Boost your electrification level

Sustainable and efficient drive concepts for the plastics industry at the K 2022

From October 19 to 26, 2022, the plastics and rubber industry will be meeting at the K trade fair in Düsseldorf. The circular economy, digitalization, sustainability and energy efficiency are the topics of focus of this year’s trade fair. Baumüller will be presenting various suitable exhibits. We will show how energy-efficient drive systems record and lower the CO2 footprint of the end product. Thanks to clever Baumüller software features, machine damage can be avoided and the emissions increased. Another trade fair display unit illustrates how the digital twin can be used to design and commission servo-hydraulic drive trains completely virtually. All use cases will be shown live at the exhibits in hall 11 on stand A45.

Injection molding machineFig. 1: Baumüller offers a comprehensive portfolio of solutions for the intelligent control and electrification of hybrid and fully-electric plastics machines

Smart use cases at the trade fair – increase energy efficiency, reduce the CO2 footprint, Industry 4.0 and intelligent drives for the IoT

Smart Efficiency: On the Baumüller trade fair stand, a hybrid machine concept shows how intelligent drives and functions in combination with servo hydraulics help to minimize the CO2 footprint. By electrifying the closing unit and using the generator energy for braking, for example, the energy consumption of the machine can be reduced. I.e. with increasing electrification, the injection casting machine becomes more energy efficient.

Smart Energy Monitoring: In the same exhibit, drive-based energy monitoring is used to present the energy consumption of the drive system transparently.
For example, after a reference run, the travel distance can be optimized in energy terms and thus the CO2 footprint of the end product can be reduced. This new software function assists in determining the Product Carbon Footprint (PCF) or prepares for future documentation obligations within the scope of the EU’s Sustainable Product Initiative (SPI).

Smart Protection: The comprehensive software package contains numerous features specially developed for the plastics sector. One example is the internal controller “Thermal pump protection” function. The SmartValue function prevents the thermal overload of internal gear pumps. This can occur in the machine cycle, particularly in case of long hold times of high pressures and low flow. If a critical threshold value is reached, a hydraulic bypass is connected to relieve the pump. Machine damage can therefore be avoided. Another advantage of Baumüller SmartValue: The drive becomes a data hub and, in addition to the pure drive tasks, can also collect additional relevant data from various sources, pre-process them as required and, for example, forward them via OPC-UA to the cloud, control unit or an edge PC.

Smart Engineering: In another use case, Baumüller shows how the digital twin supports the design and optimization of the drive system. To this end, drives and motors of the electric closing unit with toggle joint are simulated. ProSimulation also enables faster commissioning and drive optimization of the injection casting machine. In this way, time and costs can be saved. Simulation models for the servo hydraulics are also available in ProSimulation. These will be actively presented on the trade fair stand.

ProSimulationFig. 2: ProSimulation offers the possibility of testing the drive behavior realistically during the design phase, and in addition to optimal design of the drive components, also enables faster commissioning and drive optimization

Numerous companies in different segments of the plastics industry have opted for the innovative power of Baumüller for many years – including market leaders in the film manufacture, injection casting, extrusion, thermoforming and blow molding sectors, as well as the recycling sector. The solution portfolio highlights for servo-hydraulic, hybrid and fully electric plastics machines can be seen on the trade fair stand.

Compact and low-maintenance: Direct servo pump attachment with the “Performance Line”

Servo hydraulicsFig. 3: Baumüller offers drive systems for servo hydraulic solutions that are low-maintenance and energy efficient

A patented trade fair highlight is the servo pump direct “Performance Line” attachment, which is practically maintenance-free thanks to its self-lubricating internal gearing. Direct attachment also means that the coupling and pump support can be omitted. The resulting shorter installation length enables a smaller machine installation area. Due to the flexible design of the motor flange, the motor’s installation position can be freely selected and adapts to the respective machine design.

Automation and drive solutions for plastics machines

The converter series b maXX 5300 includes feed-in and regenerative units as well as drive units, which can be quickly and easily combined by an integrated drive connect system. This allows the machine builder to benefit from low installation costs and short commissioning and service times. The controllers impress with their high power density and very small installation space. The power supply units have been expanded to include peak outputs of up to 300 kW. This is ideal for the plastics sector, because short-term high peak power outputs are often needed for dynamic movements such as the opening and closing of the closing unit.

In addition to the b maXX 5300 side-by-side system, the b maXX 5500 mono units are also available. Power outputs from 1.1 to 315 kW can therefore be covered. The entire bmaXX 5000 series also offers higher safety functions such as SLS (Safe Limited Speed) and SLP (Safe Limited Position) directly in the drive and a large number of cooling options for optimum use.

Water-cooled torque motors impress with their highly compact design and optimal heat removal. Direct coupling achieves high stiffnesses and therefore very good force transfer together with ideal control properties. The execution as a hollow shaft variant improves accessibility and enables media and tools to be fed through. For example, spindle drives can be integrated in a hollow shaft. This enables optimizations in the compact machine construction and in the process engineering.

Product solutions for the plastics industryFig. 4: Product solutions for the plastics industry

Special solutions for plastics machines

Several industry-specific drive components are also exhibited on the trade fair stand. One example is a torque motor version with thrust bearings. These thrust bearing motors were designed for use in extruders. Here the extruder screw is directly coupled with the motor shaft. The motor can therefore be connected in a space-saving and direct way, even under the high prevailing axial forces.

Another example is the electrical ejector drive DSC1-135. The direct ejector is a high acceleration drive specially designed to meet the requirements of the Injection molding machine. The motor also has a special bearing to compensate for axial forces and impresses with its very good dynamic properties. Thanks to the space-saving design, optimal and flexible integration in the machine is possible. The contamination of end products in the tool space, for example, due to oil or dirt particles, is avoided by using the direct drive technology. The synchronous direct drive is therefore a cleaner, more energy efficient and extremely dynamic drive.

Life-cycle management worldwide

In addition to the development and manufacture of automation components, Baumüller as a group of companies provides numerous services for mechanical and plant engineering and for machine operators. From project planning, design and engineering through assembly and commissioning to maintenance, retrofitting and relocation, Baumüller offers support over the entire life cycle of machines and systems. Baumüller attaches particular importance to the sustainable and resource-saving production of intelligent drive and automation solutions.

Baumüller Group
K 2022, 19 - 23 October 2019
Hall 11, Stand A45 – Düsseldorf Exhibition Center, Düsseldorf

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