ENGEL AUSTRIA GmbH | 10.2016 | 1

A New Approach to Optimize Mold Cooling: iQ flow controljoachim kraglDirector Advanced Molding Systems & ProcessingENGEL MACHINERY, INC.joachim.kragl@engelglobal.com | +1 717 968 8106

ENGEL AUSTRIA GmbH | 10.2016 | 2

ENGEL AUSTRIA GmbH | 10.2016 | 3

Mutual Information Chart

Know-how generates momentum | Cooling

4

ENGEL AUSTRIA GmbH | 10.2016 | 4

24 %Up to 24 % of all scrap parts are caused by errors in mold temperature control (or lack thereof)!

(Source: Menges, G; Auffenberg, D; Hüttner, H-J: Ausschussreduzierung in der Spritzgießverarbeitung). Kunststoffberater

Know-how generates momentum | Cooling

ENGEL AUSTRIA GmbH | 10.2016 | 5

flomo | Cooling BasicsHeat Flow in the Mold

ENGEL AUSTRIA GmbH | 10.2016 | 6

• Water Temperature TM

• Heat Transfer Resistance Δ2

• Which fluid (water, oil…..)• Viscosity of the fluid• Flow rate• Bore diameter

• Heat Conduction Resistance Δ1

• Distance to cavity surface – cooling channel• Heat conductivity of the mold built material

Heat Conduction Resistance

Heat Transfer

Resistance

Influences on the Cavity Surface Temperature w

Rule of thumb: +1°C cavity surface temperature 2% longer cooling time

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 7

20

25

30

35

40

45

50

55

60

65

0 2,5 5 7,5 10 12,5 15Kühlwasserdurchfluss [l/min]

υ W [°

C]

Heat Conduction Resistance

Heat Transfer

Resistance

Influence of Channel Distance on Cavity Surface Temperature

Aver

age

Cav

ity S

urfa

ce T

empe

ratu

re[°C

]

Cooling Water Flow Rate (l/min)Cavity Wall

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 8

20

25

30

35

40

45

50

55

60

65

0 2,5 5 7,5 10 12,5 15Kühlwasserdurchfluss [l/min]

υ W [°

C]Av

erag

e C

avity

Sur

face

Tem

pera

ture

[°C]

Cooling Water Flow Rate (l/min)

Cavity surface temperature dependent on Reynold‘s number

Laminar Flow & Transition Re < 10000

Turbulent Flow Re > 10000

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 9

20

25

30

35

40

45

50

55

60

65

0 2,5 5 7,5 10 12,5 15Kühlwasserdurchfluss [l/min]

υ W [°

C]Av

erag

e C

avity

Sur

face

Tem

pera

ture

[°C]

Cooling Water Flow Rate (l/min)

Laminar vs. turbulent flow

Laminar Flow & Transition Re < 10000

Turbulent Flow Re > 10000

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 10

Influence of the fluid dynamics on the process stability

Re 20.000

UnstableProcess

StableProcess

Aver

age

Cav

ity S

urfa

ce T

empe

ratu

re[°C

]

Cooling Water Flow Rate (l/min)

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 11

21°C 22°C

23°C

25°C 24°C

26°C

20°C

6 K

22°C 24°C

26°C

30°C 28°C

32°C

20°C

12 K

Flow rate 3 l/min Flow rate 6 l/min

Influence of the flow rate on the thermal uniformity of the mold

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 12

Ave

rage

Tem

pera

ure

diffe

renc

e[°

C]

Flow rate [l/min]

Thermal uniformity

Maximum Temperature Differences

• Common recommendations- Standard Molding: 3 – 5 K- Precision Molding: 1 – 3 K

• Simulation and/or practicalverification recommended

Influence of the flow rate on the thermal uniformity of the mold

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 13

• No Information about mold temperatures

- Temperatures/Flow Rates- Continous Monitoring- Process Changes/Variations- Documentation

Flow meters with limited to no practical use

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 14

& real life installation highlights

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 15

• Process Monitoring

- Monitoring of actual values- Detection of process variations- Addition of circuits is detected and recognized- Closed/clogged circuits will be detected

Advantages of modern manifold systems

flomo | Cooling Basics

ENGEL AUSTRIA GmbH | 10.2016 | 16

flomo e-flomo e-flomo premium

ENGEL flomo | The current flomo familyThe entire range

ENGEL AUSTRIA GmbH | 10.2016 | 17

How it works | flomo – Process Monitoring

• Fail save against contamination virtually maintenance free

• No moving parts • Very low pressure loss

The Vortex-Principle:

Interference body Sensor

Tube

How it works – Vortex Sensor

ENGEL AUSTRIA GmbH | 10.2016 | 18

Intelligent electronics

Pressure / temperature sensorfor monitoring the inlet

ENGEL flomo | Components

Ball valves for main shut offflomo: manuale‐flomo: electrice‐flomo premium: electric

Flow rate / temperature sensorsin each return line

Shut off valves in supply linesflomo: manuale‐flomo: manuale‐flomo premium: electric

Figure: e‐flomo premium

Control / shut off valves in return linesflomo: manuale‐flomo: electrice‐flomo premium: electric

ENGEL AUSTRIA GmbH | 10.2016 | 19

• Visualization on machine controller GUI

• Process documentation- Set values are stored with part data- Process data log

• New Process Parameters- Flow Rate- Pressure- Temperature- Temperature difference

