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New ways of induction heatingin the injection moulding processMicro TechnologyiNNOVATION fORUMVillingen-SchwenningenFebruary 29, 2012Dipl.-Ing. M. MaierProf. Dr.-Ing. W. SchinkötheInstitut für Konstruktion und Fertigung in der Feinwerktechnik (IKFF)MM INNO2012Universität Stuttgart
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartAgenda About us Variothermal process control Induction heating in plastics processingFocus: Ceramics in injection moulding tools Details, trivia and preview on future applicationsMM INNO20122012-02 / M. Maier2
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartActuatorsPiezoelectrical Ultrasonic MotorsLinear and Rotatory Travelling Wave ActuatorsElectrodynamic ActuatorsLinear Direct DrivesSmall Scale Actuators with Moving MagnetsPrecisionInjection MoldingMoulded ComponentsDesign and ConstructionTool Design andConstructionVariothermal ProcessControl by Inductive HeatingDesignMethodologyInjection Moulding of SmallScale PartsPolymer Bound MagnetsConstruction and Designusing 2D- and 3D-CADFEM SimulationRheological SimulationsCoupled Field lpiezoelectric-dynamicOptical and Mechanical SensorsNon-Contact Distance SensorsSurface Measuring SensorMetrology and VerificationThickness Measurement Sensor2012-02 / M. MaierMM INNO2012Reliability of Small ScaleActuators3
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartVariotherm mould temperature controlIsothermal process controlVariothermal process controlWkzMWkzMWkzMWkzMPolymer meltPolymer meltSolidified melt2012-02 / M. MaierTime-varying mould temperatureMM INNO2012Constant mould temperature4
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartInduction heatingPrinciple Electric transformer:„short circuit on secondary side“eddy currents AC generated high-frequencyelectromagnetic fieldInducededdy currentsin surface2012-02 / M. MaierMM INNO2012Alternatingmagnetic field5
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartMould-integrated induction heatingwatercooledcopper inductorconventional heatbalancing systeminduction heating provides high heat fluxdue to its surpassing power density2012-02 / M. MaierMM INNO2012Dynamic mould temperature by thermal conduction:6
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartUse of ceramics as insulatingmaterial: ceramic potting compoundwatercooledinductorceramic potting compoundfor electric insulation andinductor reinforcementSeparate channels formould cooling neededmould plate (schematic)conflict:2012-02 / M. MaierMM INNO2012mould stiffnessvs.thermal dynamics7
Use of ceramics as insulatingmaterial: ceramic potting compoundExample: mould for fuel cell bipolar platesJoint lines withoutinduction2012-02 / M. Maier8
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartUse of ceramics as insulatingmaterial: ceramic coatingceramic coatingpulsed, rinductorSame channels forinductor and mouldcoolingmould plate (schematic)Example:improved mould stiffnessandthermal dynamics(both heating and cooling)MM INNO20122012-02 / M. Maier9
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartDimacer : ceramics for injection moulding toolsmachinable high performance ceramicsWear on aconventional runnersystemCeramic gate insert(eroded)2012-02 / M. MaierMM INNO2012Bilder:IFKB/Leroxid10
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartIn-mould heating of steel insertsby induction heating EckardtExamples of hybrid parts Bayer Material ScienceLap shear testCurrent research project:use of electrical discharge machinable high-performanceceramics for electromagnetically transmissive moulding toolsMM INNO20122012-02 / M. Maier11
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartIn-mould heating of steel insertsby induction heatingTarget In-mould pre-heatingof the insert part heating inductorsteel insertProcess governed bymeasured temperatureof the insert parttemperaturesensorplasticsInjection mouldedhybrid parthigh performanceceramicMM INNO20122012-02 / M. Maier12
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartDetails & triviainjection moulding machineinduction generatorthermocouple amplifierSELOGICA:2012-02 / M. MaierMM INNO2012both temperature controlled heating and coolingwithout external control unit13
Institut für Konstruktion und Fertigung in der FeinwerktechnikUniversität StuttgartPreview onpossible applications ARBURGProcessing of insert parts ARBURGProcessing of LSR by multicomponent injection moulding SikaVariotherm RTM-ProcessMM INNO20122012-02 / M. Maier14
Injection Molding Moulded Components Design and Construction Tool Design and Construction Variothermal Process Control by Inductive Heating Injection Moulding of Small Scale Parts Polymer Bound Magnets Optical and Mechanical Sensors Non-Contact Distance Sensors Surface Measuring
