Focus Vertical ALLROUNDERs www.arburg.com Injection molding machines for the ergonomic encapsulation of inserts At a glance 1 2 Ergonomics: vertical free-space system with fixed mounting platen positioned at the bottom for Application versatility: the right technology for unimpeded access to the mold. every application. If you intend to use vertical injection molding machines in your production facility, we currently offer the widest range in the entire industry – “Made by ARBURG – Made in Germany”. Our vertical ALLROUNDERs are designed especially for the encapsulation of inserts. Our perfectly graduated product range extends from the ALLROUNDER S, featuring the ALLROUNDER principle with swiveling clamping unit and interchangeable injection unit, our entrylevel vertical model, the ALLROUNDER V, the flexible ALLROUNDER T vertical rotary-table machines, through to customer-specific, specifically configured vertical machines. Furthermore, a wide variety of equipment options and ­possible combinations are available. The choice is yours: whatever your ­application requires. 1 Ergonomics A high degree of ergonomics is particularly important during the processing of inserts, in order to organize manual operations as conveniently and efficiently as possible. In the case of the entry-level ALLROUNDER V machine, this is achieved by means of the so-called vertical free-space system for the clamping unit. Tie bars are dispensed with, rendering the mold freely accessible from three sides. The fixed mounting platen positioned at the bottom effectively prevents the inserts from slipping. Moreover, the low table heights are ideally suited for manual insertion and removal. Pneumatically activated safety guards or protection with light curtain, as available on the ALLROUNDER T rotary table machines, ensure particularly efficient processes. 2 Application versatility The entire technology of the vertical ALLROUNDERs can always be matched precisely to the specific injection molding task. This is achieved thanks to: • the wide range of clamping forces and injection units • various clamping systems – molds can be closed both from above and below • the flexible vertical and horizontal arrangement of the injection units. • task-specific equipment packages, such as for thermoset and silicone processing, for example • the freely programmable SELOGICA ­control system 2 www.arburg.com · 10/2013 2 3 3 4 Automation: shorter cycle times and higher Process reliability: smooth movements thanks to productivity. servo-electric rotary tables. 3Automation 4 In order to enable simultaneous insertion and removal of items during the injection process, machine versions with rotary or sliding tables are also available. This enables shorter cycle times and thus higher productivity. The versatile configuration options ensure that vertical ALLROUNDER machines are ideally suited to production requirements at hand and can also be easily integrated in automated production lines. Automation solutions extending through to complete turnkey systems are easily achievable. Process reliability As you would expect from ARBURG, the injection units of the vertical ALLROUNDERs offer the customary high plasticizing and molded part quality. The position-regulated screw enables reproducible injection movements which are equally accurate to those of electric machines. The rotary tables of the ALLROUNDER V and T are generally servo-electrically driven. This makes them particularly fast and accurate, enabling smooth acceleration and braking. Finally, the SELOGICA control system offers numerous options for process optimization, monitoring and documentation. 5 Space optimization: compact design. 5 Space optimization The ALLROUNDER V entry-level models, in particular, impress through their compact design and small footprint. This makes them ideal for use in confined production environments. 