Energy-saving transformation of injection molding machine

Energy-saving technical transformation for high-energy consuming parts of injection molding machine
Energy-saving transformation of the injection molding machine, that is, the energy-consuming parts of the injection molding machine are subject to energy-saving technical transformation. The early injection molding machine was fully hydraulic, and the injection molding process was in a changing load state.

According to statistics, the energy loss caused by high-pressure throttling is as high as 36 percent - 68 percent , so the energy consumption cost is high. At the same time, the heating method used is generally electric heating coil heating. The heat is transferred to the material barrel through contact conduction. Only the heat close to the inner side of the material barrel surface can be transferred to the material barrel. In this way, most of the heat from the outer side is lost to the air, there is heat conduction loss, and the ambient temperature will rise. In addition, resistance wire heating has a disadvantage that the power density is low, which can not be adapted to some heating occasions requiring high temperature. The energy-saving transformation of injection molding machine adopts advanced technology to save unnecessary energy according to the principle of energy loss of injection molding machine.
Energy-saving transformation
Electromagnetic heating (IH) technology is a new high-frequency heating technology. After research and development by scientific researchers, an energy-saving and environment-friendly high-frequency heating system has been produced, and the heating efficiency has increased to 90 percent (up to 99.8 percent ). According to the installation and testing in various plastic processing enterprises, the energy-saving and environment-friendly high-frequency heating system has a very obvious energy-saving effect for plastic processing enterprises, saving up to 30 percent - 70 percent electricity. It fully reflects its energy saving advantages, saves a lot of electricity costs for plastic processing enterprises, improves production efficiency, improves workshop environment, and directly reduces indirect production costs.

Working principle of electromagnetic heating [1]
The electromagnetic heating economizer is a device that uses the principle of electromagnetic induction to convert electric energy into electromagnetic energy for heating. The electromagnetic heating economizer converts 220 V, 50/60 Hz AC power into DC power, and then converts DC power into high frequency and high voltage power with a frequency of 20-40 KHz. The electromagnetic heating equipment is specially made of high temperature resistant cable. The high frequency and high voltage current with high speed change will generate the alternating magnetic field with high speed change through the coil. When the magnetic line in the magnetic field passes through the magnetic metal material, it will generate countless small eddies in the metal body, making the metal material itself heat at high speed, thus achieving the ideal heating effect.





Due to a large amount of heat loss, the ambient temperature increases, especially in summer, which has a great impact on the production environment. Some of the on-site working temperatures have exceeded 45 degrees. Some enterprises have to use air conditioning to reduce the temperature, which leads to a second waste of energy.

The heating temperature of the electric heating pipe is as high as about 300 degree due to the use of resistance wire for heating. The thermal hysteresis is large, and it is difficult to accurately control the temperature. The resistance wire is easy to burn due to high temperature aging. The service life of common electric heating coils is about half a year, so the maintenance workload is relatively large.
Advantages of high-frequency heating products

Because the coil itself will not generate heat, the electromagnetic heating has a long service life, no maintenance and replacement costs; The heating part adopts the ring cable structure, the cable itself will not generate heat, and can withstand the high temperature above 500 degree , with a service life of up to 10 years. No maintenance is required, and there is basically no maintenance cost in the later stage.

The outer wall of the material barrel is heated by high-frequency electromagnetic action, and the heat is fully utilized, basically without loss. The heat is concentrated in the heating body, and the surface temperature of the electromagnetic coil is slightly higher than the room temperature, which can be safely touched without high temperature protection, safe and reliable.
Efficient and energy-saving
The internal heat heating method is used to directly induce the magnetic energy in the heating body and generate heat. The hot start is very fast. The average preheating time is more than 60 percent shorter than that of the resistance coil heating method. At the same time, the thermal efficiency is more than 90 percent . Under the same conditions, the power consumption is 30-70 percent lower than that of the resistance coil heating, greatly improving the production efficiency.

The coil itself does not generate heat, has small thermal retardation, low thermal inertia, the temperature of the inner and outer walls of the material barrel is consistent, and the temperature control is real-time and accurate, which significantly improves the product quality and high production efficiency.



