To learn more, contact:Wayne WangEaton Corporation Fluid Power GroupHydraulics Operations 14615 Lone Oak Road Eden Prairie, Minnesota952-937-7207 WayneWWang@eaton.com

EatOn CORPORatiOn CUSTOMER FOCUS

New Eaton KHDG5V-10 Series Valve Elevated 3000-ton Injection Molding Machine Performance

"Eaton’s release of its new size 10 Vickers® KHDG5V valve came just in time for installation on a Lien Fa injection molding machine destined for a GM assembly facility. The solenoid-oper-ated KHDG5V-10 valve, featuring a tailored PQ spool design, is managing six criti-cal control functions that were handled by multiple valves on previous Lien Fa machines."

CustomerLien Fa Injection Machinery Company, Ltd.

Markets Served Automotive, Household, Consumer, Computer, and Communication Product Industries

Background Eaton proportional directional valves are being used in the production of front bumpers for a GM car model that is as-sembled in Argentina.

The bumpers are being pro-duced on a 3,000-ton injection molding machine made by Lien Fa Injection Machinery Company, Ltd. in Taichung, Taiwan. The massive machine is equipped with the newly released size 10 Eaton Vickers® KHDG5V two-stage proportional valve that controls clamping and injec-tion functions. Other Eaton products on the machine include Vickers DG5V direc-tional control valves, KCG-3 proportional relief valves, and slip-in cartridge valves.

VKS Hydraulics Company, Ltd, an Eaton distributor in Taiwan,

combined its expertise in elec-tro-hydraulic systems for injec-tion molding machines with the Eaton valves to supply just what Lien Fa needed.

ChallengeLien Fa has produced more than 2,000 injection molding machines for installation in 60 countries during its 30-year history. Realizing that the valve requirements for the bumper project were a tall order to fill, Lien Fa contacted VKS and competitive product sources to obtain bids on the business.

Ben Chen, VKS sales man-ager, and Jones Chang, Eaton sales manager in Taiwan, went into action to sort through the valve parameters. Since the machine would be produced in Taiwan but put to work in Ar-gentina, the end-user wanted

its injection molding machine to be equipped with hydrau-lic components that have global recognition and global distributor support. Knowing that Eaton products have just that, Chen and Chang checked the box.

Studying the internal working functions of the machine, they learned that the plasticizing process needed to be con-trolled precisely — a function that would require accurate, repeatable, and smooth transition from velocity into pressure regulation. They also learned that providing the means to move the machine’s 20-ton clamp would be a huge technical challenge. But that’s not all. The heavyweight clamp would need to move gingerly, quickly, and precisely in order to improve productiv-ity and reduce scrap.

Eaton Corporation is a diversified industrial manufacturer with 2006 sales of $12.4 billion. Eaton is a global leader in electrical systems and components for power quality, distribution and control; fluid power systems and services for industrial, mobile and aircraft equipment; intelligent truck drivetrain systems for safety and fuel economy; and automotive engine air management systems, powertrain solutions and specialty controls for performance, fuel economy and safety. Eaton has 62,000 employees and sells products to customers in more than 125 countries. For more information, visit www.eaton.com Doc. no. E-VLDi-MS003-E

a GM assembly plant is producing car bumpers with a Lien Fa injection molding machine, equipped with controls products from Eaton’s Hydraulics Operations.

newly released size 10 Eaton Vickers KHDG5V two-stage proportional valve controls clamping functions.

SolutionWith all the valve require-ments identified, Chen and Chang realized Eaton’s new KHDG5V-10 valve with a tailored Eaton amplifier card would be a perfect fit for the application. They explained in their proposal how the valve’s dynamic capabilities for closed-loop control on pressure, position, and veloc-ity would meet the machine’s demanding injection-control requirements, as well as how its 2C spool would achieve smooth clamping control.

The proposal also detailed how the solenoid-operated KHDG5V-10 valve, with its tailored PQ spool design, had the capability to control plas-ticizing, injection speed, hold-ing pressure, decompression, return, and suck-back pressure — critical control functions managed by multiple valves on previous Lien Fa machines.

ResultsWith strong faith in Eaton products and the electro-hydraulic expertise of VKS, Lien Fa handed the business

to VKS, which supplied the required valves within six weeks.

Lien Fa was pleased with VKS’ short lead-time and its onsite assistance during machine startup. The customer says the machine’s increased control resulting from simpli-fying valve requirements is a significant advancement, as are achievements of the Eaton valves that include:

110 mm per second injec-tion speed

0.1 percent weight accu-racy of injection volume, in comparison to the pre-vious 4 percent accuracy with a competitive valve

Smooth clamp movement with +/- 0.1 mm position-ing accuracy, in compari-son to the previous +/- 0.5 mm accuracy using a competitive valve

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a solenoid-operated Vickers KHDG5V-10 valve with a tailored PQ spool provides injection cylinder control.

"The customer says the machine’s increased control resulting from simplifying valve requirements is a significant advancement…"