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Product news & developments

06. May. 2015

Focus set on: 50 years of DESMA


Dear friends, our valued customers,
dear ladies and gentlemen:

In 1965 we started our business operations with 7 employees occupying an area of 200 sqm in Fridingen. Today, we have over 500 employees who meet the requirements of the rubber and silicone processing industry by using a production area of around 30,000 sqm at 5 production locations embedded in a network of 35 sales and service stations.
The motto ‚50 years shaping ideas for your future‘ accompanies us through this year of anniversary and simultaneously provides us with the courage, the confidence and the inspiration to add many more chapters to a manifold corporate history.

Talking of a manifold corporate history:  in the light of our year of anniversary we take great pleasure in presenting you our ‚web special issue‘ today. In addition to a lot of information about our history, you can make your contribution by following this and by preparing your selfie video with anecdotes, memories and suggestions about and for us.

We are also going to celebrate our 50th anniversary adequately at this year’s IRC and DKT in Nuremberg from 29.06. to 02.07, please visit
http://www.desma-50years.biz/en/dkt2015/

We would like to take this opportunity to thank you for your attention, your trust, your transactions with us and for a successful relationship in the future as well.

Meeting you again in Nuremberg is already and will be a pleasure for us,
the team DESMA

09. Feb. 2015

DESMA E-Training

As a market leading company, we contribute to the steady advancement of new industry standards. Our innovations set standards that we are completing by ongoing research and development. Thus, it was time to complete our traditional range of training courses as well and to extend them by a new way of learning.

The E-training platform enables the participants to quickly and easily gain insight into complex processes of elastomer processing. Its illustration by way of graphics, animations, videos, screenshots, drawings and texts helps you to leap into the subjects interactively and flexibly. You may directly test your newly acquired knowlegdge with an integrated examination and thus put it to the test.

At the same time, the platform can be used as a training tool and reference book for fast and selective knowledge transfer. The participants therefore have quick access to latest expert knowledge of elastomer processing and elastomer technology worldwide – wherever and whenever they want.

Subsequently, they can integrate their knowledge into your company for direct use. E-training consists of 9 different training sessions with separate small examinations each. After passing them successfully, the participants can print out a final certificate and thus can prove their advanced training and increased knowledge. We also feel E-training to be a perfect preparation for our direct customer-focused courses which either can be conducted at our training center or at our customer locations.

More informations about E-Training you can find here: DESMA brings expert knowledge to the screen.

mobile communications

inspection list

09. Feb. 2015

SERVICE AT DESMA / CUSTOMER CARE CENTER

For a steady improvement of our services and performances for our customers, we recommend to conclude an inspection contract and a hotline contract. In additon to these contracts, we would like to present our TeamViewer system as another service tool.

TeamViewer

The diagnosis tool TeamViewer which already has been used successfully within the control generations DRC 1210 and 2010, is of course available within the new visualization DRC 2020 HT. Thus, the DESMA Customer Care Center is still able to resort to the functionality of this tool in order to easily and quickly perform diagnosis and maintenance on the machines. We can provide our customers and partners with swift and uncomplicated support.

TeamViewer connects your machine with our Customer Care Center via internet.

Furthermore, we now offer you the possibility to benefit from modern, safe remote maintenance without integration within your corporate network. No matter whether it is DRC 1210, DRC 2010 or DRC 2020 HT, efforts and costs are kept to a minimum.

Replace now your outdated analogous system and avail yourself of all advantages of a quick, safe and notably reliable connection. The mobile network makes a quick and cost-effective leap into this state-of-the-art technology possible.

The pictures shows the mobile communications module which can be fixed magnetically on the machine to be maintained and which is removed again after successful remote maintenance.

Get informed and discuss your requirements at hotline@remove-this.desma.biz!

Inspection contract

The inspection contract comprises a practice-oriented service package and offers you the following profitable benefits:

  • Increase in machine uptime
  • Less repairs and consequential costs
  • Repeatable and correct process results
  • Constant article quality
  • Quick cost amortisation
  • Minimization of machine downtimes
  • Increase in efficiency, productivity and added value
  • Half-yearly or yearly machine inspections by DESMA service technicians

With this pre-service, you are always on the safe side and will be informed on the current machine condition thanks to the inspection by a skilled service technician and through a special configurable check list synchrononized to your machine.
These appropriate measures help you to avoid future machine malfunctions and downtimes in time and cost-effectively.

