issue 1/2001 ergopress - jusuco oy · the first injection moulding machine to be bought on the...

ergopressNews from

Technical parts – injection-moulded onthe Ergotech EL-EXIS S

Productivity and precision:The Ergotech EL-EXIS E

Everything you ever wanted to know about injection moulding…

The first injection moulding machine from the Internet is an Ergotech

Gas meters – manufactured toextremely high standards of accuracy

Automatic start-up and shutdownfrom the Ergocontrol operatorterminal

Issue 1/2001

det_00016•ergopr•eng•1/2001•04 21.05.2001 11:15 Uhr Seite 1

EditorialErgopress and Internet

Here is the 25th issue of Ergopress. Seven years have passed bet-ween the first and current issues during which Ergopress has in-creasingly established itself as an application-engineering publi-cation with a central focus on practical problem solutions.Ergopress is being published now for worldwide distribution in atleast seven languages with a circulation of over 20.000 copies.

The widespread use the Internet has meanwhile found has causedus to position Ergopress as a link between the classical injectionmoulding journal and Demag Ergotech’s home page. For a com-prehensive overview of topical information and discussions of prac-tical problems you would want to refer to the Ergopress, whereasfor background information and additional details supplementingthe articles you are invited to visit us on the Internet. Moreover,Ergopress will now be published at shorter intervals – at least threetimes a year – and the emphasis will be increasingly on technicalsubjects that we hope will assist you in working with your injec-tion moulding machine.

In parallel with the new Ergopress we have modernised, restruc-tured and expanded our Web site. This will be successively supple-mented until summer 2001.At www.demag-ergotech.com you willbe able to find numerous examples of practical applications, estab-lish contact with our worldwide sales organisation in a fast andsimple manner, and to obtain extensive information on our servi-ces, support and finance offerings.

We hope you will find Ergopress interesting and useful reading andthat you will find our Web pages a rich source of practical infor-mation

Sincerely,

Gerd LiebigMarketing Manager

Imprint

PublisherDemag Ergotech GmbHAltdorfer Str. 1590571 SchwaigTel: 0911/50 61-232Fax: 0911/50 61-750

EditorsGerd Liebig (editor-in-chief), Dr. Sabine Pahlke, Markus Lüling

Layout/composition/printingNeuland Communication, NürnbergHoffmann Druck, Nürnberg

Printed on 100% chlorine-free bleached paper.

Latest News

The 75th Ergotech for WagoThe Wago Kontakttechnik GmbH of Sondershausen in Central Ger-many has recently put on stream its 75th injection moulding machi-ne from Demag Ergotech. A maker of electromechanical compo-nents and function modules for automation applications,Wago andDemag Ergotech have been working together as partners since1993.All injection moulding machines delivered to Sondershausento date were built in Demag Ergotech’s plant in neighbouringWiehe that specialises in the smaller-size IM machines. Cooperati-on between the two companies covers such aspects as the conti-nued development of IM machine technology and the furtheranceof operator qualifications.

Prize awarded for plastic shingleAlfred Frank from Floh-Seligenthal produces roof and facadeshingles from recycled plastic materials. His invention has won himnow third prize in the ”Golden Bulb“ competition organised by theCentral Germany’s Broadcasting Corporation (MDR). To help himget his new business off the ground, Demag Ergotech has madeavailable to the inventor an Ergotech 150/500-610 ”compact“ IMmachine which he can use free of charge for one year. In addition,Heinrich Landler, Sales Manager Germany, handed Alfred Frank astarting incentive from the IM machine builder in an amount of DM10,000 and wished him every success in building up the newbusiness segment in his plastics processing family enterprise.

Spare parts catalogue on CD-ROMSpeeding up spare parts ordering procedure: Starting in March2001, buyers of a new Ergotech have been supplied with the”ErgoParts“ spare parts catalogue also on CD-ROM. Navigation inthe spare parts listings is as simple as pointing and clicking to iden-tify the spare parts required quickly and reliably from drawings.Thespare parts selected can be placed in a shopping basket and theorder sent to Demag Ergotech’s spare parts department by fax ore-mail.An extension of this fecility to cover other countries is underpreparation.

50th Ergotech for RiesselmannRiesselmann Kunststofftechnik of Lohne has recently had the 50thinjection moulding machine installed from Demag Ergotech. Themoulder of technical parts with activities inside and outside Ger-many was congratulated on this milestone in the company’s gro-wth on the occasion of a company jubilee by Heinrich Landler, thesupplier’s sales manager for Germany.

