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Injection molding systems suppliers' data sheets.

INJECTION MOLDING SYSTEMS SUPPLIERS' DATA SHEETS

POLYMER Granulators

AUGER FEED GRANULATORS [Tabular Data Omitted]

PRESS-SIDE GRANULATORS [Tabular Data Omitted]

E-SERIES GRANULATORS [Tabular Data Omitted]

ARBURG Injection Molding Machines

ARBURG CMD Technology for the 1990's... The new Arburg CMD injection molding system represents a totally new integrated design which relies on the unprecedented compatibility of mechanical, hydraulic and electrical systems. This fully closed loop injection molding system employs a sophisticated 16-bit multi-microprocessor control in conjunction with intelligent servos on the machine to actively regulate 266 process parameters, automatically correcting deviations as they occur within each molding cycle.

CMD SERIES - Closed Loop with Active Regulation
 Model Shot Capacity (Oz.) Clamp (U.S. tons)
 170 .4-1.2 17
 270 1.2-3.14 44
 370 3.0-8.4 88


ARBURG P Toggle clamp with solid state controls including digital electronic timers and LED confirmation of sequential action on all limit switches, timers and directional valves. PID temperature control of 3 zones and 1 nozzle zone. Hydraulic screw drive with electronic tachometer, screw decompression and cold start-up screw protection.

P SERIES - Toggle Clamp/Solid State Control
 Model Shot Capacity (Oz.) Clamp (U.S. tons)
 170R .79-1.55 28
 170P .79-2.2 40
 305S 2.38-7.49 77


ARBURG-D Direct hydraulic clamp with microprocessor-programmed logic and digital control of multiple speeds and pressures for clamp movement, melt injection and cycle times. Patented regenerating clamp system and electronically controlled pump produces only pressure and oil volume required for each cycle phase with energy savings of up to 43%. This new generation of proven Hydronica machines offer real time visual display of active machine parameters with data storage for up to 60 programs, fault diagnosis in clear English, and fully programmable ejector force, injection speed and pressure. Reliable, repeatable and precise.

D SERIES -- Hydraulic Clamp/Microprocessor Control
 Model Shot Capacity (Oz.) Clamp (U.S. tons)
 220 .79-2.08 28/40
 270 .79-6.1 40/55
 320 2.38-7.49 55/83


PIVOTING CLAMP OPTIMIZES ARBURG FLEXIBILITY Injection at the mold parting line with either horizontal or vertical clamp is possible on specially equipped "U" model Arburg machines.

Support Equipment

Polymer Machinery offers a complete line of custom-built support equipment from leading manufacturers, sized expressly for Arburg machines.

CHILLERS Manufactured by ADVANTAGE ENGINEERING, INC. Air cooled models feature finned tube evaporator and expansion valve for high heat transfer efficiency and reliable operation without freezing. Condenser is prop-fan driven with full rated capacity to 85 [degrees] F. Water cooled models feature tube-in-tube condenser design for economical use of water at full rated capacity.

TEMPERATURE CONTROLLERS Manufactured by ADVANTAGE ENGINEERING, INC.

* Open and closed circuit designs to

suit all process water conditions. * Single and dual zone configurations. * Oil units available for high

temperature applications up to 500 [degrees] F.

ONE-PIECE CONVEYING SYSTEMS Manufactured by E.M.I. Two models are available: Model 9-KK-45B (for through the base discharge), Model 9-KK-45S (front and rear).

VACUUM AND PROPORTIONING HOPPER LOADERS Manufactured by NOVATEC [TM] , INC. Model VL-3 -- vacuum loader conveys up to 500 lbs./hr. Model VL-4 -- proportioning vacuum loader -- rates to 700 lbs./hr.

HOPPER DRYERS Manufactured by NOVATEC [TM] , INC. (MD Micro Dryer Series)

* Automatic regeneration cycle

provides continuous drying -- no

cartridge changing. * Dual tower design means low dew

point of --40 [degrees] F guaranteed.

MAP--MOBILE AUXILIARY PLATFORM Auxiliary equipment is dedicated to a single mold and moves along with it from machine to machine on a moveable platform. MAP dramatically reduces set-up time, making robots and other auxiliary equipment far more attractive for short molding runs.

HANDLER [TM] Robotics

UP & OUT Features:

* Up to 110 [degrees] pivot to front or rear

of machine * Fully programmable operation

with microprocessor control * Light weight, compact unit

mounts directly on small molding

machines * Fast, positive pneumatic drive * Optional adjustable mounting

base * Optional 32" stroke

UP, OUT & ROTATE Features * Multi-function end-of-arm tooling

for simultaneous sprue and/or

part handling * Fully articulated wrist action can

be programmed for precise

positioning and orientation of parts on

conveyor, assembly table or in

nested packaging * Rotates to front or rear of

machine in up to 110 [degrees] arc * Positive 100% separation of part

and sprue * Optional degating services

UP, OUT & TRAVERSE Features:

* Fully programmable with up to 10 discharge

locations on the traversing beam to suit

specific post-molding requirements * Multi-function end-of-arm tooling for

simultaneous part handling and sprue disposal * Discharge parts in any of 3 planes to

facilitate post-molding automation, eg: indexing

conveyor, indexing or stacking tables, other

assembly, printing and packaging operations.

