Final Report Summary - SONO”R”US (Machine for Microparts Moulding based on UltraSound excitation)
Executive Summary:
Under the umbrella of the SONO”R”US Project, it has been developed the first commercial moulding machine based on ultrasounds, called SONORUS 1G.This new technology brings to the market a flexible, reliable and cost efficient solution for producing complex micro-parts
Within SONO”R”US project, SONORUS 1G went through an industrialisation process which led to its validations and market launch. Moreover, several enhancements have been made to fulfil market needs as well as improving market uptake.
As a result, experts within the project have integrated into SONORUS 1G a variety of control options for the automation of the process and optimisation of a wide range of product needs. Today the machine is using the latest and greatest software routines to deliver plastic parts with high precision and performance. It also uses protected close-loop sequences that ensure the correct plastic moulding conditions. Finally, SONORUS 1G has improved its existing connectivity options in order to monitor accurately the traceability of the process.
SONORUS 1G is highly reliable and energy efficient – up to 90 times lower power consumption compared with traditional injection moulding technology-. Since no electrical heaters are needed, the process is highly energy efficient while putting the thermoplastics under a much lower risk of degradation, being ideal for production in white rooms and labs. Additionally, our low stress process involves a reduction in tooling costs estimated between 25% and 35%.
In the early 2012, a Beta Tester programme was carried out according to SONO”R”US Project plan with the aim of integrating added-value improvements to make SONORUS 1G machine more competitive. One of the main purposes of the pilot test was to collect information and advice from participants (industrial companies, universities, labs).
The Beta Tester programme gave us the chance to explore the potential markets. For instance, medical is now one of the targeted markets because plastic micro and mini parts are required with high precision and material no degradation such as catheters parts, hearing aid devices components, and dental applications. Our new revolutionary manufacturing technique has proved efficient and potential medical companies have already expressed their interest in acquiring the machine. Another example is the electronics industry, especially when it comes to overmoulding of micro-component parts. This has also resulted in another significant target market since our ultrasounds-based manufacturing process entails an important reduction in raw material consumption (no degradation, no waste in purging barrels, smaller sprues and runner systems…) which leads to saving costs.
SONO'R'US project has been co-funded by the European Union’s Seventh Framework Programme (FP7) – under the "Research for SME-Demonstration actions", managed by REA-Research Executive Agency, allowing the redefinition of the key features of the prototype developed under the SONOPLAST project (FP7).
The project, with a two-year duration (2011-2012), comprised the following partners: Ultrasion (Spanish company that commercialises industrial solutions based on high power ultrasounds) Mateu y Solé (Spanish manufacturer of plastic moulding equipment) Promolding (Dutch company specialised in injection moulding process) Cedrat (French company specialised in Ultrasounds technology development) and Ascamm (Spanish Industrial Technology Centre specialised in production of innovative industrial technologies).
Project Context and Objectives:
SONO“R”US Objective:
• The aim of the SONO“R”US project is the improvement, optimization and industrial implementation of a pre-commercial moulding machine for the production of plastic parts in the micro and mini scale size, allowing the redefinition of the key features of the prototype developed under the SONOPLAST project.
• Once the technical improvements are implemented, the new machine is tested in a real industrial environment. In addition to the technical developments, and as a parallel issue, a study on some possible new markets is carried out. The goal here is to assure that the solutions fully comply with all the requirements of the identified key-sectors.
In order to achieve the expected results, the structure of the work plan has been focused on:
1. Optimization of the prototype/machine by using technical criteria and relevant data parameters analysis.
2. Development of a pre-commercial machine: developing of 2 pre-commercial Machines (Machine1 & Machine 2) for reaching a complete validation of the technology, guarantying a proper introduction to the market.
3. Validation of the first machine (Machine 1) for an expert industrial laboratory.
4. With the best options (technical/cost analysis) from Machine 1 tests, Machine 2 fulfils the necessary requirements to be tested in industrial conditions at full capacity.
Other objectives
• By optimizing the cycle´s time the machine, it will be able to compete with the current technology in which the cost efficiency per produced piece is too low, due to elevated production volumes in considerably reduced times.
• Control system optimization, to find out and solve bugs and errors, also aiming to improve repeatability and general machine performance
• Scale up studies, aiming to test as much as case as possible, readapting the machines used in validation phase.
• Pilot demonstrations: Implementation of the Beta tester program, aiming to integrate value-added improvements to make the SONORUS machine more competitive through the knowledge obtained in the pilot demos.
Project Results:
Work Performed and Results Achieved:
During the SONO”R”US project, four main activities have been carried out and in which the following results were obtained:
A. Mechanical optimization and external units coupling:
• Mechanical and physical enhancement and integration of different external units to the machine´s frame.
• Redesign of the main framework.
• Recalculation of machine structure, forces and improvement of the system guidance.
• New feeding system with higher accuracy, and with an easy access for cleaning, adjustment and material exchange.
• Redesigned of the ejection system.
• Mold reconfiguration, adapted for a correct molding process.
• Pick & place system with pneumatic grip or suction system and fully integrate with B&R control.
• Integration of double safety system, one that prevent automatic machine operation while door is open and other that allow working with the machine cover open in manual mode (to avoid the opening and closing of the cover each time)
B. Develop of an enhanced control system:
• Improvement of the control system, mainly focus on the development of new control strategies and the optimization of the cycle´s time, repeatability, flexibility and performance.
• One of the main innovations is the control by velocity, which ensures an accurate pressure profile to cope with material requirements.
• Along with the velocity profile it is possible to introduce amplitude values for the ultrasonic vibration.
