The ELEKTRON Series - Ferromatik · 2015. 1. 23. · THE ELEcTRIcAL cAbINET – EvERyTHING IN ITS PLAcE The electrical cabinet is integrated into the machine base. This design, with

The ELEKTRON Series 500 to 4,500 kN

ELEKTRONAll-Electric Injection Molding for EveryoneThe ELEKTRON Series is the product of Milacron‘s years of innovation in all-electric injection molding technology. The ELEKTRON is designed for a full range of standard applications, and offers outstanding value to manufacturers. The advantages of all-electric injection molding include:

EcONOMy Uses 60 % less energy and 90 % less water than hydraulic injection molding machines

DyNAMIcS Parallel movements for optimal cycle times

PREcISION Exceptional part quality with excellent mold protection thanks to stroke accuracy of .01 millimeter

PRODucTIvITy Minimal rejects with maximum repeatability and machine availability

FLExIbILITy Suitable for all standard applications

cLEAN Ideal for clean room operations since no oil is used

QuIET Minimal noise – perfect for personnel-intensive operations and assembly areas

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TyPIcAL APPLIcATIONSMedical

Electrical & Telecommunication

consumer Goods

MAcHINE cONFIGuRATIONS

Clamping Unit (Clamping Force [kN])

Screw Diameter [mm]

Inje

ctio

n U

nit

(Inte

rnat

iona

l Siz

e)

3,470 70/80/90

2,290 60/70/80

1,540 50/60/70 50/60/70 50/60/70

970 45/50/60 45/50/60 45/50/60

630 40/45/50 40/45/50 40/45/50 40/45/50

450 35/40/45 35/40/45 35/40/45 35/40/45 35/40/45

300 30/35/40 30/35/40 30/35/40 30/35/40 30/35/40

120 18/25/30 18/25/30 18/25/30

55 18/20/22

500 750 1,100 1,550 1,800 2,000 2,600 3,500 4,500

3

DYNAMICOptimized Movement for Optimal cycle Times As with accumulator-driven hydraulic machines, ELEKTRON offers parallel movements as a standard feature. The result is excellent machine dynamics:

All axes can operate in parallel - standard on all machines

FEM-optimized construction of all moving and stressed parts

Power- and acceleration-optimized 5-point toggle system - large mold opening strokes in a compact design

Precise positioning of ejector via electromechanical drive system and ball screw drives

Platen guides allow for high-speed operation with perfect platen parallelism, even for heavier molds

Tie-bar spacing with a stiff platen and highly sensitive mold safety ensure long-term part-quality and mold life. The mold installation area is easily accessed, allowing for quick mold changes.

4

ELEKTRON – THE PRODucT OF A STRONG GLObAL TEAMWith locations in the US, India, China, and Germany, manufacturers in the Milacron group have been building all-electric injection molding machines for more than 25 years:

In 1985 Milacron introduces the world’s first all-electric machine

In 1992 Ferromatik Milacron presents the ELEKTRA, the first European company to offer all-electric machines

At K 2001 Ferromatik Milacron introduces third-generation all-electric injection molding machines

In 2009 Milacron presents ELEKTRON – internationally developed all-electric machine for standard applications

The ELEKTRON has been available in Europe since 2010

The ELEKTRON is based on the proven ELEKTRA series. Both machines share the same platform: service, spare parts and retrofits are available through Ferromatik Milacron’s SERVTEK customer support in Malterdingen, Germany. The high quality standards for the machines are assured worldwide through experienced product management.