BIMEX CORPORATION

[Tabular Data Omitted]

BOY MACHINES INC.

STANDARD SPECIFICATIONS

[Tabular Data Omitted]

STANDARD FEATURES -- BOY MODEL 50-M

CLAMP

Patented energy saving clamp with adjustable clamping pressure, coining and breathing

Digital adjustable low pressure mold protection with pressure and position set-up

Pulsating hydraulic ejector with adjustable position, speed, pressure and humber of strokes

Digitally adjustable three stage opening and closing speeds, four zone water manifold

Four retractable tie bars, extended guide bushings for precise mold alignment

Oversized safety gate with electric and hydraulic interlocks, mechanical drop bar safety

system

INJECTION

Screw decompression with 1/2" open nozzle, under temperature screw protection

Choice of 28mm, 32mm or 38mm nitrited screw and barrel assembly

Digitally adjustable (3) three injection speeds, (2) two injection pressures

Two stage holding pressure with selection of stroke or time dependent set-up, pressure

rampable

Four PID closed loop heating zones, (3) three barrel, (1) nozzle with actual and set value

display

Sliding hopper discharge, pivoting injection unit, automatic sprue break

MICROPROCESSOR CONTROL

Automatic operator guidance with suggested values and plausibility checks on set-up

Data memory for 53 complete mold set-ups, internal storage on RAM

Digital setting and read out of all position, time, pressure, speed and temperature values

LED control panel displays all functions, positions and alarms, RPM display

Automatic malfunction shut-down with fault display and diagnostic indicator

Linear potentiometers used for position control, hour and cycle counters, cycle time display

RS232 Bus Connector

HYDRAULIC SYSTEM

Low noise, efficient electronically controlled variable displacement radial piston pump

High capacity heat exchanger, thermostatic water-saver valve, oil level and temperature

alarm

Oil pressure and suction filters with monitoring gauges, oil pre-heating system

STANDARD FEATURES -- BOY MODEL 50 T/2

CLAMP

Newly patented locking mechanism with electronically controlled low pressure mold safety

Opening stroke is adjustable via limit switch, opening/closing speeds are digitally

adjustable

Pulsating hydraulic ejection with electronic control of ejection pressure & speed

Oversized safety gate with electric and hydraulic interlocks, mechanical drop bar safety

system

Close loop water manifold with flow and temperature indicators

INJECTION

Swivel injection unit, available with 28, 32, or 38mm nitrited screw & barrel

Electronically controlled hydraulic screw drive (10-400 rpm), with screw tachometer

Automatic sprue break

Screw decompression (suck-back) with 1/2" radius open nozzle

Sliding hopper discharge

Three stage injection pressures and two injection speeds

Independent and electronically controlled injection pressure, holding pressure, back

pressure

Cycle counter

ELECTRIC SYSTEM

Solid state 24 volt control system in machine mounted cabinet, 220 volt 3 phase 60 cycle

Digital set timers with 0.1 second adjustment in single plug-in module

Digital set pressure and speed controls

LED display signaling pressure and speed functions

LED display monitoring activation of each valve and limit switch

Circuit breakers instead of fuses/electric cabinet door interlocks

Automatic shut down features, including oil level & over temperature monitor

HYDRAULIC SYSTEM

Low noise, efficient electronically controlled variable displacement piston pump

High capacity heat exchange/thermostatic water-saver valve

Externally mounted oil filter/internally mounted suction filter & oil pre-heating system

CINCINNATI MILACRON

VISTA TOGGLE

VT Series Injection Molding Machines

Clamp Tonnage Available: Injection Capacities Available:

[Tabular Data Omitted]

Design Advantages

* Energy efficient variable volume

pump with proportional hydraulics * Interchangeable screw/barrel

combinations for full process

versatility * Efficient, precise twin cylinder

injection units * Twin guide rod injection unit

carriage to maintain nozzle

alignment * Controlled-stress chromed tie rods * Tri-directional part removal base

design * Hydraulics integrated in base for

simpler, cleaner operation * Full time oil filtration with

indicator * Durable balanced toggle mechanism

Standard Features

Control

* Closed-loop injection velocity and

pressure control

* Multi-microprocessors with

diagnostics and audible alarms

* Liquid crystal display

* Internal data storage for 40 molds

* Process monitoring displays and

alarms

* Oil over-temperature alarm

* Feed throat temperature read-out

* Barrel high/low temperature alarm

* Alarms logged with time/date

* Toggle lube maintenance schedule

* Clogged filter alarm

* Control cabinet temperature monitor

with alarm

General * DC solenoids * Closed-loop oil temperature control * Oil preheat sequence * Resettable cycle counter * Machine hour meter

Clamp * Rigid cast platens * Hardened steel chromed toggle pins

and reduced lubrication bushings * Adjustable moving platen supports * Electrically activated hydraulic die

height adjustment * SPI knockout pattern with drilled

ejector plate * Low pressure mold protect with try

again circuit * Pulsating hydraulic eject * Ratchet type, die safety jam bar

Injection * 5-stage injection pressure;

