Hylectric Machines

90010 000 kN, 1001,100 tons

Hylectric Machines
Higher performance, lower operating costs

Hylectric Benefits
Higher productivity Faster clamp Wider tiebar spacing Ideal platform for stack molding Longer mold life Excellent mold alignment Lower tonnage requirements Industry-best mold protection Better part quality Precise shot-to-shot accuracy Grease-free molding area Operator friendly Large molding area for easy access Quiet operation Windows*-based controls Three year leakproof guarantee

In todays globally competitive business environment, solutions targeting lowest part cost are needed. The Hylectric machine is designed with the needs of your molding operation in mindmaximize the output of molds and improve the operating costs of the factory.

Hylectric machines provide: Higher output Ease of use Clean operation Greater reliability Reduced maintenance Improved uptime

Hylectric machines manufacture a range of products for customers in the packaging, automotive, industrial, medical and consumer electronics markets.
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Higher Productivity

Hylectric consistently delivers cycle times 1530% faster than competitive machines in mold tests. Wide tiebar spacing combined with Reflex platens offer better tonnage utilization and often allow molders to select a smaller clamp size.

Faster clamp dry cycle Hylectrics clamp design decouples stroke and clamp-up using cylinders optimized for speed, force and efficiency A clamp accumulator efficiently provides peak oil requirements when needed for faster mold stroke and clamp-up The moving platen rides on low-friction bearings, minimizing the power and time for acceleration Regenerative mold stroke circuit provides efficient, highspeed operation Increased cavitation Hylectric machines allow molders to fit more cavities into a given clamp size by offering: Wider tiebar spacing Increased daylight Robust clamp design to support larger molds Even clamp force distribution across the entire mold face using Reflex platens The Reflex platen advantage often allows molders to use a smaller clamp size compared to competitive machines, reducing costs and floorspace requirements.

Better process capability Fast clamp dry cycles are matched with powerful injection units offering high plasticizing rates High injection rates with consistent speed and pressure lead to reduced injection and hold times Stack molding The Hylectric machine is an ideal platform for stack molding with its generous daylight and machine mounted stack mold carrier. The advantages of this carrier are: Reduced mold investment Maintenance-free operation Faster mold change times Better support and alignment of the molds center section Open access to the molding area Designed to withstand mold break force

The H1000 clamp in this 2x8 container stack molding system has a dry cycle of less than four seconds.
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Longer Mold Life

Most molders have more invested in tooling than in machinery. The Hylectric machine was designed to extend regular maintenance intervals and prolong the life of molds. Reflex platens distribute clamping forces evenly across the mold mounting surfaces which can reduce tonnage required by up to 50% Mold protection sensing occurs under mold stroke force at only 2% of full tonnage The clamp design delivers true closed loop tonnage control to minimize cycle variations and over-tonnage or flash during start-up Placing the clamp beams outside the tiebars increases clamp stiffness, improving support for heavy molds and reducing mold wear
Clamping force is directed to the molding area by the center clamp column and then redistributed evenly across the entire mold face by Reflex platens.

Case Study: 40% tonnage reduction, 31% cycle time reduction

Competitor Tonnage kN (ton) Cycle time (s) 5 000 (550) 20.0 Husky 3 000 (330) 13.8

Case Study: 15% tonnage reduction, 50% cycle time reduction

Competitor Tonnage kN (ton) Cycle time (s) 3 500 (385) 29.0 Husky 3 000 (330) 14.5

The robust clamp base and the wide bearing stance of the moving platen provide better mold alignment. As an added benet, there is greater clearance underneath the clamp base for simpler conveyor installation and removal of tall parts.
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Improved Part Quality and Efficiency

Better part quality Overall productivity is not only influenced by speed and cavitation. Yields are also increased with better part quality, which can be achieved through machine design and performance. The Hylectric machine reduces scrap rates by providing: Better control Microsecond CPU scan rates, high performance servo valves and true closed loop control for improved shot-toshot repeatability. A cleaner molding area Moving platen rides on sealed bearings instead of on the tiebars, eliminating the need for grease in the molding area. Increased tiebar spacing and platen support located outside the part drop area reduce part contact with the machine. No toggle pins, which are a source of contamination on toggle machines.

