Shanghai Daoqin Plastics Co., Ltd.

一． plastics industry in inner development 形势
现 in already 公认一 国家 or plastics year consumption amount and plastics industrial in 国民经济 in 占 位 is industrial development and important 标志之一. China plastics 资源丰富, 21世纪初 main/primary combined formed resin year output/production volume 达1.4 10,000 tons, world 第4位. and China combined formed resin output/production volume also in 以5%~10% speed degree growth. China also is plastics large 国, statistics, its year consumption amount world 第二, 仅次于 USA, China 人均消费仅 is 19kg, in world 排名第32位, is industrial 发达国家 11%~20%, can China plastics industrial also need large development, plastics machine outlook/prospects vast. according to plastics products market analysis, currently China plastics machine industry value year 约100 100 million yuan, inner market demand 约200 100 million yuan, also has very large 空间, injection molding machine demand 也逐步由南 direction expand dispersion, meanwhile belt/tape will belt/tape plastics industrial industry development.
 
二． 变 frequency renovation in injection molding industry development trend
近几 year plastics industry development 越 越迅 speed, its in injection molding industry positive 迎 一 飞 speed development machine 遇. meanwhile industry inner competition day 渐激烈, 各厂家 remove heavy product quality and Brand outer, 也越 越 heavy production cost control. from injection molding machine process process 知道, in injection molding product cost in, electrical can consumption cost very large ratio/proportion, can has decrease/reduce electrical can loss consumption, to injection molding machine and use 户 关注. 随 变 frequency speed technology 推广, frequency speed in control and energy saving field/area already day to application, especially in type negative combined using/adopting frequency control energy saving significantly. 本文以四方 injection molding machine specialized type frequency device is 例, introduction injection molding machine frequency renovation can property and renovation in 常出现 issues and versus 应处理 methods.
 
三． injection molding machine frequency renovation can property
3.1 injection molding machine basic and molding process process
     injection molding machine usually using/adopting liquid pressure 传动, its structure injection plant/unit, clamping plant/unit, liquid pressure plant/unit and electrical control plant/unit, rear function is ensure injection molding machine 预定工序 requirements （ pressure, speed degree, temperature degree, time, 位置） and as 程序准确 has 效 工 as.
     in injection molding machine in liquid pressure plant/unit main/primary 由油泵, liquid pressure control 阀, pressure electrical magnetic ratio/proportion 阀, amount electrical magnetic ratio/proportion 阀, various different as 油缸, electrical machine and its it liquid pressure parts and pipeline formed, liquid pressure system in force electrical machine belt/tape 动油泵 provide. its in, 油泵绝 large separation is amount 油泵, electrical machine usually provide 额定功 rate and speed, will electrical machine machine can is pressure can, rear toward liquid pressure system liquid pressure parts tool has pressure and amount liquid pressure 油, meet/satisfy liquid pressure machine 构驱动 negative 载 需 can amount requirements
injection molding machine molding process is according to cycle property as process, clamping ---射嘴 front 进---射胶--- holding pressure --- solvent 胶, cooling --- mold opening ---取出 products --- will by injection molding parts 放入 mold in — clamping and other processing 工序达 to certain parts product molding.
     process speed degree and pressure different process different, 即 需 liquid pressure amount different, injection molding machine 整 动 as process for electrical machine is negative process. in amount injection molding machine liquid pressure system in, electrical machine 始终以恒定转 speed provide 恒定流 amount liquid pressure 油, 各 动 as in versus more liquid pressure through 溢流阀回流, from formed electrical can 浪费. statistics, electrical liquid 阀控模式造 formed electrical can loss consumption high 达36～68%; according to injection molding machine equipment process, electrical machine consumption electrical equipment consumption electrical ratio/proportion high 达65～80%. therefore, for electrical liquid 模式进行 energy saving renovation tool has very large force.
3.2  普通 injection molding process in main/primary loss consumption
第一 is loss consumption. product and processing different, 各工序 需 liquid pressure, amount, pressure different （见附图1）. for/regarding 油泵马达而言, injection molding machine in injection molding process negative is 处于变化状态. 而泵 流 amount is according to most large amount design, its injection molding 油泵马达以恒定 转 speed provide liquid pressure amount, injection molding machine 需 流 amount small most large amount 时, more liquid pressure will through 溢流阀回流, this separation can amount loss consumption 掉.
第二 is loss consumption. liquid pressure 油流经阀 节流口时会 has pressure drop, this is loss consumption. due to direction 阀 节流面积 comparison large, therefore large separation loss consumption in ratio/proportion upper. meanwhile due to liquid pressure long full speed ring flow and liquid pressure parts machine 械剧烈 abrasion scratch, formed temperature high, large, machine lifespan shrink short and other defect phenomenon.
第三 is design amount loss consumption. usually in design in, generally 会考虑 to use property, design most large amount is 基础, therefore use 户油泵 electrical machine design amount ratio need high very more, in “ large small 车” phenomenon, formed electrical can a large amount of 浪费.

