Mold-Masters Europe 1 by Robert Kirkby MasterCARE-Team, EMEA (2012-05-11)
Master-Series I The Flagship 12 standard gate options 6 standard nozzle sizes Precise temperature control with brazed heater technology and integrated T/C 2
Master-Series I Nozzle range Hecto Deci Centi Pico Femto Femto Lite Non-Valved 12mm 16mm 8mm 6mm 5mm 5mm 3.5mm Valved 16mm 18mm 11mm 8mm 7mm 6mm n/a 3
Valved vs. Non-Valved 4
Premium valve gate solutions I Options Types of Valve Pins Tapered Pin Cylindrical Pin 5
A closer look at Valve Gating Advantages, Tapered Easy to machine Self Centering Large gates possible Good gate appearance Advantages, Cylindrical Excellent gate appearance Small gate size possible Disadvantages, Tapered Pin must close within thermal window defined by gate size and hold time. Disadvantages, Cylindrical Accurate machining of the gate is required. 6
Accu-Valve I Premium valve gate solutions Pristine cylindrical valve gating of commodity and engineering resins Continuous pin guiding 2 million cycle guarantee ACCU-VALVE CX - for Standard Resins ACCU-VALVE MEX - for Standard Resins ACCU-VALVE EX - for Standard Resins <150 shot color changes 7 CX MEX EX
Accu-Valve I Leak-proof protection Additional leak-proof protection at the manifold V-Guide System Innovative Valve Disk design prevents leakage between the valve pin and valve disk at the manifold area by creating a thermal barrier within the valve disk itself Previous Valve Disk Design New V-Guide Valve Disk Design 8
Accu-Valve I V-Guide New V-Guide Valve Disk Design 9
Accu-Valve CX 10 Gate quality that always meets your expectations Ideal for high cavitation applications, fast cycle times & fast color changes Bi-metallic design does not rely on gate steel for pin alignment Pin alignment through constant engagement in liner
Accu-Valve CX The benefits of Accu-Valve CX over other valve gate designs: Seal liner flow channels allow for fast color changes and no dead spots Continual pin alignment and optimal gate temperature creates the perfect thermal condition at the gate Resulting in minimal pin resistance and optimal gate longevity 0.0003 maximum clearance between the pin and cavity ensures that no crown flash even with very flash sensitive materials Pin is stronger and has a simpler design Any tolerance errors are completely eliminated as final gate/liner machining is done after assembly Accu-Valve CX Seal/Liner 11
Accu-Valve EX Tailored for engineering grade resins (PC, POM, etc.) Gate quality that always meets your expectations Ideal for high cavitation applications 12
Accu-Valve EX The benefits of Accu-Valve EX over other valve gate designs: Never any resistance to valve pin closure because gate temperature is always above HDT point based on detailed FEA analysis Results in even longer pin longevity as the pin is not exposed to additional stress to seal/close Double guiding mechanisms always ensure proper alignment through gate area Gate seals and liners can be made from different materials based on the cooling quality of the gate area in the cavity Resulting in even more flexibility for all applications 13
Hot-Tip I Premium open gate solution Visco-Seal : Additional leak-proof protection achieved with a thin plastic membrane that solidifies at edge of seal Seals and liners can be easily replaced in the press Liners are made from various materials depending on resin properties and requirements» Thermal cycling» Wear resistance 14
Actuation Methods 15 (2012-08)
Actuator Options I Today s Actuation Methods Individual Actuation Hydraulic Pneumatic Electric (E-VG)* Synchro-Plate Hydraulic Pneumatic Electric (E-Drive)* Cluster Actuator Hydraulic Pneumatic *For detailed information about the E-Drive or the E-VG please refer to the corresponding product presentations and Mold- Masters Resource Guide (MMRG). 16
Actuator Options I Valve Actuator Section Chart* *For detailed information please refer to the MMRG 17