We are confident that this investment pays itself off quickly and that you will be able to create a real added value due to this inspection contract.

Hotline contract

The services and added value for you, as our valued client, are:

  • Short response times in case of malfunction
  • Fast trouble shooting
  • Minimization of machine downtime in case of trouble
  • Reduced production downtimes
  • Savings in travel expenses and salary costs of the service technician assignment
  • Increase of machine uptime
  • Increase in efficiency, productivity and added value
  • In case of problems support by skilled DESMA remote service staff
  • Extension of hotline availability from 7:30-22:00 hrs

Assure yourself of this added value and touch base with us!

We would be very pleased to give you no-commitment professional advice in detail on the inspection or hotline contract. Kindly contact us at: ccc@remove-this.desma.biz

Pic. 1: possible cavity assembly

Pic. 2 & 3: recording of pressure profile & multiple-stage articles

09. Feb. 2015

APPLICATION REPORT PRESSURESENSE

FIRST RESULTS FROM EVERYDAY PRACTICE

For the elastomer injection moulding process it is important to not only have a machine which deals with the production of rubber and silicone articles as quickly as possible, the accurate control and the recording of this process are equally essential. If one has the total process completely under control, it is easier to minimize critical points.
The company DESMA embraces the challenge of increasingly complex manufacturing plants and ever-growing requirements on injection moulded parts. With the PressureSense system offered by DESMA, and which has already been applied successfully, they took a big step towards holistic process monitoring.

What does this system offer for the process sequence?

It allows recording of the inner mould pressure and thus the drawing of conclusions regarding the vulcanization curve. The switching off of individual nozzles of a DESMA FlowControl cold runner block, depending on the inner mould pressure, is part of standard applications. Thus, cavities with different volumes can be filled individually, i.e. that a mixed production with different cavity sizes is possible. 

Batch fluctuations of the compound are balanced and additionally discovered by using the recordings. Moreover, switch-over criteria such as the switch-on of dwell pressure in dependence on the mould filling can be realized in certain cases of application. Thus, the dwell pressure is always used at the same mould filling level as far as the respective application is concerned. Depending on the inner mould pressure, the machine control system takes on the injection procedure resp. the precise cavity filling (no insufficient filling or overfilling) and the corresponding switch-off of the injection operation. The plasticizing volume determination can be easily handled with it as well.

What belongs to this system and to which extent is it integrated within the machine control?

In order to use this system adequately, pressure sensors are required which are installed in the cavity at appropriate points (see pic.1: possible cavity assembly). These sensors are connected with the machine control. Since the sensors and their accessories are fully integrated within the machine control by way of corresponding software, all signals of the pressure sensors can be processed in the machine control. This enables e. g. a graphical representation of the detected pressures on the control display (see pic.2: recording of pressure profile). From this, conclusions can be made about the vulcanization process in the mould. By means of the information about the actual pressure in the cavity and the usage of a FlowControl CRB integrated within the system, the injection operation can be finished in relation to the cavities. Therefore, it is not only possible to finish the injection procedure via time or injection stroke of the injection unit, but also via the actual cavity pressure.

For what kind of applications or materials the system is suitable?

In principle the system is suitable for all types of materials and articles irregardless of the industry in which the article is used. The sole condition is that there is an appropriate place in the cavity to install the pressure sensor.

Can you cite examples which even more depict the advantages of such a system?

In order to show that the system is able to balance volume fluctuations by switching off individual nozzles of the FlowControl CRB in case of a specific inner mould pressure, DESMA presented penholders (blue-colored) on the occasion of various trade fairs and other demonstrations. Here the number of aluminium inserts was variable and consequently the required material volume as well. The machine controlled itself independently, i. e. it individually finished injecting through the FlowControl cold runner nozzles as soon as a specific mould filling (detected by inner mould pressure) was reached. 

