TECHNOLOGY | SMART FUNCTIONS
Above: The ArburgXworld customer portal with its numerous interactive apps and smart functions makes daily tasks related to injection moulding easier
platforms, all new Allrounders are equipped with an Industrial Internet of Things (IIoT) gateway and therefore offer basic connectivity.” Arburg adds that smart functions and intuitive
operation ultimately lead to higher productivity, more reliable processes, fewer errors, better part quality, and consequently to increased production efficiency. “They make daily tasks on the machine easier and offer a wide range of options for making the injection moulding process even more efficient,” says Peters. “The Arburg ALS host computer system is a central component for online data acquisition, the provision of process data and detailed planning down to the minute. Predictive maintenance is another major benefit for injection moulding companies.” He continues: “As networking increases, the
range of digital platforms for smart production is growing. These include the ArburgXworld customer portal, available as a cloud solution, with its numer- ous interactive apps that can be used to document production processes or display status information and key performance indicators, for example. The ALS-Dashboard app, for example, provides an overview of the machine fleet and process data – even on the move or when away from the com- pany. MachineDashboard is designed for status display and visualises the production process by means of trend diagrams. The VirtualControl app allows users to simulate machine control on a PC or tablet in order to create data sets offline and optimise processes. There are also numerous digital services relating to the injection moulding process.” Peters adds that benefits to the end-user are mainly the result of networking the production processes, which enables high transparency and traceability down to the individual product. In this context, the possibility of individualisation should also be mentioned – for example, by means of multi-variant parts production using an injection moulding production cell that produces flexibly from shot-to-shot due to Industry 4.0 elements, so
32 INJECTION WORLD | October 2020
that customer requirements can be integrated online into the ongoing injection moulding process. The same can be done for additive manufacturing on Arburg’s Freeformer systems. In contrast to machining, a conventional injection moulding machine does not “recognise” the mould- ed part that it produces. “In order to change this, Arburg has developed the aXw Control FillAssist and aXw Control MeltAssist for ‘smart’ filling and plasticising,” Peters says. “The filling assistant is an example of how component simulation can be integrated into the machine control system to make the simulation a part of the injection moulding process. The machine operator can see how the filling process takes place under real conditions.” With Control FillAssist the simulation model which is created offline and the part geometry are loaded directly into the Gestica control system. The machine obtains the 3D geometry of the moulded part from the filling simulation, so it knows the shot volume and can calculate the dosage volume from this. Via the Gestica, users can then interactively compare the results of the simulation with the filling behaviour of the last cycle. Rather than having to analyse curves, the installation technician is pro- vided with a 3D visualisation of the filling process on the machine, which also shows how the process will change if one parameter is set differently. The Control MeltAssist feature uses the data from the memory chip on the smart cylinder module to calculate parameters such as capacity utilisation and dwell times automatically. Material processing can thus be quickly assessed and optimised. In addition to this, module and process history data such as operating hours and cylinder module throughput are written to the memory chip. With this assistant, the Allrounder “knows” its plasticising unit. This not only facilitates on-demand maintenance (required for predictive maintenance) but also makes trouble- shooting simpler for service personnel. Virtual control is an interactive app in the
ArburgXworld customer portal that can be used, for example, to simulate machine control in order to create data records, optimise processes or train employees. In addition, the Control PressurePilot ensures bionically optimised, precise pressure control when switching from injection pressure to holding pressure. This new smart function reliably eliminates burr formation and under-filling. At the same time, mould filling becomes more consistent, with filling differences – and thus differences in component weight per shot – reduced. With only one parameter (time period), adjustments are extremely easy. The bionically optimised profile is automatically created by the control system. The
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IMAGE: ARBURG
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