3 10/2013 · www.arburg.com Application-oriented machine concepts 24.8 - 35.43 14 - 55 47.24 - 70.86 88 - 352 29.1 45.4 18 - 29.1 25.5 - 45.4 8.2 6.1 3.7 15.3 10.3 - 15.3 4.9 - 8.2 3.4 - 6.1 1.9 - 3.7 1 - 2.3 0.7 - 1.4 0.34 - 0.49 [tons] 2.3 1.4 0.5 Shot weight [g PS] forces V machines T 1 Injection units [oz] Clamping Special Sliding table Ø Rotary table [inch] stroking from … Series Practice-oriented drive technology From single-pump technology in the ALLROUNDER V entry-level model to dualpump or hydraulic accumulator technology in the ALLROUNDER T rotary table machines: the drive technology always matches the machine concept and can be coordinated perfectly. Electro-mechanical drives and a speedregulated pump drive (AES) are also available, ensuring energy-efficient operation. 14 - 220 Further special sizes and injection units available on request High flexibility: perfectly graduated product range with a variety of machine concepts. The following typical ARBURG features can also be found in the vertical ALLROUNDER: Through the use of proven, tried and tested assemblies, ­individual and cost-effective technical solutions are created that safeguard your production at competitive unit prices. You can combine clamping systems with a variety of rotary or sliding tables, clamping forces and injection units in many different ways. This enables modular and individual adaptation of machine technology to all your production tasks. SELOGICA control system 4 3 4 www.arburg.com · 10/2013 2 Adaptable injection units The injection units permit a higher plasticizing and molded part quality and can be individually adapted to each production task. Various sizes, screw diameters, cylinder and screw wear classes as well as alternative screw geometries are available. Cylinder modules for thermoset or silicone processing are also optionally available. Ergonomic clamping units 3 Ergonomic clamping units The large selection of different clamping ­systems and machine sizes, with a choice of rotary or sliding tables, is reflected in a wider spectrum of applications and ergonomic ­operation of the vertical ALLROUNDER machines. To ensure optimum design to suit individual requirements, molds can be closed both from above and below. Practice-oriented drive technology 4 SELOGICA control system SELOGICA provides the same operating system for all machine series. The machine cycle features intuitive programming using graphic symbols, enabling short set-up times. Immediate plausibility checking of all parameter entries ensures high operating reliability and convenience. This makes even complex processes easy to understand in the human-machine dialogue. Adaptable injection units 2 1 5 10/2013 · www.arburg.com Practice-oriented drive technology 1 2 Practical: the right hydraulic drive for every machine concept. Precise: reproducible injection thanks to valves situated close to the hydraulic consumers. The hydraulic technical components make the vertical ALLROUNDERs sophisticated machines that comprehensively meet everyday requirements. Our continuous model refinement guarantees you consistently high availability. So opting for our vertical ALLROUNDER machines gives you the certainty that proven machine components and stateof-the-art injection molding technology have always been combined to the best possible effect. 1 Energy-saving regulating pumps Depending on the machine concept, the ­vertical ALLROUNDER machines can be equipped with one or more pumps. The ALLROUNDER V entry-level model, for example, features a regulating pump. This permits serial machine movements with stroke-dependent, regulated ramps. The single-pump technology ensures energy-saving, low-noise operation at an attractive price. The ALLROUNDER T rotary table machines have two pumps as standard. The cycle time and sequence can be optimized through simultaneous movements. The dual-pump technology also ensures a controlled mold locking force throughout the injection molding cycle. 2 Precise control technology Fast-switching valve technology ensures precise operation combined with low energy consumption. The location of the valve system close to the hydraulic consumers improves control accuracy during injection and dosage. p/Q control as standard provides all movements with the necessary dynamics. Precise positioning is achieved by stroke-­ dependent ramps. The combination of all these features enables precision in all movements and results in perfect molded part quality. This ensures continuously high and economically efficient output levels over many years. 