COMPACT, RUGGED 2-PLATEN MACHINES FOR LARGE PERFORMANCE. MX injection moulding machines

Transcription

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

3 MX injection moulding machines for fast responses, fast cycles and high productivity Packaging KraussMaffei is among the market leaders in engineering large injection moulding machines. The MX series is a systematic onward development of the highly successful MC series. MX machines are available in the clamp force range from 800 to 4000 t. MX machines are engineered to deliver sustained performance under demanding conditions. They are compact, high-performance production systems, capable of delivering fast responses, fast cycles and high productivity. Versatile and modular they offer a wide range of configurations for optimized, applicationspecific solutions. Standard machines can be upgraded with minimal effort and adapted to any production conditions. Our product spectrum ranges from compact injection moulding machines with basic automation to highly complex manufacturing cells and planning complete production plants.

4 TRANSPARENT TECHNOLOGY Meet the machine: take a tour of an MX injection moulding machine Proven 2-platen technology High stiffness and space saving construction Absolute platen parallelism Longer mould life and premium part quality User-friendly MC 5 control system Lucid, error resistant, freely Outstanding machine dynamics Highest productivity progammable

5 High-performance plasticizing Highest repeatability Extreme modularity Highly customizable Proven screws and non-return valves Outstanding melt quality Service-friendly design Saves service time and effort Optimized drive concept Highly effective oil filtration Power-saving operation High uptime

6 DESIGN BASICS The MX series new benchmarks for large injection moulding machines All the modules that make up an MX machine is ready for integration in an existing processing operate smoothly and efficiently together. Key line, using existing moulds. elements are the 2-platen clamp, the injection unit and the hydraulic system. All MX machines More modularity operate under the operator-friendly MC 5 micro- KraussMaffei MX machines are as modular as they processor control system. The process in progress come. This means big benefits for our customers, is clearly visualized on the display screen, with for example, machine components can be swapped the emphasis on essential information. or upgraded quickly and easily. In an intensely competitive market, an easy upgrade path can make More productivity all the difference to your success. You can take The MX series is engineered to deliver sustained advantage of a profitable new opportunity, know- performance under demanding conditions. Fast ing that a quick upgrade will bring your machine MX machines up to responses and machine movements, an error- up to speed t are assembled proof, easy-to-use control system and fast cycling in a synchronized flow it all adds up to a higher yield of zero-defect assembly process. parts. MX machines are the fastest on the market in their class. More reliability The MX series is the outcome of systematic further development of the MC series, already tried and tested thousands of times in tough production situations. KraussMaffei designers and process engineers have not only boosted machine availability, they have also optimized the process for top product quality. The new MX machines combine high throughput with a very high yield of good parts. Rejects, waste and downstream costs are drastically reduced. More flexibility An MX machine is the right choice for a very wide range of applications from simple, standard injection moulding to highly complex processes. The basic version offers many outstanding features, for example, a new MX machine Page 6

7 Possible combinations of injection units and clamp units listing available screw diameters KM 800 MX SP SP SP SP /90/100 85/95/105 95/105/ /120/135 SP KM 950 MX 80/90/100 85/95/105 95/105/ /120/ /135/150 KM 1000 MX 80/90/100 85/95/105 95/105/ /120/ /135/150 KM 1100 MX 80/ /95/105 95/105/ /120/ /135/150 KM 1300 MX 85/95/105 95/105/ /120/ /135/150 KM 1600 MX 85/95/105 SP SP SP /150/165 95/105/ /120/ /135/ /150/ /175/195 KM 2000 MX 95/105/ /120/ /135/ /150/ /175/195 KM 2300 MX 95/105/ /120/ /135/ /150/ /175/ /205/220 KM 2700 MX 105/120/ /135/ /150/ /175/ /205/220 KM 3200 MX 105/120/135 KM 4000 MX SP /135/ /150/ /175/ /205/ /230/ /135/ /150/ /175/ /205/ /230/245

