Abstract:
This blog introduces a revolutionary hydraulic pump servo drive and control technology for Hydraulic Injection Molding Machine. By employing an AC permanent magnet synchronous servo motor to drive the hydraulic oil pump, this system enhances the drive-level control of injection molding machines. The result? Energy savings, rapid dynamic response, stable pressure control, and superior low-speed performance.
Practical tests and real-world applications confirm the energy-efficient design and improved control precision of this cutting-edge technology for injection molding machines.
Composition of the Hydraulic Pump Servo Drive and Control System for Hydraulic Injection Molding Machine
The servo drive system for the hydraulic pump of injection molding machines features a schematic diagram for better understanding. It comprises the following:
- AC Permanent Magnet Synchronous Servo Motor
- Servo Driver
- Hydraulic Oil Pump
- Pressure Sensor
- Encoder or Resolver
This innovative system bridges the gap between traditional hydraulic-driven systems and all-electric injection molding machines. By converting speed and pressure setpoints into analog or digital signals, the servo driver adjusts the motor to meet specific speed and torque demands. This integration ensures the hydraulic pump performs optimally for injection molding operations.
Power Consumption Analysis of Servo Pump Injection Molding Machines
The hydraulic system in a servo pump-driven Hydraulic Injection Molding Machine is pivotal. Its performance impacts:
- Product Quality
- Dimensional Accuracy
- Molding Cycles
- Production Costs
- Workplace Environment
- Operational Safety
Key features of this hydraulic system include:
- High Precision
- Energy Efficiency
- Low Noise
- Proportional Control
- Microprocessor Integration
The pressure and flow requirements vary during each injection cycle, aligning with process demands. Notably, mold clamping and opening systems use 40%-60% of the cycle’s total energy. This distribution depends on factors like the workpiece size and process intervals.
Performance Test Experiment: Hydraulic Pump Servo System
Energy Savings and Influencing Factors
The hydraulic pump servo system significantly reduces energy consumption, thanks to:
- High energy conversion efficiency of servo motors.
- Adaptive flow and pressure outputs.
- Stoppage of the servo motor during product cooling phases.
The energy-saving benefits compared to other systems:
- 20%-50% savings vs. variable pump machines.
- 30%-60% savings vs. fixed pump machines.
However, the energy savings depend on factors such as:
- Molding Process
- Material Properties
- System Configuration
- Servo Motor Efficiency
Notably, the dual-displacement plunger pump system outperforms others in energy savings.
Response Speed and Influencing Factors
A fast response time is critical for precision molding and operational efficiency. Performance tests show:
- Hydraulic pump servo system response time: 40ms-50ms.
- Variable pump system response time: 70ms-120ms.
- High-frequency response servo valve time: 25ms-40ms.
Key factors affecting response speed include:
- Hydraulic pump displacement
- Maximum servo motor speed
Pressure Control Accuracy
In pressure maintenance and high-pressure clamping, accuracy is paramount. Tests reveal:
- Significant variation in pressure control across different systems.
- Speed ranges of 20-150 rpm demonstrate low-speed pressure stability.
Summary
Performance testing highlights the hydraulic pump servo system’s advantages in reducing energy consumption, accelerating response times, and improving pressure control accuracy.
As the demand for energy-efficient solutions rises, this innovative system is poised to replace traditional quantitative and variable pump systems, becoming the mainstream configuration in Hydraulic Injection Molding Machine. With energy conservation becoming increasingly critical, this technology addresses the high energy demands of injection molding operations, making it a vital industry advancement.
