Plastics. 100% Quality Injection Molding

Transcription

1 Plastics 100% Quality Injection Molding

2 Kistler Your partner for efficiency and quality Sensors and systems for optimizing, monitoring and documenting the quality data during injection molding processes is only part of the solutions for the industry provided by the Kistler Group. With headquarters in Switzerland, we supply plastics processing solutions as well as sensors and systems for combustion engines, automotive engineering, mechanical production and biomechanical engineering. Our core competence lies in the development, production and implementation of sensors for pressure, force, torque and acceleration measurement. Kistler electronic systems and expertise used for processing measurement signals allow the analyses of physical processes, process control and optimization as well as the enhancement of product quality for the processing industry. Every year, Kistler invests 10% of its sales in research and development for innovative and efficient technical solutions at the leading edge of technology. With a combined workforce of around 850, the Kistler Group is the world market leader in dynamic measurement technology. 23 group companies worldwide and more than 30 distributors ensure close contact with the customer, individualized application engineering support and short lead times. 2

3 Table of Contents The benefits of mold cavity pressure measurement More efficient processes better quality 4 More productivity lower costs 6 The fundamentals of mold cavity pressure measurement The pressure profile and its interpretation 8 Using the mold cavity pressure in practical applications Measuring: Sensors and their positioning 10 Connecting: Safe transmission with suitable cables 14 Analyzing: Automatic process monitoring, real-time control and documentation of injection molding process 16 Analyzing: Analysis and optimization of injection molding process 18 Analyzing: Integrating into machine control systems 20 Sensors for mold cavity pressure measurement 22 Measuring chains for cavity pressure measurement 24 Sensors and systems for injection molding machines Measuring the clamping force, tie bar extension and the melt pressure 28 Sensors and measuring chains for injection molding machines 30 Product details/product range Measuring: Sensors 32 Connecting: Connecting and extension cables 50 Amplifying: Charge amplifiers 58 Analyzing: Optimizing, monitoring and documentation systems 62 /Tools 66 Technical Literature 70 Product overview by type numbers

4 The Benefits of Cavity Pressure Measurement Systems Modern injection molding technology is faced with ever more exacting requirements and a rising number of complex injection molding processes. Equipped with high-performance systems based on measuring the pressure in the mold cavity, injection molding machines are able to produce flawless high-quality parts. These systems can automatically monitor, optimize and control injection molding processes, boost productivity and cut costs. During the first decades of industrial injection molding the development of control systems focused on machine parameters alone. However, these processes had a rather limited informative value or benefit for users. From the early 1990s on, it became clear that for many applications, high process constancy and optimum part quality could only be ensured over a long period of time by using measuring systems which focused on the pressure in the mold cavity. Mold cavity pressure measurement and systems using cavity pressure for monitoring and controlling injection molding processes offer a range of technical and economical 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 the mold cavity are almost fully automatic and easy to operate. Piezoelectric sensors have proved to be suitable for both direct and indirect cavity pressure measurement. Modern system solutions operate with a closed circuit which includes mold cavity pressure recording with the help of piezoelectric sensors, smart electronic equipment and ergonomic software. The processes within the mold are crucial to the quality of the injection molded parts, yet they can never be viewed directly. Attempts at describing process phases in terms of machine parameters such as hydraulic pressure, have not yielded any success. The main reason for this lies in the fact that machine parameters cannot record the effects of sprue solidification or melt compressibility. 4

5 More Efficient Processes Better Quality Mold cavity pressure is the most informative process parameter Only a continuous documentation of the mold cavity pressure profile yields a detailed record of the processes occurring during the injection, compression and holding pressure phases of injection molding. Only this parameter correlates with all other quality-related part properties such as weight, morphology, fidelity of reproduction, flashes, sink marks, voids, shrinkage and warpage. The mold cavity pressure not only optimizes the switch-over from compression to holding pressure, in each cycle, its profile can also be used as a criterion for determining the switch-over point. It allows better maintenance of the tight part weight tolerances and numerous other quality features than any other switch-over strategy, be it based on the hydraulic pressure, screw stroke or time. Quality assurance and documentation with the help of mold cavity pressure control The documentation of the mold cavity pressure not only proves the quality of the finished part but also allows selective monitoring and early detection of process deviations. Useful algorithms such as statistic process control or neuronal networks can deliver very precise information on the effect of the mold cavity pressure and other process or machine parameters on the mold quality. Precise assessment of the molded parts requires systems which analyze their weight and dimensions as well as correlating features such as streaks and other surface defects while also providing automatic control of reject/accept gates. In the near future, most modern injection molding systems are likely to rely on an automatic determination of the optimum process parameters. Mold cavity pressure control systems are reliable and durable Despite the high number of benefits, many injection molders are still skeptical when it comes to mold cavity pressure control. On the one hand, they are averse to the investment costs and on the other hand they anticipate downtimes and follow-up costs. Experience shows, however, that improper handling of the sensors during installation, maintenance or mold changes is the main cause of machine downtimes. The systems themselves have proven their sturdiness, reliability and durability. The large-scale production of high-quality, cost-efficient parts provides a competitive edge and as such it is the decisive criterion for the success of any injection molding business. In its wake, quality assurance will attain major importance for all injection molding processes. With a view to increasingly complex processes and more exacting quality requirements, only machines with high-performance systems which are based on cavity pressure control will be able to deliver flawless highquality molded parts. Prof. Dr.-Ing. Dr.-Ing. E.h. Walter Michaeli Institute of Plastics Processing (IKV) at RWTH Aachen University 5

6 The Benefits of Cavity Pressure Measurement Systems The cavity pressure profile represents a "fingerprint" that reveals all of the important effects of injection molding conditions including process defects, irregularities and molding flaws. This curve is therefore vital in determining the correlation between these conditions and molding characteristics. Consistent application of cavity pressure measurement therefore generates benefits along the entire product chain from mold sampling through to production documentation. Mold sampling without mold filling studies Mold sampling or, to be more exact, the acceptance of molded parts for large-scale production, is a time-consuming process for processors as it often involves numerous mold corrections and trial runs. In this development phase, cavity pressure measurement systems can be used to analyze the process and to determine initial machine settings without mold filling studies. Moreover, the cavity pressure signal is an important tool for uncovering errors and problems at an early stage, which also minimizes the number of required repetitive mold sampling procedures. As these systems reduce the time consumed for mold sampling to a minimum, they also help to curb costs. Practical experience shows that mold cavity pressure systems can reduce the time and effort used for mold sampling by up to 75%. Optimum quality, minimum cooling and cycle times One essential element of process optimization is the attempt to find an efficient production method and a safe processing window. A process with an optimum cavity pressure profile will yield high-quality parts. The achievement of minimum cycle times and sufficient part quality are at the heart of this phase. Adapting the mold cavity pressure will help implement shorter Advantages During mold sampling + Initial machine settings without mold filling studies + A faster procedure saves time + Significant cost reduction During optimization + Automatic calculation of switchover point + 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 cycle times without affecting the quality of the molded parts and therefore allow the determination of optimum times for injection and holding pressure without trial and error. Fingerprint of cavity pressure ensures faster mold setup Use of this reference curve as a "fingerprint" of molding helps significantly shorten setup times. This reference curve of the cavity pressure is determined and saved during process optimization as soon as the optimum part quality has been achieved. During set-up, the machine operator only needs to change the machine setting parameters until the closest approximation between the current cavity pressure profile and the reference curve for optimum part quality has been achieved. In this way, even machines which show signs of wear and machines from different manufacturers will deliver molded parts with identical properties. This approach dispenses with the need for time-consuming part quality tests, which are normally required as a consequence of changes to the machine settings. 6

7 More Productivity Lower Costs Documented quality The cavity pressure profile determined during the production process is a clear reflection of the quality of the parts produced and is therefore useful material for documentation. This way, random checks according to the statistic process control (SPC) based on cavity pressure measurement evolve into a 100% quality assurance procedure. Cavity pressure measurement delivers the relevant data to certify of every individual injection molded part. It reduces the cost of part quality control and provides an automatic documentation of process data which is readily available for both producers and customers even years after active part production. Zero-defect production on a large scale During large-scale production, the mold cavity pressure is used for a continuous monitoring of the quality of the molded parts. If this quality fails to meet the required standards, an accept/reject flipper gate or a handling device can be used to separate the defective parts from the batch. This integrated quality assurance system ensures the detection of flawed parts at the earliest possible stage of the production and as such is prerequisite to the implementation of "lean" production condi-tions. Moreover, this approach reduces the reject quota and helps achieve an error-free production. This in turn boosts the productivity of the machine as a consequence of an improved utilization and lower production costs. Real-time control Modern cavity pressure systems allow open-loop and closed-loop control of the injection molding process. For example, in cascade injection molding the needle valve nozzles can be opened when the melt reaches a certain threshold pressure. With this method of control, the cavity For more information on this topic, please refer to p. 16 onwards. pressure allows the position of the melt to be freely and reproducibly defined and not as with using linked to a fixed position. Other examples of open-loop and closedloop control functions based on the cavity pressure profile include the injection starting for fluid signal with water and gas injection technology (WIT & GAIM), the starting signal for a stroke in injection-compression molding and many other functions. Cavity pressure is the only parameter allowing flexible control in parallel with effective process monitoring and only involves a single signal. Advantages During large-scale production + Zero-defect production + Automatic reject separation + Automatic reduction of batch scrape rate + No quality inspection required + No sorting on the machine + Reduction of customer complaints + No returned batches + Higher level of customer satisfaction + Higher supplier ranking + Moving into "Lean Production" + Real-time control of process For quality assurance + 100% certified quality for each individual part + Cost reduction for part quality control + Automatic documentation of quality data 7

8 The Fundamentals of Mold Cavity Pressure Measurement Cavity pressure Time 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 correlations facilitates the analysis and interpretation of the cavity pressure profile during active processes. The cavity pressure profile At the onset of the filling phase (1) plasticized polymer material enters the cavity. As soon as the flow front reaches the sensor (2), pressure is registered. The pressure should rise in a near-linear gradient parallel 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 compacted during the compression phase to ensure the reproduction of the contours of the mold cavity. The holding pressure phase follows after the maximum cavity pressure has been reached (4). The holding pressure phase compensates for the high thermal contraction of the polymer material i.e., the reduction of its volume following the cooling down process by introducing more material. Up to 10% of the part volume is being pushed into the cavity during this production phase. The fact that the molded part starts to cool down and solidify near the cavity wall inhibits the pressure transfer. The melt flow from the area in front of the screw to the cavity is slowed down as the viscosity of the material increases and the flow channel becomes more constricted in the process. The progressive solidification of the plasticized material in the gate area (5) and the progressive thermal contraction causes the pressure within the cavity to drop to ambient levels (6). Pressure Time Pressure Time Pressure 3 Time Pressure Time Cavity pressure Hydraulic pressure 8

9 The Pressure Profile and its Interpretation During the mold filling phase, the different characteristics of plasticized amorphous or semi-crystalline polymers are immaterial as long as their viscosity is identical. However, both materials display a different compression behavior. A higher amount of semi-crystalline material than amorphous material needs to be introduced into the cavity at the beginning of the holding pressure phase to achieve a pressure build-up. When the melt cools down during the holding pressure phase, more semi-crystalline material must be introduced into the cavity to compensate for the volume contraction and to prevent voids in the finished part. Specific characteristics of amorphous thermoplastics During the holding pressure phase of injection molding processes involving amorphous polymers such as polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), styrene-acrylo-nitrile (SAN), polymethyl methacrylate (PMMA), polycarbonate (PC) and polyvinyl chloride (PVC), the mold cavity pressure drops to ambient pressure levels parallel to the declining part temperature in the wake of an increasing viscosity and the corresponding deterioration of the pressure transfer from the area in front of the screw. Specific characteristics of semi-crystalline thermoplastics Due to an initially sufficient pressure transfer during injection molding processes involving semi-crystalline materials such as polyethylene (PE), polypropylene (PP), polyamide (PA) and polyoxymethylene (POM) there is almost no change in the mold cavity pressure during the period after the compression phase and the onset of the crystalline melting point. After that, however, the significant volume contraction during crystallization brings about a sudden drop in the pressure. The duration of the holding pressure phase depends on factors such as the wall thickness of the molded part, the degree of crystallization and the processing parameters. The crystalline melting point of semicrystalline materials for example, is dependent on the prevailing cavity pressure. Cavity pressure Cavity pressure Time Time 9

