Technology Showcase (May 01, 2005)

Injection Molding

Faster control for high-precision IMM

As part of a complete remodel of its hydraulic injection molding machines, Nissei has equipped its new FN Series high-precision model with a faster controller, new injection unit and optimized hydraulics.

With the redesign, production start-up response was reduced by about 1/3 compared with the conventional FN Series machines. As well, molding variation due to fluctuating oil temperature has been decreased by 50%.

The new TACT controller has high-speed scanning (500 microseconds). According to Nissei, it doubles the speed of the controller on previous FN models, and improves repeatability about tenfold.

Plastification is improved by use of a new screw design with a large L/D ratio and a heating cylinder. Temperature control is divided into five segments, rather than the previous four.

The FN Series consists of eight models ranging in size from 89 tons to 501 tons.

En-plas Inc. 416-286-3030

Cost-effective IMM

For general-purpose injection molding, Arburg has introduced the Allrounder 630 S ECO. This ECO version has slightly lower specifications in order to offer an attractive price/performance ratio. Those who can live without high-speed injection and machine movements can still achieve lower energy consumption, due to this machine’s twin-circuit pump technology.

The 630 S ECO comes in two versions, each with a clamping force of 2500 kN, which can be equipped with size 800 or 1300 injection units. The injection units have high plasticating levels, and can be swung out toward the front of the machine for screw changes.

Hamilton Avtec 905-568-1133

Faster, more powerful robot

Toshiba Machine’s new TH450 Scara (articulated) robot operates at almost twice the speed and with more power than the company’s high-performance SR424. Faster acceleration makes the TH450 ideal for short distance movements.

The unit incorporates a high-output motor, high-speed ball screws and a lightweight arm, to achieve three-axis speeds of 2000 mm/s. It has a 5 kg payload, and positioning repeatability of +/- 0.015 (X-Y) and +/- 0.01 (Z).

Toshiba Machine Co. America 847-709-7358

Extrusion

Stable single screw extruders

A new range of “off-the-shelf” extruders for technical applications is available from Krauss Maffei. The XS Series run highly stable processes, and are suitable for pipe, profile and co-extrusion applications.

All the XS design features are based on the proven technology of Krauss Maffei’s larger extruders. They are equipped with C4 extrusion line control and AC drives.

Krauss Maffei Corp. 859-283-0200

Compact motor for high-speed extrusion

Davis-Standard recently added torque motors to its equipment offering for some of its high-speed extrusion applications. The motor’s compact size integrates easily into the extruder design, combining both gearbox and motor functions into one efficient machine.

Design advantages include a hollow shaft, water cooling, fewer mechanical components and high rigidity. The motor is particularly advantageous for applications where it would enable processors to remove the screw from the rear of the extruder, preventing disruption of the downstream equipment.

The motor delivers screw speeds of 200 to 300 rpm.

Stephen Sales Group 905-940-5577, Auxiplast Inc. 450-922-0282

Training

IMM training series boosts graphics

Routsis Associates has expanded its Basic Injection Molding training series. “Advances in technology have allowed us to upgrade this training tool with detailed graphics and much more information on the latest molding technologies,” explains Andy Routsis, president. “Although we call it the Basic Series, it will benefit and challenge even the most seasoned processor while laying a solid foundation of molding knowledge for anyone.”

The new Basic Injection Molding series consists of three courses: Machine, Process, & Mold. Each course has been developed using the knowledge of highly skilled and experienced plastics professionals with an emphasis on safety.

Routsis Associates, Inc. 978- 957-0700

Auxiliaries

Thick film heaters optimize heat transfer

Chromalox has partnered with Ohmcraft to provide advanced thick film heating capability for plastic processing applications. Chromalox thick film heaters and sensors can be printed on a variety of metal, ceramic, glass, and plastic substrates. The company has a wider range of patterning available than anyone in the industry with the ability to pattern on flat, cylindrical, concave, obtuse, and non-linear surfaces.

Compared with traditional heating methods, Chromalox thick film heaters provide more direct surface contact to ensure optimum heat transfer. More flexibility in the heater circuit design allows for variable heat output. Lower mass designs provide very fast thermal response for excellent operating efficiency. In addition, the thick film heaters offer higher temperature and watt density designs than typical resistance wire-based heaters.

Chromalox 800-443-2640

Versatile static generator for film or in-mold labelling

A radical redesign by Meech International enables its 990v2 static generator to be mounted vertically on a wall or machine frame, or horizontally on a floor or bench for total flexibility. Applications for the 990v2 include pinning plastic film; bonding materials during the lamination of foils, film and paper and the production of folders; and holding objects precisely during high frequency molding and in-mold labelling.

Typically, the 990v2 generates static charge to create a temporary bond between materials, one of which must be insulating. It combats many problems in film handling and processing such as web wandering, shrinkage during cooling, edge curl, air pockets and wrinkle formation.

