Focus. Electric ALLROUNDERs. Injection moulding machines for complex part production.

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1 Focus Electric ALLROUNDERs Injection moulding machines for complex part production

2 At a glance [s] 1 2,5 2,0 1,5 1,0 0,5 ALLDRIVE EDRIVE / GOLDEN ELECTRIC Hydraulic [mm] ALLDRIVE EDRIVE / GOLDEN ELECTRIC Hydraulic 0 0,2 0,4 0,6 0,8 1 1,2 [cycles] Speed: shorter dry cycle times. Precision: reproducible mould filling through dynamic injection. With our ALLROUNDER injection moulding technology, ARBURG has consistently set new standards. This is a tradition we have purposefully continued with our electric ALLROUNDER machines. What does this mean for you? That spindles, motors and their control, for example, are selected exclusively according to the most stringent criteria in terms of function and quality. Made by ARBURG Made in Germany. Regardless of whether you work with our attractive entry-level GOLDEN ELECTRIC model, our EDRIVE or our highly precise, individually adaptable ALLDRIVE; whether you are at home in the medical-technology, packaging or automotive industry: You produce complex moulded parts highly efficiently and cost-effectively without exception. Performance characteristics Electric ALLROUNDER Comparable hydraulic machine Noise minimisation Speed Precision Emission minimisation Energy efficiency /2018

3 3 Electric Hydraulic 4 70 ALLDRIVE EDRIVE / GOLDEN ELECTRIC Hydraulic 5 [kwh/kg] [db[a]] ,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 [kg/h] Energy efficiency: lower specific energy consumption. Emission minimisation: lower noise level. Value: long holding pressure phases thanks to liquid-cooled motors. 1 Speed In the electric ALLROUNDER machines, the main axes for injection, dosing and mould opening and closing are servoelectrically driven as standard, and therefore fully independent from one another. High acceleration and speeds combined with simultaneous movements (with restrictions on GOLDEN ELECTRIC and EDRIVE) provide for faster cycles resulting in greater cost-effectiveness. 2 Precision In our electric ALLROUNDER machines, direct-acting play-free spindle drives ensure mechanically rigid drive axes and correspondingly dynamic movements. High- esolution, contactless position measurement by an absolute position encoder in the motor makes movement to a reference position unnecessary. The excellent positioning accuracy of all servo-electric drives permits maximum reproducibility and part quality. 3 Energy efficiency The high efficiency of the servo-electric drives and the toggle-type clamping unit of the electric ALLROUNDER machines ensure energy-efficient operation. The energy recovery of the servo motors during braking also has a beneficial effect on the machines overall energy consumption. Together, these factors combine to reduce energy consumption by 25 to 50%. 4 Emission minimisation The drives of the electric ALLROUNDER machines are liquid-cooled and are therefore especially quiet. Air turbulence is avoided and the targeted dissipation of heat considerably reduces the amount emitted into the environment. Closed drives and spindle systems reliably prevent exposure to dust caused by abrasion. The machines are therefore perfect for clean-room production of optical components, decorative parts, precision and micro components, for example. 5 Value A wide range of machining tasks can be accomplished with consistently high quality using the high-precision electric ALLROUNDER machines. The high degree of reliability of the machines and subsequent minimal variability in the process is achieved by numerous technical details. These include the adaptive temperature control for stable process conditions and the closed cooling circuit for motors and converters for rapid cycles and long holding pressure phases. 03/

