Injection Moulding Machine

Reduced Price:     399.000,– € “as it is” EX Germany.

Manufacturer:      KRAUSS MAFFEI                   Production hours:       801 hrs

Type:                     KM 1600-3500 DP MC Operating hours, total:       3,018 hrs

Built in:                  1999

Price, new             € 1,000,000.–

Price:                     bid invited

We are not rendering any guarantees for the completeness of the machine resp. of the accessories listed as many components are subject to wear.

If interested, we shall be glad to send you further records. Inspection date to be agreed upon.

Subject to prior sale.

1 Injection Moulding Machine KM 1600-3500 DP MC

Plastification:

1 cpl. thermoplast plastification in wear-proof design. Worm diameter
100mm with nonreturn valve and open nozzle
(nozzle radius 40.00mm, nozzle opening 10.00mm)

TECHNICAL DATA:

Clamp unit

– max. clamp power      16000 kN

– max. stamp travel      40mm

– min./max. tool mounting height                850 – 1555mm

– opening width                                             2390mm

– opening travel of tool at FH                      min.1540 max. 835mm

– clear width between the columns           1800mm

– clamp platens/fixed part approx.            2360 x 2355mm

– opening power                                           1250 kN

– total height of clamp unit                          7200mm

Injection unit

– working capacity                                         3500

– screw diameter                                           100 mm

– L/D relationship                                            24

– injection pressure                                         1411 bar

– piston capacity                                            2411 ccm

– injection volume                                          801 ccm/s

– screw drive capacity                                   70kW

– screw speed                                                119/200 1/min

– torque                                                          5600/3340Nm

– basic height of Y axis                                  2295 (460) mm

– X displacement                                           2300mm

– X displacement speed max.                       600-800mm/s

– Y swing mechanism                                    approx. 4/4 degrees

– Y swing mechanism                                    approx. 200/200mm

– Z displacement                                            800mm

– nozzle unit power                                        60 kN

Slit nozzle

– width min./max.                                         150-400mm

– strand thickness                                           6-12mm

– slit nozzle swing                                           approx. 300-400mm

Electro-hydraulic equipment

– nominal capacity, pump motor                90-130kW

– installed heating capacity                          65+X kW

– cylinder heating, regulated zones              11

– electr. drive                                                 70kW

Required screw diameters/clamp power/dwell time

Based on the door of the Audi convertible 123 x 70cmm

Aproj = 123cm x 70cm = 8610sq.cm

25% surcharge for partial surface minus 10% for

open regions.

Partial surface = 8610sq.cm x 1.15 = 9901.5 sqcm

Wall thickness s>2mm

Partial volume = 9901.5 sq.cm x 0.2 = 1980.3 ccm

89.22          Pump motors with insulation class F

89.45013    1 service socket, earthed, 10A in switch
cabinet, connected before main switch

89.521        3 start of subsequent pressure, depending on
inside tool pressure, adjustable on a screen.

Incl. load amplifier make Kistler, excl. tool pressure
absorber

2 Kistler load amplifiers only for graph computer

and quality control

3 bushings fastened to FWAP BGS

89.591        signal interface per Euromap 12
(previously FHK 85-12-32)
with waste signal and power supply
socket Cekon 16A for handling unit on firm WAP

89.70          Starting cycle:

change from starting up to production values for rating
travel, injection pressure, follow-up pressure, bank-up
pressure, depending on rate of shots

89.751        Quality control package:

process monitoring (actual values of cycles and
integrals) by preset tolerance ranges, indication of actual
value, storage of actual value.

Printable records

89.8033      Super Color TFT screen
in high-brightness design

89.8044      Presentation of graphs on screen, with tolerance range
and surface monitoring in specific areas for the parameters
follow-up pressure, hydraulic pressure, inner tool pressure
(provided Pos. 89.521 is installed), plastification travel,
injection speed and injection capacity.

