Volkswagen takes the first all-electric IntElect machine from Sumitomo (SHI) Demag into operation

At VW's Braunschweig plant, a fully electric IntElect 220-1100 injection moulding machine from Sumitomo (SHI) Demag was recently taken into operation for producing lighting dial trims. The machine increases energy efficiency in the production process and reduces the level of scrap.

Recently, Volkswagen AG took the first fully electric IntElect 220-1100 machine from Sumitomo (SHI) Demag GmbH, Schwaig, into operation at its Braunschweig plant. The machine produces lighting dial trims for the Golf VII. With its low energy requirement, the new machine magnificently matches the "Think Blue. Factory." concept with which Volkswagen AG is continuously increasing the sustainability of all production facilities. Furthermore, the IntElect machine offers shorter cycle times and a minimum scrap quota in manufacturing the precision components.

A significant advantage of the IntElect series compared to hydraulic machines concerns the low energy consumption of the innovative direct drives in the plasticisation and injection procedure, as well as when opening and closing the mould. In addition, the braking energy from each main axis is temporarily stored in order to provide energy for the other axes. In this way, IntElect machines save up to 85% of the energy compared to conventional solutions. Direct drives convert less energy into heat than hydraulic drives do, so in addition they require less cooling power than comparable conventional machines.

Energy efficiency is more and more important
"In our production processes along the value creation chain, energy efficiency is playing an increasingly important role. The fully electric IntElect machine from Sumitomo (SHI) Demag makes an important contribution to this," explains Marco Heinemann who is responsible for project management of new start-ups in the Braunschweig plant. Jens Pedersen, a VW employee in the works technology department, adds: "By using the IntElect, we have been able to improve the cycle time by 15% compared to a hydraulic machine. At the same time, we are able to reduce scrap because of the increased precision and repeat accuracy." Karsten Goebel, another employee in the works technology department in Braunschweig, adds that the enormously smooth running of the machine is remarkable compared to a hydraulic machine.

The Braunschweig is one of the most important system suppliers for the vehicles of the Volkswagen Group. Parts from the Braunschweig plant are installed in almost all VW vehicles, and include front axles, rear axles, steering systems, axle modules, shock absorbers/pedals as well as an extensive assortment of plastic components. 60 tonnes of granulate are delivered every day to the plastics technology area at Braunschweig, where they are processed into 500 different products, e.g. for the vehicle interior, on 132 injection moulding machines with 447 injection moulding moulds and two painting systems.

The Volkswagen brand has set clear targets for putting all its factories on a sustainable ecological footing with the "Think Blue. Factory." concept: By 2018, all Volkswagen plants are supposed to have reduced their energy and water consumption as well as the waste volumes and emissions by 25 percent. To achieve these ambitions targets, VW will continue to invest in fully electric injection moulding machines in the future.

Source: Sumitomo (SHI) Demag