavity pressure sensor type 6161AA
The type 6161AA sensor measures cavity pressure levels of up to 200bar and is suitable for industrial applications, including monitoring open- and closed-loop control of RTM processes, high pressure RTM (HP-RTM) and sheet moulding compound (SMC) processes involving pressure levels of up to 150bar. Application examples include recognition of filling errors and control of cascade filling processes through several gates and processing of low-viscosity polymers, such as liquid silicone (LSR) and elastomers. Kistler says that the sensor is also suitable for measuring the vacuum in evacuated cavities, thus recording the condition of the relevant process.
Exchangeable cables
Miniature cavity pressure sensors from Kistler’s portfolio are now available with exchangeable cables. The type 6183C pressure sensor, with a front diameter of 1mm, is the first to offer this new feature. Type 6182C sensors with a front diameter of 2.5mm are the next in line to be equipped. The change means that damaged or accidentally sheared-off sensor cables can be replaced quickly and easily.
A damaged cable of the cavity pressure sensor can easily be replaced in-situ by injection moulders themselves.
The basic sensor type can be equipped with different cables and spacer sleeves to suit different applications. This includes the option of changing from state-of-the-art single-wire to traditional coaxial wiring and vice versa. The type 6183C sensor can also be changed to wireless operation, by installing it into a retainer plate with the help of a charge-conducting spacer sleeve and a contact element. These retainer plates can be changed and installed without sensor disassembly. The type 6183C sensor is equipped with a special venting groove, intended to ensure safe injection moulding of highly gas-emitting polymer types such as polyoxymethylene (POM) or polyamide (PA).
The new sensor is available with a hard chrome-plated front or without coating; the uncoated sensor front can be aligned with the contours of the mould surface. It can be fitted with an anti-rotation lock to ensure precise positioning.
End to end monitoring
Kistler will be exhibiting a new longitudinal measuring pin for non-contact cavity pressure measuring. Injection-moulded optical parts for automotive engineering applications and domestic appliances, such as lenses, optical fibres and parts with class A surfaces, must be free of visible marks caused by ejectors or sensors. Kistler’s non-contact pressure measuring equipment is claimed to be an “elegant system solution” for cavity pressure-based process monitoring and quality assurance.
The new type 9239A longitudinal measuring pin, which has a diameter of 3mm, can be either installed in the mould structure behind the cavity wall or integrated into the compression plunger, where it measures the compression of the mould during the injection phase. Kistler says that the small dimensions of measuring pin offer mould makers wider installation options, such as in small or complex multi-cavity moulds. The sensor’s signal can be used for process optimisation, monitoring, and for quality data documentation of the production lot.
The smaller measuring pin complements the range of larger, 5mm diameter type 9247A sensors.
Process monitoring upgrade offers new features
Kistler says that the V2.4 firmware upgrade for its CoMo injection process monitoring system offers better functionality and new features intended to help processors get to zero-defect production more quickly. The integrated automatic mould recognition function incorporates automatic loading of mould data during changes. Connection errors are said to be detected quickly. So they can be remedied before they can cause any damage. Synchronised processing of uniform evaluation objects for pressure monitoring multi-cavity moulds has been made easier. Evaluation objects of the same type (e.g. maximum) can be selected across channels and subsequently processed synchronously.
CoMo process monitoring system
New options for MultiFlow, CoMo’s automatic hot-runner balancing function, include “Smooth Control” mode, which enables tip temperatures to be controlled at smaller intervals. This means that injection moulding processes involving polymers with temperature-sensitive viscosity can be controlled more accurately. Kistler says that these improvements are of particular benefit in multi-cavity mould production of thermoplastic elastomers and similar compounds. According to Kistler, individual process variations are now detected reliably, which helps to eliminate their effect on process control. MultiFlow has an automatic start-up function, which is triggered during production start-up and after production downtimes.
The CoMo injection system’s output channels for controlling reject gates or removal robots are now easily tested via “One Touch” check, which is said to provide reliable separation of rejects and makes operation more comfortable. The new upgrade allows network-based data management.
Different LabKit modules connected to the CoMo injection system
As an industrial process monitoring system, CoMo injection is equipped with connectors for multichannel technology as standard but, in some cases, sensory equipment for testing purposes may require a higher level of connective versatility. Kistler says that CoMo can be made more adaptable by the fitting of its new “Lab Conversion Kit” (LabKit), which allows the direct connection and exchange of individual sensors as required. Modules for individual charge and voltage signals and modules with integrated amplifiers for type K or J thermocouples are also available. Easy assembly and disassembly allows processors an easy switchover and full use of either multichannel cable technology or separate connections.
www.kistler.com
