Significant savings potential through functional integration

systec_servo_210_web

activeDrive_web

systec_210_hybrid component web

To meet the increasing demands of users for plastic products, they must not only be produced cost-effectively in high quality but also combine various functions within themselves. At HYBRID Expo 2015, Sumitomo (SHI) Demag demonstrates the further development of the manufacturing process for hybrid components presented at Fakuma 2014 in a compact production cell. From automotive technology to consumer electronics, functional integration is an important development focus. By combining different functions into a single component, increasingly complex tasks are being tackled with plastic products. Additionally, the products become steadily lighter through integration, contributing to efficient resource management. Injection molding technology plays a very important role in the production of such products. Only through highly automated and high-quality production solutions can resource-conserving and cost-effective manufacturing be realized.

Functional Lightweight Construction on the Systec Servo

Many forward-looking plastic products require a combination of lightweight construction and functional integration from customers. Sumitomo (SHI) Demag demonstrates both on a Systec Servo 210-430 with 2,100 kN clamping force, producing hybrid components from UD tapes, metal inserts, and plastics. Using the example of a highly demanding component, Sumitomo (SHI) Demag, together with its system partners, shows the potential of functional integration. The UD tape is preheated in a production cell and inserted into the injection mold using hot handling. The machine-side tool movement shapes the UD tape into the desired geometry. Subsequently, the deformed composite is overmolded with polypropylene (PP) in a rib structure. Simultaneously, two metal parts are inserted into the mold to absorb the load at the pivot point of the component. The complete assembly is also carried out within the production cell. The result is a high-quality, extremely lightweight hybrid component that has the necessary stiffness to transmit the high forces required for the intended function. By combining different materials, material can be saved, and a maximum degree of functional integration can be achieved. This forward-looking technology is primarily focused on the automotive industry, where lightweight construction means substituting metal with plastic. Furthermore, the use of hybrid components helps reduce the number of individual parts and manufacturing steps in vehicles while increasing process safety. An evolution in products is the use of so-called UD tapes. These fiber mats have the advantage over standard organo sheets that they can be specifically tailored by the processor to the load case of the component. This increases the stiffness of the product while maintaining the same wall thickness. In general, UD tapes offer a cost advantage over expensive organo sheets.

Enhanced Performance Through Advanced Machine Technology

Sumitomo (SHI) Demag presents itself with a space-saving, compact production cell. The core piece is a Systec Servo 210-430 with 2,100 kN clamping force. The Systec Servo machines are standardly equipped with the innovative activeDrive drive system, which uses a frequency-controlled high-performance motor in conjunction with a hydraulic pump to enable higher speeds and energy efficiency than comparable machines. The hybrid drive concept not only allows for short cycle times and parallel movements but also saves up to 60% energy during operation. Thanks to highly sensitive tool protection, the machine offers maximum operational safety with minimal maintenance effort. As Sumitomo (SHI) Demag takes responsibility for the environment, all new developments are equipped with energy-efficient and powerful hybrid servo drives. All machines in the El-Exis SP, Systec SP, and Systec Servo series also feature activeMotionControl technology as standard. This innovative axis control system allows for parallel movements with only one hydraulic pump without affecting individual components. As a result, machines equipped with activeMotionControl achieve higher injection dynamics while reducing dry cycle times. The precise movement of the axes prevents overshoot and leads to higher process accuracy and shorter cycle times. Additionally, noise levels during operation are reduced.