(1) injection high, (2) pack, (2) hold * 5-stage profiled injection velocities * 2-stage back pressure control * 2-stage screw rpm * Dual torque/rpm piston type

extruder motor * Adaptive shot control * PID temperature control * Sprue break * Cold screw start protection * Injection transfer on position,

hydraulic pressure or time * Injection unit swivel for screw

removal * Ball check or slider screw tip * Tie rod mounted for precise

alignment

VISTA HYDRAULIC

VH Series Injection Molding Machines

Clamp Tonnage Available: Injection Capacities Available:

[Tabular Data Omitted]

Design Advantages

* Energy efficient variable volume

pump with proportional hydraulics * Interchangeable screw/barrel

combinations for full process

versatility * Efficient, precise twin cylinder

injection units * Twin guide rod injection unit

carriage to maintain nozzle

alignment * Controlled-stress tie rods * Tri-directional part removal base

design * Hydraulics integrated in base for

simpler, cleaner operation * Full time oil filtration with

indicator * Traverse cylinders * Shuttle tank with simplified pre-fill

design

Standard Features

Control

* Closed-loop injection velocity and

pressure control

* Multi-microprocessors with

diagnostics and audible alarms

* Liquid crystal display or

Electroluminescent

* Internal data storage for 40 molds

* Process monitoring displays and

alarms

* Oil over-temperature alarm

* Feed throat temperature read out

* Barrel high/low temperature alarm

* Alarms logged with time/date

* Oil preheat circuit

* Clogged filter alarm

* Control cabinet temperature monitor

with alarm

* Low lube alarm

General

* DC solenoids

* Closed-loop oil temperature control

* Oil preheat sequence

* Resettable cycle counter

* Machine hour meter

Clamp * Rigid cast platens * Low pressure mold protect with

try again circuit * Automatic tie rod lubrication with

independent frequency adjustment * Prefill designed for fast trouble-free

operation * Adjustable moving platen supports * SPI knockout pattern with drilled

ejector plate * Pulsating hydraulic eject * Ratchet type, die safety jam bar

Injection * 5-stage injection pressure;

(1) injection high, (2) pack, (2) hold * 5-stage profiled injection velocities * 2-stage back pressure control * 2-stage screw rpm * Dual torque/rpm piston type

extruder motor * Adaptive shot control * PID temperature control * Sprue break * Cold screw start protection * Injection transfer on position,

hydraulic pressure or time * Injection unit swivel for screw

removal * Ball check or slider screw tip * Tie rod mounted for precise

alignment

LARGE HYDRAULIC

VL Series Injection Molding Machines

Clamp Tonnage Available: Injection Capacities Available:

[Tabular Data Omitted]

Design Advantages

* Energy efficient variable volume

pumps and precise proportional

hydraulic system * Interchangeable screw/barrel

combinations for full process versatility. * Efficient, precise twin cylinder

injection units * Simplified pre-fill design on clamp * Full time oil filtration with indicator * Advanced, reliable, rugged full

hydraulic clamp, designed in metric

for the world market

Standard Features

Control * Multi-microprocessors with

diagnostics and audible alarms * 9" electroluminescent display * Internal data storage for 40 molds * Closed loop injection velocity and

pressure control * Barrel high/low temperature alarm * Alarms logged with time and date * Oil preheat sequence * Clogged filter alarm * Control cabinet temperature monitor

with alarm * Printer interface

General * DC solenoids * Closed-loop oil temperature control * Machine hour meter * Powered operator's gate

Clamp * Rigid, cast platens * Precise clamp parallelism * Accurate, precise clamp tonnage

control * Outboard traverse cylinders for fast

clamp traversing speeds * Low pressure mold protection with

try again circuit * Adjustable moving platen supports * One-piece clamp casting with self-centering

ram * SPI knockout pattern with drilled

ejector plate * Pulsating hydraulic eject * Ratchet type die safety jam bar * Automatic tie rod lubrication

Injection * 5-stage injection pressure: (1) injection

high, (2) pack, (2) hold * 5-stage profiled injection velocities * 2-stage back pressure control * 2-stage screw rpm * Adaptive shot control * PID temperature control * Sprue break * Cold screw start protection * Injection transfer on position,

hydraulic pressure or time * Injection unit swivel for screw

removal * Ball check or slider screw tip * Tie rod mounted for precise alignment

Feed throat temperature monitoring

ACT Series Injection Molding Machines

Clamp Tonnage Available: Injection Capacities Available:

[Tabular Data Omitted]

Design Advantages

* Controlled-stress chromed tie rods * Tri-directional part removal base

design * Oilless operation * Positioning accuracy +/- .0005 inch

on all axis * Energy saving AC servo drives for:

- Clamp mechanism

- Injection

- Screw rotation

- Ejection stroke * Power consumption reduced up to 75%

Standard Features

* CNC ultra high speed multi-function

color control unit * Process monitoring system and

alarms * Ten step velocity control injection * Four step packing pressure control * Four step back pressure control * Interactive data entry menus * CRT data settings * Mold storage and auto set data for

