Productivity PLUS. Success with KraussMaffei. Munich, September, 2015, Anna-Maria Meyer (Product Marketing IMM)

Transcription

1 Productivity PLUS Success with KraussMaffei Munich, September, 2015, Anna-Maria Meyer (Product Marketing IMM)

2 Analysis of market conditions What are the motivators in the segment under 400 tons? Cost pressure Globalization, Competition PRODUCERS ARE UNDER PRESSURE Mass production Drive toward individuality (automotive) "I must get cheaper" "I must get more effective" "I must use technology" Specialization More technologies, competitive advantages "I must conserve resources" Resources Energy more expensive, oil is getting scarce

3 Page 3 Our reply: "Increased productivity" Comprehensive range of technical solutions PRODUCTIVITY

4 Page 4 Productivity PLUS Sophisticated solutions that create added value Cost pressure We reduce costs Mass production We increase efficiency Specialization We specialize you Resources We conserve resources Productivity PLUS by KraussMaffei

5 Cleverly reduce direct costs COSTS Page 5

6 Page 6 Saves valuable production areas Unique 2-platen design with self-supporting clamping unit Years of experience in the 2-platen design: Compact design Self-supporting yet extremely stable Additional space for collecting vessels, temperature control units, etc. Well suited for clean room solutions Additional installation area Better use of valuable production floor space Reduced fixed costs 10 20% savings in floor space and more space under the clamping unit.

7 Page 7 Space-saving and already fully equipped Integrated sprue chute and CE conformity Space-saving and CE compliant: No subsequent expensive retrofitting of the protective housing No lateral extensions necessary The telescoping stroke does not extend the complete stroke upwards Freely selectable waiting position for fast demolding Space savings of approx. 550 mm Complete solution with no need for any additional investment Reduction of approx in investment Four machines instead of three can be set up in the same installation space - even in halls with low ceilings.

8 Page 8 Your path to zero defect production APC stabilizes processes and maximizes profits Revolutionize your manufacturing process: Compensation of unwanted environmental factors, e.g. fluctuations in material quality, temperature, etc. APC keeps the reference value set in advance by the mold setter at a constant level Just like with a speed control, fluctuations are compensated Compensation is carried out by influencing the switching point and the holding pressure profile Calculate your personal APC advantage >> Far lower scrap rates Easier operation and faster start Easy use of a significantly higher proportion of recyclate Greater use of recycled materials and substantial reduction in scrap.

9 Page 9 Widest range of options and combinations Attractive CX ClassiX machine package Save money by investing in CX ClassiX: CX is highly flexible and satisfies all your requirements in conjunction with ClassiX Specific solutions for all industries Highly flexible configuration of CX permits over 450 basic combinations of the plasticizing unit / screw and injection unit Additional selection of more than 500 options Attractive and extensive machine package More options at an attractive price Lower machine investment Plasticizing unit x screw = 450 combinations x clamping units 4 hydraulic core-pullers on every side Enlarged platens Larger installation height. = 500 options Choice of more than 500 options from 450 combinations of the clamping unit / screw / plasticizing unit. ClassiX

10 Intelligent temperature control for superb results Dynamic Mold Heating (DMH) New surface effects: Impression of high-gloss surface Masking of joint lines Functional surfaces (e.g. anti-reflection coating) Reduced wall thickness and reduced injection pressure (or clamping force) Combination processes possible (e.g. networking reactions) High-gloss surfaces without painting or the use of film Very fast temperature changes and highly homogeneous temperature control Up to 30% thinner wall thickness and a Class A highgloss surface

11 No unnecessary buildup of pressure Active memory management Memory block with pressure sensor The optimal operating pressure is determined at all times Unnecessary buildup and retention of air pressure are avoided The memory is simply deactivated when it is no longer needed No more additional charging necessary Longer durability due to reduced wear Lower energy costs 10% saving in total energy consumption

12 The time boost for high-viscosity materials Electric drive for parallel movements Rational boost: Frequent use with high-viscosity materials and shorter residence time in the plasticizing unit Can also be used for thick-walled components with longer holding pressure phase Plastification can be performed while pressure is retained Energy efficient as energy is only consumed as necessary and the pressure does not have to be retained in contrast to a hydraulic pump Parallel processes shorten cycle times Reduced energy consumption Faster cycle times increase productivity

13 Page 13 Most economical index solution on the market New direct drive for index technology Enormous potential savings with molds: Since the drive unit is not integrated in the mold, savings are made in regard to size and material consumption The drive can be used for all index molds in the same machine. The customer saves between around 5,000 and 7,000 with each mold. The precise turn make the guide pins around the plate and pre-centering unnecessary. Simplified and more favorable mold design Up to 1 second faster cycle time as it is around 70% more precise than a hydraulic drive Savings of 5,000 7,000 per new mold.

