Precise. Productive. Energy efficient. The all-electric AX Series

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1 Precise. Productive. Energy efficient. The all-electric AX Series Engineering Passion

2 2 Machines in the AX Series Facts and figures Facts and figures regarding the all-electric AX Series Application areas Automotive industry Electrical engineering/ electronics industry Consumer goods Medical/pharmaceutical industry Clamping/injection matrix Machine/ clamping force in to Clearance (hxv) in mm AX x 360 AX x 410 AX x 410 AX x 460 AX x 510 AX x 560 AX x 660 AX x 730 Injection units (screw diameter in mm) SP 55 SP 100 SP 180 SP 380 SP 750 SP 1400 SP

3 3 The all-electric AX Series The AX machine concept includes a large modular kit for many different applications and is therefore ideally suited for a large number of industries. From 50 to 350 tonnes, the AX Series will always provide you with the right machine combination for your demanding applications. Every AX machine can be precisely equipped from an extensive range of plasticizing units, automation units and options. Highlights of the AX Series at a glance: Precise thanks to: Direct operating principles Highly accurate servomotors Intelligent closed-loop control system Productive thanks to: Short dry cycle times High availabilities High process reliability Energy efficient thanks to: Smooth-running mechanical system Highly efficient drive technology Intelligent energy management

4 Transparent technology Tour of the all-electric AX injection molding machine Flexible, fully integrated automation Extensive options catalog 5-point double toggle lever with robust mold fixing platens Smooth-running linear guides Barrier-free access

5 5 High-end plasticizing units Precise drive technology Efficient energy management Intelligent MC6 control system

6 6 Machines in the AX Series Universal clamping unit The universal AX clamping unit Versatility and efficiency coupled with high precision With clamping forces ranging between 500 and 3500 kn, the AX Series covers a wide range of products. The efficient and highly dynamic 5-point double toggle lever coupled with intelligent servodrive technology ensures maximum productivity and cost-efficiency while also providing optimum mold protection. Stable processes thanks to quick and precise movements Highly dynamic and precise servomotors move to set travel positions for the shutoff or for the ejector quickly and precisely with absolute reproducibility. Falling parts can therefore be ejected safely and reproducibly, thus preventing them from flying out. You therefore save many OK parts and reduce, in particular, the cycle time. In order that the KraussMaffei robot can demold the parts, the AX moves to the transfer positions extremely precisely and transfers the parts reliably to the gripper. This always take place with mm accuracy. Your advantages: Short dry cycle times High positioning accuracy Minimum energy consumption Low maintenance costs Clamping unit in open position (top) and closed position (bottom), wide positioning range for mold height adjustment Speed-path diagram for opening and closing the mold Speed in mm/s 1200 v = 100% v = 50% v = 20% % 80% 60% 40% 20% 0% 0 Opening stroke in %

7 7 The optimized drive system is synonymous with precise and dynamic clamping movement. Thanks to the wide positioning range of mold height adjustment, large and small molds can normally be used

8 8 Machines in the AX Series Universal clamping unit The AX features large robust mold fixing platens. The moving platen is broadly supported on linear guides. The tiebars therefore remain free of grease Frictionless production thanks to optimum clamping mechanics The play-free and smooth-running mechanics are a prerequisite for the efficiency, dynamism and precision of the AX clamping units. The kinetically optimized 5-point double toggle lever and the play-free ball screw (with recirculating ball bearings) jointly produce maximum force transmission with high speeds during opening and closing. The excellent smooth-running of the toggle lever is ensured at all times through automatic central lubrication. High degree of flexibility thanks to a large mold fitting space Large mold fixing platens and opening widths permit the universal use of many different molds. The clamping unit is very stiff due to the interconnection of the molding fixing platens from the carrier and adapter plate. The interchangeability of the adapter plates enables you to choose your own hole patterns ideal for worldwide production use. Parallel mold guidance always clean and efficient The broad support of the moving plate on precision linear guides ensures exact mold parallelism in all positions. Rolling linear guides reduce friction resistance compared with normal sliding guides or column guides by up to 80 percent. Thanks to the linear guides, the tiebars are only used for force transmission and do not touch the moving mold fixing platen in any way. There is no need for lubrication and the product area remains clean.

