08 APPLICATION MELT EXTRUSION AND BLOWING 1
ADV200 Motor control drive GF_VEDO Operator panel & control GILOGIK II Digital/analog remote I/O GFX4, GFXTERMO4 Multiloop PID temperature control TR Load cells for web tension APPLICATIONS Extrusion GF_VEDO Operator panel & control TC5, TCM Temperature sensors IN Melt pressure transducers GLK67 IP 67 remote temperature inputs ADV200 Motor control drive GILOGIK II Digital/analog remote I/O
APPLICATIONS Extrusion The process of polymer transforming takes the material to its melt condition (plastification) and forces it to pass through an orifice (threading die) FEEDING ZONE SCREEN CHANGER HOPPER MIXING ZONE GEAR PUMP GEAR BOX SCREW EXTRUDED PRODUCT DRIVE BARREL PRESSURE ZONE DIE
APPLICATIONS Extrusion PRESSURE AT THE DIE Melt temperature and pressure are monitored to check the flow stability. The pressure value is used to give the feedback to the drive to set the screw speed
APPLICATIONS Extrusion PRESSURE AT THE GEAR PUMP Used to improve the flow stability to the die Gear Pump Melt pressure sensor before the pump Melt pressure sensor after the pump
APPLICATIONS Extrusion PRESSURE AT THE SCREEN CHANGER To check the screen cleanness by reading upstream and downstream pressure Melt pressure after the screen changer Melt pressure before the screen changer Screen changer
APPLICATIONS Extrusion PRESSURE ALONG THE BARREL Screw design research and development Plastic materials evaluation The diaphragm may get in contact with semi-molten polymer
Pressure control at the gear pump APPLICATIONS Extrusion The gear pump is used to grant a costant flow-rate to the die. The flow adjustment is obtained by the pressure measure
Pressure control at the screen changer APPLICATIONS Extrusion Contamination can clog the screen and cause a pressure drop at the die, dimensional unstable products result. The screen cleanness can be controlled by reading upstream and downstream pressure (measuring the pressure before and after the screen)
Process: plastic materials recycling machines Reason for Impact choice: Dirty environment, semi solid and abrasive materials Reliability APPLICATIONS Extrusion Recycling machines
CASE HISTORY Extrusion Policarbonate sheets Process: a wide range of top-class solid, multiwall, and corrugated polycarbonate sheets production (ex. Makrolon series) that fulfill the most diverse requirements PC Application: stadium and train station roof covers, complex dome structures, skylights and barrel vaults, lightweight roof constructions for winter gardens PC advantages: energy saving (thermal insulation), protection and safety (bullet and breaking proof features), high bending resistance (building) Why we gained the customer: thanks to the Impact in contact diaphragm higher reliability (PC high abrasion effect) Competitors: Gneuss DAP series
CONSOLIDATED CUSTOMERS CONSOLIDATED CUSTOMERS Extrusion Policarbonate sheets Following a couple of examples of consolidated customers during 2008 with the Impact series : Bayer Sheet Europe (Terni plant): www.bayersheeteurope.com 6 extrusion lines for Makrolon production 5 pieces sold in 2008 (Impact IE series) Proimpianti-Dott. Gallina (Torino plant): www.gallina.it 40 extrusion lines for different industrial sectors (automotive, building, compact sheets, expanded materials) 30 pieces sold in 2007 and 30 pieces sold in 2008 (Impact IE series)
IN1 Melt pressure transducers APPLICATIONS Blowing TC5 / TCM Extruder Temperature Sensors IK4A Parison position sensors TC5 Head Temperature Sensors GTS Solid Stae Relais with heat sink GILOGIK II Real time ethernet Remote I/Os GT-C / DIGISTARII C Human machine interface and control unit MK4A / LT Mold position sensor ADV200 / XVy-EV Inverters and Servodrives TPSA Hydraulic pressure, blow pressure, leak tester
APPLICATIONS Blowing Blowing machines Target: mould opening/closure position, mould translation, Parison actuator control, pressure and temperature control at the extruder head, blow and hydraulic pressure control Pressure sensors TK series for blow pressure and TPSA series for hydraulic circuit pressure Melt pressure sensors Impact series for pressure control at the extruder die (dynamic pressures) Magnetostrictive position sensors MK4 series for mould position control and IK4 series for Parison actuator control
CONSOLIDATED CUSTOMERS CONSOLIDATED CUSTOMERS Blowing Accumulator head Sipa: www.sipa.it 50 melt pressure sensors Impact series for pressure control at the extruder die (dynamic pressures)
