Application solutions for plastics processing
GÜNTHER to exhibit at Fakuma 2018
GÜNTHER, the leader in hot runner technology, will be presenting its broad selection of innovative hot runner nozzles and systems for the plastics industry at the Fakuma trade show in Friedrichshafen, Germany from October 16 to 20, 2018.
Individual customer requests call for innovative solutions
The trend toward increasing product individualization is often associated with smaller production quantities. In the plastics industry in particular, the development toward flexibility in production technology for quickly changing products and small batch sizes is playing an increasingly important role. More and more companies are catering to individual customer requests, which ultimately means smaller batch sizes and more order changes. Typical products could include consumer goods like writing implements or components in the electronics industry and even a series of medical-technology products and interior components in the automotive sector, for example.
The production of a two-piece ABS caliper on a fully automated production cell to be shown at ENGEL AUSTRIA’s booth shows how this trend can be accommodated. The mould used here was designed and constructed by Braunform in Bahlingen and makes it possible to produce geometrically different components of the caliper with a base setup. The parts are manufactured on the production cell one after another in quick succession. After every third shot, a robot removes the component, changes the gripper and exchanges the mould inserts. Quick-change AS/DS inserts are used for the individual caliper parts. Braunform has a patent for the quick-change mechanism used here. Fully automatic changing of the mould inserts in just one minute is possible thanks to this system solution. This mould principle may be of interest to those users who have to produce similar parts in small quantities or who require a large number of variants.
Precise operation of gate points for a reliable injection process
Another challenge of this application is the fact that the two components, weighing in at 5.5 g and 3.5 g, have very different shot weights. To ensure a reliable injection process, precise and intelligent operation of the valve gate technology is indispensable. This is why Braunform relies on hot runner technology with an electric drive from GÜNTHER. Electrically driven valve gate systems feature decisive technical advantages, like the variable, yet precise, setting of the needle position and stroke length. Synchronized needle movement also enables high reproduction precision. The SMA 10 E02 stepper motor guarantees this high precision in conjunction with ideal force-displacement behaviour. Together with the corresponding DPE control unit, precise valve gate control is guaranteed. Needle adjustment in the 1/100 mm range is also possible. Valve gate systems and electric drives are easy to install and do not require a great deal of effort when it comes to mould construction. A valve gate nozzle of type 6NHF with a nominal length of 120 mm and a needle guide made of powder-metallurgical steel is used for this application. This system nozzle with the thick-film heating element (BlueFlow®) is screwed to the manifold. In addition to long service life and resistance to wear, the advantages of this nozzle include outstanding, flash-free gate point quality and minimal shear stress. Wear parts can easily be replaced, and the mould inserts require no post-processing. Thanks to thick-film heating, the individual heating output can be precisely adapted to the requirements in each section of the nozzle length. This achieves homogeneous temperature distribution, which has a positive effect on small moulded parts in particular. In addition, the system only requires a minimum start-up time, which markedly decreases the waste rate.
The fact that this kind of hot runner technology makes sense with fully electrically automated production cells where all mould functions and the valve gate hot runner are also electrically driven (in addition to the robot and handling system) can be seen by visitors for themselves at ENGEL AUSTRIA's booth in Hall A5 at the Fakuma trade show.
The advantages at a glance
GÜNTHER needle actuators enable the precise and intelligent needle control of hot runner systems with simple installation and connection technology. Harmonious opening of the individual valve gate nozzles achieves a reliable injection process, even with the smallest shot weights.
- Precise opening and closing
- Reliable injection process
- Individual cavities can be shut off
- Optimally adjusted needle
- Precise and intelligent needle control
- All moving parts can be replaced by the customer
Valve gate nozzle type 6NHF 120 with needle gate
- Long service life and wear-resistance
- Outstanding and flash-free gate point quality
- Minimal shear stress
- No replacement or subsequent reworking of the mould inserts required
- Thick-film heating element (BlueFlow®)
Visit GÜNTHER at the Fakuma trade show – Booth A2-2207 in Hall A2.