6 www.arburg.com · 10/2013 3 High performance: simultaneous, fast machine move­ 4 5 Energy saving: electro-mechanical dosage (AED). ments thanks to hydraulic accumulator technology. quality production. 4 5 Servo-electric rotary table Thanks to their servo-electric drives, the rotary tables of the ALLROUNDER V and T machines are generally independent of the injection molding process itself. This effectively reduces cycle times. Mold movements thus become fast and extremely accurate, while energy consumption is lower. Programmable, closed-loopcontrolled speed ramps ensure smooth acceleration and braking. Special machines Movement axes T Electric expansion stages In terms of drives, both electro-mechanical dosage (AED) as well as an electro-mechanical ejector system are available, which can both be moved completely independently of the hydraulic drive. In addition to reducing the cycle-time, this also saves energy and enhances precision. The ARBURG energy saving system (AES) enables the pump speed of the hydraulic drive to be adjusted continuously. This means that energy savings of up to 30 percent can be achieved in the case of medium cycle times. V 3 High-performance hydraulic accumulator technology Hydraulic accumulator technology with a central pressure accumulator enables a more dynamic and faster injection process in ALLROUNDER T rotary table machines or on special vertical machines configured to suit customer requirements. All movement axes of the machines are servo-regulated and therefore completely independent from one another. Virtually unlimited simultaneous movements can thus be performed at high speed and with great precision. Efficient: servo-electric rotary table ensures high Clamping unit Ejection Core pull Nozzle movement Injection Dosage Rotary table Sliding table Hydraulic 10/2013 · www.arburg.com Electric 7 Ergonomic clamping units 1 2 Ergonomic: Low table heights, ideal for manual activities. User-friendly: Media connections directly on the rotary table. We offer a broad range of different clamping systems, allowing the vertical ALLROUNDER to be precisely tailored to your production requirements. For the optimum processing of inserts, molds can be closed both from above or below. Different versions with rotary and sliding tables are available to enable you to work while the injection molding process is in progress. This also enables effective automated part production as well as problem-free integration of vertical ALLROUNDER machines in production lines. This high flexibility means many years of added value for your business. 1 Vertical free-space system The special advantage of the ALLROUNDER entry-level models is the configuration of their clamping units as vertical free-space systems. There are no tie bars to hinder mold installation or the insertion and removal of items. The fixed mounting platen is positioned at the bottom and effectively prevents the inserts from slipping. This setup also enables automated part feed to be achieved with ease. In addition, ergonomically efficient operation is ensured thanks to the low table heights, the guards that can be adjusted to the parting line as well as the safety guard that opens automatically and is already prepared for feeding through cables. From machine size 275 V upwards, the clamping unit can be adjusted to different mold heights. 2 Integral rotary table Ideal for automation, as well as higher output: The two-station rotary tables of the ALLROUNDER V (optional) and T (standard) machines permit simultaneous insertion and removal of molded parts. More demanding production processes can be implemented using the three-station rotary tables available for the ALLROUNDER T. Tie-barless table concepts lead to correspondingly large free spaces for securing the molds, also leaving the middle of the rotary table free for water cooling circuits and electrical connections. The cycle times are minimized by the independent, fast, precise and energyefficient servo-electric drive of the rotary tables. Programmable, closed-loop-controlled speed ramps ensure smooth acceleration and braking. 