hybrid servo-driven imms
TRANSCRIPT
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The Benefits ofHybrid Servo-Driven
Injection Molding Machines
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Pumps & CylindersServo Motor & Gear & Belt
Energy Efficiency and Repeatability is
dependent on what method is usedto deliver power to the machine axis
The Benefits of
Hybrid Servo-DrivenInjection Molding Machines
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Energy Timeline
1988 20081968 1993 1998 20031973 1978 1983 2011
H y b r i d - r e l a t e d i n n o v a t i o n s
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Energy In = Energy OutHydraulic Press ( 400-700 Ton Range )
=
Feed
throat5%
MoldCooling20-30%
ControlPower
2%
BarrelHeating
10%
Energy Balance
ElectricMotor88%
Energy In
E n e r g y
I n
1 0 0 %
Energy Out E n e r g y
O u
t
1 0 0 %
Convection &Radiation toAtmosphere
40-50%
Hot
Moldings2-5%
OilCooling20-25%
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0
5
10
15
20
25
MM 580 550 MS580
Power Consumption
KWH
3.0
20.7
Cycle time: 48 sec. / Injection time: 8 sec.Cooling time: 30 sec. / Clamp stroke: 38
( VV pumps ) ( All Electric )
3.2
( Hybrid Servo )
Comparison in dry cycle operation (heater power excluded ! during full-automatic operation)
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Energy In E n e r g y
I n
1 0 0 %
ControlPower
4%
BarrelHeating36%
ServoMotor60%
HotMoldings
5-10%Feed throat
5-7% MoldCooling50-60%
Convection &Radiation 25-30%Energy Out E n
e r g y
O u
t
1 0 0 %
=
Energy Balance
Energy In = Energy Out
Servo (400-700 Ton Range)
OilCooling
5-10
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2-Platen TechnologyTypical 2-platen deflectionwith tonnage cylinders
at corners
2-platendirect-acting ram
Tonnage checked in
Zero energy to maintain tonnage
Hybrid Servo System
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ConventionalPQ Pump System
Hybrid Servo Systems
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Variable Volume Hydraulics
! Variable volume pump! High case flow! Relies on pressure drop
across valves to operate! High min. pressure
! Fixed volume pump! For cooling the oil! Sensitive to cavitation
! Closed loop oiltemperature control! For continuous,
stable operation
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Drive
PositionFeedback
Hybrid Servo System
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Vact
Qcmd and p cmd Q and P
n act
n cmd
Qact and p act p act
System Block Diagram
Ethernet
Powerlink
Hybrid Servo System
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Features of Motor Drive System
! Regen Power! Regen to bus! 1:1 power factor
! Modular! Modular rack design
! Service! No config during replacement! Built-in network safety! Plug connections for fast replacement! Native to ethernet power link! On-board fast logic control functions! Air-cooled motors and drive
#6
#3
#5
#2
#1
#4
EthernetPowerlink
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D r i v e C a b i n e t
Hybrid Servo System
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Power Cabinet
I/O & SafetyRelays Drives
PowerConnections
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Servo Motor Drives
Dynamic Breaking
Chokes
Hybrid Servo System
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Induction Motor Servo Motor
-phase Asynchronous Motor 3-Phase Synchronous Motorwith permanent magnets
Hybrid Servo System
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Benefits :- Closed loop system- Reduced energy consumption
- RPM of Induction motor is fixed 1750- Servo motor RPM can vary from 0 to 3000 RPM in both directions
-High efficiency at low loads-Accuracy
- Very high resolution (rotation can be controlled by fraction of angle)- Fast response- High repeatability
Servo Motor vs Induction Motor
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Electro hydraulic pump Internal gear pump
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Benefits:
-
Sensitivity to contamination is reduced drastically- Fewer number of parts only two moving parts- No internal wear parts (ex. swash plate )which improvespump reliability
-
Very easy to maintain; low cost of spares- Pump can rotate in either direction to provide quickpressure control response
- Pump can be stopped intermittently during the cycle
-
Non-pulsating discharge - constant and even dischargeregardless of pressure conditions- Low operating noise
V V Piston Pump vs Internal Gear Pump
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Minimizes the influence of machine on oil temperature ." The servo system only delivers hydraulic oil as it is needed to prevent
unnecessary heat generation and to reduce oil cooling requirements" Life of the hydraulic components is extended" Enhanced oil life"
Reduction in cooling water consumptionImproved Consistency & Repeatability .
