TECHNOLOGY | SMART FUNCTIONS
Above: Engel’s iQ Process Observer continually analyses several hundred process parameters across all phases of the injection moulding process
human mind has to do in order to close the loop back to the operation of the equipment.” Fanuc says a good example of how smart functions can prevent downtime in injection mould- ing equipment is that of check-ring performance. The company’s screw and barrel technology provides a warning for when the check valve assembly is wearing, giving the user a graphical representation to know when they need to check the part. It is a key item in injection moulding, and when it wears it gives a greater variation in the process. It is something that cannot be seen without taking the screw and barrel apart. By using smart functionality to predict when it will need replacing, it avoids having to disassemble the barrel head to gain access for a visual inspection, which can typically render the machine out of production for a few hours. Looking to the future, Armstrong says that the
most effective way to improve the injection moulding process is by utilising many of the smart functions that already exist. “The core design of an injection moulding machine will not change, but the way in which it is used will,” he says. “Looking ahead, systems that allow manufacturers to gather, read, and then use feedback from machines, will instigate an improvement in productivity.” He adds: “The Roboshot all-electric injection moulding machine is designed to use smart and intelligent functionality to its absolute maximum, and is indicative of the type of production equip- ment likely to be used in the smart factories we can expect in the future. However, to fully realise the potential of a smart factory, production equipment needs to work in tandem with platforms such as Fanuc’s Field system. Suitable for industrial applica- tions ranging from sub-contract machine shops through to major production facilities alike, the Field system is an open source platform which connects a broad range of Fanuc and third-party production technology – including both new and
42 INJECTION WORLD | October 2020
legacy models dating back to 2000. Its ultimate aim is to provide fast, centralised access to all produc- tion data within a factory and help end-users take a decisive step towards Smart Factory status.” Engel has developed intelligent assistance for its injection moulding systems with the iQ Process Observer, which is able to provide an overview of the entire process for a whole batch rather than just optimise individual steps in the injection moulding process, such as injection and cooling. This makes it possible to identify changes in the process at an early stage, allowing operators to determine their causes and find a solution more quickly. The iQ Process Observer continually analyses several hundred process parameters across all four phases of the injection moulding process – plasticising, injection, cooling and demoulding. The results, split into the four phases, are immediately visible in an easy-to-understand overview on both the injection moulding machine’s CC300 control unit and the Engel E-connect customer portal.
Optimised plasticising In addition, iQ Melt Control is specifically designed to optimise the plasticising process. In real-world situations, plasticising is often faster than what the cycle requires. This can have an effect on the screw’s service life and product quality. However, improved melt homogeneity, increases process reliability. In order to ensure that this outcome is delivered automatically, iQ Melt Control deter- mines the optimum plasticising time for the specific application. Instead of plasticising at the maximum possible speed, the system makes full use of the part’s in-mould cooling time for plasticising. For this to happen, the machine operator enters the screw type and material to be processed. Then, along with the optimum plasticising time, recom- mendations for optimising the temperature and back pressure are provided. The benefits for the processor are a longer service life for the screw and a melt quality that is consistently high. This then results in parts of improved quality and higher efficiency levels. The latest addition to Engel’s range of smart functions for injection moulding is designed for barrier screw condition monitoring. The company says that
E-connect.monitor can now also analyse the condition of barrier screws and make reliable statements about their condition. The measure- ment is performed without having to remove the screw. In classical maintenance, the barrel is a “black box”. Its condition can only be assessed if production is interrupted and the plasticising screw removed. This is a time-consuming and resource-
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IMAGE: ENGEL
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