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Kistler at Fakuma 2018 - Breaking new ground with monitoring system for injection moulding

At Fakuma2018, the Kistler Group showcased its latest monitoring and control packagesfor ComoNeo, its high-quality process monitoring system that is designed todeliver efficiency and transparency for injection moulding. Unlike ever before,system users can choose their own packages from the vast range of functionsavailable in the system.

ComoNeo isthe system of choice for plastics processing companies looking to boost productquality and cost efficiency by optimizing their injection moulding processes.Kistler is constantly developing this process monitoring system - not only toaccommodate new application cases but also to ensure comprehensive optimizationin every respect coupled with maximum cost efficiency.

Based onthe measurement of cavity pressure with tried-and-tested sensors from Kistler,users are provided with modular functions to support predictive control of theinjection moulding process leading to optimum results. Support, monitoring,control and prediction make Version 3.0 of Kistler's ComoNeo the leader inprocess transparency, which is essential for Industry 4.0.


ComoNeo: guiding users to desired results

A keybenefit of this system is its ability to support users according to theirindividual levels of know-how. Kistler has integrated a prediction tool intoComoNeo: the Stasa QC software, which uses measured values and statisticalanalyses to calculate the quality of the manufactured components in advance,and to assess them within the tolerance bands. This special type of processmonitoring is particularly useful for manufacturers of high-grade parts - inmedical technology or other sectors where safety is critical, for instance.

To ensureoptimal product quality and cost efficiency for their injection mouldingprocesses, customers can tailor their own ComoNeo with these functions:

- ComoNeoPredict:allows model-based prediction of specified part quality based on the cavitypressure and temperature profiles - for optimum process parameters andtransparent processes;

- ComoNeoMerge:when multiple components are used, process technology becomes more complex -but ComoNeo 3.0 can easily accommodate this challenge; the system monitors andevaluates up to four components with different mould technologies;

- ComoNeoMultiFlow:for moulds with multiple cavities, this option allows hot runner balancingthrough individual adjustment of the nozzle temperature - to ensure identicalinjection conditions in all cavities and automatic correction of deviations;

- ComoNeoSwitch:this function ensures automated switchover from the injection phase to theholding phase at the ideal time - for balanced injection behavior and optimummould protection during the process;

- ComoNeoComposite,another new feature: injection moulding with the RTM process can now beoptimized; special RTM sensors from Kistler create the conditions forcontrolled high-quality machining of long-fibre composites;

- ComoNeoGuard:this function helps users to define monitoring windows that enable accurateseparation of good and bad parts on a step-by-step basis; the benefits:guaranteed part quality and less pseudo scrap;

- ComoNeoRecover:this feature makes it possible to reproduce a proven injection moulding processon a different machine; the user is guided through the adaptation step by step,deviations are identified and the assistant suggests corrective actions.


ComoDataCenter: transparent processes enhancequality and cut costs

As soon asComoNeo has been specifically tailored to individual application, everythingquite literally comes together in the ComoDataCenter, a database that storesall the process data and establishes a seamless communication with overarchingsystems. Users benefit from the comprehensive overview of their entireinjection moulding production, which ultimately provides for a sound basis forongoing analysis and optimization.

"We'reoffering companies a complete modular and multifunctional package that fulfilsall the requirements for intelligent and efficient injection molding. ComoNeois Industry 4.0 put into practice”, said Robert Vaculik, head of Kistler's strategicbusiness field plastics. “Mastery of new processes and greater levels ofcomplexity shows the full extent of what injection moulding can achieve interms of quality - and the potential of process-integrated quality monitoringis far from being exhausted. Development is certainly set to continue".

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