INNOVATIVE DRIVE TECHNOLOGY

Compact Drive Solutionsfor All-electric Injection Moulding Machines

Model range ZS-I / FZ – Drive for Injection and PlasticizingModel range ZS-C – Clamping Unit DriveModel range ZS-E – Ejector Drive

2

Injection units for all-electric

injection moulding machines

The demand for energy efficiency

and low noise was the reason for

the development of fully electrical

injection moulding machines, that

is the logical result.

There is the achievement of

short cycle times with high injec-

tion speeds and forces of crucial

importance.

These requirements are fulfilled

with the new drive concept of

the linear movement via toothed

racks as well as the rotation for

metering in a compact design.

Linear unit

To achieve similar power densi-

ties as with hydraulic drives, our

system uses an 4- to 8-fold

meshing on the toothed racks.

These racks have maximum

carrying capacity and force equa-

lization by herringbone.

Water-cooled three-phase servo

motors in 2- and 4-fold arrange-

ment have small inertia and en-

sure extremely dynamic driving.

Plasticizing unit

Directly with the injection unit,

the metering for the screw drive

is connected. We use the best

of the plasticizing gears series

FZ 81.3 - FZ 901.3. These are

flanged directly to the injection

gear. The motor is also water

cooled from the modular MA

series, upon request, other

motor brands via IEC flanges are

available.

Force measurement and axial

bearing

The pistons for the back-pres-

sure injection storage and a

load cell are integrated, which

pro vides means of amplifier

measurement and control

signals.

Distance measurement

system

For position feedback of the

injection plunger the motors

can be equipped with absolute

encoders. Alternatively indepen-

dent encoders are suitable for

supplying the control with the

required parameters.

Motor frequency control –

winding design

Particular importance is attached

to the selection and parameteri-

zation of the frequency inverters.

Our experts will gladly advise

you and agree the detailed

design data with you.

Drive for injection and plasticizing – Model range ZS-I / FZ

Injection unit

Motor for plasticizing unit

2- or 4-motor-systemfor injection

Plasticizing unit

3

Drive for injection and plasticizing – Model range ZS-I / FZ

Performance data

Injection

Size ZS 80-I ZS 200-I ZS 330-I ZS 450-I ZS 650-I ZS 900-I

Injection force F (kN) 80 200 330 450 650 900

Stroke h (mm) 100 160 200 240 320 380

Injection speed v (m/s) 0.33 0.33 0.33 0.33 0.33 0.33

Injection speed max. vmax (m/s) 0.45 0.45 0.45 0.45 0.45 0.45

Motor power

p (kW)(0.33 m/s) 26 66 109 148.5 214.5 297

p (kW)(0.45 m/s) 36 90 148.5 202.5 292.5 405

Motor type 2x or 4x Model range CM 11-2 11-4 21-4 31-4 61-4 121-4

Plasticizing

Size FZ 81.3 FZ 81.3 FZ 121.3 FZ 151.3 FZ 501.3 FZ 901.3

Screw diameter Ds (mm) 20 to 35 25 to 40 30, 40, 45, 50 45, 50, 60 60, 70, 80 70, 80, 90

Output torque M2 max (Nm) 900 900 1,200 1,800 6,000 11,500

Motor power p M (kW) 20 20 11-25 20-40 40-90 70-140

Motor type Model range MA 100-112 100-112 112-132 132-160 160-200 200-225

Gear choice

The following tables list the gear-

box sizes according to torques

and power limits.

The tables represent a selection;

deviating models upon request.

Dimension sheets in PDF format

or as CAD data in different 2D or

3D formats can be retrieved for

structural editing. Please contact

our Sales department for more

information.

Cooling

Integrated cooling coils for water

cooling in the gear box as well

as on the motors ensure a safe

operating. Again, you will receive

support from our experts.

Compact and efficient – com-

bining the linear movement with

the rotational movement results

in shorter cycle times and there-

fore higher cost effectiveness.

The high precision and repetitive

accuracy ensure minimisation of

defective parts and an optimised

profit margin. This pays off

especially in the manufacture

of very small, thin-walled parts,

high-precision technical parts or

in packing technology.

Electrical injection and feeding for the manufacture of precision parts in medical technology, special seals, packing etc.

4

Drive for injection and plasticizing – Model range ZS-I / FZ

A B C

D

SizeZS 80-I/FZ 81.3

ZS 200-I/FZ 81.3

ZS 330-I/FZ 121.3

ZS 450-I/FZ 151.3

ZS 650-I/FZ 501.3

ZS 900-I/FZ 901.3

Motor type injection unit CM 11-2 CM 11-4L CM 21-4 CM 21-4LL CM 31-4L CM 31-4LL CM 61-4 CM 121-4

Motor type plasticizing unit MA 100 MA 100 MA 112 MA 112 MA 132 MA 132 MA 200 MA 225

A (mm) 103 137 170 170 201 201 233 303

B (mm) 505 550 601 655 693 733 826 967

C (mm) 553 752 862 862 1,010 1,010 1,288 1,585

D (mm) 115 104 178 178 208 208 273 380

Weight (kg) 280 495 710 780 1,230 1,350 2,050 3,450

Dimensions and Weights

The specified weights are recom-

mended values and may vary

depending on the version.

All dimensions refer to the

standard design, the dimensions

for different designs like the ones

below must be taken from the

dimensions sheet.

