I-Servo Hydraulic vs i-Hydraulic Injection Molding eqhelekileyo: Uthelekiso lweendleko zeminyaka emi-5

Kutheni iMashini engabizi kakhulu ingabiza ngaphezulu

Umphathi wefektri yokubumba eDongguan wayesandula ukutshintsha i-hydraulic press endala enobunzima obuziitoni ezingama-250 nge-hydraulic press entsha efana nayo. I-press yokutshintsha yayixabisa ngaphantsi kwesiqingatha somatshini we-servo-hydraulic ofanayo. Emva kweenyanga ezilishumi elinesibhozo, ityala lombane lefektri kumgangatho wokubumba laliphezulu nge-6% kunonyaka ongaphambili - i-press eqhelekileyo yayisebenzisa amandla amaninzi kakhulu kuneyokuqala eyayiyitshintshile. Ekupheleni konyaka wesithathu, iindleko zombane eziqokelelweyo ze-press eqhelekileyo zazidlule ixabiso leprimiyamu yomatshini we-servo ofanayo, ngaphambi kokuba kuqwalaselwe ingxolo, imfuno yokupholisa, kunye nexesha lokutshintsha ioyile. Ekugqibeleni ifektri yafaka inkqubo ye-servo kwi-press ekhoyo endaweni yokuyitshintsha - kwaye yabona ukusetyenziswa kwamandla kwehla ngesiqingatha kwinyanga yokuqala epheleleyo.

Ukukhetha phakathi kwe-servo-hydraulic kunye ne-hydraulic injection molding eqhelekileyo ayisosigqibo silula "esitsha singcono". Sisibalo seminyaka emi-5 seendleko zobunini esixhomekeke kwi-tonnage yomatshini, iprofayili yomjikelo, iiyure zokusebenza, kunye neendleko zombane zasekuhlaleni. Eli nqaku lihamba ngolu balo ngokweenkcukacha - ukuba i-energy gap ijongeka njani, i-maintenance gap ijongeka njani, apho umatshini wesiqhelo usafumana khona i-premium yawo, kunye nendlela yokudibanisa amanani ukuze kufakelwe into ethile.

Indlela i-Hydraulic Press eqhelekileyo esebenzisa ngayo amandla

Umatshini wokubumba i-hydraulic oqhelekileyo osebenzisa i-fixed-pump hydraulic injection molding usebenzisa i-electric motor ngesantya esingaguqukiyo, esidla ngokuqhagamshelwa ngqo kwi-mains ngaphandle kwe-variable frequency drive. I-motor iqhuba i-fixed-displacement hydraulic pump — ngesiqhelo i-vane pump okanye i-axial piston pump — ehambisa ukuhamba okungaguqukiyo kolwelo lwe-hydraulic kuxinzelelo oluhambelana nomthwalo. Iivalvu zolawulo lwendlela, iivalvu ezilinganayo, kunye neevalvu ze-servo zomatshini ziguqula ukuhamba kunye noxinzelelo ukuze zihambelane ne-mold closure, i-injection, i-hold, i-plasticizing, kunye ne-mold open phases zomjikelo.

Injini isebenza ngesantya esipheleleyo kulo lonke umjikelo, nokuba imfuno ye-hydraulic iphantsi. Ngexesha lesigaba sokubamba - xa inxalenye ifuna iqhezu elincinci lokuhamba kwe-peak ukugcina uxinzelelo lwe-cavity - ukuhamba okugqithisileyo kudlula nge-valve yokunceda ukubuyela kwitanki, ichitha amandla njengobushushu. Ngexesha lesigaba sokuphola - xa kungekho mfuneko yokuhamba kwe-hydraulic ngaphandle kwenani elincinci le-clamp tonnage - ipompo isajikeleza ngesantya esipheleleyo, isatsala amandla apheleleyo, kwaye i-bypass valve isalahla ukuhamba okugqithisileyo. Oku kukungasebenzi kakuhle kwesakhiwo senkqubo yepompo esisigxina: i-motor kunye nepompo zisebenza kwindawo enye yokusebenza, kwaye nakuphi na ukungangqinelani phakathi kwelo nqanaba kunye nemfuno ye-hydraulic yokwenyani ilahleka njengobushushu.

