Smart compensation of process fluctuationsiQ weight control

Your objective is to supply best quality.

The solution: ENGEL iQ weight control

Highest quality shot by shot:

� detecting and monitoring of injected volume and viscosity

� controlling the injected melt volume in real-time

� automatic holding pressure correction

� improved process stability

ENGEL iQ weight control helps you keep control over all ambient production conditions. This intelligent software thinks and acts - shot by shot. It compensates fluctuations of material quality aswell as in the machine environment - without manual adjustment, fully automatic and in real-time.

The challenge: producing 100% good parts

The quality of the manufactured parts can suffer from:

� material batch quality and moisture fluctuations

� changes in ambient temperature and air humidity

� different closing behaviour of the non-return valve

� fluctuations in the media supply

� long start-up procedures after production downtimes

� short shots or flashing the cavity

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How does iQ weight control work?

Maximum precision for your productionENGEL injection moulding machines are perfectly equipped for your production requirements They achieve optimum process precision thanks to accurately repeatable screw position and speed. ENGEL iQ weight control takes this one step further and ensures a constant fill volume shot by shot - independently of external influences - guaranteeing constant part quality.

This is how ENGEL iQ weight control works

During injection the actual fill volume can vary from shot to shot due to external influences: the smart software iQ weight control analyses the current pressure curve in real-time during injec-tion and compares it with the pressure curve of a reference cycle.

When the system detects deviations of melt volume, it adjusts the injection speed profile and the switch-over point within the same cycle. When parts are filled via cascade controlled shut off nozzles, iQ weight control additionally adapts opening and closing of each of the shut-off needles according to the filling stage. These adaptions during the injection phase increase the repeatability especially for parts with a high flow-path-wall to-thickness ratio.

Changes in melt viscosity affect the part quality especiall during holding pressure phase, which is primarily relevant for parts with higher wall thickness. To compensate this disturbance, iQ weight control adapts the holding pressure value automatically, as soon as changes in viscos-ity occur.

The chart shows the injection pressure curve plotted against the screw position during the speed-controlled injection phase. This curve is a fingerprint of the mould filling; changes to the current pressure curve compared with the stored reference curve can thus provide es-sential insights into process changes.

Fluctuations in the fill volume show up as displacements of the pressure curve in x direction; viscosity changes compress or stretch the pressure curve in p direction. In practical applica-tions, it is always a combination of the two effects that occurs.

Thanks to sophisticated mathematical algorithms iQ weight control deciphers the curve and computes the volume and viscosity changes relevant in the process.

current pressure curve reference curve

pres

sure

(p)

screw stroke (x)

viscosity

material quantity

iQ weight control graphics displayThis standard function of the iQ weight control software draws a clear pictureof the current processes and sharpens your view for essential data:

Calculation of parameters by iQ weight control: You see injection pressure curves andand the reference curve determined by iQ weight control in relation to the screw stroke.Deviations are detected more quickly: By directly comparing the current injection pressure curve with the reference curve, differences can be identified more accurately.The most important process data (ACTUAL values) at a glance: iQ weight control provides you with a summarised presentation of the selected injection pressure curve.

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What benefits doesiQ weight control offer?

Permanently constant shot weightiQ weight control compensates shot-by-shot deviations and as a result reduces the part weight variance by up to 85%. Even with well established, stable processes it is well worth to utilize this intelligent software. It monitors the injection process during the production and takes adap-tive actions immediately if required. As a consequence, iQ weight control ensures process stability permanently – even though external influences change over time.

Constant filling even with deviations in material propertiesIn the past, batch changes or different moisture content often resulted in overfilled or not com-pletely filled parts. Injection parameters had to be adjusted manually. iQ weight monitor reliably detects viscosity changes, iQ weight control compensates them automatically.

Moulding good parts sooner after downtime productionAfter downtimes or interruptions it takes some time until the thermal balance is achieved again. iQ weight control adapts injection and holding pressure parameters upon production start in a way that enables the production of good parts immediately.