30 molds * Operating status monitor * Injection profile monitor with

plotting capability * Self-diagnostic functions * Production monitoring * Robot interface * Printer interface * Floppy cassette interface for

unlimited storage * Limit alarms on all barrel zones * Advanced ergonomic operator panel

design * Digital setting and indication of all

positions and speeds * Automatic purge sequence * 3 stage independent air eject * Toggle lube maintenance scheduling * Machine leveling mounts * Tool kit * Robot mounting capacity * Resettable cycle timer/counter * Overall cycle/timer counter * Generous mold space for production

versatility * Durable toggle clamp mechanism * Automatic die height adjustment * Three (3) stage clamp open speed

control * Three (3) stage clamp close speed

control * Low pressure mold protect * Rigid cast platens * Hardened steel chromed toggle pins

and reduced lubrication bushings * SPI knockout pattern with drilled

elector plate * Ejector forward dwell timer * Self adjusting, ratchet type, die safety

jam bar * Pulsating eject * Digital set and indication of barrel

and nozzle temperature * Digital indication of screw speed

and position * Cold start-up protection * Variable torque/RPM servo extruder

motor * PID temperature control of nozzle and barrel * Extruder start time delay * Slide shutoff on hopper * A-B-C screw and barrel combinations

ENGEL

STANDARD INJECTION MOLDING MACHINE SPECIFICATIONS

[Tabular Data Omitted]

HULL CORPORATION

MIGHTY MAC SERIES 25 AND 45 TON INJECTION MOLDING MACHINES

[Tabular Data Omitted]

JACO

* Reliable trouble-free operation * Low energy requirement * Operated for up to 40 hours

before shipping * User serviceable * Readily available American-made

parts * Programmable

Standard Features

Low hydraulic oil cooling requirement because of variable volume pressure compensated pump * EPROM-based programmable logic controller * Self tuning PID digital temperature control * Full hydraulic clamp system with low pressure mold protection * Machine manual with full bills of material and assembly drawings with purchased parts called out by manufacturer's name and part number as well as Jaco number * Purchased components chosen for easy availability everywhere * Allen Bradley switches and starters, Vickers' pumps and valves, etc. * Purchased components chosen for long life * Mercury contactors instead of electro-mechanical for heaters * Machines arranged for easy access for adjustment or repair * Nitrided heating cylinder * Alarm to protect machine, operator, molds and parts * Parts counter

Injection Molding Machines FOR PRECISION PLASTIC PARTS

Machines may be pictured without safety labels for purposes of better photography. Because continued product improvement is a Jaco policy, we reserve the right to modify materials and specifications.

Specifications/Selection Guide

[Tabular Data Omitted]

Options

[Tabular Data Omitted]

Options -- All models

* Process control * Core pull * Unscrewing * Special paint * Oil level & temperature alarm * Melt temperature alarm * Short shot alarm * Thermoset kit * Thermoset configuration * Larger or smaller injection unit * Bi-Metallic heating cylinder

JACO advantages

Excellent Machines. Since the fifties Jaco has constantly improved their machines adding the newest state-of-the-art features.

Fully Tested. Your Jaco machine is tested by 40 hours of production in our plant prior to shipment. When you receive your machine, it is debugged and ready for production.

Advice On Tooling. Our tool designers work with your people to insure that your tooling works efficiently with your new Jaco.

Training. We offer training for your operators, supervisors, set-up and maintenance people in our plant or yours.

Prompt Service. To reduce your service costs, most problems can be handled by telephone between your maintenance people and our service department; but, when you need a service technician, you get one fast.

Parts Availability. Since our machines are designed and built in the USA, parts are readily available from our plant and often from sources in your area. Most parts orders are shipped the day the order is received.

Technical Data -- JE Series

The J-E Series has a state-of-the-art process controller that will bond a lasting partnership between molder and machine. [Tabular Data Omitted]

Remarks: 1) The theoretical injection capacity is cross sectional area of cylinder x stroking

distance of screw. 2) The injection capacity is applicable for GP-PS and variable according to the

grade of resin, molding conditions and mold. 3) The plasticizing capacity is applicable for GP-PS. 4) The total power capacity does not include power for the mold height adjusting

motor (as it is not used while the machine is operated).

Note: Molding of PC (polycarbonate) sometimes requires a very high torque depending on the grade. So, please let us know if you plan to mold PC.

Technical Data -- JE Large-size Machine Series

[Tabular Data Omitted] Remarks: 1) The theoretical injection capacity is

cross sectional area of cylinder x

stroking distance of screw. 2) The injection capacity is applicable for GP-PS and variable according to

the grade of resin, molding

conditions and mold. 3) The plasticizing capacity is

applicable for GP-PS. 4) The total power capacity does not

include power for the mold height

adjusting motor (as it is not used

while the machine is operated).

Note: PC (polycarbonate), low temperature setting, high speed molding, engineering plastic, etc. may require a high torque depending on the grade or molding conditions. Please let us know if you plan. * The practical plasticizing capacity is improved because plasticizing can be done while the platen is opening or during ejection.

