Press Release 15 October 2014 Sumitomo (SHI) Demag shows manufacturing cell for the production of functionally integrated components Large Savings by Integrating Functions To ensure plastic products meet the increasing demands of the users, they do not only need be high-quality and cost-effective in terms of production, but they also have to combine several functions in one. At the Fakuma 2014, Sumitomo (SHI) Demag will demonstrate the production of a hybrid component in a compact production cell. Functional integration is an important development priority from automobile technology to consumer electronics. By bringing together different functions in one component, increasingly sophisticated functionalities are becoming accessible for plastic products. In addition, integration makes the products ever more lightweight, which contributes to an efficient use of resources. Injection molding plays a very important role in manufacturing such products. Only highly automated and high-quality production solutions allow to realize a cost-effective production whilst conserving the natural resources. Functional lightweight on Systec Servo For a lot of future-oriented plastic products, a combination of lightweight and functional integration is required by the customers. Both features are shown by Sumitomo (SHI) Demag on a Systec Servo 210-430 with a clamping force of 2,100 kn, on which hybrid components of organic sheets, metal inserts and plastic are produced. Using the example of a nutcracker, Sumitomo (SHI) Demag, together with its system partners, will show the potential involved in functional integration. An organic sheet is preheated in a manufacturing cell and inserted into the injection mold. The machine tool movement forms the sheet into the desired geometry. Afterwards, the formed sheet undergoes back injection molding with a honeycomb structure with polypropylene (PP) in a material-saving way appropriate for the individual load. In parallel, a
metal clip is inserted into the tool, which guarantees the right grip to crack the nut in the finished nutcracker. The complete assembly is also effected in the manufacturing cell. The result is a high-quality and extremely lightweight hybrid component, which has the necessary stiffness to transmit the high forces necessary to fulfill the envisaged function. Combining different materials allows to save material and to realize maximum functional integration. This pioneering technology has its focus in the automotive industry. This is about lightweight, i.e. replacing metal with plastic. In addition, hybrid components allow to reduce the number of individual components and steps in the vehicle whilst increasing process reliability. Increased performance through advanced technology machines Sumitomo (SHI) Demag has developed a space-saving, compact production cell, the core being a Systec Servo 210-430 with a clamping force of 2,100 kn. The Systec Servo machines are equipped with the innovative activedrive system, in which a frequencycontrolled high-efficiency motor in conjunction with a hydraulic pump allows a higher speed and energy efficiency than it does with comparable machines. The hybrid drive concept does not only allow short cycle times and parallel movements, but also saves up to 60% of energy during operation. Thanks to highly sensitive tool protection, the machine offers maximum reliability and minimum maintenance. And since Sumitomo (SHI) Demag assumes responsibility for the environment, all new developments of the company are equipped with fuel-efficient and powerful hybrid servo drives. Moreover, the activemotioncontrol technology is available in the standard version for all machines of the El-Exis SP, Systec SP and Systec Servo series. This innovative axis control system allows parallel movements with only one hydraulic pump without affecting the individual components. Thus, machines equipped with activemotioncontrol reach higher injection dynamics with a reduced dry period. The precise movement of the axes avoids overshooting and results in higher process accuracy and shorter cycle times. In addition, the noise level of the machine during operation decreases. Functional integration in partner booths The topic of functional integration also relates to less complex applications. At the booth of Sepro Robotique GmbH, Dietzenbach, an ice scraper is produced on a Sumitomo (SHI) Demag Systec multi 210-600h/200v in a two-component injection molding process. Due to
the simultaneous production of the base body and the anti-slip elements on the handle, the product is manufactured in a material-, time- and cost-efficient way. Blue Competence has a great deal more to offer At the Fakuma 2014, the German engineering federation Deutscher Maschinen- und Anlagenbau e.v. (VDMA continues their Blue Competence initiative. One goal of the initiative is to reduce the energy consumption of machinery and equipment at least by 20% by 2020. Being a member of the Blue Competence Alliance, Sumitomo (SHI) Demag supports the objectives of the VDMA and the Blue Competence initiative. At the Fakuma 2014, functional integration "Blue Competence has a great deal more to offer" will be in the focus of the initiative. The integration of various production steps allows to reduce the use of resources for the production of the plastic product. However, this is possible only through the intelligent combination of individual process steps and innovative engineering. This will be vividly demonstrated by the Systec Servo exhibit. Sumitomo (SHI) Demag Plastics Machinery GmbH Sumitomo (SHI) Demag has shaped the development of the plastics industry from its very beginning. As a specialist for injection moulding machines for plastics processing, Sumitomo (SHI) Demag and its Japanese parent company are leading the industry. The global development and production network of Sumitomo Heavy Industries and Sumitomo (SHI) Demag is comprised of four facilities in Japan, Germany and China with more than 3,000 employees. The product portfolio includes all-electric, hydraulic and hybrid injection moulding machines with clamping forces of between 180 and 20.000 kn. With more than 115,000 installed machines, Sumitomo (SHI) Demag is present in important global markets. More than 5,000 machines sold per year make Sumitomo Heavy Industries and its plastics machinery division one of the largest manufacturers of injection moulding machines in the world. At Sumitomo s headquarters in Chiba, Japan, the company manufactures machines with clamping forces in the small to medium range. Nearly 95 % of all delivered machines are equipped with an allelectric drive concept. The Germany-based facilities in Schwaig and Wiehe specialise in the production of Systec machines with hybrid drive concept and hybrid high-performance and high-speed El-Exis SP and Systec SP machines. IntElect machines with electric drives for the international market are also being produced in Germany. Sumitomo (SHI) Demag will continue operations at the former Demag facility in Ningbo/China, which came on-stream in 1998. The Chinese subsidiary of Demag Plastics Machinery (Ningbo) Co., Ltd. has been operating a local facility with a production area of 11,000 sqm since 2007. Demag Plastics
Machinery (Ningbo) Co., Ltd. is planning to expand its production capacities in Ningbo (Zhejian province). By mid-2015, the production will be stepped up from the current rate of about 650 to 1,000 injection moulding machines per year. The injection moulding portfolio is comprised of the hydraulic Systec C series with clamping forces of between 500 and 10,000 kn for the Asian market. In addition to injection moulding machines, Sumitomo (SHI) Demag offers customised and standardised systems for the part handling automation, technical and process solutions for special applications, tailored services and service concepts as well as a range of financial options to support investment in injection moulding machines. With its comprehensive sales and service network of subsidiaries and agencies, Sumitomo (SHI) Demag is present in all major markets. www.sumitomo-shi-demag.eu Contact ******* Stefanie Lauterbach, Marketing Sumitomo (SHI) Demag Plastics Machinery GmbH Phone: +49 911 5061-2915, Fax +49 911 5061-750 E-Mail: Stefanie.Lauterbach@dpg.com
<Systec_210_nutcracker> The Nutcracker is an extremely lightweight hybrid component, thanks to integration function which receives the necessary rigidity to the high forces to be transmitted during use. <activedrive> Through the innovative drive system activedrive allow a frequency-controlled high-efficiency motor in conjunction with a hydraulic pump, a higher speed and energy efficiency. All pictures: Sumitomo (SHI) Demag