The DM 502 / DM 503 / DM 504

The New Generation of Dosing Machines for Maximum Process Stability and Reliability

To optimally design a manufacturing process, component processing, automation and control must be optimally coordinated with one another. This requires a lot of experience and the highest level of precision in detail. With our DM 50x dosing equipment portfolio, we offer automation solutions for the mixing and dosing of 2-component reactive materials – especially polyurethanes, silicones, and epoxy systems.

For this, the dosing components must be prepared, i.e., stirred in the tank and loaded with air, and then conveyed to the mixing head. In the mixing head, the material components are then mixed dynamically, and the liquid sealant system is dosed in precise quantities.

Each of the process steps involved has its own specific requirements that shows how good a machine it is. Our experience acquired over decades of machine development makes the difference and ensures the reliability of our mixing & dosing machines.

The DM 50x - Automated System Solutions for Advanced Material Dosing

The sensors installed in the DM 502 dosing machine and the MK 825 PRO precision mixing head, for example, measure a wide range of data for the seamless monitoring of and compliance with critical process parameters, e. g. temperature, degree of air loading, sensor-monitored axial position of the agitator shaft, automatic control of stroke adjustment in the nozzle shut-off system DVS 3, and sensor-monitored needle positioning of the dosing valve.

This provides the machine operator with a comprehensive database on the entire FIP (Formed-In-Place) application process. This enables fast and precise data analysis for optimized process evaluation and control, as well as predictive monitoring of the material application processes and the preventive maintenance of wearing parts.

In addition to improved evaluation options, the new mixing head achieves outstanding dosing and process quality for even better results. In order to ensure an optimal application process at all times and higher machine availability, important machine parameters can be made measurable by integrated sensors on the new DM 502 dosing machine and the MK 825 PRO precision mixing head.

This makes the DM 50x machine generation the modular and flexibly configurable platform for implementing individual and simultaneously efficient, highly productive, highly reliable and correspondingly economical manufacturing solutions for simple to complex requirements.

Mixing and Dosing

A mixing and dosing system can be as precise as you want it to be, however, the components must be able to implement the target values. These include:

Material Pressure Tanks
Dosing Machine Cabinets
MK 800 Mixing Heads
Refilling Stations
Optional Extensions

Installing high quality machine components ensures that production quality levels can be achieved, and includes the material pressure-stabilizing recirculation system, a sophisticated mixing head cooling system, temperature-controlled, double-walled material pressure tanks , the NOZZLE-CONTROL for the automatic calibration of the dosing nozzle and much more.

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Material Pressure Tanks

Material preparation begins with stirring. Depending on the material system, it may be necessary to load the A component with air, for example, to obtain a fine-cell foam, or the opposite – to degas it for bubble-free clear potting. The agitator function is not only used to counteract sedimentation, but also ensures uniform air loading or degassing, and temperature distribution. For an optimal degassing process there is also the option of thin-layer degassing. This takes place in the material pressure tanks.

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Dosing Machine Cabinets

Accurate dosing can be achieved thanks to the precision gear pumps installed in our dosing machine cabinets that keep material flowing at a constant rate with our recirculation principle, even in the case of long hose routes where the material comes to a standstill after dosing and must be set in motion again for the next dosing step. Additionally, automatic refilling stations ensure material-specific preparation, homogeneous consistency, and a continuous supply of materials to the component containers of the mixing and dosing system – without exposure or contamination of the products to be filled.

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MK 800 Mixing Heads

Our MK 800 dynamic mixing heads are used for low-pressure mixing and dosing systems for the application of sealing foams, adhesives and potting compounds based on polyurethane or silicone. They are required to reliably process highly complex, liquid to highly viscous, polymer reaction materials that are required for many industrial applications. The performance of these dynamic mixing heads exceeds the capabilities of static mixers. Depending on the mixing head, discharge rates from 0.05 to 100 g/s are possible. The mixing ratio is continuously adjustable from 100:1 to 1:100.

Furthermore, this is all possible with an extremely high dosing accuracy of ±1 % of the quantity to be applied. These values can vary depending on the mixing ratios, material viscosity, and the adaptation of pumps, hoses, and mixing elements. Properties such as reactivity and abrasiveness of the material also play a major role here. The greatest possible level of material homogeneity after mixing 2-component material systems with different viscosities – even in the case of demanding, asymmetrical mixing ratios – can only be achieved with dynamic mixing.

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MK 800 Mixing Head with Stub Line for Dynamic Mixing

The MK 800 with stub line is available for dosing highly viscous, pasty 2-component material systems. This feeds the pasty A-component from the material pressure tank of the dosing system or directly from the automatic drum pumping station for containers with 30 to 200 liters via a stub line to the mixing head. The dosing valve at the end of the stub line regulates the quantity metered into the mixing chamber, where the A and B components (the hardener) are mixed together dynamically.

The MK 800 mixing head with stub line has the same equipment features as the MK 800, which is generally used for processing liquid to paste-like 2-component systems. Both mixing heads are easy to clean with the Sonderhoff high-pressure water rinse or by a component rinse and allow easy maintenance.

Refilling Stations

When used in fully automated manufacturing processes, automatic refilling stations ensure material-specific preparation, homogeneous consistency, and a continuous supply of materials to the component containers of the mixing and dosing system – without exposure or contamination of the products to be filled. Partially equipped with an automatic lifting device for more operating convenience and greater occupational and system safety. Production interruptions are therefore a thing of the past.

