该页无缩略图
world of innovation
MicroPower 15 t
The best for micro injection molding
2
PRECISE − EFFICIENT − ECONOMICAL
The optimum for all types of micro parts
The advantages
» Reliable injection molding technology for shot weights from 0.05 to 4 g
» 2-step injection unit with screw plasticizing and plunger injection
» Energy-efficient, all-electric “Drive-on-Demand“ motor system
» Innovative 5-point toggle lever clamping unit
» User-friendly through new Unilog B8 control system with integrated assistance systems
» Compact machine cell to accomodate a rotary table, robot, quality accurance system and conveyor belt
inside the machine
» Matching integrated auxiliaries available (material dryer, material loader and temperature controller)
» Easy conversion into a clean room cell by adding a laminar flow unit
» Also as 2-component machine with second injection module and an adjusted rotary table available
The machine series
MicroPower standard: 1 clamping force size – 15 t
MicroPower Medical: for clean room applications – 15 t
MicroPower Combimould: for multi-component injection molding – 15 t
3
MicroPower
The system highlights
» Clamping unit – all-electric – with optimal access
The MicroPower clamping unit is a 2-platen system, in
which the clamping force between the nozzle and the
toggle lever side is transmitted by a U frame element.
The moving platen is driven by an integrated, highprecision 5-point toggle lever. It moves the mold platen
guided with high precision on linear bearings smoothly
and with high dynamism.
» Plasticizing unit: best control of micro quantities
Three injection unit sizes are available for MicroPower
machines, with shot volumes ranging from 1.2 to 4
cm3
. In all three of these aggregates, plasticizing is
effected by a 14 mm 3-zone screw with a 20:1 L/D
ratio. Injection takes place via a plunger either 5 or 8
mm in diameter, with injection pressure of up to 3000
bar and with an injection speed of up to 750 mm/s.
» Small platen drillings – optimal force transmission
The small through holes of only 26 mm in both mold
platens enable optimal clamping force transmission
into the mold, thus providing ideal conditions for high
precision and long service life of the molds.
» All-in-one production cell available on request
The MicroPower system is totally modular. Therefore it
can be extended into a complete production cell inside
the standard machine frame by adding a WITTMANN
SCARA robot, a rotary table, an optical parts inspection system and a conveyor belt or glass container for
finished parts.
» Clean room-compatible standard concept
The standard machine frame is designed for easy
cleaning. Without any structural alterations, it can be
combined with a laminar flow unit, which supplies
class 7 clean air according to ISO 14644-1 standard.
Hygienic depositing of the finished parts is possible
within the clean room cell strictly according to cavities
in an 8-compartment depositing unit with glass
containers.
4
CLAMPING UNIT
Free mold space
» High precision
The MicroPower clamping unit meets the most stringent requirements for precision in movements and automation options. Its
high standard of precision is achieved by guidance of the system
platen on the clamping side and the mold carrier plate on the
same linear bearings. The central positioning of the toggle lever
inside the U frame clamping unit ensures symmetrical clamping
force transmission into the mold.
» One machine size as standard
– The clamping unit is available with 15 t clamping force.
– The mold platens on the ejector side come in one uniform size
of 240 x 248 mm as standard.
– The width of the fixed platen is 240 mm.
– The maximum daylight between platens is 400 mm.
» Free access and flexible automation
– Thanks to the U frame, the mold space remains free of
tie-bars.
– Ample space is provided on both sides of the U frame for the
installation of a rotary table (rotation diameter 443 or 466
mm), a parts handling robot and other auxiliaries for quality
inspection and parts depositing.
*
5
INJECTION UNIT
Specially designed for micro parts
Anti-wear options
In addition to the high-quality
standard finish, an extensive range
of optional versions with extra
anti-wear and/or anti-corrosion
protection is available. Pre-defined
option packages and a selection
matrix facilitate the choice of the
right version.
» Injection unit for extremely small quantities
The MicroPower injection unit is equipped
with a two-step plasticizing and injection
unit. It is available in three sizes.
What all three sizes have in common
is their 14 mm plasticizing screw for
processing standard-size granulates.
The injection plunger comes in
different sizes. They are available
for shot volumes ranging from
1.2 to 4 cm3
.
» One system for 3 shot volume levels
The MicroPower plasticizing and injection aggregate is a 2-step
unit. Step one is plasticizing with controlled back pressure. Step
two is a separate plunger injection unit. The plunger of this aggregate functions simultaneously as a shut-off device to separate
the melt channel of the plasticizing unit from the injection unit.
