Engineering Passion

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

Machines in the AX SeriesFacts and figures2

Facts and figures regarding the all-electric AX Series

Automotive industry Electrical engineering/electronics industry

Consumer goods Medical/pharmaceutical industry

Application areas

Clamping/injection matrix

Machine/clamping force in to

Clearance (hxv) in mm

Injection units (screw diameter in mm)

SP 55 SP 100 SP 180 SP 380 SP 750 SP 1400 SP200015 18 20 22 20 22 25 28 25 28 30 35 30 35 40 45 40 45 50 55 55 60 70 60 70 75

AX 50 410 x 360AX 80 460 x 410AX 100 460 x 410AX 130 510 x 460AX 180 560 x 510AX 230 610 x 560AX 280 730 x 660AX 350 810 x 730

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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

Flexible, fully integrated automation

Extensive options catalog

5-point double toggle lever with robust mold fixing platens

Smooth-running linear guides Barrier-free access

Transparent technology Tour of the all-electric AX injection molding machine

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High-end plasticizing units

Precise drive technology

Efficient energy management

Intelligent MC6 control system

Machines in the AX SeriesUniversal clamping unit

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 intel-ligent servodrive technology ensures maximum productivity and cost-efficiency while also providing optimum mold pro-tection.

6 Machines in the AX SeriesUniversal clamping unit

The universal AX clamping unitVersatility and efficiency coupled with high precision

Your advantages: – Short dry cycle times– High positioning accuracy– Minimum energy consumption– Low maintenance costs

Speed-path diagram for opening and closing the mold

0%20%40%60%80%100%

200

0

400

600

800

1000

1200

Speed in mm/s

Opening stroke in %

v = 100%

v = 50%

v = 20%

Clamping unit in open position (top) and closed position (bottom), wide positioning range for mold height adjustment

Stable processes thanks to quick and precise movements Highly dynamic and precise servomotors move to set travel positions for the shut-off 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 0.001 mm accuracy.

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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

Frictionless production thanks to optimum clamping mechanicsThe 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 tog-gle lever is ensured at all times through automatic central lubrication.

High degree of flexibility thanks to a large mold fitting spaceLarge 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 fix-ing platens from the carrier and adapter plate. The interchangeability of the adapter plates enables you to choose your own hole patterns – ideal for worldwide pro-duction 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.

The AX features large robust mold fixing plat-ens. The moving platen is broadly supported on linear guides. The tiebars therefore remain free of grease

8 Machines in the AX SeriesUniversal clamping unit

Ergonomic concept for easy accessibility and useWide opening safety gates on the opera-tor's side and non-operator side ensure easy accessibility to the mold and ejector, for example for set-up processes.

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.

Wide opening and barrier-free safety gates for easy accessibility to the mold and ejector

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Your advantages: - Easy accessibility- Large mold fitting space- High platen parallelism- Grease-free tiebars

Universal clamping concept for clamping forces between 500 and 3500 kN

Drive unit for clamping unit

Mold height adjustment Precision linear guide

Changeable mold fixing platensGrease-free tiebars

Symmetrical force transmission ensures optimum clamping of the mold The tightly toleranced and totally sym-metrical design of the clamping unit produces direct and uniform force exer-tion 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 dis-tributed 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 featureClamping 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 auto-

matically and effectively through clamp-ing force regulation. In every cycle the actually attained clamp-ing force is recorded by a measuring system and an actual-target comparison is performed.

If a deviation is registered, the clamp-ing force is automatically readjusted by means of mold height adjustment and precisely regulated to +/- 2 percent.

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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

Practical and functional additional fit-tings for your moldThe extensive AX options catalog contains practical solutions and powerful additional functions for your individual applications and mold technologies. Thanks to an addi-tional 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 tempera-ture control zones for the mold hot chan-nel or temperature control units ensure optimum processes in the mold through reproducible thermal conditions.

Maximum mold protection through sen-sitive mold area protectionThe 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 pro-tected.

Tolerance limit Travel force Reference travel force

Force

Detail

Time

Exceeding of tolerance band

Triggering of emergency stop

Sensitive mold area protection offers maximum protection for your mold

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Every AX machine can be precisely equipped from an extensive options catalog

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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.

