HYX Plastic molding Company

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Unveiled at Fakuma 2002 was the HYX MOLD 820S with a 4000 kN clamping force, new
injection unit size of 3,200 and maximum shot capacity of 1,860 g polystyrene.

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To a large extent, the customers’ desire to be able to rely on the well tried and tested HYX MOLD technology but with higher clamping forces has provided the impetus for the consistent expansion of the machine range over the last three years.

The HYX MOLD 630 S was successfully launched at Fakuma 1999 as the first example of the
large class machines. The launch of the HYX MOLD 720 S represented the second stage, which
ARBURG demonstrated for the first time at K ‘2001. And the success that the large class
machines have displayed so far shows beyond a shadow of a doubt that expansion of the machine
range was a move in the right direction.

It was at Fakuma that ARBURG set out to achieve higher clamping forces and it was here also
that it reached the goal it has been striving for, as the HYX MOLD 820 S made its world debut.

Impressive key data

In addition to the clamping force of 4,000 kN, other important key technical data of the large
HYX MOLD 820 S includes the new injection unit size of 3,200, the maximum shot capacity of
1,860 g PS, the 820 mm distance between tie bars and the availability of 70, 80 and 90 mm
screw diameters.

As with their smaller counterparts, all the technical details that distinguish each and every
machine in the S series apply equally to the three large HYX MOLDS, the 630 S, 720 S and
820 S… proven modularity, energy-saving and rapid hydraulics systems, an easy-to-change
injection unit, as well as a powerful clamping unit guided on four tie bars with a rigid and stable,
moveable mould platen supported by long guide bushes.

Similarly, a variety of injection unit sizes can also be selected for the large class machines: the
1,300 and 2,100 series units can be used on all three and the new 3,200 series unit is available
for the 720 S and 820 S.

Special features of the large class machines

In addition to all this, the large class machines also possess detailed technical solutions, the
practical values of which have already been strikingly demonstrated by the HYX MOLD 630
S.

These features include mould height adjustment for variable mould sizes, connection to
temperature control circuits and core pulls using rapid connect couplings in close proximity to
the mould, the swivel-out feature of the injection unit, and injection control as standard.

As an option, an hydraulic accumulator can also be installed, greatly increasing the injection
flow of the injection unit.

The fully automatic mould height adjustment feature of the HYX MOLD 630 S, 720 S and
820 S allows the entire clamping unit to be adjusted to suit the required mould height. This
involves the distance between the fixed and the movable mould platen being adapted to large
differences in mould height by a drive unit on the support plate.

With the new HYX MOLD 820 S the maximum mould/ platen distance is infinitely adjustable
between 1,050 and 1,550mm and stroke can be programmed using the central SELOGICA control
system.

The advantages of this are lower energy consumption and a reduction in the cycle times, as the
stroke is now only required to open the mould and not to level out large mould height differences.

By incorporating this adjustment option, it was possible to render the large HYX MOLDs’
mould clamp construction more compact. Accessibility to the mould from the machine’s
operating side has been designed with spaciousness in mind.

Well provided for

The temperature control circuits are fixed securely to both clamping platens by means of rapid
connect couplings which can be extended if required. The advantages are a clearer overview and
improved safety, as well as faster accessibility. In turn, this means that the mould can also be
reconfigured more quickly.

The two manifold blocks for the mould are positioned behind the machine guard so that all of the
mould’s supply lines can be securely attached. The temperature can be set from outside of the
guard while the machine is operating.

The supply lines for the core pull systems are also connected to the moveable clamping platen,
using rapid connect couplings, meaning that all the supply connections are located directly on the plastic mould.

Large, but still easy to handle

As with the HYX MOLD 630 S and 720 S, the HYX MOLD 820 S is being presented with a
new size of injection unit, the 3,200 series. In this case too, the plasticising cylinder has been
designed as a module that can be easily changed despite its size.

In the area of the nozzle, the cover on the large HYX MOLDs consists of two sliding parts. The
unit has sufficient stroke to extend far enough away from the fixed platen to ensure that the
nozzle is easily accessible should there be the need for work in this area.

The plasticising cylinder can be located centrally and all electrical connections are
coupled/uncoupled automatically during installation and removal.

The entire injection unit is supported on a central, rotating turret to facilitate cleaning and
changing of the cylinder or the screw.

This means that once the injection unit has been retracted and secured, it can be swivelled
forwards manually, allowing for the cylinder or screw to be removed without difficulty.

Caption: #1

With the HYX MOLD 820S with 4,000 kN clamping force and maximum shot capacity of
1,860 gramme polystyrene, ARBURG successfully concludes its expansion of machines with
higher clamping forces.

