technical comparison ofplasticnews.aipma.net/1dec17-seminar/anbu.pdf · hydraulic injection molding...
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TECHNICAL COMPARISON OF
ALL ELECTRIC
OVER
HYDRAULIC
INJECTION MOLDING MACHINES
ANBU 01st DECEMBER 2017
INJECTION MOULDING MACHINES
1. Hydraulic IMM1. FIXED PUMP2. VARIABLE PUMP 3. SERVO HYDRAULICS
2. Electric IMM1. BELT DRIVE2. DIRECT DRIVE
3. Hybrid IMM
HYDRAULICS Vs ALL ELECTRICQUICK VIEW DIFFERENCES
4
Hydraulic IMM Vs All Electric IMMComparison
STRUCTURE
DRIVE SOURCE
POWER TRANSMISSION
CONTROL SYSTEM
TOGGLERAM / TOGGLE /TWO PLATEN
Amplifiers &Servo motors
Induction Motor &Hydraulic Pump
Electric motor → Hydraulic pump →Piping → Valve → Piping → HydraulicCylinder
Timing belt → Ball screw
Open Loop controlClosed control injection for few models only
Closed Loop control
Hydraulic Injection Molding Machines
All Electric Injection Molding Machines
INJECTION MOLDING MACHINESTRUCTURE
The drive system of Hydraulic IMM utilizes cylinders while Electric IMM utilize servo motors with ball-screw system
Mold clamping/open-close cylinder
Plasticizing hydraulic motorHydraulic injection molding machine
Injection cylinderIU transfer cylinderEJ cylinder
Hydraulic pump Induction motorOil tank
Electro servo drive injection molding
machine
IU transfer motor
EJ servo motor Plasticizing servo motor
Mold clamping/open-close servo motor
Timing belt
Injection servo motor
INJECTION MOULDING MACHINESSTRUCTURAL DIFFERENCE
Toggle-type Clamping Sysems are widely used in All-electric injection molding machines.
STRUCTURAL DIFFERENCE
Electric Injection Molding Machines
Plasticizing servo motor
Injection servo motor
Mold clamping/open-close servo motor
Ejection servo motor
IU transfer motor
Hydraulic toggle machine
Oil tank
Plasticizing hydraulic motor
Injection cylinderIU transfer
cylinderEjector cylinder
Mold clamping/ open-close cylinder
Hydraulic pump Motor
Manifold block
Plasticizing hydraulic motor
Oil tank
Injection cylinderIU transfer
cylinderEjector cylinder
Manifold block
Hydraulic direct pressure machine
Mold clamping/ open-close cylinder
Hydraulic pump
Motor
INJECTION MOLDING MACHINEDRIVE SOURCE
INJECTION MOULDING MACHINESDRIVE SOURCE SYSTEM
Hydraulic Machine All Electric Machine
Linear Movement(Clamping / Injection / Ejection / Inj Unit)
Hydraulic Cylinders Pulley & Ball screw
Rotary Movements(Mold Thickness / Plasticizing)
Hydro Motor Servo Motor & Induction Motor
Linear Motions in Electric Machines
• The Servo Motor Rotates The Ball Screw Via Timing Belt.
• The Ball Nut Follows The Threads Of The Ball Screw In A Linear Motion As Screw Turns.
ALL ELECTRIC IMM
ball screw mechanism.flv - YouTube (360p).mp4
Ball Screw Ball Nut
• Converts Rotary Motion To Linear Motion.
• Ultra Low Friction.• Normal Efficiency Of Over
95%.• Nut Allows Ball Bearings
Full Movement Within The Nut.
• Teeth On The Belt Eliminate Slippage.
• Belt Helps To Absorb Shocks To Motor From Mechanical Collisions.
• Belt Constructed With State Of The Art Materials For Long Life.
• Designed for compact size.
• Extremely efficient cooling for heavy loads.
• Designed to withstand loads of more than 200% rated capacity.
Timing Belt Servo Motor
ALL ELECTRIC IMM
Why Should We buy An All-Electric IMM
1. Profit & Savings Less Energy consumptionOptimized capacity of Utility selectionRaw Material Saving
ADVANTAGES OF ALL ELECTRIC IMM
2. Productivity Better cycle timeLesser Rejection Rate
3. Process Quality ConsistencyRepeatability
4. Other Benefits Easy of UseMaintenance freeSuperior cleaner environmentNoise free Environment
PROFIT & SAVINGS
ALL ELECTRIC IMMEnergy Saving in Electric Machines
HYDRAULIC MACHINES ELECTRIC MACHINES
Large Induction Motor Need to Drive Pump. Small Motors To Move Each Function Of The Machine.
The Motor Always Has Some Load Put On It Due To Pump.
