kistler worldwide plastics - · pdf filekistler gmbh lemböckgasse 49f ... demag plastics...

AustriaKistler GmbHLemböckgasse 49fAT-1230 WienTel. +43 1 867 48 67 0Fax +43 1 867 48 67 [email protected]

ItalyKistler Italia s.r.l.Via Ruggero di Lauria, 12/BIT-20149 MilanoTel. +39 02 481 27 51Fax +39 02 481 28 [email protected]

United KingdomKistler Instruments Ltd.Alresford House, Mill LaneAlton, Hampshire GU34 2QJTel. +44 1420 54 44 77Fax +44 1420 54 44 [email protected]

Korea, Republic ofKistler Korea Co., Ltd.3rd Floor, Bow Building1580-1, Seocho-3 dong, Seocho-ku, Seoul 137-875Tel. +82 2 597 6013Fax +82 2 525 [email protected]

SingaporeKistler Instruments (Pte) Ltd.50 Bukit Batok Street 23#04-06 Midview BuildingSingapore 659578Tel. +65 6316 7331Fax +65 6316 [email protected]

TaiwanKistler Representative Office in TaiwanRoom 9, 8F, No. 6, Lane 180Sec. 6, Mincyuan E. RoadTaipei 114Tel. +886 2 7721 2121Fax +886 2 7721 [email protected]

ThailandKistler Instrumente (Thailand) Co., Ltd.662/43-46 Rama III RoadBangpongpang, YannawaBangkok 10120Tel. +66 2293 02234Fax +66 2293 [email protected]

Europe

GermanyKistler Instrumente GmbHDaimlerstrasse 6DE-73760 OstfildernTel. +49 711 34 07 0 Fax +49 711 34 07 [email protected]

FranceKistler FranceZA de Courtabœuf 115, avenue du HoggarFR-91953 Les Ulis cedexTel. +33 1 69 18 81 81Fax +33 1 69 18 81 [email protected]

Switzerland/LiechtensteinKistler Instrumente AG Verkauf SchweizEulachstrasse 22CH-8408 WinterthurTel. +41 52 224 12 32Fax +41 52 224 14 [email protected]

Asia

JapanKistler Japan Co., Ltd.MT Building2-7-5, ShibadaimonMinato-ku, Tokyo 105-0012Tel. +81 3 35 78 02 71Fax +81 3 35 78 02 [email protected]

China, People’s Republic ofKistler China Ltd.Unit D, 24 / F Seabright Plaza9–23 Shell StreetNorth Point, Hong KongTel. +852 25 91 59 30Fax +852 25 91 18 [email protected]

Representative Office BeijingTel. +86 10 8225 2163Fax +86 10 8225 [email protected]

IndiaKistler Instruments (Pte) Ltd.India Liaison Office2B Century Plaza560/562 Anna SalaiTeynampet, Chennai 600 018Tel. +91 44 5213 2089Fax +91 44 5213 [email protected]

Kistler worldwide

Denmark/Finland/Norway/SwedenKistler Nordic ABAminogatan 34SE-431 53 MölndalTel. +46 31 871 566Fax +46 31 871 [email protected]

NetherlandsKistler B.V. NederlandLeeghwaterstraat 25NL-2811 DT ReeuwijkTel. +31 182 304 444 Fax +31 182 304 [email protected]

America

USA / Canada / MexicoKistler Instrument Corp.75 John Glenn DriveAmherst, NY 14228-2171Tel. +1 716 691 5100Fax +1 716 691 [email protected]

Other countriesKistler Instrumente AGExport SalesEulachstrasse 22CH-8408 WinterthurTel. +41 52 224 11 11Fax +41 52 224 15 [email protected]

Headquarters

SwitzerlandKistler Instrumente AGEulachstrasse 22CH-8408 WinterthurTel. +41 52 224 11 11Fax +41 52 224 14 [email protected]

www.kistler.com

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100% QualityInjection Molding

Kistler –Your partner for efficiency and quality

2

Sensors and systems for optimizing, moni-toring and documenting the quality dataduring injection molding processes is onlypart of the solutions for the industry provi-ded by Kistler Instruments AG. With head-quarters in Switzerland, we supply plasticsprocessing solutions as well as specific sen-sors and systems for combustion engines,automotive engineering, mechanical pro-duction and biomechanical engineering.

Our core competence lies in the develop-ment, production and implementation ofsensors for pressure, force and accelerationmeasurement. Kistler electronic systemsand expertise used for processing measu-rement signals allow the analyses of phy-sical processes, process control and opti-mization as well as the enhancement ofproduct quality for the processing industry.

Every year, Kistler invests 10 % of its salesin research and development – for inno-vative and efficient technical solutions atthe leading edge of technology.

The Kistler group with more than 600 em-ployees is the leading supplier of dynamicmeasuring technology throughout theworld. Close cooperation with the custo-mer, individual application support andshort delivery times are guaranteed by thegroup's 18 member companies and morethan 30 agencies.

www.kistler.com

Product overview by type numbers

www.kistler.com 65

1200A13 511200A15 511200A41 511200A79 521200A81 521200A83 521200A89 511200A27 511200B43 511200B21 511300A81 611300A83 611315A 611356 611358 611362A 611383 611645C... 491661A... 501662B... 501666A1 491666A2 491666A3 491666A4 491667B... 501672B... 501700A62 521700A99 521700B63 521839 491939A... 491955A... 491961A... 491963A... 49

Type Page Type Page

2207A 572231 512290A... 502295A... 502805A... 592853A... 562855A4 592855A6 592859A... 562863 522885B1 59

4013A... 454079A... 374083A... 45

5039A... 555049A221 555063A1 565155A... 555227A1 565493 625613A1 575613A2 575991 625993A1 62

6152AA... 336152AB... 336152AC... 336152AD... 336155AE 366157BA... 346157BB... 346157BC... 346157BD... 346158A... 356159A... 356159A...U6 356167A... 376172AA... 386172AC... 386177AA... 386177AC... 386178A... 396182AE 356183AE... 366190A... 406192A... 416193A... 426194A... 426195A... 416829A... 39

9204B... 439211A... 439213A... 439221A... 449223A... 449232A 469827A2491 469827A1392 46

Type Page Type Page Type Page

Unisens® and PiezoStar® are registered trademarks of Kistler Instrumente AG, Winterthur, SwitzerlandWindows XP® and Windows 2000® are registered trademarks of Microsoft Corporation

Photos bySchöttli AG, Diessenhofen, SwitzerlandDemag Plastics Group, Schwaig, GermanyBIRO Edwin Bischof AG, Romanshorn, Switzerland

Table of Contents

3www.kistler.com

The benefits of mold cavity pressure measurement

More productivity – lower costs 4

More efficient processes – better quality 6

The basics of mold cavity pressure measurement

The pressure profile and its interpretation 8

Using mold cavity pressure in practical applications

Measuring: Sensors and positioning 10

Connecting: Safe transmission with suitable cables 14

Amplifying: From charges to signals 16

Analyzing: Optimizing, monitoring and documenting injection molding processes 18

Sensors for mold cavity pressure measurement

Measuring chains for cavity pressure measurement 20

Sensors and systems for injection molding machines

Measuring the melt pressure 28

Measuring the tie bar extension 29

Measuring the clamping force and mold protection 29

Sensors and measuring chains for injection molding machines 30

Product details / Product range

Measuring: Sensors 32

Connecting: Connecting and extension cables 48

Amplifying: Charge amplifiers 54

Analyzing: Optimizing and documentation systems 58

Accessories / Tools 60

Technical Literature 64

Product overview by type numbers 65

Modern injection molding technology is

faced with ever more exacting require-

ments and a rising number of complex in-

jection molding processes. Equipped with

high-performance systems based on mea-

suring the pressure in the mold cavity, in-

jection molding machines are able to pro-

duce flawless high-quality parts. These

systems can automatically monitor, opti-

mize and control injection molding pro-

cesses, boost productivity and cut costs.

During the first decades of industrial in-jection molding the development of con-trol systems focused on machine parame-ters alone. However, these processes hada rather limited informative value or be-nefit for users. From the early 1990s on, itbecame clear that for many applications,high process constancy and optimum partquality could only be ensured over a long

period of time by using measuringsystems which focused on the pressure inthe mold cavity.

Mold cavity pressure measurement andsystems using cavity pressure for monito-ring and controlling injection molding pro-cesses offer a range of technical and eco-nomical benefits such as the following:• Reduction of the reject quota• Optimization of the cycle time• Shortening of installation and setup

times• Minimization of material requirements• Reduction of personnel costs• Less energy costs• Active mold protection

Systems measuring the pressure in themold cavity are almost fully automaticand easy to operate. Quartz sensors haveproved to be particularly suitable for bothdirect and indirect cavity pressure measu-rement. Modern system solutions operatewith a closed circuit which includes moldcavity pressure recording with the help ofquartz sensors, smart electronic equip-ment and ergonomic software.

The processes within the mold are crucialto the quality of the injection moldedparts, yet they can never be viewed direct-ly. Attempts at describing process phasesin terms of machine parameters such ashydraulic pressure, have not yielded anysuccess. The main reason for this lies inthe fact that machine parameters cannotrecord the effects of sprue solidification ormelt compressibility.

The benefits of cavity pressure measurement systems

4 www.kistler.com

More productivity – lower costs

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Mold cavity pressure is the most informative process parameter Only a continuous documentation of themold cavity pressure profile yields a de-tailed record of the processes occurringduring the injection, compression and hol-ding pressure phases of injection molding.Only this parameter correlates with allother quality-related part properties suchas weight, morphology, fidelity of repro-duction, flashes, sink marks, voids, shrin-kage and warpage.

The mold cavity pressure not only optimi-zes the change-over from compression toholding pressure, in each cycle, its profilecan also be used as a criterion for determi-ning the change-over point. It allows bet-ter maintenance of the tight part weighttolerances and numerous other qualityfeatures than any other change-over stra-tegy, be it based on the hydraulic pres-sure, screw stroke or time.

Quality assurance and documentationwith the help of mold cavity pressurecontrol The documentation of the mold cavitypressure not only proves the quality ofthe finished part but also allows selectivemonitoring and early detection of processdeviations. Useful algorithms such as sta-tistic process control or neuronal networkscan deliver very precise information onthe effect of the mold cavity pressure andother process or machine parameters onthe mold quality.

Precise assessment of the molded partsrequires systems which analyze theirweight and dimensions as well as correla-ting features such as streaks and othersurface defects while also providing auto-matic control of reject/accept gates. Inthe near future, most modern injectionmolding systems are likely to rely on anautomatic determination of the optimumprocess parameters.

Mold cavity pressure control systems arereliable and durable Despite the high number of benefits,many injection molders are still skepticalwhen it comes to mold cavity pressurecontrol. On the one hand, they are averseto the investment costs and on the otherhand they anticipate downtimes and fol-low-up costs. Experience shows, however,that improper handling of the sensorsduring installation, maintenance or moldchanges is the main cause of machinedowntimes. The systems themselves haveproven their sturdiness, reliability anddurability.

The large-scale production of high-quality,cost-efficient parts provides a competiti-ve edge and as such it is the decisive cri-terion for the success of any injectionmolding business. In its wake, quality as-surance will attain major importance forall injection molding processes. With aview to increasingly complex processesand more exacting quality requirements,only machines with high-performancesystems which are based on cavity pres-sure control will be able to deliver flawlesshigh-quality molded parts.

Prof. Dr.-Ing. Dr.-Ing. E.h. Walter MichaeliInstitute of Plastics Processing (IKV) atRWTH Aachen University

The efficiency of a particular injection

molding process is determined long be-

fore it is used for large-scale production.

The consistent application of cavity pres-

sure measurement devices generates user

benefits across the entire product deve-

lopment chain – from mold sampling to

production documentation.

Mold sampling without mold filling studiesMold sampling or, to be more exact, theacceptance of molded parts for large-scaleproduction, is a time-consuming processfor processors as it often involves nume-rous mold corrections and trial runs. Inthis development phase, cavity pressuremeasurement systems can be used to ana-lyze the process and to determine initialmachine settings without mold filling stu-dies. Moreover, the cavity pressure signalis an important tool for uncovering errorsand problems at an early stage, which al-so minimizes the number of required re-petitive mold sampling procedures. Asthese systems reduce the time consumedfor mold sampling to a minimum, theyalso help to curb costs. Practical experi-ence shows that mold cavity pressure sys-tems can reduce the time and effort usedfor mold sampling by up to 75 %.

ment shorter cycle times without affectingthe quality of the molded parts and there-fore allow the determination of optimumtimes for injection, holding pressure andcooling without trial and error. Smart self-optimizing mold cavity pressure measu-ring systems can automatically determinethe change-over point and required resi-dual cooling time during the active pro-duction process. At the optimum point intime during each cycle, these systems willtransmit the corresponding demolding orchange-over signals to the machine.