The application-engineering departmentin Schwaig moving into a new buildingThe application-engineering department at the company’s head-quarters in Schwaig is moving into a bigger building. Starting fromJune, the new building will provide additional space for tests to becarried out by customers as well as for presentations and exten-ded facilities for training, conferences and tuition.


The Web site breaks down into five majorsections: “The Company”, “Ergoplus”,“Machines and Data”, “Areas of Applica-tion” as well as “Industries and Markets”.A menu bar on the right of the screen gui-des the visitor through more than 1,000pages of contents.

The section “The Company” provides fullinformation on Demag Ergotech’s world-wide activities, business developments, itsproduction bases, local offices and repre-sentatives. A historical outline tells howthe company grew from its origins as

Ankerwerk in Nürnberg to the present-day Demag Ergotech based in Schwaigand Wiehe and now they participated in amajor role in the advancement of injectionmoulding technology. Clicking the hea-ding “Worldwide presence” brings up alisting of the names and addresses of thecompany’s subsidiaries, sales and produc-tion bases with telephone numbers, faxnumbers and e-mail addresses. Vacanciesand training opportunities offered byDemag Ergotech will be found under“Careers”. Any messages that users maywish to send to the company under

“Contact” will be passed on promptly tothe person or department that can bestrespond to your request or enquiry.“ErgoPlus”, the second major section,covers the company’s comprehensiverange of services and customer support.

A click on “Events” will supply infor-mation as to when and where DemagErgotech will participate in fairs andevents worldwide and where the nextopen-house events will take place. Theheading „ErgoService” offers informationon services available – from “ErgoCare”,

Everything you ever wanted to knowabout injection moulding…… you will now find on Demag Ergotech’s newly designed Web site.At www.demag-ergotech.com we have compiled extensive information pages – starting frominformation about the company through details of machine technology and specifications toin-depth discussions of practical applications.Author: Markus Lueling

topics

Homepage of www.demag-ergotech.com

the availability of field engineers and oilservice through to hotlines for spare partsorders and information on online orderingusing the “ErgoParts” CD-Rom. Informa-tion on training facilities as well as insu-rance and finance services available withtypical examples and calculating modelsround off the “ErgoPlus” offering.

The section “Machines and Data” con-tains a complete overview of Demag Ergo-tech’s range of IM machines. All machineranges are described in detail and illust-rated by photographs and schematic func-tion diagrams. In respect of the modular“concept“and “system” machine ranges,there are tables showing all possible combinations of clamping forces, platensizes, injection units and screw diameters.

Full details are available on the ErgotechEL-EXIS high-performance family, thelarge Ergotech maXX machine, the Ergo-tech multi-component design and theErgotech “vertical” upright machinetogether with schematic function dia-grams, detailed views and specifications.

Referring to “Areas of Application”, youwill find information on equipment pack-ages for specific applications of the modu-lar Ergotechs as well as importantmethods and special processes in injec-tion moulding – from 3D-MID throughthin-wall injection moulding, LSR-proces-sing and injection moulding in clean-roomenvironments to all variants of multi-com-ponent technology. Commercial and pro-cess-relevant information for users in

various sectors and markets for injection-moulded parts will soon be added to com-plete the company’s portfolio.

Interactive elements, such as onlinecosting for the various finance checks onofffer, selection of the right IM machine onthe basis of moulded part data and confi-guring injection moulding machines inclu-ding specialised equipment will followshortly.

The Web site has been optimised for pre-sentation with Internet Explorer 5.01 andservice package 1.0. Both program pack-ages are available from Microsoft for freedownloading at:www.microsoft.com/downloads.

topics

www.demag-ergotech.com

Service, spare parts and field support

Machine ranges and specifications Injection moulding process and application technology

Quick contact with sales and service


www.portax.com/demag

The ordering function for the Ergotech e@se atwww.portax.com

topics

The first injection moulding machine to bebought on the Internet was an ErgotechAt the end of January 2001, the Gebhard u. Wagner GmbH was the first plastics processor worldwi-de to buy a new injection moulding machine on the Internet. The Ergotech e@se they ordered offersan exceptionally favourable price-performance ratio and will be delivered within as short a time asfour weeks. In selling machines on the Internet through the plastics marketplace www.portax.com,Demag Ergotech is breaking new ground. Author: Markus Lueling

As the first IM machine builder in theworld, Demag Ergotech is offering one oftheir machine ranges on the Internet asfrom January this year. To this end, thecompany is using a new-machine shop onthe plastics marketplace ww.portax.com.