Ubushushu ngokwabo abunasimahla. Ioyile ye-hydraulic kufuneka ipholiswe ukuze kugcinwe i-viscosity kwaye kuthintelwe i-oxidation, oko kuthetha ukuba i-oyile cooler eyahlukileyo (epholiswe ngamanzi okanye epholiswe ngomoya) isebenza rhoqo, itsala amandla ongezelelweyo. Imfuneko yokupholisa kwi-press eqhelekileyo ye-250-ton kwi-30 °C ambient ikhulu - ngesiqhelo ikwi-15-25% yengeniso yombane yomatshini kwi-three-shift operation.

Indlela iServo-Hydraulic System esebenzisa ngayo amandla

Inkqubo ye-servo-hydraulic ithatha indawo yemoto yesantya esingapheliyo ngemoto ye-servo yesantya esiguquguqukayo — ngesiqhelo i-motor ye-magnet esisigxina ehambelanayo (PMSM) — eqhutywa yi-variable-frequency drive (VFD). I-servo drive ilawula isantya semoto ukuze ihambelane nemfuno ye-hydraulic ngexesha langempela. Xa umjikelo ukwisigaba sokuhamba okuphezulu (ukuvala isikhunta, ukujova, ukwenza iplastiki), imoto iyanyuka iye kwisantya esiphezulu. Xa umjikelo ukwisigaba sokuhamba okuphantsi (ukubamba, ukupholisa), imoto iyanyuka iye kwisantya esiphantsi esihlangabezana nemfuno ye-hydraulic yokwenyani. Xa umjikelo uphumle (akukho ntshukumo), imoto inokuma ngokupheleleyo okanye isebenze ngesantya esiphantse sibe yi-zero.

Isiphumo kukuba umatshini we-servo-hydraulic utsala kuphela amandla awudingayo kwisigaba ngasinye somjikelo. Injini ayisebenzi ngesantya esingaguqukiyo, ipompo ayidluli ukuhamba okugqithisileyo, kwaye ukuchithwa kobushushu be-bypass-valve ochaza ukungasebenzi kakuhle kwengcinezelo yesiqhelo kuyasuswa kakhulu.I-Bosch Rexroth, Yuken, kunye nabanye abavelisi beenkqubo ze-hydraulic bapapasha amanqaku esicelo ngothelekiso lokusetyenziswa kwamandla e-servo elinganisiweyo vs ipompo esisigxina; uluhlu oluqhelekileyo kuyo yonke idatha epapashiweyo kukunciphisa amandla ngama-40–80% kwiindawo ezinezigaba zokubamba ezibalulekileyo kunye nokupholisa, kunye nokunciphisa ngama-20–40% kwiindawo ezinezigaba zokubamba ezimfutshane kunye nokupholisa.

Ukonga akulingani kulo lonke umjikelo. Ukonga okukhulu kukwisigaba sokuphola (isigaba eside kakhulu esingafunekiyo kwimijikelo emininzi), esesibini ngobukhulu kwisigaba sokubamba, kwaye esincinci kwisigaba sokujova (apho kufuneka khona ukuhamba okuphezulu kwaye inkqubo ye-servo nayo isebenza ngexesha eliphezulu). Kwi-press eqhelekileyo ye-250-ton molding, inxalenye ye-ABS engama-200 g enomjikelo wemizuzwana engama-25, isigaba sokuphola simalunga nama-50% omjikelo, isigaba sokubamba siyi-15%, isigaba sokujova kunye neseplastiki siyi-25%, kwaye isigaba sokuvula/sokuvala siyi-10%. Isigaba sokuphola kulapho umatshini we-servo ugcina khona uninzi.

