Injection Molding Machine Frequency Inverter

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Energy Saving Solution for Injection Molding Machine with
SF81 and SD610/620
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1.What is the benefit in injection molding retrofitting with VFD.
Injection Molding is a common method of plastic processing in which thermoplastic materials can be molded into
arbitrary complex shapes ,Most injection molding machines use complicated hydraulic systems to perform the
necessary work of the process. Hydraulic system flow and pressure requirements vary throughout the cycle and in
many cases ,excess fluid that is not required by the process is throttled back to the reservoir ,wasting motor
energy and producing additional thermal load on the cooling system .variable speed drives can be used to allow
injection molding machine hydraulic systems to vary the amount of fluid that is throttled ,reducing the amount of
wasted energy.
Traditional displacement
pump control system
With variable speed drive
For energy saving
Speed
regulating
for
Flow and
pressure
control

Figure 1 : Required hydraulic Fluid Flow Rate Through one cycle Figure 2 : Required pressure Through one cycle
There are some basic rules of thumb concerning VSD and
IMMs that are typically applied .Most VSD installer expect
energy saving of 20-50% of pre-retrofit motor energy use
for machines with constant displacement pumps.
Machines with variable displacement pumps will have
lower savings ,and only a few VSD distributors consider
machines with variable displacement pumps appropriated
for VSD retrofits .However ,it is generally felt that potential
energy saving is more strongly depend on cycle time
breakdown ,especially percentage idle time in the
cycle ,than on machine parameters or other process
parameters .

SF81 System provides precise pressure and flow controls for each injection molding process and solves the
energy waste issues of traditional injection molding machine. This solution helps to improve product quality,
market competitiveness and productivity.
SF81 injection molding machine servo drive regulates the speed of motor and oil pumps according to the required
pressure and flow signal in difference working process. The servo system collects real time pressure of pipe by
pressure sensor and then do signal comparison calculating with signal came from upper controller, to achieve
pressure and speed dual close loop control, automation adjust the speed of motor no need discharge excess oil
by throttle control to tank. The energy saving up to 20% to 60%
Veichi SF81 Injection Molding Machine Servo Drive for asynchronous motor
SF81 IMM special synchronous servo drive easy to install, no need pressure sensor, encoder, no need to replace
the hydraulic pump and motor exited . It is a cost-high performance AC drive that very suitable for hydraulic pump
machine: http://www.veichi.org/product/electric-drive/sf81-asynchronous-servo-control-vfd-for-injection-molding-
machine.html

The advantage feature of SF81 asynchronous
servo drive
1. Quick respond speed, high efficiency
The response speed of pressure from 0 to maximum is
0.1s is available with SF81 servo drive control. The
response speed proved much fast compare to traditional
hydraulic pressure control system with overflow valve
only help to improve the production efficiency and
shorten the work cycle.
2. Highly Repetitive accuracy of IMM system
The repetitive accuracy can be improved to 3%, higher
accuracy than traditional control method after retrofitting
by SF81 servo drive, which help to ensure the stability of
product and reduce the defective percentage.
3. Energy saving up to 25% to 70%.
Achieving 25% to 70% energy saving , that depends on
is the speed value of mould technique parameters. The
more energy saving ratio , the smaller speed value ( 0
to 99%). 70% of energy saving is possible if the speed
value during to 0 to 30%, also can get 25% energy
saving if the speed value over 90%, with little cooling
time as well.
4. Lower running noise.
Running noise reduce remarkable, more quiet running
In low speed, less than 70 DB in good condition.
5. Strong overload capacity
Overload capacity: 150% rated current for 120s, 180%
rated current for 10s, 250% rated current for 1s.
6. Lower oil temperature
The flow and pressure are controlled by SF81 servo
drive to avoid redundant heat generated, which reduc
the oil temperature, even no need refrigeration and
saving a lot of cooling water or oil.
7. Easy to maintain
It has built backup power supply circuit, which will not
effect injection machine working when SF81
synchronous servo drive are repairing.
8. Designed to special function for IMM energy
saving, has built special control channel.
Special programmable parameters suitable for IMM,
easy to set.

9. Powerful faulty restart function, No stop running
with slight alarm occur, don’t effect injection cycle.
10. Multiple channel input signal terminal, built in 0-
1A to 0-10V signal conversion card
0 to 1A/0-5A,0-10V/ 0-5V, 4-20mA/0-20A multiple
input analogy signal is available.
11. Outstanding performance
Excellent soft start ability, 0.1s of accel/ decel time that
to meet IMM operation condition very well
Large torque output, 180% rated torque output even
under 0.3Hz.
12. Easy to configure the curve of frequency -
analog signal.
Adjusting this curve according the characteristic of
hydraulic to meet requirement.
Built back up utility grid circuit
Independent air duct and water proof design

The operation principle of SF81 synchronous servo
drive
Veichi SF81 synchronous servo drive apply multiple
channel signal input control, proportional pressure and
flow signal for main stream control as for main source,
attached several signal as for auxiliary source to
adjust flow and pressure signal given when there
pressure and flow is not enough during injection cycle.
It is very easy to superposition multiple voltage or
multiple segment frequency to make flow or pressure
bigger when the pressure requirement in specify
injection cycle ( close, plastic melting and injection ) is
not enough, which will not effect the working condition.
The wasted energy of motor is minimum during whole
variable load. It can make motor run in stability and
accurately to achieve high energy saving and improve
the product quality.
Note: This diagram suits for the proportional valve with
0-1A asynchronous servo drive
2. The digital signal of diagram showed is negative
output, if the digital output ( mold open, mold lock,
injecting, melting plastic ) is positive, the common point
will be 0 V, not 24V. And the diode should be change
the direction).

