The application of KE610 in injection molding machine

2022-11-02

1.Introduction

Plastic has become one of the main materials for industry, agriculture, and civil use for the past half century. Injection molding machine is a specialized plastic molding machine. It uses the thermoplasticity of plastic to be melted by heating, then rapidly enters the mold under high pressure and is kept under pressure and cooled for a certain time to become various profiles and plastic products. The promotion of frequency converters on injection molding machines can achieve the advantages of saving energy, improving productivity and product quality, reducing oil pollution and noise pollution, and prolonging machine life. Therefore, it will be gradually promoted and applied.

2.Working principle of injection molding machine

Plastic injection molding is the use of three states (solid, liquid, and solid), with the help of injection molding machines and molds to produce the required plastic products. Although all injection molding machines are not the same, the working process of injection molding machines is basically the same and can be roughly divided into seven steps: mold clamping, injection, holding pressure, melting plastic, cooling, mold opening, and ejection (ejector forward, ejector backward, and injection seat retreat). Each step requires different working pressure and flow rate. Except for the high-pressure clamping, injection, and melting actions that require large pressure, other processes work under low pressure, and the pressure and flow rate are adjusted by pressure proportional valves and flow proportional valves. The pressure and flow rate size is controlled by adjusting the opening degree of the pressure proportional valve and the flow proportional valve.

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3.Introduction to energy consumption of injection molding machine

The power consumption of the injection molding machine is mainly consumed by the oil pump motor, so reducing the power consumption of the oil pump motor is the key to energy saving of the injection molding machine. In the hydraulic system of the quantitative pump, the motor runs at a high speed of 50HZ, and the oil supply of the pump is basically constant, far greater than the actual flow rate demand of the injection molding machine working condition, and the excess high-pressure oil flows back to the oil tank through the overflow valve, resulting in significant energy waste.

4.Energy-saving solutions for injection molding machines

After careful research and experimentation, we have successfully developed the KE610 injection molding machine dedicated frequency converter for use in injection molding machines and compression molding machines. The system automatically detects the target values of oil pump pressure and flow rate required in the injection molding machine cycle production, and analyzes and calculates these signals to realize the drive oil pump from stationary to the highest speed in only about 0.1 seconds, synchronizing with the oil valve response time, which solves the industry bottleneck of the decline in production efficiency of injection molding machines. It can achieve the same energy-saving effect as synchronous servos without changing the motor and oil pump and without changing the hydraulic system hardware.

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5.Advantages of injection molding machine transformation

Energy-saving: Save electricity to the maximum extent; the energy-saving rate is 25%-70%;

High efficiency: Quick response at startup, high production efficiency, and does not affect the cycle.

Convenience: Simple installation, no need to replace the motor and oil pump, debugging and maintenance are extremely convenient, and the usability of upper computer signal acquisition is fully considered. The failure of the servo drive will not affect production.

Stability: With a large margin design, strong protection capability, the oil temperature and noise of the whole machine operation are significantly reduced; it is suitable for high-temperature, vibration, and oil pollution environments of injection molding machines and compression molding machines.

6.Economic benefits after transformation

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7.Conclusion

Energy-saving is creating benefits. The entire electricity system can achieve one-time investment and long-term benefits after energy-saving transformation. This energy-saving transformation can reduce electricity bills and provide excellent safety protection for injection molding machines. It will help protect the service life of equipment such as motors, electronic components, and switch components, and can also play a role in soft starting of motors. This can reduce equipment investment costs and maintenance costs, improve enterprise production efficiency, and increase corporate benefits. It can also enhance the market competitiveness of enterprise products.