Reduce energy costwithout sacrificing performance The Hylectric machine combines the efficiency of an electric screw drive with the speed and pressure of hydraulic injection. This provides the best of both worlds: Approximately half of the energy consumption of a machine goes into the plasticizing of resin. This rotary motion requires little change in torque except for a small peak at start-up. An electric drive manages this economically for most applications with screw sizes of up to 135 mm. With an electric drive for plasticizing, the size of the hydraulic drive is reduced significantly. Since not all machine motions are simultaneous, power from the hydraulic drive is shared among all axes, while all-electric machines require individual motors for each axis.

Fast acting (i.e. 0.1 seconds open time) pneumatic pin shut-o nozzles provide reliable operation with reduced plastic leakage, while providing more time for recovery and mold decompression.

Linear bearings support the moving platen directly on the machine base instead of on the tiebars, eliminating the need for grease in the molding area.

 By storing and delivering energy through accumulators, hydraulics can achieve the peak power demands of injection more economically. Hylectric delivers repeatability and control equal to or better than typical claims for all-electric machines.

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Standard Features

Clamp Reflex platens Wide tiebar spacing Closed loop mold protection Closed loop clamp force control Regenerative mold stroke hydraulics for energy efficiency Large gates for easy access to mold area for part removal Mold break forceup to 10% of clamp force Euromap or SPI mold mounting faces

Injection Closed loop control of injection speed, hold pressure, back pressure, and fill pressure limiting Ring or ball check valves Wear protected screw (Colmonoy* 56) and bi-metallic barrel Quick barrel change Electric extruder drive (up to RS 135) Accumulator assisted hydraulic system and injection Mineral insulated heater bands Supported barrel

Controls Polaris ControlIntel* processor with Windows operating system User-programmable functions corepull, robots, etc. User-programmable access levels Remote diagnostics and troubleshooting capability Flat panel color operator interface with touchscreen controls Ports for parallel printer, external keyboard and mouse, external screen, ethernet and modem 20,000 machine event log and report generation Save and output 10,000 cycles of process values

Operator Friendly

Hydraulics Independent servo valve control of clamp tonnage, mold stroke and injection Variable displacement pumps High-efficiency, water-cooled pump motor Noise reducing, fully enclosed power pack High flow bypass oil filtration (three micron) with pressure drop monitoring Pressurized oil tank for minimum contamination Centralized oil collection and recovery system Quick connectors for hydraulic gauge (supplied) at key hydraulic test points Many Hylectric features simplify molding operations, improve productivity and customer support. Safety systems that exceed standards help provide a safe working environment Designed for cleanliness, backed by a three-year leakproof guarantee; the molding area is also free of lubrication Shutheight set without gear based adjustment mechanism for simple mold installation and improved reliability Water-cooled motors in enclosed hydraulic power packs reduce heat dissipation into the molding environment and reduce noise levels Intuitive Windows-based screens improve ease of operation Remote diagnostics and 24 hour call centers speed issue resolution and reduce downtime
The touchscreen control panel on Polaris Control features an intuitive Windows-based graphic interface for ease of use.

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Applications
Hylectric has over 4,000 standard configurations of clamp and injection modules to ensure an ideal application fit.

