Delta Hybrid Energy Saving System Delivers Power Efficiency and High-Quality Production for Injection Molding Machines

Injection molding machines have played a key industrial role in recent decades. The production volume of injection molding machines represents 40% of the total plastic goods output of all plastic manufacturing machinery. The traditional injection molding machine utilizes a fixed displacement hydraulic pump with induction motors. During the plastic manufacturing process, the fixed displacement hydraulic pump system needs to work under full load to maintain a constant oil flow. This causes several problems including high energy consumption, high oil temperature, high oil usage, and a shortened lifetime for the oil and hydraulic components. In addition, traditional injection molding machines do not meet the environment-friendly trend of today's industry.

Recently, a leading global machinery provider adopted the Hybrid Energy Saving (HES) System for its injection molding machinery and it achieved outstanding energy-saving performance. The remarkable improvements included:

• Up to 60% energy saving
• 50 ~ 60% oil usage savings, which enabled a 50% less oil tank volume for space savings
• Lower oil temperature by 5 ~ 10℃ and cost savings on oil cooler
• High duplication accuracy with less than 0.09% weight difference to ensure high precision results and productivity
• Longer lifetime for hydraulic components saving maintenance costs and time

Precise flow and pressure control is essential during the entire injection molding process to ensure high quality output. The Delta HES system provides innovative technologies that successfully deliver better energy efficiency and higher production quality for injection molding machines. Its outstanding features include the following.

1. The HES system employs Delta's AC Motor Drives, VFD-VJ series, and the highly responsive AC Servo Motors, ECMA series. It is able to receive commands from the injection molding machine controller and precisely control the pressure and oil flow in each manufacturing process to save on electricity consumption and improve production quality.

2. With the HES system, the servo motor only needs to operate at low speed under the pressure holding and cooling process. This allows a substantial energy savings and a lower oil temperature of 5 ~ 10℃. The system then requires lower cooler specifications or even no cooler.

3. The traditional fixed displacement hydraulic pump system requires an additional control valve to release extra oil. After adopting the HES system, the control valve can be waived from the system. It brings the benefits of 50 ~ 60% oil usage savings, enabling a smaller oil tank and smaller space requirement.

4. The HES system also comprises a high environment-resistance resolver. The resolver is resistant to earthquakes, oil and dust to ensure the stability and reliability of the injection molding machine in a harsh environment

5. The HES system supports analog command 0~10V and 3-point linear correction. It can be easily applied to old injection molding machines without changing the original controller. It also provides convergent flow multiple pumps solutions.