5

EXACTPrecise Movements Ensure Quality Parts for the Long TermAll-electrics set the standard for movement repeatability. Exact movements are assured by the machines‘ drive components and robust mechanics. This ensures consistent part quality for the long term. The stroke precision of servo-driven axes is significantly greater than even the best hydraulic systems can provide. All this makes the ELEKTRON ideal for the reliable production of high-precision parts:

Absolute stroke measurement of all machine axes with precision movements

Sensors for direct, precise, and repeatable monitoring of the injection and holding pressure

Fast, repeatable injection movements with parallel independent plasticizing

Linear guide for injection unit

Perfect integration of controls and drive components

All machine axes utilize servomotors, belt drives, and ball screw drives

Injection unit carriage movement and nozzle-holding force via clean, easily maintained system

Automatic central lubrication

6

THE ELEcTRIcAL cAbINET – EvERyTHING IN ITS PLAcEThe electrical cabinet is integrated into the machine base. This design, with separate areas for controls and power components, as well as the location of the central processor in the operator panel, offers plenty of room for the available ELEKTRON options. An Ethernet Powerlink connection guarantees fast and reliable communications between the motor, amplifier, and machine controls.

7

ENDURA touchOperator-friendly controlsThe new ENDURA touch controls were developed especially to meet the requirements of the ELEKTRON series. Machine operators will easily find their way around the system right from the start. ENDURA touch at a glance:

High-performance controls from b&R

Intuitive operations via 15” color touchscreen

No page more than two clicks away

Keypad for entering notes and information

32 function keys with LEDs, arranged around the touchscreen

various interfaces (3 uSb, RS232, Ethernet) for connecting external devices

Save mold data and screenshots to uSb keys

Setpoint and actual values shown as absolute values

Plausibility check on values entered

Process monitoring with graphically displayed minimum, maximum, and average values

Graphical display of 33 parameters for the last 150 cycles

Summary of last 3,000 alarms with date and time stamps

Display of last 3,000 setpoint-value changes (change log)

