1 ADVANCEMENTS IN INJECTION MOULDING DHAYA I TRUMAN SALES & MARKETING ENGINEER LARSEN & TOUBRO LIMITED

2 Weight reduction as industry culture Weight reduction as industry culture Higher level of functional integration Higher level of functional integration Higher levels of safety Higher levels of safety Economic & Operational efficiency Economic & Operational efficiency Evolution of revolutionary processes Evolution of revolutionary processes Short development / life cycles Short development / life cycles Exciting new applications Exciting new applications Technology induced cost efficiency Technology induced cost efficiency Built in re-cycle ability Built in re-cycle ability GENERAL TRENDS IN INDUSTRY (PRODUCT DESIGN & MANUFACTURING )

3 TRENDS - PLASTICS TECHNOLOGY Optimum utilization of resources( machine / mould) Optimum utilization of resources( machine / mould) Reduce scrap / rejects Reduce scrap / rejects High precision High precision increase complexity of molding geometry increase complexity of molding geometry Energy efficiency Energy efficiency Optimum Space utilization by process integration Optimum Space utilization by process integration Shorten logistics chain (production cell) Shorten logistics chain (production cell) Inj. Moulding going beyond Plastics Inj. Moulding going beyond Plastics

4 WHY NEED FOR ADVANCEMENT? Requirement for higher productivity Requirement for better quality Requirement to mould more intricate parts Requirement to mould more critical materials Requirement for stable process Requirement for special applications Requirement to make machine trouble free Lower energy consumption

5 HIGHER PRODUCTIVITY … Faster movements Precise control of position Good control of speed Good control of pressure More parallel operations

6 FASTER MOVEMENTS … HIGH SPEED 5 POINT TWIN TOGGLE SYSTEM ROBUST & SWIFT UNIFORM FORCE DISTRIBUTION LESS OIL REQUIREMENT ACCURATE BETTER MOULD SAFETY LONG LASTING LOW ENERGY CONSUMPTION

7 PRECISE CONTROL OF POSITIONS LINEAR TRANSDUCER

8 GOOD CONTROL OF SPEED AND PRESSURE … FAST ACCURATE QUICK RESPONSE RELIABLE LOW ENERGY CONSUMPTION MORE PARALLEL OPERATIONS

9 MORE PARALLEL OPERATIONS …

10 MORE PARALLEL OPERATIONS … Ejector operation parallel to mould movement Hydraulic core operations parallel to mould movement Dosing parallel to mould movement

11 Higher productivity Online Quality Assurance Less dependency on manpower Reduced set-up time /Quick Startup Generate MIS Data (Management Information ) Downtime logging Energy Monitoring MODERN MANAGER’S NEED ON THE MACHINE

12 PRODUCT QUALITY BY BETTER PROCESS CONTROL Repeatability Easy to optimise Accuracy Monitoring system

13 PROCESS MONITORING … PROCESS CAPABILITY - SPC GRAPH

14 PROCESS START-UP

15 PROCESS OPTIMIZATION 1)Cleary input as a table 2)All necessary setting parameters for injection with one view 3)Indication of set vs. actual values

16 AMENDMENT REPORT LOG

17 LATEST TYPES OF MACHINES Hydraulic machine with SYDFEE pump All Electric machines Hybrid machines

18 Fixed displacement Pump system Q signal P signal PLC

19 HYDRAULIC MACHINE WITH SYDFEE PUMP

20 FAST ACCURATE QUICK RESPONSE RELIABLE LOW ENERGY CONSUMPTION RELIABLE HYDRAULICS

21 Close loop for FLOW and PRESSURE Precise reproduction of set parameters Energy efficient - Power savings Faster response - Accurate process control Switch-over to hold-on based on hydraulic pressure Simple circuitry Oil temperature rise minimised ADVANTAGES OF SYDFEE PUMP

22 EXCELLENT PLASTICISING UNIT WITH GOOD SCREW DRIVE HEAVY DUTY HIGH POWER HYDROMOTOR HIGHER PLASTICISING CAPACITY BETTER HOMOGENITY ACCURATE METERING CONSISTANCY

23 SCREW Metering zoneCompersion zoneFeed Zone

24 Barrier screw Barrier endBarrier zone Barrier start Intake zone hEhE t eEeE

25 Single-flighted screw section 2-flighted screw section Melt filmBarrel wall Passive flangeActive flange Melt filmBarrel wall Passive flangeActive flange Solids bed Melt vortex Screw flight Solids bedMelt vortexScrew flight Melting Characteristics of Different Screw Concepts

