100t–450t TM SERIES - WITTMANN...

TM SERIES100 t–450 tTM SERIES

TM 100 t–450 t

PLASTICS TECHNOLOGY

INJECTION MOLDING TECHNOLOGY

2

100 t–450 t

Plastics TechnologyBATTENFELD

SPECIAL FEATURESand benetits of theTM SERIES

SPECIAL FEATURESand benefits of theTM SERIES 100 t–450 t

Clamping system

The clamping cylinder is equipped with differential gears to promote high opening and closing speeds, and to minimize dry cycle times.

Linear guides

Support for the moving platen is provid-ed by high-precision linear guides, which dispenses with the need for special adjustments to accommodate heavy molds. Lubrication is reduced to a mini-mum. The hard-chrome-plated tie-bars are free of contamination with lubricants.

Clamping platens

Rigid machine frame combined with reinforced cap bolts and low-mainte-nance toggle sleeves stand for high precision, low maintenance and long service life.

3

The compact power packages in a great machine series in 3 – platen technology with a 5-point toggle system.

Newly designed in the 100 to 450 t clamping force range, TM models stand for ultimate performance, short footprint, simple operation and maintenance, energy savings and cost-efficiency.

Proven features have been retained, with a number of beneficial new features added.

The high-performance control system offers numerous process monitoring and documentation facilities.

Thanks to a wide range of options, the TM is extremely versatile and lends itself to many special processes, such as injection-compression.

Put the TM to the test and see for yourself!

Energy-saving DFEE drive

This flexible drive concept based on electrically adjust-able (DFEE) delivery pumps promotes short cycle times. A further increase in injection performance throughparallel movements can easily be achieved by installing an additional pump system. Parallel strokes, higher injection and dosing performance can easily be achieved with an optional twin pump system!

Injection units equipped

with linear guides

and a service lifting mechanism to facilitate maintenance and the remo-val of barrels and screws.

Screws with a uniform

L/D ratio

of 22:1 and an injection pressure of 2,000 bars for the medium-diameter screws ensure excellent melt homo-geneity.

Screws equipped with

direct hydraulic drive

A high-performance hydraulic motor ensures a high plasticizing performance.

4

100 t–450 t


CLAMPING UNIT TMCLAMPING UNIT TM100 t–450 t

OUTSTANDING FEATURES OF THE TM

short footprintextremely rigid, sturdy clamping plates and machine frameprecise platen parallelism across the entire strokelow-maintenance linear guides to support the moving platenself-locking 5-point toggle systemreinforced toggle bearings with low-maintenance toggle sleeves

adhesive central oil lubrication of toggle jointshigh opening and closing speeds thanks to differential gearsshort dry cycle timesflexible parts removal in three directionshigh repeatability of all parameter settingssensitive mold safety devicemold protection thanks to precise platen parallelism, minimal platen deflection and linear guideslow-maintenance and service-friendly design of all machine parts

5

NEW INJECTION UNITS

for more flexibility

Short footprint with two pulling cylinders

High injection rates

Universal compatibility of barrels with different injection units

ULTIMATE PRECISION

and repeatability

Compact design with integrated hydraulic block and easy access to all components

Direct screw drive via low-speed hydraulic motor with optimal adaptation to individual plasticizing demands

Ultimate repeatability thanks to controlled servo-valve

A CONCEPT for improved parts quality

Optimized melt homogeneity thanks to a uniform L/D ratio of 22:1 and an injection pressure of 2000 bar with medium-diameter screws

Linear guide systems ensure precise axial move-ments of the injection unit

Carriage cylinders positioned opposite each other provide momentum-free nozzle carriage

Plasticizing systems for injection molding machines must fulfill many different requirements. By applying a universal L/D ratio of 22:1 to the three screw sizes available for each injection unit, the processing window has been optimized to meet rising quality standards.

INJECTION UNITINJECTION UNITup to 5100

HIGH-PERFORMANCEPLASTICIZING SYSTEMSHIGH-PERFORMANCEPLASTICIZING SYSTEMS

6


10 membrane keys with luminous rings are provided to control the main ma-chine functions (drive motor, heating system, operation modes)

2 USB interfaces to connect storage media (USB sticks, printer, keyboard) or devices for programming an access authorization system with passwords are also available.2 additional USB inter-faces and 2 Ethernet interfaces are located at the rear of the control cabinet.

Thanks to increased data processing capacity, functions such as the extended quality table with 12columns have become possible. The evaluation is now based on a memory depth of 10,000 shots, with all deactivated parameters also being recorded in the background.

