17/02/2009 M. Sbardolini1

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APPLICATION MELT

EXTRUSION AND BLOWING

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INMelt pressuretransducers

TC5, TCMTemperaturesensors

ADV200Motor control drive

GILOGIK IIDigital/analog remote I/O

GF_VEDOOperator panel & control

GF_VEDOOperator panel & control

TRLoad cells forweb tension

GFX4, GFXTERMO4Multiloop PID temperaturecontrol

GILOGIK IIDigital/analog remote I/O

ADV200Motor control drive

GLK67IP 67 remote temperature inputs

APPLICATIONS Extrusion

17/02/2009 M. Sbardolini

The process of polymer transforming takes the material to its meltcondition (plastification) and forces it to pass through an orifice(threading die)

APPLICATIONS Extrusion

GEAR PUMP

SCREEN CHANGER

DIE

HOPPER

GEAR BOXSCREW

BARREL

FEEDING ZONE

PRESSURE ZONE

EXTRUDED PRODUCT

DRIVE

MIXING ZONE

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APPLICATIONS Extrusion

Melt temperature and pressure are monitored to check the flow stability.

The pressure value is used to givethe feedback to the drive to set the

screw speed

PRESSURE AT THE DIE

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APPLICATIONS Extrusion

Gear Pump

Melt pressure sensor

before the pump

Melt pressure sensor

after the pump

PRESSURE AT THE GEAR PUMP

Used to improve the flow stabilityto the die

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APPLICATIONS Extrusion

Screen changer

Melt pressure before the screenchanger

Melt pressure after the screenchanger

PRESSURE AT THE SCREEN CHANGER

To check the screen cleanness byreading upstream and downstream

pressure

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APPLICATIONS Extrusion

PRESSURE ALONG THE BARREL

Screw design research and developmentPlastic materials evaluationThe diaphragm may get in contact with semi-molten polymer

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The gear pump is used to grant a costant flow-rate to the die. The flow adjustment is obtained by the pressure measure

Pressure controlat the gear pump

APPLICATIONS Extrusion

17/02/2009 M. Sbardolini

Contamination can clog the screen and cause a pressure drop at the die, dimensional – unstable products result. The screen cleanness can be controlledby reading upstream and downstream pressure (measuring the pressure beforeand after the screen)

Pressure controlat the screen changer

APPLICATIONS Extrusion

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Process: plastic materials recyclingmachines

Reason for Impact choice: • Dirty environment, semi solid

and abrasive materials• Reliability

APPLICATIONS Extrusion – Recycling machines

17/02/2009 M. Sbardolini

• Process: a wide range of top-class solid, multiwall, and corrugated polycarbonate sheets production (ex. Makrolon series) that fulfill the most diverse requirements

• PC Application: stadium and train station roof covers, complex dome structures, skylights and barrel vaults, lightweight roof constructions for winter gardens

• PC advantages: energy saving (thermal insulation), protection and safety (bullet and breaking proof features), high bending resistance (building)

• Why we gained the customer: thanks to the Impact in contact diaphragm higher reliability (PC high abrasion effect)

• Competitors: Gneuss DAP series

CASE HISTORY Extrusion – Policarbonate sheets

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Following a couple of examples of consolidated customers during 2008 withthe Impact series :

Bayer Sheet Europe (Terni plant): www.bayersheeteurope.com• 6 extrusion lines for Makrolon production• 5 pieces sold in 2008 (Impact IE series)Proimpianti-Dott. Gallina (Torino plant): www.gallina.it• 40 extrusion lines for different industrial sectors(automotive, building, compact sheets, expanded materials)• 30 pieces sold in 2007 and 30 pieces sold in 2008 (Impact IE series)

CONSOLIDATED CUSTOMERSCONSOLIDATED CUSTOMERSExtrusion – Policarbonate sheets

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GT-C / DIGISTARII C

Human machine interface and control unit

MK4A / LT

Mold position sensor

IK4A

Parison position sensors

IN1

Melt pressure transducers

TC5 / TCM

Extruder Temperature Sensors

TC5

Head Temperature Sensors

GTS

Solid Stae Relais with heatsink

GILOGIK II

Real time ethernet Remote I/Os

ADV200 / XVy-EV

Inverters and Servodrives

TPSA

Hydraulic pressure, blowpressure, leak tester

APPLICATIONSBlowing

17/02/2009 M. Sbardolini

Blowing machines• Target: mould opening/closure position, mould translation, Parison

actuator control, pressure and temperature control at the extruderhead, blow and hydraulic pressure control

• Pressure sensors TK series for blow pressure and TPSA series forhydraulic circuit pressure

• Melt pressure sensors Impact series forpressure control at the extruderdie (dynamic pressures)

• Magnetostrictive position sensors MK4 series for mould position control and IK4 series for Parison actuator control

APPLICATIONSBlowing

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• Sipa: www.sipa.it• 50 melt pressure sensors Impact series for pressure control at the

extruder die (dynamic pressures)

CONSOLIDATED CUSTOMERSCONSOLIDATED CUSTOMERSBlowing – Accumulator head

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APPLICATION – RHEOLOGICAL NOZZLES

The rheometer is an instrument suitable to measure rheological polymerproprieties. The sensors measure the pressure drop inside a smallchannel. An high accuracy and great matching among the sensors isrequired.

