کنترل هزینه کارگاه ماشین قالب گیری تزریق - هشت راه برای صرفه جویی در هزینه

For an injection molding factory, مصرف انرژی فرآیند قالب گیری تزریقی حدوداً به حساب می آید 60%. از این رو, کاهش موثر مصرف انرژی دستگاه قالب گیری تزریقی یک راه مهم برای صرفه جویی در انرژی در کارخانه قالب گیری تزریقی است.. With the continuous improvement of the energy-saving technology of the دستگاه قالب گیری تزریقی خود, reducing the overall energy consumption of the injection molding plant requires a comprehensive considera hbtion from the aspects of production management, processing technology and materials, and supporting facilities for the production workshop.

(1) Production workshop

The layout of the production workshop focuses on two considerations: to meet production requirements, while optimizing the layout according to the production process, it also meets the requirements for flexible energy use under specific production conditions.

1. Power supply, while meeting the power required for stable production, has a proper margin, so that the excess margin will not cause excessive non-functional consumption.
2. Build efficient cooling water circulation facilities and equip the cooling water system with effective insulation and heat preservation systems.
3. Optimize the overall production layout of the workshop. Many productions have sequential process coordination, and reasonable coordination can reduce the time required for turnover and energy consumption, and improve production efficiency.
4. Try to consider the most effective small units for separate control of lighting and other plant equipment.
5. Perform regular maintenance on workshop equipment to avoid damage to public facilities that affects normal operations of production and increases energy consumption. (2) دستگاه قالب گیری تزریقی

در دستگاه قالب گیری تزریقی is a big energy consumer in the injection workshop, and the energy consumption is mainly the motor and the heating.

1. Select the appropriate injection molding machine according to the characteristics of the product. “Big horse-drawn cart” injection molding often means a lot of energy waste.

All-electric injection molding machines و hybrid injection molding machines are selected, which have excellent energy-saving effects, which can save energy by 20-80%.

3. The use of new heating technolgies, such as electromagnetic induction heating, infrared heating, و غیره., can achieve 20-70% heating energy saving.
4. Use effective 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 equipment operation.
6. Use low-compression hydraulic oil to reduce the waste of working energy in the hydraulic system.
7. The use of parallel action, multi-cavity injection, multi-component injection 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, which replace the traditional quantitative pump mechanical hydraulic injection molding machine with a significant energy-saving effect.
9. Regularly maintain the heating and cooling pipelines to ensure that there are no impurities or scale blockages in the pipelines, and to achieve the designed heating and cooling efficiency.
10. Ensure that the injection molding machine is in good working condition. Unstable processing may result in defective products and increase energy consumption.
11. Ensure that the equipment used is suitable for the product being processed. مثلا, special screws are often used for PVC processing.

(3) 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 type, number of cavities, heating and cooling water channels, و غیره., all help to reduce energy consumption.

2. The use of hot runner molds can not only save materials and reduce the energy consumption of material recovery, but the molding process itself also has a significant energy-saving effect.3. The profiling quick-cooling and quick-heating molds can significantly save processing energy consumption and achieve better surface quality.

4. Ensure that each cavity is filled in a balanced manner, which helps to shorten the molding cycle, ensure the uniformity of product quality, و اثر صرفه جویی در انرژی عالی دارد.

5. استفاده از فناوری طراحی به کمک CAE برای طراحی قالب, تجزیه و تحلیل و شبیه سازی جریان قالب می تواند مصرف انرژی در اشکال زدایی قالب و تعمیرات چندگانه قالب را کاهش دهد.

6. با فرض اطمینان از کیفیت محصول, استفاده از نیروی گیره کمتر برای قالب گیری می تواند به افزایش عمر قالب کمک کند, پر شدن سریع قالب را تسهیل می کند, و به صرفه جویی در انرژی کمک کند.

7. برای اطمینان از کانال های آب گرمایش و خنک کننده موثر، در نگهداری قالب کار خوبی انجام دهید.

(4) تجهیزات جانبی

1. تجهیزات کمکی مناسب با توانایی را انتخاب کنید, که نه تنها الزامات کار را برآورده می کند, اما ثروت زیادی هم ندارد.

2. در تعمیر و نگهداری تجهیزات به خوبی کار کنید تا مطمئن شوید که تجهیزات در شرایط کاری عادی قرار دارند. Auxiliary equipment that does not work properly can cause unstable production and even poor quality parts, resulting in increased energy consumption.

3. Optimize the coordination and operation sequence of the host and peripheral equipment.

4. Optimize the mutual position of peripheral equipment and production equipment, and keep the peripheral equipment as close to the host as possible without affecting the operating conditions.

5. Many auxiliary equipment manufacturers provide systems that provide energy on demand, which can achieve significant energy savings.

6. Use quick mold change equipment to reduce the waiting time required to switch products in production.

(5) Materials

Different material processing consumes different energy, و در عین حال, poor management of materials or improper management of recycled materials will increase production energy consumption.

1. On the premise of meeting product performance, materials with lower processing energy consumption should be selected first.

2. Under the conditions of satisfying performance and cost optimization, preferentially select high-fluidity materials.

3. Note that materials from different suppliers may have different process conditions.

4. The material is dried, it is best to use it as it is dried, so as to avoid the material returning to moisture after drying and wasting energy.

5. Do a good job of material storage to prevent the material from being mixed with impurities or foreign objects, which will eventually cause defective products.

6. Some products are allowed to add a certain amount of recycled materials, but attention should be paid to the preservation and cleanliness of recycled materials to avoid defective parts due to unclean materials.

(6) Processing technology

1. On the premise of meeting product performance, use the shortest molding cycle.

2. If there are no special factors, use the processing technology recommended by the supplier for processing as much as possible.

3. For specific products and molds, all stable equipment and process parameters are saved to shorten the adjustment time when the next production replacement is performed.

4. Optimize the process, adopt lower clamping force, shorter cooling time and pressure holding time.

(7) Adopt new technology

1. Use auxiliary molding technology, such as gas-assisted, liquid-assisted, steam-assisted, micro-foam injection molding technology, و غیره.

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 use of new low-pressure molding technology shortens the molding cycle and reduces the melt temperature at the same time.

5. Adopt energy regeneration system.

(8) 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 host, but also the peripheral and factory equipment. مثلا, if the mold changing crane in the workshop fails, manual mold changes are required, which will inevitably extend the waiting time of the equipment and increase the energy consumption of the equipment.

3. Equipped with workshop energy consumption monitoring system, which is convenient for enterprises to implement 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, and whether the working performance is reliable.

5. Regularly compare with industry benchmarks to see if there is room for further improvement.

6. Establish reliable contracts and cooperative relations with suppliers, which is beneficial and harmless to enterprise energy-saving management.