Headquartered in Eching, Germany, Hekuma helps the plastics industry create sustainable competitive advantages through innovative ideas, exciting new technologies and high-performance automation systems. In addition to the complex neutrons used in the release and upstream automation of the injection molding process, the company's core competencies include the development of dedicated turnkey solutions and product solutions such as Sigma for dynamic part handling. Inside". Hekuma specializes in the medical and automotive engineering markets, as well as the fast moving consumer goods industry.

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Technology upgrades bring significant performance improvements

Recently, Hekuma's medical engineering department has created the latest generation of tip production equipment. If the company is to continue to set new industry standards with its advanced machinery, the upgrade of control technology becomes critical. Gorazd Jeri, director of software development & services at Hekuma, explained: “Beckhoff's open automation technology, especially when used in conjunction with ultra-high-speed EtherCAT communication systems, enables a real breakthrough. Compared to our competitors, Our equipment is only half the size, but it can achieve twice the output. High-speed EtherCAT communication technology makes a significant contribution to achieving 100% quality control. The ability to detect each defective workpiece online, sort them out, and Replacing these unqualified artifacts in a buffer gives our customers unparalleled added value."

Small tips require complex processing

The first part of this production system uses two electric injection molding machines, each with a 64-cavity mold. Automation mainly includes the following process steps:

1. Remove injection molded parts from the mold at high speed

2. Stack the finished parts into the circulating workpiece conveying system

3. Use a camera system to complete 100% quality control

4. Sort out the detected unqualified workpieces

5. Fill the gap from the buffer

6. Fill the combination frame with the qualified products checked

7. Print the date and lot number on the shelf

8. Stack and pack the filled shelves with a tear-off protective film

Precise processing and optimization of quality inspection

Fast and precise motion control and efficient "real-time" quality inspection require the use of large and powerful control systems and high-speed data communication systems. Gorazd Jeri? explained: “The complexity of the equipment means that they have a lot of system interfaces, which was difficult to meet with PLC technology before. To achieve this in a traditional PLC architecture, It costs a lot of money, and it also has a negative impact on the performance of the run. In any case, this requires complex operations on the PC, which in turn means using additional hardware and software, and the two Inter-communication also requires huge costs. With Beckhoff control technology, all problems are solved. And typical PC tasks such as file transfer, database connection and Ethernet communication can be easily integrated.” EtherCAT communication is highly accurate Positioning and high-speed machining have laid a solid foundation. Hekuma has used this technology to achieve axial control with a maximum deviation of only 0.005 mm, resulting in good reference value processing and extremely stable shaft operation. Gorazd Jeri? added: “There are many other new features, such as overshoot, to reduce the speed of the waste station. These functions can be implemented very simply, and the engineering workload is significant thanks to the TwinCAT NCPTP software. Reduced.” Gorazd Jeri? The shelf sorting and stacking station is used as an example to describe the importance of compactness and modularity as well as speed and precision: “Three equipped with Beckhoff AM3121 servo motor via compact EtherCAT servo motor terminal module EL7201 Control, responsible for these motion tasks.” Advanced safety functions can also be integrated into the system by using the TwinSAFEPLC terminal module EL6900.

Gorazd Jeri? has made a huge breakthrough in the performance of the Hekuma tip injection molding machine line by shifting PLC technology to PC-based control technology, and foresees future performance gains, especially through the consistent object-oriented use of TwinCAT 3 Programming and deployment of the XTS eXtended Transport System

The EtherCAT Terminal System enables a compact automation solution that can be precisely adapted to the machine module. EtherCAT also includes complete equipment safety functions – from monitoring on the injection molding machine to emergency stop via the TwinSAFE communication system.

The basis of a consistent modular machine design

With nearly 11,000 variables and more than 3,000 components, this amazing number is a good example of how complex the entire injection molding line is. Despite this, Gorazd Jeri? takes advantage of another advantage of PC-based control technology, enabling machine design that can be easily transitioned from engineering to operation: “By using Beckhoff's automation technology, we achieved consistent modularity. Machine design — whether on the hardware or in software. The various modules are extracted in this way, making them versatile regardless of application and machine type. In addition, subsequent line modifications are much simpler.”

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