8 www.arburg.com · 10/2013 3 Customized: Special machines with fixed vertical 4 Precise: C-clamp for torque-free force application. clamping unit. 3 Special clamping systems The flexible ALLROUNDER principle with swiveling clamping unit and interchangeable injection unit means that all ALLROUNDER S machines up to size 370 can operate vertically. The fixed mounting platen is always on top in these configurations. This equipment version permits up to four working positions on a single machine. Special machines with a fixed vertical clamping unit based on the ALLROUNDER S or the ALLROUNDER T rotary table machines are also available upon request. The fixed mold platens are located at the top or bottom, depending on the machine size ARBURG has a wealth of experience in this area due to already implemented individual solutions. 5 High flexibility: Product range with a variety of closing systems. 4 Mold protection In the case of the ALLROUNDER V entrylevel models, the C-clamps, which can be swiveled to both sides, provide for torquefree force application, ensuring protection of the mold. Furthermore, mold wear is minimized through the optimum guidance and bearing of the moving mounting platen. In the case of the ALLROUNDER T rotary machines and the customer-specific configured vertical special machines, the tried-and-tested four-tie-bar guidance, together with central force application, ensures high precision of the movements and mold locking. Optimum mold service life is assured by the stable clamping unit and the sensitive mold protection system. 5 Wide range of applications The large choice of different clamping systems, together with the comprehensive clamping force spectrum, allows the optimum configuration to be achieved in terms of applications and energy consumption. The flexible product range is completed by rotary and sliding tables. 9 10/2013 · www.arburg.com Adaptable injection units 1 Short set-up times The injection unit can be swiveled to the operator side for easy removal and cleaning of the screw and for replacing the cylinder modules. The screw can be removed without dismantling the cylinder module. Set-up can be performed quickly and without errors thanks to the quick disconnect coupling for the screw and the central connection of all cylinder module supply units. To ensure optimum material preparation and injection, the vertical ALLROUNDER machines offer adaptable injection units in different sizes and screw diameters. Specially coated screws in special geometries allow you to process all common plastics. The variable configuration of the injection units provides additional flexibility: vertically for injection through the upper mounting platen and horizontally for injection into the parting line. This broad range of equipment is supplemented by further hydraulic and electric expansion stages. The result is that you are fully equipped to handle any production task. Moreover, high-quality part ­production is guaranteed long term. 2 Wide variety of combinations The injection units operate both vertically and horizontally for injection into the parting line. Cylinder modules which are compatible for all series and feature different screw diameters are available for each injection unit. The equipment range is rounded off by cylinder modules for processing thermosets and silicone, highly wear-resistant bimetallic cylinders and screws with special geometries. 3 Torque-free nozzle contact The advantage of torque-free, two-tie-bar guidance of the injection units is an absolutely leak-free nozzle contact surface. Both flat and radius nozzles can be used without problem. High nozzle contact forces can be easily achieved by means of the central insertion in the mold. The build-up of the nozzle contact force is programmable and controlled. This has a positive effect on ­nozzle and mold wear. Wide variety of combinations 2 1 Short set-up times 10 www.arburg.com · 10/2013 4 Controlled injection A pressure and speed-regulated injection process ensures reproducible mold filling and high molded part quality. The screw is reliably prevented from retracting, ensuring consistent shot weights. With the positionregulated screw option developed by ARBURG, molded part quality can be further increased. This is achieved through improved control precision with regard to pressure and speed of injection. Torque-free nozzle contact A separate, closed-loop control circuit (servo control) for the injection process characterizes this feature. The hydraulic accumulator technology provides even greater dynamics and speed during injection. 