• Costs down, efficiency up: Pilot and assistance function support operators
• Competitive advantage of digitalisation: Produce quality components quickly and economically
• Interlinked: "Smart" production for more flexibility and transparency in injection moulding production
From small contract injection moulding companies to large global players, plastics processors are all facing similar challenges in the current difficult economic environment: they need to react flexibly to market changes and increasing cost pressure if they want to produce products competitively and profitably. Digitalising injection moulding processes can achieve significant benefits here if implemented correctly. Arburg has been dealing with this topic for decades and is on hand with advice and support to help its customers find the "smartest" solution in each case. Digital technologies can be used to produce plastic parts with maximum efficiency, flexibility, transparency and impeccable quality, as Arburg will be demonstrating live in arburgSOLUTIONworld and with numerous exhibits at Fakuma 2024.
Arburg has extensive expertise and a wide range of products and services for implementing customised digital solutions – from control systems and associated assistants developed and manufactured in-house to the company's own host computer and Scada system and the customer portal.
Handling data "intelligently"
The individual solution modules, correctly combined depending on the requirements and environment, provide the answer to what is probably the most important question for Arburg customers in connection with digitalisation: how do I get the data that is relevant to me and how can I use it to make my processes even better, more efficient and more competitive? The key here is that it is not the sheer quantity of data collected, but its quality and relevance that form the basis for successful process optimisation. Artificial intelligence (AI) opens up completely new prospects and possibilities when it comes to processing large amounts of data and drawing meaningful conclusions from it. For example, the relevant data can be used to create forecasts for maintenance requirements (predictive maintenance), generate paperless evaluations and documentation in real time and access injection moulding knowledge with the help of AI-supported apps. In this way, sequences can be dynamically controlled and optimised in "smart" production, allowing available resources to be used even more efficiently – for example in order planning, quality assurance, mould management and maintenance.
Communication in a standardised language
As a rule, temperature control units, robotic systems and other pieces of peripheral equipment are also integrated into the injection moulding process. The aim is for all the components to interact as simply and reliably as possible – ideally from a central control system and on the basis of synchronised values and parameters. To achieve this, data must be exchanged "in one language". The OPC UA interface, which is not tied to a specific manufacturer, is the ideal solution for this. At Fakuma 2024, for example, the LSR dosing unit will be communicating with the Gestica control system via Euromap 82.3 during the production of multi-component spatulas with an Allrounder More 2000. Communication takes place via standard Ethernet and standardised plug connectors. Devices are automatically recognised and integrated into the control system using plug and play. For standardised interlinking, all Arburg injection moulding machines are equipped with an IIoT gateway as standard and have basic connectivity.
Ideally, the "smart" machine is comprehensively interlinked, monitors its processes, controls them adaptively and actively supports operators in intuitively setting up production sequences. Using "smart" services, operators can receive quick and targeted explanations, picture-by-picture instructions and error analyses as required via remote access or an app. If any unscheduled standstills do occur, spare parts can be ordered online around the clock via an interactive catalogue.
Predictive maintenance ensures that things don't get that far. This requires "smart" communication between the machine or production cell and its centrepiece, the injection mould. At Fakuma 2024, an Allrounder 720 E Golden Electric will be equipped with a 24-cavity mould from Hack together with "Moldlife Sense", a computer system that enables sensor-controlled mould monitoring over a mould's complete life cycle, for example, and detects changes to the mould at an early stage. The measured values from various sensors can be visualised in the machine control system and individual events, such as warnings, alerts and error messages, can be displayed and documented. This allows users to identify anomalies in the process quickly and assess what needs to be done.
Setscrews for greater efficiency and reduced costs
To significantly simplify everyday injection moulding using digital products and services, Arburg has developed the arburgXworld customer portal with its many apps, the basic versions of which are even free of charge. On top of this, there are the company's own Selogica and Gestica control systems, including the associated assistance and pilot functions, which visitors can find out more about at Fakuma using a Gestica demonstration model. The control system is the "intelligent" head of the machine and can provide operators with comprehensive and active support during set-up, setup and operation – which quickly pays off in times when skilled labour is in short supply and personnel costs are high. Digital features can be used to unlock significant optimisation potential in injection moulding machines with regard to production and cost efficiency.
• The premium "MachineFinder" app helps users find the most suitable machine from the inventory and immediately provides the corresponding recommended values for initial calculations.
• To keep set-up times short, the "Set-up Assistant" supports operators step by step – from menu-guided mould installation and automatic initial calculation of parameters to teaching in the sequence.
• The "Virtual Control" app provides previews of the sequence programming and can optimise data sets directly on the PC.
