Precise. Productive.
Energy efficient.
The all-electric AX Series
Engineering Passion
2
Machines in the AX Series
Facts and figures
Facts and figures regarding the all-electric AX Series
Application areas
Automotive industry
Electrical engineering/
electronics industry
Consumer goods
Medical/pharmaceutical
industry
Clamping/injection matrix
Machine/
clamping
force in to
Clearance
(hxv) in mm
AX 50
410 x 360
AX 80
460 x 410
AX 100
460 x 410
AX 130
510 x 460
AX 180
560 x 510
AX 230
610 x 560
AX 280
730 x 660
AX 350
810 x 730
Injection units (screw diameter in mm)
SP 55
SP 100
SP 180
SP 380
SP 750
SP 1400
SP2000
15 18 20 22
20 22 25 28
25 28 30 35
30 35 40 45
40 45 50 55
55 60 70
60 70 75
3
The all-electric AX Series
The AX machine concept includes a large modular
kit for many different applications and is therefore
ideally suited for a large number of industries. From
50 to 350 tonnes, the AX Series will always provide
you with the right machine combination for your
demanding applications. Every AX machine can
be precisely equipped from an extensive range of
plasticizing units, automation units and options.
Highlights of the AX Series at a glance:
Precise thanks to:
–Direct operating principles
–Highly accurate servomotors
–Intelligent closed-loop control system
Productive thanks to:
–Short dry cycle times
–High availabilities
–High process reliability
Energy efficient thanks to:
–Smooth-running mechanical system
–Highly efficient drive technology
–Intelligent energy management
Transparent technology
Tour of the all-electric AX injection
molding machine
Flexible, fully integrated
automation
Extensive options
catalog
5-point double toggle lever
with robust mold fixing platens
Smooth-running linear guides
Barrier-free access
5
High-end plasticizing units
Precise drive
technology
Efficient energy
management
Intelligent MC6 control system
6
Machines in the AX Series
Universal clamping unit
The universal AX clamping unit
Versatility and efficiency coupled with high precision
With clamping forces ranging
between 500 and 3500 kN, the
AX Series covers a wide range
of products. The efficient and
highly dynamic 5-point double
toggle lever coupled with intelligent servodrive technology
ensures maximum productivity
and cost-efficiency while also
providing optimum mold protection.
Stable processes thanks to quick and
precise movements
Highly dynamic and precise servomotors
move to set travel positions for the shutoff or for the ejector quickly and precisely
with absolute reproducibility.
Your advantages:
– Short dry cycle times
– High positioning accuracy
– Minimum energy consumption
– Low maintenance costs
Falling parts can therefore be ejected
safely and reproducibly, thus preventing
them from flying out. You therefore save
many OK parts and reduce, in particular,
the cycle time.
In order that the KraussMaffei robot
can demold the parts, the AX moves to
the transfer positions extremely precisely
and transfers the parts reliably to
the gripper. This always take place with
0.001 mm accuracy.
Clamping unit in open position (top) and closed position (bottom),
wide positioning range for mold height adjustment
Speed-path diagram for opening and
closing the mold
Speed in mm/s
1200
1000
v = 100%
800
600
v = 50%
400
200
v = 20%
100%
80%
60%
Opening stroke in %
40%
20%
0%
0
7
The optimized drive system is synonymous
with precise and dynamic clamping movement.
Thanks to the wide positioning range of mold
height adjustment, large and small molds can
normally be used
8
Machines in the AX Series
Universal clamping unit
The AX features large robust mold fixing platens. The moving platen is broadly supported
on linear guides. The tiebars therefore remain
free of grease
Frictionless production thanks
to optimum clamping mechanics
The play-free and smooth-running
mechanics are a prerequisite for the
efficiency, dynamism and precision
of the AX clamping units.
The kinetically optimized 5-point double
toggle lever and the play-free ball screw
(with recirculating ball bearings) jointly
produce maximum force transmission
with high speeds during opening and
closing.
The excellent smooth-running of the toggle lever is ensured at all times through
automatic central lubrication.
High degree of flexibility thanks to a
large mold fitting space
Large mold fixing platens and opening
widths permit the universal use of many
different molds.