The complete machine documentation including manuals, drawings of spare parts and parts lists is also available online. In addition, users can insert their own PDF files and make them available to machine operators.

The UNILOG B6 is a new generation of control sys-tems, setting new benchmarks in user friendliness, speed and precision.

Continuity of the Battenfeld operating system and familiar symbols is maintained by incorporating ele-ments from previous generations of control systems, however with an extended graphical operator inter-face.

15” TFT color screen with unlimited touch screen functions for operation and display

Space provided for a further 7 optional mechanical switches/keys

2 rows of soft keys to select various machine functions

48 membrane keys to operate machine axes and application options

UNILOG B6UNILOG B6

A high-performance system concept that has been optimized for perfect coordination with the machine’s hydraulics and system of sensors to ensure fast and precise movements of all machine axes. Precise analysis of all relevant process variables provides the user with the necessary control facilities for demand-ing applications.

7

PP + 20% Talc

PP + 40% Talc

PP + 20% GF

PS

PVC-hart

PVC-weich

SAN

SB

PF

UP

Material Factor

ABS 0,880,88

CA 1,021,02

CAB 0,970,97

PA 0,910,91

PC 0,970,97

PE 0,710,71

PMMA 0,940,94

POM 1,151,15

PP 0,730,73

Material Factor

0,850,85

0,980,98

0,850,85

0,910,91

1,121,12

1,021,02

0,880,88

0,880,88

1,31,3

1,61,6

Clamping unit

to 210 350 525 750 1000 1330 2250 3400 5100

100 • • •• • •160 • • •• • •210 • • •• • •270 • • •• • •350 • • •• • •450 • • •• • •

POSSIBLE COMBINATIONS OF CLAMPING UNITS/INJECTION UNITS

The maximum shotweights (g) are calculated by multiplyingthe theoretical shot volume (cm³) by the above factor.

Dark grey boxes =Thermosets

SHOT WEIGHT CONVERSION TABLE

Injection unit

CLAMPING/INJECTION UNITSHOT WEIGHTCLAMPING/INJECTION UNITSHOT WEIGHT

8

TM 100/...

1000 / 1100

420 x 420

200 …. 450

380

830

140 / 26,4

1,5 - 294

.../210 .../350 .../525

25 30 35 30 35 40 35 40 45

150 175 200

22 22 22

73,6 106 144 123 169 220 193 251 318

2940 2042 1500 2835 2083 1595 2743 2100 1659

372 298 238

9,9 14,4 22,3 11,6 17,9 28,5 14,3 22,8 29,7

490 621 770

250 / 86 250 / 86 350 / 86

71,4 103 140 74,1 101 132 76,6 100 127

95 137 187 99 135 176 102 133 169

155 223 303 216 294 384 287 375 475

15 15 15

250 250 250

32 / 61 34 / 63 36 / 65

4300 4300 4400

3,9 x 1,4 x 2,0 4,1 x 1,4 x 2,0 4,4 x 1,4 x 2,0

750 / 315 750 / 315 750 / 315

TM

10

0T

M 1

00 Clamping unit

Clamping force / locking force kN

Distance between tier-bars mm x mm

Mold height mm

Opening stroke mm / kN

Maximum daylight mm

Ejector force mm /kN

Dry cycle time 1) s - mm

Injection unit

Screw diameter mm

Screw stroke mm

Screw L/D ratio mm

Theoretical shot volume cm³

Specific injection pressure bar

Max. screw speed min-1

Max. plasticizing rate (PS) 2) g / s

Max. screw torgue Nm

Nozzle stroke / nozzle contact force mm / kN

Injection rate into air cm³/s

Injection rate into air with twin-pump (option) cm³/s

Injection rate into air with hydraulic accumulator (option) cm³/s

Drive

Drive power kW

Oil tank volume l

electrical power supply without/with Europackage kVA

Weights, dimensions

Netweight (exclusive oil) kg

lenght x width x weight 3) m

max. mold weight /min. mold diameter 4) kg / mm

1) according to Euromap 6 2) according to Battenfeld norm, higher plasticizing rates possible with twin-pump (option) 3) max. length with middle screw diameter in back position 4) max. 2/3 on clamping platen

9

TM 160/...