More flexibility during mold set-upThe use of a reference curve helps to sig-nificantly shorten set-up and change-overtimes. This reference curve of the cavitypressure is determined and saved duringprocess optimization as soon as the opti-mum part quality has been achieved. Du-ring set-up, the machine operator onlyneeds to change the machine setting pa-rameters until the closest approximationbetween the current cavity pressure pro-file and the reference curve for optimumpart quality has been achieved. In thisway, even machines which show signs ofwear and machines from different manu-facturers will deliver molded parts withidentical properties. This approach dispen-ses with the need for time-consumingpart quality tests, which are normallyrequired as a consequence of changes tothe machine settings.

The benefits of cavity pressure measurement systems

6

Optimum quality, minimum cooling andcycle times One essential element of process optimi-zation is the attempt to find an efficientproduction method and a safe processingwindow. A process with an optimum cavi-ty pressure profile will yield high-qualityparts. The achievement of minimum cycletimes and sufficient part quality are at theheart of this phase. Experience shows thatin 70 % of injection molds, the cycle timeis 20 % longer than necessary. Adaptingthe mold cavity pressure will help imple-

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More efficient processes – better quality

7

Error-free production on a large scaleDuring large-scale production, the moldcavity pressure is used for a continuousmonitoring of the quality of the moldedparts. If this quality fails to meet the re-quired standards, an accept/reject flippergate or a handling device can be used toseparate the defective parts from thebatch. This integrated quality assurancesystem ensures the detection of flawedparts at the earliest possible stage of theproduction and as such is prerequisite tothe implementation of "lean" productioncondi-tions. Moreover, this approachreduces the reject quota and helps achie-ve an error-free production. This in turnboosts the productivity of the machine asa consequence of an improved utilizationand lower production costs.

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During mold sampling

+ Initial machine settings without mold filling studies

+ A faster procedure saves time

+ Significant cost reduction

During optimization

+ Automatic calculation of switch-over point and cooling time

+ Optimum cavity pressure profile

+ Minimum cooling and holding pressure times

+ Minimum cycle times

During mold set-up

+ Optimum part quality even after machine changes

+ No time-consuming part quality testing required

+ Shorter set-up times

During large-scale production

+ Automatic reject separation

+ Moving into "Lean Production"

+ Error-free production

For quality assurance

+ 100 % certified quality for each individual part

+ Cost reduction for part quality control

+ Automatic documentation of quality data

Advantages

Documented quality The cavity pressure profile determinedduring the production process is a clearreflection of the quality of the parts pro-duced and is therefore useful material fordocumentation. This way, random checksaccording to the statistic process control(SPC) based on cavity pressure measure-ment evolve into a 100 % quality assu-rance procedure. Cavity pressure measure-ment delivers the relevant data to certifyof every individual injection molded part.It reduces the cost of part quality controland provides an automatic documentati-on of process data which is readily availa-ble for both producers and customerseven years after active part production.

For more information on this topic, please refer to p. 20

The basics of mold cavity pressure measurement

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The cavity pressure within an injection

mold delivers very precise information

about the filling phase, the pack phase

and the holding pressure phase. Gaining

an insight into some physical correlati-

ons facilitates the analysis and interpre-

tation of the cavity pressure profile

during active processes.

The cavity pressure profile At the onset of the filling phase (1) plasti-cized polymer material enters the cavity.As soon as the flow front reaches the sen-sor (2), pressure is registered. The pres-sure should rise in a near-linear gradientparallel to the duration of the filling time.During volumetric filling of the cavity, the filling phase has been completed (3) and the plasticized material is compactedduring the compression phase to ensurethe reproduction of the contours of the

mold cavity. The holding pressure phasefollows after the maximum cavity pressu-re has been reached (4). The holdingpressure phase compensates for the highthermal contraction of the polymer mate-rial – i.e., the reduction of its volume fol-lowing the cooling down process – byintroducing more material. Up to 10 % ofthe part volume is being pushed into thecavity during this production phase. Thefact that the molded part starts to cooldown and solidify near the cavity wallinhibits the pressure transfer. The meltflow from the area in front of the screwto the cavity is slowed down as the visco-sity of the material increases and the flowchannel becomes more constricted in theprocess. The progressive solidification ofthe plasticized material in the gate area(5) and the progressive thermal contracti-on causes the pressure within the cavityto drop to ambient levels (6).

1 ... 2

Time

Pressure

Pressure

Pressure

Pressure

Time

Time

Time

2 ... 3

3

3 ... 6

Cavity pressure

Cavitypressure

Time

Hydraulic pressure

The pressure profile and its interpretation

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During the mold filling phase, the diffe-rent characteristics of plasticized amor-phous or semi-crystalline polymers are im-material as long as their viscosity is iden-tical. However, both materials display adifferent compression behavior. A higheramount of semi-crystalline material thanamorphous material needs to be intro-duced into the cavity at the beginning ofthe holding pressure phase to achieve apressure build-up. When the melt coolsdown during the holding pressure phase,more semi-crystalline material must beintroduced into the cavity to compensatefor the volume contraction and to preventvoids in the finished part.

Specific characteristics of amorphousthermoplastics During the holding pressure phase of in-jection molding processes involving amor-phous polymers such as polystyrene (PS),acrylonitrile-butadiene-styrene (ABS), sty-rene-acrylo-nitrile (SAN), polymethyl me-thacrylate (PMMA), polycarbonate (PC)and polyvinyl chloride (PVC), the moldcavity pressure drops to ambient pressurelevels parallel to the declining part tempe-rature in the wake of an increasing visco-sity and the corresponding deteriorationof the pressure transfer from the area infront of the screw.

Specific characteristics of semi-crystallinethermoplastics Due to an initially sufficient pressure trans-fer during injection molding processesinvolving semi-crystalline materials suchas polyethylene (PE), polypropylene (PP),polyamide (PA) and polyoxymethylene(POM) there is almost no change in themold cavity pressure during the periodafter the compression phase and the on-set of the crystalline melting point. Afterthat, however, the significant volumecontraction during crystallization bringsabout a sudden drop in the pressure. Theduration of the holding pressure phasedepends on factors such as the wall thick-ness of the molded part, the degree ofcrystallization and the processing parame-ters. The crystalline melting point of semi-crystalline materials for example, is de-pendent on the prevailing cavity pressure.

Cavitypressure

Time

Cavitypressure

Time

Using the mold cavity pressure in practical applications

10

Unisens technologyeliminates adjustments Piezoelectric sensors discharge electri-city proportionate to the cavity pres-sure. The proportionality is referred to as sensitivity and is measured in pico-coloumbs per bar (pC/bar). Under nor-mal circumstances, this sensitivity va-ries within narrow limits and must bemanually adjusted on the measuringsystem or the injection molding ma-chine.

Unisens technology made by Kistler dispenses with this fine-tuning effort as the sensors operate with a fixed sen-sitivity. Unisens facilitates machine andsystem adjustment and also preventserroneous input.

Core competence

Accurate pressure data that is suitable for

analysis can only be acquired by means

of reliable and precise measuring techno-

logy. The mold cavity pressure can be

measured directly, indirectly or in combi-

nation with the contact temperature. The

position of the sensors within the mold

plays a crucial role in this process.

At the same time, high-resolution andreliable, sturdy, maintenance-free anddurable measuring equipment is prerequi-site to the reliable acquisition of the pres-sure and temperature data during theinjection molding process. Stringent quali-ty requirements for molded parts genera-te a demand for increasingly precise mea-surement systems. These systems areexpected to register and balance minutepressure variations even at a pressure of 2 000 bar.

Kistler sensors with their dimensions meetthe exacting requirements of moderninjection molding technology and all itsspecial processing methods. They have analmost unlimited service life, deliver highlylinear measuring results, cover a wide frequency range up to 100 kHz and ope-rate independently of the temperature.Piezoelectric cavity pressure sensors madeby Kistler can withstand mold temperatu-res of up to 300 °C and any required melttemperature.

Kistler supplies a whole range of cavitypressure sensors with a standard uniformsensitivity. Equipped with Unisens techno-logy, each sensor comes with a guaran-teed uniform sensitivity within a certaintolerance range. Therefore, the electronicequipment does not require any individualadjustment.

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Installation options

Practical application

There are two installation options toaccommodate different mold concepts:

• Direct screw-mounted sensor

• Sensor with adapting spacer sleeve for direct attachment below the mold platen

Sensor fitted directlyinto the drilled hole

Sensor fitted into the drilled hole with sleeve

Installation and extraction tools

Spacer sleeve

At a glance

Measuring: Sensors and positioning

Direct and indirect pressure measurement

11www.kistler.com

Mold cavity pressure can be measured di-rectly, indirectly or in combination withthe contact temperature.

Direct cavity measurement During direct measuring, the sensor comesinto contact with the plasticized polymermaterial within the mold cavity and mea-sures its pressure directly and without atransmission aid. These sensors can be in-stalled in the drilled holes in the mold withor without an adapter. While sensors withadapters supplied by Kistler already havenarrow diameter tolerances, sensors with-out adapters require fitting by a mold en-gineer.

Most sensors allow an adaptation of thesensor front to suit the cavity structure inorder to prevent impressions in the mol-ded part. Sensors for direct measurementare available in different dimensions andwith front diameters of 9.5 mm, 6 mm, 4mm, 2.5 mm or 1 mm.

Indirect measurement behind the ejectoror measuring pinAlternatively, the force behind the ejectoror measuring pin can be determined andconverted to yield the actual pressure bymeans of the pin diameter. Indirect mea-suring behind the ejector is recommendedfor applications which do not leave enoughroom for a direct sensor. Adverse conditi-ons such as friction, bending of the ejectorpin, platen distortion or contaminateddrilling holes have a detrimental effect onthe measuring results and the correspon-ding control or monitoring operations. Di-rect measurement is clearly desirable to in-direct measurement of industrial processes.

Special sensors for molds with inserts Modern injection molding processes de-mand molds which allow easy and cost-efficient maintenance. As a result, modernmolds are disassembled easily and quicklyand mold inserts can often be removedfrom the mold while it is still installed onthe machine.

Kistler supports mold engineers with anadapter-based sensor Type 6155AE. It ismounted on the mold baseplate andequipped with single-wire technology.Insert changes no longer require a remo-val of the sensor. Thus, both the sensorand the sensor cables, which can be gui-ded through drilled holes in the baseplate,are protected from potential damage du-ring the removal or installation of the in-serts. Drilled holes in the insert ensure anaccurate positioning of the sensor.

This technology can also be used for moldswithout cavity inserts. In these cases, thesensor is not mounted to the baseplatebut to the second mold platen, where itremains even after the mold is removed.The advantages of this method are thesame as those stated above: both the ca-bles and the sensor are protected in themold platen. This approach is particularlysafe for cavity pressure sensors in com-plex mold platens with a high number ofcooling holes.

For more information on this topic,please refer to p. 43


Efficient process monitoring requires themeasurement of both the mold cavitypressure and the temperature as both pa-rameters are important for the productionprocess.

The combination pressure-temperaturesensor measures both the cavity pressureand the contact temperature in the samepoint on the molded part. While the cavi-ty pressure sensor measures the pressure,a newly developed fast-transmission me-thod is used to measure the temperature:both thermocouple cables run separately

Kistler sensors for temperature measure-ment are based on the same principle.Their front diameters correspond to thosespecified for pressure sensors (Ø 4 mm,Ø 2.5 mm and Ø 1 mm) and are compa-tible with standard cavity pressure sensors.

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Combined sensors

Temperature sensors


500

Cavity pressure (bar)

Time (s)

P near the gate

T near the gate

P away from the gate

T away from the gate

Contacttemperature (°C)

400

300

200

100

0 4 8 12 16 200

250

200

150

100

50

0

to the sensor front, where they are wel-ded to a thermocouple type K (Ni-CrN).As the thermocouple is positioned at thetip of the sensor, it measures the contacttemperature of the melt. Thus, evenminute variations in contact temperature,which can be caused by changes such asa falling or rising melt temperature, canbe monitored.



