Engineering Passion

Fast. Clean. Precise. The all-electric EX Series

Machines in the EX SeriesFacts and figures2

Facts and figures regarding the all-electric EX Series

Medical/pharmaceuticalPackaging

Medical/pharmaceutical Electrical/electronicsPackaging

Electrical/electronics

Application areas

Clamping/injection matrix

Machine/clamping force in to

Clearance (hxv) in mm

Injection units (screw diameter in mm)

SP 55 SP 180 SP 380 SP 750 SP 1000 SP 1400 SP 200015 18 20 22 25 28 30 35 30 35 40 45 40 45 50 55 50 55 60 55 60 70 60 70 75

EX 50 520 x 420EX 80 520 x 420EX 120 570 x 470EX 160 630 x 520EX 200 680 x 600EX 240 710 x 630

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The all-electric EX Series

The injection molding machines in the EX Series demonstrate their strong points wherever there is no room for compro-mise, for example in the medical technology, electronics and packaging industries. Do you have high demands in regard to performance, precision and cleanliness - or all of these simul-taneously? If so, the machines in the EX Series are just right for you.

With clamping forces ranging from 50 to 240 tons, the EX offers a unique machine concept in which the standard fea-tures include reliable processes coupled with high productivity and a clean production environment at cleanroom level.

The highlights of the EX Series at a glance:

Fast thanks to:– Short dry cycle times– High injection performance– Unrestricted parallel functions

Clean thanks to:– Encapsulated drive units– Closed lubrication systems– Lubrication-free mold fitting space

Precise thanks to:– Direct operating principles– Highly accurate servomotors– Intelligent closed-loop control system

Robust and wide mold-mounting platens

Smooth-running linear guides Barrier-free access

Transparent technology Tour of the all-electric EX injection molding machine

Flexible, fully integrated automation

Dynamic Z-toggle clamping concept

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High-end plasticizing units

High-torque direct drive for primary and secondary injection

With additional equipment for all cleanroom classes

Intelligent MC6 control system

Machines in the EX SeriesUniversal clamping unit

Injection molding machines from the EX Series are avail-able with clamping forces of 50 to 240 tons and set stan-dards across the range: The EX Series has extremely short dry cycle times and there-fore leads the way in terms of performance for all-electric machine concepts.

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The unique EX clamping unitPrecise and clean with high level of dynamics

Your advantages:– High platen parallelism– Highest safety standard available

on the market– Large mold fitting space– Optimum accessibility– Stable and lasting processes– Short cycle times

Clamping unit in the open position (top) and closed position (bottom), sym-metrical force introduction into movable mold-mounting platen and mold

High level of productivity thanks to optimized clamping-unit mechanics With its robust and fast clamping-unit mechanics, the EX Series ensures increased precision, dynamics and efficiency.

Force is transmitted to the mold sym-metrically, with zero play and, thanks to the patented Z-toggle, with only eight pivot points (compared with 20 pivot points on a classic toggle).

Using high-performance, servomotor-powered drive technology, commands are assigned to mold movements immedi-ately, highly dynamically and precisely.

Thanks to an integrated brake, the clamp-ing-unit motor ensures maximum safety standards when installing molds under a clamping force – and as standard, of course.

Generous clamping unit for a very wide application rangeBy widely bracing the movable platen on precision linear guides, the mold is guided in absolute parallel in all positions.

Using linear guides, frictional resistances are reduced by up to 80 percent when compared with sliding or column guides. The columns on the EX transmit the force alone – lubrication is not necessary and the product room stays clean.

Generous mold-mounting platens and opening widths allow the mold to be inserted flexibly. Accessibility is also an important feature on the EX because the clamping unit can be optimally reached thanks to safety gates that open widely.

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Stable processes thanks to quick and precise movementsHighly dynamic and precise servomotors move to set travel positions for the shut-off or ejector quickly, precisely and with absolute reproducibility.

Falling parts can therefore be ejected safely and reproducibly, thus preventing them from flying out. You therefore save many OK parts and reduce, in particular, the cycle time.

So that the parts can be demolded using KraussMaffei robot technology, the EX moves to the transfer position extremely precisely and transfers the articles reli-ably to the gripper. This always takes place with 0.001 mm accuracy.