Parallel mold guidance always clean and
efficient
The broad support of the moving plate
on precision linear guides ensures exact
mold parallelism in all positions.
The clamping unit is very stiff due to
the interconnection of the molding fixing platens from the carrier and adapter
plate.
The interchangeability of the adapter
plates enables you to choose your own
hole patterns – ideal for worldwide production use.
Rolling linear guides reduce friction
resistance compared with normal
sliding guides or column guides by up
to 80 percent.
Thanks to the linear guides, the tiebars
are only used for force transmission
and do not touch the moving mold fixing
platen in any way. There is no need for
lubrication and the product area remains
clean.
9
Wide opening and barrier-free safety gates
for easy accessibility to the mold and ejector
Ergonomic concept for easy accessibility
and use
Wide opening safety gates on the operator's side and non-operator side ensure
easy accessibility to the mold and ejector,
for example for set-up processes.
The safety gates are self-supporting and
do not have any interfering crossbars
on the housing. This makes every mold
change easier, even with a low crane
height, and part demolding by a robot is
speeded up.
In the case of falling parts, it is possible
to integrate both billet and sorting chutes
along with conveyor belts to transport the
parts underneath the clamping unit in a
transverse or longitudinal direction.
Your advantages:
- Easy accessibility
- Large mold fitting space
- High platen parallelism
- Grease-free tiebars
10
Grease-free tiebars
Changeable mold fixing platens
Drive unit for clamping unit
Mold height adjustment
Precision linear guide
Universal clamping concept for clamping forces between 500 and 3500 kN
Symmetrical force transmission ensures
optimum clamping of the mold
The tightly toleranced and totally symmetrical design of the clamping unit
produces direct and uniform force exertion on the moving and fixed mold fixing
platen.
Thanks to the composite structure of the
molding fixing platens based on a carrier
and adapter plate, forces are evenly distributed when clamping force builds up
and are introduced in parallel into the two
mold halves.
The high safety standard of KraussMaffei
is underlined by the standard secondary
brake on the clamping motor in every AX
machine. This is the only way to ensure
that mold installation under clamping
force is absolutely safe.
matically and effectively through clamping force regulation.
In every cycle the actually attained clamping force is recorded by a measuring
system and an actual-target comparison
is performed.
Automatic clamping force regulation as
a standard feature
Clamping force in the AX is regulated
exactly to the set value. Potential process
disturbances, which may occur due to
clamping force fluctuations caused by
thermal expansions, are eliminated auto-
If a deviation is registered, the clamping force is automatically readjusted by
means of mold height adjustment and
precisely regulated to +/- 2 percent.
Clamping unit closed and locked in position, symmetrical force transmission to the
moving mold fixing platen and the mold
Your advantages:
– Ideal force transmission to the mold
– Automatic clamping force regulation
– Sensitive mold area protection
– Wide range of additional fittings
11
Every AX machine can be precisely
equipped from an extensive options catalog
Practical and functional additional fittings for your mold
The extensive AX options catalog contains
practical solutions and powerful additional
functions for your individual applications
and mold technologies. Thanks to an additional and mobile hydraulic power pack,
core pulls or needle seal nozzles can be
directly programmed and controlled via the
MC6 control system. Pre-piped connections
for cooling water and temperature control
circuits are situated close to the mold, thus
making every mold connection easier and
keeping everything in order.
Self-optimizing and monitored temperature control zones for the mold hot channel or temperature control units ensure
optimum processes in the mold through
reproducible thermal conditions.
Maximum mold protection through sensitive mold area protection
The travel force applied when closing the
mold is detected and recorded exactly by
a measuring device. Every extraordinarily
occurring force path can therefore be
detected quickly and reliably.
Mold area protection can be adjusted to
up to 16 profiles. The required sensitivity
level can be assigned to every profile level
using a simple dropdown field.
If the set tolerance limit is exceeded, the
mold movement is stopped immediately.
The the mold is therefore effectively protected.
