The new all-electric IntElect: More compact, more dynamic, more precise and more efficient

Die neue vollelektrische IntElect benötigt weit weniger Aufstellfläche, arbeitet dynamischer, präziser, wirtschaftlicher und effizienter als ihre Vorgängermodelle und erhält als äußeres Merkmal dunkelblaue Verkleidungen. (Foto: Sumitomo (SHI) Demag) / The new all-electric IntElect with its brand-signifying navy cladding has a significantly smaller footprint and is more dynamic, precise and efficient than its predecessors. (Photo by Sumitomo (SHI) Demag)

Sumitomo (SHI) Demag Plastics Machinery GmbH of Schwaig near Nuremberg presents the new “IntElect”, a completely new generation of all-electric injection moulding machines. Developed in cooperation with its parent corporation Sumitomo Heavy Industries (SHI) and powered by a brand-new generation of highly dynamic drive motors, the new IntElect combines top-level performance with an outstanding energy footprint. Constructive innovative features reduce the space requirements and improve accessibility, ergonomics and machine precision. The new IntElect was presented in all its details at the in-house fair at the manufacturer’s production site in Wiehe/Germany on the 10th and 11th May. Particularly interesting for manufacturers of structural precision components and of industrial and optical parts, it significantly reduces the price difference between hydraulic and all-electric machines. The specialist’s objective is to enable a ROI in less than one year for all-electric applications while providing the complete range of options.

Following the successful demonstration of 500 kN model at the “K” flagship fair in October 2016 in Düsseldorf, the new and complete machine series is now available, featuring clamping forces of 500, 750, 1,000, 1,300 and 1,800 kN. An expansion of the new IntElect series both in terms of clamping force and distance between tie bars, the new 1,800 model closes the gap between large and mid-size IntElect machines. Moulders benefit from the series’ extensive modular range and additional intermediate size, which provides perfectly adapted machines with up to five different screw diameters for each injection unit.

The control cabinet is integrated into the machine base of the IntElect machines, freeing up plenty of space for downstream equipment and ensuring easy access to the nozzle area and the complete clamping unit. With its new design, the IntElect has a significantly smaller footprint than its predecessors: on average, the set-up area is 10 % less than that of comparable all-electric competitors. Even the smallest model with a clamping force of 500 kN is half a metre shorter than its predecessor.

The Sumitomo corporation has already delivered more than 60,000 all-electric injection moulding machines and produced the relevant drive technology in-house. This tried-and-tested technology and the extensive practical experience accumulated over decades of manufacturing machines for moulders all over the world has been brought to bear on the latest, revised motor generation that powers the new IntElect machine series. Minimum scanning times for the injection unit, clamping unit and ejectors ensure perfect interaction of all drive train components. Included as standard, the axle controller, perfectly tuned motors, frequency converters and machine control systems deliver an outstanding drive system that is geared towards top dynamics, precision and repeatability.

Updated motor technology and extended memory capacity for brake energy provides the groundwork for a significant optimisation of all IntElect machines, resulting in 20% savings on comparable all-electric machines.

Important elements of the machine concept include sensitive mould protection and maximum mould support. In addition to this, IntElect machines offer a whole array of different options ranging from standard profile monitoring functions to mould protection force right through to ejector and injection pressure profile monitoring. The machine’s top-of-the-range linear guide ensures maximum platen parallelism right down to the symmetric application of nozzle system force. A new FEM-assisted design of the platens improves production safety, while the stiffness of the moving and stationary platens was significantly increased by up to 30 %.

In addition to the standard version, the electric ejector packages are available with additional force and/or speed. The NC5 plus control system comes equipped with the new capacitive glass colour touchscreen with the improved brilliance and sharpness of a smartphone for safe, intuitive and comfortable operation.

A readily spotted signifier of the global platform, the IntElect’s cladding has a new navy colour, which is available as an additional standard – consistent with the Japanese machines. The optimised design of the machine surfaces ensures easy cleaning, particularly for clean-room applications.

Developing the new machine series, the manufacturer focused on cost-efficiency and a compact footprint. Thanks to the electric drives, which are manufactured in-house, specially developed and continually optimised for injection moulding machines, this machine serie’s already keen price/performance range has been made even more attractive. “We aim to be truly innovative. This means that the new IntElect does not have a random price, but the price of five years of ongoing work with the objective of building a more compact, more productive and more efficient new IntElect,“ CEO Gerd Liebig explains. “We reduced the price gap between these all-electric and hydraulic machines and can now offer an improved machine series that delivers perfect cost-efficiency and a ROI in less than one year. The demand for the first pilot machines from our customers is very promising: they are almost sold out.“