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Como Injection data sheet - .PDF file.

Injection moulding specialist Dr Doetsch Diespeck is using cavity-pressure-based monitoring from Kistler Instruments to determine the switchover to holding pressure for process optimisation for quality assurance, in order to ensure minimum rejects.

The medium-size German company focuses on producing high-quality technical components mostly for manufacturers of ball bearings, linear guides and the automotive industry.

For example, it recently had to provide injection moulding for hinge covers that protect the sensitive electric seat adjustment systems during the production of foamed car seat systems. The injection moulding machine for this project, acquired in 2008, was equipped with a machine control system that provided outputs for pressure signals and integrated cavity pressure monitoring.

Each cavity of the 2+2-cavity hot-runner family mould for the production of right-side and left-side hinge covers is equipped with Kistler 2.5mm pressure sensors.

The sensors were also used in the production of a small technical PA46 breaker plate with a shot weight of only 3.5g. The eight-cavity mould, made by the company’s in-house mould engineering department, is equipped with eight direct 1mm pressure sensors.

The Como Injection process monitoring system controlled the process by means of cavity-pressure-dependent switchover and guarantees the quality of the moulded parts by monitoring the pressure curves.

Click on the link above to download the Como Injection data sheet.

Key benefits of product application

  • According to managing director Patrick Freiherr von Twinkle, Como is fully configured for analysing and monitoring injection moulding processes. He said: ‘When it comes to direct comparison, machine control systems provide rather limited analysis options.’
  • Regarding the PA46 breaker plate project, the company said that without sensors the project would generate massive problems due to underfed parts. Automatic switchover makes the process significantly more stable.
  • The company has removed the risk of the cost of complaints and the subsequent sorting effect.
  • Cavity-pressure-dependent switchover facilitates and speeds up any setup changes: after 10 shots with the new mould, the quality is perfect again.
  • During the active production process, lot variations or changes of flow are registered immediately and can be remedied directly.
  • Assuming an out-put rate of 200,000 parts per year, von Twinkle expects the system to have paid off after 18 months.
  • The Como Injection monitoring system is not operated in fixed connection with one single machine, but, like the moulds, is flexibly used on several machines of similar size.
  • Everywhere the system is applied, the process achieves stable conditions, no matter whether the machines are electric or hydraulic, and independent of their age.
  • After several years of experience, von Twickel is able to sum up the benefits of cavity-pressure measuring and the integration of Kistler sensors and systems: ’I can look into the cavity. That constitutes an unbeatable advantage. I have not encountered any other method that would deliver similar information.’

Kistler Instruments

Established in Winterthur (Switzerland) in 1957, the Kistler Group now has a worldwide presence with 23 group companies and 30 distributors ensuring prompt, local application support and short delivery times. With a staff of more than 1,000, the Kistler Group is one of the world’s leading providers of dynamic measuring instrumentation.

Kistler’s core competence is the development, production and use of sensors for measuring pressure, force and acceleration.  Kistler’s know-how and electronic systems can be used to prepare measuring signals for use in analyzing physical processes, controlling and optimizing industrial processes, improving product quality in manufacturing and improving performance in sports and rehabilitation.

Kistler offers a comprehensive range of sensors and systems for engine development, automotive engineering, plastics and metal processing, installation technology and biomechanics.

Heavy investment in research and development, 15% of staff worldwide are engaged in research and development, has generated a number of innovations using piezoelectric, piezoresistive and capacitive techniques to provide solutions to numerous force, pressure and acceleration measuring problems. These innovations include the world’s first commercial quartz sensor, two-wire constant current technology to integrate sensors with microelectronic circuitry, high-temperature pressure sensors for use up to 400 Deg C and three-component force measuring sensors.

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