sumitomo (shi) demag plastics machinery gmbh [email protected] … · 2020. 7. 8. · sumitomo...
TRANSCRIPT
Sumitomo (SHI) Demag Plastics Machinery [email protected]
www.da-kapo.de
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.
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www.dakapo.de
Production effi ciency16 technology modules to ensure your success
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» We provide the right details which have a large effect in your production. «Dr. Tetsuya Okamura (CEO), Sumitomo (SHI) Demag
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 effi ciency 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 effi ciency experts can tackle
the challenging task of having an effective infl uence on the numer-
ous factors, which lead to increased effi ciency – for your benefi t
and in terms of ensuring optimum cost-effectiveness, secure invest-
ments 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 custom-
ised basis for your particular needs.
.
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Production effi ciency –a tradition, not a trend
Protecting the environment with innovative technologies and sus-
tainable solutions, preserving our resources and managing effi -
ciently: That is what Blue Competence stands for, the sustainabil-
ity initiative of the VDMA (German Engineering Federation), which
globally underlies the role of technological leadership for sustain-
able production.
As a member of the Blue Competence Initiative, Sumitomo (SHI) Demag consistently makes an important contribution to the pro-
tection of resources and sustainability, both in terms of production
and also manufactured products.
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activePlus – intelligent solutions with maximum effectiveness
activeCool&CleanaactiveDrivea activeAdjusta
activeDynamicsa
ToggleT
activeFlowBalancea
Without activeFlowBalance
With activeFlowBalance
activeColourChangeaLinear guides
Toggle Minimal energy intake even
with fast mould movements
Linear guidesReduction of losses through
friction and optimum
mould protection through
the highest levels of platen
parallelism
activeCool&CleanExtension of the intervals
between oil changes and
lowering of wear of the
hydraulic components
activeDynamicsHighly precise process
conduct through shortest
sampling times
activeDrive Minimisation of energy
losses in partial load and
idle speed operation
activeColourChangeFast and effi cient colour
change systematically –
at the touch of a button
activeAdjustCycle optimisation through
individually adjustable
regulation properties
activeFlowBalanceBalancing out of differing
pressure ratios with parts
critical to fi lling in multi-cavity
moulds.
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activeEcona
smartDrives Optimumdrive technologyOd activeQ/active Q+a
activeLocka All-electricdosing driveAd
Cylinder insulationC
activeRemotea
Cylinder insulationReduced energy
consumption through
lowering of the heat
emission of the plasticising
cylinder
smartDriveIncreased energy effi ciency
through speed-regulated pump
drive with hydraulic injection
moulding machines
activeEconRepresentation and optimisation
of the process settings in terms
of energy consumption and
production costs
Optimum drive technologyDrive technology specially
synchronised to the needs of
injection moulding machines
activeLockIncreased process consistency
through active closing of the
non-return valve
activeRemoteSimplifi ed machine operation
through visual integration of
peripheral devices
All-electric dosing driveIncreased level of effectiveness
through high performance direct
drive
activeQ/activeQ+Sensitive and precise
protection of moulds
through active mould
protection
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Production effi ciency modules and their effectiveness
We manage to achieve maximum
production effi ciency through effectively
coordinating the fi ve key aspects of:
• Durability• Energy effi ciency• Production performance• Availability• Product quality
Durability Energy effi ciency 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
The overview makes clear the effects of the
different activePlus technology modules
on the fi ve aspects of production effi ciency.
strong effect
very strong effect
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activeEcon operating side from the NC5 plus machine controls
activeEcon
The benefi ts to you:• The effects of process settings on
energy consumption and production
costs are made clear to see
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.
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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.
The benefi ts to you:• Oil service lifetimes of
40,000 operating hours
• Reduced wear of the hydraulic
components
• Reduced oil fi lter maintenance
costs and times
activeCool&Clean
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activeDrive
The benefi ts to you:• 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: ConverterM: Speed-controlled Motor
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
P: PumpV: Hydraulic Valve
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.
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smartDrive operating side from the NC4 machine controls
smartDrive
Using the smartDrive production
effi ciency module means that dynamic
performance adjustment to all cycle-
determined 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.
The benefi ts to you:• Reduction of energy consumption
• Low maintenance costs through
reduced pump wear
• Best price/performance ratio
Retrofi tting for
NC4 machines
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activeAdjust operating side from the NC5 plus machi-ne controls
Direct drive injection
The benefi ts to you:• Individually adjustable regulating
properties
• Reduced cycle times
• Production performance increase
of 3 – 5 % in fast mode
The benefi ts to you:• High dynamics, precision and
reproducibility as well as availability
• Optimum energy effi ciency
activeAdjust
Optimum drive technology
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.
The optimum drive technology makes
a crucial contribution towards production
effi ciency. The machine range from
Sumitomo (SHI) Demag is fi tted with
pioneering energy-effi cient 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.
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activeQProtecting 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
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+ 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.
activeDynamics
activeQ
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
activeQ and activeQ+ operating sides from the NC5 plus machine controls
The benefi ts to you:• High dynamics, precision and
• reproducibility
• Extremely short scanning times of the
• axis regulators
The benefi ts to you:• Sensitive protection of the mould even
during fast operating movements
• Reduction of machine idle times
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.