Behind the injection plunger, an injection pressure sensor is
located, which actively regulates the injection process and thus
controls the precision and consistency of the molded parts.
The advantages of the MicroPower injection unit
» Low-stress metering at low pressure
» System without check valve, therefore no damage to materials
through shear stress
» FI-FO injection process (first in – first out)
» Minimal pressure loss during injection
» Extremely small melt cushion, consequently high temperature
stability of the shot volume
» Shot weights below 50 mg possible
» All standard granulates can be
processed.
6
» Highly dynamic electric servo drive
– Short rotary times
– Parallel movements possible
– Short cycle times
» Short changeover times
– Optimal accessibility
– Easy mold insertion and removal
– Direct plug-in media connections for pneumatic
systems/water
– Media supply via covered energy chain
» Great flexibility
– Location of ejector in both injection stations
– Servo-electric ejector control for ultimate precision
– Use as a 2x1-component machine also possible
» Sensitive and accurate
The rotary plate moves virtually without friction on
its linear bearings. The mold protection system is
very finely adjustable and thus ensures optimal mold
protection.
» Clean room-compatibility as standard
– Smooth surface for fast cleaning
– Encapsulated structure
– Stainless steel cover
The all-electric rotary unit is laid out for running in the +/- 180° mode. The rotary table
features high dynamism, flexibility, operational safety and mold protection packed into
a minimum of space. The robust basic structure provides optimal clamping force transmission. In combination with the backlash-free toggle lever, it thus enables extremely
energy-efficient operation of the machine. The direct drive situated behind the rotary
table combines ultimate precision with high rotary speed.
CLAMPING UNIT − COMBIMOULD SOLUTION
Fast rotary unit
7
INJECTION UNIT − COMBIMOULD SOLUTION
Designed for molding micro parts
» Parallel operation of the injection units possible
In the MicroPower Combimould machine, both plasti-cizing
and injection units can be operated parallel to
each other. This equally applies to the ejectors, core pulls
and air valves, which can be operated parallel to the
clamping movement.
» H-H configuration
Two parallel horizontal aggregates
– Both aggregates moveable individually
– Effective thermal separation of the aggregates
» Flexible, modular, compact
– Fast changeover between the injection units
(PIM, LIM, thermoplastics)
– All standard granulates can be processed.
– Part weights below 50 mg possible
– Easy barrel change
» Ultimate prescision
– 2-step screw-and-plunger system
– Minimal injection times
– Optimal injection pressure control combined with
highly dynamic changeover to holding pressure.
2-component injection molding
A 2-component machine also is available by combining two injection aggregates placed next to each
other and using a rotary table inside the clamping unit.
8
clean room
rotary table
tempering device
camera monitoring
stacking module
handling device
material dryer
material feeder
MicroPower
Production cell “ex works”
The production cell concept is an “ex works” solution
for MicroPower injection molding machines.
The advantages of the MicroPower production cell
» Machine frame closed on all sides as standard.
Thus molding of the micro parts takes place in
an isolated environment.
» The enclosed machine cell is designed to provide
space for additional equipment modules inside
the standard cell.
» The enclosed cell can be fitted with a clean
room module. It consists of a suction filter and a
ventilation unit for laminar air flow through the
machine.
» Cost benefits, since all danger areas are covered
and certified ex works.
» MicroPower clean room production cells are
suitable for producing micro parts for medical
technology, as well as the electronics, watch
making and optical industries.
» CE mark included for every machine with an
insider solution. No separate costs for individual
examinations.
CE-certified by type examination
9
MicroPower
The option highlights
» Rotary table
The rotary table enables use of 2 bottom mold halves
to achieve shorter cycle times on the one hand, and
on the other hand to implement insertion and removal
processes. In the multi-component version, the rotary
table serves to accommodate the two different mold
halves.
» Silicone processing in micro dimensions
For liquid silicone processing, for example in the
production of medical components, a micro two-component material loader is available, including a blending and metering system. With this equipment, the
machine can be quickly converted from thermoplastics
to LIM injection molding.
» High-precision coining (Expert-pvT-Coining)
For the production of optical or micro-structured
parts, a high-precision coining system is available as
an optional equipment package. In this process, the
coining pressure is controlled with high dynamism via
the clamping stroke, depending on mold temperature
or cavity pressure.
» HiQ control for hot runners
With decreasing part size, the proportion of sprue in
the shot volume increases, due to the nature of the
system. Minimizing the proportion of sprue is given
a high priority in WITTMANN BATTENFELD product
development.
