Is injection molding machine still far from becoming 4.0 intelligent
The maintenance of injection molding machines is not very complicated, but there are many hidden problems during production, and many materials will be added during production. For example, scraps, discarded models, etc. can all be recycled and reused. We all know about such issues, but machine operation can also save a lot of costs for production. So, in terms of reducing injection molding production costs, how much contribution can machine adjusters make? Now let me introduce it to you.
Generally speaking, the production cost of injection molding workshops often occurs in the adjustment and mold replacement of injection molding machines. In order to reduce the occurrence of such errors, in addition to requiring injection molding machine operators to operate in a standardized manner, many times they also rely on the maintenance and upkeep of machine adjusters.
It is not difficult to imagine how much manpower and material resources are consumed for mold maintenance during each shutdown, and if the mold maintenance work is not done properly, such mold failures will often occur during the production process. Injection molding machines are key equipment in injection molding production, with an average price of 350000 yuan per machine, accounting for approximately 60% of the total investment in the injection molding department; If the maintenance work of injection molding machines is not done properly, equipment problems that affect normal production such as hinge wear, broken screw heads, broken Green columns, nozzle glue leakage, hydraulic oil pollution, and oil pipe leakage may occur.
In order to reduce the production cost of injection molding, machine adjusters not only need to maintain and upkeep the injection molding machine, but also need to carry out energy-saving renovations. Therefore, the quality requirements for machine adjusters naturally increase. In terms of energy-saving renovation of injection molding machines, there are generally three ways of renovation: installing a frequency converter on the injection molding machine, using new heating methods, and recycling heat.
After installing a frequency converter energy-saving device, the controller automatically detects the pressure and speed settings at all stages of the production process (mold closing, injection molding, pressure holding, material return, cooling, mold opening, and ejection), calculates the corresponding proportional control signal, and outputs it to the frequency converter. Based on the received control signal, the frequency converter dynamically adjusts the click speed to ensure that the hydraulic oil output by the oil pump generates as little reactive power backflow as possible, in order to achieve energy-saving goals.
Electromagnetic heating technology causes the metal barrel to generate heat on its own, and can wrap a certain amount of insulation material around the outside of the barrel according to the specific situation, effectively reducing heat loss and improving thermal efficiency. Therefore, the energy-saving effect is very significant, with a system energy-saving rate of 10% to 35%.
The injection molding machine is equipped with waste heat recovery equipment, utilizing the closed-loop control concept of thermal energy. Through thermal energy collection technology, the thermal energy of the injection molding machine barrel is collected, and then the collected thermal energy is used for drying materials. The wasted heat is collected and recycled, achieving a dual effect of improving the environment.
That's all for how to energy-saving retrofit injection molding machines and reduce costs. There are also methods that you can refer to, so why not share them.