GESTICA

Benchmark “Made by ARBURG”

 BENCHMARK
Simply smart:
Central control system
that makes working fun.

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How can the injection molding
process be optimized, simplified and
made more convenient? With our
GESTICA, we follow a simple but
effective principle: There’s always
room for improvement. This is why
we develop our controller tech-
nology ourselves right from the
outset – because then it is perfectly
tailored to the machines. The result:
A multitude of clever solutions
that we use to set trends and drive
digitalization forward. Secure your
technological lead – by managing
complex requirements with ease.
GESTICA: Nothing less than a seal of
quality and performance for high-
end injection molding machines!

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AT A GLANCE:
// Maintaining control over machine, mold, robotic and peripheral technology
requires a suitably powerful central control system. This calls for smart technology
that networks everything, provides active support in every operating situation, and
monitors and adaptively controls processes. And in
a way that is as simple as possible. All the features Highlights
of our GESTICA are designed for fast, secure,
and convenient operation. This is what efficient • GESTICA is fully compatible
injection molding at the highest level looks like with its predecessor SELOGICA
– for your peace of mind, entirely “Made by • Navigation with gestures
ARBURG”. This allows you to get the best out • Unique assistance functions
of all applications. \\ • “Digitally ready” connectivity
• Diverse functions for specialized
technology and sequences
• Central control system for
complete production cells

Hardware and software “Made by

ARBURG”: Our HydronICA was the world’s
first microprocessor control system in 1975.

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 Gestures, technology, and assistants make the
difference: Our GESTICA makes working faster,
surer and easier than ever before.

Graphic sequence programming

with real-time plausibility check:
Our SELOGICA revolutionized operational
philosophy as early as 1992.

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Central management Direct interaction
Digitally ready: Thanks to its highly Optimized navigation takes you
secure connectivity based on OPC-UA quickly to your destination in just a few
together with our uniform operational clicks. You can easily switch between
system, GESTICA operates efficiently parameters and associated monitoring
in terms of time and money. The full and logging functions using gestures.
integration of robotic systems and GESTICA also provides you with unique
other peripheral equipment enables assistants such as aXw Control FillAssist
sequence management even for com- for simulating the injection molding
plete production cells – and with only process directly on the machine.
one data set. Higher utilization rate? Included!
Fast cycles? Can be programmed!

Intuitive operation Autonomous control

The graphics-based operational phi- Our GESTICA monitors and regulates
losophy can be intuitively understood your processes adaptively. We achieve
and is always streamlined. Our unique a high level of operational reliability
sequence programming with real-time through two separate controllers. This
plausibility check always clearly indi- way, operating the machine does not
cates the logical position of the current affect its performance. Hardware and
programming step. software developed in-house is fully
Operating errors? Out of the adapted to injection molding. This
question! know-how forms the basis for our
pilots’ innovative control concepts.
Stable processes? Guaranteed!

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CONTROL SYSTEM
“MADE BY ARBURG”
// Easy-to-understand menu navigation, graphic sequence programming with real-time
plausibility check or secure computer structure. For us, the control system is the
central “seal of quality” of high-tech injection molding machines. This is why our
own expertise in hardware and software is so important to us – because it ensures
that the overall concepts are right too. From development to production, everything
is handled by us in-house – or as we like to put it: “Made by ARBURG”. Which is
why GESTICA offers you everything you could wish for in practice: Straightforward
induction, direct access to data, fast processes, and a high degree of reliability. In
other words: A crucial boost to your production efficiency. \\

> 10 YEARS
SPARE PARTS
For you – our exemplary service in
the area of controller technology
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Secure technology
The separate host computers for operation and process control, including GES-
TICA's multi-core technology, provide not only a high degree of operational reli-
ability but also the best possible protection against undesired third-party access.
Added to this is the closed operating system that has no need for security updates
yet allows printers, USB drives, or browsers to be easily integrated.

Central platform
Control systems as a core competence: ARBURG has been pursuing its own path
here for years with the development and production of a central platform. This
is also how we became an important control system manufacturer in Germany
almost incidentally. What does this mean for you? We also always incorporate
individual customer requests into the standard – update included.