1600 / 1760

520 x 520

225 …. 550

480

1030

180 / 41,2

1,8 - 364

.../525 .../750 .../1000

35 40 45 40 45 50 45 50 55

200 225 250

22 22 22

193 251 318 283 358 442 398 491 594

2743 2100 1659 2678 2116 1714 2490 2016 1666

378 291 190

22,7 36,2 47,1 27,9 36,3 43,9 23,7 28,6 35,5

770 998 1540

350 / 86 350 / 86 400 / 100

121 158 200 124 157 194 134 165 200

172 225 285 176 223 276 190 234 284

287 375 475 376 476 588 478 590 714

22 22 22

350 350 350

43 / 72 46 / 75 47 / 76

6300 6400 7100

4,8 x 1,5 x 2,1 5,0 x 1,5 x 2,1 5,3 x 1,5 x 2,1

1400 / 400 1400 / 400 1400 / 400

TM

16

0T

M 1

60Clamping unit



Mold height mm


Maximum daylight mm



Injection unit

Screw diameter mm

Screw stroke mm

Screw L/D ratio mm










Drive

Drive power kW

Oil tank volume l


Weights, dimensions





10

TM 210/...

2100 / 2310

570 x 570

250 …. 600

530

1130

180 / 41,2

2,1 - 399

.../750 .../1000 .../1330

40 45 50 45 50 55 50 55 65

225 250 275

22 22 22

283 358 442 398 491 594 540 653 913

2678 2116 1714 2490 2016 1666 2470 2041 1461

398 260 207

38,1 49,6 60 32,4 39,2 48,5 31,2 38,7 46,2

998 1540 1940

350 / 86 400 / 100 400 / 100

170 215 265 183 226 273 184 223 311

222 281 347 239 296 357 241 292 407

376 476 588 478 590 714 567 686 958

30 30 30

400 400 400

55 / 84 57 / 86 60 / 89

8100 8800 9000

5,2 x 1,6 x 2,3 5,5 x 1,6 x 2,3 5,6 x 1,6 x 2,3

1800 / 500 1800 / 500 1800 / 500

TM

210

TM

210 Clamping unit



Mold height mm


Maximum daylight mm



Injection unit

Screw diameter mm

Screw stroke mm

Screw L/D ratio mm










Drive

Drive power kW

Oil tank volume l


Weights, dimensions





11

TM 270/...

2700 / 2970

630 x 630

250 …. 650

600

1250

200 / 59

2,4 - 441

.../1000 .../1330 .../2250

45 50 55 50 55 65 55 65 75

250 275 325

22 22 22

398 491 594 540 653 913 772 1078 1436

2490 2016 1666 2470 2041 1461 2500 2070 1555

350 278 248

43,6 52,8 65,3 41,9 51,9 62 46,5 70 105

1540 1940 2373

400 / 100 400 / 100 500 / 129

246 304 368 248 300 419 212 296 394

330 408 494 333 403 563 284 397 529

478 590 714 567 686 958 726 1014 1351

37 37 37

550 550 550

57 / 86 60 / 89 71 / 100

10600 10800 11800

5,7 x 1,7 x 2,3 5,8 x 1,7 x 2,3 6,7 x 1,7 x 2,3

2400 / 500 2400 / 500 2400 / 500

TM

270

TM

270Clamping unit



Mold height mm


Maximum daylight mm



Injection unit

Screw diameter mm

Screw stroke mm

Screw L/D ratio mm










Drive

Drive power kW

Oil tank volume l


Weights, dimensions





12

TM 350/...

3500 / 3850

710 x 710

300 …. 710

670

1380

200 / 59

2,7 - 497

.../1330 .../2250 .../3400

50 55 65 55 65 75 65 75 85

275 325 375

22 22 22

540 653 913 772 1078 1436 1244 1657 2128

2470 2041 1461 2500 2070 1555 2500 2022 1574

318 283 178

48 59,3 70,9 53 79 120 50 76 107

1940 2373 3759

400 / 100 500 / 129 600 / 129

283 343 479 242 338 450 260 346 445

368 446 623 315 440 585 338 450 578

567 686 958 726 1014 1351 1040 1385 1779

45 45 45

650 650 650

78 / 107 90 / 119 94 / 123

14400 15400 16400

6,0 x 1,8 x 2,5 6,9 x 1,8 x 2,5 7,1 x 1,8 x 2,5

3200 / 500 3200 / 500 3200 / 500

TM

350

TM

350 Clamping unit



Mold height mm


Maximum daylight mm



Injection unit

Screw diameter mm

Screw stroke mm

Screw L/D ratio mm










Drive

Drive power kW

Oil tank volume l


Weights, dimensions





13

TM 450/...

