Sumitomo (SHI) Demag Plastics Machinery GmbH info-dpde@dpg.com www.sumitomo-shi-demag.eu All data and information provided in this brochure has been compiled and checked with due care and diligence. We believe the contents of this brochure to be accurate, but cannot guarantee its accuracy. The description in this brochure may differ from the machine s actual condition upon delivery. www.da-kapo.de
Production efficiency 16 technology modules to ensure your success
On-going technological further development and improvement of the performance capability of our products are fi rmly rooted in our company philosophy. While increasing production efficiency has now become a trend across the whole sector, this has always been part of our tradition at Sumitomo (SHI) Demag. By combining our mature range of machines with innovative and tested technologies, our production efficiency experts can tackle the challenging task of having an effective infl uence on the numerous factors, which lead to increased efficiency for your benefi t and in terms of ensuring optimum cost-effectiveness, secure investments and the highest levels of production performance. Our 16 technology modules activeplus have a direct effect on the machine technology and production processes. This results in tangible technical solutions, which we then prepare on a customised basis for your particular needs..» We provide the right details which have a large effect in your production. «Dr. Tetsuya Okamura (CEO), Sumitomo (SHI) Demag 2
Production efficiency a tradition, not a trend Protecting the environment with innovative technologies and sustainable solutions, preserving our resources and managing effi - ciently: That is what Blue Competence stands for, the sustainability initiative of the VDMA (German Engineering Federation), which globally underlies the role of technological leadership for sustainable production. As a member of the Blue Competence Initiative, Sumitomo (SHI) Demag consistently makes an important contribution to the protection of resources and sustainability, both in terms of production and also manufactured products. 3
activeplus intelligent solutions with maximum effectiveness Toggle Minimal energy intake even with fast mould movements activedrive Minimisation of energy losses in partial load and idle speed operation activecool&clean Extension of the intervals between oil changes and lowering of wear of the hydraulic components activeadjust Cycle optimisation through individually adjustable regulation properties Toggle activedrive activecool&clean activeadjust Without activeflowbalance With activeflowbalance Linear guides activecolourchange activedynamics activeflowbalance Linear guides Reduction of losses through friction and optimum mould protection through the highest levels of platen parallelism activecolourchange Fast and efficient colour change systematically at the touch of a button activedynamics Highly precise process conduct through shortest sampling times activeflowbalance Balancing out of differing pressure ratios with parts critical to fi lling in multi-cavity moulds. 4
Cylinder insulation Reduced energy consumption through lowering of the heat emission of the plasticising cylinder activelock Increased process consistency through active closing of the non-return valve activeecon Representation and optimisation of the process settings in terms of energy consumption and production costs All-electric dosing drive Increased level of effectiveness through high performance direct drive Cylinder insulation activelock activeecon All-electric dosing drive smartdrive activeremote Optimum drive technology activeq/active Q+ smartdrive Increased energy efficiency through speed-regulated pump drive with hydraulic injection moulding machines activeremote Simplifi ed machine operation through visual integration of peripheral devices Optimum drive technology Drive technology specially synchronised to the needs of injection moulding machines activeq/activeq+ Sensitive and precise protection of moulds through active mould protection 5
Production efficiency modules and their effectiveness Durability Energy efficiency Production performance Availability Product quality activeadjust activecolourchange activecool&clean activedrive activedynamics activeecon activeflowbalance activelock activeq/q+ activeremote Toggle Linear guides Optimum drive technology smartdrive All-electric dosing drive Cylinder insulation strong effect very strong effect We manage to achieve maximum production efficiency through effectively coordinating the fi ve key aspects of: Durability Energy efficiency Production performance Availability Product quality The overview makes clear the effects of the different activeplus technology modules on the fi ve aspects of production efficiency. 6
activeecon The effects of process settings on energy consumption and production costs are made clear to see activeecon operating side from the NC5 plus machine controls Making analysis of the energy consumption of the individual phases of the injection moulding cycle clear to see is the fi rst step towards effective process optimisation. With the activeecon measuring and analysis tool built into the machine controls, targeted evaluation of the energy consumption of the machine can be made as required and the optimum energy setting of the machine determined by means of a Before and After Comparison. A special feature of this solution is that the programme automatically calculates the effects on production costs. The energy values recorded per shot can therefore be projected to cover a production order and factored into the unit costs or calculation for an order. 7
