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EWIKON electric drive valve gate technologyFull process control with high precision
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The benchmark for electric valve gate technology
The EWIKON electric valve gate technology sets benchmarks in process control and precision. All relevant process parameters can be set individually according to the specific application requirements and fine-adjusted during production as well. Thus, the injection moulder gains full control of the valve pin movements. Additionally, the powerful control technology enables sequential gating as well as to approach several valve pin positions within one moulding cycle. This makes the technology the ideal solution for demanding injection moulding applications in the field of technical parts. Furthermore, the drive concept works emission-free and can be used in cleanroom applications for the medical industry without any restriction.
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• Full control of the valve pin movement
• Clean drive concept, emission-free and absolutely cleanroom compatible
• Valve pin positioning with high precision, increment: 0.01 mm. Individual adjustment for each valve pin as well as shutdown of selected valve pins possible when using single drives.
• Individual setting of process parameters such as valve pin stroke, valve pin speed and opening and closing time
• High process reliability and reproducibility
• Easy integration into the mould
• Complex movement profiles of the valve pin for special applications can be realised easily
Drive unit typesThe benchmark for electric valve gate technology
Advantages
Linear step motor as drive unit for standard valve gate systems
Linear servo motor as drive unit for systems with pull rail actuated synchronous plate
• Available in 3 versions
• Linear force of drive units: max. 800 N / 1600 N
• Valve pin speed: 1 - 20 mm/s
• Valve pin stroke: up to 16 mm
• Encoder for permanent monitoring of valve pin position with an accuracy of 1/100 mm. Automatic readjustment of valve pin in case of deviation, valve pin is deactivated when problems occur permanently
• Available in 3 versions
• Linear force of drive units: max. 8000 N / 16000 N / 30000 N
• Valve pin speed: 1 - 30 mm/s
• Valve pin stroke: up to 10 mm
• Permanent monitoring and (if required) automatic readjustment of valve pin positions. Fine adjustment of the valve pin position in the gate area
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Powerful valve pin actuation
The closing force of the step motor drive remains constant at all times, independently from the valve pin stroke. It can be further enlarged by the possibility to vary the valve pin speed. The slower the movement of the valve pin the higher the force generated. The intelligent valve pin control allows to start the valve pin closing movement with high speed and then decrease the speed just before closing the gate. An almost doubled closing force is the result. This makes the step motor drive also suitable for processing demanding, rapidly freezing materials like polycarbonate where high closing forces are required for a proper gate sealing.
2500
2000
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Valve pin speed [mm/s]5 10 15 20 25 30
Closing forces of step motor drive units
Drive unit for valve pin diameter 3 mm and 4 mm
Drive unit for valve pin diameter 2 mm
Recommended load limit
Recommended load limit
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Precise and comfortable control
The external EDC-PRO (E Drive Control) touch screen control unit allows a comfortable operation for up to 32 linear step motors. For synchronous plate systems with linear servo motor the SDC (Servo Drive Control) controller is available. This control unit contains a technically advanced servo control system with multiple functions. A simple adjustment to different injection moulding machine controls is possible by using digital signals (+24 V DC).
EDC-PRO touch screen controller for linear step motor with 7'' color touch screen display
SDC-PRO touch screen controller for linear servo motor with 7'' color touch screen display
• Operates up to 32 linear step motors • Operates 2 linear servo motors
• Automatic mode or manual operation (test mode)
• Comfortable operation via touch screen display, visualisation of valve pin positions and operating modes
• Individual setting of process parameters such as stroke length, valve pin speed, opening and closing time and closing position (optimisation of gating point quality)
• Different valve pin operation modes: normal operation (OPEN/CLOSE), function for sequential gating (delayed opening), function to approach several valve pin positions within one moulding cycle (e.g. demoulding aid)
• Time-dependent or path-dependent actuation via screw position of the injection moulding machine or by other input signals, e.g. cavity pressure measurement: Combination of signal types possible
• Storage function to save data and settings on the integrated 2 GB flash memory and a USB stick
• Permanent monitoring of the valve pin position by high-resolution position measuring system
• Connection to injection moulding machine control via digital signals (+24 V DC) or analogue signal (0 - 10 V DC)
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Demanding applications made easy
Valve pin position 1
The valve pin moves into the cavity and touches the inner core with a defined pressure. The first component for the tube wall is injected. The valve pin keeps a channel in the tube wall open. The inner core retracts and the cavity for the soft component of the seal can be filled.
Valve pin position 3
The valve pin moves to its closing position at the outer edge of the part and the finished product can be demoulded.
Valve pin position 2
The valve pin opens and the soft component for the inner seal is injected through the open channel in the tube wall.
The extensive options the valve pin control offers open up new approaches to injection moulding applicati-ons and contribute to the growing tendency of integrating additional functions into the mould.
