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With a clamping force of 1200 kN, the new e-motion 120 TL is the largest machine in its series.
With a clamping force of 1200 kN, the new e-motion 120 TL is the largest machine in its series.

From vehicles to electronic devices, more and more products are being offered in increasingly diverse design variations. For production, this translates to smaller lot sizes. At Fakuma 2018, from October 16 to 20 in Friedrichshafen, Germany, using two innovative applications, ENGEL AUSTRIA will demonstrate how small lot sizes can be realised with the efficiency and economy of large series.

Production of variations with fully automated switch-over

At Fakuma 2018, ENGEL is celebrating three premieres at the same time with a highly integrated production cell on which two-part callipers are manufactured using ABS.

A fully automated solution for the very rapid switch of mould inserts will be presented for the first time, the new size 120 of the all-electric and tie-bar-less e-motion TL series with a clamping force of 1200 kN will be introduced to the public, and thirdly, the expanded functionality of the e-flomo electronic temperature-control water manifold will be presented.

Built by Braunform, the mould with patented fast-switch mechanism allows for product changes within one minute.

With a clamping force of 1200 kN, the new e-motion 120 TL is the largest machine in its series. This upward expansion represents ENGEL's focus on the trend towards an increased use of multi-cavity moulds. Without any tie-bars in the way, the mould mounting platens can be utilised fully, so that large and bulky moulds can be fitted on comparatively small injection moulding machines.

Together with Braunform (Bahlingen, Germany) and other system partners, ENGEL is going one step further at the fair. The system solution presented there allows for a fully automated switch of the mould inserts within just one minute. To this end, the ENGEL e-motion 170/120 TL injection moulding machine is equipped with a mould that includes the fast-switch mechanism patented by Braunform. 

4.0 assistance ensures the highest measure of usable parts 

One of the challenges of this application is that both components have widely varying shot weights. In order to already produce a usable part with the first shot following the setup, the injection moulding machine continuously optimises itself with the help of three intelligent assistance systems from ENGEL's inject 4.0 programme.

While iQ weight control readjusts the melt volume for each individual shot, iQ clamp control calculates the optimal clamping force and sets it automatically. iQ flow control – the third assistance system on the team – automatically compensates temperature differences in the cooling water manifold circuit based on the measurements determined by e-flomo, and adjusts the pump speed in the e-temp temperature control units to the current process conditions.

The electronic temperature-control water manifold e-flomo makes another contribution to the short setup times. Upon installation, this new function guarantees an optimal ventilation of the temperature-control channels.

All units compactly integrated

One real eye-catcher at the Fakuma is the extremely compact layout of the production cell with the easix robot at its centre.One real eye-catcher at the Fakuma is the extremely compact layout of the production cell with the easix robot at its centre. The robot is responsible for the complete handling of the mould inserts and components, the marking of injection-moulded parts and their assembly, and the removal of the callipers from the production cell.

To this end, the injection moulding machine, the station for grippers and mould inserts, the laser printer, the assembly device and the conveyor unit are arranged around the robot in a star shape.

Two factors in particular contribute to the extremely space saving arrangement of the individual components. One is the freely definable prohibited areas of the easix robot and the other is the tie-bar-less clamping unit of the e-motion TL injection moulding machine.

With the completely automated production cell, the system partners ENGEL and Braunform are addressing customers who produce articles similar to each other in small lot sizes or with a high degree of variation. Typical products are consumer goods such as writing tools, technical components in the automotive and electronic areas, but also a range of medical technology products.

One process for infinite design options

During Fakuma, a duo 1060/350 injection moulding machine will be used for the production of highly decorated sample components.With the evolution of its foilmelt technology, at the fair, ENGEL presents a roll-to-roll IMD application with a flexibility that has not existed until now.

The joint development of the system partners
allows for thermoforming, back-injecting, and punching out in rapid sequence the most diverse surface structures from roll to roll within the mould. To change the decor, structure and functionality, only the roll has to be switched, not the mould.

With the production of differently decorated, three-dimensionally complex sample components on a duo 1060/350 injection moulding machine with integrated viper 20 linear robot at its exhibition booth, ENGEL demonstrates the high flexibility of the series-ready technology. Among others, target groups are the manufacturers of visible parts for car interiors as well as the teletronics and white goods industries.

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