10 Using the Mold Cavity Pressure in Practical Practical application Installation options Sensor fitted directly into the drilled hole Spacer sleeve Installation and extraction tools At a glance There are two installation options to accommodate different mold concepts: Sensor secured with mounting nut and Sensor with adapting spacer sleeve for direct attachment below the mold platen Accurate pressure data that is suitable for analysis can only be acquired by means of reliable and precise measuring technology. The mold cavity pressure can be measured directly, indirectly, contact-free or together 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 and reliable, sturdy, maintenance-free and durable measuring equipment is prerequisite to the reliable acquisition of the pressure and temperature data during the injection molding process. Stringent quality requirements for molded parts generate a demand for increasingly precise measurement systems. These systems are expected to register and balance minute pressure variations even at a pressure of bar. Kistler sensors with their dimensions meet the exacting requirements of modern injection molding technology and all its special processing methods. They have an almost unlimited service life, deliver highly linear measuring results, cover a wide frequency range up to 100 khz and operate independently of the temperature. Piezoelectric cavity pressure sensors made by Kistler can withstand mold temperatures of up to 300 C and any required melt temperature. Kistler supplies a whole range of cavity pressure sensors with a standard uniform sensitivity. Equipped with Unisens technology, each sensor comes with a guaranteed uniform sensitivity within a minimal tolerance range. Therefore, the electronic equipment does not require any individual adjustment. Core competence Unisens technology eliminates adjustments Piezoelectric sensors discharge electricity proportionate to the cavity pressure. The proportionality is referred to as sensitivity and is measured in picocoloumbs per bar (pc/bar). Under normal circumstances, this sensitivity varies within narrow limits and must be manually adjusted on the measuring system or the injection molding machine. Unisens technology made by Kistler dispenses with this fine-tuning effort as the sensors operate with a fixed sensitivity. Unisens facilitates machine and system adjustment and also prevents erroneous input. 10

11 Measuring: Sensors and their Positioning Direct, indirect and contact-free pressure measurement Mold cavity pressure can be measured indirectly, without contact or in combination with the contact temperature. Direct cavity measurement During direct measuring, the sensor comes into contact with the plasticized polymer material within the mold cavity and measures its pressure directly and without a transmission aid. These sensors can be installed in the drilled holes in the mold with or without an adapter. Most sensors allow an adaptation of the sensor front to suit the cavity structure in order to prevent impressions in the molded part. Sensors for direct measurement are available in different dimensions and with front diameters of 6, 4, 2,5, 1,2 or 1 mm. This allows them to be easily and reliably integrated into injection molds. Indirect measurement behind the ejector or measuring pin Alternatively, the force behind the ejector or measuring pin can be determined and converted to yield the actual pressure by means of the pin diameter. Indirect measuring is recommended for applications which do not leave enough room for a direct sensor. Some of the design rules relating to ejectors or measuring pins have to be taken into account with indirect measurement. For more information on this topic, please refer to p. 43 onwards. Contact-free measurement of cavity pressure Optical components such as lenses or light guides, and moldings with class A surfaces for the automobile industry, must not have any impressions left by sensors. Direct measuring sensors also produce changes in the temperature field near the wall of the mold that could degrade optical properties. For such critical applications the cavity pressure can also be measured without contact. Measuring pin sensors Type 9243B and 9247A are mounted in the mold structure behind the wall of the cavity, or in the compression punch, where they measure the strain of the steel caused by the cavity pressure. Positioning the sensors away from the surface of the cavity avoids them affecting the temperature field in the vicinity. For more information on this topic, please refer to p. 33 onwards. Special sensors for molds with inserts For injection molds assembled with inserts, Kistler offers the adapter-based sensor Type 6155AE. This sensor is mounted in the base plate, where it remains to protect cables and sensor during installation or removal of an insert. In the case of molds without inserts, rather than in the base plate the sensor is mounted in the second cavity plate, where it stays even when the mold is disassembled. For more information on this topic, please refer to p. 45 onwards. 11

12 Using the Mold Cavity Pressure in Practical Combined sensors Both the monitoring of moldings prone to warpage or distortion, and process analysis in general, benefit from measurement of the parameter of temperature in addition to cavity pressure. The combination pressure-temperature sensor measures both the cavity pressure and the contact temperature in the same location at the molded part. While the cavity pressure sensor measures the pressure, a fast-transmission method is used to measure the temperature: both thermocouple cables run separately to the sensor front, where they are welded to a thermocouple type K (Ni-CrN). As the thermocouple is positioned at the tip of the sensor, it measures the contact temperature of the melt. Thus, even minute variations in contact temperature, which can be caused by changes such as a falling or rising melt temperature, can be monitored. For more information on this topic, please refer to p. 40 onwards. Temperature sensors Cavity pressure (bar) Contact temperature ( C) Kistler sensors for temperature measurement are based on the same principle. Their front diameters correspond to those specified for pressure sensors (ø4 mm, ø2,5 mm and ø1 mm) and are compatible with standard cavity pressure sensors For more information on this topic, please refer to p. 41 onwards P near the gate T near the gate Time (s) P away from the gate T away from the gate

13 Measuring: Sensors and their Positioning Positioning the sensor in the mold Accurate positioning of the cavity pressure sensor is important for a sufficient duration of informative value of the measured values. Both the position of the sensor in relation to the gate and the wallthickness of the part at the installation point are of particular importance. Measurement near the gate The cavity pressure profile during the filling phase is measured when the melt flow front has reached the sensor. A meaningful and long-term measuring result is acquired near the gate and in the vicinity of the highest wall thickness as thick areas take longer to solidify. Sensor positioning should take into account both the fastest and the slowest melt setting points. In cavities with several gates, measurements should be taken from critical areas of the molded part. Practical application Basic rules for accurate sensor positioning 1. The cavity pressure sensor should be installed near the gate, where the pressure in the molded part is highest. The closer the sensor is positioned to the gate, the more detailed the delivered process information. 2. The sensor must be installed within the cavity and not in the gate. Sensors installed in the gate will fail to transmit signals and monitor the process during the residual cooling phase after the gate has been sealed or after the onset of shrinkage. 3. If possible, the sensor should be positioned at the thickest cross section of the molded part where the melt solidifies last and the duration of the pressure is most extensive. 4. The installation of a second sensor away from the gate for measuring large parts with a critical flow path/wall thickness ratio is recommended for the acquisition of additional part quality data. 5. Sensors must not be installed directly opposite the gate as they will measure an additional dynamic force component which will override and distort the cavity pressure signal. 1./ Measurement away from the gate The greater the distance from the gate, the later the melt flow front reaches the sensor, the later the pressure is registered and the higher the filling level must be to actually allow pressure measurement. Consequently, data about the filling phase cannot be displayed until the sensor has been reached. Measurement on the edge of a molded part, i.e. away from the gate or at the end of the flow path yields a signal only when the pressure rises suddenly during the compression phase. Mea surement positions away from the gate are beneficial only for protecting components such as threaded spindles or core pullers from damage caused by pressure peaks or for monitoring specific quality problems at the end of the flow path. 13

14 Using the Mold Cavity Pressure in Practical Cables ensure the accurate transmission of all signals from the sensor to the mold connector, from the mold to the monitoring system or the charge amplifier, and from the charge amplifier to the injection molding machine. Kistler cables exploiting single-wire and multichannel technology are the only means of ensuring demonstrably correct use of sensors. Connecting cable: from sensor to connector Kistler pressure sensors are available with conventional coaxial cables with two conductors or with the single-wire technology. The cables have only one wire and the connector is no longer an integral part of the cable (see box "Single-wire technology"). With multi-cavity molds, multichannel connectors bundle the connecting cables of all of the sensors and route just one cable to the process monitoring system. For each sensor, two-conductor coaxial cables have one connector, for which sufficient space has to be provided in the mold. Single-wire technology (Fig. 1) has supplanted the coaxial cable (Fig. 2) in most applications. Extension cable: from mold connector to monitoring system The sensor's connector is mounted on the outside of the mold. From here, the distance to either the Kistler CoMo Injection or DataFlow systems or to the charge amplifier, which is usually firmly installed on the injection molding machine, has to be bridged. For this application, Kistler provides extension cables in a variety of designs, depending on the production environment and the distance to be covered, and a wide range of different sheathings and cable lengths (Fig. 3, 4). Kistler multichannel cabling technology in particular has made connection of sensors to systems much simpler and more reliable. Connecting cable: from system to machine or peripheral equipment The monitoring systems and peripheral equipment or the change amplifiers and machines are linked with a connection cable. This has a connector for the system (Fig. 5) and a choice of interface for the injection molding machine or peripheral equipment (Fig. 6). For more information on this topic, please refer to p. 51 onwards. Fig. 2 Fig. 3 Fig. 6 Fig. 1 Fig Fig. 5

15 Connecting: Safe Transmission with Suitable Cables Single-wire technology With single-wire technology, the cable only has one wire without shielding and the connector no longer forms part of the cable. The shielding is provided by the injection mold instead. The very thin singlewire cable can be flexibly installed in drilled cable ducts and cut to length. A fully integrated special cut and grip system makes it easy to attach the connector to the cable. Single-wire technology cuts planning time and design costs, takes up less space in the mold, speeds up sensor mounting and allows the user to repair any damaged cable. Multichannel cabling technology In multi-cavity molds or molds with several sensors per cavity, single-wire technology provides the basis for grouping the different individual leads in a common cable. When connecting the mold and CoMo Injection or DataFlow, up to eight cables and connectors can now be replaced with just one multichannel cable and one multichannel connector Type 1708A or 1710A. By eliminating accommodation of more than one connector, multichannel cabling reduces mold space requirements. This drastically cuts cabling and setup costs and time. By relegating mix-ups to the past, Kistler multichannel technology ensures the entire process is more reliable. Advantages The most important benefits of single-wire technology: + Cost-efficient mold making + The cables run through drilled holes + Easy installation with detachable connector + Mold makers can shorten cables as required + The user can repair any cable damage + Small cable diameters and multichannel cabling allow easy installation in multi-cavity molds Multichannel cabling technology for pressure and temperature signals Combined pressure and temperature measurements are also possible with multichannel cabling: in addition to the pressure channels on the multichannel connector Type 1708A or 1710A, grip technology is used to connect the temperature channels of the pressure and temperature sensors to the miniaturized thermocouple amplifier Type 2205A with two or four channels. Connection to the CoMo Injection process monitoring system only requires a single cable for up to four temperature signals. The thermocouple amplifier supports the combined pressure and temperature sensors Type 6189A and 6190CA. Type 1710A... Advantages The most important benefits of multichannel cabling technology: + Sensor connections cannot be mixed up + Installation in the mold is quicker and easier than with coaxial cables with two conductors + Just one cable is used from the mold to the monitoring system + Compact mounting in the mold Type 2205A

16 Using the Mold Cavity Pressure in Practical The ultimate aim of process monitoring is to save money by automatically detecting rejects and reducing the cost of quality inspection. CoMo Injection is Kistler's system for cavity pressure based optimization, real-time control, monitoring and documentation of injection molding with reject separation. The system provides all of the process and quality data for process monitoring and reject separation. The compact CoMo Injection Type 2869B is easily configured and practical in this industrial application. It uses simple connection technology and process-oriented control for ease of integration into a variety of production environments. The different CoMo Injection models are equipped with up to 16 inputs for piezoelectric pressure sensors and four or eight inputs for voltage signals (for example for temperature). All of the cavity pressure sensors of a multi-cavity mold are connected to the CoMo injection unit by means of multichannel cabling. This makes connection quicker and easier, requires less space in the mold, protects against problems from cable mix-ups and shortens the setup time. CoMo Injection provides all of the functions required for process monitoring and reject separation, and ensures ease of configuration. A real-time threshold allows dynamic control of a wide range of injection molding processes on the basis of cavity pressure during the cycle. For more details of multichannel cabling, please refer to p. 15 onwards. At a glance CoMo Injection analyzes the cavity pressure profile in order to evaluate moldings and separate rejects offers all the practical tools needed for process optimization and cycle time reduction uses real-time functions for innovative control of even special processes is easily configured in steps related to the process exploits multichannel cabling for faster setting up of molds with pressure sensors offers a comprehensive, standardized base configuration operates on a standalone basis without a PC is available with an optional display; with option of comprehensive production and quality statistics plus analysis functions (CoMo MIS Type 2829A ). Easy configuration, setup and operation Configuration, setting up and operation of CoMo Injection are highly intuitive and rely on the 12,1" color touch screen display Type 5629A3 or a standard PC or laptop with browser. Operation of the CoMo Injection reflects the routine steps involved in setting up injection molding machines. The setup procedure is followed by process optimization, production and finally quality assurance. Process and quality data is managed and saved for each order and batch. Digital communication and networkability To enable integration with a machine control/handling system or scrap separation device, the CoMo Injection has a total of 12 outputs and 5 inputs, all of which are electrically isolated. CoMo Injection can be networked using Ethernet (TCP/IP). On company LANs, in parallel with injection molding production the unit allows a production monitoring and support option across different sites and even continents. Experts in one factory can then help colleagues in another remedy acute problems (trouble-shooting) and optimize processes using just the standard license-free Java TM in combination with a standard browser, such as Internet Explorer TM or Mozilla Firefox. 16

