Production efficiency

Greater efficiency - lower costs

See here how to enhance the efficiency of your plastic parts production, plan production processes in a targeted manner and tap into brand new business ideas. The video examples include performance comparisons between machines and robotic systems, the SELOGICA set-up assistant, the individualization of high-volume parts, and much more.

Individualized rocker-type light switch

Individualized rocker-type light switch
At the special Additive Manufacturing Plaza exhibition at the Hannover Messe 2015, ARBURG demonstrated a fully networked process chain involving injection molding and additive manufacturing, including host computer technology. Here, rocker-type light switches produced in high volumes were individualized.

How can several machines and the production process be efficiently controlled, documented and tracked in the context of Industry 4.0? How can high-volume parts be individualized by means of industrial additive manufacturing using the freeformer? As an exclusive partner at the Additive Manufacturing Plaza, ARBURG demonstrated precisely how it’s done based on the example of rocker-type light switches. Trade visitors were able to go through and experience the complete process chain live – from order entry, injection molding and industrial additive manufacturing through to automated packaging of the individualized products and display of the process parameters on a part-specific web page.

Robotic technology compared

Shorter cycle time with dynamic mold-entry axis
High-speed, mass production demonstrates how the MULTILIFT V robotic system with dynamic mold-entry axis reduces the mold-entry time by 38% compared with a standard mold-entry axis. This way, the cycle time for producing two cups can be shortened by 12%, to just 3.56 s.

The mold-entry axis has a speed of up to 4,000 mm/s and an acceleration of max. 20 m/s2. The mold-entry time is cut from 1.32 to 0.82 s. Over a year, this results in a production increase of more than 1.2 million molded parts. Furthermore, automation enhances process reliability and minimizes downtimes.

Industry 4.0

Integrated, personalized production
Parts-based online data acquisition and archiving ensure transparent production and 100% traceability. This entails the data integration of machines, order information and process data. The production of a toy buggy provides an example of how Industry 4.0 can work in practice.
The production process consists of five steps:

  • Enter your ID: Personalize a chipcard, have it read by the SELOGICA control system.
  • Produce the buggy: molding individual parts, laser engraving (individual QR code), assembly.
  • Check assembly: correctly installed and fitted, dimensions of roof, chassis and axles.
  • Measure the speed: buggy "test circuit".
  • Call up the buggy data: scan QR code, archived part-specific production and quality data.

The ARBURG host computer system (ALS) is of central importance here, integrating the autonomous stations in one network as well as recording and archiving all parameters. Thanks to the QR code, the process parameters of each individual buggy can be uniquely assigned and all process steps seamlessly documented.

Download

Customer magazine today 55, p. 8-9 “Data-integrated production” (PDF - 5,1 MB)

Personalized office scissors

Individualization of molded parts
Based on the example of a pair of office scissors, the flexible customization of plastic products will be demonstrated by the combination of injection molding using an ALLROUNDER and ARBURG Plastic Freeforming (APF) using the freeformer. The application also illustrates the topic of Industry 4.0.

At the injection molding station, visitors will first be able to choose between different scissor versions. In order to enable flexible and fast product changes, human and robotic system work hand-in-hand. The handle of the scissors is molded on by an electric ALLROUNDER and a DMC code is then applied by laser. The freeformer then adds individual lettering to the scissors. The data from the injection molding process and additive manufacturing is recorded via the ARBURG host computer system (ALS) and transmitted to a web server. The relevant Internet page can then be called up by means of a DMC code using a mobile device.
to the molded part

Performance comparison of machines

Hydraulic versus electric ALLROUNDER
A comparison of the performance of a hydraulic and an electric injection molding machine, both size 370 and with identical process parameters, reveals that the electric ALLROUNDER operates more productively and with greater energy efficiency.

In this comparison, a hydraulic ALLROUNDER 370 S with dual-circuit pump technology and an electric ALLROUNDER 370 A each produced technical components for droplet irrigation with a 16-cavity mold. The electric machine scored highly through its precise movements, approx. 20% faster cycle times and reduced specific energy requirement. This higher productivity also resulted in lower unit costs and a faster return on investment. 

Pickers compared

INTEGALPICKER V increases productivity
For a performance comparison, an electric INTEGRALPICKER V is used in the production of chip holders, and is also operated as a pneumatic system as a reference. The result: with a cycle time of 15.55 s, the electric picker operates approx. 9% faster than in pneumatic mode, which corresponds to an annual productivity increase of 93,782 parts.

The short intervention times of the INTEGRALPICKER V are achieved through the rapid 20 m/s2 acceleration of the entry axis (pneumatic 8 m/s2) and simultaneous movements. The picker enters the mold with three servo-electric axes. Moreover, it is integrated in the central SELOGICA control system, meaning that only one data set is required for the complete production unit.
Customer magazine today 55, pp. 18-19 "Faster and more precise" (PDF - 5,1 MB)

Optimizing robotic systems

Integrated in SELOGICA – efficiency enhanced
Process control has a significant influence on production efficiency, This is impressively demonstrated by the production of stacking boxes. Here, the MULTILIFT robotic system is fully integrated in the central SELOGICA machine control system in one instance and connected via a EUROMAP 67 interface in another.

The comparison clearly shows: when all the options that can be implemented via programming of SELOGICA are utilized in the fully integrated MULTILIFT, cycle time reductions of over 2 seconds can be achieved on 20.98 seconds. Productivity is thus higher and unit costs are reduced. 

SELOGICA Set-up Assistant

Menu-guided set-up
Menu-guided setup – with the SELOGICA Set-up Assistant module, from mold change and automatic initial calculation of the parameters, right up to the completed production sequence. Convenient, simple and reliable, in only a few logical steps that require no special programming knowledge.

This human-machine interface can also be used to teach in complex production processes, i.e. guided set-up. This allows you to program your ALLROUNDER much more efficiently with a minimum of effort. Numerous functions running automatically in the background help you here.

Flow-enhanced plastics

Increased productivity – lower energy requirement
It is clear that efficiency and cost-effectiveness in injection molding production start with product design and the selection of the right plastic – as demonstrated by a comparison of two materials, one of which has enhanced flow characteristics.

As an application example, an electric ALLROUNDER 370 E produces test parts alternately from standard PA 6 GF30 plastic and from flow-enhanced Ultramid B3WG6 High Speed from BASF. The comparison shows how the plastic with optimized flow characteristics can reduce unit costs: in this specific example, the result is 15% lower processing temperatures, 14% lower energy requirement and 9% shorter cycle times.