lNew Control Unit and AI for Injection Moulding Machines
Driving innovation and efficiency is always a key priority at ENGEL. In this Tech Talk, Hannes Fritz and Mateusz Rychlik discuss the evolution of the CC300 control unit into the CC300 plus, along with the capabilities of the iQ process observer. As product managers for control systems and digital solutions, they explain how ENGEL technologies enhance user experience and production performance.
What’s New in the CC300 Plus Control Unit?
Hannes Fritz (H.F.): The “plus” in CC300 plus represents an evolutionary enhancement of our trusted CC300—not a radical redesign, but a well-thought-out upgrade. We kept proven functions and added user-centric improvements. Notably, we’ve introduced eight haptic buttons on a state-of-the-art display. These buttons are fully programmable, tactile, and integrated into a responsive touch screen, allowing intuitive, real-time operation.
Customisation for Different Applications
H.F.: The ability to customise haptic buttons is invaluable for production environments with frequent tool or process changes. Operators can assign frequently used or critical commands, improving efficiency and safety. Up to three configuration levels per button allow greater flexibility and control.
Easy Transition for Operators
H.F.: The fundamental operation remains similar to the original CC300, making it easy for existing users to adopt. The familiar e-move knob remains, but is now more functional. The major change is from glass interface to tactile buttons, which enhance safety and precision through physical feedback.
Additional Improvements
H.F.: New features include an improved ergonomic design with double swivelling mechanisam and an optional Mifare key fob login system. This login solution is pre-configured and easily activated with a license.
Software Enhancements
H.F.: Starting with version 5.10, we’ve introduced a process checklist that guides operators through optimisation steps to reduce energy use and improve consistency. It also fully integrates with our iQ product family—iQ weight control, iQ clamp control, iQ flow control—along with tutorial access for learning support. These features contribute to “green mode” operation and better sustainability.
Smart Monitoring with AI: iQ Process Observer
Addressing Skills Shortages
Mateusz Rychlik (M.R.): Production is more complex than ever, and skilled personnel are in short supply. Our AI-supported iQ process observer monitors processes in real time and detects irregularities using intelligent algorithms. It provides clear, actionable guidance, allowing experts to focus on high-value tasks.
Supporting Less-Experienced Staff
M.R.: The system is intuitive. A traffic light display signals if intervention is needed. Timeline visualisations and clear indicators make process deviations easy to detect and address. Staff can react in time to avoid producing defective parts. Remote access via the e-connect portal enables expert support from anywhere.
Proven Benefits
M.R.: One customer reduced incident response time by 30 minutes. Another eliminated 10 hours of monthly manual SPC checks, now triggered only by real process deviations. This means fewer rejects and more uptime.
How It Stands Out
M.R.: Unlike conventional systems requiring manual configuration, the iQ process observer analyses hundreds of parameters automatically, identifies trends, and suggests corrections—no manual setup needed.
Reliable Data & Expert Knowledge
M.R.: It automatically logs all key process events and makes them easily accessible. A built-in knowledge database translates data into recommendations, helping all employees act with confidence. Experienced staff can focus on complex cases while others follow precise, guided actions.
Faster Troubleshooting
M.R.: In manufacturing, every minute counts. Early detection and practical suggestions from the observer lead to quicker fixes and fewer disruptions.
Prevention, Not Just Reaction
M.R.: By analysing up to 200,000 cycles, the system detects gradual drifts and suggests preventive measures before quality issues arise. Reference values can be saved with one click, triggering early warnings for process deviations.
Why Invest Now?
M.R.: Rising complexity, skills gaps, and cost pressure make the iQ process observer a strategic investment. It combines real-time data, machine learning, and expert guidance to create more efficient and resilient production environments.