Energy-saving variable frequency mold temperature controller

Abstract

This utility model relates to the field of mold temperature controller technology, specifically to an energy-saving variable frequency mold temperature controller, including a control module and a machine body. The machine body houses a heating tank and a variable frequency circulating pump. The heating tank stores a heating medium, with an inlet pipe on one side for the heating medium to flow in and an outlet pipe on the other side for the heating medium to flow to the variable frequency circulating pump. A heating module is detachably connected to the heating tank, and the heating module is electrically connected to a PTC heating rod. The PTC heating rod is inserted into the heating tank to heat the heating medium. The control module controls the heating power of the PTC heating rod and the rotation speed of the variable frequency circulating pump. This technical solution uses a PTC ceramic heating rod instead of a traditional nickel-chromium alloy resistance wire, significantly improving heat conversion efficiency and reducing energy loss. The positive temperature coefficient of PTC material allows it to automatically reduce heating power when the temperature approaches the target value, improving energy utilization efficiency.

Description

Technical Field

[0001] This utility model relates to the field of mold temperature controller technology, specifically to an energy-saving variable frequency mold temperature controller. Background Technology

[0002] During the plastic molding process, the mold needs to be kept at a constant temperature in order to compress the plastic into the required shape. When the mold is repaired, it needs to be cooled down quickly. For this purpose, the mold usually has a fluid channel inside. The temperature of the water flowing through the mold is adjusted by a mold temperature controller to control the temperature of the mold and realize the compression molding of the plastic.

[0003] Traditional mold temperature controllers mostly use nickel-chromium alloy resistance wire for heating, with a heat conversion efficiency of about 65% to 75%. The remaining energy is lost in the form of radiation / convection. For example, the temperature of the outer wall of the heating tank can reach 80 to 100°C, causing serious thermal pollution in the workshop. Utility Model Content

[0004] This invention aims to at least partially solve one of the technical problems in related technologies. Therefore, the purpose of this invention is to propose an energy-saving variable frequency mold temperature controller to improve energy utilization efficiency.

[0005] The objective of this utility model can be achieved through the following technical solutions:

[0006] An energy-saving variable frequency mold temperature controller includes a control module and a machine body. The machine body is equipped with a heating tank and a variable frequency circulating pump. The heating tank stores a heating medium. One side of the heating tank is provided with an inlet pipe for the heating medium to flow in, and the other side is provided with an outlet pipe for the heating medium to flow to the variable frequency circulating pump.

[0007] The heating tank is detachably connected to a heating module, which is electrically connected to a PTC heating rod. The PTC heating rod is inserted into the heating tank to heat the heating medium. The control module is used to control the heating power of the PTC heating rod and the speed of the variable frequency circulating pump.

[0008] In some embodiments of this utility model, the machine body is provided with a pipe inlet and a pipe outlet. The pipe inlet connects the fluid channel inside the mold to the inlet pipe, and the pipe outlet connects the fluid channel inside the mold to the outlet pipe.

[0009] In some embodiments of this utility model, the body is provided with a temperature gauge, which is electrically connected to the control module and is used to display the internal temperature of the heating barrel.

[0010] In some embodiments of this utility model, the heating barrel has a double-layer jacketed structure, with an insulation layer filling the space between the jackets.

[0011] In some embodiments of this utility model, the inner wall of the heating barrel is provided with a spiral guide groove, which extends spirally along the axial direction of the heating barrel.

[0012] In some embodiments of this utility model, the end face connecting the heating barrel and the heating module is respectively provided with flange one and flange two, which are connected by screws. The mating surface of flange one is provided with sealing ring one, and the mating surface of flange two is provided with sealing groove one that matches sealing ring one.

[0013] In some embodiments of this utility model, a sealing plate is provided inside the heating barrel, and the heating medium is stored in the cavity formed between the sealing plate and the heating barrel;

[0014] The sealing plate has a through hole that matches the position of the PTC heating rod. The surface of the PTC heating rod has a sealing groove. The outer surface of the sealing plate corresponding to the through hole has a sealing ring. After the PTC heating rod is inserted into the heating barrel at a suitable position, the sealing groove and the sealing ring are engaged.

[0015] In some embodiments of this utility model, the inner surface of the sealing plate corresponding to the through hole is provided with a spring check valve, and the end of the PTC heating rod is provided with a dome, which is used to open the spring check valve.

[0016] In some embodiments of this utility model, the heating barrel is provided with a positioning boss inside, and after the PTC heating rod is inserted into the heating barrel, the dome is fitted with the positioning boss.

