The Benefits of

Hybrid Servo-Driven
Injection Molding Machines
Pumps & Cylinders
Servo Motor & Gear & Belt
Energy Efficiency and Repeatability is
dependent on what method is used
to deliver power to the machine axis
The Benefits of
Hybrid Servo-Driven
Injection Molding Machines
Energy Timeline
1988
2008
1968 1993 1998 2003
1973 1978 1983 2011
Hy b r i d - r e l a t e d i n n ov a t i o n s
Energy In = Energy Out
Hydraulic Press (400-700 Ton Range)
=
Feed
throat
5%
Mold
Cooling
20-30%
Control
Power
2%
Barrel
Heating
10%
Electric
Motor
88%
Energy In
E
n
e
r
g
y

I
n

1
0
0
%

Energy Out
E
n
e
r
g
y

O
u
t

1
0
0
%

Convection &
Radiation to
Atmosphere
40-50%
Hot
Moldings
2-5%
Oil
Cooling
20-25%
0
5
10
15
20
25
MM 580 550 MS580
Power Consumption
KWH
3.0
20.7


Cycle time: 48 sec. / Injection time: 8 sec.
Cooling time: 30 sec. / Clamp stroke: 38
( VV pumps )
( All Electric )
3.2
( Hybrid Servo )
Comparison in dry cycle operation (heater power excluded!
during full-automatic operation)
Energy In
E
n
e
r
g
y

I
n

1
0
0
%

Control
Power
4%
Barrel
Heating
36%
Servo
Motor
60%
Hot
Moldings
5-10%
Feed throat
5-7% Mold
Cooling
50-60%
Convection &
Radiation 25-30%
Energy Out
E
n
e
r
g
y

O
u
t

1
0
0
%

=
Energy Balance
Energy In = Energy Out
Servo (400-700 Ton Range)
Oil
Cooling
5-10%
Servo motor in place of standard induction motor
Electro VV pump replaced by internal gear pump
Low inertia and highly dynamic speed control system
Energy optimization and monitoring diagnostics

2 Platen Toggle
Hybrid Servo Systems
2-Platen Technology
Typical 2-platen deflection
with tonnage cylinders
at corners
2-platen
direct-acting ram
Tonnage checked in
Zero energy to maintain tonnage
Hybrid Servo System
Conventional
PQ Pump System
Hybrid Servo Systems
Variable Volume Hydraulics
! Variable volume pump
! High case flow
! Relies on pressure drop
across valves to operate
! High min. pressure
! Fixed volume pump
! For cooling the oil
! Sensitive to cavitation
! Closed loop oil
temperature control
! For continuous,
stable operation
Drive
Position
Feedback
Hybrid Servo System
Servo Motor Group
! Internal gear pump
! Turns only when motion is
required
! Return line heat exchanger
! For cooling the oil
! Closed loop oil
temperature control
! Adjustable set point
! Multiple motors

Hybrid Servo System
Vact
Q
cmd
and p
cmd

Q and P
n
act
n
cmd
Q
act
and p
act

p
act

System Block Diagram
Ethernet
Powerlink
Hybrid Servo System
Features of Motor/Drive System
! Regen Power
! Regen to bus
! 1:1 power factor
! Modular
! Modular rack design
! Service
! No config during replacement
! Built-in network safety
! Plug connections for fast replacement
! Native to ethernet power link
! On-board fast logic control functions
! Air-cooled motors and drive
#6
#3
#5
#2
#1
#4
Ethernet
Powerlink
Dr i ve Cabi net
Hybrid Servo System
Power Cabinet
I/O & Safety
Relays
Drives
Power
Connections
Servo Motor Drives
Dynamic Breaking
Chokes
Hybrid Servo System
Induction Motor Servo Motor


3-phase Asynchronous Motor
3-Phase Synchronous Motor
with permanent magnets


Hybrid Servo System
Benefits:
- Closed loop system
- Reduced energy consumption
- RPM of Induction motor is fixed 1750
- Servo motor RPM can vary from 0 to 3000 RPM in both directions
-High efficiency at low loads
-Accuracy
- Very high resolution (rotation can be controlled by fraction of angle)
- Fast response
- High repeatability

Servo Motor vs. Induction Motor
Electro hydraulic pump Internal gear pump
Benefits:
- Sensitivity to contamination is reduced drastically
- Fewer number of parts only two moving parts
- No internal wear parts (ex. swash plate )which improves
pump reliability
- Very easy to maintain; low cost of spares
- Pump can rotate in either direction to provide quick
pressure control response
- Pump can be stopped intermittently during the cycle
- Non-pulsating discharge - constant and even discharge
regardless of pressure conditions
- Low operating noise
VV Piston Pump vs. Internal Gear Pump

Low Operating Noise
MS 580 MM 550
TEST STEADY STATE
POINT TIME-WEIGHTED AVERAGE *
dB(A) Difference
1 70.9 77.4 6.5
2 69.8 76.3 6.5
3 68.8 71.6 2.8
4 69.4 77.4 8
5 70.9 81.2 10.3
6 68.9 83.4 14.5
7 71.3 83.9 12.6
8 70.1 80.9 10.8
Avg 70.1 80.4
Hybrid Servo System

Minimizes the influence of machine on oil temperature.
" The servo system only delivers hydraulic oil as it is needed to prevent
unnecessary heat generation and to reduce oil cooling requirements
" Life of the hydraulic components is extended
" Enhanced oil life
" Reduction in cooling water consumption

