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TWSC Jason He

Delta Hybrid Energy system. TWSC Jason He. Hydraulic & Servo drive combination. Hydraulic system , which features a good control of both pressure and flow and easy maintains, use control in injection machine.

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TWSC Jason He

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  1. Delta Hybrid Energy system TWSC JasonHe

  2. Hydraulic & Servo drive combination • Hydraulic system , which features a good control of both pressure and flow and easy maintains, use control in injection machine. • A hydraulic system with an servo drive is not only the perfect combination of servo motor and hydraulics • By eliminating the energy losses in the high pressure system by accurate pressure and flow control.

  3. hopper C lamp cylinder Screw chamber Screw Screw rotation cylinder inject unit eject unit Clamp unit eject unit Screw rotation pump out over flow Clamp cylinder control Ejection cylinder Injection cylinder AC Master controller M Screw rotation cylinder Master controller Injection Machine-Hydraulic system

  4. Injection Machine flow chart Material feed Material charge Injection Holding Pressure • The injection molding machine is a cycle process. Cycle time may range from 10 to 100 seconds and are control by cooling time and holding pressure time of the plastics. Mold close Ejection Mold clamp Cooling

  5. hopper Screw chamber Injection cylinder Traditional Injection Machine • Hydraulic system consumption 75-80% • Heater consumption 10-15% • Cooling system consumption 5-10% • Control components consumption 1-5%

  6. Traditional Injection Machine PQ controller + Fix flow pump + Induction motor Solenoid Valve The longer time to keep pressure and cool, the more energy will be consumed. Proportional Valve Fixed pump Induction Motor

  7. Energy Saving Servo Hydraulic System Built in PQC AC servo drive + Servo Motor + gear pump Pressure command & Flow command Advantage: Energy saved & space saved, fast productions; PQ controller is not requested; oil temperature is low, and oil tank is small. Solenoid Valve VFD VJ Pressure sensor Motor Encoder

  8. Structure of a HybridEnergy System 8

  9. Hybrid Energy System

  10. Delta Solutions of Injection Machine. Hydraulic pump AC Servo Motor Delta VFD-VJ drives are designed special parameters with built in pressure flow control (PQC) for injection machine. Pressure sensors(0-10V ) Pressure 175bar, Max flow 250L/min

  11. The Diagram of Hybrid Energy System 11

  12. HES Specification<140Bar Series> 230V Series

  13. HESSpecification<140BarSeries> 460V Series

  14. HES Specification<175Bar Series> 230V Series

  15. HES Specification<175Bar Series> 460V Series

  16. HSP External Part Housing coupling Motor power: 11 : 11kW 15 : 15kW 20：20kW Pump Fluid: 040 : 40cc/rev 050 : 50cc/rev 064 : 64cc/rev 080 : 80cc/rev 100 : 100cc/rev 125 : 125cc/rev Pressure sensor

  17. HSP Nameplate Information • Example for Flow system of 100L/min,380V HSP 040 11 43 A Version: A: Standard Product Name: Hybrid Servo Pump Motor power: 11 : 11kW 15 : 15kW 20 : 20kW Pump Capacity : 025 : 25cc/rev 032 : 32cc/rev 040 : 40cc/rev 050 : 50cc/rev 064 : 64cc/rev 080 : 80cc/rev 100 : 100cc/rev 125 : 125cc/rev Input Voltage: 23: 230V 3-PHASE 43: 460V 3-PHASE

  18. HES Nameplate Information • Example for Flow system of 125L/min,230V 125 H 23 A HES - version type Main input Voltage 23: 230V 3-PHASE Pressure system 43:460V 3-PHASE G: 140Bar H: 175Bar Z: Option Flow system capacity 063:63L/min 080:80L/min 100:100L/min 125:125L/min 160:200L.min 200:200L/min 250:250L/min Series Name( Hydraulic Energy System)

  19. VJ Drive Specification Power Range • 3 phase 220V series, Power Range: 5.5kw~37kw • 3 phase 380V series, Power Range: 5.5kw~75kw Special feature • Control method: SVPWM • Speed detector : resolver • Speed and Pressure input command: • support 3 point adjustment analog inputs • Pressure feedback command: DC 0~10 Voltage

  20. VJ Drive Specification 230V Series

  21. VJ Drive Specification 460V Series

  22. VJ Drive Specification General Specification

  23. 110 VL 23 A J VFD - VFD-VJ Series Version Type Main input Voltage 23: 230V 3-PHASE 43:460V 3-PHASE Application motor capacity 185:25HP(18.5kW) 450:60HP(45kW) 055:7.5HP(5.5kW) 075:10HP(7.5kW) 220:30HP(22kW) 550:75HP(55kW) 110:15HP(11kW) 300:40HP(30kW) 750:100HP(75kW) 150:20HP(15kW) 370:50HP(37kW) Series Name(Variable Frequency Drive) Nameplate Information • Example for 15HP/11kw 220V 3 phase drive

  24. Application 1 HES_ Application_at New machine maker : (Injection Machine Capacity 150 Ton)

  25. Structure of a Hybrid Energy System

  26. HES_ Application at Delta China Plant: (Energy saving results)

  27. HES_Application_at Delta China Plant: (Energy saving results) • Energy Saving injection machine ,it take 2.6 KWH in the FAN • With hybrid energy system, the energy loss by itself and with suitable rpm to meet required speed and pressure to decrease power loss. • During product unloaded, the pump could be stopped or servo motor operated in lowest rpm. Above conditions could decrease noise and energy loss during standby.

