K2025: Arburg to premiere compact/energy-efficient vertical Allrounder

With energy costs rising, German machinery maker Arburg will showcase an energy-efficient Allrounder 475V with a clamping force of 1,000 kN at K2025. The vertical machine also boasts a small footprint and an attractive price-performance ratio and can be used for both manual and automated overmoulding of inserts, says the Lossburg-based machine maker.

At its stand 13A13, Arburg will showcase the Allrounder 475 V as part of a turnkey system that produces, marks and post-processes covers for car radio keys from PC/ABS recyclate in combination with in-mould decoration (IMD).

The new vertical machine is specifically designed for standard applications, for example for the growth sector of e-mobility as well as for electronics and medical technology. These include the manual or automated overmoulding of cables, contacts and infusion accessories.

The footprint is particularly compact but, despite this, the new vertical machine offers extra space also for larger moulds. The standard installation height is 250 mm with the option of extending it by 100 or 200 mm. Side doors and the upwardly offset clamping cylinder ensure good accessibility to the mould and ejector. An off-centre ejector is available as an option. The table height is 900 mm for improved ergonomic working.

The Allrounder 475 V has a clamping force of 1,000 kN and can be equipped with hydraulic injection units in sizes 100 to 400.

For energy-efficient operation, the machine is equipped as standard with the Arburg servo hydraulics system (ASH), which continuously adjusts the water-cooled, speed-controlled servo motors to the actual power requirement. This minimises idling losses and reduces the specific energy requirement by up to 60% compared to conventional hydraulic machines.

The new "Gestica lite" control variant ensures particularly simple and intuitive operation. Even inexperienced personnel can get to grips with this quickly, says Arburg. The clear dashboard provides everything needed for the work at a glance: information on the job, the current process and the upcoming tasks, actively supported by optional assistance functions that ensure quality plasticising and moulded part quality, adds Arburg.

If required, the vertical machine can be automated flexibly, for example with a six-axis or linear Multilift robotic system. Arburg adds it can fulfil almost any customer requirement, including simple sprue removal, difficult component handling or customised automation for complex production cells including upstream or downstream process steps, with CE-compliant machines, automation and peripherals from a single source.

At K2025, the turnkey system based around an Allrounder 475 V will show how products with quality designs and surfaces can be created efficiently for the mobility sector. This is demonstrated by the cover of a wirelesskey, featuring a design based on the "Generic Keyfob" from company Huf.

Its plastic cover is made of post-industrial recyclate (PIR) based on PC/ABS. The quality surface is created using the new PLF technology (Protective Layer Finish) for In-Mould Decoration (IMD) from partner Leonhard Kurz in combination with a structured tool insert. For this purpose, a wafer-thin PET film including decoration system is fed into the mould from the outside via a feed unit. There, the decorative film is applied to the plastic surface by means of in-mould lamination.

An Arburg logo and a textured surface are also applied to the moulded part via the mould insert. The cover is punched out in a rectangular fashion in the mould and the remaining film is rolled up in the installation space of the vertical machine. Subsequent painting is not necessary and the product can be recycled. Different films featuring a variety of designs and colours that can be used flexibly for product variants.

The fully automated application is also a practical example of the R-Cycle initiative. Data relating to recycling such as the material composition can be retrieved via a code on the component. Such digital product passports lay the groundwork for data-based material flows and a closed plastics cycle.

A Kuka six-axis robot is used for the complete part handling. It first removes the moulded part from the mould and feeds it to a laser station, where it is labelled with a code. The robot then transfers the part to a milling station and, with the gripper, guides it along the milling path to remove excess film and generate the final contour. In a subsequent cleaning station, the wireless key cover is deburred before finally getting placed on a conveyor belt by the six-axis robot and ejected from the production cell.

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