• New HMI interface (Human Module Interface) that permits the user to adjust the machine in real time and that incorporate a process trend window (tool to analyzed data from the process)
• Information can be retrieved by an FTP connection (File Transfer Protocol) that allows storing data cycle by cycle in a main server for later analysis and quality control.
• Final version of the software also includes a data base to store variables, material properties and setting for every mould tested.
C. Machine testing within an industrial environment:
• The lab machine (machine 1) and the pre-industrial machine (machine 2) have been exhaustively tested in different partner facilities and during de Beta tester program, in real working conditions.
• The pre-industrial machine validation was done according to a predefined check list
• As result of the different tests it has been designed the Full industrial machine (SONORUS 1G)
D. Adaptation of the machine for customization in potential fields:
• It was carried out a technological feasibility study to evaluate the introduction of the technology into new markets.
• Several applications were proposed base on the effect of the ultrasound effect on a given media (material). The field of application goes from the sonochemistry to the cleaning process.
• The machine has been modified to accomplish C.E. mark, to be safe and fast, and also has been improved to ensure the stability of the molding process, optimizing the sonotrode movement, the feeding system and the control system.
During the SONO"R"US project hit has been developed a lab-machine, an Industrial Machine, and a Final Machine, called SONORUS 1G. The Lab machine has been used to study the technology, aiming to improve the design for the future industrial version. The experience accumulated with lab machine performance, has been used to design the Industrial machine, used to study the technology in an industrial environment, aiming to improve the design of the Commercial Machine. Eventually, the final machine (SONORUS 1G) has been built to accomplish C.E. norms, to be safe and fast and also has been improved to ensure the stability of the molding process, optimizing the sonotrode movement, the feeding system and the control system, in order to have a product suitable for the market.
Potential Impact:
Potential socio-economic Impact:
The project has an impact in economically strategic areas like biomedicine, electronics, optics, precision engineering, automotive industry, etc. due to an increasing trend in miniaturization. Ultrasound is a highly accurate and efficient technology that can be applied with great accuracy and immediate results. It is also clean, safe and completely efficient (90 times less energy consumption compared to traditional processes) and it has been proved the feasibility of merging material using ultrasonic vibration for energy.
Main dissemination activities:
In general, the following comprehensive dissemination channels were explored: each partner's personal and professional contacts; presentations; Conferences; Project web site; Workshops; Journal articles; Press release; Involvement in networks; participation in Seminars and Trade fairs; visibility on Web portals; among others.
This are the main dissemination activities performed, and with major impact:
• Beta tester program: The aim was to integrate value-added improvements to make SONORUS machine more competitive through the knowledge obtained in the pilot demos. The programme was addressed to a small group, as we seek improvement from organisations that can generate knowledge from which we can learn. In the end, eighteen candidates apply for entering in the Beta tester programme, most of them came from the medical, automotive, electronics and micro mechanics sector. Candidates pursued high precision moulding by using high technical materials.
• Fairs: Presentation of SONORUS machine in more important specific fairs in the world
14-18th November 2011 (Barcelona) - EQUIPLAST 2011 Trade fair represented the best scenario to carry out the monitoring of the SONO”R”US project. All consortium partners assisted and had the opportunity to chat with visitors, explain the project and show the SONO”R”US machine, as well.
01 – 04 April 2012 (Orlando - Florida) - NPE 2012: In 2012, SONO”R”US was been presented in the the most important International Plastics Exhibition in the USA in which 1,830 companies offer their latest products and technologies for a wide range of sectors ( more than 60,000 visitors). More than 160 organisations showed real interest for Sonorus machine which most of them (80% of total) came from the medical sector.
26 – 28 February 2013 (Stuttgart - Germany) - Südtec / Medtec show: Ultrasion participated in the Medtec show which is targeted to medical devices. This event received 35,000 visitors. Promolding also were present in the event.
June 2012 (Bremen - Germany) - 7th International Exhibition on Smart Actuators and Drive Systems: Cedrat attended to the 13th International Conference on New Actuators is the most important market place to meet leading international specialists, to share their expertise and to start business co-operations in the field of new actuator technologies. There were about 500 participants from more than 30 countries. The range of topics also included measurement techniques, control concepts and circuits, driver components and units, system integration, layout and simulation tools etc. Cedrat got 40 contacts that were interested in usmTM.
11 - 14 February 2012 (Anaheim, USA)- MD&M (Medical Design & Manufactuting): Cedrat attended to MD&M, world’s largest medtech design and manufacturing event and connect to the inspiration, partnerships, education and technologies that drive medical device innovation.
4 - 5 April 2012 (Lyon, France): MEDTEC France: Cedrat attended to MEDTEC France 2012. The innovative concept of this conference and exhibition is that it offers medical device manufacturers a user-friendly platform to develop quality contacts, discover solutions and suppliers who can address their development problem
April 2012 (Hannover Messe): Exhibition (HMI) für Industrie: Wide spectrum – a lot of innovation and R&D managers from various industries (machine-tool, medical, airspace…). 230,000 visitors.
- Dissemination material was updated truth lifetime of the project.
- All the dissemination material underlined that Sono”r”us project has received funding from the European Union's Seventh Framework Programme managed by REA-Research Executive Agency FP7/2007-2013 under grant agreement n° 286552.
List of Websites:
Other information:
Project Public Website:
www.sonorusproject.eu
Contact Person (Project Coordinator):
Mr. Francisco Javier Portal Solé
Sonorus@mateusole.com
Mateu y Solé, S.A. Potosí, 7 bis, int.- 08030 ( Barcelona ),
Spain. Tel. (34) 93 274 55 00 - (34) 93 345 55 00
Fax (34) 93 345 56 04
