Project goal and implementation

The aim was to detect core breakages just a few tenths of a millimetre in size inside injection moulding tools as quickly as possible in order to prevent complaints, unnecessarily high costs and loss of time. The metal detector Vistus RS offered a range of benefits for the customer; the sensors are much more sensitive than competing products and they also provide more in the way of statistics. These can then be used for internal quality control and to improve the production process.

The plant that was nominated to lead the way produces products on nearly 120 injection moulding machines with more than 800 injection moulding tools. Moulds (also referred to as tools) for the production of automotive connectors in particular often have very low core diameters and up to 32 cavities. The pressures and forces present within the tool can cause the cores to wear out and subsequently break. The 'cores' can be seen within the tool as a positive contour and create the negative within the connector into which the pins (contacts) can subsequently be clipped. These types of connectors are used for example for engine control units, speedometers, sat nav systems and any other types of electronic components within a vehicle. Production takes place at the customer's premises on the latest injection moulding machines combined with the latest process technology: flexibility, efficiency and quality form the foundation here. After reviewing several concepts from a variety of different providers and several months of testing, the company opted for the freefall metal detection system Vistus RS from Minebea Intec, whose clear benefits are its detection sensitivity, ease of use and batch traceability.

Vistus is usually used in food technology but in this pilot project in the plastics industry the product impressed the customer with benefits such as maximum detection performance through optimum vibration control. The product was specifically tailored to the customer's needs for this project. This involved two detection coils being attached to one electronic unit and the software also being adapted for the customer. During the engineering phase, the team from Minebea Intec provided the customer with comprehensive support and were on hand with advice and assistance at all times. This ensured that the best solution was found for the customer.

Case Studies [Minebea Intec]