I-Servo Premium: Ixabiso leNkunzi vs Ixabiso lokuSebenza

Umatshini wokubumba injection ye-servo-hydraulic udla ngokubiza ngaphezulu kwama-30-60% kunomatshini oqhelekileyo olinganayo wetoni efanayo kunye nobukhulu beshothi. Iprimiyamu echanekileyo ixhomekeke kumenzi womatshini, umboneleli wenkqubo ye-servo, kunye neenkcukacha zomatshini. Kwi-press emeleyo ye-250-ton, iprimiyamu ye-servo kwimarike yangoku lunyuko oluneempawu ezintlanu - olunentsingiselo, kodwa alunatshintsho kumphathi wesityalo ovavanya ukuthengwa.

Le ntlawulo ifunyanwa ngokonga amandla. Ukuze ufake inombolo kwintlawulo, kufuneka izinto ezintathu: ukonga amandla ngomjikelo ngamnye, imijikelo ngeshifti nganye, kunye neendleko zombane.umgca wemveliso yenkqubo yeservoyenzelwe iinkqubo ze-servo ezisekelwe kwi-vane-pump kwizicelo zokubumba ngenaliti, kunye nokonga amandla kwinqanaba lenkqubo kuluhlu olupapashweyo. Kumatshini weetoni ezingama-250 kumjikelo wemizuzwana engama-25 oqhuba iiyure ezingama-6,000 ngonyaka (malunga ne-shift ezimbini ngokuqhubekayo), ukonga umbane wonyaka kuluhlu olunentsingiselo - lukhulu ngokwaneleyo ukuhlawula iprimiyamu ye-servo kwiinyanga zokuqala ezili-18-36 zokusebenza, kuxhomekeke kwirhafu yombane yasekuhlaleni.

Iindaba zePlasticskwayeItekhnoloji yePlastikibapapashe idatha yophando lweminyaka emininzi ebonisa ukuba oomatshini be-servo-hydraulic ngoku balawula ukuthengiswa kweendaba ezintsha kuluhlu lweetoni ezingama-50 ukuya kuma-800 kuMntla Melika, eYurophu, naseMpuma Asia, apho oomatshini beendaba abaqhelekileyo baxhomekeke kakhulu kwizicelo ezithile zeetoni eziphezulu kunye nezicelo ezikhethekileyo. Utshintsho lwemarike ngokwalo luphawu lwezibalo zokubuyisela imali: ukuba iprimiyamu ye-servo ibingafunyanwanga kwiminyaka emi-3, imakethi ibingayi kutshintsha.

Ukugcinwa: Apho Iinkqubo Ezimbini Zihlukana Khona

Iprofayili yokugcinwa kwenkqubo ye-servo-hydraulic yahlukile kwi-press eqhelekileyo kwiindawo ezintathu.

Okokuqala, i-servo motor ngokwayo inolondolozo oluphantsi kune-induction motor enamandla alinganayo - akukho bhrashi, akukho rings zokutyibilika, kwaye i-rotor yemagnet esisigxina ayifuni mbane wokuvuthela. I-VFD ineprofayili yayo yolondolozo (iifeni zokupholisa, ii-capacitors ze-electrolytic ezinobomi benkonzo beminyaka esi-8-12), kodwa izinto ezisebenzayo zemoto ngokwayo zenzelwe ubomi benkonzo ende ngaphandle kolondolozo olucwangcisiweyo.

Okwesibini, ipompo ye-hydraulic kwinkqubo ye-servo isebenza ngesantya esiguquguqukayo kwaye idla ngokuba kwi-RPM ephantsi kunomndilili osisigxina kwi-press eqhelekileyo. I-RPM ephantsi ithetha ukuguguleka okuphantsi kweebheringi, ukujikeleza okuphantsi kobushushu, kunye nobomi obude bokuvala. Idatha yasentsimini epapashwe yi-field data epapashwe yi-Ubuchwepheshe bokwenza iMoldkwaye ababoneleli beepompo zehydraulic abahlukeneyo babonisa rhoqo ukuba iipompo zevane ezikwinkonzo yesantya esiguquguqukayo zinobomi benkonzo obude ngokunentsingiselo kunepompo yevane efanayo kwinkonzo yesantya esimiselweyo kwipress efanayo.

