Several new technologies that are increasingly cost effective were exhibited at K 2010 for injection molding. Machine makers are beginning to re-invigorate hydraulic machine designing, pointing to the fact that hydraulic technology is here to stay, .
Arburg‘s exhibition highlights included a world premiere of the Selogica“Set-up Assistant“ module. The Selogica Assistant is a uniquely simple, menu-guided procedure for supervised setup, with “teaching” functions for the entire mold sequence. Operators are led through five logical steps to create an entire cycle sequence. Arburg demonstrated novel overmolding technology from German moldmaker Zahoransky Formenbau GmbH. Zahoransky’s Servo Cavity Positioning System (SCPS) indexes sets of cores and parts upward through a mold by means a of a servo-driven spindle without having to open the mold between cycles. The cores and parts eventually pass through the top of the mold for external demolding without any effect on cycle time. SCPS was demonstrated with a 12 cavity toothbrush mold running in Arburg’s all-electric Allrounder 720A with 320 ton clamp and twin injectors. A new retrofittable, two-stage micro-injection unit (2.3 cc capacity) was displayed for its electric Allrounder A machines. In hybrids, Arburg is expanding the Hi-drive line introduced at Fakuma with a bigger model-500 ton, which has a hydraulic accumulator for high-speed injection Husky Injection Molding Systems introduced all-electric injection moulding machines aimed at PET preforms and medical moulding. Husky, that has long eschewed all-electrics, was seen favouring hydraulic and hybrid technology. Two small-tonnage, all-electric presses were introduced: the H-PET AE and the H-MED AE (all-electric). Both presses will complement Husky’s product line based on the Hylectric platform, a hybrid technology that combines both hydraulic and electric power. The AE presses will be a smaller size than the Hylectric platform, but offer the same performance and quality. H-MED AE is a completely integrated, clean room compatible, all-electric system that will offer the speed, quality and control demanded by medical customers, as well as the precision and repeatability. With the launch of the H-PET AE, Husky has applied its experience in beverage packaging to develop a small, efficient and low-maintenance all-electric solution that is purpose-built for PET preform manufacturing. H-PET AE is designed for moulders in emerging markets and low-volume or custom producers in more mature economies.
KraussMaffei demonstrated overmolding a rigid thermoplastic substrate with three-component thermoset polyurethane (PUR) in the same mold. An MX large two-platen hydraulic machine molded the substrate and overmolds part of it with TPE. Another portion of the substrate will be overmolded with PUR by a KM RimStar Nano metering unit integrated with the injection machine.
Engel’s approach to PUR overmolding uses a very thin, clear coating of PUR, not for soft-touch, but to protect a decorative film back-molded with the rigid substrate in the first of two machine cycles. This combination technology could also be used to robotically dispense PUR foam-in-place seals and gaskets on freshly molded parts. Two-shot molding of a PUR seal on a thermoplastic part injects Ceracon’s one-component S-FIT PUR system, which is physically foamed with compressed air and has a heat-activated catalyst to cure in the mold. PlasmaTreat’s contribution is use of its atmospheric plasma technology to selectively treat the mold surface between cycles with an anti-stick coating to counteract the PUR’s adhesiveness. Machine builders are launching new series and upgrading or adding new sizes to existing lines. Engel, for example, has added a smaller model (100 ton) to its e-motion T all-electric tiebar presses and also is rolling out the e-cap system, an all-electric line dedicated to caps and closures and designed to compete with hydraulic accumulator machines. Engel and KraussMaffei will highlight a different sort of overmolding approach for so-called “hybrid” composites. In the past, these have involved selective “outsert” overmolding of preformed sheet-metal pieces. In the interest of weight savings, the R&D focus is shifting to long-fiber plastic reinforced sheet as the substrate. Both have approaches to forming preheated sheet in the mold and then overmolding ribs, attachment points, etc., possibly with the addition of foaming or gas assist. KM will use its CX Series 300 ton injection molding compounder to chop and blend continuous glass fibers with nylon for the overmolding compound.