5 Expandable dosage drive Optional electro-mechanical dosage (AED) enables energy savings of up to 20 percent while maintaining the same high precision. Because the electro-mechanical dosage drive operates independently, cycle times can be significantly reduced in some cases. Simul­ taneous dosing also permits longer dosage times and hence gentler melt preparation. Controlled injection Expandable dosage drive 4 3 5 11 10/2013 · www.arburg.com SELOGICA control system 1 Central management The SELOGICA system saves time and costs thanks to its unique standardized operating concept. With the simple integration of a variety of peripherals, the control system can be used for sequence management, even of complete production cells. The management of setting data is simpler than ever; there is only one data record for the entire production unit. 2 Intuitive operation All data can be accessed immediately, rapidly and easily via the SELOGICA touchscreen. The graphic operating system, which is compatible with a wide variety of technologies, is self-explanatory. The unique sequence editor with patented, real-time plausibility check always clearly indicates the logical position of the current programming step. This way, operating errors are prevented from the start. Fast access: Available sequence symbols. Maintaining control over sophisticated machine and robotic technology requires a correspondingly powerful control system. All the sub-steps in the manufacturing cycle can be programmed clearly and easily using the intuitive SELOGICA sequence editor. SELOGICA acts as a central setting and monitoring system for the entire injection molding process, including the programming of integrated robotic systems and peripherals. All technical features of SELOGICA are designed to make operation quick, safe and convenient. In this way, short set-up times can be achieved in your production facility. Data is input consistently and training is kept to a minimum, as your operators no longer have to adapt their thinking process. 3 2 Further information: SELOGICA control system brochure 12 www.arburg.com · 10/2013 Highlights 3 Fast set-up times 6JGKPRWVNQIKEQHVJG5'.1)+%#U[UVGOKU DCUGFCTQWPFVJGOQNFUGVWRUGSWGPEG CPFQRVKOK\CVKQPQHVJGKPLGEVKQPOQNFKPI RTQEGUU6JGp5GVWR#UUKUVCPVqOQFWNG UWRRQTVUFCKN[QRGTCVKQPUHTQOOGPW IWKFGFOQNFKPUVCNNCVKQPCPF CWVQOCVKEECNEWNCVKQPQHVJGRCTCOGVGTUVJTQWIJVQVGCEJKPQH VJGƂPKUJGFUGSWGPEG 4 Reliable optimization 6JG5'.1)+%#OCEJKPGEQPVTQNU[UVGOQHHGTUPWOGTQWUQRVKQPUHQTRTQEGUUQRVKOK\CVKQPOQPKVQTKPICPFFQEWOGPVCVKQP 0WOGTQWUOQNFRTQVGEVKQPFKCIPQUVKECPF UWRRQTVHWPEVKQPUUWEJCUVJGOCKPVGPCPEGFKURNC[CNNHCNNWPFGTVJGVQRKEQH OCEJKPGOQPKVQTKPI#NNOGUUCIGUCTG FKURNC[GFEQPXGPKGPVN[KPRNCKPVGZVUQ VJCVQRGTCVQTUCNYC[UMPQYRTGEKUGN[ YJCVCEVKQPJCUVQDGVCMGP • • • • • • • Control center for the entire injection molding technology Convenient sequence programming with graphic symbols Real-time plausibility checks Common data record for the entire production unit “Set-up Assistant“ module Interactive teach-in functions Water-cooling for continuous temperature control in the control cabinet Fast set-up times Intuitive operation 4 Reliable optimization 1 Central management 13 YYYCTDWTIEQO Application examples 1 2 In focus: Ergonomic encapsulation of inserts. Hybrid components: Reproducible injection through position-regulated screw. The wide range of different clamping and injection units available, the superior ergonomics and availability, easy integration in automated production lines – these are all tangible advantages that our vertical ALLROUNDER machines can bring to your production for the encapsulation of inserts. From the ALLROUNDER V entry-level model to special machines precisely tailored to your specific requirements: when you use our vertical ALLROUNDERS, you can process all known injectable material types efficiently and economically – guaranteed. 