Okwesithathu, i-oyile cooler kwi-servo-hydraulic press ayisebenzi rhoqo kuba ubushushu obuphuma kwi-bypass-valve buyancipha. Ifeni epholileyo okanye ipompo yamanzi okupholisa iyajikeleza kwaye ivale ngokusekelwe kubushushu be-oyile bokwenyani endaweni yokusebenza rhoqo. Ixesha eliphantsi lokusebenza kwe-oyile epholileyo lithetha ukuba ukugcinwa kwe-oyile epholileyo kuphantsi kwaye umbane ophuma kwi-parasitic uyancipha kwinkqubo yokupholisa.

I-press eqhelekileyo, ngokuchaseneyo, inokonakala okuphezulu kwe-bearing kwi-motor nakwi-pump, itshintsha isitywina rhoqo, kunye noxinzelelo oluphezulu lobushushu kwi-oyile olukhawulezisa i-oxidation yeoyile kwaye lunciphise ixesha lokutshintsha ioyile. Kwi-press eqhelekileyo ye-three-shift, ixesha lokutshintsha ioyile lidla ngokuba ziiyure ezingama-4,000; kwi-press ye-servo-hydraulic kumjikelo ofanayo womsebenzi, ixesha lokutshintsha lifikelela kwiiyure ezingama-6,000–8,000. Ixabiso leoyile kwiminyaka emi-5 libalulekile - i-press ye-250-ton ibamba iilitha ezingama-400–600 yeoyile ye-hydraulic, kwaye i-oyile kunye neendleko zokulahla kwinguqu nganye yinto enamanani amane kwiimarike ezininzi.

Ingxolo kunye neNdawo yokuSebenza

I-press eqhelekileyo iqhuba i-motor kunye ne-pump ngesantya esipheleleyo rhoqo, ivelisa uphawu oluzinzileyo lwe-acoustic kuluhlu lwe-78–85 dB(A) kwisikhululo somsebenzisi. I-servo-hydraulic press yehlisa isantya se-motor kunye ne-pump ngexesha lokubamba kunye nokupholisa, inciphisa kakhulu igalelo lengxolo kwinkqubo ye-hydraulic. Ingxolo iyonke yomatshini yehla iye kuluhlu lwe-65–72 dB(A), umahluko phakathi kwenqanaba lengxolo elifuna ukhuseleko lokuva ukuze kubonakale i-full-shift kunye nelinye elisemngciphekweni womda wolawulo.

Ukunciphisa ingxolo akukonga iindleko ngokuthe ngqo, kodwa kuyinzuzo yokwenyani kwiimarike ezinemithetho engqongqo yengxolo emsebenzini (i-EU OSH Directive 2003/10/EC, i-US OSHA 29 CFR 1910.95, i-China GBZ 2.2) apho imidiya eqhelekileyo ifuna ukhuseleko lokuva kubaqhubi. Iindleko zokhuseleko lokuva, uvavanyo lwe-audiometric, kunye neziseko zolawulo lwengxolo kumgangatho wesityalo aziqhelekanga ukubalwa kubalo lokubuyisela amandla kuphela - kodwa lixabiso lokwenyani kwiminyaka emi-5.

Ukuchaneka kunye nokuphindaphinda

Inkqubo ye-servo-hydraulic inenzuzo echanekileyo engasoloko ibonakala kubalo lokubuyisela amandla kodwa ibonakala kwisantya se-scrap. Ulawulo loxinzelelo oluvaliweyo olune-sensor yoxinzelelo kunye nepompo yesantya esiguquguqukayo ibamba uxinzelelo lwe-cavity ngaphakathi kwebhendi eqinileyo kunenkqubo ye-fixed-pump ene-valve ezilinganayo. Kwiindawo ezinyamezelayo — ezibonakalayo, ezonyango, ukupakishwa — ukuphuculwa kwesantya se-scrap kukodwa kunokuhlawula iprimiyamu ye-servo kwiminyaka emi-5, ngaphandle kokonga amandla.

