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SmartPower COMBIMOULD Highly versatile multi-component injection molding
SmartPower stands for the WITTMANN BATTENFELD injection molding machines with small to medium clampingforcesizes(25to400t),featuring ahighlyeffcientservo-hydraulicdrive systemcombined withacompact hydraulicclamping unit andleaninjectionunits intheinternationalstandard sizes of 60 to 3400.
Combimould stands forWITTMANN BATTENFELD's multi-component injectionmolding technology.ln this processabasicpartisproducedinthefirstinjectionmoldingstation,thenplasticcomponents indifferentcolorsormadeofdifferentmaterialsareadded inoneorseveralmoreinjectionmolding stations,allinonecyclicalsequence.Inthisway,variousmaterialaributesarecombined witheach other to create a composite part of better quality interms of visualattractiveness andfunctionality. This materialcombinationtechnology canbeused toproduce individualparts as wellasintegrated components joined togetherby assembly injectionmolding.Depending onthepartsgeometry in each case,this requires different process variants (for details see page 4).
SmartPowerCombimould from60 to400tstandsforthecombinationof SmartPowermachines with one or several additional plasticizing/injection aggregates in various configurations.
ortechnicaldetailsofstandardSmartPowermachinesseetheSmartPowerbrochure.
SmartPower Combimould Applications
》Back molding
Simplebackmolding of two orthreeplasticlayers onabasepart orcertainareasthereof isthemost frequent application.Examplesaredecorations or anti-wearprotectionlayers.
》Assembly injection molding
By targeted use of the differencesinattributes of the plasticmaterials combined with each other,assembliescanbeproduced with individual movable or detachable parts.Examples are flexible toyfigures, chainlinks,switch rockers or spout closures with resealing caps.
》Hard-softcomposites
Animportant field of applicationfor assembly injectionmoldingissealinstallation.nthisprocess,sealing lipsmadeofsiliconeorthermoplasticelastomerscan bemolded directlyontohousingbodiesortechnical parts in a second injection molding step.
》Overmolding
"Overmolding" is a special form of hard-soft combination,wheresoft,skid-resistantsurfaces arecreated onhousingpartsorappliancehandleswithelastomer layers.
Sandwichinjectionmolding-co-injection technology This processserves toproduce parts with a three-layer structure,consisting of two continuous outersurface layers andacore layer.Interms of processtechnology. this is achieved byconsecutive injection of two materials through the same nozzleinto a conventional mold. A foamed orreinforced core componentimproves the part's mechanical attributes.Costs can be reduced by using regrind and Cellmould foam technology.The surfacelayers consisting of high-grade materials provide the desired high-quality surface attributes.In the packagingindustry,barrierlayers canbeincorporated in theparts.Reproducible,attractive marbling effects canbe achieved by switching several times between two materials of different colors.Depending on the areaofapplicationandtherequirementstobemetby theproduction equipment,a sandwich adapterplate or a sandwich and interval nozzle is used.
COMBIMOULD PROCESSTECHNOLOGY Optimally coordinated solution
》Rotary unit process
The standard process
Rotaryunit technologyisthemostfrequentlyused Combimould variant.Iit is used both for overmolding and back molding.Here,the ejectorhalf of an \mathsf{X}+ X-cavity mold is mounted on a rotary unit.The rotary unit canbe designed for alternating rotation movements of +/- 180 degrees (2 stations),120 degrees (3 stations) or 90 degrees (4 stations). Following theinjectionmoldingprocessinstation 1,thebasepart produced thereis transferred to the overmolding station by opening and rotating the mold half on the ejector side.Parallel to molding the additionalcomponents in the subsequent stations,the next base part is produced in station1.The finished part is removed from thelaststation.