„It was the very short delivery and attrac-tive price that persuaded me to buy themachine I needed via www.portax.com “,said Alfred Wagner, Managing Director ofGebhard u. Wagner, to explain why hebought a machine for the first time on theInternet. The reason is that as a medium-size supplier of plastic components toautomobile and mobile phone manufac-turers, it is crucial for their injection moul-ding and die-making operation to respondquickly to any changes in market demand.To start with, Demag Ergotech offered itsspecial Ergotech e@se IM machine seriesfor sale on the Internet with five clampingforces between 25 and 100 tonnes. Simi-lar to the Ergotech “viva”, the machine iscapable of performing most productionjobs without any add-ons, but it can becomplemented by some extra featuresand a service package. The offer is targe-ted for the time being to customers inWestern and Central European countries.

An important advantage for the moulderand Demag Ergotech is in optimising com-mercial operations in sales and accounts,thereby creating a pervasive electronicprocess chain. Since it did not make eco-nomic sense for Demag Ergotech to hand-le the interfacing with customers itself, thecompany decided to enlist the services ofPortax.com GmbH. Portax organises thiskind of technical link-up with plastics pro-cessors through its marketplace for pla-stics and develops e-Commerce systemsfor handling the procurement and sale ofraw materials and other products.

Ergotech’s showroom on the Portax Web sitecan be visited at www.portax.com/demag.For users to access the ordering function,it is necessary for them to register withPortax which can be done on its Web site.More information and data about theErgotech e@se as well as the selectionand ordering functions will be found under“Shop”. A few mouse clicks is all that isneeded to issue the order and within justfour weeks, the Ergotech e@se will beinstalled ready for operation.

Alfred and Thomas Wagner with their Ergotech e@se machine bought via www.portax.com


machines & data

The injection moulding of food packaging and thin-wall technical packaging containers is anarea where the Ergotech EL-EXIS S high-performance machine has proved its mettle in a greatmany instances. The precision and high injection pressure of the machine also benefit produ-cers of sophisticated technical parts. A typical example is the complex connectors that TycoElectronics (Switzerland) AG produces on this machine.Author: Markus Lueling

Tyco Electronics (Switzerland) AG

Tyco Electronics is a member of the technology group Tyco International Ltd. whichwith a workforce of over 200,000 generates sales to the tune of USD 29 billion.Tyco Electronics produces electrical and electronic components, mostly for the auto-mobile sector. Tyco Electronics (Switzerland) AG is located in Steinach and employs270 people. The company produces 4.6 billion stampings and over 550 million pla-stic connectors for automobile electronic systems per year with total sales amoun-ting to some CHF 125 million.

Technical parts – moulded on the Ergotech EL-EXIS S

Franz Sutter, Hermann Knecht andAdrian Bitzi (from left) standing infront of an Ergotech 100 EL-EXIS S.

Franz Sutter, Hermann Knecht andAdrian Bitzi (from left) standing infront of an Ergotech 100 EL-EXIS S.

Connectors of the type produced byTyco for automobile electronic system.

Connectors of the type produced byTyco for automobile electronic system.

Aside from 60 hydraulic Ergotechs, theTyco Company also has five Ergotech EL-EXIS S equipped with electrical drive.


As many as five Ergotech EL-EXIS S ope-rated by Tyco go to show that they alsooffer advantages for the production oftechnical parts. Three units with 100 ton-nes clamping force were commissioned inSummer 2000 and another two 60 tonnesmachines were added in Spring 2001.Including the five Ergotech EL-EXIS S,Tyco’s tooling in Steinach comprises closeto 70 machines between 60 and 150 ton-nes clamping force which are being ope-rated in four shifts around the clock sevendays a week. With 360 production daysper year, the machines get up to as manyas 8,100 production hours per year.

Steinach and a sister plant in German Din-kelsbühl are distinguished as pilot anddemonstration operations for injectionmoulding for the total Tyco Group whichruns some 1,400 machines the world overincluding some 600 machines in Europe.Small wonder that Steinach is the firstTyco operation in the world to have anErgotech EL-EXIS S.

