ENGEL Integration

ENGEL Integration

Ultrasonic sensors integrated directly into ENGEL control unit

From process monitoring to active control

The ultrasound-based sensor technology from Moldsonics offers us completely new possibilities for analyzing cyclical processes in our filling processes and thus improving our tools.

Lukas WAGNER

Head of Advanced Simulations, Haidlmair GmbH

The challenge

Recycling materials often exhibit strongly fluctuating flow behavior. Until now, the sensors could only be integrated via external devices such as separate monitors, making direct intervention in the process virtually impossible.

Solution

Thanks to the ENGEL interface, the Moldsonics sensor technology is now directly integrated into the CC300 from ENGEL - for process monitoring and active control, e.g. when switching from injection to holding pressure or when controlling the cooling time.

Result

  • Simple attachment of a self-regulating process
  • Cyclical recording of quality parameters
  • Cycle time savings and scrap minimization

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Moldsonics GmbH
Hafenstraße 47-51
4020 Linz, Austria

info@moldsonics.at

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ENGEL & Zechmayer PUR

ENGEL & Zechmayer PUR

Ultrasonic sensors for high-precision POLYURETHAN flow front detection

Inline congealing analysis with Moldsonics ultrasonic technology

With Moldsonics sensor technology, it is possible for the first time to detect the PUR flow front without contact - a real benefit for our customers in terms of process reliability and surface quality.
Clemens Kastner

Head of Business Development Automotive & Mobility, ENGEL AUSTRIA GmbH

Screenshot 2025 10 09 154322 Moldsonics Ultraschallsensorik

The challenge

During PUR flooding, the flow front moves very quickly and is difficult to detect reliably. At the same time, no sensor imprints may occur on visible components - a combination that pushes conventional measuring methods to their limits.

Solution

The MoldFront sensor system detects the PUR flow front without contact and enables the venting needle to be closed precisely - for maximum process reliability and a flawless visible surface.

Result

none

Sensor imprints

< 5ms

Detection time

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Moldsonics GmbH
Hafenstraße 47-51
4020 Linz, Austria

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Ottronic Duroplast

Ottronic Duroplast

Contactless detection of thermosets

Hochdynamische Fließfrontdetektion beim Umspritzen von Elektronikkomponenten

Die Implementierung der Moldsonics-Sensorik hat unsere Prozesspräzision deutlich verbessert. Dank der berührungslosen Messung und der sofortigen Signalausgabe können wir den Duroplast-Spritzguss optimal steuern und die Qualität unserer Produkte sichern – ganz ohne Neuzertifizierung.

Mario Gschwandl

Geschäftsfeldleiter Technologie, Ottronic E-Systems GmbH

Ottronic Logo scaled Moldsonics Ultraschallsensorik

The challenge

Für die zuverlässige Verkapselung sensibler Elektronik musste die Fließfront der Duroplast-Schmelze präzise erkannt werden – trotz hoher Temperaturen und strengster Qualitätsanforderungen.

Solution

Die MoldFront-Sensorik von Moldsonics ermöglichte eine hochdynamische, berührungslose Fließfrontdetektion bis 160 °C – für exakte Umschaltpunkte und nahtlose Integration in bestehende Anlagen.

Result

  • Berührungslose Messung
  • Nahtlose Integration
  • Weniger Ausfallzeiten – automatische Abschaltung der Vakuumpumpe verhindert eine Beschädigung

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Moldsonics GmbH
Hafenstraße 47-51
4020 Linz, Austria

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Smart Plastify

Smart Plastify

Inline visualization of the melting process thanks to ultrasonic sensor technology from Moldsonics

validated on the internally heated screw from Smart Plastify

Bei der Entwicklung einer neuartigen Heiztechnologie konnten wir das Konzept unser innenbeheizten Plastifizierschnecke zum ersten Mal im Detail analysieren – mit direkt im Materialstrom erfassten Prozessdaten, ohne modellbasierte Annahmen. Moldsonics liefert die Daten, auf die wir gewartet haben.

Sebastian PÜTTER

Gründer und Geschäftsführer, Smart Plastify GmbH

Smart Plastify Logo Moldsonics Ultraschallsensorik

The challenge

The melting of plastic granulate in the screw cylinder was previously invisible - no data, no possibility for inline validation of new heating concepts.

Solution

Moldsonic's ultrasonic sensors made the real melting process visible inline for the first time, validated Smart Plastify's internally heated screw and provided practical data.

Result

  • Precise monitoring of the melting behavior
  • Visualization of solid and molten areas in the screw channel
  • Optimal process control with simultaneous energy savings

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Moldsonics GmbH
Hafenstraße 47-51
4020 Linz, Austria

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EREMA

EREMA

How EREMA realized inline wear measurement with Moldsonics

COOPERATION FOR INTELLIGENT RECYCLING

Bild: ENGEL Austria

The solution (hardware and software) developed together with Moldsonics enables our customers for the first time to monitor screw and barrel wear conditions continuously and in real time, visualize them in BluPort® and derive maintenance recommendations.

Dr. Michael Aigner

Head of Process Engineering and Product Development , Erema GmbH

Logo Erema Moldsonics Ultraschallsensorik

The challenge

Extruder screws wear out invisibly. The consequences are unplanned downtimes, long delivery times for spare parts and reduced process efficiency.

Solution

In close cooperation with EREMA, a non-contact inline wear measurement system based on ultrasound was developed. Three sensors continuously monitor the condition of the barrel and screw. The results are displayed on the machine HMI via a traffic light system and visualized in detail in the EREMA BluPort® portal.

Result

24/7

Condition monitoring

± 0,05

Milimeter Accuracy

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Logo Moldsonics

Moldsonics GmbH
Hafenstraße 47-51
4020 Linz, Austria

info@moldsonics.at

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