[0017] In some embodiments of this utility model, the outer surface of the PTC heating rod is wrapped with honeycomb-shaped thermally conductive aluminum fins, and the spacing between adjacent fins is 2mm.

[0018] The beneficial effects of this utility model are:

[0019] Compared to traditional methods, this technical solution uses a PTC ceramic heating rod instead of a traditional nickel-chromium alloy resistance wire, which significantly improves the heat conversion efficiency and reduces power consumption. The positive temperature coefficient of PTC material allows it to automatically reduce the heating power when the temperature approaches the target value, avoiding the energy loss caused by the "overshoot-cooling" of traditional resistance wires. Combined with the dynamic power adjustment of the control module, this improves the energy utilization efficiency. Attached Figure Description

[0020] The present invention will be further described below with reference to the accompanying drawings.

[0021] Figure 1 This is a perspective view of the present invention;

[0022] Figure 2 This is an internal structural view of the present invention;

[0023] Figure 3 This is a perspective view of the heating barrel and heating module in this utility model;

[0024] Figure 4 This is a cross-sectional view of the heating barrel and heating module in this utility model;

[0025] Figure 5 This is a perspective view of the heating barrel and sealing plate in this utility model;

[0026] Figure 6 This is an internal structural view of the heating barrel in this utility model;

[0027] Figure 7 This is a perspective view of the heating module in this utility model.

[0028] In the diagram: 1. Control module; 2. Machine body; 3. Pipe inlet; 4. Pipe outlet; 5. Thermometer; 6. Heating tank; 61. Inlet pipe; 62. Outlet pipe; 63. Flange 1; 631. Sealing ring 1; 64. Insulation layer; 65. Spiral guide groove; 66. Sealing plate; 661. Sealing ring 2; 662. Spring check valve; 67. Positioning boss; 7. Heating module; 71. Flange 2; 711. Sealing groove 1; 72. PTC heating rod; 73. Dome; 74. Sealing groove 2; 8. Variable frequency circulating pump. Detailed Implementation

[0029] The technical solutions of this utility model will be clearly and completely described below with reference to the embodiments of this utility model. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this utility model. Example

[0030] This embodiment aims to illustrate the basic structure and core working principle of an energy-saving variable frequency mold temperature controller, with particular focus on its energy-saving control aspects.

[0031] like Figure 1 , Figure 2 , Figure 3 As shown in the figure, this embodiment provides an energy-saving variable frequency mold temperature controller, the main structure of which includes a control module 1 and a body 2.

[0032] The main body 2 serves as a support platform, and its key internal components include a heating tank 6 for containing and heating the heat transfer medium, and a variable frequency circulating pump 8 for driving the circulation of the medium. The heating tank 6 contains heat transfer oil, water, or other suitable liquids as the heating medium. To achieve the circulation of the medium, the heating tank 6 has an inlet pipe 61 on one side to receive the cooler medium returning from the outside (usually the fluid channel inside the mold); and an outlet pipe 62 on the other side to discharge the heated medium to the variable frequency circulating pump 8.

[0033] The heating module 7 is designed to be easily detached and connected to the heating tank 6, and its core component is at least one PTC heating rod 72. During use, the PTC heating rod 72 is inserted into the heating tank 6, directly contacting the heating medium or heating it indirectly. The control module 1, through electrical connection, not only controls the on / off state and heating power of the PTC heating rod 72 (e.g., through PWM pulse width modulation or graded control), but also precisely adjusts the motor speed of the variable frequency circulating pump 8, thereby controlling the circulation flow rate of the heating medium.

[0034] During operation, the user sets the desired target temperature via control module 1. Control module 1 compares the actual temperature of the medium inside heating tank 6, fed back by the built-in temperature sensor, with the set temperature. If the actual temperature is lower than the set value, control module 1 activates PTC heating rod 72 for heating and adjusts the output power of PTC heating rod 72 according to the temperature difference and control algorithm (such as PID). Simultaneously, control module 1 drives variable frequency circulating pump 8 to pump the heat medium inside heating tank 6 out through outlet pipe 62, flowing through external mold (or other equipment requiring temperature control), absorbing heat from the mold or transferring heat to the mold, and then returning to heating tank 6 through inlet pipe 61.

[0035] The speed of the variable frequency circulating pump 8 is also adjusted by the control module 1 as needed (such as temperature difference, system load, set flow requirements, etc.) to optimize heat transfer efficiency and energy consumption. When the temperature reaches or approaches the set value, the control module 1 will reduce or even stop the heating power of the PTC heating rod 72, and may adjust the pump speed to maintain a stable temperature.

[0036] It is important to note that the variable frequency circulating pump 8 can adjust its flow rate according to actual heat load requirements, avoiding the energy waste caused by the traditional fixed frequency pump running at full speed under low load. The power of the PTC heating rod 72 can be precisely controlled as needed, avoiding energy loss caused by overshoot and frequent start-stop. Furthermore, the inherent characteristics of PTC material (its resistance increases sharply after reaching a certain temperature, limiting current) also provide certain self-limiting temperature, energy-saving, and safety features.

[0037] As an example, to integrate the mold temperature controller into the production system, the external body 2 is equipped with standardized pipe interfaces, namely pipe inlet 3 and pipe outlet 4. Pipe inlet 3 is connected to the return end of the fluid channel inside the mold through an external pipeline, guiding the returned medium to the inlet pipe 61 of the heating tank 6. Pipe outlet 4 is connected to the outlet of the variable frequency circulating pump 8, and is connected to the supply end of the fluid channel inside the mold through an external pipeline, delivering the heated medium to the mold.

[0038] During operation, pipe inlet 3 and pipe outlet 4 form a complete closed loop: heating tank 6 -> outlet pipe 62 -> variable frequency circulating pump 8 -> pipe outlet 4 -> external mold flow channel -> pipe inlet 3 -> inlet pipe 61 -> heating tank 6. The heating medium circulates continuously in this loop, transferring heat. This design provides a standardized connection method, allowing users to quickly connect the mold temperature controller to different molds or equipment. It achieves closed-loop circulation of the heating medium, reducing medium loss and contamination.

[0039] As an example, a temperature gauge 5 is installed at a suitable location on the surface of the body 2 (usually on a panel for easy observation). The core of this temperature gauge 5 is a temperature sensor (such as a thermocouple, RTD platinum resistance thermometer, etc.), whose sensing probe is typically positioned inside the heating tank 6 at a key location reflecting the temperature of the main fluid. The temperature sensor converts the measured temperature signal into an electrical signal and transmits it to the control module 1. After processing this signal, the control module 1 uses it as feedback input for closed-loop control and outputs the temperature value to the temperature gauge 5 for real-time display by the operator. Simultaneously, this temperature data is the primary basis for the control module 1 to adjust the PTC heating power and pump speed.

[0040] This design allows operators to intuitively understand the current operating temperature status of the mold temperature controller, providing necessary feedback signals to the control system and forming the basis for achieving precise temperature control.

[0041] As an example, the temperature gauge 5 can be a digital display or a traditional pointer-type instrument. Example

[0042] Based on Embodiment 1, this embodiment focuses on improving the structure of the heating barrel 6 and optimizing the connection between the heating module 7 and the heating barrel 6, aiming to improve thermal efficiency, temperature stability and ease of maintenance.

[0043] In some embodiments of this utility model, such as Figure 4As shown, to minimize heat loss and improve energy utilization efficiency, the heating tank 6 in this embodiment adopts a double-layer jacketed structure. Specifically, the heating tank 6 consists of an inner cylinder and an outer cylinder, forming a closed annular or irregularly shaped space, i.e., a jacket, between the inner and outer cylinders. This jacketed space is filled with a high-efficiency insulation material 64, such as glass wool, rock wool, aluminum silicate fiber felt, or polyurethane foam. The inner cylinder directly contains the heating medium, while the outer cylinder serves as the outer shell of the insulation layer. The heat generated by the PTC heating rod 72 is transferred to the heating medium, causing the medium to heat up. The insulation layer 64 in the double-layer jacketed structure has a very low thermal conductivity, which greatly hinders the loss of heat from the high-temperature inner cylinder to the lower-temperature external environment through thermal conduction, convection, and radiation.

[0044] In some embodiments of this utility model, such as Figure 4 , Figure 6 As shown, to further improve heating efficiency and temperature uniformity within the tank, this embodiment incorporates spiral guide grooves 65 machined or provided on the inner wall of the heating tank 6. These spiral guide grooves 65 extend spirally along the axial direction of the heating tank 6 (i.e., the mainstream direction of the heating medium). When the heating medium flows through the heating tank 6 under the drive of the variable frequency circulating pump 8, the spiral guide grooves 65 on the inner wall guide the fluid to generate a rotating or spiral-forward flow state. This spiral flow increases fluid turbulence, disrupts the laminar boundary layer near the inner wall, and promotes internal mixing of the fluid. Simultaneously, the spiral path also relatively increases the contact time and effective heat exchange area between the fluid and the inner wall of the heating tank 6 (and the internal PTC heating rod 72).

[0045] In some embodiments of this utility model, such as Figure 4 , Figure 5 , Figure 6 , Figure 7 As shown, in order to facilitate the installation, inspection and replacement of the heating module 7 (mainly the PTC heating rod 72 and its related electrical connections), the heating tank 6 and the heating module 7 are connected by a detachable flange.

[0046] For example, a flange 63 is provided on the end face of the heating tank 6 where the heating module 7 needs to be connected, and correspondingly, a matching flange 71 is provided on the mating end face of the heating module 7. The two flanges are fastened together by several screws (or bolts and nuts). To ensure the sealing of the connection and prevent leakage of the heating medium, a structure for accommodating a seal is machined on the mating surface of flange 63, such as an annular sealing ring 631 (e.g., an O-ring); while on the mating surface of flange 71, a corresponding sealing groove 711 matching the sealing ring 631 is formed. When the two flanges are fastened together with screws, the sealing ring 631 is compressed within the sealing groove 711, forming a reliable sealing surface.

[0047] During operation, the screws provide a tightening force to press the two flanges tightly together. The sealing ring 631 located between them deforms under pressure, filling the tiny gap between the flange mating surfaces, thereby preventing the leakage of internal high-pressure or high-temperature heating media. Example

[0048] Based on the foregoing, this embodiment further describes in detail the installation, sealing, and precise positioning mechanism of the PTC heating rod 72 inside the heating barrel 6, as well as its own heat transfer enhancement design, with the focus on improving the convenience of installation and maintenance, safety, sealing reliability, and heating efficiency.

[0049] In some embodiments of this utility model, such as Figure 4 , Figure 5 As shown, a fixed sealing plate 66 is installed inside the heating tank 6 (near the mounting end of the heating module 7). This sealing plate 66 separates the internal space of the heating tank 6, so that the main heating medium is stored in a specific cavity formed between the sealing plate 66 and the main body of the heating tank 6.

[0050] The sealing plate 66 has through holes that precisely correspond to the number and position of the PTC heating rods 72 to be inserted. To achieve a seal when the PTC heating rods 72 pass through the sealing plate 66, a dual approach is taken: First, at the point where the PTC heating rod 72 needs to pass through the sealing plate 66, one or more annular sealing grooves 74 are machined on its surface; second, sealing rings 661 (such as O-rings or specially shaped seals) are installed on the outer surface of the sealing plate 66 corresponding to each through hole (i.e., the side facing the heating module 7). When the PTC heating rod 72 is inserted from the heating module 7 end, passes through the through hole of the sealing plate 66, and reaches the predetermined position inside the heating tank 6, the sealing grooves 74 on its surface precisely engage and press against the sealing rings 661 installed on the sealing plate 66, forming a reliable dynamic or static seal.

[0051] The sealing plate 66 itself forms a boundary of the heating chamber. When the PTC heating rod 72 passes through this boundary, the precise fit between its own sealing groove 74 and the sealing ring 661 on the sealing plate 66 prevents the medium inside the heating chamber from leaking outward along the gap between the surface of the PTC heating rod 72 and the through hole. This constitutes the second critical seal in addition to the flange connection.

[0052] In some embodiments of this utility model, such as Figure 4 , Figure 6 , Figure 7As shown, to further improve the safety and convenience of replacing the PTC heating rod 72, this embodiment cleverly incorporates a spring check valve 662 on the inner surface of each through hole (i.e., the side facing the heating medium) of the sealing plate 66. This check valve remains closed by the spring force when no external force is applied, thus sealing the through hole. The insertion end of the PTC heating rod 72 is designed as a smooth dome 73.

[0053] When the PTC heating rod 72 is inserted, its dome 73 at the front end first contacts and pushes the valve core of the spring check valve 662, overcoming the spring force to open it, thus allowing the PTC heating rod 72 to smoothly pass through the sealing plate 66 and enter the heating chamber. When the PTC rod needs to be removed for replacement or maintenance, once the dome 73 disengages from the valve core of the check valve, the spring force immediately pushes the valve core back to its original position, closing the through hole, thereby preventing the high-temperature and high-pressure medium in the heating chamber from gushing out in large quantities from the through hole.

[0054] In some embodiments of this utility model, such as Figure 4 , Figure 6 As shown, to ensure that the PTC heating rod 72 remains in the optimal working position after being inserted into the heating tank 6 (e.g., ensuring that its heating section is fully immersed in the medium and that its end does not collide with the tank wall or other components), one or more positioning bosses 67 are provided inside the heating tank 6 (e.g., at the bottom of the heating cavity or at the far end relative to the sealing plate 66). The shape or position of the positioning boss 67 matches the dome 73 at the end of the PTC heating rod 72. When the PTC heating rod 72 is inserted to a predetermined depth, the dome 73 at its end will contact and engage with the positioning boss 67.

[0055] The locating boss 67 is designed to provide a physical limit point to prevent the PTC heating rod 72 from being over-inserted. The mating relationship between the dome 73 and the locating boss 67 ensures that the same, correct axial position is achieved with every installation.

[0056] In some embodiments of this invention, to significantly improve the efficiency of heat transfer from the PTC heating rod 72 to the heating medium, a honeycomb-shaped thermally conductive aluminum fin is wrapped around its outer surface. These fins are made of aluminum, a material with high thermal conductivity, and are arranged in a honeycomb pattern, which refers to a hexagonal unit structure resembling a honeycomb. This design greatly expands the surface area of ​​the heating rod in contact with the medium. The spacing between adjacent fins is optimized to 2 mm, which ensures sufficient heat exchange area while allowing the heating medium to flow smoothly through the fin gaps for effective convective heat transfer.

[0057] During operation, the heat generated by the PTC element is first conducted to the metal casing surrounding it, and then rapidly conducted through the highly thermally conductive aluminum fins to the extensive surface of the fins. The heating medium flowing through the gaps between the fins undergoes intense convective heat transfer with these hot surfaces, thus efficiently transferring heat from the PTC rod to the medium. The honeycomb structure may help increase structural strength and maximize surface area within a limited space.

[0058] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0059] The above description is merely an example and illustration of the present utility model. Those skilled in the art can make various modifications or additions to the specific embodiments described or use similar methods to replace them, as long as they do not deviate from the utility model or exceed the scope defined in the claims, they should all fall within the protection scope of the present utility model.

Claims

1. An energy-saving variable frequency mold temperature controller, comprising a control module and a machine body, characterized in that, The machine body is equipped with a heating tank and a variable frequency circulating pump. The heating tank stores a heating medium. One side of the heating tank is provided with an inlet pipe for the heating medium to flow in, and the other side is provided with an outlet pipe for the heating medium to flow to the variable frequency circulating pump. The heating tank is detachably connected to a heating module, which is electrically connected to a PTC heating rod. The PTC heating rod is inserted into the heating tank to heat the heating medium. The control module is used to control the heating power of the PTC heating rod and the speed of the variable frequency circulating pump.

2. The energy-saving variable frequency mold temperature controller according to claim 1, characterized in that, The machine body is provided with a pipe inlet and a pipe outlet on the outside. The pipe inlet connects the fluid channel inside the mold to the inlet pipe, and the pipe outlet connects the fluid channel inside the mold to the outlet pipe.

3. The energy-saving variable frequency mold temperature controller according to claim 1, characterized in that, The machine body is equipped with a temperature gauge, which is electrically connected to the control module and is used to display the internal temperature of the heating barrel.

4. The energy-saving variable frequency mold temperature controller according to claim 1, characterized in that, The heating barrel has a double-layer jacketed structure, with an insulation layer filling the space between the jackets.

5. An energy-saving variable frequency mold temperature controller according to claim 1, characterized in that, The inner wall of the heating barrel is provided with a spiral guide groove, which extends spirally along the axial direction of the heating barrel.

6. The energy-saving variable frequency mold temperature controller according to claim 1, characterized in that, The heating tank and the heating module are respectively provided with flange one and flange two on the end face, which are connected by screws. Flange one is provided with sealing ring one on the mating surface, and flange two is provided with sealing groove one that matches sealing ring one on the mating surface.

7. An energy-saving variable frequency mold temperature controller according to claim 1, characterized in that, The heating barrel is equipped with a sealing plate, and the heating medium is stored in the cavity formed between the sealing plate and the heating barrel. The sealing plate has a through hole that matches the position of the PTC heating rod. The surface of the PTC heating rod has a sealing groove. The outer surface of the sealing plate corresponding to the through hole has a sealing ring. After the PTC heating rod is inserted into the heating barrel at a suitable position, the sealing groove and the sealing ring are engaged.

8. An energy-saving variable frequency mold temperature controller according to claim 7, characterized in that, The sealing plate has a spring check valve on the inner surface of the corresponding through hole, and the end of the PTC heating rod has a dome, which is used to open the spring check valve.

9. An energy-saving variable frequency mold temperature controller according to claim 8, characterized in that, The heating barrel is provided with a positioning boss inside. After the PTC heating rod is inserted into the heating barrel, the dome is fitted with the positioning boss.

10. An energy-saving variable frequency mold temperature controller according to claim 1, characterized in that, The outer surface of the PTC heating rod is wrapped with honeycomb-shaped thermally conductive aluminum fins, and the spacing between adjacent fins is 2mm.

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