como injection basis process monitoring system now...
TRANSCRIPT
Kistler est leader dans la conception et la fabri-cation de capteurs de pression et température pour le process de l'industrie de plasturgie.
Kistler propose des solutions complètes de pilo-tage et surveillance des procédés de moulage par injection par la mesure de la pression empreinte.
Ces équipements contribuent à l'assurance d'une production sans défaut "Quality Molding"
New Sensors and Systems for Zero-Defect Injection Molding> Page 2
100 % Quality with BetterProcess Stability for Balda Medical> Page 3
Connector Specialist Fischer Uses Sensors to Eliminate Short Shots> Page 4
NEWSImportant information for our customers from the plastics processing industry Issue 1/2010
QUALITY MOLDING is the 100 % qual-ity seal for injection molding processes. It stands for zero-defect production of electronic, medical and automotive appli-cations thanks to cavity pressure-based process and quality monitoring, process control and hot runner balancing – inde-pendent of machine manufacturer, mold concept and peripheral systems.
QUALITY MOLDING is not dependent on the material because cavity pressure-based quality monitoring works with every material. QUALITY MOLDING is
not dependent on the injection molding machine, but is suitable for every model. QUALITY MOLDING is not dependent on the mold concept because the signifi- cance of the cavity pressure is undisputed,irrespective of the mold type. QUALITY MOLDING is not dependent on periph- eral systems because Kistler systems transmit signals that are understood by robots and reject gates.
QUALITY MOLDING powered by Kistler stands for seamless monitoring of injec-tion molding processes, the detection of
The 100 % Quality Seal for Injection Molding ProcessesZero-Defect Production Thanks to Cavity Pressure-Based Process Monitoring with New Logo
problems during the active production process and the active separation of defective parts. QUALITY MOLDING demonstrates the importance of process monitoring for 100 % quality: production processes monitored by Kistler sensors deliver high-quality parts. www.quality-molding.com
Welcome to K 2010!
From now on, you will encounter the "QUALITY MOLDING powered by Kistler"seal on many Kistler products. Our sen- sors and systems are your guarantee for 100 % quality production and this will set you apart from your competitors. QUALITY MOLDING powered by Kistler will send a clear signal to your customers that you decided for process monitoring and quality without compromise!
For an increasing number of molders, QUALITY MOLDING powered by Kistler has become an essential part of their
day-to-day operations. Find out how Balda Medical and Fischer, the specialist for connectors, benefit from the advan-tages of our sensors and systems in QUALITY MOLDING NEWS, formerly known as "Plastics News". We will also present a variety of sensor and system innovations as well as new products.
Our presentation at K 2010 is a clear commitment to QUALITY MOLDING.I am looking forward to welcoming you to our booth 10F04 in hall 10 or meeting you at our numerous partner projects. Experience QUALITY MOLDING in many live demonstrations – powered by Kistler!
Dr.-Ing. Oliver SchnerrHead of Business Unit Plastics
The CoMo Basic Type 2869B0... process monitoring system provides molders with an easy point of entry into cavity pressure-based quality assurance. The cost-efficient four-channel monitoring unit with four inputs for piezo- electric pressure sensors pro- vides a visual display of the injection molding process, monitors the maximum pres- sure reached within each cav- ity and uses a digital output to control reject gates or ro-
bots employed for separating defective parts. As with all CoMo Injection units, the CoMo Injection Basic is operated on the optional 12,1" TFT color touch display Type 5629A3 or via Ethernet in combination with a standard PC. The CoMo Injection Basic range of functions can be enhanced on a modular basis with software upgrades Type 2806A… right up to the full scope of standard CoMo Injection systems. Upgrades in-clude additional evaluation objects, real-time thresholds for switching functions, or the possibility of exporting data to the CoMo DataCenter Type 2829B... .
The new combined pressure/temperaturesensor Type 6188A… with a unique front diameter of only 1 mm measures thecavity pressure and contact temperature in the same location within the injection mold.
Target applications for the combined sen- sor are medical, electrical and high-preci- sion molding. The documentation of moldcavity pressure and contact temperature provides end users of injection molded
The new piezoelectric diaphragm sensors Type 6162A… and 6163A… are ideal for highly accurate pressure measurement during injection molding and compression molding of low-viscosity melts. The main area of application for these sensors is the production of fiber-reinforced plastic lightweight structures and composite parts developed for the automotive and aerospace industries by means of conven-tional and high-pressure RTM. The new sensors with 6 mm front diameter can also be used for injection molding and compression molding of BMC and SMC,
plastic products with reliable data on the stability of the production process and the quality of the molded products. Meas-ured in combination with the cavity pres- sure as the most reliable value for evalu- ating the quality of the molded part, the contact temperature provides useful ad- ditional process information.
thermosets and liquid silicone rubber (LSR).Sensors Type 6162A… cover the measur- ing range of 0 … 200 bar, while sensors Type 6163A… cover 0 … 1 000 bar. Both are suitable for operating temperatures of between 200 °C and 300 °C and come with a coated front as an option. Thanks to their high sensitivity, these sensors detect even minute pressure changes, which provides information on the process stability, the advancement of cross-linking and the quality of the molded component.
