product guide hotrunner systems and hotrunner · pdf filehotrunner innovations . ... •...

Product Guide Hotrunner Systems and Hotrunner Controllers

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Hotrunner innovations for the injection moulding industry

About us

For more than 35 years EWIKON has been a synonym for innovative, reliable and practical hotrunner technology at the highest technical level. Our system solutions are designed to perfectly meet the demands of our customers and offer various options to improve the quality

of the manufactured parts and to reduce costs at the same time. This has resulted in thousands of successfully realised applications for all sectors of the injection moulding industry.

• Noorconsiderablyreducedspruewaste, reduced production costs

• Improvedpartquality

• Decreasedcycletimes,increasedproductivity

• Highfunctionalandproductionreliability

• Moreflexibilityinmoulddesign

Advantages of hotrunner technology

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The latest manufacturing technology and a quality management system according to DINENISO9001:2008 guarantees a consistently high product quality. Each EWIKON hotrunner system has to pass strict functionaltests.Awell-equipped technical centre is available for material orpre-productiontests.

Content

Sales and service network.................................................................................................................................................................. 4

Manifold range ..................................................................................................................................................................................... 6

Nozzle range|standardnozzles|singletips|multi-tipnozzles........................................................................................................... 8

Valve gate systems | versions | electric drive unit ............................................................................................................................. 14

L2X Drop-In system ........................................................................................................................................................................... 18

Micro-manifold systems ................................................................................................................................................................... 19

Hotrunner systems for large parts................................................................................................................................................... 20

Hotrunner controllers ........................................................................................................................................................................ 21

Hot halves .......................................................................................................................................................................................... 22

Specials | special hotrunner solutions ................................................................................................................................................ 23

System overview | technical data ...................................................................................................................................................... 24

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Worldwide service and support

EWIKONsalesandservicenetwork

Anefficientsalesandservicenetworkensures fast and reliable customer support from mould design to system start-up.TheEWIKONheadquarters inFrankenbergincorporatetheR&D, production and sales departments and employatotalof240people.TogetherwithsubsidiariesintheUnitedKingdom,JapanandChinaaswellassales

partners all over Europe, America and Asia, EWIKON is able to provide a comprehensive customer service worldwide.

Headquarters

Subsidiaries

• UnitedKingdom• Japan• HongKong• China

• Germany

Sales partners

• Sweden• Finland• Russia• Lithuania• Poland

• Czech Republic• Slovac Republic• Hungary• Slovenia

• USA/Canada• Mexico• Spain• Portugal• Benelux• Denmark

Direct customer service with own employees for

• Austria • Switzerland • France • Italy

• Israel• Singapore• Malaysia• Indonesia• Taiwan• China

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Additional services

EWIKONoffersextensivesupportto customers – from design aid for hotrunnersystemstocustomer-specifichotrunner seminars for all areas ofpracticalapplication:

3D database available on the internet withdirect interfacestomostCADSystems

Calculation software CostCompare For economic efficiency calculation of runner systems

Moldflow analyses for optimised fillingofpartsconsideringmeltflow profiles,flowlines,airentrapments and pressure requirement. Determinationofgatingpointsand calculation of system balance

Pressure drop calculations For rheological design of EWIKON hotrunner systems

Customer-specific hotrunner seminars For machine operators and mould designers

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Superior manifold technology – the heart of your EWIKON system

Manifoldrange

The streamlined direction and distribution elements of theHPSIII-Tmanifoldsystemsenableasmoothmeltflowandquickcolourchanges

EWIKON manifolds guarantee full natural balance even in case ofmostdemandingmulti-cavity applications. This is possible due to special direction and distribution elements. Evenincriticalareasoftheflowchannel-changesofflowdirectionordistributionofthemeltflow-deadspots are avoided.

• Fullnaturalbalance

• Evenfillingofcavities inmulti-cavityapplications

• Streamlineddirectionelementswithout sharp corners or dead spots

• Smoothmeltflowforsensitivematerials

Product features + Benefits

• Excellentcolourchangebehaviour

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HPS III-T

For thermally demanding applications

• Fullnaturalbalanceforeven filling of cavities

• Streamlineddirectionelements withoutsharpcornersordeadspots

• Smoothmeltflowfor sensitive materials

• Veryquickcolourchanges

2-componentsystem Valvegatesystemwithbridgemanifold

HPS III-TE

The economical solution for standard applications

• Fullnaturalbalanceforeven filling of cavities

• Cost-savingcombinationof element and drilling technology

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The comprehensive range of HPSIIInozzlesoffersutmost flexibilityformoulddesigners and provides tailored solutions evenforthemostcomplex requirements regarding gate position, vestige quality, shotweightorcavitydistance.

