怎样降低注塑加工能耗对一家注塑制品厂而言，注塑成型过程所占据的能耗大约

怎样降低注塑加工能耗
对一家注塑制品厂而言，注塑成型过程所占据的能耗大约占到60%，因而有效降低注塑机的能耗是注塑工厂节能的重要途径。随着注塑机本身节能技术的不断提升，降低注塑工厂整体能耗需要从生产管理、加工工艺与物料、生产车间配套等方面全面考虑。
（一）生产车间
生产车间布局着重从两方面考虑：满足生产需求条件下，根据生产流程进行优化布局的同时，满足特定生产条件下灵活用能的要求。
1. 电力供应，在满足稳定生产所需电力的同时有适当的裕量，不至于富余量过大造成无功能耗过大。
2. 建设高效冷却水循环设施，为冷却水系统配备有效绝缘保温系统。
3. 优化车间整体生产布局。很多生产具有先后工序配合，合理的配合可以减少周转所需时间与能耗，提高生产效率。
4. 对照明等厂房设备尽量考虑以最有效的小单元进行分别控制。
5. 对车间设备做好定期维护保养，避免因为公用设施损坏，影响生产正常操作，进而造成能耗增加。
（二）注塑成型机
注塑机是注塑车间能源消耗大户，耗能主要为电机与加热两部分。
1. 根据制品特点选择合适的注塑机。“大马拉小车”式的注塑加工往往意味着大量的能源浪费。
2. 选用全电动注塑机与混合动力注塑机，具有优异的节能效果，可节能20-80%。
3. 采用新型加热技术，如电磁感应加热、红外加热等，可实现20-70%的加热节能。
4. 为加热、冷却系统采用有效的保温绝缘措施，减少热、冷损失。
5. 保持设备传动部件良好的润滑，减少由于摩擦增大或设备运行不稳定引起的能耗增加。
6. 选用低压缩液压油，减少液压系统工作能源浪费。
7. 采用并行动作、多腔注塑、多组分注塑等加工技术可显著节能。
8. 传统的机械液压式注塑机也有多种节能驱动系统，代替传统的定量泵机械液压注塑机节能效果显著。
9. 定期对加热冷却管道维护，确保管道内部无杂质、水垢堵塞等现象发生，实现设计的加热、冷却效率。
10. 确保注塑机处于良好的工作状态。不稳定的加工过程可能导致次品产生，并增加耗能。
11. 确保所用设备适合所加工的产品，如PVC加工常需采用专门螺杆。
（三）注塑模具
模具结构与模具状况往往对注塑成型周期及加工能耗有显著影响。
1. 合理的模具设计，包括流道设计、浇口形式、型腔数、加热冷却水道等，均有助于降低能耗。
2. 采用热流道模具，不仅可以节约材料，减少物料回收能耗，其成型过程本身也具有显著的节能效果。
3. 仿形快冷快热模具可以显著节约加工能耗，并实现更佳表面质量。
4. 确保各腔均衡充填，有助于缩短成型周期，保证制品质量均一性，有优异的节能效果。
5. 采用CAE辅助设计技术进行模具设计、模流分析与模拟，可以减少模具调试与多次修模的耗能。
6. 在保证产品质量的前提下，使用较低锁模力成型，有助延长模具寿命，利于模具快速充满，有助节能。
7. 做好模具维护工作，确保有效的加热冷却水道状况。
（四）周边设备
1. 选择适合能力的辅助设备，既满足工作要求，又不会富裕量过大。
2. 做好设备维护保养，确保设备处于正常工作状态。工作不正常的辅助设备，会引起生产不稳定甚至制件品质不良，造成能耗增加。
3. 优化主机与周边设备的配合工作与运作顺序。
4. 优化周边设备与生产设备的相互位置，在不影响操作条件下，尽可能让周边设备距离主机近些。
5. 很多辅助设备厂家提供按需供能的系统，可以实现显著节能。
6. 使用快速换模设备，减少生产中切换产品所需要的等待时间。
（五）物料
不同物料加工的耗能不同，同时物料的管理不善或回收物料的管理不当都会造成生产能耗增加。
1. 在满足制品性能的前提下，应优先选择较低加工能耗的物料。
2. 在满足使用性能与成本优化的条件下，优先选择高流动性物料。
3. 注意不同供应商的材料可能有不同的工艺条件。
4. 物料干燥处理，最好随干燥随用，避免干燥后物料返潮浪费能源。
5. 做好物料保存，防止物料混入杂质或异物，最终造成制品不良。
6. 部分制品允许加入一定再生料，但应注意再生料的保存与洁净度，避免因材料不洁产生制件不良。
（六）加工工艺
1. 在满足制品性能的前提下，使用最短的成型周期。
2. 若无特殊因素影响，尽可能使用供应商推荐的加工工艺进行加工。
3. 针对特定制品与模具，对所有稳定的设备与工艺参数进行保存，缩短下次更换生产时调机时间。
4. 优化工艺，采用较低的锁模力、较短的冷却时间与保压时间。
（七）采用新技术
1. 采用辅助成型技术，如气体辅助，液体辅助，蒸汽辅助，微发泡注塑成型技术等。
2. 采用单元化成型方案，减少中间环节。
3. 采用模内焊接、模内喷涂、模内装配、模内装饰等新技术。
4. 采用新的低压成型技术，缩短成型周期，同时可降低熔体温度。
5. 采用能量再生系统。
（八）生产管理
1. 一次性生产高品质的产品，降低不良率是最大的节能。
2. 整个生产系统的维护保养与耗能密切相关。这不仅涉及主机，还有周边及工厂设备，例如如果车间换模吊车故障，需人力换模，势必延长设备等候时间，造成设备能耗增加。
3. 配备车间能耗监控系统，便于企业有目的的实施能源分析与改善。
4. 设备停机维修保养时，不仅检查设备本身的保养内容与项目，更要注意设备与其他系统连接处的状况，工作性能是否可靠等。
5. 经常性与行业标杆进行比较，看是否还有进一步改善的空间。
6. 与供应商建立可靠合约与合作关系，对企业节能管理有益无害。

結果 (英文) 1:

How to reduce energy consumption of injection moldingA plastic products factory, occupied by the injection molding process energy consumption accounted for approximately 60%, thus effectively reduce the energy consumption of the injection molding machine is an important way of energy-saving injection molding plant. As the technology of energy-saving injection molding machine itself rising, reducing energy consumption from injection molding factory production management, process and materials, workshop support, comprehensive consideration.(A) workshopWorkshop layout focuses on two aspects: meet the needs of production conditions, according to production processes to optimize the layout at the same time, meet the requirements of specific production conditions and flexible use.1. power supply meet the stability needed for the production of electricity at the same time have adequate margin, not too much surplus without causing excessive energy consumption.2. building efficient cooling water recycling facilities, equipped with effective insulation thermal insulation systems for cooling water system.3. optimize the workshop overall layout. Many production processes with reasonably fit can reduce the turn-around time and energy required, improving production efficiency.4. lighting equipment take into account as far as possible the most effective small unit control.5. do regular maintenance of workshop equipment and avoid damage to public facilities, affecting the normal operation of production, resulting in increased energy consumption.