All-electrics make strides in performance, applications
New lines of all-electric injection molding machines making their debut at the K show targeted packaging and clean-room and precision molding applications. Key benefits include better performance, greater modularity, improved control and wider application, as well as lower cost.
KRAUSSMAFFEI CHAMPIONS MODULARITY WITH PX LINE
KraussMaffei Group GmbH, Munich, is touting the modularity and flexibility of its new PX series of all-electric injection molding machines. The PX line comes in five sizes with clamping forces from 55 to 220 tons, and replaces the company's AX series, while adding numerous options for configuring the machine.
The flexibility of the new all-electric line makes it ideal for use in medical, automotive, electrical and high-speed packaging applications. The PX series has a split machine bed with the injection unit and five-point toggle clamp mounted on their own bases rather than sharing a base. Molders can tailor their machine by selecting from a range of clamping and injection unit sizes.
Molders can link large clamping units to small injection units to exactly match the machine to what is required for production, said Hans Ulrich Golz, managing director of KraussMaffei and president of the injection molding machinery section.
KraussMaffei, represented in the U.S. by KraussMaffei Corp., Florence, Ky., offers five injection unit sizes for each clamp size; each injection unit has three or four options for screw diameters.
Also new is that the PX comes with a choice of two platen sizes for each clamping tonnage. "Versions of the PX come standard with larger platens of the respective next higher clamping force," Golz said. The larger-platen models have more clearance than the standard platen size and can accommodate larger and heavier molds even without upsizing the injection unit.
KraussMaffei identifies models with the larger platen with odd numbers. For example, the PX 51's wide platen can accommodate a 1,650-pound mold; in comparison, the PX 50's standard platen can handle mold weights up to 990 pounds. There are 44 different combinations of clamping and injection units available for the PX series, Golz said.
The PX also allows users to select faster injection speeds or more ejector force, Golz said. For applications requiring high throughputs, such as thin-wall injection molding, there is an option to double the normal injection speed. Molders can power part ejection two ways — with an electric ejector drive or by using a servo-hydraulic system that was not offered with the AX series.
PX machines use separate air-cooled servomotors for injection, plasticizing and clamping. The standard version of the PX incorporates servo hydraulics to run each axis for the injection unit and the ejector movements. The initial movement takes place using two parallel barrels. This design enables nozzle contact forces to be built up quickly when compared to the use of one electric barrel.
At the K show, KraussMaffei operated each standard size of the PX series to demonstrate the line's wide range of applications. The machines made a medical membrane, a medical Y-connector, an electrical terminal box, a flip-top cap and an automotive part with a high-quality surface.
SUMITOMO LAUNCHES SECOND GENERATION OF INTELECT
Sumitomo (SHI) Demag, Strongsville, Ohio, launched the second generation of its all-electric IntElect series, touting the machines' improved performance and compact footprint. The new IntElect generation features an updated direct-drive system that offers faster injection speeds and clamping, additional energy savings and greater accuracy, compared to the first generation. The first of the toggle-clamp machines, the 55-ton IntElect 50, was exhibited at the show. Additional models — the 75, 100, 130 and 180 — will be offered, with clamping forces of 82.5, 110, 143 and 198 tons, respectively.
The line features new, high-torque, direct-drive motors specially developed by the Sumitomo Group for precision, dynamics and energy efficiency.
Sumitomo will offer machines in standard and high-performance versions, as it did with the previous IntElect generation, with clamping forces ranging from 55 to 495 tons. The standard version is designed for applications formerly run on a hydraulic machine, while the high-performance model is for more challenging jobs.
The new IntElect series incorporates Sumitomo Demag's NC5 Plus control, which features a color touch screen. The touch screen is more responsive than the previous NC5 control interface and has the look and feel of a smartphone.
Sumitomo Demag also offers eight technology hardware/software modules under its Active Series name. Designed to run on the IntElect series, they can help a molder tailor the machine to a specific application while maximizing efficiency and output.
The modules include ActiveDynamics, which works with the direct drives, converter and control system to provide faster response times. The ActiveLock adjustable nonreturn valve increases machine precision, while the ActiveFlowBalance machine function balances pressure levels.
ActivePowerLink optimizes clamping forces and clamp locking to conserve energy, while ActiveGuide helps to ensure platen parallelism for minimal mold wear and high-quality parts. ActiveLock provides mold protection, while ActiveAdjust optimizes overall cycles for better dynamics and precision.
Also available are ActiveRemote, which allows the machine to communicate with auxiliary equipment, and ActiveEcon, which helps the user determine the optimal process settings and energy consumption levels.
The IntElect 50 was unveiled at the show, where it produced a 7.6-gram resealable closure made from PP that incorporated a complex membrane. The demonstration emphasized how the machine and its incorporated technologies provide for lower process variation, energy consumption and cycle times.