Internal memory for up to 200 mold data sets

3+3 freely configurable inputs and outputs for connecting peripheral devices

Data protection with four access levels for up to 100 machine operators

choice of three languages

8

ENDuRA TOucH cONTROLS FOR A cLEAR OvERvIEw

Every page can be accessed directly from an overview page

Enter mold data for mold closing and opening

Cylinder heating, including heating energy indicator and monitoring

Enter pressure, velocity, time and stroke

9

MAcHINE DIMENSIONS

ELEKTRON 50 — 350

ELEKTRON 450

10

A B C D E F G H I J K L M N O P Q

ELEKTRON 50 - 55 4,303 1,440 1,811 1,813 2,940 482 640 285 1,387 889 55 1,540 1,984 720 720 — —

ELEKTRON 50 - 120 4,303 1,440 1,811 1,813 2,490 512 640 285 1,387 889 55 1,540 2,004 720 720 — —

ELEKTRON 50 - 300 4,303 1,440 1,811 1,813 2,490 88 640 285 1,387 889 55 1,562 2,019 720 720 — —

ELEKTRON 75 - 120 4,475 1,565 1,831 1,965 2,510 532 790 352 1,248 915 66 1,586 2,050 783 783 — —

ELEKTRON 75 - 300 4,475 1,565 1,831 1,965 2,510 108 790 352 1,248 915 66 1,608 2,065 783 783 — —

ELEKTRON 75 - 450 4,475 1,565 1,831 1,965 2,510 -68 790 352 1,248 915 66 1,611 2,103 783 783 — —

ELEKTRON 110 - 120 4,589 1,285 2,034 2,079 2,510 532 700 322 1,304 915 66 1,642 2,105 580 705 — —

ELEKTRON 110 - 300 4,589 1,285 2,034 2,079 2,510 108 700 322 1,304 915 66 1,664 2,120 580 705 — —

ELEKTRON 110 - 450 4,589 1,285 2,034 2,079 2,510 -68 700 322 1,304 915 66 1,665 2,158 580 705 — —

ELEKTRON 155 - 300 5,215 1,455 2,018 2,470 2,745 343 890 292 1,386 935 66 1,746 2,203 670 785 516 —

ELEKTRON 155 - 450 5,215 1,455 2,018 2,470 2,745 170 890 292 1,386 935 66 1,749 2,241 670 785 604 —

ELEKTRON 155 - 630 5,215 1,455 2,018 2,470 2,745 -102 890 292 1,386 935 66 1,766 2,240 670 785 753 —

ELEKTRON 180 - 300 5,215 1,455 2,018 2,470 2,745 343 890 292 1,386 935 66 1,746 2,203 670 785 516 —

ELEKTRON 180 - 450 5,215 1,455 2,018 2,470 2,745 170 890 292 1,386 935 66 1,749 2,241 670 785 604 —

ELEKTRON 180 - 630 5,215 1,455 2,018 2,470 2,745 -102 890 292 1,386 935 66 1,766 2,240 670 785 753 —

ELEKTRON 200 - 450 6,398 1,805 2,085 2,870 3,379 -950 1,240 298 1,553 1,059 66 1,916 2,407 828 977 — —

ELEKTRON 200 - 630 6,398 1,805 2,085 2,870 3,379 -682 1,240 298 1,553 1,059 66 1,933 2,407 828 977 — —

ELEKTRON 200 - 970 6,398 1,805 2,085 2,870 3,379 -149 1,240 298 1,553 1,059 66 1,974 2,456 828 977 — —

ELEKTRON 260 - 630 6,825 1,833 2,256 3,180 3,645 -799 1,240 298 1,618 1,059 66 1,998 2,472 856 977 — —

ELEKTRON 260 - 970 6,825 1,833 2,256 3,180 3,645 -269 1,240 298 1,618 1,059 66 2,039 2,521 856 977 — —

ELEKTRON 260 - 1,540 6,825 1,833 2,256 3,180 3,645 108 1,240 298 1,618 1,059 66 2,065 2,690 856 977 — —

ELEKTRON 350 - 970 7,108 1,853 2,345 3,463 3,645 -282 1,340 298 1,663 1,057 66 2,110 2,700 883 970 — —

ELEKTRON 350 - 1,540 7,108 1,853 2,345 3,463 3,645 108 1,340 298 1,663 1,057 66 2,110 2,735 883 970 — —

ELEKTRON 450 - 1,540 7,945 2,143 2,557 3,953 3,992 265 1,436 440 1,722 955 66 2,282 2,794 1,039 1,104 — 2,789

ELEKTRON 450 - 2,290 7,945 2,143 2,557 3,953 3,992 194 1,436 440 1,722 955 66 2,596 2,715 1,039 1,104 — 2,789

ELEKTRON 450 - 3,470 7,945 2,143 2,557 3,953 3,992 -193 1,436 440 1,722 955 66 2,631 2,715 1,039 1,104 — 2,789

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clamping unit5-Point toggle systemClamp movement via ball screw and belt drive3 adjustable closed-loop opening and closing speedsClamping force adjustableAutomatic mold installation height adjustmentPosition-based ramping for accurate switching and precise speed, pressure controlsHigh-sensitivity mold safety (stroke and force) adjustable in two stages Mold safety with one try-again circuitAutomatic grease lubricationActual tonnage display on control panelSPI ejector cross Hydraulic or pneumatic core pullAir valvesMachine height increased 100 mm

EjectorEjector movement via ball screw and belt driveForward speed adjustable in two stagesSpeed and force adjustable on control panelPulsating ejector strokes, adjustable from 1 to 9Zero point adjustableEjector forward dwell timer

Injection unit3 screw diameters available per injection unitNitrided barrel and screwBimetallic barrel and hardened screwBarrel cover with perforated metalBarrel cover V2A with insulationInjection movement via ball screw and belt driveInjection speed increased5-Stage injection switchable by pressure, time, or position10-Stage back pressure5-Stage plasticizing switchable by positionDigital setting and read-out of screw RPM Screw suck-back before and after plasticizingScrew cold start protectionSemi-auto purge Intrusion molding programSprue break with timerNeedle shut-off nozzle, pneumatic operatedFeed throat temperature indication and controlMaterial hopperAdapter plate for coloring unit or hopper loader