8 DETAILED PRODUCT INFORMATION 2-platen clamp unit: Compact, fast, low-maintenance Compact and easy on the mould Multi-phase mould protection The moving platen has been engineered as a box The multi-phase mould protection mechanism structure reinforced with solid metal ribs, for can be precisely set to protect the mould against deflection-free clamp force distribution. This damage. This extends mould service life and helps minimizes stress and wear on the mould and on to keep maintenance costs low both these factors moving mould parts. have a positive effect on manufacturing costs. During travel, the moving platen is supported on Flexibility for your production the machine bed by large, solid-steel, adjustable The 2-platen clamp system with tiebars attached sliding shoes, with tiebar support and lateral through the fixed platen offers scope for wide guidance. This design eliminates any tilting flexibility in processing techniques. This includes, moment, because even when the clamp is fully for instance, profiting from the growing trend to open, the tiebars never run out of the bushings compression moulding techniques with back injec- on the moving platen. Ample spacing between the tion of decor or film inserts, or producing glazing guides guarantees that even the heaviest moulds panes or very large parts. The clamp design also remain absolutely parallel throughout opening and makes MX machines ideal for processes that make closing. very high demands on the machine in terms of platen parallelism, or special functions and different compression strokes. The MX series offers built-in growth potential. Moving platen as a deep box structure for minimal Massive, easily adjustable sliding shoe laterally stabilized and deflection and optimal support for the mould centrally lubricated for absolute platen parallelism Page 8 MX series

9 The MX 2-platen clamp unit Low maintenance Very fast locking/unlocking Self-lubricating guide bushes and glide profiles help When the mould is shut, the tiebars are locked in to ensure reliable, low-maintenance operation for place behind the moving platen by a mechanical long periods. Costs go down; machine availability locking system with intermeshing saw-toothed goes up. elements. For mould opening, all four tiebars are unlocked simultaneously, allowing fast mould movement. The system has been designed for very fast locking/unlocking and precise positioning. View inside a locking element Locking element and clamp force cylinder for very fast machine movements Detailed product information Page 9

10 DETAILED PRODUCT INFORMATION Injection unit: high performance, wear-resistance, low cleaning effort saves time Customer choice and application-specific processing window, and new material formulations. configurations Plasticizing units specified and engineered to take The MX series has the right injection unit and account of these factors are more cost-effective. the optimal screw geometry for every production This is why KraussMaffei offers not only standard task. A tightly scaled choice of working capacities screws, but also special mixing screws and high per- and screw diameters makes it possible to match formance screws (HPS-UN, HPS-AT). Work on new injection unit performance to product requirements. screw generations to meet continuously escalating This is the only machine series on the market application requirements is on-going. Most recently, offering so many clamp/injection unit combina- we launched the HPX plasticizing system for tions. Customers benefit from the best possible extremely high throughput, with up to 30% better match to their application requirements. plasticizing performance. We have the right screw for the job in hand In addition, KraussMaffei offers a wide spectrum Demands on plasticizing performance are escalating. of special screws and plasticizing units for optimum There are several reasons for this: continuous in- processing in special application areas and formula- crease in the volume of material to be plasticized, tions. lower melt temperatures, demand for better homogenization, new processes that require a wider 3-flights check valve Standard screw Multi-ball check valve HPS universal screw Central-ball check valve HPS automotive screw Page 10 MX series

11 Hydraulic direct screw drive for highest repeata- Quick-release system for the barrel bility and quality High-precision injection units Enhanced wear protection For plasticizing, a hydraulic drive for the rotational The main factors influencing wear on the screw, movement of the screw is standard. An electric barrel and check valve are the material formula- drive is an option, if production considerations tions being processed and the plasticizing rate. require plasticizing in parallel with other machine Additives used to improve processing stability, or movements. Force is transferred directly to the to give the end product specific functional proper- screw via the injection piston, which is designed as ties, cause wear through abrasion and/or corrosion a rotary piston. The forces act directly along the in different ways. If the application demands it, line of action and movement. Pressures and speeds KraussMaffei can supply specially wear-protected are transferred with extremely low friction losses, plasticizing units. making it possible to keep to very tight processing parameters. In particular, the machine s ability to Wear is not only a factor in maintenance costs, it adhere exactly to the holding-pressure profile with also affects processing stability and the recurring low back pressure plays a key role in achieving problem of products that are out of tolerance. highest processing stability and product quality. Today s sophisticated processes are strongly affected by plasticizing unit wear, leading to unacceptable reject rates and production stoppages. Wear protection plays a decisive role in ensuring consistent product quality and predictable costing. KraussMaffei protects machine components Surface treatment on a high-performance against wear using materials and processes chosen screw (the arrows mark the transition to the to ensure long machine service life and highest wear-protection layer) product quality. Quick-release systems save time and costs MX plasticizing units can be dismantled quickly and easily, eg, for cleaning or to swap screws. With the quick-release system, releasing the screw coupling and the barrel mounting takes a couple of minutes and the complete plasticizing unit can then to be lifted out of the machine by a crane. Detailed product information Page 11

