ENGEL at PLASTPOL 2018

13.04.2018

With two challenging applications on a servo-hydraulic and an all-electric injection moulding machine, ENGEL will clearly demonstrate how process consistency and quality can be combined with efficiency and economy at PLASTPOL 2018 from May 22nd to 25th in Kielce, Poland. The focus is on high-performance machines and automation as well as intelligent control technology that opens up additional optimisation potential for processors.

Power package on a small footprint

Maximum force on a comparatively small footprint – this is what ENGEL duo dual-platen injection moulding machines stand for. In terms of footprint, the ENGEL duo 500 is one of the smallest machines in this series and, with a dry cycle time of 2.6 seconds and an opening stroke of 600 mm, the fastest dual-platen machine on the market. At PLASTPOL, an ENGEL duo 3550/500 will be manufacturing engine covers from glass-fibre and mineral-fibre reinforced polypropylene in combination with an ENGEL viper 20 linear robot.

Equipped with a new-generation injection unit, the servo-hydraulic duo 500 achieves particularly high precision. Intelligent assistance systems from ENGEL’s inject 4.0 range are deployed to compensate for additional fluctuations in environmental conditions and the raw material. iQ weight control analyses the pressure profile during the injection process and compares the measured values with a reference cycle in order to adapt the injection profile, the switching point and the holding pressure profile to the current conditions for each shot. "This means that we can keep the injected melt volume constant over the entire production period and reliably prevent rejects," says Piotr Nachilo, Managing Director of ENGEL Polska based in Warsaw. "iQ weight control is already widely used by our customers and has proven itself in a wide variety of applications."

iQ for consistent processes and more efficiency

While iQ clamp control was initially only available for injection moulding machines with electrical clamping units, ENGEL is presenting the new release for use in hydraulic machines of the duo series at PLASTPOL. The software calculates mould breathing in order to determine the ideal clamping force and adapt it automatically. In the production of large-area injection moulded parts, such as engine covers, iQ clamp control opens up a great deal of potential for higher production quality. If the clamping force is too low or too high, this can lead to burn marks or flashes.

Last but not least, the third assistance system is iQ flow control. The software networks the temperature control units and the injection moulding machine and controls the rotation speed of the pumps in the temperature control units on demand. The result is significantly reduced energy consumption and the stability of the temperature control process is also enhanced. e-flomo is capable of actively controlling the temperature difference in all individual circuits and automatically setting the required flow rate for each temperature control circuit.

Together with its partner HB-Therm (St. Gallen, Switzerland), ENGEL has developed a series of particularly compact temperature control units for this new integrated temperature control solution. By linking the e-temp control units to the injection moulding machine via OPC UA, the development partners have established a milestone along the road to the smart factory. The OPC UA protocol facilitates powerful, platform-independent and above all secure communication, both at shop floor level and with superordinate control systems. For this reason, it is increasingly becoming the standard for the plastics industry.

IML integration from a single source

With a second application at PLASTPOL, ENGEL is demonstrating the great efficiency potential of integrated processes. Thanks to in-mould labelling (IML), an all-electric ENGEL e‑motion 440/160 injection moulding machine with integrated viper 12 linear robot, and IML automation from TMA AUTOMATION (Gdynia, Poland), produces ready-for-market decorated covers for food packaging in a single operation.

TMA AUTOMATION is a new ENGEL partner specialising in the automation of IML and downstream processes, such as assembly, quality assurance and palletising, in the general purpose segment in a wide range of industries. Based on a standardised system concept, TMA AUTOMATION implements highly compact and at the same time very flexible solutions. The Polish company has many excellent references, particularly in Eastern Europe. "In many projects, cooperation with local partner companies helps to improve cost efficiency and reduce the lead time for the entire plant," says Walter Aumayr, Head of Automation and Peripherals at the ENGEL headquarters in Austria. As the general contractor, ENGEL handles coordination with the automation partner for its customers and supplies the complete production cell from a single source. This also increases efficiency, as fewer interfaces often mean faster project planning.