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insert
get a grip on inserts
2_ insert
The right combination.
ENGEL insert.
In many challenges, teamwork is the key to success. This is the case where a number of people are working towards a common goal – and the same applies where a number of different materials are combined.
1 + 1 = more than 2
In many cases, technical parts only gain their required functions and mechanical properties through an intelligent combination of differing materials.
In short, material synergy must be utilised consistently.
Overmoulding with plastic fuses metal parts, glass, plastic components, electronic modules and prefabricated assemblies into finished parts with strong product characteristics.
Not only do ENGEL insert machines perform this task with maximum efficiency and security , they offer a whole series of ergonomic advantages.
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Metal and plastic
composite parts
Efficient, reliable, ergonomic production
More
productivity
Significant time savings and no delays, even with complex insertion and demoulding procedures. In machines with a rotary or sliding table, the next injection process step is performed in parallel with parts handling at another mould station.
Efficient
automation
Simple and precision insertion and holding of parts in cavities thanks to the horizontal mould parting line.
Ease of integration in complex manufacturing cells – the mould area is highly accessible from all angles.
Ergonomic
operation
Table height offers ultimate ergonomics for manual parts handling; no platform is required for the user.
4_ insert
Outstanding
energy efficiency
Low energy consumption thanks to low friction, closing pressure lock-in and electrohydraulic variable capacity pump.
Intelligent ENGEL ecodrive servo hydraulics takes energy efficiency to a level only achieved until now by all-electric machines (ecodrive is optional, or standard with the e-insert).
Shorter
handling times
Secure and time-saving: highly secure access to mould area thanks to a light curtain. No two-handed operation required to move the clamping unit and ejector.
Moreover, no wait times for opening and closing the safety gate that would normally be needed.
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The perfect solution.
In many combinations.
The wide ENGEL insert machine programme means the right solution for your specific insert application – every time
ENGEL
insert V
insert V 35 xs insert V 45 xs insert V 40 insert V 60 insert V 80 insert V 100 insert V 130 insert V 160 insert V 200 insert V 250 kN US tons
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270 single
ENGEL
insert H
insert H 30 insert H 40 insert H 60 insert H 80 insert H 100 insert H 130 insert H 160 insert H 200 insert H 250 insert H 300 insert H 400
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ENGEL
e-insert V
e-insert V 40 e-insert V 60 e-insert V 80 e-insert V 100 kN US tons
400
600
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90
110 single
rotary
shuttle
60V 200V 330V 500V 650V 860V 1060V
15 18 20 22 25 30 30 35 40 35 40 45 40 45 50 45 50 55 50 55 60
Are you looking for a complete, economically viable injection moulding solution for your insert application? One that meets all your needs as regards productivity, precision, operational safety, utilisation of space and energy efficiency? With the
ENGEL insert machine range, you're in safe hands. After all, the range is comprehensive.
Whether hydraulic or electric, vertical or horizontal injection unit; whether deploying a rotary table, sliding table or stationary platen
– the sheer diversity of variants means the right answer to virtually all insert applications. From a single machine without automation to a complex, highly integrated production cell where several machines, linear robots, industrial robots and other systems
(such as camera inspection technology) turn your product ideas into reality.