MILACRON ENHANCES ELEKTRON LINE FOR MORE APPLICATIONS
Milacron LLC, Batavia, Ohio, rolled out an enhanced version of its Elektron line of all-electric injection molding machines at the Düsseldorf fair, signaling a continuation in the development of the machine and controls. Milacron showed the first model in the new Elektron Evolution (EVO) line for the first time. It was configured with a secondary all-electric E-Multi auxiliary injection unit and new linear robot, both from Milacron. The basic Elektron series is offered with clamping forces of 44, 55 and 66 tons and is designed for a range of applications, including high-precision molding and clean rooms.
Elektron EVO uses the Mosaic control system developed for Milacron's Ferromatik series of servo-driven toggle electric machines, said CTO Bruce Catoen. The standard Elektron line uses Milacron's Endura Touch Control rather than the higher-performing Mosaic.
The newest iteration of Mosaic can now display information about hot-runner and mold-temperature control on the same screen and can also control materials-handling devices.
During the K show, an Elektron EVO with 220 tons of clamping force used co-injection and a single-cavity mold to produce a 115-gram PP container in a cycle time of 20 seconds.
Milacron's other series of all-electric machines include the Roboshot, Powerpak and Elektra lines, which are targeted at packaging, consumer goods, medical applications and multishot and sandwich molding. The product lines are part of Milacron's Advanced Plastics Processing Technologies business, which encompasses its extrusion and blow molding machinery technologies.
TOSHIBA UNITS FEATURE ENHANCED PERFORMANCE
Toshiba Machine Co. America, Elk Grove Village, Ill., updated the ECSX series of all-electric machines it introduced in 2010, launching the new ECSXII line. The new line features a more robust machine frame, and upgraded servo electric motors and components that increase standard injection screw speeds from 200mm per second to 300mm per second and improve response times while providing more precise injection and more repeatable operation.
ECSXII machines are available with clamping forces from 33 to 275 tons with machines up to 605 tons likely to be developed. The machines feature separate servomotors, designed by Toshiba but built in Japan by Panasonic, for screw charging, injection, clamping and ejection. Additional features of the redesigned machines include an angled, five-point toggle mechanism that distributes forces evenly across the platen to minimize part defects and extend mold life.
An advanced load cell system, used in combination with the machine's V50 controller, ensures accurate control of injection pressure. Toshiba said this feature can analyze and control the balance of the mold in real time without the use of internal transducers. A strain gauge automatically adjusts clamping tonnage on the fly to ensure accurate force is applied, which extends mold life.
Also standard on the ECSXII machines is the simultaneous performance of several machine motions to reduce cycle times by up to 30 percent. A clamp-relax function takes place during cooling, which helps to trim cycle times by shortening the time to release the clamp prior to mold opening. A lap-sequence function allows for injection as soon as the mold halves touch during closing, and an eject-on-the-fly function starts part ejection as the clamp is opening. Other simultaneous sequences that shrink cycle times include opening the mold while charging, and pulling the core in and out on the fly.
The ECSXII series also comes with Toshiba's iPAQET Lite data management software installed in the V50 controller, providing production monitoring, data collection and analysis. The controller also has additional programs that improve machine consistency, including dynamic self-tuning software for injection and clamping. Toshiba's new Flexible Injection Downsize System (FIDS) lets the user adjust the shot size to as small as 0.43 ounce, depending on model.
NEGRI BOSSI ADDS SECOND ALL-ELECTRIC LINE
Negri Bossi SpA, Cologno Monzese, Italy, has added a second line of all-electric toggle machines to its product line. The ELE line, which debuted at the show, will initially be offered in clamping forces ranging from 55 to 385 tons, with higher-tonnage models and multicomponent variants becoming available next year. The ELE joins Negri Bossi's eVesta Evolution series of all-electrics, which comes in five models with clamping forces ranging from 88 to 440 tons.
The new machines use the company's new Tactum multitouch controller, which allows users to move through screens by scrolling or swiping. They are equipped with Negri Bossi's new smart flex 2 locking unit, designed with a toggle geometry that is coupled specifically with electrically driven platen movements.
At the show, the company presented an ELE model with 180 tons of clamping force. It produced a lid that was labeled in the mold, running in a four-cavity mold in cycle times of less than 3 seconds. Negri Bossi's sister company, Sytrama, manufactured the side-entry robot and labeling system used in the demonstration.
In addition, Negri Bossi also unveiled a new clamp design that will likely form the basis of a new generation of machines from the company. The X-concept clamping unit has the benefits of a traditional toggle clamp yet competes with a two-platen design in terms of cleanliness and footprint, said CEO Craig Ward.
