Sumitomo (SHI) Demag Plastics Machinery GmbH in Schwaig near Nuremberg will use Fakuma 2017 to present a cross-section of its current portfolio of injection moulding machines.

Three machines will be displayed on the company's own Stand 1105 in Hall B1 of the Friedrichshafen trade fair venue and a further three exhibited in conjunction with partner companies.

The high-speed El-Exis machine has evolved over almost 20 years to become the market leader today for injection moulding of plastic packaging. Sumitomo (SHI) Demag has updated it over several generations and continually increased its clamping force range. Current models are available today in the product portfolio as the El-Exis SP with clamping forces of 1,500 to 7,500 kN. Over 2,000 machines are already in use by manufacturers of thin-walled plastic packaging, screw caps and a broad variety of closures. The proven concept employed by the machine was most recently updated again in terms of energy optimisation and is equipped with an OPC/UA interface for communication conforming to Industry 4.0 standards.

Generating a clamping force of over 2,100 kN, the Systec Multi 210/580-430h/200v incorporates both a horizontal and vertical injection unit. The system presented prior to delivery to a customer is equipped with the NC5 control and a new operator terminal, a turntable for substrate introduction and a Demag SDR 20 M robot for handling moulded parts.

The process can be burdensome, as the samples are removed, transported, and tested manually, tying up resources. Moreover, the quality of the data depends on the skills and expertise of the personnel performing the inspections. Critical parts may have narrower tolerances and require more frequent spot checks, increasing the potential for human error. Automated, reproducible random sample testing can optimize the process.

The research project with the IWK Institute for Materials Technology and Plastics Processing is focused on injection molding of a medical part. The objective is to develop a system that provides medtech manufacturers with comprehensive automated random sample inspection, generating accurate AI-based quality predictions while injection molding is still in progress.

Quality control is an essential aspect of the production process, especially when it involves parts used in automotive and medical technology applications. The entire quality control process must be designed to ensure maximum precision and reproducibility, and typically requires reams of documentation. All of this is labor-intensive and time-consuming, and is reliant on expert personnel. Automation coupled with artificial intelligence (AI) may offer an alternative.

Highlights include the latest generation of the all-electric IntElect series, a high-speed El-Exis SP machine for injection compression moulding of decorated thin-walled packaging lids and a multi-component Systec Multi injection moulding machine with an Industry 4.0 application. In addition to the IntElect machine, the latest innovation on show is the servoelectric SDR 5P sprue picker.

The IntElect is a complete series with clamping forces of 500, 750, 1,000, 1,300 and 1,800 kN. The 1,800 kN machine expands the new IntElect series, both in terms of clamping force and upward tie bar clearance, and it fills the gap which existed between models with clamping forces up to 1,300 kN and mid-sized IntElects available with forces of 2,200 to 4,500 kN. Comprehensive modularity and the introduction of intermediate sizes mean that moulders can select their machine from an even more specialised range with up to five screw diameters per injection unit.

The objective is to achieve consistently smooth and efficient part handling throughout the entire test process. Integrated safety concepts monitor the systematic progression of the individual steps in the process — as well as the “handshakes” — to guarantee process reliability while preventing data loss. The automatic system then sends the collected data via an OPC UA interface to the operator's higher-level quality assurance system and to relevant databases for analysis.

Partner companies with exhibits relating to Sumitomo (SHI) Demag machinery are Sepro Robotique (Hall A1, Stand 1203), ONI (Hall A5, Stand 5103) and the Kunststoff-Institut Lüdenscheid (KIMW, Hall A5, Stand 5312).

When starting to design an inspection concept of this sort, the focus initially is on the requirements for the part being tested. The project team collaborates with manufacturers to develop the required quality-relevant test parameters, mostly related to surface defects and dimensional accuracy. They also identity the appropriate test methods. Kistler-developed sensors make it possible to integrate mechanical pressure and force and torque tests. Experts from the company’s competence center then design the test cell accordingly. In addition to determining the number and positioning of camera stations with lighting elements, the key factor at this stage is outlining the inspection path for the part.

The IntElect control cabinet is integrated in the machine bed, enlarging the space around the machine used for downstream units and improving operator access to the nozzle area and complete clamping unit. The new IntElect design is considerably more compact than its predecessor. The installation footprint is on average 10 % smaller than that of comparable all-electric machines from competitors. For example, the 500 kN version is around half a metre shorter than its predecessor.

Dr.-Ing. Oliver Schnerr is head of sales, Integrated Solutions Automation Solutions / Vision Systems / Fastening Technology at Kistler.

Manufacturers typically rely on statistical process control (SPC) to verify quality. The frequency and scope of sample testing is defined, enabling users to monitor the production process according to predefined quality parameters.

Autonomous vehicles transport parts to the test cell and storage area. Image courtesy of OST – Ostschweizer Fachhochschule.

Additional injection molding machines producing different parts can be integrated into this setup and incorporated into the material flow with the use of autonomous vehicles. In other words, the concept allows for automation of quality control in complex production environments as long as the test cell is equipped with the appropriate inspection programs: The inspection system recognizes the different parts and triggers the relevant test program.

During injection compression moulding, plasticised material is already introduced into the cavity prior to complete locking of the mould. The machine closing movement aids distribution of plasticised material in the cavity, reduces the injection pressure requirement and the required clamping force, ensures that the pressure is distributed evenly and, as a consequence, reduces residual stress in the finished part. Warping due to shrinkage is less pronounced as a result, reducing the wall thicknesses and weight of the moulded part. Compression at the highest mould and injection movement velocity, termed speed compression, is a particular challenge for the injection moulding machine and its sensors, control and drive technology. Despite the high speeds involved, the machine guarantees to deliver a high degree of precision and exact reproducibility from cycle to cycle.

