The WITTMANN Group will present its most recent product developments in various areas at Fakuma in Friedrichshafen. The company will showcase its latest innovations in automation and peripherals from October 12-16 at booth 1204 in hall B1.
Extension of SONIC robot series
In 2019, the SONIC robot series was launched to replace the high-speed robots from the UHS series. SONIC robots come with a new design and are equipped with the ultra-modern R9 robot control system. The new SONIC 108 for use on small injection moulding machines with clamping forces from 50-tonnes upwards now joins the appliances already on the market for clamping forces from 150 to 500-tonnes.
In contrast to the larger SONIC models, the SONIC 108 has been fitted out with a fixed demoulding axis, which has proved extremely advantageous for small injection moulding machines. Short overhangs and a compact control cabinet simplify the CE-compliant housing of the automation cell. During the active demoulding stroke movement above the mould space, no axis elements are pushed towards the injection unit, which substantially simplifies the enclosure, especially in the area behind the fixed clamping plate of the machine.
The SONIC 108 has been optimised for high-speed parts removal in packaging and pick-and-place applications. It is designed for cycle times below 4s, with IN/OUT times kept below 0.9s. To facilitate this type of high-speed removal, the drive system concept has been completely revised, with SONIC 108 still able to handle payloads up to 2kg. The familiar WITTMANN functions, such as iVac vacuum control with blow-off function, axis activation, SmartRemoval and digital visualisation of the axial movements, are part of the appliance’s standard equipment. Use as an insider is also possible (i. e., for parts depositing inside the injection moulding machine’s protective housing).
For the market launch at the FAKUMA 2021, where the SONIC 108 will be presented for the first time, the appliance will be available with horizontal strokes of up to 1,500mm and vertical strokes of up to 1,000mm.
WX153 robot: new automation option for the medium clamping force range
Available from now on: the upgraded WX153 robot from WITTMANN – the ideal automation solution for injection moulding applications on machines with clamping forces from 500 to 1,300-tonnes.
The new automation solution for injection moulding applications in the medium and higher clamping force range is based on the newly upgraded WX153 robot from WITTMANN. The system consists of a cartesian axial structure with a mobile X-axis serving as a demoulding axis.
A horizontal stroke of up to 18m and a vertical stroke of up to 2,600mm are possible. An X-stroke of up to 1,400mm is available for parts removal. This 1,400mm demoulding stroke provides a maximum reach of about 1,790mm. In this context, the term “reach” designates the maximum distance between the horizontal axis and the mounting plate of the swivel axis at the lower end of the vertical axis. The reach is an essential parameter for the layout of robot systems.
Internal tubing and/or wiring in the vertical Y-tube, easily accessible lubrication points and the integrated control cabinet at the rear of the horizontal carrier are part of the WX153 robot’s standard equipment. The control cabinet has its original dimensions invariably regardless of the number of additional axes attached.
Three additional axes can be mounted to each robot at the end of its vertical axis to drive the removal gripper. Moreover, WITTMANN can build tandem robot solutions as well, that is, two traversing units acting together on the main carrier. Even in such cases, an add-on control cabinet can be dispensed with, so the space provided for it beside the injection moulding machine can be used for any necessary auxiliaries other than automation equipment.
Various optimisations still enable the WX153 to operate with a gripper weighing more than 20kg even when using three additional axes. Compared to the previous device concept, this equals a possible increase in weight by more than 30%.
TEMPRO basic Large 120: new and powerful temperature controller
For efficiency in operation, injection moulding production with large and heavy moulds requires high heating capacity on the one hand and correspondingly high flow rates in the cooling channels on the other hand. The new WITTMANN TEMPRO basic Large 120 temperature controller is the perfect solution for such tasks.
First of all, this temperature controller offers a maximum heating capacity of 36kW, a value that ensures an optimal heating time for the mould from both the technical and the economical point of view. This is of special importance whenever fast heating is necessary, for example, after a mould change. The heat accumulated in the hot steel of the mould plus the additional heat input from the melt caused by the injection moulding process must be extracted again from the mould circuit as fast as possible via the cooling channels. This is the only way to establish a homogeneous heat transfer inside the mould, which benefits the entire process.
