iq flow m2017 - molding conference 2020 - molding 2020 · engel austria gmbh | 10.2016 | 29 engel...
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ENGEL AUSTRIA GmbH | 10.2016 | 1
A New Approach to Optimize Mold Cooling: iQ flow controljoachim kraglDirector Advanced Molding Systems & ProcessingENGEL MACHINERY, INC.joachim.kragl@engelglobal.com | +1 717 968 8106
ENGEL AUSTRIA GmbH | 10.2016 | 2
ENGEL AUSTRIA GmbH | 10.2016 | 3
Mutual Information Chart
Know-how generates momentum | Cooling
4
ENGEL AUSTRIA GmbH | 10.2016 | 4
24 %Up to 24 % of all scrap parts are caused by errors in mold temperature control (or lack thereof)!
(Source: Menges, G; Auffenberg, D; Hüttner, H-J: Ausschussreduzierung in der Spritzgießverarbeitung). Kunststoffberater
Know-how generates momentum | Cooling
ENGEL AUSTRIA GmbH | 10.2016 | 5
flomo | Cooling BasicsHeat Flow in the Mold
ENGEL AUSTRIA GmbH | 10.2016 | 6
• Water Temperature TM
• Heat Transfer Resistance Δ2
• Which fluid (water, oil…..)• Viscosity of the fluid• Flow rate• Bore diameter
• Heat Conduction Resistance Δ1
• Distance to cavity surface – cooling channel• Heat conductivity of the mold built material
Heat Conduction Resistance
Heat Transfer
Resistance
Influences on the Cavity Surface Temperature w
Rule of thumb: +1°C cavity surface temperature 2% longer cooling time
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 7
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35
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60
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0 2,5 5 7,5 10 12,5 15Kühlwasserdurchfluss [l/min]
υ W [°
C]
Heat Conduction Resistance
Heat Transfer
Resistance
Influence of Channel Distance on Cavity Surface Temperature
Aver
age
Cav
ity S
urfa
ce T
empe
ratu
re[°C
]
Cooling Water Flow Rate (l/min)Cavity Wall
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 8
20
25
30
35
40
45
50
55
60
65
0 2,5 5 7,5 10 12,5 15Kühlwasserdurchfluss [l/min]
υ W [°
C]Av
erag
e C
avity
Sur
face
Tem
pera
ture
[°C]
Cooling Water Flow Rate (l/min)
Cavity surface temperature dependent on Reynold‘s number
Laminar Flow & Transition Re < 10000
Turbulent Flow Re > 10000
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 9
20
25
30
35
40
45
50
55
60
65
0 2,5 5 7,5 10 12,5 15Kühlwasserdurchfluss [l/min]
υ W [°
C]Av
erag
e C
avity
Sur
face
Tem
pera
ture
[°C]
Cooling Water Flow Rate (l/min)
Laminar vs. turbulent flow
Laminar Flow & Transition Re < 10000
Turbulent Flow Re > 10000
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 10
Influence of the fluid dynamics on the process stability
Re 20.000
UnstableProcess
StableProcess
Aver
age
Cav
ity S
urfa
ce T
empe
ratu
re[°C
]
Cooling Water Flow Rate (l/min)
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 11
21°C 22°C
23°C
25°C 24°C
26°C
20°C
6 K
22°C 24°C
26°C
30°C 28°C
32°C
20°C
12 K
Flow rate 3 l/min Flow rate 6 l/min
Influence of the flow rate on the thermal uniformity of the mold
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 12
Ave
rage
Tem
pera
ure
diffe
renc
e[°
C]
Flow rate [l/min]
Thermal uniformity
Maximum Temperature Differences
• Common recommendations- Standard Molding: 3 – 5 K- Precision Molding: 1 – 3 K
• Simulation and/or practicalverification recommended
Influence of the flow rate on the thermal uniformity of the mold
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 13
• No Information about mold temperatures
- Temperatures/Flow Rates- Continous Monitoring- Process Changes/Variations- Documentation
Flow meters with limited to no practical use
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 14
& real life installation highlights
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 15
