TECHNICAL COMPARISON OFplasticnews.aipma.net/1Dec17-Seminar/ANBU.pdf · Hydraulic injection molding...

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


DRIVE SOURCE DIFFERENCE

Steady load of hydraulic pump


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


Stable pressure during transition to holding pressure

Constantly stable


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


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.



Difference

Amount of oil



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


Power consumption

Comparison of Power Capacity

18-22 12-14（KW/hr)


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


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


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)


Small-sized machine example



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

TECHNICAL COMPARISON OFplasticnews.aipma.net/1Dec17-Seminar/ANBU.pdf · Hydraulic injection molding...

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