Sumitomo (SHI) Demag gets ‘active’ with its innovative upgrades

Sumitomo (SHI) Demag UK, manufacturer and system integrator of injection moulding equipment, has unveiled three major ‘active’ innovations designed to reduce energy consumption, increase reliability and enhance performance.
From March 2013, Sumitomo (SHI) Demag will introduce activeServo, new servo drive hydraulic pump, on its Systec hydraulic injection moulding machines. The technology enables a dramatic 50% reduction in energy consumption and has been proven to significantly lower heat and noise outputs.

The new pump, which features improved control properties and process dynamics, works in a similar way to stop-start technology in a car, whereby the motor runs only when needed using the minimum amount of energy required.  Unlike a variable delivery pump, which uses the swashplate angle to control the outlet flow, activeServo is able to completely shut off the motor when there are no flow demands.
“We’ve created a pump where oil flow is controlled precisely by changing the speed that the motor turns,” explains David Raine, Sumitomo (SHI) Demag UK’s Technical Sales Manager. “The advantage of this is that when the machine doesn’t need any oil, the pump stops and the machine doesn’t consume energy. This is hugely important for applications where equipment is idle for large periods of the cycle. This upgrade has closed the gap between hydraulic and electric efficiency.”
The firm has also introduced upgrades to its IntElect Smart machine range, activeFlowBalance and activeLock systems, both of which can be retrofitted and are particularly suited to precision moulding applications. Since their launch, these upgrades have delivered significant improvements in process optimisation and product quality.
activeFlowBalance is a processing aid that uses machine-control technology to balance pressure ratios between mould cavities. The technology counters complications such as flash formation, mould damage and under-filling for applications which, up until now, have required complex adjustments. In addition, it enables a reduction in clamp force, reducing mould wear and delivers an overall saving in energy consumption. A key advantage of activeFlowBalance is the ease with which it can be deployed. When the speed-regulated injection process is terminated, activeFlowBalance automatically starts to make use of the expansion of the melt during the transition from injection to hold pressure. This leads to partially-filled cavities being filled with lower counter-pressures, and in turn the fill levels naturally balance out without extending the cycle time.
While activeFlowBalance is currently only available on the Intlect Smart machines, Sumitomo (SHI) Demag UK is planning to realise it on its Systec Servo machine in mid-2013. “The activeFlowBalance function represents a huge technological advance,” says David Raine. “It can be used for injection processes that have a sensitive transition from injecting to hold pressure; a wide range of applications will benefit.”
A further upgrade, activeLock, provides active closing of the non-return valve to improve process consistency and repeatability. The non-return valve often forms the weak spot with the manufacture of high-precision parts. Most existing systems are closed passively through the injection procedure which causes fluctuations in the melt viscosity and frequently also leads to fluctuations in the closing behaviour. activeLock overcomes this problem by securely closing the non-return valve during the entire injection and hold pressure process. As a result, process consistency is increased, fluctuations reduced and the risk of rejects is minimised.
activeLock works using a rotating lock ring, which is closed through a counter-rotational movement of the screw. During plasticising, activeLock opens due to the rotation of the screw and the melt flows through the free channels into the space in front. Post dosing, the screw turns in the opposite direction and reliably closes the melt channels of the non-return valve. This procedure takes place independently of other process steps and is free of typical process fluctuations.
Sumitomo (SHI) Demag UK has become one of only two companies in the world to receive Blue Competence accreditation. Blue Competence is an initiative by the VDMA (German Engineering Federation), which globally underlies the role of technological leadership for sustainable production. The accreditation was presented to Sumitomo (SHI) Demag UK following its contribution to the protection of resources and sustainability, both in terms of production and manufactured products.
“Sustainability and product performance are at the heart of what we want to achieve,” says David Raine. “Our latest upgrades are testament to the company’s continual drive for innovation and our Blue Competence accreditation shows just how committed we are to leading the way in this area.”