In case of multiple-stage injection processes, different articles can be produced which e. g. have an identical "stage 1", but have differences in "stage 2" (see pic. 3: multiple-stage articles; explanation: the first two articles from left have another "2. stage" than the remaining 4 articles, but were produced in the same cycle). In addition, the point of the proper filling degree can be better determined by the pressure curve. This restricts or prevents that the second compound flows under the first article subsequently, or generally speaking, that no compound is compressed between core and inserts (with adequate mould accuracy). Eventually, the actual inner mould pressure is easier to be determined and to be repeated during vulcanization. This is especially expedient for compounds which have a very narrow process slot for processing.

The "backgrinding" problem as well is much easier to control with this system. Backgrinding develops on separating edges if there is too much pressure in the cavity. It can be obviated by finishing cavity filling in time. Whether the article will be properly filled, insufficiently filled or overfilled can already be identified via the pressure profile – and this even before the mould opens.

To sum it up one could say that the usage of PressureSense serves to increase accuracy in article production and article quality. And what is more, monitoring of the entire manufacturing process becomes more transparent and intelligible, as the operator also obtains information about what is happening in the mould during the filling and vulcanizing operation thanks to the recorded inner mould pressure curve.

11. Jun. 2014

DESMA DRC 2020 HT OPERATING PANEL WITH HAPTIC TOUCH SYSTEM

INTUITIVE HUMAN-MACHINE INTERFACE

When designing the new operating panel, DESMA put the emphasis on optimal operation together with easy, logical and clear user prompts. The special feature about it is the haptic touch effect, because the operating panel communicates with all senses of its operator: optically, acoustically and with vibrations.

Central communication with a variety of functions.

The visualization tool DRC 2020 HT can be operated intuitively. The upwardly and laterally swiveling operating panel provides ample room on its 19" screen for the display of all information required. Access to menu is realized with a personalized USB key which can be equipped with individual access authorizations. Totally eight operating levels are available.

The screen surface is fitted with a special haptic touch system which acknowledges inputs or error inputs optically, acoustically and haptically. The haptic feedback of the screen operation increases reliability in user prompts. In addition to the touch screen, only six hardware switches are required for operating and adjusting the machine. For safety reasons, machine movements during setting are not activated via the touch panel, but with two rotary switches which have to be actuated for the horizontal or vertical movements.
The function sequences and set-up parameters are not only displayed as series of numbers but also in plain text and they are fitted with icons. Furthermore, the clear and grouped arrangement of the visualization pages makes getting along with the system easier for the operators.

Optimizing energy consumption with EnergyControl actively.

With EnergyControl, DESMA has developed an energy management system which actively provides opportunities to increase energy efficiency. Among other things, the system measures the actual energy consumption which can be displayed at the machine visualization per cycle. Of special interest is the energy-optimized starting up of the machine. So far, the complete machine starting has depended on the consumer with the longest heating up time. EnergyControl switches each consumer individually on starting with the one with the longest heating-up time. At the same time, an energy management algorithm synchronizes all consumers.
The energy-saving potential through minimization of current peaks is underrated very often. The sooner switching-off of slower consumers results in reducing current peaks up to 30%! Positive side effect: in addition to pure current saving, it relieves the substation, the cooling system and the cooling-water pump.

SetupAssist promises to put an end to paper chaos.

In many factories, working instructions, control indications, documentations and partly pictures are fixed somehow at the machines. SetupAssist allows to keep such documents in the DRC 2020 HT and to assign it to the data record of the mould in question. The file format (pdf, html or videos) does not matter at all. Data relating to the mould and all other relevant information are „married“ which eventually is essential for audits. Whenever a certain mould is retrieved, the information attributed accordingly is available and is comfortably represented at the 19" display.

In addition to the operating panel DRC 2020 HT, it is possible to visualize, although in a reduced manner, a machine connected to the internet on the smart phone. Thus certain pages can be retrieved on the way, for example, in order to learn about the current state of ongoing production. Representation of the pages selected is adjusted to the smaller display. A corresponding authorization is of course necessary.

Looking into the machine from far with TeamViewer.

Together with the optional diagnosis tool TeamViewer and a tablet PC, parallel visualization on the screen is possible, but again provided that the machine is connected to the internet. This way, support can be given to the employee from (almost) every place around the globe. However, for obvious safety reasons, the possibilities for intervening are limited. It is therefore not possible to start machine movements with this „remote control“, because the danger of area cannot be seen. Only staff who stays directly at the machine concerned is allowed to carry out the actual operation of a machine. On the other hand, the input of process-relevant data is possible.