More than 90 percent of the parts produ-ced are connector housings made of PBTand polyamide 66 all of which go to theautomobile industry. The parts includemany highly complex mouldings withextremely long flow paths, some withmore than 60 cores and only a few tenthsof a millimeter wall thickness between thecores.“Some of these injection mouldingsare bordering on the limits of what is tech-nically possible”, explains ProductionManager Franz Sutter. Here it is the com-bination of a high injection capacity andthe high degree of precision ensured bythe Ergotech EL-EXIS S that are called forto fill the cavities while avoiding over-packing.The melt cushion variations of lessthan one tenth of a millimeter are a witn-ess to the extremely high degree of consi-stency and shot-to-shot repeatability.

The machine offers special benefits at theclamping end, too:A distributed-type elec-trical drive acting through a hydrostatictransmission is provided to transmit thepower to the toggle. The electric motoraccelerates the closing movement so thatthe machine time is 0.3 to 0.4 secondsshorter than that of the fastest hydraulicmachines on the market. “In producingour technical parts, the Ergotech EL-EXIScuts cycle time by anything up to 10 per-

cent compared to the hydraulic machi-nes”, claims IM shop manager AdrianBitzi.

Speed is not the only advantage that Tycoderives from the unique clamping drive ofthe Ergotech EL-EXIS S:Thanks to the pre-cise electrical drive and a high-resolution

system for stroke measurement, themachine offers a position repeatability ofthe moving platen that is several timesbetter than that of a conventional hydrau-lic machine. This is an asset where theparts on demoulding are to be picked upby grippers at exactly defined positions.Asa result,Tyco’s engineers have been expe-riencing fewer problems and productioninterruptions due to poor alignment of thepart to be transferred to robots or partshandling equipment.

The high degree of position repeatabilityof the moving platen is an essentialadvantage not only at the end of the ope-ning path but also when closing themould: Reduced mould wear. “Here wehave an advantage that is difficult to measure”, admits Franz Sutter, but: “TheErgotech EL-EXIS S runs softer speedramps. This alone goes to ensure reducedstressing of the moulds.” And if any pro-blems are encountered in demoulding,there is still the sensitive mould protectionsystem of the machine to provide activedeceleration of the mould movement.

The electrical drives for the screw and theclamping unit enhance the responsivenessof the Ergotech EL-EXIS S – with reducednoise development compared to hydrau-lic machines. Hermann Knecht, Tyco’sengineer in charge of plant and machineryis in a good position to compare the driveconcepts of injection moulding machines:

Most of the IMMs installed are of thestraight hydraulic type but, apart from thenew Ergotech EL-EXIS S units, he has alsogot an all-electric machine of Japaneseorigin which he has had for five years.“The all-electric does operate very preci-sely”, says Hermann Knecht,“but we can-not use it for all our moulds.” This means

the Swiss operators have to make com-promises in the machine loading: Some ofthe moulds can be used only on othermachines.

Here is where the Ergotech EL-EXIS Scomes in. It lends itself to the productionof technical parts that are on the borderof the limits of what is technically feasibleand require moulds that would cause pro-blems in other machines. The electricaldrive of the clamping unit makes forimproved responsiveness and shortercycles coupled with a high degree of pre-cision. The Ergotech EL-EXIS S high-per-formance machine is indeed suitable notonly for the classical applications of pack-aging and thin-wall parts – the advanta-ges of its unique performance profile alsomake it superbly suited for the productionof technical parts.

For further information visit:www.tyco.com

In brief

Tyco Electronics (Switzerland) pro-duces connectors for automobileelectronics.The Ergotech EL-EXIS S high-per-formance injection mouldingmachine facilitates the filling ofparts with extreme flow-path-to-wall-thickness ratios and ensures ahigh degree of positioning accu-racy in transferring the mouldingsto the parts handling equipment.

www.demag-ergotech.de/Anwendungsgebiete/Pc Dünnwand

machines & data

Generously dimensioned tiebarsand platens. Stationary platen is

designed with reinforced central area

Clamping unit with AC servo-driveand hydrostatic transmission for dynamicacceleration of the toggle

Energy-efficient centralhydraulics for ejectors, core pullsand nozzle closure and contact

Hydraulic central accumulatorfor high injection capacity

and dynamic acceleration

Electric screw drive using frequency-controlled, low-noise AC servomotor

for high plasticising output and shortest

cycles

NC4 control panel with Ergocontroloperator interface for convenient setting

up, monitoring and recordingVariable-delivery pump

with accumulatorHighly sensitive sensor

system for mould protectionM

M

M

P

www.demag-ergotech.com Machines and Data Ergotech EL-EXIS S

Principle of drive system for the Ergotech EL-EXIS Sdet_00016¥ergopr¥eng¥1/2001¥04 21.05.2001 11:16 Uhr Seite 7

