This page contains a Flash digital edition of a book.
electrical and electronic | Connectors


Sumitomo (SHI) Demag project managed a multi-component connector moulding system for Molex Ireland, delivering fi rst production within six months of design freeze, writes Chris Smith


Turnkey system delivers for Molex Molex Ireland


turned to Sumi- tomo Demag’s project


management team to


develop the production


system for this new two-shot connector for pump maker Grundfos


Injection moulding equipment maker Sumitomo (SHI) Demag played a key role in the development of a new range of multi-component connectors for interconnect products manufacturer Molex Ireland, working closely with specialist mouldmaker Hofmann Innovation and hot runner manufacturer Männer as well as moulding technical consultancy G&A Moulding to deliver a fully-proven turnkey manufacturing system to the factory fl oor. The complex manufacturing project involved


production of a two-shot sealed connector that was to be used by pump maker Grundfos in its latest energy-effi - cient product line. Annual production rates would run into several million pieces a year. The project was critical to Molex as it would open up a new global market for the company, enabling it to target applications requiring rugged sealed multi-component connectors.


New technology Molex opted for a completely new manufacturing process for the connectors, involving the use of an 8+8-cavity two-component mould designed to manufac- ture the connector inserts in a single moulding process. A key requirement of the production system was to achieve a strong and reliable bond between the hard PBT fi rst shot polymer and the fl exible TPE used to create the seal in the second shot. The company’s schedule called for initial production within six months of freezing the part design; Sumitomo Demag says this presented a considerable challenge to


30 INJECTION WORLD | April 2013


the project participants as lead times for a multi-compo- nent tool of this type are typically in excess of 20 weeks. “We were confi dent that Sumitomo (SHI) Demag


could provide the right equipment as they had a successful installation base of multi-component injection moulding equipment worldwide,” says Molex process engineer Donal Costello. “But more importantly we needed them to work


effectively as technology partners with the other stake holders of this project. It was their extensive network of very competent and innovative experts, plus their ability to help us turn this challenging project around in the short timeframe, which set them apart from their competitors,” he says. The project was managed by the Sumitomo Demag


team in the UK together with the projects department at the company’s headquarters at Schwaig in Germany, who also selected and worked closely with the tooling and hot runner suppliers. A 350 tonne multi-component machine was selected for the task and confi gured with an 840 main injection unit with a piggy-backed 120 second unit. The Multi 350-840H/120R machine, which is based on the company’s Systec hydraulic base design, is also equipped with a 180˚ integrated rotary turntable. Parts are unloaded from the machine by an inte-


grated Harmo beam robot, which places them onto an indexing conveyor from where they are loaded into storage containers via a chute system. Cavity identifi ca- tion is maintained through the production process. Sumitomo (SHI) Demag was able to secure two


www.injectionworld.com


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56