Choosing a Servo Injection Molding Machine
Servo injection molding machines represent a specialized category designed to leverage the thermoplastic properties of plastics, effectively heating and melting materials for quick molding into various products. However, traditional injection molding machines are often criticized for their high energy consumption, making servo models more appealing. Let’s delve into how to make the right selection for a servo injection molding machine.
What Does “Servo” Mean?
In contemporary industrial applications, “servo” refers to a follow-me system that fulfills specific command requirements. Within injection molding, the servo system interprets signals from a computer, adjusting the speed and torque of the servo motor for precise control of speed and pressure. During operation, feedback is gathered through a rotating variable pressure encoder and pressure sensor, known as closed-loop control, ensuring stable performance and quality output.
Benefits of Servo Injection Molding Machines
One of the primary challenges facing traditional injection molding machines is their significant energy consumption. Transitioning to servo energy-saving machines offers numerous advantages:
Energy Efficiency:
Servo machines can significantly lower energy usage. For instance, over 80% of a traditional injection molding machine’s power consumption can stem from the motor alone, resulting in substantial energy waste. High electricity costs exacerbate this issue.
Adaptive Power Control:
Servo machines can adjust power based on real-time operational needs, leading to reduced energy expenses across the production line. Additionally, these machines can halt completely when idle, extending their lifespan.
Improved Operational Efficiency:
Traditional machines often require continuous operation, which can lead to low daily efficiency. Servo energy-saving controls optimize voltage and current, stabilizing high-speed operations and enhancing productivity.
Ease of Maintenance:
Unlike traditional models that may necessitate complete replacement upon damage, servo machines typically only require replacing the faulty driver, streamlining repairs and minimizing downtime.
Addressing Performance Limitations
Some users may find certain injection molding machines underwhelming. The prevalent design involves a servo motor driving an oil pump to perform mechanical actions. If there’s a mismatch between the motor, oil pump, and other main power components, users may experience pressure drops at higher speeds. In extreme cases, overheating can trigger motor overload protection, resulting in machine shutdowns and disrupting production. These issues are often linked to subpar mechanical design, product positioning, and cost factors.
Tips for Selecting a Servo Injection Molding Machine
1. Choose the Right Servo System
Select a servo system that offers higher power and torque capabilities, as this directly impacts the machine’s ability to handle high-pressure actions. It’s advisable to physically test the machine’s performance limits, ensuring it can maintain pressure under sustained loading conditions (recommended duration of at least 40 seconds).
2. Motor and Oil Pump Compatibility
Due to the rapid acceleration and deceleration of the servo motor, maintaining axial alignment and buffering is crucial for prolonging the lifespan of motor bearings and oil pumps.
3. Displacement and Speed Considerations
Focus on key metrics that influence operational efficiency, such as oil pump displacement and speed. Generally, a larger oil pump displacement correlates with higher machine efficiency. When selecting pump displacement, balance the required flow rate with speed, ensuring the design remains within safe operational limits. While lower speed can enhance responsiveness, it may also inflate costs, so consider price positioning when finalizing your choice.
By keeping these factors in mind, manufacturers can make informed decisions when selecting servo injection molding machines, ultimately enhancing efficiency and productivity in their operations.