17 Analyzing: Automatic Process Monitoring, Real-Time Control and Documentation CoMo MIS the Manufacturing Information System CoMo MIS Type 2829A consists of a central database in which the process data of all of the installed CoMo Injections is continuously stored via Ethernet. A browser is used to retrieve from the database information about all of the current and completed production jobs and batches. Measuring chain with CoMo Injection Type 2869B, reject diverter and CoMo MIS Type 2829A... in network Statistics module in CoMo MIS Type 2829A... User interface of Curve Viewer The following information about all batches is clearly displayed: status of batch (in production or completed), percentage of good parts, with indication of whether reject rate lies within defined tolerances, result of last cycle ("OK"/"not OK"), total number of cycles and number of good cycles. At the same time the logically arranged display allows direct access to the CoMo Injection allocated to the batch. Thus, the current process data and curve are just a click away from this overview of a particular batch. The Curve Viewer allows all stored process data to be displayed in the form of curves. There is also a whole range of easily chosen display options, such as curve superimposition, extensive analysis functions, selection of cycles and channels, etc. The data of a batch can be opened directly in an included statistics program. This allows detailed evaluation of the process data and production of quality documents. 17

18 Using the Mold Cavity Pressure in Practical The software tool DataFlow is used for process analysis, process optimization and monitoring of molds with more than 8 cavities. It supports the user along the entire process chain from mold validation, setup and process optimization to production monitoring including statistical analysis and documentation. The optimum analysis of measured process data is prerequisite to the utilization of cavity pressure and contact temperature measurement equipment. DataFlow provided by Kistler operates with tools which support users across the entire process chain from mold sampling, setup and process optimization to production monitoring including statistical analysis and documentation. These functions are based on the determination of the cavity pressure and the contact temperature. Additional information such as the hydraulic pressure can also be processed. DataFlow is easy to operate as it runs on conventional personal computers or notebooks under Windows XP and Windows Used in conjunction with Kistler electronic equipment (system Type 2865B or multi-cavity system Type 6829A ), DataFlow offers a comprehensive analysis and optimization system. It also handles monitoring and documentation of injection molding with more than cavities, even accommodating multicomponent techniques and multi-cavity family molds. DataFlow can control equipment such as reject gates and reversible belt conveyors or operate robot placing processes to ensure that all parts are separated into rejects and good parts. 18

19 Analyzing: Injection Molding Process Analysis and Optimization DataFlow provides a range of tools across the entire process chain: During mold sampling and optimization, DataFlow provides process data in a variety of different graphics in order to speed up the mold sampling process and to utilize the full optimization potential. During process optimization, DataFlow can be used to determine process tolerance limits and to evaluate processing properties based on the measured data. In this way, the system reduces mold sampling times and ensures a fast optimization of the process. The determined tolerance limits can be used for monitoring part properties and quality assurance during the production process and dispense with the need for manual examination. During mold set-up, cavity pressure reference curves can be stored. Optimized molds can be operated fast and efficiently on different machines and the optimum operating point can be determined quickly. During production DataFlow calculates from the measured process data maximum values, freely definable integrals, the filling index and the injection work. Moreover, the system allows the definition of tolerance ranges. Transgression of these tolerance ranges by the values recorded from the current process will either trigger an optical notification or lead to an activation of the reject gates or robots. DataFlow provides automatic quality assurance for molds with large numbers of cavities and integrates it into the process. Trend graphics can predict errors in the active production process to eliminate them. Networking statistics allow statistical production analysis (cp, cpk values, production distribution) for the purpose of documentation. Automatic reports provide a documentation of quality for customers. Statistics data generated by DataFlow can be used to detect and eliminate weak points in the production process and help to determine the reject quota while the production monitoring function can then be used to directly identify the cause of excessive rejects. 19

20 Using the Mold Cavity Pressure in Practical Charge amplifiers convert the charge output by a piezoelectric pressure sensor into a proportional voltage, which can be used as an input variable for monitoring and control processes. Smart charge amplifiers can also utilize algorithms to transmit signals, e.g. for a cavity pressure based switchover of the injection molding machines, which can be integrated directly into the machine's control system. This switchover from the injection phase to the holding pressure phase based on mold cavity pressure is a standard feature of modern injection molding machines. The cavity pressure sensor is connected to the control system via a charge amplifier, which is accommodated in a robust case. The charge amplifier's output signals are analog. The real-time operation of charge amplifiers allows reliable control of highspeed processes on the basis of cavity pressure. In addition to cavity pressure, the contact temperature is another important process parameter which can be used to complement cavity pressure in process monitoring. For more information on this topic, please refer to p. 59 onwards. Kistler supplies a wide range of charge amplifiers for integration into machine control systems. While Type 5039A is a single-channel charge amplifier, the Type 5155A is equipped with several channels for charge and temperature. The 1-, 2- and 4-channel amplifiers always have the same type of case and the same connector with an identical pin allocation. This minimizes the integration effort, even with constantly changing configurations. Charge amplifiers are indispensable for cavity pressure measurement. To accommodate the wide variety of control hardware it is recommended that injection molding machine manufacturers factory fit suitable charge amplifiers to their machines. Type 5049A... Type 5039A... Type 5155A

21 Analyzing: Integrating into Machine Control Systems SmartAmp: Self-optimizing switch-over The switch-over point is an important process parameter with a significant effect on the quality and production cost of the molded part. The change over from injection to holding pressure must be executed in conjunction with a volumetric cavity filling. Traditional methods use the injection time, the screw stroke or the hydraulic pressure to determine the switch-over point. All these methods operate according to the same principle, which involves the definition of a threshold to trigger the switchover. A suitable threshold is determined manually by means of repeated fillings without holding pressure. This approach is time-consuming, costly and has two major disadvantages: Modification of the injection profile requires a changing or reestablishing the threshold As the switch-over point does not account for process or material fluctuations, the switch-over is delayed or triggered prematurely The cavity pressure profile yields accurate information on the volumetric filling process. Independent of the mold geometry, the cavity pressure rises dramatically after the holding pressure phase due to the compression of the melt. This kink in the curve has its starting point exactly at the onset of the volumetric filling process. Therefore, it is ideal for triggering the switch-over process in the machine. Kistler has developed an algorithm, which is integrated into the SmartAmp charge amplifier to analyze the cavity pressure profiles of a wide variety of different parts and determine the switch-over point in real time. By using the cavity pressure, SmartAmp technology with "self-optimizing switch-over" identifies the switch- over point in a fully automatic and selfoptimizing procedure. The signal transmitted by the SmartAmp triggers an automatic switch-over from injection to holding pressure. The self-optimizing switch-over process is preceded by a fully automatic learning phase, which lasts 4 to 16 production cycles. This period is used to determine optimum parameters for the algorithms integrated into the charge amplifier. The system significantly reduces the reject quota and controls the effects of batch variations on the process during the cycle. Due to the automatic recognition of the switch-over point, which dispenses with the repetitive process of mold filling studies, the SmartAmp significantly facilitates mold set-up. SmartAmp technology is integrated into the Type 5049A... one-channel charge amplifier and into the Type 5155A... multichannel charge amplifier. Pressure (bar) Self-optimizing switch-over Time (s) Pressure (bar) Conventional switch-over Time (s) 21

22 Using the Mold Cavity Pressure in Practical Sensors for measuring mold cavity pressure and contact temperature during injection molding Direct Measurement Variable Pressure Pressure and Temperature temperature Pressure range Standard Low pressure Standard/ bar bar low pressure Material Thermo- Thermosets Thermo- Thermosets Thermo- Thermoplastics Elastomers plastics Elastomers plastics plastics LSR LSR Thermosets Elastomers LSR Front ø (mm) of sensor A B... 1,2 6184A... 2,5 6158A A A B A B B B B A A CA B AE 6167A A A A A... With single-wire technology, the sensors Type 6152A, 6157B, 6159A, 6167A, 6172A, 6177A, 6178A, 6182B, 6183A and 6184A can be ordered in the multi-cavity system Type 6831B. Indirect pressure measurement Dimensions (mm) ø3,5 9210A... ø6 9211B B... ø12,6 9204B... 6x6 9223A... 12,6x9,5 9221A... Contact-free pressure measurement Dimensions (mm) M5 M A B... Note: The Type numbers in the tables designate the sensors. 22

23 Explanation of Type Designations All Kistler sensors are available with coaxial or single-wire cabling technology. When selecting sensors it is important to use the correct suffix of the cable designation for the matching combination of sensor and cable. Type designations for single-wire cabling technology Type designations for coaxial cabling technology The single-wire sensors can be used with single- or multichannel technology. For single-channel technology these sensors are supplied with connectors (sensor type designation E or E1). All single-channel connectors with single-wire and coaxial cabling technology are 1-channel male Fischer connectors. For multichannel technology in combination with the multichannel connectors Type 1708A0 (4 channels) or Type 1710A0 (8 channels), sensors without connectors (sensor type designation G or G1) are used. System Type 6831B contains sensors and multichannel connectors. The sensor type designations for single-wire technology have the following suffixes: The sensor designations for coaxial cabling have the following suffixes: Sensors for operating temperatures up to 200 C (with the exception of lowpressure sensors) are available with cable lengths of 0,2 / 0,4 / 0,6 and 0,8 m (example: Type 6157BA0,4 for 0,4 m cable length). The suffix SP indicates a custom specific length between l min = 0,1 m and l max = 5 m, example for 3 m cable length Type 6157BASP l = 3 m. Sensors for operating temperatures up to For all sensors with single-channel technology BNC extension cable Type 1661A, 1667B, TNC extension cable Type 1662A and 1672B For all sensors with single-wire technology without connector (Type variants G and G1) 4-channel connector Type 1708A0 and extension cable Type 1995A, 8-channel connector Type 1710A0) and extension cable Type 1997A For combined pressure and temperature sensors Type 6190CA and 6189A BNC extension cable Type 1661A and 1667B, TNC extension cable Type E Single-wire technology with 1.5 m cable length and single-channel connector. Example: Type 6157BAE E1 Single-wire technology with 5 m cable length and single-channel connector. Example: Type 6157BAE1 G Single-wire technology with 1,5 m cable length without connector for multichannel applications with connector Type 1708A0 or Type 1710A0 (order connector separately). Example: Type 6157BAG G1 Single-wire technology with 5 m cable length without connector for multichannel applications with connector Type 1708A0 or Type 1710A0 (order connector separately). Example: Type 6157BAG1 300 C and for low-pressure processes are equipped with cable length 0,4 m (example: Type 6157BB0,4). The suffix SP indicates a custom specific length between l min = 0,1 m and l max = 5 m, example for 3 m cable length Type 6157BBSP l = 3 m. Sensor types for coaxial technology are indicated in the tables by " " (example: Type 6157BA ). Sensor types with custom length are indicated in the tables by "SP" (example: Type 6157BASP). 1662A and 1672B, compensation lead Type 2290A and 2295A For combined pressure and temperature sensors Type 6190CA and 6189A without connector (Type variants G and G1) Temperature amplifier Type 2205A Multichannel connector Type 1708A Multichannel connector Type 1710A... For temperature sensors with connector Compensation lead Type 2290A... and 2295A... For all temperature sensors without connector (variants G and G1) Temperature amplifier Type 2205A 23

