Injection molding is one of the main molding methods to make thermoplastics into various products, compared with other plastic molding methods, injection molding method has the advantages of molding products with complex structure and size, strong adaptability to plastics, short molding cycle, high production efficiency and easy automation.
Worldwide, injection molding accounts for about 30% of the total plastic molding, and the annual production capacity (number of units) of injection molding machines is about more than 50% of the total annual output of plastic processing machinery. Hydraulic system is an important part of the injection molding machine, at present, most of the injection molding machines at home and abroad use the hydraulic system to complete the plasticizing, mold clamping, injection, pressure holding and mold opening and other injection molding processes, so the demand for electrical energy is great, and the consumption of energy has become one of the main costs in injection molding production.
In recent years, some small and medium-sized injection molding production enterprises in the Pearl River Delta region have used frequency converter technology to carry out energy-saving transformation of the hydraulic system of injection molding machines, which has greatly reduced the electric energy consumption in injection molding production, thereby significantly reducing the production cost of injection molding products and bringing considerable economic benefits to enterprises.
One. Working characteristics of injection molding machine
1.1 Duty cycle
The injection molding process of the injection molding machine is a periodic process that starts from the mold clamping action, in this periodic process, the hydraulic system must complete a series of actions: mold clamping, mold opening, overall movement of the injection seat, pressure holding and ejection of products, etc.
1.2 Working parameters
In a working cycle, the main working parameters of the injection molding machine that are closely related to the hydraulic system are: injection pressure, injection rate, clamping force, holding pressure, etc.
(1) Injection pressure is an important factor to overcome the flow resistance of molten materials when they flow through nozzles, runners and mold cavities, ensure the stability of mold filling, and ensure the accuracy and pass rate of injection molded products. When the screw diameter is constant, the amount of injection pressure is determined by the hydraulic system.
(2) The injection rate is a parameter that characterizes the speed of the melt filling the mold cavity, which directly affects the quality and productivity of the product, and its size is controlled by the working oil flow of the injection cylinder.
(3) The clamping force is the largest clamping force that the clamping mechanism of the injection molding machine can exert on the mold, and it becomes the parameter of the nominal injection molding machine specifications together with the injection volume. For the hydraulic-knuckle clamping device, the clamping force is determined by the hydraulic system and the knuckle joint mechanism; In the case of a fully hydraulic clamping device, the clamping force is determined by the hydraulic system of the injection molding machine.
(4) Holding pressure is one of the important injection molding process parameters, the selection of holding pressure and holding time directly affects the quality of injection molding products, and the holding pressure is determined by the hydraulic system as well as the injection pressure.
Two. Hydraulic system of injection molding machine
The hydraulic system is an important part of the injection molding machine, and it must meet the different requirements of the pressure and speed required at each stage of the work cycle. The hydraulic system should have the characteristics of good working stability, high repeatability and sensitivity, low noise and energy saving. The hydraulic system is mainly composed of hydraulic pumps, valves, cylinders and circuits.
In injection molding production, according to the needs of the injection molding process, the working flow and working pressure provided by the hydraulic system to the injection molding machine should be constantly changing, therefore, the power consumed by the hydraulic system of the injection molding machine should also be constantly changing with the change of working flow and working pressure.
Three. System composition
In order to use the frequency converter to adjust the flow of the hydraulic pump of the injection molding machine, the working flow of the hydraulic oil required in different stages of the injection molding process of the injection molding machine is collected by the signal acquisition device (sensor), and the given value of the flow is transmitted to the PLC (programmable controller) in the form of current value, and the actual output flow of the hydraulic oil of the pump is detected by the output flow detection piece at the same time, and the obtained detection signal is converted into a voltage value by the current/voltage converter and transmitted to the PLC, and the PLC compares the actual flow rate with the given flow. According to the comparison results, the PLC outputs the given speed value of the drive motor and transmits it to the inverter, which adjusts the number of revolutions of the drive motor/pump, so as to adjust the output flow of the hydraulic pump, so that it can meet the different flow requirements of each stage of the injection molding cycle and meet the requirements of energy saving.
Four. Features of the inverter:
1. Operate under a very small slip rate, low loss and high power factor;
2. The speed regulation range is wide, the frequency can be from a few herhz to hundreds of hertz, and the speed regulation accuracy is high, and the accuracy can reach 0.5%-1%;
3. It can accelerate and decelerate smoothly and automatically and smoothly;
4. The energy-saving effect is very obvious, generally up to more than 30%;
5. The protection function is complete, and the maintenance workload is very small.
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