ARBURG - Getting designs right the first time
ARBURG is one of the world‘s leading manufacturers of injection molding machines. Through its central development and production processes at the company’s headquarters in Lossburg, Germany; they guarantee the high quality standard for which ARBURG products are famous the world over. That‘s why they use the best tools, such as Zuken‘s CR-5000 software, in the +development department.
ARBURG took the first step towards its present business area in 1954 by building their first injection molding machine. This was manufactured for the company‘s own use, to encapsulate flash unit contacts with plastic. High market demand resulted in the company starting to mass-produce injection molding machines two years later.
The company has since become a global player whose electric, hybrid and hydraulic ALLROUNDER injection molding machines are in demand all over the world. Their areas of application include the production of plastic parts for the automotive industry, communication and consumer electronics, medical technology, optics, domestic appliances and packaging.
The range of products is rounded off by robotic systems, customized fully automated manufacturing cells and other peripherals.
- CR-5000 is a pivotal element in enabling ARBURG to respond flexibly to both market and customer requirements in extremely short development cycles.
- With CR-5000 the company now has a tool for a fast and reliable design process, which enables error-free products right from the start of development thanks to a constraints-based design process.
- The constantly increasing requirements in high-speed PCB design are effortlessly met by the combination of CR-5000 Board Designer, Lightning Realize and the Dragon Autorouter
The modular injection molding machines made in Lossburg really do live up to the name ALLROUNDER. They can be adapted to suit the exactly and individual requirements of the application – from the simple injection molding solution to fully automated manufacturing cells, which ARBURG supplies as a general contractor.
The benefits of the central SELOGICA control system become clear, particularly in automated processes – as even complex processes can be controlled and programmed easily and securely.Read more
For engineer Werner Faulhaber, head of the electrical engineering development department, one of today‘s key challenges is “being able to respond flexibly to both market and customer requirements in extremely short development cycles. It is rather unusual for a machine construction company to develop and produce its own control technology for its injection molding machines. But this has given us extensive know-how which enables us to devise the most efficient solution together with our customers in a practical and competent manner.”
And that‘s a job which involves more than 170 employees from the development and technical processing departments. After all, ARBURG not only attaches a great deal of importance to first-class product and manufacturing quality, but to customer proximity and comprehensive advice in all areas of injection molding too. This customer proximity leads to a complex development process, which in turn requires appropriate software tools, such as a powerful system to create complex highspeed PCB designs.
When the previous CAD development system was replaced in 2008, the company evaluated several software suppliers. Werner Faulhaber explains the process: “First of all, we had to find out what products could be interesting for us. We collected and weighted our special decision-making criteria in a matrix. This resulted in three suppliers who were asked to demonstrate what they could do. The task involved autorouting between an Intel® chipset and a DDR2 SDRAM working memory. We also included other sources of information, such as forums and reference customers, in our decision-mak ing process.”
In terms of the complex requirements which arise as a result of using IC technologies such as these, the conformity of the PCBs is guaranteed from development right through to production. This is implemented by parallel development and verification, co-simulation of analog and digital circuits and programmable components, and optimization of the signal integrity, power supply, blocking, and EMC behavior. Selected DFM techniques are also used in parallel with the design process.
ARBURG is also developing and building the control technology for its injection molding machines in-house.
For Werner Faulhaber, it was also important “that we could use existing modules and switching parts from tested and proven circuits. We were able to automate and convert all of the existing data with ease.”
Reduced Development Costs
After slightly more than a year‘s experience, Werner Faulhaber can already draw an initial conclusion:
“The constantly increasing requirements in high-speed PCB design are effortlessly met by the combination of CR-5000 Board Designer, Lightning Realize and the Dragon Autorouter. The simulation results of the signal integrity tests and our measurement results on the finished design match very well. The uniform structure of the design rules within Design Gateway, Board Designer, Lightning and the Dragon Autorouter is a key benefit, as you can avoid manual interaction when changing between the individual development modules. For the pilot project, we deliberately selected our most complex control systems. Here, we were using the Intel® Celeron M and Intel® Core™ Duo technology, which is a familiar notebook technology. It was clear to us that if the new design process could satisfy these very stringent requirements, it could be used successfully to process all other designs in our company. We were impressed by how the pilot project proved this.“
Other benefits of the Zuken software, according to Werner Faulhaber, include “reduced development costs thanks to time savings and improved quality. We will also be making more use of new CR-5000 functions, which enable innovative modern designs and technologies.“
No Manual Interaction
The testability (in-circuit test, ICT) of the design has to be considered in the development stage. To this end, the design rules and library are closely coordinated.
The XDF Interchanger module delivers the PCB data in an output format, which can be read directly from an interface in the Teradyne ICT test device used by ARBURG. There is therefore no need for error-prone, manual interaction.
The keyboard geometries and enveloping bodies, which are important for collision checks, are imported using the CATIA interface Board Interchanger. In turn, the finished layout is exported as a 3D model to the mechanical design tool CATIA, which is also where the design drawings required for PCB assembly are created.
This integration also forms the basis for consolidating electronics development, design, and production planning and control. The connection of the schematic tool Design Gateway to a foreign language database is currently being evaluated. Because ARBURG has customers all over the world, the aim is to be able to create multilingual schematics at all times.
“This will improve our already excel-lent sales and service for our own organizations in 24 countries and our trade partners in more than 50 countries,“ says Werner Faulhaber.