COMMENT SUMITOMO
All-electric injection moulding machines have many excellent qualities, including greater precision, higher power density and lower carbon emissions. Yet there’s a preconception that these systems are more expensive to repair. Ashlee Gough, area sales manager at Sumitomo (SHI) Demag UK delves into
CAPACITY PLANNING IS A MOVING TARGET Struggling to stay on top of everything is one of the greatest challenges for production engineers. Yet, Mean Time Between Failure (MTBF) is one of the simplest reliability measurements for polymer processors.
It is also probably the most valuable KPI for equipment-reliant operations as it provides an accurate method for measuring machine availability, and helps with the planning of maintenance schedules, as well as capacity planning. With fewer moving and wear parts, the time- less on all-electric moulding machines. Proving this, a study of the overall machine MTBF on a Sumitomo (SHI) Demag IntElect2 under warranty was on average 4.4 years – double that of an equivalent hydraulic machine. This MTBF metric is not just attributed to the machine design, but also how well an operative repeatedly handles or interacts with this valuable asset. A poorly executed repair job or implementing a bump can just as easily result in a low MTBF result.
SAME OR SIMILAR SERVICE TIME Electric machines are less mechanically complex.
12 June 2024 Irish Manufacturing
Studies conducted by Sumitomo (SHI) Demag
revealed that a 130 ton hydraulic machine operating 24/5 needed 39 hours of routine service work, compared to just six hours for an equivalent IntElect2 model. Analysing and treating oil in order to maintain its
are essential routine maintenance task on hydraulic systems. The timing of these tasks are critical and any delay or neglect can drastically increase the risk the proper standards realistically takes a couple of is required, this not only results in unplanned downtime but also comes at a great expense. Additionally, hydraulic hoses should be regularly inspected. It is recommended that they are replaced every ten years. Contamination and airlocks are always a danger when replacing hydraulic hoses. Because of this, it is recommended that this work should be undertaken by a professional. Hydraulic machines with accumulator technology should ideally have the bladder replaced periodically. Inspecting the accumulator housing for cracks every ten years using x-ray is equally advisable.
DRIVES ARE EXPENSIVE TO REPAIR Typically, all-electric machines have the reputation of being expensive to repair when they go wrong.
This view is often based on the cost of replacing an entire drive system. Many moulding machine suppliers source their
all-electric drives from external OEMs, which makes it more challenging to source component replacements, exchange or access service support. In the best-case scenario, moulders might be
able to source and switch out a power or control module. Yet in most instances, sourcing a new complete drive is the reality, which of course, runs at a premium cost. That’s one of the key reasons why Sumitomo (SHI) Demag has an R&D centre dedicated to drive development and designs and builds its own drive motors, designed purely for injection moulding machines, in-house. Being able to source individual replacement boards is a more sustainable solution for customers. Spares are also held for immediate shipment. Drives that are designed to be modular are also
modules, when you can replace just the one that’s failed? It can be the difference between several complete drive replacement which could run into a few thousand.
INFRASTRUCTURE SAVINGS TAKES A LONG TIME The savings when switching to all-electric are
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