24 Using the Mold Cavity Pressure in Practical Sensors, cables, charge amplifiers and systems 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 sensors, connecting cables, extension cables if required, charge amplifiers, connection cables or complete systems. The chains are used to set up control circuits for monitoring, optimizing and controlling injection molding processes and for documenting the acquired process data. Machine-integrated systems Machine-integrated systems acquire measuring data and/or transmit switching signals to the machine's control unit. These systems are available with one channel for pressure measurement or with multichannel systems for combined pressure and temperature measurement. The charge amplifiers are integrated into the injection molding machine. The machine's control system is responsible for process documentation. Machine-Integrated Systems Measure Connect Extend Amplify Option One-channel pressure measurement P 1667B..., 1672B A A A A... One-channel measurement, with SmartAmp function P 1667B..., 1672B A A A A... Pressure and temperature measurement with up to 4 channels, with SmartAmp function 4 P T 1667B..., 1672B A A10 P+T 2295A B..., 1672B A... Alternative option for P: 1661A..., 1662A... Standard equipment SmartAmp Alternative option 24

25 Measuring Chains for Cavity Pressure Measurement Mobile systems Although Kistler systems operate independently of the injection molding machine, they can still use process signals from the machine for analysis and actively transmit switching signals to it. CoMo Injection is the process monitoring and documentation system. DataFlow is used for process analysis and optimization. Kistler systems are available with a number of channels for pressure and temperature or voltage measurement. As they can be used for different injection molding machines, they offer the benefit of accommodating existing molds modified with cavity pressure measurement systems. Multi-cavity pressure measurement systems Multi-cavity systems compile pressure measurement data from up to 32 cavities in one charge amplifier. While they operate independently of the injection molding machine, they can still process signals transmitted by the machine for analysis and actively transmit switching signals to the machine. An external PC or notebook computer equipped with Kistler DataFlow software controls the process. Connect Analyze 25

26 CoMo Injection Process Monitoring and Documentation Measure Connect Extend Analyze Connect 12-channel system for up to 2 x 4 pressure sensors plus 4 voltage inputs up to 4 P 1708A0* 1995A A43A... Digital I/Os 1500A42A... Digital outputs Example: 2 x 4 pressure sensors up to 4 P 1708A0* 1995A... CoMo Injection 2869B1...*** 1200A49A1**** Network 12-channel system for up to 8 pressure sensors plus 4 voltage inputs Example: 4 combined pressure and temperature sensors bis 4 P/T 1710A0** 2205A141** 1997A A1A... CoMo Injection 2869B2...*** 1500A43A... Digital I/Os 1500A42A... Digital outputs 1200A49A1**** Network 24-channel system for up to 2 x 8 pressure sensors plus 4 voltage inputs bis 8 P 1710A0* 1997A A43A... Digital I/Os 1500A42A... Digital outputs Example: 2 x 8 pressure sensors bis 8 P 1710A0* 1997A... CoMo Injection 2869B3...*** 1200A49A1**** Network *Sensors and connectors in system 6831B **Sensors, connectors and amplifiers in system 6833A... DataFlow System for Process Analysis and Monitoring with up to 16 Channels System with up to 16 channels for notebook or desktop PC Measure Connect Extend Amplify Option up to 16 P up to 16 T or up to 8 P/T 1667B..., 1672B A A B..., 1672B... Alternative for P: 1662A... and 1661A... Signal conditioner DataFlow System for Process Analysis and Monitoring with up to 64 Channels System with up to 64 channels for desktop computer up to 64 P 6829A... Standard solution Alternative Additional option 26

27 Analyze CoMo MIS 2829A-03-2 Scrap separation device USB Ethernet Scrap separation device CoMo MIS 2829A-03-2 Ethernet USB Scrap separation device Ethernet USB CoMo MIS 2829A-03-2 ***Choice of different moduls in system 2869B ****Included in system 2869B Connect Analyze 1500A43, l = 7 m Trigger/digital outputs DataFlow 2231A1, l = 5 m Trigger USB USB Package 2865B... Signal conditioner 2805A A A USB cable 1700A62, l = 5 m Trigger/excitation 1200A85, l = 5 m Digital output 1200A A A95A1 A/D card Parallel USB DataFlow 2805A A-02-2 Measurement signals 1200A83, l = 5 m 2855A6 27

28 Sensors and Systems for Injection Molding Machines In addition to the measurement and utilization of the cavity pressure, there is a wide range of other parameters such as the clamping force, tie bar extension and nozzle pressure to be measured during the operation of an injection molding machine. These measurements are particularly important for various reasons, including the growing importance of electric injection molding machines. Measuring the clamping force and mold protection Measurement of the surface strain (which is proportional to applied force), for example on a toggle link or the back plate of the clamp unit, can be used directly to determine the clamping force and to protect the mold. The strain transmitter Type 9238AQ is mounted on the machined surface with an M6 screw. Due to the high linearity of the signal, only a single sensor is needed to measure the high clamping forces and the small forces during mold movement. The strain transmitter Type 9238AQ combines the sensor and the charge amplifier in a single unit, which has two signal outputs providing in parallel the signals representing the mold movement force and the clamping force. This allows simple integration into the control system of injec- tion molding machines. Both measuring ranges and other functions, such as signal inversion and signal offset, can be software preset. Combining the sensor and the electronics in a single case makes the unit extremely robust and affords the best possible protection under tough production conditions. Type 9238AQ

29 Measuring the Clamping Force, Tie Bar Extension and Melt Pressure Equipping all tie bars with a sensor allows the measurement of forces on the individual tie bars to ensure parallelism of the mold platens and the mold itself, detection of overloads in individual tie bars and the active prevention of cracks in the tie bars. The charge amplifier required for this application is included in the Type 9827A... measuring chain. Measuring the tie bar extension Measurement of the tie bar extension involves the installation of Type 9827A sensors directly into the drilled holes in the tie bar. They transmit a signal which is proportional to the force during mold movement and clamp force. Measuring the melt pressure In view of recent developments in the area of electric injection molding machines, the measurement of the melt pressure has become increasingly important, as classic control parameters such as the hydraulic pressure are no longer available. As measurement sensors recording the current consumption or the torque are located at a distance from the mold, they are not as suitable for accurate control functions as the direct measurement of the melt pressure in the area in front of the screw. The Type 4013B sensors provide fast highprecision measurement, which meets all requirements of electric injection molding machines. The piezoresistive sensors, which can be used for pressures of up to bar and temperatures of up to 350 C, deliver detailed process information and are also suitable for process monitoring with hydraulic machines. Further areas of application for these sensors include pressure measurement in hot-runner systems. In addition to pressure monitoring in the hot-runner, the acquired information can be used for control purposes. The sensor can be equipped with a temperature measurement feature for a precise determination of the melt temperature directly on the sensor's measuring component. Type 9827A... Type 4013B

30 Sensors and Measuring Chains for Injection Molding Machines Systems for injection molding machines Measure Connect Extend Amplify Option Measuring the melt pressure 350 C 4618A... Analog 1500A B A A... Digital 1500A57 Measuring the melt pressure 300 C 4618A... Analog 1500A A... Digital 1500A A A... Mold protection and clamping force 1787A5 9238AQ... Measuring the tie bar extension 1500A A... Standard equipment Alternative option 30

31 Connect Analyze 31

32 Measuring The cavity pressure built up during injection molding can be measured directly, indirectly, contact-free or in combination with the contact temperature. During direct measurement the sensor touches the plasticized material within the cavity to determine the pressure directly, without the use of transmission pins. Alternatively, the force can be measured behind an ejector pin or measuring pin and translated into the actual pressure using the pin diameter. A third method is contact-free measurement of the compression strain of the steel caused by the cavity pressure. This is achieved with the help of measuring pin sensor mounted behind the wall of the cavity. These are only used for moldings subject to the most stringent surface finish or optical requirements. In addition to this, Kistler offers special sensors for molds with inserts. Combined pressure-temperature sensors measure both the mold cavity pressure and the contact temperature at the exact same location on the molded part. Kistler sensors for temperature measurement alone are compatible with standard mold cavity pressure sensors. In addition to the measurement and utilization of the cavity pressure, there is a wide range of other forces such as the nozzle and hot-runner pressure, the tie bar extension and the clamping force to be measured during the operation of an injection molding machine. For these measuring tasks, Kistler also provides optimized sensors to suit specific applications. Direct cavity pressure measurement Direct cavity pressure measurement (low-pressure processes) Direct cavity pressure and contact temperature measurement Direct contact temperature measurement Indirect cavity pressure measurement Contact-free cavity pressure measurement Melt pressure and temperature sensor systems Clamping force measurement and mold protection Tie bar extension Hydraulic pressure measurement 32

33 Measuring Direct cavity pressure measurement Front diameter 6 mm Unisens 4 ø6 ø10 Type 6152AA... Type 6152AC... Measuring range bar Overload bar Sensitivity pc/bar 9,4 (Unisens) 9,4 (Unisens) Cabling single-wire/coaxial single-wire/coaxial Exchangeable cable yes yes Available types 6152AAE, 6152AAE1, 6152ACE, 6152ACE1, 6152AA, 6152AAG, 6152AC, 6152ACG, 6152AAG1, 6152AASP 6152ACG1, 6152ACSP Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C Options Silicone-filled gap 6152AAA ACA... The diaphragm-free piezoelectric sensor has a sleeve design. Unisens technology allows easy configuration of measuring systems. The sensor Type 6152AC... is the chromium-plated version of the sensor Type 6152AA... for handling glass fiber reinforced materials. Suitable for thermoplastics, thermosets, elastomers and LSR. The sleeve design is particularly practical for large molds. Mounting nut Type 6453* Spacer sleeve Type 6462 Data sheet 6152A_ Front diameter 6 mm for high-temperature applications Unisens Type 6152AB... Type 6152AD... Measuring range bar Overload bar Sensitivity pc/bar 9,4 (Unisens) 9,4 (Unisens) Cabling coaxial** coaxial** Exchangeable cable yes yes Available types 6152AB, 6152ABSP 6152AC, 6152ACSP Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C ø6 ø10 The diaphragm-free piezoelectric sensor has a sleeve design. Unisens technology allows easy configuration of measuring systems. The sensor Type 6152AD... is the chromium-plated version of the sensor Type 6152AB... for handling glass fiber reinforced materials. Suitable for thermoplastics, thermosets, elastomers and LSR. The sleeve design is ideal for large molds at temperatures in excess of 200 C. Mounting nut Type 6453* Spacer sleeve Type 6462 Data sheet 6152A_ * included accessories ** length 0,4 m and custom specific only 33

34 Measuring Direct cavity pressure measurement Front diameter 4 mm Unisens 8 ø4 ø7 Type 6157BA... Type 6157BC... Measuring range bar Overload bar Sensitivity pc/bar 9,4 (Unisens) 9,4 (Unisens) Cabling single-wire/coaxial single-wire/coaxial Exchangeable cable yes yes Available types 6157BAE, 6157BAE1, 6157BCE, 6157BCE1, 6157BA, 6157BAG, 6157BC, 6157BCG, 6157BAG1, 6157BASP 6157BCG1, 6157BCSP Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C Diaphragm-free piezoelectric sensor. Unisens technology allows easy configuration of measuring systems. The sensor Type 6157BC... is the chromiumplated version of the sensor Type 6157BA... for handling glass fiber reinforced materials. Suitable for thermoplastics, thermosets, elastomers and LSR. Mounting nut Type 6457* Spacer sleeve Type 6459 Data sheet 6157B_ Front diameter 4 mm for high-temperature applications Unisens Type 6157BB... Type 6157BD... Measuring range bar Overload bar Sensitivity pc/bar 9,4 (Unisens) 9,4 (Unisens) Cabling coaxial** coaxial** Exchangeable cable yes yes Available types 6157BB, 6157BBSP 6157BD, 6157BDSP Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C ø4 ø7 Diaphragm-free piezoelectric sensor. Unisens technology allows easy configuration of measuring systems. The sensor Type 6157BD... is the chromiumplated version of the sensor Type 6157BB... for handling glass fiber reinforced materials. Suitable for thermoplastics, thermosets, elastomers and LSR at mold temperatures in excess of 200 C. Mounting nut Type 6457* Spacer sleeve Type 6459 Data sheet 6157B_ * included accessories ** length 0,4 m and custom specific only 34

