IPF2008: Exhibiting Various Types of Injection Molding Machines and Next-generation Composite Materials based on Molding Technologies with Plastics and Molded Products at the Core
Nissei Plastic Industrial Co., Ltd. will exhibit at International Plastic Fair (IPF) 2008 from November 7th through 11th at Makuhari Messe, Tokyo, under the main theme of Intelligent Molding - Creation of Ideals. Visitors to the show can view eight Nissei injection molding machines under various themes such as higher quality, energy saving, and environmental compatibility centered on hybrid-type machines utilizing the X Pump. Also on show are various other exhibits, including next-generation composite materials, and quality and production monitoring systems. Outline of Machine Exhibits 1. NPX7-1F Hybrid-type Ultra-compact Injection Molding Machine This injection molding machine with clamping force of 69 kN (7 tons) is outfitted with the X Pump and is for molding small precision parts. Nissei Plastic commands in excess of a 40% market share in Japan for machines for molding precision parts with clamping forces of 1 - 19 tons, and it is one of the company's strongest areas. On the show floor, the theme will be a proposal for one-touch tool changing, and the machine will be equipped with magnet clamps embedded in the platens (option). Molding of clutch rings in a four-cavity mold and quick tool changing will be demonstrated. The key features of this machine are (1) Achievement of an energy conservation effect of an approximately 40% reduction in electricity consumption versus Nissei's hydraulic machine (model NP7), (2) injection ramp-up time features a high response of 25 ms, and (3) injection speed is 230 mm/s, and stable control in the ultra-low speed range is achieved. The injection mechanism adopted is a rotating ram-type in-line screw system that was independently designed incorporating ideas from our machines dedicated to connector molding. Besides exhibiting effectiveness in terms of stable plasticizing and mixing, and color and material changes, the mechanism is further characterized by its excellent low inertial force and low noise. The clamping mechanism adopted is of the direct pressure clamping type that uses a linear guide on die plate portion. Because the mold opening and closing is carried out in a stable manner using a set clamping force, uniform application of pressure to the mold is obtained and furthermore, high precision is achieved for low pressure clamping, and repeatable precision molding can be achieved. Moreover, machine precision can be maintained over an extended period. 2. PNX40-5A Hybrid-type Injection Molding Machines Especially for VOLTIGA Applications This machine is based on a PNX Series hybrid-type injection molding machine equipped with the X Pump and with clamping force of 405 kN (40 tons) that has been modified especially for the molding of VOLTIGA next-generation composite materials. On the show floor, under the theme of introducing VOLTIGA next-generation composite materials that display the attributes of carbon nanotubes (CNTs), molding of couplings for automotive fuel tanks in a two-cavity mold will be demonstrated. At the show, the special VOLTIGA machine will be fitted with a customized VT screw designed to extract the maximum benefits from CNT resin composite materials. Furthermore, even for materials other than composite materials such as nylon resin, the VT screw is effective in reducing physical deterioration and gas generation. The key characteristic of Nissei's hybrid-type molding machines is the Hybrid X Pump System that adopts the innovative X Pump System. This Hybrid X Pump System combines servomotor drive technology and hydraulic drive technology, as the driving source for the injection molding machine and it is totally different from standard hybrid systems. By controlling the rotation of the servomotor, the motor provides driving power only when required (it stops when not required). As a result, up to an approximately 55% reduction in energy consumption is possible compared with Nissei hydraulic machines and furthermore, compared with conventional hydraulic machines, energy efficiency has been greatly improved and for this reason, the rise in the temperature of the hydraulic oil is suppressed and cooling water requirements are thereby reduced. As a result, reductions in cooling water facility (such as cooling towers) expenses as well as maintenance costs are possible. In addition, this machine can handle a wide range of molding tasks from thin wall to thick wall on account of a wide applicable range of injection speeds from low to high speed and the capability of applying high injection holding pressure for extended periods. 3. FNX80-9ALM Hybrid-type Injection Molding Machines Especially for LSR Applications This machine is especially for molding of liquid silicone rubber (LSR) and is based on a 792 kN (80 tons) FNX Series hybrid-type injection molding machines fitted with an X Pump. On the show floor, under the theme of flashless molding of liquid silicone rubber, molding of seal rings will be demonstrated in an 8-cavity tool. This machine is equipped with a special injection unit and a two-liquid material feeding / metering unit, and by employing closed-loop control using the TACT controller, stability of the injection process is enhanced. This time, furthermore, the following functions have been added to the conventional LSR specification: 1) a material chute valve for the hopper throat, 2) a shutoff nozzle at the nozzle tip, and 3) a dedicated nozzle for the B liquid, among others. The features of this machine are as follows:
