HRSflow offers hot runner solutions for all sizes, weights and complex automotive components, along with fast lead times. Hot runners used for automotive applications must produce flawless parts using difficult-to-process resins and therefore require special devices when handling several thousand gramms such as for a bumper or IP. Sequential controlled system is the standard and proven method to control the plastic melt flow front and the weld line position in order to have superior part quality in medium-large part molding applications.

HRSflow has two advanced solutions for pin speed control in order to obtain a smooth fill and a stable molding process that result in an optimal surface quality and optimal balancing.

The first advanced solution is the new FLEXflow, powered by HRSflow, an electrically driven system to accurately adjust valve pins in aesthetical surface applications such as bumpers, instrument panels, door panels, and in general any large part that requires sequential cascade molding as well as quality optical parts whatever the size. It guarantees a completely independent management of each pin during the opening and closing stages by precisely controlling each valve pin's position, acceleration, velocity and stroke. The result is an optimal control of both the filling and packing time with a direct benefit on the part warpage too. The new electrical cylinder meets the requirements for high aesthetic quality, removing major defects such as flow marks, weld lines and flash on injection points.

FLEXflow also represents an ideal solution for the fine tuning of weld line position and when a complex filling pattern balance is required, even involving GF material where structural problems could arise. Moreover it meets the requirements of molding applications within a narrow process window and engineered material. The total absence of oil makes it suitable for clean rooms.

Summarizing, the new electrical cylinder has several benefits compared to conventional air/oil cylinders:

  • improved part-to-part consistency thanks to stable process repeatability;
  • optimized balancing, reducing over-packing and clamping force;
  • hydraulic connections are eliminated (no more oil leakage);
  • maximum flexibility in multicavity/family tool design;
  • reduced energy consumption;
  • accurate process control;
  • easy to use and easy maintenance.

The simpler troubleshooting solution offered is FLEXspeed, a device to avoid the generation of flowmarks by adjusting the oil flow of the hydraulic cylinder thanks to the ability to control the pin speed opening and closing. Indeed, the flowmark is due to the instability of the flow front in sequential systems, thereby creating an unaesthetic mark on the part. The initial opening speed of the valve pin is reduced to avoid  a drastic  pressure drop. The material flow speed can be regulated by means of a flow valve control in order to open the external pins slowly, thereby avoiding pressure loss. Ten different speeds can be set in order to optimize the result on the part. FLEXspeed can also be provided with directional valve control on the injection machine. This is the right solution for aesthetic applications such as embossed doors, un-embossed bumpers, luggage covers, embossed IP, internal pillars (L >50cm), unpainted door treads and unpainted side skirts.

These two speed processes enables us to improve the process efficiency and to obtain advanced quality parts.

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