COMPLETE THERMAL SYSTEM SOLUTIONS

Transcription

1 W A T L O W PLASTICS PROCESSING COMPLETE THERMAL SYSTEM SOLUTIONS

2 Tradition of Excellence Watlow has provided plastics processors with product innovations for injection molding, extrusion, blown film, thermoforming and blow molding for more than 50 years. We understand how vital selecting the right auxiliary equipment can be in helping a plastics processor meet a goal of higher productivity and greater yield. It goes beyond the costs of heaters, sensors or controllers; it is performance that counts. With Watlow s thermal components, processors can count on less downtime due to increased heater reliability and on a reduction in operating costs due to energy conservation both of which help achieve greater output. Quality, innovation and reliability are the hallmarks of our family of heaters, sensors and controllers. Watlow provides not only traditional thermal solutions, but also innovative, high-performance technologies to meet the specific processing demands of industries such as automotive, medical and packaging, which require highly-engineered resins and tight tolerances. Whether an OEM, custom or captive processor, Watlow has your thermal solution with our traditional products, new technologies, engineering services and global manufacturing capabilities. Kronau, GERMANY Facility St. Louis, Missouri, USA Facility

3 Global Manufacturing and Sales Support To better serve the plastics industry, Watlow operates 13 manufacturing facilities and over 40 technical support centers in Asia, Europe and North America. As a global company, we support international design guidelines and agency approvals. We have hundreds of factory-trained sales engineers, each with an average of 15 years of experience, and distributors located throughout the world. Watlow sales engineers provide the support plastic manufacturers need. We invite you to blend the thermal expertise of our sales engineers with the existing capabilities of your electrical, electronic and mechanical engineering team. Our sales engineers are available to complement your team at any stage of your project from concept through prototyping and beyond project completion - one more way Watlow can help you build distinct performance advantages. Watlow Worldwide Sales and Technical Offices Table of Contents Watlow Manufacturing Facilities Watlow Direct Sales Offices Injection Molding...4 Extrusion/Blown Film...5 Blow Molding...6 Thermoforming...7 Heater Solutions...8 Sensor and Controller Solutions.14

4 Injection Molding MI Band Heater Case History Problem: Increase energy savings and reduce operations costs Solution: Watlow s MI band heaters provide exceptional heat transfer, high watt densities and prolonged heater life. To improve efficiency, Watlow performed an energy assessment of the MI band heaters versus its current mica heaters. The MI band heater saved the company $0.04 per kilowatt hour. This is a savings of over $4,000 a year. Regardless of your injection molding system, Watlow s family of thermal solutions provides the high-performance, reliability and accuracy needed to optimize your process. Whether OEM or end user, many of today s applications require process control data, as well as history documentation to comply with various policies and regulations. Many processors proactively seek products that offer both traceability and product repeatability. Applications include: Automotive Consumer products Medical, dental equipment Small appliances, hand tools Agricultural equipment Containers and closures Aircraft, aerospace Personal care products Computer, business and office equipment Electrical, electronics Furniture, fixtures Recreation, toys and sporting goods Communications equipment Foodservice, institutional products Packaging Transportation Building and construction Products like our barrel/band heaters are ideal for highly engineered or filled resins that require higher temperature and tighter tolerances. Regardless of your machine tonnage, Watlow has the following products to meet your needs: Barrel heaters Hot runner nozzle heaters Hot runner manifold heaters Barrel temperature controllers Power controllers Temperature sensors An array of plastic parts are formed by injecting melted resin from the barrel into a sealed steel mold under high pressure. 4 - Injection Molding