Sensitive mold area protection offers maximum protection for your mold
Force
Triggering of
emergency stop
Exceeding of
tolerance band
Detail
Time
Tolerance limit
Travel force
Reference travel force
12
Machines in the AX Series
First-class injection unit
The first-class AX injection unit
Precise and productive with maximum efficiency
In the AX injection unit, the ideal
interaction between excellent
plasticizing and precise drive
technology ensures first-class
shot weight constancy. The
AX machine reproduces parts
with the highest quality and
efficiency - shot for shot. High
availability and reliability make
it the productive leader for
every production process.
Excellent melt quality for every application
KraussMaffei plasticizing units are characterized by excellent melt quality coupled
with high plasticizing capacity, and form
the centerpiece of every AX machine.
With screw diameters ranging between
15 and 75 mm, and a large number of
high-tech, wear-resistant HPS-M mixing screws, the AX machine covers a wide
range of applications for many different
types of plastic.
In the high temperature design up to 450° C,
there are no limits to the production
of technical parts with the highest
possible mechanical, chemical and
thermal demands.
With every AX machine you obtain the
suitable plasticizing unit for your application and therefore the best possible conditions for optimum parts quality.
KraussMaffei plasticizing units are synonymous
with excellent melt quality coupled with high
plasticizing capacity.
13
The impressive features of the
AX include its excellent reproducibility and high availability
Reproducible processes thanks to
built-in precision and dynamism
The injection movement is driven by
highly precise and dynamic servomotors,
and is transmitted directly to the screw
via a play-free and directly acting spindle
system.
Thanks to their extremely dynamic
response, the motors regulate the set process parameters of speed, path and pressure in the minimum tolerance range very
quickly and precisely.
The injection pressure is measured directly
in the force flow as an absolute value by
means of a sensitive sensor. This ensures
precise regulation of holding and back
pressure.
By combining extreme repeatability and
optimum plasticizing, the AX machine
offers ideal conditions for first-class shot
weight constancy.
First-class shot weight constancy
Grams
Grams
24.48
24.4690
24.46
+/- 0.001 g
24.4680
24.44
24.4670
24.42
0
40
80
120
160 Shot
80
90
Best plasticizing + absolute precision = first-class shot weight constancy
100
110
120 Shot
14
Machines in the AX Series
First-class injection unit
Configuration of the AX injection unit from
SP 55 to SP 750 / Ø 15 – 55 mm
Your advantages:
– First-class shot weight constancy
– High process reliability
– High level of productivity
– Excellent melt quality
– Low energy consumption
– High reliability and availability
– Flexible and practical use
15
Plasiticizing drive unit
Plasticizing unit with quick-change system
Spindle system
Aggregate drive unit
Injection drive unit
Precision linear guide
Configuration of the AX injection unit from
SP 1400 to SP 2000 / Ø 55 – 75 mm
Lowest energy consumption thanks
to maximum efficiency
In the AX injection unit the most efficient
drive technology comes up against the
lowest moments of inertia, thus producing
maximum efficiencies in every injection
process.
The losses are low and the effect is high
thanks to the play-free and smooth-running spindle mechanics, as well as the
highly efficient servomotors.
In particular, the most energetic process
steps, plasticizing, injection and holding
pressure are therefore highly efficient.
High reliability and stable processes
for increased productivity
Excellent reproducibility and high availability make the AX a productive high
performer in every ambitious injection
molding company.
Stable processes lead to high parts
quality, climate-related process readjustments are reduced and OK part output is
increased.
Extremely low maintenance, fast attainment
of productive phases and their reliability lead
to high availability of the AX machine.
Practical application and flexible uses
Due to the easy accessibility and visibility
of the nozzle, the AX contains ideal conditions for every mold setter.
The KraussMaffei quick change system
makes every cylinder change easy, quick
and absolutely safe thanks to automatic
screw detection.
On request, the AX can also be equipped
with adaptions to smaller screw diameters
for an even wider range of applications.
16
Machines in the EX Series
Control system
Usability is our top priority
The new MC6 control system with SplitScreen
technology and Eco function
With innovative features such as
SplitScreen technology, the MC6
control system offers you greater
convenience and usability
17
Do you get the most energyefficient machine setting?
Always! - Simply press the
Eco button
The new MC6 control system
meets all of your usability needs.