Practical application

13

Accurate positioning of the cavity pressu-re sensor is important for a sufficient du-ration of the signal transmission and in-formative value of the measured values.Both the position of the sensor in relationto the gate and the wallthickness of thepart at the installation point are of parti-cular importance.

Measurement near the gate The cavity pressure profile during the fil-ling phase is measured when the meltflow front has reached the sensor. A mea-ningful and long-term measuring result isacquired near the gate and in the vicinityof the highest wall thickness as thick are-as take longer to solidify. Sensor positio-ning should take into account both thefastest and the slowest melt setting points.In cavities with several gates, measure-ments should be taken from critical areasof the molded part.

Measurement away from the gateThe greater the distance from the gate,the later the melt flow front reaches thesensor, the later the pressure is registeredand the higher the filling level must beto actually allow pressure measurement.Consequently, data about the filling phasecannot be displayed until the sensor hasbeen reached. Measurement on the edgeof a molded part, i.e. away from the gateor at the end of the flow path yields asignal only when the pressure rises sud-denly during the compression phase. Mea-surement positions away from the gateare beneficial only for protecting compo-nents such as threaded spindles or corepullers from damage caused by pressurepeaks or for monitoring specific qualityproblems at the end of the flow path.

Basic rules for accurate sensor positioning

1. The cavity pressure sensor should beinstalled near the gate, where the pres-sure in the molded part is highest. Thecloser the sensor is positioned to thegate, the more detailed the deliveredprocess information.

2. The sensor must be installed withinthe cavity and not in the gate. Sensorsinstalled in the gate will fail to transmitsignals and monitor the process duringthe residual cooling phase after the gatehas been sealed or after the onset ofshrinkage.

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3. If possible, the sensor should be posi-tioned at the thickest cross section of themolded part where the melt solidifieslast and the duration of the pressure ismost extensive.

4. The installation of a second sensoraway from the gate for measuring largeparts with a critical flow path/wall thick-ness ratio is recommended for the acqui-sition of additional part quality data.

5. Sensors must not be installed directlyopposite the gate as they will measurean additional dynamic force componentwhich will override and distort the cavitypressure signal.

Positioning the sensor inthe mold

1./3. 2. 4. 5.


14

Cables ensure the accurate transmission

of all signals from the sensor to the mold

connector, from the mold to the charge

amplifier and from the charge amplifier

to the injection molding machine or to

the electronic analysis equipment. In or-

der to accommodate a wide variety of

customer requirements, Kistler provides

an extensive range of different connec-

ting and extension cables.

Connecting cable: From the sensor to the plug Kistler pressure sensors are available withclassic two-wire coax cables or with thenew single-wire technology. Two-wirecoax cables have a connector plug at theend, which needs to be accommodated inthe mold. The new technology cable hasonly one wire and the connector plug isno longer integrated into the cable (seeinfo-box "Single-wire technology"). Two-wire technology (Fig. 1) is being increa-singly replaced by single-wire technology(Fig. 2).

Extension cable: From the connector plugto the charge amplifierThe sensor's connector plug is mountedon the outside of mold. The cable mustconnect the connector plug with the charge amplifier, which is usually firmlyinstalled in the injection molding machine,or with DataFlow, Kistler's analysis system.For this application, Kistler provides exten-sion cables in a variety of designs, depen-ding on the production environment andthe distance to be covered, and a widerange of different sheathings, colors andcable length (Fig. 3, 4).

Connection cable: From the charge amp-lifier to the machine or analysis equipmentThe charge amplifier and downstreamequipment are linked using a connectingcable. This cable is equipped with a con-nector for the multi-pin input socket ofthe charge amplifier and compatible inter-faces to the injection molding machine orPC cards for signal processing by a note-book or a PC (Fig. 5, 6, 7).

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Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7




The most important benefits of single-wire technology:

+ Cost-efficient mold preparation

+ The cables run through drilled holes

+ Easy installation with detachableconnector

+ Mold makers can shorten cables asrequired

+ The technology is fully compatible withother cables and existing electronicequipment

+ Broken cables can be repaired by theoperator

+ Small cable diameters allow easy instal-lation in multi-cavity molds

Advantages

Connecting: Safe transmission with suitable cables

15

Single-wire technologyConventional two-wire connecting cablesare being increasingly replaced by single-wire technology. The new technology ca-ble has only one wire without shieldingand the connector is no longer integratedinto the cable. The shielding is provided bythe injection molding machine instead.Maxwell's law, established by JamesClerk Maxwell in 1864, explains why thisnew technology yields the same measu-ring results as the old approach. Similar tothe conditions in Faraday's cage, there areno electric fields in the drilled hole or wellof the injection mold. Faraday's cage pre-vents interference from external sourcessuch as electric motors or hot runners.This has been proven to be valid by scien-tific research as well as by the successfulindustrial application of single-wire tech-nology.

The single-wire cable has a very small diameter and can be flexibly installed in drilled cable ducts and cut to length asrequired. A special cut-and-grip system,which is fully integrated into the connec-tor, helps to attach the connector to thecable. As single-wire technology is usedwith standard connecting cables and stan-dard charge amplifiers, it does not incurany additional investment costs. Easierhandling cuts mold costs. Single-wiretechnology also requires less engineeringand significantly facilitates sensor installa-tion. The service-friendly design guaran-tees easy handling during potential moldor sensor changes. Another decisiveadvantage: as operators can repair single-wire cables themselves, maintenance costsfor mold cavity pressure measurement aresignificantly lower.

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Sensors used for multi-cavity molds withmore than four cavities can be connectedto a mold-mounted charge amplifier with-out a connector by using the cut-and-griptechnique. This method has the advan-tage of reduced space requirements onthe mold as well as particularly short sen-sor installation and set-up times. There isno more danger of mixing up cables. Themulti-cavity system (Type 6829A...) iscomprised of charge amplifiers and sensors.


Kistler supplies a wide range of differentcharge amplifiers. While Type 5039... is apure single-channel charge amplifier, thenew generation starting with Type 5155…is equipped with several channels forcharge and temperature. The 1, 2 and 4-channel amplifiers have identical housingsand connector with an identical pin lay-out. Even for changing configurations,the integration effort is therefore reducedto a minimum.

Charge amplifiers are prerequisite to cavi-ty pressure measurement. In order to ac-commodate the wide variety of controlhardware it is recommended that injectionmolding machine manufacturer supplysuitable charge amplifiers with the machine.


16

Charge amplifiers convert charges trans-

mitted by a piezoelectric pressure sensor

into a proportional voltage, which can be

used as an input variable for monitoring

and control processes. Smart charge amp-

lifiers can also utilize specific algorithms

to transmit signals, e.g. for a cavity-pres-

sure related change-over of injection mol-

ding machines.

The cavity pressure related change overfrom the injection phase to the holdingpressure phase is a standard feature ofmodern injection molding machines. Thecavity pressure sensor is connected to the control system via a charge amplifier,which is encased in a sturdy housing. Thecharge amplifier's output signals are ana-log and immediately available via an ana-log/digital converter card (A/D conver-ter). The real-time operation of chargeamplifiers even allows the control of high-speed processes based on cavity pressure.

In addition to the cavity pressure, the partsurface temperature is another importantprocess parameter used for process moni-toring. During machine start-up, it candetect that the process is stationary andstart the production process.

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Type 5039A...

Type 5049A...

Type 5155A...


Based on the cavity pressure upon volu-metric filling of the cavity, smart chargeamplifiers automatically generate a signalwhich causes the injection molding ma-chine to change-over from injection toholding pressure. Used in conjunctionwith temperature measurement equip-ment, these amplifiers can cut the ma-chine's residual cooling time to the requi-red minimum and determine the demol-ding point in a self-optimizing operation.

Amplifying: From charges to signals

17www.kistler.com

Type 2859A... PiCo

The following chapter providesdetailed information on smart charge amplifiers of the SmartAmpbrand supplied by Kistler.

Smart charge amplifiers Charge amplifiers with smart algorithms,which enhance the amplifying process,can generate control signals from the ca-vity pressure profile and the contact tem-perature. These are used as input valuesfor injection molding machines, wherethey serve to increase the repeatability ofthe injection molding process in order toensure the reliable production of highquality parts.

Chargeamplifier

WireSensor


18

Smart charge amplifiers use algorithms

for the self-optimizing change over from

injection pressure to holding pressure or

for automatically reducing the residual

cooling time to the required minimum.

A convenient software tool can be used

to document the measured pressure and

temperature values for the purpose of

process optimization and quality control.

SmartAmp: Self-optimizing change overThe change-over point is an important pro-cess parameter with a significant effect onthe quality and production cost of the mol-ded part. The change over from injectionto holding pressure must be executed inconjunction with a volumetric cavity filling.

Traditional methods use the injection time,the screw stroke or the hydraulic pressureto determine the change-over point. Allthese methods operate according to thesame principle, which involves the defini-tion of a threshold to trigger the change-over. A suitable threshold is determinedmanually by means of repeated fillingswithout holding pressure. This approach istime-consuming, costly and has two majordisadvantages: • Modification of the injection profile

requires a changing or reestablishingthe threshold

• As the change-over point does not account for process or material fluctuations, the change-over is delayed or triggered prematurely

The cavity pressure profile yields accurateinformation on the volumetric filling pro-cess. Independent of the mold geometry,the cavity pressure rises dramatically afterthe holding pressure phase due to thecompression of the melt. This kink in thecurve has its starting point exactly at theonset of the volumetric filling process.Therefore, it is ideal for triggering thechange-over process in the machine.

Kistler has developed an algorithm, whichis integrated into the SmartAmp chargeamplifier to analyze the cavity pressureprofiles of a wide variety of different partsand determine the change-over point inreal time. By using the cavity pressure,SmartAmp technology with ”self-optimi-zing change-over" identifies the change-over point in a fully automatic and self-optimizing procedure. The signal trans-mitted by the SmartAmp triggers an auto-matic change-over from injection to hol-ding pressure.

The self-optimizing change-over processis preceded by a fully automatic learningphase, which lasts 4 to 16 productioncycles. This period is used to determineoptimum parameters for the algorithmsintegrated into the charge amplifier.

The system significantly reduces the rejectquota and controls the effects of batchvariations on the process during the cycle.Due to the automatic recognition of thechange-over point, which dispenses withthe repetitive process of mold filling stu-dies, the SmartAmp significantly facilitatesmold set-up.

SmartAmp technology is integrated intothe Type 5049A... one-channel chargeamplifier and into the Type 5155A... multi-channel charge amplifier.

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Self-optimizingchange-over

Conventualchange-over

Pressure (bar)

Time (s)

Pressure (bar)

Time (s)

Automatic recognition of the change-over point

+ Shorter set-up times

+ Automatic compensation of viscosity variations

+ Automatic compensation of process variations

+ Highly stable process

Automatic cooling time calculation

+ A significantly improved efficiency dueto a reduction of cycle cooling times

+ A constant demolding temperature guarantees a reliable temperature-related part quality and a constant profile of the cavity wall temperature

Advantages

Analyzing: Automatic optimization of injectionmolding processes

19www.kistler.com

Automatic cooling time calculationScientific studies have revealed that themajority of injection molding processes iscarried out with excessive cooling times.The cooling time used during the injectionmolding of thermoplastic materials is de-termined empirically or estimated with thehelp of the cooling time formula and thenentered into the machine's control sys-tem as a constant parameter. In order to compensate for process variations such aschanges in the temperature or control-related variations to ensure a sufficientlysafe production, the set cycle time oftenexceeds the required minimum by between10% and 20%. This approach is detrimen-tal to an efficient production process.

Another disadvantage of time-constantdemolding is a fluctuation in the qualityof the molded part, as it cannot compen-sate for variations in the process, the ma-chine control and the material. These de-viations, however, can have an adverseeffect on warpage, dimensional stabilityand other properties.

Self-optimizing part removal is availableas an option to the Type 5155A... family ofcharge amplifiers. It can be integrated intothe machine control system or used asadditional equipment to be configuredwith the included Windows® software anda notebook computer. The injection mol-ding machine must be equipped with a"mold open" input port to accommodatethis application.

Kistler's combined pressure and tempera-ture sensors are ideal for measuring thepart surface temperature and the moldcavity pressure.