5 Extrusion/Blown Film Product quality begins upstream, and Watlow s family of thermal solutions provides products that bridge the gap by providing evidence of overall product quality, assuring process repeatability and shortening overall startup time. Watlow provides thermal solutions for a wide array of extrusion applications. Applications include: Blown film and cast film Profile, shapes and rods Flat sheet and web extrusion Wire and cable coating Pipe tubing and conduit extrusion Watlow manufactures a variety of reliable, agency-approved heaters, sensors and controllers for your extrusion process equipment. Below is a list of Watlow s extrusion thermal solutions: Barrel heaters Sprue heaters Die and former heaters Temperature controllers Power controllers Temperature sensors EZ-ZONE ST Plastics Extrusion Equipment Case History Problem: A plastics extrusion manufacturer needed to increase data acquisition capabilities on their extrusion equipment. The engineering effort of new plastic compounds required a lot of intimate process control information. The project time required to bring the R&D center online was on a very tight schedule. Solution: The extrusion machine was specified to utilize 15 EZ-ZONE ST integrated control loop products to control and monitor 15 zones. To meet the desire for process and equipment related data acquisition, the EZ-ZONE ST with digital communications capability was identified to provide a system performance data to a PLC. Since its integration into the system, the EZ- ZONE ST has offered greater reliability to monitor system relation information within the thermal control zone. This plastic was heated in a barrel and then blown into film. Extrusion/Blown Film - 5

6 Blow Molding FIREROD Heater Case History Problem: An OEM was experiencing difficulty processing on its blow molding equipment. They decided to internally heat the screw of the extruder/gearpump to optimize the performance of the line. Solution: Watlow heated the rod internally with a FIREROD heater containing an internal thermocouple for temperature control. With this approach, approximately 50 percent or more of the energy imparted to the resin came from direct thermal conduction rather than mechanically induced friction. Additional benefits of the new design included lower melt temperatures, higher throughput capacity and improved gear pump energy efficiency. The art and science of making hollow plastic containers that are indispensable parts of everyday life are all part of blow molding. Common processing techniques such as extrusion, stretch blow, injection and co-extrusion are all utilized in forming these parts. Applications include: Personal care products Automotive components Household products Double-walled cases and toner Aggressive chemicals cartridges Sporting goods Food and beverage packaging Toys Medical feeding containers Whether it is a diverse and complex part that requires high performance such as an elastically functional automotive component; or a high volume hollow piece such as a single serve PET water bottle, the front-end blow molding process still requires an exacting thermal solution. Regardless of your resin choice or final part shape, Watlow has the following thermal solutions for your application requirements: Barrel and band heating Temperature controllers Power controllers Communications Temperature sensors 6 - Blow Molding Plastic bottles are formed by inflating a hot bubble or tube of plastic inside a hollow mold.

7 Thermoforming Thermoforming part design has developed rapidly and in recent years it has become more multifaceted. Because thermoforming offers advantages such as superior finished part quality and the ability to form large parts, processors are investing in larger and faster machines and expanding both upstream and downstream services. Applications include: Vacuum forming High definition thermoforming Pressure assisted thermoforming Drape forming Press forming Line bending Although thermoforming consists of a broad range of materials, material thickness and processing levels, Watlow can help optimize your process. Whether you require a sealed face heater to keep sheet/roll contaminants away from the element while offering ease-of-cleaning and longer life, or overall precise process control Watlow has the following thermal solutions for your thermoforming applications: Heaters Temperature controllers Power controllers Temperature sensors Radiant Heaters Make Thermoplastic Sheets Stampable Case History Problem: A customer utilized polypropylenebased, glass reinforced structural plastic in automobile front-ends, power mower shrouds, snow shovels, etc. The company needed a way to pre-heat the plastic with low investment. Solution: Watlow s RAYMAX 1120 radiant panel heaters were used to preheat the plastic sheet material, which was then conveyed to a die where the final configuration was conformed. RAYMAX 1120 heaters operated at a lower temperature than quartz tubes and emitted a greater percentage of infrared energy with minimal wavelength, for better penetration of the plastic material. The heater also met the need for even temperature heating. Watlow specified and designed a complete system within two weeks. Many plastics products are shaped through thermoforming where the plastic is heated until soft and either a two-sided mold closes on the sheet to form a shape or a vacuum pulls the pliable plastic against the mold. Thermoforming - 7