Presentation of stamp travel, follow-up pressure, hydraulic
pressure, 3 x inner tool pressure, plastification travel and
injection speed.Accessories

02.30          1 set of tools

50.40          Deduction for supplying the machine without
hydraulic central ejector.
Hydraulic and electr. control of ejector will be
included. (No subsequent fitting.)

52.20          In series monitored “back” position of hydraulic ejector
and of tool ejector plate

62.00          Regenerative pump control system

64.50          Media control for
supervision of oil tub

71.01          Injection stamping cycle (stamp cycle and
stamp speed to be set at screen)
additional, proportionate quantity control for
achieving a stamping speed of max. 18mm/s.

72.32          Hydraulic core puller control, 2fold, at movable
WAP (speed and pressure to be set at screen).

Socket assignment per Europmap 13 (Han 16A).

Assembly of core puller valves at BGS

Oil supply for delivery position:

Closing nipple Messrs. Stäubli SBA 087103 PA/JV

Oil supply for injection position:

Clutch Stäubli SBA 081103 PA/JV

72.38          Hydraulic core puller control, 3fold, at fixed
WAP (speed and pressure to be set at screen).

Socket assignment per Europmap 13 (Han 16A).

Assembly of core puller valves in BGS

Oil supply for delivery position:

Closing nipple Stäubli SBA 087103 PA/JV

Oil supply for injection position:

Clutch Stäubli SBA 081103 PA/JV

89.07          Ejection of cooled down nozzle plug

89.2001      Fan at switch cabinet

89.807        Maintenance instructions:

depending on performance (operating hours,
cycle periods) the maintenance intervals are
calculated automatically; the screen will show
an alarm once maintenance work will be due.

89.819        Main language German

for screen texts, printer texts and machine plates

89.968        Mainframe interface per specification RS 232.

Adjustment software for the computer system not
included. To be furnished by supplier of computer.

89.969        BDE interface comprising 5 potential-free contacts on
terminal strip in switch cabinet for connecting BDE
systems such as Kienzle, Datapact, etc.

96.68          Machine coat:

– machine painted in two tints of patterned coating

RAL 5013 cobalt blue

RAL 9002 greyish white

– movable doors           RAL 1007 chrome yellow

88.5432      32 temperature controls for hot tool channel.

Adaptive controls (self-optimizing), including
plug and socket connection Han 16 E for capacity
and Han 16 A for temperature feeler.

Plug assignment per Euromap 14.

Capacity per control point max. 2 kW

Capacity per control point max. 3.6 kW

Plug type and assignment per Peguform standards.

Control points for tool heating furnished with fusible
cut-outs (Socomec) 16 A. Each range separated into
5 outlets furnished with fine fuses 6.3 A with failure
alarm.

72.70          5 twin check valves for holding the cores

72.60          Pressure maintaining pump for core puller

63.63          Full-flow filter after all hydraulic pumps
(exception: axial piston pump and pressure
maintaining pump for core puller

Clamp unit, vertikal, with reversed columns.

The clamping mechanism is located at the BFAP.

Raised clamping unit by 585mm by substructure.

Distance FFAP – nozzle centre (in lowest position)

460mm.

FEH min.                           850mm

FEH max.                        1555mm

Opening width max.     2390mm

Opening power (1250KN) less the weight of the
moveable tool half.

Injection unit incl. machine bed same as KM 420/3500 DP

Order 644023/2.

With modification for 110 kW pump group (re. SP 4350/5700).

Power of the nozzle unit to be started at the lowest position
only (basic height = 2190mm).

Automatic positioning travel of the unit during the injection process
in longitudinal direction of the machine (x-axis).

Automatic height adjustment of the unit (z-axis).

Manual swivel mechanism in the horizontal position of the unit.

12fold cascade control, hydraulic. Double-acting valves for
shut-off needle nozzles. Each nozzle is separately opened and
closed depending on screw travel.

