Injection Machines produce thin-wall precision parts.
Press Release Summary:
Rated at 165 and 275 tons, all-electric Roboshot SiB Machines offer 17-385 tons clamp force. When equipped with 18 mm screw, Roboshot 165 can inject as little as 0.63 oz at over 35,550 psi with max velocity of 13 ips and rate of 5.1 in.³/sec. Equipped with 32 mm A barrel/screw combination, Roboshot 275 delivers shot size of 114 g with 39,816 psi pressure at max speed of 13 ips and rate of 16.2 in³/sec. Windows CE-based control provides operator interface and custom menu.
Original Press Release:
New 165- and 275-ton Roboshot Injection Machines for Thin-Wall Precision Parts Deliver Small Shots at High Speed/Pressure
Validation to FDA requirements available as option on all Roboshot models
June 2005 - Two new Roboshot SiB injection machines, rated at 165 and 275 U.S. tons, have just been introduced to provide ultra-high-performance injection for precision medical, mobile phone, cosmetics and automotive parts. Combining a rigid clamping system with high-pressure injection capability as standard features, both the 165 and 275 Roboshot models deliver the performance needed for tight tolerance molding with large molds and small shot sizes. When equipped with an 18 mm screw, the new Roboshot 165 SiB-m can inject as little as 18 g (0.63 oz) at over 2450 bar pressure (35,550 psi) with a maximum velocity of 330 mm/sec (13 in./sec.) and a rate of 84 cc/sec (5.1 cu. in./sec).
"The performance of these machines is ideal for micro molding, using all the advantages of the all-electric platform for extreme high-pressure parts," says Roboshot Product Manager Kent Royer. "Most significant is the Roboshot injection unit's ability to accelerate with an astonishing force of 0.86g's. This is achieved by using a low-mass, high-power injection motor, recently developed by Fanuc, the world leader in servomotor technology, which has produced more than 22,000 Roboshot machines to date."
Often compared to a supercharged automotive engine, "the new injection motor gives the Roboshot the fastest acceleration in the industry for an all-electric machine, while offering positioning and pressure switch-over capability superior to a hydraulic machine," Royer adds. "Hydraulic machines equipped with accumulators can accelerate quickly, but it is also difficult for them to stop because of the inertia. When the Roboshot's motor changes speed and position, everything is precisely controlled because of the mechanical linkage of the rigid ballscrew/motor combination. With microsecond velocity profiling at high speeds, the processing window opens up wider to give tighter processing capability leading to reduced scrap."
The Roboshot 275 equipped with the 32 mm "A" barrel/screw combination can provide a shot size of 114 g with 2746 bar pressure (39,816 psi) at a maximum speed of 330 mm/sec (13 in./sec.) and rate of 265 cc/sec (16.2 cu.in./sec).
Generous tie-bar spacing and max/min mold-height specifications on both machines provide exceptional flexibility for handling the tooling required for high-performance molding, including automation. The 165-ton machine offers tie-bar spacing of 510x510 mm (20x20 in) and platen size of 750x750 mm (29.5x29.5 in). The 275-ton Roboshot provides tie-bar spacing of 710x710 mm (28x28 in) and platen size of 1030x1030 mm (40.6x40.6 in). Both models have optional increased tonnage and long tie bar options that provide extended capability.
"These Roboshot models fill specialized roles, predominantly in medical molding, cosmetics, mobile phone and connector industries," said Milacron Marketing Director Bob Strickley. "Thin-wall, precision parts require more steel in the mold cavities and a high performance clamp, matched with clean, oil-free operation to eliminate any contamination hazard. Precision molders have requested these sizes, as well as others, in the Roboshot series of machines. As standard models, these machines carry the advantages of a proven design that leads the market in North America and Asia. They further extend the capabilities of the Roboshot to the new performance level North American molders are pursuing for global competitiveness."
The SiB machine platform
The all-electric Roboshot SiB series combines new servo technology, 10X faster control updates, a reduced-inertia injection unit and new advanced artificial intelligence (AI) capabilities for the highest "robotic" consistency and ease of operation. SiB models are available with 17 to 385 U.S. tons clamp force. With 0-to-330 mm/s injection acceleration times of 27ms, the SiB series' performance is ideal for molding thin-wall and precision parts. The Roboshot can provide reduced cycle time with overlapped functions and AI control for mold/ejector protection and metering/injection, making the SiB ideal for high-production, "lights out" molding of medical devices, gears and packaging products. "Many installed Roboshot machines in North America operate in a 'lights out' environment," Strickley added
Artificial Intelligence features and control
SiB models add significant new AI features enhancing Roboshot's operational saving capabilities. New AI Ejector Protection and enhanced AI Mold Protection reduce tool damage costs. Roboshot's patented AI Mold Protection has been refined to a new level by dividing the mold closing-force profile into three zones, allowing separate high-force limits to be set for each zone. This enables tighter mold protection and minimizes false alarms in a zone of normally low closing force, while increasing the alarm limits where the clamp must overcome sticking cores or pins.
AI Ejector Protection functions in a similar way, learning the ideal ejector-force profile by monitoring the load on the eject servomotor. A high-load "band" is set around this profile, and if ejector force exceeds this safe range, the cycle stops instantly. The system is so sensitive it can be used to pass/fail part quality by detecting over-packing and flash conditions.
The AI Metering Function "learns" an ideal recovery cycle, and then modulates screw RPM to achieve repeatability of ±0.2 sec or less on every cycle. Used in conjunction with AI Pressure Profile Control, part weight variance is nearly eliminated, even when using regrind blends. The operator can tune AI Pressure Profile and Metering, and profiles can be transferred from one Roboshot machine to another to duplicate molding performance.
A new Windows CE-based control offers a new operator interface layout with multiple ways to "jump" to any screen, and a "custom menu" feature that allows operators to create a personalized menu. A 12-operator ID log with password provides additional tracking capability on the production floor.
Networked with the optional Mold 24I software package, the current Roboshot line-up, as well as previous generations, can provide the customer with complete process and production tracking capability for ISO or FDA requirements.
Injection unit temperature control
Roboshot SiB machines now feature a new injection unit temperature-control system that improves molding stability by holding variation to ±0.2°C or less. A synchronized barrel/nozzle heat-up function offers faster heat-up times, while minimizing black speck problems caused by overheating. Additionally, Milacron can provide its WEARSTAR or KLEARSTAR injection packages for high wear materials and optical products, along with other application-specific screws and barrels to further enhance performance.
Wide range of options
SiB machines are designed for simple interface to Fanuc's SR Mate robots for part removal, insert molding, gate cutting and palletizing. Other options include air eject and productivity-enhancing pre-injection. Pre-injection (injection before full clamp tonnage is achieved) helps eliminate gas burn and short shots through improved mold venting. It also delivers a uniform "coining" pressure to the part, improving surface consistency and helping minimize warp/sink marks.
To see the full range of Roboshot and other Milacron plastics processing technologies, visit plastics.milacron.com on the web.
Sales inquiries from the NAFTA region should be directed to:
English
Sherry Kinzie
Milacron Marketing Company
4165 Halfacre Rd.
Batavia, OH 45103
Tel: 513.536.2370
Fax: 513.536.2441
Sherry_Kinzie@milacron.com