14 Take-out automation of threaded parts Unscrewing systems Take-out automation for complex components: Use on molds used to make threaded components, e.g. by core-retraction Integration of take-out automation process in MC6 control system Process Designer has its own page integrated into the standard The electrical connection is made at the frequency inverter Easy retrofitting creates flexibility in production Operation using MC6 allows optimum clarity for all processes Broader range creates additional pillar

15 Solutions which are really worthwhile EFFECTIVENESS Page 15

16 Page 16 Fastest and most universal type of mold change Integrated magnet clamping plate from Stäubli Easiest operation thanks to integration in MC6: Commands such as "Magnetize" and "Demagnetize" can be easily and conveniently implemented No additional operating philosophy required for the mold setter Fail-proof safety system Automated fault detection ensures the best possible production reliability Long service life of more than 20 years Maximum process reliability Straightforward operation via MC6 Absolute reliability in manufacturing Long service life protects your investment Fastest set-up and amortization after just 1.5 years.

17 Page 17 Cost-effective, simple mold installation Bayonet lock Mechanical clamping system: No screwing or adjusting Mold setter only has to click the mold into place Mold is secured with a single hand movement System supplied from a single source, making complex retrofitting unnecessary Quick installation saves work time and reduces machine downtimes Solution from a single source Inexpensive and extremely straightforward moldchanging system from a single source

18 Page 18 Operation via a single control system Integration of many additional functions in the MC6 All relevant peripherals integrated: Central control and operation of peripheral systems with the MC6 control system Settings data specific to the application (or mold) saved and loaded onto the MC6 control system Central monitoring of all parameters in the actual value log (of the MC6 control system) Central registration of all events and alarms in the peripheral systems (on the MC6 control system) PSG hot runner control KraussMaffei automation Stäubli magnetic clamping plate Easy and clear control of the complete process Direct, central access to all peripheral systems and documentation Secure monitoring of all systems Only one operating philosophy for all peripherals enormously simplified operation

19 Page 19 No limits to your mold Larger platens up to XXL and high mold weights More volume means more flexibility: Size of the platens increased to the XXL version Use of large and heavy molds with the same clamping force Very easy extension of the tiebars and adaptation of the linear guide based on the 2-platen design 22% increase in the volume of the mold Use of complex molds, e.g. multi-daylight molds +22% Standard Standard Extended XXL CX x 560 mm / 2.5 kg 630 x 460 mm / 2.5 kg 630 x 630 mm / 2.5 kg CX 250 / x 630 mm / 3.4 kg 710 x 630 mm / 3.4 kg 810 x 720 mm / 3.4 kg Use of larger molds with the same installation space More flexibility Use of heavier molds CX x 710 mm / 4.7 kg 800 x 710 mm / 4.7 kg 950 x 860 mm / 6.7 kg CX x 800 mm / 6.7 kg 900 x 800 mm / 6.7 kg 1040 x 970 mm / 11.4 kg 40% larger mold volume overall

20 Page 20 Big becomes small Adaption of the plasticizing unit Very easy retrofitting: Use of all screw diameters with the adapter unit across 2 plasticizing sizes Adapter perfectly matches smaller units No change in the length or installation position Easier conversion to original state Greater flexibility in machine utilization Use of lower shot weights High flexibility in injection molding production Service-friendly and very easy retrofitting Prevents lengthy alterations Easy adaption of the plasticizing unit without changing the existing machine.

