Hot, cold and digital

The latest innovation in hot runner systems as well as cold runner solutions for processing of LSR

by Giovanna Marconi

4-drop Coolshot cold runner system

Innovation, process efficiency and digitization are key theme for Ewikon (Hall 1, Booth C11) that at K fair presents a new nozzle range for vertical multi gating and solutions for process monitoring and cold runner solutions for the efficient processing of LSR.

Multi-tip nozzle for the vertical gating

The HPS III-MV multi-tip nozzle for the vertical gating of parts is now available in a new and even more powerful version. With an optimized installation geometry and a coil heater which is integrated into the pressure tube the nozzle features state-of-the-art hot runner technology with a stable heating and an even temperature profile. It is particularly suitable for the processing of technical resins with narrow processing windows as well as fibre-reinforced materials as used for electronic parts, technical parts and automotive parts. Two nozzle body diameters are available. They can be combined with several tip insert sizes for simultaneous gating of two up to maximum six parts with pitch diameters from 10.5 up to 25 mm. Thus, an optimal adaption of the nozzle to different application requirements, shot weights and resins is possible.

The new benchmark for LSR processing
1 Valve gate technology with electric linear step motors
Leading technology from the hot runner sector. Valve pin positioning with high precision. Minimised time expenditure for system setup and readjustments during production.
2 Easy-to-maintain balanced manifold technology
Balanced flow channels and streamlined flow channel layout for quick colour changes. The manifold package can be easily disassembled and opened for cleaning.
3 Optimised cycle times and perfect gating points thanks to advanced nozzle technology
An excellent thermal separation is achieved by using different tip designs for the water cooled cold runner nozzles. This allows optimised cycle times for various types of LSR.
4 Homogeneous heating of the cavity plate
Heated separator plate with powerful coil heaters and separate temperature control for each cavity. Considerably more even temperature profile when compared with cartridge heaters.
5 Quick clamping device for deinstallation of the cavity plate
After the end of production or in case of a temporary interruption the hot cavity plate can be easily separated from the cold runner nozzles. A cross-linking of the LSR in the cold runner is prevented.

The front installation option allows a particularly quick maintenance. After dismantling of the cavity plate the nozzle is easily accessible for replacement or exchange of the tip inserts. In addition to the standard version for installation under a manifold a single nozzle version is available. Since the multi-tip concept has a part of the melt distribution already integrated into the nozzle the manifold can be kept small and compact. This reduces the total flow path length and facilitates the processing of materials which are sensitive in terms of temperature and residence time such as POM as well as the direct gating of small or micro parts. At the same time a very energy-efficient process becomes possible because the contact points between hot runner system and mould are significantly reduced.

Process monitoring

HPS III-MV multi-tip nozzle

With smart Control Ewikon shows the world’s first process monitoring device for hot runner systems and takes a further step towards industry 4.0. The compact process monitoring and diagnosis unit is optionally available for new hot halves and is delivered readily wired and mounted on the wiring box of the system. smart Control monitors, analyses and logs all relevant process and system parameters over the entire life cycle of the mould.  For the injection moulder this means more transparency in the production process. Data such as nozzle and manifold temperatures of the hot runner system, running times and downtimes of the mould as well as shot numbers are permanently collected and logged. When defined critical values are exceeded a warning signal can be triggered and – if required – submitted by e-mail. All data can be exported by using WLAN or Ethernet.

A browser-based user interface which has been developed by Ewikon allows a clear visualization of the data and is accessible by IP address from mobile devices or over the company network. In case of system error the data can be transmitted to Ewikon for quick remote diagnosis. This allows an early initiation of specific maintenance activities and minimizes the downtime of the mould. Three digital inputs and two digital outputs allow the processing of additional digital signals.

The digital future for mould
smart Control monitors and analyses hot runner system performance over the entire life cycle of the mould and adds more transparency to the production process. Here are the main features:
1 Permanent system monitoring
All relevant process and system parameters (e.g. running times, downtimes, temperature history) are permanently monitored, analysed and logged. When critical values are exceeded a warning signal is triggered.
2 Reduced downtimes
In case of system errors the data can be transmitted to EWIKON. This allows a quick remote diagnosis and an early initiation of specific maintenance activities.
3 Optionally available for new hot halves
4 Compact design
Easy and space-saving installation.

Cold runners for LSR

The Coolshot high performance cold runner system allows the process-reliable and efficient processing of various types of LSR. As a key technology the system features the technologically leading Ewikon electric drive valve gate system which already has been successfully used for years in hot runner applications worldwide.
When processing LSR the electric step motors used allow the positioning of the valve pins with high precision in steps of 0.01 mm and thus a perfect fine-balancing of the cavity filling. The adjustment of the valve pin length by using the controller is possible at any time without cycle interruption instead of requiring manual adjustment work at the mould. Thus, the expenditure of time for system setup and re-adjustments during production is considerably reduced. Furthermore, the advanced control technology allows permanent monitoring and automatic adjustment of the valve pin positions by using encoders.
The touch screen panel offers a comfortable operation and features remote control access by using a tablet PC (iOS, Android, Windows) with VNC viewer. Depending on the LSR type used the water-cooled cold runner nozzles are available with different tip versions.
Thus, the thermal separation can be tailored to the process. This allows to achieve quick cycle times even for applications which require colder mould temperatures.

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