16 16

Open controller architecture in injection molding machines

Isolators for high-voltage installations, manufactured with the
injection molding process.
17
industry.application
DESMA supplies complete system solutions
for the processing of elastomers: Modular
machine concepts, the in-house mold shop and
a worldwide service network ensure efcient
production processes. DESMA also supports
and advises its customers at all stages from
project engineering right through to the nal
acceptance. At its state-of-the-art test center,
the DESMA Process Engineering Center in
Fridingen, new processes are continually
being tested for processing elastomers and
made ready for series production. Here in the
development phase we already work closely with
the users of our machines, Joachim Smolka,
team leader for software development at
DESMA, describes the important benet of this
center.
CLOSE COLLABORATION
The software specialist also
appreciates this kind of collaboration
with Bachmann. He remembers the
time in Feldkirch over 10 years ago
when, together with the Bachmann
application engineers, he converted
the automation of DESMA systems to
a completely new platform: the M1.
We had erected a 160 ton injection
molding machine in the basement of
the Bachmann factory for this task
and developed a completely new
software, Joachim Smolka recalls.
The change was necessary because
the control platform previously
used by DESMA had reached the
limits of its capabilities. Various automation
solutions had been assessed beforehand and
we nally chose the Bachmann system. The
performance of the M1 was indisputable and
the Bachmann visualization concept seemed
to us a considerably better solution than
those of other competitors, Joachim Smolka
describes the considerations at that time. The
ability to have control of the visualization was
an important criteria for us in choosing the
system. The special machine building sector in
which we operate is a very demanding market,
Klaus Mattes, head of electrical engineering,
explains. Particularly in the visualization, we
needed a tool that gives the maximum degree of
freedom.
INTUITIVE OPERATION A TOP PRIORITY
We were the rst to replace the alphanumeric
line displays still customary at the time with
Bachmann's graphical displays, Joachim Smolka
remembers. The DRC 1210 visualization enabled
DESMA to bring color into the display, and a
short time later DESMA took the somewhat
usual step at the time of using the DRC 2010
15 touch screens as operator panels in machine
building: Almost 2000 of these systems are
now successfully in use worldwide. As in those
Klckner DESMA Elastomertechnik GmbH is a company based in Fridingen on the Danube
(D), and is one of the leading suppliers worldwide of injection molding machines for
elastomers. DESMA systems are used for the manufacture of demanding rubber and
silicone molded articles, including items for the automotive and shipbuilding industries,
electrical supply, medical technology, process engineering and the production of
household goods. For more than 10 years, the machine builder has relied on the
Bachmann M1 automation system for the control and visualization of its system solutions.
Klckner DESMA Elastomertechnik GmbH has
500 employees worldwide and combines
under one roof system technology, machine
building and mold shop for molded elastomer
and silicone articles.
With the M1 system
we are well placed for
the future.
Joachim Smolka
Team leader for software development
at DESMA
18 18
days, the user-friendliness of the systems is
the top priority: The operation of the DESMA
injection molding machines should be a pleasant
experience and should thus also increase
motivation and efciency. The company's
DESMA RUBBER CONTROL (DRC) offers a unique
visualization concept to the rubber industry,
enabling machines to be set up and operated
simply, intuitively and quickly.
ROBUSTNESS REQUIRED
The automation components are integrated
in a central switching cabinet directly at the
machine. The entire arrangement is very
compact so that machines with a clamping
force of 750 tons can be supplied in one
piece: Because dismantled transportation is
unnecessary, faster installation is guaranteed,
Klaus Mattes describes an important benet of
the DESMA systems. With injection pressures
of up to 3,500 bar, the vibrations caused by the
injection molding machine place a considerable
mechanical load on the electronic components.
With its robust design and absence of any
rotating elements such as fans or hard disks, the
Bachmann M1 system can withstand this easily.
DESMA vertical injection molding machine
D 968.400 from the BENCHMARK series
with 4,000 kN clamping force.
INJECTION MOLDING
Injection molding is a molding technique
primarily used in processing rubber, that
enables molded parts to be produced
economically in large quantities with a
high degree of accuracy. On the DESMA
machines, ribbon-shaped elastomer, solid or
liquid silicone is drawn in (pressed in) using
a special feed screw in the injection unit,
plasticized at approx. 70 C and injected into
a mold at high pressure.
The space or cavity of the mold determines
the shape and the surface structure of
the nished part. The injected elastomer
vulcanizes in the mold at approx. 170 C.
Factbox
19
industry.application industry.application
VALUABLE TOOLS FOR
DEVELOPMENT AND SERVICE
The developers at DESMA wouldn't do without
the Scope function integrated in the Bachmann
SolutionCenter. This enables us to record data
in real time for ne tuning the mechanical
settings on the machine in the injection
molding process, Klaus Mattes explains its
use and adds: The innovative VARIO cold
runner technology enables us for the rst
time to variably adjust the nozzle distances in
order to cover different molds. A mold can be
used several times by simply adjusting nozzle
positions, thus offering major savings for small-
batch productions. The Low Level Debugger in
the SolutionCenter has also been valued by the
DESMA engineers as a useful tool: A meter
becomes unnecessary since you can measure
the current inline and see what the software is
seeing, Joachim Smolka adds.
READY FOR THE FUTURE
State-of-the-art and exible machine concepts
are the basis for turnkey complete systems that
are successful, Klaus Mattes encapsulates the
philosophy of the south German company. The
open control architecture of injection molding
machines enables complex automation systems
to be integrated. The scalability of operation also
enables the system to be set up according to the
know-how of the user and to ensure user safety
with increasingly more complex production
processes. DESMA is therefore well placed for
the future with the Bachmann M1 system as a
basis for the automation.
Intuitive operation:
DESMA RUBBER CONTROL DRC 2010
The Scope functionality
in the SolutionCenter
supports us in the
implementation of
complex control tasks.
Klaus Mattes
Head of electrical engineering at
DESMA