Two selections of JSW state-of-the-art process controllers: 1. uPACS-5000 (C5) 14" color CRT. 2. uPACS-300011 LED mounted on fixed platen. [Tabular Data Omitted]

MANNESMANN DEMAG Plastics Machinery

CAS-CAP [TM] NC III MULTI-MICROPROCESSOR CONTROL MAKES YOUR LIFE EASY:

* Miniaturized ergonomic control

console-- IBED. * All inputs/controls from operator's

station. * User selected English, Spanish,

French or German menus. * Sixty mold setups in memory

for instant reload. * Digital setting and display

of all machine parameters. * Self-tuning PID temperature

control -- barrel, nozzle,

feed throat. * SPC with automatic part rejection. * Production Data Acquisition. * Error messages displayed and accumulated

in 250 clear text phrases. * Password lockout of set points (3 levels). * Fully programmable START-UP &

SHUTDOWN. * 4 serial interfaces for computers

or auxillaries. * Multiple microprocessors including

16 bit CPU. * Programmable temperature

reduction on malfunction. * 9 definable soft keys for auxillary

equipment control. * Self-diagnostics including bit status

from IBED. * 2 information screens for alphanumeric

user memory.

Technical Specifications for MACHINE SIZES of 66 to 358 tons

[Tabular Data Omitted]

BETTER REPEATIBILITY, BETTER RELIABILITY

INJECTION UNIT FEATURES * Injection profiling in 8 user-defined segments. * 2 stages of screw speed. * 2 stages of back pressure. * 10 stages of holding pressure. * Patented "Double Ring" non-return

valve. * Pull-back before or after

recovery. * High speed injection

by accum. or regen.

circuit.

CLAMP UNIT FEATURES * Computer designed

5-point toggle. * Automatic clamp force

control. * Central grease lubrication

with monitoring. * Roller platen supports. * Multi-step, multi-stroke eject function. * Hydraulic die height motor with gear drive. * Cast platen to minimize deflection.

HYDRAULIC SYSTEM FEATURES * True digitally controlled flows and pressures. * Simultaneous control of flow and pressure. * Extremely accurate long term repeatability. * Energy efficient cartridge valves wherever

feasible. * Variable volume or fixed stage pumps

for efficiency. * Automatic monitoring of fluid level

and temperature.

PLUS, Several Important Options * CAS-CAP central computer system. * 4 variations of quick mold change

from a simple mechanical type to a fully

automated system. * Robots and other automation equipment

including -- stacking, separating, indexing,

conveying, packing, layering, labeling and

weigh/counting. * Multi-color, multi-component machines, * Integrated hot runner zones, up to 48. * Integrated auxillary equipment controls, i.e., mold

temperature control, dryers, loaders, etc.

Technical Specifications for MACHINE SIZES of 441 to 882 tons

[Tabular Data Omitted]

NEW REED Series TJ Injectin Molding Machines

[Tabular Data Omitted]

AMERICA'S MOLDING MACHINE

REED'S New "TJ" series gives you everything you always wanted in a molding machine...and more! Cycle Master II micro-computer controls-now with 10 times the power of previous controls...Data-Key convenience for storing mold data...Greater plasticating capacity...Simplified, clean, accessible hydraulics...Radial piston screw drive motor that provides quiet, efficient operation...Highly responsive mold protection through patented Hydro-Toggl [TM] clamp...Automatic clamp force setting that you can change "on the fly"...Safety features that exceed industry standards...Reed's renowned energy-saving ability that saves thousands a year per machine. REED's new generation of "TJ" machines-from 150 to 1000-tons--provide the greatest flexibility and moldability available. And they are backed by REED's unparalleled quality and worldwide service.

Notes: 1. Recovery rate, expressing instantaneous

rates, based on Styrene @ 420 [degrees] F, melt

temperature. 2. Values for 2 1/2" and 1 5/8" units are test

values. All others are extrapolated from 2 1/2"

values. All tests performed with 16:1 L/D. 3. Rated at 10,000 PSI injection pressure. 4. SPI Strain gage certified. 5. Dependent upon mold design and plastic

material used.

Technoplas Super High Speed Injection Molding System

PROBLEMS OF CONVENTIONAL MULTI-STAGE INJECTION MOLDING MACHINES

Ordinarily the flow behavior of the resin in the mold does not correspond with the screw forward speed because plastic material in the mold cavity is a viscoelastic compressive fluid. Thus, there are many problems in conventional multi-stage injection molding methods where the screw forward speed is controlled in accordance with the geometry of a molded product. Particularly in the high speed injection region, the molding condition is likely to become unstable, because the resin behavior becomes complicated due to the addition of the difficult factor of inertia of the plastic fluid which generates surge pressure. Therefore, while conventional multi-stage injection molding methods can be practical in screw forward limit molding performed in thin wall cup molding, in precision molding where a cushion amount is required, stable molding cannot be expected. In fact, there is no effectiveness at all for a molded product requiring fine and small metering. Injection molding systems with high injection horsepower are useful only if they are provided with an accurate control system. It is the Technoplas SIM servo control system alone that produces the high speed injection power and precision which is unparalleled in the world and therefore unavailable anywhere else.

CAVITY PRESSURE PROFILE CONTROL

The cavity pressure profile control method developed by Technoplas is substantially different as compared with conventional multi-stage injection molding methods in their controlling objects. The Technoplas method does not control screw forward speed or injection pressure. Instead, it controls resin flow behavior itself in the mold. Thus, rather than setting the screw position, this control system feeds back continuously increasing cavity pressure profile. Depending on the nature of the control system, conventional multi-stage injection molding methods (control of speed at screw position and injection pressure) cannot avoid the generation of excessive cavity surge pressure within the packing area just before the completion of filling. This will cause a flashing , burr, deformation, or damage of the mold as well as overpacking, resulting in a poor quality product. However, with the Technoplas pressure profile control method, the surge pressure can be restricted by setting the cavity pressure at packing and with continuous feedback control (loading feedback) of the rapid rising process of the cavity pressure. Thus, super high speed molding is achieved easily.