》Indexplateprocess For complexpartdesign
Inindexplatetechnology,therotation and transfer mechanism is an integral part of the mold.This processmustbe appliedif the second component is to be added on both sides of the part.To this end,the preformmustbetransferredtoa station toreceivea modified shape onbothsides.Thisis carried outwith thehelpof anintermediate plateinside themold,also known asindex plate,by which the parts are lifted out ofstation1,turned andthenre-inserted intostation2. The drive systemfortheindexplateiseitherintegrated in the mold or maybe connected to the machine with a servo-electric drive.Rotations of +1 180 degrees(2 stations), 120 degrees (3 stations) or 90 degrees (4 stations) are possible.Theindex plate system offers themaximum possible flexibilityformoldedparts engineering.
》Transfer process
Forspecial cases and small seriesprojects
This process is used as an alternative to the index plate process where the molded part No. 1, due to its geometry,has aninsufficientcontactareaontheindexplate forbeing transported bytheindexplatebetween the injectionmoldingstations.Othertypesofapplications are combinations of bulky inserts (such as screwdrivers or knife blades) with plastic components,ora low-cost production alternativefor small series.
》Valvegateretractionprocess
Toaddflatcomponentswithoutpartstransfer
Invalvegatetechnology,the second componentis addedwithoutpriormoldopeningandrotation.The differentgeometryrequired insidethecavityisproducedbyahydraulicvalvegatewhich,whenretracted， providesthespaceforaddingthe second component.
In spite of a longer cycle time due to serial productionsteps,thevalve gateprocess maybe ofinterest economicallyinmold technologyforsmall numbers of unitsbecause of thelowercost of mold technology. Insomecases,the compactmold designevenallows the use of smallermachines.However, a possible use stronglydependsonthedesignofthemoldedpart and onflat geometries of the additions.
(3) Sensitiveandprecise
In theSmartPower clamping system,the exclusive function of the tie-bars is to provide the force bond between the external platens.The moving platen travelswithout tie-bar contact onthelinearbearings,virtuallyfree of friction. The tie-bars and the machine frame canbe supplied with a greater length as an option.
》Fastmovements
The moving platen is driven by two traveling cylinders mounted in a diagonal position.The combination of these traveling cylinders witha hydraulic differential gear system enables fast movements.The traveling cylinders are dimensioned for high mold opening forces.
》Amplespaceandsymmetricalforcedistribution
Generously dimensioned mold platens and a clamping system withevenly distributed centralhydraulicforcetransmissionoffertheoptimalenvironment for all types of molds.The free space between the tie-bars and the machine frame provides ample space for lateral media supply connections and keeps the ejection chutefree.
》Flexible in the mold space
The SmartPowerclampingsystemis designed according to a modular concept and can be easily adapted to larger opening strokes or mold heights,which is oftennecessarytoaccommodatemulti-componentmolds.
》Tie-barremovaldeviceavailableasstandard
For the insertion of bulky or extra-large molds,one of the tie-bars canbe retracted and subsequently returned to its original position in just a few steps.
SERVO-ELECTRICROTARYUNIT Fast and precise
ForSmartPower Combimouldmachines,rotaryunits withaservoelectricdrive andrangingfrom600 to 1090~\mathsf{mm} indiameter are available as an option.
》Specifictechnical data
Shortrotationcycletimesthankstoservo-electricdrive
Allrotaryunitsarelaidoutforrotaryfeed-throughofthe connected media-for up to 12 media circuits(temperature control,pneumatics,hydraulics)as well as power circuits and sensors.
-All rotary units are available for 2, 3-and 4-station operation.
-Availableforbothreversing and round-loop cycles Accurate positioning with electronic rotation angle measurement End position dampening Indexing device
Rotation parallel to machine and robot movements possible
-Rotationmodule can be deactivated via control system
-Easy,flexible installation and removal possible
》Extension options
Extendednumberofmedia circuits Customized ejectorpositions Installationof magneticmoldplatens Datatransfermodules
INJECTION UNIT The right combination for every application
Inadditiontothe(horizontal)aggregateincludedinseriesproduction,SmartPowerCombimouldmachines can befitted with additionalaggregates inV(vertical),L(horizontalatthe rearof the machine),S(diagonalor"piggy-back")orH-H(horizontal,parallel sideby-side)configurations.Thehydraulicdrive modules are alllocatedinsidethemachineframeandareactivatedviaindependentamplifersystems.Simultaneous, paralleloperationofallinjectionunitsispossibleasstandard.Allprocessvariantscanbeset individuall.
