News. Machinery Plastics Electronics Weighing and Analysis in the Laboratory. Professional In-Process Controls Relies on Correct Balance Choice

Transcription

1 Machinery Plastics Electronics Weighing and Analysis in the Laboratory 3 News Professional In-Process Controls Relies on Correct Balance Choice Modern powder injection molding processes require professional in-process controls, particularly when manufacturing technically demanding components. Good Weighing Practice (GWP ) prevents measurement errors and ensures the quality of the powder injection molded parts within the context of in-process controls. Precise Weight Determination Micro-components made out of fine plastics, metal or ceramics powders can be produced using powder injection molding techniques. The components produced may appear to be identical, but often weigh slightly differently. The differences can be subject to production tolerances or the machines or staff involved in production. The average piece weight must therefore be determined with extreme accuracy using a suitably precise balance. For this reason it is important to know whether the balance in-use is suitable or if it should be replaced with an appropriate one. GWP for Practical Decision Making Advice The first stage of any GWP consultation process involves determining the average individual weight per shot and machine. For example, in metal injection molding application, a variation of ±0.2% might be determined per shot with a confidence factor of 95%. In this case, the mean weight of the average individual part is g. The more the individual values of the parts being counted vary in relation to the mean, the greater the probability of an error occurring if an unsuitable balance is used. During the second stage of the process, GWP specialists formulate the requirements of the weighing process, such as

2 Good Weighing Practice Publisher Mettler-Toledo AG Laboratory Division Im Langacher CH-8606 Greifensee, Switzerland Production Segment Marketing LAB Switzerland the importance of the measurement, the desired confidence factor or the potential possible errors due to users, environment and technology. In addition, customer requests are considered regarding issues of ergonomics, user-friendliness and the investment framework. During the third and final stage, the typical minimum initial weight of the balance used is recorded on-site using an accredited procedure in compliance with ISO This includes determinations of measurement uncertainty and minimum weight. These values are compared and checked against the results obtained from the GWP analysis. Micro-components used in a camera for automatic focus function. The above analysis may reveal, for example, that a semi-micro balance is required to meet the minimum requirements for in-process controls. Excellence XS or Excellence Plus XP balances not only ensure compliance with the required minimum initial weight of g, but are also sturdy and easy to operate. They offer excellent measuring performance and stability (even when subjected to the heavy vibrations caused by injection molding machines in the vicinity), providing the perfect basis for optimal in-process controls. Competitive Advantages with GWP In a best-case scenario, existing balances may be further operated without any changes having to be made. However, the GWP consultation process often reveals that the entire weighing process can be further optimized. A traceable, risk-based analysis for a company s quality system is produced along with valuable information for the control of inspection, measuring and test equipment. Good Weighing Practice is a guideline that offers improved control over your entire measuring process. Weighing recommendations can be specifically tailored to quality requirements, risk and industry regulations. Employees will immediately profit from the greatly simplified testing procedures which are designed to save time and costs. Secure and traceable quality documentation is also automatically available for auditors. Weigh without risk with GWP. Comply easily with regulations and realize consistent high product quality. GWP customers have the advantage above competition within the global injection molding industry. The high level measurement quality provides a powerful sales case for winning over end customers. } Subject to technical changes. Mettler-Toledo AG 02/09 Printed in Switzerland. 2

3 Moisture Analyzing Rubber Industry on the Road to New ISO Standards In order to achieve higher efficiency when carrying out quality tests, the Japan Rubber Manufacture Association aims to establish moisture determination with the halogen drying method as laid out in the new ISO standard. METTLER TOLEDO s expertise provides the most suitable method. High Tyre Requirements The tyre production industry is one of the largest consumers of natural and synthetic rubber. The safety and quality of tyres are strictly regulated and all raw materials must undergo several quality tests. The ISO248 International Standard specifies two methods for the analysis of moisture and other volatile matter contents in raw rubber: the hot mill method and the oven method. Both are labour intensive and times consuming which was reason enough for the Japan Rubber Manufacturers Association (JRMA) to evaluate alternative determination methods. With METTLER TOLEDO, JRMA found the technical support and expertise in moisture analysis they were looking for. Faster to the Finish Line with Halogen Drying Moisture in natural and synthetic rubber is very low, i.e. <1% moisture content (typically % MC) and reproducible results are difficult to obtain. Test series with Halogen Moisture Analyzers have shown that the same results can be obtained as with the reference method in the oven. Measurement time, however, is significantly five times shorter. METTLER TOLEDO instruments function efficiently and accurately even at the factory production site where they can be easily cleaned from carbon black and other particulate materials. JRMA is convinced that its members will appreciate the implementation of an efficient and cost-effective method for moisture determination. Their aim is to establish halogen drying in the revised ISO248 and to obtain better and faster methods for the rubber industry in order to produce high quality, reliable tires. } HR83 3