21 Page 21 Access all areas Optimum accessibility No time lost: All machines are designed such that the operator is able to easily reach all important areas The generous ejector area make the job of changing the mold much easier Large doors for extremely easy access to the machine The picker moves to its park position for mold changing no disassembly Ergonomic and pleasant work Simplified setup saves time The operator is able to easily reach all relevant parts of the machine

22 Page 22 Keeps longer, works more precisely and all for a reasonable price The flexible ejector coupling Available for CX and GX : Developed and manufactured by KraussMaffei Compensates axial offset 1 set of thread adapters for mold ejector bolts with various female thread sizes Union nut with matching hook wrench Nitrided and oxidized surfaces ensure long service life and corrosion protection Connection with zero play > Precise Allows min. axial offset > Flexible Quick and reliable set-up > Efficient Lower procurement costs and longer durability

23 Page 23 Intuitive control system in future MC6 Multitouch Intuitive and easy control of SGM and automation: High-resolution, capacitive 24" HD monitor Freely configurable favorite fields Personalized RFID interface Innovative SlideX technology for "perceptible" control of all axis movements WizardX programming assistant makes automation programming very easy Individual, flexible workstation design ExtraScreen: More space to display additional pages in real time SplitScreen: All production processes at a glance Intuitive machine control system which makes set-up really easy.

24 Everything centrally in view at all times Camera integrated into MC6 Fast process monitoring thanks to live video stream: Monitoring and visualization of critical process steps Better clarity for unmanageable system parameters and poorly visible areas Optional live image access from up to 4 built-in cameras Live image with SGM robot integration; panel can be switched to robot hand-held Production monitoring at a glance Faster reaction in case of malfunctions for increased productivity

25 Page 25 Always the right solution Manual or fully automatic bar pulling Trend toward ever larger molds: Solution for few changes: Hydraulic bar-pulling device with manually unscrewed bolts Solution for frequent changes: Hydraulic bar-pulling device with automatic interlock Fast and convenient solution Quick and simple mold changes Allows mold set-up even in low-ceiling halls Fast mold changes with outstanding platen parallelity

26 Page 26 Protects mold investment & prevents production stops Intelligent hot runner control PSG hot runner control: Self-optimizing temperature control: An intelligent algorithm compares target and actual values and intelligently regulates the process Integration into MC6: No new control philosophy Mold protection: With comprehensive monitoring of technical parameters Enhanced process reliability Continuous analysis ensures that potential failures are detected in good time Immediate fault detection creates time to procure spares without time pressure Leakage detection means no total electrical loss due to overfeed > Safeguards investments Installation of hot-runner control points into switch cabinet on the non-operator side: Saves valuable production space Immediate fault detection + countermeasures to prevent production stops

27 Your key to success SPECIALIZATION Page 27

28 Page 28 Successful specialization based on CX CX is the perfect platform for all technologies Customer demands on plastic parts are growing: Consumers want premium quality surfaces Legislation demands fire protection and optimum electrical insulation Environmental responsibility and conservation of resources make weight-saving lightweight solutions and material conditioning/recycling imperative KraussMaffei is a leading player in the development of new technologies for function integration PolySet MuCell Clean Form Deco Form IMC Fiber Form Production of plastic parts with additional functions Long-term success with the technological leader, KraussMaffei SilcoSet Multinject Specialization creates long-term competitive advantages

29 Page 29 We will gladly share our knowledge with you Years of know-how in all areas Various experts are ready and waiting: International project engineering AWETA supports commissioning locally Product & Technology Management monitors market trends Excellently equipped TechCenter 11 machines plus machines exclusively for training Commissioning in TechCenter guarantees an immediate production start Direct exchange with experienced experts Stay up-to-date with respect to trends and new technologies Set trends with us instead of following your competitors.

30 Page 30 Fast entry into MK technology Bolt-on unit Mobile bolt-on units for multi-components: Steplessly adjustable in the machine's longitudinal axis Freely variable lateral adjustment Simple mold changing because the bolt-on unit can be moved completely out of the clamp zone Wide choice of plasticizing units based on our range of standard screws Autonomous bolt-on units make upgrades easy Complete control of the process thanks to separate controller and energy supply Easy manufacture of products with additional functions increase the unit price