The Servo Motors Use Energy Only When They Run
High power consumption during Injection And Increased Volume For Charging
The Servo Motors are Off During ideal Times Such As Part Cooling Time.
No regeneration of power saving during High speed into Low speed
Regeneration of Power is possible and ensures that saving is about 20%
ENERGY SAVINGS
• The transmission thru hydraulic oil via long piping and valves, resulting in Large transmission loss. (Energy efficiency is about 66%)
• The transmission thru ball screws and servo motor, provides transmission with a superior efficiency rate. (Energy efficiency of 90% or more)
Hydraulic injection molding machines
Electric servo drive injection molding machines
Servo motor Belt Ball screwElectrical power
Load
>90 %100 %
Motor Coupling Hydraulic pump
HoseFilters Valve Hose
Valve Piping Hydraulic cylinder
PipingHeat dissipation
Tank
Piping
Electrical power
Hydraulic motor
Load 100 %
66 %
POWER TRANSMISSION DIFFERENCES
17
Power consumption of Electric IMM is very less because the servo motors only operate when necessary.
Hydraulic injection molding machine
Electric servo drive injection molding machine
Hydraulic injection molding machine:0.90 kWh/shot
Electric servo drive injection molding machine:0.32 kWh/shot
<Comparative energy consumption>
Cycle reduction 6.9 s
Cycle reduction
Time (sec)
Comparison of Molding Energy Consumption
Ener
gy c
onsu
mpt
ion
(kw
)
0
40
60
80
100
120
20
Plasticizing CoolingMold
opening RemovalMold
closingInjec-tion
Pressure holding
Below is the comparison of 850-ton Electric IMM that consumes 1/3 of the power used by a Hydraulic IMM
ENERGY SAVINGS
POWER TRANSMISSION
Electric servo drive injection molding machines
DRIVE SOURCE DIFFERENCE
Steady load of hydraulic pump
Hydraulic injection molding machines
No steady load
Mold closing
Injection/Pressure holding Cooling
Measuring
Mold opening Ejection
Mold closing
Injection/Pressure holding Cooling
Measuring
Mold opening Ejection
Hydraulic Machine Steady Load on pump even during No load
Electric Machine No steady Load Because motor operates only when necessary
ENERGY SAVINGS
19
PROFIT – Part Weight StabilityFrequent variation of pressure & speed in Hydraulic IMM causes part weight variation.However, the use of high degree of feedback control in Electric IMM provides constantly stable pressure and speed and so NO VARIATION IN PART WEIGHT
Variation in molded product weight is 50% or less than that of Hydraulic IMM
960
970
980
990
1000
0 5 10 15 20 25 30
Shot count
Mas
s (g
)
Range: 4.8 gHydraulic injection molding machines
960
970
980
990
1000
0 5 10 15 20 25 30
Constant variation in pressure during transition to holding pressure
Variation
Hydraulic injection molding machines
Stable pressure during transition to holding pressure
Constantly stable
Electric servo drive injection molding machines
Pressure waveform Pressure waveform
Speed waveform
Speed waveform
Time Time
Pre
ssur
e/S
peed
850t 850t
Pre
ssur
e/S
peed
Electric servo drive injection molding machines Range: 2.2 g
Shot count
Mas
s (g
)
CONTROL SYSTEM
Differences• Typical Hydraulic CPU Scan Time = 20ms• All-Electric Servo Scan Time = upto 62.5micro seconds• Typical Hydraulics Response Time = 50ms• All-Electric IMM Response Time = 1ms• Allows Injection Time Control To 0.001sec.
• Clamp/Screw/ Ejector stroke Micron level
• Positional Set Points Will NOT Overshoot.
• Optimized Mold Protection Can Be Set
• Easier To Set Machine For Automation.
Best of Electric IMM
22
CONTROL SYSTEM DIFFERENCES
Electric servo drive injection molding machines: Closed control
Hydraulic injection molding machines: Open control
[Example: Speed control]
Disadvantage: Large variance with speed command value
Advantage: Motor operation speed is detected and control functions to ensure no variance with speed command value
Controller Speed command Movement
Hydraulic pump
Hydraulic cylinder
Movement
(Closed control = Feedback control)
ControllerSpeed command
MotorDetection speed
Encoder
Ball screw
Hydraulic Machine
Open loop control or few closed loop control with lag in accuracyMostly All functions are not closed loop
Electric Machine
All functions are fully closed loopHighly precise control
PRODUCTIVITY
24
Compared to Hydraulic IMM, All Electric IMM’s can provide molding performance with high level of consistency and repeatability.
