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    注塑機電液伺服智能節電控制裝置

    發布日期:2021-04-12 16:01??來源:八環天能電氣

    注塑機電液伺服智能節電控制裝置
    Intelligent electricity-saving control device of plastic injection molding machine
     
    注塑機使用現狀
    Status quo of plastic injection molding machine
    注塑機的電能消耗主要表現在以下幾個部分:
    Electric energy consumption of plastic injection molding machine consists of the following parts:
    1、液壓系統油泵的電能消耗。
    2、加熱器的電能消耗。
    3、循環冷卻水泵的電能消耗。
    1. Electricity consumption of oil pump of hydraulic pressure system
    2. Electricity consumption of heater
    3. Electricity consumption of recycling cooling water pump
     
    其中液壓油泵的用電量占整個注塑機用電量的80%以上,所以降低其耗電量是注塑機節能的關鍵。
    The electricity consumption of oil pump of hydraulic pressure system accounts for 80% of that of the whole plastic injection molding machine, so it is crucial to lower the electricity consumption.
    目前絕大多數的注塑機都屬于液壓傳動的定量泵注塑機,液壓傳動系統中的動力由電機帶動油泵提供。在注塑周期過程中的變化,注塑機在不同工序下需要的流量和壓力不同,必須依靠流量閥和壓力閥調節不同工序所須的流量和壓力,由于定量泵不可調節輸出功率,因此多余的能量只能在擋板、油路泄露、油的溫升中被消耗了,加劇了各種閥的磨損,又造成油溫過高,電機噪音過大,以及機械壽命縮短等現象。并且在設計電機的容量比實際需要高出很多,存在“大馬拉小車”的現象,造成電能的大量浪費。針對這一現象我公司開發出注塑機節能控制系統,很好的解決了上述問題,受到了注塑行業的一致好評。
    At present, most of plastic injection molding machine is of constant rate pump with hydraulic gear, and the power in the hydraulic gear system is provided by oil pumps driven by motor. In the process of plastic injection period, plastic injection molding machine needs different runoffs and pressures at different working procedures, which have to be adjusted through flow valve and pressure valve. Since constant rate pump can not adjust the output power, surplus energy is consumed in baffle, oil pipe leakage, and oil temperature rise, which results in the friction of various valves, high oil temperature, high motor noise, and short mechanic service life. In addition, the designed capacity of motor is much higher than the actual value, which leads to the great waste of electricity energy. Nevertheless, the energy-saving control system developed by our company well solves the above problem, and wins the good appraisal in the plastic injection industry.
     
    節電原理
    Electricity-saving principle
    傳統的注塑機是采用定量泵供油的,注塑過程的各個動作對速度、壓力的要求也不一樣,它是通過注塑機的比例閥采用溢流調節的方式將多余的油旁路流回油箱,在整個過程中,電機的轉速是不變的,故供油量也是固定的,而由于執行動作是間隙性的,也并不可能是滿負載的,因此定量供油就有很大的浪費空間。注塑機智能節電控制裝置正是針對這一浪費空間,通過信號采集單元實時檢測來自注塑機數控系統的比例壓力和比例流量信號,適時調整各個工況動作所需的電機轉速(即流量調節),讓泵出的流量和壓力,剛好能滿足系統的需要,而在非動作狀態時(主要是在冷卻狀態),讓電機停止運行或緩慢運行,因此對注塑機進行節電改造能夠帶來巨大的節能效果。
    Traditional plastic injection molding machine relies on constant rate pump in oil supply, and each action in the process of plastic injection may have different requirements on speed and pressure. The surplus oil flows back to the oil tank through the proportioning valve in the way of flooding adjustment. In the whole process, the rotation speed of motor remains unchanged, so the oil volume is fixed as well. Furthermore, the action is intermittent, and not of full load, so a great amount of oil is wasted. To solve the problem, the intelligent electricity-saving control device of plastic injection molding machine, through signal collection, checks the proportioning pressure and proportioning runoff signal from the digital control system at real times, making timely adjustment to the motor rotation speed (namely runoff adjustment) required by each working condition. The runoff and pressure from the pump just meet the needs of the system, and the motor may stop operation or become slow in non-action status (mainly the cooling status). Therefore, the device can greatly reduce the electricity consumption of plastic injection molding machine.
     
    產品特點
    Product features
    注塑機原有控制方式及油路不變,只需在原油泵主電機接線處串入注塑機智能節電控制裝置,采集流量、壓力信號反饋于控制單元進行自動優化計算,并作簡單調試即可完成。
    采用“市電/節能運行”轉換控制方式,保留油泵電機原有啟動及運行線路不變,確保萬一節能控制器發生故障檢修時仍能切換到市電狀態工作以保持正常生產。
    改造后注塑機液壓油發熱明顯降低,一般比改造前平均油溫降低15℃~20℃以上;注塑機冷卻用水量可節省30%以上,并有效減緩液壓元器件的老化問題。
    After the rebuilding, the temperature of hydraulic oil declines by 15℃~20℃ on average; the usage of cooling water is down by 30%; and the aging of hydraulic components is delayed obviously.
    The original control way and oil route of plastic injection molding machine remain unchanged, it is just needed to install the intelligent electricity-saving control device at the wiring part of the major motor, and make suitable connection switch of runoff and pressure proportion control line, and lastly make simple debugging.
    Adopt the “municipal power/energy-saving operation” conversion control mode. The original startup and operation route of motor are not changed so as to ensure that the system can be switched to the municipal power status for normal production in case of failures of energy-saving controller.
     
    注塑機運行噪音明顯降低,開、鎖模振動減輕,延長設備和模具的使用壽命,改善工作環境。
    用電功率因數提高,油泵主電機平滑啟動,啟動時無大電流沖擊并可減少配電設備容量。
    大量節省電能,降低能源消耗,節約生產成本,節電率可達到10%-40%。
    The operating noise is lowered greatly, and the opening and locking die vibration reduced; the service life of equipment and die is prolonged, and working environment improved
    The electricity power factor is increased, and the major motor of oil pump is started smoothly. There is no big current rush at the startup, and the capacity of distribution equipment is lowered.
    Lower the energy consumption and save the production cost. The electricity-saving rate is as high as 10% to 40%.

    行業應用:
    注塑機、壓油機、鞋機、壓鑄機、磚機、型材擠出機、吹瓶機、打包機、折彎機、裁斷機等;



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