Stäubli & Tecnomagnete launch new QMC123 magnetic mould clamping system.

Although the original principles of the plastics injection moulding process remain, the sector has evolved significantly over the years through the development of new polymers and thermoplastics, ever more efficient machinery, the capability to manufacture complex multi-cavity moulds, and of course the introduction of automation. The pace of development and evolution within the sector has never been faster than in today’s highly competitive environment, as businesses continue their quest for greater flexibility, quality, and productivity.

A necessity of achieving these high levels of efficiency is the requirement to product different parts with the same injection moulding machine, by changing moulds. However, the time required to remove and replace moulds is unproductive. The traditional methods, still in use by some manufacturers today use bolts or mechanical clamps. Both can result in a lengthy process and pose safety risks to the operators involved.

The need for JIT (just in time) production, especially within the automotive sector has exacerbated this challenge. JIT production was one of the catalysts behind the development of alternative mould clamping solutions, in order to reduce mould change times and maximize productive time. Initially, quick mould change concepts using spare hydraulic circuits on the injection moulding machine were seen as a possible solution. However, hydraulic systems had disadvantages including the fact that they can be energy intensive and are potentially less clean. Clearly the future of quick mould change solutions lay in another technology – that of magnetic clamping.

Magnetic work holding and clamping systems, powered by permanent electro-magnetic technology, were initially used in machine tool applications to secure workpieces. Italian based Mag-Autoblok  Tecnomagnete S.p.a., designed and developed patented solutions which have since become a mainstay in a number of industries. The company also pioneered magnetic mould-clamping specifically for the plastic injection moulding sector in the early 1990’s. This technology has proven to be simpler, cleaner, and altogether more efficient, and is used by a growing number of plastics processers, especially those who have adopted electrically powered injection moulding machines.

Stäubli's developments and innovations surrounding clamping force display and safety, make a major contribution to the recent strategic partnership between Stäubli and Mag Autoblok – Tecnomagnete. The combined expertise of the two companies has taken the capabilities of magnetic clamping technology to a new level, with enhancements and improvements across several key areas. Stäubli has always had a strong relationship with the plastics industry through its Fluid Connectors Division which designs and manufactures, a wide range of quick mould change solutions.

Stäubli offers a holistic, single source approach to the plastics sector with solutions designed to enhance process efficiencies, reduce mould change times, and improve operator safety, all of which are recognised internationally for their quality, reliability, and performance.

New Features and Functionality Combined with Familiarity

An essential part of the co-development process for QMC123, which is the latest feature-packed version of this technology, was to ensure that the new system not only retained the previous system’s attributes of robustness and reliability, but also a level of familiarity for existing customers who have been using the current system since 2010. QMC123 provides greater levels of information and features a new and easier to use operator touch screen interface.                                         
This enables the validation of the various safety points during mould changing operations. The IMAG-Editor software enables the clamping force for each mould to be calculated prior to loading, based upon the press on which it will be used. This information highlights any potential problems ahead of production. Furthermore, intuitive guidance is provided for the operator, not only during set up, but also to assist in diagnosing warnings or error conditions, enabling faster and safe resolution.

The manufacturing processes for the QMC123 magnetic platen design has also optimized to guarantee better measurement accuracy of the magnetic clamping forces. The system is also able to detect flux changes before actual mould movement takes place, further increasing levels of safety. Overall, the new QMC123 technology embodies long established, successful, and proven principles with a range of new enhancements through product evolution. The combination of improved ease of use, the precise measurement of clamping forces, and improved safety features, provide new levels of functionality. The QMC123 Magnetic Clamping Solution will also play a key role as part of a SMED (Single Minute Exchange of Die) strategy, by minimizing the time between the last good part and the first good new part. In addition, with its data acquisition capabilities, this new generation technology is also compatible with the principles of Industry 4.0.

The launch of the new QMC123 solution follows an extensive period of product development from both parties, followed by field testing to evaluate performance and reliability across multiple production environments. With the QMC123 solution compatible with moulding machines ranging 50T to upwards of 4,000T, this latest generation technology will no doubt establish itself as the benchmark in the plastics sector.