Welcome to the second part of this series about Cyber Physical
Production Systems (CPPS) in plastics industry. (Here is link to part I). In
this part, we will have a detailed look on how parts will be produced by the
injection moulding technique in the future using CPPS applications. I would
like to present to you the point of views of the major injection moulding
machine manufacturers regarding future developments. These will have a major
influence on, whether the CPPS will be a successful story in the future, or not.
Arburg: The
concept of Arburg is based on the individualization of plastic parts in a large
production series. This can be made by combining additive manufacturing with the
injection moulding technique in a digitally networked process chain. In the opinion
of Arburg, Industry 4.0 consists in an individual solution integrated in mass
production. For example, Arburg presented
at the Hannover Fair 2015 (Germany) the production of a “rocker-type light
switch”. This is a mass produced part by injection moulding. However, it can combine
an individualization step by using the Arburg’s Freeformer. For example, the
customer can “paint” his/her signature in a digital terminal (e.g: tablet).This
information is stored on a chip card, which is later placed in the controlling
unit of the injection moulding machine, where part of the information is
converted by laser into a data matrix
code on the backside of the produced light switch. Then, the light switch is
placed into the Freeformer (additive manufacturing unit), where the information
from the chip card is again read and the signature printed on the surface of
the light switch. After this process, an automated quality check is done and
the light switch is packed. In parallel, a homepage with all the relevant production
information is set up enabling worldwide accessibility. The following
youtube-video helps understanding it better.
ENGEL’s
injection
4.0 approach aims at reaching
optimal efficiency, productivity, availability, quality, and flexibility on the
production site. Injection 4.0 has basically 3 core elements: smart machines
(focus on self-adapting, decentralized systems), smart production (horizontal
and vertical data integration) and smart services (focus on remote maintenance
tools). How those three work along each other was shown at the FAKUMA 2015
(Germany). Apart of that, injection moulding machines can be equipped with the
iQ (intelligent Quality)-weight control as well as with the iQ-clamp control.
The iQ-weight control enables a response to viscosity changes during processing.
Every final part will have consistency in weight through the right timed switch
over from the injection pressure to the packing pressure. The iQ-clamp control estimates
the mould breathing and applies the necessary amount of clamping force. This
allows keeping the mould breathing constant although process conditions might
change.
Prof. Helmar Franz from Haitian pointed out at the 2nd International Injection Moulding
Conference 2015(Germany) that the future challenges are in the integration of
injection moulding techniques into other technologies such as thermoforming,
die casting, and additive manufacturing, as well as to integrate other
conversion techniques into the injection moulding technique. Apart of that,
future challenge lies in using the, as he calls it “big data meet machinery”, which
can result in the development of new business models.
Krauss
Maffei continuous its way towards Industry 4.0 with the Adaptive Process
Control (APC), which facilitates quality control by analyzing material induced
interferences over a viscosity number. As a consequence, underfilling and
overfilling processes are minimized. The change-over point will be estimated
for each shot ensuring that switch-over follows at the right time. We still
tend to have a constant process replication, which is from a quality point of
view not efficient enough to resolve influences of material and external
manufacturing conditions.
Sumitomo
Heavy Industries is known for all-electric injection moulding
machines. They put their future outlook in improving the “Zero Molding”, which was
implemented in 2008. The idea of “Zero Molding” together with its functions
Flow Front Control (FFC), Minimum Clamping Mold (MCM), and Simple Process
Setting (SPS) is to enable an optimal production of plastic parts with minimum
defects, faults, and losses. The future zero failure technology, which meets
also the idea of CPPS will contain a web based dialog between production sites,
local affiliates, and SHI Demag. Furthermore, Sumitomo will also provide
platforms for data storage, informatics visualization, and diagnostic
processing.
Let’s jump to the last but not
least manufacturer: Wittman-Battenfeld:
“Wittmann 4.0” is called their main key stone in realizing an overall
integration. The new B6p controlling unit of the injection moulding
machine allows to connect and control all attached robotics and periphery
devices in one uniform windows surface. This allows an optimal organization of
the whole production process, starting from material supply to automation
process. The data is collected and stored in the central mould database. In
case the mould is changed to other machines, the central computer will provide
the devices with the right data. Another learning effect is reached by storing
all production errors and make them accessible. Summing it up: Battenfeld
believes that together with the Internet of things approach, the injection
moulding machines will start communicating, “talking” more to the peripheral
equipment allowing to increase productivity.
To sum up: there are already similarities
in the approaches of all the manufactures, especially when it comes to control occurring
process instabilities caused by material or external influences (ENGEL’s iQ
weight control; Kraus Maffei’s Adaptive Process Control or Sumitomo’s Zero Moulidng
strategy). Furthermore, allover production strategies, where the injection
moulding machine is not just a well-connected piece within the production, have
entered the prototype phase. Fact is that we still plan our products in
a linear way but the world around us changes in an exponential way. CPPS might
helping combating a more exponential way of thinking in the world of plastics manufacturing.
I believe that in the next five years fully integrated CPPS will be state of
the art in plastics industry.
Share this knowledge with your
friends!
Greetings,
Herwig
Literature:
[1] Proceedings 2nd IIMC, IKV Aachen
[2] Kunstoffe, 9/2015, p.103
[3] Kunstoffe, 9/2015, p.32 - 40