4 Efficient machine designs Distance between tie bars [mm] 920 x x x x x x x x x 270 ALLDRIVE ALLDRIVE / EDRIVE Clamping forces [kn] Injection units according to EUROMAP Shot weight [g PS] 2, Innovative drive technology The servo-electric drives with their play-free, direct-acting spindle drives on the main axes ensure precise, fast and energy-saving movements. This is achieved, among other things, by energy recovery during braking. Auxiliary axes such as ejector, nozzle movement and core pulls may alternatively be driven hydraulically. The designs of our electric ALLROUNDERs are both performanceoriented and cost-efficient: Clamping and injection units in a range of sizes can be combined with machines suitable for all of your applications. This high level of flexibility ensures that you always achieve competitive unit costs. The GOLDEN ELECTRIC is our comprehensively standardised entry-level model at an unbeatable price. In the case of higher requirements in terms of equipment, our EDRIVE offers additional features. And the more demanding your production tasks become, the more interesting our high-end ALLROUNDER A will become for you. The machine technology, however, always remains highly compatible across all the machine series: the SELOGICA control system, tie-bar spacing, ejector quick-connect coupling and cylinder modules are identical for all ALLROUNDER machines. Innovative drive technology /2018

5 2 Precise clamping units The clamping units are designed so that moulds from other machine series can be used without the need for additional conversion. The double five-point toggle operates with high force and speed as well as performing positioning with great precision and reproducibility. Automatic clamping force control ensures a constant locking force (not available for GOLDEN ELECTRIC). 3 High-quality injection units The injection units are equipped with mutually independent drives for injection and dosing. The cylinder modules are compatible with all series and are available in several sizes and different wear-resistance categories. Special cylinder modules, for processing thermosets or silicone, for example, are also available. 4 SELOGICA control system The SELOGICA provides the same operating system for all machine series. The machine cycle features intuitive programming using graphic symbols, enabling short set-up times. Immediate plausibility checking of all parameter entries ensures high operating reliability and convenience. This makes even complex processes easy to understand in the human-machine dialogue. Precise clamping units SELOGICA control system High-quality injection units / Distance between tie bars [mm] 570 x x x x 370 GOLDEN ELECTRIC Clamping forces [kn] Injection units according to EUROMAP

6 Innovative drive technology 1 Extreme precision: planetary roller screw drive of the ALLROUNDER A machines. The innovative drive systems of our electric ALLROUNDERs make these machines reliable and powerful. In other words: highly cost-effective for your company. Despite their high dynamics, these machines operate extremely energy efficiently. In essence, this is because all the important moving axes are driven servo-electrically. A further benefit is energy recovery during braking. Furthermore, you can also opt to equip individual axes with hydraulic drives. The major advantage of this system: You can tailor your machine precisely to the requirements at hand. Precisely according to your needs, as you expect from ARBURG. Movement axes Clamping unit Ejection Core pull Nozzle movement Injection Dosage Hydraulic Electric A / E / GOLDEN ELECTRIC 1 Servo-electric drives The mechanically rigid servo-electric drives provide play-free power transmission via direct-acting spindle drives and in some cases reduction gears to enable simultaneous, highly precise and energy-saving movements. In line with their relevant applications, the ALLROUNDER GOLDEN ELECTRIC and E, machines feature ball screw drives, while highly stable planetary roller screw drives are used the ALLROUNDER A machines. Excellent acceleration values and final speeds are achieved thanks to the high torques and rotational speeds. The closed cooling circuit for the motors and converters also plays an important role here. Consequently, the electric ALLROUNDER machines operate dynamically, powerfully and with extreme precision. Following start-up, they are quickly ready for operation. This is also supported by the absolute position measuring system of the servomotors, which dispenses with travelling to reference positions /2018