A persuasive factor for the customer inRussia is the straightforward operation of the Ergotechs

A persuasive factor for the customer inRussia is the straightforward operation of the Ergotechs

Gas Device manufactures gas meters on22 Ergotech injection moulding machines

Located not far from Moscow, Gas Device, a member of the Stojtransgas Group, produces gas meterson Ergotech machines. Surface accuracy and absolute tightness of the central body of the meter unitare clearly a key requirement in producing the gas meters. Author: Gerd Liebig

Gas meters with an extremely high accuracy

industries & markets


In the last few decades, gas meters werea rare piece of equipment in Russianhomes. Depending on the size of housesand regional developments and decisions,gas meters are increasingly accepted inRussian households. In fact, gas metershave meanwhile become standard in70% of new buildings: There is a steadilygrowing market for this equipment whichis manufactured in a complex process andmust guarantee 100% tightness.

Gas Device is the leading Russian com-pany making gas meters and one of themajor companies in this field in Europe.The gas meters are produced under alicence from an Italian manufacturer. Highproductivity is vital for Gas Device – “butwe must maintain competitiveness with-out sacrificing quality”, emphasises Mr.Bytschin, Managing Director of Gas Devi-ce. He and his staff seem to be doingexceedingly well in reconciling theserequirements which is borne out by a mil-lion sophisticated and high-precision gasmeters produced in their injection moul-ding operation per year that go on thegrowing Russian market. Primary consi-derations for Gas Device in procuring theirinjection moulding machines are ease ofoperation, short cycles and a consistently

high surface quality. “Gas meters fromGas Device stand for superior reliability inmeasuring accuracy and absolute safety inoperation”, explains Bytschin. The gasmeters come calibrated for ten years.Incorporating a high-tech diaphragm cap-sule from Bersdoff, they warrant absolu-tely reliable operation under most exac-ting climatic conditions with temperaturesranging from –40 to +60 °C. Gas metersare the company’s first principle product.What other products they will add is stillthe management’s secret. However, thestrong growth of the company suggeststhat new business segments will becarefully reviewed for sustained yield andthat interest will focus on products desi-gned to meet special quality or precisionrequirements.

Demag Ergotech is a system supplier toGas Device and to date has delivered 22machines to the Russian company withclamping forces ranging from 35 to 250tonnes. In setting up its individual pro-duction components, Gas Device relies onindividual partnerships to monitor thecomplex process and to optimise produc-tion flow. This relates to such aspects ascentralised supply of materials, selectionof high-grade equipment throughout the

factory and a pervasive supervision systemwhich measures surface accuracy andpractically rules out down-times. Modern3D-measuring technology is provided tosupervise consistent product quality whichhelps to maintain the high standard ofquality of the certified company.

Every ten seconds, this automated pro-duction system, which is set up to meetspecial quality requirements, produces,inspects and releases an item for reliableoperation. A workforce of 152 is employ-ed by Gas Device to manufacture anupmarket plastic product, the substantialdemand for which in Russia lets Ergo-tech’s customer look forward to sustainedgrowth.

In brief

Gas Device, a Russian company,produces a million gas meters ayear. As a system supplier to theinjection moulding operations ofthis customer, Demag Ergotechprovides the equipment to assurethe high quality of the meters, thespecified surface accuracy andabsolute tightness.

Russia’s premier plastic fair – the Inter-plastica – took place in Moscow at theend of November 2000.At the opening ofthe fair, Helmar Franz, Chairman of DemagErgotech’s Board and Olaf Kassek, Mana-ging Director of Ergotech’s Moscow sub-sidiary Demag Plastservice had the privi-lege of meeting Dr. Swinarenko, firstDeputy Minister for Industry and Scienceof the Russian Government, at their stand.The minister showed great interest in theErgotech 100 EL-EXIS S on display, amachine to produce closures for PET-bott-les. He was seemingly impressed by the

short cycle time and the almost noiselessoperation of the machine. The ErgotechEL-EXIS on show at the fair was the 50thinjection moulding machine sold byDemag Ergotech to Russia in 2000.