9 9 Wide opening and barrier-free safety gates for easy accessibility to the mold and ejector Ergonomic concept for easy accessibility and use Wide opening safety gates on the operator's side and non-operator side ensure easy accessibility to the mold and ejector, for example for set-up processes. Your advantages: - Easy accessibility - Large mold fitting space - High platen parallelism - Grease-free tiebars The safety gates are self-supporting and do not have any interfering crossbars on the housing. This makes every mold change easier, even with a low crane height, and part demolding by a robot is speeded up. In the case of falling parts, it is possible to integrate both billet and sorting chutes along with conveyor belts to transport the parts underneath the clamping unit in a transverse or longitudinal direction.

10 10 Grease-free tiebars Changeable mold fixing platens Drive unit for clamping unit Mold height adjustment Precision linear guide Universal clamping concept for clamping forces between 500 and 3500 kn Symmetrical force transmission ensures optimum clamping of the mold The tightly toleranced and totally symmetrical design of the clamping unit produces direct and uniform force exertion on the moving and fixed mold fixing platen. Thanks to the composite structure of the molding fixing platens based on a carrier and adapter plate, forces are evenly distributed when clamping force builds up and are introduced in parallel into the two mold halves. The high safety standard of KraussMaffei is underlined by the standard secondary brake on the clamping motor in every AX machine. This is the only way to ensure that mold installation under clamping force is absolutely safe. Automatic clamping force regulation as a standard feature Clamping force in the AX is regulated exactly to the set value. Potential process disturbances, which may occur due to clamping force fluctuations caused by thermal expansions, are eliminated automatically and effectively through clamping force regulation. In every cycle the actually attained clamping force is recorded by a measuring system and an actual-target comparison is performed. If a deviation is registered, the clamping force is automatically readjusted by means of mold height adjustment and precisely regulated to +/- 2 percent. Clamping unit closed and locked in position, symmetrical force transmission to the moving mold fixing platen and the mold Your advantages: Ideal force transmission to the mold Automatic clamping force regulation Sensitive mold area protection Wide range of additional fittings

11 11 Every AX machine can be precisely equipped from an extensive options catalog Practical and functional additional fittings for your mold The extensive AX options catalog contains practical solutions and powerful additional functions for your individual applications and mold technologies. Thanks to an additional and mobile hydraulic power pack, core pulls or needle seal nozzles can be directly programmed and controlled via the MC6 control system. Pre-piped connections for cooling water and temperature control circuits are situated close to the mold, thus making every mold connection easier and keeping everything in order. Self-optimizing and monitored temperature control zones for the mold hot channel or temperature control units ensure optimum processes in the mold through reproducible thermal conditions. Maximum mold protection through sensitive mold area protection The travel force applied when closing the mold is detected and recorded exactly by a measuring device. Every extraordinarily occurring force path can therefore be detected quickly and reliably. Mold area protection can be adjusted to up to 16 profiles. The required sensitivity level can be assigned to every profile level using a simple dropdown field. If the set tolerance limit is exceeded, the mold movement is stopped immediately. The the mold is therefore effectively protected. Sensitive mold area protection offers maximum protection for your mold Force Triggering of emergency stop Exceeding of tolerance band Detail Time Tolerance limit Travel force Reference travel force

12 12 Machines in the AX Series First-class injection unit The first-class AX injection unit Precise and productive with maximum efficiency In the AX injection unit, the ideal interaction between excellent plasticizing and precise drive technology ensures first-class shot weight constancy. The AX machine reproduces parts with the highest quality and efficiency - shot for shot. High availability and reliability make it the productive leader for every production process. Excellent melt quality for every application KraussMaffei plasticizing units are characterized by excellent melt quality coupled with high plasticizing capacity, and form the centerpiece of every AX machine. With screw diameters ranging between 15 and 75 mm, and a large number of high-tech, wear-resistant HPS-M mixing screws, the AX machine covers a wide range of applications for many different types of plastic. In the high temperature design up to 450 C, there are no limits to the production of technical parts with the highest possible mechanical, chemical and thermal demands. With every AX machine you obtain the suitable plasticizing unit for your application and therefore the best possible conditions for optimum parts quality. KraussMaffei plasticizing units are synonymous with excellent melt quality coupled with high plasticizing capacity.

