Focus. Hybrid ALLROUNDERs. Injection moulding machines for high production capacities.

Transcription

1 Focus Hybrid ALLROUNDERs Injection moulding machines for high production capacities

2 At a glance 1 2 2,5 HIDRIVE Electric Hydraulic [s] 2,0 1,5 1,0 0, Production capacity: a powerful combination of sophisticated machine technology. Cycle time reduction: short dry-cycle times. Our hybrid ALLROUNDERs enable you to achieve high performance in cycletime optimised thermoplastics processing. With the HIDRIVE machine series, we combine the best from the ARBURG modular system: a powerful combination of sophisticated electrical and hydraulic machine technology Made by ARBURG Made in Germany. Reliable, highly-functional and energyefficient that s how the ALLROUNDER H machines work in your production. Day after day, 24 hours around the clock. Performance characteristics Hybrid ALLROUNDERs Comparable electric machine Comparable hydraulic machine Energy optimisation Production capacity /2015

3 3 Energy consumption [%] HIDRIVE Electric Hydraulic 4 [mm/s] HIDRIVE Electric Hydraulic 0 0,2 0,4 0,6 0,8 1 1,2 [s] [years] 5 1,40 1,20 1,00 0,80 0,60 0,40 0,20 0,00 Basis for calculation: additional cost of machine 20, Cycle time reduction [%] Energy optimisation: energy consumption is similar to that of electric machines. Dynamics: injection is comparable to that of electric machines. Cost-efficiency: rapid return on investment. 1 Production capacity The hybrid ALLROUNDER machine concept has been configured with the particular aim of achieving high production capacities. The machines provide high injection performance in relation to the relevant clamping force, and combine: servo-electric clamping units from the ALLROUNDER A and generously dimensioned injection units with hydraulic accumulator technology 2 Reduced cycle times All movement axes operate completely independently of one another. In this way, simultaneous drive movements can be achieved whatever the application. The extremely short dry cycle times of the servo-electric clamping units allow for fast cycles. Special features such as injection on the fly (simultaneous injection while the mould is closing) or dosage that takes place across several cycles are also available. 3 Energy optimisation The high levels of efficiency of the servoelectric dosage drive and the toggle-type clamping unit ensure energy-efficient operation of the hybrid ALLROUNDERs. The energy recovery of the servo motors during braking also has a beneficial effect on the machines overall energy consumption. Moreover, the hydraulic drive features a performance-adapted pump and an efficiency class IE2 electric motor. Together, these factors combine to reduce energy consumption by up to 40 percent. As an indication of this energy-optimised operation, all HIDRIVE machines bear the ARBURG e² energy-efficiency label. 4 Dynamics In addition to the dynamic mould movements of the servo-electric clamping unit, hydraulic accumulator technology also significantly contributes to the achievement of shorter cycle times. This enables high-volume, dynamic injection flows, which are highly advantageous in the mass production of technical components. At the same time, a position-regulated screw ensures maximum reproducibility and part quality. 5 Cost-efficiency The sophisticated hybrid ALLROUNDER technology provides for reliable operation and maximum availability. High acceleration and final speeds combined with simultaneous machine movements result in significantly greater cost-efficiency through reduced cycle times. Furthermore, numerous technical detail solutions, such as the automatic mould height adjustment, are aimed at the sustainable minimisation of set-up times. This also makes the daily production much more efficient. 08/

4 Performance-oriented machine concept Distance between tie bars [mm] 920 x x x x x x x x x 270 Clamping forces [kn] Injection unit according to EUROMAP Shot weight [g PS] Productive drive technology The energy-efficient drive technology is tailored to ensure consistently high production capacity with short cycle times. All movement axes work independently thanks to servo-electric drives and performanceadapted hydraulic accumulator technology. The entire technology is robust, durable and wear-resistant. At the same time, energy consumption remains low. The concept of our hybrid ALLROUNDERs is both performanceoriented and efficient: existing sophisticated electric and hydraulic clamping and injection units, as well as the intelligent SELOGICA control system, are combined to produce a powerful and cost-efficient machine series. Thanks to the high flexibility of our modular design system, a machine series has been created that provides you with uncompromising production capacity. With the ALLROUNDER H machines, you can satisfy any requirements at competitive unit costs, no matter how demanding your production tasks become. Precise clamping units 1 2 Productive drive technology /2015