26 INTELECT – ELECTRIC MACHINE

27 M Injection by motor 1 (linear movement) Metering by motor 2 (rotary movement) Injection and metering

28 Opening and closing movements are powered by high-torque motors High-torque motor

29 Ejector system

30 Mould protection system Master curve Offset curve Collision case Piston speed travel Kraftverlauf Protection range Kolbengeschwindigkeit force 15 mm Collision point

31 ADVANTAGES OF ELECTRIC MACHINE Short cycle times High precision/position accuracy Fast response in acceleration & deceleartion Torsion free drives/ Mould safety Reinforced platens/ high performance screws Parallel motions Energy efficiency Low noise level

32 MOVEMENTS ON AN INJECTION MOULDING MACHINE Mould Movements Metering/ Plasticising Ejectors Injection Nozzle Unit Core Pull

33 THE NEW DRIVE CONCEPT: ERGOTECH EL-EXIS S Servomotor Hydrostatic gear for opening and closing Variable capacity pump with central accumulator Cores

34 CUSTOMER BENEFITS: REDUCED ENERGY CONSUMPTION Electric drive for plasticising (main energy consumer) Electric drive for mould movement Reduced supply for pump station(15 kW instead of 45 kW) Deceleration energy of mould movement used for plastcising

35 ENERGY CONSUMPTION 100 % 90 % 75 % 50 % Conventional Fast M/C with Constant Delivery Pumps Fast M/C with Constant Delivery Pumps + E-Drive Variable Delivery Pump Hydraulics + Electric Screw Drive ERGOTECH EL-EXIS S Fully Electric Machine

36 TYPICAL ADVANTAGES OF DIFFERENT MACHINE CONCEPTS - higher performance (injection) - easier for linear movements - one motor for different functions (ejector, cores,..) - lower installed energy - lower invest - smaller space requirements - integration to modularity lower energy consumption - higher precision - no oil leckage - lower noice level - higher dynamic electric drivehydraulic drive

37 TRENDS – MATERIAL TECHNOLOGY Property potential of polymers far from being exhausted Property potential of polymers far from being exhausted Glass and metal substitution at its peak Glass and metal substitution at its peak Polymers competing each other Polymers competing each other MIM/CIM gaining grounds MIM/CIM gaining grounds Use of Natural Fibres Use of Natural Fibres Thermosets back on the growth track Thermosets back on the growth track Nano technology as a sunrise technology Nano technology as a sunrise technology Easy flow/fast cool properties for moulding efficiency Easy flow/fast cool properties for moulding efficiency

38 TRENDS- MOULD TECHNOLOGY  Stack moulds  Multi axis indexing moulds  Moulds for In-mould labeling and MID  Cavity count at its peak  Complex Hot runner  High mould rigidity

39 THIN WALLED TECHNOLOGY High transparency Increased impact resistancy Reduced shot weight Very low cycle times High injection speed Rigid Moulds and platens Parallel functions ( machine)

40 Cycle time :ca. 5.5s Cavities:4+4 STACK Machine: Ergotech El-EXIS S PP (CD-Cover) High L/T ratios Tougher materials High cavitation Large volumes LEAD TO MACHINE COMPLEXITY THIN WALLED TECHNOLOGY

41  Combination of materials Metal /plastic/alloys Thermoset / thermoplastic / elastomer  Combination of process Injection and compression molding Injection molding and surface finishing tech In mould decoration  Reduction or integration of functions Direct compounding Online fabrication  Revolutionizing machine design All electric/hybrid technologies On line assembly/ quality control TECHNOLOGY LEAPS

42 TRENDS - NEW APPLICATIONS Stimuli for new applications New / modified plastics New / modified plastics New / extended processing methods New / extended processing methods Fresh potential through new application developments Fresh potential through new application developments Economic efficiency / costs Economic efficiency / costs Increasing / charging demands on existing applications Increasing / charging demands on existing applications

43 IN-MOULD LABELING TECHNOLOGY

44 PC-film HPF / film moulding IN-MOULD LABELING WITH PRINTED FILMS

45 PRACTICAL EXAMPLES OF IN-MOULD DECORATION (IMD)

46 APPLICATION FOR IN-MOULD DECORATION (IMD) IN “AUTO INDUSTRY”

47 TYPICAL MID APPLICATIONS

48 MULTI COLOR / MATERIAL TECHNOLOGY

49 MULTI- COMPONENT / MULTI- COLOUR PARTS

50 MULTI COLOR COMPONENTS FOR MOTOR INDUSTRY

51 THANK YOU