Based on the part surface temperatureand the mold cavity pressure, the Smart-Amp technology involving automatic coo-ling time measurement (status-relateddemolding) determines the optimum coo-ling time for each individual cycle andtransmits an analog signal to open themold. In this way, the optimum coolingtime is set for each individual cycle inorder to guarantee constant temperature-related part quality while the productionruns with maximum efficiency.

20

Kistler DataFlowThe optimum analysis of measured pro-cess data is prerequisite to the utilizationof cavity pressure and part surface tem-perature measurement equipment.DataFlow provided by Kistler operateswith tools which support users across theentire process chain from mold sampling,setup and process optimization to produc-tion monitoring including statistical analy-sis and documentation. These functionsare based on the determination of thecavity pressure and the part surface tem-perature. Additional information such asthe hydraulic pressure can also be proces-sed.

DataFlow is easy to operate as it runs onconventional personal computers or note-books under Windows XP® and Windows2000®. Used in conjunction with Kistlerelectronic equipment (Type 2859A and2853A signal conditioners or Type 6829Amulti-cavity systems), DataFlow offers acomprehensive optimization and docu-mentation system for all injection moldingprocesses, which also accommodatesmulti-component techniques and multi-cavity family molds.

DataFlow can control equipment such asreject gates and reversible belt conveyorsor operate robot placing processes toensure that all parts are separated intorejects and good parts. The networkingcapability of the included statistics toolprovides production data where it is need-ed, e.g. for production planning, controlor quality assurance.

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21

DataFlow provides automatic quality con-trol and integrates it into the process.Trend graphics can predict errors in theactive production process to eliminatethem. Networking statistics allow statisti-cal production analysis (cp, cpk values,production distribution) for the purpose ofdocumentation. Automatic reports providea documentation of quality for customers.Statistics data generated by DataFlow canbe used to detect and eliminate weakpoints in the production process and helpto determine the reject quota while theproduction monitoring function can thenbe used to directly identify the cause ofexcessive rejects.

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Dataflow provides a range of tools acrossthe entire process chain:

During mold sampling and optimization,DataFlow provides process data in a vari-ety of different graphics in order to speedup the mold sampling process and to utili-ze the full optimization potential.

During process optimization, DataFlowcan be used to determine process toleran-ce limits and to evaluate processing pro-perties based on the measured data. Inthis way, the system reduces mold sam-pling times and ensures a fast optimizati-on of the process. The determined tole-rance limits can be used for monitoringpart properties and quality assuranceduring the production process and dis-pense with the need for manual examina-tion.

During mold set-up, cavity pressure refe-rence curves can be stored. Optimizedmolds can be operated fast and efficient-ly on different machines and the opti-mum operating point can be determinedquickly.

During production, DataFlow will calcu-late maximum values, integrals, whichcan be defined as required, the filling in-dex and the injection force from the mea-sured process data. Moreover, the systemallows the definition of tolerance ranges.Transgression of these tolerance rangesby the values recorded from the currentprocess will either trigger an optical noti-fication or lead to an activation of the re-ject gates or robots.

Analyzing: Optimizing, monitoring and documentinginjection molding processes


22 www.kistler.com

Sensors for cavity pressure and part surface temperature measurement

Direct Measurement

Variable Pressure Pressure and Temperaturetemperature

Pressure range Standard Low pressure Standard/low pressure

Process Injection molding Reaction Injection InjectionIM molding molding

Material Thermo- Thermosets Thermoplastics Thermosets RIM Thermoplastics Thermoplasticsplastics Elastomers Elastomers Thermosets

LSR LSR ElastomersLSR

Front- (mm)Sensor

9,5 4079A...6 6152A... 6152A... 6172A... 6172A...4 6157B... 6157B... 6177A... 6177A... 6190A... 6192A...

6155AE 6167A...2,5 6158A... 6178A... 6194A...

6159A... 6195A...6182AE

1 6183AE 6193A...

The sensors type 6152A..., 6157B..., 6159A..., 6167A..., 6182AE and 6183AE with single-wire-technology can be used in the 6829Amulti-cavity system.

Note: The Type numbers listed in the tables describe the sensors.

Indirect pressure measurement

Dimensions (mm)12,6 9204B...6 9211A...

9213A...12,6 x 9,5 9221A...6 x 6 9223A...

Sensors for cavity pressure measurement

23www.kistler.com

Sensor cables

Sensors Type Connecting Cables Type Extension cables Type

4079A... integral 4767A...6152AA..., 6152AC... 1961A..., 1963A... 1667B..., 1672B..., 1661A..., 1662A...6152AB..., 6152AD... 1955A... 1667B..., 1672B..., 1661A..., 1662A...6152A...E 1666A1, 1666A3 1667B..., 1672B..., 1661A..., 1662A...6155AE integral 1667B..., 1672B..., 1661A..., 1662A...6157BA..., 6157AC... 1961A..., 1963A... 1667B..., 1672B..., 1661A..., 1662A...6157BB..., 6157BD... 1955A... 1667B..., 1672B..., 1661A..., 1662A...6157B...E 1666A1, 1666A3 1667B..., 1672B..., 1661A..., 1662A...6158A... integral 1667B..., 1672B..., 1661A..., 1662A...6159A... 1645C..., 1963A... 1667B..., 1672B..., 1661A..., 1662A...6159A...U6 1645C..., 1963A... 1667B..., 1672B..., 1661A..., 1662A...6159AE 1666A2, 1666A4 1667B..., 1672B..., 1661A..., 1662A...6167A... 1645C..., 1963A... 1667B..., 1672B..., 1661A..., 1662A...6172A... 1645C..., 1963A... 1667B..., 1672B..., 1661A..., 1662A...6172A...E 1666A2, 1666A4 1667B..., 1672B..., 1661A..., 1662A...6177A... 1645C..., 1963A... 1667B..., 1672B..., 1661A..., 1662A...6177A...E 1666A2, 1666A4 1667B..., 1672B..., 1661A..., 1662A...6178A... 1645C..., 1963A... 1667B..., 1672B..., 1661A..., 1662A...6178A...E 1666A2, 1666A4 1667B..., 1672B..., 1661A..., 1662A...6182AE integral 1667B..., 1672B..., 1661A..., 1662A...6183AE integral 1667B..., 1672B..., 1661A..., 1662A...6190A... integral 1667B..., 1672B..., 1661A..., 1662A..., 2290A..., 2295A...6192A... integral 2290A..., 2295A...6193A... integral 2290A..., 2295A...6194A... integral 2290A..., 2295A...6195A... integral 2290A..., 2295A...9204B... 1645C... 1667B..., 1672B..., 1661A..., 1662A...9211A... integral 1667B..., 1672B..., 1661A..., 1662A...9213A... integral 1667B..., 1672B..., 1661A..., 1662A...9221A... 1645C... 1667B..., 1672B..., 1661A..., 1662A...9223A... 1645C... 1667B..., 1672B..., 1661A..., 1662A...

24

Machine-integrated systemsMachine-integrated systems acquire mea-suring data and/or transmit switching sig-nals to the machine's control unit. Thesesystems are available with one channelfor pressure measurement or with multi-channel systems for combined pressureand temperature measurement. The chargeamplifiers are integrated into the injectionmolding machine. The machine's controlsystem is responsible for process docu-mentation.

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Sensors, cables, charge amplifiers and

electronic analysis equipment must be

combined in an efficient way. Only the

perfect interaction of all components

across the measurement chain can ensure

a stable operation of the cavity pressure

measurement system to the full benefit

of the user.

Measuring chains are comprised of sen-sors, connection cables, extension cablesif required, charge amplifiers and analysisequipment. The chains are used to set upcontrol circuits for monitoring, optimizingand controlling injection molding proces-ses and for documenting the acquiredprocess data.


25

Mobile systemsWhile mobile systems operate indepen-dently of the injection molding machine,they can still process signals transmittedby the machine for analysis and activelytransmit switching signals to the machine.An external PC or notebook computerequipped with Kistler DataFlow softwareis responsible for controlling the process.Mobile systems are available with onechannel for pressure measurement or as

multi-channel systems for combined pres-sure and temperature measurement. Asthey can be used for different injectionmolding machines, they offer the benefitof accommodating existing molds modi-fied with cavity pressure measurementsystems.

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Measuring chains for cavity pressure measurement

Multi-cavity pressure measurementsystems Multi-cavity systems compile pressure mea-surement data from up to 32 cavities inone charge amplifier. While they operateindependently of the injection moldingmachine, they can still process signals trans-mitted by the machine for analysis andactively transmit switching signals to themachine. An external PC or notebook com-puter equipped with Kistler DataFlow soft-ware controls the process. As mobilesystems they can be used on differentinjection molding machines.

26 www.kistler.com

27www.kistler.com

Sensors and systems for injection molding machines

28

In addition to the measurement and utili-

zation of the cavity pressure, there is a

wide range of other forces such as the

nozzle pressure, the tie bar extension

and the clamping force to be measured

during the operation of an injection mol-

ding machine. Measurement of these for-

ces is important in view of the acceptan-

ce of electric injection and beyond.

In view of recent developments in thearea of electric injection molding machi-nes, the measurement of the melt pressu-re has become increasingly important, asclassic control parameters such as thehydraulic pressure are no longer available.As measurement sensors recording thecurrent consumption or the torque arelocated at a distance from the mold, theyare not as suitable for accurate controlfunctions as the direct measurement ofthe melt pressure in the area in front ofthe screw. The Type 4013A… sensorsprovide fast high-precision measurement,which meets all requirements of electricinjection molding machines.

The piezoresistive sensors, which can beused for pressures of up to 3 000 bar andtemperatures of up to 350 °C, deliver de-tailed process information and are alsosuitable for process monitoring with hy-draulic machines. Further areas of applica-

tion for these sensors include pressuremeasurement in hot-runner systems. In addition to pressure monitoring in thehot-runner, the acquired information canbe used for control purposes. The sensorcan be equipped with a temperature mea-surement feature for a precise determina-tion of the melt temperature directly onthe sensor's measuring component.

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Measuring the melt pressure

29

Measurement of the forces applied on the moving mold half of injection moldingmachines helps determine the machine'sclamping force, and protects both themold and the machine. Kistler force mea-surement systems are used to determineboth the very high clamping forces andthe very low mold movement forces.

Two methods of force measurement aresuitable: the first method, measurementof the tie bar extension, is taken fromstructural machine elements, while thesecond method, measurement of the sur-face extension, is taken from areas suchas the toggle clamp connecting rod. Measurement of the tie bar extension in-

volves the installation of Type 9827A…sensors directly into the drilled holes inthe tie bar. They transmit a signal which isproportional to the force. Only one sensoris sufficient for a precise determination ofthe clamping force and all mold movementforces. The forces measured during moldmovement that can be used for protectingthe mold.

Equipping all tie bars with a sensor allowsthe measurement of forces on the indivi-dual tie bars to ensure parallelism of themold platens and the mold itself, detecti-on of overloads in individual tie bars andthe active prevention of cracks in the tiebars. The charge amplifier required forthis application is included in the Type9827A... measuring chain.

Measurement data on the surface exten-sion mounting acquired from a sensor onstructural machine components such asthe toggle clamp connecting rod can beused for direct determination of the clam-ping force and for the purpose of moldprotection, as the measured extensionsare proportional to the active forces. Type9232A sensors are mounted to the ma-chined surface with a M6 screw. Due tothe high linearity of the signal, this mea-surement method can be applied by usingonly one single sensor for measuring boththe high clamping forces and the lowmold movement forces. The charge amp-lifiers have been adapted to suit specificmachinery.

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Measuring the tie barextension

Measuring the clampingforce and mold protection

Sensors and measuring chains for injection molding machines

30 www.kistler.com

31www.kistler.com

Measuring

32 www.kistler.com

Direct cavity pressuremeasurement

Direct cavity pressure measurement (low-pressure processes)

Direct cavity pressure and contact temperature measurement

Direct contact temperaturemeasurement

Indirect cavity pressuremeasurement

Melt pressure and temperaturesensor systems

Clamping force measurementand mold protection

Tie bar extension

The cavity pressure built up during injecti-on molding processes can be measureddirectly, indirectly or in combination withthe contact temperature. During directmeasurement the sensor touches the pla-sticized material within the cavity todetermine the pressure directly, withoutthe use of transmission pins.