Flexibility for your standard applications

Nozzle range

• Variousgatingoptions, highflexibilityinmoulddesign

• Homogeneoustemperatureprofile

• Exchangeabletipinserts,heaters and thermocouples

• Frontinstallationforeasyaccessandreplacement


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Gating options

HPS III-S nozzle

The EWIKON standard nozzle for all materials andshotweights.Fordirectgatingwithtipor open gating.

HPS III-SXE single tip

The single tip solution for utmost process reliability for allmaterialsincludinghigh- temperature thermoplastics. Atleasttwoseparateheaters guarantee a most homogeneous temperature profile.

Open gatingDirectgatingwithtip Variousversionsofgatebushesandscrew-ongatebushesincludingover-dimensionedversionstoadaptto free form contours

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Nozzle range

Solutions for close cavity spacing and multi-gating

Severalversionsofslimnozzlesandmulti-tipnozzlesareavailablefor demanding hotrunner applications.

• Extremelyclosedistancesbetweencavities inmulti-cavitymoulds

• Forcomplexpartgeometrieswithgatingpoints inhard-to-reachareas

• Forinternalgatingofslimparts

• Multi-gating


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HPS III-MV multi-tip nozzle

Forverticalmulti-gatingofparts. Smallpartscanbegatedsimultaneously withclosedistancesbetweencavities. Multi-pointgatingofsinglepartsis possibleaswell.

HPS III-S3 nozzle

For direct gating of parts in multi-cavitypackagingand medical applications. Suitableforinternalgating, externalgatingorgatingin hard-to-reachareas.

HPS III-S3 multi-tip nozzle module

UptofourHPSIII-S3nozzlescanbe integratedintoamulti-tipnozzlemodule whichallowsextremelyclosedistancesbetweencavities.Thetemperatureof each nozzle can be controlled separately.

The special tip geometry of the HPSIII-S3nozzlepreventsstringing infast-cyclingmoulds

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Nozzle range

Nozzles for side gating

WiththepatentpendingHPSIII-MHmulti tip concept EWIKON offers tailored solutions for all applications wheresidegatingorgatingindifficult-to-accessareasisrequired.Allnozzlesare available as system nozzles for use withamanifoldorassingletips.

• Directgatingwithtiporopengating

• Sidegatingonvisiblesurfaces

• Forstandardmouldinserts

• Goodgatequalitythroughshearaction


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HPS III-MH nozzle for standard side gating

HPSIII-MHnozzlesare the standard side gating solution for use in standard mould inserts.Duetotheopenflowchannellayout quickcolourchangesarepossible.

HPS III-MH nozzle for direct side gating

The solution for linear or radial direct side gating of parts in compact multi-cavitymoulds.Sinceonlystandard mouldinsertsarerequiredacost-efficient mould design can be realised. The tip inserts are installed from the parting line of the mould in the last assembly step after the nozzle body has been installed. Thus,theycanbeexchangedeasilyif requiredwithouthavingtodismantlethe mould.Theuseofangledtipswithany requiredangleallowsuniquegating positionsindifficult-to-accessareas.

Easy replacement of tip insert: After removing the endcoverflangethetipinsertiseasilyaccessibleand can be pulled out of the mould insert for replacement

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Valvegatingoffersexcellent surfacequalityofpartsaswell as considerably increased process reliability. EWIKON valve gate systems are available in various designswithmultipledriveoptions. Thus, it is possible to perfectly adapt the valve gate system to your specific application requirements and mould layout.