activecool&clean Oil service lifetimes of 40,000 operating hours Reduced wear of the hydraulic components Reduced oil fi lter maintenance costs and times The high-performance activecool&clean cooling and fi ltering system ensures optimum oil quality and long oil service lifetimes of up to 40,000 hours. A laminar, pulsation-free oil fl ow ensures optimum dirt separation in a discrete low pressure circle in the generously sized fi ne mesh fi lter as well as optimum warmth transfer in the cooler. This leads to long fi lter lifetimes and intervals between oil changes. Clean oil with a low particle load also considerably reduces wear in the other hydraulic components. The reduction of down times caused by maintenance work and the higher cooler fl ow temperatures generated through the optimum warmth transfer allow for all-year re-cooling without any additional costs for refrigerators an important contribution to economical production. 8
activedrive Reduced energy consumption with energy saving of up to 50 % when compared with standard hydraulics Highest dynamics in every cycle sequence Best price/performance ratio Considerably reduced exposure to noise Also available as a retrofi t for Systec machines C: Converter M: Speed-controlled Motor P: Pump V: Hydraulic Valve activedrive is an innovative drive concept for saving energy, consisting of a frequency-regulated high-performance engine combined with an hydraulic pump. The dynamic performance adjustment to all needs dictated by cycles ensures optimum levels of effectiveness, as only in this way can as much performance be made available as is required in each cycle sequence. The results are minimal losses and signifi cant savings in energy, especially in the partial load area as well as during idle speed operation. 9
smartdrive Retrofitting for NC4 machines Reduction of energy consumption Low maintenance costs through reduced pump wear Best price/performance ratio smartdrive operating side from the NC4 machine controls Using the smartdrive production efficiency module means that dynamic performance adjustment to all cycledetermined needs can also be achieved for machines with NC4 controls. Intelligent evaluation of the pump signal allows the pump engine speed to be regulated according to the process requirements via a supplementary converter. Operation is completely built into the NC4 machine controls and is undertaken using a simple screen layout. Consistent product quality is achieved via the process data and further individual settings. In addition, by providing the energy requirement needed in each phase of the production run, high process stability is ensured. 10
activeadjust activeadjust operating side from the NC5 plus machine controls Individually adjustable regulating properties Reduced cycle times Production performance increase of 3 5 % in fast mode Optimum regulating properties can be selected using activeadjust without any external assistance by using a slider system. This provides the advantage of enabling the injection moulding machine, which is designed to cover a wide range of applications ex works, to be individually adjusted to your product. Acceleration and deceleration ramps can accordingly be optimally selected for a hard or soft operating mode, according to mould. This function provides a considerable reduction in cycle time and produces noticeable increases in production performance. Highest parts quality is achieved through the infl uencing of the dynamics at which the change is made from injection to hold pressure. activeadjust also offers possibilities for optimising ejection and dosing. Optimum drive technology Direct drive injection High dynamics, precision and reproducibility as well as availability Optimum energy efficiency The optimum drive technology makes a crucial contribution towards production efficiency. The machine range from Sumitomo (SHI) Demag is fi tted with pioneering energy-efficient drives as standard. This is how the El-Exis with its hybrid drive concept fulfi ls the expectations placed on high-performance machines. IntElect s electrical drive technology with high-torque direct drives and drive components made by ourselves has been especially developed and constructed for precision injection moulding. Minimal inertia combined with direct power transfer ensure high levels of dynamism, freedom from play and high system rigidity. 11