 图一: injection molding machine 工序图 and can consumption for 照图
 
四． 变 frequency device in injection molding machine energy saving renovation in advantages
4.1  speed energy saving
according to injection molding machine process requirements, pressure 阀, low pressure 阀, pressure 阀, pressure 阀 开关信号经转换 rear add in frequency device 输入端 as is frequency device frequency rate to 定信号, frequency device through for its 进行实时采样并 through CPU处理, make frequency rate ratio/proportion 阀 模拟信号 formed 线形变化, in need pressure and amount relatively small process process in make electrical machine speed reduce, from reduce electrical machine 输出功 rate, in cooling and semi formed product process in can let electrical machine 停转, make electrical machine in negative scope/range inner can amount loss consumption to most small degree.
4.2  improve/increase rate energy saving
无功功 rate increase loss and equipment hot, more main/primary is is rate reduce electrical has rate reduce. 由公式S²=P²+Q², Q=S*SINφ, P=S*COSφ, its in: S-视 in rate. Q-无功功 rate, P- has rate, COSφ-功 rate 因数. can 知, 当COSφ越 large, has rate     P越 large. 普通定 amount injection molding machine COSφ value in 0.6-0.8 between, use frequency speed plant/unit rear, due to frequency device inner electrical 容 补偿 function, make COSφ≈1, from decrease small loss consumption, increase large electrical has rate.
4.3  soft energy saving
due to electrical machine is 直接启动 or Y/△启动, electrical and other 于(3-7)倍额定 electrical 流, this for machine electrical equipment and electrical electrical formed heavy impact, but also also increase electrical amount requirements, 启动时 generate large electrical and for equipment use lifespan is 不利. use frequency energy saving plant/unit rear, utilizing frequency device soft function will make electrical from 零开始, most large value by made in frequency device accelerated in electrical 流限幅 water inner, generally ultra- 1.7倍额定 electrical 流, decrease light for electrical impact and for electrical amount requirements, long equipment and mold use lifespan.
 
五． 变 frequency device energy saving renovation principle
    type negative 载 工 as features can 知, 泵 流 amount and speed formed positive ratio, 泵 扬程 and speed formed positive ratio, electrical machine rate and speed formed positive ratio,如 lower 述公式 示:
Q2/Q1=N2/N1; H2/H1=(N2/N1)2; P2/P1=(N2/N1)3
its in Q is amount, N is speed, H is 扬程.

图2: control and frequency control energy saving comparison
    图2 to 出 阀门 control and frequency control types lower energy saving comparison. has injection molding machine system using/adopting control, amount 由QA decrease/reduce to QB时, due to tube/pipe retardant features, as 点由A点转移B点, consumption rate and 0EBF formed positive ratio. using/adopting frequency control, this 时因阀门 full 开, its tube/pipe retardant features 不变, as 点由A点转移 to C点, consumption rate and 0ECH formed positive ratio. therefore, from 图2 in can 看出, using/adopting frequency speed ratio control more add energy saving, 且随 转 speed reduce, electrical machine 输出功 rate formed 立方关系 decrease/reduce. this 样, according to injection molding process adjustment electrical machine speed, can to energy saving 目.
    currently versus electrical machine large more using/adopting frequency speed, electrical machine 同步转 speed 公式:
n=60（1-S）f/p
its in, n is electrical machine speed; s is rate; f is electrical frequency rate; p is for 数.
由 upper can 知, electrical frequency rate can electrical machine speed. therefore, using/adopting injection molding machine ratio/proportion amount and ratio/proportion pressure control 信号同步 control 油泵马达 变 frequency device, make electrical machine speed and injection molding machine as pressure, amount formed positive ratio, from make 溢流阀 回流 amount decrease to most small, liquid pressure system and injection molding machine production rate versus 匹配, can to energy saving 目. statistics, its mono machine electrical rate can 达25～65%.    
 