SUPER HIGH SPEED INJECTION MOLDING

The reason why molding under such amazingly high injection power as 125kW becomes possible is due not only to the different control systems but also dependent on the total dynamic balance of a very quick responding and large quantity flow hydraulic system and an injection mechanism with minimum inertia of the moving parts. Super high speed injection with the Technoplas SIM shows considerably different phenomena compared with the conventional high speed injection. What it offers not only improves the quality of current precision molded products but now also allows ordinarily impossible components to be molded, thus infinitely extending the field of applications for precision plastics products.

MERITS OF SUPER HIGH SPEED INJECTION

In the case of super high speed filling, as the melted polymer fluid flows in a nearly non-compressive state. there is no elastic pressure variation ordinarily seen in conventional high speed injection, and the resin expansion at the front end is uniform and stable. Viscosity is considerably lowered by heat generation at the gate section, the flow resistance becomes much smaller, and the amount of flow increases several times. Through a very narrow gate, in which the material could not flow with conventional machines, the material can smoothly flow and can fill the cavity easily with very low pressure. Accordingly, cavity damage and mold deformation are avoided. With extremely high filling speed, contraction is minimum and uniform. Bad effects like mold distortion, etc. caused by holding pressure-a serious deficiency in the world of injection molding-can be prevented because gate sealing time is significantly shortened. As the temperature reduction is minimum during the high speed flow, flow distance can be extended several times. (L/t) Residual stress is kept at a minimum and its distribution is uniform. Thus, elastic recovery by heat process is smaller and a high quality product with minimum residual stress is obtained.

CONSIDERATION OF THE MOLD DESIGN

To make super high speed injection possible, a corresponding mold design is necessary. There are three points for considering the counterplan of the mold.

1) Consideration of venting (vent design)-provides vent

grooves on the parting surface over the entire

circumference continuously. In some cases, it is necessary

to provide sprue, runner, core, ejector pin and vent

pin and connect with exhaust device (option).

2) Countermeasure for burr-make clearance less than 10 [Mu]

3) Gate design-selection of gate location, distance, and size

especially the direction of gate is a decisive factor

for the success of super high speed injection molding. Further, in the case of super precision molding products:

4) Design of mold cooling water circuit. These measures are not only necessary for super high speed injection molding but also for conventional molding. The difference is whether this basic philosophy is applied to the design thoroughly or not.

Technoplas Cavity Pressure Profile Control System

The Technoplas system does not set and control injection molding conditions, such as screw forward speed and pressure. Instead, it sets and controls material flow behavior in the mold die i.e., cavity pressure profile. This means that the objectives of control are substantially different from those with conventional multi-stage injection molding methods.

Setting of cavity pressure profile

IV (injection speed): Injection speed until material reaches gate PSV (Initial injection speed): Injection speed until material pressure reaches SSP SSP (Setting of press for starting control): Cavity pressure where control starts operating SP (Cavity pressure setting): Cavity pressure setting required for the product's dimension and weight. ST (Filling Time): Filling time from SSP to SP HT (Holding Pressure time): Holding pressure time to hold set cavity pressure constant Gate Seal: Time until set cavity pressure is reduced.

Operation

When injection initiation signal from the injection molding machine is received, injection takes place at the speed initially set at IV. Then injection proceeds at the speed set at PSV and the material is injected into the cavity. PSV cuts off at the point when sensor senses material pressure. Injection horsepower is continuously corrected and controlled by the servo system minimizing the difference value between the feedback signal from sensor and pre-set cavity pressure profile. After the duration of SET TIME, cavity pressure is maintained within a plus or minus 5kg/[cm.sup.2] deviation from the SET PRESSURE. If pressure deviates beyond this range from the set pressure at this time, the alarm buzzer will sound. After filling is completed, holding pressure control maintains the set pressure constant. In case the operation mode is in GATE SEAL, the cavity pressure starts to decrease, even if injection pressure is increased, because of cooling and solidification of the material at gate section. At this time, the control function stops and an "injection complete" signal is sent to the molding machine. In case that operation mode is in HOLD TIME, after passing the SET TIME, the control output signal of "injection complete" is issued and the control function stops.

Effectiveness (Compared to multi-stage injection methods)

* Stability and repeatability of molding operation.

