AX series injection moulding machines

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1 Easy entry to all-electric injection moulding energy efficient and productive AX series injection moulding machines

2 IN PARTNERSHIP WITH INDUSTRY KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide Automotive White goods Construction Life Sciences Electrical / electronics Whatever you aim to achieve in plastics or rubber processing, KraussMaffei is your partner. We are the only company with intensive expertise across the three main engineering fields. And we have a strong track record in integrating this expertise to develop new processes and systems. Ready for any challenge Our Injection Moulding Machinery Division supplies machinery and systems from 35 to 4,000 tonnes for standard applications and for all processing variants, together with fully automated solutions. We have a strong customer base in all the relevant industries worldwide. Our Reaction Process Machinery Division supplies machines and complete systems for processing polyurethanes and other reactive materials. Completing our product portfolio, Automotive Component Systems supplies foam moulds, cutters and routers. Our customer base is wide, with a focus on the automotive, construction and white appliances industries. Our Extrusion Technology Division supplies machinery and systems for compounding, for pipe, profile and sheet extrusion, physical foaming, and the production of technical rubbers and intermediates for tire production. Machinery from the company s range from single extruders to complete extrusion lines is used in many industries, including chemicals, pharmaceuticals, automotive, construction, furniture and packaging. People for Plastics We are the people for plastics. We are your partners from the first exploratory discussion, through development to commissioning, servicing and operating your system, and final disposal. At all times, you are assured of outstanding competence in planning and engineering, as well as reliable and fast spare parts, service and support. Adding value for customers We put our expertise to work for your success. With machine ranges engineered for modularity, we can deliver application-specific solutions based on our wide range of standard modules and specially engineered solutions. This strategy offers customers technical and cost advantages. Close to customers around the world As an international company, KraussMaffei has a presence in all the major markets for the plastics and rubber processing industries and employs over 3,000 people worldwide. Our sales and service network keeps us close to all our customers around the world. Page 2 AX series injection moulding machines

3 Easy entry to all-electric injection moulding and the KraussMaffei product world AX injection moulding machines Packaging The AX series is KraussMaffei s newest range of all-electric injection moulding machines. The machine concept is based on a toggle clamp. These reliable, lean machines are an easy entry into the world of electric injection moulding. Your business will profit from this reliable and cost-saving machine, engineered for high repeatability and low power consumption. High-calibre components include KraussMaffei s tried-and-tested plasticizing units and absolutely dependable drive systems. As a result, AX machines deliver consistent part quality and constant production conditions. Furthermore, they are maintenancefriendly and flexible. Detailed product information Page 3

4 TRANSPARENT TECHNOLOGY Meet the machine: take a tour of an AX injection moulding machine Compact manufacturing cell with fully-integrated linear robot 5-point toggle proven technology, easy to maintain and service Page 4 Moving platen with precision linear guides supported on the machine bed Generous daylight between tiebars and large mould fixing area AX series injection moulding machines

5 Operator-friendly MC5 control with touchscreen and VARAN bus Proven screws and non-return valves from KraussMaffei s huge product spectrum to process a wide range of materials and deliver excellent melt quality All-electric drives for high repeatability and energy efficiency Water-cooled converters reduce heat radiation to the production environment Controlled power input saves energy by regenerative braking Detailed product information Page 5

6 Detailed product information AX clamp unit: Energy-optimized double toggle for top repeatability The all-electric AX series will ultimately cover the clamp force range 50 to 350 tonnes ideal for a very wide spectrum of standard applications. The 5-point double toggle is mature, proven technology. With its optimized power/stroke conversion, it guarantees excellent machine dynamics and low power consumption. Improved clamp concept for high precision The 5-point double toggle system is an established design for electric injection moulding machines, where it ensures high repeatability and precision closing. For the AX, the toggle system was substantially improved. Optimally engineered pivot points and a powerful recirculating ball screw ensure sensitive transmission of force and fast opening and closing. The screw spindle is driven by a cam belt. Automatic central lubrication ensures smooth toggle movement. Even relatively modest motor output generates high speeds and forces. This rugged system features low power consumption, high precision and stable processes over long production runs. Optimized mould fixing platen for perfect force application The ribbed structure of the mould-fixing platens makes the clamp stiffer. Force is applied optimally to the mould. The two-part platen structure substrate plus fixing platen makes it easier to accommodate different drilling patterns, thread types and sizes. The mould fixing platens: variable transmission of force through the pivot points and recirculating ball screw, and adaptability due to two-part structure (substrate and fixing platen). Page 6 AX series injection moulding machines

