TECH N I C A L I N F O R M AT I O N

TB-E73-e-03/2001, COPYRIGHT by ENGEL

Machine Specification
Ever-Q

Albin Burghofer
 VERTRIEBSGESELLSCHAFT M.B.H.
TECHNICAL INFORMATION, TB-E73-e-06/00, COPYRIGHT by ENGEL

ENGEL Machine Specification EVER-Q

ADVANTAGES BY EVER-Q

• Machine ability proof according to ISO 9001 (element 9 - process control)

• prevents mould provings and productions with wrong data
• prerequisite for the employment of statistic methods for process optimization
(e.g. Expert Control)
• enables quality assurance via process data
• facilitates the data exchange between the machines
• early recognition of machine errors and wear
• important decision basis for necessary maintenance

MACHINE Parameters
Process Parameters
EVER-Q Specification

MOULD MOULDED PARTS RAW MATERIAL

Temperature Quality Features Specification
Specification Techn. Specification
QUALITY ASSURANCE
STATISTICAL ONLINE
PROCESS CONTROL PROCESS CONTROL
SPC for Product Features CPC for Process Data
QUALITY DATA STATISTICS PROCESS DATA COLLECTION

Figure: Quality assurance in the injection moulding process.

The injection moulding process for manufacturing an injection moulded part is mainly influenced by the raw material,
by the mould with temperature control system, and by the injection moulding machine. Useful quality assurance
concepts comprise all fields and factors, which have and/or can have influence on achieving a requested quality.
The mechanisms and interfaces of quality assurance are described comprehensively in the ISO 9001. The demands
on a quality management system are to design the systems and processes so that a continuous quality improvement
can be reached and assured.

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 VERTRIEBSGESELLSCHAFT M.B.H.
TECHNICAL INFORMATION, TB-E73-e-06/00, COPYRIGHT by ENGEL

For assuring the requested quality of the injection moulded part often the statistic process control (SPC) for product
properties and the continuous process control (CPC) for relevant process data are used.
Assuring the quality also means to preserving the state which had led to the once desired quality. Therefore it must
be ensured that by a well-planned maintenance of the production, equipment wear does not lead to a displacement
of the operating point. Quite especially when quality-relevant process parameters of the machine are used for quality
control, a cyclic check of the machine sensors is necessary.
In this sense EVER-Q has been developed. EVER-Q offers the possibility to document the process capabiltiy of the
injection moulding machine already at the purchase during the acceptance tests and to check it later again at a certain
moment, e. g. in a 3 year period.

For the program-part of EVER-Q a CAT (Computer Aided Testing) system has been developed, which enables a
partial automatic control of the fixed test sequence. The machine set-up, measured value recording as well as the
processing of the measured values are supported. Some of these functions are only possible with a certain ebias
and system version.

PC-supported test and measuring system for establishing the machine speci-
fication CAT - system

<- Machine setting and control

Actual values from the machine ->

COM 1(2)

COM 2(1)

SPRITZGIESSMASCHINE
Sequence:

Calibrated Production of calibrated

thermal furnace values.
Recording of the measured
values via serial interface
and/or by additional trans-
Calibrated sensors for ducers.
P
U
pressure and stroke
Storage of the data in certain
form and order.
Printout in form of tables Evaluation with standard
and graphics software (Excel).
"Certificate"

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 VERTRIEBSGESELLSCHAFT M.B.H.
TECHNICAL INFORMATION, TB-E73-e-06/00, COPYRIGHT by ENGEL

All the examinations are based on rules created by ENGEL in cooperation with an external institute, which are unform
basics for the preparation and execution of the measurements. They further include indications of the conditions under
which the measurements shall take place. The kind of execution as well as the condition under which the
measurements shall take place are modelled on the recommondation of the EUROMAP10. Primarily it is provided
to determine the accuracy of the measuring system of the control system including the sensors. This is achieved by
a comparative measurement utilizing a calibrated measuring device. (calibration of the measuring chain). Afterwards
the relevant technical features of the individual structural units and/or sequences are determined practice-oriented.
(structural unit examination)

STEPS TO THE MACHINE SPECIFICATION

MACHINE
Machine specification

EVALUATION EVALUATION

Measuring accuracy, tolerance indication Accuracy, tolerances

MEASURED VALUE MEASURED VALUE ACTUAL VALUE

DISPLAY DISPLAY
external screen of the control Machine parameter
unit screen

STRUCTURAL UNIT MEASURING

EXTERNAL MEASURING CHAIN EQUIPMENT
MEASURING
EQUIPMENT Control system Mechanics, Hydraulics Control system
Sensors Heating Sensorics

MACHINE SETTING SET VALUE

Setting according to defined measurement Setting machine parameters in the control unit
instruction

CALIBRATION OF THE MEASURING

STRUCTURAL UNIT EXAMINATION
CHAIN

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 VERTRIEBSGESELLSCHAFT M.B.H.
TECHNICAL INFORMATION, TB-E73-e-06/00, COPYRIGHT by ENGEL

Example for the "calibration of the measuring chain":

Measuring chain hydraulic pressure

2

1,5
1
[bar]
[bar]
Deviation [bar]

0,5
Abweichung
Deviation

0
16,2 32,2 48,1 63,8 79,6 95,6 111,4 127,3 143,4 159,1
-0,5
-1

-1,5 OGW
-2 Actual value dev.
Istwertabweichung
Set value
Sollwert [bar][bar] UGW

The actual value deviation and the linearity of the display are checked. This examination is done for all process
relevant measuring chains.