13 13 The impressive features of the AX include its excellent reproducibility and high availability Reproducible processes thanks to built-in precision and dynamism The injection movement is driven by highly precise and dynamic servomotors, and is transmitted directly to the screw via a play-free and directly acting spindle system. Thanks to their extremely dynamic response, the motors regulate the set process parameters of speed, path and pressure in the minimum tolerance range very quickly and precisely. First-class shot weight constancy Grams Grams Shot Best plasticizing + absolute precision = first-class shot weight constancy Shot +/ g The injection pressure is measured directly in the force flow as an absolute value by means of a sensitive sensor. This ensures precise regulation of holding and back pressure. By combining extreme repeatability and optimum plasticizing, the AX machine offers ideal conditions for first-class shot weight constancy.

14 14 Machines in the AX Series First-class injection unit Configuration of the AX injection unit from SP 55 to SP 750 / Ø mm Your advantages: First-class shot weight constancy High process reliability High level of productivity Excellent melt quality Low energy consumption High reliability and availability Flexible and practical use

15 15 Plasiticizing drive unit Plasticizing unit with quick-change system Spindle system Aggregate drive unit Injection drive unit Precision linear guide Configuration of the AX injection unit from SP 1400 to SP 2000 / Ø mm Lowest energy consumption thanks to maximum efficiency In the AX injection unit the most efficient drive technology comes up against the lowest moments of inertia, thus producing maximum efficiencies in every injection process. The losses are low and the effect is high thanks to the play-free and smooth-running spindle mechanics, as well as the highly efficient servomotors. In particular, the most energetic process steps, plasticizing, injection and holding pressure are therefore highly efficient. High reliability and stable processes for increased productivity Excellent reproducibility and high availability make the AX a productive high performer in every ambitious injection molding company. Stable processes lead to high parts quality, climate-related process readjustments are reduced and OK part output is increased. Extremely low maintenance, fast attainment of productive phases and their reliability lead to high availability of the AX machine. Practical application and flexible uses Due to the easy accessibility and visibility of the nozzle, the AX contains ideal conditions for every mold setter. The KraussMaffei quick change system makes every cylinder change easy, quick and absolutely safe thanks to automatic screw detection. On request, the AX can also be equipped with adaptions to smaller screw diameters for an even wider range of applications.

16 16 Machines in the EX Series Control system Usability is our top priority The new MC6 control system with SplitScreen technology and Eco function With innovative features such as SplitScreen technology, the MC6 control system offers you greater convenience and usability

17 17 Do you get the most energyefficient machine setting? Always! - Simply press the Eco button The new MC6 control system meets all of your usability needs. Whether you are working with a KraussMaffei control system for the first time or you are accustomed to its MC5 predecessor MC6 technology is so intuitively accessible that you will work better and more efficiently than ever before. Everything in sight - thanks to the new SplitScreen technology SplitScreen technology is one of the special highlights of the MC6: Thanks to the split-screen display, you can see the most important production processes simultaneously. In parallel with the actual value cycles, you can control, for example, the injection process. Clarity thanks to the ProcessDesigner tool The integrated ProcessDesigner tool provides a clear visual presentation of all current processes and enables you to modify them, depending on requirements, by means of simple drag-anddrop movements or swiping movements. Destination reached with just two taps thanks to a drop-down menu and a favorites bar To ensure that handling the control unit is as user-friendly as possible, deeper navigation levels have generally been avoided with the MC6. Based on the credo "reaching the destination as quickly as possible", a clear overall concept with individually configurable favorites bars is produced. In order to guarantee optimum use, the machine keypad only provides the keys which can be selected in regard to the operating states of the machine. Our user- friendly principle is rounded off by a special field for selecting systems. You can therefore directly select all components of the machine up to automation and technology. Go Eco! Energy efficiency at the push of a button In keeping with our overall energy-efficient design, the MC6 control system has an "Eco button". This allows you to configure the machine in the most energyefficient manner at the touch of a button. Intelligent user profiles Thanks to standardized role profiles from the machine operator and mold setter through to the production manager you can assign different authorizations quickly and easily. Of course, you can also create additional hierarchy levels and assign individual rights to users. Another feature of the MC6 is the resistive dual-touch function which also allows the screen to be operated by a person wearing gloves. With the Windows 7 Embedded operating system, the MC6 is ideally equipped for today's technologies and those in future. The MC6 control system can be ordered in more than 30 languages. And best of all: Every feature is available not only with the control system, but also on the handheld pendant. Your advantages: User-friendly function principle Simple process control thanks to SplitScreen and ProcessDesigner Clear structures Standardized user administration Two-way operation of automation and machine possible The MC6 control system impresses customers with its clear overall concept. Here using ProcessDesigner as an example. You can operate the automation both from the handheld pendant and from the injection molding machine. And, with the MC6, even reverse operation of the injection molding machine is easy from the robot's hand-operated console.