Cost-Efficient Point of Entry to 100 % Quality Injection Molding
New Combined Pressure and Temperature Sensor
High-Sensitivity Sensors for RTM, BMC, SMC and LSR
CoMo Injection Basis Process Monitoring System Now Available as 4-Channel Starter Model
World Premiere for Injection Molders of Medical, Electronic and High-Precision Parts
Even More Reliable Process Monitoring Data on Fiber-Reinforced Plastic and Thermoset Part Production
The pressure/temperature sensor range with the new 1-mm combined sensor Type 6188A… on the left
Highly sensitive sensors Type 6162/6163A… for pressure measurement of low-viscosity melts
The CoMo Basic Injection process monitoring system is connected to an injection molding machine
The production of POM lancet holders for lancing devices and PC/ABS housing shells for blood sugar monitoring systems is faced with many challenging parts such as openings and operating components at the end of the flow path, which in-volves the risk of insufficient reproduction due to incomplete mold filling. In order to minimize this risk, Balda Medical GmbH & Co. KG of Bad Oeynhausen/Germany analyzes all parameters that affect the quality of molded components as part of the mold qualification process and prior to production start-up and operates with Kistler process monitoring systems to meet their quality assurance require-ments.
The visual display of the cavity pressure alone allows the optimization and stabili-
Balda Medical Opts for Cavity Pressure MonitoringMedical Engineering Specialist Benefits from Process Monitoring – Not Just During Large-Scale Production
Filigree lancet holders for a lancing device made from PTFE-modified POM
Housing shells for blood sugar monitoring systems made from a PC/ABS blend
Only signals from the CoMo Injection system switch the reject gate from "defect" to "good".
The CoMo Injection system decides whether the robot will pass the finished shells to assembly or not
zation of the production process. The manufacturer increased the injection pres-sure, introduced a pressure-dependent switchover from injection to holding pressure, extended the holding pressure
period and successfully enhanced thepart quality. Dr.-Ing. Oliver Pfannschmidt,Head of Engineering was impressed: "Cavity pressure measurement alone pro-duces the required results. No other sys- tem compares to this ability to provide reliable information on the resulting part quality."
"We also experience benefits during changeovers and installations," Rainer Koops, Head of Production explains. "Our start-up times are shorter, we quickly reach a stable process and we produce less rejects during the initialphase." Oliver Pfannschmidt: "We use cavity pressure measurement for all com-plex and tricky aspects of the process, which allows us to evaluate the part quality on-line."
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Contact elements facilitate the transmis-sion of pressure signals within the mold. The contact areas of contact elements that are installed in different mold plates provide the connection between the cables. This way, sensor cables need no longer be guided through several mold plates.
Single-wire cables simply plug into the contact elements. Damaged cables or time-consuming, expensive and compli- cated cabling during sensor and mold in- stallation become a thing of the past.
Kistler offers contact el- ements for one pressure channel Type 1712A… and 4-channel contact elements Type 1714A... .
Easy Transmission of Pressure SignalsContact Elements Allow Easy Equipment of Injection Molds
Contact elements Type 1712A... for one and 1714A… for four sensor signals (not available in the US)
For several years, Fischer GmbH & Co KG of Sinsheim/Germany has been relying onstrategic cavity pressure monitoring by Kistler sensors and systems to ensure a reliable reproduction of plug connectors and electronic houses for customers from the automotive and electronic industry. Erich Fischer, Head of Production and shiftsupervisor Martin Weinzettel are con-vinced that there is no room for cutting corners when it comes to the quality of their injection molded parts because they know that defects cause problems during component assembly or lead to complaintsfrom OEMs and tier-1 suppliers.
Fischer has identified incomplete filling of the cavity, so-called short shots, as the most important cause of bad-quality in-jection molded parts. In the past, Fischer never managed to avoid the occurrence of incomplete molded parts or minor de- fects at the end of the flow path, despite his best efforts - until he introduced proc-ess monitoring based on the cavity pres- sure. "Even if a production process is completely stable, you can never be sure that the parts are completely reproduced. In cases where machine, mold, hot run-ner and material are finely tuned, cavity
www.quality-molding.com www.kistler.com
pressure monitoring is a very reliable tool for improving the quality of the molded parts and eliminating any cause for cus- tomer complaints," Erich Fischer explains.
Fischer is currently operating twenty pro-cess monitoring systems. More than 100 molds are equipped with cavity pressure sensors. "Virtually all our new molds are equipped with sensors and we already retrofitted most of our older molds, too," Martin Weinzettel points out.
Erich Fischer: "Cavity pressure measure-ment is also useful for sampling new molds,for process start-ups and for process op-timization. The pressure profile is a direct indicator of the smooth operation of dis- tributors, tips and controllers. Since we are working with Kistler systems, we have completely eliminated the occurrence of short shots."
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Fischer Eliminates Short ShortsTHE QUALITY MOLDING EXPERTS
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Only Cavity Pressure Ensures 100 % Reliability – Even for Stable Processes
Erich Fischer, Head of Production (left), and shift supervisor Martin Weinzettel rely on CoMo Injection
Fischer manufactures a variety of molded parts and monitors production processes with the help of cavity pressure measurement
The cavity pressure profile acts like a fingerprint of the conditions that produce the molded part. It is the most informative value for part quality evaluation. Deviations from the optimum profile are clear indications of process fluctuations that lead to part defects ranging from incomplete mold filling to overfilling and dimen- sional discrepancies. Hence, cavity pressure measurement has become established as the modern approach to 100 % part quality thanks to 100 % monitoring of large-scale injection molding processes and stands for fast and strategic production start-up without defects.
Kistler offers the most extensive sensor portfolio for all injection molding techniques with easy installation options and intuitive, easy to use, network-compatible systems. Kistler is the world’s leading provider of pres- sure and temperature sensors for the plastics processing industry and the only manufacturer to offer end-to-end monitoring of injection molding processes from one single source.
100 % Quality with Cavity Pressure Measurement