Product Application

Product Application
Delta Industrial Automation
Case
Issued by
Applicable to
Key words
Application: Delta Hybrid Servo System for Plastic Material Injection Machine
Solution Center
Date
January, 2011
Pages
4
VFD-VJ series hybrid servo drive
Hybrid servo, energy-saving, plastic material injection, old equipment replacment
Delta Hybrid Servo System Used with Traditional Injection Machines
Traditional injection machines consist of four parts, that include a hydraulic pump, a heating unit, a cooling
system and the control system and components. While each part consumes much energy, the hydraulic pump
consumes up to 75% or more of the machine’s total energy requirement. Different amounts of pressure and flows are
injected into the claming, injection, pressure hodling, cooling and ejection stages. The hydraulic pump is always
under an unstable loading status. The overflow valve and the ratio valve adjust the flow and pressure when the
system requests more than the set flow and pressure. This process is an example of high-pressure throttle that can
cause energy losses up to 40~75%. The energy-saving Delta Hybrid Servo System precisely controls the pressure
and flow required at each stage, greatly reducing the amount of energy wasted at high-pressure throttle. At the same
time, the oil temperature in the system is lowered.
Application Description
1.
Before replacing the system for experienced manufacturers, old system information is provided as a basis for
designing the new system. Information includes:
 Maximum work pressure of the system (kg/cm2)
 Maximum system flow (L/min), which can also be calculated by: traditional motor revolutions per minute (rpm)
x oil pump output (cc/r)
 Maximum work voltage: Delta’s system provides 220V and 380V
2.
Before replacing the old system, An injection molding machine operator must collect the following information by
using a hanging meter: operation time per cycle, total mold production quantity, pressure holding time, cooling
time, mold reference number, and total power consumption.
3.
A week after replacing the old system, observe the results by recording the following information daily: operation
time per cycle, total mold production quantity, pressure holding time, cooling time, mold reference number, and
total power consumption.
With solid experience and advanced technology, Delta Industrial Automation offers efficient and reliable solutions and service – we are
your most trustworthy partner.
COPYRIGHT © 2008 DELTA ELECTRONICS, INC. ALL RIGHTS RESERVED.
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Product Application
Delta Industrial Automation
System Structure
Single-drive mode:
Multiple-drives mode:
With solid experience and advanced technology, Delta Industrial Automation offers efficient and reliable solutions and service – we are
your most trustworthy partner.
COPYRIGHT © 2008 DELTA ELECTRONICS, INC. ALL RIGHTS RESERVED.
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Product Application
Delta Industrial Automation
Application Cases
Case 1- Injection Molding Machine: 100T
System Specification:
1. Maximum work pressure: 175 Bar
2. System flow: 100L/min
3. Voltage: 380V
Single-drive mode (drives and accessories):
1. Servo hybrid AC motor drive: 18.5kW
2. Servo motor: 14 kW
3. Hydraulic pump: 45 cc/r
Energy saving results:
1. Compared with the old high energy consuming injection system, the new system is more productive and
precise.
2. The old injection system was a mold with 2 cavities for half-automated industrial fan production. Power
consumed per hour is 7.3 degrees.
3. The new energy-saving Delta Hybrid Servo System reduces power consumption to 1.78 degrees, which
saves up to 76% of the energy required. .
Date
Replacement
Part
number
Production
time per cycle
(sec.)
Production
Time
Watt
Power
consumption
per hour
Mold
quantity
505
- A mold with 2
cavities
-Half-auto
industrial fans
production
606
- A mold with 2
cavities
-Half-auto
industrial fans
production
Cooling: 12
Jun. 5,
2010
Before
438
Pressure
holding: 2.8
4H
29.5
7.3
1 cycle: 27
Cooling: 12
Jun. 10,
2010
After
438
Pressure
holding: 2.8
5H
8.9
1.78
1 cycle: 27
Product
Case 2 – Injection Molding Machine: 140T
System specifications:
1. Maximum work pressure: 140 Bar
2. System flow: 74L/min
3. Voltage: 380V
Single-drive mode (drives and accessories):
1. Servo hybrid AC motor drive: 15kW
2. Servo motor: 11 kW
3. Hydraulic pump: 32 cc/r
Energy saving results:
1. The old injection system was a mold with 8 cavities that fully-automated the production of RS-232 plugs.
Power consumed per hour is 8.7 degrees.
2. The new energy saving Delta Hybrid Servo System reduces power consumption to 3.45 degree, which
achieves energy savings of up to 61%.
With solid experience and advanced technology, Delta Industrial Automation offers efficient and reliable solutions and service – we are
your most trustworthy partner.
COPYRIGHT © 2008 DELTA ELECTRONICS, INC. ALL RIGHTS RESERVED.
-3-
Product Application
Delta Industrial Automation
Date
Replacement
Material
Production
time per cycle
(sec)
Production
time
Watt
Power
consumption
per hour
Mold
quantity
14H
122.4
8.7
2,520
- A mold with 8
cavities
- Automated
RS-232 plug
production.
14H
48.3
3.45
2,352
- A mold with 8
cavities
- Automated
production.
Cooling: 3
Nov. 17,
2010
Before
ABS
Pressure
holding: 0.5
1 cycle: 20.8
Cooling: 3
Dec. 28,
2010
After
ABS
Pressure
holding: 0.5
Product
1 cycle: 20.8
Case 3 – Injection Molding Machine: 250T
System specification:
1. Maximum work pressure: 140 Bar
2. System flow: 144 L/min
3. Voltage: 380V
Multiple-drives mode (drives and accessories):
1. Servo hybrid AC motor drive: 15 kW*2pcs
2. Servo motor: 11 kW + 7.5 kW
3. Hydraulic pump: 40 cc/r + 32 cc/r
Energy saving results:
1. The old injection system was a mold with 1 cavity for automated plastic box production. Power consumed
per hour is 9.3 degrees.
2. The new energy saving Delta Hybrid Servo System reduces power consumption to 3.3 degrees, which
saves energy by up to 65%.
Date
Replacement
Material
Production
time per cycle
(sec)
Production
time
Watt
Power
consumption
per hour
Mold
quantity
Cooling: 13
May 1,
2010
Before
PP
Pressure
holding: 4.8
9H
84
9.3
870
- A mold with 1
cavity
-Automated
production
9H
30
3.3
930
- A mold with 8
cavities
- Automated
production
1 cycle: 33
Cooling: 13
Jun. 20,
2010
After
PP
Pressure
holding: 4.8
Product
1 cycle: 33
Conclusion
Since 2006, the injection molding machine industry has begun to develop energy-saving servo products. There
are rising numbers of energy saving models being invented as the environmental protection issue gains ground. The
productivity for machine manufacturing has achieved 80%. Delta has long been dedicated to the mission "To provide
innovative, clean and efficient energy solutions for a better tomorrow". The IABU finally contributed energy saving
servo control technology in 2009. With years of practice in the market, the energy saving has been outstanding. This
hybrid servo energy saving technology will continue to transform the old plastic injection machine with the ultimate
goal of reducing energy consumption and bringing about a better tomorrow.
With solid experience and advanced technology, Delta Industrial Automation offers efficient and reliable solutions and service – we are
your most trustworthy partner.
COPYRIGHT © 2008 DELTA ELECTRONICS, INC. ALL RIGHTS RESERVED.
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