Special controls for closing the nozzles as in order 607483
(No. 326619H4)

1) Closure depending on travel, or at end of follow-up pressure,
at the latest.

2) Closure depending on travel or at a delay at start of follow-up

pressure.

Initial oil flow for opening the needle:

Clutch Stäubli SBA 08.1103 PA/JV

Initital oil flow for closing the needle:

Closing Nipple Stäubli SBA 08.7103 PA/JV

Pressure relief for cascade control.

– Safety doors at BS and face side (SS) of clamp

– Design in several parts by telescope principle

– Operating panel at cornerBS/SS movable so that
operation will be possible from BS and SS while
watching the complete clamp area.

– Plugged operating panel allows for easy disassembly

– Integrated acknowledgement button

– Platform with safety appliance at BGS at the level of
the clamp area of the FWAP for plugging the media
connections

– Access through safety door at the SS via customer’s

working platform. (Included in point 4.5)

Manual production process without robot in HA operation

– Tool and safety door at SS open (door at BS always remains shut)

– Bringing in of clamp frame with decor into inner tool area.

– Positioning and fastening at upper part of tool with pneumatic
cylinder.

– Triggering of the tool valves via push-buttons, for BS and
BGS each (switch box fastened at tool).

– Parallel release via core puller software

– Operation of vacuum valves (switch box fastened at tool)

– Leaving the inner tool area, release of safety bolt, closing of

door, acknowledgement, closing and injection.

– Opening of safety doors while the tool is open.

– Removal of clamp frames and finished workpiece

Automatic production process with robots in VA-operation

– Operating panel plugged to sheathing BS between clamp
and injection unit

– Housing of robots with safety doors

– One robot will insert clamp frame of SS

– Pneumatic fastening of clamp frame via robot signal.
Operation of vaccum valves integrated into process

(possible robot signal).

– Further details about automatic operation to be discussed with
customer.

Electric motor driven screw drive

Software and electric for 3 separate vacuum cycles, one pump
per cycle (Becker, type 114.100 SA/K), one vacuum valve,

one ventilation valve. Activation via operating panel.

First start-up of pump by “Vacuum On”.

Pump switches off upon expiration of pre-selected interruption
period.

“Vacuum Off” with selectable delay after the start of injection.

Negated control of ventilation valves by vacuum valves.

Additional information under pt. 104.2-104.5.

Assembly of pumps and valves on top of BWAP.

Pumps and valves furnished by Peguform.

Preparation of machine for Stäubli clamp system,
consisting of:

Drilling pattern in FFAP and BFAP

One hydraulic valve for FWAP; 2 hydraulic valves for
BWAP (safety cycle)

Intgration of control into MC3 F

Assembly of mech., electr., hydr. function test. Data about

position and size by Mr. Zobel (Peguform).

Grooves for Enerpac lifting ledges (width x depth 28x48mm)
and centering guide/central guide (width x depth 30×5) as well
as drilling pattern for consoles at FFAP. Tool insertion either BS
or face side.

Data defined by Mr. Zobel (Peguform)

Special control system for operating the hydraulic lifting ledges
in E-operation (exclusively) while the machine is open and with
activated key switch (identical with order 644023).

Supply of cooling water at FWAP and BWAP (via energy chain)
at BGS each.

Max. temperature 95°C.

Each one cycle with 1 1/4″ hose at bulkhead plate.

Connection to tool (bulkhead inside thread 1″) with screwed nipple
(Stäubli MAM 155 155 LN) and plugged nippled (Stäubli
GPL 25.6105)

Wedge-type machine support for injection unit, make Bilz

12 anchor screws M36x400 DIN 529, to be supplied to customer
at first.

4) Closing of nozzle after end of follow-up pressure and
compression relief before plastification.

5) Delay times (to be set via screen) for opening and closing
of nozzle each.

Two tank connections K 1 1/2″ with one stop valve each for
external oil filter, make Peguform.

Provision of oil collecting tub by Peguform.

