1. Production Workshop
The layout of production workshop is mainly considered from two
aspects: satisfying the production demand, optimizing the layout
according to the production process, and meeting the flexible
energy requirements under specific production conditions.
1. Electric power supply, while meeting the needs of stable
production of electricity, has appropriate margin, so as not to
cause excessive surplus and non-functional consumption.
2. Construct efficient cooling water circulation facilities and
equip the cooling water system with effective insulation and
insulation system.
3. Optimize the overall production layout of the workshop. Many
production processes have successive coordination. Reasonable
coordination can reduce turnaround time and energy consumption, and
improve production efficiency.
4. Controlling plant equipment, such as lighting, as far as
possible, with the smallest and most effective units.
5. Maintain the workshop equipment regularly to avoid the damage of
public facilities, affecting the normal operation of production,
and resulting in increased energy consumption.
2. Injection Molding Machine
Injection moulding machine is a major energy consumer in injection
moulding workshop, which mainly consumes two parts: motor and
heating.
1. Choose the suitable injection moulding machine according to the
product characteristics. The injection moulding process of "big
horse trolley" often means a lot of energy waste.
2. Selection of all-electric injection moulding machine and hybrid
power injection moulding machine, has excellent energy-saving
effect, can save 20-80%.
3. By using new heating technologies, such as electromagnetic
induction heating and infrared heating, 20-70% of heating energy
can be saved.
4. Effective insulation measures are adopted for heating and
cooling systems to reduce heat and cold losses.
5. Maintain good lubrication of transmission parts and reduce the
increase of energy consumption caused by increased friction or
unstable operation of equipment.
6. Choose low-pressure hydraulic oil to reduce the waste of working
energy in hydraulic system.
7. Parallel action, multi-cavity injection molding, multi-component
injection molding and other processing technologies can
significantly save energy.
8. Traditional mechanical hydraulic injection moulding machine also
has a variety of energy-saving driving systems, replacing the
traditional quantitative pump mechanical hydraulic injection
moulding machine energy-saving effect is remarkable.
9. Maintain heating and cooling pipes regularly to ensure that
there are no impurities and scale blockage in the pipes, so as to
achieve the designed heating and cooling efficiency.
10. Ensure that the injection moulding machine is in good working
condition. Unstable processing may lead to defective products and
increase energy consumption.
11. Ensure that the equipment used is suitable for the products
processed, such as PVC processing, special screw is often used.
3. Injection Mold
Mold structure and die condition often have a significant impact on
injection molding cycle and processing energy consumption.
1. Reasonable die design, including runner design, gate type,
number of cavity, heating and cooling water, can help to reduce
energy consumption.
2. Using hot runner die can not only save material and reduce
energy consumption of material recovery, but also have significant
energy-saving effect in the forming process itself.
3. Shape-copying quick-cooling and fast-heating dies can
significantly save processing energy consumption and achieve better
surface quality.
4. Ensuring the balanced filling of each cavity can shorten the
forming cycle, ensure the uniformity of product quality, and have
excellent energy-saving effect.
5. Using CAE-aided design technology for die design, die flow
analysis and simulation can reduce the energy consumption of die
debugging and multiple die repair.
6. On the premise of guaranteeing the quality of products, the use
of lower clamping force can help prolong the life of the die,
facilitate the rapid filling of the die, and help save energy.
7. Do a good job of mould maintenance to ensure the effective
condition of heating and cooling water channel.
4. Peripheral Equipment
1. Choose the appropriate auxiliary equipment to meet the
requirements of the work, but not too rich.
2. Maintenance of equipment to ensure that the equipment is in
normal working condition. Abnormal auxiliary equipment will lead to
unstable production and even poor quality of parts, resulting in
increased energy consumption.
3. Optimize the coordination work and operation sequence between
the main engine and peripheral equipment.
4. Optimize the location of peripheral equipment and production
equipment, and make peripheral equipment as close as possible to
the host without affecting the operation conditions.
5. Many auxiliary equipment manufacturers provide on-demand energy
supply system, which can achieve significant energy saving.
6. Use rapid die changing equipment to reduce the waiting time
needed for switching products in production.
5. Materials
The energy consumption of different materials processing is
different. At the same time, the improper management of materials
or the improper management of recycled materials will lead to the
increase of production energy consumption.
1. On the premise of meeting the performance of products, materials
with lower processing energy consumption should be preferentially
selected.
2. Under the condition of satisfying the optimization of service
performance and cost, high flowability materials should be selected
first.
3. Note that materials from different suppliers may have different
process conditions.
4. Material drying treatment, it is best to use with drying, to
avoid waste of energy after drying material moisture.
5. Do a good job of material preservation, prevent materials from
mixing into impurities or foreign bodies, and eventually lead to
poor products.
6. Certain recycled materials are allowed to be added to some
products, but attention should be paid to the preservation and
cleanliness of recycled materials so as to avoid bad parts due to
unclean materials.