7 Variants 2 3 For the purposes of adaptation to the applications, various performance variants are available for the ALLROUNDER A: Compact alternative: small-accumulator hydraulic system. 2 Integrated hydraulics The integrated servo-hydraulics allow for energy-efficient operation of the secondary axes on the electric ALLROUNDERs. This allows serial sequences to be implemented for ejector, nozzle movement, core pulls or needle-type shut-off nozzle at an attractive price/performance ratio. The electric ALLROUNDERs can also be used for existing, hydraulically operated moulds. For particularly complex moulds with simultaneous sequences, an integrated small hydraulic accumulator system is available as an alternative on the EDRIVE and ALLDRIVE models. Maintenance-friendly: automatic central oil lubrication of the clamping unit. 3 Reliable technology The entire servo-electric drive technology is robust, durable and wear-resistant. The automatic central oil lubrication system and the grease lubrication points that converge outside the machine panelling effectively minimise the maintenance effort for the toggle-type clamping units (depending on model series and size). Because lubrication can take place during operation without interrupting production, machine availability also increases. Media connections and interfaces are located on the rear of the machine to ensure easy access. The automatic mould height adjustment and good accessibility of the area around the mould, ejector and nozzle also result in significantly reduced set-up times. With this reliable technology, continuous, uninterrupted machine uptime is achieved. Performance variant L1 Designed for technical parts and particularly energy-saving operation. Performance configuration similar to standard hydraulic machine with two pumps Regulated mould locking in two stages Serial secondary axis movements via servo-hydraulics Performance variant L2 Ideal for high-speed applications and complex processes. Shorter dry cycle times and higher injection speeds Controlled mould locking in several stages Functional upgrades such as injection compression moulding and venting optionally available Simultaneous movements of secondary axes via small hydraulic accumulator system Performance variant L3 Designed for thin-walled applications and the highest demands on machine performance. All adaptations of performance variant L2 Higher injection speeds Reinforced mounting platens Dosage across cycles 03/

8 Precise clamping units 1 Automatic clamping force control The mould height adjustment effectively helps the operator to reduce set-up times. The clamping unit can conveniently be adapted to different mould installation heights. Automatic clamping force control produces a constant locking force (not available for GOLDEN ELECTRIC). This ensures that thermal expansion of the mould is fully compensated. 2 Five-point toggle system The double five-point toggle features a stable construction with multiple guidance and support points. This provides for absolutely symmetrical force application during movements and mould locking. Drive power and construction are also designed for heavy moulds. Despite the compact design, relatively large opening strokes are possible. Practical: automatic clamping force control. The toggle-type clamping unit of the electric ALLROUNDER machines operates cost efficiently and with high precision. Moreover, this technology boasts highly energy-efficient running characteristics, bringing you effective savings on a daily basis. The kinematics of the double five-point toggle is optimally adapted to the servo-electric drive. The high-performance design of the clamping units on the GOLDEN ELECTRIC, EDRIVE and ALLDRIVE machines ensures short dry cycle times. Furthermore, the simultaneous movements of the clamping unit and ejector significantly reduce cycle times in your production facility. 1 2 Automatic clamping force control Five-point toggle system /2018

9 3 Mould protection The box design of the movable mounting platen is supported on the machine base over the entire stroke. Together with four-tie-bar guidance, this ensures maximum parallelism and high precision. The result: optimal mould service life. Highly sensitive tie bar strain measurement is also implemented for active mould protection. 4 Precise positioning Precise travel to the required set positions simplifies the transfer of parts to robotic systems. The spindle-driven, rigid ejector system reduces the possibility of uncontrolled release of moulded parts as they are ejected. This enables precise, reproducible set-down of moulded parts. 5 Good accessibility The generous tie-bar spacing allows easy handling, even in the case of large moulds. Set-up times are kept short thanks to the safety guard open at the top and the ejector rapid release coupling, which is standard on all machine series. The safety guard, which has been enlarged towards the rear of the machine, offers ample space for attachments and media connections can be routed directly to the mounting platens. Good accessibility 4 5 Mould protection 3 Precise positioning 03/