》Vconfiguration
Injectionfrom above,alsointo the mold parting line
Positioned diagonally above horizontal injection unit
Compact machine design
-Small footprint
-S and H aggregates movable independently
-Individually adjustable,moment-free nozzle contactforce
-Excellent nozzle accessibility
》Lconfiguration
Injectionfrom the non-operatorside,eveninto the mold parting line
-Slide device free onthe rear of the fixed platen
-Injection unit supported onlinear guides
-Large adjustment range
-Access to the nozzlesand to the mold from the rearvialargeoperatorsafetygate
-Fixedplatenfreeforstandardlinearrobot
-Nozle position stroke measurement incl. display in control system
》H-H configuration
Two parallel horizontal aggregates
-Both aggregates movable independently of each other
- Good thermal separation of the aggregates
Compact configuration
-Easy barrel change
-Brief material testing
H-H combination and other configurations and more than2injection units upon request
DRIVETECHNOLOGY Efficient through "Drive-on-Demand'
Fast response,precise,economical
"Drive-on-demandistheinnovativecombinationofafast-response,speed-controlled,air-cooledservo motorwithafixed displacement pump.Thisdrive unit isonly activated whenrequired formovements and pressure generation.During cooling periods orcycle breaksfor partshandling,the servo driveis switched offand consumes no energy.Whenin operation,“Drive-on-Demand" is the basisforhighly dynamic, controlled machine movements and short cycle times.
In the SmartPowermachine series,the“Drive-on-Demand”systemisstandard.Inthis way,it already complies today with the EU EnergyEfficiencyDirective.
Parallel operation of all injection aggregates possible
In theCombimouldmachines,every plasticizing/injection unit is drivenby its own pump aggregate. The additionalaggregateforthesecond injectionunit isintegrated intheoiltankuptoaggregatesize 350,frominjectionunit size525upwards asasecond hydraulicmodulebesidethestandardaggregate. This concept allowsunrestricted paralleloperationofallinjectionunits including ejectorandcore pulls parallel to the clamping stroke.
Sinceallmotorsandpumpscomewithasoundinsulatedenclosure,theoperatingnoiseleveliskept below 65 dbA.It is thus just as low as that of theSmartPowersingle-component machines.
UNILOG B8 Complex matters simplified
The Unilog B8machine control system is the WITTMANN BATTENFELDsolution to facilitate the operation of complex processes forhuman operators.Forthis purpose, theintegratedindustrial PChasbeen equipped with an enlarged intuitivetouchscreen operator terminal.Thevisualizationscreenistheinterfaceto the newWindows10 loT operating system, which offers extensive process controlfunctions.Next to the pivotable monitorscreen,a connected panel/handset ismounted on the machine's central console.
