ENERGY MANAGEMENT | TECHNOLOGY
through a fast-responding mould protection system and there is maximum cycle efficien- cy with comprehensive parallel functions. Energy efficiency measures also include deceleration energy recovery via a KERS system. Energy cost savings can reach a value of €30,000 per year with 6,000 hours production time, compared to a hybrid high performance machine with accumulator injection in the 400 tonne range. The machines are claimed to be user-friendly due to the new Unilog B8 control system with integrated assistance systems and ‘plug and produce’ extension options can create a complete production cell with Wittmann peripheral equipment and Wittmann 4.0 integra- tion package.
Sustainability is just one aspect that is driving plastic injection moulders to opt for more energy efficient systems, claims Nigel Flowers, UK Manag- ing Director at Sumitomo (SHI) Demag. “Yet, reducing an organisation’s energy consumption is not just good for the environment, it also signifi- cantly impacts Total Cost of Ownership (TCO) and Return on Investment (ROI), and helps a moulder achieve greater resilience,” he says. “Robust data will always be central to the decision making process. Until recently, machinery suppliers have struggled to put into context the tangible benefits and quantify and compare performance data in relation to energy consumption, investment and planned maintenance costs, mould wear and output quality. Commercial evidence is clearly important for moulders. For it to be credible takes years of testing. Sumitomo (SHI) Demag has known for many years that all-electric machines offer greater energy efficiency and enhanced precision, yet it was only with the launch of the IntElect2 range that we were able to share with customers robust, hard statistics measuring the energy benefits of all-electric compared to an equivalent hybrid machine.”
Flowers points out that in the UK, for example, the injection moulding machine market is split 25% electric/75% hydraulic. For industries where precision is paramount, such as medical devices, the switch to all-electric has been more rapid. However, all-electric injection moulding is far from a universal panacea and there are a number of legacy systems being used that continue to perform well. Additionally, there are some produc- tion areas better suited to hydraulic and hybrid systems, notably those requiring higher tonnages, for example the automotive and other heavier engineering sectors. “For legacy hydraulic injection moulding
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systems, the gearboxes create friction and add to energy losses,” Flowers adds. “Electrical direct drives available on hybrid and all-electric systems evade this issue. Kinetic energy can also be recovered through the use of multiple frequency drives installed on a common power bus. This means that the braking energy of one drive can be passed on to another via the inverter, rather than being lost. For example, while the clamping unit is braking, the energy generated can be used for the energy-intensive step of plasticisation. “For plastic moulders, having centralised monitoring of real time machine and energy performance will be critical to achieving zero machine downtime, which is the ultimate goal. It is why Sumitomo (SHI) Demag created the ActivePlus technologies as it measures four critical aspects of machine performance, including energy efficiency. ActiveRemote forms part of this technology package, which utilises industrial 3G mobile technology to provide real-time monitoring and troubleshooting of machine settings and issues, linking customer injection moulding machines securely to our service management system.” The new IntElect2 range of all-electric machines
feature a new motor design. The company says that the range provides a 24% increase in production output, up to 47% reduction in energy consumption and 62% faster machine ROI – typically around 18 months - and enhanced mould safety, when compared to an equivalent Systec Servo machine. Capital costs are around 12% lower than first-gener- ation IntElect. The machine’s improved drive system provides enhanced top dynamics, precision and repeatability. The new 400v motor design is shorter and features new types of spindle. Its encapsulated windings improve heat transmission, while the new load cell improves precision, in addition to reducing heat sensitivity. In dry cycling, the company says that the IntElect 500 uses 2.15 kW/h. UK trade moulder Omega Plastics recently installed its second IntElect machine to replace a
May 2018 | INJECTION WORLD 51
Above: The IntElect2 from Sumitomo (SHI) Demag is on average 10% smaller than equivalent all-electric models
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