NPE 2018: ENGEL reinforces expertise

Highest quality and highest efficiency will be ENGEL's foremost focus at NPE2018 from May 7 to 11 in Orlando, Florida, via its multiple, exciting injection moulding applications.  

 

From automotive to technical moulding, to teletronics and on to medical and packaging: Each industry presents its specific challenges, even though the principal trends may be the same. Process integration and automation are continuing to gain importance in North America and ENGEL as a systems solutions provider ensures that even complex processes can be easily and securely controlled. 

 

In the automotive sector, ENGEL will present in North America for the first time a fully automated, integrated production cell for the DecoJect process. This technology combines injection moulding and IMG (in-mold graining), opening new possibilities for the production of premium interior automotive components. As opposed to conventional in-mould decorating processes, DecoJect does not simply transfer the paint from the foil to the component, but rather the foil is punched out and remains on the component. This way, in addition to color and pattern, surface structure and haptics are also addressed. At the same time, it significantly increases the scratch-resistance of the surfaces. At NPE, ENGEL will produce interior upper door trim with various surface structures on a duo 5160/1000. With its advanced expertise in automation, ENGEL provides an essential contribution to the efficiency and flexibility of the process. Heating the foil and removing the component from the mould is handled by an ENGEL viper linear robot. In addition, in an easiCell placed directly next to the clamping unit of the injection moulding machine, an ENGEL easix articulated robot is integrated with the laser station for the precision cutting of the foils. 

 

A duo 5160/1000 injection moulding machine used for the production of ready to install door panels. 

 

For healthcare application, ENGEL is slated to demonstrate the production of interdental brushes known as "scrub!" and developed by Pheneo (Germany) on a clean-room version of the all-electric e-motion 170/110 T injection moulding machine. Together with the grip surface and core, up to 500 bristles can be formed in a single-component injection mould. Extremely delicate in the bristle area, the high-performance precision 8-cavity mould comes from Hack Formenbau (Germany), with Hekuma (Germany) providing the automation. A highly integrated, automated production cell will be presented, built in the modularised HEKUflex design by Hekuma. Immediately after injection moulding, the parts will be inspected by a vision system and packed in retail bags, 16 parts to each. A bag leaves the production cell every four seconds.

 

Integrated into the CC300 control of the e-motion, the iQ assistance systems compensate for process fluctuations in real time. 

 

In the teletronics industry, the subject of process integration often revolves around plastic/metal hybrid composite components. With the production of thermal switch housings at the NPE, ENGEL proves that it can also forge tailored solutions for this challenge. From the punching of the contacts to the inspection and labeling of ready-to-use electronic components, all work steps are fully automatic. The raw material for the brass carrier plates is fed directly from a reel and prepunched including a thread. The thread is servo-electrically tapped before the carrier plates – still on the line – are overmolded with glass-filled nylon on an ENGEL insert 60V/35 vertical injection moulding machine. Quality control happens within the production process. In addition to the camera inspection, high-voltage testing is integrated into the tool, thus already guaranteeing a one hundred percent short-circuit inspection during production. In order to ensure seamless traceability, the good quality parts are labeled by laser before the sprue and carrier tabs are removed and the components are separated from the belt. Eight ready to install parts leave the production cell every 20 seconds. 

 

Highest degree of efficiency with the best quality and shortest cycle times will the be focus for the packaging application. For the production of 26 mm caps with tamper-proof bands made from HDPE, ENGEL is presenting a state-of-the-art solution at the NPE. The production cell will run at a cycle time of two seconds, and also achieving outstanding energy efficiency and the highest degree of process consistency. At the core of the highly-integrated solution is an all-electric e-cap 2440/420 US injection moulding machine, equipped with a 96-cavity mould by ZMoulds (Austria). On the periphery, ENGEL integrates a dry-air system by Eisbär Trockentechnik (Austria), and an optical inspection system by Intravis (Germany) into the overall concept. To combine minimal energy consumption with outstanding process consistency and precision in the production of beverage caps, ENGEL relies on the all-electric high-performance machines of the e-cap series, which, with clamping forces of 120 to 460 US tonnes, were developed specifically for this market segment. With their high-performance servo-drives, the ecap machines ensure the required plasticizing capacity and maximises part production quality even when using the new high-strength HDPE materials with an MFI significantly lower than 2 or even 1 g/10 min.  

 

In the technical moulding exhibition area of ENGEL at the NPE2018, the focus is on the advanced processing of liquid silicone (LSR). Lenses for LED headlights will be produced on an e-victory 310/120 US injection moulding machine equipped with a two-cavity mould by ACH solution (Austria). These technical parts represent a wide range of applications. From automotive to construction to street lighting, LSR is rapidly gaining in importance. This is due to its special characteristics. Highly transparent LSR has a lower yellowing index than standard lens materials, is UV-resistant, and stable across a very broad temperature range of -20 to +150 °C. In addition, even complex lens geometries can be efficiently and consistently produced with injection moulding.

 

ENGEL AUSTRIA GmbH 

Tel: +43 (0)50/620-3800

E-mail: martin.streicher@engel.at; sales@engel.at

Website: www.engelglobal.com

NPE booth: West Hall, Booth W3303