Whether you are working with a
KraussMaffei control system for the first
time or you are accustomed to its MC5
predecessor – MC6 technology is so intuitively accessible that you will work better
and more efficiently than ever before.
Everything in sight - thanks to the new
SplitScreen technology
SplitScreen technology is one of the special highlights of the MC6: Thanks to the
split-screen display, you can see the most
important production processes simultaneously. In parallel with the actual value
cycles, you can control, for example, the
injection process.
Clarity thanks to the ProcessDesigner
tool
The integrated ProcessDesigner tool
provides a clear visual presentation of
all current processes and enables you
to modify them, depending on requirements, by means of simple drag-anddrop movements or swiping movements.
Destination reached with just two taps –
thanks to a drop-down menu and a favorites bar
To ensure that handling the control unit is
as user-friendly as possible, deeper navigation levels have generally been avoided
with the MC6. Based on the credo "reaching the destination as quickly as possible",
a clear overall concept with individually
configurable favorites bars is produced.
In order to guarantee optimum use, the
machine keypad only provides the keys
which can be selected in regard to the
operating states of the machine. Our user-
friendly principle is rounded off by a special
field for selecting systems. You can therefore directly select all components of the
machine up to automation and technology.
Go Eco! Energy efficiency at the push of
a button
In keeping with our overall energy-efficient design, the MC6 control system has
an "Eco button". This allows you to configure the machine in the most energyefficient manner at the touch of a button.
Intelligent user profiles
Thanks to standardized role profiles – from
the machine operator and mold setter
through to the production manager –
you can assign different authorizations
quickly and easily. Of course, you can
also create additional hierarchy levels
and assign individual rights to users.
Another feature of the MC6 is the resistive
dual-touch function which also allows the
screen to be operated by a person wearing gloves. With the Windows 7 Embedded operating system, the MC6 is ideally
equipped for today's technologies and
those in future. The MC6 control system
can be ordered in more than 30 languages. And best of all: Every feature is
available not only with the control system,
but also on the handheld pendant.
Your advantages:
– User-friendly function principle
– Simple process control thanks to
SplitScreen and ProcessDesigner
– Clear structures
– Standardized user administration
– Two-way operation of automation
and machine possible
The MC6 control system impresses customers
with its clear overall concept. Here using ProcessDesigner as an example.
You can operate the automation both from the
handheld pendant and from the injection molding machine. And, with the MC6, even reverse
operation of the injection molding machine is
easy from the robot's hand-operated console.
18
Machines in the AX Series
Economic efficiency
Total economic efficiency
Higher productivity with lower use of resources
Sustainability through minimum energy
and water consumption
Thanks to its high overall efficiency, the
AX consumes very little energy even with
different loads and applications.
By contrast with comparable hydraulic
injection molding machines, energy consumption is often reduced by 50 percent
and more.
Due to the low friction losses, the internal cooling load and, thus, cooling water
consumption are very low and savings of
up to 70 percent are entirely normal.
Technical parts/2.0 D stroke: Throughput in kg/h (cycle time)
Hydr. IMM
Energy consumption in kWh/kg
AX Series
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
7.2 (16s)
Your advantages:
– Minimum energy consumption
– Lower water consumption
– Short cycle time thanks to parallel
functions
– Lower sound pressure level
– Low heat emissions
– Lower maintenance costs
– Higher productivity with low use
of resources
15.6 (17.5s)
28.4 (19s)
43.9 (20,5s)
65.5 (22s)
Thin-wall parts/0.5 D stroke: Throughput in kg/h (cycle time)
Hydr. IMM
Energy consumption in kWh/kg
AX Series
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0,4
0.3
0.2
0.1
4.8 (6s)
9.8 (7s)
17.1 (8s)
25.2 (9s)
36.0 (10s)
19
High availability and increased output
lead to higher productivity
The high availability of the AX is based on
the characteristics of high reliability,
low maintenance requirements and a fast
response. The AX is therefore available for
more production hours.
Cycle time comparison
Machine with serial functions
Close mold
Injection
Holding pressure
Parallel functions, for example opening
ejection during opening of the mold, are
included in every AX machine as a standard
feature and can be used without restriction. Cycle times can therefore often be
reduced by 10 percent and more. Due to
its high precision, the AX ensures stable
processes and reliably produces a higher
number of OK parts.