4 Piece Counting Time is Golden Piece Counting with METTLER TOLEDO's Solutions The synergy of Excellence X-Platforms and Industrial Terminals is perfectly employed by one of Geneva s world famous watchmakers who utilize the advantages of the IND-Terminal s robustness along with the high resolution and performance of precision balances. METTLER TOLEDO s tailored solutions guarantee the highest accuracy in industrial applications. Counting Pieces at Meroz Piece Counting with Absolute Reliability Situated in the vicinity of the Plan-les- Ouates industrial zone in Geneva, Switzerland, Meroz is a partner of the world s most prestigious Swiss watchmaker delivering springs, wheels, cogs and other delicate components. In order to portion the pieces prior to packaging, Meroz utilizes the piece counting application of METTLER TOLEDO s Precision Balances. The X404SDR and X64001L platforms have been connected to the IND690 terminal, which is flexible enough to simultaneously control up to four balances. An X404SDR Precision Balance is used as a reference balance. A few pieces are first counted by hand and used as a reference. Subsequently they are transferred to the 64 kg capacity X64001L Platform Balance. Finally, larger quantities are placed onto the weighing pan. The weight is expressed as the number of pieces in the weighing pan. This same measurement application has been installed into the automatic storage facility of their neighbouring production facility. Pieces produced and/or delivered by external suppliers are weighed, counted, portioned and routed via a conveyer belt for watch assembly. METTLER TOLEDO is the Name for Quality When employing the piece counting application, repeatability is crucial. Reliable results and high performance are prerequisites as some watches are assembled from solid gold components. Both stability and robustness are also required for this industrial environment (IP protection 69K). Software packages built into the terminal support nine different applications invaluable for counting, filling, check-weighing and formulation etc. Both IND-terminal and X-balances are also available as ATEX Zone 2 versions which are applicable for hazardous areas (category 3G). Weighing pieces instead of individual manual counting speeds up the whole process enormously and reduces human error which, in turn, reduces costs. The industrial terminal offers intelligent process monitoring. In combination with the precision of the Excellence X- Platforms, (210 g to 64 kg capacity and 0.1 mg to 1 g readability), they offer unsurpassable benefits for a wide spectrum of industrial processes. Trust METTLER TOLEDO s tailored solutions for precise applications to count even the smallest pieces with absolute reliability! The watchmaker of Geneva claims that METTLER TOLEDO s name is synonymous with quality. IND Terminal } } 4

5 DSC Cost Reduction in Vehicle Construction Using DSC for Plastics Testing In the last few decades, plastics have become an indispensable material for constructing new vehicles. Its versatility has meanwhile penetrated practically every element of a car. In order to guarantee a consistent high quality, it is appropriate to perform efficient tests from goods receipt right up to the finished part. Dynamic Scanning Calorimetry (DSC) has efficiently accompanied the development and quality management of plastic products for many years. Plastics can be found everywhere: from the engine to the body and interior. It is important for the manufacturers to make sure that the quality is high and consistent as rejects or even the re-call of a whole vehicle series due to a single component defect may incur immense financial and reputation costs. The exterior shell of a polyamide 12 (PA12) hydraulic line exhibited a small discoloration defect and it was important to clarify whether this was due to a foreign substance or a changed PA12 polymer matrix. The defect was removed from the line with a scalpel. The sample weight was measured as mg. The analysis applying DSC1 and STAR e software revealed an additional melting effect at approx. 205 C in both the first and the second heating processes. Such an effect was not found in the other areas of the part. This clearly indicates that a foreign substance was present which exhibits a melting effect at 205 C. The temperature level, where the effect occurs, suggests that the substance is a polyamide 6 (PA6) that accidentally entered the production process. DSC1 Due to the reduced weight compared to metals, the emission of climate-damaging CO2 is clearly lower, plastics do not oxidize and are mostly recyclable and safety belts, airbags and child seats all make everyday's life safer. This example demonstrates that even the smallest measuring effects, caused by minute sample quantities or weak, thermally induced changes can quickly be detected and dealt with using the stateof-the-art DSC sensor technology from METTLER TOLEDO. } 5

