Control software optimizes clamping force in injection molding process

An addition to the ENGEL iQ family of products was introduced recently with the goal of  sustainably improving the quality of the production process, and finished products. While the iQ weight control software launched by ENGEL  at Fakuma 2012 optimizes the injection process, this time around the focus is in  developing iQ clamp control on the injection molding machine's clamping unit. The software continuously adjusts the clamping force and keeps the mold breathing constant even under fluctuating process conditions.

During the injection process, the inflowing melt exerts pressure that pushes the two halves of the mold apart by a couple of thousandths or hundredths of a millimetre. This process is known as mold breathing. If the mold breathing is too great or too small, this can cause rejects due to flashes or burn marks (diesel effect). If the clamping force is too high, the mold is also subject to excessive stress and clamping force build-up unnecessarily consumes more energy.

To optimize the  clamping force manually, the mold breathing can be determined with the help of a gauge, which is an inaccurate approach as the results are heavily dependent on the position of the gauge. In addition, it takes much experience to interpret them. Many injection molders, thus, work with the maximum clamping force available instead of adapting it to the respective process.

WIth the new CC300 control unit, ENGEL has developed an iQ clamp control software that automatically determines and adopts the optimal clamping force on an objective basis. It is the first machine control unit worldwide that is capable of autonomously determining a process-relevant target value.

The iQ clamp control significantly reduces the risk of quality deficiencies, ensures optimal mold ventilation, protects the mold against overfilling and boosts energy efficiency. As a starter, the new software is being offered for ENGEL injection molding machines with electrical clamping units up to clamping forces of 2200 kN.