  28. Up grade Old machine Old system information is provide as a basis for designing the new system, Information includes: • Max. work pressure of the system(kg/cm^2) • Max.system flow(L/min), (Originally Motor rate speed and pump displacement) • Max. work voltage: Delta’s system provides 220V& 380V • Check Signal on Pressure and Flow command valve whether 0-10 V or 0-1A Example: • Max. pressure system : 140bar(kg/cm^2), • Originally Motor rate speed : 978rpm & Fix pump displacement: 65cc/r , Max. flow system to calculation = 978rpm*65cc/r=63.5L/min • Input voltage:380V 4. Structure of a Hybrid Energy System: HES063G43A(refer to page 13 & 19)

  29. Old machine information Nameplate of Induction motor Nameplate of Injection machine System pressure 140 bar Originally motor rate speed 975 rpm

  30. Old machine information Model name: SQP21-21-11-10B-18 = 65CC+35CC=100cc/Rec PS.1. Start End Pump displacement to 65 L/min at 1000 rpm = 65 cc/Rev 2. Cover End Pump displacement to 35 L/min at 1000 rpm = 35 cc/Rev

  31. Before replacing the old system information collect An injection machine operator must collect the following information by using a power meter and Plastic master controller: • Operation time per cycle. • Total mold production quantity per 1Hr and to recorder 8 Hr. • Pressure holding time. • Cooling time. • Mold reference number. • Plastic melted time. • Total power consumption per 1Hr_ by power meter and to recorder 8 Hr .

  32. after replacing the old system information collect A week after replacing the old system observe the results by recording the following information by using a power meter : • Operation time per cycle. • Total mold production quantity per 1Hr and to recorder 8 Hr • Pressure holding time. • Cooling time. • Mold reference number. • Plastic melted time. • Total power consumption per 1Hr and to recorder 8 Hr.

  33. Old Machine Modify install mode • The rack were installed Hydraulic pump & servo motor & VJ drive， Also need connect to pipe and wiring to Injection machine. • Originally Motor and fix pump don’t remove outside. • One month after replacing the old system , that stable machine to continue running , Can to plan that Hydraulic pump & servo motor& VJ drive to move in machine inside

  34. Prepare to part before replacing the old system • Prepare to pipe , wire , part depend on Delta HES manual

  35. Prepare to part before replacing the old system • To refer toDiagramof hydrauliccircuitandhydraulic components to modify

  36. To refer toDiagramof hydrauliccircuitandhydraulic proportional valve to modify Proportional Valve of pressure Proportional Valve Of flow

  37. Signal on Pressure and Flow command valve is 0~1A need select converter card Signal output of Pressure command Signal output of flow command

  38. The Pump inlet use to pipe diameter please follows below as: PS. 1.Pipe length must be 1.5M and under. 2. Max. pump rate speed be 2500rpm and under.

  39. Application 1 Up grade old machine for HES at Delta china plant :(Clamp force is 100 ton)

  40. Structure of a Hybrid Servo System

  41. Up grade old machine for HES at Delta china plant:(Before improving & improved of effect compare)

  42. Up grade old machine for HES at Delta china plant:(Energy save effect compare) • Traditional injection machine ,it take 7.3 KWH in the Fan.( machine umber) • When changing it to Delta hybrid energy system , it only needs 1.87 KWH in the Fan. • Energy saving result is higher than expect (up to 75%) • It also keep the levels of product production and accuracy

  43. Up grade old machine for HES at Delta china plant :(Energy consumption compare) TW Power bill ( The calculation is based on 12 hours per day & 265 days a year.) Before improving:7.37KWH/1HR*12HR*265(day)*$3.5/kwh=NT$82028/year improved:1.78KWH/1HR*12HR*265(day)*$3.5/kwh=NT$19811/year

  44. Application 2 Up grade old machine for HES Application in Tainan:(clamp force is 180 ton)

  45. Structure of a Hybrid Servo System

  46. Up grade old machine for HES Application in Tainan:( Before improving of measurement power consumption)

  47. Up grade old machine for HES Application in Tainan Plastics_ Large round pipe

  48. Up grade old machine for HES Application in Tainan:(Energy save effect compare) • Traditional injection machine ,it take 6 KWH in the large round pipe • When changing it to Delta hybrid energy system , it only needs 1.3 KWH in the large round pipe. • Energy saving result is higher than expect (up to 74%)

  49. Up grade old machine for HES Application in Tainan:(Energy consumption compare) TW Power bill, Before improving:6KWH/1HR*12HR*265(day)*$3.5/kwh=NT$66780/year improved:1.3KWH/1HR*12HR*265(day)*$3.5/kwh=NT$14469/year

  50. Application 3 Up grade old machine for HES Application in China:(clamp force is 130ton)

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