Fakuma 2018: On the Road to Digitalisation with Arburg

The Arburg experts will be on hand at a number of stations to guide trade visitors along the path towards future-proof and efficient plastic parts production. These include new assistance packages, a first insight into a new customer portal and examples of "smart services".

All the exhibits will be on view in the new colour scheme. The new-look Allrounder 820 H will be seen for the first time in a 'Packaging' version, while the Arburg Turnkey Control Module (ATCM), a data collector for complex turnkey systems will also make its debut. Further highlights will include a practical example of Industry 4.0 and LSR processing for the production of micro components. Arburg's dedicated recruiting stand will round off Arburg's trade-fair presence.

"Our 'Road to Digitalisation' at the Fakuma 2018 is a bold and practical statement of the approach we want to take with our customers in order to stay on the road to success in the future digital era," explains Michael Hehl, Managing Partner and Spokesperson for the Management Team. "On this road, visitors will be able to pick up a host of new ideas and obtain detailed information from our experts about the six new Arburg assistance packages, the benefits of augmented reality in service and find out about the launch of our new customer portal. The six injection moulding exhibits in mint green, light grey and dark grey will also provide for a new look at our stand. This new colour scheme will be used for all our Allrounders from the start of 2019."

"Road to Digitalisation": on the path to success with Arburg

The focus at the trade fair is on digital transformation, an area in which Arburg leads the industry. One of the company's objectives is the "smart" machine, which monitors its own processes, controls them adaptively and actively supports the operator in every situation. Arburg has created new assistance packages for this task, which will be presented at six stations:

• "4.set-up" actively supports machine operators with set-up and parameter entry.
• "4.start-stop" simplifies production start-up, reduces the number of start-up parts and increases production capacity.
• "4.optimisation" is designed for product optimisations aimed at enhancing part quality and reducing unit costs.
• "4.production" gives experienced operators greater flexibility and freedom when programming functions.
• "4.monitoring" offers detailed process and quality monitoring and seamless documentation.
• "4.service" makes it possible to quickly help customers through direct access to the machine control system and via online support, thereby increasing machine availability.

The new Gestica control system and the Selogica ND (new design) will be presented at further stations, while the potential of augmented reality (AR) for the "smart" service will also be demonstrated. The Arburg host computer system ALS, which is the central building block of Industry 4.0, also ensures that information technology is integrated in production. Relevant production and quality data can be recorded, archived and shared.

Customer portal: new services in the cloud

For even greater customer proximity, Arburg is strengthening its range of services and will present a first insight into a new customer portal at the Fakuma 2018. It will provide a variety of services in a clear, well coordinated way using a cloud-based solution. Central applications (apps) include, for example, the "machine overview", which clearly displays important information and documents for each machine, and the "spare parts catalogue". The added value and opportunities for the future offered by the launch of a new customer portal will be presented by the Arburg experts in person to interested visitors at the trade fair stand.

Premiere: Turnkey system with ATCM

The Arburg Turnkey Control Module (ATCM) will be presented for the first time at the Fakuma 2018. This data collector for complex turnkey systems from Arburg isualises the entire process, captures the corresponding data and transmits the part-specific data sets, e.g. for archiving or to an analysis system for "big-data" evaluation. The centrepiece of the turnkey system is an electric Allrounder 470 A with a clamping force of 1,000 kN, which produces two housing parts for a spirit level in 46 seconds using a 1 + 1-cavity family mould. The two moulded parts are removed from a Multilift V and assembled on an assembly station along with three bubble levels to produce the finished spirit level. The process also includes several test steps and the labelling of each spirit level with a QR code. The ATCM uses OPC-UA interfaces to collect the information from the injection moulding process and the camera inspection and assigns it to the relevant component by means of the QR code. Visitors will be able to scan this code with their smartphones and view the corresponding process data on a part-specific website.

Practical example of Industry 4.0: Tension straps manufactured on demand

The practical example of elastic tension belts will demonstrate how individual customer wishes can be integrated into the ongoing injection moulding process online. The order is then transferred directly to the control system via the OPC UA communication protocol. A turnkey system based around a vertical Allrounder 375 V injection moulding machine is automated with a six-axis robot compactly positioned within the installation space. It produces the elastic tension straps "on demand" yet economically in high volumes and multiple variants - flexibly from shot-to-shot, without any conversion of the machine.

Injection moulding highlights

A special 'Packaging' version of the hybrid Allrounder 820 H in new design and with new Gestica control system will be seen for the first time. This high-performance machine for the packaging industry features a clamping force of 3,700 kN and a redesigned size 2100 injection unit. Adapted valve technology can be used, for example, to achieve even greater dynamism, reproducibility and injection speeds of up to 500 mm/s. The exhibit shown at the Fakuma 2018 will produce four thin-walled IML containers with a capacity of 500 millilitres in a cycle time of around 3.8 seconds.

Another highlight is the production of micro components made from LSR. At the heart of this manufacturing cell is an electric Allrounder 270 A with a clamping force of 350 kN, equipped with a size 5 micro-injection unit and a 4-cavity mould. It produces 0.038-gram slit valves in a cycle time of around 20 seconds. The liquid silicone is premixed by means of a cartridge and injected with an 8-millimetre screw. Handling is performed by a Multilift H 3+1.

An electric Allrounder 570 E Golden Electric with a 2,000 kN clamping force will produce a high-precision technical component for housing optical components in a cycle time of around 55 seconds. It is compactly automated with a vertical entry Multilift Select. The PPA (GF35) component is removed and the sprue is separated. This is followed by optical measurement and set-down on a conveyor belt.

In addition to the six injection moulding exhibits at the Arburg exhibition stand, nine other machines will produce complex plastic parts on partner stands.

Freeformer: Additive manufacturing of functional parts

The potential of the Freeformer and Arburg Plastic Freeforming (APF) will also be on view at the Fakuma 2018. This open system can process a wide range of original materials and allows custom settings comparable to those in injection moulding. In order to demonstrate a wide range of parts, various APF products will be presented shortly before the formnext 2018 trade fair, together with details of their production. There will also be also an interactive station where visitors can test the quality and functionality of various functional components for themselves. Trade visitors can then get the latest information about the Freeformer and the APF process at the formnext from 13 to 16 November (Arburg stand E 70, hall 3.1).

Smart services in the "Road to Digitalisation" area

Arburg will present its range of training courses and services using a hydraulic Allrounder 370 S - for example the Arburg Remote Service ARS for fast, efficient and secure online support. There will also be an example on the subject of predictive maintenance, which is becoming increasingly important as machines and components are digitally integrated.

Dedicated recruiting stand

In addition to the Arburg stand in Hall A3, employees from the HR department will also be on hand at the Fakuma with a dedicated recruiting stand. Professionals and newcomers to the industry will have an opportunity to chat with the Arburg experts there and find out about the numerous opportunities for permanent positions, as well as for dissertation work, practical semesters and internships.