Proportional valve wiring schematic
To SF81 drive
Specification of SF81
Model Power(KW)
Rated
current (A)
SF81-T3-7R5K 7.5 16
SF81-T3-011K 11 25
SF81-T3-015K 15 32
SF81-T3-018K 18 38
SF81-T3-022K 22 45
SF81-T3-030K 30 60
SF81-T3-037K 37 75
SF81-T3-045K 45 90
SF81-T3-055K 55 110
SF81-T3-075K 75 150

Veichi SD610/620
Electro
Hydraulic
Servo
System
Energy Saving
High Precision
High Efficiency
Noise Reduction
Long Working
China No. 1 brand.

The advantage of electro hydraulic system, please refer the catalog of electro
hydraulic
Energy Saving.
The electro employ pressure and flow double close loop control o hydraulic system supply the oil
according to the actual demand with
employing pressure and flow double close loop control mode. It will overcome the high energy
consumption of high pressure leakage in general constant displace pump. It can achieve energy
saving up to 30% to 80%.
Precision
Improving the pressure stability with close loop pressure control mode. The pressure fluctuation less
than ±0.3bar, high duplication accuracy.
High efficiency
The system response speed up to 20ms, improve the explosive moments, increasing the productivity.
Lower noise
The electro hydraulic system noise limit to 65dB, improve the operation environment.
Long service lifespan
The temperature rise of oil is 3℃ to 10℃, working in 35 ℃ in door temperature no need cooling water,
reduce the water using sharply.
Reduce the oil changing frequency, extend the service lifespan of oil quick wear parts.

Systemworkingprinciple
Controlmode

Comparison of retrofitting for IMM with VFD, synchronous PMSM motor, SF81 asynchronous
servo drive:
1. Retrofitting with frequency inverter of IMM.
a. Retrofitting with V/f frequency inverter can bring us energy saving but there are some problem happen.
b. Not good control accuracy without feedback control, low efficiency, lower energy saving, sometime effect
product quality, product quality not stable.
c. This is solution is very popular before 2010 even with vector control inverter, but now it was weed out
gradually
d. Veichi AC70 with running curve adjusting features can remedy short point of retrofitting with inverter.
2. Retrofitting with asynchronous motor
a. High energy saving, higher efficiency and outstanding accuracy control with close loop feedback
b. Stable flow and pressure to make sure good quality of product
c. Lower investment, no need replace the exits motor, short payback.
3. Retrofitting with SD610/620 Electro-Hydraulic Servo Drive with permanent magnet
synchronous motor
High energy saving, high efficiency and good accuracy control can be achieve with vector control servo drive and
synchronous motor. But costly installation and retrofitting expense, long payback with synchronous motor replace
Solution
general fixing
pump
variable capacity
pump
V/f frequency
inverter
PMSM with servo
drive motor
asynchronous
sevo drive
Energy Saving NO A little 20% to 40% 25% to 75% 25% to 75%
stability middle level Middle level Low High High
Dynamic response Middle level Middle level Slow High High
Noise Middle High Middle Low Low
Oil temperature High Middle Middle Middle Low
Maintenance cost Low High Middle High Low
Investment cost Low Middle Middle High Middle

Energy saving effect budget of servo system retrofitting for constant replacement pumps.
IMM clamping force, Motor power, before retrofitting power consumption, after retrofitting power
consumption, Annual energy saving, Annual electrical charge saving
IMM mould
clamping force
The power
of motor
Energy
consumption/hour(before
retrofitted with fixed pump)
Energy
consumption/hour(after
retrofitted with SF81 drive)
Energy Saving
per year KW.H/Y
Cost Saving(
CNY)
T Kw.h Kw.h/h Kw.h/h Kw.h/Year CNY/Year
58T 7.5 3.375 2.025 17739 14191.2
90T 11 4.95 2.97 26017 20813.6
120T 13 5.85 3.51 30748 24598.4
160T 115 6.75 4.05 35478 28382.4
200T 18.5 8.325 4.995 43756 35004.8
250T 22 9.9 5.94 52034 41627.2
300T 30 13.5 8.1 70956 56764.8
360T 37 16.65 9.99 87512 70009.6
450T 45 20.25 12.15 106434 85147.2
530T 55 24.75 14.85 130086 104068.8
650T 60 27 16.2 141912 113529.6
800T 74 33.3 19.98 175025 140020
900T 82 36.9 22.14 193946 155156.8
1000T 90 40.5 24.3 212868 170294.4
1250T 110 49.5 29.7 260172 208137.6
1500T 120 54 32.4 283824 227059.2
Note:
1. Before retrofitting, calculating with 45% load power consumption per hours
2. After retrofitting, calculating with average energy saving 60%, 70% IMMs after with retrofitting can achieve 60% energy saving.
3. Annual energy saving calculating with 24 hours, 365 days.
4. Electrical charge is 0.8 CNY per hour, 1USD for 6.1CNY.
5. The budget will be difference according to difference condition. above table only for reference.

Injection Molding Machine Frequency Inverter

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