Unilog B8
Highlights
》Operating logic
withahighdegreeofself-explanation,similar moderncommunicationdevices
》2majoroperating principles
Operating/movementfunctionsviatactilekeys Processfunctions on touch screen(access via RFID, key card or key ring)
_{\mathfrak{D}} Processvisualization via 21.5" touch screen display (full HD), pivoting laterally
》Newscreenfunctions
UniformlayoutforallWITTMANNappliances
Recognition of gestures(wiping and zooming by
finger movements)
Containerfunction-splitscreenforsub-functions
and programs
》Statusvisualization
uniform signaling system across the entire WITTMANN Group
-Headline onthe screen with colored status bars and pop-upmenus
AmbiLEDdisplayonmachine
》Operatorassistance
QuickSetup:processparametersettingassistant using anintegratedmaterial database anda simple query system to retrievemolded part data with machine settings pre-selection Extensivehelplibraryintegrated
COMBINATION OPTIONS SmartPower Combimould
| SmartPowerCombimould60/80/90 | |||||
| Injectionunit | 60 H | 130 H | 210 H | 350H | |
| 60 | V-L-S | V-L-s | V-L-S | ||
| 130 | V-L | V-L-S | V-L-S | ||
| 210 | V-L | V-L | V-L-S | ||
| V-L-S | |||||
| SmartPowerCombimould110/120 | |||||
| Injection unit | 130 H | 210 H | 350 H | 525 H | |
| 60 | V-L-S | V-L-S | V-L-S | V-L-S | |
| 130 | V-L-S | V-L-S | V-L-S | V-L-S | |
| 210 350 | V-L | V-L-S | V-L-S | V-L-S | |
| V-L | V-L | V-L-S | V-L-S | ||
| SmartPowerCombimould XL120/160/180 | |||||
| Injectionunit | 210 H | 350 H | 525 H | 1000 H | |
| 60 | V-L-S | V-L-S | V-L-S | 750 H V-L-S | V-L-S |
| 130 | V-L-S | V-L-S | V-L-S | V-L-S | V-L-S |
| 210 | V-L-S | V-L-S | V-L-S | V-L-s | V-L-S |
| 350 | V-L | V-L-S | V-L-S | V-L-S | V-L-S |
| Injectionunit | 350H | 525 H | SmartPowerCombimouldXL180/210/240 750 H | 1000 H | |
| 60 | V-L-S | V-L-S | V-L-S | 1330 H V-L-S | |
| 130 | V-L-S | V-L-S V-L-S | V-L-S | V-L-S | |
| 210 | V-L-S | V-L-S | V-L-S | ||
| 350 | V-L-S | V-L-S V-L-S | V-L-s V-L-S | V-L-S | V-L-S V-L-S |
| SmartPowerCombimouldXL240/300/350/400 | |||||
| Injection unit | 525 H | 750 H | 1000H | 1330 H | 2250 H |
| 60 | V-L-S | V-L-S | V-L-S | V-L-S | |
| 130 | V-L-S | V-L-S | |||
| V-L-S | V-L-S | V-L-S | V-L-S | V-L-S | |
| 210 350 | V-L-S | V-L-S | V-L-S | V-L-S | |
| V-L-S | V-L-S | V-L-S | V-L-S | V-L-S | |
| H | horizontal | S | slanted from above |
| V | vertical | L | horizontal fromrear |
DATA SmartPower Combimould 60-400
| SmartPowerCombimould 60/80/90 | SmartPowerCombimould 110/120 | SmartPowerCombimould XL120/160/180 | ||||||||||
| Injection unit H | 60 130 | 350 130 210 | 525 | 210 350 525 | 750 1000 | |||||||
| Weight") | kg | 4700 4800 | 4900 6300 | 350 6400 6400 | 6500 9300 | 9300 9500 9500 | ||||||
| L | mm | 4900 4200 | 4600 | 5300 | 10200 | |||||||