rotary
shuttle
60H 200H 330H 500H 650H 750H 860H 1060H 1560H 2460H 3660H
15 18 20 22 25 30 30 35 40 35 40 45 40 45 50 45 50 55 45 50 55 50 55 60 55 60 70 60 70 80 70 80 90
rotary shuttle
50V 170V 310V 440V
15 18 20 22 25 30 30 35 40 35 40 45
ENGEL
e-insert H
e-insert H 40 e-insert H 60 e-insert H 80 e-insert H 100 kN US tons
400 50
600
800
1000
70
90
110 single rotary shuttle
50V 170V 310V 440V
15 18 20 22 25 30 30 35 40 35 40 45 insert
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ENGEL
insert V
– with vertical injection unit
Clamping unit: hydraulic, vertical, closing from the top
Hydraulic, vertical injection unit
High injection performance, excellent process stability
Outstanding injection process control
(alternatively: energy efficient ENGEL ecodrive drive technology)
Compact design
Ideal ergonomic working height
Light curtain to safeguard mould area
ENGEL
insert H
– with horizontal injection unit
Clamping unit: hydraulic, vertical, closing from the top
Hydraulic, horizontal injection unit
High injection performance, excellent process stability
Outstanding injection process control
(alternatively: energy efficient ENGEL ecodrive drive technology)
Ergonomic working height
Light curtain to safeguard mould area
Stationary mould fixing platen
Hydraulic rotary table
Hydraulic sliding table
Very small footprint
Corresponding performance data
Two-circuit hydraulics for synchronous movement
Limited option pool insert V
single-xs
(xs = extra small)
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Stationary mould fixing platen
Hydraulic rotary table
Hydraulic sliding table
Small footprint
Outstanding performance data
Two-circuit hydraulics for synchronous movement
Comprehensive range of options, including customised solutions insert V
single
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8_ insert insert V
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(xs = extra small)
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rotary
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shuttle-xs
(xs = extra small)
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shuttle
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Stationary mould fixing platen
Hydraulic rotary table
Hydraulic sliding table
Outstanding performance data
Two-circuit hydraulics for synchronous movement
Comprehensive range of options, including customised solutions insert H
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shuttle
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Standard
Optional insert
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10_ insert
ENGEL
e-insert V
ENGEL e-insert V single
ENGEL e-insert V rotary
ENGEL
e-insert H
ENGEL e-insert H single
ENGEL e-insert H rotary
Electric, precise, energy efficient.
Electric meets hydraulic. The ENGEL e-insert brings together the best of both worlds. The machine combines the unbeatable precision of a servo-electric injection unit with the efficiency of a vertical, hydraulic clamping unit.
The result is injection moulded parts of outstanding quality and precision , produced with incredibly low energy consumption. Intelligent ENGEL ecodrive servo hydraulics, installed as standard in the e-insert, makes a big difference to energy savings.
The excellent process stability of the ENGEL e-insert meets the highest standards in the production of technical parts.
Open/close mould
Rotary/sliding table
Ejection
Injection
Plasticising
Building up contact force
hydraulic/ecodrive
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Optional insert
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12_ insert
Requirements on the design of the mould area can differ greatly, especially in the area of vertical injection moulding machines. Here, flexibility of machine specification is a much more important factor in successful parts production than is the case in other machine series. Thanks to the company's decades of experience, the mould area of ENGEL insert machines offers many advantages:
ergonomic working height
through safeguarding with light curtain
(even with multiple workstations) thanks to user-programmable sequence control
Three basic designs are available for the mould area:
ENGEL insert rotary
| Rotary table
For most vertical machine applications, the rotary table version is the most cost-efficient: during the time-consuming insertion and demoulding procedure, the next parts are already being injected simultaneously in another bottom mould half. This concept has the potential to raise productivity by a high percentage , even compared with horizontal injection moulding machines.
Mould temperature control: benefits of tie-bar-less clamping unit
Since the rotation axis of ENGEL rotary tables is invariably tie-bar-less, electric cables, water pipes and hydraulic pipes can low to the moulds easily be routed from be-
. Additional temperature control circuits can be installed from above in the case of technically demanding applications.
ENGEL insert
ENGEL insert
V 35 rotary-xs
ENGEL insert
V 45 rotary-xs
ENGEL insert
V 40 rotary
ENGEL insert
V 60 rotary
ENGEL insert
V 80 rotary
ENGEL insert
V 100 rotary
ENGEL insert
V 130 rotary
ENGEL insert
V 160 rotary
ENGEL insert
V 200 rotary
ENGEL insert
V 250 rotary
ENGEL insert
H 30 rotary
ENGEL insert
H 40 rotary
ENGEL insert
H 60 rotary
ENGEL insert
H 80 rotary
ENGEL insert
H 100 rotary
ENGEL insert
H 130 rotary
ENGEL insert
H 160 rotary
ENGEL insert
H 200 rotary
ENGEL insert
H 250 rotary
ENGEL insert
H 300 rotary
ENGEL insert
H 400 rotary
40 US
50 US
50 US
70 US
90 US
110 US
150 US
180 US
230 US
280 US
40 US
50 US
70 US
90 US
110 US
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US
180 US
230 US
280 US
340 US
440 US
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Option insert
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ENGEL insert single
| Stationary platen
The single version is specifically designed for production with just one bottom mould half . One major advantage is the very small footprint, especially with the single-xs version.