Prominent visitors to Demag Ergotech


Dr. Swinarenko talking with Helmar Franz and Olaf Kassek

(from left)


The Ergocontrol operator terminal assists the operator stepby step – from the setting-up of the mould through pro-gramming of the injection unit to process optimisation. Spe-cial functions are provided to assist in starting the machineand shutting it down automatically. An online link to DemagErgotech offers help in overcoming any problems with machi-ne technology.Author: Dr. Sabine Pahlke

Automatic Start-up and shutdownHow the Ergocontrol operator terminal helps to start production and maintain unmanned operation

Control of Ergotech injection mouldingmachines with the Ergotech control oper-ator terminal is identical for all machineranges – whether standard, multi-compo-nent or vertical machines. In establishingthe sequence of the pages to be pro-grammed and in designing each individu-al page, our control system engineershave been logically guided by the opera-tor’s needs and workflow. For details onhow Ergocontrol has provided greater fle-xibility in programming the clamping endand the injection unit, please refer to theErgopress issues 4 (1/2000) and 5(2/2000).

Extensive automated aids for starting andstopping production effectively reducecosts and manning requirements.

Co-ordinated machine start-up

The start-up program of Demag Ergotech’s IM machines enables oil pre-heating, cylinder heating, mould tempe-rature control or the multi-outlet unit tobe cut in without operator intervention.Allprocedures can also be started in a step-ped sequence with programming by date,day and time facilitating and acceleratingthe start-up of the machine (Fig. 1). Anyphases that as a matter of experienceneed more time than others, can be star-ted earlier. Typically, the heating phase ofthe cylinder temperature control system islonger than the oil preheating phase.These optimised preparatory phases of theindividual energy consumers of the machi-ne reduce energy consumption to thenecessary minimum.

The stepped start-up of several machinesis apt to confer another economic benefitin injection moulding operations: The successive (serial) start of the machinesavoids power peaks that might entitle thepower supply company to charge the userin a higher electricity tariff category.

Three-stage start of production

The moulding start-up program definesthe running-up of the IM machine duringthe initial start-up or after productiondown-times by a three-step variation ofthe principal parameters (Fig. 2). An inte-grated shot counter establishes when thechange-over to the second and third sta-ges is to be effected. Stage three brings upthe normal operating mode. In this man-ner, it is possible to gradually raise theinjection speed, injection pressure limita-tion and hold pressure level. It also makesit possible to match up metering strokes(e.g. change-over point) or time preselec-tions (e.g. cooling time) to productionconditions in the start-up mode.

Set-up catalogue for existingtooling

In order to enable the operator to com-mence production with moulds that havepassed trials quickly and conveniently,Demag Ergotech provides the so-calledtooling catalogue. This catalogue offersthe possibility of storing the set-up datafor a number of moulds and any supple-mentary information as required. For aquick start-up of production, the user canselect the appropriate data set from the

machines & data


catalogue and read it in to the controlsystem.As a result, all important data andinformation for a smooth production start-up can be called up for commercial mould-ings at the click of a button.

Controlled end of production

The purging program (Fig. 3) controls therun-down of production, for instance, atshift end or when the specified number ofitems under an order have been comple-ted. For effective cleaning of the machine,the purge program provides a selection ofmetering and injection cycles. The shut-down matrix (Fig. 4) defines off-normalconditions that require a shut-down of thepump, mould heating system, cylinderheating system or multi-outlet unit, orwhether stopping is required upon com-pleting the production batch. Disconnec-

ting the multi-outlet unit is relevant whereperipheral equipment is connected that isalso required to be shut down in the eventof abnormal operation or upon reachingthe end of production.

Online support and service

The Ergolink remote diagnosis system isnow also available for ISDN connections.Ergolink is complementary to Ergocontroland designed to provide online diagnosisand online maintenance support. Via amodem and telephone connection, thesystem links up the machine to DemagErgotech’s technical service departmentto permit data exchange in both direc-tions.The system makes it possible for theservice engineer to run any required testroutines and to view the results on hismonitor. In addition to diagnosis and

remedial action, Ergolink can be used toperform software updates and to com-municate all machine setting data to theservice specialists. It is also possible tocarry out process optimisation throughonline inspection and to vary any relevantprocess parameters.

In brief

Ergocontrol, the operator termi-nal for all Ergotech injectionmoulding machines, provides fun-ctions for the automatic start-upand shut-down of production.Benefits for day-to-day operationinclude optimised energy conser-vation and minimised manningrequirements.