| W | mm | 1450 | 1500 | 1650 | ||||||||
| H | mm | 2100 | 2100 | 2200 | ||||||||
| 350 | ||||||||||||
| Injection unit V 60 130 210 60 210 350 130 | ||||||||||||
| HV | mm | 3400 | 3400 3600 | 3500 | 130 3500 3700 | 60 3600 | 210 3600 3800 | 3900 | ||||
| EV | mm | 170 | 190 | 3800 | 220 | |||||||
| DV | mm | 60 | 60 | 60 | ||||||||
| W | mm | 90 | 90 | 115 | ||||||||
| SV | mm | 75 | 100 | 125 | ||||||||
| Injectionunit L 60 | 130 210 60 | 210 350 | ||||||||||
| BL | mm | 1600 | 1600 | 1850 | 1600 | 130 1600 | 210 1850 | 350 1850 | 60 1600 | 130 1600 | 1850 | 1850 |
| EL | mm | 195 | 215 | 245 | ||||||||
| DL | mm | 60 | 60 | 60 | ||||||||
| VL | mm | 90 | 90 | 115 | ||||||||
| SL | mm | 75 | 100 | 125 | ||||||||
| InjectionunitS | 60 | 130 | 210 | 60 | 130 | 210 | 350 | 60 | 130 | 210 | 350 | |
| HS | mm | 2600 | 2600 | 2750 | 2650 | 2650 | 2800 | 2900 | 2650 | 2650 | 2800 | 2900 |
| ES | mm | 30 | 30 | 30 | ||||||||
| AS | mm | 125 | 125 | 150 | ||||||||
| SmartPowerCombimould XL180/210/240 | SmartPowerCombimould XL240/300/350/400 | ||||||||||
| 350 | 525 750 | 1000 | 1330 | 525 | 750 | 1000 | 1330 | 2250 | Injection unit H | ||
| 13000 | 13200 13200 | 13700 | 13700 | 16200 | 16200 | 16900 | 16900 | 18900 | kg | Weight!) | |
| 5800 | 7200 | mm | L | ||||||||
| 1800 | 1950 | mm | W | ||||||||
| 2400 | 2500 | mm | H | ||||||||
| 60 | 130 | 210 | 350 | 60 | 130 | 210 | 350 | Injection unit V | |||
| 3800 | 3800 | 4000 | 4100 | 4000 | 4000 | 4200 | 4300 | mm | HV | ||
| 245 | 295 | mm | EV | ||||||||
| 75 | 75 | mm | DV | ||||||||
| 150 | 150 | mm | W | ||||||||
| 125 | 175 | mm | SV | ||||||||
| 60 | 130 | 210 1850 | 350 | 60 | 130 | 210 | 350 | Injection unit L | |||
| 1600 | 1600 | 1850 | 1600 | 1600 1850 | 1850 | mm | BL | ||||
| 270 | 325 | mm | EL | ||||||||
| 75 150 | 75 | mm | DL | ||||||||
| 150 | mm | VL | |||||||||
| 125 | 175 | mm | SL | ||||||||
| 60 | 130 | 210 | 350 | 60 | 130 | 210 | 350 | Injection unit S | |||
| 2750 | 2750 | 2900 30 | 3000 | 2850 | 2850 | 3000 | 3100 | mm | HS | ||
| 30 | mm | ES | |||||||||
| 150 | 200 | mm | AS | ||||||||
| 60 | 130 | 210 | ||||||
| Screw diameter | mm | 14 18 | 22 | 18 22 | 25 | 30 | 25 30 | 35 |
| Screwstroke | mm | 70 90 | 90 | 90 110 | 125 | 125 125 | 150 | 150 |
| Screw L/D ratio | mm | 20 | 20 20 | 22 | 22 | 22 | ||
| Theoreticalshotvolume | cm3 | 10.8 22.9 | 34.2 | 22.9 41.8 | 61.4 | 88.4 | 61.4 106 | 144 |
| Specific injection pressure | bar | 3000 2593 | 1736 | 3000 2864 | 2218 | 1540 | 2940 2042 | 1500 |
| Max.screw speed | min"1 | 436 | 278 | 310 | ||||
| Max. plasticizing rate (PS)2) | g/s | 1.5 4.4 | 6.4 | 2.8 4.1 | 7.5 | 10.7 | 8.2 12 | 18.6 |
| Screw torque | Nm | 65 120 | 231 | 120 238 | 340 | 357 | 340 490 | 490 |
| Nozzle stroke/contact press | mm/kN | 250/47 | 250/47 | 250/86 | ||||
