TECHNOLOGY for the Injection Molding Industry Molding from the Plastic s Point of View
Why RJG Technology? Our Outstanding Reputation The Next Level of Process Control RJG has been globally recognized for utilizing the most effective tools to not only gather data from the plastic s point of view, but record, analyze, and use that data to significantly improve part quality and lower costs. Results of Using RJG Technology: Improved cycle time Improved machine utilization Reduced scrap Improved quality Reduced time to market (faster startups, reduced cycle times, decreased downtime) Ability to uncover and fix problems Detailed reports Ability to replicate a process anywhere in the world RJG Technologies LTD RJG Headquarters RJG Germany NC Training Center CAEpro CO LTD RJG China RJG Mexico RJG France GA Training Center Next Innovation RJG (S.E.A.) PTE LTD Global Support Unlike Any Other We don t just sell you a product, we will work with you from the very beginning to find the source of your problem and determine a real solution. We will even come help you get set up to ensure you start off on the right foot. We re here to support you, even after you re making great parts. Our Technology Options Process Monitoring Systems It s not enough to have sensors in a mold, you have to have a way to display and read the data they collect. We have two process monitoring systems to help you do just that: the edart System and the CoPilot. They both reveal when a process is out of match and record data, but the way they function and display data differs greatly. Plant Networking Systems Imagine being able to access all of your machines from a single remote webpage. Our networking systems allow you to do just that. The edart Data Manager provides you with current cycle data for all edarts, and The Hub provides you with data from all of the CoPilots on your floor. Cavity Pressure Monitoring Cavity pressure sensors are placed in the mold to monitor what is happening from the plastic s point of view. Through utilizing sensor technology, you re able to know whether it s a good part before the mold even opens. RJG improved our quality and the robustness of our tools. We re now able to sort, contain, eliminate mold damage, and minimize scrap. That cost savings allowed us to get a third press in the shop, which also has RJG on it. After as much as we ve saved with RJG s equipment, it s too expensive not to use. We ll never have a machine without RJG equipment installed again. - Magna Mirrors of America Utilizing RJG s technology gave us the ability to see inside the process and understand what was going on. The edart graphs allowed us to see the interaction of the press and cavity at the same time with respect to plastic pressure. Our customers now have an increased confidence in our capabilities, and we have become the least of their concerns in the supply chain. - Nypro Healthcare Within the first day of implementation, we could see the impact of RJG s technology. We have greatly improved the quality of our products and can now document and validate the results with confidence. Having this data allows us to provide accurate information to our customers and be proactive in many aspects that, under normal procedures, would have been based on assumptions. - Dana Molded Products Cost is what keeps people from diving into this technology, but you either pay for it now or later. The bottom line is that our customers never receive process related rejects, and the overall quality rating for their end product is higher. You can t catch everything with manual inspection, and one defective gear is too many in our customers eyes. - Winzeler Gear
Process Control: The edart System Process Control: edart Software Options The Industry Leader in Process Control The edart System is the most comprehensive and powerful process monitoring and control system for plastic injection molding applications. It helps users gain control over the two greatest variables in injection molding: people and plastic. The system is essential for any molder who wants to stabilize their injection molding process, contain bad parts, and/or control their process to ensure parts of the highest quality, while reducing the cost to make them. Find the Root of the Problem This software provides numerical and graphical tools both in the plant overview (through the EDM) and at the machine that let users get to the cause of the problem. The edart System can quickly answer questions like: Has the hold pressure changed? Is the screw mixing differently? Has someone adjusted the cooling time? And has the viscosity been rising? This shortens the time to find the root cause, increases utilization, and provides constant feedback that quality procedures for process setups are being followed. Know When a Process is Out of Match All edart users can create templates for their processes. When a process moves outside of that template, they are notified via the system overview screen. A quick glance will let users know which processes aren t running to template and how much they have deviated. Get Started Quickly and Easily The software platform works seamlessly with RJG s Lynx sensors. Upon plugging a Lynx sensor into the system, the program automatically recognizes it and allows users to assign it to a mold or machine. This ability to plug and play means less time setting up and more time making quality parts. Three Software Options to Choose from RJG offers 3 software options: edart conx for stabilizing your machines, edart flx for abnormal part containment, and edart apex for full process control. If more functionality is needed, conx and flx units can be upgraded to an apex. conx flx apex conx: Stabilize the Process The edart conx software module provides users with the ability to view machine conditions, giving them the ability to easily verify that a process is repeatable. It may not be practical to put cavity pressure into every mold all at once, but the next best thing is to monitor the machine and material and make corrections in a systematic way. The edart conx software identifies when the right machine setup is running and the material viscosity is in a specified range. flx: Catch and Contain Bad Parts The edart flx software module provides users with the ability to view incavity behavior, such as pressure and temperature. Data collected from the edart allows processors to set alarm bands to catch and contain short shots quickly with minimal setup. To ensure proper part diversion, the flx software can see short shots before the mold opens and control the timing of conveyors and robots. This eliminates the time-consuming, costly process of hand sorting each part. apex: Gain Complete Process Control The edart apex software allows users to see and adjust process conditions in real time. This system brings the machine and mold information together into one user interface. apex allows users to know when a job is operating within tolerance and provides real-time data about what is happening with their process. This enables users to keep up with the ever growing demand for absolute quality and produce good parts shot after shot. Additional Software Options Valve Gate Control turns the edart System into a valve gate sequence controller. It allows the balance of filling using opening by volume and sequencing of knit lines. The biggest benefit comes from using in-cavity pressure or temperature sensors read by the edart System to control when the valves open or close. This can dramatically reduce the effects of material changes. Shuttle Control is used for insert molding with two or more mold bases. Using one or more mold base position inputs allows the edart System to determine which base is active (being injected) and which sensor alarms to use. It automatically figures out which sensors are active by using pressure detected. Other software modules exist, depending on your needs.
