INDUSTRY FOCUS Automotive Supply Chainy
component injection moulding system. Historically, multi-component machines have been designed on a large footprint to accommodate the tool and turntable. This is because, when co-injecting multiple materials, the number of cavities usually doubles, plus, rotating the mould 180° by turntable requires more mould space. By increasing the mould space on the IntElect2 Multi, Sumitomo’s engineers have succeeded in developing a multi- component machine that is, in fact, more compact.
Multi-component injection moulding is evolving in new directions, underpinned by new generation all-electric technology
the product design process and operation of the machine are far more complicated for multi-component products. Many of the disadvantages of multi- component manufacturing stem from the fact it has historically been performed on hydraulic machines. These are diffi cult to confi gure for diff erent materials – the pump system may have to be changed, for example. They are also heavy on energy consumption as the hydraulic motor is connected to an electric power unit that works at maximum power in every phase of the moulding process.
All-electric has the answers All-electric multi-component systems are starting to emerge as a viable alternative, off ering better speed, precision and energy effi ciency over their hydraulic counterparts.
When working with two materials, perfecting the injection-process control is even more critical, given that a second material is being injected on top of the fi rst shot.
All-electric machines use servo drives, enabling moulders to achieve greater precision and repeatability. For example, servo technology is critical for the smooth and fast rotation of the mould between the injection of the fi rst and second material to ensure components are perfectly
26 October 2020 | Automation
positioned to receive the second shot. Ultimately, this more precise operation translates to shorter cycle times compared to hydraulic concepts.
Electric machines also consume less
energy because they have several servo motors, one for each machine function, only working when required. With hydraulic machines, the pump is always on and working, even when the machine is idle.
Hence, although the initial capital outlay is higher, an electric machine will yield a viable ROI (return on investment) through lower energy consumption, reduced maintenance and faster cycle times.
Next-generation multi-shot machine September 2019 saw the launch of the IntElect2 Multi, Sumitomo (SHI) Demag’s most advanced multi-component electric machine yet. This new machine addresses the global movement towards more complex parts that feature two diff erent materials. With its dynamic motor design, the IntElect2 Multi promises an increase in production output up to 20%, a reduction in energy consumption up to 60% and faster ROI – typically around 18 months – compared to its predecessor. The machine fi lls a gap in the market for a more compact, energy-effi cient, multi-
Given the complexity and value of multi-component tools, the IntElect2 Multi includes an advanced mould safety system as standard. Featuring high-resolution sensors built into the toggle system itself, the machine can detect even the slightest change in force patterns and respond accordingly. Additionally, the machine assists moulders in monitoring ejector force, enabling the detection of parts and mould elements that have jammed, issues that arise with wear in the ejector system and broken ejector rods.
The versatile machine is equally suited to sustainability-led sandwich moulding, allowing for the production of soft-touch lids for shampoo bottles or toothbrushes that are overmoulded with diff erent colours in soft TPV, for example. Additionally, moulders can use an inner foam material wrapped in rigid plastic, resulting in a lighter-weight component and savings on materials, or combine hard and soft materials to improve the aesthetics and comfort of parts. Another option: covering an inner glass-fi bre material with an unfi lled material delivers increased stiff ness and creates a brilliant surface. With the market set to expand by a steady CAGR of 6.5% in the next four years, the resurgence of multi-component is clearly here to stay.
http://uk.sumitomo-shi-demag.eu/ CONTACT:
Sumitomo (SHI) Demag
automationmagazine.co.uk
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