Arburg: Hybrid Machine Technology
Allrounder Hidrive: Hybrid Drive System Combines Benefits Of Electrics And Hydraulics
- Expansion: Hybrid Allrounder with new machine technology in three sizes
- Hybrid alternative: Energy saving, efficient, reduced costs and carbon footprint
- Performance variants: Comfort, Premium and Ultimate – a suitable solution for all requirements
The injection moulding market is in need of modular, adaptable drive systems that can harness the benefits of both electric and hydraulic technology – namely speed and precision paired with power and dynamics. The new, finely graduated hybrid machine technology from Arburg is comparable to all-electric machines in terms of both dry cycle times and injection speeds. This makes the new Allrounder Hidrive (H) an energy-saving alternative to hydraulic machines and an economical alternative to electric machines, unlike anything previously available on the market.
The hybrid Allrounder Hidrive machines are currently available in sizes 470, 520 and 570, and combine an energy-efficient and precise electric clamping unit with a powerful and dynamic hydraulic injection unit.
Hybrid technology a hit with injection moulding companies
The new, finely graduated hybrid machine technology is comparable to all-electric machines in terms of both dry cycle times and injection speeds. The new hybrid machines also boast an optimised energy footprint and reduced cycle times, making them a perfect fit for the times: they save energy, conserve resources and at the same time are efficient in production, user friendly and reliable. In a survey of visitors to the Arburg Anniversary Days 2023, 96 and 95 per cent of respondents rated the new hybrid Allrounder 470 H milestone machine as a suitable replacement for hydraulic machines and electric machines respectively. The new machine technology is suitable for technical injection moulding as well as for demanding applications, for example in the automotive and packaging industries.
Precise electric drive technology
With subsidiary AMKmotion joining the Arburg family, the development and production of the entire powertrain can now be handled in-house. This not only applies to Allrounder injection moulding machines, including the inverter and motor and therefore the centrepiece of the closing system, but also to mould technology, for example.
The planetary roller screw drive in combination with liquid-cooled motors is ideally suited to high-end injection moulding tasks. Using this electric direct drive, which is integrated into the hybrid machines in the Premium and Ultimate performance variants, for example, all positions can be started up extremely quickly and precisely while achieving load-resistant power transmission and a high power density over a long service life – even when the machine is running at full load. Automatic clamping force regulation, which generates a consistent locking force and thus automatically compensates for the thermal expansion of the mould, is available as an option.
Dynamic hydraulic injection unit
Homogeneous material preparation and precise injection are additional prerequisites for high-quality part production. The hydraulic drives, which have been tried and tested in injection moulding for decades, are sophisticated, robust, low maintenance and durable. They are particularly well suited to high levels of material throughput and generate high forces that can be maintained during any length of holding pressure phase. Depending on the performance variant, the hybrid Allrounders in the Hidrve series combine regulated injection, dynamic hydraulic accumulator technology and an energy-saving servo-electric dosage drive to achieve a high plasticising flow rate.
Three performance variants for optimal adaptation
The hybrid Allrounder Hidrive is available in the “Comfort”, “Premium” and “Ultimate” performance variants and can be customised precisely to the respective requirements. This new generation of machines incorporates many technical innovations that are only available from Arburg. These include a new oil management concept, flow rate splitting and extended use of the Arburg servo hydraulic system.
- The “Comfort” performance variant is intended for technical, thick-walled or relatively simple moulded parts that are typically manufactured in cycle times of 10 to 45 seconds.
- The “Premium” performance variant is further optimised in terms of production efficiency, achieving a dry cycle time of 1.2 seconds. This machine can be used for a variety of demanding applications, such as manufacturing precision components for the automotive and electronics industries. Its standard equipment includes a planetary roller screw drive and the Arburg electro-mechanical dosage (AED) function for a longer dosage time. In addition, the machine features Arburg’s new flow rate splitting for simultaneous, independent movements of two hydraulic secondary axes.
- For its part, the “Ultimate” performance variant is specifically designed for demanding, high-speed processes, such as thin-walled applications in the packaging technology industry. The dry cycle times are significantly shorter than that of the Premium performance variant. The standard equipment for Ultimate machines also includes AED as well as hydraulic accumulator technology and the Gestica control system with the aXw Control ScrewPilot function, which compensates for disruptions in the filling process and stabilises mould filling. All together, this provides for a level of injection precision equivalent to that of an electric injection unit. Dosage across cycles is also possible (optional feature).
Reduced energy requirement thanks to the Arburg servo hydraulic system
All three performance variants are equipped with the Arburg servo hydraulic system (ASH). With this technology, the drive system adjusts continuously to the actual power requirement thanks to a speed-controlled, water-cooled servo motor. One major advantage of this is that when the machine is at a standstill, the pump drive also stops, meaning no more idling losses. This ensures energy-efficient, low-emission operation and yields up to 50 percent energy savings, particularly for processes with long cooling times. Depending on the specific application, the Allrounder 470 H “” can save up to 12,000 kg of CO2 per year. At the same time, the machine’s cooling requirements and noise level are also significantly reduced.
High injection speeds
The “Premium” and “Ultimate” performance variants of the hybrid Allrounders meet the highest requirements in terms of dynamics and process capability thanks to its hydraulic accumulator technology. This works with a process-optimised accumulator volume and an energy-saving charging circuit. All axes of motion can be independently controlled and driven by means of separate control valves. The hydraulic accumulator ensures a consistent pressure level. The result: quick, dynamic simultaneous movements and more process setting options, such as injection during mould closing or embossing.
Easy to operate and maintain
User-friendliness and reliability are also important criteria for the new machine in order to save time and money on service and maintenance.
Thanks to a new oil management concept, the new Allrounder 470 H requires around 35 per cent less oil. The required cooling water capacity can be reduced by up to 70 per cent. The dry cycle time is also reduced by about one third.
Predictive maintenance is an important keyword here: for example, the machine automatically reports when the oil filter is due to be changed soon. Oil filters and connections are more accessible and the mounting locations for the central lubrication system, pneumatic system and interfaces have also been optimised.
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