Release time：2021-12-13
1、 Production workshop
The layout of the production workshop focuses on two aspects: meeting the production requirements, optimizing the layout according to the production process, and meeting the requirements of flexible energy use under specific production conditions.
1. While meeting the power requirements of stable production, the power supply has appropriate margin to avoid excessive reactive power consumption caused by excessive margin.
2. Establish efficient cooling water circulation facilities and equip the cooling water system with an effective insulation system.
3. Optimize the overall production layout of the workshop. Many production processes have sequential collaboration. Reasonable collaboration can reduce the time and energy consumption required for turnover and improve production efficiency.
4. Try to use effective small units to control lighting and other plant equipment separately.
5. Carry out regular maintenance of workshop equipment to avoid damaging public facilities, affecting the normal operation of production and further increasing energy consumption.
2、 Injection molding machine
It is the main energy consumption of the injection molding locomotive room, which is mainly composed of motor and heating.
1. Select the appropriate injection molding machine according to the product characteristics. "Big horse pulling small car" injection molding often means a lot of energy waste.
2. All electric injection molding machine and hybrid injection molding machine are selected, which can save energy by 20-80%.
3. New heating technologies such as electromagnetic induction heating and infrared heating can achieve 20-70% heating energy saving.
4. Heating and cooling system, take effective insulation measures to reduce heat and cold losses.
5. Keep the transmission parts of the equipment well lubricated and reduce the increase in energy consumption caused by increased friction or unstable operation of the equipment.
6. Select low compression hydraulic oil to reduce the waste of working energy of hydraulic system.
7. Using parallel action, multi cavity injection molding, multi-component injection molding and other processing technologies can significantly save energy.
8. The traditional mechanical hydraulic injection molding machine also has a variety of energy-saving drive systems, which can replace the traditional quantitative pump mechanical hydraulic injection molding machine with remarkable energy-saving effect.
9. Regularly maintain the heating and cooling pipes to ensure that there are no impurities, scale blockage and other phenomena inside the pipes, so as to achieve the designed heating and cooling efficiency.
10. Ensure that the injection molding machine is in good working condition. Unstable processing may lead to product defects and increase energy consumption.
11. Ensure that the equipment used is suitable for processing products, such as PVC processing, which usually requires the use of special screws.
3、 Injection mold
Mold structure and mold conditions often have a significant impact on injection molding cycle and processing energy consumption.
1. Reasonable mold design, including runner design, gate form, number of cavities, heating and cooling water channels, will help to reduce energy consumption.
2. Using hot runner mold can not only save materials and reduce the energy consumption of material recovery, but also have a significant energy-saving effect in the molding process itself.
3. Profiling rapid cooling and heating mold can significantly save processing energy consumption and obtain better surface quality.
4. Ensuring the balanced filling of each cavity is helpful to shorten the molding cycle, ensure the uniformity of product quality, and have excellent energy-saving effect.
5. Using CAE aided design technology and mold flow analysis and Simulation in mold design can reduce the energy consumption of mold debugging and multiple mold repair.
6. On the premise of ensuring the product quality, the use of low mold locking force for molding is helpful to prolong the service life of the mold, help the mold fill quickly, and help save energy.
7. Do a good job in mold maintenance to ensure effective heating and cooling water channel conditions.
4、 Surrounding equipment
1. Choose the auxiliary equipment suitable for the ability, which not only meets the job requirements, but also will not be too rich.
2. Do a good job of equipment maintenance to ensure that the equipment is in normal working condition. Abnormal auxiliary equipment will cause unstable production and even poor quality of parts, resulting in increased energy consumption.
3. Optimize the collaboration and operation sequence between the host and surrounding devices.
4. Optimize the mutual position of surrounding equipment and production equipment, and make the surrounding equipment as close to the host as possible without affecting the operating conditions.
5. Many auxiliary equipment manufacturers provide on-demand energy supply systems that can achieve significant energy savings.
6. The use of rapid die change equipment reduces the waiting time required to switch products in production.
5、 Materials
The energy consumption of different materials processing is different. At the same time, poor management of materials or improper management of recycled materials will increase the energy consumption of production.
1. On the premise of meeting product performance, materials with low processing energy consumption are preferred.
2. Under the condition of meeting the use performance and cost optimization, high liquidity materials are preferred.
3. Please note that materials from different suppliers may have different process conditions.
4. It is better to dry the materials together with drying to avoid wasting energy due to the moisture regain of the dried materials.
5. Take good care of the materials to prevent them from mixing with impurities or foreign matters, which will eventually lead to poor products.
6. Some recycled materials are allowed to be added to some products, but attention should be paid to the preservation and cleaning of recycled materials to avoid defects due to unclean materials.
6、 Processing technology
1. On the premise of meeting the product performance, use the shortest molding cycle.
2. If there are no special factors, try to use the processing technology recommended by the supplier for processing.
3. For specific products and molds, save all stable equipment and process parameters to shorten the adjustment time of the next production change.
4. Optimize the process, adopt lower clamping force, shorter cooling time and holding time.
7、 Adopt new technology
1. Adopt auxiliary molding technology, such as gas assisted, liquid assisted, steam assisted, micro foaming injection molding technology, etc.
2. Adopt unitized forming scheme to reduce intermediate links.
3. New technologies such as in mold welding, in mold spraying, in mold assembly and in mold decoration are adopted.
4. The new low-pressure forming technology can shorten the forming cycle and reduce the melt temperature at the same time.
5. Adopt energy regeneration system.
8、 Production management
1. To produce high-quality products at one time and reduce the defect rate is a great energy saving.
2. The maintenance of the whole production system is closely related to energy consumption. This involves not only the host, but also peripheral equipment and factory equipment. For example, if the mold changing crane in the workshop breaks down and requires manual mold changing, the waiting time of the equipment will inevitably be extended and the energy consumption of the equipment will be increased.
3. Equipped with workshop energy consumption monitoring system, it is convenient for enterprises to implement energy analysis and improvement purposefully.
4. When the equipment is shut down for maintenance, it is not only necessary to check the maintenance contents and items of the equipment itself, but also pay attention to the connection between the equipment and other systems, whether the working performance is reliable, etc.
5. Regularly compare with industry benchmarks to see if there is room for further improvement.