This machine is ideally suited to small batches and the overmoulding of bulky inserts. It offers particular benefits in the production of parts on metal bands subsequently separated outside the machine. Very short insertion and removal times are possible thanks to belt feed units integrated into the mould.
ENGEL insert shuttle
| Sliding table
The concept is particularly beneficial where a rotary table is not viable due to the quality of inserts and where inserting and removing parts is relatively time-consuming.
The ENGEL insert shuttle has a sliding table with stations alternately to the left or right of the injection station for the purposes of parts handling. Each station is fitted with an ejector.
14_ insert
High
operating safety
Safeguarding against unauthorised access in the mould area
The mould area is safeguarded by a light curtain .
Where an unauthorised intervention into the mould area is made, all machine movements shut down immediately and securely. As an option, the light curtain in front of the mould area can be extended to the side workstations of the rotary table.
Safeguarding against hot material
Horizontal injection units are secured by a swivel-type splash guard, which provides optimum protection against outflows of hot melt when the mould is open . The mould manufacturer or the operator of the mould must secure the parting line of closed moulds with a protective cover or suitable immersion edge. This means there is no need for an extra safety shield in front of the mould, while the full freedom of the mould area is retained. If required, however, an appropriate safety shield on the movable mould mounting platen is optionally available (national regulation in North America).
North America
Owing to safety requirements, the version for North America (for the ENGEL insert US) differs in two key respects:
1. The distance between the light curtain and the mould area is greater.
In addition to the vertical light curtain elements, shorter horizontal elements are also integrated to safeguard the area close to the mould.
2.
A height-adjustable splash guard is mounted on the movable mould mounting platen to safeguard the parting line against purging of hot melt.
After mounting the mould, the operator must adjust the guard in such a way that the parting line is securely covered when the mould is closed.
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16_ insert
ENGEL injection unit |
Hydraulic
High performance, excellent process stability
Excellent injection process control
The hydraulic ENGEL injection units score extra points with reliable control of the injection moulding process. Compared to conventional injection controllers, the 'clamped system' of injection plungers included in the standard version with the highly sensitive electronic controllers reacts extremely quickly to disturbing influences and any process-related changes. This ensures excellent quality injection moulded parts and high reproducibility . Moreover, the electrohydraulic variable capacity pumps installed as standard in the ENGEL insert enhance control accuracy.
A servo valve is also optionally available for optimisation at very low injection speeds (comes as standard in the ENGEL ecodrive).
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ENGEL
technology modules
18_ insert
ENGEL injection unit |
Electric
The guarantee of perfect product quality
High-precision injection process control
Electric ENGEL injection units combine high-precision movement in the injection process with very high reproducibility. This significantly raises quality in products with minimal wall thicknesses in particular. Very high process stability ensures a very low number of rejects, thereby cutting costs further and increasing productivity .
High-performance injection: with precision and energy efficiency
The thinner the walls of the injection moulded part, the greater the advantage of precision with electric injection units – and the higher the injection performance that is needed. So far, high-performance injection has only been possible via hydraulic storage batteries, which entails very high energy loss. Now the ENGEL e-insert electric injection units offer injection speeds of up to
330 mm/s in several power stages, and greater precision comes as standard.
Plasticising unit
A range of barrel and screw configurations is available for optimum tuning of plasticising to the application. The barrel is mounted on the injection unit by means of a quick coupling. The plasticising unit is pressed torque-free against the mould, whereby the required force is set on the machine control unit .
Ideal add-ons for the ENGEL insert and ENGEL e-insert: Special process technologies or applications also call for special equipment on injection moulding machines.
rubber
| Screw injection unit adapted to rubber processing through process technology.
LIM
| Equipment package for liquid silicone processing, with screw or plunger injection unit according to the application.
HTV
| Plasticising unit and process software for processing solid silicone. Stuffing device optionally available.
HART-PVC
| Equipment package and plasticising unit for processing hard PVC.
duroplast
| Plasticising unit and process software for processing duroplast.
Focus
on energy
With servohydraulic ENGEL ecodrive and more.
When it comes to saving energy,
overall efficiency counts
Saving energy means cutting costs. To ensure an injection moulding machine can achieve its full energy saving potential, though, it's not enough to restrict individual components (such as hydraulic pumps or their drive motors) to low energy consumption: the right overall concept must be applied.