35 Measuring Direct cavity pressure measurement Front diameter 4 mm in mounting sleeve Type 6155AE Measuring range bar Overload bar Sensitivity pc/bar 2,5 Cabling single-wire Exchangeable cable no Machinable front yes Coated front no Operating temperature Melt (at the front of the sensor) C <450 Mold (sensor, cable) C Connection C ø6 ø4 Diaphragm-free piezoelectric sensor with 4 mm front diameter. The sensor is integrated into a sleeve and can be mounted in the mold platen. Mold platens or inserts can be removed without detaching the sensor. Suitable for thermoplastics. Ideal for molds with inserts. The sleeve design can also be used in standard molds to protect the sensor cable. Washers 4x Type 6530A0,1* Mounting plate Type 6540A Extension sleeve, 20 mm Type 6530A20 Extension sleeve, 50 mm Type 6530A50 Data sheet 6155A_ Front diameter 2,5 mm 10 Type 6182B Type 6182BC Measuring range bar Overload bar Sensitivity pc/bar 2,5 2,5 Cabling single-wire single-wire Exchangeable cable no no Available types 6182BE, 6182BG 6182BCE, 6182BCG Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C ø2,5 ø4 Diaphragm-free piezoelectric sensor with small shoulder. The sensor Type 6182BC... is the chromium-plated version of the sensor Type 6182B... for handling glass fiber reinforced materials. Suitable for thermoplastics. The small dimensions of the Type 6182B... make it particularly suitable for multicavity molds and small parts. Spacer sleeve Type 6464A1* Mounting nut Type 6458 Data sheet 6182B_ * included accessories 35

36 Measuring Direct cavity pressure measurement Front diameter 2,5 mm 10 Type 6158A... Measuring range bar Overload bar Sensitivity pc/bar 2,5 Cabling coaxial Exchangeable cable no Available types 6158A, 6158ASP Machinable front yes Coated front no Operating temperature Melt (at the front of the sensor) C <450 Mold (sensor, cable) C Connection C ø2,5 ø4 Diaphragm-free piezoelectric sensor with small shoulder. Suitable for thermoplastics. The small dimensions of this sensor make it ideal for small parts. Spacer sleeve Type 6464A1* Mounting nut Type 6458 Data sheet 6158A_ Front diameter 2,5 mm 10 ø7 ø2,5 Type 6159A... Type 6159A... U6 Measuring range bar Overload bar Sensitivity pc/bar 2,5 2,5 Cabling single-wire/coaxial single-wire/coaxial Exchangeable cable yes yes Available types 6159AE, 6159A, 6159AEU6, 6159A U6, 6159AG, 6159ASP 6159AGU6, 6159ASPU6 Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C Diaphragm-free piezoelectric sensor. The sensor Type 6159A...U6 is the chromiumplated version of the sensor Type 6159A... for handling glass fiber reinforced materials. Suitable for thermoplastics. Ideal for small parts. Mounting nut Type 6457* Spacer sleeve Type 6459 Data sheet 6159A_ * included accessories 36

37 Measuring Direct cavity pressure measurement Front diameter 1,2 mm with side cable outlet 6,4 ø3,5 ø1,2 Type 6184AA Measuring range bar Overload bar Sensitivity pc/bar 1,2 Cabling single-wire Exchangeable cable no Available types 6184AAE, 6184AAG Machinable front yes Coated front no Operating temperature Melt (at the front of the sensor) C <450 Mold (sensor, cable) C Connection C Smallest diaphragm-free cavity pressure sensor. Side cable outlet. Suitable for thermoplastics. The extremely small dimensions of this sensor make it ideal for very small parts and small modular molds. Spacer sleeve Type 6466* Mounting nut Type 6465* Thrust washer Type 6470* Data sheet 6184A_ Front diameter 1 mm 11,5 ø1 ø4 Type 6183A... Type 6183AC... Measuring range bar Overload bar Sensitivity pc/bar 2,5 2,5 Cabling single-wire single-wire Exchangeable cable no no Available types 6183AE, 6183AG 6183ACE, 6183ACG Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C The diaphragm-free piezoelectric sensor with the smallest frontal area. The sensor Type 6183AC... is the chromium-plated version of the sensor Type 6183A... for handling glass fiber reinforced materials. Suitable for thermoplastics. The small dimensions of this sensor make it ideal for extremely small parts and small modular molds. Spacer sleeve Type 6464A1* Mounting nut Type 6458 Data sheet 6183A_ * included accessories 37

38 Measuring Direct cavity pressure measurement Front diameter 6 mm for low-pressure processes 4 ø6 ø10 Type 6172AA... Type 6172AC... Measuring range bar Overload bar Sensitivity pc/bar Cabling single-wire/coaxial single-wire/coaxial Exchangeable cable yes yes Available types 6172AAE, 6172AAE1, 6172ACE, 6172ACE1, 6172AA, 6172AAG, 6172AC, 6172ACG, 6172AAG1, 6172AASP 6172ACG1, 6172ACSP Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C Options Silicone-filled gap 6172AAA ACA... Diaphragm-free piezoelectric sensor with very high sensitivity. The sensor Type 6172AC... is the chromium-plated version of the sensor Type 6172AA... for handling glass fiber reinforced materials. These sensors can be used for processes involving low cavity pressures, such as foam injection molding or compression injection molding. They are suitable for thermoplastics, thermosets, elastomers and LSR at pressures below 200 bar. The sleeve design allows easy mounting particularly in large molds. Mounting nut Type 6453* Spacer sleeve Type 6462 Data sheet 6172A_ Front diameter 4 mm for low-pressure processes 8 ø4 ø7 Type 6177AA... Type 6177AC... Measuring range bar Overload bar Sensitivity pc/bar Cabling single-wire/coaxial single-wire/coaxial Exchangeable cable yes yes Available types 6177AAE, 6177AAE1, 6177ACE, 6177ACE1, 6177AA, 6177AAG, 6177AC, 6177ACG, 6177AAG1, 6177AASP 6177ACG1, 6177ACSP Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C Diaphragm-free piezoelectric sensor with very high sensitivity. The sensor Type 6177AC... is the chromium-plated version of the sensor Type 6177AA... for handling glass fiber reinforced materials. These sensors can be used for processes involving low cavaty pressures, such as foam injection molding or compression injection molding. They are suitable for thermoplastics, thermosets, elastomers and LSR at pressures below 200 bar. Mounting nut Type 6457* Spacer sleeve Type 6459 Data sheet 6177A_ * included accessories 38

39 Measuring Direct cavity pressure measurement Front diameter 4 mm with diaphragm for low-pressure processes 8 ø4 Type 6167A... Measuring range bar Overload bar 500 Sensitivity pc/bar 16,5 Cabling single-wire/coaxial Exchangeable cable yes Available types 6167AE, 6167AE1, 6167A, 6167ASP Machinable front no Coated front no Operating temperature Melt (at the front of the sensor) C <450 Mold (sensor, cable) C Connection C ø7 Piezoelectric low-pressure sensor with diaphragm design. Sensor for low-viscosity materials as used for IC coating. Cavity pressure up to 200 bar. Mounting nut Type 6457* Spacer sleeve Type 6459 Data sheet 6167A_ Front diameter 2,5 mm for low-pressure processes 10 Type 6178A... Type 6178AC... Measuring range bar Overload bar Sensitivity pc/bar Cabling single-wire single-wire Exchangeable cable no no Available types 6178AE, 6178AG 6178ACE, 6178ACG Machinable front yes no Coated front no yes Operating temperature Melt (at the front of the sensor) C <450 <450 Mold (sensor, cable) C Connection C ø2,5 ø4 Diaphragm-free piezoelectric sensor with very high sensitivity. The sensor Type 6178AC... is the chromium-plated version of the sensor Type 6178A... for handling glass fiber reinforced materials. Sensor for processes involving low cavity pressure, such as foam injection molding or compression injection molding. It is suitable for thermoplastics at pressures below 200 bar. The small dimensions of this sensor make it ideal for multicavity molds and small parts. Spacer sleeve Type 6464A1* Mounting nut Type 6458 Data sheet 6178A_ * included accessories 39

40 Measuring Direct cavity pressure and contact temperature measurement Front diameter 2,5 mm 10 ø2,5 ø4 Type 6189A... Measuring range, pressure bar Measuring range, temperature C Overload, pressure bar Sensitivity, pressure pc/bar 6,5 Thermocouple Type K Cabling single-wire and compensation lead Exchangeable cable in Kistler factory Available types 6189A *, 6189AG**, 6189ASP Machinable front no Coated front no Operating temperature Melt (at the front of the sensor) C <450 Mold (sensor, cable) C Connection (connector) C The combined pressure and temperature sensor measures the pressure and the contact temperature at one location within the cavity. Dimensionally compatible with Type 6182B, 6178A and 6158A. Suitable for thermoplastics. Ideal for measuring both process variables with a single bore. Spacer sleeve (L = 50 mm) Type 6464A3*** Data sheet 6189A_ Front diameter 4 mm 8 ø4 ø7 Type 6190CA... Measuring range, pressure bar Measuring range, temperature C Overload, pressure bar Sensitivity, pressure pc/bar 9 Thermocouple Type K Cabling single-wire and compensation lead Exchangeable cable yes Available types 6190CA *, 6190CAG**, 6190CASP Machinable front no Coated front no Operating temperature Melt (at the front of the sensor) C <450 Mold (sensor, cable) C Connection (connector) C The combined pressure and temperature sensor measures the pressure and the contact temperature at one location within the mold. Dimensionally compatible with Type 6157A..., 6167A... and 6177A.... Suitable for thermoplastics, thermosets, elastomers and LSR. Ideal for measuring both process variables with a single bore. Mounting nut Type 6457*** Spacer sleeve Type 6459 Data sheet 6190CA_ * lengths 0,4 / 0,8 / 1,2 / 1,6 / 2 m ** cables can be shortened by customer, length 2 m *** included accessories 40

41 Measuring Contact temperature measurement Front diameter 4 mm Type 6192B... Measuring range C Thermocouple Type K Cabling compensation lead Exchangeable cable no Available types 6192B *, 6192BG**, 6192BG1***, 6192BSP Machinable front no Coated front no Operating temperature Mold (sensor, cable) C Connection (connector) C ø4 ø7 The special design of this temperature sensor gives it a very fast response. Measures the contact temperature. Dimensionally compatible with Type 6157A..., 6167A..., 6177A... and 6190CA.... Suitable for thermoplastics, elastomers and LSR. Mounting nut Type 6457**** Spacer sleeve Type 6459 Data sheet 6192B_ Front diameter 2,5 mm 10 Type 6195B... Measuring range C Thermocouple Type K Cabling compensation lead Exchangeable cable no Available types 6195B *, 6195BG**, 6195BG1***, 6195BSP Machinable front no Coated front no Operating temperature Mold (sensor, cable) C Connection (connector) C ø2,5 ø4 The special design of this temperature sensor gives it a very fast response. Measures the part surface (contact) temperature. Dimensionally compatible with Types 6158A..., 6182B... and 6178A.... Suitable for thermoplastics, elastomers and LSR. Ideal for small parts and multi-cavity molds. Spacer sleeve Type 6464A3**** Mounting nut Type 6458 Data sheet 6195B_ * length 0,4 m only ** cables can be shortened by customer *** cables can be shortened by customer, length 5 m **** included accessories 41

42 Measuring Contact temperature measurement Front diameter 2,5 mm Type 6194B... Measuring range C Thermocouple Type K Cabling compensation lead Exchangeable cable no Available types 6194B *, 6194BG**, 6194BG1***, 6194BSP Machinable front no Coated front no Operating temperature Mold (sensor, cable) C Connection (connector) C ø7 ø2,5 The special design of this temperature sensor gives it a very fast response. Measures the part surface (contact) temperature. Dimensionally compatible with Type 6159A.... Suitable for thermoplastics, elastomers and LSR. Mounting nut Type 6457**** Spacer sleeve Type 6459 Data sheet 6194B_ Front diameter 1 mm 11,5 Type 6193B... Measuring range C Cabling compensation lead Exchangeable cable no Available types 6193B *, 6193BG**, 6193BG1***, 6193BSP Machinable front no Coated front no Operating temperature Mold (sensor, cable) C Connection (connector) C ø1 ø2,5 The special design of this temperature sensor gives it a very fast response. Measures the contact temperature. Dimensionally compatible with Type 6183A.... Suitable for thermoplastics, elastomers and LSR. Ideal for extremely small parts and multi-cavity molds. Spacer sleeve Type 6464A3**** Mounting nut Type 6458 Data sheet 6193B_ * length 0,4 m only ** cables can be shortened by customer *** cables can be shortened by customer, length 5 m **** included accessories 42

