Plastics. be in motion

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1 Plastics be in motion

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3 Added value for our customers Our goal is to enable more flexibility in your machine design and to ensure your machine users the necessary productivity and efficiency in production, thereby giving your machines a competitive edge. That is why the focus of our development is not just the entire system of a machine, but also the added value that we make available to our customers with the modularization of machines, the scalability of components and efficient engineering through flexible technology blocks Your technology partner in the plastics industry Application Extrusion Application Electrical injection moulding machines Application - Servopumps for injection moulding machines Application Blow-moulding Application Handling systems Direct drive technology DST / DSD/DSC b maxx 5000 / b maxx 5600/5700 Switchgear cabinet production & sheet metal solutions Services for the plastics industry 3

4 4 Baumüller - your technology partner in the plastics industry

5 Your benefits Numerous companies working in diverse areas of the plastics industry have, for many years, put their trust in the innovative power and competence of Baumüller. Baumüller played a pioneering role in the development of high-torque motors and the servo pump. Baumüller provides dynamic and precise application solutions from a single source. We develop innovative solutions tailored to your individual requirements for use as individual components or comprehensive systems which give you a decisive advantage over your competitors. Increased process quality due to extremely high precision and dynamic cycle times Considerable reduction in energy costs thanks to our direct drive technology Increased availability of the machine due to low-maintenance drive elements Cost benefits due to increased power density of the machine Reduced life-cycle costs Comprehensive range of services available throughout the entire life cycle of your machines Benefit from our made-to-measure solutions for demanding applications! 5

6 Application Extrusion Precise control dynamics for synchronous processes and constant quality at the highest level. Energy-efficient direct drives reduce the costs of your extrusion plant throughout its life cycle and also make a compact machine design possible. Many of the leaders in the market use Baumüller water-cooled DST high-torque motors to drive an extrusion screw. The low-noise direct drive requires no gearbox and is therefore compact and provides maximum torque at very low speeds. The omission of gearbox, coupling and belts leads to a more compact engineering design of the machine and considerably reduces the maintenance requirement. This series of motors features an integrated thrust bearing. This is particularly important in extrusion technology as it absorbs the axial forces acting to the rear caused by the counter-pressure in the process section. The nominal load units of the modular converter series b maxx 5700 provide the highest performance levels in continuous operation. Although the output of the 5700 series is higher than the standard units, it only takes up the same constructional volume as a result of the compact design. The heat from the switchgear cabinet is systematically removed by water cooling. This minimises the space required in the switchgear cabinet and provides a cost saving. 6

7 Cost effectiveness Calculation of energy efficiency and cost reduction: Increase in the system efficiency by around 10 % due to omission of a gearbox and use of efficient synchronous technology. With a machine shaft output of 100 kw, 7200 operating hours per year and energy costs of 0.08 per kwh, an annual energy cost reduction of approx. 6,600 is achieved. Your benefits at a glance significant reduction in energy consumption reduced floor area of your machine maintenance-free drive elements and therefore increased availability of your machines integrated thrust bearing and screw mounting sensor-free synchronous operation possible increased overall efficiency of the drive system compact in-line arrangement of the drives is possible PLC in the drive and external temperature control system 7

8 Application Electrical injection molding machines Short cycle times, highest levels of precision and reduction in energy costs Many leading manufacturers of injection molding machines are replacing their hydraulic systems with Baumüller direct drive solutions. As the screw is powered electrically: the repeatability of the injection process is increased the waste produced by a machine is reduced and productivity increases as a result the energy consumption of the machine is significantly reduced With fully-electric injection molding machines: manufacturing is carried out in short cycle times to a higher degree of precision the energy consumption of the machine is further reduced the noise produced by the machine is reduced the maintenance requirement is minimised Baumüller provides one-stop comprehensive solutions Peak load converter for high levels of overload Energy-efficient high-torque motors with hollow shaft Software templates to assist the control system Highly dynamic axes for handling Linear motors for ejector function Water and air-cooled motors and converters Wide spectrum of field buses Configuration management by ProMaster 8

