K 2025: From the AI-supported “Ask ARBURG” app to the Virtual Twin

GESTICA lite, a new control variant that is extremely interesting for standard machines, is celebrating its premiere at K 2025. It features a distinctively robust industrial panel. The software basis is identical to GESTICA and their data records are fully inter-compatible. The new version is reassuringly easy and intuitive to operate using the extended user interface, even for non-specialists; at the same time, flexibility is maintained for experienced operators. The “Dashboard” is a distinctive new feature on the user interface. The screen homepage clearly displays all the crucial functions for day-to-day work in a clear format. Those functions include information on the job, the current process and direct access to the most important parameters and key figures - all supported intelligently and actively by assistance functions. The touch function can be used to jump directly to the detailed parameter pages for the clamping and injection unit, temperatures and robotic system. The new “Status Center” offers added value with access to all pending alarms, while the “Help Center” provides access to online support. The “Tasks” area is dedicated to maintenance, material supply and parts disposal. Here, individual notes can be added to the digital “Pinboard” for collaborative work, eliminating the need for paper notes on the machine. This is complemented by simplified navigation and search with AI functionality as well as rapid support for the operator when troubleshooting thanks to assisted workflows with visual solution trees. Assistance and pilot functions such as the “aXw EnergyAssist” or the “aXw Control RecyclatePilot” are available as options. At the K 2025, four exhibits - the electric ALLROUNDER TREND and the vertical ALLROUNDER 475 V - are already equipped with this new control variant. Individual features can also be explained on a demonstrator monitor.

ARBURG offers smart assistants and pilots for its machine control systems to make everyday injection moulding work much easier with digital products and services. The “aXw Control MoldlifeAssist” - the “Moldlife Sense” computer system from partner Hack Digital Solutions, which is fully integrated into the GESTICA - is new and particularly predestined for complex moulds and endurance runners. This now enables "smart" communication directly between the machine or production cell and the injection mould on base of the the Euromap 82.5 interface. The associated hardware is a connector on the fixed mould plate and a box on the rear of the machine. This means that one system can be used for several moulds.

The “MoldlifeAssist” function supports the set-up, monitoring and maintenance of the mould and improves availability and operator safety. Its “Set-Up Assistant” with digital alignment aid guides the operator step by step visually through the entire set-up operation and process. During daily operation, the tool is monitored over its entire life cycle in terms of temperature, acoustics, breathing and alignment using integrated sensor technology (condition monitoring). The measured values from various sensors can be visualised in the GESTICA control system and individual “Events” - such as warnings, alarms and error messages - can be displayed and the tool data logged and documented. Another major advantage is the option of predictive maintenance. This prevents expensive unscheduled downtime periods while also avoiding the need for costly maintenance. Instead, the “MoldlifeAssist” enables condition-based maintenance cycles and also assists with maintenance. A maintenance logbook can be called up via GESTICA and all maintenance points can be acknowledged and documented.

At K 2025, the “MoldlifeAssist” will be getting showcased as part of a digitally networked production cell based around an electric ALLROUNDER 570 A, which produces caps for injector pens.

The arburgXworld customer portal with its numerous apps and features is no less intelligent than the assistants and pilots in the control system. One highlight at K 2025 is the virtual twin to GESTICA lite. This new feature will be available in the “Virtual Control” premium app from 2026. This will not only make it possible to optimise a program directly on the PC, but also to run it in an automatic cycle in order to further optimise the process and cycle time. Based on the data set of an injection moulding application, the complete cycle, including injection, holding pressure, etc., can be simulated and the associated graphics and curve diagrams displayed. The integration of automation or the time span until the granulate container needs to be refilled can also be simulated in advance using such a virtual twin. At K 2025, the virtual twin of the ALLROUNDER 1000 e TREND, which produces connectors at the trade fair stand, will be demonstrated live on a monitor.