21. Feb. 2014

Waste-free production of precision articles with ZeroWaste - no residual material and no rework

The company Klöckner DESMA Elastomertechnik GmbH, Fridingen, has developed the ZeroWaste technology for the waste-free production of even smallest precision articles. The DKG* Product Award winning production system is based on the classical ITM (Injection-Transfer-Moulding) method with temperature-controlled ITM pot.

Reducing costs with waste-free injection moulding

With ZeroWaste ITM, DESMA presented a technique to produce parts without waste. This method is based on the well-known ITM procedure (Injection Transfer Moulding) with a temperature-controlled pot together with a patented needle-shaped shut-off system. This enables to produce the smallest precision parts without runner. This method is ideally suited for small parts up to a diameter of 30 mm. Reworks which would be otherwise necessary, such as runner separation, are no longer required. Further essential advantages are shorter cycle times and consequently higher productivity. Thanks to runner-free direct injection, material savings of 30 to 50% are absolutely realistic in the production of gaskets with the ZeroWaste ITM technology.

At the K show, this technique was demonstrated on an injection moulding machine D 969.300 SEALMASTER S3 with 3,000 kN clamping force which produced gaskets for the automotive sector.
In production, the machine first injects the material into a temperature-controlled injection chamber, also named pot. During this phase the hydraulically actuated needles keep the nozzles closed and the clamping unit is unpressurized. If the pot is filled, the clamping unit is closed, the needles release the nozzle and the material flows through the distributing channel and the nozzles into the cavities. Afterwards, the needles close the nozzles again which results in separating the articles from the remaining sheet in the pot. Advantages in process are little nozzle distances of 30 to 32 mm, a natural balancing of distribution which means that adjusting work is not required. This method provides perfect conditions for automated production.

*DKG: German Rubber Society

21. Feb. 2014

Optimal process optimization with Propter - Process optimization for first-time users

Optimizing processes is often a book with seven seals and in vain without comprehensive specialized knowledge. Measurable success, however, can be achieved by using intelligent, computer-assisted systems, but in many cases customers shrink back from the costs. DESMA customers have now the opportunity when purchasing a new machine to test a free light version of the optimization software Propter during 60 days. With Propter, also inexperienced users are in a position to optimize processes and to obtain a constantly high article quality.

Process optimization for testing

Early 2013 the companies Klöckner DESMA Elastomertechnik GmbH, Fridingen and CAS GmbH & Co. KG, Reinbek, reached a cooperation settlement in order to utilize the specific process know-how for DESMA injection moulding machines. As of now, DESMA supplies new injection moulding machines with the optimization software Propter integrated in the machine control system. Customers have now the option to test a light software version for the period of 60 days upon activation. Afterwards they can decide whether they want to buy and continue to use this slim version or to change over to the full version.

Compared to the full version, PropterLight has a distinctly reduced performance scope. This has, however, the positive effect that this version can be understood after a relatively short time of instruction.
Propter supports operators and setters like a Sat-Nav by providing them with proposals regarding the perfect machine adjustment for each case. The objective is to produce secured part quality with highest possible productivity within an optimal working window.
Fluctuations of batches and parameters are collected with a process model and incorporated in the control algorithms. When the batch is changed, one has to take the material date into consideration only. In the full version, the system determines cure time independently while considering the respective process status during the current cycle. With Propter, setters can use the process expert knowledge now integrated in the machine for a trouble-free and efficient production. Trouble-shooting for an optimal machine setting is no longer required and thus relieves the setter accordingly.

As against the starting variant, more parameters can be closed-loop controlled with the Propter full version. PropterLight is designed to enable users to deal with the advantages of a process optimization system. To this end, the software works with a simplified process model. Nevertheless, the starting version gives the chance to take safety margins out of the process and to produce within a considerably tighter range of tolerance. The notorious „margin for anxiety“ can already be eliminated with PropterLight. Potential for improvement can be immediately identified, used and incorporated in an efficiency calculation in order to assess, for example, the productivity advantage of an investment in Propter or PropterLight.