Fig. 4: The shut-down matrix defines the conditions underwhich production is stopped

Fig. 3: The purging program provides for controlled emptyingof the plasticising unit

machines & data

Fig. 1: The machine-start-up program readies the machine foroperation under defined conditions and without operatorintervention

Fig. 2: The moulding start-up program provides for productionto start in the automatic mode


JPK is in the process of expanding its production facilities by adding another 25 Ergotechs; the company will then have a total of 50 Demagmachines in operation. Photos courtesy JPK.

JPK (Malaysia) SDN. BHD, plastic moulder located in Shah Alam, placed an order with DemagErgotech for another 25 injection moulding machines. Included in this large order is the 50thDemag machine to be delivered to this ambitious company.Talking to Gerd Liebig, Demag Ergotech’s Marketing Manager, Ivy Liew, owner of JPK, explai-ned the secret of her success.

Growing in partnership –with customers and suppliers

JPK, which had been established in late1989, started small-scale production inMalaysia in 1992, which was mainly con-cerned with the assembly of plastic partsfor the Japanese audio, video and house-hold appliances industries. As Malaysiansuppliers started to develop their own plastics pro-cessing operations, JPK grew fast, boughtsome second-hand injection mouldingmachines in 1992, and progressively

expanded its own facilities. Five years ago,the company moved to new premises andshortly afterwards added a branch factoryin the North of Malaysia. The new Ergo-techs installed since October 2000 wenton stream in early 2001.

At present, JPK is operating 134 injection-moulding machines and, on completion ofthe installation of the Demag machines onorder, there will be a total of 159. With a

workforce of some 750, the company pro-duces precision parts and mechanicalcomponents for consumer electronics, stilland video cameras as well as computerswith part of the moulds required beingmade in-house.

After a long period of producing exclusivelyfor Sony, the company’s list of customerstoday also includes Pioneer,Matsushita,JVC,Aiwa, Philips, Minolta, Canon and Xyratex.



In brief

The Malaysian injection moulderJPK relies on the confidence esta-blished in co-operating with allpartners along the value-creationchain. Demag Ergotech providessupport for the moulder’s staff inthe form of training programs andso helps to improve the company’scompetitiveness.


Ergopress: Mrs. Liew, what is the secretof your success?Ivy Liew: I think what is very importantis the confidence that exists between usand our customers and also the confiden-ce between our suppliers and us. I have tosupport my customers to be and remaincompetitive. If my customers stop placingorders with me, my production is zero.Thesame applies to my suppliers. Expandtogether with my customers, that is myphilosophy, which has won me thebacking of my customers. When a custo-mer places an order with me, he can puthis mind at rest and be sure that there willbe no problems.

Ergopress: Now you are supplying yourproducts to both Japan and Europe. Hasthis had any effect on your supplier struc-ture?

Ivy Liew: I feel that a company thatrests on several pillars is simply more sta-ble.And if my company is a stable one, mycustomers will have the benefit of it. In thepast, we had only Japanese machines. Butsince we want to maintain our position inthe world’s top league technologically, wehave to examine closely whether or not,say, the Demag machines offer advanta-ges over those from Japan. It is absolute-ly necessary for us to keep monitoring ouroperations for productivity and competiti-veness.At the moment, we are looking formore customers also in the European mar-ket. Our specific product expertise plus ourpartnership with Demag Ergotech haveworked out as a successful combination.

Ergopress: What improvements are youplanning specifically?Ivy Liew: It is of the essence that weshould constantly strive for improvementsin order to remain at the top.What I meanis improvements in technology, in engi-neering in general, and also in manage-ment. To this end, we are organisingvarious training programs. We definitelywant to continue to work together withour suppliers to promote injection-moul-ding technology.

Ergopress: What can we in DemagErgotech do to assist you?Ivy Liew: I have discussed with Ergo-tech what assistance we could get. Forinstance, I want my operators to thoroug-hly know and get the best out of themachines I have bought. Therefore, trai-ning of my employees is a most importantaspect. Malaysia does not have a long

record of precision injection moulding andthis is the reason why it is just not possi-ble to find really experienced people. Mostof our employees are very young and joinus directly from school or college. I wantmy people to be able to upgrade theirskills and technical know-how.

Ergopress: What is your vision of futu-re partnerships?Ivy Liew: Our supplier must be makinga profit in order to be able to support us.Therefore, we have to join forces with himso that he can supply equipment at a rea-sonable price and we, in turn, can pass onthe price to our customers for them toremain competitive. We will continue tomake every effort to improve our ownoperations to ensure that Malaysia will beable to keep competitive at world-classlevel.

