IntElect Smart - asaf. ¢  SE Range IntElect Performance IntElect Smart 2. Dynamik and

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  • 1

    IntElect Smart Allelectric IMM

  • Sumitomo (SHI) Demag – Technical Co-operation

    SE Range IntElect Performance

    IntElect Smart

    2

  • Dynamik and precise

    clamp  Energy recovery

    NC5+ controlParellism of mould platen  Precision and reduction of

    wear and tear of mould

    Space  Optional

    intagration of

    hydraulic

    aggregate

    IntElect Smart

    activeRemote

    activeEcon

    activeQ

    Sensetive mould

    protection

    Screw with constant L/D ratio (20:1 and 25:1)

     Highly homogenious melt

    quality

     Brilliant colour distribution

     Easy cylinder change

    Toggle  Robust, stabil, efficient

    and fast

    3

    file:///C:/Users/gladigau/PG_Eigene/03_Pr?sentation Produktionseffizienz/activeremote.ppt file:///C:/Users/gladigau/PG_Eigene/03_Pr?sentation Produktionseffizienz/activeEcon.ppt file:///C:/Users/gladigau/PG_Eigene/03_Pr?sentation Produktionseffizienz/ActiveQ.ppt

  • Sensible Injection

    pressure monitoring

    in axis of screw

    Fast ejector  Dynamic movement

    Linear

    guidance

    Free access (3 sides)  Convinient possibilities

    for automation

    Ridge machine bed  Highest support and

    stiffness

    IntElect Smart

    4

  • Standard Synchro drive High-Torque Direct drive

     High rpm

     Low torque

     Gear needed (belt)

     High torque

     Medium rpm

     No gear

     High stiffness

     Low noise level

     Low clearance

    Smart – Optimised drive concept

    5

  • 6

    Injection unit

    Injection drive:

    •Low inertia of drive mass,

    •Small and compact  highly dynamic

    Dosing drive:

    •Short

    •High torque

    Integrated spindle IU 110 Injection speed

    Fast acceleration

    High speed

    Smart – Optimised drive concept

  • Smart – Optimised drive concept

    7

  • • Load cell in longitudinal axis

    • High resolution

    • Directly along axis of force

    • Auto calibration

    • Patented

    IntElect Smart – Injection pressure measurement

    8

  • 9

    Cooling

    Ejector 

    Cooling

    Ejector 

    Faster cycle time due to parallel movement (separate drives)

    Cycle using sequential movements

    Cycle using parallel movements

    Higher productivity

    Cycle

    Mould  Mould 

    Injection

    Holding

    Dosing Nozzle 

    Dosing

    Cycle time

    reduction

    Mould open

    Ejector

    Cycle

    Mould close

    Injection

    Holding

    Nozzle Dosing

    Nozzle

    Nz 

    IntElect Smart - Efficiency

  • 10

    Less noise

    Comparing to noise level of car

    inside while driving

    IntElect 50 km/h

    71 dB(A) hydr. machine 160 km/h

    61 dB(A)

