Innovative process for lightweight construction and Automated insert over-molding John Ward ARBURG, Inc.

Transcription

1 Hybrid Components Innovative process for lightweight construction and Automated insert over-molding John Ward ARBURG, Inc.

2 Our company ARBURG Central Manufacturing Facility 2

3 Hybrid Components Long-Fiber Direct Injection Molding 3

4 Long-fibre direct injection molding Objective Integrating longer fibres in parts Targeted improvement in mechanical properties Substitution of metallic materials High-strength lightweight construction Cost-effective series production at reduced unit costs 4

5 Long-fibre direct injection molding Longer fibres in the part = increased strength Servo-electric side feeder conveys fibres directly into the liquid melt Cutting device cuts endless fibre strands, into lengths of mm long Two-stage screw 1. Melt plastic granulate 2. Feed fibres and homogenise material 5

6 Long-fibre direct injection molding Example: Airbag-Housing Cavities 2 Part weight 330 [g] Material PP GF 30 6

7 Long-fibre direct injection molding Example: Airbag-Housing Fibre lengths that can be added to the part Length pro oportion [% %] Long fibre granulate ~ 30 % of fibres longer than 2 mm Long-fibre direct injection moulding with 16 mm fibres ~ 50 % of fibres longer than 2 mm Areas for determining the annealing residue Gate Fibre length [mm] Source: SKZ Extract from laboratory report on material testing 7

8 Long-fibre direct injection molding Possible improvement potential Increased strength through the use of longer fibres in the part 1 Standardise ed materia al charact teristics 0,8 Rigidity Strength Toughness Fibre length [mm] Source: Thomason and Vlug Influence of fibre length (PP/GF qualitative) 8

9 Long-fibre direct injection molding Advantages compared to long fibre granulates Reduced destruction of fibres during melt preparation Increased strength through the use of longer fibres in the part Targeted influencing of part properties 9

10 Long-fibre direct injection molding Advantages compared to long fibre granulates Individual adjustment of fibre length, fibre content and material combination Use of less expensive base materials 10

11 Long-fibre direct injection molding Long fibres all possibilities Large material variety: individual reinforcement of all common plastics with glass fibres Low investment costs: used on standard injection molding machines with clamping forces of 275 tons and higher Maximum flexibility: conventional to injection molding via a thermoplastic cylinder module possible at any time 11

12 Long-fibre direct injection molding Long fibres all possibilities Fast reconfiguration: universal application on various ALLROUNDERs thanks to the enclosed construction of the side feeder Highly resilient lightweight parts: automation with robotic system for combination with organic sheets 12

13 Hybrid Components Long-Fiber Direct Injection Molding With Organic Sheets 13

14 Long-fibre direct injection molding with organic sheets Two organic sheets of different thicknesses as inserts Functional and reinforcement elements through long-fibre direct injection molding Cavities 1 Part weight 202 [g] Material PP + GF Presentation selection 14

15 Long-fibre direct injection moulding with organic sheets ALLROUNDER 820 S Energy-saving servo-hydraulics: speed-controlled pump drive for single-circuit pump technology - Long-fibre direct injection moulding: fibres are added directly to the liquid melt - Combination with organic sheets produces high-strength, lightweight composite components - Designed for high-volume production: reliable and efficient process sequence 500 mm Cavities 1 Part weight Material 202 [g] PP + GF Presentation selection 15

16 Long-fibre direct injection molding with organic sheets Cycle-optimised and materialprotecting process sequence - Six-axis robotic system heats organic sheets in the gripper by means of a heating plate - The organic sheets are heated to forming temperature by means of an IR heater - Simultaneous heating of different thicknesses by setting the gripper at an angle - Suction devices used to transfer organic sheets to the mould without damage - Shaping of the organic sheets in the LIPA mould* * Lightweight Integrated Process Application Presentation selection 16

