香港塑膠工程師學會. K-Fair Advanced Plastic Manufacturing Technology Study Mission to Germany and Austria October 2016

Transcription

1 香港塑膠工程師學會 K-Fair Advanced Plastic Manufacturing Technology Study Mission to Germany and Austria October 2016

2 K-Fair 2016 in Dusseldorf, Germany - 23rd October, 2016

3 Study Mission : K-Fair 2016 Pre-arranged booth visit Details explanation by the exhibitors and provide interaction chance between the delegates and the exhibitors Diversification on visiting various nature of exhibitors Machinery Moldmaking Institute Material Company KraussMaffei Technologies GmbH EMDE Wittmann Battenfeld GmbH Institut für Kunststoffverarbeitung (IKV) ARBURG GmbH & Co KG KRAIBURG TPE GmbH & Co. KG Zahoransky Nature Machinery Mold Machinery Institute Machinery Material Mold

4 Study Mission : Factory Visit Diversification on visiting various nature of plant Applied Technology Institute Injection Molding Machinery Extrusion Machinery Packaging Machinery Automation Production Plant Date 24-Oct 24-Oct 25-Oct 26-Oct 26-Oct 27-Oct Company Fraunhofer Institute for Production Technology IPT Reifenhäuser GmbH & Co RPC Bramlage GmbH RPC Formatec GmbH Krones AG ENGEL AUSTRIA GmbH

5 NEW TECHONOLGY INTRODUCTION HIGHLIGHT IN K-FAIR 2016

6 Overview of innovative technology Trend Digitization of the value chain Industry 4.0, individualized production Fully-integrated manufacturing system Automation with new processing art and increased efficiency, ultimately reduction of manpower Lightweight Construction Automation processing system for the adaption of new material, carbon composite, hybrid materials & reinforcing plastics

7 1. I4.0 Production Cell Institut für Kunststoffverarbeitung (IKV) Large-series production of lightweight foamed, continuous fiber-reinforced thermoplastic hybrid parts The saddle consists of a molded LGF-PP foam and is optionally supplemented by UD laminates on the top and underneath Production parameters can be varied from one shot to another Shot volume, part thickness and type of fiber reinforcement. Continuous documentation From the input of the original order, via the production data to the subsequent quality assurances

8 2. Composite Processing Technology Fraunhoufer IPT Load & Waste Optimized Composite Blanks Automated processing of unidirectional fibre tapes with various matrix materials Adjustable fibre orientation for laminate construction to optimize layer structure Kinematic Gripper Short adaption time by selfadaptive kinematics Handle complex geometries Winkle-free placement

9 3. Composite Processing Technology Fraunhoufer IPT Multi-Tech Tape Placement Unit Different heating sources Different semi-finished tape Laser-Assisted Composites Processing Tape and prepreg laying / winding No Curing Time Precise Temperature control Near-net shape part manufacture Load-optimised firber orientation & laminate structure

10 4. ProFoam - Arburg Physical foaming of glass-fibre reinforced thermoplastic Without additional shearing and mixing unit Without undesirable use of a chemical blowing agent Impregnating plastic pellets with nitrogen under low pressure before they are fed into the barrel. Production of lightweight thermoplastic product Resilient, low-distortion, homogeneous foam Structure Minimize sinkholes, shrinkages Produce longer average glass-fibre length Able to adjust the reduced wall thickness, Reduce wall-thickness Maximum 30% weight saving High-gloss surface by dynamic mould temperature control

11 5. Hybrid Components Wittmann Battenfeld Production of a plastic-metal hybrid structural component Thermoforming of metal sheet blanks combined with insert molding in an injection mold with PA Forming, bonding, and overmolding take place in a single work Copolyamide-based adhesion promoter reduces the weight by up to 20% Surface-finishing of the metallic part still subject to improvement

12 6. Integrated metal/plastic injection molding Institut für Kunststoffverarbeitung (IKV) Complex plastic components with integrated strip conductors Complex three-dimensional geometries can be produced Integrated into a multi-component injection molding machine, complex strip conductors are injection molded directly onto a plastic substrate Encapsulated and insulated with an additional plastic layer

13 7. 2K Micro Injection Moulding Wittmann Battenfeld Multi-component injection molding of micro and nano parts a 2-component plug inside a sound recorder head made of PC & electrically conductive PC is manufactured with a singlecavity mold Two parallel injection units & parts-transporting clean room rotary disk

14 8. FiberForm KraussMaffei Thermoforming of composite sheets Back injection with filled thermoplastic resin No-post processing required, Short-cycle time