Umbutho weeNjineli zePlastikiipapasha amaphepha obuchwephesha malunga nokuchaneka kokubumba kwe-servo-hydraulic injection, kuquka ukutshintshatshintsha kobunzima bokudubula kunye nedatha yokuphindaphinda ubukhulu. Inzuzo yokuchaneka okushicilelweyo incinci kwiindawo ezinokunyamezelana okukhululekileyo (ngesiqhelo ukuncipha kwe-10-20% kukutshintshatshintsha kokudutyulwa) kwaye inentsingiselo kwiindawo ezixineneyo (ukunciphisa kwe-30-50%).

Apho i-Hydraulic eqhelekileyo isaphumelela khona

Umatshini wokucinezela we-hydraulic osetyenziswa kwi-fixed-pump awusasetyenziswa. Iindidi ezintathu zendlela osetyenziswa ngayo zisathandwa.

• Oomatshini abathwala iitoni ezininzi kakhulu (ngaphezulu kweetoni ezili-1,500).I-premium yenkqubo ye-servo ilinganiswa ngokulinganayo ngamandla emoto; xa i-tonnage iphezulu kakhulu, i-premium ye-servo epheleleyo iba nkulu ngokwaneleyo ukuba ixesha lokubuyisela lidlule. Ezinye izicelo ezikhethekileyo ze-tonnage ephezulu zikwafuna iimpawu ezithile zempendulo eguquguqukayo ezingaboneleliyo ngendlela ecocekileyo njengenkqubo yepompo esisigxina ene-accumulator enkulu.
• Izicelo zomsebenzi eziqhubeka nomjikelo omde.Ukuba umatshini wokushicilela usebenzisa umjikelo wemizuzwana engama-90 kwindawo enodonga oluqinileyo enesigaba sokubamba ixesha elide kunye nokusebenza okuqhubekayo kwe-three-shift, umatshini we-servo usagcina amandla kodwa imali egciniweyo iyancitshiswa kwinani elincinci lemijikelo ngonyaka. Ixesha lokubuyisela liyanda, kwaye umatshini wesiqhelo uba nokhuphiswano olungakumbi.
• Ukufakelwa okunqongopheleyo kwemali.Isikhululo esinebhajethi encinci yemali kunye notyalo-mali olufutshane sinokukhetha ngokwengqiqo indlela eqhelekileyo yokushicilela iindleko zemali kuphela, ingakumbi ukuba iindleko zombane zasekuhlaleni ziphantsi.

Ngaphandle kwezi ndidi zintathu, inkqubo ye-servo-hydraulic yeyona ikhethwayo ngokuxhomekeke kwixabiso lilonke leminyaka emi-5 lobunini. Idatha yemarike iyakuqinisekisa oku: isabelo se-servo sokufakelwa kwee-press ezintsha sininzi kwiindawo ezininzi nakwiindidi ezininzi ze-tonnage, ngaphandle kwezicelo ezikhethekileyo ze-tonnage ephezulu ezichazwe apha ngasentla.

Ukwakha iphepha lokusebenzela le-TCO leminyaka emi-5

Uthelekiso lwexabiso lilonke leminyaka emi-5 lobunini phakathi kwe-servo-hydraulic kunye ne-common press luneziqendu ezine zexabiso: imali, amandla, ukugcinwa, kunye nexesha lokungasebenzi. Nganye ibalwa ngokwahlukileyo.

Ixabiso lenkunzi lixabiso lokuthenga umatshini kunye nokufakelwa, ukuthunyelwa kwempahla, uqeqesho, kunye nokugunyaziswa. Iprimiyamu ye-servo ngumahluko phakathi kwexabiso lenkunzi loomatshini ababini.

Ixabiso lamandla yi-kWh edibeneyo kwiminyaka emi-5, iphindaphindwe ngerhafu yombane yendawo. Ukonga amandla komatshini we-servo ngumahluko phakathi kwamandla okushicilela aqhelekileyo kunye namandla okushicilela e-servo kwixesha elifanayo.