StandardOption

SPEcIFIcATIONS

12

StandardOption

Injection unitControl for coloring unit Auto heat startup and shutdownActual current display of heating zonesDisplay of set and actual temperature with bar graphHeaterband and thermocouple failure detectionHeat standby after achieving set number of cyclesTemperature and tolerance range monitoring for each zone

controlsHigh-performance controls from B&RIntuitive operations via 15" color touchscreenNo page more than two clicks awayKeypad for entering notes and information32 function keys with LEDs, arranged around the touchscreenVarious interfaces (3 USB, RS232, Ethernet) for connecting external devicesSave mold data and screenshots to USB keysSetpoint and actual values shown as absolute valuesPlausibility check on values enteredProcess monitoring with graphically displayed minimum, maximum, and average values Graphical display of 33 parameters for the last 150 cyclesSummary of last 3,000 alarms with date and time stampsDisplay of last 3,000 setpoint-value changes (change log)Internal memory for up to 200 mold data sets 3+3 freely configurable inputs and outputs for connecting peripheral devices Data protection with four access levels for up to 100 machine operatorsChoice of three languages

Drive TechnologyClosed-loop control of all pressures, strokes and speedsServo-driven mold, ejector, plasticizing and injection movementsHigh-speed Ethernet POWERLINK connection between motor, amplifier and machine controlsParallel mold, ejector and plasticizing movements

OtherEuromap mold mounting patternMounting patterns to Euromap standards for robots on fixed platenMoving platen supported on machine frame by glide shoesCooling water batteryHosing from cooling water battery to stationary or moving platenPart removal possible from two sidesInterface for robot to Euromap 67Interface for conveyor beltReceptacle packagesElectric panel integrated in the machine base

13

ELEKTRON 50 Technical Data and Clamp Dimensions

clamping unit 50

Clamping Force kN 500

Tie Bar Clearance (H x V) mm 320 x 320

Clamping Platens Size (H x V) mm 470 x 490

Mold Opening Stroke mm 260

Distance Between Platens max. mm 670

Mold Installation Height min. / max. mm 150 / 410

Mold Weight max. (moving / fixed) kg 290 / 145

Opening Force kN 165

Ejector Force kN 25

Ejector Stroke mm 125

Dry Cycle (Euromap 6) s-mm 1.7 - 224

Injection unit 55 120 300

Screw Diameter mm 18 20 22 18 25 30 30 35 40

Injection Pressure max. bar 2,500 2,345 1,939 2,444 2,016 1,400 2,500 1,943 1,488

Stroke Volume max. cm³ 19 24 29 31 59 85 113 154 201

Injection Weight max. (PS) g 17 21 26 28 54 77 103 140 183

Screw Stroke mm 75 75 75 120 120 120 160 160 160

Unit Stroke mm 180 180 180 250 250 250 250 250 250

Nozzle Holding Force kN 30 30 30 30 30 30 30 30 30

Injection Rate cm³/s 52 64 78 52 101 145 117 159 208

Screw Speed min -1 400 400 400 400 400 400 400 400 400

Recovery Rate g/s 3.2 4 5 3 9 13 18 25 32

Active Screw Length L/D 22 21 19 20 20 20 22 23 20

Number of Heating Zones 3+1 3+1 3+1 3+1 3+1 3+1 4+1 4+1 4+1

Total Heating Capacity kW 4.8 4.9 4.9 4.6 6.7 7.9 9.2 11.2 11.2

General Data 50 - 55 50 - 120 50 - 300

Total Connected Power kW 11.3 11.4 11.4 11.4 12.7 14.7 20.9 22.3 22.3

Machine Dimensions (L x W x H) m 3.94 x 1.29 x 1.84 3.94 x 1.29 x 1.86 3.94 x 1.29 x 1.87Net Weight kg 3,000 3,200 3,400

