I.D.milano Product Design - Hot-Runner Controller Case Study

HRS Flow

01 FIMER welder
02 TELSEY gateway
03 MOTOROLA cellphones
04 Hot Runner Controller
05 Telsey set top box

hot-runner, colin anderson, product design, design, pro/engineer, idmilano, product development

"I.D.milano Running Hot"
An Italian manufacturer of hot runner systems came to us when it was time to design their first integrated control system.

The Challenge
Our client for this project had years of experience creating hot runner gating systems for plastic injection moulding machines. They now wanted to complete their product offering with a modular, computer-based, system controller for up to 12 presses. There was a packaging challenge: an enormous number of large connectors, circuit breakers, system boards and heat sinks to place (and service) on a mobile platform. There was an ergonomic challenge: how to size the structure and how to place, orient and protect the touch-sensitive display. There was a cost challenge: how to design, develop, and manufacture a machine whose production volumes were unknown.

The Solution
I.D.milano adopted a practical, 2-pronged, hands-on approach. On the one hand, they used Pro/Engineer Wildfire to create a flexible assembly model that enabled their engineers to quickly evaluated multiple configurations for the most compact, service-friendly layout that would also cope with the machines considerable cooling requirements.

On the other hand, I.D.milano designers created a full scale mock-up using polystyrene and foam-core panels. The purpose was not to evaluate aesthetics, but to get a better understanding of human-factor issues and practical issues related to cabling and serviceablity.

After several iterations, the layout of the CAD model and the prototype converged to a single, optimized design.

The Result
The final design adopted a layered, symmetrical approach to component layout. At the centre of the machine there is a vertical cooling tunnel lined with large heat sinks. The heat-generating control circuitry is mounted on the other side of these sheet metal walls. A third layer is comprised of a myriad of circuit breakers that are mounted on hinged doors on either side of the machine. These can be locked for safety. All the connectors are mounted cleanly and out of side on the rear of the machine and the whole machine is wrapped in a cosmetic, easily-cleaned shell.

The monitor is hinged on the top of the machine with a large handle in front for easy positioning of the machine. Cosmetically, the designers wanted a machine that sits on a cast iron base and is clad in RIM panels. Due to uncertainty about potential orders, initial machines were produced in welded, painted sheet-metal.