5 2 Precise clamping units The clamping units are identical to those of the electric ALLROUNDER A machines. The double five-point toggle operates with high force and speed, positioning with high precision and reproducibility. Automatic clamping force control ensures a constant clamping force. Considerable reductions in cycle times can be achieved through extremely short dry-cycle times. 3 High-performance injection units The injection units operate in an energyoptimised way with high injection performance and simultaneously rapid cycles. This is achieved via the position-regulated screw with hydraulic accumulator technology combined with servo-electric dosage. Further significant features are short set-up times and high plasticising and moulded part quality. A long service life is assured by the highly wear-resistant cylinder modules. 4 SELOGICA control system SELOGICA provides the same operating system for all machine series. The machine cycle features intuitive programming using graphic symbols, enabling short set-up times. Immediate plausibility checking of all parameter entries ensures high operating reliability and convenience. This makes even complex processes easy to understand in the human-machine dialogue. SELOGICA control system High-performance injection units /

6 Productive drive technology 1 Energy saving: servo-electric dosage. The sophisticated drive technology of the hybrid ALLROUNDERs forms the basis for the high degree of availability, performance and reliability in your company. Specially tailored to the achievement of high production capacities, our modular design combines electric speed and precision with hydraulic power and dynamics, combined to perfection! So with the HIDRIVEs, you integrate machines into your production facility which not only operate particularly cost-effectively, but are also extremely energy-efficient. Movement axes Clamping unit Ejection Core pull Nozzle movement Injection Dosage Hydraulic Electric H 1 Servo-electric drives Dosage, as well as mould opening and closing are servo-electrically driven. These drives are characterised by simultaneous, highlyprecise and energy-saving movements. High torques and motor speeds enable excellent acceleration values and final speeds. Another contributory factor is the closed cooling circuit for the motors and converters. High-resolution, contactless position measurement by an absolute position encoder in the motors makes movement to a reference position unnecessary. In short, performance is coupled with speed and precision /2015

7 2 3 Precise: reproducible injection thanks to valves situated close to the hydraulic consumers. Maintenance-friendly: load-dependent, automatic central lubrication of the clamping unit. 2 Adaptive hydraulic accumulator technology Injection and the auxiliary ejector, nozzle movement and core pull axes are all hydraulically driven. Alternatively, the ejector and core pulls can also be driven servo-electrically. Here, hydraulic accumulator technology ensures simultaneous, precise and dynamic movements at high speeds. Exceptionally precise movement and positioning is guaranteed by control via stroke-dependent ramps and fast-switching valve technology located close to hydraulic consumers. All of the above factors enable you to produce moulded parts of the highest quality. Charging of the pressure accumulator is regulated, so that the pressure level is automatically adapted to the current demand, ensuring that the hydraulic drive works in an energy-efficient manner. Energy consumption is also reduced thanks to the performance-adapted pump in combination with an efficiency class IE2 electric motor. 3 Reliable technology The entire drive technology is robust, durable and wear-resistant. Compact, liquidcooled servo motors and solid, highly-stable planetary roller screw drives guarantee long, continuous and reliable machine operation. Their maintenance requirements are kept to a minimum by automatic central lubrication of the clamping unit. Media connections and interfaces are located on the rear of the machine to ensure easy access. The automatic mould height adjustment and good accessibility of the area around the mould, ejector and nozzle also result in considerably reduced set-up times. This also means greater cost efficiency in day-to-day operation. 08/

8 Precise clamping units 1 Automatic clamping force control The mould height adjustment effectively helps the operator to reduce set-up times. The clamping unit can be readily adapted to different mould installation heights. The automatic clamping force control generates a constant locking force, ensuring that heat expansion of the mould is fully compensated. 2 Five-point toggle system The double five-point toggle features a stable construction with multiple guidance and support points. This provides for absolutely symmetrical force application during movements and mould locking. Drive power and construction are also designed for heavy moulds. Despite the compact design, relatively large opening strokes are possible. Practical: automatic clamping force control. The toggle clamping unit of the hybrid ALLROUNDERs operates with high precision and cost-efficiency. Moreover, this technology boasts highly energyefficient running characteristics, bringing you effective savings every day. The kinematics of the double five-point toggle are optimally adapted to the servo-electric drive. The extremely short dry-cycle times of the HIDRIVE machines as well as the simultaneous movements of the clamping unit and ejector can achieve significant reductions in your cycle times. 1 2 Automatic clamping force control Five-point toggle system /2015

