Precise plastic parts in record time
Baumüller supplies a highly dynamic and compact drive system for the BOY Electric injection molding machines from Dr. Boy GmbH & Co. KG
How can small, technically complex plastic parts be injection molded quickly and efficiently? With injection molding machines from BOY. The newly developed, fully electric BOY Electric injection molding machine series with a clamping force range from 350 to 800 kN offers high dynamics and parallel movements. Thanks to highly dynamic drives and a compact design, the machine combines high production speed with a minimal footprint.
Injection molding processes are common practice today. They are used to produce technical components, toys, packaging, and more. The machine's task is to manufacture high-quality plastic parts in record time. “More than 50 percent of the machines we sell produce technical components,” explains Martin Kaiser, Technical Director at Dr. Boy GmbH & Co. KG.
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Minimal installation space for precise injection molded parts
The fully electric BOY Electric injection molding machines offer even greater precision in position detection, enable dynamic motion sequences, and reduce cycle times through parallel clamping force build-up for injection.
Dr. Boy GmbH & Co. KG, based in Neustadt-Fernthal, is a leading manufacturer of injection molding machines with clamping forces up to 1,250 kN.
BOY's success story began in 1968 with the launch of the BOY 15. Its compact design, ease of use, economic efficiency, and some completely new technical solutions revolutionized fully automated production in plastic injection molding. Through continuous research and consistent further development, BOY now offers a whole range of injection molding machines for all requirements. Since the company was founded, over 50,000 injection molding machines have been delivered to all continents.
End users have very high expectations: “The all-electric injection molding machine offers a clever combination of energy savings and increased precision,” explains Martin Kaiser.
BOY relies on an efficient drive system from Baumüller. The solution consists of the dynamic DSD2 servo motor series, the compact DSC2 servo motors, the b maXX 5300 series system including the b maXX 5000 power supply unit, and the servo hydraulics software module integrated in the inverter. The software runs on the softdrivePLC contained in the drive.
Patented back pressure measurement without additional components
BOY Electric offers all the advantages of a fully electric injection molding machine in terms of high dynamics and parallel movements. Injection, dosing, and ejection have been implemented electromechanically in the machine in collaboration with Baumüller. The optimal and most efficient solution was selected for each movement.
At the heart of the machine is the newly designed electromechanical universal injection unit. The patented back pressure measurement is unique in the injection molding market. A force sensor records the force transmitted to the screw at the injection mechanism and evaluates it in the Baumüller servo drives. “We spent a long time thinking, trying things out and tinkering. It took about a year from the idea to the implementation,” says Martin Kaiser, who has been working at BOY for 18 years.
Electromechanical drive technology offers many advantages: even more precise position detection, dynamic motion sequences, and shorter cycle times thanks to parallel clamping force build-up for injection.
The dynamic DSD2 servo motor series enables shorter cycle times through parallel closing force build-up for injection molding. 
The compact servo controllers of the b maXX 5300 modular system reduce wiring effort thanks to integrated safety functions
Servo motors for increased dynamics
Both Baumüller's dynamic DSD2 and compact DSC2 servo motors are used, which were designed for the highest acceleration requirements and best start-stop qualities. These have an excellent torque-inertia ratio. This ensures maximum dynamics, i.e., fast and precise manufacturing of injection molded parts. The movements of the individual drives must be synchronized with high precision in order to achieve accurate results. The servo motors have very good running characteristics and, in combination with Baumüller's b maXX servo drives, enable high positional and speed accuracy. The components work together perfectly and are very energy-efficient, as they share energy in the DC link network.
The b maXX 5300 modular system with integrated safety functionality controls the electric drive axes with high precision and can be integrated into the smallest of spaces. This opens up numerous possibilities for expanding the machine.
The two-platen clamping unit with lubricant-free tool installation space is supplied by energy-saving servo hydraulics. Together with pressure intensifier and differential pressure technology, hydraulic pressure is dynamically converted into clamping plate movement and energy-efficiently into clamping force. In order to flange the servo motor to the pump in the best possible way, Baumüller has developed a customer-specific solution together with BOY. This enables very compact motor-pump combinations.
The b maXX servo drives impress with their drive intelligence for servo-hydraulic applications, which Baumüller developed in partnership with BOY: “The highly dynamic pressure and volume flow control in a cycle time of 125 µs achieves the highest precision and repeat accuracy that we need for the optimal operation of our compact injection molding machines,” emphasizes Martin Kaiser.
The precise positioning of the electromechanical ejector enables parallel, precise, and highly dynamic handling movements to be achieved.
The new electromechanical ejector enables even more accurate position detection and very direct control. This allows parallel, precise, and highly dynamic movements to be achieved in conjunction with clamping plates or handling movements. These not only save cycle time, but also protect the product, tool, gripper, and machine. The electromechanical ejector offers a major advantage in very slow traverse movements, as stick-slip effects, which are common in hydraulics, are avoided.
The dosing drive is highly efficient and offers significant energy savings potential for high material throughput rates. In addition, its low-noise, quiet operation improves the working environment.
“The design is flexible. The motors can be optimally adapted to the conditions in our injection molding machines, both mechanically and electrically,” says Martin Kaiser, praising the collaboration with Baumüller. Baumüller supported BOY with drive dimensioning and initial commissioning of the all-electric injection molding machine.
Perfect teamwork
Dipl.-Ing. Martin Kaiser, Technical Director at BOY: "We have been working with Baumüller for 15 years now. Particularly noteworthy is the consistently excellent advice and support, even for special drives that are only required in small quantities. Baumüller has a very good delivery performance for series production, which has been maintained even in times of electronic component shortages. Baumüller responds flexibly to delivery time requests and offers excellent technical support. Help is provided quickly and competently."
BOY develops and manufactures exclusively at its production site in Neustadt-Fernthal, Germany. This is where compact injection molding machines with clamping forces of up to 1,250 kN are produced.
Conclusion
The fully electric BOY Electric injection molding machine is dynamic, fast, and precise. It can be used to injection mold a wide variety of plastic parts in record time. The close partnership between BOY and Baumüller has resulted in a compact drive system that benefits from high dynamics, precise control, and a space-saving drive concept. For more than 15 years, new innovative injection molding machines with state-of-the-art solutions have been developed in cooperation with Baumüller. Thanks to flexible and customer-specific adaptations and further developments of the drive system, the BOY Electric offers high production speed and a minimal footprint.
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