All-electric injection molding machines have revolutionized the injection molding industry by offering significant advantages over traditional hydraulic systems. By utilizing advanced servo motor technology for electrical control, these machines achieve unparalleled precision, efficiency, and cost-effectiveness. Below, we delve into the key benefits, working principles, and technical characteristics of all-electric injection molding machines.
Key Advantages of All-Electric Injection Molding Machines
Energy Efficiency and Cost Savings
- Power Consumption: All-electric machines consume 50% to 70% less energy compared to hydraulic systems due to the efficient use of servo motors.
- Reduced Cooling Requirements: These machines eliminate the need for hydraulic oil and significantly lower the cost of cooling water.
High-Precision Control
- Precision Injection: Servo motors enable precise, long-term control of each injection molding phase, ensuring high accuracy in product dimensions.
- Wide Speed Range: Unlike hydraulic machines limited by valve and accumulator constraints, servo motors provide seamless control across a range of speeds, from extremely low to very high.
Environmental Benefits
- Reduced energy consumption aligns with sustainability goals by lowering carbon footprints.
- Elimination of hydraulic oil reduces environmental hazards and simplifies maintenance.
Comparative Injection Speed Performance
Hydraulic Injection Molding Machines
- Can achieve faster injection speeds using accumulator technology.
- Speed control is restricted due to the action characteristics of hydraulic valves and accumulators, making it less adaptable for low-speed operations.
All-Electric Injection Molding Machines
- Superior speed control allows for operation across a wide spectrum, from ultra-slow to rapid speeds, enabling enhanced flexibility.
- Servo Motor Precision: Ensures smooth transitions and consistent performance even at low speeds.
Working Principles of All-Electric Injection Molding Machines
All-electric injection molding machines integrate advanced production control methods to achieve high efficiency, energy savings, and environmental protection. Below is an overview of the working process:
Key Stages of the Injection Molding Process
- Material Feeding and Melting: Raw materials are measured, fed, and heated to a molten state.
- Injection Phase: High pressure is applied to inject molten plastic into the mold cavity.
- Pressure Holding and Cooling: The plastic solidifies into the desired shape within the mold.
- Product Ejection: The mold opens, and the product is ejected, completing the process.
Servo Control System Requirements
The performance of all-electric machines heavily depends on the servo control system’s precision and stability. The following characteristics are essential:
High Precision
- Servo systems must provide high positioning accuracy for precise injection molding.
- Speed Regulation: High-quality speed control ensures consistent product quality.
Fast Response
- Enables multi-stage injection for complex products by quickly adapting to forming parameter changes.
Wide Speed Regulation Range
- Supports diverse processes, such as switching from high-speed mold movement to low-speed clamping for safety.
High Torque at Low Speed
- Ensures stable operation during low-speed phases, critical for maintaining product integrity.
Advanced Servo Motor Features
Key Characteristics of Servo Motors
- Smooth Operation: Minimal torque fluctuations, even at low speeds.
- Overload Capacity: Supports low-speed, high-torque demands.
- Fast Response: Small inertia and low electromechanical time constants ensure rapid performance.
- Durability: Designed for frequent starts, stops, and reversals without degradation.
Action Control
- Servo motors ensure precise coordination of all movement mechanisms, which is critical for producing high-quality products.
Structure and Components of All-Electric Injection Molding Machines
Main Hardware Framework
The control system comprises six key components:
- Human-Machine Interface: User-friendly interface for process control.
- Motion Controller: Coordinates servo motor movements.
- Logic Controller: Manages operational logic.
- Servo Drive: Powers and regulates servo motors.
- Temperature Control Unit: Maintains optimal processing conditions.
- Sensors: Monitors position, temperature, pressure, and speed.
Core Functional Units
- Injection Servo Motor: Drives forward movement of the injection screw.
- Screw Rotation Servo Motor: Enables rotation for material feeding.
- Shooting Platform Motor: Facilitates the reciprocating motion of the platform.
High-Precision Control and Feedback
Control Systems
- Semi-Closed-Loop Control: Uses encoder signals for speed adjustments.
- Full-Closed-Loop Control: Employs pressure sensor data for precise pressure management.
- Ultra-Low-Speed Control: Achieved using grating rulers for exact position feedback.
Signal Processing
- Digital interfaces between process controllers and servo motor drives minimize interference and enhance stability, enabling fine-scale control.
Summary
All-electric injection molding machines represent a significant leap forward in the injection molding industry. By leveraging servo motor technology, these machines achieve superior energy efficiency, precision, and adaptability compared to traditional hydraulic systems. Their innovative design not only meets the demands for high-quality, complex products but also aligns with modern environmental and cost-saving priorities. As industries increasingly prioritize efficiency and sustainability, all-electric injection molding machines stand out as the optimal choice for advanced manufacturing.
