Automatically Optimizing Injection Molding Energy Efficiency

At K 2022, KraussMaffei will introduce smart assistants, control upgrades and hardware add-ons that will optimize the energy efficiency of its injection molding machines. KM says its BluePower servodrive control for hydraulic pumps can optimize the machine’s production and energy efficiency. As an example, KM put forward the potential energy savings for a GX 1300 injection molding machine with a clamp force of 1325 metric tons (m.t.). Assuming 6000 production hours, a 2.5-lb shot (1155g) and a cycle time of 60.3 seconds, KM says using the BluePower servodrive would save up to 75,000 kWh/yr. In the U.S., given current average electricity rate of 10.42 cents/kWh, annual energy savings would be nearly $8000 with a reduction of CO₂ emissions of up to 30 tons.

KM also points to the Weekly Timer function on its MC6 control, which can be taught exactly when oil preheating and barrel and mold heating have to be started to ensure the press is ready to go at the start of production and machine-waiting times can be eliminated. This can also be configured individually for each day of the week and can compensate for ambient temperature fluctuations as weather conditions change.

KM is also putting forward its EcoPac insulating strips for the barrel, promising up to 40% less energy consumption during injection molding. The EcoPac insulating sleeves are wrapped around the barrel and available for all injection unit sizes. Stabilizing the temperature profile and increasing process stability, the insulative strips can reduce heating time by up to 30%. Doing so, can lead to energy consumption savings of up to 40%, enabling a quick return on investment. As an example, KM says if an MX 1000 injection molding machine with a clamp force of 1000 tons utilized the insulation over 6000 production hours, energy consumption would be cut by up to 24,000 kWh, while as much as 9.6 fewer tons of  CO₂ would be released.

For machine operators that might lack the time to optimize a process, KM is offering the EcoButton. This function allows the machine control to look at plasticizing time or speed, clamping force, injection pressure limit and accumulator pressure and determine the optimum energy values for each. After a few reference cycles, optimized parameters take effect for each one. Finally, the company says its dataXplorer can assign the energy consumption to each individual process step and serves as the interface to an energy management system.