Tailor-made mixing and dispensing systems!
Mixing head, material preparation, process control and automation layout, individually configured
Product life cycles which become ever shorter lead to new forms of construction and designs of various industrial components. Thus, dispensing systems and automation solutions that can be flexibly adapted to every requirement are in high demand. Our core competence therefore includes developing, consulting and selling of the appropriate technology for a particular situation, regardless of whether you want to operate a Sonderhoff Engineering system as a stand-alone unit or to integrate it into a complex production line.
System solutions are developed and implemented in close collaboration with material suppliers and our customers – always based on the latest safety standards, technical performance and environmental compatibility. Our highly specialised engineers ensure this.
Our mixing and dispensing systems – for the application of polyurethane, silicone and other reactive substances – consist essentially of three modules: the mixing head, the material preparation and process control and automation. Therefore, there are numerous different equipment options that allow you to tailor the system layout to your own production process.
We differentiate between two technologies: the classic low pressure technology for mixed-cell polyurethane foam, and the newly developed medium pressure technology 2K CC for closed-cell polyurethane foam, which distinguishes itself through the most minimal level of water absorption – get in touch!
The six basic system types:
The DM 402/403 is a 2- or multi-component high-performance low pressure semi- or fullyautomatic mixing and dosing system for gasket, gluing and potting applications of different types of parts. The DM 402/403 precisely processes liquid, medium to high viscose media such as polyurethane, silicones, epoxy resins and other polymer reaction substances.
SMART-M und L
The SMART is a 2-component dispensing cell for semi- or fully-automatic use for gasketing, gluing and potting the widest range of parts. The system enables high-precision processing of liquid, medium and high viscosity polymers, such as polyurethane, silicone, epoxy resin or other polymer reactive substances. The dispensing cell is available in two sizes: SMART-M und SMART-L.
Dispensing cell 3E
The new dispensing cell 3E – Economic, Efficient, Ecological – is a 2-component low-pressure mixing and dispensing system for use in partly automated production for foam sealing, gluing and potting. The dispensing cell 3E is designed as an entry-level model for standard uses and is economical even in small batch sizes. An immediate production start is possible. Set-up, plug in, produce!
DM 402 CC
The new medium pressure mixing and dispensing system DM 402 CC for the dispensing of foam seals made of closed-cell polyurethane foam is a world first. It combines the advantages of the 1- and 2-component sealing technology. The closed-cell polyurethane foam FERMAPOR® CC distinguishes itself through the lowest possible water absorption and is a cost-effective alternative to single component polyurethane foam.
The DM 50 and DM 70 are 1 or 2-component mixing and dispensing systems for use in manual production. The mixing of the materials to be used can be achieved through a static mixing head (MK 20) or a dynamic one (MK 50) All parts are housed on a moveable chassis. The DM 50 and DM 70 allow the manual application of different material by means of a hand applicator.
Plants with 6-axis robots
In systems with 6-axis robots the robot armature picks up the part and moves it according to design under the fixed mixing head. The material is thus applied seamlessly from the start to finish. With high material viscosity, upside-down applications are also possible. For Sonderhoff-developed MOLD’N’SEAL inline production, dispensing systems and 6-axis robots are combined with an injection moulding system.
The components of the mixing and dispensing system
The combination possibilities are what make it so versatile
The dynamic mixing head
Small may be the mixing head in comparison to the total system, but its importance for the result is huge. Our mixing heads contain numerous patented technologies ensuring outstanding homogenisation of the material components, exact dispensing quantity control and the greatest possible process regularity. The specially designed agitator design ensures gentle mixing even after few rotations. Thus, in dynamic mixing, only little reaction energy need be imparted through friction. This leads to fewer rinsing spurts and lower material waste.
The precise nozzle closing system “Stop-Drop DVS-3” in the mixing head ensures an exact, almost invisible join at the ends of the continuous stream of foam. The patented high-pressure water rinsing process in the mixing chamber makes Sonderhoff mixing heads additionally reliable.
For the low-pressure process we offer numerous different mixing head types.
Material preparation and process control
Further core parts of a mixing and dispensing system are the material preparation and the process control that belongs to it. Here are not only system and process parameters determined but also all process data recorded. For the true art lies in the preparation and controlled supply of the material systems. Our systems are as much suitable for the application of foam seals as for potting and glues, and can even be configured so that a combination of these applications can be achieved by a single machine! For example, a filter is framed with a foam seal and the filter-packet coated with potting.
And in order to optimise the result, according to the requirements of the application, further technologies are methods for material conditioning can be brought to bear, such as recirculation, nucleation, tempering or thin-film degasification.
NEW: Next to the long-standing low-pressure process for foams with mixed-cell structure, we now offer you our patented medium-pressure process FIP CC, which produces almost closed-cell foam!
Other equipment options
Every application is different, and thus every production process has its own requirements. To react flexibly to these and offer an optimal system layout, other equipment options are available, such as:
One- and two-level shuttle table
Automatic refill station
The special advantage of our technologies lies in the possibility of automating the application process, either as an isolated solution or inline. The basis for this is the very precise CNC-controlled linear robot. With this, the highest possible reproducibility of the mixing head positioning over the part is achieved. Additionally, the dispensing system can be adjusted to the timing cycle of your production. Sonderhoff offers you the following variety of system concepts:
• 3-axis linear robot on steel profile base framework
• 3-axis robots in a dispensing cell
• mixing head processing unit
• 6-axis robots on base plate, combined with a dispensing system
• dispensing machine and 6-axis robots combined with injection moulding system (MOLD’N’SEAL inline production)
Either the processing unit of the linear robot moves the mixing head precisely over the part, or a 6-axis robot lifts the part and holds it under the fixed mixing head. With 3-axis linear robots a processing area for the mixing and dispensing head of up to X/Y/Z 3,000 x 1,000 x 500 mm is achievable. With the implementation of 6-axis robots, there are practically no limits, and with the use of material systems of a suitable viscosity, even upside-down application is possible.