(B) injection molding machineInjection molding machines injection molding plant energy consumption energy consumption for motor and heating of two main parts.1. product characteristic selection of injection molding machine. "Big horse-drawn car" type of injection molding often means a lot of wasted energy.2. use all electric injection molding machine with hybrid injection molding machine, with excellent energy-saving effects can be energy-saving 20-80%.3. the introduction of new heating technologies, such as infrared heat and electromagnetic induction heating and 20-70% heating energy-saving can be achieved.4. for the heating and cooling system with effective insulation measures reducing the loss of heat, cold.5. keep good lubrication the equipment components and reduce the friction increases or increased energy consumption due to unstable operation of the device.6. use low compression of hydraulic oil, and reduce the waste of energy in hydraulic system.7. adopt parallel actions, multi-cavity injection moulding, multicomponent injection molding processing technology can be a significant energy saving.8. traditional mechanical-hydraulic injection molding machine also has a variety of energy-saving drive systems to replace traditional fixed displacement pump hydraulic injection molding machines with remarkable energy savings.9. periodic heating and cooling piping maintenance, ensure the internal impurities, scale blockage phenomenon occurs, for designing heating and cooling efficiency.10. ensure that injection moulding machine in good working condition. Unstable processes can lead to defects and increased energy consumption.11. ensure that the devices are suitable for the processing of products such as PVC-processing often needs special screw.(C) injection moldMould and die less often of injection molding cycle and process energy consumption has a significant impact.1. rational mold design, including design, gate form heating cooling water channel, number of cavities, will help to reduce energy consumption.2. adopt hot runner mold, can not only save materials, reducing energy consumption of materials recovery and its forming process itself has significant energy saving effects.3. copying faster processing of fast mold can significantly reduce energy consumption and achieve better surface quality.4. ensure balanced filling the cavity, helps to reduce the cycle time to ensure product quality and uniformity, excellent energy-saving effect.5. use CAE computer aided design technology for the mold design and mold flow analysis and simulation, the dissipated energy can reduce debug and repair many times.6. on the premise of ensuring product quality and use the lower clamping force shaped, will prolong tool life, conducive to rapid tooling is full, help save energy.7. do tool maintenance work, ensuring effective heating cooling channels.(D) the peripheral equipment1. ability to select secondary device meets the job requirements, and not too much richer.2. equipment maintenance, make sure that the device is in normal working state. Auxiliary equipment is not working properly, can cause instability or poor product quality, resulting in increased energy consumption.3. optimize the hosts work with peripheral equipment and operation sequence.4. optimize the position of peripheral equipment and production equipment, without affecting the operating conditions and peripheral equipment as possible host in close proximity.5. auxiliary equipment manufacturers to provide on-demand energy supply system, you can achieve significant energy saving.6. use quick die change equipment, reducing the waiting time needed for production switching products.