EVOS - the next stage of evolution
EVOS formula = evolution x SynErgy: such was the manner in which Netstal presented its latest machine range at the K 2007 in Düsseldorf. Preserving the positive features of SynErgy while incorporating progressive innovations: this was the fundamental principle behind the launch of EVOS as the next evolutionary stage and replacement for the renowned and highly popular SynErgy range. In the following article we take a closer look at the new improvements and innovations.
Constantly focusing on the limits is absolutely imperative with a high performance machine such as the EVOS. Accordingly, the Netstal engineers have once again looked long and hard at the entire range as well as the machine elements and components, before introducing appropriate improvements and innovative developments.
Closer inspection of the modular assembly reveals that the clamping forces, tie bar distances, opening strokes and mould build-in heights have all been increased or enlarged.
Current combination options encompass four clamping unit sizes each with either three or four injection units, the largest of which features a nominal size of 8000. By enhancing the clamping force and plastification performance Netstal has taken into account the continuing trend towards increasing the number of injection mould cavities.
Quality through durable construction
To ensure even greater process stability and reproduction during manufacture, various machine components have been bolstered. For example, the moving platen has been further strengthened against flexing. In terms of stack moulds, the EVOS offers an optional guide carriage, which can be simply mounted on the existing linear guide. As necessary, an additional machine base support can also be mounted on the chute opening, thereby affording the best possible stability for the mould mounting area even in the case of extremely heavy moulds.
On the injection unit, the mounting of the plastification unit onto the injection and metering unit has been strengthened enormously, above all allowing the EVOS to withstand maximum loads during extremely fast cycle times. Thanks to these and other additional improvements, the EVOS boasts an exceptionally stable construction and, consequently, outstanding durability even when subjected to particularly heavy loads.
Further enhanced customer benefits thanks to progressive innovations
In developing the EVOS range, close attention has been paid to fulfilling the increased requirements of processors to the best possible extent and transforming the experience gained with the SynErgy into innovations incorporated into the machine design. The most significant features are summarised below:
"¢ Compact installation space
Recessed handles on the safety cover have enabled a significant reduction in the width of the machine.
"¢ Sealed lubrication on the toggle lever
Thanks to sealed circulatory lubrication, the EVOS boasts a particularly clean clamping unit that provides a saving of up to 150 litres of lubricating oil a year.
"¢ Customised ejector construction
Ejector forces can be individually tailored to specific customer requirements, while the optional booster allows shrivelled-on parts to be simply and easily removed.
"¢ Increased injection pressure
With the second largest screw diameter applying 2100 bar of injection pressure for each plastification, a peak value is achieved that also allows extremely thin-walled parts to be produced in the shortest of injection times.
In addition, the increased pressure allows all standard clamping applications to be achieved using the middle screw with an aspect ratio of 24 L/D, which in turn impacts positively on the melt characteristics and melt quality.
"¢ Flexible interfaces for individual line routing
In this respect, EVOS is setting new standards in allowing customers to organise line routing as specifically and as close to the mould as possible. This point is addressed in greater depth below.
Energy consumption providing the impetus for innovation
Throughout recent years, energy consumption has developed into a mega-trend in all sectors of industry and has also been a considerable factor during the further stages of developing the EVOS. Even at the basic design phase, Netstal opted for the hybrid route in terms of the axle drives and incorporated electrically driven metering.
Additional savings on energy consumption have also been achieved by using state-of-the-art electrically operated valves for the main axle, injection units and mould, whereby reduced pilot oil consumption has lowered power consumption by up to 1 kW per valve.
However, a primary factor is the increased performance that, thanks to greater layout precision in terms of the hydraulic circuitry, is apparent in the increase of usable kinetic energy and enables applications with extremely dynamic requirements to be implemented.
The innovations in terms of dynamics and energy consumption have successfully increased productivity as compared to the SynErgy or comparable competitive machines, thereby also facilitating a significant reduction in specific energy consumption.
Flexible solutions for individual needs
Netstal has been offering system solutions for many years and, as a result, has gained extensive experience in terms of how Netstal injection moulding machines become part of an efficient production system through the integration of moulds, handling equipment and additional peripheral items.
The incorporation and routing of the required lines such as water, air or electricity is an important factor in achieving enhanced productivity. Consequently, Netstal has taken great care with the EVOS to ensure a flexible line layout with convenient connections. For example, the supply of cooling water has over a thousand possible combinations, thereby ensuring that the cooling water reaches the mould without temperature loss.
The air valves have also been cleverly positioned in order to enable a more precise process. Moreover, the EVOS fulfils a major need with its predetermined temperature equipment interfaces which allow for up to eight devices on the front and the non-user side of the clamping unit. The electrical connections, with the "Euromap 66" interface option, are placed directly in these positions, on the machine frame or on the switch cabinet.
Evolution for efficient production
The EVOS enhancements and innovations mentioned above represent merely part of the evolutionary steps undertaken with this machine range. A whole host of other additional improvements have contributed to successfully offering the customer the most efficient injection moulding machine and most efficient system to date. Moreover, the long-standing experience of Netstalʼs application engineers provides yet further assurance that the individual needs of processors can be effectively addressed. Ultimately, the crucial factor is that of fulfilling the expectations of a high-performance Netstal machine by ensuring enhanced productivity for many years.
» Download: Foto: EVOS
» Download: Foto: EVOS injection unit / EVOS Spritzaggregat
» Download: Foto: Recessed handle on the safety cover / Eingelassener Griff am Schutzverdeck
» Download: Foto: Mould mid-platen support / Werkzeug-Mittelplattenabstützung