For further information, please visit:www.jpkm.com

Ivy Liew, owner and General Manager of JPK (Malaysia) SDN. BHD.


The Ergotech EL-EXIS E series of injection moulding machines combines the advantages of elec-trical drives with the benefits of hydraulic drives and offers an optimum solution in terms ofproductivity and precision for each of the six machine movements. Two distributed electricaldrives for mould opening and for the plasticising and injection movements confer upon thenew Ergotech EL-EXIS E extremely high degrees of precision and reproducibility coupled withexceptionally energy-effective operation. Author: Markus Lueling

Economy and precisionThe Ergotech EL-EXIS E

machines & data


machines & data

The drive concept of the Ergotech EL-EXISE fast-cycling machine attracted world-wide attention in the injection-mouldingworld when it was shown for the first timeat K’98. Each movement of the machineis equipped with the optimum drive – thisprinciple has been persuading an increa-sing number of moulders to look to theErgotech EL-EXIS E high-performancemachine for better results: Using electri-cal drives for precision and economy, buthydraulic drives for powerful movements

and high injection capacity.

Where precision and dimensional consi-stency, very close weight tolerances andlow energy consumption plus optimumefficiency are at a premium without a highinjection capacity being required, a preci-sion IM machine will fill the bill withoutthe need for an accumulator: Here DemagErgotech offers a well thought-out, inno-vative solution: The Ergotech EL-EXIS E.The new Ergotech EL-EXIS E provides two

distributed electrical drives for the threemain movements of the IM machine: Pla-sticising, injection, and mould movement.The salient feature of this new world-wideunique and patented drive concept of theinjection unit is the use of a single servo-motor to drive the screw rotation andinjection motion. The injection movementis provided by a hydrostatic transmissionwith a variable-delivery pump, whereasscrew rotation is controlled by the servomotor. The electrical drive only cuts in the

P

M

M

P M

machines & data

The Ergotech EL-EXIS E with 150 tonnes clamping force

plasticising or injection phases. Duringplasticising, the back-pressure in thehydraulic circuit is used to assist the servomotor via the pump – an additional bonusin terms of low energy consumption anda higher level of responsiveness.

The reason for the higher precision of theinjecting and holding pressure functions isin the compact drive unit being locatedclose to the load. This results in a verysmall control loop that responds quicklyand without any significant transmissionlosses to any change in the controlledvariables. This drive concept makes theErgotech EL-EXIS E a genuine alternative

to the all-electrical machine. At the clam-ping end, there is an electric motor drivingthe five-point toggle through a hydrosta-tic transmission – similar to the configu-ration of the Ergotech EL-EXIS S. A redu-ced-size, compact hydraulic power packpowers the three auxiliary movements –core pullers, ejectors, and nozzle closu-re/contact. This central hydraulic powerpack for the secondary motions of themachine is a major advantage of the Ergotech EL-EXIS E over all-electric machi-nes which call for an additional hydraulicpower pack to be provided. Essentially,therefore, the Ergotech EL-EXIS E is anelectrically operated machine with an

integrated central hydraulic system.Thanks to its novel drive concept withelectrically operated main-axis motionsand an optimised hydraulic system for thesecondary functions, the Ergotech EL-EXIS Eprovides the injection moulder with muchgreater processing latitude while its lowenergy usage is comparable to that of all-electric machines.

The machine offers substantial benefits inproducing components of the type thatcall for sophisticated parallel functions ininjection moulding machines. Typically,these include optical lenses, connectorsand gears. Even where energy conservati-on is a primary consideration in invest-ment decisions, the Ergotech EL-EXIS E byvirtue of its outstanding economiesshould be the moulder’s first choice.

The Ergotech EL-EXIS E series is at presentavailable with clamping forces from 60 to150 tonnes. The series is scheduled to beextended in the medium term to 350 tonnes.

In brief

The new Ergotech EL-EXIS E is anelectrically operated injection-moulding machine with an inte-grated central hydraulic powerpack for the secondary motions.Extensive parallel functions and ahigh position repeatability facili-tate the production of precisionparts with energy consumption atan extremely low level.

www.demag-ergotech.com Machines and Data Ergotech EL-EXIS E

The energy-efficient compact hydraulic system powers the secondary movements


issue 1/2001 ergopress - jusuco oy · the first injection moulding machine to be bought on the...

Documents