4500 / 4950

800 x 800

300 …. 770

760

1530

250 / 81

3,0 - 560

.../2250 .../3400 .../5100

55 65 75 65 75 85 75 85 95

325 375 425

22 22 22

772 1078 1436 1244 1657 2128 1878 2412 3012

2500 2070 1555 2500 2022 1574 2500 2110 1689

389 244 152

72 107 160 68 104 146 65 91 118

2373 3759 6048

500 / 129 600 / 129 600 / 129

333 465 619 358 476 612 355 456 570

363 507 675 390 519 668 387 497 622

726 1014 1351 1040 1385 1779 1291 1659 2072

55 55 55

800 800 800

102 / 131 106 / 135 111 / 140

19300 20300 21300

7,4 x 2,0 x 2,5 7,6 x 2,0 x 2,5 8,0 x 2,0 x 2,5

4000 / 630 4000 / 630 4000 / 630

TM

450

TM

450Clamping unit



Mold height mm


Maximum daylight mm



Injection unit

Screw diameter mm

Screw stroke mm

Screw L/D ratio mm










Drive

Drive power kW

Oil tank volume l


Weights, dimensions





14

Electrical componentsOperating voltage 230/400 V-3Ph, 50 Hz

Common voltage supply <=TM 160 with 230/400 V

Software for operating hours counter

Closing / Opening - 5 profile steps

Ejection forward/back - 3 profile steps

Nozzle forward/back - 3 profile steps

Injection / Holding pressure - 10 profile steps

Screw speed / Back pressure - 6 profile steps

Purging program

Stroke zero offset settings

Start-up program

Adjustable injection pressure limitation

Switchover to holding pressure MASTER / SLAVE by injection time, screw stroke/injection volume and injection pressure

Self-teaching temperature controller

Display of temperature inside electrical cabinet

Seven-day timer

Access authorization via USB interface

Access protection via password system

User programming system “APS”

Freely configurable screen pages “User page”

Freely configurable status bar

Physical, process-related units

15“TFT colour screen

Automatic dimming

Logbook with filter function

Hardcopy function

Notepad function

Internal data storage via USB connection or network

Online language selection

Online selection of imerial or metric units

Online operator manual

Time Monitoring

Quality table

Events protocol (logbook) for 10000 events

Cycle time analysis

Parts counter with good/bad part evaluation

12 Trend diagrams

12 SPC Charts

Actual value graphics with 16 curves

4 Envelope curves

Injection Integral supervision

Metering Integral supervision

Alarm message via E-MAIL

USB - 2x operating unit, 2x control cabinet

2 Ethernet interfaces inside electrical cabinet

Printing via USB connection or network

Paint RAL 9002 / RAL5002 ultramarine blue

STA

ND

AR

D F

EA

TU

RE

SS

TA

ND

AR

D F

EA

TU

RE

S

HydraulicHydraulic unit with variable pressure and speed axial piston pump

Oil filtration by fine flow filter with electrical clogging indicator

Oil level indicator with alarm

Closed-loop oil temperature control with oil pre-heating

Oil temperature monitoring

Oil tank with connections for external oil filtration

Separate hand keys for core pulls

Display of actual system preasure via touchscreen

Clamping unit

Clamping force adjustable via touchscreen

Closing and opening speed adjustable

Closing and opening force adjustable

Mould safety program

Moving platen supported by positioned linear guides

Platen drillings and register rings according to EUROMAP

Fixing holes for robot on top of the fixed platen according to EURO-MAP/VDMA

Hydraulic mold close inhibit, electrically monitored on operator side

Central hydraulic multi-stroke ejector, adjustable

Flexible parts removal from 3 directions

Injection unit

Injection closed loop controlled via servo valve (only with S-version)

Screw L/D=22 with check valve, screw and barrel nitrated

Thermocouple failure monitor

Maximum temperature supervision

Plug-in ceramic heater bands

Temperature control of feed throat integrated

Open nozzle

Swiveling injection unit up to .../1330 injection unit

Purge guard electrically monitored

Hopper of V2A stainless steel can be shut and emptied

Selectable barrel stand-by temperature

Physical units - bar, ccm, mm/s etc.