43 Measuring Indirect cavity pressure measurement Diameter 12,6 mm 9,5 ø12,6 M 2,5 Type 9204B... Measuring range kn Overload kn 12 Sensitivity pc/n 1,6 Dimensions mm ø12,6 Cabling single-wire/coaxial Exchangeable cable yes Available types 9204B, 9204BE, 9204BG, 9204BSP Operating temperature C Piezoelectric force sensor with M2,5 mounting thread. Mounted behind a measuring or ejector pin to enable indirect measurement of cavity pressure. Suitable for all injection molding processes. None Data sheet 9204B_ Diameter 6 mm 6 ø6 Figure shows Type 9211B... Type 9211B... Typ 9213B... Measuring range kn , ,5 Overload kn 3 3 Sensitivity pc/n 4,4 4,4 Dimensions mm ø6 ø6 Cabling single-wire/coaxial single-wire/coaxial Exchangeable cable no no Available types 9211BE, 9211B, 9213BE, 9213B *, 9211BG, 9211BSP 9213BG, 9213BSP Operating temperature C Piezoelectric force sensor. Sensor Type 9213B has an M2,5 mounting thread. Mounted behind a measuring or injector pin to enable indirect measurement of cavity pressure. Ideal for multi-cavity molds and small parts. Suitable for all injection molding processes. Thrust washer Type* 9211B: 9411, 9213B: 9413 Data sheet 9211B_ Data sheet 9213B_ Diameter 3,5 mm 4,7 ø3,5 Type 9210A Measuring range N Overload N 300 Sensitivity pc/n 10 Dimensions mm ø3,5 Cabling single-wire Exchangeable cable no Available types 9210AAE, 9210AAG Operating temperature C Smallest piezoelectric force sensor with side cable outlet. The Type 9210AG version is supplied without connector for use with multichannel connector Type 1708A0 or 1710A0. Suitable for thermoplastics. The extremely small dimensions of this sensor make it ideal for extremely small parts and small modular molds with inserts. Washer Type 9406** Data sheet 9210A_ * included accessories 43

44 Measuring Indirect cavity pressure measurement Measuring tongue W Figure shows Type 9223A... L H Type 9221A... Type 9223A... Measuring range kn ,5 Overload kn 12 3 Sensitivity pc/n 3,3 4,5 Dimensions LxWxH mm 72,3x12,6x9,5 30x6x6 Cabling single-wire/coaxial* single-wire/coaxial* Exchangeable cable yes yes Available types 9221AAE, 9221ACE, 9223AE, 9223A, 9223ASP 9221AA, 9221AC, 9221AASP, 9221ACSP Operating temperature C Piezoelectric force sensor. Sensor Type 9221AA... is equipped with a standard cable or single-wire technology, Type 9221AC... with a metal-sheathed cable. Mounted behind a measuring or ejector pin to enable indirect measurement of cavity pressure. The indirect principle means molds can be upgraded quickly. Suitable for all injection molding processes. None Data sheet 9221A_ Data sheet 9223A_ * length 0,5 m and custom specific only 44

45 Measuring Contact-free measurement of cavity pressure Longitudinal measuring pin, M10 31,5 Type 9243B... Measuring range µe ±1 500 Thread M10 Sensitivity pc/µe 15 Cabling single-wire Exchangeable cable yes Available types 9243BE Operati perature C ø8 M10 Figure shows Type 9243B with hollow preloading bolt Type 6427A1 Longitudinally sensitive pin for measuring strain. Contact-free measurement of cavity pressure. The sensor is screwed in place behind the wall of the mold and measures the compressive strain of the steel to determine the cavity pressure. Particularly suitable for optical components. Hollow preloading bolt Type 6427A1* Finishing tool Type 1300A21 Tubular socket wrench, 8 mm Preload tester Type 5991 Data sheet 9243B_ Longitudinal measuring pin, M5 Type 9247A... Measuring range µe ±1 400 Overload µe ±2 000 Sensitivity pc/µe 8,6 Cabling single-wire Exchangeable cable yes Available types 9247AE Operating temperature C ,3 ø4,4 M5x0,5 Longitudinally sensitive pin for measuring strain. Contact-free measurement of cavity pressure. The sensor is screwed in place behind the wall of the mold and measures the compressive strain of the steel to determine the cavity pressure. Particularly suitable for optical components. Finishing tool Type 1300A79 Tubular socket wrench, 55 mm, Type 1300A9 Preload tester Type 5991 Data sheet 9247A_ * included accessories 45

46 Measuring Cavity pressure systems/sets Multi-cavity system with charge amplifier Unisens Type 6829A... Sensors 6152, 6157, 6159, 6167, 6182 or 6183, single-wire types only Number of sensors per system Measuring range bar depends on sensor type Overload bar depends on sensor type Sensitivity pc/bar Unisens (depends on sensor type) Cable length m 1,5 single-wire Machinable front depends on sensor type Coated front depends on sensor type Operating temperature Melt (at the front of the sensor) C <450 Mold (sensor, cable) C Charge amplifier C Multi-cavity system consisting of sensors and multichannel charge amplifier for direct mounting on the mold. Simple cut and grip connection of sensors. Irrespective of the number of sensors, the charge amplifier is connected to the measuring system with just one cable. Unisens technology ensures easy configuration of measuring systems. Suitable for molds with more than 16 pressure sensors. Please see the relevant tables for information about the characteristics of the individual sensors. See also measuring chains on page 26/27. DataFlow Type 2805A Data sheet 6829A_ Multi-sensor set for cavity pressure measurement Unisens Type 6831B... Sensors 6152, 6155, 6157, 6159, 6167, 6172, 6177, 6178, 6182, 6183, 6184, 9204, 9210, 9211, 9213 Multichannel connector 4-channel (Type 1708A0) or 8-channel (Type 1710A0) Measuring range bar depends on sensor type Overload bar depends on sensor type Sensitivity pc/bar Unisens (depends on sensor type) Cabling m 1,5 single-wire Machinable front depends on sensor type Coated front depends on sensor type Operating temperature Melt (at the front of the sensor) C <450 Mold (sensor, cable) C Connection C Multi-sensor set for pressure measurement, consisting of sensors and multichannel connector. Simple cut and grip connection of sensors. Unisens technology ensures easy configuration of measuring systems. Equipping molds with 2 to 16 sensors. Please see the relevant tables for information about the characteristics of the individual sensors. 4-channel connecting cable Type 1995A... 8-channel connecting cable Type 1997A... Data sheet 6831B_

47 Measuring Cavity pressure systems/sets Multi-sensor set for pressure and temperature measurement Unisens Type 6833A... Sensors 6189A, 6190CA Number of sensors Multichannel connector for pressure 4-channel (Type 1708A0) Multichannel temperature amplifier 2- or 4-channel (Type 2205A ) Measuring range bar Overload bar Measuring range C Sensitivity pc/bar Unisens (depends on sensor type) Cabling single-wire and compensation lead Machinable front no Coated front no Operating temperature Melt (at the front of the sensor) C <450 Mold (sensor, cable) C Thermocouple amplifier C Multi-sensor set consisting of sensors, multichannel connector for pressure and temperature amplifier. Equipping molds with 2 to 4 combined pressure and temperature sensors. Please see the relevant tables for information about the characteristics of the individual sensors. 4-channel connecting cable Type 1995A... 4-channel connecting cable Type 1457A Data sheet 6833A_

48 Measuring Clamping force measurement and mold protection Piezoelectric strain transmitter 28 68,1 ø26,9 Type 9238AQ Number of measuring ranges 2 Measuring range µe ± or ± Overload µe Adjustable output voltage VDC ±1 10 Maximum output voltage VDC ±10,5 Number of signal outputs 2 Resolution mv ±5 Signal inversion yes Adjustable offset VDC 0 ±9 Operating temperature C Connection Lumberg M12x1, 8-pin Parameter interface RS-232C Strain transmitter for indirect force measurement. Ranges of the 2 measuring channels independently adjustable signal inversion and live zero. The measurement channels are provided in parallel at two outputs. All parameters can be set via an RS-232C interface. The transmitter is mounted with an M6 screw. Clamping force and mold protection measurement on injection molding machines. The independently adjustable measuring ranges can be freely modified to suit all strain situations. The simultaneously available signals for clamping force and mold protection allow easy integration into machine control systems. Connecting cable Type 1787A5 Data sheet available on request Tie bar extension Piezoelectric strain measuring chain 31 Figure shows Type 9827A1392 ø16 Type 9827A2491 Type 9827A1392 Diameter mm Measuring range µe ±500 ±500 Overload µe ±1 000 ±1 000 Sensitivity mv/µe 10,4 7,3 Operating temperature C Power supply V DC Output voltage V DC ±5 ±5 Exchangeable cable no no Measuring chain consisting of piezoelectric longitudinal measuring pin with integral cable and miniature charge amplifier. The sensor is screwed or clamped into the structure. Clamping force measurement, mold protection measurement and tie bar breakage monitoring on injection molding machines. Connector 8-pin Type 1500A27 Preload tester Type 5991 Data sheet 9827A_ Hydraulic pressure measurement K-Line pressure transmitter Figure shows Type RAG G1/2" Type RAG Measuring range bar 0, Output signal V/mA 0 10 / 4 20 Thread G1/4" / G1/2" / 7/16" 20 UNF-3A Universal high-precision pressure transmitter. Hydraulic pressure measurement. Hirschmann cable connector including gasket Type 1500A89 Data sheet RAG_

49 Measuring Melt pressure and temperature measuring chains 350 C sensor 28,6 Type 4013B... Measuring range bar Sealing surface flat Thread 1/2" 20UNF Standard cable length m 2 (integrated) Operating temperature Sensor C Connection C Electronics C Options Temperature measurement optional ø7,8 ø10,5 Piezoresistive measuring chain consisting of sensor with integral cable, extension cable and amplifier (analog: Type 4618A... or digital: Type 4620A...). This chain can measure both the pressure (static and dynamic) and the temperature. The data sheet allows selection of a suitable chain. Control and monitoring of injection molding machines and hot-runner systems. Extension cable Type 4757A...** Analog amplifier Type 4618A...*** Connector Type 1500A57*** Digital amplifier Type 4620A...*** Connector Type 1500A61*** Data sheet available on request 300 C sensor Type 4083A... Measuring range bar Sealing surface flat Thread 1/2" 20UNF Standard cable length m sp* Operating temperature Sensor C Connection C Electronics C Options Temperature measurement optional 28,6 ø7,8 ø10,5 Piezoresistive measuring chain consisting of sensor with cable and amplifier (analog: Type 4618A... or digital: Type 4620A...). This chain can measure both the pressure (static and dynamic) and the temperature. The data sheet allows selection of a suitable chain. Control and monitoring of hotrunner systems by pressure and temperature measurement. Connecting cable Type 4767A...** Analog amplifier Type 4618A...*** Connector Type 1500A57*** Digital amplifier Type 4620A...*** Connector Type 1500A61*** Data sheet available on request * custom length (l min. = 0,5 m/l max. = 10 m) ** included accessories *** optional 49

50 Connecting and Transmitting Cables ensure correct transmission of all signals. Kistler accommodates a wide variety of customer requirements by providing an extensive range of different connection and extension cables. Connecting cables link the sensor to the connector. Kistler pressure sensors are available with conventional two-conductor coaxial cables or the new Single-wire technology. The Single-wire technology cable has only one conductor and the connector is no longer integral. Extension cables are used to bridge the gap between the connector in the mold and the CoMo Injection process monitoring system, DataFlow analysis system or charge amplifiers incorporated in the machine. Kistler offers a variety of extension cables, with different sheaths and lengths depending on the production environment and distances. The multichannel cabling technology allows connection of up to eight standard sensitivity (Unisens) sensors via a single cable from the mold to the CoMo Injection process monitoring system. The multichannel system groups all of the different individual cables into a common cable. Instead of up to eight cables and connectors, one multichannel cable and one multichannel connector now suffice to connect mold and monitoring system. The monitoring, optimization and analysis systems are linked with connection cables, for example for linking process monitoring systems, injection molding machine or reject gates. Connecting cable Extension cable Connecting cable 50

