automation | IMD Right:The
decorative IMD transfer foil, which runs
through the tool from the top, is positioned precisely
during the tool clamping operation
production is carried out under clean room conditions within a laminar flow module from Radolfzell, Germany-based Max Petek Clean Room Technology. This purifies the air coming in to the processing area using a filter fan unit. The system meets Clean Room Class ISO 7 requirements. However, the cell concept goes significantly beyond the usual requirements for this type of clean room module to include the machine and automation areas. This allows all subsequent processing steps, such as the separation of the sprue, UV curing and cleaning, to be carried out in encapsulated system modules which are sealed by bulkheads. While all of the functional and decorative aspects of the display are defined in the mould itself, the finishing steps carried out outside of the tool play a major role in ensuring the quality of the final component. The six-axis robot uses a three-sided gripper system to remove the injection moulded display from the mould prior to inserting a new IML label, then places the component onto a workpiece carrier. The carrier transports the component to the encapsulated laser separation station, where a CO2
laser with evacuation cleanly
Below: The production system, including robotic automation, foil handling, clean room, foil cleaning and UV curing, is all contained within a single enclosure
removes the film sprue. A separate conveyor belt removes the separated film sprue directly from the cell, while the component itself travels on in the workpiece carrier to the robot access area. The robot again picks up the display and transfers it
to the Cleanmaster 3D UV curing unit supplied by Dresden, Germany-based Kist, where the finish from the decoration foil is hardened. The robot then picks up the component again and transfers it to the Cleanmaster 3D Combination cleaning station, which is located below the UV station. From here, brushes ensure careful and thorough removal of all of the foil residues from the peripheral edges of the moulding, with any separated particles again evacuated by vacuum. “Here we use an absolutely practice-tested, reliable
form of cleaning for IMD production”, says Hausmann. “Clean room tests have shown that, particularly on high gloss surfaces such as piano black, UV curing with subsequent cleaning is advantageous for removing traces of still unhardened finish paint.” Not all foils develop the same amount of flake. One of the benefits of Kist’s Combination unit approach, according to Hausmann, is that the curing and cleaning sequence can be adapted to suit the sensitivity of the process and the tendency of the decoration system to create flakes. The Sumitomo Demag production cell is based on a modular design, which makes it possible to use the same cell concept worldwide. Starting with the same basic equipment design, modules can be added or removed to achieve the desired degree of automation depending on the wage cost level at the production location.
In addition, the standardised interface between the injection moulding machine and automation ensures short start-up times and maximum flexibility, according to the company. Using a single industrial robot to perform all of the handling functions for the component and functional label contributes to quicker start-up and a reduction of overall system complexity. The suspended six-axis robot and extremely compact automation housing also reduces the floor space required by the complete cell to a minimum, says Sumitomo Demag.
Click on the links for more information: ❙
www.sumitomo-shi-demag.eu ❙
www.kurz.de ❙
www.polyic.com ❙
www.jacobplastics.com (HBW Gubesch) ❙
www.reinraumtechnik.com (Max Petek) ❙
www.staubli.com ❙
www.gwk.com
32 INJECTION WORLD | July/August 2013
www.injectionworld.com
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