Injection molding.

An extended range of large toggle presses, improved fast-cycling machines, and new offerings in vertical presses were among the highlights at NPE not previously reported in our coverage of this show. Other important developments include a number of new control systems, warpage and shrinkage analysis for fiber-filled materials, flow analysis for sequential gating, and integrated deflashing equipment and controls for thermoset molding. News in components includes check valves, hot runners, robots, QMC systems, and mold heating/cooling equipment.

ENHANCED TOGGLE PRESSES

A new 725-ton toggle press from Cincinnati Milacron's U.S. Plastics Machinery Div., Batavia, Ohio, marks the company's entry into the large toggle machine market. (Until now, Milacron's largest toggle was 550 tons.) The new Vista VT725, the first of a new design, is part of a range of sizes that will extend up to 1500 tons. The new large Vista toggle is an extension of Milacron's VL line of large presses, and shares a low base design and many of the same components. It's equipped with a 32-bit VSx graphical controller.

The VT725 has 38.2 x 38.2 in. between tiebars (said to be unusually generous), stroke of 39.4 in., and daylight of 78.7 in. (Milacron plans to enlarge the daylight specs on the VT110 and VT165.) Overall machine length has been shortened by 3 ft. through rerouting hydraulic piping on the injection unit and moving the clamp manifold from the end to the side of the machine. Milacron has added similar space-saving features on its smaller toggle presses, shortening them as much as 2 ft.

A change to an improved variable-volume pump on the VT725 is said to reduce peak noise by 3 to 4 dbA. On VT presses from 110 to 550 tons, an optional Bosch variable-volume servo pump is newly available at no additional charge and is said to achieve up to 40% energy savings. The closed-loop pump controls speed and pressure without requiring relief valves as throttling devices, and moving the servo control valve to the pump itself is said to eliminate a 200-400 psi pressure drop.

A new HTG toggle machine line for the worldwide market was on hand from Van Dorn Demag, Strongsville, Ohio. The company has translated its long-standing HT line into metric design with injection units that use components compatible with Demag injection units. The HTG series initially will be available with Van Dorn Demag's new Pathfinder controls; by next year, the HTG line will be available with Demag's NC4 control.

FAST HYDRAULIC PRESSES

A new 600-ton accumulator-assisted hydraulic press was shown by HPM Corp., Mt. Gilead, Ohio. The H600, with HPM's new Command 9000 controller and overlapping injection and clamp cycles, molded 21-oz HDPE thin-wall cups in a 12-cavity mold on an 8.6-sec cycle.

Ferromatik Milacron (a new Milacron subsidiary that markets the former Klockner line) upgraded its K200S (220-ton) high-speed, high-precision injection press to run even faster than before, achieving a dry-cycle time of 1.6 sec. The unit has a hydraulic clamp and accumulator. With the prefill tank repositioned above the clamp cylinder, parts can now be removed along the axis of the machine.

A new machine for molding bottle crates was demonstrated by Krauss-Maffei Corp., Florence, Ky. The line is available in three tonnages: 600 and 715 tons, as well as an 1100-ton press for two-cavity bottle-crate molding. The 600-ton and 715-ton presses have high-capacity 5.1-in.-diam. plasticating units capable of injecting 4.4 oz/sec of HDPE. The presses are said to mold 15 x 11.5 x 12.5 in. crates in less than 30 sec.

VERTICAL PRESSES

The first hydraulic clamp ever from Newbury Industries, Inc., Newbury, Ohio, appeared on a 10-ton vertical press. The single-station machine is the smallest in the Newbury line and features a cost-effective air-cooling system as an alternative to the more expensive oil heat exchanger.

A new 75-ton vertical-clamp, vertical-injection, C-frame press was introduced by PH Trueblood, Columbus, Ohio. Key features are said to include simplified setup and an Allen-Bradley SLC-500 programmable controller for manual and semiautomatic operation. Price is around $70,000.

A vertical rotary coinjection press with the capability to perform low-pressure injection as well as structural foam was exhibited by Presma Corp., U.S. affiliate of American Jet Stream, East Brunswick, N.J.