51 Connecting and Transmitting Connecting cables for cavity pressure sensors Single-wire connecting cables Type 1666A1 Type 1666A3 Type 1666A2 Type 1666A4 Use for sensor with exchangeable with exchangeable with exchangeable with exchangeable cable, Unisens cable, Unisens cable, standard cable, standard Length m 1,5 5 1,5 5 Operating temperature C Color blue blue green green Combined pressure and temperature cables Type 2219B... Type 2219BG Type 2219BG1 Use for sensor 6190CA 6190CA without 6190CA without with connectors connector for use with connector for use with Type 2205A Type 2205A Length m 0,4 / 0,8 / 1,2 / 2 5 1,6 / 2 / sp* Operating temperature C Coaxial cables, Teflon -sheathed Type 1961A... Type 1645C... Use for sensor with exchangeable with exchangeable cable, Unisens cable, standard Length m 0,2 / 0,4 / 0,6 / 0,8 / sp* 0,2 / 0,4 / 0,6 / 0,8 / sp* Operating temperature C Color blue green Coaxial cables, steel-sheathed Type 1963A... Type 1955A... Use for sensor with replaceable cable with replaceable cable Length m 0,4 / sp* 0,4 / sp* Operating temperature C * custom length (l min. = 0,1 m/l max. = 5 m) 51

52 Connecting and Transmitting Multichannel technology for cavity pressure sensors Multichannel connectors for Single-wire technology Type 1708A0 Type 1710A0 Number of channels 4 8 Use for sensor all single-wire sensors all single-wire sensors Connection cut and grip cut and grip Operating temperature C Figure shows Type 1710A0 Connectors form part of the sensor system Type 6831B and 6833A Single-wire sensors for these connectors have the suffix G and G1 (e.g. 6157BAG) Extension cables with flexible steel sheath Type 1995A... Type 1997A... Number of channels 4 8 Length m 1 / 2 / 5 / sp* 1 / 2 / 5 / sp* Connector on system 4-channel 8-channel Connector in mold 4-channel 8-channel Operating temperature C Adapter boxes single-channel to multichannel Figure shows Type 5415A1 Adapter boxes multichannel Figure shows Type 5415A3 Adapter cables multichannel to single-channel Type 5415A1 Type 5415A2 Number of channels 4 8 Connector on system 4-channel 8-channel Connector in mold 4 x 1-channel BNC 8 x 1-channel BNC Operating temperature C Type 5415A3 Type 5415A4 Number of channels 8 8 Connector on system 8-channel 2 x 4-channel Connector in mold 2 x 4-channel 8-channel Operating temperature C Type 1991A... Type 1999A1A0,5 Type 1999A2A0,5 Number of channels Length m 2 / 5 / sp* 0,5 0,5 Connector on system 4-channel 4 x BNC 8 x BNC Connector in mold single-channel 4-channel 8-channel Operating temperature C * custom length (l min. = 0,3 m/l max. = 20 m) 52

53 Connecting and Transmitting Single-channel technology for cavity pressure sensors Single-channel connector for single-wire technology Type 1839 Use for sensor all single-wire sensors Connection cut and grip Operating temperature C Extension cables, single-channel for pressure, Viton -sheathed Type 1667B... Type 1672B... Length m 1 / 2 / 5 / sp* 1 / 2 / 5 / sp* Connector on system BNC TNC Connector in mold single-channel single-channel Operating temperature C Extension cables, single-channel for pressure, steel-sheathed Type 1661A... Type 1662A... Length m 2 / 5 / sp* 1 / 2 / 5 / sp* Connector on system BNC TNC Connector in mold single-channel single-channel Operating temperature C Quick couplings for pressure Type 1700B5** Type 1705B7** Operating temperature C Single-channel technology for contact temperature sensors High-temperature extension cables Type 2290A... Type 2295A... Length m 2 / 5 / sp* 1 / 2 / 5 / sp* Connector on system open ends single-channel for temperature Connector in mold single-channel single-channel Operating temperature C Cables are also used for the thermocouple in combined sensors Type 6189A and 6190CA. * custom length (l min. = 0,1 m/l max. = 20 m) ** quick coupling (coaxial) for automatic mold changing, both types are required 53

54 Connecting and Transmitting Connection cables for CoMo Injection Type 2869B Cables for display Type 5629A3 Type 1200A103A Length m 0,5 / 2 / 5 / 10 / 15 Application connection of display Type 5629B3 Cables for digital signals Type 1500A42A Type 1500A43A Connection open ends open ends Length m 0* / 7 / sp** 0* / 7 / sp** Application connection to handling system connection to machine signals or reject gate (digital outputs (digital I/Os Type 2869B ) Type 2869B ) Proximity switch Application Type 2231A1 trigger (start signal) Cable for analog signals Type 1500A47A Connection open ends Length m 0* / 7 / sp** Application connection of analog signals Cables for thermocouple amplifier Type 2205A Figure shows Type 1457A1A Type 1457A1A Type 1457A2A Connection connector open ends Length m 1 / 2 / 5 / sp** 1 / 2 / 5 / sp** Application connection of Type 2205A connection of Type 2205A or 5869A10 or 5689A10 Adapter box for thermocouple amplifier Type 2205A and voltage signals Connection Application Type 5689A10 terminal block box for connecting Type 2205A and voltage signals * connector only ** custom length (l min. = 1 m/l max. = 15 m) 54

55 Connecting and Transmitting Connection cables for CoMo Injection Type 2869B Power supply for CoMo Injection Figure shows Type 1500A45A Type 1500A45A... Type 5781A2 Type 5783A1 Type connecting cable AC adapter DIN rail power supply Length m 0* / 7 / sp** Voltage, input 24 VAC VAC VAC Voltage, output 24 VDC 24 VDC 24 VDC Connection open ends power plug terminals Application supply with supply supply external 24 V V V Connection cables for DataFlow system Type 2865B... Trigger input and digital outputs for proximity switch for DataFlow system Type 2865B Figure shows Type 2231A1 Type 1500A43A Type 2231A1 Connection open ends proximity switch Length m 0* / 7 / sp** 5 Application connection of trigger and digital proximity switch for starting outputs to machine, handling measurement system or reject gate Connection cables for DataFlow Type 2805A and 6829A Signal cable for sensor system Type 6829A... and A/D card Type 2855A6 Length m 5 Application Type 1200A83 connection of analog signals from Type 6829A to A/D card Type 2855A6 Reset/Operate and power supply Type 1700A62 Connection open ends Length m 5 Application power supply and Reset/Operate signal to Type 6829A * connector only ** custom length (l min. = 1 m/l max. = 15 m) 55

56 Connecting and Transmitting Connection cables for DataFlow Type 2805A and 6829A PC adapters for analog signals Figure shows Type 1200A95A1 PC slot covers for digital outputs for A/D card Type 2855A6 Type 1200A95A1 Type 1200A95A2 Connection 1 x D-Sub 37 neg. 2 x D-Sub 37 neg. Number of channels Application connection for 32 output connection for 64 output signals to A/D card Type signals to A/D card Type 2855A6, 4 digital outputs 2855A6, 4 digital outputs (TTL) (TTL) Type 1200A79 Type 1200A81 Connection D-Sub 37 pos. D-Sub 9 neg. Application slot cover for 24 digital slot cover for 4 digital outoutputs (TTL) for A/D puts (TTL) for A/D card card Type 2855A6 Type 2855A6 and PC adapter Type 1200A95A Converter TTL to dry contacts Type 2863 Connection Application screw type terminals converter for digital outputs from TTL to dry contacts (MOSFET) for direct control of reject gates or handling system with slot cover Type 1200A81 Cable for digital outputs Connection Application Type 1200A85 open ends connecting cable for 24 digital outputs with Type 1200A

57 Connecting and Transmitting 57

58 Amplifying Charge amplifiers convert charges output by a piezoelectric sensor into a proportional voltage that can be used as an input variable for monitoring and control processes. Kistler offers a wide variety of amplifiers: single-channel charge amplifiers or multichannel amplifiers for charge and temperature. Charge amplifiers enhanced with smart algorithms can generate control signals from the cavity pressure curve. These are used as input variables to increase the repeatability of the injection molding process so that machines produce consistently high-quality parts. Temperature amplifiers convert the thermal voltage of temperature sensors. Both temperature sensors and the thermocouples of combined pressure and temperature sensors can be connected. Voltage amplifiers allow connection of different input voltages to the Kistler DataFlow System Type 2865B.... The amplifier interface is used for connecting amplifiers that require a power supply. A/D cards are used for DataFlow in combination with the Type 6829A. 58

59 Amplifying Charge amplifiers for integration into injection molding machines Charge amplifiers for pressure sensors Figure shows Type 5049A... Type 5039A... Type 5049A221 Number of channels 1 1 Number of measuring ranges 2 2 Measuring range pc ± ± Ratio measuring range I/ measuring range II 10 / 4 / 2 4 Measuring range I pc ± ± (adjusted for injection molding) Measuring range II pc ±5 000 ±5 000 (adjusted for injection molding) Power supply V DC Output signal V ± ± Sensor connection TNC or BNC neg. TNC neg. Connection for supply, output signal Binder 8-pin pos. Binder 14-pin pos. and control signals SmartAmp (self-optimizing switch-over) no yes Options Current output ma no Charge amplifier in industrial case. Special types for injection molding: Type 5039A221 (TNC connection) or Type 5039A222 (BNC connection). Integration into injection molding machines for connecting piezoelectric cavity pressure sensors for visualization and control. For Type 5039A... connector Type 1500A57* For Type 5049A... connector Type 1500A61* TNC/BNC adapter Type 1708 Data sheet 5039A_ Data sheet 5049A_ Amplifier for pressure and temperature sensors Type 5155A... Number of channels 1, 2 or 4 charge or 1 charge and 1 temperature or 2 charge and 2 temperature Number of measuring ranges for charge 2 Measuring range ± Ratio of measuring range I/ measuring range II 10 / 4 / 2 Measuring range I pc ± (adjusted for injection molding) Measuring range II pc ±5 000 (adjusted for injection molding) Measuring range, temperature C Output signal V 0... ±10 Power supply V DC Sensor connection (pressure) TNC or BNC neg. Sensor connection, temperature Fischer 2-pin neg. Connection for supply, signal outputs D-Sub 25 pos. and control signals SmartAmp (self-optimizing switch-over) on channel 1 Options Current output ma Multichannel charge amplifier and thermocouple amplifier in industrial case. See data sheet for choice of type of charge amplifier. Integration into injection molding machines for connecting piezoelectric cavity pressure sensors for visualization and control. Connecting cable Type 1200A73 D-Sub connector incl. cover Type 1557A10 Data sheet 5155A_ * included accessories 59

60 Amplifying Temperature amplifiers for CoMo Injection Type 2869B Multichannel temperature amplifier Type 2205A Measuring range C or Thermocouple Type K Number of channels 2 or 4 Operating temperature range C or 4-channel temperature amplifier for mounting in mold; for type K thermocouples. Connection of up to 4 combined pressure and temperature sensors (temperature signal) or 4 temperature sensors to CoMo Injection Type 2869B. External case Type 5700A23 Mounting tool Type 1300A20 Data sheet 2205A_ Modules for DataFlow system Type 2865B 4-channel charge amplifier Figure shows Type 5063A1 Type 5063A1 Type 5063A2 Number of channels 4 4 Number of measuring ranges 2 2 Measuring range pc ± ± Ratio measuring range I/ measuring range II 4 4 Measuring range I (adjusted for injection molding) pc ± ± Measuring range II (adjusted for injection molding) pc ±5 000 ±5 000 Connection Type 4 x BNC neg. 1 x 4-channel connector Data sheet 5063A_ channel voltage amplifier Type 5227A1 Number of channels 4 Measuring range V ±10 Gain, adjustable 1 / 2 / 5 / 10 Connection Type 4 x BNC neg. Data sheet 5063A_ channel thermocouple amplifier Type 2207A Number of channels 4 Thermocouple Type J and K Number of measuring ranges 2 Measuring range I C Measuring range II C Connection Type screw type terminals Phoenix Data sheet 5063A_

