APC plus by KraussMaffei: Increased precision and repeatability

APC plus features many new intelligent features that make injection molding more stable and more precise as a whole.

The premiere of the Adaptive Process Control machine technology by KraussMaffei, better known as APC, at Fakuma 2014 was more than memorable. At the forthcoming K 2016, the company will launch the updated version of the system. APC plus boasts numerous new smart functions for a more precise and stable injection molding. Considering the current trend to use more recycled materials, the upgraded technology makes processing them easier. APC plus is ideal for multicomponent injection molding, processing silicone or thermoplastics, but also for special applications, including cascade injection molding or manufacture of thin-walled items.

Towards zero-flaw production

Head of Machine Technology at KraussMaffei, Dr. Reinhard Schiffers, explains: “The new APC plus now makes it possible to compensate for troublesome fluctuations in the manufacturing process during injection molding even faster and with greater precision. Our customers profit from exceptionally high precision and consistently high component quality.” The new system is even more learning-oriented than APC was and detects process instabilities caused by varying ambient humidity or temperature, viscosity fluctuations, etc. APC plus takes the necessary steps to smoothen the detected fluctuations.
The updated control technology allows operator to select material and filler type from a dropdown list of 20 basic materials in order to account for their specific characteristics. “This makes the injection molding machine capable of, for the first time, responding to faults based specifically on the material and taking corrective action in the holding pressure phase,” emphasizes Dr. Schiffers. Moreover, APC plus accounts for the dependence of melt compressibility on pressure. This allows for an even better precision in correcting process fluctuations, since it provides more exact data on how much melt is injected into mold cavity. Finally, the algorithm for prediction of nonreturn valve closing behavior was refined to enable a greater accuracy in identifying the optimum changeover point.

Ideally fit for cascade injection molding

The new APC plus system steps after the original APC in that it is perfectly fit for processing silicone or thermoplastics, and for multicomponent injection molding. Another benefit is optimum part quality in special applications, e.g. in cascade injection molding where opening times of needle nozzles are controlled so as to keep mold fill level constant despite viscosity fluctuations from shot to shot. All the current machine series by KraussMaffei, hydraulic and electric alike, benefit from APC plus.

Industry 4.0

The updated process control function is naturally congruent with the Plastics 4.0 strategy adopted by KraussMaffei for the implementation of Industry 4.0 concept. The three areas of Plastics 4.0 are intelligent machines, interactive production and intelligent services. APC plus exemplifies the first one, smart machines, meaning self-adapting, intelligent process equipment enabling quality and output improvements.