4. FNX280-71A Hybrid-type Injection Molding Machine This machine is a general-purpose type FNX Series hybrid-type injection molding machine fitted with an X Pump and with clamping force of 2,740 kN (280 tons). On the show floor, under the theme of stable molding of regrinded material through pressure control inside the cylinder, molding of container closures in a 16-cavity tool will be demonstrated. The key characteristic of Nissei's hybrid-type molding machines is the Hybrid X Pump System that adopts the innovative X Pump System. This Hybrid X Pump System combines servomotor drive technology and hydraulic drive technology as the driving source for the injection molding machine and it is totally different from standard hybrid systems. By controlling the rotation of the servomotor, the motor provides driving power only when required (it stops when not required). As a result, up to an approximately 55% reduction in energy consumption is possible compared with Nissei hydraulic machines and furthermore, compared with conventional hydraulic machines, energy efficiency has been greatly improved and for this reason, the rise in the temperature of the hydraulic oil is suppressed and cooling water requirements are thereby reduced. As a result, reductions in cooling water facility (such as cooling towers) expenses as well as maintenance costs are possible. In addition, this machine can handle a wide range of molding tasks from thin wall to thick wall on account of a wide applicable range of injection speeds from low to high speed and the capability of applying high injection holding pressure for extended periods. 5. NEX15-1FN Hydraulic Servo-type Compact Precision Injection Molding Machine This machine is a hybrid-type injection molding machine with clamping force of 147 kN (15 tons) that used hydraulic servovalve control and is designed for molding of ultra-fine precision components as typified by fine pitch connectors. On the show floor, a bar flow test piece will be molded in a single cavity tool under the theme of a molding machine that can produce an in-spec part from the first shot. This injection mechanism of the machine is equipped with a fast response hydraulic servovalve, while the clamping mechanism is of the toggle type and capable of fast molding cycles through adoption of a servomotor. This hybrid molding machine exhibits its power in small capacity molding, thin-wall molding, and molding variable thickness parts based on its low inertia and fast response that are not achievable with an all-electric-type molding machine. The key features of this fast response injection mechanism based on hydraulic servovalve control are:
6. NEX50-5E Electric Injection Molding Machine This machine is a 490 kN (50 tons) clamping force type from the NEX Series of all-electric injection molding machines, which represent a mainstay type of machine for Nissei. On the show floor, under the theme of reject cavity discharge through using in-mold cavity pressure, molding of connectors in an eight-cavity mold will be demonstrated. In terms of new functionalities, a monitoring function to observe the entire injection process, a new version of the mold protection function, and an energy consumption monitor have been added in order to respond to detailed customer needs. Key features of the NEX Series are an automatic clamping force compensation function and high precision metering control that are included as standard. The automatic clamping force compensation function was developed in order to give a direct pressure clamping feel to the toggle mechanism. Utilizing technology related to the direct pressure clamping mechanism accumulated over many years, Nissei successfully developed a function that enables the user to use a toggle clamping mechanism with the same sensation as a direct pressure clamping mechanism. This function automatically compensates for variations in clamping force in the toggle clamping due to rising tool temperature during automatic or continuous operation of the molding machine and moreover, enables the clamping force to be changed during automated operation. In high precision metering control, either prepack, which realizes high-precision metering during molding, or precision metering can be selected as the control mode. 7. NEX110-18EPI Electric-type Pulp Injection Molding Machine Accompanying the advance of global warming, countermeasures for it have become urgent matters and amid this situation, developing molding materials and molding process technologies with lower environmental footprints has become an important social responsibility. Pulp injection molding (PIM), in which the major components are pulp and starch water, is a manufacturing method for which future expectations are held as a substitute for petroleum-based resins. This machine is based on a 1,080 kN (110 tons) clamping force type from the NEX Series of all-electric injection molding machines, which represent a mainstay type of machine for Nissei, and it is a machine designed specifically for PIM. On the show floor, under the theme of a pulp molding system proposed for reducing the environmental footprint, lids will be molded from pulp and starch in a four-cavity tool. The pulp molding specifications are as follows: 1) Special low compression short screw, cylinder. 2) Cooling blower for injection cylinder. 3) Material stirring unit. 4) Control of slight mold opening / closing. The main features of pulp injection molding are as follows:
