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TECHNOLOGY | ENERGY MANAGEMENT


Right: The new Netstal Elios 10000


Below: The Netstal Elios 7500 injection unit and the main hybrid drive with


adaptive drive control and energy recuperation from the


clamping unit


external peripheral controllers that are OPC UA-based.” Two of the latest products that Netstal has developed that offer significant energy savings have a combined electric and hydromechanical drive system to provide bigger clamping units. Netstal first presented the Elios hybrid range at K2016 with models from 450-750 tonne. The machines offer high performance, for example, the Elios 7500 has a dry cycle time of 1.9s. However, there is an increased demand for models with an even higher clamping force. With higher-cavity moulds that require a higher clamp- ing force and larger clamping surface, the output volume and productivity of thin-wall packaging can be further increased. The recently released Elios models with 880- and 1,000-tonne clamping force cover these requirements. Netstal says that the two new models – Elios 8800 and Elios 10000 – provide performance combined with optimum efficiency that is ideal for demanding thin-wall applications. The machines are designed for fast, precise and long-term continuous operation. According to the company, the performance and efficiency of the Elios clamping unit is due to the actuation concept for the toggle lever. In the Elios series, the crosshead moves the lever mechanism of the clamping unit and is actuated by a combination of a servo-electri- cally driven rack-and-pinion gear and two hydro- mechanical synchronised cylinders. The actual travel movement is fully electric, while the two cylinders run synchronously. In the clamping force build-up phase, which in the case of toggle-lever machines takes place automatically due to the toggle lever geometry, the two cylinders support the locking process. The advantage of this solution is that energy can be recuperated during travel movement via the servo-electric drive. Due to the additional cylinders, the driveline can also be kept slim, which improves the dynamics and


IMAGE: KRAUSSMAFFEI


acceleration capability. The drive concept and robust design of the machine results in fast motion cycles. The Elios 10000 has a dry cycle time of 2.2s, as per Euromap specification. The modular design means that the high-perfor- mance injection units are also used in the new Elios models. With screw diameters of 80-100 mm, two different injection units are available as standard. If other dimensions are required, additional combi- nations can be realised on request. The twin valve technology achieves good injection performance, both in terms of the maximum achievable injection speed but also in dynamics. At pressures of up to 2,400 bar, injection times of a few tenths of a second can be achieved. This allows wall thick- nesses to be minimised and material savings achieved. A large power reserve is also an advan- tage in the processing of recycled raw material. The company adds that the dual drive of the clamping unit integrates well into the overall adaptive drive system. All electrically driven axes are combined through the connection between the power converters to form an electrical DC link in which energy can circulate virtually unhindered. The servo-electric motor of the main drive is also integrated into this intermediate circuit, therefore the energy generated during braking processes of the clamping unit can be used directly and trans- ferred to the hydraulic accumulator by means of an energy conversion. Netstal says that the system provides good


energy efficiency. In addition, there is great power potential available, especially for the highly dynamic actuation axes such as the injection process. The user benefits from an efficient machine that also offers sufficient power reserves for future applications. Sumitomo (SHI) Demag uses high torque direct drives in its injection moulding machines which, it says, can achieve lower energy consumption and better performance than a traditional belt driven electrical axis. The company says that the highly dynamic direct drives provide more power and


16 INJECTION WORLD | June 2021 www.injectionworld.com


IMAGE: KRAUSSMAFFEI


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