10 High-quality injection units 1 Wide variety of combinations Cylinder modules that are compatible for all series and have three different screw diameters are available for each injection unit. Also available are cylinder modules for processing silicone, for micro-injection moulding plus highly wear-resistant bimetallic cylinders and screws with special geometries. 2 Short set-up times The injection unit can be swivelled to the operator s side for easy removal and cleaning of the screw and for replacing the cylinder modules. The screw can be removed without dismantling the cylinder module. Set-up can be performed quickly and without errors thanks to the screw s rapid release coupling and the central connection of all cylinder module supply units. Maintenance-friendly: easy screw changes thanks to swivelling injection unit. Homogeneous material preparation and precise injection form the basis for high-quality part production. This is ensured, for example, by the mechanically rigid drive axes of the electric ALLROUNDER machines, which ensure superior process control. Added to this is the potential for energy savings, particularly through the optimised servo-electric dosage drive. With the ALLDRIVE, you maintain full control of your cycle times thanks to simultaneous nozzle movement and dosage across cycles. An additional benefit: the entire injection unit is easily accessible for setup and cleaning work. These are all tangible advantages that are guaranteed to put you ahead of the competition. 2 Wide variety of combinations 1 Short set-up times /2018

11 3 Torque-free nozzle contact The advantage of torque-free, two-tie-bar guidance of the injection units is an absolutely leak-free nozzle contact surface. Both flat and radius nozzles can be used without problem. High nozzle contact forces are reliably achieved thanks to central insertion in the mould. The build-up of the nozzle contact force is programmable and controlled. This has a positive effect on nozzle and mould wear. 4 Precise injection A reproducible mould filling is achieved through several factors: servo-electric injection with force and position control, dynamic acceleration and precise measurement of all current pressures via paraxial sensors. The screw is reliably prevented from retracting, ensuring consistent shot weights. Liquid-cooled motors enable fast cycles and long holding pressure phases. 5 Direct dosage drive The injection and dosage drives are mutually independent. This enables controlled back pressure. Simultaneous dosing on the ALL- DRIVE also permits short cycle times as well as longer dosage times and hence gentler melt preparation. The high overall efficiency of servo-electric drives leads to obvious energy savings plus increased precision. Torque-free nozzle contact Precise injection Direct dosage drive /

12 SELOGICA control system User-friendly: simultaneous monitoring of robot and machine sequence. 1 Central management The SELOGICA system saves time and costs thanks to its unique standardised operating concept. With the simple integration of a variety of peripherals, the control system can be used for sequence management, even of complete production cells. The management of setting data is simpler than ever; there is only one data record for the entire production unit. 2 Intuitive operation All data can be accessed immediately, rapidly and easily via the SELOGICA touchscreen. The graphic operating system, which is compatible with a wide variety of technologies, is self-explanatory. The unique sequence editor with patented, real-time plausibility check always clearly indicates the logical position of the current programming step. This way, operating errors are prevented from the start. Maintaining control over sophisticated machine and robotic technology requires a high-performance control system. All the sub-steps in the manufacturing cycle can be programmed with ease using the intuitive graphic sequence editor of the SELOGICA. SELOGICA acts as a central setting and monitoring system for the entire injection moulding process, including the programming of integrated robotic systems and peripherals. All the SELOGICA s technical features are designed to make operation quick, safe and convenient. In this way, short set-up times can be achieved in your production facility. Data is input consistently and training is kept to a minimum, as your operators no longer have to adapt their thinking process. 3 2 Further information: SELOGICA control system brochure /2018

13 Highlights 3 Fast set-up times The input logic of the SELOGICA system is based on the mould set-up sequence and optimisation of the injection moulding process. The Set-up Assistant module supports daily operations from menu-guided mould installation and automatic calculation of the parameters through to teach-in of the finished sequence no indepth knowledge required. 4 Reliable optimisation The SELOGICA machine control system offers numerous options for process optimisation, monitoring and documentation. Numerous mould protection, diagnostic and support functions, such as the maintenance display, all fall under the topic of machine monitoring. All messages are displayed conveniently in plain text, so that operators always know precisely what action has to be taken. Control centre for the entire injection moulding technology Convenient sequence programming with graphic symbols Real-time plausibility checks Common data record for the entire production unit Set-up Assistant module Interactive teach-in functions Water-cooling for continuous temperature control in the control cabinet Fast set-up times Intuitive operation 4 Reliable optimisation Central management 1 03/

