Sumitomo (SHI) Demag - Press Release For Fakuma 2015 (3)

In mid-2015, the IntElect all-electric high-precision injection moulding machine from Sumitomo (SHI) Demag was equipped with a range of new standard features, which will be presented at the Fakuma trade show for the first time. As a result, production processes with IntElect machines are now more reliable and repeatable, while the parts are produced with higher precision and higher quality. In addition to this, the new features improve the machine’s usability both in operation and during mould changes. The Fakuma exhibit presents the automatic balancing of a four-cavity mould for industrial precision parts with a reliable reproduction of surface details even under challenging filling conditions. This machine with its production efficiency modules was specially designed to accommodate the high precision requirements of manufacturers of industrial parts from the E+E, optics and automotive industry.

The IntElect’s interactive user navigation facilitates and accelerates mould set-up procedures significantly, while a new reference run option for clamping units and other enhanced purging functions make machine operation even easier.

Several injection units for IntElect machines are now available with screws in five instead of three different diameters, which allows more versatility for processors and compliance with required residence times even for variable product ranges.

During injection, the injection pressure profile can now be monitored with high precision. An adjustable tolerance band allows better process control and protects the mould from overfilling. Measured value acquisition (MVA) for process analysis and optimisation now provides a selection of user-defined as well as pre-defined screens, which facilitates data processing. Additional options with new graphs enhance the MVA’s application range. The new, standard display of the machine’s energy consumption provides documented proof of the efficient operation of IntElect machines.

Specially developed by Sumitomo (SHI) Demag, the “activeDynamics” production efficiency module, an all-electric drive concept, ensures the smooth interaction of all drive train components: motors, frequency-converters and control system are perfectly attuned to each other, which reduces axis control scan rates to a minimum and ensures high dynamics, precision and repeatability.

The wide range of optional equipment for IntElect machines has also been updated. The ejector force profile across the entire forward and backward stroke can now be monitored with a high level sensitivity. This enhancement not only offers a new level of mould protection, but also allows high-speed ejector movements. Another optional add-on is the new, integrated hydraulic unit with servo drive for higher nozzle travel speeds, which can also be used for the core pullers.

The “activeFlowBalance” balances irregular, fluctuating filling levels in multi-cavity moulds and prevents negative effects such as flashes, underfilling or the Diesel effect. This module uses the expansion of the compressed plasticised material at the point of changeover from injection to holding pressure to top up the filling levels in the partially filled cavities, which happens as a result of their lower counter-pressure. This way, pressure and cavity levels are balanced out naturally. This tried-and-tested function was enhanced and is now even easier and safer to use.

The “activeLock” adjustable non-return valve actively closes prior to the injection process, which ensures a constant closing behaviour during each cycle. Benefits of this module are better repeatability, fewer process fluctuations and a lower risk of producing waste scrap.

Other production efficiency modules in operation in the exhibited machine are the “activeAdjust” axis optimisation module, the “active” active mould protection module and the new “activeMouldWater” module for electronic cavity temperature and flow rate monitoring. The NC5 plus control system analyses this important process data, which improves the accuracy of process monitoring and allows an early detection of potential interferences with the temperature control system or the mould.

Fakuma exhibit: automatic balancing of a four-cavity mould for high-precision parts

At Fakuma, an IntElect 100-340 with a clamping force of 1,000 kN and an SDR 11S linear robot will be operating in an integrated, space-saving protective housing. The robot takes the parts from the cavity, removes the sprue and passes them on to the downstream inspection stations, where optical measuring and temperature distribution monitoring by means of an IR camera ensure 100% quality control. The part, a cover for couplings to an AdBlue feed pipe made from PA66-GF15, has several complex structures at the end of the flow path, which poses a filling challenge and tends to produce flashes. The results delivered by the four-cavity mould manufactured by Giebeler GmbH, Eschenburg/Germany, illustrate how the IntElect machine’s “activeFlowBalance” module improves the filling quality while optimising the stability of the production process and the quality of the moulded part. This is paired with significantly lower energy consumption than hydraulic injection moulding machines and more harmonious and faster cycles with parallel machine and robot movements. The robot is able to move into the mould parting line in a synchronised way while the mould is still opening. This way, it can remove the moulded parts at the full mould opening stroke, and vice versa: the machine can start closing the mould while the robot is still moving away from of the mould parting line.

Alongside the IntElect 100, Sumitomo (SHI) Demag will show two additional IntElect 50 machines in live operation at their partner companies’ stands: Sepro (Hall A1, Stand 1203) and ONI (Hall A5, Stand 5103). Sepro will demonstrate the highly complex production of a plug connector made from PBT-GF30 in a delicate mould with sophisticated separations, which was manufactured by Stamm AG, Hallau/Switzerland.

At their own stand, Sumitomo (SHI) Demag will show two additional exhibits: an El-Exis SP 200 high-performance machine will produce gourmet food containers with extremely short cycle times and, in a production unit, a Systec Servo 210 will be producing complex, decorated lightweight parts.

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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.

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 all-electric drive concept. 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.

Demag’s German facilities in Schwaig and Wiehe produce the Systec Servo range with hybrid drive as well as the El-Exis SP and Systec SP range of high-speed, high-performance machines. The all-electric IntElect range for international customers is also being produced in Germany.

As early as 1998, Sumitomo (SHI) Demag set up its first production site in Ningbo/China. In 2015, the Chinese subsidiary Demag Plastics Machinery (Ningbo) Co., Ltd. installed a new facility with a 13,000 m² floor space. It is earmarked for the production of the Systec C range 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.