8 Heater Solutions MI Band Heaters MI band heaters are constructed of Watlow s exclusive mineral insulation a material with much higher thermal conductivity than the mica and hard ceramic insulators used in conventional heaters. Operating temperatures to 760 C (1400 F) Watt densities to 35.6 W/cm 2 (230 W/in 2 ) for nozzle heaters Watt densities to 15.5 W/cm 2 (100 W/in 2 ) for larger barrel bands Higher watt densities than any other barrel heater, which contributes to faster heat-up and through-put to increase productivity High thermal conductivity of MI in a low mass construction gives almost instant response to temperature control Permanently attached clamp bars eliminate cumbersome clamping straps, which makes installation easier Injection molding barrel heating Hot runner nozzle heating Extruder barrel heating Die and former heating Blow mold heating Ceramic Knuckle Band Heaters Ceramic knuckle band heaters are designed to provide highperformance barrel heating at higher temperatures. This is achieved because of the ceramic insulation, which provides excellent insulation and long heater life. Operating temperatures to 760 C (1400 F) Watt densities to 6.97 W/cm 2 (45 W/in 2 ) for nozzle heaters Ceramic insulator allows for high temperature operation, longer heater life and accurate heating Aluminized steel cover, which provides excellent protection from abrasion Radiation or conduction heat transfer ensures a dependable heat transfer method Injection molding barrel heating Extruder barrel heating Blown film die heating 8 - Heater Solutions

9 Heater Solutions THINBAND Mica Heaters Watlow redesigned the mica band heater, creating the patented THINBAND heater. THINBAND heaters deliver fast and install easily, keeping costs down and machines running. Sheath temperatures to 480 C (900 F) Watt densities to 8.5 W/cm 2 (55 W/in 2 ) Flexible, one-piece design makes installation faster on plastic processing equipment because the heater can be opened to the full diameter of the barrel without internal damage Same day shipment on more than 1,000 variations QUICK CLAMP opens to fit over barrels and snaps in place with one easy flip of its latching lever (no need to remove other heaters) Injection molding barrel heating Extruder barrel heating Blown film dies Hot runner nozzle heating Special Mica Band Heaters Several specialty mica band heaters have been constructed over the last 50 years through solving complex and unique applications with Watlow s engineering expertise and experience. Sheath temperatures to 480 C (900 F) Watt densities to 7.0 W/cm 2 (45 W/in 2 ) Patented clamping strap assures heat transfer Low mass design allows fast heat-up and quick response Design variations provide user convenience and heater protection Injection molding barrel heating Extruder barrel heating Hot runner nozzle heating Cast-in Heat/Cool Band Heaters Heat/cool band heaters from Watlow are made of cast aluminum providing high thermal conductivity and extremely uniform surface temperatures for extrusion barrels. Permanent molds are utilized to ensure exacting precision batch-tobatch. Operating temperatures to 270 C (700 F) of 319 or 356 aluminum Watt densities to 9.3 W/cm 2 (60 W/in 2 ) on the tubular sheath Optimized cooling tubes all instant cooling, which improves efficiency of extruder barrel Watlow s complete foundry capabilities assure precise and uniform placement of the element in the casting Extruder barrel heating Blow mold heating Heater Solutions - 9