9 Cost effectiveness Calculation of energy efficiency and cost reduction: As the overall efficiency has been increased, energy savings of up to 50 % in the drive energy are possible. With a shot output of 400 kg per hour, 7,200 operating hours per year, original energy consumption of 1 kwh per kg and energy costs of 0.08 per kwh, this means annual savings of 46,000. * * Energy savings of 20 % have been assumed for the purposes of this calculation. Comparison of energy flow in injection moulding Fully hydraulic machines Hybrid and electrical machines Control system Plastic melt Hydraulic motor Valve Pump Motor Control system Plastic melt Servo controller Torque motor Your benefits at a glance Parallel function possible which achieves shorter cycle times Increase in process capability and quality with direct drive solutions Marked reduction in energy consumption No flow losses by using hydraulic fluids that are converted to heat Noise reduction through omission of gearbox Reduction in mechanical friction losses Reduction in life cycle costs as a result of reduced maintenance requirements Is designed for use in clean rooms 9

10 Application Servopumps for hydraulic and hybrid injection molding machines With the servo pump, Baumüller has combined the advantages of hydraulic power transmission with the advantages of servo drive technology. Servo pump drives for hydraulic supply systems consist of a constant pump driven by a servo motor. The volume and pressure can be precisely regulated through highly-dynamic modification of the motor speed. If neither volume nor pressure are required, then the motor remains at a standstill and does not consume energy. For pressure regulation: the motor always runs at the slowest speed. It only uses as much energy as is required to ensure continued pressure regulation. Efficient machine solution with Baumüller The integrated Baumüller regulation functionality means it can be easily integrated into existing machine control systems, without having to modify the software. This produces very good regulation results and simplifies commissioning. The regulation of the drive and the low energy consumption of the components, above all in the partial load range, produces a highly efficient yet economical solution, which you can use in your machines to give you decisive advantage over the competition. 10

11 Cost effectiveness Annual electric power costs in a conventional hydraulic machine operated continuously for 300 days with power costs of 0.10 per kwh: 30 kw/h * 7,200 h * 0.10 = 21,600 Typical reduction in energy consumption of 30 %: 21,600 * 0,3 = 6,480 Amortisation of the initial costs: < 1 year In this case the following factors are not taken into consideration at this point: reduced cycle times improved accuracy reduced climate control requirement, smaller cooling system long service life of oil, etc. Your benefits at a glance Significant reduction in energy consumption Excellent regulation properties and repeatability Minimum reaction time with high and low pressure Noise reduction by up to 20 db(a) Integrated regulation in converter; adjustment to accommodate hydraulic non-linearities Servo regulation increases degrees of freedom in machine design Significantly improved levels of efficiency as regulated asynchronous motor with adjusting pump 11

12 Application Blow-molding The blow-molding process places the highest demands on a plastics machine - above all on its drive system. Complex shapes must be produced with a high degree of repeatability and one tenth of a millimeter precision. A fully-electric blow-moulding machine fitted with Baumüller drive systems gives you a decisive advantage in terms of precision and economy over fully-hydraulic machines. A direct drive motor at the plasticizing axis rises the performance and saves energy. Your benefits: less waste reduced noise emission low energy consumption Advantages for your machine concept Water-cooled motors: high levels of dynamics and power density high degree of protection (IP54) very compact design low noise because no ventilator fan is required simple systematic heat dissipation robust and virtually maintenance free high speed setting ranges Water-cooled converters: compact design frees up space in the switchgear cabinet no additional climate control equipment high power density simple commissioning with graphic user interface brief mains failures are bridged all common field bus systems are available 12

13 Application Handling systems Baumüller also offers economical and efficient solutions to support your material handling application and also post-production and further processing of plastic parts, such as inserting, removal, deburring, installing or sorting. From the motor to converter and regulation technology through to control systems and software solutions for movement functions, Baumüller offers a wide variety of handling and automation concepts including the visualization software. For example, we provide one-stop drive solutions for foil extrusion, foil winding and foil printing. System solutions Modularisation of machines with continuous rapidcycling manufacturing processes presents special challenges to the real-time capability of the drive, control and field bus technology. Baumüller provides automation solutions with centralised or decentralised control system architecture and solutions for the dynamic processes with exacting real time demands. The b maxx-driveplc brings intelligence into your drive. This will allow you to realise the control system functionality in the converter and time-critical functions. The b maxx provides userfriendly availability of complex technological drive functions in the machine, such as winder, tensioner and register control systems or electronic cam discs. 13