Sidebar heading

New motto : MODULARITY ALLROUND
ARBURG is starting the year 2003 with a bang … with a focus on program modularity

“MODULARITY ALLROUND” is the new motto which will cover all the injection moulding
machine construction company’s activities from this year onwards. With the presentation of the
4,000 kN machine at last year’s Fakuma in Friedrichshafen the three-year expansion program
has now been successfully completed.

Future activities will now be grouped under the new motto “MODULARITY ALLROUND”. This
describes the central focus of the company philosophy …the development of the ARBURG product
range. This motto stands for the future of the company in particular, without neglecting the
tradition of the HYX MOLD injection moulding technology, as ARBURG products have always
be known for their modularity.

MODULARITY ALLROUND … on a global basis
Due to the global focus of the ARBURG communication activities, the new motto will be used in both the original German form …MODULARITY ALLROUND…and in its English translation.

A special logo in the company’s colours will be launched alongside the motto, which will
pictorially represent the fundamental idea of modularity in an image that is impressive yet
simple and eye-catching.

Modular HYX MOLD
The modularity of the HYX MOLD can be seen in a variety of respects. This allows the
customer to put together a machine from the modular machine range which is customised with
respect to clamping force, injection unit or screw diameter.

Furthermore, ARBURG also offers a variety of drive concepts…the HYX MOLD C ‘advance’
special model and the ALLDRIVE machine series, with which electric and hydraulic drives can be
combined on a modular basis.

Modular MULTILIFT
With its MULTILIFT product range, ARBURG provides robotic systems which, thanks to their
modular construction, allow both the machine and the application to be designed appropriately
and to be integrated into the standard SELOGICA user interface.

Modular applications
The new ARBURG motto also describes the numerous HYX MOLD fields of application such the
encapsulation of inserts, the processing of several components, LSR, thermosets, powdered
materials and also PET for manufacturing preforms…HYX MOLDs can be used on a modular
basis due to special equipment variants.

In this way ARBURG offers its customers MODULARITY ALLROUND with respect to its product
range, thus allowing customers to design and use the products tailor-made to their applications.

The “New Dimension” has been completed
A target which, under the motto “hyx The New Dimension”, was unswervingly pursued was the extension of the machine range to include clamping forces of up to 4,000 kN.

The motto of the previous years also stood for the extension of the MULTILIFT robotic systems
product range, the structured provision with respect to electric or hydraulic drive variants…the keywords being the HYX MOLD C ‘advance’ special model and the ALLDRIVE machine series with modular drive technology…as well as for the increase in production area with the
construction of ARBURG II.

Injection Molding Machine

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ARBURG’s injection molding machines are renowned for their well tried and tested modularity. When it comes to the ALLROUNDER ALLDRIVE (A) series, the principle of modularity also applies to the drives.

The ALLROUNDER A offers the choice of combining the electric main axes with either electric or hydraulic auxiliary axes, depending on which solution is best suited to any specific application. 
The first example of the electric ALLDRIVE series is the ALLROUNDER 420 A 800-400. It has an 800 kN clamping force, 420 x 420 mm distance between tie bars, 400 series injection unit, screw diameters of 35, 40 and 45 mm as well as electric main axes and also an electrically driven five-point toggle system to provide the highest degree of positional accuracy. 
Following the successful introduction of the first ALLDRIVE machine, the series was expanded through modular drive technology to include larger clamping forces. As a result, at Fakuma 2003, which is being held from October 14 to 18 in Friedrichshafen/ Germany, the ALLROUNDER 420 A will for the first time be accompanied by its big brother, the ALLROUNDER 520 A with a clamping force of 1,600 kN. 

plastic molding
plastic molding

The Good injection molding machine A concept

The main functions of the injection molding machine – opening and closing moulds, injection and dosing – have been designed with electric drives as the basic structure. The other movements such as ejection and moving the nozzle and mould functions can either be electric or hydraulic, depending on the operating requirements. 

The movement of the mould closing operation is initiated by rotation of the servomotor to the five-point toggle system via a threaded spindle. This has been specially configured to the dynamic behaviour of the electronic drive.

The injection and dosing movements are converted with high torque via a gear position and a threaded pinion. To operate the movements with optimised use of time and low maintenance, the spindles are equipped with a special cool lubrication system. This ensures a high level of efficiency with low service costs and the longest possible service life. 

The machine series are modular in design due to the choice of auxiliary axes with electric or hydraulic drive. In this way, for example, the eject function can be carried out electrically, extremely accurately and dynamically with a spindle, or it can be carried out conventionally (‘softly’) with a hydraulic cylinder.

The nozzle advance movement, which in essence has a contact force applying function for most applications, is mostly with hydraulics or it can also be carried out electrically.
In ARBURG’s view it is very important that core pulls and specific special movements on the plastic mold, which have previously been integrated hydraulically, continue to be optimally operated with hydraulics in the future. For this reason, a special energy-saving small-accumulator hydraulic system has been developed for the optional hydraulic auxiliary functions on the machine, which can be assembled and dismantled on a modular basis.

