iQ flow M2017 - Molding Conference 2020 - Molding 2020 · ENGEL AUSTRIA GmbH | 10.2016 | 29 ENGEL...

ENGEL AUSTRIA GmbH | 10.2016 | 1

A New Approach to Optimize Mold Cooling: iQ flow controljoachim kraglDirector Advanced Molding Systems & ProcessingENGEL MACHINERY, [email protected] | +1 717 968 8106


Mutual Information Chart

Know-how generates momentum | Cooling

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


flomo | Cooling BasicsHeat Flow in the Mold


• 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


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



20

25

30

35

40

45

50

55

60

65


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



20

25

30

35

40

45

50

55

60

65


υ W [°

C]Av

erag

e C

avity

Sur

face

Tem

pera

ture

[°C]


Laminar vs. turbulent flow

Laminar Flow & Transition Re < 10000

Turbulent Flow Re > 10000



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

]




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



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



• No Information about mold temperatures

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

Flow meters with limited to no practical use



& real life installation highlights



• 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 e-flomo e-flomo premium

ENGEL flomo | The current flomo familyThe entire range


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


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


• 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


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

flomo | Energy Considerations


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



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]



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)



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


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


- 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


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


• 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 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


iQ flow controlAdvantages

Overview screen

Optimized pump speed

Fully remote

controlledT-control

+

iQ flow control

e-flomo /e-flomo premium e-temp


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


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


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


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


Thank you!

iQ flow M2017 - Molding Conference 2020 - Molding 2020 · ENGEL AUSTRIA GmbH | 10.2016 | 29 ENGEL...

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Transcript of iQ flow M2017 - Molding Conference 2020 - Molding 2020 · ENGEL AUSTRIA GmbH | 10.2016 | 29 ENGEL...