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activeLock
The benefi ts to you:• Improved precision and reproducibility
• Fewer rejects
• Increased process consistency
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.
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
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Toggle
All-electric dosing drive
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.
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.
All-electric dosing drive
The benefi ts to you:• Low energy consumption, even with
dynamic mould movements
• High availability and durability
The benefi ts to you:• The level of effectiveness of the largest
consumer can be doubled
• Protective dosing through reduced
speeds
• Higher shot weights possible
Toggle
Motor
Pump
Valve
Hydro motor
Converter
Motor
Gear
�1
�2
�3
�4
�total
~0.4...0.7
�total
0.8
Converter
Motor
~0.88...0.93�total
�1
�2
�3
�1
�2
Reduction of elements in the effi ciency chain to increase energy effi ciency
Hydraulic drive for dosing unit
Electric drive for dosing unit with gear-down
Electric direct drive for dosing
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Linear guides
Cylinder insulation
Linear guides
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.
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.
Insulation sleeve
The benefi ts to you:• Minimal friction
• Highest level of platen parallelism
• Reduced mould wear
The benefi ts to you:• Fast pay-back
• Simple retrofi tting
• Reduction of energy consumption and
heating performance of up to 40 %
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activeFlowBalance
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
Without activeFlowBalance
With activeFlowBalance
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.
The benefi ts to you:• 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
Cavity fi ll level at switching point
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The benefi ts to you:• 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 effi ciency of the entire
system
• Very fl exible equipping also for
complex automation tasks
activeRemote
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.
smartRemote operating side from the NC5 plus machine controls
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The benefi ts to you:• 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
activeColourChange
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 effi ciently,
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.
Problem-free colour change in the shortest time
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We can provide you with many intelligent
and, above all, effective options to increase
production effi ciency by using our high
performance technology modules.
The overview shows you which modules
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
are available for which machine series
respectively.
Production effi ciency modules and their use
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» 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
Producing in ways which are fl exible, fast, high-quality and
cost-effective is more important today than ever. Our high-performance machine range and our 16 innovative activePlus production effi ciency 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 effi ciency 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.
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Production effi ciency and more – Your production effi ciency experts
Advice and ideasThe 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.
DesigningOur 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.
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.
AutomationOptimum cost-effectiveness and effi cient
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 up-
and down-stream processing steps are
covered by us in close cooperation with our
network partners. Our experts ensure that
everything fi ts together.
Customer serviceHighest 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 effi ciency modules.
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Production effi ciency – tradition, not a trendWe 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 effi ciency. 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
effi ciency 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
effi ciency, durability and product quality are
what we regard as the fi ve crucial aspects
of our innovations and the key for ensuring
Sumitomo Heavy Industries
Demag Plastics Group
1949Extruder forwire coating
1963Extrusion facilities
for blown fi lms
1967First injection
blow-mouldingmachine
1969Complete range of injection
moulding machines
1972Sandwich injectionmoulding machine
1972First multi-component
machine
1983Injection moulding machinefor CD optical data carriers
1990First electric injection
moulding machine(SE series, hybrid)
1950First injection moulding
machine (Anker)
1956First single-screw injection moulding machine in the
world (Anker)
1961First elastomer processing on Anker screw injection
moulding machines
1963First thermoset processing on
Anker screw injection moulding machines
19675-point toggle
1971First programmable injection moulding
machine (punched tape)
1973First digitally controlled
injection moulding machine (digital
hydraulics)
1975First PLC-controlled injection moulding
machine
1979First PLC-controlled injection
moulding machine with screen
1983Introduction of p/Q control pump (DFE)
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Sumitomo (SHI) Demag
未来をみつめてReady for the future
Der Zukunft voraus
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.
1993PET injection
moulding system
1998All-electric injectionmoulding machine
(SE-S series)
1999Lockable non-return valve
2003All-electric 2C
injection moulding machine
2005All-electric ultra-high-performance injection
moulding machine
2005All-electric
dosing drive
2008All-electric
large machine CL 7000, 550 t
2008Merger of Sumitomo Heavy Industries and Demag Plastics Group
2011Over 100,000 injection
moulding machines in the global market
1992Ergotech modular system machine
1996Multi complete modular system
machine
1998Hybrid El-Exis S high-speed injection moulding machine
Active mould protection activeQ
2003All-electric IntElect injection moulding
machine
High-torque direct drives
2009Combination DFEE pumps and
frequency-controlled drive activeDrive
Schwaig plant becomes Centre of Competence for hydraulic
and hybrid machines
2010Individual control
system activeAdjust
Periphery integrationactiveRemote
2010Hybrid high-speed injection moulding machine El-Exis
SP
Expansion of IntElect smart series up to 450 t
2011Lockable
non-return valve activeLock
Flow front monitoring
activeFlowBalance
Optimised drive system
activeDynamics
2009Wiehe plant becomes Centre of Competence for electric machines
IntElect smart combines IntElect with drive
technology from SHI
2006SL screw
2012NC5 plus
relaunch control
2012SE-EV –
New all-electric injection moulding
machine from Sumitomo
IntElectmulti – fi rst all-electric multi component
injection moulding machine
activeColourChangeChange of colour
at the touch of a button
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