EWIKON electric drive valve gate technologyFull process control with high precision

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The benchmark for electric valve gate technology

The EWIKON electric valve gate technology sets benchmarks in process control and precision. All relevant process parameters can be set individually according to the specific application requirements and fine-adjusted during production as well. Thus, the injection moulder gains full control of the valve pin movements. Additionally, the powerful control technology enables sequential gating as well as to approach several valve pin positions within one moulding cycle. This makes the technology the ideal solution for demanding injection moulding applications in the field of technical parts. Furthermore, the drive concept works emission-free and can be used in cleanroom applications for the medical industry without any restriction.

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• Full control of the valve pin movement

• Clean drive concept, emission-free and absolutely cleanroom compatible

• Valve pin positioning with high precision, increment: 0.01 mm. Individual adjustment for each valve pin as well as shutdown of selected valve pins possible when using single drives.

• Individual setting of process parameters such as valve pin stroke, valve pin speed and opening and closing time

• High process reliability and reproducibility

• Easy integration into the mould

• Complex movement profiles of the valve pin for special applications can be realised easily

Drive unit typesThe benchmark for electric valve gate technology

Advantages

Linear step motor as drive unit for standard valve gate systems

Linear servo motor as drive unit for systems with pull rail actuated synchronous plate

• Available in 3 versions

• Linear force of drive units: max. 800 N / 1600 N

• Valve pin speed: 1 - 20 mm/s

• Valve pin stroke: up to 16 mm

• Encoder for permanent monitoring of valve pin position with an accuracy of 1/100 mm. Automatic readjustment of valve pin in case of deviation, valve pin is deactivated when problems occur permanently

• Available in 3 versions

• Linear force of drive units: max. 8000 N / 16000 N / 30000 N

• Valve pin speed: 1 - 30 mm/s

• Valve pin stroke: up to 10 mm

• Permanent monitoring and (if required) automatic readjustment of valve pin positions. Fine adjustment of the valve pin position in the gate area

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Powerful valve pin actuation

The closing force of the step motor drive remains constant at all times, independently from the valve pin stroke. It can be further enlarged by the possibility to vary the valve pin speed. The slower the movement of the valve pin the higher the force generated. The intelligent valve pin control allows to start the valve pin closing movement with high speed and then decrease the speed just before closing the gate. An almost doubled closing force is the result. This makes the step motor drive also suitable for processing demanding, rapidly freezing materials like polycarbonate where high closing forces are required for a proper gate sealing.

2500

2000

1500

1000

500

Forc

e [N

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Valve pin speed [mm/s]5 10 15 20 25 30

Closing forces of step motor drive units

Drive unit for valve pin diameter 3 mm and 4 mm

Drive unit for valve pin diameter 2 mm

Recommended load limit

Recommended load limit

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Precise and comfortable control

The external EDC-PRO (E Drive Control) touch screen control unit allows a comfortable operation for up to 32 linear step motors. For synchronous plate systems with linear servo motor the SDC (Servo Drive Control) controller is available. This control unit contains a technically advanced servo control system with multiple functions. A simple adjustment to different injection moulding machine controls is possible by using digital signals (+24 V DC).

EDC-PRO touch screen controller for linear step motor with 7'' color touch screen display

SDC-PRO touch screen controller for linear servo motor with 7'' color touch screen display

• Operates up to 32 linear step motors • Operates 2 linear servo motors

• Automatic mode or manual operation (test mode)

• Comfortable operation via touch screen display, visualisation of valve pin positions and operating modes

• Individual setting of process parameters such as stroke length, valve pin speed, opening and closing time and closing position (optimisation of gating point quality)

• Different valve pin operation modes: normal operation (OPEN/CLOSE), function for sequential gating (delayed opening), function to approach several valve pin positions within one moulding cycle (e.g. demoulding aid)

• Time-dependent or path-dependent actuation via screw position of the injection moulding machine or by other input signals, e.g. cavity pressure measurement: Combination of signal types possible

• Storage function to save data and settings on the integrated 2 GB flash memory and a USB stick

• Permanent monitoring of the valve pin position by high-resolution position measuring system

• Connection to injection moulding machine control via digital signals (+24 V DC) or analogue signal (0 - 10 V DC)

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Demanding applications made easy

Valve pin position 1

The valve pin moves into the cavity and touches the inner core with a defined pressure. The first component for the tube wall is injected. The valve pin keeps a channel in the tube wall open. The inner core retracts and the cavity for the soft component of the seal can be filled.

Valve pin position 3

The valve pin moves to its closing position at the outer edge of the part and the finished product can be demoulded.

Valve pin position 2

The valve pin opens and the soft component for the inner seal is injected through the open channel in the tube wall.

The extensive options the valve pin control offers open up new approaches to injection moulding applicati-ons and contribute to the growing tendency of integrating additional functions into the mould.