Example for "Structural unit examination"

Back pressure linearity

2
1,5
Sollwertabweichung [bar]
Set value deviation [bar]

1
0,5
0
-0,5 0 5 10 15 20 25 30 35 40

-1
-1,5
OGW
-2 Set value deviation (bar)
Sollwertabweichung [bar]
Staudruck - Sollwert [bar] UGW
Back pressure set value [bar]

The correspondance of the actual value to the set value is proven. This examination is done for all process relevant
machine parameters.

Back pressure reproducibility

11,50

11,00

10,50
Staudruck [bar]
Back pressure [bar]

10,00

9,50
OGW
9,00 Back press.(PSx)
Staudruck (PS x)
8,50 UGW

8,00
1 2 3 4 5 6 7 8 9 10

The reproducibility for each of the relevant parameters is determined.

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 VERTRIEBSGESELLSCHAFT M.B.H.
TECHNICAL INFORMATION, TB-E73-e-06/00, COPYRIGHT by ENGEL

The difference between the standard function control every machine has to go through and EVER-Q is that the sensors
of the machine are checked. Measurements are made with material as well and the results are documented (compared
with tolerance limits) and processed graphically to be able to see the difference when you do the same test again e.g. 3
years later once.

SUMMARY OF AN EVALUATION

Tol. ± in tolerance
1.1 Measuring chain cylinder temp. Actual value display 3.00 °C YES
Measuring chain oil temperat. Actual value display 3.00 °C YES
Measuring chain traverse temp. Actual value display 3.00 °C YES
1.3 Cylinder temperature Control deviation 2.00 °C YES
2.1 a) Measuring chain clamping force Actual value display 2.00 % YES
2.1 b) Clamping force Linearity 3.00 % YES
2.2 Clamping force Reproducibility 3.00 % YES
2.3 Mould platen parallelism Difference 0.10 mm YES
3.1 Measuring chain screw stroke Actual value display 0.20 % YES
3.2 a) Measuring chain hydr.pressure Actual value display 1.00 % YES
3.2 b) Injection pressure Linearity 2.00 % YES
3.3 Holding pressure Linearity 2.00 % YES
3.4 Holding pressure Reproducibility 0.50 % YES
3.5 Speed Linearity 2.00 % YES
3.6 Speed Reproducibility 1.00 % YES
3.7 Stroke switchover Reproducibility 0.05 % YES
4.1 a) Metering stroke Reproducibility 0.20 % YES
4.1 b) Back pressure Reproducibility 1.00 bar YES
4.1 c) Screw speed Reproducibility 1.00 % YES
4.1 d) Plasticizing time Reproducibility 5.00 % YES
4.1 e) Hydraul.pressure switchover Reproducibility 3.00 % YES
4.1 f) Shot volume Reproducibility 0.50 % YES
4.2 Non-return valve Tightness 0.10 mm/s YES
4.3 Back pressure Linearity 2.00 bar YES

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 VERTRIEBSGESELLSCHAFT M.B.H.
TECHNICAL INFORMATION, TB-E73-e-06/00, COPYRIGHT by ENGEL

EVER-Q
Werksprüfzeugnis
Specific test report
Gegenstand / Object: Spritzgießmaschine

Hersteller / Manufacturer: Fa. Engel Maschinenbau GmbH

Type / Type: ES1300/250

Maschinennummer / Machine Number: 17746

Auftraggeber / Orderer: Fa.

Auftragsnummer / Order Number: 10338/018

Seitenanzahl / Number of pages: 27

Die Prüfungen erfolgen auf der Grundlage genau definierter Messvereinbarungen. Dieses Werks-
prüfzeugnis dokumentiert die Rückführbarkeit der Maschinensensorik auf nationale Normale und
dokumentiert die Maschinenfähigkeit. Für die Einhaltung einer angemessenen Frist zur Wieder-
holung der Messungen ist der Benutzer verantwortlich.

The tests occur on exactly defined measurement agreements. This Certificate documents that the
machine sensorics can be traced back to national standards and documents the machine capa-
bility. For observing a reasonable period for repeating the measurements the user is responsible.

Leitung ENGEL Qualitätswesen Prüfer

Mangagement ENGEL Quality Assurance Inspector

................................... . ................................
Ing. H. Schönberger J. Kollingbaum

Engel Maschinenbau Gesellschaft m.b.H. TEL. +43 72 62 620 -0

Ludwig-Engel-Str. 1 FAX +43 72 62 620 6009
A-4311 Schwertberg, Austria

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 Engel Vertriebsgesellschaft m.b.H., A-4311 Schwertberg, Austria
Tel. +43 72 62 620 - 0, Fax +43 72 62 620 - 3009, E-Mail: [email protected], http://www.engel.at