61 Amplifying Modules for DataFlow system Type 2865B 4-channel amplifier interface Type 5613A1 Type 5613A2 Type 5613A3* Number of channels Measuring range V ±10 ±10 ±10 Supply voltage for for external amplifiers VDC Connection Type 4 x D-Sub 9 neg. 4 x D-Sub 9 neg. 1 x D-Sub 15 neg. Data sheet 5063A_ A/D card for DataFlow Type A/D card, 64-channel Type 2855A6 Number of channels 64 PC type Desktop Type of card PCI Data sheet 2805A_ * for direct connection of temperature amplifier Type 2205A with cable Type 1457A1A 61

62 Analyzing CoMo Injection Type 2869B... is the Kistler system for cavity pressure based optimization, monitoring and documentation of injection molding. It is suitable for process optimization, real-time process control, process monitoring with reject separation and quality data documentation. This compact industrial system is easily configured. It uses simple connection technology, process-oriented control and is readily integrated into a variety of production and computing environments. CoMo Injection allows location-independent web browser access to current process cycle and statistical production data of injection molding facilities located worldwide. DataFlow Type 2805A... runs on conventional personal computers or notebooks and is easy to use. It offers a comprehensive analysis, optimization and documentation system for all injection molding processes including multi-component techniques. The system Type 2865B... includes DataFlow and all of the associated hardware and software components. 62

63 Analyzing Systems CoMo Injection process monitoring system Figure shows Type 2869B3... Type 2869B1... Type 2869B2... Type 2869B3... Number of charge inputs (connectors) 8 (2 x 4-channel) 8 (1 x 8-channel) 16 (2 x 8-channel) Number of measuring ranges Automatic selection of charge measuring range yes yes yes Number of voltage inputs (connectors) 4 (1 x 4-channel) 4 (1 x 4-channel) 8 (2 x 4-channel) Voltage measuring range V Voltage inputs Type differential differential differential Digital outputs Digital inputs Evaluation objects Real-time thresholds for each channel Measurement time s Dimensions (LxHxW) 208x70x x70x x70x172 Operating temperature range C CoMo Injection Type 2869B... is a compact system for data acquisition, process monitoring, visualization and control. The charge measuring ranges (±2 000, ±5 000, ±20 000, ± pc) are selected automatically. The display Type 5629A3 is available for use as an option. It can be selected directly for inclusion in the system with the Type numbers 2869B.... Details are to be found on the data sheet. Injection molding process optimization, monitoring and documentation. CoMo Injection Type 2869B... can be used to control the injection molding process in real-time. CoMo MIS database Type 2829A See data sheet for further accessories Data sheet 2869B_ Display for CoMo Injection Type 2869A Display size 12,1" Type 5629A3 Touch screen display for operating the CoMo Injection Type 2869B without a PC. In the Type 2869B... the display can be chosen directly and is then included in the accessories. Direct connection to CoMo Injection Type 2869B... or a network for operating and displaying a number of CoMo Injection units. None Data sheet 2869B_

64 Analyzing Systems DataFlow process optimization and analysis system Modules not included Type 2865B Dimensions mm 302x400x107 Number of channels 16 Number of slots 4 Digital outputs 4 Operating temperature range C 0 40 System requirements computer operating system Windows 2000, Windows XP Professional Memory MB RAM min. 128 Interfaces 2 x USB Bus frequency MHz >100 Processor clock rate MHz >600 The system Type 2865B... consists of a 16-channel signal conditioner and Windows software. This is a universal system for data acquisition and evaluation and includes a statistics program. The signal conditioner can be fitted with 4 plug-in modules (each with 4 channels), which have to be ordered separately. Mold validation, process optimization and analysis of injection molding processes. Charge amplifier modules Type 5063A... Thermocouple amplifier Type 2207A... Voltage amplifier Type 5227A... Voltage amplifier Type 5613A... Data sheet 2865B_

65 Analyzing Software CoMo MIS Manufacturing Information System System requirements Computer operating system Minimum computer hardware requirements Type 2829A-03-2 Windows Server 2003, Windows XP Professional Service Pack 2/3, Windows Vista available on request Database, statistics tool and Curve Viewer for accessing and evaluating process data acquired with CoMo Injection Type 2869B. The data is transmitted via Ethernet from the CoMo Injection to the database computer. The number of licenses* must be specified when placing an order. Additional licenses can be ordered under Type 2829A Process analysis, production analysis, statistics and evaluation of the efficiency of all production orders and batches monitored with CoMo Injection Type 2869A.... To enable analysis the process curves can be viewed with the integral Curve Viewer module. None Data sheet 2829A_ DataFlow for desktop computer Type 2805A-02-2 System requirements Computer operating system Windows 2000, Windows XP Professional Memory MB RAM 128 min. Interface USB, Ethernet Processor clock frequency MHz min. 600 Bus frequency MHz 100 min. PCI slot 1 DataFlow is a universal program for acquisition and evaluation of injection molding data with up to 64 channels. The notebook version is offered with signal conditioner under Type 2865B.... Type 2805A-02-2 can be used in combination with multi-cavity system Type 6829A.... The package includes the statistics software. Mold validation, setting up, process optimization and production monitoring on the basis of cavity pressure. The statistics program allows comprehensive documentation of all productions. A/D card Type 2855A6 Data sheet 2805A_ * a license is required for each CoMo Injection Type 2869B

66 /Tools Kistler offers a range of accessories for mounting and calibrating sensors. Accessory sets for applications such as forming and checking sensor bores include step drills, countersinks, twist drills, reamers, taps, finishing tools, socket wrenches and lapping tools. Measuring and testing equipment complete Kistler's extensive product range. Cordless service units measure and check insulation resistances. Preload measuring units are used for insitu measurement of charges, e.g. measuring the preload of piezoelectric strain sensors required for mounting. These compact, lightweight units with integral charge amplifier avoid being tethered to the mains. Test sets are used for checking cavity pressure sensors already mounted in the mold. They provide a direct digital display of their pressure sensitivity in pc/bar. 66

67 /Tools Tools Extraction tools for sensors Type 1315A Type 1358A Type 1362A Outside diameter mm ø5,8 ø3,8 ø5,8 Length mm Thread Type M5 M3x0,35 M5 Sensors Type 6152AA..., 6152AC..., 6158A..., 6178A..., 6152AB/AD..., 6157BA..., 6159A..., 6182A/B..., 6183A..., 6157BB/BD..., 6167A..., 6177A..., 6189A..., 6193A/B..., 6190A B/C..., 6192A/B..., 6195A/B A/B..., 9223A... Tubular socket wrench for mounting nuts Type 1383 Type 1356 Type 1363 Outside diameter mm ø10 ø5 ø4,4 Length mm Sensors Type 6152A..., 6157B..., 6158A..., 6178A..., 6184A 6159A..., 6167A..., 6182A/B..., 6183A, 6172A..., 6177A..., 6193A/B..., 6190A/B/C..., 6192A/B..., 6195A/B A/B... Accessory set for sensors Type 1300A81 Type 1300A83 Description Forming and checking Forming and checking sensor bores for sensor bores for 4 mm 4 mm front diameters and 2,5 mm front diameters Sensors Type 6157B B..., 6159A, 6177A... Repair set for Single-wire cables Type 1207 Number of repair sets 5 Hydraulic pressure connection for RAG sensors Type 1209 Connection SMA 3 Length mm 400 Included accessories measuring hose adapter EMA 3-R 1/4 * custom length 67

68 /Tools Testing tools Insulation tester Type 5493 Measuring range Ω Description service instrument for measuring insulation resistances Application checking insulation of piezoelectric sensors and connecting cables Data sheet 5493_ Preload tester Type 5991 Measuring range pc ± Output voltage V 0... ±1 Description preload tester for charge measurements Application measurement and testing of sensor preload. Output for monitoring function Data sheet 5991_ Test set for cavity pressure sensors Type 5993A1 Type 5993A1Y49 Test force N min. 70 min. 70 N max. 125 max. 125 For sensors 6152A, 6155A, 6155A, 6158A, 6157B, 6158A, 6159A, 6182B, 6159A, 6182B 6183A Description handheld test instru- handheld test instrument with test pin and ment with test pin and connecting cables connecting cables Application checking operation of checking operation of mounted sensors mounted sensors Data sheet 5993A_

69 /Tools 69

70 Technical Literature Special publications and application brochures Plastics Injection Molding Quality Assurance and Documentation with DataFlow Single-Wire Technique Extremely simple simply brilliant Plastics CoMo Injection Injection Molding Process Monitoring Injection Molding Transparent Pressure A Quality Criterion for Optical Parts Theory Measuring with Crystals PiezoStar Crystals A New Dimension in Sensor Technology

71 Product overview by type numbers Type Page Type Page Type Page Type Page Type Page 1200A B B AA B A B A AB A A A AC B A B A AD B A95A B A AE A A95A A A BA A A103A A A BB AQ A BC B A A BD A A A A A A A A A A A A A A A...U6 36 RAG A A A A A AA A A1A0, A AC A2A0, A AA A AC A1A A A A A2A A A AC A42A B A B A43A 54, BG A BC A45A BG A A47A A1 54, A AC C A A1Y AA A A A A A CA A A B A A B A B A B B B A B B B A Unisens and PiezoStar are registered trademarks of Kistler Holding AG, Winterthur, Switzerland Windows XP and Windows 2000 are registered trademarks of Microsoft Corporation Viton is a registered trademark of DuPont Performance Elastomers Teflon is a registered trademark of DuPont Photos by Schöttli AG, Diessenhofen, Switzerland Sumitomo (SHI) Demag Plastics Machinery, Schwaig, Germany BIRO Edwin Bischof AG, Romanshorn, Switzerland 71

72 Kistler worldwide Europe Austria Kistler GmbH Lemböckgasse 49f 1230 Wien Tel [email protected] Czech Republic/Slovakia Kistler, s.r.o. Zelený pruh 99/ Praha 4 Tel [email protected] Denmark/Norway/Sweden Kistler Nordic AB Aminogatan Mölndal Tel [email protected] Finland Kistler Nordic AB Särkiniementie Helsinki Tel [email protected] France Kistler France ZA de Courtabœuf 1 15, avenue du Hoggar Les Ulis cedex Tel [email protected] Germany Kistler Instrumente GmbH Daimlerstrasse Ostfildern Tel [email protected] Italy Kistler Italia s.r.l. Via Ruggero di Lauria, 12/B Milano Tel [email protected] Netherlands Kistler B.V. Nederland Leeghwaterstraat DT Reeuwijk Tel [email protected] Switzerland/Liechtenstein Kistler Instrumente AG Verkauf Schweiz Eulachstrasse Winterthur Tel [email protected] United Kingdom Kistler Instruments Ltd. 13 Murrell Green Business Park London Road Hook, Hampshire RG27 9GR Tel [email protected] Asia America e Sän , Kistler Group China Kistler China Ltd. Unit D, 24/F Seabright Plaza 9-23 Shell Street North Point Hong Kong Tel [email protected] India Kistler Instruments (Pte) Ltd. India Liaison Office 2B Century Plaza 560/562 Anna Salai Teynampet, Chennai Tel [email protected] Japan Kistler Japan Co., Ltd. 23 rd floor, New Pier Takeshiba North Tower , Kaigan, Minato-ku Tokyo Tel [email protected] Headquarters Switzerland Kistler Group Eulachstrasse 22, 8408 Winterthur Tel Fax [email protected] Korea, Republic of Kistler Korea Co., Ltd. Gyeonggi Venture Anyang Technical College Center , Anyang-Dong, Manan-Gu, Anyang-City, Gyeonggi-Do Tel [email protected] Singapore Kistler Instruments (Pte) Ltd. 50 Bukit Batok Street 23 #04-06 Midview Building Singapore Tel [email protected] Taiwan Kistler Representative Office in Taiwan Room 9, 8F, No. 6, Lane 180 Sec. 6, Mincyuan E. Road Taipei 114 Tel [email protected] Thailand Kistler Instrument (Thailand) Co., Ltd. 26/56 TPI Tower, 20th Floor Nanglingee Rd., (Chan Tat Mai Rd.) Thungmahamek, Sathorn Bangkok Tel [email protected] USA/Canada/Mexico Kistler Instrument Corp. 75 John Glenn Drive Amherst, NY Tel [email protected] Australia Australia Kistler Instruments Australia Pty Ltd G21 / 202 Jells Rd. Wheelers Hill, Victoria 3150 Tel [email protected] Other countries Kistler Instrumente AG Export Sales Eulachstrasse 22, 8408 Winterthur Switzerland Tel [email protected]