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Industry 4.0 - current trend of automation and data exchange in injection molding technologies at K

Industry 4.0 - current trend of automation and data exchange in injection molding technologies at K

Industry 4.0 or the fourth industrial revolution, is the current trend of automation and data exchange in manufacturing technologies. It includes cyber-physical systems, the Internet Of Things and cloud computing. Industry 4.0 creates what has been called a "smart factory" and will be the important "mantra" for injection molders at K 2016. For producers of plastic parts it promises to be a real game-changer, allowing every processing detail to be attached to a component for immediate recall from anywhere in the world at any time. Some of the injection molding technologies being featured at K 2016 include:

Milacron will mark its European show debut at K 2016 with its co-injection PET Technology. The M-PET 300, is a servo-hydraulic co-injection PET system, which combines key components across Milacron's product portfolio - machines, clamps, injection unit, post mold cooling, co-injection hot runner, mold and robots - into a single solution. The M-PET system will be utilizing a state of the art co-injection hot runner system and co-injection nozzles featuring Kortec technologies. The New Mold-Masters M-AX servo axis controller is Milacron's most technologically advanced controller to date. The M-AX controller has the same powerhouse TempMaster Adaptive Process System (APS) used to control temperature in our entire temperature control line up but also contains an unmatched ability to control motion functions as well. Milacron's SmartMold module allows different pieces of equipment to talk to each other, improving process quality and efficiency all while providing improved information and metrics. It collects data and reports the data via the cloud or LAN, and also allows for the scheduling of regular and preventive maintenance.

Netstal will demonstrate the Elios 7500, a new high performance injection molding machine with a clamping force of 7500 kN. An extremely high-performance, robust and highly precise machine that is optimally tailored to meet the rigorous demands of the competitive thin-wall packaging market. The Elios 7500 will be in continuous operation at K: With a cycle time of 4 seconds, more than 43,000 round lids with a part weight of 2.8 grams are produced per hour in a 24+24 stack mold. The Elios is currently the fastest (measured according to Euromap) dry cycle in its size class, due to its newly developed and especially energy-efficient electrical clamping unit. The centrally aligned 5-point dual toggle lever ensures optimum introduction of force into the center of the mold installation space, and therefore uniform distribution of the clamping force. The robust design effectively prevents any deformation of the mold plates. The very large pillar distance and the extremely ample opening stroke facilitates the installation of stack molds or simple molds with large cavities. Husky Injection Molding Systems will launch of its next-generation system for high-output beverage closure molding, HyCAP4, that includes several new capabilities and features that combine industry-leading performance and productivity with energy efficiency. The system is also equipped with intelligent features that make it easier to use, with simplified controls for faster process set-up and improved repeatability. To optimize productivity and efficiency while producing high-quality, lightweight closures, Husky made adjustments such as electrification of the clamp motion, servo-variable pumping technology and a regenerative clamp stroke. Combined, these enhancements deliver up to 40% improvement in energy consumption over the previous generation, without sacrificing performance, explained Husky. Additionally, by integrating more intelligence into the system, operators of all skill levels are able to maximize productivity and part consistency. Enhancements include a new part eject assist feature to ensure a consistent freefall of closures at the fastest cycles, and sensor-driven mold alignment to reduce mold wear. Husky's patented intelligent Mold ID technology helps to further simplify start-up and improve ease of use while providing information on mold maintenance, process set-up and operation for each start-up. Jomar has announced the launch of its next-generation injection blow molding (IBM) machine series that incorporates a unique custom-designed servo-driven hydraulic system. The Jomar IntelliDrive Series delivers major improvements in energy consumption, output and performance while also maintaining the machine's footprint. It features precise servo-driven hydraulics that reduces energy consumption by 40-50% and boasts a dry cycle time of 1.8 seconds, which is significantly faster than standard hydraulic machines. Along with the lower energy and utility costs, the IntelliDrive series offers a reinforced main platen, which reduces the possibility of deflection. The machine also features a closed-loop system for the machine's clamping system, which delivers exact control over the clamp's speed and position. The IntelliDrive series has a higher degree of control over the machine's internal functions, resulting in more efficient use of energy.

Sumitomo SHI Demag will showcase networking solutions for all aspects of injection moulding machines under the banner Electrified 4.0. Of particular interest to the customer is that Sumitomo (SHI) Demag not only equips new machines with Industry 4.0 solutions, but offers retrofitted solutions for plant that is already in operation. This ensures production efficiency throughout the life of the machine.

Wittman will introduce Unilog B8 controller for all its injection machines. It has a larger, 21.5-in. color multi-touch screen, capable of displaying two pages at once, and it runs under the new Windows 10 IoT ("internet of things") operating system. Wittmann will also run an 1100-ton MacroPower press in the first public demonstration of its Condition Monitoring System (CMS), part of its "Smart Services". Key machine status data will be measured by sensors, processed by the machine's controller, and passed on to a corporate or plant MES system for maintenance planning.

Arburg will present a mini smart factory linking an Allrounder injection machine with its Freeformer 3D printer and a seven-axis robot. A total of 27 machines will be on display at K with a focus on: Entry-level electric series: ALLROUNDER GOLDEN ELECTRIC, lightweight construction, silicone and high-speed machines, Automation ranging from pickers to turnkey systems, Innovative cube-mould technology for two component closures, Injection moulding of a wristwatch from two different liquid silicones (LSR), High-speed medical technology application

Haitian will have three recent developments at the show.
The "p" (for packaging) version of the Venus II all-electric series (150 to 450 m.t.) is aimed at high-speed, high-cavitation applications with cycle times above 4 sec, such as caps and closures for cosmetics. It comes with a square platen, modified machine bed to handle heavy molds, and a 25:1 L/D injection unit with speeds up to 350 mm/sec and a special ballscrew to avoid overheating during fast cycles. A 300-m.t. model will mold an IML cup in 4.4 sec. The new Jupiter II plus series, an enhancement of the Jupiter II. These two-platen models now have significantly faster clamp movements, new linear guides that eliminate lubricant and friction on the tiebars, optimized platen structure that reduces deformation, and a new Keba controller with 15-in. screen offering double-page view .

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Lemo machine for bags on roll

Lemo machine for bags on roll