Valvegatetechnology

More process reliability and part quality

• Differentdriveversions,integratedintothe clamping plate or the nozzle housing

• Permanentvalvepinguideplacedinthefrontarea of the nozzle. The valve pin remains guided during thewholeoperationcycle.Thisensuresmaximum operationalreliabilityandreducesvalvepinwear

• Electric,pneumaticorhydraulic valve pin actuation


• Excellentpartqualitywithbarelyvisiblegatemarks

• Nostringing

• Reducedcycletimes

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HPS III-NVI

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HPS III-NVE

The valve gate system for standard applications with different drive options:

Drive unit integrated into the clamping plate, electric, pneumatic and hydraulic valve pin actuation

Drive unit fixed on the manifold, pneumaticvalvepinactuation,simplifiedmouldlayout

Joint valve pin actuation with synchronous plate, electric,pneumaticandhydraulicactuation.Valvepinsopensimultaneously, particularlysuitableformulti-cavitymouldswithclosecavityspacing

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2

3

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HPS III-MH

Compact valve gate nozzle with drive unit integrated into the nozzle housing. Easy to integrate into the mould, as there is no need to place actuator components behind themanifold.Particularlyadvantageousforuse in single applications, stackmouldsandtandem moulds.

Valve gate nozzle with lateral melt feed* and valve pin actuation with synchronous plate. The technology allowsaminimumdistancebetweencavitiesofonly 6mmandisideallysuitableforthemulti- point gating of medical parts or overmoulding applications in the electronical industry. Furthermore, applications whichrequireagatingpoint on a horizontal surface closetoverticalwalls,e.g. onto flanges of syringes and analysis tubes, can be realised.

(*)patentpending;10716535.9

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Valvegatetechnology

Electric drive valve gate technology- the new dimension of valve gate precision

The electric drive unit for valve gate systemsoffersvalvepinactuationwithhighprecisionaswellasparticularlyeasy installation into the mould. When usedwithelectricinjectionmouldingmachines, fully electric manufacturing cells can be realised. Furthermore, this clean drive version is perfectly suitable for cleanroom applications.

• Linearstepmotor.Valvepinpositioningwithhigh precision,increment:0.01mm,individualadjustment for each valve pin possible

• Individualsettingofprocessparameterssuch asvalvepinstrokelength,valvepinspeed,opening andclosingtimeaswellasclosingposition

• Cleanoperatingmedium,noaerosols,unlimited suitability for cleanroom applications

• Increasedprocessreliabilitybymonitoringfunction forvalvepinpositionandautomaticre-adjustment in case of deviation


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Precise and comfortable control

TheexternalEDC-PRO touch screen control unit operates up to 32 step motors in automatic or manual setting mode.Itallowstheindividual setting ofprocessparameterssuchasstrokelength, valve pin speed, opening time, closing time and closing position. In demanding applications sequential opening of the valve pins is possible as wellastoapproachvariousvalvepinpositionswithinonemouldingcycle.

The easy integration into the mould design is another advantage of the electricdriveunit.Thedrivescanbeinstalledeasilywithouttheneedfor supply bores in the clamping plate.

Permanent monitoring of valve pin position

All electric drive unit sizes feature encoders enabling a permanent monitoring and loggingofthevalvepinpositionwithanaccuracyof1/100mm.Ifthereareany deviations,thevalvepinconcernedisreadjustedautomatically.Shouldthisnotbepossibleforexampleduetoagateblockedbycontamination,anerrormessage appearsafteradefinablenumberoffailedattempts.Ifrequested,thedriveunit concernedisswitchedoffcompletely.

For operation of synchronous plate systems linear servomotors in differentsizesareavailable

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L2Xhotrunnersystem

The compact Drop-in hotrunner system

The hotrunner solution for easy integra-tionintothemouldwitheasytomaintainconnecting technology. The nozzles are screwedintothemanifoldmakingthesystemabsolutelyleakproofandavoidingdowntimes.Thesystemisdeliveredcompletelyassembledwithnozzles,manifold and sprue bush and also includesthecompletewiringandtheconnectorbox.Thus, it is particularly easy to integrate into the mould construction by simply inserting the complete unit into the matchingpre-machinedcutouts.

• Deliveredcompletelyassembledandwired

• Leakproofsystem,nozzlesscrewedintothemanifold, high production reliability

• Easy integration into the mould


• Available for direct gating withheatconductivetip or valvegatingwithcooledpneumaticdriveunits

Cooled pneumatic drive units for valve gate version

• Highheatingpowerduetodirectheatingofthe meltbearingpressuretubewithcoilheater

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The compact Drop-in hotrunner system

The solution for high-cavitation moulds

• Micro-manifoldswithfourscrewed-inheat conductive tip inserts each

• Easydesignofhigh-cavitationmouldsbased onstandardised16-dropclusterscombined withabridgemanifold

• Reducedspacerequirementforelectricwiringallows averycompactmoulddesignwithmaximumstability


• Highmaintainability.Easyexchangeoftipinserts after removal of the mould inserts

192-drophothalf for a medical application

• Onlyonecontrolzonepermicro-manifold. Considerablyreducedcontrolexpenditure

TheEWIKONmicro-manifoldtechnologyisastandardisedsolutionfortheefficientlargescaleproductionofpolyolefinepartswithsmallshotweightsinmouldswithanextremelyhighnumberofcavities. Targetbranchesarethepackagingandmedical industry. Complete hot halves withmicro-manifoldtechnologyareofferedas16,32,64,96,128and192-dropversionswithstandardiseddimensions.

