sumitomo (shi) demag plastics machinery gmbh [email protected] … · 2020. 7. 8. · sumitomo...

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.

SD_ProdEff_GB_RZ_0513.indd 24 24.05.13 10:30

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 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


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.


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


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


20

» 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.


21

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


sumitomo (shi) demag plastics machinery gmbh [email protected] … · 2020. 7. 8. · sumitomo...

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