18 18 Machines in the AX Series Economic efficiency Total economic efficiency Higher productivity with lower use of resources Sustainability through minimum energy and water consumption Thanks to its high overall efficiency, the AX consumes very little energy even with different loads and applications. By contrast with comparable hydraulic injection molding machines, energy consumption is often reduced by 50 percent and more. Due to the low friction losses, the internal cooling load and, thus, cooling water consumption are very low and savings of up to 70 percent are entirely normal. Technical parts/2.0 D stroke: Throughput in kg/h (cycle time) Energy consumption in kwh/kg Hydr. IMM AX Series (16s) 15.6 (17.5s) 28.4 (19s) 43.9 (20,5s) 65.5 (22s) Your advantages: Minimum energy consumption Lower water consumption Short cycle time thanks to parallel functions Lower sound pressure level Low heat emissions Lower maintenance costs Higher productivity with low use of resources Thin-wall parts/0.5 D stroke: Throughput in kg/h (cycle time) Energy consumption in kwh/kg Hydr. IMM AX Series , (6s) 9.8 (7s) 17.1 (8s) 25.2 (9s) 36.0 (10s)

19 19 Cycle time comparison Machine with serial functions Close mold Injection Holding pressure Plasticizing Cooling Open mold Ejecting Cycle time 12.2 s s AX Series with parallel function Close mold Injection Holding pressure Plasticizing Cooling Open mold Ejecting Cycle time 10.8 s High availability and increased output lead to higher productivity The high availability of the AX is based on the characteristics of high reliability, low maintenance requirements and a fast response. The AX is therefore available for more production hours. Parallel functions, for example opening ejection during opening of the mold, are included in every AX machine as a standard feature and can be used without restriction. Cycle times can therefore often be reduced by 10 percent and more. Due to its high precision, the AX ensures stable processes and reliably produces a higher number of OK parts. Low emissions produce a pleasant climate AX machines ensure a pleasant working climate in every company. Compared with conventional hydraulic injection molding machines, sound emissions in the AX are reduced by more than 5 db(a). Thanks to the high efficiency of the mechanics and drive technology, the heat emissions to the external environment are very low. This is very important, especially in air-conditioned production, for example in cleanrooms. Saving

20 20 Machines in the AX Series Automation solutions The economic production cell Competent automation solutions from a single source KraussMaffei offers you complete automation solutions from a single source that match the AX Series. From universal linear robots and well thoughtout gripper solutions through to turnkey automation cells, the AX can be completed with numerous automation tasks and therefore extended to become a flexible and economic production cell. Maximum mobility thanks to modular design The linear robots in the LRX Series are perfectly suited for typical pick & place solutions with fast demolding. If required, the LRX robots also perform other tasks in the injection molding process: insertion, demolding, processing and many more besides. A suitable linear robot with adapted axis lengths and manual axis combinations are available preconfigured for every clamping force. A large number of other axis designs, extensions and manual axis combinations make the LRX extremely mobile. More OK parts in a short space of time increase your productivity Matching the AX Series with servomotors, parallel movements of all servoaxes and early entry in the LRX substantially reduce the mold open time and allow short demolding times of less than 1 second. Highly precise gears and robust mechanics ensure high repeatabilities of +/- 0.1 mm even at high travel speed. The ServoFloat function also ensures careful demolding, even for filigree parts, and therefore increases OK part output. More room thanks to a compact production cell, linear robot integrated in the AX The optionally available production cell is the ideal solution for economic part demolding. The AX safety enclosure has been extended to accommodate the conveyor belt and also helps to protect the robot. As a result, there is no need for an additional robot safety fence or the safety gate. Compared with traditional safety enclosures, this compact concept reduces the production area by around 25 percent. If the safety gate on the operator's side is opened, the conveyor belt also moves sideways and the operator has free access to the mold. Linear robots in the LRX Series (payload) Clamping force kn X [mm] LRX 50 (payload: 5 kg) LRX 100 (payload: 10 kg) LRX 150 (payload: 15 kg) LRX 250 (payload: 25 kg) Y [mm] Z [mm] X [mm] Y [mm] Z [mm] /T /T /T /T /T 2500 X [mm] Y [mm] Z [mm] X [mm] Y [mm] Z [mm]

