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Modifications e-motion

Modifications e-motion. R. Brandstetter / 02/2010. Electric machines - Portfolio. S … Standard H … High P … Premium. Roadmap electric machines. EM-T 50: mechanical platform of EMX and EM-T will be reviewed EM-T 100: Prototype release march 2010

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Modifications e-motion

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  1. Modifications e-motion R. Brandstetter / 02/2010

  2. Electric machines - Portfolio S … Standard H … High P … Premium

  3. Roadmap electric machines • EM-T 50: mechanical platform of EMX and EM-T will be reviewed • EM-T 100: Prototype release march 2010 • EM-T 180: New development of a EM-T 200 because of new (market-)requirements • EM-T 225: Canceled, will be covered with EM-T 200 & EM-T 280 • EM-T 280 .. 500: medium term adapted to KEBA & BRC (cost potentiales) • EM 55 .. 150: currently no development planned • EMX 180: Optimizing will be checked

  4. e-motion (Tiebar less) e-motion T (Toggle) e-victory (Hybrid) e-max (Toggle) Electric machines – Clamping units

  5. IN-LINE 50-440 TWIN 740-1640 DIRECT DRIVE 2440-7440 Electrical machines – Injection units

  6. 3440 ! Electrical machines – Injection units Injection speed in [mm/sec]

  7. Watercooled Servo motor for Plasticizing Direct driven spindle for Injection (2 motors– watercooled) Ball spindles for injection (Closed lubrication system – no grease) Direct Drive Unit 2440 (3440)

  8. Direct Drive Unit 2440 (3440)

  9. Direct driven spindles for injection (4 motors – watercooled) Direct Drive Unit 5540 (7440)

  10. Concept e-DUO • Direct-Drive Injection unit • Injection: 2/4 Servo motors/spindles (depending on injection unit size) • Plastizicing: Servo drive • Carriage unit: 2 spindles – 1 Servo motor) • Mould movement • 2 Spindles with each one servo motor • Tiebar locking via 2 asynchronous motors • Ejector • 1 Servo motor/spindle • Clamping force • Hydraulic aggregat built into the frame

  11. Electric machines – „Specific features“ • Ejector • Stroke not calibrated • Mass inertia lead to damage • eg: Standard ejector EM-T 380 (vmax = 222mm/sec, Fmax = 70kN) • 6,2mm up to stand still at max. brake torque • if non-braked to mech. stop • v = 100%: 480kN !!! • v = 50%: 120kN !!! • Thermal Overload • Set-up mode!!! • Option: Spring loaded Ejector coupling

  12. Electric machines – „Specific features“ • Ball threaded spindle failures • General • Overload (Force, temperatures) • Alignment failure • Less lubrication • Injection spindle • at Twin unit (Inline unit without problems) • => Observe work instruction (QW-AA-P01-003) • Clamping- & Ejector spindle • Alignment of the spindle • Observe work instruction (QW-AA-P01-032) • Activities • Qualifying of suppliers (NSK, Umbra, HiWin) • Early recognition of spindle damages (noise, surface, grease color, temperature (< 70°C), lubrication function) • Exchange oil 1x/Year at oil lubricated spindles

  13. Electric machines – „Specific features“ • Ball threaded spindle failure – Adjustment Calibration position offset motor 2 Calibration position offset motor 2 = Motor angle – Motor angle 2

  14. Electric machines – „Specific features“ • Ball threaded spindle failures • General • Overload (Force, temperatures) • Alignment failure • Less lubrication • Injection spindle • at Twin unit (Inline unit without problems) • => Observe work instruction (QW-AA-P01-003) • Clamping- & Ejector spindle • Alignment of the spindle • Observe work instruction (QW-AA-P01-032e) • Activities • Qualifying of suppliers (NSK, Umbra, HiWin) • Early recognition of spindle damages (noise, surface, grease color, temperature (< 70°C), lubrication function) • Exchange oil 1x/Year at oil lubricated spindles

  15. Electric machines – „Specific features“ • Belt topics (esp. carriage unit) • Recently increased belt crackes • Mainly on carriage unit • Reason open (Plastic material, overload, etc. ?) • Belt tension • Belt must be not retensioned • In repair the tension must be measured before and set after the exchange to the same value • Activities • Yearly visual check according maintenance manual ! • additional increased check during service missions ! • => Observe work instruction(DP-AA-P01-034e)

  16. inlet outlet Electric machines – „Specific features“ • Lubrication optimized toggle lever • Concept • Flow-through lubrication with oil in- / outlet in the bolt • Problem • Particle emission at fixed bearing positions • No functional interference • Activities • clamped intermediate crank as improvement

  17. Max. power (short-term) Construction range (60% - 80%) Thermal permanent curve Electric machines – „Specific features“ • Thermal limitationed cycles • Incraesed with long holding pressure time with high pressure • Problem regards to all el. axis

  18. Holding pressure characteristic – Standard cycle Basis : short cycle 6 sec Screw DM 40 mm

  19. Max. holding pressure with unlimited holding time

  20. Improvement potential error analyses • Exact error description • Actual status report (machine in error situation) • Exact description of the error situation • History of the error • Error frequency, problem repeatable • Recording with graphic program (Oscilloscope) • PDP Recordings • Screenshots • …

  21. Oscilloscope • Predefined profiles are since software version 1.20 available (HD0:\DATA), but in the program oscilloscope is no access prepared to this directory. The profiles can be read only from HD1. Starting from V 2.0 it is possible to access the directory HD0:\DATA direct in the oscilloscope. • Solution V 1.20: copy the files (*.swo) to HD1 with KVS-Explorer • 3 possibilities to store the measurement: • Export in BIN-format (can be only read back and displayed in a machine) • Export in txt-format (can be opened and handled with MS-EXCEL) • Hardcopy

  22. Exercise 1 - Oscilloscope • Measure the following signals during the nozzle movement forward: • Nozzle position actual value • Motor servo speed set value • Motor servo speed actual value • Motor servo moment set value • Motor servo moment actual value • Nozzle contact pressure actual value • Export the measured curves in BIN- and TXT-format to forward them to the Engel service department

  23. Solution exercise 1 - Oscilloscope

  24. Exercise 2 - Oscilloscope • Problem: • Mould is closed, clamping force is built up, after a few minutes it is no more possible to open the mould (in set-up mode too) • Measure the relevant signales and export the measured curves in BIN- and TXT-format

  25. Solution exercise 2 - Oscilloscope

  26. Danke / Thank you

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