10 Heater Solutions Metric K-RING and Mini K-RING Thanks to the innovative design, plastic molders no longer have to compromise with sloppy fit tolerances, uneven temperature profiles or short heater life. The metric K-RING and mini K-RING heaters take nozzle heating technology a step ahead of the competition. Operating temperatures to 650 C (1200 F) Watt densities to 50 W/cm 2 (320 W/in 2 ) on inside diameter Brass casting construction protects heater from damage, as well as maximizes transfer of heat to heated parts Precision machining of length and inside diameter gives accurate fit tolerances Sealed construction eliminates contamination and stainless steel outer casting protects the brass body, acting like an insulator Hot runner nozzle heating Sprue heating Die and former heating FIREROD Cartridge Heaters With premium materials and tight manufacturing controls, the FIREROD heater continues to provide superior heat transfer, uniform temperatures and resistance to oxidation and corrosion even at high temperatures. Operating temperatures to 760 C (1400 F) on Incoloy sheath Watt densities to 62 W/cm 2 (400 W/in 2 ) Nickel-chromium wire is precisely wound and centered in the unit assuring even, efficient distribution of heat to the sheath Magnesium oxide insulation of specific grain and purity, swaged to the proper density, results in high dielectric strength and contributes to faster heat-up Incoloy sheath resists oxidation and corrosion from many chemicals and environments Hot runner nozzle heating Hot runner manifold heating Die and former heating Custom Cast and Interference Fit Construction (IFC) Heaters Watlow s custom cast and IFC heaters help solve many plastic processing problems, such as high watt densities, high temperatures, harsh environments and atypical configurations. These heaters are available with integrated thermocouples and offer benefits like reduced lead times and minimal tooling. Operating temperatures above 350 C (660 F) Precisely molded tubular elements enhance heat transfer patterns Various sized cooling tubes cast into heater body offer liquid cooling capability Multiple termination options, shapes and sizes provide design and application flexibility Die and former heating 10 - Heater Solutions Incoloy is a registered trademark of Special Metals Corporation.

11 Heater Solutions MI Strip Heaters The Watlow MI strip is a thin, responsive heater that sets unmatched standards for performance and durability. It makes use of the most advanced heater construction techniques, including embedding a nickel chromium element wire in Watlow s exclusive mineral insulation. Sheath temperatures to 760 C (1400 F) Watt densities to 15.5 W/cm 2 (100 W/in 2 ) Higher watt densities than other strip heaters contribute to faster heat-up Exclusive mineral insulation combines high dielectric strength and superior thermal conductivity, which transfers heat rapidly to the sheath Die and former heating Mica Strip Heaters Watlow s mica strip heater is an economical and reliable source of heat for plastics equipment. A mere 15 mils (0.4 mm) thick mica insulator on both sides of the resistance element insulation and offers little resistance to efficient heat flow. Sheath temperatures to 480 C (900 F) on zinc-coated units Sheath temperatures to 650 C (1200 F) on stainless steel units Watt densities to 8.5 W/cm 2 (55 W/in 2 ) Flat resistance ribbon generates heat over a broad area, and puts the heat source closer to the work Low mass construction heats-up faster to provide quick response to control input Excellent dielectric strength is guaranteed Die and former heating Cast-in Heat/Cool Bands for Plastic Extrusion Machines Case History Problem: A plastics manufacturer has extrusion machines, which require both heating and cooling. Cooling is required on extruder barrels to offset heat generated by frictional shear as the screw pump pushes plastic melt through the barrel and die head. Solution: Watlow s UL component recognized cast-in aluminum heat/cool bands provide a solution for the extrusion application. Cast-in heat/cool bands are designed to match the heating and cooling needs of extruders by offering longer heater life than band heaters, utilizing aluminum to deliver a very uniform a heat pattern on the barrel, providing rugged construction and offering a 12.7 mm (0.5 in.) O.D. tubing cast in for maximum cooling capacity. UL is a registered trademark of Underwriter s Laboratories, Inc. Heater Solutions - 11

