Fully electric Optical Disc Subsystem

The exceptional global success of the e-Jet from Netstal is due to the system’s outstanding ability to manufacture all optical disc formats, particularly DVD-9 and DVD-R. In addition, these machines are also equipped for the production of HD DVD, Blu-ray disc or HD VMD.

The e-Jet design is characterised by a whole range of superb technical features:

Lubricant-free clamping unit

The four-column clamping unit with 500 kN of clamping force has a crank-driven, position-regulated, open and close movement. The mold and tooling area is completely lubricant-free due to the use of encapsulated bearings, column casings and encapsulated gearing that uses minimum amounts of oil. The clamping unit has a pre-defined production stroke of 50 mm and a maximum inspection stroke of 320 mm for stamper and mold changes. Precision linear guides for the moving platen provide for the highest degree of accuracy and a minimum of mold wear. This clamping unit is suitable for both CD and DVD manufacturing processes. Complex mechanical conversion work when changing from CD to DVD production is avoided. Adjustments to be made in the event of a production change are limited to the mold change, starting up a new program and an automatic resetting procedure for setting coining force regulation.

Compact injection unit

The extremely compact injection unit is equipped with a 32 mm diameter plastisizing unit and has a maximal injection pressure of 1400 bar. A stroke-optimised crank drive provides for rapid injection speeds of up to 250 mm/s. Additionally, all injection and metering process parameters are regulated. Parallel to the clamping unit, the injection unit linear guides on the machine frame also enable precise nozzle position adjustment (nozzle closed or open).

Efficient removal robotics

A highly dynamic servo drive with gearing provides optimal positioning and a top operating speed of up to 9 m/s. The maximal acceleration achieved is equivalent to 50 times the acceleration due to gravity (g earth = 9.81 m/s2). The monitored vacuum threshold (disc and sprue) and the removal arm, optimised with respect to inertia, also contribute to the extremely fast removal robotics

Intelligent DSP control

Integrated into the safety cover and making its debut on the e-Jet is the newly designed control box, which incorporates an ergonomically positioned 15” TFT colour screen. In addition to being user-friendly, the new control box is notable for its exceptionally good accessibility with respect to maintenance work. Additionally, up to four temperature sensors are integrated into the machine frames and regulated via the control box.