Alternatively, the force can be measuredbehind an ejector pin or measuring pinand translated into the actual pressureusing the pin diameter. In addition to this,Kistler offers special sensors for moldswith inserts.

Combined pressure-temperature sensorsmeasure both the mold cavity pressureand the contact temperature at the exactsame location on the molded part. Kistlersensors for temperature measurementalone are compatible with standard moldcavity pressure sensors.

In addition to the measurement and utili-zation of the cavity pressure, there is awide range of other forces such as thenozzle and hot-runner pressure, the tiebar extension and the clamping force tobe measured during the operation of aninjection molding machine. For these mea-suring tasks, Kistler also provides optimi-zed sensors to suit specific applications.

Measuring

www.kistler.com 33

Technical Data Type 6152AA... Type 6152AC...

Measuring range bar 0 ... 2 000 0 ... 2 000

Overload bar 2 500 2 500

Sensitivity pC/bar -9,4 (Unisens) -9,4 (Unisens)

Cable length m 0,2 / 0,4 / 0,6 / 0,8 / sp* / 0,2 / 0,4 / 0,6 / 0,8 / sp*/single-wire**,*** single-wire**

Exchangeable cable yes yes

Connector Fischer 1 pin neg. Fischer 1 pin neg.

Machineable front yes no

Coated front no yes

Service temperatureMelt (at the front of the sensor) °C <450 <450

Mold (sensor, cable) °C 0 ... 200 0 ... 200

Connection °C 0 ... 200 0 ... 200

Options

Silicone-filled gap 6152AAA... 6152ACA...

Front diameter 6 mm Unisens

Direct mold cavity pressure measuring

PropertiesThe diaphragm-free piezoelectricsensor has a sleeve design. Unisenstechnology allows an easy configu-ration of the measuring systems.Sensor Type 6152AC... is a coatedvariation of sensor Type 6152AA... .

Areas of ApplicationSensors suitable for thermoplastics,thermoset materials, elastomers andLSR. The sleeve design is practicalfor large molds with pressures inexcess of 200 bar.

AccessoriesMounting nut Type 6453****Spacer sleeve Type 6462Dummy sensor Type 6552Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...

Data sheet 6152A_000-028

Technical Data Type 6152AB... Type 6152AD...




Cable length m 0,4 / sp* 0,4 / sp*




Coated front no yes



Connection °C 0 ... 200 0 ... 200

Front diameter 6 mm for high-temperature applications Unisens

PropertiesThe diaphragm-free piezoelectricsensor has a sleeve design. Unisenstechnology allows an easy configu-ration of the measuring systems.Sensor Type 6152AC... is a coatedvariation of sensor Type 6152AB... .

Areas of ApplicationSensors suitable for thermoplastics,thermoset materials, elastomers andLSR. The sleeve design is practicalfor large molds with pressures inexcess of 200 bar and temperaturesup to 300 °C.

AccessoriesMounting nut Type 6453****Spacer sleeve Type 6462Dummy sensor Type 6552Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...

Data sheet 6152A_000-028* customized length (l min. = 0.1 m / l max. = 5 m)** single-wire cable length 1,5 m; Order key 6152AAE; 6152ACE*** single-wire cable length 5 m; Order key 6152AAE1**** included

4

ø6

ø10

4

ø6

ø10

Measuring

34 www.kistler.com

Technical Data Type 6157BA... Type 6157BC...




Cable length m 0,2 / 0,4 / 0,6 / 0,8 / sp*/ 0,2 / 0,4 / 0,6 / 0,8 / sp*/single-wire**,*** single-wire**




Coated front no yes



Connection °C 0 ... 200 0 ... 200

Front diameter 4 mm Unisens


PropertiesThe diaphragm-free piezoelectricsensor. Unisens technology allowsan easy configuration of the mea-suring systems. The sensor Type6157BC... is a coated variation ofthe sensor Type 6157BA... .

Areas of applicationSuitable for thermoplastics, thermo-set materials, elastomers LSR at apressure of more than 200 bar.

AccessoriesMounting nut Type 6457****Spacer sleeve Type 6459Dummy sensor Type 6545Extension cable TNCType 1662A..., 1672B...1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...

Data sheet 6157B_000-030

* customized length (l min. = 0.1 m / l max. = 5 m)** single-wire cable length 1.5 m; Order key 6157BAE; 6157BCE*** single-wire cable length 5 m; Order key 6157BAE1**** included

Technical Data Type 6157BB... Type 6157BD...




Cable length m 0,4/ sp* 0,4/ sp*




Coated front no yes



Connection °C 0 ... 200 0 ... 200

Front diameter 4 mm for high-temperature applications Unisens

PropertiesDiaphragm-free piezoelectric sen-sor. Unisens technology allows aneasy configuration of the measu-ring systems. The sensor Type6157BD... is a coated variation ofsensor Type 6157BC... .

Areas of ApplicationSuitable for thermoplastics, thermo-set materials, elastomers, LSR for apressure of more than 200 bar andmold temperatures of more than200 °C.

AccessoriesMounting nut Type 6457****Spacer sleeve Type 6459Dummy sensor Type 6545Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B…


ø4

8

ø7

ø4

8

ø7

Measuring

www.kistler.com 35

Technical Data Type 6158A... Type 6182AE



Sensitivity pC/bar -2,5 -2,5

Cable length m 0,4 / sp* 1,5 single-wire

Exchangeable cable no no


Machineable front yes yes

Coated front no no



Connection °C 0 ... 200 0 ... 200

Front diameter 2.5 mm


PropertiesDiaphragm-free piezoelectricsensor with a small collar.

Areas of applicationSuitable for thermoplastics. With itssmall dimensions, the sensor Type6182AE is particularly suitable formulti-cavity molds and smallerparts.

AccessoriesSpacer sleeve Type 6464**Mounting nut Type 6458Dummy sensor Type 6558Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...

Data sheet 6158A_000-031 Data sheet 6182A_000-037

* customized length (l min. = 0.1 m / l max. = 5 m)** included

Technical Data Type 6159A... Type 6159A...U6



Sensitivity pC/bar -2,5 -2,5

Cable length m 0,2 / 0,4 / 0,6 / 0,8 / sp*/ 0,2 / 0,4 / 0,6 / 0,8 / sp*/single-wire** single-wire**




Coated front no yes



Connection °C 0 ... 200 0 ... 200


PropertiesDiaphragm-free piezoelectric sensor.Sensor Type 6159A...U6 is a coatedvariation of sensor Type 6159A... .

Areas of applicationSensor for thermoplastics.Particularly suitable for small parts.

AccessoriesMounting nut Type 6457***Spacer sleeve Type 6459Dummy sensor Type 6549Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...

Data sheet 6159A_000-032* customized length (l min. = 0,1 m / l max. = 5 m)** single-wire cable length 1.5 m; Order key 6159AE; 6159AEU6*** included

ø4ø2,5

10

10

ø7

ø2,5

ø4ø1

11,5

Measuring

36 www.kistler.com

Technical Data Type 6183AE...

Measuring range bar 0 ... 2 000

Overload bar 2 500

Sensitivity pC/bar -2,5

Cable length m 1,5 single-wire

Exchangeable cable no

Connector Fischer 1 pin neg.

Machineable front yes

Coated front no

Service temperatureMelt (at the front of the sensor) °C <450

Mold (sensor, cable) °C 0 ... 200

Connection °C 0 ... 200

Front diameter 1 mm


PropertiesSmallest diaphragm-freepiezoelectric sensor.

Areas of applicationSuitable for thermoplastics,thermoset materials. With itssmall dimensions, the sensoris particularly suitable for multi-cavity molds.

AccessoriesSpacer sleeve Type 6464*Mounting nut Type 6458Dummy sensor Type 6579Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...


* included

Technical Data Type 6155AE


Overload bar 2 500



Exchangeable cable yes



Coated front no




Front diameter 6 mm with mounting sleeve

PropertiesDiaphragm-free piezoelectric sensorwith 4 mm front. The sensor is inte-grated into a 6 mm sleeve and canbe mounted on the mold platen.Mold platens or inserts can be re-moved without disassembling thesensor. Using 20 mm or 50 mmextension sleeves, the sensor lengthcan be adapted to suit individualmold requirements. The innovativesensor prevents damage to cablesduring mold disassembly.

Areas of applicationSuitable for thermoplastics. Idealfor molds with inserts. The inno-vative sleeve design can also beused in standard molds for protec-ting the sensor cable.

AccessoriesWasher Type 6530A0,1*Mounting plate Type 6540AExtension sleeve 20 mmType 6530A20Extension sleeve 50 mmType 6530A50Dummy sensor Type 6554 Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...


ø4

ø6

8

11,9

ø9,5

M 12x1

Measuring

www.kistler.com 37

Technical Data Type 4079A...

Measuring range bar 0 ... 5 / 10 / 20 / 50

Overload bar 15 / 15 / 30 / 70

Sensitivity V/bar 2 / 1 / 0,5 / 0,2

Cable length m 2 / 5 / 10 / sp*


Connector 4 pin neg.

Machineable front no

Coated front no




Front diameter 9.5 mm with diaphragm design (measuring chain) for low-pressure processes


PropertiesPiezoresistive measuring chain con-sisting of sensor, cable and ampli-fier Type 4620A... with diaphragmdesign for static long-term measu-rement.

Areas of applicationSensor for processing reactivepolymers (RIM) with long cycletimes.

AccessoriesConnection cable Type 4767A...**Digital amplifier Type 4620A...**




Measuring range bar 0 ... 200

Overload bar 500


Cable length m 0,2 / 0,4 / 0,6 / 0,8 / sp*




Coated front no




Front diameter 4 mm with diaphragm for low-pressure processes

PropertiesPiezoelectric sensor withdiaphragm design.

Areas of applicationSensor for low-viscosity materialsas used for IC coating.

AccessoriesMounting nut Type 6457**Spacer sleeve Type 6459Dummy sensor Type 6545Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...

Data sheet 6167A_000-033* customized length (l min. = 0.1 m / l max. = 5 m)** included

ø4

8

ø7

Measuring

38 www.kistler.com


Measuring range bar 0 ... 200 0 ... 200

Overload bar 300 300

Sensitivity pC/bar -45 -45

Cable length m 0,4 / sp*/ single-wire** 0,4 / sp*/ single-wire**




Coated front no yes



Connection °C 0 ... 200 0 ... 200

Options

Silicone-filled gap 6172AAA... 6172ACA...

Front diameter 6 mm for low-pressure processes


PropertiesDiaphragm-free piezoelectric sensorwith a very high sensitivity. Thesensor Type 6172AC... is a coatedvariation of the sensor Type6172AA... .

Areas of applicationSensor for processes involving alow mold cavity pressure such asfoam molding or compression mol-ding. Suitable for thermoplastics,thermosets, elastomers and LSRwith a pressure below 200 bar. Thesleeve design allows easy installation,particularly in large molds.




Measuring range bar 0 ... 200 0 ... 200

Overload bar 300 300

Sensitivity pC/bar -45 -45

Cable length m 0,4 / sp*/ single-wire** 0,4 / sp*/ single-wire**




Coated front no yes



Connection °C 0 ... 200 0 ... 200

Front diameter 4 mm for low-pressure processes

PropertiesDiaphragm-free piezoelectric sensorwith a very high sensitivity. Thesensor Type 6177AC... is a coatedvariation of the sensor Type6177AA... .

Areas of applicationSensor for processes operating witha low mold cavity pressure such asfoam molding or compression mol-ding. Suitable for thermoplasticselastomers and LSR with a pressureof below 200 bar.


Data sheet 6177A_000-513* customized length (l min. = 0.1 m / l max. = 5 m)** single-wire cable length 1.5 m; Order key 6172AAE; 6172ACE*** single-wire cable length 1.5 m; Order key 6177AAE; 6177ACE**** included

4

ø6

ø10

ø4

8

ø7

ø4ø2,5

10

Measuring

www.kistler.com 39


Measuring range bar 0 ... 200

Overload bar 300

Sensitivity pC/bar -10

Cable length m 0,4 / sp*/ single-wire**




Coated front no




Front diameter 2.5 mm for low-pressure processes


PropertiesDiaphragm-free piezoelectric sensorwith a very high sensitivity.

Areas of applicationSensor for processes operating witha low mold cavity pressure such asfoam molding or compression mol-ding. Suitable for thermoplastics be-low 200 bar. Ideal for multi-cavitymolds and small parts due to smallsensor dimensions.