PP11 PP33

PP22

PPvKvK

Viscosity

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APPLICATION - HOT MELT

• Hot–melt applicators are machines designed for the application of adhesives and thermoplastic material

• They need to control the pressure of the glue• Due to the small dimensions the most used Melt pressure version is the

exposed capillary one

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IJ/MJ – Melt pressure sensor forInjection Moulding Machines

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APPLICATIONS Injection Molding Machine

MK4-AMold position

LTEjector position

IJInjection pressure

MK4-AInjection screw position

MK4-ACarriage position

GILOGIK IIDigital analog remote I/O

GTS/GFXTERMO4Solid state relayMultiloop PID temperature control

ADV200 / XVy-EVMotor control inverter

GF_VEDOOperator panel & control

TPSAHydraulic circuit pressure

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Screw positionNozzle pressureMould pressure

Ejector force

Mould temperature

Melt temperature Hydraulic pressure

APPLICATIONS Injection Molding Machine

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Nozzle pressure measurement advantages:• Direct measurement of injection and back pressure• Final product higher quality (repeatibility in dimensions

and weight)• Easy Process Parameters Tuning• Statistic Process Control• Better quality by a better control of the holding phase• Easy transfer of the machine settings (for a new production process or different machine) • Higher reliability related to the cavity measurement (only one sensor); it’s enough one

sensor for different moulds• No mould re-workings• Higher measurement precision related to the load cell

solution through a pressure direct measure• Easy to install (doesn’t require machine customizations)

APPLICATIONS Injection Molding Machine

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IJ/MJ – ELECTRIC MACHINE APPLICATION

INJECTION PHASE

Injection pressure direct control inside the nozzle during the holding phase.

LOADING PHASEBack pressure check during the material loading

ADVANTAGES

• Melt pressure direct measure

• Measure depends on the process variable only (and not on the machinevariable)

• Piece weight in grams more precise control

• Process and final product absolute repeatability

• Standard product without customizations for different type of machines

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IJ/MJ – HYDRAULIC MACHINE APPLICATION

INJECTION PROCESS TODAY

• BY QUOTA, holding phase

• BY PRESSURE TRANSDUCER IN THE HYDRAULIC CIRCUIT, holding phase, compacting phase and back pressure

• BY MEL PRESSURE SENSOR INSIDE THE MOULD, holding phase, compactingphase

INJECTION PROCESS WITH IJ OR MJ SENSOR INSIDE THE NOZZLE

• Melt pressure direct measure

• Measure depends on the process variable only (mm/bar oil)

• Piece weight in grams more precise control

• Process and final product absolute repeatability

• Unique positioning (nozzle) without mould workings (hole for sensor inside the moulds)

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IJ IJ -- SimulationSimulation of of anan injectioninjection cyclecycle

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MELT SENSORS - THE PRODUCTION

GEFRAN SPA

(PROVAGLIO D’ISEO)

GEFRAN ISI

(WINCHESTER-BOSTON)

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GEFRAN GROUP

• 25 YEARS EXPERIENCE IN MELT SENSORS MANUFACTURING

• GEFRAN IS ONE OF THE MOST IMPORTANT MELT SENSOR MANUFACTURERS IN THE WORLD

• FIRST SUPPLIER FOR ITALIAN MANUFACTURERS• EXPORT QUOTA EXCEEDING THE 80 % • FIRST MARKET: GERMANY

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price

performancesM series filling Hg (35/2000 bar)

400 °C

W series filling Oil (FDA approved)

(35/1000 bar)315°C

K series filling Nak(Mercury free)(35/1000 bar)

540°C

FULL PRODUCT RANGE

IE-IN-IX series(100/1000 bar)

350°C

I3 series(100/1000 bar)

350°C

IJ series fluid free (100/3000 bar)

350°C

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Static pressures Dynamic pressures

Oil

W -2,3 (mV/V)-E, N (analogue)-X, F (Atex, FM)-D (CANopen)

Mercury

Nak

I -3,E,N,X (analogue)

M -2,3 (mV/V)-E, N (analogue)-X, F (Atex, FM)-D (CANopen)

K -2,3 (mV/V)-E, N (analogue)-D (CANopen)

MJ -N (analogue)-D (CANopen)

I -E,N,X (anal.)IJ -N (analogue)

-D (CANopen)Impact

Melt pressure sensors product range

EXTRUSION

17/02/2009 M. Sbardolini

Static pressures Dynamic pressures

Oil

W -2,3 (mV/V)-E, N (analogue)-X, F (Atex, FM)-D (CANopen)

Mercury

Nak

M -2,3 (mV/V)-E, N (analogue)-X, F (Atex, FM)-D (CANopen)

K -2,3 (mV/V)-E, N (analogue)-D (CANopen)

MJ -N (analogue)-D (CANopen)

Impact

Melt pressure sensors product range

BLOWING

I -3,E,N,X (analogue)

I -E,N,X (anal.)IJ -N (analogue)

-D (CANopen)BLOWING BLOWING

17/02/2009 M. Sbardolini

Static pressures Dynamic pressures

Oil

W -2,3 (mV/V)-E, N (analogue)-X, F (Atex, FM)-D (CANopen)

Mercury

Nak

M -2,3 (mV/V)-E, N (analogue)-X, F (Atex, FM)-D (CANopen)

K -2,3 (mV/V)-E, N (analogue)-D (CANopen)

MJ -N (analogue)-D (CANopen)

Impact

Melt pressure sensors product range

INJECTION

I -3,E,N,X (analogue)

I -E,N,X (anal.)IJ -N (analogue)

-D (CANopen)INJECTION