14 Direct drive technology Direct drive technology compared to the combined motor/gearbox Cost and energy efficiency: Combined motor/gearbox Friction losses caused by wear-based mechanical components Fan motors often used for climate control High costs due to maintenance intervals Direct drives solution Increased overall efficiency by reducing friction losses in the system Minimizing time and cost-expensive maintenance intervals by eliminating technically complicated pulley and toothed gears Significant reduction of energy costs and CO 2 emissions Running noise: Increased noise pollution caused by the gearbox Fan motors often result in additional energy demand Motor operates with almost no noise, no gearbox Integrated water cooling No additional measures required to suppress noise Space requirement: Combined motor and gearbox require a lot of installation space Assembly kit solution enables a high level of integration Compact design, relatively little installation space required Reduction in machinery footprint Service, maintenance, assembly: Regular maintenance intervals when using gearbox and constant oil controls Limited service life of gearbox Utilization of numerous components complicates the assembly; resulting in higher logistic expenses Almost no maintenance costs Long service life of motors Virtually an oil-free system Simple assembly and logistics because less components are required; this results in greater MTBF Reduction in service and maintenance costs as well as decreased machine downtime 14

15 Direct drives technology compared to the hydraulic system Cost and energy efficiency: Hydraulic systems Lower overall efficiency of the hydraulic system because the high system losses heat generation, thus increasing overall machine temperature Fan motors often result in additional energy demand Direct drives solution System losses are negligible as no additional medium, such as hydraulic oil, is required Concurrent machine functions possible, resulting in shorter cycle times Reduction in energy costs and increase in productivity Running noise: Operating noise of valves Tendency to vibrate due to pressure surges and the related noise emission Elimination of valves No noise emission caused by vibration tendencies, as the pressure build-up no longer occurs No additional measures required to suppress noise Space requirement: Hydraulic systems require a large installation space Tighter mounting spaces are achievable No additional space requirement is necessary for hydraulic systems Reduction in machinery footprint Service, maintenance, assembly: Filtering of hydraulic liquid is critical Temperature-dependent viscosity of hydraulic oils Danger of leakage, resulting in housekeeping and environmental concerns Utilization of numerous components complicates the assembly; this results in higher logistic expenses Reduction in maintenance costs due to the omission of hydraulic fluid Almost oil-free system, eliminating cost-intensive disposal Simple assembly and logistics because less components are required; this results in less interference Reduction in service and maintenance costs as well as decreased machine downtime 15

16 DST The powerful high-torque motors Very good smooth running characteristics Energy-efficiency is maintained through wide speed/load range Suitable for sophisticated direct drive technology High torque at low velocities Low-noise Water cooling in a stainless steel design Compact and robust design Smooth housing surface easy to keep clean Permanent field high-torque motors IP54 type of protection Encoder: Resolver, SinCos encoder (option) Other encoders on request Water-cooled variants of the DST high-torque motors are available. Capacity Torque Acceleration Technical data DST Type P N n N M 0 M 0MAX [kw] [hp] [min -1 ] [Nm] [lbf ft] [Nm] [lbf ft] DST DST DST DST DST DST2-560* up to 1200 up to 1609 up to 300 up to up to up to up to The values quoted are maximum values. For details, refer to the technical documentation. * In preparation, preliminary data Subject to modifications 16

17 DSD/DSC Water-cooled servo motors Very high torque density due to efficient water-cooling Water cooling system made of stainless steel Optimum integration in the standard module in terms of connection technology and manufacturing technology Simple connection of cooling medium using quick-fit plug connections Energy-efficient thanks to high efficiency Low noise Smooth casing surface not liable to contamination with dirt Permanently excited synchronous motors Very good true running characteristics Up to IP65 protection Encoder: Resolver, SinCos encoder (option) Version without encoder available on request Capacity Torque Acceleration DSC1-135 Direct-ejector for injection molding machines Compact design and high dynamic as well as overload capacity Special bearings to compensate axial process forces Special mechanical interface for the connection of the spindle Maximum torque up to 560 Nm, rated torque up to 280 Nm, speed range up to 2000 rpm With multi-turn encoder by default, other encoders optional The 16-pole motor can be used in other applications with high acceleration requirements and is extremely compact in design at the same time. Technical data DSD/DSC W Type P N n N M 0 M 0MAX [kw] [hp] [min -1 ] [Nm] [lbf ft] [Nm] [lbf ft] DSD W DSD W DSD W* DSC W DSC W The values quoted are maximum values. For details, refer to the technical documentation. * In preparation, preliminary data Subject to modifications 17