Functional aesthetics
With its glass front, integrated hardware keys, and light design for status feedback
signals, our GESTICA operating unit has a premium look and feel that has won us
a Red Dot Design Award. We achieve excellent ergonomics with features such as:
• 15.6 inch screen for working without moving your head
• Full HD screen with high contrast and luminosity
• Swiveling operating unit, height-adjustable from size 1020 upwards

Sustainable production: Our

controller technology is produced at
a central location.

Tested quality: We use our own

laboratories to ensure a high level of
reliability for our GESTICA.

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 OUR TECHNOLOGY LOVES
YOUR CHALLENGES!

Ergonomic and secure:

Hardware keys make “blind” operation
of sensitive movements possible.

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Clear and convenient:
User interface optimized for
direct and fast access to data.

Award-winning and functional:

Design of the operating
unit with full HD screen and
integrated LED light strips.

Intuitive and clever: With the

EASYslider, movements are precisely
controlled during set-up.

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 Nothing is impossible: Diverse
functions for robotic systems
and specialized technology.

NAVIGATION AND
PROGRAMMING: INTUITIVE
// GESTICA is our human/machine interface – making it the benchmark for all
injection molding machines worldwide. Our high-quality technology and gesture
control designed for industrial use set the standard for convenient working. Two
examples illustrate this: A log function for up to 2,500 cycles makes trends recog-
nizable and enables direct production optimization. The machine documentation
is available online directly at the controller. We have continued to make refine-
ments – so that it is easier for you in practice. \\

SYMBOL
BY
SYMBOL towards an individual production sequence

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 Creating sequences
Getting there faster more easily
We have designed the GESTICA user The benchmark has been set – once • Real-time plausibility check: Logical
interface to work intuitively with ges- again! Because sequence programming positioning of the respective pro-
tures. Our features for flexible and fast with real-time plausibility checks is an cess step and completeness checks
menu navigation: ARBURG function that is unrivalled to for entries
• Parameter or keyword search date and one that we are constantly
• Task-specific homepage – accessible refining. That is real practicality that only
via home button Nothing could be easier: ARBURG can deliver! Even demanding
• Quick navigation to language and • Predefined basic sequences: sequences such as the position-related
operating rights For quick adaptation to the pro- start with simultaneous machine move-
• Switch to full-screen mode duction task ments or processes such as multi-com-
• Direct navigation from cycle • Efficient dialog box: Direct access ponent injection molding can be
sequence – divided into start, to insert, move and delete symbols implemented with confidence.
production, and stop
• Switching between a function’s
menu pages by swiping
• Adjusting views via zoom

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ASSISTANTS: MORE VALUE
// What distinguishes the best user interfaces from the good ones is primarily
their range of functions. Clever assistants that actively help you simpli-
fy your work are definitely a factor too. This is another area where our
GESTICA sets global standards. Our strategic approach is to ensure that the
machine “knows” its environment. With our innovative assistance func-
tions, we provide active help in all areas. From set-up and start-up, through
optimization and production, to monitoring and service. This is added
value, and you can use it to cut straight through the complexity from the
very first second. \\

Produce your first good part quickly and

reliably: Our FillAssist ensures more efficiency
during set-up and changeover.

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 Clear and simple: Our CycleAssist
makes potential savings in the cycle
transparent for you.

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THE CLUE’S IN THE NAME:
OUR ASSISTANTS
FillAssist MeltAssist
aXw Control FillAssist knows your aXw Control MeltAssist knows the
part. If you import an STL file, a mold built-in cylinder module. Plasticizing
filling study is created online. From capacity utilization and residence
this, suitable injection process param- times are calculated automatically. As
eters are determined for the machine a result, material preparation can be
and process. Simulation software and quickly evaluated and optimized, and
previous knowledge are not required, sources of error eliminated. In addition,
so your preparation and programming the running performance (screw stroke
effort is reduced. In addition, FillAssist and throughput) and load (pressures,
also animates the filling level of the temperatures, etc.) of the plasticizing
part in relation to the current posi- process are also stored in the module.
tion of the screw in real time as a 3D This speeds up service calls and makes
graphic. So even experts save valuable performance-based maintenance possi-
set-up time. Simple! ble. Really practical!