By the way, both systems are completely integrated in the machine control, which means that separate hardware is not necessary.

www.e-training.desma.biz

The new manual

27. Nov. 2013

DESMA brings expert knowledge to the screen and on the desk

With the new e-training platform, the company Klöckner DESMA Elastomertechnik GmbH, Fridingen, brings expert knowledge about the topic elastomer processing on domestic PCs. With the web-based, interactive learning program, the machine manufacturer chiefly addresses the employees of its customers who are interested in advanced training or brushing up their knowledge without the rush of daily business. This offer for knowledge transfer is completed by the presentation of the new manual „Basics for Elastomer Injection Moulding“.

Full access to valuable expert knowledge

Special focus is set on machine setters and operators. In order to control modern manufacturing systems optimally and to take advantage of all opportunities, broad expertise is required which calls for continuous advanced training. Often there is not much time left to do so. Additionally, manufacturing processes are increasingly relocated close to the customer's site enabling, for example, to supply just in time. Here the focus is frequently set on the machine only, whereas the new employees are steamrolled by technical requirements.
However, in well-established factories as well, there is demand for knowledge – even if it is just about brushing up long-forgotten details.

For all these needs, DESMA now offers in addition to the classical courses from machine operation to application technology training, two new possibilities for tailored learning of expert knowledge,

  • the interactive knowledge platform e-training and
  • the new manual „Basics for elastomer injection moulding“.

E-training provides registered users with access to state-of-the-art expert knowledge of elastomer processing. Understanding the roots of elastomer processing and the injection moulding technique is one goal. A great advantage is that the users are then able to directly apply this knowledge in their companies.

Apart from instructions, there are currently four learning modules available on the interactive knowledge platform:

  • Elastomer processing – definitions, thermoplastic elastomers (TPE), process technique of elastomer injection moulding, injection and dwell pressure phase as well as cold runner technology
  • DESMA rubber injection moulding machines & equipment – presentation of the new S3 machine series
  • Control system DRC2020HT – presentation and explanation of the operating panel with basic operator pages as well as examples of operation
  • Errors in injection moulding – explanations regarding influencing factors such as gas entrapments, insufficiently cross-linked spots, cracks in the article (backgrinding) or premature vulcanization (scorch).

The contents of this offer are continuously extended. Handling it is very easy. One can work through the pages like in a textbook. The descriptions and explanations are completed with numerous graphics and pictures as well as animation movies or videos. The expected time for learning is indicated at each individual learning block. If wanted, knowledge can be tested in a small exam.
Another great asset of the bilingual (German/(English) knowledge platform is its availability worldwide. No matter where, whether at the domestic PC or on one’s way with the smart phone, the web-based knowledge platform can be reached globally. Only a registration is required.

The icing on the cake is DESMA’s presentation of the new manual „Basics of elastomer injection moulding“. This book offers concentrated information from project engineering to material, from manufacturing methods including production equipment to process control and from setting strategy to process optimization. Registration for e-training at www.e-training.desma.biz.

PressureSense

Display of inner mould pressure

27. Nov. 2013

Reproducible elastomer processing - flexibility thanks to FlowControl and PressureSense

The company Klöckner DESMA Elastomertechnik GmbH, Fridingen, presents a world’s first with their new nozzle technology FlowControl-PressureSense to the specialist audience. This system closes the cold runner nozzle in dependence on the inner mould pressure. It allows to compensate batch fluctuations and to reproducibly control the filling degree of the cavities. Furthermore, the PressureSense module enables the production of articles in a mould with cavities of different size. And what is more, the PressureSense modul can be upgraded.

Flexible energy input saves cure time.

For at least ten years, the FlowControl cold runner technology of DESMA is synonymous with process optimization and increase in capacity, shorter cure times as well as reduced material and production costs. Along with the new module PressureSense, flexibility in production is raised distinctly.
The patented FlowControl cold runner system is suitable for almost all elastomers. It is fitted with individually controllable shut-off nozzles. This makes flexible nozzle arrangement and production of parts of different size in one mould possible. In order to minimize pressure drops, the FlowControl technique does without disturbing needles in the compound channel. There only is a short needle stump of 15 mm at the nozzle outlet.