12 DETAILED PRODUCT INFORMATION Hydraulics: precision control, fast response, flexible upgrades Energy-saving pump drive Dependable control valves At each processing stage, the regenerative pump All speed and pressure variables for controlling MX drive supplies precisely the oil volume necessary to operation are entered as digital values. The electroni- generate the required pressure. Energy consumption cally activated proportional valves, monitored by an is reduced to a minimum. additional internal control circuit, ensure high repeatability and maintain set values over long production Fast response times runs. KraussMaffei is committed to supplying The pressure- and flow-regulated pumps achieve machines which meet your criteria for consistent very fast response times. The hydraulic system production cycles and highest product quality. with its mix of constant- and variable-delivery pumps reacts to calls for rapid changes in speed In addition to the variable pump drive, MX as effectively as to calls for very small changes in machines have a separate control valve, close to the pressure, eg, during the holding-pressure phase. consumer, for the injection and plasticizing process. Pressure and speed are closed-loop controlled for absolutely repeatable cycles. Control valves close to consumers for a highly consistent Encapsulated hydraulic drive, soundproof housing and stable process. Page 12 MX series

13 Easy and maintenance-friendly access to all hydraulic valves in the injection unit and clamp Hydraulic components are linked to the central oil-cooled drive motors have an additional sound- machine control system via advanced bus technology. reducing effect. The drive unit itself is completely This guarantees fast and reliable data processing enclosed in a soundproof housing, which further and immunity to interference internal or external. reduces noise emissions. The actual noise emission The result is outstanding product quality and high is an operator-friendly 72 dba. machine availability the best route to a good return on your investment. MX machines are designed Housing sections can be removed individually and to be service- and repair-friendly; components can access to all hydraulic elements is fast and easy. be replaced fast and easily, keeping stoppages and This helps to reduce time and effort for mainte- downtime to a minimum. nance and repairs. Effective noise reduction A sure investment for your future There is a direct mechanical connection (no flexible When component replacement is easy, it follows elements) between the drive motor and the pump. that upgrades to give your machine expanded func- The main benefits are fast response times and the tionality are easy too. Fast, simple and above all elimination of wear parts. The compact drive/pump cost-effective upgrading by means of plug&play unit also does without an additional housing which modules puts you in a strong position to take would tend to transform vibrations into noise. The advantage of future opportunities. Detailed product information Page 13

14 PRODUCTS AND APPLICATIONS Versatile and adaptable MX machines with an outstanding track record in many industries MX machines feature compact design, large A proven success in many industries performance and unbeatable modular versatility. With their engineering strengths and cost efficiencies, MX machines are the machine of Unique in their class choice for many applications in different industries, The MX series comprises injection moulding especially in the automotive industry. They are machines from 800 to 4000 t. We offer a choice of also used to manufacture storage and transport clamp and injection unit combinations unmatched containers, housings for machines and power tools, in the market. This makes it possible to configure furniture elements and electrical and electronic a machine that is ideally suited to all production equipment. requirements. As a KraussMaffei customer, you always get an application-specific machine. Opera- Massive modularity ting within an optimized processing window is a Over 150 possible configurations mean that you guarantee for highest productivity and top quality can be sure of an MX injection moulding machine products. that s right for your project. For example, once you ve opted for a 1600 t machine, there are 18 screw diameters to choose from. Manufacturing cell with industrial robot

15 Applications across industry Automotive Storage and transport containers MX injection moulding machines have the versa- Plastic containers are often the answer when it tility to meet the diverse requirements of the auto- comes to safe storage and cost-effective transport motive components industry, producing anything of all sorts of products and commodities and from door trim sections to boot lids. MX machines are ideal for making big containers. Machinery and appliances Furniture It s difficult to imagine today s machinery, appli- The furniture industry was quick to appreciate ances and power tools without plastic components the potential and advantages of plastics and MX machines can be relied on to supply the to invest in advanced MX machines to produce specified quality. them successfully. And much, much more Whatever sector you produce for and whatever you want to injection mould, the MX series will Electrical/electronics often be the ideal solution for engineering excel- Plastic components are indispensable across the lence and a good return on your investment. Talk electrical and electronics industries they can be to our experts about your project: our know-how mass produced at low unit cost on MX machines. and resources are at your service. Products and applications Page 15

