Machines

SMART Line
The standard injection molding machines of the Extra, HT, Dragon and Santosh machine ranges provide the keenest price/performance ratio and shortest delivery times to ensure maximum cost-efficiency for standard applications. The machines are sold as part of Demag Plastics Group`s Smart Line.
Machines of the Smart Line are produced close to the customer at Demag Plastics Group`s facilities in Germany, the US, India and China all of which received a DIN/ISO 9001 or VDI certificate and meet the most stringent quality requirements.
They are built with standardized components and are supplied with safety equipment, housings, automation options and features to suit regional requirements. All machines of the Smart Line are equipped with ergonomic Demag control technology and a uniform set of hydraulic and electronic components.
The Smart Line is comprised of the Extra machine series, which is built in Germany for the European market and western industrial countries, the HT range, which is built in Strongsville/USA for the US market, the Dragon series from China, built for the Chinese market and the Santosh range, which is built in India for the Indian subcontinent and selected export markets in Africa, Asia and Australia.

PERFORMANCE Line
Modular injection molding machines of the hydraulic Concept/System, Titan (Caliber/MaXX) and the electric IntElect machine ranges provide maximum versatility and cost-efficiency for changing processing requirements. The modular construction of the machines and their customized configuration options allow for extension, upgrading and adaptation to suit specific applications as well as their integration into system solutions or highly automated production cells. All machines of the Performance Line are equipped with the popular NC4-contol operator terminal.
The modular machines are produced on a large scale at Demag Plastics Group`s facilities in Germany and the US, all of which received a DIN/ISO 9001 or VDA certificate.
The Performance Line is comprised of the Concept/System machine range with hydraulic or hydro-mechanical clamping unit, the Titan (Caliber/MaXX) machine range with a short two-platen clamping unit and the all-electric IntElect machine range.

IntElect: the smart all-electric solution between 500 kN - 3,500 kN
Concept/System: modular and all-hydraulic with clamping forces of 250 kN - 1,100 kN
Concept/System: modular with toggle clamp with clamping forces of between 1,250 kN - 4,200 kN
Large System: more force for large parts with clamping forces of between 4,200 kN - 15,000 kN
Titan: the new performance category with clamping forces of up to 20,000 kN

ELITE Line
With special injection molding machines of the Elite Line, Demag Plastics Group caters for the exclusive requirements of corporate end users in the high-end and high-tech segment. The EL-EXIS S, Multi, Vertical, Praxis and Newbury machine ranges unite the versatility of all Demag modular systems with specific features such as high-speed, multi-component processing or insert molding. The high-quality equipment of all members of the Elite Line is the cornerstone of automated system solutions to suit the requirements of special applications and the specific demands of corporate end users.
Machines of the Elite Line are manufactured centrally in Demag Plastics Group facilities in Germany and the US, which were certified DIN/ISO 9001.The Elite Line comprises the EL-EXIS S machine range with modular drive technology for high-speed applications, Multi with several injection units for multi-component processing as well as Vertical, Newbury and Praxis with vertical clamping units for insert molding. Experienced Demag Plastics Group product managers support Elite Line customers with their competent expertise in all areas of application, their insights into the market and their knowledge about individual products.

EL-EXIS S: High-performance, high-speed processing in the clamping force range of between 600 kN and 5,500 kN
Multi: Solutions for multi-component injection molding
Multi-Plug: Upgrading your system to multi-component technology
Vertical: Rotation to counter the force of gravity for clamping forces of between 350 kN and 6,500 kN




Robots

Tailored automation – Linear robots made by Demag
Inserting, part removal, stacking, secondary finishing – linear Demag robots of the DR 6xx range can manage straightforward and complex tasks with high precision and speed. Equipped with heavy duty, smart technology, these handling specialists can exploit new rationalization potential, and due to their durability and reliability, your investment will pay off quickly.

DR 6xx

The main X, Y, Z robot beam axes – Handling heavy duty-loads with high speed and minimum vibration.
Z stroke - Traverse axis
The traverse axis consists of an accurately machined steel support. Precise parallelism of the guide rails as well as rack-and-pinion drives guarantee low-vibration movements and minimum wear on robots executing high-performance production sequences in continuous duty.
Y stroke – Vertical stroke
The vertical axis is made of steel and is configured for high acceleration and delays. All larger robot models from DR 633 and higher are equipped with a patented telescoping stroke – with separate rack-and-pinion and synchronous belt drives. The speed of the gripper, which moves twice as fast as the telescoping rod it is attached to, promotes minimum removal times even for long vertical strokes.
X stroke – Strip stroke
The mounting profile consists of a sturdy tensional aluminium profile rod (DR 612 to DR 643) with a high torsional stiffness or a sturdy steel rod (DR 653 and 663). Minimum weight and high stiffness promotes minimum vibration as well as accurate picking and placing even at high speed.