18 b maxx 5000 The safe, modular servo controller Technical data b maxx 5000 Supply units DC link power DC link peak power 1) Overload Dimensions Type Frame size [kw] [hp] [kw] [hp] factor W x H xd [mm] x 395 x 280 / 210 2) x 395 x 280 / 210 2) x 395 x 280 / 210 2) x 395 x 280 / 210 2) 5072 * x 395 x 250 3) 5073 * x 395 x 250 3) 5074 * x 395 x 250 3) 5075 * x 395 x 250 3) 18

19 Technical data b maxx 5100 Regenerative units DC link power DC link peak power 1) Overload Dimensions Type Frame size [kw] [hp] [kw] [hp] factor W x H x D [mm] x 395 x 280 / 210 2) x 395 x 280 / 210 2) 5182 * x 395 x 250 3) 5183 * x 395 x 250 3) 5192 * x 395 x 250 3) 5193 * x 395 x 250 3) Supply units, regenerative units: Supply voltage: V ± 0% AC Supply frequency: 50/60 Hz Electronics supply: external 24 V DC Supply rated voltage: 400 V DC link rated voltage: 540 V (supply unit), 640 V (regenerative unit) Certification: CE, cul *) In preparation 1) for 150 seconds 2) depth air cooling / depth cold plate 3) depth water cooling Height and depth without mounting brackets; Depth including required bending radius of connecting cables Subject to alteration Technical data b maxx 5300 Axis units I N I MAX typ. motor rating 1) Overload Dimensions Type Frame size [A] [A] [kw] [hp] factor W x H x D [mm] x 3 2 x 9 2 x x x 395 x 280 / 210 2) x 6 2 x 18 2 x x x 395 x 280 / 210 2) x 395 x 280 / 210 2) x 395 x 280 / 210 2) x 395 x 280 / 210 2) x 12 2 x 24 2 x x x 395 x 280 / 210 2) x 20 2 x 40 2 x x x 395 x 280 / 210 2) x 30 2 x 60 2 x x x 395 x 280 / 210 2) x 395 x 280 / 210 2) x 395 x 280 / 210 2) 5372 * x 395 x 250 3) 5373 * x 395 x 250 3) 5374 * x 395 x 250 3) 5375 * x 395 x 250 3) 5382 * ,7 225 x 395 x 250 3) 5383 * ,5 225 x 395 x 250 3) Axis units: Electronics supply: external 24 V DC DC link voltage: 540 V rated voltage Chopping frequency: 4/8 khz Certification: CE, cul For further information, see the b maxx complete catalogue *) In preparation 1) Load cycles as per EN ) depth air cooling / depth cold plate 3) depth water cooling Height and depth without mounting brackets; Depth including required bending radius of connecting cables. Subject to alteration 19

20 b maxx 5600/5700 The application specific servo drive Using the peak load and nominal load units of the 5600 and 5700 model ranges in the b maxx 5000 series of converters, drives can be dimensioned to suit the actual power requirements of your application and are therefore significantly more efficient when in operation. Your benefits at a glance Optimised drive solution for specific industry requirements Different sizes available for compatible drive dimensions Less space required in the control cabinet due to smaller devices and the use of water cooling, control cabinet therefore less expensive to manufacture Water cooling in the control cabinet provides a cost-effective solution Compatible with other devices in the b maxx series Safety functions acc. to IEC Technical data b maxx 5600/5700 b maxx 5600 I N I MAX Overload Dimensions Type Frame size [A] [A] factor 1) W x H x D [mm] 5632-F x x F x 681 x F x 681 x F 2) x 550 x F 2) x 550 x F 2) x 550 x F 2) x 710 x F 2) x 710 x 285 b maxx 5700 I N I MAX Overload Dimensions Type Frame size [A] [A] factor 1) W x H x D [mm] 5755-F 2) x 550 x F 2) x 710 x F x 660 x 340 1) for 1 second with a cycle of 5 seconds 2) compact design, water-cooled Subject to alteration 20