" Servo system closed loop control considerably improves cycleconsistency and repeatability vs. conventional hydraulic injection
molding machines
System benefits :
Hybrid Servo Systems
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Operating EfficiencyMODEL Fixed Pump 3000 VV Pump 3200 VV Pump 4400 Hybrid Electric 3000 Servo 4400
TYPE II Platen II Platen II Platen II Platen II Platen
US TONNAGE 3300 3520 4400 3300 4400
CONNECTED POWER (KW) 338 365 1087 370
SCREW DIAMETER (MM) 155 150 140 155 140
MATERIAL TPO TPO TPO TPO TPO
CYCLE 45.3 105 50.3 39.8 50.3
SHOT WEIGHT (OZ.) 144 246 160 144 160
THRU PUT (KG/HR.) 325 240 325 370 325
AVERAGE KWH 246 139.9 164.2 126.5 100.4
EFFICIENCY (KWH/KG) 0.757 0.583 0.505 0.342 0.309
Efficiency
!"!!! !"$!! !"%!! !"&!! !"'!! !"(!! !")!! !"*!! !"+!!
,, --- &!!!
,. &%!!
,/ ''!!
01 &!!!
,2 ''!!M i l a c r o n S e r v o 4 4 0 0
B r a n d A H y b r i d E l e c t r i c 3 0 0 0
M i l a c r o n V V P u m p 4 4 0 0
B r a n d A V V P u m p 3 2 0 0
B r a n d B F i x e d P u m p 3 0 0 0
Kwh/kg
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The Material Matters
Each material requires a different amount ofenergy to bring it to the appropriate temperaturefor molding.
This specific amount of energy is sometimes calledSpecific Enthalpy
Units are kw-hr/kg or hp-hr/lb
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Hybrid Servo Efficiency
1100 1500 2000 2600 3300 4400
Model MS 1125-6610 MS1500-10100 MS2000-16000 MS2600-23000 MS3300-34000 MS4400-48000Injection Unit 6610
( 10100) 10000 10100(125MM) 16000 16000(140 MM) 23000 23000(160MM) 34000 34000(180MM) 48000 48000
% screw recovery 33.9% 38.2% 44.5% 46.8% 43.4% 45.7%Shot size hdpe 39.2 64.96 101.36 151.2 215.32 295.12lb./hr. hdpe 336.0 448.4 507.4 659.4 794.2 888.4Efficiency kwh/lb. 0.134 0.145 0.158 0.140 0.125 0.133
Increase in efficiency assume .3 Kwh/lb. 0.166 0.155 0.142 0.160 0.175 0.167Hrs. year 5000.000 5000.000 5000.000 5000.000 5000.000 5000.000Energy cost $0.068 $0.068 $0.068 $0.068 $0.068 $0.068Savings (cost to run Machine) $19,001 $23,602 $24,492 $36,024 $47,444 $50,635Savings (cost to remove wasted energy) $3,800 $4,720 $4,898 $7,205 $9,489 $10,127
344567 26894:; 8;" ?6579@; A%%B+!% A%+B&%& A%CB&C! A'&B%%C A()BC&%
D?0;04E F6750 * =06? 26894:; A$(&B+C! A$C$B$($ A$C+B&(& A%C$B*() A&+'B%&+ A'$!B!+
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Annual SavingsHybrid Servo 4400 vs. Hydraulic 3000
Annual Savings Ms 4400 vs. MM III 3000
Hours Production per year 6000 50 weeks6 days week 20 hrsday
Energy Cost $/kwh 0.07Part wt oz 160Cycle 50.3kg/hr 325Efficiency difference MS vsMM III kwh/kg 0.448
Annual savings machine $61,179.93Energy removal Cost $12,235.99
Annual energy savings $73,415.91
Reduced stabilization timeReduced by 3cycles $6,210.00 $ 200/hr. burden rate
$ .7 lb. material cost
Total annual savings $79,625.91
Present Value 5 years savings $344,739
Hybrid Servo System
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Energy Monitor
" Overall operating efficiency" Power used each process
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Energy Monitor
Energy impact example:Automotive fan shroud processed on Servo IMM at .1 kwh / lb.
compared to a hydraulic result in the range of .3 kwh / lb.
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Hybrid Servo Systems
For more information on Milacron hybrid
servo injection molding machines or toreceive a cost quotation, contact us :