Sumitomo Demag will combine two-shot molding with in-mold decoration (IMD) using two different films on one part. This IDM-Multi-K process will be demonstrated on a hydraulic Systec multi 210 press producing an auto interior part under Class 10,000 cleanroom conditions. It will use clear and colored resins and both translucent and “piano black” IMD films for a day/night viewable panel. Sumitomo Demag is also expanding its hydraulic Systec line with larger models of up to 1000 ton; sizes up to 2000 ton are in the pipeline. Variable-speed pump drive, called Active Drive has been added to its hydraulic presses, reportedly cutting energy consumption by as much as 45%, depending on the cycle. Four new models up to 450 tons were introduced in its IntElect Smart all-electric line. The IntElect Smart series (50 to 450 tons) is based on Japanese SE electric drive technology and is the company’s all-electric version with the highest speed and precision. The IntElect Performance version is based on Demag technology and has water-cooled electric drives (vs. air-cooled on the Smart series), which makes it optimal for some cleanroom uses. Also on display was a new generation of its El-Exis hybrid dedicated to high-speed packaging operations. The El-Exis SP ranges from 150 to 750 ton and has a hybrid clamp, direct-drive servo screw rotation, accumulator-assisted injection, and NC5 control with touchscreen and keypanel (an enhancement of the NC4 predecessor).
Wittmann Battenfeld exhibited its completely redesigned all-electric Microsystem micromolder, now available in 5 and 15 tons. Also displayed was its water-assist Projectile Injection Technology (Aquamold PIT) and new Ball-Filled Mold (BFM) for faster heat/cool molding. The company displayed four additional models in its new EcoPower all-electric series, extending the range from 55 to 300 ton.
Haitian of China has added to the Zhafir Venus Series of all-electrics introduced at NPE 2009 a new VE/p (packaging) version with increased injection speed and response time of 25 millisec, as well as a special high-performance screw. The VE/p is said to cost 30-40% less than most premium all-electric machines from Europe or Japan. Another premiere from Haitian is the Zhafir Mercury Series of all-electric tieberless machines with two-stage injection for high-end molding jobs. Production will begin in 2011 of models from 30 to 500 ton. Haitian is bringing out a lower-cost version of its Mars series “hybrids,” which are hydraulic toggle machines powered by a servo pump. The new Mars Eco series from 60 to 1000 ton is aimed at “simple standard parts”. It has a “streamlined” option package and prices around half those of European standard presses.
Negri Bossi introduced a completely new all-electric design, the FE Series of 120 to 400 ton. It has an improved belt drive, energy-recovery system, max. injection speed of 230 mm/sec, and new CANbus touchscreen control. Negri Bossi’s Vector Series of hybrid toggles with electric screw drive has been redesigned. Ranging from 800 to 1500 ton., the line has a new gearbox that’s quieter and more efficient, increased stroke on the clamp and ejector, easier access to the mold area, quick-change injection unit, variable-volume pumps, and touchscreen controls. It’s Janus modular hybrid toggle line has been expanded with the new Smart Energy system (Janus SE), which combines energy efficiency approaching that of an all-electric with performance above that of electric machines. From 160 to 900 ton, Janus SE combines a variable-speed electric pump motor and a hydraulic accumulator. Negri Bossi is also introducing the VS-E Series of modular hydraulic toggles with a servo pump drive, said to cut energy consumption by 45% vs. standard hydraulics. This is one variant of the brand-new modular VS Series of 110 to 430 ton hydraulic presses. They have quick-change injection units, larger mold capacity, variable-volume pumps, and new Columbia controller with 15 inch TFT screen. Ferromatik Milacron Europe demonstrated a high-speed 300 ton Vitesse hybrid machine molding rectangular lids in a 4+4 stack mold with PP film labels in one parting line and paper labels in the other, on 5-sec cycles. The F-Series displayed will gradually replace the existing Ferromatik Milacron lines, including the Elektra all-electrics, Vitesse hybrids, and K-Tec hydraulics. The complete F-Series will span 10 models from 50 to 650 ton aimed at packaging, consumer goods, and medical parts. This single machine series will be highly modular to allow a choice of emphasis on performance, energy consumption, dynamics, or precision. Molders can mix and match electric or hydraulic drives for each machine axis, providing customized all-electric, hybrid, and hydraulic options.
Netstal introduced two new hybrid models; with the Elion brand that has designated its all-electric range, though the new machines incorporate the hybrid injection unit of it’s Evos line. The new Elion 2200 (220 ton) and 2800 (280 ton) have electric clamp and screw drive but hydraulic injection. They are also the first machines to show off the new, freely programmable aXos sequence control. Current Netstal machines have a fixed sequence that can be influenced by over 15,000 parameters. With aXos, any sequence the process requires can be programmed. Inconsistencies will be highlighted automatically before activation. The system includes an auxiliary control definition page, and freqently used auxiliary controls, like a core puller, will be built into the system. Molders can use the pre-configured auxiliary controls or build their own with a few clicks. Besides the main screen, there is an icon-based upper screen and folding membrane keyboard for manual operation.