For an injection molding product factory, the energy consumption of the injection molding process accounts for about 60%, so effectively reducing the energy consumption of the injection molding machine is an important way for the injection molding factory to save energy. With the continuous improvement of the energy-saving technology of the injection molding machine itself, reducing the overall energy consumption of the injection molding factory needs to be fully considered in terms of production management, processing technology and materials, and production workshop facilities.
First. Production workshop
The layout of the production workshop focuses on two aspects: the condition of meeting the production demand, optimizing the layout according to the production process, and at the same time meeting the requirements of flexible energy use under specific production conditions.
1. Power supply, while satisfying the power required for stable production, has an appropriate margin, so that the excess margin will not cause excessive reactive power consumption.
2. Build high-efficiency cooling water circulation facilities and equip the cooling water system with an effective insulation system.
3. Optimize the overall production layout of the workshop. A lot of production has sequential process cooperation, reasonable cooperation can reduce the time required for turnover and energy consumption, and improve production efficiency.
4. For plant equipment such as lighting, try to use the most effective small units for separate control.
5. Regularly maintain the equipment in the workshop to avoid damage to public facilities that affect the normal operation of production and increases energy consumption.
second. Injection molding machine
The injection molding machine is a major energy consumer in the injection molding workshop, and the energy consumption is mainly two parts of the motor and the heating.
1. Select the appropriate injection molding machine according to the characteristics of the product. The "big horse-drawn cart" type of injection molding often means a lot of energy waste.
2. The use of all-electric injection molding machines and hybrid injection molding machines has excellent energy-saving effects, which can save energy by 20-80%.
3. Using new heating technology, such as electromagnetic induction heating, infrared heating, etc., can achieve 20-70% heating energy savings.
4. Adopt effective thermal insulation measures for heating and cooling systems to reduce heat and cold losses.
5. Keep the transmission parts of the equipment well lubricated, and reduce the increase in energy consumption caused by increased friction or unstable operation of the equipment.
6. Use low-compression hydraulic oil to reduce energy waste in the hydraulic system.
7. Using parallel action, multi-cavity injection molding, multi-component injection molding, and other processing technologies can significantly save energy.
8. The traditional mechanical hydraulic injection molding machine also has a variety of energy-saving drive systems, replacing the traditional quantitative pump mechanical hydraulic injection molding machine with remarkable energy-saving effects.
9. Regularly maintain the heating and cooling pipelines to ensure that there are no impurities and scale blockages inside the pipelines to achieve the designed heating and cooling efficiency.
10. Make sure that the injection molding machine is in good working condition. Unstable processes can lead to defective products and increased energy consumption.
11. Make sure that the equipment used is suitable for the product being processed. For example, PVC processing often requires a special screw.
three. Injection mold
Mold structure and mold conditions often have a significant impact on the injection molding cycle and processing energy consumption.
1. Reasonable mold design, including runner design, gate form, number of cavities, heating and cooling channels, etc., all help to reduce energy consumption.
2. The use of hot runner molds can not only save materials and reduce energy consumption for material recycling, but the molding process itself also has a significant energy-saving effect.
3. The profiling fast cooling and fast heating mold can significantly save processing energy consumption and achieve better surface quality.
4. Ensure that each cavity is filled evenly, which is helpful to shorten the molding cycle, ensure the uniformity of product quality, and have excellent energy-saving effects.
5. Using CAE-assisted design technology for mold design, mold flow analysis and simulation can reduce the energy consumption of mold debugging and multiple mold repairs.
6. Under the premise of ensuring product quality, using lower clamping force for molding can help prolong the life of the mold, facilitate quick filling of the mold, and help save energy.
7. Do a good job in mold maintenance to ensure effective heating and cooling water channel conditions.
four. Peripheral equipment
1. Choose the auxiliary equipment suitable for the ability, which can not only meet the work requirements but also not have too much wealth.
2. Do a good job in equipment maintenance to ensure that the equipment is in normal working condition. Auxiliary equipment that is not working properly will cause unstable production or even poor quality of parts, resulting in increased energy consumption.
3. Optimize the cooperation and operation sequence of the host and peripheral equipment.
4. Optimize the mutual position of peripheral equipment and production equipment, and make the peripheral equipment as close as possible to the host machine without affecting the operating conditions.
5. Many auxiliary equipment manufacturers provide on-demand energy supply systems, which can achieve significant energy savings.
6. Use quick mold change equipment to reduce the waiting time for switching products during production.
five. Materials
The energy consumption of different materials processing is different, and at the same time, poor management of materials or improper management of recycled materials will increase the energy consumption of production.
1. Under the premise of satisfying the performance of the product, materials with lower processing energy consumption should be selected first.
2. Under the condition of satisfying performance and cost optimization, high-fluidity materials are given priority.
3. Note that materials from different suppliers may have different process conditions.
4. It is best to use the material as it dries, so as to avoid the waste of energy after drying.
5. Do a good job of material preservation to prevent the material from being mixed with impurities or foreign matter, which will eventually cause defective products.
6. Some products are allowed to add some recycled materials, but attention should be paid to the preservation and cleanliness of recycled materials to avoid defective parts due to unclean materials.
Six, processing technology
1. On the premise of satisfying the performance of the product, use the shortest molding cycle.
2. If there are no special factors, use the processing technology recommended by the supplier as much as possible for processing.
3. For specific products and molds, all stable equipment and process parameters are saved to shorten the adjustment time for the next production change.
4. Optimize the process, adopt lower clamping force, shorter cooling time and holding time.
steven. Adopt new technology
1. Adopt auxiliary molding technology, such as gas-assisted, liquid-assisted, steam-assisted, micro-foaming injection molding technology, etc.
2. Adopt a unitized molding scheme to reduce intermediate links.
3. Adopt new technologies such as in-mold welding, in-mold spraying, in-mold assembly, and in-mold decoration.
4. The new low-pressure molding technology is adopted to shorten the molding cycle and reduce the melt temperature at the same time.
5. Adopt an energy regeneration system.
Eight. Production management
1. One-time production of high-quality products, reducing the defect rate is the greatest energy saving.
2. The maintenance of the entire production system is closely related to energy consumption. This involves not only the main machine but also peripheral and factory equipment. For example, if the mold-changing crane in the workshop fails, manpower is required to change the mold, which will inevitably prolong the waiting time of the equipment and increase energy consumption of the equipment.
3. Equipped with a workshop energy consumption monitoring system, it is convenient for enterprises to carry out energy analysis and improvement purposefully.
4. When the equipment is shut down for maintenance, not only check the maintenance content and items of the equipment itself but also pay attention to the condition of the connection between the equipment and other systems, whether the working performance is reliable, etc.
5. Regularly compare with industry benchmarks to see if there is room for further improvement.
6. Establishing a reliable contract and cooperative relationship with suppliers is beneficial and harmless to the energy-saving management of the enterprise.