Lightweight technology for the automotive industry
With an example from the automotive industry,Wittmann Battenfeld will demonstrate at the K 2019 its competence in Cellmould structured foam technology, which enables the production of extremely light-weight parts as are required primarily in the automotive industry to reduce fuel consumption and/or increase the battery range. On a MacroPower 1100/12800 with an energy-efficient servo drive, a seat bench support for a German sports car will be manufactured from PP with a single-cavity mold supplied by Frimo, Germany. The machine is equipped with the SEDE combined nitrogen and pressure generator unit developed and manufactured by Wittmann Battenfeld. The nitrogen required for this technology is taken from the ambient air and compressed to the working pressure of up to 330 bar. The material processed will be a type of PP suitable for automotive applications supplied by Borealis. It is the type ME225SY, which contains 25 % post-consumer recycling material and 25 % talcum. With the use of recycling material in passenger car interiors, Wittmann Battenfeld makes a significant contribution to promoting the recycling economy in the automotive industry. The parts will be removed and deposited by a WX152 robot from Wittmann.
On this machine, the CMS condition monitoring system from Wittmann Battenfeld has been installed, too, which ensures continuous condition monitoring of the most important machine parameters. The current condition of the MacroPower 1100 can be read out from a CMS info and control station placed directly next to the machine. Beside this machine, there is also an Airmould/Cellmould info stand, where visitors can get detailed information about the processes being demonstrated.
High-tech sheet for the automotive industry
A second application for the automotive industry will be presented on a machine from the SmartPower series in XL configuration. With a SmartPower 240 XL, a module for a car headliner with a functional surface will be produced with a single-cavity mold supplied by Georg Kaufmann, Switzerland. The module consists of an operating section mounted at the center and lighting sections on each side. For the production of this module, the IMD VARIOFORM process developed by Leonhard Kurz Z (hall 5, booth A19 - E09) is used. In this process, a partially translucent decoration sheet is combined with a functional sheet with a printed-on sensor structure on the inside of the molded part. The poly TC sensor demonstrates the touch operation of light on/off and dimming functions as well as setting of the color of the LED light source behind it.
The machine is equipped with an automation system from Wittmann Battenfeld Deutschland in Nuremberg. It consists of a WX142 robot from Wittmann with a C axis and an infrared radiation heater on the Y-axis to heat the continuous sheet used for this application. The WX142 inserts the functional sheet with sensor structure into the mold. The next step is to pull the IMD Varioform sheet through, heat it and then thermoform it using a vacuum. During the same production step, both sheets are overmolded. In this application, the sensor sheet can be optionally selected via a touch button. In this way, it is possible to injection-mold parts either with or without sensor sheet.
LSR application on EcoPower 160
One of Wittmann Battenfeld’s main application technology themes at the K 2019 will be silicone injection molding. Wittmann Battenfeld will demonstrate its expertise in this area at its booth in hall 15 by producing a valve for medical technology from an LSR formulation on a machine of its all-electric EcoPower series, an EcoPower 160/350, with a 16-cavity mold supplied by Nexus, Austria (hall 12, booth E49-01). The injection unit in open design enables easy integration of the LSR metering unit. The Nexus Highline metering unit comes with a new servomix metering system with OPC-UA integration. In the mold, latest cold runner technology is used including Timeshot needle shut-off control. Parts removal and depositing will be handled by a WX142 robot from Wittmann.
Recycling economy with a product from the packaging industry
“Circular economy” is not only a modern buzzword, but also a strategic focus of Wittmann Battenfeld. At the K 2019, Wittmann Battenfeld will present one of its current projects jointly with a partner company.
Here, cosmetic jars with lids will be manufactured from a material completely based on natural ingredients on an EcoPower 240/1100H/130L COMBIMOULD using a 4+4-cavity mold. This material can be recycled without any loss of its functional properties. The jar is injected by the machine’s main aggregate, the lid by the L aggregate. The machine is equipped with a fully integrated W842 pro robot from Wittmann, which takes a round paper label from a magazine and inserts it on the clamping side for the bottom of the jar. Next, the W842 pro removes the parts from the nozzle side and passes the jars on to a W818 robot, which inserts them into a screwing station. The W842 pro then transfers the lids for the jars to the screwing station, where they are screwed onto the jars and deposited.
In addition to the Airmould, Cellmould and condition monitoring system info stands, there will also be an info corner presenting the TEMI+ MES package at the Wittmann Battenfeld booth. TEMI+ is able to work with injection molding machines as well as robots and auxiliary appliances around the machines. This makes it possible to obtain complete, comprehensive data acquisition and analysis of the quality parameters from all appliances involved in the production of a part.
Info point for plasticizing systems
The plasticizing system of an injection molding machine is the central unit determining the quality of a plastic component. Wittmann Battenfeld supports its customers with tailor-made solutions in terms of geometries, materials and surface finish. At the K 2019, visitors will have an opportunity to gather information about the latest developments at a separate info point.
Central material supply
The machines at the Wittmann Battenfeld booth are supplied mainly via a central material handling system from WITTMANN. In addition to a drying system for PET, mobile ATON dryers and Gravimax gravimetric blenders will be used. Feedmax central material loaders and stand-alone material loaders complete the picture.