TECHNOLOGY | SMART FUNCTIONS
combined, manufacturers maximise overall equipment effectiveness (OEE) through capacity and productivity on their entire fleet, while keeping overheads manageable. Powerful cloud analytics will expand to drive predictive maintenance, predict failures of additional components crucial to optimising OEE and spare parts programs. On a modern machine, all aspects of the machine’s operation that are significant to product quality can be handled by the machine’s controller or through a remote interface. Wittmann Battenfeld believes that the most
Above: Base level monitoring on Milacron’s Mosaic+ control system
reducing costs for maintenance, tooling upkeep and labour,” adds Bish. “The M-Powered applica- tions generate a strong return on investment with a demonstrated ability to improve yield, save labour, and automatically issue reports. With tools like Mold Safety Monitoring, automation tools are safer for operators to be near because fewer human touches are necessary. Additionally, automation is extremely useful for repetitive processes – thus sparing the workforce from repetitive-stress injuries. It also mitigates the risks associated with human error.” In addition, less training or experience is needed
for operating any process, as the machine and remote technicians can solve or troubleshoot issues. “M-Powered technology allows end-users greater self-regulation, greater connectivity between machines, and improved communication between humans and machines,” says Jump. “These applica- tions work to reduce waste and time needed for maintenance actions, contributing to more efficient and therefore more sustainable manufacturing.” Milacron says that it strives to increase efficiency
and create leaner processes so that customers can utilise their talent to solve problems quickly. This shift stems from an aging workforce, as well as exposure to innovative technologies it continues to roll out. The company adds that for connecting older machines to M-Powered control systems, additional hardware may be needed compared to those with a Mosaic+ control or the machine’s control can be upgraded through the company’s retrofit and rebuild department. “The shift to implementing automation technolo- gies will continue to grow,” says Bish. “Not only to reduce labour but so that processors can minimise hands-on involvement with increasingly complex, high-precision parts. With IIoT and automation
36 INJECTION WORLD | October 2020
important area for smart functions within the plastic injection moulding process is process control, in particular process control within the plasticising unit. “There are complex processes occurring within the cylinder that can be optimised by the machine, automatically, with alterations specific to each shot,” says Benjamin Pearson of the Process Engineering and Development Department. “Analysis of the process is also an important feature that enables early detection of process deviations. For the machine user, the major benefit is ease of use. These functions should be semi-automatic in configuration and use minimal user inputs. The automatic nature of the functions leads to fewer interactions required by the user to maintain part specification, and therefore one user could be responsible for more machines. For the company, these functions can allow recycled or regranulated materials to be used, while maintaining tight product specifications, which will reduce raw material costs. The end user should also benefit from a high quality injected product. The reduced material wastage lowers production costs and results in a lower overall carbon footprint.” He continues: “Cost is the ultimate driving force behind smart functions within the injection mould- ing process. Smarter, more networked machines, in theory, require fewer personnel to use and monitor them. There is also an increase of components produced more ecologically, with recycled granu- late and biodegradable materials. These materials can add more deviating factors to an injection process and smart functions can help alleviate them. Smart functions are the next evolutionary step for injection moulding process control.” Wittmann Battenfeld says all of its smart func-
tions are software-based and do not require any hardware modifications. “These include HiQ Flow, which automatically adapts the switchover point and the following holding pressure, within the same shot, to account for fluctuations in the material viscosity,” says Pearson. “Therefore, the part weight deviations are smaller and the scrap
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IMAGE: MILACRON
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