Servo motor/Ball screw
Closed control system
Control system differences
Control cycle differences
Variation reduced to 1/16
Control provides high speed and position
repeatability
Improved Productivity
Control cycle inmicro seconds
Power transmission differences
Improved speed/position
accuracy
PRODUCTIVITY
25
MOLD OPENING/CLOSING
Hydraulic injection molding
machines
Electric servo drive injection
molding machines
Mold closing
Mold closing
Injection/Pressure holding
Injection/Pressure holding
Cycle
Cycle
Cooling
Cooling
Plasticizing
Plasticizing
Mold opening
Mold opening
Removal
Removal Approx. 14% reduction
Cycle time (sec)
Molding cycle time comparison with 850-ton machine (standard operation)
Hydraulic Machine
Mold return position variation is highAccuracy can be improved but increases cycle time
Electric Machine
Mold return position is constant even at very high speed operation
Reduces molding cycle
DURING HIGH SPEED MOLD OPEN/CLOSE
PRODUCTIVITY
26
MOLD OPEN POSITION STABILITY
No Variation in moving platen return position results in the reduction of alarms such as removal robot chuck errors and cycle interruptions.
Comparison of Platen Return Position(850 ton/Setting 1,200 mm)
1195
1200
1205
1210
0 10 20 30 40 50
Shot count
Mov
able
pla
ten
posi
tion
(mm
)
Variation 0.0 mm
Hydraulic injection molding machines
All electric injection molding machines
Mold flow: 5 mmVariation: 1.2 mm
PRODUCTIVITY
QUALITY
Part Weight Trend Chart
232.0
232.2
232.4
232.6
232.8
233.0
0 10 20 30 40 50 60 70 80 90 100Shot
Par
t Wei
ght [
g]
Laptop PC Top Cover
Material: PC/ABS
g
gg%g%
Maximum 232.522Minimum 232.408Average(X) 232.463Range(R) 0.114R/X 0.0490Std Dev(σ) 0.02503σ/X 0.0323
350 T Machine
0.1≧Precision molding ⇒g
Consistency & Repeatability
UTILITY CAPACITY SELECTION.,
30
The amount of cooling water used is greatly reduced due to factors such as that no cooling water is needed for Electric Machines
Hydraulic injection molding machine Electric servo drive injection molding machine
<Example for 280-ton machine>
Difference
Cooling water processing / supply costs
Comparison of Cooling Water Costs
Difference
Amount of cooling water Supply/Process
151200 20,73670 9.6
130464
(t/day)
(Rs6/t)
Per Year
Savings on Utility Selection
1. Calculation of Cooling tower Capacity & Cooling tower motor Capacity
2. Lesser Cooling water consumption for machine
3. With the same hydraulic setup and power capacity, , more no of All-Electric machines can be added
31
Hydraulic fluid (oil) is not necessary so periodic maintenance of hydraulic equipment is also not required.
Savings on Utility Selection
<Example for 280-ton machine>
Difference
Amount of oil
Hydraulic injection molding machine
Electric servo drive injection molding machine
Comparison of Oil Costs
Oil costs
Per Year
(L)
RS200/L) 0
0520
104000
104000
1. No Hydraulic oil requirement
2. No Oil cleaning and periodic oil replacement avoided
3. No oil leakage and so Cleaner environment maintained
4. Maintenance issues reduced due to oil contamination and other hydraulic valve/Pump related
32
The overall Power capacity requirement will be less
Hydraulic injection molding machine Electric servo drive injection molding machine
<Example for 280-ton machine>
Power consumption
Comparison of Power Capacity
18-22 12-14(KW/hr)
Savings on Utility Selection
1. Lesser Power Capacity Requirement
2. With the same hydraulic setup and power capacity, more no of All-Electric machines can be added
3. Increase in Production and Decrease in Rejection
Project wise no of machine req is less
Cycle time Seconds 39 34
OTHER BENEFITS..,
Electric Servo Drive Injection Molding Machines
MOLD SAFETYMold is Safe From damage - More Precision and Sensitive mold protection
3. Highly sensitive detection of microscopic foreign matter pinched in the mold due to improved mold protection sensitivity.
1. No damage to molds due to improved speed control functions for mold opening/closing.
4. Angular pin shearing and slide core scratching are reduced due to a multi-stage mold protection function.
2. Damage to the tension link of the runner plate is reduced due to the stabilized stopping position during mold opening.
17 Environment-Friendly MachineLess CO2 Emission
CO2 emission is greatly reduced due to reduced energy consumption and shortened cycle.