21 21 Your advantages: Short cycle and demolding times High OK part output thanks to safe demolding High machine and personal safety, CE conformity Smarter programming operation with WizardX Integrated control system with central operating unit Machine and automation system as optical and functional unit Flexibility thanks to numerous extension options Fully integrated production cell Integrative system: The perfect symbiosis of a machine and automation technology The injection molding process and automation form one unit via the integrated control system with VARAN-BUS technology. Process data are available in real time. Programming and operation are easy and do not call for any in-depth programming knowledge. To permit optimum teaching and ergonomic programming, all LRX/LRX-S machines have a handheld pendant with a touchscreen display whose operating steps are identical with the machine's control panel. With the integrated solution, the entire process can be controlled via a common operating panel. The machine and robot data are saved in one dataset. This also ensures maximum data security and excellent optimum operating convenience. 20 safety zones, of which 5 are dynamic, increase the efficiency of the control programs. Machine panel operates automation (Automation) Machine Automation panel operates machine AX as an integrated production cell with wider safety enclosure, LRX, chute and conveyor belt Work is made easier through mutual operation - the injection molding machine can be controlled by the automation handheld pendant - and vice versa

22 22 Machines in the AX Series Further information Further information which might also interest you Are you looking for a suitable automation solution for your AX machine, and are you also interested in the mid-size machine segment? Or do you want further information about our core competence, plasticizing? You can read more here: Linear robots in the LRX/LRX-S Series: Basic modules for economic production cells Machines in the GX Series the new dimension of injection molding The perfect plasticizing system satisfy complex requirements You can find our brochures and flyers on other topics online at: On request, we will also be pleased to send you the information and technical data for our products free of charge.

23 23 KraussMaffei A strong brand in a unique global group Cross-technology system and process solutions Whether in Injection Molding, Reaction Process Machinery or Automation the KraussMaffei brand stands for pioneering and cross-technology system and process solutions in plastics processing worldwide. For decades, our expertise, innovative ability and passionate commitment to plastics engineering have been your competitive edge. As a cross-industry system provider, we offer you modular and standardized systems as well as solutions customized to your needs. There for you around the world With our worldwide sales and service network, we offer our international customers an excellent basis for a successful business relationship. Due to the close proximity to our customers, we are able to answer your individual inquiries very quickly. We work out the best possible technical and economical solution for your product and production requirements together with you. Test our machine technology for your applications and let our experts put together an individualized service package for you. Individualized service Our employees from customer service, application technology and service help you with your questions and needs on every topic dealing with machines, systems and processes around the globe, quickly and with a high level of expertise. We have developed an extensive customized service spectrum with our lifecycle design, which accompanies you throughout the entire lifecycle of your machines and systems. Take advantage of the personal interaction and flexibility we offer in our practically oriented seminars. We carry out customer-specific trainings either at your location or at our sales and service locations. KraussMaffei Group Comprehensive expertise You can find additional information about KraussMaffei at: Unique selling proposition Technology 3 The KraussMaffei Group is the only provider in the world to possess the essential machine technologies for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands: Injection Molding Machinery, Automation, Reaction Process Machinery and Extrusion Technology. The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your highly skilled and integrated partner. Use our comprehensive and unique expertise in the industry. You can find additional information at: The KraussMaffei Group has a global presence. Countries with subsidiaries are marked in dark blue. In the white-colored regions, the Group is represented by over 570 sales and service partners.

24 Precise. Productive. Energy efficient. The all-electric AX Series The AX machine is our response to your questions for economic part production. Precise. Productive. Energy efficient. The all-electric machines in the AX Series ensure reproducible and reliable molding with minimum use of resources. Smooth running and robust mechanics in conjunction with efficient servomotors and an intelligent closed-loop control system ensure high process reliability along with high availability and excellent machine efficiency. This makes the machines in the AX Series reliable and energy efficient high performers in the ambitious and cost-conscious injection molding company now and in the future WE. 4th edition 10/15. IMM 102 A BR 08/2013 EN KraussMaffei reserves the right to make technical changes Printed in Federal Republic of Germany.