Actuator Options I Comparison Chart Actuator Unit Minimum Pitch Type Fluid Piston Force Competitive Design 25 mm Individual Pneumatic MM Syncro-Plate 20 mm Multi-Pin Act. Pneumatic MM Syncro-Plate t.b.d. Multi-Pin Act. Hydraulic Please refer to catalogue pages MM PN2300 44.3 mm Individual Pneumatic 596 N (@90psi) MM HY550X 25 mm Individual Hydraulic 865 N (@ 400psi) E-Drive* (reg. valve pin holders) 17.3 mm Multi-Pin Act. Electric STD Power Rate: Electric 33000 N (Peak) 15000 N (Continuous) E-Drive* (mag. valve pin holders) 29.5 mm Multi-Pin Act. High Power Rate: 50000 N (Peak) 24000 N (Continuous) E-VG (55mm Solenoid) 58 mm Individual Electric E-VG (75mm Solenoid) 78 mm Individual Electric Small Synchro-Plate* 15 mm Multi-Pin Act. Hydr. / Pneu. Please refer to catalogue pages 18
Design Options The HY8400/HY8500 resolves issues with applications where high injection pressures are required by increasing the closing force of the actuator 19
Features Similar to HY7100 / HY6500 design Uses air or oil HY8500 for cylindrical valve gating HY8400 for non-cylindrical valve gating Cylinder top Centers air/oil flow to provide even downward pressure on the larger piston diameter Piston Increases closing force without increasing supplied pressure Wiper Seal Reduces contamination entering actuator unit 20
Advantages The HY8400/HY8500 has advantages over standard HY65/7100 units: 21
Components 22
E-Drive I Powerful. Precise. Clean. Syncro plate valve pin actuation with servo motor control Fully enclosed valve gating system with electro-mechanical actuation Applicable for 2 up to 128 cavities Oil-free actuation, all electrical (no oil/air power) Suitable for clean room applications High performance system for absolute stable production processes Sustainable production/part quality Cost-effective solution based on TCO 60% less energy consumption compared to hydraulic valve gate systems >50 % reduced maintenance costs due to extended maintenance cycles Magnetic Pin Option 23
E-Drive I System Features Fully enclosed and all electrical (no oil/air power) suitable for clean room applications 60% Energy savings compared to hydraulic valve gates Applicable for 16 to 32 cavities Higher cavitations possible with dual servos (future) 24
E-Drive I Components View Valve pin (synchro) plate Idlers (2) Servo and gear box Tensioning idler Ball Screws (2) 25
E-Drive I Section View 26
E-Drive I Servo Drive and Ball Screw Solution Belt and ball screw mechanism is over 90% mechanically efficient All movements are based on rolling No sliding (friction) losses Servo drive actuation High accuracy and repeatability Variable speed and Acceleration High Torque Precision Control 27
E-Drive I Features: Solid support Synchro plate design allows pillar support from HR intermediate plate to mold backing plate, resulting in stronger mold 28
E-Drive I Features: Freedom in Cavity Layout Outboard location of E-drive mechanism allows substantial freedom for cavity positioning 29
E-Drive I Ease of Use and Maintenance Easy valve pin position and stroke set-up Top plate automated in the controller Modular design Ease of access Entire E-drive can be removed by removing top plate bolts and easing belt tension No o-rings 30
E-VG I Electric valve gate solution High energy savings High closing force Fast cycle times 75 mm Sequential Valve Gate Control Simple, Easy to Use Controller Great flexibility 55 mm 31
E-VG I Advantages Cleanroom Friendly EVG is suitable for cleanroom applications as it produces almost no particulate pollution Reliability EVG is covered by a 2 year warranty and it saves on maintenance costs as it has no wear components Reusability Actuators can easily be removed and used on future molds 32
E-VG I Advantages Sequential Valve Gate Control Allows for sequential opening of valve gates in base functionality Pin motion sensor option for sensing whether the pin has not been able to close Flexibility Individual cavities can be remotely turned off without temperature changes in the nozzles Simple and easy to use controller with touch screen interface 33
E-VG I Mold-Masters unique Solenoid Detail Solenoid comprises of a permanent magnet holding the anchor in either one of the two end positions. To switch position, two electro-magnets are used; one to weaken the permanent magnet s magnetic field and the other to pull the anchor. PERMANENT MAGNET ELECTROMAGNET ELECTROMAGNET 34