Advantages of modern manifold systems

ENGEL flomo | Visualization/Documentation

Return Set Flow Rate

Return Set Temperature

Return Actual Temp.Supply Actual Pressure

Circuit on/offFlow Rate Differential

ENGEL AUSTRIA GmbH | 10.2016 | 20

50 %Up to 50 % energy savings through intelligent und considerate usage with the available resources

flomo | Energy Considerations

ENGEL AUSTRIA GmbH | 10.2016 | 21

Thermolator Energy

1,661 kWh/hPump Drive Energy

1,459 kWh/h

Heating Engery

0,202 kWh/h 12,2%

87,8%

Energy Flow: Thermolator

flomo | Energy Considerations

ENGEL AUSTRIA GmbH | 10.2016 | 22

Measured Flow Rate – Required Flow Rate

• Reduction of flow rate by 50 %

- No detectable process influence- Stable Operating Point

Connector:

Material: PBT

Flow Rate: 12,4 l/min

Set Point: 70°C

Flow Rate [l/min]Ave

rage

Cav

ity S

urfa

ce T

empe

ratu

re [

°C]

flomo | Energy Considerations

ENGEL AUSTRIA GmbH | 10.2016 | 23

Influence of Pump Size

• 2 Thermolators – 60 l/min – 6 bar- Flow Rate 12,4 l/min- Power 1460 W

• 2 Thermolators – 30 l/min – 5 bar- Flow Rate 9,7 l/min- Power 600 W

• 1 Thermolator 30 l/min – 5 bar- Flow Rate 7,8 l/min- Power 340 W

- 16,7%Total Energy

-28,4%Total Energy

Flow Rate (l/min)In

stal

led

mot

or p

ower

(kW

)Pr

essu

re(b

ar)

flomo | Energy Considerations

ENGEL AUSTRIA GmbH | 10.2016 | 24

Total Energy 3,29 kWh/h

Machine: e-mac 50/50Mold: 1-fachThermolator: 2 x PIOVAN TPH6

Set point 70°CShotweight: 4,81 gCycle Time: 54,8 s

Controller Energy Drive Energy

Heating Energy

ThermolatorEnergy

Lens „light skin“flomo | Energy Considerations

ENGEL AUSTRIA GmbH | 10.2016 | 25

Optimization | Minimized loss

Common situationLong hoses

Serial connection of circuits

Quick-connect couplings

Water manifold close to the moldShort hoses

Minimized pressure drop

Minimized heat loss

flom

o

e-flo

mo

e-flo

mo

prem

ium

ENGEL AUSTRIA GmbH | 10.2016 | 26

- Hydraulic balancing results in even mold temperature distribution

Uneven distribution of cooling water

Heat picture without hydraulic balancing Heat picture after hydraulic balancing

Optimization | Hydraulic balancingProcess optimization

ENGEL AUSTRIA GmbH | 10.2016 | 27

Optimization | Hydraulic balancing

• Base circuit: diameter Ø 10 mm• Insert circuit: diameter Ø 6 mm• Cavity inserts

• High requried cooling capacity• Low flow rates

Hydraulic imbalance is caused by different bore diameters and lengths.

Hydraulic imbalance in injection molds

ENGEL AUSTRIA GmbH | 10.2016 | 28

• Reduction of the flow rate in the base mold toRe ~ 20.000

• Increase of the flow rate in the cavity insertsfrom Re 16.900 to Re 33.500

• Cooling time reduction ~ 7 %• Flat part s = 2 mm• PP

Hydraulic imbalance compensation

Optimization | Hydraulic balancing

ENGEL AUSTRIA GmbH | 10.2016 | 29

ENGEL e-temp

One stop service Sales and service by ENGEL

User interface integrated into the CC300 e-temp needs no operating panel

All process information is displayed on CC300

New and innovative functionsSaving energy in combination with e-flomo and

iQ flow control

ENGEL AUSTRIA GmbH | 10.2016 | 30

iQ flow controlAdvantages

Overview screen

Optimized pump speed

Fully remote

controlledT-control

+

iQ flow control

e-flomo /e-flomo premium e-temp

ENGEL AUSTRIA GmbH | 10.2016 | 31

Fixe

d pl

aten

Clearly arranged

Correlations well visualised

Fast set-up

Alarm visualization

Easy error search

Temperature controlat a glance

Temperature control overview

mou

ldCore 1

Core 2

Circ. 1

Circ. 2

Circ. 3

Circ. 4

Hot run 1

Hot run 2

Moveable moldhalf

Stationaymold half

iQ flow control

ENGEL AUSTRIA GmbH | 10.2016 | 32

Temperature difference control - (T – controlled)

Difference between the supply and the return temperature of a cooling channel

Is a measure for a uniform temperature distribution

What does the temperature difference (T) describe?

Proven practical values are available

Uniform temperature distribution even with process deviations

Set values are not dependent on mold size

Advantages of T control

52°C

50°C

52°C

T=2°C

T=2°C

Set value

Set value

3 l/min50°C

12 l/min

Separate T control for each circuit with iQ flow control

iQ flow control

ENGEL AUSTRIA GmbH | 10.2016 | 33

Example of energy savings

EM 170/80TL / 2 cavity number pad / PP

2 temperature control devices e-temp H8

Supply temperature 35 °C

Shot weight 30,3 g

Insulated barrel

Cycle time 30 s

Intelligent pump speed control saves energy

Energy consumption without iQ flow control

Thermolator2520 W: 57%

drives940 W; 21%

heating730 W; 16%

control unit250 W; 6%

iQ flow control

ENGEL AUSTRIA GmbH | 10.2016 | 34

Example of energy savings

EM 170/80TL / 2 cavity number pad / PP

2 temperature control devices e-temp H8

Supply temperature 35 °C

Shot weight 30,3 g

Insulated barrel

Cycle time 30 s

Intelligent pump speed control saves energy

Reduced energy consumption with iQ flow control

savings1980 W; 45%

Thermolator540 W; 12%

drives940 W; 21%

heating730 W; 16%

control unit250 W; 6%

iQ flow control

ENGEL AUSTRIA GmbH | 10.2016 | 35

Thank you!