31 Page 31 More precision, more performance, lower energy consumption CX Hybrid Series The best hydraulics and electrics: Hydraulic clamping unit Every axis of the injection unit has its own separate electric drive. Parallel plasticizing and ejection High injection speeds up to 300 mm/s. Clean production, cleanroom-compliant Fast cycles for high productivity Wide range of options for special processes Higher efficiency thanks to electric drives 20 30% lower energy consumption and higher shot weight consistency by a factor of 5

32 Page 32 Leading know-how on the growth market SilcoSet technology (LSR & HTV) Processing of LSR: Many years of know-how in processing silicones Reliable cooling for a safe process right up to the nozzle tip Perfect clamping behavior thanks to the check valve developed in-house The water-cooled, pneumatically activated extension nozzle ensures process-reliable material feed Machines are also equipped for the new formulations Exact shot weight consistency even with 256 cavities Easy changeover from thermoplatstic processing to silicone processing 100% process reliability thanks to the best components

33 Page 33 Fast and flexible automation solution Mobile automation cell Mobile cell with IR robot: Cell is mounted on rollers and can by moved by just one operator. Suitable for the clamping force range tons Robot payload (Kuka Agilus) 6 kg, reach 900 mm Built-in conveyor (1500 x 400 mm) Optionally also suitable for clean room solutions No retroactive teaching of the demolding point Simple and effortless docking and undocking "plug-and-play" principle High automation workload wherever it is needed.

34 Page 34 Robot and machine form a single unit with us System solution Automation & SGM Application example - plastic cutlery: Demolding 96 cutlery parts with robot 1, transfer to robot 2 Forks, knives and spoons are consolidated into a cutlery set in 3 steps in the drawer system Cycle time 7.6 s, demolding time 0.9 s Principle of the "flying saw" Automation and SGM from a single source Innovative solution could hugely reduce unit price of articles Linear machines 300 HS and 300 UHS on a KM cavity family mold Realization of new orders creates growth

35 Page 35 Savings of weight, material and clamping force Foaming with MuCell technology Physical foaming: Gas is fed directly into the plastic melted plastic The viscosity of foamed materials is very low - less pressure in the mold Gas discharge within the cavity allows the holding pressure to be significantly reduced or even completely eliminated The foaming process takes place evenly spread within the cavity less warpage Cycle time saving up to 20% Component weight reduced by up to 10%, thus significant material savings Low-stress, warpage-free and dimensionally accurate components 8% less component weight and 30% shorter cycle time. (e.g. door module for BMW Mini)

36 Page 36 Plastic and strip conductors in one shot IMKS - integrated metal/plastic injection molding Pioneers through team work: The procedure was initially developed by IKV in the course of the excellence cluster "Integrated Production Technology for High-Wage Countries" at Aachen University (RWTH) in collaboration with KraussMaffei and Krallmann. Combination of metal die-casting and plastic injection molding in a single production cell Applications: LED lights, printed circuit boards, plug connectors, sensors etc. Single-stage process for increased productivity Fewer fault sources due to function integration quality enhancement 100% in-house production as purchase of semifinished products is completely eliminated

37 Page 37 Leading in the field of compression molding CX eminently suitable thanks to stable clamping unit CX greatly suited for compression molding: Basic precondition: A stable clamping unit in order to guarantee platen parallelity The full hydraulics ensure ideal interplay between closing and opening movement of a compression molding operation Very easy programming with the MC6 Flexible start conditions A sixteen-step compression profile Variable synchronization with machine movements Insertion of freely selectable waiting times Reduced warpage and tension > Better parts quality, dimensional stability and surface quality Machine and control technology offer perfect preconditions Very simple process programming with the MC6 for excellent user-friendliness in complex processes

38 Page 38 System qualified as per GMP guidelines CleanForm technology for clean room production Production under extremely clean conditions to GMP Class A: Use of injection molding machines which are clean-room-compatible and which work extremely cleanly Free-standing 2-platen design of the CX and "room in room" solution allows space saving in the clean room Safety housing can optionally be finished in stainless steel Saving costs > Expensive clean room area reduced to a minimum Perfect machine and automation concept for increased productivity "Room-in-room" solution: Only the clamping unit section is located in the clean room The perfect solution for exacting medical manufacturing.

