Kistler Instruments Ltd. - PRODUCT NEWS
Cut Time - Cut Waste -Cut Costs
The new Kistler Stasa QC software for injection moulding requires significantly fewer physical trials to increase process stability and part quality whilst optimizing cycle and set-up times.
With the help of a statistical Design of Experiments (DoE), it systematically determines the effect of relevant machine parameters on part quality and optimizes the operating point, taking into account all optimization targets. A stabilized process, high part quality and short cycle times translate into higher output rates and significant savings.
The system uses sophisticated D-Optimal Design based algorithms to dramatically reduce the time and cost of setting up an injection moulding machine for optimal product quality combined with the shortest cycle time. The traditional, trial and error method, which involves adjusting one parameter at a time in a series of practical on-machine tests, expensive in terms of both time and material wastage, is replaced by a systematic approach to DoE using PC based simulation to determine the best machine settings. The system derived experiments are then run on the moulding machine to determine the practical results. Any combination of attributive and continuous data results is then fed back into the Stasa QC system to produce a comprehensive model of the process. This is model is then run in simulation and optimised before being tested on a machine. In this way, the amount of machine time needed to determine the optimal machine settings is reduced dramatically.
The primary advantage of using the Stasa QC process simulation and visualization is that running the initial tests on a PC allow a wide range of parameters to be changed interactively by clicking and dragging with the mouse. The effects of the changes and the significance of each parameter on each quality feature are shown on-screen immediately without the need to run empirical experiments, saving time and materials. The Stasa QC software offers a very cost-effective alternative to the costly and time consuming conventional method.
From the beginning of the machine setting process, the software uses a systematic, scientifically corroborated and objective approach to optimizing the operating point to improve the process quality and cycle time. No other machine setting other than the best operating point can achieve the best combination of high quality and short cycle times. Stasa QC can determine this best operating point not only during machine setting but also during production.
Using innovative data-based modelling methods, Stasa QC identifies the precise correlation between machine settings and part quality enabling the software to determine the ideal, "centred process" at the click of a mouse taking into account statistical fluctuations of part dimensions. The best machinery operating point is that which gives the largest process window and the shortest cycle time to achieve maximum production and minimum defective parts.
The integrated data storage and report generator provide end-to-end documentation of the setting procedure and all optimization results providing process clarity for the factory floor, management and customer.
New Kistler Stasa QC software offers lower overall production costs, with shorter cycle times, fewer defective parts, faster production start-up and fewer experiments. The result is a more stable and minimum defect production with fewer in-process adjustments. The end result is a uniform process setting approach on the factory floor, especially important during large-scale production plus more readily available, accurate process information, with fully reproducible and recordable results.
Established in Winterthur (Switzerland) in 1957, the Kistler Group now has a worldwide presence with 25 group companies and 30 distributors ensuring prompt, local application support and short delivery times. With a staff of more than 1050, the Kistler Group is one of the world's leading providers of dynamic measuring instrumentation with a turnover of 210 million Swiss Francs (GBP 145M) in the 2010 financial year.
Kistler's core competence is the development, production and use of sensors for measuring pressure, force and acceleration. Kistler's know-how and electronic systems can be used to prepare measuring signals for use in analysing physical processes, controlling and optimising industrial processes, improving product quality in manufacturing and improving performance in sports and rehabilitation.
Kistler offers a comprehensive range of sensors and systems for engine development, automotive engineering, plastics and metal processing, installation technology and biomechanics.
Heavy investment in research and development, 15% of staff worldwide are engaged in research and development, has generated a number of innovations using piezoelectric, piezoresistive and capacitive techniques to provide solutions to numerous force, pressure and acceleration measuring problems. These innovations include the world's first commercial quartz sensor, two-wire constant current technology to integrate sensors with microelectronic circuitry, high-temperature pressure sensors for use up to 400 Deg C and three-component force measuring sensors.
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