In this system, as the flow behavior of material in the mold

is controlled to be constant, stability in quality and

repeatability naturally result. Control accuracy is within 0.1% in

weight. The higher the injection speed, the more accuracy

of parts weight is obtained (because of the smaller resin

temperature change inside the cavity). * Irrelevancy to shot volume

Shot volume of less than 1g can be controlled because this

system controls cavity pressure instead of controlling the

material amount, the screw forward speed, or the injection

pressure. * Constant molding condition

In multi-stage injection molding methods, an adjustment for

molding conditions is required when a different injection

molding machine is used, even if the mold and the material are

all the same. But the Technoplas system can maintain the

same conditions regardless of the machine, because it

controls the flow behavior of the material in the mold cavity. * Reduction of loss time and scrap components in

startup period

It takes time for the resin and the mold temperature to be

stabilized because the flow behavior of the material is

continuously changing during this stabilization period. Thus, the

parts molded in this period are not ordinarily usable. In this

system, however, because the material flow in the mold is

servo controlled even during the temperature stabilizing

period, good components are obtained with the smallest initial

waiting time. * Protection of mold

In case of multi cavity molds, if one gate of a cavity is

clogged, it will affect the other cavities and cause over packing

which could destroy the mold. However, in the Technoplas

system, this will never occur because each cavity pressure

is controlled to be a constant value. * Quick determination of optimum molding conditions

In order to determine optimum mold and resin temperatures,

it is necessary to automatically control the volume of parts

to be constant in each one of the shots. In case of a multi-stage

molding method, in order to change the parts volume,

the screw progress speed and pressure should be readjusted

accordingly. Thus, a huge number of combinations of

conditions and a long preparation time are usually needed to

find the optimum conditions. In the case of the Technoplas

machine, only the cavity pressure profile must be adjusted

to find optimum molding conditions.

VAN DORN PLASTIC MACHINERY CO.

Superior Quality and Service

Van Dorn Plastic Machinery Company manufactures injection molding machinery ranging in clamp force from 55 to 3000 tons. A choice of control systems and other pre-engineered options is available to meet specific application requirements. For CIM (Computer Integrated Manufacturing) installations, Van Dorn integrates manufacturing cells to include SPC/QA systems, robotics, automatic mold change systems, parts removal and other auxiliary equipment.

Headquartered in Strongsville, OH, Van Dorn Plastic Machinery Company also operates plants in Brunswick and Cleveland, OH, and Duncan and Fountain Inn, SC.

Quality Assurance

Van Dorn's commitment to quality is more than the quality designed into the machinery. The Van Dorn Quality Assurance Program incorporates extensive testing and quality checks during manufacturing and at point-of-shipment plus a quality assurance followup after shipment. Our goal is to provide machinery to our customers that is of the highest quality in the industry.

Field Service

Van Dorn maintains regional service offices in major cities from coast-to-coast. Factory trained Service Engineers provide fast response to requests for machine service and advice on machine maintenance and operation.

Customer Training

Van Dorn's Customer Training Facility, located in Strongsville, Ohio, provides comprehensive training on all Van Dorn machinery and control systems, including hands-on experience in Van Dorn's two demonstration labs. Training programs at the customer's plant can also be arranged.

Replacement Parts

Van Dorn provides a single source for quality OEM parts, competitive pricing, and fast delivery. An extensive, computerized inventory of replacement parts is maintained to assure customers of quick delivery. All orders from stock are shipped within 24 hours.

HT Series Toggle Clamp Injection Molding Machines 85 to 500 tons clamp force

[Tabular Data Omitted]

Standard Features

Injection Unit In-line injection unit for true center-line transfer of force

from piston to screw Radial piston screw drive motor (20 oz. and up),

selectable for high speed or high torque; 14 oz.: dual

torque gear-type motor; smaller than 14 oz.: single

torque gear-type motor Screw speed tachometer with digital set and display Barrel high/low temperature alarms Cold screw startup protection Sprue break, selectable for nozzle break away, sprue

move away, or sprue break OFF Intrusion molding capability Screw pullback (decompression) before and/or after

screw rotate Swing-away hopper with shutoff slide Pivoting injection unit for easy screw removal

Clamp Unit Horizontal linkage arrangement for easy visibility and

access to the ejector plate Hardened steel toggle pins Self-lubricating bushings Wedge-type adjustable platen supports with self-lubricating

pads that slide on hardened steel ways Slow mold break-away Multiple eject sequences, center ejection capability and

positive stops Full SPI mold mounting and knockout pattern Motorized die height adjustment with pushbutton

operation and automatic power lock

Hydraulic Piston-type variable volume pump that is quiet, rugged,

and energy efficient Proportional directional valves for precision flow control Proportional relief valve for injection and system

pressure control Cartridge valves that perform relief and divert functions Selectable oil preheat sequence 24V DC solenoids for accurate response

General Closed-loop oil temperature control Full-time oil filtration including 10 micron filter and visible

and audible alarm Visible and audible high oil temperature alarm and low oil

level alarm Large part drop area with 3-way access for conveyors

and automated parts removal systems Choice of control systems Pre-engineered options are also available for the HT.

Consult your Van Dorn Representative for more

information on these options.