Process Control: The CoPilot Process Control: The CoPilot Your Process Match Assistant Functioning as a notification system, a communication tool, and a coach, the purpose of the CoPilot is to provide a simple and practical program that is so easy to use that technicians of all experience levels can insure their process stays within the validated limits. Through real-time notifications, step-by-step walkthroughs, automatic part diversion, and more, the CoPilot helps to bridge the skills gap, reduce scrap, and minimize time wasted on sorting through suspect parts. Process Change Logs Easy to Use for All Experience Levels One of the biggest problems ailing the manufacturing world today is lack of skilled employees. Imagine having a machine that was so easy to use, anyone could start making good parts with little to no training. Enter the CoPilot. With step-by-step instructions, molders can know exactly what to change on the machine, by how much, and in what order. Real-Time Notifications Avoid unknowingly making bad parts by receiving real-time notifications when a process is not running properly. The moment a process strays from the set parameters, the screen turns red and displays how many cycles have run out of match. The bright red screen is easy to see from afar and notifies you exactly how far back to check for suspect parts. When you touch the screen, you can clearly see which variable is out of match and follow step-by-step instructions to put it back. The CoPilot also records change log data, which shows what process was changed, when it changed, and who fixed the issue. It can be difficult to prove to end users and customers that a process was within specifications when a specific part was created, which can be detrimental if the part fails. Process change logs provide management with a better picture of what is happening on the shop floor and documentation that a process has remained within limits. That helps prove a part failure wasn t due to the fact that your process was out of match. Users are prompted to fill out change logs upon adjusting machine settings, so you don t have to worry about whether or not they re being recorded. Process out of Match Automatic Part Diversion Step-by-Step Instructions The CoPilot observes actual machine settings and offers instructions to bring a process back into set parameters. If the problem isn t fixed in the right order, it can cause other variables to go out of match. That s why the CoPilot walks you through a step-by-step order that is driven by scientific molding principles by prioritizing the most important out-of-specification variables. Once all variables are back within parameters, the screen turns green, notifying you that everything is in match. If a process does go out of limits, any non-conforming parts are automatically contained, eliminating the need to sort through them by hand. This greatly reduces time spent on sorting through cycles of parts wondering which ones are good or suspect, and, in turn, reduces scrap from tossing potentially good parts away due to uncertainty. Simplified Process Audits Many molders have some form of manual process check that goes on this usually involves one or more employees doing a manual comparison to ensure that the set points on each press match what is on the setup sheet. The CoPilot has the ability to monitor and perform this check in real time, 24/7. This will dramatically reduce or eliminate the time spent on manual checks and free up time to focus on other tasks.
Networking: edart Data Manager Networking: The Hub Network and Manage Your edart Systems RJG s edart Data Manager (EDM) is a complete software solution for networking and managing your edart network. Features and Benefits Automatic backup of all edart data Cross copy feature allows mold files to follow the mold from press to press Overview of all machines with the ability to view any unique process Time synchronization of all edart Systems on the network Network and Manage Your CoPilot Systems The Hub allows injection molders and plant managers to monitor their entire plant floor from a single remote access point. It provides a single, simple interface that allows users to access, support, and view all of the CoPilot systems on their network from a web browser. The Hub clearly shows which machines are producing good, bad, and suspect parts and why. See Potential Problem Areas With detailed job summary reports, managers can quickly deploy resources to resolve ongoing problems. Know What s Happening on the Floor You can immediately know whether a process is running to its established limits and ensure that alarms are set and on. You can also know what happened when they left the plant, including: alarm changes, alarm outputs fired, excessive rejects, machine sequencing issues, and more. Receive Detailed Process Statistics In-depth statistical analyses allow users to analyze processes and determine variations. That means you can pinpoint problems using data. View Historical Cycle Data The enhanced version allows you to view current and past processes running on any individual CoPilot System with summary data and graphs. You re able to view cycles over time and look at longterm data trends. That means it records every shot so you can see exactly what happened with a specific shot on a specific day at a specific time. Every edart on One Platform The EDM will become the center piece of your edart network, providing a single, simple interface to perform all the functions needed to access, support, and use the edart System. The EDM can become the gateway between the existing plant network and the edart network. Advanced System Overview The advanced system overview function allows you to view all of the edart Systems on your network from the web browser on your desktop. You can see which presses are down and for how long, what jobs they are running, the number of good and reject cycles, and more. The process viewer allows you to view the current process running on any edart System with real time cycle and summary data.