CycleAssist EnergyAssist
aXw Control CycleAssist knows your aXw Control EnergyAssist knows the
programmed production sequence. start and end of production. This
The current times of each cycle step makes it very easy to heat up or deacti-
are graphically compared to previous- vate the cylinder module and mold in a
ly defined reference values – broken uniform and controlled manner. Ther-
down in detail according to start, delay mal decomposition of the material or
and running time. With a click, you can damage to the hot runner are reliably
display unproductive time segments prevented. Now that’s energy-efficient
and perfectly coordinate cycle steps. working!
High productivity included!

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CONTROL AND REGULATION:
AUTONOMOUSLY
// If a machine does what it is supposed to do, then it also works really efficiently.
Our GESTICA takes care of this, monitors the process for you, and keeps it stable
with complete autonomy. This is exactly what our pilots are aiming at – adap-
tive process control and regulation. One of these
smart solutions is the aXw Control ScrewPilot with Features of the ARBURG pilots
position-regulated screw for stable mold filling
with high dynamics. This produces flawless parts, •R
 eal, high-quality controls
especially when it comes to the most demand- directly in the current cycle
ing geometries. So sit back, relax, and enjoy the • No mere readjustment of
smooth production of your quality products. \\ setting parameters
• Interaction of smart software
and precise machine technology
• Fast detection and correction
of interference effects

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PressurePilot RecyclatePilot
Our “aXw Control PressurePilot” with Not just for recyclate: “aXw Control
its bionically optimized pressure control RecyclatePilot” analyzes the injection
when switching from injection pressure process and detects deviations from a
to holding pressure delivers significant previously saved reference curve. Using
advantages: The process window for adaptive process control, it ensures a
robust injection molding is expanded. constant component weight without
At the same time, mold filling is more any additional sensors in the injection
constant and balancing is significant- mold. This smart solution makes the
ly improved – especially with higher processing of many materials and, in
cavity numbers. particular, batch changes safer.

ReferencePilot
The aXw Control ReferencePilot con-
trols the holding pressure curve in real
time via a pressure sensor in the mold.
This is the only way to reliably coun-
teract viscosity fluctuations and screw
wear. Besides better reproducibility,
the ReferencePilot also enables the
number of start-up cycles to be greatly
reduced.

REPRODUCIBLE

MOLD FILLING
with our ScrewPilot – fluctuations in the shot
weight can be significantly reduced

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 INTEGRATION AND
CROSS-LINKING:
COMPREHENSIVE
// More rational workflows, more productivity, improved part
quality, greater process reliability and transparency – all of
this can only be achieved with a uniform and all-embrac-
ing injection molding management system. This is why the
robotic systems and peripheral devices can be fully integrat-
ed into GESTICA, enabling central, effortless management
of entire production cells. With our connectivity modules,
data exchange with higher-level systems is also no problem.
“Wir sind da.” – we're by your side, even when you need to
digitize your production! \\

Mobile control system (option):

Can be used universally for multiple
machines and robotic systems.

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Central parameter Standardized
entry operational systems
GESTICA takes over the control of Only one control system for the
robotic systems and mold heating cir- machine, robotic system and peripheral
cuits. Commercially available peripheral devices – that has clear benefits for you:
devices can also be integrated via stan- • One data set – no adaptation
dardized interfaces. Monitoring inputs required
enable you to make the process control • Low training requirement - same
dependent on the granulate feed, approach for all machines
compressed air or the water supply, for • Easy set-up – consistent sequence
example. Additionally, freely program- programming
mable in/outputs are available. • Higher-level monitoring – high
degree of process reliability
Central storage of • Flexible and also synchronous pro-
setting data cess control – short cycle times

Convenient data storage on compact

flash cards or USB drives: One data set
contains all the parameters for the en-
tire production unit. That makes both
management and set-up easier, faster
and more reliable.

Identical basis: Typical

ARBURG sequence program-
ming for six-axis robotic system.

Photo: KUKA Roboter GmbH

LANGUAGE
1
for the machine, robotic system
and peripheral devices

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 Connected systems:
Providing data on internal
or external platforms.