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clamping unit 75

Clamping Force kN 750





Mold Installation Height min. mm 150 / 480



Ejector Force kN 25








Screw Stroke mm 120 120 120 160 160 160 180 180 180

Unit Stroke mm 250 250 250 250 250 250 250 250 250



Screw Speed min -1 400 400 400 400 400 400 400 400 400

Recovery Rate g/s 3 9 13 18 25 32 28 40 43

Active Screw Length L/D 20 20 20 22 22.9 20 22 22.8 20



General Data 75 - 120 75 - 300 75 - 450



15


clamping unit 110

Clamping Force kN 1,100








Ejector Force kN 30








Screw Stroke mm 120 120 120 160 160 160 180 180 180

Unit Stroke mm 250 250 250 250 250 250 250 250 250



Screw Speed min -1 400 400 400 400 400 400 400 400 400

Recovery Rate g/s 3 9 13 18 25 32 28 40 43

Active Screw Length L/D 20 20 20 22 23 20 22 22.8 20



General Data 110 - 120 110 - 300 110 - 450



16


clamping unit 155





Distance Between Platens max. mm 1,030


Mold Weight max. (moving / fixed) kg 1,125 / 560


Ejector Force kN 35


Dry Cycle (Euromap 6) s-mm 2 - 364






Screw Stroke mm 160 160 160 180 180 180 200 200 200

Unit Stroke mm 250 250 250 250 250 250 300 300 300



Screw Speed min -1 400 400 400 400 400 400 400 400 400

Recovery Rate g/s 18 25 32 28 40 43 40 47 56

Active Screw Length L/D 22 22.9 20 22 22.8 20 22 22.2 20



General Data 155 - 300 155 - 450 155 - 630



17


clamping unit 180









Ejector Force kN 35


Dry Cycle (Euromap 6) s-mm 2 - 364






Screw Stroke mm 160 160 160 180 180 180 200 200 200

Unit Stroke mm 300 300 300 300 300 300 300 300 300



Screw Speed min -1 400 400 400 400 400 400 400 400 400

Recovery Rate g/s 18 25 32 28 40 43 40 47 56




General Data 180 - 300 180 - 450 180 - 630



18


clamping unit 200









Ejector Force kN 45


Dry Cycle (Euromap 6) s-mm 2.2 – 399 (estimated)






Screw Stroke mm 180 180 180 200 200 200 240 240 240

Unit Stroke mm 300 300 300 300 300 300 300 300 300



Screw Speed min -1 400 400 400 400 400 400 350 350 350

Recovery Rate g/s 28 40 43 40 47 56 46 58 80



Total Heating Capacity kW 11.1 13.1 13.1 12.8 14.8 14.8 16.6 20 20

General Data 200 - 450 200 - 630 200 - 970



19


clamping unit 260









Ejector Force kN 60


Dry Cycle (Euromap 6) s-mm 2.52 – 462

Injection unit 630 970 1,540



Stroke Volume max. cm³ 251 318 393 382 471 679 550 792 1,078


Screw Stroke mm 200 200 200 240 240 240 280 280 280

Unit Stroke mm 400 400 400 400 400 400 400 400 400


Injection Rate cm³/s 207 262 324 317 392 565 550 792 1,087

Screw Speed min -1 400 400 400 350 350 350 300 300 300

Recovery Rate g/s 40 47 56 46 58 80 46 70 90



Total Heating Capacity kW 12.8 14.8 14.8 16.6 20 20 20 25.4 25.4

General Data 260 - 630 260 - 970 260 - 1,540



20


clamping unit 350



Clamping Platens Size (H x V) mm 1,030 x 1,030




Mold Weight max. (moving / fixed) kg 2,630 / 1,320


Ejector Force kN 75



Injection unit 970 1,540

Screw Diameter mm 45 50 60 50 60 70

Injection Pressure max. bar 2,300 2,058 1,429 2,300 1,942 1,427

Stroke Volume max. cm³ 382 471 679 550 792 1,078

Injection Weight max. (PS) g 348 429 618 500 720 981

Screw Stroke mm 240 240 240 280 280 280

Unit Stroke mm 400 400 400 400 400 400

Nozzle Holding Force kN 30 30 30 30 30 30

Injection Rate cm³/s 317 392 565 550 792 1,087

Screw Speed min -1 350 350 350 300 300 300

Recovery Rate g/s 46 58 80 46 70 90

Active Screw Length L/D 22 24.2 20 22 23.6 20

Number of Heating Zones 4+1 4+1 4+1 4+1 4+1 4+1

Total Heating Capacity kW 16.6 20 20 20 25.4 25.4

General Data 350 - 970 350 - 1,540

Total Connected Power kW 58.3 60.2 60.2 67.3 69.2 69.2

Machine Dimensions (L x W x H) m 7.00 x 2.10 x 2.50 7.40 x 2.10 x 2.50Net Weight kg 16,500 17,300

