Power Accumulating Device for Injection Molding Servo Amplifiers
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Solution Overview
Problem
Existing power supply systems for electrically driven injection molding machines require high power capacity during peak processes like injection molding, leading to increased electricity bills and potential voltage drops in factories, especially when multiple machines operate simultaneously.
Innovation Solution
A power supply device comprising an AC/DC converter and a power accumulating device that stores energy in a capacitor, allowing for the supply of a higher DC voltage to servo amplifiers during peak demand, reducing the need for large power capacity and smoothing power consumption across processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large servo motor of high output is employed to meet the high power demand during injection process, then the injection process can be performed at high speed with complex and fine shapes, but the power capacity required for the power receiving equipment increases and electricity bill becomes high
Solution Approach 1:
The power accumulating device stores electric energy in advance during periods when power demand is low (such as during mold clamping, mold opening, or ejecting processes), so that the stored energy can be supplied during the injection process when high power is needed. This preliminary energy accumulation allows the system to provide high output power temporarily without requiring the power receiving equipment to have large power capacity.
2Speed
If a large servo motor is used to provide high output power for injection process, then super-high speed injection molding can be achieved, but the maximum power required increases causing voltage drop and breaker tripping when multiple machines operate simultaneously
Solution Approach 1:
The power accumulating device acts as an intermediary energy storage element between the power receiving equipment and the servo motor. It decouples the maximum power requirement from the continuous power consumption, allowing the servo motor to receive high power temporarily during injection without requiring the power receiving equipment to be sized for maximum power. This intermediary buffer prevents voltage drops and breaker tripping.
3Power
If the power capacity of power receiving equipment is increased to accommodate peak power demand, then high output power can be supplied during injection process, but the electricity bill increases due to contracted maximum power
Solution Approach 1:
The system changes the temporal distribution of power consumption by accumulating energy during low-demand periods and releasing it during high-demand periods. This parameter change in power delivery timing allows the power receiving equipment to be sized based on average power consumption rather than peak power consumption, reducing the contracted maximum power and thereby reducing the electricity bill while still providing sufficient power during injection processes.
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
This solution reduces the required power capacity in power receiving equipment, lowers electricity bills, and prevents voltage drops by providing high voltage DC power during peak processes, allowing for efficient operation of multiple injection molding machines without overloading the power supply.
Implementation Method 1
the power accumulating device is configured to accumulate electric power supplied from the DC circuit in a capacitor
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3D
AI summary
A power supply device for supplying an electric power to a servo amplifier is configured by an AC/DC converter and a power accumulating device. Among a molding cycle, during a process where an amount of consumed power is small, a DC voltage is supplied to the servo amplifier from the AC/DC converter and a power is accumulated in the power accumulating device. In a process such as an injection process where a large power is required, a high DC voltage is supplied to the servo amplifier from the power accumulating device in place of the AC/DC converter.