Sensor Technology: Overview Why Measure Cavity Pressure? Simply put, what happens in the mold stays in the part. Cavity pressure sensors are the proven way to know without a doubt what is happening to the plastic as it forms the part. Pressure data can help identify common molding problems, such as sinks, shorts, voids, warp, dimensional variation, and more. If you re aware of these issues, you can make adjustments where needed to ensure lower cost, a higher quality product, and a happier customer. Why Measure Temperature? Temperature is critical to the manufacturing of many parts, especially those made with semi-crystalline materials or tight dimensional tolerances. Changes or breaks in cycle time can dramatically impact thermodynamic stability. Installation of a temperature sensor can help you diagnose problems and prevent the shipment of imperfect parts. Choosing the Right Sensor In order to gather the correct data, it s essential to have the right sensor in the right location. There are a variety of sensors and specialized installation techniques to choose from, so it may feel a little overwhelming at first. We d love to help you pick out the perfect sensor for your application. Sensor Technology: Hardware Options Cavity Pressure Sensors We have a large variety of pressure sensors that vary in size, tolerances, and installation techniques to fit a wide variety of applications. There are three types of systems to choose from: Single Channel Each sensor has its own adapter and is installed in the machine individually. This is good for single sensor applications. Multi-Channel Up to eight sensors are connected to a single adapter, making installation easier, the footprint smaller, and the cost lower. It also minimizes cables around the mold. Lynx Embedded As shown in the image below, each sensor is equipped with its own Lynx adapter, allowing it to connect to the edart System and digitally display data. These sensors are embedded directly into the mold plate with a single external connection point. Temperature Sensors We have various temperature sensors to choose from, depending on your application. Temperature sensors are used to analyze temperature variation inside the mold cavity, and they vary in size, range, and installation techniques. Mold Deflection The Mold Deflection Sensor measures how much the mold parting line opens on each cycle. When the mold clamps, the pin is pressed flush with the parting line, and the full force is applied to the sensor this is recorded as zero deflection. As the mold cracks, the force decreases. For each incremental decrease in force, the sensor reports an increase in deflection. Test and Installation Kits We offer three different tester and installation kits: the Sensor evaluator, the Lynx Button Installation Kit, and the Flush Mount Sensor Installation Kit. The evaluator provides diagnostics on typical sensor problems and detects sensor installation errors. The Lynx Button Sensor Installation Kit includes the tools and documentation that help ensure correct installation of 1/2 button style sensors. The Flush Mount Sensor Installation/Check Kit contains the tools and documentation to install and check dimensions of the pockets for 4 mm Piezoelectric Flush Mount style cavity pressure sensors.
Locations USA RJG USA (Headquarters) Traverse City, MI phone: +01 231 947-3111 SE Regional Training Center Woodstock, GA phone +01 678 401-7494 North Carolina Training Center Gibsonville, NC +01 336 310-8594 e-mail: sales@rjginc.com web: www.rjginc.com Mexico RJG Mexico Chihuahua, Mexico phone: +52 614 4242281 e-mail: sales@es.rjginc.com web: es.rjginc.com France RJG France Arinthod, France phone: +33 384 442 992 e-mail: sales@fr.rjginc.com web: fr.rjginc.com Germany RJG Germany Karlstein, Germany phone: +49 (0) 6188 44696 11 e-mail: sales@de.rjginc.com web: de.rjginc.com UK/Ireland RJG Technologies Ltd Peterborough, England phone: +44 (0)1733 232211 e-mail: sales@rjginc.co.uk web: www.rjginc.co.uk Italy Next Innovation Srl Milano, Italy phone: +39 335 178 4035 e-mail: sales@it.rjginc.com web: it.rjginc.com Singapore RJG (S.E.A.) PTE LTD Singapore, Republic of Singapore phone: +65 6846 1518 e-mail: sales@swg.rjginc.com web: en.rjginc.com China RJG China Chengdu, China phone: +86 28 6201 6816 e-mail: sales@cn.rjginc.com web: zh.rjginc.com Korea Caepro Seoul, Korea phone: +82 02-2113-1870 e-mail: sales@ko.rjginc.com web: www.caepro.co.kr www.rjginc.com RJG Headquarters