(E) itemsDifferent energy of the material processing different materials simultaneously mismanagement or improper management of recyclable materials will result in increased energy consumption.1. meet the premise of performance, should choose a lower energy consumption of processed materials.2. in conditions of satisfaction with performance and cost optimization, choose a high flow material.3. the note material of different suppliers may have different processing conditions.4. drying process, preferably with dry, avoid wasting energy material damp after drying.5. are kept to prevent materials mixed with impurities or foreign bodies, resulting in poor products.6. some products allow adding renewable materials, but the preservation of renewable and clean, avoid parts due to unclean side.(Vi) processing1. the premise of meeting the performance, use the shortest possible cycle time.2. If there were no special factors, using suppliers recommended a process as possible for processing.3. for a specific product and tooling, to save all the stable equipment and process parameters, shortening production turn time next time.4. the optimization process, lower clamping force, a shorter cooling time and pressure holding time.(G) the adoption of new technologies1. using assisted technologies, such as gas-assist, liquid supplement steam-assisted, Microcellular injection molding technology.2. adopt modular programme to reduce intermediate links.3. welding of mold, mold spray, new technologies such as in-mold Assembly, mold decoration.4. the introduction of new low pressure moulding technology, shortening the cycle time, and can reduce the melting temperature.5. the use of energy regeneration system.(H) production management1. disposable production of high-quality products, reduced defective rate is one of the largest energy conservation.2. the entire production system is closely related to the maintenance and energy consumption. This involves not only the host, there are accessories and factory equipment, for example, if workshop retooling crane faults and requirements change, will prolong the waiting time, resulting in increased consumption.3. equipped with plant energy monitoring system, easy to implement enterprise has the purpose of energy analysis and improvement.4. when equipment breakdowns and maintenance not only checks the device itself is maintained and the project, pay attention to the device is connected to another system, reliability of performance.5. regularly with industry benchmark to compare and see if there is room for further improvement.6. reliable contracts and partnerships with suppliers of enterprise energy management is good.

結果 (英文) 2:

How to reduce the energy consumption of injection molding process
for an injection plant, the energy consumption of the injection molding process occupies approximately accounted for 60%, thus effectively reducing the energy consumption of the injection molding machine is an important way to energy-efficient injection molding factory. With the continuous improvement of injection molding machine itself, energy-saving technologies, reducing overall energy consumption requires a comprehensive injection molding plant from the viewpoint of production management, processing technology and materials, such as supporting the production workshop.