7 Large, precision linear guides for the moving platen reduce friction and guarantee platen parallelism. Less friction = more accurate movements The moving platen is guided on four precision linear guides to ensure high platen parallelism and avoid tilting. The smooth-gliding guides are centrally lubricated, helping to minimize maintenance effort. Roller-bearing technology reduces frictional resistance by 80% compared with conventional guide units. The benefit is almost zero mould wear, so that, even in high-volume production, there will be no drop-off in repeatability and parts quality towards the end of a production run. Precision part ejection with parallel function cuts cycle time The platens are predrilled to accommodate different ejector positions, adding to the flexibility of the system. Like the rest of the AX, ejection is electric. A parallel ejector function can cut cycle time by up to 15%. Highly accurate and repeatable ejector movements ensure precision demoulding. Easy access to the mould and ejector saves time during mould changes and boosts productivity. Detailed product information Page 7

8 Detailed product information AX plasticizing unit: Proven quality made by KraussMaffei All KraussMaffei s considerable expertise in this area has gone into engineering the AX plasticizing units. The combination of plasticizing quality and performance makes the AX an unbeatably reliable machine at an entry-level price. Proven plasticizing unit for consistent, high quality AX plasticizing units are engineered and manufactured to the same exacting quality standards that KraussMaffei applies to components for its CX and EX machines. The wear protection and manufacturing tolerances of plasticizing components, check valves, screws and barrels are identical to those of the other KraussMaffei machine series. And it guarantees the same outstanding performance. The wear parts in the plasticizing unit are extremely long-lasting. AX plasticizing units are interchangeable with those of the EX and CX series. Interchangeability brings flexibility gains, because processors can use equipment they already have on hand. Stoppages are reduced and machine uptime is improved. KraussMaffei plasticizing units have a reputation for good melt quality and for achieving excellent results with a huge range of different materials. Easy access for easy operation The plasticizing unit of an AX machine swings sideways for easier access. Components can be swapped within minutes cutting downtime and increasing flexibility. Access to the feed hopper is as easy as with the other machines. The nozzle cover can be flipped open, it also has a viewing window, which makes operation easier. The operator can keep a continuous eye on the product situation and can react quickly if required. The AX injection units are teamed with tried-andtrusted plasticizing units, identical to those used in our CX and EX machines. Page 8 AX series injection moulding machines

9 A swing-out plasticizing unit and nozzle viewing flap make AX machines easier to maintain and service. Performance reserves for a broad range of applications The injection unit delivers the performance you need. The speeds have been selected to ensure the AX is suitable for the broadest possible range of applications. An indexing, water-cooled flange keeps plasticizing conditions constant, ensuring consistently good melt quality. Parallel operation allows plasticizing to continue in parallel with mould opening/closing and part ejection. This cuts cycle time significantly for high-throughput applications. Optional injection pressure boost for complex parts Higher injection pressure for high-spec technical parts is an option we offer to increase the application bandwidth for the AX. Our market and engineering expertise has ensured that the AX is a versatile machine that will give you wide scope in planning your production. Detailed product information Page 9

10 Detailed product information AX series control and drive systems: Intelligent software, effective power-saving technology KraussMaffei combined advanced software solutions with high-performance motors to supply a highly efficient machine. The result is a drive package that is extremely economical, reliable and easy to operate. Intelligent drive concept: efficient, compatible, fast reacting AX machines are powered by electric drives with optimized servomotors capable of regenerating braking energy. This solution cuts power consumption by up to 10%, anywhere in the world. The implicit converter technology we ve used ensures that the machine is compatible with almost all voltages and power supplies around the world. The smoothly operating precision transmission with belt drives limits the masses that must be moved, contributing to lower power consumption. Water cooled converters with leak monitoring (type class HT11) help to keep production areas cooler. High-response servomotors and the powerful MC5 control system deliver exactly reproducible machine movements and reduce energy consumption. MC5 microprocessor control: precision and high-speed data transfer The MC5 control scans movements 500 times a second with a resolution of mm. This precise mapping of every stage contributes to a constant injection moulding process within close tolerances. Data communication is via a VARAN bus, currently the fastest interface in the plastics industry. In addition to fast data transmission rates, this allows data exchange in real time. Self-explanatory operation with a large 19 touchscreen The operator interface to the MC5 control is intuitive and the 19 touchscreen, which is standard, adds to the operator-friendliness of the whole AX. Easy-to-understand, full-colour process graphics facilitate error diagnosis. Touchkeys show only the relevant functions for the next input, making set-up and operation intuitive. Freely assignable favourite touchkeys take operators quickly to essential parameters. People used to working with conventional MC5 control systems can switch easily to the MC5 Touch. AX machines use optimized servomotors capable of cutting power consumption by up to 10% compared with conventional drives. Page 10 Included as standard: 19 touchscreen AX series injection moulding machines

