ENGEL is introducing an electric, tie-bar-less injection moulding machine, the victory electric 220, which the company describes as a world first in terms of design. The machine combines ENGEL's tie-bar-less technology with the attributes of electric drive systems, namely high energy efficiency, precise reproducibility, short cycle times and a reduced footprint. It will be unveiled at K 2025 in Düsseldorf, Hall 15, stands B42 and C58, as the core of a fully automated production cell for fittings. The cell covers the entire manufacturing flow from moulding to assembly and quality assurance. A family mould supplied by toolmaker ifw produces four parts in one shot, two 90-degree elbows and two 45-degree elbows, processing polypropylene from Borealis at a shot weight of 4 x 80 grams. The tie-bar-less layout provides a large, unobstructed mould area, facilitating core-pull layouts and automation, while the integrated digital assistance suite is aimed at lowering scrap and boosting overall equipment effectiveness. Digital systems include iQ hold control for automatic optimisation of holding pressure time, iQ weight control plus to compensate viscosity fluctuations shot by shot, and iQ process observer that analyses up to 1,000 parameters and provides AI-based recommendations. A digital set-up assistant guides mould changes and can cut set-up time by up to 80 percent. Automation is fully integrated, with parts dropping onto a built-in Z-conveyor, camera-based detection and handling by ENGEL easix articulated robots. An automated unit by Lüers inserts and tests seals before finished fittings exit the cell.
World premiere at K 2025: The new electric tie-bar-less ENGEL victory electric 220 takes centre stage in a fully automated production cell for fittings – compact, electric, efficient, and designed for maximum productivity.
Machine concept and application
The victory electric 220 combines the compact dimensions of a tie-bar-less design with an enlarged platen area and unobstructed access to the mould space. This simplifies the use of large tools and complex core-pull configurations typical of fitting production, and can allow the use of smaller machine sizes for a given mould envelope. High accessibility contributes to shorter set-up times. As an electric machine, it targets high energy efficiency, precise reproducibility and short cycle times, while the elimination of hydraulic circuits reduces routine maintenance requirements. The concept is aimed at increasing flexibility and reducing the footprint in highly automated manufacturing cells.
Digital assistance and process control
The production cell integrates several digital assistance systems. iQ hold control automatically optimises the holding pressure time and, according to ENGEL, can increase part output by more than ten percent in many applications. iQ weight control plus compensates for viscosity fluctuations in every shot using speed- or pressure-based control with two parameters, which can reduce scrap by up to 50 percent. Complementing these functions, iQ process observer analyses up to 1,000 process parameters per cycle, detects deviations and provides AI-based recommendations to stabilise the process and maintain consistent part quality. A digital set-up assistant guides operators step by step through mould changes, enabling faster and safer changeovers and, depending on the scenario, reducing set-up time by up to 80 percent.
Integrated automation and handling
Parts are demoulded and drop directly onto a built-in Z-conveyor, eliminating a removal gripper and saving two seconds per cycle, which is advantageous for product variants with changing elbow angles or diameters. A camera system detects the parts on the belt. An ENGEL easix articulated robot picks them and transfers them to a second easix unit, which feeds an automated ring insertion station supplied by Lüers. Seals are inserted, checked for tightness and the fully assembled fittings are discharged from the cell. The arrangement is designed to align machine concept, digitalisation and automation for high overall equipment effectiveness and reliable process stability with a broad product mix.
More fittings, less effort: Robust and precise production with the new ENGEL victory electric reduces costs and sustainably increases output.