9 3 Mould protection The elongated box design of the moving mounting platen is supported on the machine base over the entire length of the stroke. Together with four-tie-bar guidance, this ensures high precision. The stable clamping unit and the active mould protection system with its extremely sensitive tiebar strain measurement ensure optimum service life of the mould. 4 Precise positioning The heart of the mechanically rigid clamping system is the solid, highly stable planetary roller screw drive. This ensures extremely precise travel to the required set positions, simplifying the transfer of parts to robotic systems. Extremely precise, reproducible ejection of moulded parts is achieved by means of a spindle-driven rigid ejector system. 5 Good accessibility The generous tie-bar spacing allows easy handling, even in the case of large moulds. Set-up times are kept short thanks to the safety guard open at the top and the ejector rapid release coupling, which is standard on all machine series. The safety guard, which has been enlarged towards the rear of the machine, offers ample space for attachments and media connections can be routed directly to the mounting platens. Good accessibility Precise positioning Mould protection 08/

10 High-performance injection units 1 Short set-up times The injection unit can be swivelled to the operator s side for easy removal and cleaning of the screw and for replacing the cylinder modules. The screw can be removed without dismantling the cylinder module. Set-up can be performed quickly and without errors thanks to the screw s rapid release coupling and the central connection of all cylinder module supply units. 2 Wide variety of combinations Cylinder modules that are compatible for all series and have three different screw diameters are available for each injection unit. Also available are cylinder modules for processing silicone, highly wear-resistant bimetallic cylinders and screws with special geometries. This enables energy-optimised applications with different materials and moulded part weights. Maintenance-friendly: rapid release coupling for screw. Homogeneous material preparation and precise injection form the basis for high-quality part production. On the hybrid ALLROUNDERs, this is achieved through the combination of positionregulated screw, hydraulic accumulator technology and energy-saving servoelectric dosage. With the large, dynamic injection flow rate of the HIDRIVE machines, thin-walled components can also be reliably produced. You maintain full control of your cycle times thanks to the dosage across cycles and the simultaneous nozzle movement. An additional benefit: the entire injection unit is easily accessible for set-up and cleaning work. These are all tangible advantages, that are guaranteed to put you ahead of the competition. 1 Short set-up times /2015

11 3 Torque-free nozzle contact The advantage of torque-free, two-tie-bar guidance of the injection units is an absolutely leak-free nozzle contact surface. Both flat and radius nozzles can be used without problem. High nozzle contact forces are reliably achieved thanks to central insertion in the mould. The build-up of the nozzle contact force is programmable and controlled. This has a positive effect on nozzle and mould wear. 4 Position-regulated screw Reproducible mould filling and high moulded part quality are achieved by: precision control of injection pressure and speed with the ARBURG positionregulated screw dynamic acceleration with hydraulic accumulator technology All in all: an injection unit with high injection performance and precision. 5 Direct dosage drive The high overall efficiency of the servo-electric drive results in significant energy savings as well as increased precision. The fact that it operates independently allows the cycle time to be significantly reduced in some cases. Simultaneous dosing also permits longer dosage times and hence gentler melt preparation. Wide variety of combinations Torque-free nozzle contact Position-regulated screw Direct dosage drive /

12 SELOGICA control system User-friendly: simultaneous monitoring of robot and machine sequence. 1 Central management The SELOGICA system saves time and costs thanks to its unique standardised operating concept. With the simple integration of a variety of peripherals, the control system can be used for sequence management, even of complete production cells. The management of setting data is simpler than ever; there is only one data record for the entire production unit. 2 Intuitive operation All data can be accessed immediately, rapidly and easily via the SELOGICA touchscreen. The graphic operating system, which is compatible with a wide variety of technologies, is self-explanatory. The unique sequence editor with patented, real-time plausibility check always clearly indicates the logical position of the current programming step. This way, operating errors are prevented from the start. Maintaining control over sophisticated machine and robotic technology requires a correspondingly powerful control system. All the sub-steps in the production cycle can be programmed clearly and easily using the intuitive SELOGICA sequence editor. SELOGICA acts as a central setting and monitoring system for the entire injection moulding process, including the programming of integrated robotic systems and peripherals. All technical features of SELOGICA are designed to make operation quick, safe and convenient. This allows short set-up times to be achieved in your production facility. Data is input consistently and training is kept to a minimum, as your operators no longer have to adapt their thinking process. 3 2 Further information: SELOGICA control system brochure /2015

