Wittmann Battenfeld: Conservation of resources through energy-efficient plant technology, wall thickness and weight reduction

Wittmann Battenfeld, Kottingbrunn Austria, presents its new Wittmann design machines and systems for the first time at K 2022, further demonstrating the Wittmann Group’s efficiency as a single source for the entire injection molding system, from machine to automation to peripherals with networking capability via Wittmann 4.0.

Injection pressure for thin walls

In ICM injection pressure moulding, the melt is injected into a mould that is not completely closed. The final shaping is done after the mold is completely closed by displacing the molten into the cavity. This allows the tool to be filled with less pressure, resulting in less deformation of the part. ICM allows processing an extended range of materials with particularly efficient and energy consuming materials. It also offers innovative solutions when traditional processes reach their limits. This process enables the smallest wall thickness and is precisely repeatable and accurate mapping of surface structures.

Wittmann Battenfeld will introduce this technology using the high-speed EcoPower Xpress 160/1100+. The 230ml cup is made of Sabic polypropylene with a wall thickness of 0.28mm and is produced using Glaroform’s four-cavity mould. In particular, the short injection times required for the ICM process can be achieved thanks to the high-speed EcoPower Xpress’ high-speed dynamic driving technology. The machine is equipped with a quadruple IML system from Beck Automation. This system is characterized by its high speed and compact design. A special feature of the system is the automatic mode of all four labels. Each label is always placed in the exact same place on the IML core, regardless of its position in the journal. On the one hand, this reduces rejections, and on the other hand, operating effort, since it is no longer necessary to manually set the label magazines. The quality check of the Verstraete IML label cups is carried out by an Intravis 10-camera vision system built into the system.

Structural foams and the use of natural fibers save weight

Interior door panels are made from natural and recycled fiber mats, manufactured using MacroPower 1100 and a tool from Frimo. Photo: FREMO

With the MacroPower 1100/12800, equipped with an energy-saving servo motor, speed-controlled and constant pump, Wittmann Battenfeld uses a tool from Frimo to produce a lightweight interior door panel. Wittmann Battenfeld is based on the use of natural materials and recycling. The interior door panel is made of a specially light natural fiber mat, the map pocket made of Borealis recycled polypropylene is excessively shaped. In order to achieve an additional reduction in material and weight, the Cellmould structural foam technology, developed and patented by Wittmann Battenfeld, is used. The resulting reduction in materials benefits the environment in several ways. On the one hand, this saves valuable raw materials, and on the other hand, the parts are lighter, which reduces the car’s fuel consumption and increases the battery range of electric cars. In this application, pre-cut natural fiber mats are picked up from an insulating pile using a WX152 robot and placed in an infrared heating station. The hot mats are then placed in the injection mold using a built-in clutch for removal and insertion into one half of the fixed mold, where they are shaped, trimmed and over-shaped. The end and trimmings are removed from the fixed mold half before the natural fiber mat is inserted and then brought to the stowed position.

MacroPower is equipped with the newly developed Wittmann CMS Lite condition monitoring system. This monitoring system constantly determines the “health” of the servo hydraulic axles, from which the condition of the pump and axle valves can be derived.

New SmartPlus device with high-tech automation and digitization

At this year’s K trade fair, Wittmann Battenfeld will demonstrate his diverse expertise in digitalization and automation in particular by producing a spirit level with a new SmartPlus series machine with a new B8X controller. SmartPlus hydraulic servo features are highly economical, energy efficient and repeatable. By utilizing proven technologies and selected options, this machine offers excellent value for money.

In the automation hive with the SmartPlus 90, the spirit level is made of ABS using a 1+1 cavity mold from Sola. Fig: Wittmann Battenfeld

With the SmartPlus 90/350, equipped with a Wittmann CMS Lite condition monitoring system and automation cell designed and manufactured by Wittmann Battenfeld Germany, the spirit level is made of ABS using 1+1 cavity molding from Sola. In the first step, the upper and lower parts of the spirit level cap are injected. The top is placed in a laser station and printed. At the same time, the lower part, placed on the shelf, was equipped with Sola spirit levels. Then the upper part is pressed against the lower part with a predetermined force. The finished parts are transported to a test station, where the position of the flasks is checked using a sighting system. After inspection, the final spirit levels are removed with the WX138 robot from Wittmann and placed on a conveyor belt.

Conserve resources through lightweight construction technology

In addition to the machines and systems presented, Wittmann Battenfeld will also present the latest developments in the field of Airmould internal gas compression technology. The new Airmould 4.0 pressure control unit can be seen as well as the new manual control for this technology. At the Airmould/Cellmould Center, company experts are available to visitors for advice on the use of Airmould technology and Cellmould’s structural foam technology. Both technologies allow significant material savings in the manufacture of plastic parts, which also affects the weight of parts and the costs of their manufacture.

Other exhibits

Using renewable energies without losses and processing alternative materials without fluctuations In addition to processing liquid silicon in the standard and micro scale, lightweight construction using internal gas pressure, IML/IMD technology for textured and functional surfaces, and a work cell equipped with voice control and augmented reality, are other focal points of Wittmann Battenfeld’s entrepreneurial business.

www.wittmann-group.com

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