Engel exhibit first-of-its-kind injection moulding machine at Plastec West

Manufacturer of plastic injection moulding machines, Engel, have exhibited the first-of-its-kind production of its cleanroom version of an all-electric Engel e-motion injection moulding machine, at Plastec West 2017.

The company demonstrated a three-component compound, designed to produce an interdental brush with up to 500 fine bristles.

Until now, interdental bushes have consisted of three components which are usually produced in separate processes. New technology from system partners, Engel and manufacturer Hack and Hekuma now allows up to 500 bristles to be moulded directly in single-component injection moulding.

Visitors to Engel’s booth can see the company’s e-motion 170/100 injection moulding machine. To help create the integrated production cell, a high performance eight-cavity precision mould has been added. The compound utilised also makes an important contribution as it provides stability for the grip and core, while at the same time allowing for a soft bristle.

Responsible for the automation is Hekuma. Immediately following injection moulding, the parts are automatically packed, 16 pieces each into retail sales bags, with a bag leaving the production cell every four seconds. Every 50th shot is delivered to a camera module which performs a 360-degree inspection. The robot holds the product in front of the camera and rotates it. A total of five pictures are taken and analysed.

The single-component design and the exceptional level of process integration achieve an increase in production efficiency when compared with well established products and methods currently on the market, Engel claim.

A significant demand is placed on the mould when eight cavities are completely filled with up to 500 bristles each. Engel’s iQ products have to compensate for fluctuations in the ambient conditions or raw materials.  

Shot by shot, iQ weight control analyses the pressure profile at screw positions and adjusts both the switchover point and the injection profile to the current conditions. At the same time, iQ clamp control monitors the mould breathing for each shot separately and adjusts the clamping force automatically, and the new iQ flow control adapts the pump speed in the temperature control unit to current requirements. Together with the electronic Engel e-flomo water manifold system, iQ flow control keeps temperature control conditions in the mould constant, and increases energy efficiency. The decentralised intelligence, directly on the machine, guarantees maximum process consistency, preventing rejects and ensuring competitive unit costs.