» WITTMANN auxiliaries in micro dimensions
The optional Wittmann 4.0 auxiliaries integration package is the basis for “Plug & Produce” technology of
WITTMANN BATTENFELD injection molding machines
with auxiliary units from WITTMANN.
WITTMANN auxiliaries specially developed for the
MicroPower:
– Tempro plus D Micro 100/140/160
– Drymax Micro F2-15 compact + material loader
– W8VS2 Vertical SCARA
– W8VS4 Vertical SCARA
OPTIONEN
Flexible – proven – powerful
1010
UNILOG B8
Complex matters simplified
Unilog B8
Highlights
» Operating logic
with a high degree of self-explanation, similar to
modern communication devices
» 2 major operating principles
– Operating/movement functions via tactile keys
– Process functions on touch screen (access via RFID,
key card or key ring)
» Process visualization
via 21.5\" touch screen display (full HD),
pivoting laterally
» New screen functions
– Uniform layout for all WITTMANN appliances
– Recognition of gestures (wiping and zooming by
finger movements)
– Container function – split screen for sub-functions
and programs
» Status visualization
uniform signaling system across the entire
WITTMANN Group. Headline on the screen with
colored status bars and pop-up menus
» Operator assistance
Extensive help library integrated
The Unilog B8 machine control system is the WITTMANN BATTENFELD solution to
facilitate the operation of complex processes for human operators. For this purpose,
the integrated industrial PC has been equipped with an enlarged intuitive touch screen
operator terminal. The visualization screen is the interface to the new Windows® 10
loT operating system, which offers extensive process control functions. Next to the pivotable monitor screen, a connected panel/handset is mounted on the machine’s central
console.
11
“Single point entry”
via router into the Industry 4.0
world
Wittmann 4.0 system
With Wittmann 4.0, a machine and its robots and auxiliaries are transformed into a uniform technical organism,
which communicates externally via a specific IP address.
Such a “Single point entry” with an integrated internal
firewall substantially increases cyber security.
With its communication standard Wittmann 4.0, the WITTMANN
group offers a uniform data transfer platform between injection
molding machines and auxiliary equipment from WITTMANN. In
case of an appliance change, the corresponding visualizations and
settings are loaded automatically via an update function, following
the principle of “Plug & Produce”.
Connection of auxiliaries via Wittmann 4.0
» WITTMANN robots with R9 control system
– Operation of robots via the machine’s monitor screen
– High-speed communication between machine and robot to
synchronize movements
– Important machine movements can be set via the R9 robot
control system
» WITTMANN Tempro plus D temperature controllers
– Setting and control of temperatures via the machine’s control
system possible
– All functions can be operated either on the unit or via the
machine’s control system
Integration in MES system
The integration of machines and complete production cells in an
MES system is a prerequisite for an efficient and transparent production facility according to the Industry 4.0 concept.
Depending on customers’ requirements, small and medium-sized
companies as well as global players are offered a compact MES
solution based on TEMI+. With the Windows® 10 IoT operating
system it is also possible to have selected status information from
all connected machines on the production floor shown under SmartMonitoring on the display screen of every machine.
WITTMANN 4.0
Barrier-free communication
12
APPLICATION TECHNOLOGY
Outstanding competence
» Combimould
Two or more plastic materials in different
colors or with different attributes can be
combined into one part by upgrading the
standard MicroPower with a second micro
aggregate or by combining several machines
into one production unit.
» Insert molding
When individual parts such as plug contacts
need to be insert-molded, an insert station on
a rotary table outside the mold is available
for this purpose. A high-precision SCARA
handling robot and a metal parts feeding
station can be integrated into the machine as
additional modules.
» Clean room injection molding
When medical components or electronic parts
need to be manufactured in a particle-free
environment, the MicroPower concept offers
excellent conditions with its easy-to-clean
mold environment and an optional clean air
supply system.
» Reel-to-reel molding
To produce electronic parts, punched structures are fed through the clamping unit and
insert-molded. The ample mold mounting
space of the MicroPower offers optimal conditions for this process.
Photo: mikrotechnik Freudenreich GmbH & Co. KG Photo: Micro Systems (UK) Ltd.
13
» PIM (CIM/MIM) − Powder Injection Molding
Powder injection molding (PIM) is a manufacturing process for series production of parts
made of metallic or ceramic materials. PIM is
the ideal process to make complex, functional
components with stringent material requirements in large quantities.
» Microstructures
The quality of the plastic melt generated gently and at a constant temperature inside the
MicroPower injection unit is particularly
suited for high-precision reproduction of
micro structures inside the mold, from sensor
structures to Fresnel lenses or copy protection
holograms.