Improved Consistency & Repeatability.
" Servo system closed loop control considerably improves cycle
consistency and repeatability vs. conventional hydraulic injection
molding machines



System benefits :
Operating Efficiency
Operating Efficiency
MODEL Fixed Pump 3000 VV Pump 3200 VV Pump 4400 Hybrid Electric 3000 Servo 4400
TYPE II Platen II Platen II Platen II Platen II Platen
US TONNAGE 3300 3520 4400 3300 4400
CONNECTED POWER (KW) 338 365 1087 370
SCREW DIAMETER (MM) 155 150 140 155 140
MATERIAL TPO TPO TPO TPO TPO
CYCLE 45.3 105 50.3 39.8 50.3
SHOT WEIGHT (OZ.) 144 246 160 144 160
THRU PUT (KG/HR.) 325 240 325 370 325
AVERAGE KWH 246 139.9 164.2 126.5 100.4
EFFICIENCY (KWH/KG) 0.757 0.583 0.505 0.342 0.309
Efficiency
!"!!! !"$!! !"%!! !"&!! !"'!! !"(!! !")!! !"*!! !"+!!
,, --- &!!!
,. &%!!
,/ ''!!
01 &!!!
,2 ''!!
M i l a c r o n S e r v o 4 4 0 0

B r a n d A H y b r i d E l e c t r i c 3 0 0 0

M i l a c r o n V V P u mp 4 4 0 0

B r a n d A V V P u mp 3 2 0 0

B r a n d B F i x e d P u mp 3 0 0 0
Kwh/kg
The Material Matters
Each material requires a different amount of
energy to bring it to the appropriate temperature
for molding.
This specific amount of energy is sometimes called
Specific Enthalpy
Units are kw-hr/kg or hp-hr/lb
Hybrid Servo Efficiency
1100 1500 2000 2600 3300 4400
Model MS 1125-6610 MS1500-10100 MS2000-16000 MS2600-23000 MS3300-34000 MS4400-48000
Injection Unit 6610
( 10100) 10000 10100
(125MM) 16000 16000
(140 MM) 23000 23000
(160MM) 34000 34000
(180MM) 48000 48000

% screw recovery 33.9% 38.2% 44.5% 46.8% 43.4% 45.7%
Shot size hdpe 39.2 64.96 101.36 151.2 215.32 295.12
lb./hr. hdpe 336.0 448.4 507.4 659.4 794.2 888.4
Efficiency kwh/lb. 0.134 0.145 0.158 0.140 0.125 0.133
Increase in efficiency assume .3 Kwh/lb. 0.166 0.155 0.142 0.160 0.175 0.167
Hrs. year 5000.000 5000.000 5000.000 5000.000 5000.000 5000.000
Energy cost $0.068 $0.068 $0.068 $0.068 $0.068 $0.068
Savings (cost to run Machine) $19,001 $23,602 $24,492 $36,024 $47,444 $50,635
Savings (cost to remove wasted energy) $3,800 $4,720 $4,898 $7,205 $9,489 $10,127
344567 26894:; 8;" <=>?6579@; A%%B+!% A%+B&%& A%CB&C! A'&B%%C A()BC&% A)!B*)%
D?0;04E F6750 * =06? 26894:; A$(&B+C! A$C$B$($ A$C+B&(& A%C$B*() A&+'B%&+ A'$!B!+*
Annual Savings
Hybrid Servo 4400 vs. Hydraulic 3000
Annual Savings Ms 4400 vs. MM III 3000
Hours Production per year 6000 50 weeks
6 days week 20 hrs
day
Energy Cost $/kwh 0.07
Part wt oz 160
Cycle 50.3
kg/hr 325
Efficiency difference MS vs
MM III kwh/kg 0.448
Annual savings machine $61,179.93
Energy removal Cost $12,235.99
Annual energy savings $73,415.91
Reduced stabilization time
Reduced by 3
cycles $6,210.00 $ 200/hr. burden rate
$ .7 lb. material cost
Total annual savings $79,625.91
Present Value 5 years savings
$344,739
Hybrid Servo System
Energy Monitor
" Overall operating efficiency
" Power used each process
segment
" Last Cycle
" Reference Cycle



Customer: Machine: MS580-105
Part: Fan Shroud S.O 3019925 H5201AE010012
Shot Weight: 1249 grs 44.1 ozs Material: PS Date: 03-May-11
Dimensions: 28 x 18.5" x 4.5" x .140 1 Cavity
5401126 FSCR,4880B BAR 20.0 NC 135M 1 Actuals
Cycle 60 secs
Clamp 11.22 secs
Fill 5.78 secs
Recovery 22 secs
Recovery Rate 2.00 ozs/sec
lbs/hr 165 lbs/hr
Cushion 0.375 in
Xfer 0.5 in
Xfer psi 850.0 psi
Start Time 9:51:
Start EPT 0.2 kWh
0.4104
Stop Time 10:40:42
Stop EPT 15.1 kWh
0.83 hrs
Average kWh 18.0
0.44
Shot Weight 43.85 ozs
Cycle Time 60.00 secs
lbs/hr 164.4 lbs/hr
kWh/lb/h 0.110
Energy Monitor
Energy impact example:
Automotive fan shroud processed on Servo IMM at .1 kwh / lb.
compared to a hydraulic result in the range of .3 kwh / lb.

For more information on Milacron hybrid
servo injection molding machines or to
receive a cost quotation, contact us:
513-536-2000
milacron@milacron.com