Machines in the AX SeriesFirst-class injection unit

The first-class AX injection unitPrecise and productive with maximum efficiency

Excellent melt quality for every applicationKraussMaffei plasticizing units are char-acterized 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 mix-ing 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 applica-tion and therefore the best possible con-ditions for optimum parts quality.

KraussMaffei plasticizing units are synonymous with excellent melt quality coupled with high plasticizing capacity.

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Reproducible processes thanks to built-in precision and dynamismThe 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 pro-cess parameters of speed, path and pres-sure in the minimum tolerance range very quickly and precisely.

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.

First-class shot weight constancy

Best plasticizing + absolute precision = first-class shot weight constancy

0 8040 9080 100120 110160 120Shot Shot

24.4224.4670

24.44

24.468024.46

24.48 24.4690

Grams Grams

+/- 0.001 g

The impressive features of the AX include its excellent repro-ducibility and high availability

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

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Configuration of the AX injection unit from SP 55 to SP 750 / Ø 15 – 55 mm

Machines in the AX SeriesFirst-class injection unit

Lowest energy consumption thanks to maximum efficiencyIn 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-run-ning 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 avail-ability make the AX a productive high performer in every ambitious injection molding company.

Stable processes lead to high parts quality, climate-related process readjust-ments 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 usesDue to the easy accessibility and visibility of the nozzle, the AX contains ideal condi-tions 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.

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Configuration of the AX injection unit from SP 1400 to SP 2000 / Ø 55 – 75 mm

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Plasiticizing drive unit Plasticizing unit with quick-change system

Aggregate drive unit Precision linear guide

Spindle system

Injection drive unit

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With innovative features such as SplitScreen technology, the MC6 control system offers you greater convenience and usability

Usability is our top priority The new MC6 control system with SplitScreen technology and Eco function

Machines in the EX SeriesControl system

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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 intu-itively accessible that you will work better and more efficiently than ever before.

Everything in sight - thanks to the new SplitScreen technologySplitScreen technology is one of the spe-cial highlights of the MC6: Thanks to the split-screen display, you can see the most important production processes simulta-neously. 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 require-ments, by means of simple drag-and-drop movements or swiping movements.

Destination reached with just two taps – thanks to a drop-down menu and a favor-ites barTo ensure that handling the control unit is as user-friendly as possible, deeper navi-gation levels have generally been avoided with the MC6. Based on the credo "reach-ing 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-

The new MC6 control system meets all of your usability needs.

friendly principle is rounded off by a special field for selecting systems. You can there-fore directly select all components of the machine up to automation and technology.

Go Eco! Energy efficiency at the push of a buttonIn keeping with our overall energy-effi-cient design, the MC6 control system has an "Eco button". This allows you to con-figure the machine in the most energy-efficient manner at the touch of a button.

Intelligent user profilesThanks 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 wear-ing gloves. With the Windows 7 Embed-ded 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 lan-guages. 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 Pro-cessDesigner as an example.

You can operate the automation both from the handheld pendant and from the injection mold-ing machine. And, with the MC6, even reverse operation of the injection molding machine is easy from the robot's hand-operated console.

Do you get the most energy-efficient machine setting? Always! - Simply press the Eco button

18 Machines in the AX SeriesEconomic efficiency

Total economic efficiencyHigher 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 con-sumption is often reduced by 50 percent and more.

Due to the low friction losses, the inter-nal cooling load and, thus, cooling water consumption are very low and savings of up to 70 percent are entirely normal.

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

7.2 (16s) 15.6 (17.5s) 28.4 (19s) 43.9 (20,5s) 65.5 (22s)

Technical parts/2.0 D stroke: Throughput in kg/h (cycle time)

0.8

0.6

0.4

0.5

0.7

0.9

1.1

0.2

0.1

0.3

1.0

1.2

Energy consumption in kWh/kg Hydr. IMM AX Series

4.8 (6s) 9.8 (7s) 17.1 (8s) 25.2 (9s) 36.0 (10s)

Thin-wall parts/0.5 D stroke: Throughput in kg/h (cycle time)

0.8

0.6

0,4

0.5

0.7

0.9

1.1

0.2

0.1

0.3

1.0

1.2

Energy consumption in kWh/kg Hydr. IMM AX Series

High availability and increased output lead to higher productivityThe 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 restric-tion. 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 cli-mate. 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.