AccessoriesSpacer sleeve Type 6464***Mounting nut Type 6458Dummy sensor Type 6558Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...

Data sheet 6178A_000-514* customized length (l min. = 0.1 m / l max. = 5 m)** single-wire cable length 1.5 m; Order key 6179AE*** included


Sensors 6152, 6157, 6159, 6167, 6182 or 6183 single-wire Types only

No. of sensors / system 4 ... 32

Measuring range bar depending on sensor Type

Overload bar depending on sensor Type

Sensitivity pC/bar Unisens (depending on sensor Type)


Connector MIL 41 pin

Machineable front depending on sensor Type

Coated front depending on sensor Type

Service temperatureMelt (at the front of the sensor ) °C <450


Charge amplifier °C 0 ... 60

Multi-cavity systems with sensors Type 6152, 6157, 6159, 6167, 6182 or 6183 Unisens

Direct cavity pressure measuring for multi-cavity molds

PropertiesMulti-cavity system comprised ofsensors and multi-channel chargeamplifier for direct installation onmold. Cut-and-clamp technique en-sures easy connection of the sensor.The charge amplifier is connectedto the measuring system with onlyone cable, independent of thenumber of sensors.

Unisens technology ensures easyconfiguration of the measuringsystems.

Areas of applicationSuitable for molds with more thanfour pressure sensors. For informationon the application of individual sen-sors, please consult the correspon-ding tables.

AccessoriesSee measuring chains on p. 26/27.


Measuring

40 www.kistler.com


Pressure measuring range bar 0 ... 2 000

Temperature measuring range °C 0 ... 200

Pressure overload bar 2 500

Pressure sensitivity pC/bar -2,5

Thermocouple Type K

Standard cable length m 0,4 / 0,8 / 1,2 / 1,6 / 2 / sp*


Pressure connector Fischer 1 pin neg.

Temperature connector Fischer 2 pin neg.


Coated front no




Front diameter 4 mm

Direct mold cavity pressure and contact temperature measuring

PropertiesThe combination pressure/tempera-ture sensor measures the pressureand the part surface temperatures(contact temperatures) at one loca-tion within the cavity. The specialdesign of the sensor requires onlya very short reaction time for tem-perature measuring. Dimensionallycompatible with Type 6157A...,6167A... and 6177A... .

Areas of applicationInjection molding of thermoplastics.Ideal for the acquisition of majorprocess values with only one drilledhole.

AccessoriesMounting nut Type 6457**Spacer sleeve Type 6459Dummy sensor Type 6545Extension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...Extension cable Type 2290A...,2295A...

Data sheet 6190A_000-039* customized length (l min. = 2 m / l max. = 3.5 m)** included

ø4

ø7

8

ø2,5ø4

10

Measuring

www.kistler.com 41


Measuring range °C 0 ... 200

Thermocouple Type K

Cable length m 0,4 / sp*

Exchageable cable no


Coated front no





Front diameter 4 mm

Direct contact temperature measuring



Thermocouple Type K




Coated front no






PropertiesDue to its special design, this tem-perature sensor has very short reac-tion times. Measures the part surfa-ce temperature (contact temperatu-re). Dimensionally compatible withTypes 6157A..., 6167A..., 6177A...and 6190A... .

Areas of applicationSuitable for thermoplastics,elastomers and LSR.

AccessoriesMounting nut Type 6457**Spacer sleeve Type 6459Dummy sensor Type 6552Extension cable Type 2290A...,2295A...


PropertiesDue to its special design, this tem-perature sensor has very short reac-tion times. Measures the part surfa-ce temperature (contact temperatu-re). Dimensionally compatible withType 6158A..., 6182A..., 6178A... .

Areas of applicationSuitable for thermoplastics, elasto-mers and LSR. Ideal for small partsand multi-cavity molds.

AccessoriesSpacer sleeve Type 6464**Mounting nut Type 6458Dummy sensor Type 6558Extension cable Type 2290A...,2295A...



ø4

8

ø7

ø2,5

10

ø7

ø4ø1

11,5

Measuring

42 www.kistler.com



Thermocouple Type K




Coated front no






Direct contact temperature measuring



Thermocouple Type K




Coated front no





Front diameter 1 mm

PropertiesDue to its special design, this tem-perature sensor has very short reac-tion times. Measures the part surfa-ce temperature (contact temperatu-re). Dimensionally compatible withType 6159A... .

Areas of applicationSuitable for thermoplastics, elasto-mers and LSR, ideal for small parts.

AccessoriesMounting nut Type 6457**Spacer sleeve Type 6459Dummy sensor Type 6549Extension cable Type 2290A...,2295A...


PropertiesDue to its special design, this tem-perature sensor has very short reac-tion times. Measures the part surfa-ce temperature (contact temperatu-re). Dimensionally compatible withType 6183A... .

Areas of applicationSuitable for thermoplastics, elasto-mers and LSR, ideal for micro partsand multi-cavity molds.

AccessoriesSpacer sleeve Type 6464**Mounting nut Type 6458Dummy sensor Type 6579Extension cable Type 2290A...,2295A...


* customized length (l min. = 0,1 m / l max. = 5 m)** included

M 2,5

9,5

ø12,6

6

ø6

Measuring

www.kistler.com 43

Technical Data Type 9211A... Type 9213A...

Measuring range kN 0 ... 2,5 0 ... 2,5

Overload kN 3 3

Sensitivity pC/N -4,4 -4,4

Dimensions mm Ø 6 Ø 6

Cable length m 0,5 / sp* 0,5 / sp*



Service temperature °C -40 ... 150 -40 ... 150

Diameter 6 mm

Figure shows Type 9211A...

PropertiesPiezoelectric force sensor. SensorType 9213A is equipped with anM2.5 fastening thread.

Areas of applicationIndirect mold cavity pressure sensorthat is behind a measuring or ejectorpin. Ideal for multi-cavity molds orsmall parts. Indirect measurementallows easy mold upgrading and issuitable for all injection moldingprocesses.

AccessoriesExtension cable TNCType 1662A..., 1672B...Extension cable BNCType 1661A..., 1667B...

Data sheet 9211A_000-131Data sheet 9213A_000-132

* customized length (l min. = 0,1 m / l max. = 3 m)

Technical Data Type 9204B...

Measuring range kN 0 ... 10

Overload kN 12

Sensitivity pC/N -1,6

Dimensions mm Ø 12,6

Cable length m 0,2 / 0,4 / 0,6 / 0,8 / sp*



Service temperature °C -50 ... 200

Diameter 12,6 mm

Indirect mold cavity pressure measuring

PropertiesPiezoelectric force sensor withM2.5 fastening thread.

Areas of applicationIndirect mold cavity pressure sensorthat is fitted behind a measuring orejector pin. Indirect measurementallows easy mold upgrading and issuitable for all injection moldingprocesses.



* to suit customers requirements

B

L

Measuring

44 www.kistler.com


Measuring range kN 0 ... 10 0 ... 2,5

Overload kN 12 3

Sensitivity pC/N -3,3 -4,5

Dimensions l x w x h mm 72,3 x 12,6 x 9,5 30 x 6 x 6

Cable length m 0,2 / 0,4 / 0,6 / 0,8 / sp* 0,2 / 0,4 / 0,6 / 0,8 / sp*




Measuring tongue

Indirect mold cavity pressure measuring

Figure shows Type 9223A... PropertiesPiezoelectic force sensor. SensorType 9221AA... is equipped with astandard cable, Type 9221AC... isequipped with a metal-sheathedcable.

Areas of applicationIndirect mold cavity pressure gaugefor measuring behind a measuringor ejector pin. Indirect measurementallows easy mold upgrading. Suitablefor all injection molding techniques.


Data Sheet 9221A_000-133 Data Sheet 9223A_000-134

* customized length (l min. = 0.1 m / l max. = 2 m)

H

ø7,8

ø10,5

ø7,8

28,6

ø10,5

28,6

Measuring

www.kistler.com 45



Sensitivity mV/bar 3,33

Linearity %FSO <± 1

Sealing area flat sealing

Thread 1/2 - 20UNF

Standard cable length m 2 m (integrated)

Service temperatureSensor °C 0 ... 350


Electronics °C 0 ... 60

Options

Temperature measurement optional

350°C sensor

Melt pressure and temperature sensors



Sensitivity mV/bar 3,33

Linearity %FSO <± 1

Sealing area flat sealing

Thread 1/2 - 20UNF

Standard cable length m sp*

Service temperatureSensor °C 0 ... 300


Electronics °C 0 ... 60

Options

Temperature measurement optional

300°C sensor

PropertiesPiezoresistive measuring chain com-prised of sensor with integratedcable, extension cable and amplifier(analog: Type 4618A... or digital:Type 4620A...). This measuringchain can record both the pressure(static and dynamic) and the tem-perature. Consult the data sheet forselecting a suitable measuring chain.

Areas of applicationControl and monitoring of injectionmolding machines and hot-runnersystems.

AccessoriesExtension cable Type 4757A...*Analog amplifier Type 4618A...**Plug Type 1500A57**Digital amplifier Type 4620A...**Plug Type 1500A61**


PropertiesPiezoresistive measuring chain com-prised of a sensor with integratedcable, extension cable, amplifier(analog: Type 4618A... or digital:Type 4620A...). This measuringchain can record both the pressure(static and dynamic) and the tem-perature. Consult the data sheet forselecting a suitable measuring chain.

Areas of applicationControl and monitoring of hot-runner systems by pressure andtemperature measurement.

AccessoriesConnection cable Type 4767A...**Analog amplifier Type 4618A...***Plug Type 1500A57***Digital amplifier Type 4620A...***Plug Type 1500A61***


* customized length (l min. = 0.5 m / l max. = 10 m)** included*** optional

* included** optional

4017

15

ø16

31

Measuring

46 www.kistler.com

Technical Data Type 9232A

Measuring range µε ± 600

Overload µε ± 900

Sensitivity pC/µε -80

Service temperature °C 0 ... 70


Connection 10 ... 32 UNF neg.

Piezoelectric strain sensor

Clamp force measurement and mold protection

Technical Data Type 9827A2491 Type 9827A1392

Diameter mm 12 16

Measuring range µε ± 500 ± 500

Overload µε ± 1 000 ± 1 000

Sensitivity mV/µε -10,4 -7,3


Power supply V DC 10 ... 36 10 ... 36

Output voltage V DC ± 5 ± 5


Piezoelectric strain measuring chain

Tie bar extension

PropertiesHigh-resolution piezoelectric surfacestrain sensor for force measurement.The sensor is screwed to the machi-ned structure with an M6 fasteningscrew. Please specify the maximumstrain for clamping force and moldprotection to allow selection of thecharge amplifier.

Areas of applicationMeasures clamping force and moldprotection in injection moldingmachines. The charge amplifier isspecially adapted to suit the appli-cation and has one output for theclamping force and one output formold protection.

AccessoriesConnection cable Type 1939A...Charge amplifier Type 5155A...*


PropertiesMeasuring chain, comprised ofpiezoelectric longitudinal measu-ring pin, integrated cable andminiature charge amplifier. Thesensor is clamped or screwed tothe machined surface.

Areas of applicationMeasures clamping force andmold protection and monitors tiebar rupture in injection moldingmachines.

AccessoriesPlug 8 pin Type 1500A27Preload tester Type 5991


Figure shows Type 9827A1392 * included

* defined to suit customer requirements

www.kistler.com 47

Connecting and transmitting

48 www.kistler.com

Extension cable

Connection cable

Connection cable

Cables ensure the accurate transmissionof all signals from the sensor to the moldconnector, from the mold to the chargeamplifier and from the charge amplifierto the injection molding machine or thedata aquisition equipment. In order toaccommodate a wide variety of customerrequirements, Kistler provides an extensiverange of different connecting and exten-sion cables.

Connection cables link the sensor to theconnector plug. Kistler pressure sensorsare available with classic two-wire coaxcables or with the new single-wire tech-nology. Two-wire coax cables have a con-nector plug at the end, which needs to beaccommodated in the mold. The newtechnology cable has only one wire andthe connector plug is no longer solderedto the cable. Two-wire technology isincreasingly replaced by single-wire tech-nology.

Extension cables are used to bridge thegap between the connector and the char-ge amplifier or the DataFlow, Kistler'sanalysis system. For this application,Kistler provides extension cables in avariety of designs, depending in the pro-duction environment and the length re-quired, in a wide range of different sheat-hings, colors and cable lengths.