14 Application examples 1 2 Mass-produced medical technology products: short cycle times for optimum unit costs. Precision injection moulding: excellent reproducibility with servo-electric drives. The production of medical technology components in a clean room, the highvolume manufacture of packaging items, the production of safety-critical technical parts, e.g. in the automotive industry, or of high-precision small parts at a consistently high quality level with 100% reproducibility: these are the requirements that are covered perfectly by our electric ALLROUNDER machines. With our attractive entrylevel GOLDEN ELECTRIC model, the EDRIVE or the highly precise, individually adjustable ALLDRIVE; our sophisticated technology proves its worth day after day - right in your company. 1 Mass-produced medical technology products Electric ALLROUNDER machines are suitable for high-speed applications, such as in medical technology, for example, because of their direct and dynamic servo-electric drives and high precision. Short dry cycle times are important here. Simultaneous ejector and mould movements are perfectly co-ordinated to ensure reliable, precise demoulding at high speeds. The machines are also perfectly suited to use in clean rooms. This is thanks to their low-emission and smooth-running drive technology as well as the systematic omission of belt drives and air-cooled motors. This ensures low turbulence and minimal particle contamination due to production processes. But customer-specific options for individual adaptations, such as V2A machine panelling are also virtually unlimited. 2 Precision injection moulding A high degree of reproducibility, as re quired for technical parts in the auto motive industry, for example, is achieved in particular through the mechanically rigid drive axes of the electric ALLROUNDER machines. The excellent positioning accuracy of the servo-electric drives guarantees the smooth further processing of moulded parts in subsequent automated processes, especially when employing robotic systems for part removal or insertion tasks. Further information: Application expertise brochure Robotic systems brochure 14

15 3 4 5 Optical parts: compression injection moulding through simultaneous movements. Micro-injection moulding: extremely small shot weights thanks to micro-injection module. Automation: ALLROUNDER machines and robotic systems from a single source. 3 Optical parts The liquid-cooled motors of the electric ALLROUNDER machines enable long holding pressure phases, such as are necessary for thick-walled optical parts, for example. The servo-electric drives ensure high precision. With the ALLDRIVE, all types of compression injection moulding are also possible. The compression moulding sequence can be freely programmed via the SELOGICA control system. The starting conditions can be individually selected, for example, and compression moulding axes flexibly combined. Finally, dosing across cycles permits optimum, uniform material preparation, a reduced material temperature and therefore shorter cooling times. 4 Micro injection moulding To achieve the smallest possible shot weights, ARBURG s product range includes a size 5 micro injection unit for the electric ALLROUNDER A machines. This combines an 8-mm injection screw with a second screw for melting the material. The perfect interplay of the two screws continuously feeds the melt forwards from the material feed to the tip of the injection screw. This ensures a fully-implemented first-in, first-out method of operation. A homogeneously prepared, newly dosed melt is available for every shot. 5 Automation The combination of ALLROUNDER machines and robotic systems forms the basis for complete production cells, which are developed by the ARBURG project department together with the customer. All upstream and downstream production steps in the injection moulding process are automated. The service offerings available from ARBURG covers optimisation of moulded parts and support during the mould design process, complete assembly and commissioning of the individual components and installation at the owner s premises, plus all the necessary services. 15

16 Distances between tie bars of 270 x 270 to 920 x 920 mm Clamping forces from 350 to 5000 kn Injection units from 5 to 2100 (according to EUROMAP) Film ARBURG GmbH + Co KG Arthur-Hehl-Strasse Lossburg Tel.: contact@arburg.com With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia, Spain, Czech Republic, Turkey, Hungary Asia: People s Republic of China, Indonesia, Malaysia, Singapore, Taiwan, Thailand, United Arab Emirates America: Brazil, Mexico, USA For more information, please go to ARBURG GmbH + Co KG The brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG. All data and technical information have been compiled with great care. However we accept no responsibility for correctness. Individual illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and operation of the machine. ARBURG GmbH + Co KG DIN EN ISO certified _EN_GB_ Subject to alterations Printed in Germany