    IntElect only ¼ of noise level as per subjective perception

    Average noise

    level

    IntElect Smart - Environmental

  • 11

    Design optimised for servo drive

    Kinematics current range

    i= F

    s /F

    k

    Steady

    acceleration Soft Force increase

    Kinematics previous range

    Cross head stroke

    Deceleration Steep

    Force

    increase

    i= F

    s /F

    k

    Toggle

    Cross head stroke

  • Optimised toggle

    12

  • Optimised toggle

    13

  • 14

     Direct drives

     Linear guidance, low friction

     Energy recovery

     activeEcon

     Optimised toggle

     Cylinder insulation

    IntElect Smart Energy efficiency

  • 15

    Light plate

    (PMMA) 350 ton

    16,1 g 16,3 s

    Trunk

    (ABS) 50 ton 55,1 g 85,7 s

    Cover

    (ABS) 50 ton

    KFZ-Stecker

    (PC) 100 ton 19,1 g 19,0 s

    306 g 70,0 s

    8,4 g 11,0 s

    Connector

    (PS) 100 ton

    Energie-

    verbrauch

    IntElect

    0,956 kWh/kg

    0,81 kWh/kg

    0,82 kWh/kg

    0,58 kWh/kg

    0,78 kWh/kg

    Energie-

    verbrauch

    hydr. SGM

    1,83 kWh/kg

    1,79 kWh/kg

    1,72 kWh/kg

    0,86 kWh/kg

    1,95 kWh/kg

    48 %

    55 %

    52 %

    33 %

    60 %

    Item Gewicht Zyklus-

    zeit

    Energie-

    einsparung

    Pending on application and material

    Ø > 50 % Energy saving vs. hyd. IMM

    Item Gewicht Zyklus-

    zeit Item Gewicht

    Energie-

    verbrauch

    IntElect

    Zyklus-

    zeit Item Gewicht

    Energie-

    verbrauch

    hydr. SGM

    Energie-

    verbrauch

    IntElect

    Zyklus-

    zeit Item Gewicht

    Energie-

    einsparung

    Energie-

    verbrauch

    IntElect

    Zyklus-

    zeit Item Gewicht

    Energy

    Consumption

    Hyd. IMM

    Saving

    Energy

    consumption

    IntElect

    Cycle

    time Item

    Shot

    weight

    IntElect Smart Energy consumption

  • Pipette

    ELECTRONIC

    Connectors

    AUTOMOTIVE

    Valve housing

    Medical

    Connectors

    IntElect Smart

    PACKAGING

    Closures and containers

    16

  •  Based on Sumitomo drives

     Perfect combination of drives, inverter, control

     Shortest response time for injection, holding and dosing

     10 times faster than NC5  20 times faster than NC4

     Enable highly dynamic movement

     Highly dynamic in combination with precision and repeatability

     Servo card using own processor

    18

    Standard control activeDynamics

    Servo card

    Motor

    CPU

    CPU

    Servo card

    Motor

    activeDynamics IntElect Smart – Injection control

    Control via CPU Control via servo card

  • 19

    activeDynamicsStandard

    activeDynamics

    Result:

     300mm/s in 0,05s 300mm/s in 0,025s

  • 20

    Result:

     Pressure profile very accurate and highly dynamic

    activeDynamics

    activeDynamicsStandard

  • 21

    Acceleration to 200 mm/s  0,025 s

    Breaking from 200 mm/s to 0  0,02 s

    Pressure reduction from 1400 to 250 bar  0,04 s

    Sample: Cup

    Smart 100-340 (Ø25 mm)

    Material: PP MFR 100

    Wall section: 0,33 mm

    Flow length: 100 mm

    Injection time: 0,14 s

    Injection speed: 200 mm/s

    Inj. pressure max.: 1400bar

    Holding time: 0,15 s

    Holding pressure: 250 bar

    Cycle times: 3,3 s (2,8 s)

    Negative stroke for pressure release

    Injection press.

    Screw stroke

    Injection speed

    activeDynamics

  • Optimisation of switch over process by activeFlowBalance

    (pressure compensation)

    activeFlowBalance mould will be

    stopped and kept at position to

    compensate pressure differences in

    melt system

    activeFlowBalance

    Advantages

    Reduction of:

    •Pressure peak

    •Flashing

    •Under filling

    •Venting problems

    •Inconsistent melt front speed

    •Inconsistent distribution of part quality

    Very easy operation

    22

    activeFlowBalance - IntElect Smart

  • G ra

    tb ild

    u n

    g

    F(vE)

    High pressure

    Low pressure

    Unbalanced filling process/ w/o activeFlowBalance:

    Cylinder Runner 2-Cavities

    activeFlowBalance V

    e n

    tin g

    2xVE

    23

  • F(vE=0)

    Pressure compensation

    High pressure

    Low pressure

    Unbalanced filling process/ with activeFlowBalance:

    Cylinder Runner 2-Cavities

    24

    activeFlowBalance

  • 25

    Cylinder

    Runner

    Cavity

    Pressure compensation in melt system

    activeFlowBalance

  • 26

     Definition: Switch over position = when 1st cavity is filled

    v/p=20mm v/p=17mm v/p=14mm v/p=12mm

    v/p=9mm v/p=8,5mm v/p=8mm v/p=7,8mm

    Poor balancing 6-cavity mould

    29 30 31

    32 33 34

    activeFlowBalance - Sample: Dia frame

  • 27

    Result: Reduction of cavity weight spread due activeFlowBalance.

    Filling grade after activeFlowBalanceFilling grade at v/p

    1,75

    1,8

    1,85

    1,9

    1,95

    2

    2,05

    2,1

    2,15

    2,2

    0 0,05 0,1 0,15 0,2 0,25 0,3 0,4

    activeFlow-time [s]

    W e ig

    h t

    [g ]

    1,75

    1,8

    1,85

    1,9

    1,95

    2

    2,05

    2,1

    2,15

    2,2

    0 0,05 0,1 0,15 0,2 0,25 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1

    holding pressure time (after activeFlow) [s]

    M a s s e [

    g ]

    Kavität29

    Kavität30

    Kavität31

    Kavität32

    Kavität33

    Kavität34