Reproducible mold cooling in the production process
The functionality of injection molding machines is constantly evolving, and digitalization (Industry 4.0) in particular is opening up a host of new possibilities for networking and optimizing the production environment of injection molding machines. The basis for these new possibilities is data collected during the injection molding process.
The sophisticated measurement and control technology of modern injection molding machines today allows a deep insight into the manufacturing process. Process-relevant variables such as pressures, speeds and temporal processes can now be recorded, analyzed, evaluated and monitored very precisely. In addition, the correlations with the associated mold-internal processes are known so that the filling and demolding process can be precisely controlled. In contrast, the thermal processes that occur in injection molding are still relatively unknown or at least not easily accessible for more precise analyzes. Thus, mold cooling is an area that still leaves many questions unanswered and in which there is still a lot of potential for optimization.
Recording and monitoring of thermal parameters
Even today, machines are often equipped with simple cooling water distributors or mechanical water batteries, which, at best, allow the water flow to be visually monitored using a float. With the new cooling water monitoring system, Netstal offers a flexible and powerful solution. At the heart of the monitoring system are the fully integrated and extremely compact measuring manifolds from the Danish industry leader Mouldflo. The cooling water distributors, specially designed for high-performance applications, can be mounted flexibly and as required on all sides of the clamping plates and enable the recording of all relevant measurement data for mold cooling. They are also seamlessly integrated into Netstal’s media supply concept.
The new water distributors from Mouldflo, specially designed for high-performance applications, mounted on a clamping plate
The water flow rates are measured using the so-called vortex principle, which enables flow measurement without moving parts. In addition to the flow rates per cooling water circuit, the inlet and outlet temperatures as well as the inlet and outlet pressure at the manifold are measured as standard. This data enables comprehensive recording and monitoring of the cooling processes in the mold. All measurement data is clearly displayed on one page on the Axos 9 control unit and provides a comprehensive overview of the status of the thermal processes in the injection mold at all times. Of course, all values can be provided with a monitoring tolerance so that the machine can detect immediately if something changes in the cooling conditions.
The overview page provides a complete overview of the current status of the cooling water monitoring system
Production reliability is everything
Together with the new cooling water monitoring system from Netstal, the customer has a complete overview of all quality-relevant process parameters. Using the flexible and application-specific configurable process monitoring module from Axos (Q-page), this data can now be used to effectively monitor the production process. In addition to a detailed statistical evaluation, all data can be provided with a monitoring tolerance. In the event of deviations, the machine can react with an alarm or with a freely programmable procedure. This way ensures that the machine reliably delivers the required quality.
Digital networking via OPC-UA
The network-based communication standard OPC-UA is becoming increasingly established in the plastics industry. Various interfaces are already available between the system components involved, such as the interface to temperature control units provided in accordance with the Euromap 82.1 recommendation. In addition, the host computer interface in accordance with Euromap 77 forms the most important communication platform “to the outside world”, e.g. to overarching control systems. This digital networking means that all data recorded by the machine is available at all times and can be used to track and document the entire production system, including the cooling water monitoring data.
Future potential for increasing efficiency
At the moment, the focus is on ensuring product quality. However, the new possibilities created by the recording of process data and networking also help to optimize processes, reduce energy consumption and further improve efficiency. Netstal is at the forefront here and proves this time and again with innovative solutions. At Netstal we are constantly working on innovative solutions to further maximize the production efficiency of our customers.
So give us a challenge and let you us discuss together how we can support you in optimizing your value chain.
Fakuma 2024
Experience the reproducible Mouldflo mold cooling system in production use at Fakuma 2024. You can find all information about our presentation on our event page.