The charge amplifier and downstreamequipment are linked with a connectioncable. It is equipped with a connector formulti-pin input of the charge amplifierand compatible interfaces to the injectionmolding machine or PC cards for signalprocessing by a notebook or a PC.


www.kistler.com 49

Technical Data Type 1666A1 Type 1666A3 Type 1666A2 Type 1666A4

For sensors Type Unisens Unisens Standard Standard

Connector M4 x 0,35 pos. / Fischer 1-pin neg.

Length m 1,5 5 1,5 5

Service temperature °C 0 ... 200 0 ... 200 0 ... 200 0 ... 200

Color blue blue green green

Single-wire cables

Connecting cable for pressure sensors

Technical Data Type 1839

For sensors Type All single-wire sensors

Connector Cut-and-clamp technique for single-wireFischer 1-pin neg.


Single-wire plugs

Technical Data Type 1961A... Type 1645C...

For sensors Type Unisens Unisens

Connector M4 x 0,35 pos / Fischer 1-pin neg. M4 x 0,35 pos / Fischer 1-pin neg.

Length m 0,2 / 0,4 / 0,6 / 0,8 / sp* 0,2 / 0,4 / 0,6 / 0,8 / sp*

Service temperature °C 0 ... 200 0 ... 200

Color blue green

Coax cables



For sensors Type all all

Connector M4 x 0,35 pos. / Fischer 1-pin neg. M4 x 0,35 pos. / Fischer 1-pin neg.

Length m 0,4 / sp* 0,4 / sp*


Color steel steel

Coax cables, steel braided



For sensors Type 9232

Connector UNF 10-32 pos. / BNC

Length m sp*


Color green

Coax cable for strain sensor Type 9232A

* customized length (l min. = 0.1 m / l max. = 20 m) Data sheet 000-351


50 www.kistler.com

Technical Data Type 1667B... Type 1672B...

Connector Fischer 1-pol. pos. Fischer 1-pin pos.BNC pos. TNC pos.

Length m 2 / 5 / 10 / sp* 2 / 5 / sp*


High-temperature cables, Viton-sheathed

Extension cables for pressure sensors


Connector Fischer 1-pin pos. Fischer 1-pin pos.BNC pos. TNC pos.

Length m 2 / 5 / 10 / sp* 2 / 5 / sp*


High-temperature cables with flexible metal sheathing


Connector Fischer 2-pin pos. Fischer 2-pin pos.open ends Fischer 2-pin pos.

Length m 2 / 5 / 10 / sp* 2 / 5 / sp*


High-temperature extension cables

Extension cables for temperature sensors

* customized length Data sheet 000-351




www.kistler.com 51

Technical Data Type 1200B43 Type 1200B21

Connector D-SUB 37 pos. D-SUB 37 pos. / D-SUB 9 neg.PC Card PC Card

Length m 0,5 5

Signal cables for signal conditioner Type 2859A.../2853A... for notebook with A/D card Type 2855B1

Connection cables


Connector D-SUB 37 pos. / D-SUB 9 neg. D-SUB 37 pos.D-SUB 37 neg. D-SUB 37 neg.

Length m 5 5

Signal cables for signal conditioner 2853A.../2859A...for desktop PC with A/D card Type 2855A3/A4/A6


Connector D-SUB 9 neg. D-SUB 9 negD-SUB 9 pos. D-SUB 9 pos.

Length m 0,75 5

Communication cables for signal conditioner Type 2853A.../2859A...for connection with serial interface (RS-232-C) for desktop PC and notebook

Area of application Connection of analog signals fromType 2853A..., 2859A... to A/D cardType 2855B1

Connection of analog signals fromType 2853A..., 2859A... 2855B1;with 4 additional digital outputs(TTL) on D-SUB 9 neg. plug

Area of application Connection of analog signals fromType 2853A..., 2859A... to A/D cardType 2855A3/A4/A6 (max. 16channels); W. digital outputs (TTL)on D-SUB 9 neg. plug

Connection of analog signals fromType 2853A..., 2859A... to A/D cardType 2855A3/A4/A6 (max. 32channels. Digital outputs with Type1200A79 or 1200A81 only

Area of application Connection Type 2859A..., 2853A...to desktop PC/notebook (RS-232-C)

Connection Type 2859A..., 2853A...to desktop PC/notebook (RS-232-C)

Technical Data Type 1200A15 Type 2231

Connector open ends Proximity switchD-SUB 15 pos. D-SUB 15 pos.

Length m 5 5

Trigger input and digital outputs for signal conditioner Type 2853A.../2859A...

Area of application Connection of trigger toType 2853A..., 2859A... andType 2853A..., 2859A...,digital outputs on machine,handling devices or reject gate

Proximity switch for activation of themeasuring process; Connection toType 2853A..., 2859A...


52 www.kistler.com

Technical Data Type 1700B63 Type 1700A99 Type 1200A83

Connector MIL 41 pin pos. / MIL 41 pin pos. / MIL 41pin pos. /D-SUB 9 neg. D-SUB 37 neg. D-SUB 37 neg.PC card

Length m 5 5 5

Signal cables for charge amplifier Type 6829A... to desktop PC with A/D card Type 2855A3/A4/A6or notebook w. A/D card Type 2855B1

Connection cables

Technical Data Type 1700A62

Connector open endsMIL 4 pin neg.

Length m 5

Reset/Operate and excitation voltage for multi-channel charge amplifier Type 6829A...

Area of application Connection of analogsignals from Type6829A... to A/D cardType 2885B1 (max. 16channels); With 4 addi-tional digital outputs(TTL) on D-SUB 9 neg.plug

Connection of analogsignals from Type6892A... to A/D cardType 2855A3/A4 (max.16 channels). With 4additional digital outputs(TTL) on D-SUB 9 neg.plug

Area of application Excitation voltage and Reset/Operate signal for Type 6829A...


Connector feature connector feature connectorD-SUB 37 pos. D-SUB 9 neg.

PC slot covers for digital outputs for desktop A/D cards Type 2855A3/A4/A6

Area of application Slot cover for 24 additional digitaloutputs (TTL) for A/D cards Type 2855A3/A4/A6

Slot cover for 4 additional digitaloutputs (TTL) for A/D cardsType 2855A6


Connector D-SUB 9 pos.terminal screws

Converter TTL to zero-potential switches for Types 1200B43, 1700B63, 1200A81

Area of application Converter for digital outputs fromTTL to zero-potential switches(MOS-FET) for direct control ofreject gates or handling systems withcables Type 1200B43 and 1700B63and slot covers Type 1200A81

Connection of analogsignals from Type6892A... to A/D cardType 2855A3/A4(max. 16 channels), or2855A6 (max. 32channels. Digital out-puts with Type1200A79 or 1200A81only

www.kistler.com 53

Amplifying

54 www.kistler.com

Charge amplifiers convert charges trans-mitted by a piezoelectric pressure sensorinto a proportional voltage, which can beused as an input variable for monitoringand control processes. Kistler supplies awide range of different charge amplifierssuch as single-channel charge amplifiersor multi-channel amplifiers for charge andtemperature.

Charge amplifiers with smart algorithms,which enhance the amplifying process,can generate control signals from thecavity pressure profile and the contacttemperature. These are used as inputvalues for injection molding machines,where they serve to increase the repeata-bility of the injection molding process toensure high quality of the produced parts.

Charge amplifiers are encased in a sturdyhousing. Their output signals are analogand immediately available via an analog/digital converter card (A/D converter).The real-time capability of the charge am-plifiers allows the control of high-speedprocesses based on cavity pressure.

Based on forces such as the cavity pres-sure, smart charge amplifiers can automa-tically change over from injection to hol-ding pressure or determine the optimaldemolding point in a self-optimizing ope-ration.

Amplifying

www.kistler.com 55

Technical Data Type 5039A... Type 5049A221

No. of channels 1 1

No. of measuring ranges 2 2

Measuring range I pC ±5 000 ... ±50 000 ±2 0000

Ratio measuring range I/ measuring range II 10 / 4 / 2 2

Measuring range I (adjusted to injection molding) pC ±20 000 ±20 000

Measuring range II (adjusted to injection molding) pC ±5 000 ±5 000

Power supply V DC 18 ... 30 18 ... 30

Output signal V ±0 ... 10 ±0 ... 10

Sensor connector TNC or BNC neg. TNC neg.

Connection supply, output signal, control signals Binder 8 pin pos. Binder 14 pin pos.

Options

SmartAmp self-optimized switch-over no yes

Output current mA 4 ... 20 4 ... 20

Charge amplifiers for pressure sensors

Charge amplifiers for integration into injection molding machines

PropertiesCharge amplifier in industrialhousing. Special types for injectionmolding Type 5039A221 (TNCconnection) or Type 5039A222(TNC connection).

Areas of applicationIntegration into injection moldingmachines for connecting piezo-electric cavity pressure sensors forvisualization and control.

AccessoriesFor Type 5039A...plug Type 1500A57*For Type 5049A...plug Type 1500A61*TNC-BNC-Adapter Type 1708


* included


No. of channels 1, 2 or 4 load,or 1 load and 1 temperatureor 2 load and 2 temperature

Measuring ranges load 2

Measuring range I ±5 000 ... ±50 000

Ratio measuring range I/ measuring range II 10 / 4 / 2

Measuring range I (adjusted to injection molding) pC ±20 000

Measuring range II (adjusted to injection molding) pC ±5 000

Measuring range temperature °C 0 ... 200

Output signal V 0 ... ±10

Power supply V DC 18 ... 30

Sensor connector (pressure) TNC or BNC neg.

Sensor connector (temperature) Fischer 2 pin neg.

Connection supply, signal outputs, control signals D-SUB 25 pos.

Options

SmartAmp self-optimizing switch-over on channel 1

Automatic cooling time calculation Only option: 1 channel load and 1 channel temp.

Output current mA 4 ... 20

Amplifier for pressure and temperature sensors

PropertiesMulti-channel charge amplifierand thermocouple amplifier in anindustrial housing. Consult datasheet for selecting the appropriatecharge amplifier.

Areas of applicationIntegration into injection moldingmachines for connecting piezo-electric cavity pressure sensors andtemperature sensors for visualizationand control.

AccessoriesConnection cable Type 1200A73SUB-D plug incl. cover Type1557A10


Figure shows Type 5049A...

56 www.kistler.com

Amplifying


Case dimensions Notebook-size 19" rack mount

Dimensions WxHxD W231 x H55 x D300 mm 3 HE/84 TE

No. of channelsIntegrated charge amplifier 4 -

No. of channelsIntegrated thermocouple amplifier 4 -

Vacant slots (4 channels) 1 8

Digital outputs for controllingreject gates or handling devices 4 (zero-potential switch) 4 (zero-potential switch)

Service temperature range °C 0 ... 40 0 ... 60

Options

4-channel charge amplifier Type 5063A1 5063A1

4-channel voltage amplifier Type 5227A1 5227A1

4-channel thermocouple amplifier Type 2207A 2207A

4-channel amplifier interface Type 5613A1/A2 5613A1/A2

Signal Conditioner

Signal conditioner

Figure shows Typ 2859A...

PropertiesBoth signal conditioners are modu-lar and can be extended SystemsType 2859A14 (parallel port) and2859A15 (USB) are supplied withsignal conditioner Type 2859A andDataFlow, A/D card, proximityswitch as well as all cables requiredfor operation with notebook.

Areas of applicationIn combination with the Dataflowsoftware, this product allows thevisualization, optimization andmonitoring of the injection moldingprocess.

AccessoriesCharge amplifier Type 5063A1Voltage amplifier Type 5227A1Thermocouple amplifier Type 2207AAmplifier Interface Type 5613A1/A2Proximity switch Type 2231



No. of channels 4

No. of measuring ranges 2

Measuring range I pC ±5 000 ... ±50 000

Measuring range I/ II ratio 4

Measuring range I (balanced for injection molding) pC ±20 000

Measuring range II (balanced for injection molding) pC ±5 000

Connector Type BNC neg.

4-channel charge amplifier

Modules for signal conditioner Type 2853A... and 2859A...


No. of channels 4

Measuring range V ±10

Adjustable amplification 1 / 2 / 5 / 10

Connector Type BNC neg.