Thanks to the Z-toggle clamping con-cept, the EX machines are extremely fast, precise and clean.

Speed-path diagram for opening and closing the mold

0%20%40%60%80%100%

200

0

400

600

800

1000

1200

1400

Speed in mm/s

Opening stroke in %

v = 100%

v = 50%

v = 20%

Universal clamping concept for clamping forces ranging from 50 to 240 tons

Mold-height- adjustment drive unit

Encapsulated mold-height adjustment

Transmission unit Clamping-unit motor

Linear guide Tiebars that no longer act as guides

Z-toggle Ejector motor Large mold-mounting platens

Automatic clamping force regulation as a standard feature The clamping force in the EX is regu-lated exactly to the set value. Poten-tial process disturbances, which may occur due to clamping-force fluctua-tions caused by thermal expansion, are eliminated automatically and effectively through clamping-force regulation.

In every cycle, the clamping force that is actually attained is recorded by a measuring system and an actual-target comparison is carried out.

If a deviation is registered, the clamping force is automatically readjusted by means of mold-height adjustment and precisely regulated to +/- 2%.

Practical and functional:Additional equipment for your moldThe extensive EX options catalog contains practical solutions and powerful addi-tional functions for your individual appli-cations and mold technologies.

Thanks to an additional hydraulic power pack, core pulls or needle shut off nozzles can be directly programmed and controlled via the control system.

Connections that have been pre-piped via water distributor for cooling-water and temperature-control circuits are situated close to the mold, thus making every mold connection easier and keeping everything in order.Self-optimizing and monitored tem-perature control zones for the mold hot

channel or heat-balancing units ensure optimum processes in the mold through reproducible thermal conditions.

Sensitive mold area protection for maximum mold protectionThe travel force applied when closing the mold is detected and recorded exactly by a measuring device. Every extraordinarily occurring force path can therefore be detected quickly and safely.

Mold area protection can be adjusted to up to 16 profiles. The required sensitivity level can be assigned simply to every pro-file level using a dropdown field.

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If the set tolerance limit is exceeded, the mold movement is stopped immediately. The mold is therefore effectively protected.

Your advantages:– Saving of OK parts– Practical solutions for every application– Wide range of additional equipment– Effective mold protection

EX Series with practical additional equipment

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Tolerance limit Travel force Reference travel force

Force

Detail

Time

Exceeding tolerance band

Triggering emer-gency stop

Sensitive mold area protection offers maximum protection for your mold

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The EX machine reproduces high-quality articles with great efficiency. High performance and reliability make it the productive leader for every production process.

Machines in the EX SeriesFirst-class injection unit

The outstanding EX injection unitStrong and direct – shot by shot

Excellent melt quality for every applicationKraussMaffei plasticizing units are characterized by excellent melt quality coupled with high plasticizing capacity, and form the centerpiece of every EX machine.

With screw diameters of 15 to 75 mm and a large range of standard and high-per-formance screws, the EX Series covers almost all application areas.

In the high-temperature version, rated for up to 450 °C, there are no limits to the production of technical parts which meet the highest mechanical, chemical and thermal criteria.

For high throughputs, we can offer you a wide range of high-performance screws (HPS), as well as our wide-ranging expe-rience and expertise as a manufacturer.

KraussMaffei plasticizing units are synonymous with excellent melt quality coupled with high plasticizing capacity.

Your advantages:– Optimum melt quality– Completely wear-resistant and

maintenance-free injection-pressure measurement

– High plasticizing capacity– Manufacturer expertise– First-class reproducibility

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Using dynamic precision to directly achieve reproducible processesPowerful high-torque drive units ensure high injection performance that is imme-diately transferred to the screw via a direct-acting spindle system with zero play.

Thanks to their extremely dynamic response, the motors regulate the set process parameters of "speed", "path" and "pressure" in the minimum toler-ance range very quickly and precisely.

Using a sensitive sensor system, the injection pressure is measured directly in the force flow as an absolute value.

This ensures precise regulation of holding and back pressure.

By combining absolute repeatability and optimum plasticizing, the EX Series offers ideal conditions for first-class shot weight consistency.