» LIM – Liquid Injection Molding
LIM designates the injection molding process
for making elastic parts from 2-component
liquid silicone rubber (LSR). LIM micro parts
are used for optical and medical applications.
» High-precision micro parts
In addition to standard plastics processing,
the MicroPower injection unit is an ideal
choice for manufacturing high-precision parts
from engineering plastics such as POM, PEEK
or PSU.
Photo: Frauenhofer IFAM
14
STANDARD
Base machine
Paint RAL 7047 tele grey 4
Rectangular main beam on one-piece base frame
Built-in control cabinet
Part transp. on operator side, or parallel to machine axis
Drillings for auxiliary equipment – like robot, camera, etc. – operator
sided on rectangular main beam
Clamping unit
Clamping system: 5-point toggle with servo-electric direct drive
Servo-electric mold height adjustment
Clamping and opening forces for mold safety system adjustable
Mold safety program with envelope curves monitoring for optimal mold
cover
Precise platen parallelism with low-maintenance moving platen support
Platen drillings metrical as per EUROMAP
Clamping force displayed on screen
Clamping force monitoring incl. display via screen
Servo-electric ejector
Mechanical ejector couple
Cooling hole in the mold mounting platen
Injection unit
Servo-closed loop control
Increased injection performance
Screw drive by 3-phase servo motor, screw speed continuously adjustable via screen
Barrel, screw, distributor block and injection nozzle in hot-work tool
steel, injection piston TIN coated
Thermocouple failure monitor
Plug-in ceramic heater bands
Open nozzle
Quick removal for injection nozzle and cylinder
Hopper of V2A stainless steel can be shut and emptied
Linear bearings for the injection unit
Selectable barrel stand-by temperature
Decompression before and/or after metering
Physical units – bar, ccm, mm/s etc.
Screw protection
Auxiliary screw speed indication
Linear interpolation of holding pressure set values
Bar chart for barrel temperature with set value and actual value display
Selectable injection pressure limitation
Changeover from injection to holding pressure depending on stroke,
time and pressure
Safety gate
Maintenance-free safety gate locked by electromagnet
Safety gate with electric monitoring according to CE standard
Safety gate on the rear side
Cooling and conditioning
Watercooling with open cooling system
Feeding zone with controlled cooling system
Additional equipment
Operating instructions
User manual
Electrics
Operating voltage 230/400 V-3PH, 50 Hz
Common voltage supply for drive and heat
Separate voltage supply for drive and heat USA/CDN
USB – 1 x operating unit
1 Ethernet interface (switch cabinet)
Printer via USB connection or network
Signal lamp at the machine
Control system
Control system Unilog B8 – 21,5‘‘ multi-touch screen (full HD)
Software for operating hours counter
Closing/opening – 5 profile steps
Ejection forward/back – 3 profile steps
Injection/holding pressure – 10 profile steps
Injection parallel to clamp force build-up
Screw speed/back pressure – 6 profile steps
Parts counter with good/bad part evaluation
Purging program
Stroke zero offset settings
Start-up program
Adjustable injection pressure limitation
Switchover to holding press. MASTER/SLAVE by injection time, screw
stroke/injection vol. and injection pressure
Self-teaching temperature controller
Display of temperature inside electrical cabinet
Seven-day timer
Access authorization via USB interface, password system and RFID
authorization system
Freely configurable status bar
Physical, process-related units
Energy consumption monitoring for motors and heating
Automatic dimming
Logbook with filter function
User programming system (APS)
Cycle time analysis
Energy measurement displayed
Freely configurable screen pages „user page“
Notepad function
Hardcopy function
Internal data storage via USB connection or network
Online language selection
Online selection of imperial or metric units
Operator manual incl. hydr., mech. and el. schedules online
Time monitoring
Basic Quality Monitoring (1 freely configurable network connection,
quality table with 1000 storage depth, events protocol (logbook) for
1000 events, actual value graphics with 5 curves, 1 envelope curves
monitoring)
Injection integral supervision
Metering integral supervision
Alarm message via Email
SmartEdit – sequence editor
15
OPTIONS
Clamping unit
Servo electric rotary table
Mechanical mold safety mechanism
SPI bolt pattern
Ejector platen safety device as per EUROMAP 13
Parts chute for separation of good/bad parts
Nickel plated platen in lieu of standard
Air valve, action initiated (ON) and timer (OFF)
Non-standard layout of fastening bores in clamping/nozzle platen
