Energy expenditure - emission utilisation

Transcription

1 Energy expenditure - emission utilisation Examination of the vulcanisation process with respect to consumption and utilisation

2 Contents Introduction Where are the energy consumers in an injection moulding machine? Detect, analyse and optimise potential savings in an injection moulding machine. Summary / outlook Discussion

3 Introduction In general terms, the subject of energy savings is more current than ever before, from commercial, environmentaland energy policy perspectives. Also when considering industrial investment decisions, energy costs are constantly gaining in importance. Why is this the case?

4 Naturally, one major reason for this is the development of the price of electricity for industrial consumers. The table here contains an extract from Eurostat, the statistical information service for the European Union. This clearly shows that energy costs in the listed member states have risen on average by approx. 45% since 2005.

5 Where are the "energy munchers" in an injection moulding machine

6 Energy consumers in an injection moulding machine Injection unit Extraction Lighting Vacuum pump Controller Ejection stations Sliding tables, etc. high energy consumption moderate energy consumption low energy consumption Temperature control Pneumatic system Hydraulic drive Mould heating Heating plates

7 Energy consumers in an injection moulding machine The main energy requirement arises due to the heating elements, e.g. the heating plates, direct mould heating and the plasticisation of the material. Hydraulik Hydraulic Antriebe drives The hydraulics with motor, pumps and drives "only" constitute a moderate consumer. Heizplatten Heating plates Electrical components account for the smallest proportion of consumption. Temperierung Material temperature Material control Elektrokomponenten Electrical component Steuerung control

8 Detect, analyse and optimise potential savings in an injection moulding machine

9 Potential energy savings in an injection moulding machine Electrical equipment Injection equipment Drive technology Mould temperature control Use of frequency converters and motor switch-off function Energy savings due to the use of EFE injection technology Energy savings due to the use of servo hydraulic drives Energy savings in mould temperature control

10 Motor switch-off function and the use of frequency convertors

11 Energy consumption measurements on a VCEFE 1000/630 with a frequency convertor and motor switch-off during process-related standstill periods 3 Close machine 10 Injection 10 Post pressing 120 Heating time 30 Plasticisation 3 Open machine 40 Operation 186 Cycle time 160 nonfunction time

12 Potential savings

13 Conclusion Clear savings are possible through the use of a motor switch-off system and a frequency convertor. The specific measure that is ultimately appropriate is decisively determined by the individual times (heating time, plasticisation time, operating time, etc) within the complete cycle. As a broad rule of thumb, it is however possible to say that a frequency convertor is better suited for use with thin-walled articles, with short heating times, than a motor switch-off system.

14 Energy savings due to the use of EFE injection technology

15 Compared with conventional injection moulding technology, EFE technology has a positive influence not only on productivity but also on the energy balance of the machine. This is because in terms of figures, shorter heating times constitute the greatest energy savings factor in this area.

16 Electricity consumption in normal operation without EFE injection technology Energy consumption 2.63 kwh Without EFE injection technology End of heating time Power consumption with "normal" system operation. A heating time of 1,160 seconds was required for these articles. The total power consumed during a single production cycle stood at kwh. During the heating time, the power consumption remains at a constant high level, caused by the heating energy and the no-load losses of the motor.

17 Comparison of measuring results End of heating time: 670 seconds with EFE throttle setting to 80% End of heating time: 1160 seconds without EFE injection technology End of heating time: 670 seconds with EFE throttle setting to 80% + motor switch-off function

18 Advantages of the EFE injection system Due to the considerably shorter cycle times, the energy consumption required for the production of an article is considerably reduced. The minimised machine demand preserves raw materials resources, production space and therefore all of the associated costs.

19 Energy savings due to the use of servo hydraulic drives

20 Today, energy efficiency is commonly represented by servo hydraulic drive systems. It is necessary to note here that these systems offer outstanding advantages, but are not the sole remedy for the reduction of energy consumption. Decisive here is the composition of the complete cycle. Especially important are the post-pressing times, operating times and heating times.

21 Compare constant pump, variable pump, servo pump

22 Advantages of a servo hydraulic drive system Reduction in energy consumption dependent on the respective cycle. Reduced heat transfer into the system. Lower oil consumption and maintenance costs. Increased process accuracy, dynamics and drive speeds Considerable reduction in noise development The start-up power peaks at the convertor may decrease due to power limitation High efficiency, no idle current occurs

23 Energy savings with mould temperature control

24 Insulation technology & thermal insulation - vital prerequisites for constant processes! It is fundamentally essential to ensure that heat losses due to convection, thermal radiation and thermal conductance are avoided. Measures: Insulate the heating plates on the machine side Adjust mould sizes to the heating plates Equip moulds with thermal insulation Equip injection units with thermal insulation Source: IKV-Aachen

25 Advantages due to LWB heating plate technology Insulation plates in sandwich construction with additional heat shield, in order that the heating energy is applied precisely where it is required at the mould. This also enables higher temperatures (up to 400 C), with considerably longer service lives

26 Advantages due to LWB heating plate technology Individually controlled annular heaters with various capacities enable precise and energyefficient temperature control from outside to inside. Copper heating plates can be optionally used. These offer rapid conductivity, reduce the heat-up time and thereby also the energy consumption, whilst also further improving the even temperature distribution. With appropriate thermal insulation, control accuracy of ± 1 C is attained.

27 Summary

28 Attain the optimum efficiency of the overall system It is not enough to simply examine the hydraulic drive of a rubber injection moulding machine alone, or to consider other individual components separately. The machine undergoing analysis - as well as its production process - is instead to be seen as a complete system, in which all components must be optimised to create a functional and efficient whole. Our machines, injection and drive technology as well as our know-how are your success factors for the economical and energy-efficient manufacturing of elastomer products.

29 Think outside the box! It is not only the machine itself that offers energy saving potentials. The production environment also offers many opportunities for optimisation.

30 Think outside the box! Don t use only efficient components, look at your production in a whole also!

31 Contact to surrounding equipment! To get a connection to the surrounding equipment (to use things like waste heat) you have to fulfill some requirements before. Requirements: Common medium Consumer with a fitting energy level Technical capabilities: Bundeling Recovery Re-use

32 Contact to surrounding equipment! Examples for potential consumers in the process Surface coating metal parts Mould cleaning Dipping-bath

33 Discussion

34 Legal note LWB STEINL Your competent partner for injection moulding applications Sonnenring 35 D Altdorf/Germany Tel.: +49 (0) 871/308-0 Fax: +49 (0) 871/