六． 四方变 frequency device application
6.1四方 injection molding machine specialized frequency device features
    injection molding machine specialized frequency device （E520 series ） is according to injection molding machine as features design frequency speed device. through for electrical 流, electrical pressure 信号 采集, 经CPU处理 rear for electrical machine versus 应 调 speed, from meet/satisfy injection molding machine process requirements. it tool has below/following features:
    （1） tool has combined injection molding machine specialized frequency rate to 定信号通道
general purpose frequency device frequency rate to 定信号 standards is 0～10V electrical pressure or 4～20mA electrical 流信号, injection molding machine specialized frequency device tool has 0～1A/10V信号接收通道. 四方E520 series frequency device can 直接入0～1A electrical 流信号, need another add 装信号转换 electrical 路.
    （2） 载 can force strong/high, speed degree fast
    generally injection molding product process cycle versus for relatively short, from 10几秒 to separation and other. molding product from mold opening to clamping, requirements process as speed. using/adopting frequency control 时, electrical machine negative frequency 繁变化, this requirements frequency device has very strong/high can force. 四方E520 series frequency device according to 阀控信号进行 fast speed rise drop speed, add decrease speed time can 达0.5～1s.
6.2变 frequency renovation electrical 路
    injection molding machine frequency renovation using/adopting frequency ＋工 frequency control methods. its control electrical electrical degree table/sheet, 四方变 frequency device and frequency 旁路接触 device and other formed, control electrical 路由工 frequency /变 frequency 切换开关, 启动, 复位开关, 指示灯 and other formed.
（1） 变 frequency control electrical 路
    图3 to injection molding machine frequency energy saving renovation electrical 路图. in, QF is device, KM1, KM2, KM3 is device. in renovation injection molding machine still injection molding machine has control electrical in 星-三角转换 electrical 路, this can renovation meanwhile maintain injection molding control features. using/adopting frequency 旁路目 is is in frequency device fault/failure can 直接切换 to frequency 运行, effect/influence production.

图3: injection molding machine frequency energy saving renovation electrical 路图
（2）变 frequency control control electrical 路
图4 is injection molding machine frequency control electrical frame 图. in, SB is frequency /变 frequency 转换开关, selection grade 开关; SB1 is frequency device 停止按钮, SB2 is frequency device 启动按钮; L1 is electrical 源指示灯; L2 is frequency 运行指示灯; L3变 frequency 运行指示灯; L4 is frequency device fault/failure 指示灯, its fault/failure 信号由变 frequency device TA, TC输出; KM1, KM2变 frequency 运行接触 device; KM3 is frequency 运行接触 device.

