Asynchronous servo energy-saving

A, and the principle of injection molding machine servo non-inductive vector

1. The asynchronous servo - servo non-inductive vector transformation principle of energy conservation

The traditional injection molding machine is the retrofit converter and synchronous servo energy-saving quantitative pump set to variable pump:

The first way V/F control and energy saving effect is poor product cycle (small) investment and benefit.

Second way synchronous servo control and energy saving effect is good high precision does not affect the cycle of the high cost of (investment) maintenance is not convenient to can't get the original system operation may affect the customer production.

Third way servo precision non-inductive vector control and energy saving effect and the synchronization effect does not affect the cycle (investment costs) in convenient maintenance can switch the original operating system does not affect the customers to use.

Original each action of velocity and pressure of the process of injection molding requirements is different also, it is by injection molding machine of proportional valves with the method of overflow adjust excess oil bypass flow back to the fuel tank, in the whole process, the speed of the motor is a constant torque is not large, so the oil is fixed, and the execution action is clearance, is not can be full load, so the quantitative oil supply is a big waste of space, according to the measured at least 50%. Servo precision non-inductive vector energy saving for it a waste of space, real-time detection from every movement control injection molding machine nc system and the rate of pressure and flow signal, timely adjust the motor speed and torque required to condition of action (flow control), the pump flow and pressure, but just enough to meet the needs of the system, while in a state of action (mainly in the cooling condition and pressure), stop the motor running, so energy saving space will further increase, so the energy-saving reconstruct to servo non-inductive precision injection molding machine vector can bring huge energy saving effect.

Servo non-inductive vector control flow chart of framework

2. The servo non-inductive vector control system of energy saving device

We adopt servo precision non-inductive vector operation technology (refer to the electrical schematic diagram), servo non-inductive vector real-time detection from the injection molding machine computer board each action reaction pressure and flow signal and my company's flow rate and pressure as the feedback signal is equivalent to the feedback signal of synchronous servo system of injection molding machine panel as given value fairly and synchronous servo control mode in after internal processing, different torque output, adjust the motor power and speed control, i.e., the output power and the synchronous automatic tracking control of pressure and flow, the equivalent of quantitative pump into servo precision energy-saving variable pump, the hydraulic system and the machine running the required power matching, eliminated the original system of high-pressure overflow loss of energy. Can greatly reduce the mold, open mold, stable production process, improve product quality, reduce mechanical failure and prolong the service life of the machine, and to save electricity.

Second, the vector control servo non-inductive characteristics

Servo precision non-inductive vector is suitable for injection molding machine and die casting machine dedicated to build asynchronous motor energy-saving software into synchronous servo motor control technology, adopts the high precision of the control strategy has the faster dynamic response, current limiting technology and hardware optimization design, make the products with super overload ability, can guarantee in the case of load fluctuate frequently, servo precision non-inductive vector don't trip. And has the following features:

1. High reliability

Improve the reliability of the design, such as redundant design, derating design, etc., all components are all made of industrial or military rank, key components all adopt the imported components, such as mitsubishi IPM module, BHC capacitance, IXYS rectifier bridge, etc. Key circuits are all made of high integration, thick film IC, thus ensuring the reliability of the whole machine;

2. The utility analysis of power consumption

11 kw 1 single pump injection molding machine, load rate is: 60%

Motor power is: 11 kw motor number 6 p current for: 28 a 380 v electricity according to the average 0.85 yuan/degree:

Before modification

(current) A

Before modification

Power (kw)

Run before modification

(h) day/degrees

Run before modification

(monthly) day/degrees

Run before modification

(every year) month/degrees

Run before modification

(combined)

16.8 A

8.4 KW

24

30

11

16.6 A

8.4 KW

24 = 201.6

30 = 6048

11 = 66528

= 56548.8 yuan

Calculated according to the actual data of the injection molding machine before modification monthly annual electricity consumption is: 66500 degrees, electricity consumption of yuan for every year

: 56500 yuan.

The servo precision non-inductive vector energy saving analysis

Motor power is: total 11 kw motor current is: 28 a 380 v electricity according to the calculation of average in 0.85 yuan/degree of power saving rate 40%

After transforming

(current) A

After transforming

Power (kw)

After running

(h) day/degrees

After running

(monthly) month/degrees

After running

(every year) month/degrees

After running

(combined)

10.08 A

5.04 KW

24

30

11

10.08

5.04 kw

= 120.96

3628.8

39916.8

33929.2 yuan

Before the original transform consumption is 56550 yuan each year - after energy-saving reconstruction of consumption is 3.393 yuan each year = 2.26 yuan to save the people about 22600, customer investment cost of equipment in about a year to recover the cost.

System of a complete set of equipment debugging for 11000, this system is not to cross site wiring and accessories, and other equipment.

Keep its oil injection molding machine control original way, adopts advanced microcomputer control technology, make the quantitative pump servo precision energy-saving pump and injection molding machine hydraulic system matching with the machine running the required power, no high pressure throttling the overflow of energy losses, improve the oil pump motor power factor above 0.96, power saving rate is generally 30% ~ 60%, all the investment costs recoverable in 6 ~ 18 months.

3. Soft start saving energy

Due to the motor to start or Y/Δ start directly, starting current is equal to (3-7) times rated current, which can cause serious damage to mechanical and electrical equipment and power grid, but also for power grid capacity requirements are too high, the large current when starting and vibration to the detriment of the service life of equipment. And energy-saving reform after using servo precision non-inductive vector, vector control with servo non-inductive start function will make the start current is starting from scratch, no more than rated current, the maximum to reduce the impact to the grid and the requirement of power supply to prolong the life of the equipment and mold.

4. The dynamic power factor compensation and energy saving

Reactive power not only increase the line loss and equipment of fever, mostly because of lower power factor. By the formula of S2 = P2 + Q2

Q = S * SIN Φ, P = S * COS Φ, among them: S - apparent power and reactive power Q -, P - active power, COS Φ - power factor. Known as COS Φ is larger, the greater the active power P. Common quantitative pump injection molding machine COS Φ value at zero. 6-0. Between 8 and the use of servo non-inductive after vector control the torque and energy saving device, due to the servo non-inductive vector control internal filter capacitance makes cosine Φ material 1, reducing reactive power loss, increase the active power of power grid.

5. Strong overload capacity and speed of dynamic response

Servo precision non-inductive vector control adopts advanced control algorithms and unique current limiting technology, to ensure that in the process of injection molding, can withstand the start-stop without tripping the impact of heavy load, in order to ensure the continuity of production process. High speed of dynamic response, maximum limit reduce product cycle delay phenomenon.

Improve the EMC design: servo non-inductive EMC design scheme of vector control using perfect, internal layout optimization design, USES the many kinds of EMI countermeasures, make sure to reduce the interference of the electrical system in the injection molding machine to the minimum, guarantee the stability of its work.

As the production of plastic products are widely used and its rapid growth, has become the building materials, electrical and electronic plastics machinery, petrochemical, automobile, machinery, packaging and other industries of important technical equipment, servo precision non-inductive vector control applied in injection molding machine and energy saving transformation, energy saving method is effective and worth promoting to the plastic products industry.