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WITTMANN - State-of-the-art injection molding technology and peripherals for the Asian market
WITTMANN at the Chinaplas in Guangzhou
The increasing relevance of the Asian market is unmistakable: WITTMANN was able to expand its exports of injection molding machines to this economic region significantly in 2010 - and that trend is also continuing in 2011. As a result, Chinaplas has become an important event for the Group. For the domestic supply of various peripheral equipment and robots for the Chinese market, the WITTMANN Group is represented by a local production facility. Above all, WITTMANN appreciates the high level of interest that Asian manufacturers have in the latest technology. "In the dynamics of this young, technology-driven market, we see a tremendous potential for the future," says Dr. Werner Wittmann, CEO and owner of the WITTMANN Group.
Along with the latest injection molding machines, visitors at the WITTMANN stand will also have the opportunity to see automation and state-of-the-art peripheral equipment.
At the Chinaplas, the company is unveiling two machines of the new PowerSeries from WITTMANN BATTENFELD: one of these new machines will be from the allelectric EcoPower model series and the other will be the MicroPower, which has been designed for the injection molding of miniature and micro-components.
The machines of the EcoPower model series - available in a clamping force range from 55 to 300 t - stand out for their precision, cleanliness, cost-effectiveness and energy-efficiency. In the development of the EcoPower, particular attention was paid to the installation dimensions and compact integration. WITTMANN TEMPRO plus C series temperature controllers can be integrated directly into the machine frame, thereby enabling a significant reduction in the required footprint and the associated facility costs. Chinese processors appreciate the advantages of this technology and a large share of the machines supplied to China feature the EcoPower configuration.
An EcoPower with a clamping force of 110 t will be exhibited at the Chinaplas. The machine is equipped with a WITTMANN W811 robot, a DRYMAX D30-70-PDC dryer and a TEMPRO plus C140 temperature controller.
The MicroPower - available in a clamping force range from 5 to 15 t - is of particular interest in the cost-effective manufacture of miniature and micro-components. This makes it especially attractive for industries which are growing at a lightning pace in Asia, such as the electronics sector or medical technology. The whole system is specifically designed for the manufacture of miniature and micro-components - not only the machine itself, but also the complete pallet of peripherals, ranging from material dryers for smaller volumes and throughputs, and material conveyance systems, to dedicated temperature controllers developed for appropriate performance characteristics. One of the most interesting features of this machine series is its innovative two-step screw-plunger injection unit with a shot volume ranging from 0.05 to 3 cm3. This injection unit can be used to inject thermally homogeneous melt, resulting in premium-quality parts while ensuring extremely stable production and short cycle times. Short cycle times combined with low consumption of material and energy make the MicroPower extraordinarily costeffective.
At the Chinaplas a medical clamp with a part weight of 0.003 g is manufactured from POM supplied by Ticona within a cycle time of 4 seconds on a MicroPower 15/7.5 with a 4-cavity mold from Microsystems UK. The parts are removed by a W8VS2 WITTMANN robot with a handling weight of 2 kg, which has been developed for the highly dynamic and precise removal of micro parts, and passed on to a camera integrated in the production cell and in the machine's control system for quality inspection. The parts are subsequently separated according to cavities and stacked in a stacking module.
WITTMANN auxiliary equipment as stand-alone solution
In addition, the WITTMANN Group is introducing their latest auxiliary equipment for plastics processors at CHINAPLAS 2011. Numerous newly developed and efficient solutions in the fields of automation, tempering, material conveying, blending, granulation, and drying will be presented.
The new robot series W818 is based upon the proven design of the W811 systems. Various modifications have permitted the payload to be increased up to 6 kg. Furthermore all W818 models will be equipped with absolute drives as a standard. For example - shifting the reference point of the program will only take a few seconds. The series is consisting of the following models: W818, W818S (with a subarm for sprue picking), W818T (with a telescopic vertical axis) and the W818TS (with a telescopic vertical axis and sub-arm).
With the recently developed W828 robot WITTMANN offers a new partner for IMMs in the range of 200-400t. One of the main advantages of this unit is the long kickstroke axis with compact dimensions behind the Z-axis. The payload is 10 kg for both the single axis and sub-arm models. Typically, this robot is to be controlled by the proven R8.2 control.
The new wheel dryer DRYMAX Aton unites the advantages of a constant dew point with high energy efficiency. The dryer achieves these very contradictory requirements through the completely new structure of the wheel as well as by a patented operating mode, the so called EcoMode.
The WITTMANN drying wheel consists of a series of chambers, which houses a loose accumulation of molecular sieve. This construction explains the high energy efficiency, as strong air circulations on the molecular sieve enable increased energy and heat transfer. Current honeycomb wheels in contrast consist of linear carrier foils, to which the desiccant is attached to, but from a design standpoint only minor air circulations are achieved. This results in higher energy consumption in relationship to their dry air capacity.
Depending on the degree of water load of the dryer the DRYMAX Aton works either in continuous wheel mode or the energetically preferable quasi-2-bed mode, the EcoMode. The dry air capacity reaches 70 m³/hr or 120 m³/hr, whereas any compact dryer configuration consisting of 1, 2 or 3 drying hoppers can be realized. The dew point reaches in practically all climatic ambient conditions a value of -40°C (-40F) to - 60°C (-75F).
The FEEDMAX B and BS/6 series loaders are built for highest functionality and demanding applications. The modular design of these vacuum loaders guarantees flexibility to meet individual customer requirements for material throughput as well as for simple cleaning.
TEMPRO plus D: The New Temperature Controller with Touch Screen
The TEMPRO plus D embodies additional developments from the already successful TEMPRO plus C series. As a unique enhancement, the new plus series has a color touch screen control providing a superior user interface.
The new WITTMANN temperature controller generation is technically based on the successful TEMPRO plus C series. The D series employs a pressure free fluid tank for the 90 °C model, while the pressurized heating and cooling chamber units are available for temperature ranges of 140 °C, 160 °C up to even 180 °C. Several versions of the new TEMPRO plus D model are offered in either single zone as well as dual zone configurations to meet the varying demands of the users.
The new gravimetric blender GRAVIMAX 14V presents itself with a completely new material mixing bowl, which opposes the creation of static charges in the master batch. Usually the master batch or different material combinations have tendencies to accumulate static charges, which is further aggravated by the previous conveying process or the motions in the mixer. However this static causes problems for a homogeneous mixture and directly influences the blending result.
The new mixing bowl with integrated "charge breakers" produces a uniform mixing of the single components, which were precisely dosed in the previous step by the WITTMANN specific RTLS (= Real Time Live Scale) method.
SUMO Junior 2 Compact Granulator
The SUMO Junior 2 C screenless granulator fits perfectly into the product portfolio between the SUMO Minor 2 and Junior 2 granulators. Because of the reduced floor space requirements (approximately 40% less than the Junior 2) this granulator is ideally suited for use beside the molding machine. Like the Junior 2, this model is also designed for the recycling of bigger sprues and hard or filled plastic parts.
- Cutting chamber: 240 x 346 mm
- Knives: 2
- Rollers: 3
- Power: 1,5 kW
- Rotor speed: 27 rpm
- Average throughput: 20 kg/hr
In addition the granulator model MAS2 is displayed as representative of the MAS series of compact granulators. The WITTMANN MAS series conventional granulators have been developed specifically for the recycling of soft to medium hard plastics.
The very compact design allows the MAS granulators (MAS1 to MAS4) to be used directly beside the injection molding machine. The hoppers are manufactured with a special sandwich design to provide optimal sound insulation for low noise operation.
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