1, Production workshop
The layout of production workshop is mainly considered from two aspects: under the condition of meeting the production demand, optimize the layout according to the production process, and meet the requirements of flexible energy use under the specific production conditions.
1. The power supply, while meeting the power demand of stable production, should have appropriate margin, so as not to cause excessive non functional consumption due to excessive surplus.
2. Build efficient cooling water circulation facilities and equip cooling water system with effective insulation and heat preservation system.
3. Optimize the overall production layout of the workshop. Many production processes have sequential coordination. Reasonable coordination can reduce the time and energy consumption required for turnover and improve production efficiency.
4. The lighting and other plant equipment shall be controlled separately with the most effective small unit as far as possible.
5. The workshop equipment shall be maintained regularly to avoid the damage of public facilities, which may affect the normal operation of production and increase the energy consumption.
2,Injection molding machine
Injection molding machine is a big energy consumer in injection workshop, which mainly includes motor and heating.
1. Select appropriate injection molding machine according to product characteristics. "Big horse pull small car" type injection molding often means a lot of energy waste.
2. Select the full electric injection molding machine and hybrid injection molding machine, with excellent energy saving effect, which can save 20-80% energy.
3. New heating technologies, such as electromagnetic induction heating and infrared heating, can achieve 20-70% heating energy saving.
4. Adopt effective insulation measures for heating and cooling system to reduce heat and cold losses.
5. Keep the transmission parts of the equipment well lubricated to reduce the increase of 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, multi-component injection 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, replacing the traditional quantitative pump mechanical hydraulic injection molding machine has significant energy-saving effect.
9. Regularly maintain the heating and cooling pipes to ensure that there is no impurity or scale blocking in 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 defective products and increase energy consumption.
11. Ensure that the equipment used is suitable for the products to be processed. For example, special screw is often required for PVC processing.
3, Injection mold
Mold structure and mold condition often have a significant impact on injection molding cycle and processing energy consumption.
1. Reasonable mold design, including runner design, gate form, cavity number, heating and cooling channel, etc., can help to reduce energy consumption.
2. The use of hot runner mold can not only save materials and reduce the energy consumption of material recovery, but also has significant energy-saving effect in the molding process itself.
3. The profiling quick cooling and quick heating die can significantly save processing energy consumption and achieve better surface quality.
4. Ensure the balanced filling of each cavity, help to shorten the molding cycle, ensure the product quality uniformity, and have excellent energy-saving effect.
5. Using CAE aided design technology for mold design, mold flow analysis and simulation can reduce the energy consumption of mold debugging and multiple mold repair.
6. On the premise of ensuring the product quality, the use of lower mold locking force is conducive to extending the life of the mold, rapid filling of the mold, and energy saving.
7. Do a good job in mold maintenance to ensure effective heating and cooling water channel conditions.
4, Peripheral equipment
1. Select the auxiliary equipment suitable for the capacity, which not only meets the work requirements, but also will not be too rich.
2. Do a good job in equipment maintenance 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 cooperation work and operation sequence between the host and peripheral equipment.
4. Optimize the mutual position of peripheral equipment and production equipment, and keep the peripheral equipment as close to the host as possible without affecting the operation.
5. Many auxiliary equipment manufacturers provide on-demand energy supply system, which can achieve significant energy saving.
6. Use the rapid mold change equipment to reduce the waiting time for product switching in production.
5. Materials
The energy consumption of different materials processing is different, at the same time, the poor management of materials or the improper management of recycled materials will cause the increase of production energy consumption.
1. On the premise of meeting product performance, materials with lower processing energy consumption shall be selected preferentially.
2. Under the condition of satisfying the optimization of service performance and cost, the materials with high fluidity are preferred.
3. Note that different suppliers may have different process conditions.
4. The material should be dried and used at the same time to avoid energy waste after drying.
5. Keep the materials well to prevent impurities or foreign matters from mixing into the materials, which will eventually lead to poor products.
6. Some products are allowed to be added with certain recycled materials, but attention shall be paid to the preservation and cleanliness of recycled materials to avoid poor parts due to unclean materials.
6, Processing technology
1. Use the shortest molding cycle on the premise of satisfying the product performance.
2. If there is no special factor, use the processing technology recommended by the supplier as much as possible.
3. Save all stable equipment and process parameters for specific products and molds, and shorten the adjustment time for the next replacement of production.
4. Optimize the process, adopt lower clamping force, shorter cooling time and holding time