Turning-out device with servo motor, installed on ejector plate
Injection unit
Grooves in the feeding zone of barrel for improved feeding
High temperature heaterbands up to 450 °C
Barrel insulation
Enter block with additional connection for nitrogen supply in lieu of
standard
Wear and corrosion resistant injection unit AK+
Equipment package for liquid silicone
Equipment package for PIM (MIM/CIM)
Equipment package for technical plastics (PC, PMMA, ABS)
Equipment package for bioresorbable materials
Screw in special geometry
Conversion kit injection unit reduction to size 3 in AK+
Vacuum package: vacuum pump incl. interface, vacuum valve, vacuum
sensor
Material hopper in DURAN glas design, 0.6 litres in volume
Connecting flange for customer-supplied hopper drier or drying unit
Equipment packages available in lieu of standard and/or in addition
Safety gate
Pneumatic safety gate at the operator side
Initiation of the next cycle by closing safety gate in semi-auto operation
Front side safety system for manual part removal
Pneumatic
Pneumatic maintenance unit incl. pressure regulation
Pneumatic core pullers incl. pressure regulator
Additional compressed-air controller
Cooling and conditioning
Watercooling with closed cooling system
Hosting of cooling circuits on the fixed platen of the moving platen
Integrated WITTMANN temperating units and dryer
Cooling circuits 2x additionally without shut-off valve
Granulat/dryer/feeder
Integrated WITTMANN dryer/dew point sensor
Integrated WITTMANN feeder
Robot/handling unit
W8VS2 WITTMANN Vertical SCARA Robot with 3 servo axis
W8VS4 WITTMANN Vertical SCARA Robot with 4 servo axis
Teachbox R8.2/R9
Additional valve
Additional vacuum circuit (Venturi)
Additional vacuum circuit (Venturi with blow-off function)
I/O expansion control cabinet (8I/8O)
Interface for COGNEX camera
Adapter for gripper plate (EOAT) with crash sensor
Conveyor belt
Electrics
Temperature control zone for hot runner
Special voltage
Control cabinet cooler
Interface for handling equipment
Temperature control interface digital, serial 20 mA TTY protocol
CAN-Bus-interface for mold conditioner as per EUROMAP 66-2
Interface for WITTMANN dryer integrated
Interface for WITTMANN temperating units integrated
Interface for robots as per EUROMAP 67
Interface for robots as per EUROMAP 67 with add. signals for rotary table
Interface for conveyor belt and dosing unit
Interface for full integration of robot incl. Ethernet switch
Host computer interface/PDA (EUROMAP 63)
Relays contact parallel to plasticizing
Kistler module for cavity pressure dependent switchover
BNC connectors for injection process analysis
Machine fault (potential-free contact)
Part inlay monitoring via vacuum
Signal tower with acustic element
CEE socket 16 A
Protection of the socket circuits via residual-current-operating circuit
breaker with 30 mA conventional tripping current
Additional emergency-stop button, mounted on the rear of the machine
Interface evacuation with software (incl. vacuum valves for rotary table)
Interface for freely configurable mold monitoring
Control system
Energy consumption analysis
Switch over to holding pressure by cavity or melt pressure
Switch over to holding pressure by external signal
Injection compression and venting sequences
Second injection data setting for automatic start up
HiQ Cushion − melt cushion control
HiQ Flow − injection integral control
HiQ Melt − monitoring of material quality
Injection compression program/Extended injection compression program
Gate start special program
Special program according to customer specification
User specific limiting input value system
Program in US dimensions
RJG eDart interface
Expert Quality Monitoring (4 freely configurable network connections,
quality table with 10000 storage depth, events protocol (logbook) for
10000 events, actual value graphic with 16 curves, 4 envelope curves
monitoring, SPC charts, trend diagrams)
Add. screen text not according to EU (max. 2 languages in add. to German)
Second injection parameter record for lower mold allocation or injection
parameter change-over during start-up phase
Variotherm processing package
Additional euipment
Special paint and/or touch-up paint
Tool kit
Levelling pads
Lighting in mold space
Distance blocks 100 mm for leveling mounts
Spare parts package
Sprue-cut-off-appliance with air nozzle
Clean room box
Visual quality inspection
Ionization
8-fold parts depositing
WITTMANN BATTENFELD GmbH
Wiener Neustädter Strasse 81
2542 Kottingbrunn | Austria
Tel.: +43 2252 404-0
info@wittmann-group.com
www.wittmann-group.com
MicroPower | Article number: 30062636 (English) | 2022/08 | Subject to change. | Printed in Austria.