11 Detailed product information AX options: productive manufacturing cell with a small footprint Customer benefits were top of the agenda in developing the concept for the AX series. KraussMaffei s understanding of customer benefits goes well beyond the production situation. Reliable demoulding, and space-saving and economical material flows are some of the key factors in cost-competitive production. We offer a manufacturing cell option, with a fullyintegrated LRX robot, that delivers all these benefits and saves space at the same time. Integrated control concept for machine and robot The LRX linear robot is fully integrated in the AX machine s MC5 control via the Ethernet VARAN bus. Robot data are logged and stored together with the injection moulding machine data. The LRX program can be started and stopped using function keys on the touchscreen. AX machine + LRX robot = higher productivity per square metre In the AX automation version, the safety housing is extended by the width of the conveyor belt; this area is also the robot s safety envelope. This solution saves the cost of an additional safety enclosure with a door for the robot. Moreover, the integrated, compact concept results in a machine footprint about 25% smaller than an equivalent system. The switching cabinet for the LRX robot is mounted on the robot s Z axis; so that it doesn t take up floorspace. A conveyor belt for parts transport can be installed across the front face of the machine. This opens up more flexibility for siting the machine in the production area. Operator safety a top priority Safety is high on the agenda of the AX concept. The safety housing is in compliance with the latest standards and with the EU Machinery Directive. The manufacturing cell (AX + LRX) is naturally CE compliant. This all adds up to a very high level of safety. The AX/LRX manufacturing cell is compact with a small footprint; parts are dropped inside the safety housing. Detailed Produktinformationen product information im Detail Page 11

12 Your benefits Super-saver lower power consumption, smaller footprint, minimal training effort The AX series combines all the advantages of all-electric machine technology with typical KraussMaffei characteristics. The machines are energy-saving and environmentally friendly, compact and slim, and they promise a high return on investment. You can rely on proven technology, unbeatable know-how and reliable components. And an outstandingly user-friendly, easy-to-learn operating system. Your entry to the world of all-electric injection moulding The AX machines complete KraussMaffei s portfolio of all-electric standard injection moulding machines for standard applications. Whatever industry segments you produce for, the AX is your ideal entry to electric injection moulding. Cutting manufacturing costs The AX is a lean and economical machine lower energy costs, less maintenance effort, shorter training, faster mould changing. Your effort and costs are cut to the minimum. The AX series was engineered from start to finish to save you money with regenerative braking, low-friction precision guides and slimline production cells. AX machines pack a punch AX machines are lean when it comes to space requirements, power consumption and labour; but they re generous with reliability and flexibility. High reliability is the result of time-tested components, like the optimized 5-point double toggle, the precision linear guides for the moving platen and the high-performance KraussMaffei plasticizing units. High-response servomotors and the MC5 control system, with its intuitive operator interface, complete this powerpack for costeffective injection moulding. AX series machines are future-proof and efficient. Engineered for a sustainable high return on your investment The AX is available as a standalone machine or as a compact automated production cell. The production cell with its integrated LRX linear robot is a complete system solution. You ll find the AX series flexible and future-proof. Because you can configure an application-specific machine from a wide choice of plasticizing units and over 500 special options, the AX will master your production challenges now and give you the flexibility to respond to future challenges. You ll profit from the intelligent engineering for which KraussMaffei is renowned. The AX comes with excellent prospects for high and sustained returns on your investment. Page 12 AX series injection moulding machines