• With the help of an AI-supported variant analysis, the injection moulding simulation is automated with the "FillAssist" assistance function and "learns" the effects of changes to machine parameters. The filling simulation integrated into the control system is designed to quickly reach the good part and enter a stable production phase on start-up.
• "EnergyAssist" automatically heats up or deactivates the cylinder module and mould in a consistent and controlled manner, thereby significantly reducing the energy requirement and costs.
• "CycleAssist", which enables the control system to know the programmed cycle, reduces part costs for customers by optimising cycle times. Unproductive times can be eliminated and the cycle time optimised at the click of a button. At Fakuma 2024, this will be demonstrated in a packaging application, for example, with an electric Allrounder 520 A.
• In turn, "Meltassist" automatically calculates the plasticising capacity utilisation and residence times and actively helps to save material.
Improving part quality
One challenge in terms of part quality is the processing of alternative and demanding plastics, particularly post-industrial recyclates (PIR) and post-consumer recyclates (PCR). Even with batch changes or non-homogeneous virgin material, pilot functions in the Gestica control system can ensure stable processes.
• "aXw Control RecyclatePilot" utilises the existing machine sensor systems to reliably even out fluctuating material qualities and keep the shot weight constant. This significantly reduces the reject rate.
• Errors in the filling process can be compensated for with "ScrewPilot" to ensure stable mould filling, while
• "PressurePilot" provides bionically optimised pressure regulation to avoid underfilling or burr formation. Both pilot functions are active in the production of medical syringe plungers with a hybrid Allrounder 570 H.
• "ReferencePilot" enables precise holding pressure regulation with the aid of cavity pressure sensors.
The data from the injection moulding process as well as data relevant to quality and service can also be made available to higher-level software tools and platforms. With the Arburg Turnkey Control Module (ATCM) Scada system, process and quality data can be combined on a part-specific basis and important system functions can be visualised. To achieve this, the injection moulding machine, automation systems and peripheral equipment each send all relevant data to the ATCM. This makes every single moulded part 100 per cent traceable. At Fakuma 2024, a vertical Allrounder 375 V producing vacuum housings will be on show. The part-specific data from the injection moulding process and automation are linked to the results of the visual inspection of the insert. The fully automated application is also an application example of the R-Cycle initiative, in which digital product passports are used to record relevant recycling data in real time during the product life cycle and create the foundation for data-based material flows.
Increasing planning efficiency and creating transparency
IT-networked injection moulding production requires machines to be connected to a manufacturing execution system (MES). The Arburg host computer system ALS is a central MES that can be used to digitally plan, optimally utilise and effectively control the entire production process and track all relevant information.
As early as the planning phase, an assistant can make suggestions for a best-fit machine based on collected production data and user-dependent criteria thanks to an intelligent algorithm. All the information on orders, production progress, set-up times and maintenance is available centrally. The associated data sets can be transferred to the injection moulding machine in a fully automatic process. With the trend towards paperless production, the number of linked production documents is also increasing. Relevant documents are provided for the respective order, regardless of location or media.
One major advantage is that production data can be recorded and analysed in real time. Key performance indicators (KPIs), key figures and production reports help management make the right decisions and adapt to changing conditions with agility. For continuous quality assurance, it is possible to carry out statistical process monitoring (SPC) and evaluate the process parameters of the injection moulding machines in real time, regardless of location.
All in all, ALS ensures greater flexibility, efficiency and transparency in production. On average, overall equipment effectiveness (OEE) and overall plant efficiency can be significantly increased by around 26 per cent with ALS. Linking to the arburgXworld customer portal opens up even more possibilities. ALS and the customer portal are also available as mobile versions for smartphones and tablets. A new and groundbreaking feature is the AI-supported "Ask Arburg" app, for example, which contains easily accessible, comprehensive injection moulding knowledge from Arburg and can answer specific questions about all Arburg products and processes relating to injection moulding.
Summary and outlook
Arburg's comprehensive expertise is embedded in its digital services and products. They are powerful tools that contribute significantly to the future-proofing and resilience of a plastics processing company. They can be used to optimise production sequences, record data in real time and improve and document the quality of moulded parts. This means that getting started with digitalisation is very easy and flexible and pays for itself quickly. Complex production environments and high-precision components in particular require precise process control, and this is where the host computer system, in conjunction with the arburgXworld customer portal, can achieve significant benefits in terms of transparency, process reliability and energy and production efficiency.
As the number one in the industry when it comes to digital transformation, Arburg is also working intensively in the field of artificial intelligence. The aim is for AI-based systems to learn correlations themselves and actively readjust processes in order to optimise the yield and quality of injection moulded parts in series production. Arburg's vision is that, with the help of AI, every injection moulding machine in the future will not only know the processes, but also the products it produces.
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