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5 Reasons Why You Want to Upgrade To A Hybrid Injection Molding Machinery
Hybrid injection molding machines have been on the market for a couple of decades now, and have proven themselves to be the standard choice in many facilities.
Hybrid injection molding machines are different compared to standard hydraulic injection molding machines in that they use a servo motor coupled to a hydraulic pump to circulate the oil used to provide the hydraulic pressure which actuates the components of the machine. The use of a servo pump allows for continuous adjustments to the actual power requirements, low emissions, less noise, and energy savings.
Hybrid injection molding machines are different compared to standard hydraulic injection molding machines in that they use a servo motor coupled to a hydraulic pump to circulate the oil used to provide the hydraulic pressure which actuates the components of the machine. The use of a servo pump allows for continuous adjustments to the actual power requirements, low emissions, less noise, and energy savings.
1. Energy Savings
Compared to standard hydraulic machines, hybrid injection molding machines typically provide 40% to 60% in energy savings. This is because the servo pump only runs when hydraulic pressure is needed, where as a standard hydraulic machine runs the pump continuously. Because there is no need for movement during the cooling stage of the process, the longer the cooling time, the more energy savings you will see.
Compared to standard hydraulic machines, hybrid injection molding machines typically provide 40% to 60% in energy savings. This is because the servo pump only runs when hydraulic pressure is needed, where as a standard hydraulic machine runs the pump continuously. Because there is no need for movement during the cooling stage of the process, the longer the cooling time, the more energy savings you will see.
Hybrid machines that utilize toggle clamping mechanisms are more energy efficient than the direct ram style clamping units that many manufacturers use. Toggle mechanisms are more energy efficient in creating the clamping tonnage, and locking the mold halves together to maintain pressure.
2. Longer Hydraulic Oil and Machine Life
Hybrid machines also run the hydraulic oil at a lower temperature because there is less circulation required. This leads to an extended lifespan of the oil, servo pump, and other mechanical components involved. Less maintenance means less downtime and more production with the hybrid injection molding machines.
Hybrid machines also run the hydraulic oil at a lower temperature because there is less circulation required. This leads to an extended lifespan of the oil, servo pump, and other mechanical components involved. Less maintenance means less downtime and more production with the hybrid injection molding machines.
3. Less Demand for Process Cooling Equipment
When hydraulic oil runs at a lower temperature, it requires less cooling from your chiller or cooling tower. Today most injection molding machines come equipped with a water saver valve that adjusts the amount of water that flows through the heat exchanger to provide just the right amount of cooling so that you are not wasting money on excessive cooling. There are machines without a water saver valve so make sure your machine manufacturer adds this feature. Using less water from your tower or chiller reduces the heat load on your water system which will end up saving you money in the long run.
When hydraulic oil runs at a lower temperature, it requires less cooling from your chiller or cooling tower. Today most injection molding machines come equipped with a water saver valve that adjusts the amount of water that flows through the heat exchanger to provide just the right amount of cooling so that you are not wasting money on excessive cooling. There are machines without a water saver valve so make sure your machine manufacturer adds this feature. Using less water from your tower or chiller reduces the heat load on your water system which will end up saving you money in the long run.
4. Faster Response and Closed Loop Process
Servo motors have a faster response time than standard hydraulic pumps, which leads to faster cycles and decreased cycle times. They also offer more precise controls and a more consistent process due to the encoders that track each turn to the exact rotation position. This means higher quality parts and less scrap..
Servo motors have a faster response time than standard hydraulic pumps, which leads to faster cycles and decreased cycle times. They also offer more precise controls and a more consistent process due to the encoders that track each turn to the exact rotation position. This means higher quality parts and less scrap..
5. Faster ROI
Although hybrid injection molding machines are slightly more expensive than standard hydraulic molding machines, all of the above benefits provide a very fast return on investment. Hybrid machines are also typically faster than standard hydraulic machines, so you will be able to make more parts in the same amount of time.
The case study below showcases an old Mitsubishi hydraulic injection molding machine that was retrofitted with a hybrid servo system.
Although hybrid injection molding machines are slightly more expensive than standard hydraulic molding machines, all of the above benefits provide a very fast return on investment. Hybrid machines are also typically faster than standard hydraulic machines, so you will be able to make more parts in the same amount of time.
The case study below showcases an old Mitsubishi hydraulic injection molding machine that was retrofitted with a hybrid servo system.
Conclusion:
To some, the hybrid models promise the best of the both worlds by bringing together the benefits of an electric motor and hydraulics.
Here are some of the benefits of a hybrid injection molding machine:
Here are some of the benefits of a hybrid injection molding machine:
- Diversity: the possible combinations for hybrid injecting molding machines open up new degrees of design flexibility.
- Best of both: Hybrid molding machines combine the energy savings and accuracy of electric molders with the force-generating capacity of a hydraulic unit.
- Replaced motor: Hybrids have replaced fixed-speed DC pump motors with variable-speed AC drives so the pump only operates when required and uses the necessary amount of oil for process efficiency.
- Less downtime: These require less maintenance and experience less downtime than an all-hydraulic or all-electric molding machines.
- Price point: Falls nicely between all-hydraulic and all-electric molding machines, making it an affordable option. Especially for medical device manufacturers.
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