13 Highlights 3 Fast set-up times The input logic of the SELOGICA system is based on the mould set-up sequence and optimisation of the injection moulding process. The Set-up Assistant module supports daily operations from menuguided mould installation and automatic calculation of the parameters through to teach-in of the finished sequence no in-depth knowledge required. 4 Reliable optimisation The SELOGICA machine control system offers numerous options for process optimisation, monitoring and documentation. Numerous mould protection, diagnostic and support functions, such as the maintenance display, all fall under the topic of machine monitoring. All messages are displayed conveniently in plain text, so that operators always know precisely what action has to be taken. Control centre for the entire injection moulding technology Convenient sequence programming with graphic symbols Real-time plausibility checks Common data record for the entire production unit Set-up Assistant module Interactive teach-in functions Water-cooling for continuous temperature control in the control cabinet Fast set-up times Intuitive operation 4 Reliable optimisation Central management 1 08/

14 Application examples 1 2 High-output production: short cycle times for optimum unit costs. Mass-produced technical components: excellent reproducibility with servo-electric drives. The concept of our hybrid ALLROUNDERs is always an attractive alternative. Whether your needs are high precision and reproducibility or speed and dynamics, the performance characteristics of the machines comprehensively meet a multitude of injection moulding requirements. From high-output production, through mass-produced technical components, to thin-walled moulded parts, the HIDRIVE machines prove their reliability in everyday use. Time after time. 1 High-output production All movement axes of the hybrid ALLROUNDERs work independently and can be perfectly co-ordinated even at high speeds. The intuitive sequence editor of the SELOGICA control system always ensures the necessary transparency, particularly in the case of simultaneous movements. Thanks to their successful combination of energy-saving servo-electric and energy-optimised hydraulic drives, ALLROUNDER H machines can combine the shortest cycle times with energy-saving operation in an ideal way. This ensures cost-efficient part production in every respect. 2 Mass-produced technical components If you require a high degree of reproducibility for your production, as with technical parts, for example, the combination of position-regulated screw (PRS) and injection via hydraulic accumulator offered by the ALLROUNDER H is of particular interest. The moulded part quality achievable with an injection system of this kind is comparable to that of the electro-mechanical version. A good example of this is the mass production of technical components in medical technology. Further information: Application expertise brochure Robotic systems brochure 14

15 3 4 5 Packaging items: short dry cycle times through servo-electric clamping unit. Thin-walled items: highly dynamic injection flow rate. Automation: ALLROUNDER machines and robotic systems from a single source. 3 Packaging items For the production of packaging items, ALLROUNDER H machines with a combination of hydraulic accumulator technology, servo-electric clamping units and the special Packaging (P) version are perfectly suited to the task. Important criteria here are, above all, short dry cycle times, simultaneous movements and dynamic injection. Particularly in multi-shift operation, where the machines work around the clock, the reliable ALLROUNDER drive technology with planetary roller screw drives and liquid-cooled servo motors has proven itself time and again. 4 Thin-walled items The hydraulic accumulator technology of the HIDRIVE machines unites dynamic acceleration and high injection speed in one ideal combination. These characteristics, in particular, are decisive success factors for the filling of items with widely differing wall thicknesses and long flow paths, or thinwalled moulded parts. The outstanding positioning accuracy of the servo-electric clamping unit also guarantees the smooth processing of moulded parts in subsequent automated processes, especially when using robotic systems for part removal or insertion tasks. 5 Automation The combination of ALLROUNDERs and robotic systems forms the basis for complete production cells, which are developed by the ARBURG project department together with the customer. All upstream and downstream production steps in the injection moulding process are automated. The service range available from ARBURG covers optimisation of moulded parts and support during the mould design process, complete assembly and commissioning of the individual components and installation at the owner s premises and all the necessary services. 08/

16 Distances between tie bars of 270 x 270 to 920 x 920 mm Clamping forces from 350 to 5,000 kn Injection units from size 70 to 4600 (according to EUROMAP) Film ARBURG GmbH + Co KG Postfach Lossburg Tel.: +49(0) Fax: +49(0) contact@arburg.com With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia, Spain, Czech Republic, Turkey, Hungary Asia: People s Republic of China, Indonesia, Malaysia, Singapore, Thailand, United Arab Emirates America: Brazil, Mexico, USA For more information, please go to ARBURG GmbH + Co KG The brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG. All data and technical information have been compiled with great care. However we accept no responsibility for correctness. Individual illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and operation of the machine. ARBURG GmbH + Co KG DIN EN ISO certified _EN_GB_ Subject to alterations Printed in Germany