8. TNX50R5V Hybrid-type Vertical Injection Molding Machine This machine is a hybrid-type vertical type injection molding machine fitted with an X Pump with clamping force of 532 kN (50 tons).that incorporates a turntable. On the show floor, under the theme of insert molding by a new vertical type hybrid machine, a pocket mirror will be molded in a two-cavity tool from AS resin and a mirror insert. The key characteristic of Nissei's hybrid-type molding machines is the Hybrid X Pump System that adopts the innovative X Pump System. This Hybrid X Pump System combines servomotor drive technology and hydraulic drive technology as the driving source for the injection molding machine and it is totally different from standard hybrid systems. By controlling the rotation of the servomotor, the motor provides driving power only when required (it stops when not required). As a result, up to an approximately 55% reduction in energy consumption is possible compared with Nissei hydraulic machines and furthermore, compared with conventional hydraulic machines, energy efficiency has been greatly improved and for this reason, the rise in the temperature of the hydraulic oil is suppressed and cooling water requirements are thereby reduced. As a result, reductions in cooling water facility (such as cooling towers) expenses as well as maintenance costs are possible. In addition, this machine can handle a wide range of molding tasks from thin wall to thick wall on account of a wide applicable range of injection speeds from low to high (300 mm/s) speed and the capability of applying high injection holding pressure for extended periods. The clamping mechanism adopts a turntable type direct pressure clamping unit with many features that are superior to toggle clamped alternatives, such as uniform application of pressure, direct advance when opening and closing the mold, accurate clamping force, and the ability to maintain the precision of mold clamping. Furthermore, reduced cycle time has been achieved through utilizing electric servomotors for rotation and ejection. 9. VOLTIGA Next-generation High Performance Composite Materials Products have been developed by Nissei's Nanomaterials Business that started in September 2007 based on composite formation technology for nanomaterials typified by carbon nanotubes (CNTs) combined with plastics VOLTIGA next-generation high performance composite materials are twice as strong as steel, and possess five times the electrical conductivity of copper. They are compounded using an innovative uniform dispersion technology developed by Nissei that combines the supermaterial CNT with a resin matrix. The composite material possesses extremely excellent multifunctional properties such as electrical conductivity, thermal conductivity, strength, and surface flatness. Compared with other composite materials such as glass fiber types, the material is characterized by its ease of processability, dimensional stability of molded products, and processed surface finish. For these reasons, expectations can be held of great effects in terms of conferring new functionalities to molded products, as well as total cost reductions. On the show floor, a PNX40 hybrid-type molding machine especially designed for processing VOLTIGA will be used to demonstrate molding of VOLTIGA next-generation high performance composite materials. Besides molding of couplings for automotive fuel tanks, various functionalities and properties will be introduced through a panel display. 10. Nissei FP System A cassette tooling system that supports production of multiple lots in small volumes that is part of the Nissei Flexible Product System that comprehensively supports everything from product design through to molding. At the show, 1) a simplified tooling system develop independently by Nissei and comprising a base block and a unit mold will be displayed as the FP system, and total cost reduction, shortening of set-up operation time, and in-company standardization will be proposed. Furthermore, 2) A sample tool system conforming to ISO and JIS standards will be displayed. Simultaneous locking on three surfaces via a one-touch system is possible through an innovative mechanism developed independently by Nissei, and when a cooling circuit is attached, it is possible to simultaneously connect it up. 11. 3D TIMON Resin Flow Analysis Software 3D TIMON is a comprehensive analysis oriented software package for the production technology and molding technology sectors, as well as research institutes. Its key features are 1) fully-fledged analysis system spanning packing, holding pressure and deformation, 2) wide range of option modules answering to various industries, 3) voxels used for analysis mesh and for this reason, a significant shortening of the set-up time for analysis that is normally required is possible and 4) major effects are exhibited for verifying and correcting molding defects, and this contributes to shortened lead times for product development. 12. PQ Manager Quality Control/Production Management System This quality control and production management system can be applied to a variety of applications, from group control of quality and production information for up to 50 molding machines to quality analysis of a single molding machine, by connection of a server and a LAN. On the show floor, a demonstration will be carried out by connecting two molding machines on display: a NEX15 and a NEX50. The major characteristics are:
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