(A) production workshop
production workshop layout focuses on two aspects to consider: satisfy the production demand conditions, according to the production process at the same time to optimize the layout to meet specific production conditions and flexible energy requirements.
1. electricity supply, at the same time meet the stability needed for the production of electricity appropriate margin, not surplus caused by excessive consumption of too much non-functional.
2. Efficient cooling water facilities construction, the cooling water system is equipped with effective insulation insulation system.
3. optimize overall production workshop layout. Many production processes have successively with reasonable combinations can reduce the turnaround time required and energy consumption and improve productivity.
4. lighting plant and equipment as much as possible to consider the most effective small units are controlled.
5. Workshop equipment do regular maintenance to avoid damage due to utilities, affecting the normal operation of production, thus resulting in increased energy consumption.
(B) injection molding machine
is an injection molding machine shop large energy consumption, mainly for electrical and heating energy consumption of two parts.
1. Select the appropriate injection molding machine according to product characteristics. Injection processing "big horse cart" type often means a lot of energy wasted.
2. The selection of all-electric injection molding machines and hybrid injection molding machines, with excellent energy-saving effect, can saving 20 to 80%.
3. The use of new heating technologies such as electromagnetic induction heating, infrared heating, can achieve 20 to 70% of heating energy savings.
4. The heating and cooling system uses thermal insulation effective measures to reduce the heat, cold loss.
5. Keep good lubrication equipment transmission parts, reduce the power consumption increases friction or instability caused by an increase in equipment operation.
6. Use low compression hydraulic oil, reduce hydraulic system energy waste.
7. The parallel operation, multi-cavity injection molding, multi-component injection molding and other processing techniques can be significant energy savings.
8. The conventional mechanical hydraulic injection molding machine also has a variety of energy-saving drive system, instead of the traditional quantitative pump mechanical hydraulic injection molding machine energy-saving effect is remarkable.
9. Regular maintenance of heating and cooling pipes, ensure that the internal pipeline free of impurities, scale blockage occurs, the realization of the design of heating, cooling efficiency.
10. Ensure that the injection molding machine in good working condition. The process may lead to instability defect generation, and increase energy.
11. ensure the equipment used for the processing, such as PVC processing often requires the use of special screws.
(C) injection mold
and die mold structure condition tend to have a significant impact on the injection molding cycle time and processing power consumption.
1. reasonable mold design, including the flow channel design, gate form, Cavity, heating cooling water, etc., all contribute to reduce energy consumption.
2. The use of hot runner molds, not only can save materials, reduce energy consumption material recovery, the molding process itself also has significant energy savings.
3. Copying fast cooled fast hot mold can significantly save energy processing, and to achieve a better surface quality.
4. Make sure that each chamber balancing filling helps shorten the molding cycle to ensure product quality and uniformity, excellent energy saving effect.
5. The use of CAE-aided design technology for mold design, mold flow analysis and simulation, debugging can reduce mold and multiple repair mode energy consumption.
6. Under the premise of ensuring product quality, the use of a lower clamping force molding, help extend die life, which will help mold quickly filled, saving power.
7. mold maintenance work to do to ensure effective heating and cooling condition of the watercourse.
(Iv) Peripherals
1. Select the appropriate capacity auxiliary equipment, both to meet the job requirements, without excessive opulence.
2. do equipment maintenance, ensure that the equipment is in normal working condition. Auxiliary equipment is not working properly, it will cause the production of unstable or poor quality parts, resulting in increased energy consumption.
3. Optimization of work with the operating sequence of the host and peripheral devices.
4. Optimize the mutual position of peripheral equipment and production equipment, without affecting the operating conditions, as far as possible from the host computer peripheral equipment closer.
5. Many auxiliary equipment manufacturers to provide systems for energy demand, can achieve significant energy savings.
6. Use the quick die change equipment to reduce the production of switch products required waiting time.
(V) material
of different materials processing energy is different, while mismanagement materials or recyclable materials mismanagement will cause an increase in energy consumption.
1. Under the premise to meet product performance, should give priority to lower processing material consumption.
2. Under meet the performance and cost-optimized conditions, the preference for high mobility materials.
3. Note the different material suppliers may have different process conditions.
The material drying, preferably with drying with the use of the material after drying damp to avoid wasting energy.