In particular, the underlying hydraulic concept must deliver high levels of energy efficiency. This critical basis is supplemented by drive components that also operate energy-efficiently.
In the ENGEL insert and e-insert, the two factors are perfectly harmonised.
High efficiency in the machine's basic hydraulic concept
+
High efficiency of individual hydraulic drive and control components
ENGEL: leading the way
These machines operate according to a hydraulic concept that places a very low energy requirement on the central hydraulic system. The hydraulic drive units have always set the standard for the sector in terms of energy efficiency and control quality .
After all, it was more than 20 years ago when ENGEL replaced PQ hydraulics – conventional at the time – with modern, energy saving EHV hydraulics.
Now ENGEL has taken another critical step forward with the new servohydraulic ENGEL ecodrive, which combines the benefits of hydraulics and servo drives.
It all adds up to even better control accuracy and impressive energy efficiency.
Fixed displacement pump
Hydraulic variable capacity pump
Electric variable capacity pump
Fixed displacement pump + servomotor
PQ EHV
Evolution of hydraulic drive technology
ENGEL ecodrive insert
_21
Perfect combination: electric injection unit and
ENGEL ecodrive
No holding force thanks to
'lock-in' closing pressure
Where hydraulic accumulators with relatively high energy consumption were once used, ENGEL now offers high-performance yet energy-efficient electric injection units that provide injection speeds of up to
450 mm/s. This is only available in combination with the
ENGEL ecodrive, however; otherwise no-load power losses in hydraulic pumps operating in parallel would offset the energy savings of the electric injection unit.
It goes without saying that all speeds and pressures of the individual hydraulic machine movements are regulated. However, the required pressure is hydraulically maintained where practical, thereby holding clamping force and nozzle contact force. This reduces the energy for keeping these forces to zero. As cycle times increase, energy savings also rise to significant levels.
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ENGEL ecodrive – the revolutionary hydraulic concept with major advantages:
Outstanding energy efficiency
Much less cooling water needed
Very low noise level
Ideal for clean room applications
‚On board‘ hydraulics for operating core-pulls
Standard in ENGEL insert, optional in ENGEL e-insert
22_ insert
ENGEL ecodrive |
Intelligent hydraulics
ENGEL ecodrive means serious energy savings. Compared to conventional hydraulic machines, the intelligent servohydraulic system enables customers to make energy savings of up to 70 percent . How is this achieved? The drive is only active during movement; virtually zero energy is consumed when idle (during cooling times, for instance). When the servohydraulic machine does move, it does so with extreme efficiency – thanks in part to a innovative pressure regulation system.
Another advantage lies in the fact that the hydraulic system is 'on board': this makes the ecodrive ideal for moulds with hydraulic components, such as core-pulls. The machine runs very quietly thanks to the servo hydraulics, and its thirst for cooling water is drastically reduced – in most cases it requires none at all.
How the ENGEL ecodrive works Drive downtime when idle
In the ENGEL insert and ENGEL e-insert, the ecodrive system comprises a servomotor with fixed displacement pump (instead of a permanently running asynchronous motor with variable capacity pump). Energy efficiency derives from several criteria, but two main points in particular:
When idle, the ENGEL ecodrive saves the flushing or idling energy consumed by conventional hydraulic systems.
An idle pump consumes no energy. This is effectively supported by the energy efficient machine concept (e.g. 'lock-in' closing pressure).
No control valves in the central drive unit for speed and pressure regulation system
In conventional systems, control valves invariably cause energy loss because of the pressure difference.
By contrast, the ENGEL ecodrive regulates speed and pressure without control valves. This results in considerable efficiency gains.
P
U
Servo controller
Fixed displacement pump
M
S
Speed is regulated via the rotational speed of the fixed displacement pump, with no additional losses in pressure and energy. The patented pressure regulation system is unique: instead of using a pressure control valve, it utilises newly developed control algorithms directly via the rotational speed of the pump.
U insert
_23
Cooling water savings of up to 100%
The ENGEL ecodrive raises energy efficiency by drastically reducing the energy losses sustained by conventional hydraulic machines.
