How digital solutions assure injection moulding process control

Tony Borthwick, ENGEL UK Technical Director, discusses the importance of digital solutions in the control of injection moulding processes and how ENGEL’s assistance systems can unlock the full potential of your machines.

I've been working at ENGEL for 34 years, of which 8 years at our Headquarters in Austria. I have worked in roles as a service engineer, technical help and business development over this time. My current role at ENGEL UK is to look after everything related to After-Sales Support, which includes Service, Spare Parts Sales and Training. Customer satisfaction is a critical goal for us to help sustain our reputation and help towards future machine sales and the responsibility for this stops at my door for all UK and Ireland customers.

Efficiency and control are more important and relative than ever before. The challenges our customers face mean that it is important to use all tools available to reach their OEE goals and minimise waste.

Digitalisation improves the traceability of information and this is crucial to be able to maximise machine efficiency. The ultimate goal achieved through digitalisation can be cost savings, sustainability and coping with labour shortages. Achieving a stable injection moulding process and controlling it automatically is vital, and this is where digital assistance systems can make a significant difference.

Yes, anyone with an ENGEL machine experiencing variability in their process, environment, or material can benefit from our digital products. Our iQ portfolio includes products that can assist businesses from single operators to multinationals, improving and controlling their injection moulding process control by standardising operations and minimising setting variations.

set-up assistant: The set-up assistant is designed to facilitate seamless changeovers or tool changes, thereby optimising tool changeover times. It ensures a sequential operation, significantly reducing the risk of human errors or machine setup mistakes. This is particularly crucial in today's landscape, where there is a notable shortage of qualified personnel. By optimising tool changeovers, it effectively minimises errors and enhances the injection moulding process control.

iQ weight control: This feature maintains a consistent shot volume or weight, ensuring high repeatability. It effectively minimises environmental variations, including changes in tooling temperature, ambient factory temperature fluctuations between day and night, and seasonal variations. The software dynamically optimises the injection volume throughout the injection moulding process, significantly reducing the impact of viscosity changes when post-consumer regrind is incorporated, making it an incredibly powerful tool for injection moulding process control.

iQ flow control: This system facilitates automatic adjustment of mould temperatures via machine-controlled water heaters. It optimises the management of temperature and cooling circuits, thereby enhancing product quality through precise control of tool temperature. The speed control pumps are a crucial component, reducing cooling water consumption, minimising waste, and ultimately lowering energy costs.

Parameter-Limits: These tools are essential once the tool is set, and high repeatability is achieved. They provide a parameter limits mask, derived from machine settings, to prevent incorrect settings by employees. This ensures a validated process window, allowing only authorised personnel to make changes, while others operate within nominal settings that do not compromise part quality or dimensions.

iQ clamp control: Automatically adjusts the clamping force, reducing tool and machine wear by optimising the force applied. This can result in significant energy savings, particularly if the initial clamping force was set excessively high.

iQ hold control: Automates the calculation of the correct hold time, a typically time-consuming task that adds little value during part setup. This can lead to reduced cycle times and energy savings.

iQ process observer: This AI-powered system uses intelligent algorithms to continuously monitor part quality, detecting process deviations early to reduce downtime and scrap. It evaluates process stability during startups and stabilization phases. When issues occur, smart in-system guidance highlights the root causes – such as conflicting parameter settings – and provides clear, actionable suggestions to bring the process back to optimal performance quickly and efficiently.

e-connect: The customer portal from ENGEL is a comprehensive online platform that supports the entire lifecycle of the injection moulding production – from design and sampling to production, maintenance, and service.

ENGEL can also offer remote assistance via e-connect.24, viewing machines live to troubleshoot issues, saving valuable time and resources by eliminating the need for on-site visits.

ENGEL UK offers two options: new machines come with many iQ products for a free 50-hour trial, and existing machines can receive a 3-month trial license for products like iQ weight control.

Companies can contact their local ENGEL representative or email us. Reach out for an initial discussion on their goals and how ENGEL’s digital assistance systems can help. We can also arrange a visit to our Warwick UK office for a live demonstration.