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
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 spindleIU 110 Injection speed
Fast acceleration
High speed
Smart – Optimised drive concept
• 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
DosingNozzle
Dosing
Cycle time
reduction
Mould open
Ejector
Cycle
Mould close
Injection
Holding
NozzleDosing
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
accelerationSoft Force increase
Kinematics previous range
Cross head stroke
Deceleration Steep
Force
increase
i=F
s/F
k
Toggle
Cross head stroke
14
Direct drives
Linear guidance, low friction
Energy recovery
activeEcon
Optimised toggle
Cylinder insulation
IntElect SmartEnergy efficiency
15
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
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
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
Gra
tbild
un
g
F(vE)
High pressure
Low pressure
Unbalanced filling process/ w/o activeFlowBalance:
Cylinder Runner 2-Cavities
activeFlowBalanceV
en
ting
2xVE
23
F(vE=0)
Pressure compensation
High pressure
Low pressure
Unbalanced filling process/ with activeFlowBalance:
Cylinder Runner 2-Cavities
24
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]
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
28
activeFlowBalance
29
activeLockRing NRV Ball NRV
Open when injection starts Closed during injection
NEW!
activeLock - IntElect Smart
30
activeLockRing-NRV
InjectionAxial locking
Dosing
Rotary locking
activeLock
Eliminating back flow by usage of activeLock
Injection
Dosing
31
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
32
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
33
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
34
- 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
35