Conventional hydraulic machines:
The supplied electrical energy that is not
utilised for the various machine movements in the form of kinetic energy is converted into heat energy. Most of this heat energy is supplied to the
hydraulic oil and then transferred to the external
cooling water treatment plant via the usual oil
cooler.
With the exception of high-performance applica-
tions, the ENGEL ecodrive reduces energy losses to such an extent that only slight warming of
the hydraulic oil takes place. Consumption of
coolant in oil coolers is reduced to very low volumes (and to zero in many cases).
The 'noiseless' machine
The ENGEL ecodrive is not only energy efficient in the extreme, it also runs quietly. In the absence of permanently running hydraulic pumps, noise levels are significantly reduced.
'On board' hydraulics
The ENGEL ecodrive meets every requirement for energy efficient, space saving production with hydraulic core-pulls. The ecodrive also provides two fully independent drive units for synchronous movement of the ejector, core-pulls and nozzle (standard in the rotary and shuttle versions).
Oil temperature: indicator
of
energy efficiency
in hydraulic machines
24_ insert
ENGEL
CC300
smart operation of machine and peripherals
The ENGEL CC300 is based on a simple operator interface and groundbreaking process integration. With this smart control in fully integrated production systems, the machine as well as peripherals such as the infra-red oven, the dosage machine, or the robot, can be steered through the production process as easily as though you were just using your smartphone. Ergonomic design, individual confi gurability and modern operator control logic make controlling and monitoring highly integrated, automated systems much simpler, safer and easier.
higher productivity
start without a reference run perfectly synchronised movement progressions
intuitive operation
uniform, clear and logical operation targeted information with no screen changes, customisation possible colour guide system to diff erentiate between machine and robot control
simple adjustment of sequences
Conduct adjustment tasks independently thanks to menu-guided sequence programming individual assignment of tasks and roles
variable handling
direct, safe and stepless control of all movements with e-move, on the panel or using the ergonomic, lightweight C70 handheld unit
increased safety
perfect, common data management of machine and robot sign-in by chip card for individual assignment of user roles and tasks
ergonomic design
individually adjustable, functional and robust hardware with revamped and simplifi ed user interface individual settings are loaded upon sign-in with chip card
best readability
generous display with excellent contrast in all light conditions and from any angle insert
_25
26_ insert
Focus on automation
The injection moulding machine is in many cases only one element of the overall, often complex production cell.
Robots and automation components perform a wide range of tasks . These ranges from insert-placing and take-off actions at the injection mould, including mounting and checking operations, to packaging of the finished product.
The aspect of cost-effectiveness is usually founded in the overall concept and not its individual components.
This is precisely where the vertical ENGEL insert delivers significant benefits to the overall concept through its multi-station layout.
More flexibility
The mould area on the ENGEL insert is easily accessible from all sides . A robot can easily move in and out of the mould, and the benefit of the standard light curtain is retained in the case of side-on insertion and retraction. Where mould maintenance is necessary, operators can also be sure of fast and secure access.
More productivity.
Very often, loading a mould with inserts takes a relatively long time. In the case of the ENGEL insert, the next injection cycle cannot be held up. Therefore, as it overmoulds the next parts, the robot is able to place and remove inserts – without delaying the cycle .
The number of vertical machines with automation is continuing to rise – and no wonder, as an auto matic insertion process guarantees the secure and proper positioning of parts in the mould. This minimises interruptions to production and the number of rejects.
60 years
| Experience with vertical machines
ENGEL has been making vertical machines for more than 60 years.
That's a lot of experience
in highly sophisticated vertical machines such as those in the
ENGEL insert range.
The list of ENGEL insert customers reads like a Who's Who of the industry.
The intelligent machine concept promises advantages across a wide range of sectors in the form of
technical parts, automobile and electronic components and special applications for medical engineering
. Major global businesses and innovative SMEs alike depend on the efficiency of ENGEL insert. Worldwide.
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ENGEL AUSTRIA GmbH | Ludwig-Engel-Straße 1 | 4311 Schwertberg, Austria
Tel. +43 50 620 0 | Fax +43 50 620 3009 | [email protected] | www.engelglobal.com
The information, product features and pictures contained in this brochure are intended exclusively as a technical guide. ENGEL is not responsible for any technical changes or print/typographical errors . Reproduction in whole or in part is prohibited without the prior written consent of ENGEL AUSTRIA GmbH.
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