<Calculation formula>CO2 emissions =Power consumption (kWh) ×
0.555 (CO2 emission coefficient)
1800T
Hydraulic Electric180T Segment filter 2 47,704 21,578 26,126 (55%)350T Cover part 1 64,664 28,771 35,893 (56%)450T Cover part 1 84,238 41,239 42,999 (51%)650T Air conditioner front cover 1 96,432 52,267 44,165 (46%)850T Box-shaped container 1 205,722 82,476 123,246 (60%)
Model Molded product Total cavities
CO2 emission (kg/year) Reduction of CO2emission(kg/year)
Automobile exterior parts 1 420,731 178,717 242,014 (58%)
0
10,000
20,000
30,000
40,000
50,000
150-ton hydraulic injection molding machines
180-ton electric servo drive injection molding machines
Emission by hydraulic
Emission by electric
47,704 kg 21,578 kg
-26,126 kg (-55% reduction)
+
This reduction is equivalent to the amount absorbed by 1,866 cedar trees, equivalent to a forested surface
area of 2.1 ha or 1.6 times that of the Tokyo Dome.
23,510 kg
-2,626 kg
Reduction due to power saving
Reduction due to shortened cycle
CASE STUDY..,
Case StudyEnergy saving
Sl No Description All Electric Machine Servo Hydraulic Machine
01 Cycle Time 55.60s 55.65s
02 Total energy consumed 4.06KW/Hour 5.25KW/Hour
03 Specific energy consumption
0.27 0.35
Part Material Shot wt Cycle time
Shower doom ABS 232 g 55.30
Special Remarks,1. Energy study carried out with the same cycle time for the same mould.2. The cost of energy consumed for utility (like additional water supply for the oil cooler) is not included
Case StudyEnergy saving & Productivity
Part Material Shot wt Cycle time
Shower doom ABS 232 g 51.46 - 55.65s
Special Remarks,1. Energy study carried out with the best cycle time for the same mould on each machine.2. The cost of energy consumed for utility (like additional water supply for the oil cooler) is not included
Sl No Description 180T All Electric Machine Hydraulic 160T Machine
1 Total energy consumed 4.56KW/Hour 5.25KW/Hour
2 Specific energy consumption
0.28 0.35
% Saving (Energy) 20% 0%
3 Cycle time 51.46 55.65
Productivity 7.5% More 0%
3.0 10.5 10.0 2.5 2.0
1.5 10.0 10.0 1.5 2.0
0.0 5.0 10.0 15.0 20.0 25.0 30.0
J110AD-180H
Mol
d cl
osin
g
Injection/Pressure holding Metering/Cooling
Molding cycle reduction of 3.0 s
(10.7%)
25.0 s
28.0 s
Small-sized machine example (100T)
• Molding Data
Electric servo drive injection molding machine
132,900
Production count comparison (One year)Production count
(pieces)
1,242,1731,109,272
Cycle (sec)
28.025.0
Increased production of 110T Machine
Increased production:
132,900 pieces
Electric servo drive injection
molding machine
Hydraulic injection molding machine
PRODUCTIVITY Cycle Reduction
Molded product Lens Cover
Total cavities 4
Material PC
Cycle time 25.0 s
Molded product mass 84 g
• Cycle comparison
Mol
d op
enin
g
Rem
oval
• Increased production amount due to cycle reduction (24 hours, 30 days, 12 months)
Hydraulic injection molding machine
Small-sized machine example
Electric servo drive injection molding machine
Hydraulic injection molding machine
Molding Examples/Running Costs (Small-Sized Machines)
• Molding example
• Running costs comparisons
Molded product Lens Cover
Total cavities 4
Material PC
Cycle time 25.0 s
Molded product mass 84 g
41% decrease(-2,28,768 INR/year)
Total cost Total cost
Cooling water
Oil
Power
TOTAL COSTHydraulic injection molding machine 5,79,120Electric servo drive injection molding machine 3,50,352Difference with hydraulic injection molding machine 2,28,768
0
100
200,000
300,000
400,000
500,000
600,000
700,000
Hydraulic Machine 100T Electric Machine 100T
Cooling Water
Oil
Power
39% DOWN(-228768 )
Total CostINR 5,79,120
Total CostINR 3,50,352
Power consumption comparison Hydraulic injection molding
machine Electric servo drive injection
molding machine Power consumption (kW) 7.6 5.2 Electricity costs (7.5 INR/kW/h) 4,92,480 3,36,960 Difference with hydraulic injection molding machine (Per year) 1,55,520
Oil costs comparison Hydraulic injection
molding machine Electric servo drive
injection molding machine Amount of oil used (L) 200 0 Oil costs (200 INR/L) 24,000 0 Difference with hydraulic injection molding machine (Per year) 24,000
Cooling water costs comparison Hydraulic injection
molding machine Electric servo drive
injection molding machine Cooling water amount (t/day) 29 7.2 Cooling water costs (INR6/t) 62,640 13,392 Difference with hydraulic injection molding machine (Per year) 49,248
CONCLUSION..,
IF WE PREFER…,• Better Energy Savings• Increased Productivity• Increased Quality• Material Savings• Ease Of Use• Cleaner Environment
&
MORE PROFIT
All Electric
Injection Molding Machines
Electric Machine movie01.wmv
Thank You