HEILBRONN-headquartered Kaco, a leading global manufacturer of high precision, application-oriented sealing solutions for the automotive, engine and machinery industries, establishes a new production line in China for transmission components. These components are resistant to temperatures of about 150 °C and also to particularised media, so that functionality is guaranteed throughout the life cycle of the vehicle, says Kaco.
It describes the measurement of the outer diameter as between 100-300 mm. It adds that the company deals with rubber-metal compounds and multiple injections of different materials and / or other inlay components.
“The requirements for the products to be manufactured were not possible using commercially available elastomer machines, ” says Kaco, expounding that the range of very different diameters added demands to the high process reliability and performance, and the combination of 1K parts and 2K parts of a machine. With these challenges, Kaco relies on Maplan’s specially configured MTF200HF200/320editionS with PC5000touch control from its factory’s construction kit.
The MTF200HF200/320editionS consists of an overhead injection unit with 200 ccm and a horizontally arranged FIFO injection aggregate also with a volume of 200 ccm and an injection pressure of 2,500 bar. The clamping force is 3,200 kN. The tool engineering from Kaco used on this machine is based on the so-called “Fast Double Shuttle”. The particularly rapid shuttle is possible through parallel hydraulic movements of the machine, which can save up to 10% of the cycle time according to the manufacturer’s data. Perfection as a must-have, as Simon Kayser, Director of Technology Projects and New Methods, said, “is an absolutely dimensionally stable sealing which is enormously important for perfect sealing function. Very narrow tolerances belong to precision. ”
The real highlight of the machine results from the tool engineering from Kaco in conjunction with clean injection of the Maplan injection units. “The cold runner,” said Kayser, “helps to optimally distribute the rubber and saves material.” Clean injection into the cold runner is provided by the MTF200HF200/320editionS with a movable horizontal injection unit. “The unit drives without lifting. This allows a clean splashing in a fast cycle,” Kayser said. The injection unit compresses the material during injection in the cold runner. Due to the contact pressure, the rubber then can sufficiently relieve tension again in the direction of the injection unit. In addition, the cold runner remains free of contamination – there is no “old rubber” in the cold runner.
Meanwhile, Kaco has developed the Fred radial shaft sealing rings, in response to client demand for sealing with higher efficiency and functionality. Kayser said that the said sealing rings minimoise friction losses. “Our piston actuator for dual clutches and automatic transmission consumes less and provides greater comfort in mobility. Our plasma-activated PTFE seals are a new approach to sustainable manufacturing solutions with high functionality.”
Kayser also added that Kaco developed the world’s first and only noise-free mechanical seal specifically for water pumps.