4-channel voltage amplifier



Amplifying

www.kistler.com 57

Signal conditioner for signal preparation

Technical Data Type 2207A

No. of channels 4

Thermocouple Type J and K

No. of measuring ranges 2

Measuring range I °C 0 ... 400

Measuring range II °C 0 ... 200

Connector Type Phoenix terminal connector

4-channel thermocouple amplifier


No. of channels 4 4

Measuring range V ±10 ±10

Power supplyfor external amplifiers VDC 24 ±15

Connector Type SUB-D 9 neg. SUB-D 9 neg.

4-channel amplifier interface


Modules for signal conditioner Type 2853A... and 2859A...


Analyzing

58 www.kistler.com

The DataFlow software is a convenienttool for documenting the measured pres-sure and temperature values as quality-related data for the purpose of processoptimization. DataFlow operates withtools which support users across the en-tire process chain from mold sampling,setup and process optimization to produc-tion monitoring including statistic analysisand documentation. These functions arebased on the the cavity pressure and thepart surface temperature as inputs for cal-culation.

DataFlow runs on conventional personalcomputers or notebooks and is easy tooperate. DataFlow offers a comprehensiveoptimization and documentation systemfor all injection molding processes whichalso accommodates multi-componenttechniques and multi-cavity molds. Data-Flow can control equipment such as de-fect gates and reversible belt conveyors orcan operate robot placing processes toensure that all parts are separated intodefects and accepts and good parts.

The networking capability of the includedstatistics tool provides production datawhere it is needed, e.g. for productionplanning, control or quality assurance.

Analyzing

www.kistler.com 59

Technical Data Type 2855B1 Type 2855A4 Type 2855A6

No. of channels max. 16 16 32

PC Type Notebook Desktop Desktop

Card Type PC Card PCI Card PCI Card

Resolution bit 12 16 16

A/D card



System requirementsOperating system Windows 2000®, Windows XP® Professional

Memory MB RAM min. 128

Interface RS-232-C

Processor clock frequency MHz min. 600

Bus frequency MHz min. 100

Vacant slot (notebook) PC Card

Vacant slot (desktop) PCI

DataFlow software

Software for monitoring and statistics

PropertiesDataFlow is a universal dataacquisition and analysis systemfor injection molding processes.Production statistics can be com-piled via a network.

Areas of applicationMold trials, retrofitting, process opti-mization and production monitoringbased on the mold cavity pressure.The statistics software allows precisedocumentation of all produced parts.

AccessoriesSignal Conditioner Type 2859A...Signal Conditioner Type 2853A...


Accessories/Tools

60 www.kistler.com

Kistler offers a range of accessories formounting and calibrating sensors. Acces-sory sets for applications such as checkingsensor bores include step drills, counter-sinks, twist drills, reamers, taps, reamingtools, socket wrenches and lapping tools.

Measuring and calibration tools completeKistler's extensive product range. Battery-operated service units can measure veryhigh insulation resistance values of up to4·1013 . They are used for checking pie-zoelectric sensors, charge amplifiers, elec-trometer amplifiers, cables and also com-ponents such as condensers.

Preload measurement units are used forin-situ measurement of charges, e.g. mea-suring the preload of piezoelectric strainmeasuring sensors required for installation.This measuring equipment is small, light-weight and they operate independently ofthe network with an integrated chargeamplifier.

Test sets are used for checking cavity pres-sure sensors, which have already been in-stalled in the injection mold. They providea direct digital display of their pressuresensitivity in pC/bar.

Accessories/Tools

www.kistler.com 61

Technical Data Type 1315A Type 1358 Type 1362A...

Outer diameter mm Ø 5,8 Ø 3,8 Ø 6

Length mm 50 150 150, sp*

Thread Type M5 M3 x 0,35 M3

Sensors Type 6152A..., 6157B..., 6158A..., 6178A..., 6190A..., 6192A..., 6159A..., 6167A..., 6182A..., 6183A..., 6194A... 6177A... 6193A..., 6195A...

Extraction tools for sensors

Tools

* customized length Data sheet 1300_000-068

Data sheet 1300_000-068


Technical Data Type 1383 Type 1356

Outer diameter mm Ø 10 Ø 5

Length mm 300 150

Sensors Type 6152A..., 6157B..., 6158A,... 6178A..., 6159A..., 6167A..., 6182AE, 6183AE, 6177A..., 6190A..., 6193A..., 6195A...6192A..., 6194A...

Tubular socket wrench for mounting nuts


Description Manufacturing and Manufacturing andchecking sensor checking sensorbores for 4 mm bores for 4 mm andfront diameters 2,5 mm front diameters

Sensors Type 6157B... 6152A...

Accessory set for sensors

62 www.kistler.com

Accessories/Tools


Measuring range Ω 1011 ... 4 x 1013

Description Battery-operated service instrument for measuring insulation resistances

Area of application Insulation testing of piezoelectric sensors, input cables andconnection cables

Insulation tester

Calibration & testing tools

Data sheet 5493_000-354


Measuring range pC ±100 000

Output voltage V 0 ... ±1

Description Battery-operated preload tester for on-the-spot measurement of charges on site

Area of application On-the-spot sensor preload measurement and testing.With one output for monitoring function

Preload tester

Data sheet 5991_000-340


Test force N min. 70N max. 125

Description Battery-operated handheld test instrument with test pin andconnection cables. Displays the sensitivity of sensors.

Area of application Testing the function of integrated sensors

Test set for cavity pressure sensors


www.kistler.com 63

64 www.kistler.com

Technical literature

Thermoplastic 900-319

Plastics Processing – Productivity Increases and Cost Reductions 920-231

Measuring technologyfor low-pressure processes – Validation of flaw mechanisms affecting in-mold foaming of automotive cockpit components 920-249

Injection Molding – Quality Assurance and Docu-mentation with DataFlow 500-389

Single-Wire Technique – Extremely simple – simply brilliant 500-401

Injection Molding – Quality Assurance and Docu-mentation with DataFlow 500-389

Measuring with Crystals 900-335

PiezoStar Crystals – A New Dimension in Sensor Technology 920-240

Special publications and application brochures

Plastics Theory

Kistler –Your partner for efficiency and quality

2

Sensors and systems for optimizing, moni-toring and documenting the quality dataduring injection molding processes is onlypart of the solutions for the industry provi-ded by Kistler Instruments AG. With head-quarters in Switzerland, we supply plasticsprocessing solutions as well as specific sen-sors and systems for combustion engines,automotive engineering, mechanical pro-duction and biomechanical engineering.

Our core competence lies in the develop-ment, production and implementation ofsensors for pressure, force and accelerationmeasurement. Kistler electronic systemsand expertise used for processing measu-rement signals allow the analyses of phy-sical processes, process control and opti-mization as well as the enhancement ofproduct quality for the processing industry.

Every year, Kistler invests 10 % of its salesin research and development – for inno-vative and efficient technical solutions atthe leading edge of technology.

The Kistler group with more than 600 em-ployees is the leading supplier of dynamicmeasuring technology throughout theworld. Close cooperation with the custo-mer, individual application support andshort delivery times are guaranteed by thegroup's 18 member companies and morethan 30 agencies.

www.kistler.com

Product overview by type numbers

www.kistler.com 65

1200A13 511200A15 511200A41 511200A79 521200A81 521200A83 521200A89 511200A27 511200B43 511200B21 511300A81 611300A83 611315A 611356 611358 611362A 611383 611645C... 491661A... 501662B... 501666A1 491666A2 491666A3 491666A4 491667B... 501672B... 501700A62 521700A99 521700B63 521839 491939A... 491955A... 491961A... 491963A... 49

Type Page Type Page

2207A 572231 512290A... 502295A... 502805A... 592853A... 562855A4 592855A6 592859A... 562863 522885B1 59

4013A... 454079A... 374083A... 45

5039A... 555049A221 555063A1 565155A... 555227A1 565493 625613A1 575613A2 575991 625993A1 62

6152AA... 336152AB... 336152AC... 336152AD... 336155AE 366157BA... 346157BB... 346157BC... 346157BD... 346158A... 356159A... 356159A...U6 356167A... 376172AA... 386172AC... 386177AA... 386177AC... 386178A... 396182AE 356183AE... 366190A... 406192A... 416193A... 426194A... 426195A... 416829A... 39

9204B... 439211A... 439213A... 439221A... 449223A... 449232A 469827A2491 469827A1392 46

Type Page Type Page Type Page

Unisens® and PiezoStar® are registered trademarks of Kistler Instrumente AG, Winterthur, SwitzerlandWindows XP® and Windows 2000® are registered trademarks of Microsoft Corporation

Photos bySchöttli AG, Diessenhofen, SwitzerlandDemag Plastics Group, Schwaig, GermanyBIRO Edwin Bischof AG, Romanshorn, Switzerland

AustriaKistler GmbHLemböckgasse 49fAT-1230 WienTel. +43 1 867 48 67 0Fax +43 1 867 48 67 [email protected]

ItalyKistler Italia s.r.l.Via Ruggero di Lauria, 12/BIT-20149 MilanoTel. +39 02 481 27 51Fax +39 02 481 28 [email protected]

United KingdomKistler Instruments Ltd.Alresford House, Mill LaneAlton, Hampshire GU34 2QJTel. +44 1420 54 44 77Fax +44 1420 54 44 [email protected]

Korea, Republic ofKistler Korea Co., Ltd.3rd Floor, Bow Building1580-1, Seocho-3 dong, Seocho-ku, Seoul 137-875Tel. +82 2 597 6013Fax +82 2 525 [email protected]

SingaporeKistler Instruments (Pte) Ltd.50 Bukit Batok Street 23#04-06 Midview BuildingSingapore 659578Tel. +65 6316 7331Fax +65 6316 [email protected]

TaiwanKistler Representative Office in TaiwanRoom 9, 8F, No. 6, Lane 180Sec. 6, Mincyuan E. RoadTaipei 114Tel. +886 2 7721 2121Fax +886 2 7721 [email protected]

ThailandKistler Instrumente (Thailand) Co., Ltd.662/43-46 Rama III RoadBangpongpang, YannawaBangkok 10120Tel. +66 2293 02234Fax +66 2293 [email protected]

Europe

GermanyKistler Instrumente GmbHDaimlerstrasse 6DE-73760 OstfildernTel. +49 711 34 07 0 Fax +49 711 34 07 [email protected]

FranceKistler FranceZA de Courtabœuf 115, avenue du HoggarFR-91953 Les Ulis cedexTel. +33 1 69 18 81 81Fax +33 1 69 18 81 [email protected]

Switzerland/LiechtensteinKistler Instrumente AG Verkauf SchweizEulachstrasse 22CH-8408 WinterthurTel. +41 52 224 12 32Fax +41 52 224 14 [email protected]

Asia

JapanKistler Japan Co., Ltd.MT Building2-7-5, ShibadaimonMinato-ku, Tokyo 105-0012Tel. +81 3 35 78 02 71Fax +81 3 35 78 02 [email protected]

China, People’s Republic ofKistler China Ltd.Unit D, 24 / F Seabright Plaza9–23 Shell StreetNorth Point, Hong KongTel. +852 25 91 59 30Fax +852 25 91 18 [email protected]

Representative Office BeijingTel. +86 10 8225 2163Fax +86 10 8225 [email protected]

IndiaKistler Instruments (Pte) Ltd.India Liaison Office2B Century Plaza560/562 Anna SalaiTeynampet, Chennai 600 018Tel. +91 44 5213 2089Fax +91 44 5213 [email protected]

Kistler worldwide

Denmark/Finland/Norway/SwedenKistler Nordic ABAminogatan 34SE-431 53 MölndalTel. +46 31 871 566Fax +46 31 871 [email protected]

NetherlandsKistler B.V. NederlandLeeghwaterstraat 25NL-2811 DT ReeuwijkTel. +31 182 304 444 Fax +31 182 304 [email protected]

America

USA / Canada / MexicoKistler Instrument Corp.75 John Glenn DriveAmherst, NY 14228-2171Tel. +1 716 691 5100Fax +1 716 691 [email protected]

Other countriesKistler Instrumente AGExport SalesEulachstrasse 22CH-8408 WinterthurTel. +41 52 224 11 11Fax +41 52 224 15 [email protected]

Headquarters

SwitzerlandKistler Instrumente AGEulachstrasse 22CH-8408 WinterthurTel. +41 52 224 11 11Fax +41 52 224 14 [email protected]

www.kistler.com

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