High-torque direct drives for dynamic and repeatable sequences of movements

Grams

+/- 0.029 g

First-class shot weight consistency

Excellent plasticizing + absolute precision = first-class shot weight consistency

0 8040 9080 100120 110160 120Shot Shot

252 255.5

253255.6

255.7

255.8

254

255

256

257 255.9

Grams

Your advantages:– High efficiency– Low energy consumption– Custom technological upgrades– Outstanding injection performance

Low energy consumption thanks to high efficiencyOn the EX injection unit, the drive power output from the servomotors is directly and efficiently transferred to the screw.

High efficiency levels are achieved as a result, particularly during the energy-intensive "injection", "holding pressure" and "plasticizing" process steps.

Although the EX injection unit has high power reserves, only the energy that is required for each respective application is consumed.

Wider range of applications thanks to technological upgradesThe machines in the EX Series can optionally be equipped for the most var-ied processing techniques and to meet your application exactly.

From processing thermosets (DuroSet) or liquid silicone rubber (SilcoSet) through to foaming processes (CellForm) or mul-

ticomponent technology (Multinject) – the EX Series leaves almost nothing to be desired.

If necessary, the EX Series can also be retrofitted with KraussMaffei technology.

Standard injection unit from SP 55 to SP 750 / 15 – 55 mmUltra injection unit from SP 55 to SP 380 / 15 - 45 mm

Plasticizing unit with quick-change system

Injection motor

Precision linear guidesDrive unit

Plasticizing motor

EX Series with SilcoSet equipment for processing liquid silicone rubber (LSR)

12 Machines in the EX SeriesFirst-class injection unit

"Ultra" injection unit – strengthened drive units for the best performanceThin-walled applications with a high ratio for the flow path and wall thicknesses require excellent injection performance.

The ultra injection units in the EX Series offer pure injection performance and can optionally be used for all plasticizing sizes with screw diameters of 15 - 75 mm.

Advantages – such as low energy con-sumption and high precision – are still extensively offered by the all-electric ultra injection unit.

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Standard injection unit from SP 1400 to SP 2000 / 55 - 75 mmUltra injection unit from SP 750 to SP 2000 / 40 - 75 mm

13Plasticizing motor

Plasticizing unit with

quick-change system

Injection motor

Precision linear guideDrive unit

EX 200-1400 with ultra injection unit

EX – injection speeds

Injection unit SP 55 SP 180 SP 380 SP 750 SP 1000 SP 1400 SP 2000

Standard (mm/s) 300 300 300 300 300 250 200

Ultra (mm/s) 800 600 550 500 450 450 450

14 Machines in the EX SeriesCost-efficiency

Total cost-efficiencyHigher productivity with lower use of resources

Sustainability through minimum energy and water consumption Thanks to its high overall efficiency, the AX consumes very little energy even with different loads and applications.

By contrast with comparable hydraulic injection molding machines, energy con-sumption is often reduced by 50 percent and more.

Due to the low friction losses, the inter-nal cooling load and, thus, cooling water consumption are very low and savings of up to 70 percent are entirely normal.

Your advantages:– Minimum energy consumption– Lower water consumption– Short cycle time thanks to parallel

functions– Low sound pressure level– Low heat emissions

7.2 (16 s) 15.6 (17.5 s) 28.4 (19 s) 43.9 (20.5 s) 65.5 (22 s)

Technical parts/2.0 D stroke: Throughput in kg/h (cycle time)

0.8

0.6

0.4

0.5

0.7

0.9

1.1

0.2

0.1

0.3

1.0

1.2

Energy consumption in kWh/kg Hydr. IMM EX Series

4.8 (6 ) 9.8 (7 s) 17.1 (8 s) 25.2 (9 s) 36.0 (10 s)

Thin-walled parts/0.5 D stroke: Throughput in kg/h (cycle time)

0.8

0.6

0.4

0.5

0.7

0.9

1.1

0.2

0.1

0.3

1.0

1.2

Energy consumption in kWh/kg Hydr. IMM EX Series

Outstanding productivity thanks to high availability and faster cyclesThe high availability of the EX is based on the characteristics of high reliability, low maintenance requirements and fast response. The EX is therefore available for more production hours.

