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IntElect SmartAllelectric 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

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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

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6

Injection unit

Injection drive:

•Low inertia of drive mass,

•Small and compact highly dynamic

Dosing drive:

•Short

•High torque

Integrated spindleIU 110 Injection speed

Fast acceleration

High speed

Smart – Optimised drive concept

Smart – Optimised drive concept

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• Load cell in longitudinal axis

• High resolution

• Directly along axis of force

• Auto calibration

• Patented

IntElect Smart – Injection pressure measurement

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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

DosingNozzle

Dosing

Cycle time

reduction

Mould open

Ejector

Cycle

Mould close

Injection

Holding

NozzleDosing

Nozzle

Nz

IntElect Smart - Efficiency

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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

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Design optimised for servo drive

Kinematics current range

i=F

s/F

k

Steady

accelerationSoft Force increase

Kinematics previous range

Cross head stroke

Deceleration Steep

Force

increase

i=F

s/F

k

Toggle

Cross head stroke

Optimised toggle

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Optimised toggle

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14

Direct drives

Linear guidance, low friction

Energy recovery

activeEcon

Optimised toggle

Cylinder insulation

IntElect SmartEnergy efficiency

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Light plate

(PMMA) 350 ton

16,1 g 16,3 s

Trunk

(ABS) 50 ton55,1 g 85,7 s

Cover

(ABS) 50 ton

KFZ-Stecker

(PC) 100 ton19,1 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 GewichtZyklus-

zeit

Energie-

einsparung

Pending on application and material

Ø > 50 % Energy saving vs. hyd. IMM

Item GewichtZyklus-

zeitItem Gewicht

Energie-

verbrauch

IntElect

Zyklus-

zeitItem Gewicht

Energie-

verbrauch

hydr. SGM

Energie-

verbrauch

IntElect

Zyklus-

zeitItem Gewicht

Energie-

einsparung

Energie-

verbrauch

IntElect

Zyklus-

zeitItem Gewicht

Energy

Consumption

Hyd. IMM

Saving

Energy

consumption

IntElect

Cycle

timeItem

Shot

weight

IntElect SmartEnergy consumption

Pipette

ELECTRONIC

Connectors

AUTOMOTIVE

Valve housing

Medical

Connectors

IntElect Smart

PACKAGING

Closures and containers

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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

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Standard control activeDynamics

Servo card

Motor

CPU

CPU

Servo card

Motor

activeDynamics IntElect Smart – Injection control

Control via CPU Control via servo card

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activeDynamicsStandard

activeDynamics

Result:

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

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Result:

Pressure profile very accurate and highly dynamic

activeDynamics

activeDynamicsStandard

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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

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activeFlowBalance - IntElect Smart

Gra

tbild

un

g

F(vE)

High pressure

Low pressure

Unbalanced filling process/ w/o activeFlowBalance:

Cylinder Runner 2-Cavities

activeFlowBalanceV

en

ting

2xVE

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F(vE=0)

Pressure compensation

High pressure

Low pressure

Unbalanced filling process/ with activeFlowBalance:

Cylinder Runner 2-Cavities

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activeFlowBalance

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Cylinder

Runner

Cavity

Pressure compensation in melt system

activeFlowBalance

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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

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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]

Weig

ht

[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]

Masse [

g]

Kavität29

Kavität30

Kavität31

Kavität32

Kavität33

Kavität34

Start activeFlow End activeFlow

aFB-time Holding pressure (550bar specific)

activeFlowBalance

Different flow lines

Quelle: Customer

Reduced imbalance due to balanced conditions

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activeFlowBalance

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activeLockRing NRV Ball NRV

Open when injection starts Closed during injection

NEW!

activeLock - IntElect Smart

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activeLockRing-NRV

InjectionAxial locking

Dosing

Rotary locking

activeLock

Eliminating back flow by usage of activeLock

Injection

Dosing

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pclose = 182,5bar

tclose = 0,16s

pclose = 0bar

tclose = 0s

Suck back 5mm Screw 25mm

Dosing =200rpm

Back press. = 120bar

Pressure in front of NRV

Pressure behind NRV

Standard NRV activeLock

activeLock

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Shot weight Melt cushion

absolute Fluctuation absolute Fluctuation

NRV g g cm³ cm³

Standard 42,094 0,037 6,485 0,190

activeLock 42,035 0,017 4,719 0,087

Delta 54% 54%

activeLock – Sample Connector housing

Source: Customer application

Machine Smart 160/520-500

Screw L/D=20, SC-Ø=35mm

Part Connector housing

Material PBT GF-20

Shot weight 42,0g

Part weight 4,8g

Cycle time 14,9s

Cavities 8

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Clamp force 1

Clamp force 2

Clamp force 3

Locking force

Speed adjustable

Result: Better venting

Improved maintenance interval (mould)

IntElect Smart - Clamp force built up simultaneous

Filling problems due to lack of venting

- Graphical display energy

consumption

- Consumption of a single axis

displayed

- Detailed analyses for each axis

IntElect Smart – activeEcon (Option)

Integrated energy control and more

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- Consumption measured:

- Drives

- Heating

- Total

- Comparison of different machine

set ups

Optimisation of energy

consumption

- Results:

- Consumption/cycle (Wh)

- Consumption/kg plastic

resin (kWh/kg)

- Average consumption (kW)

- Actual consumption (kW)

activeEcon

Integrated energy control and more

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- Material cost, energy cost

and hourly machine rate can

be entered.

- activeEcon displays energy

consumption and production

cost for current production.

- Data saved with mould

catalogue. Comparison with

previous production possible.

activeEcon

Integrated energy control and more

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