In order to achieve the high

injection forces of up to 900 kN,

the injection unit is operated with

four arrow-toothed racks with

8-fold tooth engagement. Two

pinion shafts each are driven by

one of the four asynchronous

motors. This principle ensures

a high dynamic response and

efficiency of this drive with abso-

lutely low-noise operation. The

directly flanged dosing unit con-

sists of the well-proven 3- stage

shaft-mounted gears with water-

cooled electric motor.

Special designs

The injection drive can be equip-

ped with a single synchronous

servo motor for an even greater

dynamic response on request.

Our drive specialists will be

happy to advise you.

5

Clamping unit drive model range ZS-C

Once the solution of a rack drive

with preceding reduction stage

had been introduced successfully

for the injection movement, it

made obvious sense to develop

this principle further for the posi-

tive locking. Previous electrical

solutions normally use a ball

screw drive but a rack drive has

essential advantages over this

with regard to the efficiency and

development of noise.

Four asynchronous motors with

4-fold tooth engagement on the

rack ensure the necessary per-

formance density and dynamic

response. In order to achieve a

short design despite the compa-

ratively large stroke, a telescopic

seal was developed which enc-

loses the extended rack oil-tight

with telescopic sleeves and is

flexibly configurable depending

on the required stroke.

Size ZS 80-C ZS 125-C ZS 210-C ZS 350-C

Clamping force Fclamp (kN) 2,000 3,000 5,000 8,500

Axial force Fa (kN) 80 125 210 350

Stroke h (mm) 480 560 700 800

Speed v (m/s) 1 1 1 0.85

Motor power P1 (kW) 80 125 210 300

Motor type 4x Model range CM 11 21 31 61

Performance data

The illustration on the left shows

the assembly and position for

a cross-head drive with open

mould (toggle lever moved in)

and gives an indication of the

short design.

This results in optimisation of the

installation length because the

drive determines the total length

of the machine directly.

.

To increase the

efficiency, a single

synchronous servo motor

can also be fitted for the

positive locking drive as for the

injection drive on request.

6

Clamping unit drive model range ZS-C

H

B EC

FF

F

G G

ø D

ø S ø

RL* K* A M*

J

J

ø P

N (Stroke)

Size ZS 80-C ZS 125-C ZS 210-C ZS 350-C

A (mm) 460 540 690 900

B (mm) 140 165 230 280

C (mm) 185 235 320 415

D (mm) 17.5 22 26 33

E (mm) 328 320 415 456

F (mm) 70 80 100 140

G (mm) 120 145 200 240

H (mm) 440 550 720 810

J (mm) 345 390 450 550

K (mm) * 305 335 420 440

L (mm) * 240 285 400 420

M (mm) * 405 520 570 665

Stroke N (mm) ** 480 560 700 800

P (mm) 100 140 180 230

R (mm) 150 180 230 280

S (mm) 36 50 80 95

** The stroke may vary depending on customer requirements.* With modified stroke the dimensions K, L and M vary accordingly.

Dimensions

7

Ejector drive model range ZS-E

The ZS series is completed by

the ejector drive. The challenge

here is the small installation

space given by the space condi-

tions with the toggle lever moved

in. This rack drive also has much

greater efficiency in comparison

with ball screw drives and there-

fore significantly improves the

energy balance. This drive also

features low-noise operation.

The comparatively low forces

and the required speed are

achieved with a single synchro-

nous servo motor and a rack with

double tooth engagement. To

achieve a small size, a telescopic

seal is also used here although

the strokes are not comparable

with those in the positive locking

drive.

Size ZS 25-E - 550 ZS 25-E - 1100 ZS 40-E ZS 60-E

Ejection force Fa (kN) 25 25 40 60

Stroke h (mm) 100 125 165 185

Speed v (m/s) 0.3 0.3 0.3 0.3

Motor power P1 (kW) 7.5 7.5 12 18

Motor type Single synchron servo motor

Performance data

The immensely compact design

was enabled by the single motor

drive, the corresponding reduc-

tion to the two rack pinions and

the telescope.

The dimensions and weights of

the ejector drive can be found on

the next page.

Ejector drive ZS 40-E with mounted motor.

Further information Knödler-Getriebe GmbH & Co. KG

Schönbuchstrasse 1

D-73760 Ostfildern

Phone 0049 - 711 - 448 140

info@knoedler-getriebe.de

www.knoedler-getriebe.de

Edi

tion

04/1

4 · Z

S-e

· S

ubje

ct to

tech

nica

l mod

ifica

tions

Consulting service

Call us if a standard gear is

unsuitable for your area of appli-

cation. Our experts will gladly ad-

vise you and help you to find the

right solution for every technical

challenge. We will also be happy

to send you dimension sheets in

PDF format in advance.

Ejector drive model range ZS-E

Size ZS 25-E - 550 ZS 25-E - 1100 ZS 40-E ZS 60-E

Stroke (mm) 100 125 165 185

A (mm) 184 222 279 327.5

B (mm) 84 97 114 142.5

C (mm) 221 221 268 275.5

D (mm) approx. 151 approx. 151 approx. 174 approx. 197

E (mm) approx. 113 approx. 113 - -

F (mm) - - approx. 194 approx. 212

G (mm) 215 215 222 265.5

Weight (kg) 40 43 64 88

D

E

F

GC B Stroke

A

D

E

F

GC B Stroke

A

Dimensions and Weights