17 Long-fibre direct injection molding with organic sheets Inline quality assurance - Monitoring of the temperature of the heated organic sheets with an infrared camera prior to insertion in the mould - Flexural testing of finished parts - Graphic visualisation of quality parameters Presentation selection 17

18 Long-fibre direct injection molding with organic sheets Innovative production details - Continuous overmolding of organic sheets ensures there are no open fibres - Injection takes place through the organic sheets without damaging the fibre structure (e.g. for screw domes) - Efficient use of organic sheets specific areas reinforced with sections of different thicknesses - Stable bonding of sections through positive surface compression molding Presentation selection 18

19 Long-fibre direct injection molding with organic sheets Weight reduction with composite components mm long component weighs around 200 g only - Substitution of metals through plastics [g] g 62 % g 0 Die-casting Composite part Presentation selection 19

20 Long-fibre direct injection molding with organic sheets ALLROUNDER 820 S mm Cycle time [s] 40 Energy requirement for pump drive [kwh/h] 4.3 Energy requirement* [kwh/h] 9.0 Material throughput [kg/h] Spec. energy requirement* [kwh/kg] 0.68 Cavities 1 Part weight 202 [g] Material PP + GF * without peripherals, fibre feed, mould temperature control and hot runner Presentation selection 20

21 Hybrid Comonents Automated Insert Over Molding 21

22 Automotive turnkey solution: connector carrier Finished part Metal insert Cavities 4 Plug contacts Part weight* Material 10 [g] PBT * without inserts Presentation selection 22

23 Automotive turnkey solution: connector carrier ALLROUNDER 375 V Fully automated production cell: Three six-axis robots and a rotary table machine operate in synchrony - Components are produced in a single step in a round-the-clock three-shift operation - Quality in high volumes: Production cell reliably produces over 3,000 parts per shift - SELOGICA controls complete production cell - Complete solution from a single source ARBURG takes charge of complete system integration * without inserts Cavities 4 Part weight* Material 10 [g] PBT Presentation selection 23

24 Automotive turnkey solution: connector carrier Rotary table machine Metal inserts fed in via trays Working area of the three six-axis robotic systems Finished parts ejected via trays Feeder cell with Scara robot for plug contacts Presentation selection 24

25 Automotive turnkey solution: connector carrier 1. Robotic system Provision of metal inserts in the right position 2. Robotic system Configuring the machine and removing finished parts Feeder cell Provision of plug contacts in the right position 3. Robotic system Quality assurance and setting down of finished parts 25

26 Automotive turnkey solution: connector carrier 1. Robotic system - Pick-up of metal inserts from a tray rotational position of parts is random - Metal inserts aligned by means of "event-driven rotation" separate turning station ti not required - Aligned metal inserts (4 pieces.) are supplied via a turning station 26

27 Automotive turnkey solution: connector carrier Feeder cell - Camera system records position of plug contacts - Scara robot picks up plug contacts from any position - Aligned plug contacts (4 x 2 pieces) supplied via a turntable 27

28 Automotive turnkey solution: connector carrier 2. Robotic system - Complex gripper performs multiple tasks - Pick-up of correctly aligned inserts - Pick-up of the finished parts from the mold - Positioning of inserts in the mold 28

29 Automotive turnkey solution: connector carrier 3. Robotic system - Zero error production by means of a 100% camera inspection - Set-down of good parts in trays 29

30 Automotive turnkey solution: connector carrier ALLROUNDER 375 V Cycle time [s] 33 Short cycle times high productivity - Provision of correctly positioned inserts without extension of cycle time - Rotary table machine enables removal and insertion during the injection molding process - Perfectly harmonised system components Cavities 4 Part weight* 10 [g] Material PBT * without inserts 30

31 THANK YOU FOR YOUR ATTENTION ARBURG GmbH + Co KG Arthur-Hehl-Strasse D Lossburg, Germany Tel.: +49 (0) Fax: +49 (0) contact@arburg.com