Iindleko zokulungisa zizinto eziqokelelweyo kunye nomsebenzi othatha iminyaka emi-5. Umatshini we-servo uhlala unolondolozo oluphantsi olunxulumene nepompo, utshintsho oluphantsi lweoyile, kunye nolondolozo oluphantsi lwe-cooler. Umatshini wesiqhelo unokonakala okuphezulu kweebheringi kwimoto nakwipompo kwaye usetyenziswa kakhulu yioyile.

Ixabiso le-scrap kunye nexesha lokungasebenzi lixabiso lezinto ezikhutshiweyo kunye nexabiso lemveliso elilahlekileyo ngexesha lokungasebenzi elingacwangciswanga. Umatshini we-servo unolawulo oluqinileyo loxinzelelo kunye nesantya esiphantsi se-scrap; umatshini wesiqhelo unesantya esiphezulu se-scrap kwiindawo ezixineneyo kodwa akukho ngxaki kwiindawo ezikhululekileyo.

Imali eyongiweyo yeminyaka emi-5 yomatshini we-servo yimali eyongiweyo yamandla kunye nemali eyongiweyo yokugcinwa kunye nemali eyongiweyo ye-scrap/downtime, ngaphandle kweprimiyamu ye-servo. Ukuba isiphumo sihle, umatshini we-servo uyaphumelela. Ukuba ayikho, umatshini wesiqhelo uyaphumelela kwiminyaka emi-5.

Isakhelo seSigqibo: Imibuzo emihlanu ekufuneka uyibuze ngaphambi kokuba uyicacise

Kwindawo ethile yokufakela, isigqibo se-servo vs esiqhelekileyo sinokuncitshiswa sibe yimibuzo emihlanu.

1. Ithini iprofayili yomjikelo?Izigaba zokubamba ixesha elide kunye nokupholisa zikhetha i-servo. Iijikelo ezimfutshane ezinemfuno ephezulu yokuhamba kwamanzi kuyo yonke i-favorite yesiqhelo okanye i-servo enomahluko omncinci.
2. Ithini ishedyuli yokusebenza?Ukusebenza rhoqo kwe-three shift kwandisa ukonga amandla. Ukusebenza kwe-time enye kunye nexesha elide lokungasebenzi kuyayinciphisa imali yokonga kuba ucinezelo lucinyiwe phantse imini yonke.
3. Ixabisa malini umbane wengingqi?Iimarike ezixabisa kakhulu (iYurophu, iJapan, inxalenye enkulu yeMpuma Asia) ziyayikhawulezisa imbuyekezo. Iimarike ezixabisa kancinci (iindawo ezithile zaseMbindi Mpuma, uMntla Melika onegesi yendalo eninzi) ziyayicothisa imbuyekezo.
4. Yintoni ukunyamezelana kwenxalenye?Izixhobo ezinyamezelayo kakhulu (ezonyango, ezibonakalayo, ukupakishwa okuthile) ziyandisa inzuzo ye-servo ngokusebenzisa izinto ezilahliweyo ezisezantsi. Izixhobo ezinyamezelayo ezikhululekileyo ziyayinciphisa le nxalenye yokonga imali.
5. Yintoni imiqathango yemali?Ukuba iprimiyamu yenkunzi ayinakuxhaswa ngemali ngexabiso elifanelekileyo, ixesha lokubuyisela imali libalulekile nokuba uqoqosho lwenqanaba leprojekthi lulungile.

Kwi-press eqhelekileyo yeetoni ezingama-250 kumjikelo wemizuzwana engama-25 eqhuba ii-shift ezimbini ngokuqhubekayo kwimarike yerhafu ephakathi, imbuyekezo ikwinqanaba leenyanga ezili-18-36. Kwi-press ye-100 yeetoni kumjikelo wemizuzwana eli-12 eqhuba i-shift enye kwimarike yerhafu ephantsi, imbuyekezo inokwandiswa ukuya kwiminyaka emi-4 nangaphezulu.iphepha lokusebenzela lokuhlawula iprojekthiibandakanya zonke izinto ezintlanu eziguquguqukayo kwaye ivelise isindululo esithile seprojekthi.

Imibuzo Ebuzwa Rhoqo: I-Servo vs i-Hydraulic Injection Molding eqhelekileyo