NEWS IN THERMOSETS 

The automated Rollaveyor deflashing system with microprocessor control was introduced by Hull/Finmac Div. of Hull Corp., Warminster, Pa. The versatile unit can accommodate large or small parts of simple or complex shapes, in batch or continuous operation, as a discrete unit or as part of a small manufacturing cell. The unit was demonstrated as part of Hull's new One-Step molding/deflashing system, which includes a new 110-ton Mighty-Mac thermoset press equipped with second-generation Smart Mold closed-loop control.

A new MC3 control, demonstrated by Bucher Inc., Buffalo Grove, Ill., on a 265-ton thermoset BMC press, provides real-time color graphic display of stuffer pressure, screw backpressure, injection pressure, and injection volume vs. time.

UNIFIED CONTROL FAMILY

Cincinnati Milacron has a new unified family of 32-bit microprocessor-based controls with enhanced features including common screen layouts and common commands. The controls family consists of the VSx (386-type) and brand-new CAMAC 486 (monochrome) and CAMAC 486 Plus (color) systems. They feature digital closed-loop control, full graphics, and SPC software. Standard on all controls is high-speed event detection, digital servo control, and open architecture. The CAMAC 486 and 486 Plus have high-resolution screens.

Several features are aimed at flexibility and ease of use. There are eight pages of setup information, and any four can be displayed in screen windows at any one time. A new user-configurable Quick Set page lets you copy any setpoints onto this one page. These controls also have remote setup and diagnostic capability, so a service technician with a PC can check a machine's setup from anywhere in the world.

Van Dorn Demag's German parent has also acted to make its controls consistent across the Demag product line. The Demag NC4 control, available on the Demag ErgoTech series (120-330 tons) since K'92 in Dusseldorf, Germany, is now also offered on the Demag D series presses, which start at 400 tons.

MORE NEW CONTROLS

Kawaguchi's KM-B2 toggle presses (represented by Tomen America, Buffalo Grove, Ill.) have been upgraded with enhanced operating speed and controls simplicity. All basic operating parameters can be set on a single screen page. This same page can be used to monitor the machine program. An option displays pressure, speed, and position in real time for every sequence of the machine cycle. Actual and set data are displayed along with optional corrective measures. A 16-bit CPU is said to improve response time. Automatic mold height adjustment is actuated after mold dimensions and clamp tonnage are entered.

A new-generation MAC VI-E graphical controller was demonstrated on Mitsubishi's MS-III press, sold here by MC Machinery Systems, Wood Dale, Ill. Features are said to include greatly simplified operation and easy setup. The control automatically computes and sets up all initial molding conditions based on the input of clamp stroke, mold thickness, ejector stroke, part weight and wall thickness, and resin type. The MAC VI will be available on MM series presses later this year.

A new high-end color-graphic control with SPC calculations for 35 variables was introduced by HPM. Features include temperature control for up to 16 zones, real-time velocity graphs of clamping and injection, 10-step open/closed-loop velocity profile, five-step open/closed-loop pack-pressure profile, five-step open/closed-loop hold-pressure profile, five-step open-loop screw-speed profile, five-step open-loop backpressure profile, screw decompression before and/or after rotation, and automatic shot-size adjustment.

Boy Machines, Exton, Pa., has made its fully closed-loop Procan control available on its 30M (40-ton), 50M (55-ton), and 80M (88-ton) presses. Previously, the controller had been available on its 24-ton press. The Procan control is fully closed-loop on all machine functions, including velocities and pressures, and has SPC/SQC features.

A new PLC-based injection molding control system was introduced by Allen-Bradley Co., Highland Heights, Ohio. The Pro-Set 700 interface is a 4-in. flat-panel touchscreen that provides SPC/SQC functions, SPI communications, alarming and messaging, and storage of part and press data.