Plasticizing
Cooling
Open mold
Evaluation
12.2
12.2s s
Cycle time
AX Series with parallel function
Low emissions produce a pleasant climate.
AX machines ensure a pleasant working
climate in every company. Compared with
conventional hydraulic injection molding
machines, sound emissions in the AX are
reduced by more than 5 db(A).
Close mold
Injection
Holding pressure
Plasticizing
Cooling
Open mold
Evaluation
10.8 s
Cycle time
0
1
2
3
4
5
6
7
8
9
10
11
12
Saving
Thanks to the high efficiency of the
mechanics and drive technology, the heat
emissions to the external environment are
very low. This is very important, especially
in air-conditioned production, for example
in cleanrooms.
20
Machines in the AX Series
Automation solutions
The economic production cell
Competent automation solutions from a single source
KraussMaffei offers you complete automation solutions from
a single source that match
the AX Series. From universal
linear robots and well thoughtout gripper solutions through
to turnkey automation cells,
the AX can be completed with
numerous automation tasks
and therefore extended to
become a flexible and economic
production cell.
Maximum mobility thanks to modular
design
The linear robots in the LRX Series are
perfectly suited for typical pick &
place solutions with fast demolding. If
required, the LRX robots also perform
other tasks in the injection molding process: insertion, demolding, processing
and many more besides.
A suitable linear robot with adapted axis
lengths and manual axis combinations
are available preconfigured for every
clamping force. A large number of other
axis designs, extensions and manual axis
combinations make the LRX extremely
mobile.
More room thanks to a compact production cell, linear robot integrated in the AX
The optionally available production cell
is the ideal solution for economic part
demolding.
More OK parts in a short space of time
increase your productivity
Matching the AX Series with servomotors, parallel movements of all
servoaxes and early entry in the LRX
substantially reduce the mold open time
and allow short demolding times of less
than 1 second. Highly precise gears and
robust mechanics ensure high repeatabilities of +/- 0.1 mm even at high travel
speed.
The AX safety enclosure has been
extended to accommodate the conveyor belt and also helps to protect the
robot. As a result, there is no need for
an additional robot safety fence or the
safety gate. Compared with traditional
safety enclosures, this compact concept
reduces the production area by around
25 percent.
If the safety gate on the operator's side
is opened, the conveyor belt also moves
sideways and the operator has free
access to the mold.
The ServoFloat function also ensures
careful demolding, even for filigree
parts, and therefore increases OK part
output.
Linear robots in the LRX Series (payload)
Clamping
force
kN
LRX 50 (payload: 5 kg)
LRX 100 (payload: 10 kg)
X
[mm]
Y
[mm]
LRX 150 (payload: 15 kg)
X
[mm]
Y
[mm]
Z
[mm]
500
420
1000
1500
–
800
420
1000
1500
550
1000
420
1000
1500
550
1300
620
1000
1500
550
1800
620
1200
1500
550
1200
1500
–
2300
–
–
–
550
1200
2000
900
2800
–
–
–
550
1200
2000
900
3500
–
–
–
–
–
–
900
LRX 250 (payload: 25 kg)
Z
[mm]
X
[mm]
Y
[mm]
Z
[mm]
X
[mm]
Y
[mm]
Z
[mm]
–
–
–
–
–
–
–
–
1200
1500
–
–
–
–
–
–
1200
1500
–
–
–
–
–
–
1200
1500
–
–
–
–
–
–
–
–
–
–
–
1400/T
2000
–
–
–
1400/T
2000
900
1500/T
2500
1400/T
2000
900
1500/T
2500
21
Your advantages:
– Short cycle and demolding times
– High OK part output thanks to safe
demolding
– High machine and personal safety,
CE conformity
– Smarter programming operation with
WizardX
– Integrated control system with central
operating unit
– Machine and automation system as
optical and functional unit
– Flexibility thanks to numerous extension options
– Fully integrated production cell
Integrative system: The perfect symbiosis of a machine and automation
technology
The injection molding process and automation form one unit via the integrated
control system with VARAN-BUS technology. Process data are available in
real time. Programming and operation
are easy and do not call for any in-depth
programming knowledge. To permit
optimum teaching and ergonomic programming, all LRX/LRX-S machines have
a handheld pendant with a touchscreen
display whose operating steps are identical with the machine's control panel.