This system is safe and easy to operate with clear voltage/current displays for instant verification.

Meech International 800-232-4210

Simplified control reduces robot cost

A new, simplified control system reduces the cost of the latest models of Conair Generation IV beam robots by 10% or more. The Model 4020 and 4030 robots have the same high-performance mechanical features as other units in this top-of-the-line automation family.

The ultra-simple Progress electronic control system uses 32-bit microprocessors and an icon-driven user control panel. Like other Conair robot controls, they use an Embedded Program Source (EPS) system to allow robot cycles to be created from previously written source programs stored in memory. These source programs are freely programmable templates developed by Conair or the customer prior to setup.

The Progress control also supports direct programming and off-line programming.

The new Model 4020 and 4030 high-speed beam robots are intended for use on molding machines with clamps up to 500 or 1000 tons respectively. They are available in all the basic drive configurations, including pneumatic, CNC electric drive and brushless servo drive. A more compact wrist block design reduces mold opening requirements.

Electro-pneumatic components are mounted on the vertical arm rather than the elevated horizontal beam for easy, floor- level access.

Stephen Sales Group 905-940-5577

Two food packaging-approved mold releases

IMS Company has introduced two new mold releases, developed with input from molders who use release products daily. S-6 silicone spray mold release is a mid-range 6% concentration for higher release ability. It contains no ozone-depleting substances and is approved for food packaging.

Formulated with a medium concentration of medium viscosity lecithin, L-6 paintable lecithin mold release minimizes crazing and stress
cracking in polyethylene. L-6 is approved for use when molding food packaging, and can be used for molded parts that will be painted, plated, printed or hot stamped.

IMS Company 440-543-1615

Photo-quality printing on large balls

Challenged by a major manufacturer of basketballs and footballs, Pad Print Machinery of Vermont has developed a pad printing system for balls using the company’s XE Series of pad printing machines.

The size and shape of the balls presented some material handling challenges. “We engineered a system for them that prints 100 degrees over the curved surface of the balls and produces a color-rich lifelike photo reproduction,” says Julian Joffe, president.

The XE machines feature servo controls and PC-based software that allows management production monitoring and troubleshooting. With a 20-gigabyte hard drive, the machines can store and instantly recall an unlimited number of jobs and parameters, which contributes to quick and seamless changeover from one job to the next.

Pad Print Machinery of Vermont 800-272-7764

Gas-assist controller handles non-gas jobs too

A new gas-assist controller that can simultaneously direct a gas-assist project and a non-gas-assist job is available now from Epcon Gas Systems. For the first time since the debut of gas-assist injection molding, molders have the option to use gas-assist auxiliary equipment for non-gas applications.

“Should a molder lose a gas-assist job or have the volumes reduced, they’ll no longer be stuck with that investment sitting idle,” explains Jon Erikson, Epcon president.

The Epcon Advanced III can control the following functions to two injection molding machines at the same time:

* Patented gas assist pressure profiling control of up to four outlets;

* Twelve valve gate sequencer;

* Sixteen zone temperature controller.

Epcon Gas Systems 248-601-0100

Materials

On-line color selection, ordering

PolyOne has launched a free, online tool that allows customers to select from more than 100 standard catalog colors, and also permits real-time online ordering of colorants. The OnColor color selector incorporates Pantone color referencing and identifies resin- and application-specific colorants.

The online tool provides users with detailed information about each hue. For example, technical news, ideal applications, suggested manufacturing processes and quantity pricing are immediately available by clicking the color.

The OnColor selector does not require a software download. It can be found at www.polyone.com/oncolor.

PolyOne Corp. 866-Polyone

Light stabilizer approved for food packaging

BASF’s Uvinul 5050 H light stabilizer has received FDA approval for use in polyolefins that come into contact with food, such as woven tape bags for flour and grain, packaging films and milk containers. Uvinul 5050 H is a sterically-hindered amine which prevents plastics from degrading by scavenging the free radicals that are formed when plastics are exposed to UV light.

Uvinul 5050 H is supplied in a free-flowing, low-dusting form.

BASF Canada Inc. 800-267-2955

Thinner walls for plastic/metal hybrid parts

Plastic/metal hybrid technology, the combination of plastic and metal for structural components, is well established in the automotive industry. To optimize the performance of hybrid technology, Lanxess has developed a new high-flow grade of nylon to permit reduced wall thickness on large hybrid parts.

The Durethan BKV 30 EF grade of nylon 6 has 50% higher flowability than a comparable standard nylon 6, without adversely affecting modulus of elasticity, stiffness, elongation at break or flow line strength, according to Lanxess.

For higher stiffness, Lanxess also offers a highly-filled nylon 6 grade which incorporates about 60% glass fibres. This grade is derived from Easy Flow Durethan, and has the same flowability as a standard nylon 6 with 30% glass fibres. At room temperature, the tensile modulus of this material is 20,000 MPa.

Lanxess Corp. 412-809-1000