Electric movement concept in blow molding- KBB machine series

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Rebecca Ford
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1 High Performance Plastics and Rubber Machines For The Indonesian Market Conference in blow molding- KBB machine series in blow molding- KBB machine series Author: Dietmar Michels Version: 1.0 Date: September, 05 th

2 Agenda 01 Kautex Maschinenbau GmbH - Introduction 02 Advantages & limitations of electrical movement concepts 03 Different concepts 04 Realization movement concept 05 Energy consumption 2

3 01 Kautex at a glance High-end extrusion blow molding machines Automotive, packaging and special applications Market leader for plastic fuel systems production lines Our assets: Over 65 years of experience Highly skilled and motivated employees Vision & Mission The best extrusion blow molding machines No.1 in service Innovation leader 3

01 Kautex Worldwide China Locations: Shunde & Shanghai Shunde & Shanghai, Sales, Service, Training, Research & Development Production, Logistics, HR, Finance, IT 113 Service in 14 countries Germany

4 01 Kautex Worldwide China Locations: Shunde & Shanghai Shunde & Shanghai, Sales, Service, Training, Research & Development Production, Logistics, HR, Finance, IT 113 Service in 14 countries Germany Location: Bonn Sales, Service, Training, Research & Development, Production, Logistics, Technikum, HR, Finance, IT 360 Russia USA Location: Moscow Sales, Service 6 Location: North Branch Sales, Service, Training Logistics, Technikum 18 India NEW Location: Bangalore Sales, Service 3 Sales network in 45 countries Italy Location: Oligate Olona Sales, Service 2 4

5 01 Market Applications 5

6 01 Consumer Packaging Body Care/Cosmetics Body care detergents Detergents Lube Oil & Chemicals Food Pharmaceutical food pharmaceutical 6

7 01 Industrial Packaging Body care IBC and Drums Jerry Cans PC Water Bottles food pharmaceutical 7

8 01 Automotive Body Fuel Systems care detergents Motor Management Parts Functional Components Other Tanks food pharmaceutical 8

9 01 Specialties Toys, Sporting Goods & Body Structural care Parts Type IV Composite Pressure Cylinders food Other pharmaceutical Specialities 9

10 Agenda 01 Kautex Maschinenbau GmbH - Introduction 02 Advantages & limitations of electrical movement concepts 03 Different concepts 04 Realization movement concept 05 Energy consumption 10

11 02 Why electrical movement concept? Technical challenge Complicated maintenance Fast cycle Noise reduction Repeatability Clean production Less energy consumption 11

12 02 Advantages & limitations Advantages: No valve, no pipe, no cylinder. Precise movements. Fast movements. Reduced noise level. Oil free production. Fast start up / Repeatability. Energy recovery

13 02 Advantages & limitations Limitations: Lubrication is necessary as well. Different troubleshooting and maintenance (new challenges). No energy savings at extruder drive and heat capacity. Force limitations? (mold closing, calibration, carriage, WTC). Short lifecycle of specific electronic components

14 Agenda 01 Kautex Maschinenbau GmbH - Introduction 02 Advantages & limitations of electrical movement concepts 03 Different concepts 04 Realization movement concept 05 Energy consumption 14

up/down Wall thickness > parison thickness Extruder

15 03 Different concepts Movements electrical driven: Carriage > for-/backwards Mold > open/close Blowpin > up/down Wall thickness > parison thickness Extruder bobbing > up/down Take out device > article handling 15 15

16 03 Different concepts Conversion motor rotation to linear movement Spindle - Higher wear out - Need to be greased - Limited life time + Fast movement + Precise movement 16 16

17 03 Different concepts Conversion motor rotation to linear movement Tooth-Belt - Noisy - Lower precision - High elasticity + Easy to replace + Low manufacturing costs 17 17

Fast and smooth movements + Precise movements (carriage) + No

18 03 Different concepts Conversion motor rotation to linear movement Crank shaft - Fixed mold thickness - Higher manufacturing costs + Fast and smooth movements + Precise movements (carriage) + No lubrication necessary + Economical + High forces (clamping) + High durability 18 18

19 Agenda 01 Kautex Maschinenbau GmbH - Introduction 02 Advantages & limitations of electrical movement concepts 03 Different concepts 04 Realization movement concept 05 Energy consumption 19

symmetrically distributed to the clamp Less wear Improved torque

20 04 Realisation movement concept Example: calibration unit Construction as planetary screw assembly, Calibration force symmetrically distributed to the clamp Less wear Improved torque Calibration set point +/- adjustable via touch screen Automatic lubrication 20

21 04 Realisation movement concept Example: carriage unit Construction as crank system High speed Smooth and precise movement ( similar sinus curve) Maintenance friendly Lubrication free 21

04 Realisation movement concept Example: clamping unit Crank system Two different clamping versions are available (clamp unit CU1 or CU2 ) Advantage: Reduced moving masses for high

22 04 Realisation movement concept Example: clamping unit Crank system Two different clamping versions are available (clamp unit CU1 or CU2 ) Advantage: Reduced moving masses for high shuttle speed Reduced mass (40% less than previous system) Mold thickness compensation Clamping force adjustment Automatic lubrication system Linear guidings Quick mold change system 22

23 04 Realisation movement concept Clamp force adjustment: Clamp force adjustment via screen. Integrated loads cells for display and supervision of clamping force 23 23

24 Agenda 01 Kautex Maschinenbau GmbH - Introduction 02 Advantages & limitations of electrical movement concepts 03 Different concepts 04 Realization movement concept 05 Energy consumption 24

25 05 Energy consumption Example: energy recovery concept All motion axes drives connected via bus. Braking energy is fed to bus capacitor and is used by other drives. Surplus energy is fed back to electricity grid. No energy dissipation to braking resistor. 25

Energy consumption (kwh/h) 05 Energy consumption 150 140 130 Electric machine Hydraulic machine Energy recovery All electric machine versus comparable hydraulic machine 120 110 100 90 80 70 60 Equal

26 Energy consumption (kwh/h) 05 Energy consumption Electric machine Hydraulic machine Energy recovery All electric machine versus comparable hydraulic machine Equal heating head/extruder Equal extruder drive Equal output hydraulic machine Motion Heating Extruder Total All electric machine consumes about 42 % less electric energy than a hydraulic machine. - Based on monolayer production - Processed material Lupolen 3010D /Hostalen ACP 5231 D 26 26

27 05 Energy consumption Energy overview Information about actual energy consumption for different modules

28 All electric Kautex blow molding machine KBB 28 28

29 Thank you for your attention! Kautex Maschinenbau Kautexstrasse Bonn Germany T F info@kautex-group.com

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