With the integrated solution, the entire
process can be controlled via a common
operating panel. The machine and robot
data are saved in one dataset. This also
ensures maximum data security and
excellent optimum operating convenience.
20 safety zones, of which 5 are dynamic,
increase the efficiency of the control programs.
Machine panel operates automation
(Automation)
Machine
Automation panel operates machine
AX as an integrated production cell with wider safety enclosure, LRX, chute
and conveyor belt
Work is made easier through mutual operation the injection molding machine can be controlled
by the automation handheld pendant - and vice
versa
22
Machines in the AX Series
Further information
Further information
which might also interest you
Are you looking for a suitable
automation solution for your
AX machine or do you want
further information about our
core competence, plasticizing?
You can read more here:
– Linear robots in the LRX/LRX-S Series:
Basic modules for economic production cells
– The perfect plasticizing system –
satisfy complex requirements
You can find our brochures and flyers on other
topics online at: www.kraussmaffei.com.
On request, we will also be pleased to
send you the information and technical
data for our products free of charge.
23
KraussMaffei
A strong brand in a unique global group
Cross-technology system and
process solutions
Whether in Injection Molding, Reaction
Process Machinery or Automation – the
KraussMaffei brand stands for pioneering and cross-technology system and
process solutions in plastics processing
worldwide. For decades, our expertise,
innovative ability and passionate commitment to plastics engineering have been
your competitive edge. As a cross-industry system provider, we offer you modular
and standardized systems as well as
solutions customized to your needs.
There for you around the world
With our worldwide sales and service
network, we offer our international
customers an excellent basis for a
successful business relationship. Due
to the close proximity to our customers,
we are able to answer your individual
inquiries very quickly. We work out the
best possible technical and economical
solution for your product and production
requirements together with you. Test our
machine technology for your applications
and let our experts put together an individualized service package for you.
KraussMaffei Group
Comprehensive expertise
Individualized service
Our employees from customer service,
application technology and service help
you with your questions and needs on
every topic dealing with machines, systems and processes – around the globe,
quickly and with a high level of expertise.
We have developed an extensive customized service spectrum with our lifecycle
design, which accompanies you throughout the entire lifecycle of your machines
and systems. Take advantage of the personal interaction and flexibility we offer
in our practically oriented seminars.
We carry out customer-specific trainings
either at your location or at our sales and
service locations.
You can find additional information about
KraussMaffei at: www.kraussmaffei.com
Unique selling proposition Technology3
The KraussMaffei Group is the only provider in the world to possess the essential machine technologies for plastics and
rubber processing with its KraussMaffei,
KraussMaffei Berstorff and Netstal
brands: Injection Molding Machinery,
Automation, Reaction Process Machinery
and Extrusion Technology.
The group is represented internationally
with more than 30 subsidiaries and over
ten production plants as well as about
570 commercial and service partners.
This is what makes us your highly skilled
and integrated partner. Use our comprehensive and unique expertise in the
industry.
You can find additional information at:
­www.kraussmaffeigroup.com
The KraussMaffei Group has a global presence.
Countries ­with subsidiaries are marked in dark blue.
In the white-colored regions, the Group is represented
by over 570 sales and service partners.
The AX machine is our response to your questions
for economic part production.
Precise. Productive. Energy efficient.
The all-electric machines in the AX Series ensure
reproducible and reliable molding with minimum use
of resources. Smooth running and robust mechanics in conjunction with efficient servomotors and an
intelligent closed-loop control system ensure high process reliability along with high availability and excellent
machine efficiency.
This makes the machines in the AX Series reliable
and energy efficient high performers in the ambitious
and cost-conscious injection molding company now
and in the future.
www.kraussmaffei.com
1.0 WE . 2 nd edition 08/13. IMM 102 A BR 08/2013 EN ··· KraussMaffei reserves the right to make technical changes ··· Printed in Federal Republic of Germany.
Precise. Productive. Energy efficient.
The all-electric AX Series