The injection molding machine, which has been transformed by electromagnetic heating equipment, adopts the internal heating mode, and the heat is concentrated in the heating body, with little external heat dissipation. The surface temperature of the equipment can be improved to human touch, and the ambient temperature is reduced from more than 100 degree when the original resistance coil is heated to normal temperature, which greatly improves the working environment of the production site, effectively improves the enthusiasm of the production workers, and reduces the cost of ventilation and cooling in the plant area in summer. Based on the concept of "people-oriented", we will create an environmentally friendly, safe and comfortable production environment for the factory and front-line production personnel.
Editing and broadcasting of servo energy-saving transformation
The injection molding machine using the injection molding machine servo system has double closed loops of system pressure and flow. The hydraulic system supplies oil according to the actual flow and pressure, which overcomes the high energy consumption caused by the high-pressure overflow of the ordinary quantitative pump system. The motor operates at the set speed during the high flow stages such as pre-molding, mold closing, injection, etc. The motor speed is reduced during the low flow stages such as pressure maintaining, cooling, etc. The actual energy consumption of the oil pump motor is reduced by 35 percent - 75 percent


The energy-saving device is a set of energy-saving and environment-friendly control system of injection molding machine that collects the waste heat of high temperature gun barrel and sends it back to the drying barrel to realize the recovery and utilization of waste heat. The system is composed of heat recovery components, transmission components and control components. It can convert the heat of the injection molding machine barrel into the heat of drying material, which can completely save the electricity consumption of the drying cylinder due to drying material, and will not have any impact on the normal use of the injection molding machine. It is safe and reliable.


Reduce thermal energy emissions and use thermal energy closed-loop control technology to reduce workshop temperature

The waste heat recovery and energy saving device of the injection molding machine is equipped with a heat collecting hood, a hot air conveying system, an automatic cooling system, a hot air automatic compensation system, an automatic electric control system, and a filtering device. The purpose of the components configured for the waste heat recovery and energy saving device of the injection molding machine: 1. The heat collecting cover --- collects the heat energy from the outside of the barrel (instead of the heat pipe of the traditional dryer) 2 Hot air conveying system - the heat energy collected by the heat collector hood is sent to the drying barrel through the fan for use as drying plastic raw materials 3. Automatic cooling system - When the heat energy collected by the heat collector cover exceeds the normal temperature of the plastic drying material, the system will automatically work to cool the drying material temperature and make the drying material temperature reach normal 4. Automatic compensation system for hot air - when the heat energy collected by the collector hood does not reach the normal temperature of plastic baking, the system will automatically work to raise the baking temperature, resulting in normal baking temperature. 5 Automatic electronic control system - automatically controls the use of various components, resulting in normal drying 6. Filter device - filter material barrel blows out dust to keep the workshop clean Expected effect of waste heat recovery and energy saving device of injection molding machine 1 After installing the waste heat recovery and energy saving device of the injection molding machine, it can save more than 35 percent of the electricity consumption of the electric heating part (gun barrel and dryer), which will greatly reduce the production cost and improve the competitiveness of your company. 2. After installing the waste heat recovery and energy saving device, the waste heat of the injection molding machine barrel can be recycled and reused, and the hopper heating pipe can be completely removed. Therefore, the temperature of the production workshop will be greatly reduced (the temperature of the production workshop can be reduced by 3-5 degrees), so as to truly eradicate the problem of high temperature in the workshop and help employees work in a suitable working environment. 3. Due to the dual filtering device, the device can completely filter the dust in the filter barrel, effectively prevent the air pollution in the production workshop, and play a certain role in protecting the health of employees. 4. After the installation of the device, the capacity and power of the power distribution system wasted by the traditional dryer can be saved. 5. After installing the environment-friendly all-injection molding machine energy-saving plastic dryer, your company's power consumption can be greatly improved. The extra power can be used to add other equipment without adding transformers. To provide certain convenient conditions for your company's expansion of production