Mold-Masters Europe

Mold-Masters Europe
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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
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Master-Series I Nozzle range
Hecto
Deci
Centi
Pico
Femto
12mm – 16mm
8mm
6mm
5mm
5mm
16mm – 18mm
11mm
8mm
7mm
6mm
Femto Lite
Non-Valved
3.5mm
Valved
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n/a
Valved vs. Non-Valved
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Premium valve gate solutions I Options
Types of Valve Pins
 Tapered Pin
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 Cylindrical Pin
A closer look at Valve Gating
Advantages, Tapered
Disadvantages, Tapered
 Easy to machine
 Pin must close within
 Self Centering
 Large gates possible
‘thermal window‘
defined by gate size
and hold time.
 Good gate appearance
Advantages, Cylindrical
Disadvantages, Cylindrical
 Excellent gate appearance
 Accurate machining of
 Small gate size possible
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the gate is required.
Accu-Valve I Premium valve gate solutions
 Pristine cylindrical valve gating of
ACCU-VALVE CX - for Standard Resins
commodity and engineering resins
ACCU-VALVE MEX - for Standard Resins
 Continuous pin guiding
 2 million cycle guarantee
ACCU-VALVE EX - for Standard Resins
 <150 shot color changes
CX
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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
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New V-Guide Valve Disk Design
Accu-Valve I V-Guide
 New V-Guide Valve Disk Design
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Accu-Valve CX
 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
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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
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Accu-Valve EX
 Tailored for engineering grade resins (PC, POM, etc.)
 Gate quality that always meets your expectations
 Ideal for high cavitation applications
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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
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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
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Actuation Methods
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(2012-08)
Actuator Options I Today’s Actuation Methods
 Individual Actuation
 Synchro-Plate
 Hydraulic
 Hydraulic
 Pneumatic
 Pneumatic
 Electric (E-VG)*
 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 MoldMasters Resource Guide (MMRG).
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Actuator Options I Valve Actuator Section Chart*
*For detailed information please refer to the MMRG
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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
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:
Please refer to
catalogue pages
33000 N (Peak)
Electric
E-Drive* (mag. valve pin holders)
29.5 mm
15000 N (Continuous)
High Power Rate:
Multi-Pin Act.
50000 N (Peak)
24000 N (Continuous)
E-VG (55mm Solenoid)
58 mm
Individual
Electric
E-VG (75mm Solenoid)
78 mm
Individual
Electric
Please refer to
catalogue pages
Small Synchro-Plate*
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15 mm
Multi-Pin Act.
Hydr. / Pneu.
Design Options
 The HY8400/HY8500 resolves issues with applications where high injection
pressures are required by increasing the closing force of the actuator
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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
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Advantages
The HY8400/HY8500 has advantages over standard HY65/7100 units:
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Components
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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
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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)
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E-Drive I Components View
Valve pin
Idlers (2)
(synchro) plate
Servo and gear box
Tensioning idler
Ball Screws (2)
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E-Drive I Section View
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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
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E-Drive I Features: Solid support
 Synchro plate design allows pillar support from HR intermediate plate to mold
backing plate, resulting in stronger mold
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E-Drive I Features: Freedom in Cavity Layout
 Outboard location of E-drive mechanism allows substantial freedom for cavity
positioning
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E-Drive I Ease of Use and Maintenance
Top plate
Easy valve pin position and stroke set-up
 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
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E-VG I Electric valve gate solution
 High energy savings
 High closing force
75 mm
 Fast cycle times
 Sequential Valve Gate Control
 Simple, Easy to Use Controller
 Great flexibility
55 mm
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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
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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
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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
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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
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E-VG I Mold-Masters Unique Force/Stroke Curve
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Backup-Slides
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Mold-Masters I Product & Service Portfolio
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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
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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%
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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
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MasterCARE I Service offerings
 System installation
 Complete support management
 System trails
 Technical consulting for new systems
 System refurbishment
 Seminars (on-site/off-site)
 Retrofitting and repairs
 Technical trainings
 Onsite repairs to systems
 Service and maintenance contracts
 System cleaning
 Trouble shooting
 Dedicated Contact
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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
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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
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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
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Success in the Field - CX
Customer: Major Caps and Closures Company
•Push pin mark for symmetry
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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
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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
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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
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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
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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
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