It is advantageous that the heat input at the nozzle tip caused by friction when material escapes is immediately transferred to the cooled nozzle body. This, in turn, avoids heat input into the compound channel – and thus an uncontrolled increase in stock temperature.
The FlowControl nozzles are actuated by individual hydraulic cylinders which are integrated in a separate plate that is placed behind the actual cold runner block. Force transmission to the shut-off nozzles is performed externally with compression-tension rods. A hydraulic block in the injection moulding machine actuates the individual cylinders. The stand-alone control and actuation of the individual nozzles enable variable nozzle balancing. The shut-off points per nozzle are input through the volume injected or time-controlled right at the machine control. The once-stored data are again available for mould changes at a later date.

New: cold runner nozzles close in dependence on inner mould pressure.

As an option for determining the shut-off points per nozzle, DESMA offers the module FlowControl-PressureSense. Pressure sensors measure the inner mould pressure to this end. If the specified filling degree is reached, a signal is output to shut the nozzles. Manual adjustments due to batch fluctuations of compound, or in case of parts of different size and the different volumes involved are then not required. The pressure profile is graphically displayed on the operating panel during cure time as well. This permits to determine the optimal shut-off point easily.

The benefits of FlowControl-PressureSense are a constant, reproducible filling degree and thus uniform article quality with minimum material flash.
The FlowControl-PressureSense module can be upgraded to existing moulds and FlowControl cold runner systems. Several FlowControl cold runner blocks with appropriate PressureSense equipment are available for interested customers at the DESMA Process Engineering Center in Fridingen.

Typical examples of application of the 2-deck production are e.g. pipe seals, pharmaceutical stoppers, mould seals...

...O-rings

Calculation taking an O-ring production as an example

Calculation taking an O-ring production as an example

Central cold runner block to distribute material

Advantages: doubling of cavity number, efficiency is enhanced, production costs are lowered

ActiveFeed system is also ideally suited for feeding paste silicone in stripe format

PlastControl the active non-return valve for optimal precision accuracy

26. Jun. 2012

Multi-dimensional success. – 2-deck production plus cold runner system lowers costs

New S3 machines optimally suited for 2-deck production with central cold runner system. To lower production costs through 2-deck article production.

A 2-deck production is feasible on both horizontal and vertical machines by way of the central arrangement of the cold runner system. Especially as for mass-produced articles that are very often manufactured by using 2-platen moulds, the 2-deck production can be realized very efficiently. Machine-wise there are only a few additions required to realize the 2-deck production. If the 2-deck production is fitted with a central cold runner system, productivity will be enhanced and in addition runner waste will be at the same time reduced to a minimum. 
With the same machine size, productivity can be enhanced by an average of 70%. The extra investments for a second mould and the 2-deck cold runner system as well as additions on the injection moulding machine are causing extra costs to the average value of 30% only.

It is particularly easy to automate the 2-deck production on horizontal machines. Apart from output increased by 70 %, the specific space requirement due to saving another machine is also a strong argument. On the other hand, this means that a machine with lower clamping force can be used to achieve the same output.
Since all DESMA injection moulding machines are equipped with HighPressure (HP) injection units having up to 3,500 bar injection pressure, sufficient pressure reserves for high-viscosity compounds are available even if using multi-nozzle central cold runners.

ECONOMIC EFFICIENCY
If and how such a production is profitable is shown by the following calculation taking an O-ring production as an example:

As a supplier of turnkey systems, DESMA relies on the integration of cold runner systems within the control system of the injection moulding machine. The newly developed machine generation S3 hosts special features which are providing big advantages particularly for the 2-deck production:

FEATURES OF NEW S3 SERIES
The new driving concept ServoGear for dynamic and precise machine movements with lowest noise emission. For the production of precision seals e. g., a precise closed-loop control of the injection movement is required especially for extremely different injection profiles. This is ensured by the ServoGear  hydraulics at best precision possible. This energy-saving hydraulic concept is fitted with a two-pump system. Thus, a kind of 3-speed gear is available. Slow movements = small pump, medium-fast movements = big pump, very fast movements = both pumps together. Thanks to the ServoGear  hydraulics, the total energy consumption is reduced by 10-13%. The savings of the kinetic energy amount to an average of 45% with a 4-minute cycle as against a standard closed-loop controlled hydraulics.