13 Applications across industry The AX is an asset in many sectors from the automotive industry to consumer goods and the electrical and electronics industries Plastics processors find the AX the right machine for many applications right across industry. These machines are the perfect answer for efficient, repeatable production of the simple standard products widely in demand in many areas. Easy access and generous mould fixing dimensions mean that mould changes are fast and simple. Automotive From handwheels for seat adjustment to fixing clips AX machines are dependable workhorses producing bulk products in reliable quality at very low unit costs. Electrical/electronics AX machines are fast, precision machines. As such they re ideal for electronics applications such as producing connectors or mobile phone housings. Lifestyle Producing large volumes of products with highspec surfaces such as lids for cosmetic jars or lipsticks is a task that AX machines do supremely well and cost-effectively. Home and DIY Constant shot weights and tight tolerances are important in manufacturing technical components, eg, for garden tools or power tools. AX machines are ideal for this type of application. Applications across industry Page 13

14 SERVICE WORLDWIDE Service, support and spare parts when you need them, where you need them Rely on us for a fast and competent response to all your service needs anywhere in the world. Whatever you need from troubleshooting and training to spares or repairs we re on the job. We re dedicated to supplying service quality on a par with the outstanding quality of our machines and systems. We offer far more than spare parts and hotlines. We ll work with you to choose the best and most cost-effective solution for your operation. We ll help you test new applications and we ll plan customized service packages. All-round service Our service offering is broad. We ll configure your system, install and commission it, train your staff, plan measures to minimize your downtime risk and maximize productivity, and carry out maintenance, repairs and upgrades. You ll find us fast, reliable and competent. Our hotline is manned by highlytrained and experienced service technicians. If necessary, we ll get a technician to you quickly. Remote diagnosis, interfacing directly with your machine s control system, can be a practical alternative. Spares for all important wear parts are available at short notice. We re continuously expanding our service network to speed up spare parts shipment. Talk to us about the right service solution for your business. Page 14 Customer trials and prototyping in our test lab The Reaction Process Machinery Division operates a test lab fitted with the latest machinery and equipment. We can run trials, produce prototype parts and fine-tune processes on your behalf. We can work with you to test and evaluate processes, machines and equipment in order to identify the best approach for a particular project. Our highlyqualified application engineers are there to help you. Training with high hands-on content Courses are held in our lab and training centre, or, optionally, on your premises. We offer clearly-structured basic and advanced training in operation, process control and maintenance for KraussMaffei reaction process machinery. On request, we ll plan and hold special courses on topics of your choice. All participants spend a high proportion of their training working hands-on with original KraussMaffei machines. A well-structured training program produces skilled operators and technicians, which will positively impact your up-time and productivity. AX series injection moulding machines

15 At your service worldwide Team Europe Injection Moulding Service Team Injection Moulding Spare Parts Team Team America/Spain Injection Moulding Service Team Injection Moulding Spare Parts Team Team Asia/ Near East Injection Moulding Service Team Injection Moulding Spare Parts Team How to contact us Apart from you can contact us on the service hotline or by post at this address: Hotline Phone: Fax: Injection Moulding Service KraussMaffei Technologies GmbH Krauss-Maffei-Str Munich Germany Detailed product information Page 15

16 KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide. KraussMaffei machines and systems are used wherever plastics and rubber are converted into products. As a knowledge-driven technology company, we build on many decades of experience and a strong commitment to research and development. KraussMaffei s new AX series offers easy entry into the world of all-electric injection moulding they re fast, energy-efficient and economical. They re engineered to deliver high repeatability and stable processes. And they re compact machines with a small footprint. Along with the 5-point double toggle, all AX machines have a high-performance KraussMaffei plasticizing unit, the self-explanatory MC 5 control system and a 19 touchscreen as operator interface. AX series are competitively-priced standard machines using mature and proven technology. Operators don t need extensive training to get a maximum of flexibility and productivity out of these machines. With 500 options, the basic AX machine can be adapted to the special requirements of different industries. 2.0 WE. 1 st edidion 10/08. SGM 102 A PRO 10/2008 GB KraussMaffei reserves the right to make technical changes. KraussMaffei Technologies GmbH Krauss-Maffei-Strasse Munich Phone Fax