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Hybrid Allrounder 520 H produces high-quality moulded parts from ABS recyclate

At NPE 2024, a hybrid Allrounder will demonstrate how ABS recyclate can be processed into high-quality moulded parts and returned to the material cycle. The exhibit from the Hidrive series is equipped with Arburg's new hybrid machine technology, which is not only excellent at saving energy and conserving resources, but is also efficient in production, user-friendly and reliable. This allows users to harness the benefits of both electric and hydraulic technology – namely speed and precision paired with power and dynamics.

Arburg's finely graduated hybrid machine technology is comparable to all-electric machines in terms of dry cycle times and injection speeds. This makes the new Allrounder Hidrive (H) an energy-saving alternative to hydraulic machines and an economical alternative to electric machines, unlike anything previously available on the market.


ABS recyclate returned to the cycle

At NPE 2024, an Allrounder 520 H "Premium" with a clamping force of 1,500 kN will be processing 100 per cent recycled ABS from SEG, made from recycled washing machines, dryers and refrigerators. A 1+1+1-cavity family mould is used to produce a machine base, feed hopper and controller on a scale of 1:18 in a cycle time of around 50 seconds. These are then separated from each other in a cutting station and complete a 15-part set for a model Allrounder. A Multilift Select V 8 linear robotic system removes the moulded parts and sets them down in a box. A box changer provides around two hours of autonomy.


Sensor controlled mould monitoring

The "aXw control ReferencePilot" control assistant and a pressure sensor ensure that the holding pressure is regulated very precisely based on the pressure profile in the mould and that fluctuating material viscosity is compensated for. The result is high-quality moulded parts with similar properties to those made from virgin material, but with a significantly smaller carbon footprint.

In this application, the Moldlife Sense computer system enables sensor-controlled mould monitoring over the complete life cycle. The recorded data is passed via an OPC-UA interface directly to the Gestica control system, which displays corresponding malfunctions as well as performance-dependent maintenance intervals, thereby enabling predictive maintenance.


Cost- and resource-saving alternative

The Hidrive series combines an electric energy-efficient and precise clamping unit with a powerful and dynamic hydraulic injection unit. It is characterised by attractive purchase and operating costs as well as a very good energy balance and carbon footprint.

A novelty in the new hybrid Allrounder "Premium" machines is flow splitting as standard, with cutting-edge Varan valve technology used to split the main pump's available flow volume when required. This enables simultaneous movements of hydraulic auxiliary axes with programmable control such as the ejector and core pull – without technology stages or multi-pump technology. This saves energy, costs and space on the machine and increases production efficiency.

Thanks to a new oil management concept, the Allrounder machines require up to around 35 per cent less oil. The required cooling water capacity can be reduced by up to 70 per cent and the dry cycle time is also reduced by around 40 per cent.


Three performance variants for optimal adaptation

The hybrid Allrounder Hidrive is currently available in sizes 470, 520 and 570 and in three performance variants: "Comfort", "Premium" and "Ultimate". The first two variants feature the Arburg servo hydraulic system (ASH) as standard, with the speed-controlled, water-cooled servo motor adapting continuously to the actual power requirement, thus enabling particularly energy-efficient and low-emission operation. At the same time, however, the machine's cooling requirements and noise level are also significantly reduced.

The "Premium" performance variant achieves dry cycle times of 1.2 seconds and can be used for a wide range of applications such as the production of precision components for the automotive and electronics industries. Its standard equipment includes a planetary roller screw drive and the Arburg electro-mechanical dosage (AED) function for longer dosage times.

The "Ultimate" variant is specially designed for high-speed and sophisticated processes. AED is included as standard equipment here too, alongside hydraulic accumulator technology, which ensures a constant pressure level. The result: quick, dynamic simultaneous movements and more process setting options. The Gestica control system with "aXw Control ScrewPilot" function compensates for errors in the filling process and keeps the mould filling stable. All together, this provides for a level of injection precision equivalent to that of an electric injection unit.

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