  • With the new swiveling FIFOAdvanced, material changing can be realized very simply.
  • The new DRC 2020 HT with haptic touch display offers breakthrough user prompting and the optionally integrated SetupAssist which explains the entire setting-up procedure to the machine operator and hence makes the well-known notes glued on the control cabinet superfluous.
  • An actively driven feed roller "ActiveFeed" enables the feeding of even strongly fluctuating rubber strips or low-viscosity elastomers.
  • The hydraulically driven non-return valve PlastControl  is a strong asset particularly for processing low-viscosity compounds. The non-return valve guarantees optimal plasticizing accuracy and, moreover, material changing is of unequalled ease. 

Further information at www.desma.biz

    ServoGear

    ServoGear

    Comparison of fixed displacement pump to variable capacity pump

    Comparison of fixed displacement pump to variable capacity pump

    Fixed displacement pump with servo-drive, standard solution

    Fixed displacement pump with servo-drive, standard solution

    Fixed displacement pumps with servo-drive, DESMA standard solution

    Fixed displacement pumps with servo-drive, DESMA standard solution

    ServoGear hydraulics for two axes

    ServoGear hydraulics for two axes

    04. Aug. 2011

    The silent innovation - ServoGear

    Since the machine cycle in the elastomer injection moulding process is still varying very much from the one of thermoplastic processing, further developments can be transferred to elastomer processing to a certain extent only. This is why fully electric machines are not able to establish themselves for rubber injection moulding.

    The consistent use of variable capacity pumps was the ideal solution in the light of long cycle times and the required high pressures and forces. In this case the energy consumption could be strongly reduced as against fixed displacement pumps.

    DESMA machines of the S3 generation are from now on equipped with the ServoGear  hydraulics. This means that generally a fixed displacement pump is being driven with a servomotor. This kind of driving technology is already available at reasonable prices especially for the lower and medium-scale performance range. 

    For a further increase of efficiency, the ServoGear  hydraulics was developed with two pumps per driving axis. Similar to a gearbox in vehicles, it is possible to reach big forces at low speeds as well as high speeds at low forces. If little oil volume is required (e. g. with dwell pressure), a small pump is required only. This is comparable to the first gear of a car when starting on a hill. If higher speeds are necessary, the big pump is used (e. g. for injection). If fast movements shall take place with low pressure being required (in case of mould movements), both pumps can be simultaneously switched to one consumer. This way, the drives are optimally used without the risk of overload (high torque at low speed).

    If axes are supposed to be operated parallelly, each axis is provided with a servo-drive with two pumps.

    In additon to the energy being saved, the accuracy of the hydraulic movements is clearly improved through ServoGear. This accuracy is now defined by the servomotor. Such motors have been used in machine tools for many years. The actual hydraulics takes over the function of the gear.

    In this connection, very positive mention should be made of the noise level. The familiar noises of a fixed displacement motor with one or several variable capacity pump(s) do no longer exist. The injection moulding machines equipped with the ServoGear  hydraulics sound like a machine tool.

    TeamViewer

    TeamViewer

    09. May. 2011

    TeamViewer – Remote maintenance via internet

    The diagnosis tool TeamViewer  which has already been used successfully with the control system generations DRC 1210 and 2010 is of course also available with the new visualization DRC 2020 HT. Thus the Customer Care Center of DESMA can keep resorting to the functionality of this tool in order to implement swiftly and easily diagnoses and maintenances on the machines.

    We can help our customers and partners in a quick and uncomplicated way.

    With TeamViewer  we establish a connection to your machine via internet, even despite firewalls.

    The TeamViewer  is started on OP page 960.

    The password has to be transmitted to the Customer Care Center department of DESMA enabling them to establish a connection to the machine. This is required for safety reasons. At every start of TeamViewer  a new password is generated. An internet connection must be available on the machine enabling the use of TeamViewer. To this end support of the customer IT department is required. IP addresses in the range of 10.xxx.xxx.xxx cannot be used.When having finalized the maintenance works, TeamViewer  is ended by the receiver key.

