DS-JUN26-PG41_Layout 1 25/06/2026 09:44 Page 1
DRIVES, CONTROLS & MOTORS
FEATURE
DRIVING INJECTION MOULDING MACHINE OPERATION
Kris Thacker, technical sales manager, Sumitomo (SHI)
Demag, examines why drive controls are fundamental to the
operational capabilities of injection
moulding machines D
rive technology has seen incremental improvements over the years, resulting in variations in performance across different
models of injection moulding machines. Some drives achieve faster acceleration and enable quicker braking; others are engineered with a focus on energy efficiency. The choice of drive control can shape not only
the speed and responsiveness of the machine, but also its energy profile and suitability for specific moulding applications. As drive technologies continue to evolve, understanding these distinctions becomes essential for optimising both performance and efficiency.
CHOOSING A DRIVE Controlling the injection pressure and process optimisation is essential for mouldability. Much like a gearbox, the drive in every injection moulding machine transforms the rotational speed into a linear movement. The science is the same for all drives across the ages, whether it is hybrid, variable frequency, electric servos, electric belt, direct drives or all-electric drives. The choice of drive in injection moulding used
to be application dependent as the requirements for sector and processing applications need to factor in so many varying aspects. This included holding patterns, rapid changes in acceleration and deceleration, cooling times and component removal. With the arrival of mass production and trade
globalisation, the 1980s and 1990s machine hierarchy was characterised by widespread adoption of hydraulic drives. These were hydraulic fixed displacement or hydraulic variable displacement drives, and featured a motor, pump, valve and hydromotor. Mould shops continue to use these machines today. However, a score of 0.46 for relative efficiency
means that more than half of the input energy is being wasted. This could be improved by optimising processing parameters. Yet, given the elevated energy costs, a relative efficiency rating of 0.46 strongly suggests that your
www.designsolutionsmag.co.uk
Sumitomo (SHI) Demag’s advanced electric direct drive technology is featured on the IntElect and PAC-E
current machine may have reached a point of significant inefficiency. Switching to a model with an all-electric
belt drive or direct drive will reduce cycle time, save energy and improve moulding precision and part quality.
“Ultimately, the choice of drive control
can shape not only the speed and
responsiveness of the machine, but also its energy profile and suitability for specific moulding applications”
Sitting between all-electric and hydraulics
are servo hydraulic systems. These provide a high-performance and more energy-efficient alternative, while retaining the benefits of hydraulic force. Often achieving a relative efficiency rating of over 0.85, these moulding machines use a variable speed drive motor to drive either a fixed or variable displacement pump. Found predominantly in advanced
manufacturing, robotics, automotive and aerospace, the servo hydraulic market still supports manufacturers. Now, the focus is on the next generation of servo motors. These will be powered by drives that combine the power density of hydraulics with the precision, control, energy efficiency and smart connectivity of electric drives.
OPTIMISED ELECTRIC EFFICIENCY At 0.92 relative efficiency, high torque electric direct drives represent the most consistent efficiency benchmark. Some of the highest performing machines with all electric drives can reduce energy consumption by over 80% compared to hydraulic technology. Additionally, the evolution of technologies now means that electric drives are increasingly viable for processing faster applications including caps and closures, as well as heavier loads such as automotive parts. But even here, electric drive variants can,
and do, vary. For example, an all-electric direct drive can be very different to a belt drive electric axis. A belt drive, for example, will typically couple the servo motor to the axis via a belt and ball screw assembly. Although noisy (from rotational velocity) and more complex to control, its relatively low mass and low inertia support quick and precise changes. Conversely, an all-electric direct drive will
couple the motor to the ball screw controls. This is especially important for controlling platen stiffness. These drives adapt especially well to velocity changes, with little overshoot. Marginally more energy efficient (~4-5%) than belt/gear systems, all-electric direct drives can also perform several tasks simultaneously in parallel operation. Sumitomo (SHI) Demag continues to
distinguish itself in the market through its advanced electric direct drive technology. This too has a huge impact on efficiency and machine reliability. The company designs and manufactures its own drive motors entirely in-house, meaning they are all tailored to meet the unique operational demands of injection moulding machines.
Sumitomo (SHI) Demag Plastics Machinery UK
https://sumitomo-shi-demag.co.uk
JUNE 2026 DESIGN SOLUTIONS 41
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52