12 Heater Solutions Cable/Coil Heaters The versatile Watlow cable heater can be formed to a variety of shapes as dictated by its many plastics applications. Cable heaters are small diameter, high performance units, fully annealed and readily bent to a multitude of configurations. Continuous operating temperatures to 650 C (1200 F), with pulsing temperatures to 815 C (1500 F) Sheath watt densities to 6.20 W/cm 2 (40 W/in 2 ) High ductility allows the heater to be cold-formed into almost any shape Ranges from 1 mm (0.04 in.) to 5 mm (0.18 in.) diameter, the cable heater packs a lot of heat into a tiny space The heater s low mass allows for quick response to both heating and cooling Optional square or rectangular cross section for improved heat transfer to mating part Hot runner nozzle heating Sprue heating Injection molding nozzle heating Layered Heaters Watlow s innovative thick film manifold heaters allow hot runner operations to gain more control over temperature uniformity while reducing overall cycle times. Operating temperatures to 450 C (842 F) for manifold heaters Radiant watt densities to 5.43 W/cm 2 (35 W/in 2 ) Very low thermal mass allows faster thermal response Moisture-resistance non-porous glass film construction eliminates need for soft starting, minimizes current leakage and ultimately lowers costs Hot runner manifold heating Hot Runner Manifold Case History Problem: An injection molding customer required a more efficient heating method for their hot runner system to increase start-up and throughput. Solution: Watlow provided thick film manifold heaters with multi-zone and distributed wattage. Thick film technology offered the molder multiple benefits to meet the needs of the application. Not only did thick film provide increased overall system controllability, but also allowed for cost savings in a reduction of steel mass on the hot half, as well as heater inventories. Watlow also provided custom CAD designs to fit the exact requirements of the manifold, allowing heat to be put precisely where it was needed Heater Solutions

13 Heater Solutions Tubular Milled Groove WATROD milled groove heaters provide the uniform heat required in hot runner molds. Watlow s WATROD tubular heaters are precision-formed and customized to your hot runner mold applications. Sheath temperatures to 870 C (1600 F) for Incoloy Watt densities to 15.5 W/cm 2 (100 W/in 2 ) Formed to milled groove putting heat where it is needed most Precision-wound custom engineered resistance wire for evenly distributed heat, heater efficiency and reliability Incoloy or stainless steel sheath for high-temperature and to retain shape Hot runner manifold heating Incoloy is a registered trademark of Special Metals Corporation. Tubular Immersion Mold temperature control is extremely important because the temperature of mold surfaces with which molten plastic comes into contact, changes as the room temperature changes. Watlow s tubular immersion heaters provide consistent mold control regardless of the season. Sheath temperatures to 870 C (1600 F) for Incoloy Watt densities to 15.5 W/cm 2 (100 W/in 2 ) Quick delivery: same day shipment for stock units and next day shipment for assembly units Incoloy or stainless steel sheath for high-temperature and to retain shape Injection molding mold temperature control units RAYMAX Radiant Heaters Watlow s diverse RAYMAX heater line allows you to solve virtually any plastics application requiring radiant heat. Watlow s capabilities cover a wide range of needs, from contamination-resistance surfaces, to fast-responding high temperature panels, to replaceable tubular elements. Operating temperatures to 930 C (1700 F) for quartz radiant heaters Operating temperatures to 700 C (1300 F) for panel radiant heaters A full line of RAYMAX heaters includes panel and quartz tube styles with capabilities to match the ideal temperature and watt density requirements of your application Fast delivery on all standard replacement parts, which decreases downtime Thermoforming Blow mold heating Heater Solutions - 13

14 Sensor and Controller Solutions Temperature Sensors Manufactured to recognized agency standards, Watlow thermocouple temperature sensors deliver reliable, accurate temperature measurement. Watlow offers Type J thermocouple sensor assemblies in-stock. These sensors meet the most popular demands of the plastics industry. Made-to-order and non-stock ANSI Type E, K and T thermocouples are also available. EZ-ZONE ST Integrated Control Loop The EZ-ZONE ST is a solid state controller that offers complete thermal system control in one package. You get a PID temperature controller already connected to a high amperage solid state relay with the option of adding a properly sized heat sink, an over/under temperature limit, a shut-down power contactor, digital communications and a flexible remote user interface (RUI). Lower overall cost per loop ownership Reduced manufacturing, service and installation costs Modular system allows for flexible use of platform across customer s product line Professionally designed system by the temperature experts Optional current monitoring feature Optional Modbus communication System diagnostics Advanced controllability algorithms, offers TRU-TUNE+ adaptive tuning Agency approvals: UL, CSA, RoHS and W.E.E.E Power Controllers Watlow s DIN-A-MITE family of solid state power controllers provide SCR control, heat sink, wiring and touchsafe exterior in one package. The DIN- A-MITE family of controllers offer easy installation, DIN-rail or sub-panel mounting and four styles to meet most power controller needs with ratings from 18 to 100 amps with voltages from 120 to 600V~(ac) Sensor and Controller Solutions The E-SAFE mercury-free relay from Watlow provides reliable and accurate power switching for plastics processing applications. The E-SAFE Relay can exceed the performance of typical mercury relays while fitting within the same footprint. It bridges the gap between mercury displacement relays (MDRs) and solid state relays (SSRs) by providing superior power switching in a nonmercury solution at a lower cost. This mercury-free relay also provides longer contact life and higher performance than a typical mechanical relay. The Watlow SERIES CZ18 is a compact 22 mm and 18 amp solid state contactor that is excellent for switching nozzle heaters. The 22 mm thin profile takes up minimal space and is a snap to install with DIN-rail mounting. The CZ18 is rated up to 600 V~(ac), so it can be used in applications anywhere in the world. Watlow stocks over 20 different solid state relays and heat sinks that customers can match to their specific application with same day shipment. These Watlow solid state products include agency approvals like UL, and CSA, and the CE mark. UL is a registered trademark of Underwriter s Laboratories, Inc.