VPN

arburgXworld

ATCM ARS

IIoT
ALS host gateway Expert
computer systems
system

Peripheral
devices
Switch

Robotic systems

Connected equipment:
Data exchange within the injection
molding cell on the basis of OPC UA.

arburgXworld: ARBURG customer portal – our digital services

ALS: ARBURG host computer system – our MES (manufacturing execution system)
ATCM: ARBURG Turnkey Control Module – our SCADA system (supervisory control and data acquisition)
ARS: ARBURG Remote Service – our remote service tool
IIoT: Industrial Internet of Things (Industry 4.0)

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 FULLY NETWORKED – JUST THE
WAY YOU WANT IT!
Digitally ready Connected equipment
Simple, standardized networking – the OPC UA is the EUROMAP standard for
OPC UA communication platform highly efficient data exchange within
creates ideal conditions for this with its an injection molding cell. For you,
manufacturer and language-indepen- this means increased ease of use, for
dent technology. And this is precisely example through a shared data set for
what our flexible connectivity modules machine, robot system, and peripher-
are based on: For process control with- al devices. We are already making it
out limits between ALLROUNDERs and possible for you to use this technology
their production environment. For the for data integration today – e.g. for
online provision of process informa- hot runner controllers, temperature
tion to higher-level software tools and control units, and LSR dosing units.
platforms. or to put it briefly: And thanks to the open design of our
For practice-oriented digitalization! switch, you are already prepared for
extensions.

Connected systems
Our “basic connectivity” with IIoT
gateway enables you to use machine
controller data at higher levels:
• ALS: Production management
and detailed planning
• arburgXworld: Production overview
and process documentation
• ATCM: Collection of process data

NETWORKED •
for complete production cells
ARS: Machine diagnostics and
INTERACTION external process support
• Expert systems (e.g. for mold
cavity pressure): External process
on the basis of an industrial monitoring
Ethernet network

Further information:

i arburgXworld brochure
Host computer system brochure

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RANGE OF FUNCTIONS:
ENORMOUS
// ARBURG has developed its central control platform in a way that makes even
special processes and special sequences standard. In practice, this means that you
draw on a huge range of functions. To keep things simple and manageable for
you in this area too, we offer task-specific assistance packages that you can use to
selectively expand your options at any time. So nothing is impossible! \\

4.set-up 4.start-stop
Guided set-up: You receive active Fast production start-up:
support during set-up and parameter Starting up and deactivating
input, leaving you more time for demanding processes becomes easier,
productive tasks. Features include: and your start-up parts are reduced.
• Pre-set parameters automatically Features include:
• Teach production sequences • Energy-efficient operation with the
• Partial sequence for manual aXw Control EnergyAssist
operation • Start-up parameters and cycles
• Define adjustment ranges for oper- • Automatic start-up for inserts and
ators depending on the program multi-component molds
• Time- and situation-dependent
temperature management for
molds with hot runner

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 Avoid faulty operation:
Specifically limit how parameters
can be edited in the data set.

Start securely: Set start-up parameters

once and always execute them automatically
at the start of production.

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 Selectively optimize:
Sequences can be accessed centrally
and are freely programmable.

Document seamlessly:
Our connectivity module allows you
to use production data flexibly.

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WE WILL HELP YOU GET THE
MOST OUT OF YOUR PROCESS!

4.optimization 4.monitoring
Assured quality and productivity: Get Controlled system status: Comprehen-
even more out of your machine in sive monitoring functions enable you to
each case – because every split second detect deviations early and seamlessly
counts. Features include: document them. Features include:
• Program functions freely and • Monitoring of actual values
not cyclically through reference curves
• Program secondary axes • External alarm inputs for any
multiple times peripheral signals
• Program repetition group • Many other monitoring functions
• Special functions for ejectors

4.production 4.service
More programming freedom: Time-saving online support:
Special sequences become standard Have faults analyzed quickly, efficiently
and even complex molds can be mas- and safely in a remote process – for
tered quickly. Features include: even greater machine availability.
• Injection during mold closing – Features include machine diagnostics
“injection on-the-fly” and process support through
• Movements across cycle times remote access.
• Extended mold locking

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 523370_EN_US_032024 · Subject to alterations
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ARBURG GmbH + Co KG
Arthur-Hehl-Straße
72290 Lossburg
Tel.: +49 7446 33-0
www.arburg.com
[email protected]

© 2024 ARBURG GmbH + Co KG | All data and technical information have been compiled with great care. However we accept no responsibility for correctness. Individual
illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and
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operation of the machine.