K2022: DESMA to show production solutions for sustainable future design

Company press release (edited)

Fridingen, Germany - At K2022, DESMA will present new developments, which have been triggered, among other things, by e-mobility, the structural change in the energy supply sector and by major projects in the infrastructure sector.

The global megatrends require new production solutions, applications and automation strategies, which have already led to many new machine and process developments.

This is demonstrated by the example of our new DESMA 968.160/50/x ROTARY COMPACT with integrated rotary system for four molds, which is the perfect basis for highly efficient process automation of large series.

By dividing the vulcanization time among four stations, the cycle time can be reduced to approx. 30 % of a standard cycle, which ensures maximum utilization efficiency of the connected process automation.

This process is particularly suitable when long vulcanization times and insert placement tasks are required. Furthermore, additional downstream processes can be integrated in the actual demolding station.

The integrated electrically driven rotary system enables fast movement times and can also move to intermediate positions precisely with high accuracy.

An intermediate station can also be approached for free spraying, e.g. to avoid having to move the die completely away during a compound change or to prevent the carryover of waste material in the event of a lengthy interruption to production. A simple mould change with integrated quick clamping system is also integrated.

The FIFO-A injection unit is available as a high-pressure version and can be equipped with FlowControl+ nozzle technology to further reduce heating times and for nozzle closing. Alternatively, our proven rotary valve gate nozzle is available as a nozzle shutter.

A total of five regulating pumps provide multiple parallel movements to reduce machine times to a minimum. This production technology allows the use of molds with a low number of nests and yet maximum output thanks to four available moulds.

Another special feature is that the machine can also be operated with three or two moulds, or even just one. This means that it is also possible to continue operating the machine with somewhat lower productivity if mold repair or mold cleaning is necessary.

The greatest advantage of this machine technology is that molds and automation systems can be designed with a relatively low degree of specialization, even for the high-volume mold, and the greatly reduced cycle time enables highly efficient operation of the entire process automation system. Basically, it is a rotary machine arranged within the dimensions of a typical 400 ton machine.

XpertForum

DESMA will also offer an insight into its entire range of services and, in addition, with the digital XpertForum also offers visitors who cannot travel to the fair the possibility to be there "live" and to inform themselves about news.

This is also a contribution to sustainability, as remote participation can save large amounts of CO². In addition, we show "live" a virtual machine acceptance from our plant in Fridingen. This kind of machine or mold acceptance, or even test runs, has become established at DESMA with its own film team.

SEALMASTER+

The company will also be presenting our completely newly developed SEALMASTER+ machine platform for horizontal machines live at our booth.

Thanks to its modular design, it offers maximum variability and productivity, such as up to 50% more usable mold area for maximum output increase, depending on the hotplaten configuration.

A completely newly developed clamping unit with decisively reduced friction values for maximum dynamics and best positioning accuracy offers 60% more opening stroke to cover a wide range of mould heights, 30 % more clear width for double-deck moulds for double productivity, and 27% greater tie bar spacing for easy mold changes and maximum brush width utilization.

A new brushing and demolding technology has been positioned directly on the tie bar for shortest approach distances and perfect alignment.

The redesigned machine enclosure ensures the best accessibility to all components, and a new machine base with special mounts for heavy-duty rollers for safe insertion into production.

To ensure best accessibility for maintenance, all temperature control units and the vacuum pump are positioned on a retractable service rack.

The optimally ergonomically arranged, newly developed ServoGear hydraulic unit also ensures maximum ease of servicing, 70% of the hydraulic lines are piped, and the hydraulic tank is made entirely of stainless steel.

A key detail is that 50% less hydraulic oil is required and even a lifetime filling with independent checking and cleaning by the Hydrofit+ is optionally available.

Adaptive hydraulic controllers for the fastest and most dynamic cycles, even with a wide range of mould weights, have made 50% faster travel speeds possible.

In addition, conveyor belt ejection is possible on 3 sides for even more variable and flexible use of automation.

With the same machine dimensions, the SEALMASTER+ is also available as a 4000kN version. Furthermore, the hot platen temperature accuracy has been improved again, +/- 1.5 °C for homogeneous temperature distribution over the entire mold surface.

A 60% reduction in nozzle length, thanks to the new lift-off FiFo B injection unit, results in significantly shorter injection times and higher available injection pressure. The completely newly developed ActiveFeed Generation for feeding problematic compounds with quick-release cassette for easy compound change.

Depending on the requirements of the respective injection molding process, the FlowControl cold runner, optionally with PressureSense technology, or the ZeroWaste ITM pot, combined with the latest mold technology,
can provide optimum, sprue- and waste-free articles in high quality with low reject rates, making a further contribution to sustainable and resource-saving elastomer article production.

The control of valve gate or ZeroWaste ITM technology, as well as brush systems and / or other automation, is carried out centrally via the machine control system, and all sensors and, for example, the cavity pressure can also be monitored and documented via our PressureSense technology.

With the DRC 2030 TBM control generation and trend-based visualization, all processes are under full control at all times. Combined with the SmartConnect products, full networkability, including traceability and all remote service tools, can be used to guarantee maximum plant availability and process traceability.