Function Field of application

Several valve pin positions are approached within one moulding cycle

Multi-component applications where both components can be gated without the need to move the part to another cavity

Ejector function; the valve pin acts as demoulding aid after the filling process

During injection the valve pin fixes an insert part or a core

Before injection the valve pin punctures an insert part which is then back-injected

Delayed opening and closing of the valve pins

Sequential injection moulding, cascade injection moulding without flow lines

Multi-gating of parts: Shifting of weld lines into uncritical areas of the structure

Family moulds: Precise filling of parts with different shot weights

Tubes and inner seals of plastic fittings are two-component injection-moulded within one cycle. The EWIKON electric valve gate system approa-ches three valve pin positions in this application. The valve pin is not only used to seal the gate, but also acts as a moveable mould core while the PP component for the tube wall is injected.

Please unfold for further technical data

Example: multi component application

Linear step motor – Drive unit types Linear step motor – Controllers

EDC-PRO 4-zone and 8-zone controllers with accessories

4-zone controller

68151.104

8-zone controller

68151.108

Signal cable 3 m, 6-pin 1 piece 60070.043

1 piece 60070.043

Motor cable 4-zone

1 piece60070.024

2 pieces60070.024

Encoder cable 4-zone

1 piece60070.027

2 pieces60070.027

Fault registration cable 6 m 1 piece60070.031

1 piece60070.031

Signal cable, analogue, 3/6 m 1 piece 60070.038-V03/V06

1 piece 60070.038-V03/V06

Required connecting plugs for mould:

Motor connection socket 4-zone

1 pieceflat: 63050.001 high: 63050.002

2 piecesflat: 63050.001 high: 63050.002

Encoder connection socket 4-zone, incl. cables

1 piece63050.003

2 pieces63050.003

EDC-PRO master / slave control units 16-zone to 32-zone (8-zone steps) with accessories

8-zone controller Master

68151.108

8-zone controller Slave

68151.118

Signal cable 3 m, 6-pin 1 piece 60070.043

Motor cable 4-zone

2 pieces60070.024

2 pieces60070.024

Encoder cable 4-zone

2 pieces60070.027

2 pieces60070.027

Fault registration cable 6 m 1 piece60070.031

Signal cable, analogue, 3/6 m 1 piece 60070.038-V03/V06

Required connecting plugs for mould:

Motor connection socket 4-zone

2 piecesflat: 63050.001 high: 63050.002

2 piecesflat: 63050.001 high: 63050.002

Encoder connection socket 4-zone, incl. cables

2 pieces63050.003

2 pieces63050.003

Master unit

Slave unit

Linear step motor with encoder

for nozzles with valve pin Ø 2 mm

19858

for nozzles with valve pin Ø 3 mm

19888

for nozzles with valve pin Ø 4 mm

22888

for nozzles with valve pin Ø (dim. D) 2 mm 3 mm 4 mm

Valve pin opening speed 1 - 20 mm/s 1 - 20 mm/s 1 - 20 mm/s

Valve pin closing speed 1 - 20 mm/s 1 - 20 mm/s 1 - 20 mm/s

Maximum valve pin stroke 11 mm 11 mm 16 mm

Maximum valve pin closing force 800 N 1600 N 1600 N

Maximum permissible environmental temperature

for drives70 °C / 158 °F

Resolution 0.01 mm 0.01 mm 0.01 mm

Dimension A 56.4 mm 85.6 mm 85.6 mm

Dimension B 61.8 mm 92.5 mm 92.5 mm

Dimension C 76.2 mm 90.8 mm 90.8 mm

Linear step motor with encoder

z285-02

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Linear servo motor – Drive unit types and controllers

z285-03

Drive unit types

SDC-PRO controller with accessories

Linear servo motor

18255

Linear servo motor

18253

Linear servo motor

18266

Maximum valve pin stroke 10 mm 10 mm 10 mm

Valve pin speed 1 - 30 mm/s 1 - 30 mm/s 1 - 30 mm/s

Maximum closing force of synchronous plate * 8000 N 16000 N 30000 N

Resolution < 0.01 mm < 0.01 mm < 0.01 mm

Dimension A 260 mm 340 mm 283 mm

Dimension B 74 mm 97 mm 127 mm

Dimension C 150 mm 195 mm 149 mm

Dimension D 78 mm 98 mm 112 mm

* System design by EWIKON according to the specific application requirements

1-zone controller

68151.301

2-zone controller

68151.302

Signal cable 3 m, 6-pin 1 piece 60070.043

1 piece 60070.043

Motor connection cable M23 servo drive unit 3/6 m

1 piece 63050.110-V03/V06

2 pieces 63050.110-V03/V06

Resolver cable M23 servo drive unit 3/6 m

1 piece 63050.120-V03/V06

2 pieces 63050.120-V03/V06

Fault registration cable 6 m 1 piece 60070.031

1 piece 60070.031

Signal cable, analogue, 3/6 m 1 piece 60070.038-V03/V06

1 piece 60070.038-V03/V06

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EWIKON Heißkanalsysteme GmbH Siegener Straße 35 35066 Frankenberg / GermanyTel: +49 6451 501-0E-Mail: info@ewikon.com www.ewikon.com

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