Screw protection

Linear bearings for the injection unit

Safety gate

Monitored safety gate, CE-confirmed

Maintenance-free safety gate locked by electromagnet

Safety gate free for mould change and handling by robot

Cooling and conditioning

Cooling-water flow controller with temperature gauges in return lines, up to 100t: 4-way, from 350t: 6-way

15

OP

TIO

NA

LFE

AT

UR

ES

OP

TIO

NA

L F

EA

TU

RE

S

Hydraulic E S

Hydraulic accumulator for fast injection incl. loading pump and par-allel ejector movement and core pull movement via double pump –– •

Extra large oil cooler • •Core pull movement and parallel ejection with DFEE double pump –– •

Core pull movement and parallel ejection incl. Fast injec-tion with DFEE double pump –– •

Injection parallel to clamp force build-up (with hydraulic accumulator) –– •

Hydraulic core pulls. Limit switch function according to EUROMAP 13. Pressure and speeds adjustable • •

Pneumatic core pull • •Pneumatic manifold for Mouldmaster nozzle (controlled 1 nozzle or more parallel in the mould) • •

Hydraulic manifold for Mouldmaster nozzle (controlling 1 nozzle or more parallel in the mould) • •

Filter in water inlet of oil cooler • •Adapter with ball valve on the oil tank for oil maintenance • •Separate bypass filtration unit • •

Clamping unit

Non-standard mould hight after customers request • •Isolation platens • •T-slots in mould platens • •SPI bolt pattern • •Ejector cross in clamping platen as per EUROMAP/SPI • •Maximum ejector force increased • •Mechanical ejector couple • •Ejector platen safety device • •Mechanical mould safety mechanism • •Unscrewing device with hydro-motor additional to standard ejector • •Parts chute for separation of good/bad parts • •Photoelectric ejection check • •Air valve, action initiated (ON) and timer (OFF) • •Quick mold clamping system magnet., hydr. or mech. –– •

Injection unitGrooves in the feeding zone • •High torque screw motor in lieu of standard • •High temperature heater bands (max. 450° C) • •Screw drive by a.c. servo-motor –– •Ball type screw tip • •Needle type shutoff nozzle with spring, pneumatic opera-ted or hydraulic operated • •

Melt temperature- or pressure sensor in cylinder head –– •Hydraulic cross-bolt type shutoff nozzle (from SPE2250) • •Open Airmould®-nozzle, pressure controlled –– •Relief valve for nozzle pressure control (standard from 350t) • •Wear resistant screw and barrel AK+ • •Barrel insulation • •Screw with mixing section or barrier section • •Hoppermagnet • •Hopper loader UNIFEED A1 (till SPE1330) • •

Safety gate

Operating safety gate at the rear side • •Front side gate safety system for manual part removal • •

E S

Pneumatic safety gate at the operator side • •Initiate next cycle by closing safety gate in semi-auto operation • •Safety gate clearance operator side/rear side extended • •Safety gate rear side lowered at the top of the upper tiebar • •

Cooling and conditioning

Additional flow controller with temperature gauges • •Shut-off valve for cooling water battery • •Blow out valve for cooling water battery • •Hosting of cooling circuits on the fixed platen for the moving platen • •

Electrical components

Temperature control zone for hot runner • •Non-contact stroke transducers (standard from 350t) –– •Special voltage • •Control cabinet cooler • •Closed loop temperature control of mould • •Additional socket • •Fuse protection for sockets • •Power factor correction and active power optimization –– •Interface for handling equipment • •Energy consumption analysis –– •Integrated Tandemmould –– •Switch over to holding pressure by cavity or melt pressure • •Switch over to holding pressure by external signal • •Purging program through the open mold • •Melt cushion control –– •Audible alarm • •Analog temperature control interface • •Temperature control interface digital, serial 20mA TTY protocol –– •CAN-Bus-interface for mold conditioner as per EUROMAP 66-2 –– •CAN-Bus-interface for hot runner as per EUROMAP 66-2 –– •Interface for Airmould® mobile/integrated as well as EUROMAP 62 –– •

Interface for robots as per EUROMAP 67 • •Adaptor from EUROMAP 67 to EUROMAP 12 • •Interface for conveyor belt • •Scale interface • •Host computer interface/PDA (EUROMAP 63) –– •Relays contact parallel to plasticizing • •Machine fault (potential-free contact) • •BNC connectors for injection process analysis –– •Remote diagnostics via network • •Interface for common data storage with Battenfeld robot –– •Interface for vacuum pump –– •Second injection data setting for automatic start up –– •

Accessories

Special paint • •Tool kit • •Touch-up paint • •Levelling pads • •USB stick for data storage • •

THE POWER to SUCCEED

Battenfeld Kunststoffmaschinen Gesellschaft m.b.H.Wiener Neustädter Strasse 81 · 2542 Kottingbrunn · AustriaTel. +43 2252 404-0 · Fax +43 2252 [email protected]

www.battenfeld-imt.com M/3

/

/T

M 1

00t–

450

t20

00/1

0/07

(TS

/10/

07)·

Nar

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Sub

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100t–450t TM SERIES - WITTMANN...

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