A new Temperature Control Module (TCM) for the 1771 I/O injection molding control system was introduced by Allen-Bradley Co., Highland Heights, Ohio. It uses an autotuning method called tuning-assisted zone control, which is said to be faster and more accurate than most current barrel-temperature controllers. The TCM module is capable of monitoring up to eight temperature inputs and providing up to eight heating and eight cooling time-proportioned outputs.

SMART HOT-RUNNER CONTROL

A new 386 PC-based hot-runner control system from Fast Heat, Inc., Elmhurst, Ill., is said to be easy to use, with context-sensitive help screens and a built-in training program for new operators. The Symphony 2000 is modular, allowing easy expansion from eight to 96 zones and "hot-swap" replacement of power modules. It's also caster-mounted for mobility. The terminal stores setup parameters for 20 molds, along with information on material type and color used previously with each setup.

Especially unusual is the patent-pending Digi-Mold ID feature, whereby the controller stores setup data and other mold information (e.g., who built it and when) on a small circuit board mounted in the hot half of the mold. This way, key data remain with the mold and can be reloaded into the controller whenever the tool is run.

Built-in intelligence automatically "rewires" (in software) miswired heaters and thermocouples upon startup. In addition, if a thermocouple fails, the system will automatically control that zone based on temperatures of surrounding zones. Other features of the system include historical charting and data storage for SPC evaluation or ISO 9000 compliance, Ethernet interface, and single-screen diagnostics. Price is $10,000-12,000 for a 12-zone system.

MORE HOT-RUNNER NEWS

Mold-Masters Ltd., Georgetown, Ont., completed its Dura line of nozzles with the Pico Shot, a compact 208-240 v, externally heated nozzle for shot sizes below 30 g. The company introduced a three-year warranty on the Dura nozzles, which is extended to five years when Mold-Masters supplies the hot half and SM20 temperature controller.

Mold-Masters expanded the graphical interface on the SM20 controller to include troubleshooting, self-correction, and ability to monitor and adjust a number of remote controllers.

Also new from Mold-Masters is the Angled Tip hot-runner system that permits pinpoint side gating when mounted onto an angled manifold. The firm is also working on a hot-runner system for metal-powder injection molding.

The Mini Hot-Runner System for small parts was introduced by Fast Heat. It permits closer drop pitch and shorter stack height of the hot half. Thus, smaller part weights can be run on standard cycles with less risk of material degradation caused by long residence times. Three different styles are offered: single- or dual-level or modular.

A new Center Flow Gating System from Fast Heat uses a flow-through bushing with integral heating. The system also has compact pitch, allowing increased cavitation.

Heater, thermocouple, and tips on the new HP bushing from Incoe Corp., Troy, Mich., can be changed in the mold. The HP is designed for fast-cycling multi-cavity applications such as thin-wall containers.

A new nozzle from Melt Design Inc., Lombard, Ill., is said to avoid freezing-off when molding nylon. Also new is an easy-clean, two-stage nozzle filter.

A hot-runner design manual has just been published by Husky Injection Molding Systems, Bolton, Ont. The manual is said to help mold designers and molders select the right gating method for the application.

QUICK COLOR CHANGE

Cincinnati Milacron demonstrated 2-min color changes "on the fly," based on technology licensed exclusively to Milacron for injection molding purposes by Bemis Manufacturing Co. of Sheboygan, Wis. Keys to the technology are a pair of CC120 liquid-color metering pumps from Ferro Corp.'s Liquid Coatings & Dispersions Div., Edison, N.J., and a special grooved barrel zone just downstream of the feed section. The groove is the site where liquid colorant is introduced; it's said to prevent smearing of colorant on the barrel wall and reduce screw slippage.

CHECK VALVES

A new bronze spinner valve from Zeiger Industries, Canton, Ohio, is designed for high-speed non-filled molding and features a welded bronze overlay on the check ring to prevent barrel scoring. If the ring's outside diameter wears, the bronze overlay can be rewelded to its original dimensions, saving the cost of total ring replacement. For worn or special barrel dimensions, the bronze overlay can be oversized to match the barrel's inside diameter.