APPLICATION RHEOLOGICAL NOZZLES The rheometer is an instrument suitable to measure rheological polymer proprieties. The sensors measure the pressure drop inside a small channel. An high accuracy and great matching among the sensors is required. P 2 Viscosity P vk P 1 P 3
APPLICATION - HOT MELT Hot melt applicators are machines designed for the application of adhesives and thermoplastic material They need to control the pressure of the glue Due to the small dimensions the most used Melt pressure version is the exposed capillary one
IJ/MJ Melt pressure sensor for Injection Moulding Machines
LT Ejector position MK4-A Mold position GF_VEDO Operator panel & control APPLICATIONS Injection Molding Machine IJ Injection pressure MK4-A Injection screw position GILOGIK II Digital analog remote I/O GTS/GFXTERMO4 Solid state relay Multiloop PID temperature control TPSA Hydraulic circuit pressure MK4-A Carriage position ADV200 / XVy-EV Motor control inverter
APPLICATIONS Injection Molding Machine Mould pressure Nozzle pressure Screw position Ejector force Melt temperature Hydraulic pressure Mould temperature
APPLICATIONS Injection Molding Machine Nozzle pressure measurement advantages: Direct measurement of injection and back pressure Final product higher quality (repeatibility in dimensions and weight) Easy Process Parameters Tuning Statistic Process Control Better quality by a better control of the holding phase Easy transfer of the machine settings (for a new production process or different machine) Higher reliability related to the cavity measurement (only one sensor); it s enough one sensor for different moulds No mould re-workings Higher measurement precision related to the load cell solution through a pressure direct measure Easy to install (doesn t require machine customizations)
INJECTION PHASE IJ/MJ ELECTRIC MACHINE APPLICATION Injection pressure direct control inside the nozzle during the holding phase. LOADING PHASE Back pressure check during the material loading ADVANTAGES Melt pressure direct measure Measure depends on the process variable only (and not on the machine variable) Piece weight in grams more precise control Process and final product absolute repeatability Standard product without customizations for different type of machines
IJ/MJ HYDRAULIC MACHINE APPLICATION INJECTION PROCESS TODAY BY QUOTA, holding phase BY PRESSURE TRANSDUCER IN THE HYDRAULIC CIRCUIT, holding phase, compacting phase and back pressure BY MEL PRESSURE SENSOR INSIDE THE MOULD, holding phase, compacting phase INJECTION PROCESS WITH IJ OR MJ SENSOR INSIDE THE NOZZLE Melt pressure direct measure Measure depends on the process variable only (mm/bar oil) Piece weight in grams more precise control Process and final product absolute repeatability Unique positioning (nozzle) without mould workings (hole for sensor inside the moulds)
IJ - Simulation of an injection cycle
MELT SENSORS - THE PRODUCTION GEFRAN SPA (PROVAGLIO D ISEO) GEFRAN ISI (WINCHESTER-BOSTON)
GEFRAN GROUP 25 YEARS EXPERIENCE IN MELT SENSORS MANUFACTURING GEFRAN IS ONE OF THE MOST IMPORTANT MELT SENSOR MANUFACTURERS IN THE WORLD FIRST SUPPLIER FOR ITALIAN MANUFACTURERS EXPORT QUOTA EXCEEDING THE 80 % FIRST MARKET: GERMANY
FULL PRODUCT RANGE price IE-IN-IX series (100/1000 bar) 350 C W series filling Oil (FDA approved) (35/1000 bar) 315 C K series filling Nak (Mercury free) (35/1000 bar) 540 C I3 series (100/1000 bar) 350 C IJ series fluid free (100/3000 bar) 350 C M series filling Hg (35/2000 bar) 400 C performances
Melt pressure sensors product range Static pressures Dynamic pressures Oil Mercury W M -2,3 (mv/v) -E, N (analogue) -X, F (Atex, FM) -D (CANopen) -2,3 (mv/v) -E, N (analogue) -X, F (Atex, FM) EXTRUSION -D (CANopen) MJ -N (analogue) -D (CANopen) Nak K -2,3 (mv/v) -E, N (analogue) -D (CANopen) Impact I -3,E,N,X (analogue) I IJ -E,N,X (anal.) -N (analogue) -D (CANopen)
Melt pressure sensors product range Static pressures Dynamic pressures Oil Mercury W M -2,3 (mv/v) -E, N (analogue) -X, F (Atex, FM) -D (CANopen) BLOWING -2,3 (mv/v) -E, N (analogue) -X, F (Atex, FM) -D (CANopen) MJ -N (analogue) -D (CANopen) Nak K -2,3 (mv/v) -E, N (analogue) -D (CANopen) Impact I -3,E,N,X BLOWING (analogue) I IJ -E,N,X (anal.) -N BLOWING (analogue) -D (CANopen)
Melt pressure sensors product range Static pressures Dynamic pressures Oil Mercury W M -2,3 (mv/v) -E, N (analogue) -X, F (Atex, FM) -D (CANopen) -2,3 (mv/v) -E, N (analogue) -X, F (Atex, FM) -D (CANopen) MJ -N (analogue) INJECTION -D (CANopen) Nak K -2,3 (mv/v) -E, N (analogue) -D (CANopen) Impact I -3,E,N,X (analogue) I IJ -E,N,X (anal.) INJECTION -N (analogue) -D (CANopen)