Source | Barnes Molding Solutions
Barnes Molding Solutions highlights the automated hot runner solution, IntelliGate, from one of its umbrella companies, Synventive Molding Solutions. The IntelliGate hot runner functions to ensure the melt is transferred to the next nozzle at the optimal moment, as the shut-off needle detects where the melt front is located. This enables the respective nozzle to then open automatically.
When large parts are manufactured via injection molding, the cascade (a series of nozzles placed in the mold) is more often than not the method of choice. These nozzles open in a staggered sequence, enabling the melt to flow into the respective part of the component.
However, manually adjusting the control for this process proves to be a time-consuming task for the operator. The technician is left to determine the best moment to open the next nozzle through a series of tests and partial fillings, as the flow front inside the mold cannot be observed.
Utilizing Barnes’ IntelliGate solution, operators can automatically detect the position of the flow front. A sensor element — integrated directly into the shut-off needle — detects the rise in temperature that occurs near the mold wall when the melt passes by. These “intelligent” hot runner needles can be produced up to 1,000 mm in length.
The fully wired, plug-and-play technology, enables the entire cascade to be integrated within the hot runner (including a connector box), eliminating the need for a separate controller. However, this has not changed the footprint of the new hot runner, making it possible to retrofit existing Synventive systems with this technology.
Additionally, the IntelliGate hot runner reacts automatically when the viscosity of the molding material changes, affecting the flow speed. The process stabilizes again in about seven shots — all without operator intervention or correction. This solution offers both time and cost savings for moldmakers in the long run.