High-performance servomotors and parallel functions come as standard on each EX and can be used unrestrictedly. As a result, cycle times can potentially be reduced by over ten percent.

Due to its high precision, the EX reliably ensures stable processes and produces the maximum number of OK parts.

Low emissions produce a pleasant climate. EX machines ensure a pleasant working climate in every company. Compared with conventional injection molding machines, significantly lower sound-pressure levels are measured on the EX.

Thanks to the high efficiency of the mechanics and water-cooled drive technology, thermal emission is kept to a minimum. This is very important, especially in air-conditioned production, such as in cleanrooms, for example.

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Cycle time comparison

Machine with serial functions

Close mold

Injecting

Holding pressure

Plasticizing

Cooling

Open mold

Ejecting

Cycle time

EX Series with parallel function

Close mold

Injecting

Holding pressure

Plasticizing

Cooling

Open mold

Ejecting

Cycle time

0 1 2 3 4 5

12.2 s

Saving

5.67 s

5.05 s

16 Machines in the EX SeriesIdeal interaction between automation and machine

Our extensive know-how in the areas of injection molding machinery and automation is your economic advantage. Standardized elements combined with customer-specific solutions form the basis for high flexibility in production. The integrated CE-approved safety concept ensures a high safety standard and reduces the machine costs.

Ideal interaction between automation and machineProven overall economic concept

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WizardX programming assistantEasy to recognize by the "magic wand symbol"

Ideal interaction between automation and machineProven overall economic concept

Maximum variability thanks to standardized automation systems. The linear robots from the LRX Series are ideally suited for simple pick & place solutions and quick removal. They also perform a very wide range of tasks in the injection molding process: Insertion, demolding, processing and much more besides. Thanks to integration in the con-trol unit of the machine, all work steps can be very easily programmed and saved with the dataset of the injection molding machine. This automatically ensures the right combination of dataset and program – an advantage which also considerably increases machine safety.

The industrial robot (IR) guarantees maximum flexibility during complex demolding and a wide range of other assembly steps or production steps. The intelligent control system concept featuring a simplified user interface and an extended expert mode is suitable for every user group and helps you reach your goal with often just two clicks. The user interface of the handheld pendant can also be selected in the beginner mode or expert mode depending on the user authorization and hierarchy.

WizardX – Smarter programming The dialog-based programming assistant in the MC6 control system allows even beginners to create basic demolding processes in the shortest possible time. The interactive communication between the user and the control system makes manual programming superfluous and eliminates programming errors.

Integrative system: The perfect symbiosis of machine and automationAs a system partner, we supply auto-mation technology and a machine on request as a fully integrated overall concept. The machine and handling system form a functional unit in this case. The joint control system allows both functional units to be controlled on any control panel: Automation technol-ogy and machine. The perfect symbiosis of a machine and automation technology is rounded off by a standard safety hous-ing. The machine can be operated via the handheld pendant of the robot – and vice versa.

The control system: Intelligent and integratedThe injection molding process and auto-mation form one unit via the integrated control system with VARAN-BUS tech-nology. Process data are available in real time. Programming and operation are easy and do not call for any in-depth programming knowledge. To permit optimum teaching and ergonomic pro-gramming, all LRX/LRX-S machines have a handheld pendant with a touchscreen display whose operating steps are identi-cal with the machine's control panel.

With the integrated solution, the entire process can be controlled via a common operating panel. The machine and robot data are saved in one dataset. This also ensures both maximum data security and excellent operating convenience. 20 safety zones, of which five are dynamic, increase the efficiency of the control programs.

Your advantages:– Smarter programming and operation

with WizardX– Integrated control system with central

operating unit– Machine and automation system

as optical and functional unit– Standardized discharge and set-up

options– CE conformity– Wide range of automation systems

from pick & place to highly complex solutions

Machine panel operates automation

Automation panel operates machine

Machine

Automation

Work is made easier through mutual operation – the injection molding machine can be controlled by the automation handheld pendant – and vice versa

With innovative features such as SplitScreen technology, the MC6 control system offers you greater convenience and usability

Usability is our top priority The new MC6 control system with SplitScreen technology and Eco function

18 Machines in the EX SeriesControl system

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Whether you are working with a KraussMaffei control system for the first time or you are accustomed to its MC5 predecessor – MC6 technology is so intu-itively accessible that you will work better and more efficiently than ever before.