E-VG I Mold-Masters Unique Force/Stroke Curve 3 times higher stroke forces available than competitive systems 60% more closing force compared to a pneumatic system A 3 mm pin can close against a hold pressure of up to 23,000psi 35
E-VG I Mold-Masters Unique Force/Stroke Curve 36
Backup-Slides 37
Mold-Masters I Product & Service Portfolio 38
Master-Series I The Manifold Technology Patented 2-piece brazed manifold technology Unique in the industry Runners are carefully milled and polished, with no sharp corners or dead spots, promoting fast and precise color change Endless configurations of runner routes that drilling doesn t allow for 39
Master-Series I The Manifold Technology Cast-in heaters improve temperature uniformity versus pressed in heaters Multiple melt channels for different materials can be designed in the same manifold reducing the overall stack height by up to 22% 40
NEW I IRIS I Co-Injection Technology Unique barrier molding solution for i.e. food and beverage containers Barriers to protect the product and ensure a long shelf life Such barriers are typically created using glass, metal or plastic, with liners or multiple layers IRIS co-injection technology is a revolutionary alternative to these traditional packaging methods IRIS co-injection is achieved via the combination and integration of Mold-Masters key technology elements Single source supply of the melt distribution and control system with global service and support Lower capital investment with the ability to use existing tooling and machinery Production flexibility as the IRIS system can easily be moved to other machines and locations 41
MasterCARE I Service offerings System installation System trails System refurbishment Retrofitting and repairs Onsite repairs to systems Complete support management Technical consulting for new systems Seminars (on-site/off-site) Technical trainings Service and maintenance contracts System cleaning Trouble shooting Dedicated Contact 42
MasterCARE I Benefits First customer contact for any service issue Global field service Dedicated team of specialists 24/7 spare parts hotline Global spare parts services Part centers on all continents Immediate support Resolution of issues in the shortest time possible 43
MasterSOLUTION I Offerings Custom engineered solutions Technical training and consulting Mentoring program (co-development program) Large program management incl. risk assessments Trouble shooting SAMP > Solution Assessment Management Program CAMP > Cause Assessment Management Program 44
MasterSOLUTION I Benefits Quick turnaround and solution finding process Direct contact, from beginning to end Cost effective solutions, tailored to your needs Integrated Risk Management through project due diligence Global pool of industry experts Extended development capacities Ongoing knowledge management and transfer Worldwide Project Management Individual, cost effective and time-to-market product solutions 45
Success in the Field - CX Customer: Major Caps and Closures Company Push pin mark for symmetry 46
Success in the Field - CX Customer: Major Medical Company System Description: Master-Series Femto, 2 Pilot Drop Systems, 2 Production Molds 48 Drop Systems Material: PP Processing Temp: 232 C; Mold Temp: 38 C Plastic Part Size: 2g Plastic Part: Medical Parts 47
Success in the Field - CX Customer: Major Personal Care Company System Description: Master-Series Pico 96 Drop System with Syncro Plate Quantity 2 Material: PP Processing Temp: 255 C; Mold Temp: 35 C Plastic Part Size: 2.0g 48
Success in the Field - EX Customer: Major Medical Company System Description: Master-Series Femto Material: PC/ABS Blend Processing Temp: 282 C; Mold Temp: 99 C Plastic Part Size: 0.14g Plastic Part: Medical Part In production December, 2006 49
Success in the Field - EX Customer: Major Medical Company System Description: Master-Series Femto 4 Drop Material: PC/ABS Blend Processing Temp: 282 C; Mold Temp: 99 C Plastic Part Size: 0.14g Successful EX implementation could not close the gate of the Husky system 50
Success in the Field - EX Customer: Major Medical Company System Description: Master-Series Centi, 12 Drop Material: PS + K-Resin + Zinc Styrate Processing Temp: 230 C; Mold Temp: 30 C Plastic Part Size: 19.28g, 17X17X264mm 51