New servo energy-saving injection molding machine

2022-08-16
  • Detail

In this era of energy shortage, energy conservation and environmental protection have become the theme of the development of modern society, especially for the plastic machine industry. As equipment selection, we must adopt high-tech equipment and carry out supporting transformation for the weak links of production process, which is conducive to improving and developing the core technology of manufacturing and processing of injection molding machines, Research and develop servo energy-saving injection molding machines with high technological content and high added value. In addition to retaining the original excellent functions of the traditional injection molding machine, the servo energy-saving injection molding machine is also equipped with a high-performance servo variable-speed power control system. By using AC servo drive to replace the traditional hydraulic, DC, stepping and BD variable-frequency speed drives, the dynamic response and torque density are further improved, the operation cycle of the system is significantly shortened, and the productivity and reliability of the equipment are improved, The service life of the equipment is prolonged. In the whole molding process of the injection molding machine, through the corresponding frequency output of different pressure and flow, and the accurate closed-loop control of pressure and flow, the better matching and automatic adjustment of the servo motor to the technological achievements of injection molding original new materials are successfully realized, which is lack of machine energy demand. Due to the integration of the advantages of traditional hydraulic injection molding machine and all electric injection molding machine, servo energy-saving injection molding machine is favored by customers in the market. In view of the reason why it is popular with customers, this paper will focus on this new servo energy-saving injection molding machine in detail

the comparison between the traditional injection molding machine and the servo energy-saving injection molding power control system is well known. The traditional injection molding machine uses an ordinary motor to drive the quantitative pump to work. Its working principle is: the motor drives the oil pump to suck oil from the oil tank and pressurize it for output, and controls the pressure, flow and direction of the oil through various control valves, so as to ensure that the equipment can move in the required direction with a certain force (or torque) and speed, So as to realize each process of injection molding. However, in this process, because the speed of the injection pump is not adjustable, the excess oil can only be discharged into the oil tank through overflow, resulting in a waste of heat and energy. Compared with the working principle of traditional injection molding machine, servo energy-saving system divides the power system of injection molding machine into six elements, namely servo motor, encoder, gear pump, servo driver, pressure sensor and drive control module. Among them, the drive control module is the key and core that is different from the traditional injection molding machine. The specific working process and key technologies can be summarized as follows: 1 The servo driver receives the pressure (P) and flow (q) commands sent by the injection molding machine controller, converts them into speed commands and transmits them to the servo motor. The servo motor drives the gear pump to rotate, while the gear pump outputs the pressure flow according to the command. At the same time, the pressure sensor collects the system pressure information and feeds it back to the servo driver, and the servo motor feeds back the speed information to the servo driver. Then, the servo driver feeds back the actual pressure and flow information to the injection molding machine controller through conversion. By comparing the actual flow and pressure with the commanded flow and pressure, the injection molding machine controller timely adjusts the commanded flow and pressure, so as to achieve closed-loop control. 2. The response speed of the servo system can reach 0.03ms, which is much higher than the response speed of the variable displacement pump of 0.3ms, thus significantly improving the control accuracy. 3. Another key point in the design of the system is to select a suitable servo system for the injection molding machine. Here, this injection molding machine changes the design method of injection molding power configuration: choose the power configuration of the injection molding machine directly from the product requirements, and list the pressure, flow and time requirements of each step of injection molding, so as to calculate the actual power required by each step, and then calculate the power of the whole cycle, so as to determine the selected servo power configuration. The advantage of this is that it strengthens and clarifies the power requirements from the details of the replacement steps that must be ordered from the original manufacturer in each step, so that it can not only meet the production requirements of products, but also just fully meet the production requirements, so as to control energy waste from the source and achieve energy-saving effects. The basic principle of energy saving can be seen from the above analysis that the electric energy consumption of the injection molding machine mainly comes from the motor oil pump. For the traditional injection molding machine, the oil pump motor is running at full speed. Even without oil pressure, the motor is still idling at the rated speed and consumes electric energy. In contrast, the energy-saving control system of the new injection molding machine realizes the variable-speed control of the oil pump motor. Another reason for passing the internal test is to improve the process control and synchronously track the pressure. In the process of using each experimental machine, there are some detailed different forces and flow conditions, which successfully realize the control of different speeds in different stages, so as to achieve the purpose of power saving. In other words, the servo controller adjusts the speed of the oil pump motor and changes the output power of the oil pump, so that it can output corresponding signals according to different process stages such as mold closing, glue injection, pressure maintaining, cooling and mold opening. By controlling the driver and the output of the oil pump, the excess energy in the injection molding process can be saved. As a closed-loop system with high response, the power saving effect of the whole system is very significant. According to different products, the system can achieve 30% - 80% power saving effect, and the thicker the wall thickness of the product, the longer the cooling time, the more power saving

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