    Quicklock, image 1

    Quicklock, image 1

    Quicklock, image 2

    Quicklock, image 2

    Quicklock, image 3

    Quicklock, image 3

    Quicklock, image 4

    Quicklock, image 4

    Quicklock, image 5

    Quicklock, image 5

    Quicklock, image 6

    Quicklock, image 6

    23. Mar. 2011

    QuickLock – quick-clamp system for injection moulds

    Moulds for elastomer injection moulding machines need to be changed at regular intervals. This process partly takes 30 to 60 minutes especially in case of big moulds in vertical clamping units and partly several hours in case of non-preheated moulds.  

    The usage of QuickLock can reduce this mould changing time and thus the machine downtime considerably. A preheated simple 4-platen mould can be changed within 5 instead of 30 minutes before.

    This is made possible through a mechanical clamp system with hydraulic unlocking. The operator only needs to pull resp. to insert two rods each on the heating platens and the hydraulic lifting devices.

    It is easy to identify whether the locking rods are available or not. With the rods being inserted, the system is totally safe and a fall protection therefore also exists already on the upper plate. Thus, redundant safety is given.

    The upper and lower mould half is clamped against the heating platen by means of disk springs in order to achieve a good temperature transfer. Now only a connection without pre-stress takes place on the core lifter brackets because a heat transfer is not desired.

    The locking rod of the upper mould half is pushed into the heating platen, the corresponding counterparts are projecting on top of the mould.

    There is nothing projecting on the lower mould half. The mould can therefore be put down and transported as usual. The clamp elements can completely disappear in the lower heating platen. Thus there is nothing that projects when the mould needs to be changed. As soon as the mould lies in the machine, the clamp element moves out of the heating platen and dips into the mould.

    The design of QuickLock allows its easy dismantling also in case of errors. The whole system complies with maximum requirements on safety and is integrated within the corresponding declaration of conformity of the injection moulding machine. Moulds which are not intended for the usage of QuickLock can still be fixed in the usual way. The T-slots for mould fastening are still available.

    By way of a transport device, the complete mould can be safely uplifted above the QuickLock elements with a forklift truck.

    DESMA 969.070 ZU with hydraulic clamp device and control system DRC 1210

    DESMA 969.070 ZU with hydraulic clamp device and control system DRC 1210

    machine floor plan

    machine floor plan

    D 969.318 Z2 with clamp and support device

    D 969.318 Z2 with clamp and support device

    17. Feb. 2011

    New special machine for pump stators

    For many years DESMA has been the globally leading manufacturer of special machines for the production of pump stators. Especially for larger stators, machines without clamping unit are used. Up to a length of 10 m, pump stators are produced by using the injection process. For this purpose, special machines are available with one or two injection units which are able to inject alternately more than 300 kg of rubber by way of the multi-shot procedure. Typically vulcanization is then carried out in an autoclave.

    DESMA has now developed a special machine particularly for medium-sized stators which makes the production of stators up to a shot weight of 6,890 cm³ possible. The injection unit features a maximum injection pressure of 1,010 bar and has been also designed for multi-shot applications.

    As against customary stator machines, the stator is not being arranged along the longitudinal axis of the injection unit, but vertically i. e. 90° up. The main advantage is that far less space is required for the entire plant and the simplified feeding and unloading due to the integrated clamp device. Typically for DESMA, the injection unit works according to the FIFO principle and is equipped with a retractable nozzle.

    The new D 969.070 ZU machine is as of now available with the latest visualization DRC 2020 HT which provides the operator with a perfect user surface with tactile feedback due to its Haptik Touch option.

    The new D 969.070 ZU thus complements the series of pump stators.

    The following machines are available for the production of large-sized pump stators:

    • D 969.142 Z with 14,200 cm³ injection volume
    • D 969.160 Z2 with twin-inject with 2 x 8,100 cm³ injection volume
    • D 969.318 Z2 with twin-inject with 2 x 15,900 cm³ injection volume

    These so-called in-line machines are either available with or without clamp and support device.

    Small stators as long as 1,000 mm can alternatively be produced on the DESMA standard machines with complete clamping unit. Vulcanization is then carried out under clamping force in the mould carrier.