Also new from Zeiger is the "ZpringLok" self-closing, spring-loaded non-return valve. The patent-pending ring valve is said to allow the molder to run a wider array of materials and provide a streamlined flow path. Positive shutoff is provided by the spring mechanism actuating the ring for maximum repeatability; a bronze overlay eliminates scoring.

STRONGER BARRELS

New "unibody" bimetallic barrel construction from Xaloy Inc. of Pulaski, Va., is said to practically eliminate the risk of pressure failure for barrels running within their design pressure and temperature ranges. Resistance to injection pressure in the as-cast condition is reportedly about one-third higher than that of 4140 alloy steel.

Based on proprietary metallurgy and materials, the new construction replaces traditional sleeved units, which can fail from misfits between the barrel and sleeve, according to Xaloy.

GAS-ASSIST NOZZLE

For gas-assist molding, a new rotary resin-shutoff nozzle from Gain Technologies, Sterling Heights, Mich., is mounted between the injection cylinder and standard nozzle and is said to eliminate resin leaks.

MOLD ALLOY

Hettinga Technologies, Des Moines, Iowa, is now marketing a new cast mold alloy from Lips N.V. of The Netherlands. Called Cunial, this proprietary alloy of copper, nickel, and aluminum is said to give more uniform heat transfer and greater machinability than steel. It is also said to provide corrosion resistance and the ability to incorporate contoured cooling lines during casting.

LUBRICATED EJECTOR PINS

A new series of UltraPin ejector pins from D&L Progressive Components, Wauconda, Ill., are coated with a thin layer of permanently bonded alloy to serve as a lubricious barrier between the pin and core insert, combatting metal-to-metal wear.

NEW ROBOTS

Three new lines of robots were introduced by Automated Assemblies Corp., Clinton, Mass. The AZ series for presses from 500 to 4000 tons includes modular and interchangeable stroke lengths. These robots can be configured with a mixture of pneumatic and servo drives. They have a telescoping vertical arm for faster takeout. The new AT series for presses of 50-300 tons is available in 18-32 in. vertical stroke lengths. New SE-310 side-entry robots are table-mounted and suited for low overhead clearance.

PET PREFORM MOLDING

Two new developments for PET preform injection molding were announced at the show. First, Krupp Corpoplast, Edison, N.J., reports that its newest and largest Pet-O-Mat preform injection molding system has 72 cavities and uses a proprietary thermal-gated hot-runner system along with a special 605-ton injection press. The latter has a clamp, base, and hydraulics from Engel, plus a Krupp injection unit. One such 72-cavity molding system is operating in the U.S.

Second, a new line of free-standing side-entry robots for preform demolding was introduced by Husky Injection Molding Systems Ltd., Bolton, Ont. The robots are said to run smoother and faster and carry bigger payloads than the company's former platen-mounted side-entry robots. The robot has its own floor-mounted frame, which sits next to the press clamp and is attached to the press base. The robot frame supports the traversing beam at its ends, minimizing vibration and permitting higher payloads. The frame also lowers this beam from its previous location on top of the platen to slightly above the machine's centerline height, reducing the carriage size, permitting faster acceleration, and shortening molding cycles by 0.5 sec. Lower overall height also makes dehumidification enclosures smaller and more efficient. Robot payload capacities are 220-660 lb.

QUICK MOLD CHANGERS

A new line of horizontal mold-change tables was introduced by Cincinnati Milacron for its VL series presses from 725 to 4000 tons. The system includes a wide range of tables for a variety of mold sizes and weights, and reportedly combines rugged construction with simple "crane-style" and manual operation. The company claims that even the largest molds can be changed in under 10 min when combined with Milacron's mold-clamping and connection systems.

LOW-COST OIL CLEANERS

Cincinnati Milacron also announced that it has extended its line of electrostatic oil cleaners with a new lower-cost MR series. Smaller and less expensive than older models, the new MR series is significantly more efficient, has double the cleaning capacity, and removes particulates as small as 0.1 microns, the company claims.