1 Encapsulation of inserts The main area of application for vertical ALLROUNDER machines is the encapsulation of inserts. The machine technology is clearly adapted to this task. For example, the vertical free-space system permits free access to the mold from three sides on ALLROUNDER V entry-level models. For the reliable processing of even complex inserts, the mold can also be closed from above. In addition, there are machine versions with rotary or sliding tables, which enable automated and fast encapsulation of high-precision parts in series production. In rotary table machines such as the ALLROUNDER T, excellent positioning accuracy of the servoelectric drive guarantees the smooth further processing of molded parts in subsequent automated processes, for example when employing robotic systems. 2 Hybrid components In addition to thermoplastic items, parts made from thermoset or silicone, for example, can also be produced on appropriately configured vertical ALLROUNDER machines. ­This is of particular interest to the electrical and electronics industries, but also to the automotive sector with its wide range of connectors. The high degree of reproducibility that can be achieved with the vertical ALLROUNDER machines by combining the position-regulated screw (PRS) and dynamic injection via hydraulic accumulator is particularly important in this context. The molded part quality achievable is comparable to that of the electro-mechanical version. Further information: Application expertise brochure Robotic systems brochure 14 www.arburg.com · 10/2013 4 5 5QWTEG&GWVUEJG6GEJPQRNCUV)OD* 3 /WNVKEQORQPGPVRCTVU5WRGTKQTƃGZKDKNKV[VJCPMU +PNKPGRTQFWEVKQP2TQFWEVKQPU[UVGOUGURGEKCNN[ #WVQOCVKQP#..4170&'4OCEJKPGUCPFTQDQVKE VQXGTUCVKNGEQPƂIWTCVKQPQRVKQPU EWUVQOK\GFVQVJGCRRNKECVKQP U[UVGOUHTQOCUKPINGUQWTEG 3 Multi-component parts 6JGOQFWNCTEQPEGRVQHVJGXGTVKECN #..4170&'4YKVJKVUXGTUCVKNGEQPƂIWTCtion options is also important when more VJCPQPGEQORQPGPVJCUVQDGRTQEGUUGF *GTGFKHHGTGPVRTCEVKEGQTKGPVGFOQFWNGU ECPDGEQODKPGFVQRTQXKFGVJGKFGCNOCEJKPGHQTCP[CRRNKECVKQP6JGHTGGN[RTQITCOOCDNG5'.1)+%#EQPVTQNU[UVGO OCMGUVJGEQQTFKPCVKQPQHUGXGTCNKPLGEVKQP WPKVUCPFOQNFHWPEVKQPUUKORNGVQWPFGTUVCPFCPFENGCTCVCNNVKOGU 4 Inline production 6WTPMG[TGGNVQTGGNRTQFWEVKQPU[UVGOUCTG LWUVQPGQHOCP[GZCORNGUQHCWVQOCVGF KPNKPGRTQFWEVKQP(QTGZCORNGKHNGCFHTCOGUCTGGPECRUWNCVGFTGRTQFWEKDKNKV[TGNKCDKNKV[CPFRTQFWEVKXKV[CTGVJGMG[EQPEGTPU5JQTVE[ENGVKOGUCXQKFCPEGQHUJQTV UJQVUCPFOKPKOK\KPITGLGEVRCTVUCTGJKIJN[ UKIPKƂECPV6JGEQPƂIWTCVKQPQHVJGXGTVKECN #..4170&'4OCEJKPGUECPDGVCKNQTGFRGTHGEVN[VQUWEJFGOCPFKPIRTQFWEVKQPVCUMU 6YQGZCORNGUUGTXGCUCPKNNWUVTCVKQP 2TGEKUGNKHVKPIQHVJGECTTKGTUVTKRKUGPUWTGF VJTQWIJVJGTGIWNCVGFGLGEVQTYJKNGOCZKOWORTQEGUUEQPVTQNKUCEJKGXGFVJTQWIJ VJGKPVGITCVKQPQHCNNRGTKRJGTCNUKPFKG 5'.1)+%#EQPVTQNU[UVGO 5 Automation 6JGEQODKPCVKQPQH#..4170&'4UCPFTQDQVKEU[UVGOUHQTOUVJGDCUKUHQTEQORNGVG RTQFWEVKQPEGNNUYJKEJCTGFGXGNQRGFD[ VJG#4$74)RTQLGEVFGRCTVOGPVVQIGVJGT YKVJVJGEWUVQOGT#NNWRUVTGCOCPFFQYPUVTGCORTQFWEVKQPUVGRUKPVJGKPLGEVKQP OQNFKPIRTQEGUUCTGCWVQOCVGF6JGUGTXKEG TCPIGCXCKNCDNGHTQO#4$74)EQXGTUQRVKOK\CVKQPQHOQNFGFRCTVUCPFUWRRQTVFWTKPIVJGOQNFFGUKIPRTQEGUUEQORNGVGCUUGODN[CPFEQOOKUUKQPKPIQHVJGKPFKXKFWCN EQORQPGPVUCPFKPUVCNNCVKQPCVVJGQYPGToU RTGOKUGUCPFCNNVJGPGEGUUCT[UGTXKEGU 15 10/2013 · www.arburg.com Different clamping systems available with rotary or sliding tables | Clamping forces from 14 to 450 tons | Injection units from 0.5 to 94.3 oz (30 to 4600 according to EUROMAP) (KNO ARBURG GmbH + Co KG 9KVJNQECVKQPUKP'WTQRG)GTOCP[$GNIKWO&GPOCTM(TCPEG7PKVGF-KPIFQO+VCN[0GVJGTNCPFU#WUVTKC2QNCPF5YKV\GTNCPF5NQXCMKC 5RCKP%\GEJ4GRWDNKE6WTMG[*WPICT[^#UKC2GQRNGoU4GRWDNKEQH%JKPC+PFQPGUKC/CNC[UKC5KPICRQTG6JCKNCPF7PKVGF#TCD'OKTCVGU^#OGTKEC$TC\KN/GZKEQ75# (QTOQTGKPHQTOCVKQPRNGCUGIQVQwww.arburg.com. #4$74))OD*%Q-) 6JGDTQEJWTGKURTQVGEVGFD[EQR[TKIJV#P[WVKNKUCVKQPYJKEJKUPQVGZRTGUUN[RGTOKVVGFWPFGTEQR[TKIJVNGIKUNCVKQPTGSWKTGUVJGRTGXKQWUCRRTQXCNQH#4$74) #NNFCVCCPFVGEJPKECNKPHQTOCVKQPJCXGDGGPEQORKNGFYKVJITGCVECTG*QYGXGTYGCTGWPCDNGVQIWCTCPVGGKVUEQTTGEVPGUU+PFKXKFWCNKNNWUVTCVKQPUCPFKPHQTOCVKQPOC[FGXKCVGHTQOVJGCEVWCN FGNKXGT[EQPFKVKQPQHVJGOCEJKPG6JGTGNGXCPVXCNKFQRGTCVKPIKPUVTWEVKQPUCTGCRRNKECDNGHQTVJGKPUVCNNCVKQPCPFQRGTCVKQPQHVJGOCEJKPG ARBURG GmbH + Co KG &+0'0+51EGTVKƂGF A'0A75A5WDLGEVVQCNVGTCVKQPU 2TKPVGFKP)GTOCP[ 2QUVHCEJ.QUUDWTI6GN (CZ YYYCTDWTIEQOGOCKNEQPVCEV"CTDWTIEQO