Arburg: Focus on energy efficiency and solutions for specific sectors with new hybrid and electric Allrounders

This year, Arburg´s (www.arburg.com) trade fair stand at the Fakuma in Friedrichshafen will be very much in keeping with the spirit of the "energy efficiency" mega-trend. In its capacity as a trendsetter in the field of energy-efficient machines, Arburg´s product range features two complete Allrounder machine series, the electric Alldrive and the hybrid Hidrive, which fully meet these high standards. A total of five of the nine exhibits belong to these two series and consequently bear the Arburg "e2" energy-efficiency label.

The Allrounder A and H machines excel not only in their energy-efficient operation, but also in their versatility in terms of sector-specific solutions, their flexibility with regard to automation and their potential to reduce cycle times. It is therefore fitting that these energy-efficient, high-performance machines will be presented at the Fakuma with applications from growth sectors in the injection moulding industry, such as packaging, medical technology and optics - some of which will be integrated in complex production cells.

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Allrounder Hidrive: Designed for maximum productivity
The Hidrive machine series, which had its debut at the Technology Days in spring, will also enjoy a prominent position at the Fakuma. These hybrid machines take the best from Arburg´s modular system to create a high-performance machine concept: They combine the servo-electric clamping unit of the Allrounder A, the hydraulic injection unit of the Allrounder S with hydraulic accumulator technology and servo-electric dosage to form a powerful machine series for optimised cycle times. The Hidrive machines are characterised by maximum production performance and reduced energy consumption at a highly attractive price/performance ratio. As will be demonstrated at the Fakuma, they therefore lend themselves perfectly to the production of components for high-end sectors.

Such areas include medical technology, which, as well as precision and hygiene, also requires high-speed qualities from a machine. The fact that the Hidrive series meets all of these requirements is demonstrated by the Allrounder 520 H with a clamping force of 1,500 kN and a size 800 injection unit. Equipped with a 32-cavity mould with a full hot runner system, the machine will produce syringe barrels from PP in a cycle time of just six seconds. This is achieved by means of the rapid, dynamic mould movements of the servo-electric toggle-type clamping unit, the simultaneous movements of independent movement axes, the excellent injection dynamics and the large injection flow.

The use of the new Hidrive series in the automated automotive sector will be demonstrated by Arburg with the production of a plug insert. This extremely precise technical moulded part will be produced in a cycle time of 14 seconds on an Allrounder 370 H with a clamping force of 600 kN, a size 290 injection unit and a 4-cavity mould. Part removal and sprue separation are performed by a vertically operating Multilift V robotic system, which sets down the moulded parts separately by cavity to ensure detailed quality assurance - as required by the automotive industry. The Selogica control system, in which the robotic system is fully integrated, guarantees a smooth and fast production process and manages everything on a central basis.

Allrounder Alldrive: enhanced electrical precision options
Thanks to their fully electric equipment, the electric Allrounder A machines combine speed and precision with high energy efficiency. Noise and emissions are correspondingly low, which makes these machines especially suitable for the manufacture of high-end moulded parts.

Arburg will present an extremely interesting application from the challenging area of optics on the new, smallest electric machine. The Allrounder 270 A with a clamping force of 350 kN and a size 70 injection unit will produce an optical fibre with surface microtextures with the greatest precision. Optical fibres are employed wherever light is to be fed and emitted in a targeted manner - in lighting and fibre optic technology, for example. An Arburg Thermolift material dryer and conveyor with dry air unit will be used to prepare the PC granulate. A temperature control unit with an interface with the machine ensures a precise mould temperature, which is absolutely essential in the production of optical components. After the vertically operating Multilift V robotic system has removed the part, it travels to a measurement point, where the parts are illuminated in a targeted way by a light source to check the quality and function of the light waveguide. Next, the moulded parts are set down on a conveyor belt in a defined arrangement. Here, all functions of the peripherals are integrated in the Selogica control system, so that the entire, complex production process, including quality checks, can be handled easily and securely.

When it comes to speed and productivity, packaging technology makes by far the highest demands. These demands are easily met by the new, large Allrounder 720 A (Photo), which has rounded off the top end of Arburg´s electric machine series since the Technology Days, as will be demonstrated by a high-speed thin-walled application. This machine, with a distance between tie bars of 720 x 720 millimetres and a clamping force of 3,200 kN, will be exhibited at the trade fair with the new size 1300 electric injection unit. This combines dynamic, precise injection movements with high energy-saving potential, particularly where the servo-electric dosage drive is concerned. The drives of the individual axes, which are completely independent from one another, enable simultaneous movements and therefore, in many cases, a considerably reduced cycle time.

Individual project systems with great flexibility
In addition to all this, several complex production cells demonstrate how parts can be mass-produced fully automatically.