5. A good save material, to prevent the material mixed with impurities or foreign body, eventually leading to bad products.
6. Some products allow adding some recycled materials, it should be noted that the preservation of renewable materials and cleanliness to avoid adverse material dirty parts.
(F) process
to meet product performance 1. Under the premise of using the shortest cycle times.
2. If there is no influence of special factors, as far as possible the use of vendor-recommended process for processing.
3. For specific products and mold, for all stable equipment and process parameters to save, shorten the next tune-up time when changing production.
4. The optimization process, using a lower clamping force, a shorter cooling time and holding time.
(Vii) the introduction of new technology
1. The use of assisted molding technology, such as gas-assisted, auxiliary liquid, steam-assisted, micro-foam injection molding technology.
2. The use of a unit forming programs to reduce intermediate links.
3. The use of in-mold welding, in-mold coating, in-mold assembly, in-mold decoration and other new technologies.
The introduction of new low-pressure molding technique, to shorten the molding cycle, while reducing the melt temperature.
5. The use of renewable energy systems.
(Viii) Production Management
1. disposable production of high-quality products, reduce the defect rate is the greatest energy savings.
2. The entire production system is closely related to the maintenance and energy consumption. This involves not only the host, as well as peripheral and factory equipment, such as cranes fault if the workshop for mold, you need manpower for mold, bound to prolong the waiting time, resulting in increased device consumption.
3. The workshop is equipped with energy monitoring system, to facilitate the implementation of the enterprise purpose of energy analysis and improvement.
4. equipment maintenance shutdown, not only to check the contents of the device itself maintenance and projects, but also to pay attention to the situation with other devices connected to the system at the working performance is reliable.
5. Recurrent compare with the industry benchmark, to see whether there is space for further improvement.
6. contracts with suppliers to establish a reliable and cooperative relations, enterprise energy management hurt.

結果 (英文) 3:

How to reduce the energy consumption of injection molding process, the energy consumption of injection molding process is about 60%, which is an important way to reduce the energy consumption of injection molding machine. With the continuous improvement of energy saving technology in the injection molding machine, reducing the overall energy consumption of the injection molding plant needs to be considered comprehensively from the aspects of production management, processing technology and materials, production workshop, and so on. The layout of the production workshop in the production workshop is mainly from two aspects: to meet the requirements of production and optimize the layout according to the production process and meet the requirements of the flexible use of the specific production conditions.
1. power supply,In order to meet the requirements of the stability of the power needed for the same time, there is an appropriate margin, not too large to produce a large amount of excess capacity.
2. construction of efficient cooling water recycling facilities for the cooling water system with an effective insulation insulation system.
3. optimization workshop overall production layout. Many production processes have successively working procedure, reasonable coordination can reduce the time and energy consumption, improve production efficiency.
4. lighting and other plant equipment as far as possible to consider the most effective small units for control.
5. on the workshop equipment to do regular maintenance, to avoid damage to public facilities, affect the production of normal operation, and thus cause energy consumption.
(two) injection molding machine injection molding machine injection molding machine is a large energy consumption, energy consumption is mainly for the two part of the motor and heating.
1. according to the characteristics of products to choose a suitable injection molding machine. "Big horse pull car" type of injection molding process often means a lot of energy waste.
2. selects all electric injection molding machine and the hybrid injection molding machine, has the outstanding energy saving effect, can save energy 20-80%.
3. adopts new heating technology, such as electromagnetic induction heating, infrared heating, etc., can realize the 20-70% heating energy saving.
4. for heating, cooling system using effective insulation measures to reduce heat, cold loss.
5. maintain good lubrication of equipment,Reduce the increase in energy consumption due to the increase of friction or the operation of the device.
6. selection of low compression hydraulic oil, reduce the hydraulic system work energy waste.
7. adopts the technology of parallel operation, multi cavity injection molding, injection molding and other processing techniques, which can save energy.
8. traditional mechanical hydraulic injection molding machine also has a variety of energy-saving drive system, instead of the traditional quantitative pump mechanical hydraulic injection molding machine energy saving effect is remarkable.