A research project is exploring new avenues for AI-assisted automated optical quality assurance during the injection molding process.

Switzerland-based Kistler, a developer of measurement systems and sensors, is collaborating with the Eastern Switzerland University of Applied Sciences (OST) in researching advanced quality-control technologies. In particular, Kistler is involved in a project with the university’s IWK Institute for Materials Technology and Plastics that fully automates the inspection of injection molded parts while harnessing the power of AI to hone quality predictions while injection molding.

In addition to standard equipment, electric ejector packages are also available with increased force and/or speed. The NC5 plus control system is now equipped with a capacitive glass colour touchscreen and, with improved display brilliance and sharpness, can be operated as safely, intuitively and comfortably as a smartphone.

Updated motor technology and expanded storage potential for brake energy have further optimised the energy efficiency of IntElect machines. Savings of 20 % are achieved when compared to equivalent allelectric machines.

With an IntElect 50/360-110 on display, Sumitomo (SHI) Demag is presenting the latest generation of its IntElect electric injection moulding machines at Fakuma. The injection mould for polyamide bobbins is provided by Siemens, while material for the 500 kN machine is supplied by Motan Colortronic. The new servoelectric SDR 5P sprue picker makes its début in the Sumitomo (SHI) Demag portfolio on this exhibit.

The molded parts are serialized using individual QR codes and sorted onto trays. While production is still in progress, Kistler’s ComoNeo system monitors cavity pressures via pressure sensors. With support from appropriately trained AI, ComoNeoPREDICT software generates quality predictions for the individual parts. Driverless transport vehicles convey parts selected for spot checks to the optical test cell. This is the first time autonomous transportation has been used in this context. The parts then pass through the predefined inspection program and are checked for dimensional stability and surface defects as well as injection molding anomalies, such as black specks or moisture splay. Issues specific to plastics processing such as shrinkage due to cooling and crystallization are also taken into account.

Sensitive protection and maximum mould support are important components of the machine concept. The IntElect offers a package of options ranging from standard sensitive profile monitoring of the mould protection force to monitoring of the ejector force and injection pressure profiles. The cutting-edge linear guide system ensures maximum plate parallelism and symmetric application of the nozzle system force. New mould clamping plates designed with the assistance of FEM analysis also contribute to improved production safety, while the stiffness of moving and stationary plates has been significantly increased by up to 30%.

A completely new generation of highly dynamic drive motors developed in cooperation with the parent company Sumitomo Heavy Industries (SHI) ensures maximum performance levels and an excellent energy balance are achieved with the new IntElect. Design innovations reduce space requirements and improve machine accessibility, ergonomics and precision. The new IntElect is primarily of interest to manufacturers of precision assemblies, engineering components and optical parts.

With a clamping force of 1,200 to 10,000 kN and up to four injection units, the Systec Multi injection moulding machine series covers every process variant in multi-component engineering and is primarily aimed at sophisticated applications in the automotive industry.

During unique laser labelling of the moulded part, the injection moulding machine transmits all significant process data relating to the completed shot to a manufacturing execution system (MES) from BFA (www.bfa.ch) which stores this following fixed correlation with the DMC. This unique assignment of process data can be viewed by visitors to the Fakuma trade fair stand. A hand-held laser scanner scans the DMC and the MES outputs the stored process data for the part in question. Smart signs on the product aid unequivocal long-term tracing of the manufacturing process history at any time and during serial installation. The injection moulder also obtains a retroactive and comprehensive insight into the manufacturing cycle parameters with the aid of this Industry 4.0 application.

The research project is also investigating possible ways to automate data matching and the adaptation of neural networks. Manufacturers not only gain the benefit of improved data quality from optical inspections, they can also design their entire process to be as rigorous and error-free as possible, even in complex production environments where a variety of different parts need to be tested.

Following inspection, the autonomous vehicle transports the tested parts to the warehouse and the test cell sends the analyzed data to higher-level QA or MES systems. Experts can then compare the quality data with the quality forecasts previously generated by ComoNeo PREDICT. If variances occur, the AI models are retrained using new test data.

The series visor manufactured live is an interior component for fitting inside a series-production car. The polycarbonate (PC) support is overmoulded with ABS from the vertical plasticising unit to achieve partial galvanising. Following removal from the cavity, the robot transports the moulded part to a laser marking station. Instead of depositing the part here, it positions it in front of the Datalogic marking laser (www.datalogic.com) which applies a data matrix code (DMC). This means that the moulded part is uniquely labelled before the robot deposits it for the first time.

The production cell designed as a complete solution around the El-Exis SP 200 produces decorative lids for food containers. Sumitomo (SHI) Demag is presenting this exhibit in a joint project with Rouxel (www.rouxel-sa.com) as the injection compression mould manufacturer, Machines Pagès (www.machinespages.net) as a specialist for high-speed extraction robots and downstream moulded part handling, Verstraete (www.verstraete-iml.com/de) as experts for decorative labels and Borealis (www.borealisgroup.com) as the polyolefin generator.

While maintaining comparable mechanical properties, injection compression moulding of thin-walled plastic parts can considerably reduce the wall thickness of the product and, consequently, the amount of material consumed. Sumitomo (SHI) Demag demonstrates this advantage at Fakuma on a high-performance ElExis SP 200-920 injection moulding machine with a clamping force of 2,000 kN. It achieves material savings of 25% when compared to the standard injection moulding process. Given the dominant role materials play in production costs, this represents a significant cost advantage for injection moulders.