Micro-manifoldtechnology

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Tailored solutions for large part moulding

Hotrunnersystemsforlargeparts

EWIKON hotrunner systems for large parts are designed and manufactured inclosecooperationwiththecustomeraccordingtohisspecificapplicationrequirements.Nomatterwhetherasystemforlarge-scaleproduction,economicsmall-batchproductionoraprototypemouldisrequired- EWIKONoffersthetailoredsolution.The broad range of available nozzle lengths,gatingoptionsandflow channeldiametersallowstheperfectadjustment of the system to mould layoutandshotweight.EWIKONhotrunner systems for large parts aredeliveredaspre-assembled Drop-Inhotrunnermodules.

• Flexiblesystemdesignwithvariablenozzlepitch, screwed-innozzles,opengatingorvalvegating

• DeliveredasDrop-Insystemwithcompleteelectric wiringandallconnectorsandsupplylinesforvalve gate operation according to your requirements


• Completedocumentationwithassemblydrawing, partslist,electricalwiringdiagramandconnecting diagramforhydraulic/pneumaticsupplyandcooling

• Easytomaintain,exchangeablemanifoldheater elements, nozzle heater bands and thermocouples. Easyvalvepinreplacementwithnoneedto disassemble the system

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Precise control technology for all systems

HPS-C-PRO+

HPS-C-PRO+high-techcontrollers are designed to provide highest reliability and a most precise control behaviourcombinedwithadvanced intelligent support and monitoring featuresaswellaserrordetection functions. The controllers are available inversionsupto192controlzonesand feature a touch screen control unit for comfortable operation.

HPS-C-SLOT+

HPS-C-SLOT+isthecost-efficient and fully featured slot controller for hotrunnersystemswith2-24controlzones. It is availablewithoptional touch screen offering additional functions.

EWIKON hotrunner controllers

For reliable control of your hotrunner systemEWIKONoffersacompleterangeofadvancedcontroltechnology-fromthe economic, modular controller to the high-techcontrolsystemwithtouchscreen to meet highest demands, for exampleformulti-cavityapplications.

HPS-C-SLOT+2-and24-zonecontroller

HPS-C-PRO+ hotrunner controller withtouchscreencontrolunit

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The complete hotrunner solution for easy installation

HothalvesfromEWIKON

All EWIKON systems can be delivered as complete hot halves. The already integrated hotrunner system allowsafastandefficientinstallationandstart-upandrequirespracticallynoon-siteadjustments.Agrowingpercentage of customers use hot halves to speed up their mould projects significantly.

Especiallyindemandingmulti-cavityvalvegate applications the advantages of the hot half concept becomeparticularlyobvious.Thepackagecontainsbores and connectors for the pneumatic, hydraulic orelectricsupplyofthedriveunits,length-adjusted valvepinsandthecompleteelectricwiring.

Pleaseunfoldfor systemoverview

• Mouldhalfwithalreadyintegratedhotrunnersystem

• Completewiring

• Deliveredasthermallyandelectricallytested systemwithdetaileddocumentation

• Practicallynoon-siteadjustmentsrequired, thus speeding up of mould projects


• 3-yearwarranty,ifusedwithEWIKONhotrunner controllers and EWIKON connecting components

64-dropvalvegatesystem.Synchronousplatewithdrive pistons in the clamping plate

16-dropvalvegatesystem.Synchronousplatewithpullrail actuation.Externallinearservomotor

96-dropsystem for direct side gating

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EWIKONSpecials

Multi-component hotrunner systems and stack moulds

Hotrunner systems for micro

injection moulding machines

EWIKON hotrunner systems for micro injection moulding machinesenablethespruelessproductionofpartswitheventhesmallestshotweights.Duetothesimpledesignof tip inserts, manifold and sprue bush only one control zoneisnecessarytooperatetheunit,keepingthecontrol-lerexpenditurelow.Aversionwithseparatetemperaturecontrolforeachgateisavailableaswell.Allsystemsare delivered as fully assembled hot halves for easy installation.