15 Sensor and Controller Solutions Temperature Controllers Watlow offers several powerful lines of controllers that combine performance and flexibility in a compact design for your plastics processing equipment. Controller Type Industry Number of Control Loops Inputs Outputs Power Supply Size Mounting Communications Control Mode Agency Approvals EZ-ZONE ST with TRU-TUNE+ adaptive tuning 1 up to 32 with Modbus 1 Universal 2 digital Optional V~(ac) 24V~(ac/dc) Back panel or DIN-rail mount Standard Bus Modbus PID Adaptive UL CE CSA SERIES SD with TRU-TUNE+ adaptive tuning 1 1 Universal V~(ac) 24V~(ac/dc) 1 4, 1 8, 1 16, 1 32 DIN-panel mount EIA/TIA 485 Modbus RTU WATVIEW HMI PID Adaptive UL CE CSA NEMA 4X (IP65) SERIES SD_D 1 1 Universal 1 or V~(ac) 24V~(ac/dc) 1 16 DINpanel mount DeviceNet PID UL, CE CSA NEMA 4X (IP65) SERIES PD 1 or 2 1 or 2 Universal plus 0,1 or 2 Current Transformer 2, 3 or 4 24V~(dc) DIN-rail mount EtherNet/IP Modbus TCP HTML (web pages) SMTP ( ) TFTP 10-base T Ethernet PID UL CE CSA MLS or or 32 Analog 36 Digital 12-24V~(dc) 1 8 DIN Horizontal, Sub-panel mount analog input module WATVIEW EIA/TIA 485 and 232 Modbus RTU PID UL C-UL CE PPC to 48 16, 32, 48 or 64 Analog Up to V~(dc) DIN-rail or fastener, sub-panel mount 2 communication ports ANAWIN3 EIA/TIA 485 and 232 Modbus RTU PID Adaptive UL C-UL CE DeviceNet is a trademark of the Open DeviceNet Vendors Association. Modbus is a trademark of Schneider Automation Incorporated. EtherNet/IP is a trademark of ODVA Sensor and Controller Solutions - 15

16 Watlow Products and Technical Support Delivered Worldwide Lackland Road St. Louis, Missouri USA Phone: FAX: WATLOW Worldwide Business Centers Asian Technical Support & Sales Offices Australia China Japan Korea Malaysia Singapore Taiwan European Technical Support & Sales Offices France +33 (01) Germany +49 (0) Italy +39 (02) Sweden United Kingdom +44 (0) Spain Latin American Technical Support & Sales Office Mexico North American Technical Support & Sales Offices To be automatically connected to the sales office nearest you call: WATLOW2 Your Authorized Watlow Distributor is: Printed in the USA on Recycled Paper, 15% Postconsumer Waste Watlow Electric Manufacturing Company COR-PLAS-0606