Constant shot weight despite of aviscosity change in moulding a flat partout of ABS (machine: e-motion 80 TL)

7,38

7,36

7,34

0 5 10 15 20 25 30 40 45

par

t w

eig

ht (g

)

cycle

7,4

7,42

without iQ weight control

with iQ weight control

change in viscosity

4,75

4,70

4,55

0 20 40 60 80 100 120 140 200

par

t w

eig

ht (g

)

cycle

4,80

4,85

4,90

4,95

5,00

with iQ weight control

without iQ weight control

10 mins downtimeproduction start

Shorter starting phase with thin parts out of PP (machine: victory 120)

5,22

5,21

5,2

10 20 30 40 50 70

par

t w

eig

ht (g

)

cycle

with iQ weight control

without iQ weight control5,19

5,23

Reduction of shot weight variance by 85% in mouldinga vibration arm of a razor made of PPS (machine: e-victory 160 combi)

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Your benefits What our customers say

improved cost-efficiency in your production

� improves productivity

� significantly lower scrap rate

� faster ramp-up after machine downtime

reliable high part quality

� enhances process and weight repeatability

� makes the process independent of environmental influences

� compensates for fluctuations in the raw material

� removes the need for repeated manual readjustment

major benefits for low effort

� available for all ENGEL machines

� switch on and reduce scrap rate

� smart, state-of-the-art user interface

� no additional hardware required

� complete integration in CC300 and therefore easy retrofit

The results of the test series are unambiguous and repeatable. Thanks to the iQ weight control software, weight fluctuations were reduced from 0.02 g to 0.003 g. This is equivalent to a weight constancy improvement of 85%. We are now totally satisfied with a reject rate of 0.047%. Based on this, we have been able to re-duce the quality control overhead, and improve the efficiency of the manufacturing process.”

In the past, parts that were not completely filled had repeatedly been aproblem with our thin-walled polyolefin products. Since we introducediQ weight control as a monitoring and control solution in this area, complaints have dropped by 100%. And the operation is easy and intuitive. Our investment in iQ weight control was really worth it in every respect.”

Frank Breunig,Initiative, Project & Process EngineerProcter & Gamble Manufacturing GmbHSchwalbach am Taunus, Germany

Reduction in weight variance

from 0.02 to 0.003 g

Rolf SchauppCEO LAWAL Kunststoffe GmbHLangenau, Germany

Complaintsdropped by 100 %

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ENGEL servicesalways there where you need us

560 of the best equipped service technicians55 support hotline technicians9 production plants29 sales subsidiaries60 representatives

Your concern is our challenge

It is important to always keep your injection moulding equipment in top shape and con-stantly available. The wide range of services offered by ENGEL ensures that you can produce competitively at any time. It does not matter whether your production cell is a single machine or a complex integrated system solution. ENGEL makes it possible for you to utilise all options for optimisation at any time, and therefore consistently get the most out of your machine over the long term. In addition, we offer professional training for machine operators as well as fast worldwide delivery of spare parts and their professional replacement. Diverse maintenance contracts also guarantee top-level machine availability. Our goal is the best possible perfor-mance of your ENGEL machinery.

Support – we assist you on-site

� save costs incurred by downtime

� immediate support 24/7, worldwide

� knowledgeable help from the ENGEL service team

� for ENGEL injection moulding machines of any generation

� for all ENGEL technologies and any control unit version

Upgrade – install reliable added value

� for all ENGEL injection moulding machines

� professional upgrade solutions

� to supplement and optimise

� equip machines for use with completely new applications

� utilise machines with greater cost-effectiveness

Know-how – increase your competence

� thorough training with a comprehensive transfer of know-how

� make optimal use of machine potential

� individual seminars and training programs for you and your staff

� informative events on industry-specific topics

� take advantage of efficient, targeted and practical information, instruction and training

� either at your own facility or at one of the worldwide ENGEL training centres

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ENGEL AUSTRIA GmbH | Ludwig-Engel-Straße 1 | 4311 Schwertberg, AustriaTel. +43 50 620 0 | Fax +43 50 620 3009 | sales@engel.at | www.engelglobal.com

The information, product features and pictures contained in this brochure are intended exclusively as a technical guide. ENGEL is not responsible for any technical changes or print/typographical errors . Reproduction in whole or in part is prohibited without the prior written consent of ENGEL AUSTRIA GmbH.

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