Everything in sight - thanks to the new SplitScreen technologySplitScreen technology is one of the spe-cial highlights of the MC6: Thanks to the split-screen display, you can see the most important production processes simulta-neously. In parallel with the actual value cycles, you can control, for example, the injection process.

Clarity thanks to the ProcessDesigner tool The integrated ProcessDesigner tool provides a clear visual presentation of all current processes and enables you to modify them, depending on require-ments, by means of simple drag-and-drop movements or swiping movements.

Destination reached with just two taps – thanks to a drop-down menu and a favor-ites barTo ensure that handling the control unit is as user-friendly as possible, deeper navi-gation levels have generally been avoided with the MC6. Based on the credo "reach-ing the destination as quickly as possible", a clear overall concept with individually configurable favorites bars is produced. In order to guarantee optimum use, the machine keypad only provides the keys which can be selected in regard to the operating states of the machine. Our user-

The new MC6 control system meets all of your usability needs.

friendly principle is rounded off by a special field for selecting systems. You can there-fore directly select all components of the machine up to automation and technology.

Go Eco! Energy efficiency at the push of a buttonIn keeping with our overall energy-effi-cient design, the MC6 control system has an "Eco button". This allows you to con-figure the machine in the most energy-efficient manner at the touch of a button.

Intelligent user profilesThanks to standardized role profiles – from the machine operator and mold setter through to the production manager – you can assign different authorizations quickly and easily. Of course, you can also create additional hierarchy levels and assign individual rights to users. Another feature of the MC6 is the resistive dual-touch function which also allows the screen to be operated by a person wear-ing gloves. With the Windows 7 Embed-ded operating system, the MC6 is ideally equipped for today's technologies and those in future. The MC6 control system can be ordered in more than 30 lan-guages. And best of all: Every feature is available not only with the control system, but also on the handheld pendant.

Your advantages: – User-friendly function principle– Simple process control thanks to

SplitScreen and ProcessDesigner– Clear structures– Standardized user administration– Two-way operation of automation

and machine possible

The MC6 control system impresses customers with its clear overall concept. Here using Pro-cessDesigner as an example.

You can operate the automation both from the handheld pendant and from the injection mold-ing machine. And, with the MC6, even reverse operation of the injection molding machine is easy from the robot's hand-operated console.

Do you get the most energy-efficient machine setting? Always! - Simply press the Eco button

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EX CleanForm meets the highest cleanliness requirements Even the standard model from the EX Series can be used without any problems in cleanroom classes 7 and 8 in accor-dance with the ISO standard.

Using direct drive units and hermetic casings, hardly any particles are emitted.

The rinsing effect of the clean air flow continues to be effective within the machine thanks to the open design principle.

The EX meets all requirements per-fectly with regard to optimum acces-sibility, which is a prerequisite for good cleanability.

The EX Series can optionally be further equipped and can therefore be individu-ally adapted to your requirements. For example, raising the machine can make it much easier to clean your floors.

Machines in the EX SeriesCleanForm

EX CleanForm – the clean injection molding machineClean, reliable and transparent

The EX Series sets new stan-dards for manufacturing in cleanrooms. In sectors, such as medical technology, where there is no room for compro-mise on cleanliness and pro-cess reliability, the EX Series can play to all its strengths. It produces articles with extreme cleanliness and precision, and to top it all off, it is still very fast and energy efficient.

Your advantages:– Extreme cleanliness– High process reliability– Optimum accessibility– Custom solutions– Minimal particulate loads– Minimal thermal loads– Open and transparent

EX 160-750 CleanForm – with a zero- emission design. Encapsulated and water-cooled servo drive units, as well as optimum accessibility for simple cleaning.

Particle-free clamping unit for clean production For a particle-free product room within the clamping unit, all particle sources have been eliminated in the EX Series.

Thanks to the closed lubrication system for the Z-toggle, the lubricant-free col-umns and the fully encapsulated drive units (clamping movement, ejector and mold-height adjustment), the EX provides the ideal conditions for an absolutely clean product room.

