Presentation Kistler Group / Intranet / January 2012. Dr... · Presentation Kistler Group /...
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Presentation Kistler Group / Intranet / January 2012
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013 2
Zero Defect Injection Molding
with Cavity Pressure Monitoring
Dr.-Ing. Oliver Schnerr
Head of Sales & Head of Business Field Plastics
Automotive Summit 2013
Bangkok, Thailand
20 – 21 June 2013
Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
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Overview
Kistler Group
Our values – your benefits
measure. analyze. innovate
Technologies
Measurable variables
Applications and markets
References
Further information
Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
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Kistler Group
Everything from a Single Source
Development and production
of sensors, electronics
and systems for measuring
pressure
force
torque
acceleration
Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
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Kistler Group
International headquarters in
Winterthur, founded in 1959
Production sites at seven
locations in CH, USA and
Germany
23 sales companies and 21 sales
offices
Active in over 50 countries
worldwide
1 200 employees around the
world, 500 of whom are based in
Switzerland
Collaboration with more than
50 universities
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Kistler worldwide
Production Center
Buffalo NY (USA)
Competence Center
Wetzlar (D)
Tech Center
Stuttgart (D) Production Center
Lorch (D)
Tech Center
Shanghai (CN)
Competence Center
Schönaich (D) Production Center
Winterthur (CH)
Tech Center
Detroit (USA)
Production Center
Meerane (D)
■ Production Center
■ Competence Center
■ Tech Center
Competence Center
München (D)
■ Sales Center
Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
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Kistler Group – Key Figures
Billings 2012: 279 Millions CHF
Long-term annual growth of more than 10 % in the last 10 years
10 % of the turnover are reinvested in R&D
Influences on Quality in Injection
Molding
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Material
Operator
Temperature
Abrasion Enviroment
(Day/Night/
Humidity)
Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Quality Assurance in the Process
Chain
Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
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Disadvantages of the Established
Quality Assurance
Only Spot Check
Manual quality control needs man power
Delayed reaction to process problems
Follow on operations e.g. assembly operations might be done
with non conforms products
Defect parts at customers might occur
Downgrading in Supplier Ranking
Sorting operations might be necessary
Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
„In-Process“-Quality Assurance
in Injection Molding
Monitoring the quality-determine, measurable process value
directly in the injection molding process
Automatic quality control
All produced parts are checked
Zero defect production
Detection of scrap at the earliest stage
Documentation of all produced parts
Statistical analysis of quality and production process
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Realisation of the „In-Process
Quality Assurance“
Measuring of the relevant process value where the quality is
made
In the mold
The most important process value for quality:
Cavity Pressure
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Cavity Pressure Sensors
Direct Sensor 6184A...
Indirect Sensor 9210A...
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Injection Compression Holding
Qu
ality
Surface,
Crystallinity,
Orientation in
surface layers...
Forming of
contour, short
shot, flash
Dimensions, weight, sink mark, warpage, shrinkage, orientation...
Cavity Pressure and Quality
Maximum pressure
Switch-over
Sealing of gate Werk
zeugin
nendru
ck
Zeit
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Cavity Pressure and Material
Variation
MFI=70
MFI=45
MFI=15
Cavity P
ressure
[b
ar]
Time
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Cavity Pressure and Material
Variation
MFI=70 MFI=45 MFI=15
Cavity P
ressure
Inte
gra
l [
bar*
s]
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Cavity Pressure and New Material
and Regrind
New material Regrind
Cavity P
ressu
re I
nte
gra
l [
ba
r*s]
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Cavity Pressure and Mold
Temperatures
Werkzeugtemperatur 65°C Werkzeugtemperatur 70°C
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
System for In-Process Quality
Monitoring
Good/ Bad
Separation
Database with
Process and
Quality Data
QS-Document
Process Analysis
Scrap
Gate
Monitoring
system
System Process Data
Mold with
Cavity Pressure
Sensors
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Monitoring of Production of Door
Handle
Industry Automotive Exterior
4 Cavity Tool
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Problem Statement
Door handle produced with gas assisted injection molding
Flash on upper parting line results defective parts after painting
Defects only apparent after a few days
Minor process fluctuations and gas-leakages are not easily
detected during moulding
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Solution
Monitoring of cavity pressure in all 4 cavities with a 4 mm
pressure sensor
Monitoring of cavity pressure maximum during injection and
gas injection phase for flash detection
Monitoring of integral to detect gas leakages
Optimization of process and gates
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Results
Automatic bad part separation
Scrap after painting reduced to
zero
Documentation of Quality
Constant process condition after
modification of gates (Pressure
maximum constant)
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Control
System
System
Automatic Hot Runner Balancing
- Multiflow
Mold with
Cavity Pressure
sensors
Process Data
Hot runner tip
temperatures
After Cycle
Parameters
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Example: Technical Part
Mold 16 Cavities
16 Cavity Pressure Sensors
Material: PA 6
Part Weight: 0,17 g
Shot Weight: 6,65 g
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Unbalanced Process and Mold
Filling
Dt
1
2
3
4
5
6
7
8
Cavity filling
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Unbalanced Process and Mold
Filling
1
2
3
4
5
6
7
8
Dt
Cavity filling
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Unbalanced Process and Mold
Filling
1
2
3
4
5
6
7
8
Dt
Cavity filling
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Unbalanced Process and Mold
Filling
1
2
3
4
5
6
7
8
Dt
Cavity filling
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Unbalanced Process and Mold
Filling
1
2
3
4
5
6
7
8
Dt
Cavity filling
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Unbalanced Process and Mold
Filling
1
2
3
4
5
6
7
8
Dt
Cavity filling
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Automatic Balancing of Process
Cycle 1 Cycle 5
Cycle 40
Cycle 15
Cycle 25 Cycle 55
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Balanced Process and Mold
Filling
Results with MultiFlow 1
2
3
4
5
6
7
8
Cavity filling
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Balanced Process and Mold
Filling
Results with MultiFlow 1
2
3
4
5
6
7
8
Cavity filling
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Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Dt
Balanced Process and Mold
Filling
Results with MultiFlow Dt = 11 ms
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0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
1 400 1200 2000
Manuell
Multiflow
Automatic Balancing
Long Term Behavior
Kistler Multiflow
Zeit
Fill
ing T
ime D
iffe
rence D
t [s
]
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Result of Different Balancing Procedures
Method Time / Cycles Needed for
Balancing
Result Dt [s]
Manual Balancing Standard
Solution
½ Day 0,126
Manual Balancing based Cavity
Pressure
60 Cycles 0,069
Automatic Balancing with
Multiflow
23 Cycles 0,011
Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013
Summary
Cavity pressure measurements open the possibility to
integrate a automatic quality assurance directly in the
injection molding processes
The „In-Process“ quality assurance detects bad parts at the
earliest stage and offers a 100% monitoring of all produced
parts
The manual quality assurance can be eliminated
The automatic hot runner balancing system Multiflow
stabilizes the process, leads to constant part quality and adds
new benefits to the “In-Process” quality assurance systems
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