Hybrid Servo-Driven IMMs

8/11/2019 Hybrid Servo-Driven IMMs

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The Benefits ofHybrid Servo-Driven

Injection Molding Machines


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Pumps & CylindersServo Motor & Gear & Belt

Energy Efficiency and Repeatability is

dependent on what method is usedto deliver power to the machine axis

The Benefits of

Hybrid Servo-DrivenInjection Molding Machines


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Energy Timeline

1988 20081968 1993 1998 20031973 1978 1983 2011

H y b r i d - r e l a t e d i n n o v a t i o n s


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Energy In = Energy OutHydraulic Press ( 400-700 Ton Range )

=

Feed

throat5%

MoldCooling20-30%

ControlPower

2%

BarrelHeating

10%

Energy Balance

ElectricMotor88%

Energy In

E n e r g y

I n

1 0 0 %

Energy Out E n e r g y

O u

t

1 0 0 %

Convection &Radiation toAtmosphere

40-50%

Hot

Moldings2-5%

OilCooling20-25%


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0

5

10

15

20

25

MM 580 550 MS580

Power Consumption

KWH

3.0

20.7

Cycle time: 48 sec. / Injection time: 8 sec.Cooling time: 30 sec. / Clamp stroke: 38

( VV pumps ) ( All Electric )

3.2

( Hybrid Servo )

Comparison in dry cycle operation (heater power excluded ! during full-automatic operation)


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Energy In E n e r g y

I n

1 0 0 %

ControlPower

4%

BarrelHeating36%

ServoMotor60%

HotMoldings

5-10%Feed throat

5-7% MoldCooling50-60%

Convection &Radiation 25-30%Energy Out E n

e r g y

O u

t

1 0 0 %

=

Energy Balance

Energy In = Energy Out

Servo (400-700 Ton Range)

OilCooling

5-10


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2-Platen TechnologyTypical 2-platen deflectionwith tonnage cylinders

at corners

2-platendirect-acting ram

Tonnage checked in

Zero energy to maintain tonnage

Hybrid Servo System


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ConventionalPQ Pump System

Hybrid Servo Systems


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Variable Volume Hydraulics

! Variable volume pump! High case flow! Relies on pressure drop

across valves to operate! High min. pressure

! Fixed volume pump! For cooling the oil! Sensitive to cavitation

! Closed loop oiltemperature control! For continuous,

stable operation


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Drive

PositionFeedback

Hybrid Servo System


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Vact

Qcmd and p cmd Q and P

n act

n cmd

Qact and p act p act

System Block Diagram

Ethernet

Powerlink

Hybrid Servo System


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Features of Motor Drive System

! Regen Power! Regen to bus! 1:1 power factor

! Modular! Modular rack design

! Service! No config during replacement! Built-in network safety! Plug connections for fast replacement! Native to ethernet power link! On-board fast logic control functions! Air-cooled motors and drive

#6

#3

#5

#2

#1

#4

EthernetPowerlink


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D r i v e C a b i n e t

Hybrid Servo System


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Power Cabinet

I/O & SafetyRelays Drives

PowerConnections


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Servo Motor Drives

Dynamic Breaking

Chokes

Hybrid Servo System


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Induction Motor Servo Motor

-phase Asynchronous Motor 3-Phase Synchronous Motorwith permanent magnets

Hybrid Servo System


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Benefits :- Closed loop system- Reduced energy consumption

- RPM of Induction motor is fixed 1750- Servo motor RPM can vary from 0 to 3000 RPM in both directions

-High efficiency at low loads-Accuracy

- Very high resolution (rotation can be controlled by fraction of angle)- Fast response- High repeatability

Servo Motor vs Induction Motor


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Electro hydraulic pump Internal gear pump


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Benefits:

-

Sensitivity to contamination is reduced drastically- Fewer number of parts only two moving parts- No internal wear parts (ex. swash plate )which improvespump reliability

-

Very easy to maintain; low cost of spares- Pump can rotate in either direction to provide quickpressure control response

- Pump can be stopped intermittently during the cycle

-

Non-pulsating discharge - constant and even dischargeregardless of pressure conditions- Low operating noise

V V Piston Pump vs Internal Gear Pump


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Minimizes the influence of machine on oil temperature ." The servo system only delivers hydraulic oil as it is needed to prevent

unnecessary heat generation and to reduce oil cooling requirements" Life of the hydraulic components is extended" Enhanced oil life"

Reduction in cooling water consumptionImproved Consistency & Repeatability .