Formulti-componenthotrunnersystemstheEWIKONmanifoldtechnologywith directionelementsallowsacomplexandspace-savingflowchannellayout.Thus,very close gating points often required by theseapplicationscanberealisedwithoutany problem.

Coaxial valve gate system

TheEWIKONcoaxialvalvegateallowstheinjectionoftwocomponentsviaoneinjectionpoint.Itconsists ofacentrevalvepinandasecondhollowvalvepin surroundingit.Theirworkingprincipleisthatplastic melt can be injected either through the centre valve pinorificeortheringgapformedbythehollowvalvepin.Usingthecore-backmethodwithmovingmouldcore,two-componentpartswithfrontandrearlayer caneasilybeproduced.Byappropriatecoordination of valve pin positioning and movement during injection, theproductionofpartswithacompletelyseparated corelayer(sandwichmethod)ispossibleaswell.

Stackandtandemmouldscanbe realised in every possible configuration. EWIKONofferssolutionswithleakproofvalve-to-valvemelttransitionaswellaswithstandardspruebartechnology.

4-componenthotrunnersystem

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Systemoverview

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EWIKON nozzle range

HPSIII-S/ HPSIII-SXE HPSIII-S3 HPSIII-MV HPSIII-MH

open gating

HPSIII-MHdirect gating withtip

Directgatingwithtip --

Open gating -- --

Multi-gating/angle/

max.no.ofgates

/0°/4(Multi-tip- module)

/0°/4(Multi-tip- module)

/0°/6 /90°/4 /0°-90°/8

Usewithgate bushes -- -- -- --

Available as single tip (SXE) --

Front installation option

Lengths[mm] 19-350(-600(1)) 39-189 30-150 30-130 60-168(3)

Flowchannel diameters[mm]

4,5-18(22-30(1)) 3 6 (2)/10(2) 6 (2) 6 (2) /10(2)

Close cavity spacing --

(linear version)

Quickcolour changes --

Max.processing temperature[°C] 400 400 300 300 350

PE

PP

TPE

PS

ABS

SAN -- --

PMMA

PA -- --

POM

PET -- -- --

PC -- --

PPS -- -- -- --

LCP -- --

PEEK -- -- -- --

PC-HT -- -- -- --

PSU -- -- -- --

PES -- -- -- --

PI -- -- -- --

Reinforced(GF) -- --

suitable pleasecontactEWIKON --notsuitable(1)forlargesystems (2)inletchannel (3)longernozzlelengthsavailableonrequest

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EWIKON manifold range

HPSIII-TE HPSIII-T

Fully balanced

Flowchanneldiameter[mm] 4-14 (16-30(1))

4-14(16-30(1))

TobecombinedwithHPSIIIstandardnozzles

suitable pleasecontactEWIKON --notsuitable(1)forlargesystems

EWIKON valve gate systems

HPSIII-NVI HPSIII-NVE

Driveunitforvalvepin integrated into the nozzle housing

in the clamping plate

Valvepinactuation pneumatic/hydraulicelectric/pneumatic/

hydraulic/mechanical (synchronous plate)

Multi-gating/angle/ max.no.ofgates /0°/4 --

Available as single tip --

Permissiblenozzletypes/flowchanneldiameters[mm] HPSIII-S/6-18(22-30(1)) HPSIII-S/4,5-18(22-30(1))

HPSIII-S3/3

suitable pleasecontactEWIKON --notsuitable(1)forlargesystems

Detailed technical data on our products are available in our main catalogues. Furthermore, please visit our website www.ewikon.com for latest information: SelectEWIKONhotrunnercomponentsfastandeasilyinour 3D database,configurateandimportthemviadirectinterfacesintothemostcommonCADsystems.Theselectedcomponentsincludingallnegativegeometriescanbedownloadedfreeofchargebyourcustomers.ThesedataaswellasourmaincatalogueswhichareavailableinPDFformatareupdatedatregularintervals.

EWIKON Heißkanalsysteme GmbH SiegenerStraße35 35066FrankenbergTel: +496451501-0Fax:+496451501-202E-Mail:[email protected]

YourEWIKONPartner:

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WIKON03/2017EN

product guide hotrunner systems and hotrunner · pdf filehotrunner innovations . ... •...

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