Another industry-specific solution from the packaging sector that will be on show is an in-mould labelling system constructed around an electric Allrounder 570 A with a clamping force of 2,000 kN and size 800 injection unit with barrier screw. As a thin-walled application, the IML mould produces six yoghurt tubs with a rounded base, each with a capacity of 125 grams. The moulded part weight is 6.3 grams, the six tubs made of PP are produced in a cycle time of only 3.5 seconds. Performance in terms of material preparation is correspondingly high, at almost 40 kg/h. The IML system from Swiss Robotics was specially adapted for this application, and its outstanding features are fast movements and high productivity. As well as label handling with insertion directly in the mould, the system also performs part removal and stacks the finished tubs. Short access times can be achieved on the basis of the simultaneous, high-precision machine movements. A high level of safety is guaranteed by linking the system to the Selogica control system in which further peripherals of the production cell - the vacuum conveyor and the day container, which provides the required amount of material - is integrated.

Another interesting feature is the energy consumption measurement, which allows the operator not only to monitor the energy used during the injection moulding process online via the Selogica machine control system, but also to optimise it on a targeted basis.

This option is also a feature of the largest Allrounder 920 S, with a clamping force of 5,000 kN, size 4600 injection unit and hydraulic accumulator technology, which produces the well-known folding crate patented by Ifco Systems. As an application from the area of technical injection moulding, the integration of the following operations in the production process will be impressively demonstrated.

The vertically operating robotic system Multilift V will remove the five individual parts, which have a total weight of 900 grams, from the family mould with a full hot runner system and needle shut-off nozzle. The parts are subsequently set down on an assembly and press-fitting station, where they are joined to form the folding crate. The mould´s 33 control circuits have been integrated compactly in the machine. Material is supplied centrally with gravimetric colour dosage, enabling the colour to be changed quickly, making for highly flexible production. Here too, the entire system, including the peripherals, is programmed and controlled centrally in the tired-and-tested manner using the Selogica control system.

The extremely compact fully automatic system on which the familiar Arburg buggy is produced is spectacular to watch at work. As well as the encapsulation of inserts, this application from the area of technical injection moulding focuses on the integration of downstream assembly processes. The production cell consists of a vertical Allrounder 375 V with a clamping force of 500 kN and size 170 injection unit and six-axis robotic system. The complex movement sequences of this system offer superior flexibility with a comparatively small footprint.

A highlight of this application is the extremely simple programming of the six-axis robotic system, thanks to the integration of the tried and tested Selogica control sequence editor in its user interface. Communication with the Selogica control system is via the robotic interface and an additional fieldbus expansion. Thanks to this real-time connection, complex mould entry operations are very easy to implement. It is also very easy to move the system from a station after a cycle has been interrupted.

The robotic system is responsible not only for the insertion of the metal axles but also for complete part removal, sprue separation and complete assembly of the individual parts. The cycle time per buggy is 30 seconds, the moulded part weight is 25 grams.

The subject of "simple robotic system programming" is completed by the Allrounder 420 C Golden Edition exhibit with the Multilift V Select. Thanks to its teach-in function, the robotic system learns the positions it has to move to in order to pick up and set down parts with the utmost precision. To this aim, all the positions of the robotic system are travelled to manually in succession and confirmed with the "Teach" button. All the necessary parameter entries are then checked automatically in the control system. Simultaneously, the Selogica control system independently generates the robotic sequence and integrates it in the machine cycle.

Moreover, the permissible operating range of the robotic system can be configured with the greatest of ease, further increasing safety. Visitors to the Arburg stand will be able to see for themselves that no special programming skills are required for this innovative method of programming robotic systems.

Planning and maintenance for greater cost efficiency
Half of the exhibits operate with a robotic system or are incorporated in complex production cells. This proves the ever increasing importance of automated solutions for the economical production of high-quality products.

Moreover, ensuring consistently high product quality, optimising production capacity utilisation, minimising downtime and thereby ultimately also enhancing the energy efficiency of production is becoming increasingly important for reasons of economy. Arburg will demonstrate how this objective can be achieved through centralised production planning and control with the Arburg host computer system (ALS), which will provide access to all the exhibits. ALS offers a comprehensive overview of the entire production and rapid, secure access to current data relating to ongoing injection moulding production. ALS enables both effective planning and implementation of injection moulding production. At the same time, machine and mould maintenance can be precisely planned - an aspect of increasing importance in terms of preventive maintenance. All questions on this topic will be answered by the Arburg Service Team on the stand. Furthermore, a corresponding course has been added to the training program.

Targeted trade fair programme
Once again this year, visitors to the Fakuma will receive targeted information with regard to the latest developments in injection moulding technology. Above all, the company will present powerful machine technology and applications that result in energy-efficient injection moulding production. Setting the trend are the new members of the electric Allrounder Alldrive series and their new size 1300 injection unit and the new high-performance hybrid Allrounder Hidrive machines with energy-efficient drive technology for the production of injection moulded parts with reduced cycle times.

The focus provided by the machines will be complemented by the presentation of several project applications, which clearly demonstrate how the integration of upstream and downstream processes enable the fast, low-cost production of moulded parts. The applications on show are primarily aimed at the fields of packaging, medical technology, optics and technical injection moulding. These are all injection moulding sectors in which Arburg sees a high potential for growth in the years to come, and is therefore offering targeted solutions for smooth, high-quality part production.

Arburg GmbH + Co KG, Lossburg, Germany

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