16 CUSTOMER BENEFITS Long-term benefits for productivity and low unit costs Outstanding machines and competent support Best melt quality and errorproof operation from our experts make KraussMaffei the right Wear-protected plasticizing units with extremely choice, if you are looking for a partner to get new long service lives ensure outstanding melt quality ideas and projects moving fast and successfully. and long-term reproducibility. Yield and quality are We can help your business to gain the competitive consistently high, productivity increases and costs advantage that leads to sustained success. Put our are reduced. The operator-friendly, flexible MC 5 expertise in system solution and our experience in control system, with touchscreen option, makes many reference projects to work for you. for easy and errorproof operation. Plug&play components make upgrades and expansions easy. Short cycle times Higher machine availability boosts productivity Fast MX machines set new benchmarks for cycle- and reduces costs. Quality and productivity are key time reduction. Fast cycles increase productivity and factors in your ability to compete successfully in the reduce manufacturing costs. MX machines are the marketplace. fastest in their class. From entry-level machines to factory planning Lowest wear and low unit costs As your system partner, KraussMaffei supplies The moving platen, constructed as a rigid box, provi- complete solutions to match your requirements. Our des optimal support for every size of mould. A wide product and service offering ranges from compact processing window, flexibility and effective wear injection moulding machines with basic automation, reduction measures help to increase productivity and through highly sophisticated manufacturing cells with reduce costs. Effective guide and support elements for post-mould processing, to planning complete factories. the clamp ensure maximum platen parallelism and And planning is not the end of the story: we will also avoid wear and damage to moulds and the machine. undertake to manage the installation and commissio- Precise and reliable hydraulic systems ensure stable ning of a complete plant right through to production Relatively simple, processes over long production runs and increase start-up. Production automation is one of our areas or highly complex, system availability. Our engi-neering knowhow deli- of excellence from robots to integrating complete our production cells vers higher productivity and lower unit costs. manufacturing systems. are always highly efficent

17 MX benefits for you: Compact and rugged production system for sustained productivity Outstanding melt quality and absolute platen parallelism Fast cycles and high yield of good parts High production flexibility, versatile for different tasks Lowest mould wear and low-maintenance Modular machine for easy conversions and upgrades Project examples 1. Machine with basic 2. Complex manufacturing cell 3. Factory planning/ automation: with post-mould processing: just-in-time production For a basic solution, we supply In addition to the machine, We supply a complete turnkey the machine plus the robot, we supply the robot and post- solution, from planning your temperature control elements processing equipment, eg, for factory to installing your systems and mould fixing system. trimming and assembly and peripherals. System solutions from the experts: Our project experience is your security Mould-fixing equipment Our highly-qualified project engineers have many Mould transport and quick-change systems years experience in planning and managing Materials supply and conditioning various projects. You can trust their extensive Mould heating/cooling know-how in manufacturing-cell automation and Automated part-removal, linear and industrial rely on your project being completed successfully robots for post-mould processing Post-mould processing (assembly, coding, trimming, etc.) and on time. Fastest time-to-market for your new products gives you a competitive advantage worldwide. Plant layout and factory planning concepts Support, also extended workbench, for customer engineering departments Trouble-free project completion Professional project management Optimized time-frame for turnkey projects Customer benefits Page 17

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

19 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 Injection Moulding Service on the service hotline or by post at KraussMaffei Technologies GmbH this address: Krauss-Maffei-Str. 2 Hotline Phone: Fax: Munich Germany

20 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 The MX series is a systematic onward development of the highly successful MC series of large machines. The fastest machines of their size on the market, MX machines are available in the clamp force range from 800 to 4000 t. They are engineered to deliver sustained performance under demanding conditions. Versatile and modular, the MX series offers a wide choice of injection units for application-specific configurations. These are compact, highperformance machines, engineered for fast cycles, minimal mould wear, best melt quality, maximum platen parallelism and very low production costs. KraussMaffei Technologies GmbH Krauss-Maffei-Strasse Munich Phone Fax WE. 2nd edition 04/09. SGM 049 B PRO 10/2007 GB KraussMaffei reserves the right to make technical changes. commitment to research and development.