Negri Bossi developed two versions of the X-concept clamp, a 700 unit and an 800 unit. They have the capabilities of larger clamping units, but with smaller footprints. The X-concept clamping unit has a toggle geometry that allows for better distribution of mass in the clamping system while remaining rigid. The locking mechanism of the X-concept toggle clamp can be actuated electrically or hydraulically, or have a hybrid drive. The company's U.S. operation is Negri Bossi North America, New Castle, Del.
WITTMANN BATTENFELD TARGETS PACKAGING WITH ECOPOWER EXPRESS
Wittmann Battenfeld GmbH, Vienna, introduced EcoPower Express, a new all-electric line of injection molding machines for high-speed packaging applications.
The machines are based on the company's EcoPower line but are larger, with clamping forces ranging from 240 to 500 tons. The direct-drive, beltless machines have a five-point double toggle clamp. Machines in the standard EcoPower and EcoPower Medical lines have clamping forces from 55 to 300 tons.
The EcoPower Express machines use highly dynamic servo-driven motors that deliver precise injection and accurate platen opening and closing movements. A rack-and-pinion drive operated by two water-cooled servomotors handles injection. While more compact, the new injection unit is 40 percent more responsive than an accumulator system. Injection speeds up to 600mm per second are possible, and the machines handle injection pressures from 29,020 to 36,275 pounds per square inch.
Clamping is also achieved through a direct-drive, rack-and-pinion system, operated by a servomotor with a digital absolute encoder. Maximum clamp closing speeds up to 1,800mm per second are possible. The machines are designed so that the clamping force builds up parallel to injection, which optimizes cycle time. They use Wittmann Battenfeld's new Unilog B8 control system.
The company, which has a U.S. operation,Wittmann Battenfeld Inc., Torrington, Conn., said the first deliveries of the new machines are planned for the third quarter of 2017. At the K show, an EcoPower 400/1100+ machine supporting a Wittmann W837 robot and side-entry in-mold-labeling system produced lids from PP in an eight-cavity tool in a 4.7-second cycle.
HAITIAN EXTENDS VENUS II ALL-ELECTRIC LINE
Haitian International, Hong Kong, introduced an all-electric series of injection molding machines targeted at packaging applications. Haitian, parent of Zhafir Plastics Machinery GmbH, Ebermannsdorf, Germany, is represented in the U.S. by Absolute Haitian Corp., Worcester, Mass.
The company has extended its Venus II series of fully electric injection presses with a new "p" version. The new Venus II/p targets packaging projects with cycle times of more than 4 seconds, which includes a multitude of items such as containers, caps and closures.
At the show, Haitian demonstrated the capabilities of the series with the first available model in the line, a VEII3000/1700p. It produced an in-mold labeled cup in 4.4 seconds. A Cartesian robot from Sepro Robotique and automation equipment from Machine Pagès, both of France, were integrated into the molding cell at the show.
The VE II/p line will have machines with clamping forces ranging from 165 to 495 tons and unique features, including a redesigned injection unit with a special ball screw that prevents material from overheating. The configuration delivers response times of 35 milliseconds and injection speeds up to 350mm per second.
The p version also has a square platen — not used in standard Venus II models — to create more room and a modified machine bed for greater stability. Haitian updated the Venus line by redesigning the five-point toggle to reduce platen inertia and minimize joint stress while increasing the performance of the toggle.
CHEN HSONG DEBUTS LOWER-COST ALL-ELECTRIC MODEL
Chen Hsong Group, Hong Kong, represented in the U.S. by Gluco Inc., Jenison, Mich., showed a lower-cost, all-electric injection molding machine for packaging applications.
The new SuperMaster EJ series delivers the fast acceleration, high-precision motion and accurate positioning and pressure control of a top-of-the-line all-electric unit at a cost closer to a servo-hydraulic machine, according to the company.
Chen Hsong incorporated servomotor and controller technology from Taiwan and BNR controls from Europe into the model line for robustness and reliability. The model has four servomotors that control all movements in the machine, including screw recovery, injection, clamping and ejection.
Chen Hsong said the SM EJ series is suited to thin-wall and medical products. The line, which starts off with the 100-ton SM90EJ model, will likely grow to a range of machines with clamping forces from 55 to 330 tons, the company said.
Mikell Knights, senior correspondent
Contact:
Absolute Haitian Corp., 508-459-5372, www.absolutehaitian.com
Gluco Inc., 616-457-1212, www.chenhsong.com
KraussMaffei Corp., 859-283-0200, www.kraussmaffeigroup.us
Milacron LLC, 513-536-2000, www.milacron.com
Negri Bossi North America, 302-328-8020, www.negribossi.com
Sumitomo (SHI) Demag, 440-876-8960, www.sumitomo-shi-demag.us
Toshiba Machine Co. America, 888-593-1616, www.toshiba-machine.com
Wittmann Battenfeld Inc., 860-496-9603, www.wittmann-group.com