activedynamics High dynamics, precision and reproducibility Extremely short scanning times of the axis regulators activedynamics is the all-electric drive technology developed by Sumitomo (SHI) Demag. It ensures optimum interplay of all the components involved in the drive train. By ensuring perfectly synchronised engines, frequency converters and machine controls, extremely short sampling times of the axis regulators can be achieved. When combined with the design focused on high dynamics, this results in an optimum total system, best adapted to meeting the needs of injection moulding machines. activeq Sensitive protection of the mould even during fast operating movements Reduction of machine idle times deviations. Sensitive protection of the moulds is therefore possible, even during fast operating movements. Damage or appearances of wear are discovered at an early stage and any unscheduled standstills caused by damage to moulds are effectively prevented. activeq and activeq+ operating sides from the NC5 plus machine controls activeq Protecting the injection mould is one of the key tasks of an injection moulding machine. activeq fulfi ls this task and at the same time ensures high productivity due to short cycle times. Measuring and monitoring the required forces during the mould movement allows for active and immediate reactions to be made to any activeq+ While activeq takes effect when the mould is being closed, activeq+ also offers an additional option, which also checks the opening. This means that in the case of stack moulds, sliders etc., the highest level of security is provided for the means of production and a valuable additional use is created for our customers. 12
activelock Improved precision and reproducibility Fewer rejects Increased process consistency The non-return valve frequently forms the weak spot with high-precision parts. Traditional systems are only closed passively through the injection procedure and the injection pressure occurring. Fluctuations in the melt viscosity then frequently also lead to fl uctuations in the closing behaviour, the melt cushion and therefore of the shot weight and of the quality of the parts. Active closing of the non-return valve is possible with activelock. A defi ned closing movement before the injection during the turning back of the screw completely closes the non-return valve and ensures absolutely consistent closing behaviour which can be actively infl uenced. The non-return valve is securely closed during the entire injection and hold pressure process. Process consistency is increased, fl uctuations reduced and the risk of rejects is minimised. 13
Toggle Toggle Low energy consumption, even with dynamic mould movements High availability and durability Robust and durable machine manufacture that is what the toggle provides. The mechanical conversion ensures highest level of dynamics and working speed with minimal energy consumption and secure locking without any additional energy requirement. The central application of force and the high rigidity have reliable effects in the centre of the platen. The forceful kinematics of the double toggle ensures short locking times and strong opening forces. Particularly in the fi nal positions, the large movement of the toggle is countered by a relatively small movement of the clamping platen, meaning that the opening and closing procedures are undertaken in a very sensitive manner. All-electric dosing drive All-electric dosing drive Hydraulic drive for dosing unit Motor Pump 1 2 Electric drive for dosing unit with gear-down Converter Motor The level of effectiveness of the largest consumer can be doubled Protective dosing through reduced speeds Higher shot weights possible 1 2 Electric direct drive for dosing Converter Motor 1 2 Plastifi cation is the largest consumer of energy in an injection moulding machine. At the same time, even the most up to date hydro-engines have comparably low levels of effectiveness. Corrective actions are created by the all-electric dosing drive. Direct drives operating without gears are used in the process in many sizes in the series. The level of effectiveness of the primary consumer, the dosing drive, can therefore practically be doubled using it. Decoupling the dosing from the other movements of the machine creates scope for reducing the speed or increasing the plastifi cation. Valve Hydro motor 3 4 Gear 3 total 0.8 total ~0.88...0.93 total ~0.4...0.7 Reduction of elements in the efficiency chain to increase energy efficiency 14
Linear guides Linear guides Minimal friction Highest level of platen parallelism Reduced mould wear The linear guides of the movable platen with guidance carriages mounted on roller bearings ensure minimal losses through friction and optimal platen parallelism with their wide guidance base and accessible side rails, even with heavy moulds. Lubricant-free columns also cut maintenance costs. The technology of the linear guides therefore helps ensure, in addition to low energy consumption, minimal mould wear. Cylinder insulation Insulation sleeve Fast pay-back Simple retrofi tting Reduction of energy consumption and heating performance of up to 40 % The cylinder insulation sleeves, which are obtainable and can be retrofi tted as options, lower energy losses through heat emission by the plasticising cylinder. This reduces energy consumption and shortens cylinder warm-up times. The durability of the heating tapes is extended through reduced switching cycles and the lower emission improves the indoor climate. The insulation sleeves can be easily mounted under the standard guard plate of the plasticising cylinder and adjusted at its heating zones. If the process requires it, the insulation can be removed in individual zones. Due to the savings in the region of up to 40 % of the heating performance, purchasing the cylinder insulation frequently already pays for itself in the fi rst year. 15