39 Considerate handling of finite resources RESOURCES Page 39

40 Page 40 Save material, time and energy with high performance HPS-M screw Screw and RSP ensure optimum results: Thanks to improved homogenization performance, savings can be made especially with the expensive batch proportion Lower scrap rates and reduced downtimes Better component quality thanks to improved mixing behavior Special reinforcement of the screw increases the service life by 50% Reduction in color master batch costs Uniform color distribution in the component Use of complex materials Easy color change Batch savings of up to 30% and color change up to 20% quicker

41 Page 41 Machine is fully ready KraussMaffei weekly time clock (WTC) Intelligence even before the start of production: In the past: The machine operator specifies the starting time for the preheating phase of the injection unit and hydraulic fluid Losses after heating Nowadays: The machine operator specifies the required time for start of production The MC6 control unit automatically starts to preheat the barrel and the oil Optimum planning of the start of production Energy savings thanks to accurate heating Pinpoint start of production with preheated hydraulic fluid and barrel heating with no waiting times Use of resources only when necessary and only as long as required.

42 Page 42 Measurably lower energy consumption BluePower Vario Drive Variable-speed asynchronous motor: Can be retrofitted at any time Optimum machine operation since the intelligent drive system continuously learns this and always specifies the energy-efficient working point Improved efficiency thanks to controllable pressure and controllable quantity Less cooling capacity required for oil cooling Parallel movement possible due to additional pump BluePower Low energy consumption More comfortable work on the machine Lower cooling water consumption Up to 40% less energy consumption

43 Page 43 Cost and resources savings over the entire service life Comparison of SPX10 with pneumatic drives Saving resources over the entire service life: The energy-efficient servo drive is driven almost entirely electrically and reduces the consumption of expensive compressed air by more than 99% 85% energy saving Higher load on pneumatic drives for a change after about 6 years Lower wear lower maintenance costs Energy-efficient demolding of sprue without the use of expensive compressed air No prescribed maintenance intervals Reduced labor costs 99% lower compressed air costs, 85% electrical power savings compared to pneumatic drives

44 Page 44 Enormous potential for saving material Fewer rejects and more recycled material with APC Saving resources over the entire service life: APC records the melt viscosity direct upon injection and corrects any differences by adjusting the switching point and the holding pressure in the same shot The shot weight is within a tight tolerance range fewer rejects APC makes it much easier for a higher proportion of recycled materials to be used Substantially lower scrap rates Lower quality assurance costs Increased proportion of recycled materials conserves valuable resources and reduces costs More than $ 4,200 per year savings potential with a throughput of 27 kg/h

45 Page 45 Less energy lost BluePower insulating sleeve Saving resources over the entire service life: Multi-layered, glassfiber-reinforced fleece thickness approx. 25 mm Temperature-resistant to 500 C, low surface temperatures on the insulating sleeve Safe for user and easy to clean (PTFE coating) BluePower ROI in approx. 1 to 2 years Heating up time reduced by between 20% and 30% 20 to 40% less heating energy 40% saving in heating energy

46 Page 46 Always in optimum energy mode Eco button in the MC6 Included in standard scope of delivery: Calculation of optimum energy values Within 5-20 cycles in fully automatic mode Representation of identified setpoint values Representation of energy consumption before and after optimization User can "Accept", "Change" or "Reject" the new settings values BluePower Change process to energy-saving mode at the touch of a button No negative impact on component quality or of cycle time The optimum for energy saving simply for every process

47 Page 47 Elimination of reactive power BluePower Economizer Eliminating invisible energy guzzlers: Reactive power is inevitably created when asynchronous machines are operated Induction due to the magnetic field of the rotor High reactive power = lower cos phi Better utilization and load relief at existing transformer stations Additional usable capacity on internal company power supply network Reduction of line losses in the network BluePower Operation of machine with power factor after 1 Creation of free capacity when extending the system Energy costs reduced by up to 15%

48 Page 48 Improved cost-efficiency Extensive automation solutions An automation solution for every requirement: Linear robots of the KraussMaffei LRX series are your first choice for standard processes > Reduced production costs, increased product quality Industrial robots of the IR series are true allrounders > Used for complex demolding and automation tasks When things have to move quickly > Lateral demolding robots of the SR series for total cycle times of less than 4 s. Machine + automation solutions from a single source Automation solutions perfectly matched to the processes and technologies of KraussMaffei Improved cost-efficiency and modern production