Presentation Kistler Group / Intranet / January 2012. Dr... · Presentation Kistler Group / Intranet ... Flash on upper parting line results defective parts after ... The automatic

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


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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


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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

Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013 6

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


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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)


http://images.google.ch/imgres?imgurl=http://www.heringloh.de/Fangbericht06/Sonne.jpg&imgrefurl=http://www.heringloh.de/Fangbericht6.htm&h=174&w=248&sz=4&tbnid=CSHNZ4hvGSwJ:&tbnh=74&tbnw=105&start=166&prev=/images?q=tag+sonne&start=160&hl=de&lr=&sa=N

http://images.google.ch/imgres?imgurl=http://privat.eure.de/mora/no4.jpg&imgrefurl=http://privat.eure.de/mora/sofi.htm&h=316&w=400&sz=23&tbnid=xdIf9yhfX-0J:&tbnh=94&tbnw=119&start=74&prev=/images?q=nacht+mond&start=60&hl=de&lr=&sa=N

Quality Assurance in the Process

Chain


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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


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„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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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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Cavity Pressure Sensors

Direct Sensor 6184A...

Indirect Sensor 9210A...

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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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Cavity Pressure and Material

Variation

MFI=70

MFI=45

MFI=15

Cavity P

ressure

[b

ar]

Time

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Cavity Pressure and Material

Variation

MFI=70 MFI=45 MFI=15

Cavity P

ressure

Inte

gra

l [

bar*

s]

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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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Cavity Pressure and Mold

Temperatures

Werkzeugtemperatur 65°C Werkzeugtemperatur 70°C

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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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Monitoring of Production of Door

Handle

Industry Automotive Exterior

4 Cavity Tool

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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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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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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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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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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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Unbalanced Process and Mold

Filling

Dt

1

2

3

4

5

6

7

8

Cavity filling

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Filling

1

2

3

4

5

6

7

8

Dt

Cavity filling

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Filling

1

2

3

4

5

6

7

8

Dt

Cavity filling

28



Filling

1

2

3

4

5

6

7

8

Dt

Cavity filling

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Filling

1

2

3

4

5

6

7

8

Dt

Cavity filling

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Filling

1

2

3

4

5

6

7

8

Dt

Cavity filling

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Automatic Balancing of Process

Cycle 1 Cycle 5

Cycle 40

Cycle 15

Cycle 25 Cycle 55

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Balanced Process and Mold

Filling

Results with MultiFlow 1

2

3

4

5

6

7

8

Cavity filling

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Filling

Results with MultiFlow 1

2

3

4

5

6

7

8

Cavity filling

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Dt


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

]

36 Zero Defect Injection Molding with Cavity Pressure Monitoring/ Srr / 21 June 2013

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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



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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Documents

Presentation Kistler Group / Intranet / January 2012. Dr... · Presentation Kistler Group / Intranet ... Flash on upper parting line results defective parts after ... The automatic