How does the horizontal injection molding machine achieve the perfect combination of high efficiency and energy saving and intelligent production?

Technological innovation: the energy-saving revolution of large-tonnage injection molding

In today's booming plastic processing industry, the 220T 562g energy-saving horizontal injection molding machine redefines the production standards of large and medium-sized plastic products with its excellent performance. The equipment integrates a number of industry-leading technologies to achieve a breakthrough performance of 30% reduction in energy consumption while maintaining a strong clamping force of 220 tons.

The core technological innovation is mainly reflected in three major systems:

Intelligent hydraulic energy-saving system: The intelligent hydraulic power unit composed of servo motor imported from Germany and a high-response variable pump is adopted, and the output of the oil pump is dynamically adjusted according to the actual load demand through real-time closed-loop control technology. The system is equipped with a patented dual flow-pressure feedback sensor with a sampling frequency of 1000Hz to ensure that the hydraulic output is perfectly matched to the process requirements. Compared with conventional dosing pump systems, the energy saving effect is up to 40%, and the noise is reduced by 15 decibels. The specially designed hydraulic oil circuit is optimized by CFD fluid simulation, which reduces the pressure loss by 60% and controls the oil temperature rise within 5°C, greatly extending the service life of hydraulic components. The system also has an intelligent learning function that can automatically record the energy consumption characteristics of different products and continuously optimize energy-saving strategies.

Precision injection control system: Equipped with the latest generation of high-precision injection control module in Japan, using nano-scale displacement sensor and servo valve group with 0.1ms response speed, to achieve injection pressure control accuracy of ±0.5bar and position repeatability of ±0.01mm. The feedforward feedback composite control algorithm is innovatively applied, which can predict the change of melt flow characteristics in advance and compensate for it in real time, effectively solving the lag problem of traditional PID control. For difficult forming processes, the system provides three-dimensional control curves of multi-speed - multi-stage pressure and multi-stage position, and supports up to 20 stage process parameters to be set independently. The actual measurement shows that the control system reduces the fluctuation range of product weight to ±0.3%, which is far better than the industry ± standard requirement of 1.5%.

Efficient temperature control system: adopts a modular design of dual-circulation temperature control architecture to separate the barrel heating from the mold temperature control management. The barrel section adopts a new ceramic heating ring with nano insulation layer, and the thermal efficiency is increased to 98%; The mold section adopts an oil temperature machine controlled by independent PID, and the temperature fluctuates ± 0.3°C. The innovative heat pipe rapid heat transfer technology increases the heat exchange efficiency by 25%, and with the intelligent preheating algorithm, the traditional 1-hour preheating time is shortened to 36 minutes. The system has 32 built-in temperature monitoring points, which can display the temperature field distribution in each region in real time and automatically balance the temperature difference through AI algorithms. The specially designed energy-saving mode automatically lowers the temperature of non-critical areas during standby, further reducing energy waste.

Comparison of equipment performance parameters:

Intelligent production: a new experience of digitally empowered injection molding

The intelligent control system of this horizontal injection molding machine takes the user experience to a whole new level. The 15-inch industrial-grade touch screen integrates a complete MES system interface to realize the digital management of the whole process from order placement to quality traceability.

Smart Operation highlights include:

Adaptive Process Optimization System: Using intelligent algorithms based on machine learning, the system can automatically store and optimize more than 200 sets of process parameter combinations. By monitoring key metrics such as injection pressure, temperature profile, and product size in real time, the mapping relationship between raw material characteristics and optimal process parameters is automatically established. When a new batch of raw materials is detected, the system will automatically recommend a fine-tuning plan for parameters compared with historical data to achieve intelligent production of "material change without machine adjustment". This feature is especially suitable for multi-mix and low-batch production scenarios, which can reduce mold trial waste by up to 60%.

Remote diagnosis and maintenance platform: Built-in 5G IIoT module, which supports real-time upload of equipment operation data to the cloud. Engineers can view equipment status, alarm records, and key parameter trends at any time through the dedicated app. The system has intelligent analysis of fault codes, which can automatically match solutions in the knowledge base, and supports remote video diagnosis for complex problems. Equipment health reports are automatically generated from historical fault data, with predictive maintenance accuracy of over 85%, significantly reducing unplanned downtime.

Mold life cycle management system: Automatically identify the mold identity through RFID technology, and record the process parameters, production quantity and maintenance records of each use in detail. The system has built-in intelligent algorithms that automatically calculate the remaining service life and warn maintenance needs in advance according to the mold material, structure and usage conditions. Support electronic management and intelligent scheduling of mold maintenance records to ensure that key molds are always in the best condition and extend the service life of molds by more than 30%.

Energy monitoring and optimization system: Equipped with 32 high-precision energy consumption monitoring points, it can display the energy consumption proportion and power curve of each subsystem (hydraulic, electric, thermal, drive, etc.) in real time. The system automatically identifies abnormal energy consumption fluctuations, intelligently analyzes energy-saving potential points and gives optimization suggestions. Support energy consumption data by shift, product and process, generate energy efficiency KPI reports, help enterprises establish a sound energy management system, and achieve continuous energy conservation improvement.