Design to be agreed upon with KM.

Socket combination:

2 x earthed 16 A

3 x CEE 32 A

positioned beneath switch cabinet

Software for special control system (Decoform)
Closing power profile depending on screw travel, incl.
hardware electronics, hydraulic, additional graph “closing
power (kN)” and “tool breath (mm)” via “injection period (sec)”.
Including the inductive displacement pick-up of the amplifier
board and wiring (assembly at the tool not included).

System separation (simultaneous injection – stamping).

VERTICAL MACHINE FOR SOURCE FLOW AND STRAND
POSITIONING
Process description source flow

– Closing of tool until s27 (stamp travel < 40mm)

– Start of injection
- and start of simultaneous, screw travel-depending
closing power profile (stamping)

– Cooling period

– Plastification

– Opening of tool

– Ejection

Process description strand positioning

– Advance of injection unit upto a defined
travel point of the X-axis

– Start of injection

– and start of X-axis (return stroke of aggregate)

– and start of Y-axis

– Closing of tool until s27 (stamp travel < 40mm)

– Start of stamping profile

DESCRIPTION OF PEGUFORM PROCESS

– Bringing in of pre-shaped skin or foil with
pre-shaped insert into movable tool side (top)
and clamping with vacuum

– Or bringing in of pre-heated foil with clamping frame
into movable tool side (top) and clamping with vacuum.

– Closing of tool until stamp travel is achieved.

– Advance of tool slider at upper side of tool

– Forward travel of injection unit

– Start of injection and start of screw travel-depending
closing power profile

– Cooling phase

– Plastification

– Back travel of slider

– Opening of tool and ejection of workpiece with core puller

– Discharge of workpiece with robot during the
tool-opening phase or after the tool-opening phase.

Stamping of opening, max. stamp travel 40mm with
3-stage speed profile.

Start depends on screw travel.

Additional block including tank pipe 50×3 (3000 psi) for
achieving a speed of approx. 18mm/s.

Slit nozzle

– Width min/max                                          150-400mm

– Strand thickness                                        6-12mm

– Radius of slit nozzle                                    approx. 300-400mm

Stepless width regulation, programmable by automatic lid system.

Variable strand thickness by changing of insets.

Procurement by KA 12.

The dead weight of approx. 300 kg requires a support
(jib (drwg. 669 7698).
Adjustment of injection housing.

Instructions about operating materials same as with
KM 3200 (No. 32C619H4).

Preparation for the pre-heating of materials.

Software and optional programme with modification
or robot interface.

Use of each one regulating point for basic capacity resp.
production performance, pre-setting of performance via
ED regulator. Performance made available at machine
socket. Design as with KM 250 DF No. 2034470.

Density (PP+20Talk.) = 1.04g/ccm

Unit weight = 1980.3 ccm x 1.04g/ccm = 2059.51g

Yield factor 0.85

Stroke volume = 2059.51 / 0.85 = 2422.95ccm

150 bar inside pressure/closing power

Fs = 8610 sq.scm x 1.5kN/sq.cm = 12915 kN

Dwell time = tv = xa 87 sec.

At a minimum shot weight of 800 the yield is 39%,
at a dwell time of 226 sec.

Dates:

BAS                                                              01/12/98

End of assembly                                         02/02/99

End of commissioning                                25/02/99

End of test runs                                           30/04/99

Tests about continuous operation to be agreed upon with Mr. Klotz!

Special control system: opening of the single vacuum
valves depending on closing travel via screen input

Additional supply of pneumatic core puller for fixing
the clamping frames for robot operation
(electr. hardware and software only).

Amplification of power for the pre-heating of materials
(regulating point 33 and 34), so that totally approx. 28kW
will be available.

Additional supply of cover plates for cable conduit beneath
switch cabinets.

Exchange of impuls-controlled pneumatic valve (SN 6253156)
against 5/3-way valve “deaerated in centre position” (SN
6438446).