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Cycle time comparison

Machine with serial functions

Close mold

Injection

Holding pressure

Plasticizing

Cooling

Open mold

Evaluation

Cycle time

AX Series with parallel function

Close mold

Injection

Holding pressure

Plasticizing

Cooling

Open mold

Evaluation

Cycle time

0 1 2 3 4 5 6 7 8 9 10 11 12

12.2 s

Saving

12.2 s

10.8 s

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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 pro-cess: 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 productivityMatching the AX Series with servo-motors, 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 repeat-abilities 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 produc-tion 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 con-veyor 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.

Machines in the AX SeriesAutomation solutions

The economic production cell Competent automation solutions from a single source

KraussMaffei offers you com-plete automation solutions from a single source that match the AX Series. From universal linear robots and well thought-out 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.

Linear robots in the LRX Series (payload)

Clamping forcekN

LRX 50 (payload: 5 kg) LRX 100 (payload: 10 kg) LRX 150 (payload: 15 kg) LRX 250 (payload: 25 kg)

X[mm]

Y[mm]

Z[mm]

X[mm]

Y[mm]

Z[mm]

X[mm]

Y[mm]

Z[mm]

X[mm]

Y[mm]

Z[mm]

500 420 1000 1500 – – – – – – – – –

800 420 1000 1500 550 1200 1500 – – – – – –

1000 420 1000 1500 550 1200 1500 – – – – – –

1300 620 1000 1500 550 1200 1500 – – – – – –

1800 620 1200 1500 550 1200 1500 – – – – – –

2300 – – – 550 1200 2000 900 1400/T 2000 – – –

2800 – – – 550 1200 2000 900 1400/T 2000 900 1500/T 2500

3500 – – – – – – 900 1400/T 2000 900 1500/T 2500

Integrative system: The perfect sym-biosis of a machine and automation technologyThe injection molding process and auto-mation form one unit via the integrated control system with VARAN-BUS tech-nology. 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 pro-gramming, all LRX/LRX-S machines have a handheld pendant with a touchscreen display whose operating steps are identi-cal 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 pro-grams.

AX as an integrated production cell with wider safety enclosure, LRX, chute and conveyor belt

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 exten-

sion options– Fully integrated production cell

Machine panel operates automation

Automation panel operates machine

Machine

(Automation)

Work is made easier through mutual operation - the injection molding machine can be controlled by the automation handheld pendant - and vice versa

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22 Machines in the AX SeriesFurther information

Further informationwhich might also interest you

You can read more here: – Linear robots in the LRX/LRX-S Series:

Basic modules for economic produc-tion cells

– The perfect plasticizing system – satisfy complex requirements

You can find our brochures and flyers on other topics online at: www.kraussmaffei.com. On request, we will also be pleased to send you the information and technical data for our products free of charge.

Are you looking for a suitable automation solution for your AX machine or do you want further information about our core competence, plasticizing?

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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.

KraussMaffeiA 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 pioneer-ing and cross-technology system and process solutions in plastics processing worldwide. For decades, our expertise, innovative ability and passionate commit-ment to plastics engineering have been your competitive edge. As a cross-indus-try system provider, we offer you modular and standardized systems as well as solutions customized to your needs.

There for you around the worldWith 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 indi-vidualized service package for you.

Individualized serviceOur employees from customer service, application technology and service help you with your questions and needs on every topic dealing with machines, sys-tems and processes – around the globe, quickly and with a high level of expertise. We have developed an extensive custom-ized service spectrum with our lifecycle design, which accompanies you through-out the entire lifecycle of your machines and systems. Take advantage of the per-sonal 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.

You can find additional information about KraussMaffei at: www.kraussmaffei.comKraussMaffei Group

Comprehensive expertise

Unique selling proposition Technology3

The KraussMaffei Group is the only pro-vider in the world to possess the essen-tial 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 com-prehensive and unique expertise in the industry.

You can find additional information at: www.kraussmaffeigroup.com

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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 mechan-ics in conjunction with efficient servomotors and an intelligent closed-loop control system ensure high pro-cess 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.

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