activeflowbalance Machine function with simple operation for balancing out different pressure ratios in the cavities Considerable reduction of rejected parts (burr formation, under-fi lling) Avoidance of mould damage through even and optimum pressure ratios Without activeflowbalance With activeflowbalance Cavity fill level at switching point An uneven and fl uctuating balancing of the multi-cavity moulds can be successfully balanced out using activeflowbalance. Negative effects such as burr formation, under-fi lling and mould damage are avoided in future. The activeflowbalance machine function makes use of the expansion of the compromised melt during the transition from injection to hold pressure, which leads to partially fi lled cavities being fi lled more through their lower counter-pressure. The fi ll levels balance out naturally and without extending the cycle time. 16
activeremote Simplifi ed, central operation of machine as well as robot and peripheral technology through integration into the NC5plus controls Simple integration of all types of full touch screen devices Increased efficiency of the entire system Very fl exible equipping also for complex automation tasks smartremote operating side from the NC5 plus machine controls activeremote is an intelligent extension tool of our intuitive NC5 plus switching centre for increasing fl exibility while controlling and integrating peripheral technology of all kinds. Useful functionalities and the most varied partner systems are integrated into the operating interface via VCN (Virtual Network Computing). The capturing, processing and visualisation of production and process data allows for comprehensive supervision and control of every single production phase. Faults in the production run immediately become visible and can be rectifi ed directly, before rejects are created. 17
activecolourchange Up to 5 different liquid colours can be automated Fast, fully automatic colour change in only a few cycles and without machine idle time No adjustment of the process settings required High savings in personnel, material and energy costs with very high levels of product fl exibility Lowest rejection rate Problem-free colour change in the shortest time With the new and innovative activecolourchange colour system, we combine the advantages of liquid colours with the advantages of standard plastifi cation. This allows for plastic parts to be coloured homogeneously and efficiently, virtually at the touch of a button. The special feature of the process lies in the fact that the fusing procedure and the colouration process run separately. That ensures a very consistent dosing procedure, even with the smallest amounts of colour, in the case of full plastifi cation without the screw undergoing smearing. The complete change of colour is concluded in just a few cycles. Due to the closed system, the operator does not come into contact with the liquid colour and no cleaning costs occur in principle. 18
Production efficiency modules and their use Systec < 1.300 kn Systec 1.300 kn El-Exis SP IntElect < 2.200 kn IntElect 2.200 kn activeadjust activecolourchange activecool&clean activedrive activedynamics activeecon activeflowbalance activelock activeq activeq+ activeremote Toggle Linear guides Optimum drive technology smartdrive Retrofi t for NC4 machines All-electric dosing drive Cylinder insulation Not available or not necessary Optionally available Standard We can provide you with many intelligent and, above all, effective options to increase production efficiency by using our high performance technology modules. The overview shows you which modules are available for which machine series respectively. 19
Producing in ways which are fl exible, fast, high-quality and cost-effective is more important today than ever. Our highperformance machine range and our 16 innovative activeplus production efficiency modules provide an excellent basis for this. Yet that is not enough: Solution-focused planning, high investment security and the targeted creation of competitive advantages are what we aim to provide for you and which we aim to achieve with our well-founded expertise, which extends beyond just purely technical matters. Our production efficiency experts with their comprehensive specialised knowledge of machine, control and operating technology as well as a range of services offering you that extra something required are much in demand. In addition, the strong engineering expertise to be derived from our network of partner companies of leading manufacturers of peripheral and mould technology as well as process integration are also there to provide you with support.» Technologies and processes individually adapted to your operating frameworks our added extra to help keep you in the lead. «Shaun Dean (COO), Sumitomo (SHI) Demag 20
