One step ahead - ELION series expansion
The ELION series unveiled at K 2004, which was specifically and uncompromisingly developed as an all-electric injection moulding machine, has meanwhile secured a large share of the market and gained a high level of acceptance with our customers. Thanks to its exceptional precision and performance, the ELION is rightly described as the best all-electric injection moulding machine on the market.
However, market requirements in terms of per-formance and output are constantly evolving. The number of mould cavities is continuously increasing, which also gives rise to an increase in dimensions. In addition, energy consumption is now afforded a great deal of significance for both ecological and economic reasons. As such, the decision to expand the clamping force of the current ELION series from 50 to 175 tons to over 200 tons and thus maintain optimum energy efficiency was a logical move.
The basis for larger clamping forces was the established ELION clamping unit concept, marked by the extremely stable construction and optimum performance and energy efficiency of the crankshaft driven toggle lever system.
A typical application for 200-ton-plus Netstal clamping forces is the manufacture of thin-walled packaging and caps. As the performance level of all-electric injection units can no longer really do justice to these requirements, the expanded ELION clamping units will be combined with the established, high-performance, hybrid-driven injection unit from the EVOS machine. This too is a logical consequence for achieving optimal energy efficiency.
The ELION with hybrid drive concept
Netstal will initially unveil the ELION with hybrid drive concept at the K trade fair in Dusseldorf. Typical applications, namely the manufacture of thin-wall flower pots and bottle caps, will be demonstrated on two new machines with respective clamping forces of 2200 and 2800kN.
The aforementioned requirement for an increased number of cavities (flower pot from 4 to 6/bottle cap from 48 to 64) has been achieved through an expansion of the clamping forces and greater tie-bar distances. As such, the distances are up to 20% greater than on conventional machines with comparable clamping forces.
The new performance data is also impressive. Even the dry cycles fulfil every need, with 1.3 seconds for the ELION2200 and 1.4 seconds for the ELION2800 setting new market standards. Injection performance, which constantly has to be first rate for the applications mentioned, is easily achieved with peak values of 1,100mm/sec for the 2000 injection unit and 1,400mm/sec for the 2900 injection unit. The most important data is listed in the table below.
Netstalʼs philosophy has always been to use state-of-the-art technology to achieve the best possible levels of performance and energy efficiency. In the case of high-performance applications, which typically include thin-walled packaging and caps as well as high-precision technical parts and medical products, choosing a suitable drive concept is decisive. Thanks to the hybrid drive technology, the combination of an all-electric clamping unit and hydraulically driven injection unit creates optimum framework conditions. As a consequence, the ELION2200-2000 and ELION2800-2000 models being unveiled at the K trade fair use up to 30% less energy than conventional drives.
Expanded ELION clamping unit "“ established concept incorporating new innovations
Development of the new all-electric clamping unit with clamping forces of initially 220 and 280 tons, and subsequently 350 and 450 tons, has focussed on the tried and tested ELION toggle lever concept. The toggle lever is moved by an electric servo motor via a crankshaft. This technical layout ensures that force is applied centrally and guarantees maximum rigidity over the whole clamping unit. Expansive moving platen linear guides additionally contribute to a high level of stability and precision. This minimises mould wear even in the case of very fast cycles and long production runtimes, in turn ensuring a constant and high degree of precision.
As is standard at Netstal, all the structural components are designed to last throughout the entire service life of the machine, an aspect also supported by the long-established, closed-loop lubrication system for the clamping unit, which features permanent oil filtration. A lubricant-free mould installation area is therefore guaranteed, which also makes the larger ELION models perfect for use in clean rooms.
Also new is the flexible ejector layout. In terms of the new clamping units, the ejector can be powered electrically or hydraulically with various forces (standard, high force1, high force 2) depending on the application and requirements. In addition, so-called booster cylinders are available specifically for cap production that increase the ejector force by a further 100kN.
Meeting individual customer needs thanks to modular design
The modular concept introduced with the EVOS range of machines has now been steadily developed for the ELION, enabling the injection moulding machine to be optimally configured for the respective application area.
Complete modularity is achieved when the available clamping forces and injection unit sizes of a range provide for all logical combinations. For this reason, new all-electric injection units are currently being developed, meaning that all-electric models with clamping forces of 220 to 450 tons will also be on offer in the near future.
Modular design affords maximum flexibility
Thanks to the so-called modular construction, in future customers can determine the layout of in-jection machine components and drive concepts to optimally meet their needs and requirements. Such components also include the unique aXos control system developed by Netstal and new on the market, which will be integrated into both the ELION and EVOS series from the start of 2011. The freely-programmable sequences and extremely high level of flexibility offer unparalleled user friendliness.
Conclusion
The introduction of the high-performance and energy-efficient hybrid ELION2200 and 2800 is once again evidence of Netstalʼs technological leadership and innovation capability. Both models are sure to become standard items in the field of high-performance injection moulding applications, consequently laying down a further milestone in the market "“ well and truly in line with the Netstal motto, "one step ahead!"
» Download: Foto: ELION hybrid
» Download: Foto: Technische Vergleichsdaten / Comparative Technical Data
» Download: Foto: Baukastensystem / Modular System