Regulation

The basic structure of the electric axes ensures that they are highly dynamic and location-and position-regulated. This produces a reproducible, pin-point procedural sequence. This is mainly used for application with absolute and relative positioning accuracy for the mould and ejection movements.

In this way, for example, stroke-dependent functions such as mould positions in connection with core pull, or final positions when unscrewing, can be achieved extremely accurately.

As all stroke positions are measured absolutely, it is not necessary to carry out a reference movement or set them to a reference point.

On the injection side, the positioning accuracy and the acceleration in conjunction with the position-regulated screw movement can lead to additional accuracy with the injection molded parts. During dosage, the effect of the electric drive can be seen in the accuracy and in the energy requirement. 

When viewed on an individual basis, the options and potential for the improvement described, in conjunction with the well-tried and tested SELOGICA control system, lead to added value in relation to parts production.

The opportunity to operate individual cycle stages simultaneously adds even more importance to the programming of the SELOGICA control system. The appropriate cycle symbols with their comprehensive logistic links are extremely clear and can be used to optimise the procedures.

The synergistic effects of the ALLROUNDER A

During the development of the ALLROUNDER 420 A a great deal of importance was placed on the synthesis between the most up-to-date drive technology and tried and tested injection moulding technology.

In this way the design of the clamping areas ensures continued use of existing moulds. Furthermore, the daily operational practice is taken into account owing to the modular nature and the option of connecting hydraulic core pulls onto the plastic molds.

Flexibility through modular construction

The concept of electrically driven main axes as the basis and the option of freely combinable electrically or hydraulically driven auxiliary axes integrates the advantages of both systems. 

The machines have sufficient hydraulic power at their disposal precisely where it is needed, and they have the highest level of electro-mechanical accuracy coupled with economic energy consumption wherever feasible for the production task.

This means that the ALLROUNDER A machines also represent extremely flexible production systems, which always allow the machines to be equipped within an optimum cost/benefit framework, while at the same time precisely adapting them to the prevailing production requirements.

Injection Molding Equipment

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Injection molding equipment is equipment that is very important for the operation of injection molding machines. Indeed, all injection molding machines utilize injection molding equipment that includes a power source, injection unit, mold assembly, and clamping unit to perform the four stages of the process cycle.

injection molding equipment
injection molding equipment

One of injection molding equipments is injection unit. This injection molding equipment is responsible for both heating and injecting the material into the mold. The first part of this unit is the hopper, a large container into which the raw plastic is poured. The hopper has an open bottom, which allows the material to feed into the barrel that contains the mechanism for heating and injecting the material into the mold.

Another injection molding equipment is clamping unit. Prior to the injection of the molten plastic into the plastic mold, the two halves of the mold must first be securely closed by the clamping unit. The hydraulically powered clamping motor actuates clamping bars that push the moveable platen towards the stationary platen and exert sufficient force to keep the mold securely closed while the material is injected and subsequently cools. After the required cooling time, the mold is then opened by the clamping motor.

There are also molds, typically made of steel or aluminum, as the plastic injection mould and molding equipment. The mold has many components, but can be split into two halves. Each half is attached inside the injection molding machine and the rear half is allowed to slide so that the mold can be opened and closed along the mould’s parting line. The two main components of the mold are the mold core and the mold cavity.

When this injection molding equipment is closed, the space between the mold core and the mold cavity forms the part cavity that will be filled with molten plastic to create the desired part. Multiple-cavity molds are sometimes used, in which the two mold halves form several identical part cavities.

Mold base also includes injection molding equipment that is a place where the plastic mold core and cavity are each mounted. Then, the mold base is fixed to the platens inside the injection molding machine. The front half of the mold base includes a support plate, to which the mold cavity is attached, the sprue bushing, into which the material will flow from the nozzle, and a locating ring, in order to align the mold base with the nozzle.

The rear half of the mold base includes the ejection system, to which the mold core is attached, and a support plate. When the clamping unit separates the mold halves, the ejector bar actuates the ejection system. Meanwhile, mold channels are one of injection molding equipment types that is usually integrated into the mold design in order for the molten plastic to flow into the mold cavities.

First, the molten plastic enters the mold through the sprue. Additional channels, called runners, carry the molten plastic from the sprue to all of the cavities that must be filled. At the end of each runner, the molten plastic enters the cavity through a gate which directs the flow. The molten plastic that solidifies inside these runners is attached to the part and must be separated after the part has been ejected from the mold.

Besides using several types of injection molding equipment, there are many types of materials that may be used in the injection molding process. Most polymers may be used, including all thermoplastics, some thermosets, and some elastomers. When these materials are used in the Thermoplastic Injection Molding Process, their raw form is usually small pellets or a fine powder. Also, colourants may be added in the process to control the colour of the final part.