21

512

M24 Ø1

60H830

MAX.1640

Ø110

Ø164

Ø27

1020

980

Ø52.4

1240

1530

Ø150

Ø200

0-200

*944

MIN.350

MAX. 820

M20X50

*1009

280

420

560

700

840

980

1120

101.6

152.

440

6.4

711.2

1230

101.6152.4406.4

711.2

2804205607008409801120

470

820

OP. GATE INSIDE NON-OP. GATE INSIDE

All Dimesnsions Are In MM* Inside Gate Dimensions

StationaryPlaten

MovingPlaten

R15Ø4

512

M24 Ø1

60H830

MAX.1640

Ø110

Ø164

Ø27

1020

980

Ø52.4

1240

1530

Ø150

Ø200

0-200

*944

MIN.350

MAX. 820

M20X50

*1009

280

420

560

700

840

980

1120

101.6

152.

440

6.4

711.2

1230

101.6152.4406.4

711.2

2804205607008409801120

470

820



StationaryPlaten

MovingPlaten

R15Ø4

512

M24 Ø1

60H830

MAX.1640

Ø110

Ø164

Ø27

1020

980

Ø52.4

1240

1530

Ø150

Ø200

0-200

*944

MIN.350

MAX. 820

M20X50

*1009

280

420

560

700

840

980

1120

101.6

152.

440

6.4

711.2

1230

101.6152.4406.4

711.2

2804205607008409801120

470

820



StationaryPlaten

MovingPlaten

R15Ø4

512

M24 Ø1

60H830

MAX.1640

Ø110

Ø164

Ø27

1020

980

Ø52.4

1240

1530

Ø150

Ø200

0-200

*944

MIN.350

MAX. 820

M20X50

*1009

280

420

560

700

840

980

1120

101.6

152.

440

6.4

711.2

1230

101.6152.4406.4

711.2

2804205607008409801120

470

820



StationaryPlaten

MovingPlaten

R15Ø4


clamping unit 450



Clamping Platens Size (H x V) mm 1,240 x 1,200




Mold Weight max. (moving / fixed) kg 5,725 (3,815 / 1,910)

Opening Force kN 1,260

Ejector Force kN 110



Injection unit 1,540 2,290 3,470



Stroke Volume max. cm³ 550 792 1,078 905 1,232 1,608 1,385 1,810 2,290

Injection Weight max. (PS) g 523 753 1,025 861 1,172 1,530 1,318 1,722 2,179

Screw Stroke mm 280 280 280 320 320 320 360 360 360

Unit Stroke mm 400 400 400 400 400 400 400 400 400


Injection Rate cm³/s 550 792 1,078 427 580 758 580 758 961

Screw Speed min -1 300 300 300 250 250 250 220 220 220

Recovery Rate g/s 46 70 90 56 77 101 61 86 114

Active Screw Length L/D 22 23.6 20 26.7 22.9 20 25.7 22.5 20


Total Heating Capacity kW 20 25.4 25.4 39.6 39.6 39.6 57.9 57.9 57.9

General Data 450 - 1,540 450 - 2,290 450 - 3,470



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Changes reserved. 23

Ferromatik Milacron GmbH I Riegeler Str. 4 I 79364 Malterdingen I Germany+49 (0)7644 78-0 I [email protected] I www.ferromatik.com

Documents

The ELEKTRON Series - Ferromatik · 2015. 1. 23. · THE ELEcTRIcAL cAbINET – EvERyTHING IN ITS PLAcE The electrical cabinet is integrated into the machine base. This design, with