Engel improves operator ergonomics, thus boosting productivity
Injection moulding machines that you can talk to are still science fiction, but as human-machine interaction continues to grow closer, communication is becoming increasingly easy. Intuitive control logic plays an important role here, such as the next generation CC 200 machine control unit recently presented by Engel. Another important step to shortening the man-machine divide is that of extending control logic by optimising operator ergonomics.
The extension module portfolio for modern injection moulding machines is continually being adapted and extended to reflect the individual application technology requirements placed on it. However, operational complexity seems to grow in parallel to the growth of the hardware and software module range. This makes it all the more important to keep the man-machine interface as simple as possible despite a wider choice of options.
This requirement has found its way into the manufacturer`s specifications document as an intuitively logical control system with a simplified user interface. Engel fulfils this requirement with the next generation type CC 200 control unit by integrating familiar controls from the world of the PC, sequence programming that relies on pre-programmed program sequences and touch screen based input options throughout its full machine range from small to large scale machines.
The latest evolutionary step, the CC 200 machine control unit, sees Engel taking a further step. Whereas previous development stages have focused almost entirely on software development and process controls, the last stage of development has concentrated on improving ergonomics. One further objective of the design project was that of giving the operator terminal a more prominent position within the complete system, the "injection moulding machine".
Whereas product preparation overheads on earlier machine generations concerned fitting and setting up the injection mould or plasticising unit for the main part, today's biggest overhead is automation of the injection mould and its environment. Besides this, the trend towards multiple-component injection moulding has also meant a paradigm shift in operator activities. Programming of move sequences, such as core-pull sequences, or the integration of robot movements into the injection moulding cycle demand more of the operator than simple setting up of injection moulding cycles.
To be able to handle these tasks in the best possible way, a package of accompanying measures has been implemented. On the one hand, the ENGEL Training Centre has added new course modules, on the other hand, the user interface and control panel have been optimised. On top of this, a decision was made to shift the terminal closer to the operator and to invite the operator to communicate with the machine. The aim was to facilitate controls as a whole, thus reducing error rates. This meant giving ergonomic aspects priority over aspects of mechanical engineering functionality. The task of implementing this project was assigned to Peschke Design from Vienna.
One major factor in the specifications document was that of improving control safety. This included both a logical, and at the same time convenient, layout of critical controls, and a clear, at-a-glance arrangement. To facilitate working at the control panel with the operator's sights firmly fixed on the control elements, the screen, the injection mould or other machine components, the elements were arranged in line with the sequence hierarchy and frequency of use. To make it as easy as possible for users to move to the new system, most pictograms and the layout of the traditional logic of earlier generations of control units was kept.
Easy identification of functions is just as essential to easy operations as the ability to customise the operating situation to the size of the operating staff. To ensure a relaxed working position for the operator the ability to adjust the whole terminal was important. Measures for reducing interference from light effects (dazzling, mirroring) were a further important design criterion.
The results are impressive. The new control panel not only offers easier and
more intuitive programming of machine functions, but reduces the physical load
on the operator thanks to its ergonomic design which more closely reflects the human physique. The results are a measurable boost in productivity, less accidents and sick leave, as well as less operator errors. The ability to visualise quality is another useful effect. Design and ergonomics communicate quality in a universal language that does not need any further explanation. An important step towards improving human/machine communications has been taken, and work on further steps is in progress.