Reduction of process gases thanks to nozzle and cylinder extractor Process gases are the greatest source of contamination during injection-molding production – during production and par-ticularly during the heating and empty-ing procedure when starting up.

Thanks to the optionally available nozzle and cylinder extractor, these aerosol and particle emissions can be effectively reduced, and thermal loads on the clean-room can also be minimized.

Open design principle ensures optimized air flow Effective clean air flow in the area around the mold is a prerequisite for clean and stable parts production.

The open design principle of the EX clamping unit greatly enhances air flow through the machine.

Using perforated plates (optional), the rinsing effect in and around the product room can be increased once more.

Z-toggle with a closed lubrication system and lubrication-free columns for clean products

The nozzle and cylinder extractor reduces all particle and thermal emissions Air-flow openings to aid laminar flow

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Especially in molding for medical and pharmaceutical applications, absolute cleanliness is a must. EX Series has been explicitly engineered for clean-room production.

22 Machines in the EX SeriesFurther information

Further informationwhich might also interest you

Are you looking for the appropriate auto-mation solution for your EX machine? We can offer you the right robot for every production task. You can also equip your EX with a special clamping system or various accessories.

We have also compiled extensive infor-mation on the subject of service for you.You therefore increase the flexibility of your injection molding machines for con-stantly occurring new process require-ments and permanently extend their per-formance level. We are happy to provide you with detailed information on this.

You can find more information about the following for example:– Ideal for the pharmaceutical and pack-

aging industry– Side-entry robots in the SR series– Industrial robots in the IR series– Linear robots in the LRX/LRX-S series– Life Cycle Service:

Production partner– Verifiably clean production of injection-

molding applications – CleanForm production cells

You can find our brochures and flyers on other topics online at: www.kraussmaffei.com. On request, we would also be happy to send you information and technical data for our products free of charge.

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The KraussMaffei Group has a global presence. Countries with subsidiaries are marked in dark blue. In the white-colored regions, the Group is represented by over 570 sales and service partners.

KraussMaffeiA strong brand in a unique global group

Cross-technology system and process solutions Whether in Injection Molding, Reaction Process Machinery or Automation – the KraussMaffei brand stands for pioneer-ing and cross-technology system and process solutions in plastics processing worldwide. For decades, our expertise, innovative ability and passionate commit-ment to plastics engineering have been your competitive edge. As a cross-indus-try system provider, we offer you modular and standardized systems as well as solutions customized to your needs.

There for you around the worldWith our worldwide sales and service network, we offer our international customers an excellent basis for a successful business relationship. Due to the close proximity to our customers, we are able to answer your individual inquiries very quickly. We work out the best possible technical and economical solution for your product and production requirements together with you. Test our machine technology for your applications and let our experts put together an indi-vidualized service package for you.

Individualized serviceOur employees from customer service, application technology and service help you with your questions and needs on every topic dealing with machines, sys-tems and processes – around the globe, quickly and with a high level of expertise. We have developed an extensive custom-ized service spectrum with our lifecycle design, which accompanies you through-out the entire lifecycle of your machines and systems. Take advantage of the per-sonal interaction and flexibility we offer in our practically oriented seminars. We carry out customer-specific trainings either at your location or at our sales and service locations.

You can find additional information about KraussMaffei at: www.kraussmaffei.comKraussMaffei Group

Comprehensive expertise

Unique selling proposition Technology3

The KraussMaffei Group is the only pro-vider in the world to possess the essen-tial machine technologies for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands: Injection Molding Machinery, Automation, Reaction Process Machinery and Extrusion Technology.

The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your highly skilled and integrated partner. Use our com-prehensive and unique expertise in the industry.

You can find additional information at: www.kraussmaffeigroup.com

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y.The injection molding machines in the EX Series demonstrate their strong points wherever there is no room for compromise, for example in the medical technology, electronics and packaging industries. Do you have high demands in regard to performance, precision and cleanliness - or all of these simul-taneously? If so, the machines in the EX Series are just right for you.

With clamping forces ranging from 50 to 240 tons, the EX offers a unique machine concept in which the stan-dard features include reliable processes coupled with high productivity and a clean production environment at cleanroom level.

Fast. Clean. Precise.The all-electric EX Series