" Servo system closed loop control considerably improves cycleconsistency and repeatability vs. conventional hydraulic injection

molding machines

System benefits :



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Operating EfficiencyMODEL Fixed Pump 3000 VV Pump 3200 VV Pump 4400 Hybrid Electric 3000 Servo 4400

TYPE II Platen II Platen II Platen II Platen II Platen

US TONNAGE 3300 3520 4400 3300 4400

CONNECTED POWER (KW) 338 365 1087 370

SCREW DIAMETER (MM) 155 150 140 155 140

MATERIAL TPO TPO TPO TPO TPO

CYCLE 45.3 105 50.3 39.8 50.3

SHOT WEIGHT (OZ.) 144 246 160 144 160

THRU PUT (KG/HR.) 325 240 325 370 325

AVERAGE KWH 246 139.9 164.2 126.5 100.4

EFFICIENCY (KWH/KG) 0.757 0.583 0.505 0.342 0.309

Efficiency

!"!!! !"$!! !"%!! !"&!! !"'!! !"(!! !")!! !"*!! !"+!!

,, --- &!!!

,. &%!!

,/ ''!!

01 &!!!

,2 ''!!M i l a c r o n S e r v o 4 4 0 0

B r a n d A H y b r i d E l e c t r i c 3 0 0 0

M i l a c r o n V V P u m p 4 4 0 0

B r a n d A V V P u m p 3 2 0 0

B r a n d B F i x e d P u m p 3 0 0 0

Kwh/kg


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The Material Matters

Each material requires a different amount ofenergy to bring it to the appropriate temperaturefor molding.

This specific amount of energy is sometimes calledSpecific Enthalpy

Units are kw-hr/kg or hp-hr/lb


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Hybrid Servo Efficiency

1100 1500 2000 2600 3300 4400

Model MS 1125-6610 MS1500-10100 MS2000-16000 MS2600-23000 MS3300-34000 MS4400-48000Injection Unit 6610

( 10100) 10000 10100(125MM) 16000 16000(140 MM) 23000 23000(160MM) 34000 34000(180MM) 48000 48000

% screw recovery 33.9% 38.2% 44.5% 46.8% 43.4% 45.7%Shot size hdpe 39.2 64.96 101.36 151.2 215.32 295.12lb./hr. hdpe 336.0 448.4 507.4 659.4 794.2 888.4Efficiency kwh/lb. 0.134 0.145 0.158 0.140 0.125 0.133

Increase in efficiency assume .3 Kwh/lb. 0.166 0.155 0.142 0.160 0.175 0.167Hrs. year 5000.000 5000.000 5000.000 5000.000 5000.000 5000.000Energy cost $0.068 $0.068 $0.068 $0.068 $0.068 $0.068Savings (cost to run Machine) $19,001 $23,602 $24,492 $36,024 $47,444 $50,635Savings (cost to remove wasted energy) $3,800 $4,720 $4,898 $7,205 $9,489 $10,127

344567 26894:; 8;" ?6579@; A%%B+!% A%+B&%& A%CB&C! A'&B%%C A()BC&%

D?0;04E F6750 * =06? 26894:; A$(&B+C! A$C$B$($ A$C+B&(& A%C$B*() A&+'B%&+ A'$!B!+


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Annual SavingsHybrid Servo 4400 vs. Hydraulic 3000

Annual Savings Ms 4400 vs. MM III 3000

Hours Production per year 6000 50 weeks6 days week 20 hrsday

Energy Cost $/kwh 0.07Part wt oz 160Cycle 50.3kg/hr 325Efficiency difference MS vsMM III kwh/kg 0.448

Annual savings machine $61,179.93Energy removal Cost $12,235.99

Annual energy savings $73,415.91

Reduced stabilization timeReduced by 3cycles $6,210.00 $ 200/hr. burden rate

$ .7 lb. material cost

Total annual savings $79,625.91

Present Value 5 years savings $344,739

Hybrid Servo System


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Energy Monitor

" Overall operating efficiency" Power used each process


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Energy Monitor

Energy impact example:Automotive fan shroud processed on Servo IMM at .1 kwh / lb.

compared to a hydraulic result in the range of .3 kwh / lb.


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For more information on Milacron hybrid

servo injection molding machines or toreceive a cost quotation, contact us :

[email protected]

Hybrid Servo-Driven IMMs

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