New Amplifier Family with Fieldbus Connection to Injection Molding Machines means Integral Process Monitoring and Automatic Switching

Kistler is presenting the new family of multichannel amplifiers, Type 5159A… with fieldbus connection for equipping injection molding machines. The amplifiers have inputs for charge signals of piezoelectric pressure sensors or signals from Type K, J, N and L thermocouples. These signals provide information about the molding conditions in the mold and can be used to optimize, monitor and control the process. Kistler will launch its new family of amplifiers on Stand 10F04 in Hall 10 at K 2010, the world-leading International Trade Fair for Plastics and Rubber to be held between 27th of October and the 3rd of November 2010 in Düsseldorf.

A Wide Variety of Interfaces for Injection Molding Machines
The new amplifiers are modular and fully digital. They are intended for amplifying up to four input signals from pressure and/or temperature sensors. BNC connectors or connectors for multichannel cabling can be chosen as charge inputs. In terms of signal outputs and interfaces, the new amplifiers offer different options: communication with the injection molding machine using fieldbus technology with VARAN client, including integration of Euromap 75 is one new possibility. Alternatively, up to four analog outputs (±10 V), 24 V control and status lines and digital I/O interfaces are available.

Automatic Switching
The automatic switching option already familiar from the multichannel charge amplifier Type 5155A… will also be available for the Type 5159A… . During injection molding of thermoplastics it automatically detects volumetric filling of the mold and gives the injection molding machine a signal to switch from injection to holding pressure phase. This automatic switch-over option reduces the effort involved in setting up, as the amplifier automatically sets the switching point for the machine without manual optimization. During production the amplifier automatically readjusts the switching point to keep the attributes of the finished part more consistent in the event of process fluctuations. The controllers of today's injection molding machines provide one input for the signal for automatic switching as a standard.

Kistler will present its portfolio of products for plastics processors, moldmakers and manufacturers of plastics machinery on Stand 10F04 in Hall 10 at K 2010 – the International Trade Fair for Plastics and Rubber to be held from the 27th of October to the 3rd of November 2010 in Düsseldorf. On its own stand, Kistler will demonstrate quality assurance of injection molding of a medical part on the basis of mold cavity pressure.

At K 2010 Kistler will also be providing live demonstrations of the capabilities of its sensors and systems on nine separate injection molding machines on stands of partnering companies in Halls 10, 11, 13, 14, 15 and 16. The spectrum of applications range from the development of new methods of processing through optimization of injection molding processes to quality assurance and process control in large-scale production.

Background: Quality Assurance with Mold Cavity Pressure

The cavity pressure curve is considered to represent a fingerprint of the injection molding process. It is the most informative characteristic for evaluating the quality of the part. Deviations from the optimum curve are clear indications of process fluctuations that lead to part defects ranging from incomplete mold filling to flashing or dimensional discrepancies.

As the supplier with the largest and widest range of sensors for all methods of injection molding, simple connection technology and intuitively easy to operate, networkable systems, Kistler is the only manufacturer to offer complete monitoring of injection molding from a single source. Kistler is the world's leading manufacturer of pressure and temperature sensors for use in the plastics processing industry.

Kistler Group

Kistler’s core competence is the development, production and use of sensors for measuring pressure, force, torque and acceleration. Kistler’s know-how and electronic systems can be used to prepare measuring signals for use in analyzing physical processes, controlling and optimizing industrial processes, improving product quality in manufacturing and improving performance in sports and rehabilitation.

Kistler offers a comprehensive range of sensors and systems for engine development, automotive engineering, plastics and metal processing, installation technology and biomechanics.

A worldwide sales presence in the form of 25 group companies and 30 distributors ensures customer proximity, application support on an individual level and short lead times.

With a staff of about 1 000, the Kistler Group is one of the world’s leading providers of dynamic measuring instrumentation. The Kistler Group achieved turnover of 166 million Swiss Francs in the 2009 financial year.