图4: injection molding machine frequency control electrical frame 图
（3）变 frequency main/primary parameters 设置
    以四方E520 series frequency device in injection molding machine in application is 例, frequency device using/adopting ratio/proportion amount ＋ ratio/proportion pressure 两路信号 control, main/primary parameters setting table/sheet 1 示.
F0.0=1,                  F0.1=1,
F0.7=1                   F3.19=2
F0.8=0.7,               F0.9=1.8,
F3.1=0.12,             F3.2=0.76
F3.3=0.12,             F3.4=0.70
F3.5=0.5,               F3.6=0.5                
table/sheet 1: 四方E520 series main/primary parameters setting
（4）E520 series injection molding machine specialized frequency device features
1． and injection molding machine 同步运行, debugging formed use rear 无需任何 adjustment; make more mold and processing parameters, 均无需 for frequency energy saving control device adjustment.
2． renovation rear injection molding machine liquid pressure hot obvious reduce, generally ratio renovation front 平均油 temperature reduce 15~20℃ above; liquid pressure use lifespan can to long; injection molding machine cooling use water amount can 节省30％ above.
3．  for system function, （1）, frequency device 自身 保护; （2）, for electrical machine 保护; 如: electrical made, 载, short or 输出接 and other （3）, for 因误操 as machine loss 伤进行保护; 如: to melt temperature degree strong/high solvent 胶引起火箭头, 炮筒, screw or solvent 胶马达 loss bad and other.
4．  injection molding machine 运行噪音 obvious reduce, 开, 锁模振动 decrease light, long equipment and mold use lifespan, improvement as ring 境; use electrical rate improve/increase, 油泵主 electrical machine slip 启动, 启动时无 large electrical impact can decrease/reduce electrical equipment amount.
5．  long 油路密封组 parts use lifespan, decrease/reduce machine repair rate, a large amount of 维护费 use.
6．  injection molding parts processing cycle long, energy saving 效果越 good;
 
七． debugging in 常出现 issues and methods
 7.1 debugging front precautions
    injection molding machine frequency energy saving electrical renovation versus comparison relatively simple. in renovation front detailed understanding injection molding machine 工况, injection molding machine process process/workflow. debugging attention/notes below/following 事项: front injection molding machine has electrical 路接线 methods, 包括主 electrical and control electrical 路; fine injection molding machine frequency is positive 常, 油泵马达 is 否经常处于 载状态; according to injection molding machine mold and injection molding process injection molding machine electrical renovation can; control 信号线路 attention/notes positive negative property need 接反; 信号线 and 主回路线 need separation 开布线 and other.
7.2 debugging Common issues and methods
    due to injection molding machine process property, in renovation in to various fault/failure, below/following is in injection molding machine frequency renovation in to issues and methods.
    （1） 变 frequency device frequency rate 无变化
due to frequency device using/adopting injection molding machine electrical 流信号进行调 speed, frequency device rear can can frequency rate is 0.0（ has frequency device is 0） phenomenon, its main/primary causes 包括: 信号极 property 接反; 信号取错; 信号接线端口 and parameters setting 不符; injection molding machine electrical fault/failure and other. this type of fault/failure 时, 应先查明 injection molding machine control type is electrical 流信号, electrical pressure also is control 信号（部 separation machine type ）, and positive negative property is and frequency device control for 应.
    （2） 油泵噪音 large
变 frequency device rear has injection molding machine 会发出异常 噪音, this 时应判断噪声源 in 何处, is electrical machine also is 油泵. is 油泵 噪音, can can causes has: injection molding machine liquid pressure less, has gas 吸入; injection molding machine device or retardant 塞; injection molding machine 油泵叶 sheet/slice abrasion loss relatively heavy. to 该情况应先检查 injection molding machine 油泵, troubleshooting fault/failure rear can 运行. another, injection molding machine low speed high pressure as 状态时, 也会出现油泵噪音异常情况, this 时应适当 improve/increase speed degree to 定.
    （3） temperature degree control dry 扰
另一 injection molding machine frequency device renovation in 常遇见 issues, is renovation rear injection molding machine dry can positive 常运行. injection molding machine add hot mono generally using/adopting hot electrical testing temperature degree, this type of testing parts easy 受谐波 dry 扰, from formed injection molding machine temperature degree and control 不准确. this can from below/following troubleshooting dry 扰: amount shrink short frequency device and injection molding machine electrical machine between 连线, force use metal soft tube/pipe sleeve/set 装, force and temperature degree testing need 靠近走线; in frequency device 近端主回路线缆 upper add electrical resistant device or magnetic ring; frequency device can 靠接; or to injection molding machine internal temperature electrical electrical electrical add retardant 容滤波 electrical 路, 如图5 示.

图5: injection molding machine temperature degree dry 扰滤波 electrical 路图
    in, A+ is hot electrical 偶端, B+接 temperature degree control sheet/plate, 处理时即 in temperature degree testing （ hot electrical 偶）线路 in for add above retardant, device parts remove dry 扰.