Function Field of application
Several valve pin positions are approached within one moulding cycle
Multi-component applications where both components can be gated without the need to move the part to another cavity
Ejector function; the valve pin acts as demoulding aid after the filling process
During injection the valve pin fixes an insert part or a core
Before injection the valve pin punctures an insert part which is then back-injected
Delayed opening and closing of the valve pins
Sequential injection moulding, cascade injection moulding without flow lines
Multi-gating of parts: Shifting of weld lines into uncritical areas of the structure
Family moulds: Precise filling of parts with different shot weights
Tubes and inner seals of plastic fittings are two-component injection-moulded within one cycle. The EWIKON electric valve gate system approa-ches three valve pin positions in this application. The valve pin is not only used to seal the gate, but also acts as a moveable mould core while the PP component for the tube wall is injected.
Please unfold for further technical data
Example: multi component application
Linear step motor – Drive unit types Linear step motor – Controllers
EDC-PRO 4-zone and 8-zone controllers with accessories
4-zone controller
68151.104
8-zone controller
68151.108
Signal cable 3 m, 6-pin 1 piece 60070.043
1 piece 60070.043
Motor cable 4-zone
1 piece60070.024
2 pieces60070.024
Encoder cable 4-zone
1 piece60070.027
2 pieces60070.027
Fault registration cable 6 m 1 piece60070.031
1 piece60070.031
Signal cable, analogue, 3/6 m 1 piece 60070.038-V03/V06
1 piece 60070.038-V03/V06
Required connecting plugs for mould:
Motor connection socket 4-zone
1 pieceflat: 63050.001 high: 63050.002
2 piecesflat: 63050.001 high: 63050.002
Encoder connection socket 4-zone, incl. cables
1 piece63050.003
2 pieces63050.003
EDC-PRO master / slave control units 16-zone to 32-zone (8-zone steps) with accessories
8-zone controller Master
68151.108
8-zone controller Slave
68151.118
Signal cable 3 m, 6-pin 1 piece 60070.043
Motor cable 4-zone
2 pieces60070.024
2 pieces60070.024
Encoder cable 4-zone
2 pieces60070.027
2 pieces60070.027
Fault registration cable 6 m 1 piece60070.031
Signal cable, analogue, 3/6 m 1 piece 60070.038-V03/V06
Required connecting plugs for mould:
Motor connection socket 4-zone
2 piecesflat: 63050.001 high: 63050.002
2 piecesflat: 63050.001 high: 63050.002
Encoder connection socket 4-zone, incl. cables
2 pieces63050.003
2 pieces63050.003
Master unit
Slave unit
Linear step motor with encoder
for nozzles with valve pin Ø 2 mm
19858
for nozzles with valve pin Ø 3 mm
19888
for nozzles with valve pin Ø 4 mm
22888
for nozzles with valve pin Ø (dim. D) 2 mm 3 mm 4 mm
Valve pin opening speed 1 - 20 mm/s 1 - 20 mm/s 1 - 20 mm/s
Valve pin closing speed 1 - 20 mm/s 1 - 20 mm/s 1 - 20 mm/s
Maximum valve pin stroke 11 mm 11 mm 16 mm
Maximum valve pin closing force 800 N 1600 N 1600 N
Maximum permissible environmental temperature
for drives70 °C / 158 °F
Resolution 0.01 mm 0.01 mm 0.01 mm
Dimension A 56.4 mm 85.6 mm 85.6 mm
Dimension B 61.8 mm 92.5 mm 92.5 mm
Dimension C 76.2 mm 90.8 mm 90.8 mm
Linear step motor with encoder
z285-02
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Linear servo motor – Drive unit types and controllers
z285-03
Drive unit types
SDC-PRO controller with accessories
Linear servo motor
18255
Linear servo motor
18253
Linear servo motor
18266
Maximum valve pin stroke 10 mm 10 mm 10 mm
Valve pin speed 1 - 30 mm/s 1 - 30 mm/s 1 - 30 mm/s
Maximum closing force of synchronous plate * 8000 N 16000 N 30000 N
Resolution < 0.01 mm < 0.01 mm < 0.01 mm
Dimension A 260 mm 340 mm 283 mm
Dimension B 74 mm 97 mm 127 mm
Dimension C 150 mm 195 mm 149 mm
Dimension D 78 mm 98 mm 112 mm
* System design by EWIKON according to the specific application requirements
1-zone controller
68151.301
2-zone controller
68151.302
Signal cable 3 m, 6-pin 1 piece 60070.043
1 piece 60070.043
Motor connection cable M23 servo drive unit 3/6 m
1 piece 63050.110-V03/V06
2 pieces 63050.110-V03/V06
Resolver cable M23 servo drive unit 3/6 m
1 piece 63050.120-V03/V06
2 pieces 63050.120-V03/V06
Fault registration cable 6 m 1 piece 60070.031
1 piece 60070.031
Signal cable, analogue, 3/6 m 1 piece 60070.038-V03/V06
1 piece 60070.038-V03/V06
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EWIKON Heißkanalsysteme GmbH Siegener Straße 35 35066 Frankenberg / GermanyTel: +49 6451 501-0E-Mail: info@ewikon.com www.ewikon.com
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