9. regularly on heating and cooling pipeline maintenance, to ensure that the internal pipeline without impurities, scale blockage phenomenon, to achieve the design of the heating and cooling efficiency.
10. to ensure that the injection molding machine is in good working condition.The unstable machining process may lead to inferior, and increase energy consumption.
11. to ensure that the use of equipment for the processing of products, such as the use of special PVC processing.
(three) the structure and mold of injection mold die often have a significant effect on the injection molding cycle and energy consumption.
1. reasonable mold design, including the flow channel design, gate form, the type of cavity number, heating cooling water, etc., are helpful to reduce energy consumption.
2. uses hot runner mold, not only can save material, reduce material recycling energy consumption, the process itself has a significant energy saving effect.
3.Fast cooling fast thermal profiling mould can significantly save energy consumption and processing, achieve better surface quality.
4. to ensure that the filling of the cavity is helpful to shorten the molding cycle, to ensure the quality of the product is uniform, and has excellent energy saving effect.
5. using CAE aided design technology for mold design, mold flow analysis and simulation, it can reduce the mold debugging and the energy consumption of many times.
6. in the premise of ensuring the quality of the product, the use of lower clamping force molding, help to extend the life of the mold, the mold is full of fast, help energy saving.
7. to do the mold maintenance work, to ensure the effective heating cooling water channel condition.
(four) peripheral equipment
1.Choose the auxiliary equipment for the ability, not only to meet the work requirements, but also not rich.
2. good equipment maintenance, to ensure that the equipment is in normal working condition. The work is not normal auxiliary equipment, will cause the production of unstable or even poor quality, resulting in an increase in energy consumption.
3. to optimize the operation and operation sequence of the host and peripheral equipment.
4. optimization of the peripheral equipment and production equipment, the location of the operation, in the condition of no influence, as far as possible to make the surrounding equipment closer to the host.
5. a lot of auxiliary equipment manufacturers to provide on-demand system, can achieve significant energy saving.
6. using fast and changing device,Reduce the waiting time needed to switch products in production.
(five) the energy consumption of different materials is different, and the management of the material is not good or the improper management of the material will cause the increase of production energy consumption.
1. to meet the performance of the premise, the priority should be given to the lower processing energy consumption of the material.
2. to meet the use of performance and cost optimization of the conditions, the first choice of high mobility materials.
3. note that different suppliers of materials may have different process conditions. Drying process of
4. material, with the best drying with use, avoid the waste of energy after drying damp.
5. good material preservation,To prevent the material mixed with impurities or foreign body, resulting in poor products.
6. part of the product allows to add a certain recycled material, but should pay attention to the preservation of renewable materials and clean degree, to avoid the material is not clean produce parts bad.
(six) processing technology
1. to meet the performance of the premise, the use of the shortest molding cycle.
2. if there is no special factors, the use of the recommended processing technology for processing. . for a particular product and die, for all stable equipment and process parameter save next replacement production machine tune time to shorten.
4. optimization process, the lower clamping force,Shorter cooling time and holding time.
(seven) the use of new technologies, such as gas assisted, liquid assisted, steam assisted, micro foam injection molding technology, etc., using the new technology
1.
2. adopts the method of the unit to reduce the intermediate link.
3. adopts new technology, such as mold welding, mold spray, mold assembly, and interior decoration.
4. uses new low pressure molding technology, shorten the molding cycle, and can reduce the melt temperature.
5. uses energy regeneration system.
(eight) production management
1. a one-time production of high quality products, reduce the rate is the largest energy saving.
2.Maintenance and energy consumption of the whole production system is closely related to. This is not only related to the host, as well as the surrounding and factory equipment, such as the replacement of the workshop for crane failure, the need to change the human model, is bound to extend the waiting time of the equipment, resulting in increased energy consumption.
3. is equipped with workshop energy consumption monitoring system, which is convenient for enterprises to implement energy analysis and improvement.
4. equipment maintenance, not only check the maintenance of the equipment itself and the project, but also to pay attention to the connection between the equipment and other systems, the performance is reliable, etc..
5. regular and industry benchmark for comparison, to see whether there is further improvement in space.
6.With the supplier to establish a reliable contract and cooperative relations, the enterprise energy saving management useful.