Production efficiency and more Your production efficiency experts Automation Optimum cost-effectiveness and efficient production solutions are best achieved with overall solutions which have been thought through. Sumitomo (SHI) Demag linear robots and intelligent multi-axis robotics as well as all other needs for upand down-stream processing steps are covered by us in close cooperation with our network partners. Our experts ensure that everything fi ts together. Advice and ideas The goal of continuously increasing productivity requires solution-focused thinking from the start and begins with the injection parts and the technologies being deployed. Our experts work with you to develop the best solution for your production. Designing Our application experts draw up your individual system design against a detailed background in terms of technical procedures and taking into account the factors dependent on the process. The best security for deciding in favour of the right investment for you. Customer service Highest quality and lowest possible unit costs mean it is necessary for the machines to run and always to be at the cutting edge of technology. Our experts assume the responsibility for ensuring this. ErgoCheck Our experts will put your machine through its paces at regular intervals or whenever you want. ErgoCheck checks all process parameters relevant for ensuring quality and all basic and security functions. EnergyCheck We measure the energy consumption of individual production stages and of the entire injection moulding process in a detailed analysis. This means that it is possible to calculate beforehand how much can be saved by integrating in one of our production efficiency modules. Retrofi t Being fully up to date in technological terms does not immediately mean having to invest in a new machine. Our comprehensive retrofi t programme allows your machine to be optimally updated by equipping it with injection and clamping units or controls. Training courses As well as technology, the human factor also provides a crucial contribution to your success. Constantly increasing requirements mean that staff need on-going training and accreditation. This includes being trained to become aware of potential opportunities to increase production effi ciency. 21
Sumitomo Heavy Industries 1969 Complete range of injection moulding machines 1990 First electric injection moulding machine (SE series, hybrid) 1949 Extruder for wire coating 1963 1967 Extrusion facilities First injection for blown fi lms blow-moulding machine 1972 Sandwich injection moulding machine 1983 Injection moulding machine for CD optical data carriers 1950 1956 1963 First injection moulding First single-screw injection First thermoset processing on machine (Anker) moulding machine in the world (Anker) Anker screw injection moulding machines Demag Plastics Group 1961 First elastomer processing on Anker screw injection moulding machines 1967 5-point toggle 1971 1972 First programmable First multi-component injection moulding machine machine (punched tape) 1973 First digitally controlled injection moulding machine (digital hydraulics) 1975 First PLC-controlled injection moulding machine 1983 Introduction of p/q control pump (DFE) 1979 First PLC-controlled injection moulding machine with screen Production efficiency tradition, not a trend We have made a key contribution towards shaping injection moulding technology from the start and can count ourselves among the pioneers when it comes to production efficiency. In 1956, our predecessor company, Ankerwerk Gebr. Goller in Nuremberg, constructed the fi rst one screw injection moulding machine. A milestone on the road to increasing efficiency in machines was already reached in 1967 with the development of the fi rst 5-point toggle. We are still consistently following the path of developing innovative technologies. Production performance, availability, energy efficiency, durability and product quality are what we regard as the fi ve crucial aspects of our innovations and the key for ensuring 22
Der Zukunft voraus Ready for the future 1993 PET injection moulding system 1999 Lockable nonreturn valve 1998 All-electric injection moulding machine (SE-S series) 2003 All-electric 2C injection moulding machine 2006 SL screw 2005 All-electric ultra-highperformance injection moulding machine 2008 All-electric large machine CL 7000, 550 t 2009 Combination DFEE pumps and frequency-controlled drive activedrive Schwaig plant becomes Centre of Competence for hydraulic and hybrid machines 2010 Hybrid high-speed injection moulding machine El-Exis SP Expansion of IntElect smart series up to 450 t Sumitomo (SHI) Demag 2011 Over 100,000 injection moulding machines in the global market 2012 NC5 plus relaunch control 1992 Ergotech modular system machine 1996 Multi complete modular system machine 1998 Hybrid El-Exis S high-speed injection moulding machine Active mould protection activeq 2003 All-electric IntElect injection moulding machine High-torque direct drives 2005 All-electric dosing drive 2008 Merger of Sumitomo Heavy Industries and Demag Plastics Group 2009 Wiehe plant becomes Centre of Competence for electric machines IntElect smart combines IntElect with drive technology from SHI 2010 Individual control system activeadjust Periphery integration activeremote 2011 Lockable non-return valve activelock Flow front monitoring activeflowbalance Optimised drive system activedynamics 2012 SE-EV New all-electric injection moulding machine from Sumitomo IntElectmulti fi rst all-electric multi component injection moulding machine activecolourchange Change of colour at the touch of a button the sustainable success of our products. From the very start, they have determined and accompanied our entire product development and enable us and our customers: to be ready for the future. 23