NPE News Wrap-Up: CAD/CAE Software

MOLD-ANALYSIS UPGRADES

The second module in a new computer-based training program from Moldflow, Inc., Shelton, Conn., uses practical examples to show how mold-analysis software can be applied to optimize the design of plastic parts. "Beyond the Plot" is an interactive self-paced program utilizing a series of short "core modules" and sophisticated graphics.

The second stage of Moldflow's "Dynamic Series" was demonstrated at NPE. The first stage, introduced last October, organizers and integrates several analysis tools to make them faster and easier to use. The second stage brings six analysis tools--MF/Warp, MF/Stress, MF/Shrink, MF/Gas, MF/Tsets, and MF/Optim--into the Windows operating environment.

The third stage, which becomes commercially available this month, delivers advances in warpage and shrinkage analysis for fiber-filled materials. It also reportedly makes significant advances in prediction of gas penetration during gas-injection molding, specifically in properly accounting for the second stage of gas penetration during packing.

Other new developments from the company include advanced insert-molding analysis capabilities, ability to customize the Moldflow operating environment, enhancements to MF/Cool, and improvements to MF/Flow's automatic inject-time and weld-line predictions.

NEW CAD FEATURES

A new version of EMS integrated design and analysis software from Intergraph Corp., Huntsville, Ala., features automatic generation of ribs, and is capable of adding draft at any time during the preparation of a model.

NPE News Wrap-Up: Heating & Cooling

NOVEL HOT/COLD UNIT

A versatile dual temperature-control system that heats and chills at once was introduced by the Sterlcool and Sterlco divisions of Sterling Inc., Milwaukee. Powered through a single electrical connection and displaying heating and cooling settings on one panel, it can be set up to run separate hot and cold zones or configured as a dedicated chiller or dedicated hot-water unit.

MINI CONTROLLER

The compact Micro-Max temperature-control unit from Sterlco can be used vertically or horizontally and requires less than 1 sq ft of floor space. It delivers automatic control of processing temperatures up to 250 F.

NEW CHILLERS

Thermal Care, Niles, Ill., introduced the new TMW series of "small-footprint" central chillers that use 75% less refrigerant than standard chillers. The company also expanded its line of central chillers to include a multi-circuit unit incorporating scroll compressors. Scroll compressors use fewer parts than reciprocating compressors and provide higher efficiency, the company says.

Also, a redesigned WN line of belt chillers includes electric cylinder unloading for more accurate control during partial-load operation.

A new line of water chillers with capacities from 0.5 to 60 tons was introduced by Motivair Corp., Amhurst, N.Y. Features include an evaporator mounted inside the chilled water tank for close temperature control, stainless-steel pump with bypass to prevent dead-heat conditions, and cycling compressor operation that saves energy with varying loads. Microprocessor controller has alarms and RS communication capability.

A new line of STC central chilling units was introduced by the Sterlcool Div. of Sterling Inc. These air- or water-cooled units are said to reduce energy consumption by as much as 15%.

NEGATIVE-PRESSURE UNIT

Thermal Care also introduced a new line of Vactherm positive/negative-pressure mold-temperature controllers designed to eliminate coolant leaks in a mold. In negative-pressure operation, vacuum level can be adjusted to the exact amount necessary to stop the leak without drawing air into the water circuit, providing better temperature control at a lower flow rate than competitive designs.

HEATING ELEMENTS

New ceramic heater bands from Heatron, Inc., Leavenworth, Kans., are said to feature high-temperature capability and special staggered ceramic forms for additional strength, electrical insulation, and thermal conductivity. Units up to 45 w/sq in. and 480 v are available, as are a wide range of diameters and widths, including metric sizes.

A new mini-cable heater with hermetically sealed adapter from Watlow, St. Louis, is said to eliminate failures in the adapter area from overheating and moisture contamination. A no-heat tail section with 0.058-in. diam. easily conforms to mold cavities and reportedly makes the unit an excellent replacement for nozzle heaters used in multi-cavity molds.

Watlow also introduced a quick clamp for its Thinband heaters for fast and easy installation and replacement.