Auxiliary axes C, A, B: with pneumatic drives and servo drives.
C axis with swivelling placement gripper (standard) - The high-torque C axis with pneumatic drive supports two limit positions (0° and 90°) and optional locking at 90°.
A axis with pivot gripper hand (optional) - The pivoting A axis is operated with a pneumatic drive and supports two positions (0°/180°) or three positions (0°/90°/180°).
B axis with pivoting vertical arm (optional) - The pivoting vertical arm was specially designed for complex stacking tasks and changing removal jobs. The B axis is a motor-driven 0°-270° module with 15° gradation.

Drives: asynchronous or synchronous movement.
Depending on production requirements, Demag robots can be equipped with the following pre-programmed drive kits to suit individual applications:
Asynchronous servo drive with optional sequences or parallel movement of the main axes.
Synchronous servo drive with standard, high-speed or ultra-high speed design - each option with parallel operation of the main axes

Control cabinet: standalone or integrated versions.
DR 6xx series - All DR6xx Demag robots are offer optional standalone or integrated control cabinets. Small control components leave ample room inside the control cabinet: depending on their size, robots can be equipped with up to six servo-controlled axes and extensive controls for downstream equipment.
DR 6xx COMPACT series - In many areas of application, linear robot controls can dispense with an extensive number of I/Os for downstream equipment. In these cases, the entire robot control system can be stored in the Z main beam of the unit. This smart solution is available for the entire DR 6xx COMPACT series.

Control and signal transmission: with teach-in control and CAN bus system.
Demag robots of the DR 6xx and DR6xx COMPACT series are equipped with a high-performance teach-in control and a tried-and-tested CAN bus system. Due to the reduced cable and connector plug requirements, particularly for connection with continuously moving structural robot components, this system offers the benefit of a significantly improved process safety. All signal and sensor wiring for the gripper hand, for example, is bundled to correspond to one structural control element at the moving carriage on the strip stroke. The structural element is then connected to both the control units inside the control cabinet and the remote control via one CAN bus cable.
Demag injection moulding machines can communicate with Demag robots by means of an optional CAN bus interface. The benefit of this feature lies in the fact that the robot`s set data is stored together with the corresponding machine setting program. Moreover, all functions of the production unit with relevance for every-day production processes from activation and deactivation of the robot or other automation equipment to plain-text error messages are controlled by the Ergocontrol system of the injection moulding machine.

Operation and programming: comfortable and easy.
A convenient robot control system and the so-called "Teach Box" with LCD colour monitor and graphic as well as a graphical user interface provide comprehensible robot programming and operation with a strong focus on practical application. Both beginners as well as experienced operators programming the robots are supported by a graphical teach-in programming sequence, a pre-programmed standard sequence, optional menu-driven plain-text programming, and storage of system and application programs on separate smart media-cards.




Control Systems
NC4 control – Convenient setting, control and documentation.
The name Demag is commonly associated not only with machines but also with the high-performance NC4 control system. Yet, even the most efficient and ergonomic control system requires a suitable user interface for full access to and control of all machine functions. NC4 control the operator terminal of Demag machines offers precisely these features. Operation is uniform for all machines and models, however large or small. In accordance with the ergonomic principles of Demag`s product range, NC4 control provides convenient and logical operator support across the process sequences from set-up and process optimization to production and documentation.

NC4 control at a glance - Clearly presented information on a colour screen.
A particularly large colour monitor provides a clear overview at a glance. The distinct and clear presentation of the text facilitates machine operation and relieves the operator. Despite the need for a comprehensive supply of information, all screen pages offer a straightforward and logical structure without providing an excessive amount of information. In addition to this, the NC4 control accommodates operators with 19 language options, up to three of which can be installed at any one time and selected at the touch of a button. All values can be displayed as metric or US/British measurements.

NC4 control – hot keys and symbol keys for faster operation.
NC4`s logical and clear layout of all operation keys facilitates machine operation. At every programming stage, hot keys and international symbol keys provide access to additional display screens which follow from the last programming step in a logical or process-related sequence.