• Process Monitoring
- Monitoring of actual values- Detection of process variations- Addition of circuits is detected and recognized- Closed/clogged circuits will be detected
Advantages of modern manifold systems
flomo | Cooling Basics
ENGEL AUSTRIA GmbH | 10.2016 | 16
flomo e-flomo e-flomo premium
ENGEL flomo | The current flomo familyThe entire range
ENGEL AUSTRIA GmbH | 10.2016 | 17
How it works | flomo – Process Monitoring
• Fail save against contamination virtually maintenance free
• No moving parts • Very low pressure loss
The Vortex-Principle:
Interference body Sensor
Tube
How it works – Vortex Sensor
ENGEL AUSTRIA GmbH | 10.2016 | 18
Intelligent electronics
Pressure / temperature sensorfor monitoring the inlet
ENGEL flomo | Components
Ball valves for main shut offflomo: manuale‐flomo: electrice‐flomo premium: electric
Flow rate / temperature sensorsin each return line
Shut off valves in supply linesflomo: manuale‐flomo: manuale‐flomo premium: electric
Figure: e‐flomo premium
Control / shut off valves in return linesflomo: manuale‐flomo: electrice‐flomo premium: electric
ENGEL AUSTRIA GmbH | 10.2016 | 19
• Visualization on machine controller GUI
• Process documentation- Set values are stored with part data- Process data log
• New Process Parameters- Flow Rate- Pressure- Temperature- Temperature difference
Advantages of modern manifold systems
ENGEL flomo | Visualization/Documentation
Return Set Flow Rate
Return Set Temperature
Return Actual Temp.Supply Actual Pressure
Circuit on/offFlow Rate Differential
ENGEL AUSTRIA GmbH | 10.2016 | 20
50 %Up to 50 % energy savings through intelligent und considerate usage with the available resources
flomo | Energy Considerations
ENGEL AUSTRIA GmbH | 10.2016 | 21
Thermolator Energy
1,661 kWh/hPump Drive Energy
1,459 kWh/h
Heating Engery
0,202 kWh/h 12,2%
87,8%
Energy Flow: Thermolator
flomo | Energy Considerations
ENGEL AUSTRIA GmbH | 10.2016 | 22
Measured Flow Rate – Required Flow Rate
• Reduction of flow rate by 50 %
- No detectable process influence- Stable Operating Point
Connector:
Material: PBT
Flow Rate: 12,4 l/min
Set Point: 70°C
Flow Rate [l/min]Ave
rage
Cav
ity S
urfa
ce T
empe
ratu
re [
°C]
flomo | Energy Considerations
ENGEL AUSTRIA GmbH | 10.2016 | 23
Influence of Pump Size
• 2 Thermolators – 60 l/min – 6 bar- Flow Rate 12,4 l/min- Power 1460 W
• 2 Thermolators – 30 l/min – 5 bar- Flow Rate 9,7 l/min- Power 600 W
• 1 Thermolator 30 l/min – 5 bar- Flow Rate 7,8 l/min- Power 340 W
- 16,7%Total Energy
-28,4%Total Energy
Flow Rate (l/min)In
stal
led
mot
or p
ower
(kW
)Pr
essu
re(b
ar)
flomo | Energy Considerations
ENGEL AUSTRIA GmbH | 10.2016 | 24
Total Energy 3,29 kWh/h
Machine: e-mac 50/50Mold: 1-fachThermolator: 2 x PIOVAN TPH6
Set point 70°CShotweight: 4,81 gCycle Time: 54,8 s
Controller Energy Drive Energy
Heating Energy
ThermolatorEnergy
Lens „light skin“flomo | Energy Considerations
ENGEL AUSTRIA GmbH | 10.2016 | 25
Optimization | Minimized loss
Common situationLong hoses
Serial connection of circuits
Quick-connect couplings
Water manifold close to the moldShort hoses
Minimized pressure drop
Minimized heat loss
flom
o
e-flo
mo
e-flo
mo
prem
ium
ENGEL AUSTRIA GmbH | 10.2016 | 26
- Hydraulic balancing results in even mold temperature distribution
Uneven distribution of cooling water
Heat picture without hydraulic balancing Heat picture after hydraulic balancing
Optimization | Hydraulic balancingProcess optimization
ENGEL AUSTRIA GmbH | 10.2016 | 27
Optimization | Hydraulic balancing
• Base circuit: diameter Ø 10 mm• Insert circuit: diameter Ø 6 mm• Cavity inserts
• High requried cooling capacity• Low flow rates
Hydraulic imbalance is caused by different bore diameters and lengths.