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Optional Extensions

Additional equipment options can be ordered for the DM 50x dosing machine series which further increase the process and dosing accuracy, e.g.:

Part recognition sensor
AIR-CLEAN, pneumatic nozzle cleaning device
NOZZLE-CONTROL dosing nozzle measurement unit
WEIGHT-CONTROL dosing weight control
HOT-CLEANER UNIT for cleaning the mixing elements with PU hot cleaner.
LBM 3 air loading measuring and control unit
PELTIER mixing head cooling system
High pressure water rinsing unit for cleaning the mixing chamber

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Control and Monitoring

A control system should not only act when it receives a command, but should also continuously collect data itself, evaluate it prognostically, and proactively adjust the production parameters accordingly.

That is why we have installed numerous sensors in our control system that continuously provide measurement data on the crucial influencing factors during the production process. Thus, the smallest changes are not only documented, but above all, form the basis for simultaneous forecast calculations that allow countermeasures to be taken before the specified tolerance limits are exceeded.

Our control and monitoring system includes:

Control Cabinets
Control Panels

Control Cabinets

Scalable and durable control components from well-known manufacturers are installed in a protected and climate controlled, high-quality brand-name switch cabinet. Inside, the switch cabinet offers enough space for future expansions. The easy-to-use unique mounting plug-in system enables the addition of additional control components and ensures a high degree of flexibility for possible future changes.

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Control Panels

For operation of the DM 502 dosing machine, the multifunctional MP 2 mobile panel with 10.1-inch touchscreen or the new CONTROL 2 multi-touch operating panel enlarged to 21.5 inches offer a user-friendly menu with central navigation and a uniform layout of the user interface.

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The excellent visualization of the control panels enables intuitive menu navigation for the operator, while universally understandable symbols make the menu operation independent from languages. Additionally, it is possible to adapt the user interfaces to the different tasks and preferences of the machine operator.

Automation Solutions

Automation systems perform two main functions: an accurate component feed and removal process (component handling) and the accurate repeated movement of the mixing head. This integration into a production process must take into account at least as many criteria as the requirements profile for the material formulation.

Just like the machine components, all movement components must be able to precisely implement the control commands – and reliably repeat the movement sequences repeatedly. On the one hand, this involves the movement of the mixing head above the component or the component moved by a 6-axis robot under a fixed mixing head nozzle, and on the other hand the automation of the component feed and removal process. Coordinating the movement sequences of the component and the mixing head is an art in and of itself, and therefore at the same time the second crucial pillar of a production process with a reliable degree of repeat accuracy.

We offer a range of options and industry-specific experience for the design of your customized automation. Whether you need a semi-automatic stand-alone solution or integration into fully automatic production lines - our specialists will always have the right solution.

Our automation solutions include:

3-Axis Linear Robots (LR-HD and LR-HE Plus)
6-Axis Robots
2-Axis Mixing Head Traversing Unit (MKVE)
Shuttle Tables (WT 1-LEVEL and WT 2-LEVEL)

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3-Axis Linear Robot (LR-HD and LR-HE plus)

High acceleration, tight radii, and flowing movements over long contours – no problem for the LR-HE plus and LR-HD linear robots. The dynamic 3-axis linear robots are characterized by high stiffness and acceleration values over a very large travel range. For the highest precision in terms of repeat accuracy, the CNC linear robot with its low level of deviation of ±0.2 mm over 2 m usually has an advantage over the 6-axis robot. Preferred fields of application are those with high application speeds in conjunction with rapid changes in direction.

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6-Axis Robots

The DM 50x mixing and dispensing machine can also be operated with the use of 6-axis robots for parts handling and mixing head guidance. By cooperating with renowned manufacturers such as ABB and Kuka, we provide successful references for automation with 6-axis robots.

Both the mixing head and the component can be guided using 6-axis robots. Thus, allowing elegant solutions to be implemented, particularly for geometrically demanding components with difficult-to-access contours or multiple applications on different sides of a part.

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By intelligently linking automated movements before, during, and after the application process, customized system layouts can be designed, both as stand-alone production units or fully automated and integrated inline production.

Axis Mixing Head Traversing Unit (MKVE)

The 2-axis mixing head traversing unit (MKVE) is designed to provide precise movement of the mixing head in the X and Z directions and is available optionally with an electric or pneumatic drive. With versatile attachment options, this traversing unit allows for efficient and exact repetitions and movements.

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Shuttle Tables (WT 1-LEVEL and WT 2-LEVEL)

The shuttle and sliding table concept enables the continuous processing of parts by two pick-up plates in shuttle mode. These are located next to each other on one level, in the case of WT 1-LEVEL, or above each other on two levels, in the case of WT 2-LEVEL. The insertion area for the components is separated clearly and safely away from the traversing area of the CNC robots. The shuttle tables have a stable aluminum base frame with leveling feet. The aluminum pick-up plates are prepared with a hole pattern for attaching the workpieces or workpiece fixtures.

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Technical Service

The productivity of a machine is significantly determined by its reliable availability. This is why we ensure the intelligent minimization of error-related downtimes and maintenance-related production interruptions.

Our service package includes the interplay of a proactive inhouse service offering, for example by means of risk analyses, as well as an experienced and skilled on-site service offering and a quick response online service – in other words: Remote Collaboration. With this we support you with the reliable planning and execution of your production processes, as well as predictive maintenance.

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