6 One Click Titration One Click Titration Powerful System for the Labs The Titration Excellence line combines application flexibility with the optimally efficient operation in titration. This satisfies the requirements of an innovative company like Blaser Swisslube exactly. The most demanding applications are made quick and simple using LabX titration PC software. Powerful Evaluation Saves Time Blaser Swisslube is a worldwide operating company and a leading producer of lubricants and cutting fluids for the metal working industry. The quality control laboratory carries out titration analyses such as TAN, TBN, saponification numbers and many more. Due to the large sample variety and complex composition, each individual analysis requires a different evaluation. The METTLER TOLEDO Excellence Titrators offer a new algorithm which also recognizes weak equivalence points. Thomas Schmid, head of quality control, is thrilled. In the past we had to find the equivalence point of many titration curves manually. The T90 Excellence Titrator now also recognizes very weak inflection points. This saves us a lot of time and strongly increases the reliability of our results. Titration Excellence System and LabX Titration Software Obviously there are still a few titration curves that are impossible to evaluate automatically. In this case, the curve is opened in the PC software LabX Titration and the result is found by graphical re-evaluation. The unique dual mode allows the user to work with both the touch screen terminal at the titrator and with the PC LabX Titration software LabX Titration. Analyses can be quickly initiated directly from the titrator and curves can be checked in LabX Titration. This makes working with the system far simpler. PowerShower Prohibits Sample Carry-over Thomas Schmid s team usually runs three determinations of the same sample and efficiency is further improved by using the Rondo 60 Sample Changer. The three samples are placed on the sample changer rack and the analysis is started with a single click. Other sample series are Quick Base Numbers (BN) The IP400 standard specifies conductivity titration to determine the BN of lubricants. Using the Conductivity Board integrated in the Excellence Titrator, a BN determination is completed three times faster than common potentiometric applications. Blaser Swisslube achieves the same results with far less maintenance. analyzed immediately afterwards. Due to the PowerShower rinsing unit, sample carry-over is prevented therefore providing consistently accurate results. By using the new Excellence Titrator T90 with LabX Titration and Rondo 60 Sample Changer, Blaser Swisslube has made titration far simpler and more efficient in their laboratory. } } 6

7 Micro Balances Particulate Matter Measurement for Diesel Engines Diesel engines have been becoming popular due to their economical advantage whilst emitting less CO2 than gasoline engines. However, diesel engines have the disadvantage of emitting more NOX and Particulate Matter (PM). Reducing the PM emissions from diesel engines is the big challenge for the automotive industry. Filter Weighing with Micro Balance Gravimetric PM filter measurement with a microbalance is an established measurement method. As defined by strict regulations in respective countries, it is the only method which realizes both direct traceability and calibration. Due to the stringent emission amount of 0.1 g, an ultra micro balance is necessary to meet requirements. The new filter weighing kit for the MX/ UMX Balance from METTLER TOLEDO is the best solution to meet these requirements. Two weighing pan sizes (for 47 mm & 70 mm) are included and filters are always weighed in the ideal position. The robust stainless steel housing eliminates air turbulence and heat transfer, therefore ensuring a faster stabilization time and better weighing performance. The automated draft chamber and SmartSens (Infrared sensor on the terminal) perform the operation without touching the balance a combination that makes the measurement in the glove box much easier and safer than ever. The draft chamber can be opened on the left or right side depending on the dominant hand of the operator. Complete Filter Weighing Application METTLER TOLEDO has a comprehensive software solution for storing all measurement data even when measuring numerous filters per day LabX. LabX Software can not only deal with unlimited number of filters, but also ensure perfect data traceability. LabX can create weighing methods according to the workflow. The weighing procedure is fully guided via pop-up dialogues on the balance display the operation can be carried out without handling a PC. LabX can also export data to EXCEL on demand for flexible data evaluation. } UMX2 Microbalance 7

8 New Products and Technologies From METTLER TOLEDO METTLER TOLEDO delivers powerful solutions that simplify work in laboratories around the world. Combining our state-of-the-art technologies with our applicative competence, we have a strong value proposition to make: accurate results and productivity second to none. Weighing Solutions and Analytical Instruments Meeting Emissions Standards With Minimal Costs Determining the weight of particulate matter is a key task in the automotive industry. F-A747 Filter Robot allows fast and easy measurement of particulate matter at any time. Up to 60 samples can be read in via barcodes. All steps from the start right up to residual weighing are performed automatically, quickly and without the slow process of transferring samples. } XP505 Comparator Peak Performance up to 520 g The new XP505 Comparator offers 520 g capacity with unique 0.01 mg readability over its full range. It allows to weigh into heavy tare containers, determine smallest weight differences of heavy goods or determine the weight of tiny electronic parts. The intuitive touchscreen display and hand-free operation make it the first choice for demanding applications in the metal & electronics industry. } LabX Balance Software Version 1.5 New: Inbuilt Job Templates and GWP Support! In this new version of LabX balance software, 25 ready-to-use job templates are integrated. It is even easier to get up and running with applications such as Moisture Content Determination, Filter Weighing, Standard Solutions, Density Determination and many more! Using the full on screen user guidance, on both balance and PC, LabX balance 1.5 also helps you work according to GWP guidelines, making lab work easier and more efficient. } One Click TM Water Determination Simple & Secure Water determination is made simple and secure with the new line of Karl Fischer titrators offering unique Touch Screen operation with user specific Short Cut buttons. Every user can start his or her routine tasks with One Click TM. The Solvent Manager is controlled by the titrator and exchanges the solvent and reagents without exposing the user to chemicals. A wide variety of samples is covered by Volumetric and Coulometric titrators and gas-phase extraction ovens. } Mettler-Toledo AG Laboratory Division Im Langacher CH-8606 Greifensee, Switzerland Your METTLER TOLEDO contact: For more information