Closure molding ExperienceHusky is the largest primary processing equipment supplier to the plastic closure industry Longer mold lifeprotects expensive mold components such as tamper evident slide inserts, ejector sleeves, rotary cores, shutoffs and vents Part qualitydimensional stability - Injection accuracy and repeatability reduce part weight variation, improve processing window and provide more consistent part dimensions - Melt qualityscrews and drives specifically designed for closure production. Uncompromised melt delivery when matched with a Husky hot runner Versatility - Optional 2-stage injection for high cavitation systems virtually no recovery limitation and more effective mold decompression - Best range of strokes and shutheights in the industry allow a broad range of applications in the same machine

Medical and cleanroom Wide tiebar spacing of the Hylectric clamp creates a large area of unobstructed air flow around the molding area The enclosed powerpack reduces noise and eliminates airborne particulates, while the water cooled motor eliminates turbulence from cooling fans Hydraulic manifolds are directly mounted to the actuators eliminating unnecessary hoses which generate particles through constant rubbing The moving platen is supported by sealed low friction linear bearings outside the tiebars with an extended lubrication cycle, which keep tiebars free of lubricant Dual seal technology and oil recovery system on clamp and injection unit hydraulic circuits contribute to a clean molding environment (e.g. HL120 recently Class 10,000 certified running pharmaceutical sample cups)

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Thinwall packaging with 2-stage injection Independently sized extruder and injection plunger optimize residence time and injection control Separate plasticizing and injection allow for continuous recovery, faster cycles and better melt quality No check valve required, providing improved shot control, wider shot range and greater application flexibility Superior performance realized with throughputs up to 700 kg/hour (1524 lbs./hour) with peak injection rates exceeding 10 000 cm / second (610 in. /second)
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Multi-level stack molding Over 1,600 stack molds built to-date by Husky Husky builds over 100 stack mold hot runners per year Stack molding significantly increases the output of the machine, has a higher output per capital and a higher output per floorspace, resulting in reduced part cost the 4x8 lid system (pictured above) runs at less than 5.6 seconds in a 5 000 kN (550 ton) Hylectric machine Hylectrics generous tiebar spacing allows for in-mold automation and in-mold labeling SlideChutes reduce the press opening stroke required to less than 50 mm (2 in.) per face and have a total cycle time of 0.4 seconds for flat parts The patented stack mold carrier system aligns the mold in the press and makes it very easy to install, remove and service

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Challenge Us!

In head-to-head tests, the Hylectric machine consistently delivers significant reductions in tonnage and cycle time over a wide range of applications. Our worldwide Technical Centers are equipped and ready to demonstrate how Hylectric can reduce your operating costs. We have focused beyond hardware for over 40 years by helping our customers with automated workcells and efficient factory designs. Today, regional teams continue to work with customers to reduce operating and part costs. In the past seven years, we have delivered system solutions to 43 of the top 100 molders.
Using Hylectric, a 10 second cycle time reduction was realized over competitive systems molding the same part.

We assisted this customer to design and integrate three complete in-mold labeling workcells for molding returnable crates.
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A Perfect Fit

Parts in the box are what really matters at the end of the day. Thats why we need high productivity from our injection molding machines. Huskys Hylectric machine meets our demands. We get consistently fast cycles and the Hylectrics wide tiebar spacing allows us to run higher cavitation molds in smaller machines. The Polaris Control gives us excellent shot-toshot repeatability, which means high quality parts and low scrap rates. Huskys Reflex platen design reduces deflection, resulting in less wear and longer mold life. Hylectric is the ideal machine for our closure molds.
Thomas Anderegg, CEO Corvaglia Closures

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Head Office 500 Queen Street South Bolton, Ontario Canada L7E 5S5 Tel. (905) 951 5000 Fax (905) 951 5384 Asia 101 Ba Sheng Road Shanghai Waigaoqiao Free Trade Zone P.R. China 200131 Tel. (86) 21 5048 4800 Fax (86) 21 5048 4900 Europe Zone Industrielle Riedgen Technical Center, B.P. 93 L-3401 Dudelange Luxembourg Tel. (352) 52 11 51 Fax (352) 52 11 5 4458 Latin America 5301 Blue Lagoon Drive Suite 600 Miami, Florida USA 33126 Tel. (305) 261 3003 Fax (305) 262 2988 North America 45145 West Twelve Mile Road Novi, Michigan USA 48377 Tel. (248) 735 6300 Fax (248) 735 6400

www.husky.ca
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06-058 June 2006

Cover: HL500 RS115/100.

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