HP Series Hydraulic Clamp Injection Molding Machines 275 to 3000 tons clamp force

[Tabular Data Omitted]

Standard Features

Injection Unit In-line injection unit for true centerline transfer of force

from piston to screw Radial piston screw drive motor (20 oz. and up),

selectable for high speed or high torque. For 14 oz.

injection units, a dual torque gear-type motor is used. Screw speed tachometer with digital set and display Barrel high/low temperature alarms Thermocouple break alarm, including location Cold screw start-up protection Screw pullback (decompression) before and/or after

screw rotate Swing-away hopper with shutoff slide Pivoting injection unit for easy screw removal

Clamp Unit Double acting side cylinders and single acting main ram Slow mold break-away Eject on-the-fly, multiple eject sequences, center ejection

capability and positive stops Full SPI mold mounting and knockout pattern Ratchet type stop bar

Hydraulic Piston type variable volume pump that is quiet, rugged,

and energy efficient(*) Proportional flow valve that provides flow sensing for

variable volume pump control Proportional relief valves for injection and clamp

pressure control Cartridge valves that perform relief, flow, and on/off

funtions 24V DC solenoids for accurate response

General Closed-loop oil temperature control Full-time oil filtration including 10 micron filter and visible

and audible filtration alarm Visible and audible high oil temperature alarm and low oil

level alarm Easily accessible manifolds with drip pans Choice of control systems Pre-engineered options are available for the 275-3000

HP. Consult your Van Dorn Representative for

information regarding these options and special application

requirements.

(*)3000 tom models use a fixed pump system.

Screws, Barrels, and Tip Assemblies

To meet your specific processing requirements, Van Dorn offers a wide range of screws, barrels, and tip assemblies. Van Dorn's quality OEM parts are manufactured in the company's Fountain Inn, SC plant using premium grade materials, exacting specifications, precision machining equipment, and advanced surface treatment techniques. [Tabular Data Omitted]

XALOY MATERIALS Cylinder Linings

[Tabular Data Omitted]

Hardfacings for Screws
Stellite #6: Cr: 28%, C: 1.1%, W: 4%,
 Balance Cobalt; 34-37RC.
 Recommended to run with X-101
 cylinder lining material.


Stellite #12: Cr: 29%, C: 1.4%, W: 8%,
 Balance Cobalt; 38-42RC.
 Recommended to run with X-101
 cylinder lining material.


Colmonoy #56: Cr: 13%, C: .6%, Bi: 3.7%,
 B: 2.7%, Fe: 3.7%, Balance
 Nickel: 48-52RC. Recommended
 to run with X-101, X-306, and
 X-800 cylinder lining material.


X-330: This is a PTA applied "Low Iron" nickel alloy for hardfacing screws. It is designed to be compatible with Xaloy's X-309 "Low Iron" cylinder lining material.

X-380: This is a PTA applied nickel/tungsten alloy for hardfacing screws. It is designed to be compatible with Xaloy's X-800 cylinder lining material.

The X-800/X-830 combination provide maximum abrasive & corrosive wear resistance. * Welding Techniques: PTA, TIG, OXY/ACTYLENE and MIG * Platings Applied: Chrome, Electroless NICKEL, NYE-CARB, TITANIUM NITRIDE and UNION CARBIDE.

PHOTO : SIL (A) & SPL (AE) Series

PHOTO : SIL & SPL Series

PHOTO : Designed for Automation

PHOTO : CHILLERS Manufactured by ADVANTAGE ENGINEERING, INC.

PHOTO : TEMPERATURE CONTROLLERS Manufactured by ADVANTAGE ENGINEERING, INC.

PHOTO : ONE-PIECE CONVEYING SYSTEMS Manufactured by E.M.I.

PHOTO : VACUUM AND PROPORTIONING HOPPER LOADERS Manufactured by NOVATEC [TM], INC.

PHOTO : HOPPER DRYERS Manufactured by NOVATEC [TM], INC.

PHOTO : MAP -- MOBILE AUXILIARY PLATFORM

PHOTO : UP & OUT Fast foolproof 100% sprue removal

PHOTO : UP, OUT & ROTATE Pick and place delicate parts with speed, accuracy and flexibility

PHOTO : UP, OUT & TRAVERSE A full-function part and sprue handling system designed for maximum

PHOTO : versatility and repeatability

PHOTO : HORIZONTAL CLAMP Straight Molding

PHOTO : VERTICAL CLAMP Insert Molding

PHOTO : 3,5" optical disc material: PC

PHOTO : Wire guide for dot printer material: PA

PHOTO : Wire guide for dot printer material: PA

PHOTO : Bobbin for dot printer material: TPX

PHOTO : Shutter for floppy shell case material: POM

PHOTO : Bearing material: PPS

PHOTO : Rack gear material: PPS

PHOTO : IC flat package material: PES

PHOTO : Printer carriage material: PPS

PHOTO : Copy machine toner case material: PA

PHOTO : Pick up lens holder material: PPS

PHOTO : Pick up lens holder material: PPS

PHOTO : Guide roller for video deck material: POM

PHOTO : Daisy wheel material: Polyarylate

PHOTO : Magnetic head for video deck material: PPS

PHOTO : Print circuit board material: PES

PHOTO : Optical fiber connector material: PPS

PHOTO : Optical fiber connector material: PPS

PHOTO : IC package material: PES
COPYRIGHT 1990 Gardner Publications, Inc.
No portion of this article can be reproduced without the express written permission from the copyright holder.
Copyright 1990, Gale Group. All rights reserved. Gale Group is a Thomson Corporation Company.

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Title Annotation:1990-1991 Manufacturing Handbook and Buyers' Guide
Publication:Plastics Technology
Article Type:buyers guide
Date:Jul 15, 1990
Words:6360
Previous Article:The right roll for wrinkle-free web processing.
Next Article:Reinforced plastics equipment: product lines reviewed.
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