All-electric. IntElect. Maximum E ciency – Highest Precision
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All-electric. IntElect. Maximum Efficiency - Highest Precision

The IntElect Technology, competence and experience. With more than 65,000 electric injection moulding machines delivered around the world, Sumitomo (SHI) Demag sets the benchmark in electrical machine engineering. Our goals are maximum dynamics, the highest level of efficiency and 100% production quality along with full mould safety. Being the only European manufacturer of electric injection moulding machines, we design and produce all the core electrical drive components in our company. This is the only way the IntElect can achieve maximum dynamics and precision with the highest level of...

The IntElect Your benefits at a glance. – Company developed drive technology In our in-house research & development centre we develop, manufacture and test our direct drives and converter technology as well as control system components all of which are designed to be used specifically in injection moulding machines. This allows the highest level of dynamics with maximum precision and efficiency and thus the highest repeatability. – Intelligent machine design Thanks to the high level of expertise in the field of electric drive technology, the complete control system of the machine can be...

– Comprehensive mould safety The new CentrePressPlaten have been designed using finite element analysis. This provides up to 20% more platen rigidity and, in combination with linear guides and other design components, guarantees a high degree of mould safety even with higher mould weights. – Intuitive control The intuitive control of the IntElect provides a variety of options for process monitoring and control. The intuitive and easily programmed control with predefined flexible machine sequences allows the user to fully utilise the IntElect’s flexibility and effi

Efficiency Application-based motor design. Up to 20% less energy consumption Up to 10% more production capacity The combination of company developed drive motors and frequency converters as well as the entire servomotor control system allows us to produce one of the most efficient injection moulding machines on the market. Compared to conventional full-electric injection moulding machines, the IntElect consumes up to 20% less energy. Higher production capacity is possible due to an on average two percent higher machine availability which combined with dynamic, precise and parallel movements...

In-house development for drive technology In our in-house research and development centre we develop the best direct drives for injection moulding machines. Our research involves various topics, including magnetic flux analysis, thermal stress simulation, materials analysis and the overall production process, therefore we can provide drive motors which are specifically designed for the requirements of injection moulding machines. This level of dynamics, precision and efficiency cannot be achieved with standard drive motors. Since the direct drives as well as their controls are precisely...

Parts quality Meeting the highest quality requirements. The tightest process window Long-term production stability Due to the use of direct drives, mechanical tolerances are minimised. Compared to other drive technologies, significantly fewer components are within each other’s force flux. In addition to the sophisticated control technology and additional efficiency components, this forms an important basis for achieving the highest precision. Due to the longstanding experience in the construction of electric injection moulding machines in combination with the IntElect’s individual drive...

Dynamic injection movements With the combination of high dynamics and speed, the IntElect allows process applications that cannot be achieved with other full-electric injection moulding machines. Due to the unconditional precision and repeatability, the IntElect will allow a wide range of demanding applications. Not only high accelerations, but also fast deceleration both are an essential prerequisite for high quality of parts. For instance, it is possible to consistently avoid burrs during injection by very rapid switching from injection pressure to holding pressure. Diagram: Dynamics of...

Parts quality Additional efficiency components. activeLock Quality assurance activeLock ( IntElect) Standard non-return valve Due to our activeLock technology, it is possible to reduce shot weight fluctuations by up to 60%. The switchable non-return valve prevents the melt from flowing back into the plasticizing cylinder at the beginning of the injection phase. This ensures that your injection moulded parts can be produced with the highest quality. Diagram: Shot weight distribution per cycle HIGHEST PRECISION. Injection cycle

activeFlowBalance Quality assurance Part weight in shot [g] — activeFlowBalance — without activeFlowBalance Due to our ActiveFlowBalance technology component, it is possible to balance filling fluctuations in injection moulds. In doing so, the negative effects of uneven mould filling are compensated for and a uniform moulding quality is achieved when multiple cavity moulds are used. This reduces the reject rate and increases the quality of your parts. Diagram: Weight distribution in the individual cavities for an injection process

Mould safety Quality with full safety. Monitoring with profile Maximum platen parallelism IntElect protects your investment in every respect. Our active mould protection system activeProtect uses a specially developed mould protection sensor and software which by means of an envelope curve monitors the force flux during the closing movement. This allows the machine to detect even the smallest objects and your mould is perfectly protected. Additionally, it is possible to monitor the force of the ejector and the injection pressure curve of the machine. This guarantees maximum protection even at...

Clamping plates with 20% higher rigidity The new mould platens (CentrePressPlaten CPP) of the IntElect have been precisely optimised for the application by means of the finite element analysis. Conventional platens can deform during locking, depending on the type and shape of the mould. This deflection is transferred to the injection moulded parts by the mould. Our platens (CPP) intelligently distribute forces in the platen and thus offer up to 20% more rigidity than conventional clamping plates. Fig. Force flux and pressure distribution in a conventional clamping plate Fig. Force flux and...