To create ideal conditions in this respect, the TEMPRO basic Large 120 is optionally equipped with a new frequency-controlled pump. This pump model, known as the SpeedDrive pump, comes with an output of 4kW, can handle a maximum flow rate of 300l/min and generates a maximum pressure of five bar. With the SpeedDrive pump, users can set the correct parameters for further process regulation – motor speed, flow rate, pump pressure and differential temperature. An approach that makes a vital contribution to process stability. Automatic adjustment of the parameter settings within a certain tolerance margin also optimises the uptime of the equipment in production. Using a SpeedDrive pump can be seen as a synonym for energy-efficient pump operation since it is generally sufficient to operate the pump under partial load to comply with the selected parameter settings.
The development of the new TEMPRO basic Large 120 was prompted by increasing tendencies on the market towards the necessity for fast heating of large moulds while simultaneously providing the subsequently required high cooling performance. After all, such a solution must also contribute to optimising the cycle time. Consequently, the cooling function of TEMPRO basic Large 120 has taken the form of an extremely effective direct cooling system for the mould water.
One example of the phenomenal cooling performance of TEMPRO basic Large 120: a differential temperature of 60°C between mould water and cooling water is the result of an extremely high cooling performance of 175 kW!
As an option, a stainless steel vortex flow measurement device is available for the temperature controller, with a measurement range from 20 to 400l/min to cover all conceivable applications.
TEMPRO plus D200 for high-temperature applications
Numerous new applications require special solutions for mould tempering. This is why the TEMPRO plus D range of temperature controllers from WITTMANN, well-known and proven on the market worldwide, has now been extended by adding the new TEMPRO plus D200 model – a water tempering device for temperatures up to 200°C.
With this appliance, WITTMANN has responded to the general market trend towards higher process temperatures and fulfilled the numerous customers’ wish for water temperature controllers to handle high-temperature applications.
High water temperatures – and the resulting high-pressure levels – place hefty demands on the wear resistance of moulds and mechanical components, a fact constantly kept in mind throughout the development of TEMPRO plus D200.
CARD primus compressed air dryers with VacuJet loader
The new compressed air dryers from the CARD series have been an integral part of the WITTMANN product portfolio since 2020.
This successful series of appliances is being extended by two new additions, the CARD primus 10 and the CARD primus 20. CARD primus appliances are offered as package solutions, each including a VacuJet material loader with delivery hose and suction lance as well as the actual compressed air dryer. They come with drying silos of either 10 or 20l capacity and are suitable for temperatures of up to 200°C.
On these appliances, the desired drying temperature can be set via a touch screen operating panel. At the end of the pre-drying phase, a signal is issued to release an automatic production start-up. The material drying data can be exported via a USB port or via OPC UA.
With the integrated week timer, the use of the dryers can be ideally adapted to ongoing production planning, and they are ready to run immediately as soon as dried material is required. In the CARD primus models, the compressed air consumption is very finely and precisely adjusted to the actual demand by an intelligent digital air volume control system.
Loading the dryer via a VacuJet loader ensures a continuous material supply, and the dryer recognises automatically when the drying temperature must be lowered.
If the interval between two conveying cycles exceeds a certain period of time, this is interpreted as “no material consumption”, and the dryer then starts the necessary actions to protect the material and to reduce energy consumption.
CARD dryers can be mounted directly onto the machine feed. In combination with a claw flange, the appliances can be pushed into a parking or emptying position.
If quick-change adapters are used on CARD dryers, this will save time when transferring the dryers from one machine to another.
From typical small-quantity applications, all the way to downstream drying directly on the consumer: CARD dryers cover an extensive range of applications – and ultimately offer an unbeatable price-performance ratio, especially as CARD primus package solutions.
Overworked G-Max 23 and G-Max 33 beside-the-press granulators
The G-Max series of compact beside-the-press granulators is specifically designed for closed-loop material recycling of sprues/runners that are discharged from injection moulding machines up to 500-tonne clamping force.
The WITTMANN G-Max series packs a lot of smart engineering into a very compact footprint in order to operate quietly and efficiently, grinding soft to medium-hard plastic sprues and defective parts made of PP, PE, ABS and PU.
The design of the G-Max series of granulators has been standardised, based on the design of G-Max 13. Accordingly, the models G-Max 23 and G-Max 33 now come with larger hopper openings. Customers are now given a choice between a fixed and a rotatable version of material outlets.
A Poly-V belt transmission drives the granulators of the G-Max series. And for small beside-the-press granulators, only WITTMANN can offer a belt drive with an automatic tensioning system.
The material screens of the G-Max series are available with screen perforation in different sizes. This ensures suitability for varying materials and throughputs.
The tiltable material hopper simplifies the cleaning and servicing of the appliance enormously. For instance, a screen change can be carried out without tools, and the time required for servicing is reduced to a minimum.