| Injection rate into air | cm3/s | 28.6 47.3 | 70.6 | 28.6 42.8 | 55.2 | 79.5 | 59.5 85.7 | 117 |
| Barrel heating power | kW | 2.9 5.5 | 6.3 | 5.5 6.3 | 9 | 10.4 | 9 10.4 | 10.4 |
| Number of heating zones | 4 | 4 | 4 | |||||
| 350 | ||||||||
| Screwdiameter | mm | 30 35 | 40 | |||||
| Screw stroke | mm | 150 | 175 175 | |||||
| ScrewL/Dratio | mm | 22 | ||||||
| Theoretical shot volume | cm3 | 106 169 | 220 | |||||
| Specific injection pressure | bar | 2835 | 2083 1595 | |||||
| Max.screw speed | min"1 | 298 | ||||||
| Max. plasticizing rate (PS)2) | g/s | 11.6 | 17.9 28.5 | |||||
| Screw torque | Nm | 600 | 621 621 | |||||
| Nozzle stroke/contact press | mm/kN | 250/86 | ||||||
| Injection rate into air | cm3/s | 74.1 101 | 132 | |||||
| Barrel heating power | kW | 10.4 10.4 | 12.9 | |||||
| Number of heating zones | 4 | |||||||
Rotary table on the moving platen
| 60/80 /90 | 110 /120 | XL 120/ 160/ | XL 182/210 / | XL 240 /400/ | ||
| Diameterrotationunit D | mm | 600 | 680 | 750 | 910 | 1090 |
| Height stand,/from6 cooling circ. | mm | 120 | 120 | 120/140 | 180/200 | 180/200 |
| Weight | kg | 450 | 550 | 700 | 1300 | 1700 |
| Rotation time 180° | 1.0 | 1.0 | 1.2 | 1.4 | 1.6 | |
| Number of cooling and/ or hydraulic circuits | Z1 - Z4 | 2 x G 3/8" | 2 x G 3/8" | 2 x G 3/8" | 4 x G 3/8" | 4 x G 3/8" |
| Min.mold diameter | mm x mm | 246 x 246 | 296 x296 | 346 x346 | 396x396 | 446 x 446 |
| Max.mold diameterw | mm | 650 | 720 | 800 | 945 | 1120 |
| Max.total mold weight | kg | 900 | 1100 | 2000 | 3000 | 3000 |
| Max.mold weight on rotation unit | kg | 600 | 700 | 1200 | 2000 | 2000 |
| Max.mold torque on rotation unit | kgm | 135 | 135 | 230 | 600 | 600 |
| SEPCTEUROMSAP | inch | 7" × 7" | 16" x 4" | 16" x 4" |
Due to the great variety of TPE types,the bonding strength mustbe checked in each individual case.
The bonding strength also depends on the part geometry,process conditions and processes involved.
Bonding of thermoplasticmaterialsinmulti-component injectionmolding
| TPE based on polyamide | TPE-polyester- elastomers | TPE based on polyolefin | TPE based on styrene | TPEthermoplas- ticplyurethane | TPE types with modified adhesi- veproperties | |
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| CA | ||||||
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| PBTP | ■ | 口 | ■ | # | ||
| PC | ■ | 口 | ■ | 口 | # | |
| PC/ABS | ■ | 口 | ■ | 口 | # | |
| PC/PBT | ■ | 口 | ■ | 口 | ||
| PC/PET | ■ | 口 | ■ | 口 | ||
| PE | ■ | 口 | 口 | |||
| PETP | ■ | |||||
| PMMA | 口 | 口 | ||||
| POM | ■ | |||||
| PP | ■ | ■ | # | |||
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| PAN | ■ |
WITTMANNBATTENFELDGmbH WienerNeustadterStrasse81 2542 Kottingbrunn|Austria Tel.: +43 2252 404-0 info@wittmann-group.com www.wittmann-group.com