Two components – one user interface.
NC4 provides a second keypad for the second injection unit, which is used during two-component injection moulding processes. Special equipment such as a rotary table for transferring parts during multi-component injection moulding can also be programmed on the same interface.

Chip card provides extra security.
NC4`s integrated chip card reader provides you with an additional security level which allows users to release or inhibit certain control system function groups in order to authorise only selected operators to change machine settings for the purpose of process optimisation.

Additional display screens for different processing methods.
Special processing methods such as gas-assist (GIT), in-mould decorating, the wide variety of multi-component injection moulding and other special techniques are becoming increasingly important. Ergocontrol can already accommodate them with a number of required additional display screens, which also provide the ergonomic operation our customers have come to expect.

Easy handling of multi-componentsprocessing with Ergocontrol.
Flexible operation means utilising the existing machine technology to accommodate a host of multi-component applications. Numerous complex machine sequences profiles have been added to the existing range of Ergocontrol options for machine processing sequences.
Simple acquisition means that the Ergocontrol system obviates the need for time-consuming retraining of machine setters, since the operation of standard functions is identical to that required for single-component machines.

Safe monitoring of complex processes.
In short: The combination of the Ergocontrol menus "Machine operation" and "Mould operation" provides a clear display of information and allows safe programming as well as documenting of straightforward as well as complex injection moulding processes.

Documentation, printing and data storage
NC4 is the ideally equipped for all documentation tasks. The integrated thermal printer can be used to print out selected statistical process parameters or complete screens according to time or number of shots. The disk drive allows you to save your mould set-up and handling data as well as the complete machine set-up data. This benefit saves time and money, particularly for processes which require frequent product changes. Naturally, you can also save important process parameters to disk or transmit them to a master PC.

The new NC5 control system: Efficient, intelligent and convenient.
The new NC5 is the perfect control system of the future. It is the logical advancement of the tried-and-tested Demag control system: equipped with the NC5, every Systec is controlled by a high-performance system for easier machine access and control. The reason for this is the system’s functionally and logically organised control structure, which is closely tailored to the very requirements of the operator. In correspondence with the ergonomic principle of Demag machines, it conveniently supports the operator’s every step, from machine setting and process optimisation to production and documentation. Intelligent modules provide valuable application-oriented assistance.

Logically organised colour touch screen.
The extra large screen provides a clear picture of the machine’s processes at a glance. The screen is designed as a touch screen to allow on-screen machine operation. The easily legible screen font facilitates the work and reduces operator fatigue. Despite the fact that all required details are displayed, the screen pages have a concise, logical and uncluttered structure. The NC5 offers a choice of 19 languages, up to three of which are defaults that can be selected at a touch of the button. All values can be displayed both in metric and imperial units of measurement.

Hotkeys and icon keys for faster operation.
On the new operator terminal, the user can choose between a touch screen or the traditional integrated keyboard for data input. At every stage of the process, the operator can select additional screens with a logical or process-related connection to previous programming sequences by using convenient hotkeys or international-standard icon keys.

Two components, one user interface.
The NC5 provides a complete second function keypad for operating the second injection unit during two-component injection moulding. The same operating terminal can be used to program special equipment such as a rotary table for transferring multi-component mouldings.

USB interface for fast data exchange.
The operator logs onto the system at a defined access level using a USB stick. Two additional USB interfaces also allow the storage of data and screen pages.

Additional screen pages for different processing techniques.
Specialised processes such as gas-injection technology (GIT), in-mould decorating and the wide range of multi-component injection moulding techniques are on the increase. The NC5 controller comes prepared and provides the additional screen pages required for these processing methods. These screens are based on the familiar operating methology.

Multi-component technology made easy.
More versatility: the modular Systec machine technology allows the operation of a maximum number of multi-component applications. The NC5 options for machine sequences were enhanced by several complex machine sequence profiles.
Easy operation: there is no need for time and cost-consuming relearning, as the operation of all standard functions does not differ from single-component machines.

Safe monitoring of complex processes
The more complex a process, the more logical and user-friendly the structure of the interface between machine and operator needs to be. The NC5 controller meets this very requirement. With its substantially enhanced range of functions, it exclusively caters to the specific needs of the operator.

Documenting, printing, storing.
For documentation purposes, the integrated thermal printer provides statistical process parameters or complete screen shots, which can be selected according to time period or number of shots. The NC5 allows the convenient management of machine settings and mould data as well as their storage on any required data carrier via USB interface. This will save time and money wherever frequent product changes occur. Naturally, all quality-related process parameters can be stored locally or transmitted to a central computer.




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