Hydraulic imbalance in injection molds
ENGEL AUSTRIA GmbH | 10.2016 | 28
• Reduction of the flow rate in the base mold toRe ~ 20.000
• Increase of the flow rate in the cavity insertsfrom Re 16.900 to Re 33.500
• Cooling time reduction ~ 7 %• Flat part s = 2 mm• PP
Hydraulic imbalance compensation
Optimization | Hydraulic balancing
ENGEL AUSTRIA GmbH | 10.2016 | 29
ENGEL e-temp
One stop service Sales and service by ENGEL
User interface integrated into the CC300 e-temp needs no operating panel
All process information is displayed on CC300
New and innovative functionsSaving energy in combination with e-flomo and
iQ flow control
ENGEL AUSTRIA GmbH | 10.2016 | 30
iQ flow controlAdvantages
Overview screen
Optimized pump speed
Fully remote
controlledT-control
+
iQ flow control
e-flomo /e-flomo premium e-temp
ENGEL AUSTRIA GmbH | 10.2016 | 31
Fixe
d pl
aten
Clearly arranged
Correlations well visualised
Fast set-up
Alarm visualization
Easy error search
Temperature controlat a glance
Temperature control overview
mou
ldCore 1
Core 2
Circ. 1
Circ. 2
Circ. 3
Circ. 4
Hot run 1
Hot run 2
Moveable moldhalf
Stationaymold half
iQ flow control
ENGEL AUSTRIA GmbH | 10.2016 | 32
Temperature difference control - (T – controlled)
Difference between the supply and the return temperature of a cooling channel
Is a measure for a uniform temperature distribution
What does the temperature difference (T) describe?
Proven practical values are available
Uniform temperature distribution even with process deviations
Set values are not dependent on mold size
Advantages of T control
52°C
50°C
52°C
T=2°C
T=2°C
Set value
Set value
3 l/min50°C
12 l/min
Separate T control for each circuit with iQ flow control
iQ flow control
ENGEL AUSTRIA GmbH | 10.2016 | 33
Example of energy savings
EM 170/80TL / 2 cavity number pad / PP
2 temperature control devices e-temp H8
Supply temperature 35 °C
Shot weight 30,3 g
Insulated barrel
Cycle time 30 s
Intelligent pump speed control saves energy
Energy consumption without iQ flow control
Thermolator2520 W: 57%
drives940 W; 21%
heating730 W; 16%
control unit250 W; 6%
iQ flow control
ENGEL AUSTRIA GmbH | 10.2016 | 34
Example of energy savings
EM 170/80TL / 2 cavity number pad / PP
2 temperature control devices e-temp H8
Supply temperature 35 °C
Shot weight 30,3 g
Insulated barrel
Cycle time 30 s
Intelligent pump speed control saves energy
Reduced energy consumption with iQ flow control
savings1980 W; 45%
Thermolator540 W; 12%
drives940 W; 21%
heating730 W; 16%
control unit250 W; 6%
iQ flow control
ENGEL AUSTRIA GmbH | 10.2016 | 35
Thank you!
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