21 Switchgear cabinet production & sheet metal solutions Individual switchgear cabinets, sheet metal solutions, control desks and machine cladding in stainless steel and black plate. Use individual design to stand out from the crowd. As a system provider of sheet metal and wiring solutions, we manufacture according to your requirements, from the customer-specific sheet metal components to fully-wired electrical systems. We take the strain out of your manufacturing process and supply cost-optimised prototypes, individual parts or complete series. Products and solutions Machine cladding systems Control desks and control stands Specially designed switchgear cabinets Customised engineering designs according to customer requirements Wired switchgear systems Our services Design advice Planning, development, design Pro-E, STEP, IGES, PDF, DXF Sheet metal processing using state-of-the-art machinery: punching, bending, welding, riveting, press-fitting of ST 1203, ALMG 3 and V2A Powder coating structured or smooth, colour according to customer requirements Surface treatment anodising, coating, labelling, screen printing Prefabrication, final assembly, module assembly Series wiring in acc. with specified circuit diagrams Cable harness manufacturing Dispatch, packaging and logistics according to customer requirements 21

22 Services for the plastics industry Service throughout the entire life cycle of your machines The network of Baumüller subsidiaries and partners all over the world is available to you and your customers as a service partner. We offer a wide range of one-stop innovative and solution-oriented services round the clock and on site, wherever your machines are in service. Our common goal: increased availability of your machines and systems. Development and consulting Baumüller is an innovative development and consulting partner for the textile industry. Our specialists are on hand right from the concept stage of your machines to assist you in development of the ideal solution for your drive and automation system specially adapted to your specific application. Training Whether it be complex automation systems or individual components we can train your employees using application-specific training modules that are fully matched to your requirements. Your employees can then use the knowledge acquired to get the most out of their machines. Training courses can be held on site or at our training centre, the Baumüller Academy. We also offer courses for your end customers, for example in the correct application of the drive system or systematic troubleshooting. 22

23 Global 24 hour service hotline: Maintenance A professionally maintained machine supports reliable production and the safety for your employees. In addition, this gives you reliable and conclusive information on the condition of your machines. Your machines and systems are carefully inspected and maintained using state-of-the-art testing and measuring instruments. In the event of irregularities we will inform you of the causes and provide appropriate solutions. Spare parts In order to be able to rectify a breakdown immediately, the correct replacement components and spare parts must be available at short notice. We can develop a comprehensive service concept with you and put together a technically appropriate and cost-effective selection of components and spare parts. If necessary, we can supply missing components throughout the world, day and night by express courier. Repair Our many years of experience and technical equipment in our worldwide branches means we can provide high-quality repair services for your complete drive train ranging from the replacement of defective parts to complete overhaul. Many of our subsidiaries and partners have experience in the repair of converters and motors by other manufacturers. This provides your end customers with an additional advantage: One-stop service. Installation / commissioning of machines & systems From the installation of individual components to the relocation of complete manufacturing lines and the commissioning of turnkey plants: Our experienced specialists and the detailed procedure developed with you ensure the professional and safe installation and commissioning of your machines and systems all over the world. We implement every project in accordance within the agreed timescales and in compliance with the stipulated guidelines and quality standards. 23

24 Baumüller Nürnberg GmbH, Ostendstraße 80 90, Nürnberg, Phone: +49 (0) , Fax: +49 (0) Baumüller Anlagen-Systemtechnik GmbH & Co. KG, Ostendstr. 84, Nürnberg, Phone: +49 (0) , Fax: +49 (0) Baumüller Reparaturwerk GmbH & Co. KG, Andernacher Straße 19, Nürnberg, Phone: +49 (0) , Fax: +49 (0) Baumüller DirectMotion GmbH, Flugplatzweg 2, Bad Gandersheim, Phone: +49 (0) , Fax: +49 (0) All data/information and particulars given in this brochure is non-binding customer information, subject to constant further development and continuously updated by our permanent alteration service. Please note that all particulars/figures/information is current data at the date of printing. These particulars are not legally binding for the purpose of measurement, calculation or cost accounting. Prior to using any of the information contained in this brochure as a basis for your own calculations and/or applications, please inform yourself about whether the information you have at your disposal is up to date. Therefore, no liability is assumed for the correctness of the information en.10/16.10E 10/16