15 9. T-RTM KraussMaffei A pre-shaped semi-finished fiber layers is infiltrated with matrix materials and hardened to form thermoplastic PA 6 in a press mold Low Viscosity (5 mpa s) similar to water allows the matrix material to penetrate the fiber layers even with low internal mold pressures. High flow capacity allows for low minimum wall thicknesses and allows the fiber volume content to be as high as about 60%. Near-net-shape production lower material consumption

16 10. ColorForm Krauss Maffei Integrated process steps for parts with finished surfaces in a single work station Production of high-gloss surface product Combination of multi-component injection molding and polyurethane processing flow-coating the substrate of the basic body with PUR or PUA Layer thicknesses of mm possible

17 Advanced plastic processing consultancy service HKPC SERVICE IN MANUFACTURING

18 Latest Technology Development Micro-Injection Moulding To develop an innovative and advanced micro-injection moulding machine Micor-connetor net weight: g Plasticizing, Metering and Injection Unit Micro-filter net weight: g Mesh size: 80mm Clamping Unit

19 Latest Technology Development Mucell Co-injection Moulding An integrated system to produce high-quality automotive components with significant reduction in weight and energy consumption, and improvement of part qualities and productivity A Mucell Co-injection System Application

20 Latest Technology Development Overmoulding Tandem Machine (ITF/APAS) To develop a cost-effective method for the production of large-thin-wall automotive parts through the innovative development of a twocomponent tandem injection moulding machine A typical tandem machine Potential Application Sequence for tandem moulding

21 Latest Technology Development LSR Injection Moulding To develop an innovative and patentable Liquid Silicone Rubber (LSR) injection moulding machine with an over-moulding system to support local plastic machinery manufacturers to open up new high-end machinery markets Production Sample Schematic Configuration of the HKPC Integrated LSR Injection Moulding System LSR Injection Moulding Machine Turn Table for Co-injection Schematic Configuration of the HKPC Standard LSR Injection Moulding Module

22 Latest Technology Development Metal-Plastic Overmoulding To develop a sliding core mechanism for transferring the injection moulded plastic preform to the metal cavity To investigate the know-how of overmoulding low melting point metal alloy on thermoplastic and to demonstrate the production of metalplastic component with conductive tracks in one moulding cycle Overmoulding Test Mould Flow Length and Bonding Behavior Evaluation Prototype Sample

23 Latest Technology Development Infrared Localized Mould Heating By using infra-red heating system to heat up a localized region on a mould surface for eliminating weldlines so as to produce high-quality weldlineless moulding To be used with a suitable mould cooling system so as to achieve realtime heating and rapid cooling Conceptual Design of Infra-red Mould Heating for Injection Moulding Applications

24 Latest Technology Development Carbon Composite Parts Manufacturing To develop local capability in various forms of carbon composite product manufacturing techniques Hot Press Moulding * Resin Infusion * Autoclave Vacuum Bagging * HKPC is equipped for this technology.

25 HKPC - Project Development ITF Innovation and Technology Fund - Collaborative project Research & Development Cash Rebate Scheme

26 Innovation and Technology Fund (ITF) 創新及科技基金 Aim: The Government hopes that, through the ITF, Hong Kong companies could be encouraged and assisted to upgrade their technological level and introduce innovative ideas to their businesses.

27 Innovation and Technology Fund (ITF) - Collaborative project 創新及科技基金 合作項目 - The technology shall be adopted by an individual company - The industry co-applicant should contribute at least 50% of the total project cost within the project period. - The IP rights generated may be owned by the industry coapplicant if contribution more than 50% - The co-applicant is eligible for R&D cash rebate scheme.

28 Innovation and Technology Fund (ITF) - Collaborative project 創新及科技基金 合作項目 Examples: i) Innovative machine/system development ii) Innovative manufacturing process development For Collaborative projects (Implementation agent: HKPC) - Total project cost HK$1 million R&D expenditure by the company HK$500K (50%) HK$300K (60%) HK$500K (50%) ITF Collaborative project Actual expenditure by the company HK$200K (40%) R&D Rebate scheme

29 Research and Development (R&D) Cash Rebate Schem Aim: Reinforce the research culture among private companies and encourage them to establish stronger partnership with designated local public research institutions e.g. HKPC. Cash rebate equivalent to 40% of its expenditure No ceiling Repeatable

30 Thank You! Ir. Samson Kwok-wai SUEN Principal Consultant, Smart Manufacturing and Materials, Hong Kong Productivity Council Tel: