Hydraulic Drive Output Selection for Injection Molding Energy Efficiency
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Solution Overview
Problem
Conventional hydraulic drive apparatuses for injection molding machines do not provide accurate information on the operation state, leading to inefficient energy usage and wasteful energy consumption due to the influence of hydraulic circuit configurations, where the actual mold closing speed does not drop proportionally with reduced drive output.
Innovation Solution
A drive method that involves detecting physical quantities such as motor current and mold closing time for different drive outputs, allowing users to select optimal drive outputs based on energy consumption and operation state, thereby optimizing energy savings and avoiding wasteful energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the drive output of the hydraulic drive source is lowered to reduce energy consumption, then the motor current decreases significantly, but the mold closing speed does not drop proportionally due to hydraulic circuit losses
Solution Approach 1:
The system introduces feedback mechanisms by detecting actual physical quantities (motor current, mold closing time, operating state) and providing this information back to the control unit. This allows the system to monitor and adjust drive output based on actual performance, enabling precise energy optimization while maintaining accurate awareness of operation state despite hydraulic circuit losses
Solution Approach 2:
The invention replaces direct mechanical observation of operation state with electronic detection and information processing. Sensors detect physical quantities (current, time, position) and convert them into electrical signals for processing, substituting mechanical measurement methods with more precise electronic measurement and information display systems
2Loss of energy
If the drive output is reduced to save energy, then motor current drops by about 40%, but the mold closing time increases only slightly by about 10%
Solution Approach 1:
The system dynamically adjusts drive output based on detected operation state and energy consumption data. Rather than using fixed drive output settings, the control unit can optimize the drive output in real-time based on actual mold closing time and energy consumption patterns, allowing flexible balancing between energy savings and productivity requirements
Solution Approach 2:
The invention changes operating parameters (drive output percentage) and monitors the resulting changes in physical quantities (motor current, mold closing time). By detecting and comparing these parameter changes, the system identifies optimal drive output settings that achieve desired energy savings while maintaining acceptable productivity levels
3Ease of operation
If conventional hydraulic drive apparatus is used without accurate operation state detection, then the system is simple to operate, but energy is wasted due to inability to optimize drive output
Solution Approach 1:
The system performs self-diagnosis and self-optimization by automatically detecting operation state and energy consumption, then using this information to determine optimal drive output settings. The control unit can automatically adjust parameters or provide recommendations, reducing the need for manual optimization while eliminating wasteful energy consumption
Solution Approach 2:
The invention introduces an information intermediary layer between the hydraulic drive system and the operator. Detection units and control units serve as intermediaries that gather data, process information, and present optimized settings to the operator, making energy optimization accessible without requiring deep technical knowledge
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables users to make informed decisions on drive output settings, leading to improved energy efficiency and reduced energy consumption by providing accurate information on operation states and energy usage, thus optimizing energy savings in hydraulic systems.
Implementation Method 1
a servomotor for driving the hydraulic pump, in which the discharge flow rate and discharge pressure of the hydraulic pump are controlled through control of the rotational speed of the servomotor
Implementation Method 2
a hydraulic drive apparatus for an injection molding machine disclosed in Japanese Patent No. 3455479 is an example of a conventional drive apparatus which drives a hydraulic actuator provided in an injection molding machine by means of a hydraulic drive source
Data Source
AI summary
An actuator is driven by use of a power drive source, while drive output of the power drive source is switched among a plurality of different drive outputs. Values of a physical quantity regarding an operation state of the actuator and a physical quantity regarding energy consumption corresponding to the operation state are detected. One of the drive outputs is selected on the basis of the detected values and in accordance with a predetermined selection method, and the actuator is driven with the selected drive output.