Plastic Injection Machines are essential for production, but either wasted electrical energy! The most important agenda item of recent times in our country and the world is "energy and energy saving", and many countries and almost all scientists are closely involved and working on this issue. As a result of these studies, new technologies and applications are being developed.
"It has been determined that we have the potential to save approximately TL 7.5 billion worth of energy that can build four Keban Dams, including 30% in the building sector, 20% in the industrial sector and 15% in the transportation sector. With the evaluation of our current potential in energy saving, the country's economy and companies will have an unmnesing contribution in reducing production costs.
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Why Should I Save Money?
Our growing industry attracts the attention of many companies, both domestically and internationally, thus causing new competitors to come after them. The main way to increase your competitiveness against increasing competitors is through lowering production and operating costs.
Among these costs, energy costs will of course be one of the leading items. In order to reduce these costs, companies are aiming to minimize the cost per product by trying to evaluate every opportunity they can save energy, from the lighting of the factory to the machines that produce it.
At the beginning of these works, the amount of energy consumed by the machine is reduced by adding drivers (inverters) to machines that work with stop-and-go logic and making the necessary adjustments.
The goal is to create a target. Plastic Injection Machines
Most of the plastic injection machines that are active in our country are of Chinese origin. The very low efficiency of the main (body) engine used in these machines is the main reason for increasing the amount of energy consumption. However, during the running time of the injection machine, the Power x Time chart is as follows;
As can be seen from the graph, the machine engine is running idle at the time of cooling of the goods, but consumes high values of energy. With the closed cycle inverter application, the machine can prevent energy consumption by stopping the engine completely as soon as it is idle.
Other points of savings are transaction intervals. For example, if you want to create ironing and receiving range, hinge opening and repellent hitting range, such as the range of closing the hinge after the pusher is returned. This consumption barrier rate depends on the mammoth produced, the cycle time, the invertere to be used and the knowledge and skill of the technical team who will make the essential application.
How does the system save electricity?
The operation of this system is the same as the operating principle of the hydraulic servo motor machine known to everyone. This means that the engine only works when it is needed. The engine generates the necessary power for the required time (i.e. running) out of need (goods cooling, manual pick-up, etc.) and is completely stopped at times (0 Current).
However, even in fully automated machines and when cooling times are 0 sn, savings of up to 25% can be achieved depending on your mold, mammoth and operating conditions.
You save extra money on molds where you can't work fully automatically, i.e. when you have to manually pick up the mousse, where you expect the mold engine to turn on the mold for metal nuts, screws, threaded parts you line up, or from machine failure, mold failure, mold replacement, thread-open waits due to use, and engine shutdown during tea and meal breaks.
In addition, hydraulic pumps will be less worn and long-lasting as they will turn less, oil life and pump life will be longer as the oil temperature will drop between 5-12 C° according to the machine, chiller cooling will consume less energy as it will be less engaged.
We have saved between 15% and 70% in our applications to this day, in different machines and in different molds (from the energy spent by the electric motor). This is a saving provided through the engine of the machine, and with the factors we just counted, this savings rate increases even more.
Who Are We and Why Omron?
Omron is a Japanese brand and has a total product portfolio of 700,000 items of 200,000 kinds that can be the solution for all kinds of applications in the field of industrial automation.
With more than 300 local centers, 17 factories worldwide are a global company providing the highest quality solutions to its customers as soon as possible. In addition, it is a reference to industrial automation technologies by financing 40% of its annual profit in R&D studies.
Mechatronics Electric, which takes responsibility for sales and implementation, has separated our technical team according to the sectors and has been provided to specialize in both domestic and international trainings in its fields.
We have successfully implemented more than 300 application per year with our 2-person sales and expert technical team of 4 people, which we have dedicated exclusively to energy saving of plastic injection machines. Zero error feedback and customer satisfaction from our applications have also been our pride.
Our Difference in Practice;
With our high quality devices that can provide 150% torque at 0 Hz produced in Japan with Japanese technology, we perform your application by completely stopping the engine (0 Current) and increasing your energy savings rate, not at very small times like other brands at the time of commodity cooling.
The Current x Time chart of one of the applications we have done above is shown. As shown in this chart, the engine is completely stopped and kept at a maximum torque of 0 current.
Due to the Double Rating feature available on our drives and the igbt of one drive larger than each drive, it can withstand higher currents in the same kWs and control it without errors.
Examples include:
300 Tons Haitian Plastic Injection Machine
Engine 45 KW
Cycle time ( Cycle ) 28 s. Printed finished rebar fastening apparatus
14.62 kw/h of electrical energy consumed in the hour before application
Electrical energy consumed per hour after application 6.5 kw/h
Saved electrical energy profited 55.5% percentageally.
250 Tons Haitian Plastic Injection Machine.
Engine 37 kW
Cycle time 51 s.
Printed finished pipe attachment
The electrical energy consumed in the pre-application hours is 19.20 kw/h.
Electricity consumed per hour after application is 7.93 kw/h.
Saved electrical energy profited 58% percentageally.
Saving every kW/h energy you can save is a contribution to the country's economy, nature and your own budget.
Omron Mechatronics Center
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