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The role of discrete intelligent drive in energy-saving injection molding machine

2025/04/21 By Topstar

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In the current global economic environment, energy efficiency is a primary concern for every manufacturer in the plastics manufacturing industry, especially in some European countries. To make injection molding machines more energy-efficient, Topstar uses discrete intelligent drives in the control system of the energy-saving injection molding machine represented by all electric injection molding machines. This control strategy fundamentally changes how servo motors respond and execute molding cycles. Discrete intelligent drives no longer rely on continuous feedback loops mediated by central controllers; instead, they delegate real-time trajectory generation and motion control directly to servo drives. This architectural shift significantly reduces communication latency, improves speed and accuracy, and makes molding more energy-efficient.

Precise control of energy-saving injection molding machines through decentralized control

Discrete intelligent drives redefine motion control of energy-saving injection molding machines. Unlike traditional centralized systems, they allow drives to operate independently, reducing dependence on continuous communication with the central controller. During the molding cycle, the servo drive generates its operating curve based on preloaded parameters, enabling instant adjustments to position, speed, and pressure. This autonomy eliminates the delay caused by round-trip data transmission and increases response speed by 8 to 16 times. For example, during high-speed clamping or injection phases, the drive can correct deviations immediately without waiting for external commands. The result? Compared to traditional hydraulic systems, smoother operation, tighter tolerances, and up to 30% energy savings.

Solving communication delay issues for energy-saving injection molding machines

Traditional control systems have latency issues when transmitting data between the central controller and the servo motor. Discrete intelligent drives solve this problem by storing key parameters, such as mold temperature thresholds or injection pressure limits, directly in their internal memory. Once the initial setup is complete, the drive executes the pre-programmed profile autonomously in every cycle.

For all-electric injection molding machines, this means:

  • There is no need to wait for real-time speed instructions from the controller.
  • Maintain consistent repeatability over thousands of cycles.
  • Eliminate timing mismatches during multi-axis operations.

This approach is particularly effective in high-speed applications such as thin-wall packaging and preform production, where defects caused by microsecond delays can be avoided.

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Servo motor real-time control

In a discrete intelligent drive architecture, the servo drive continuously monitors its internal state and executes predefined motion profiles with microsecond accuracy. This decentralized control model enables energy-saving injection molding machines to manage complex movements such as screw reciprocation and injection curves on their own without relying on high-frequency data exchange with the central controller. This makes the system very stable and can respond instantly to minor disturbances, such as changes in material viscosity or slight changes in mold temperature, without waiting for other instructions. With instant decision-making, discrete intelligent drives achieve consistent, high-fidelity servo performance, directly translating into improved part consistency and reduced scrap rates.

The main advantages can be achieved:

  • Pressure control accuracy within ±0.5%.
  • Position repeatability within 0.01 mm.
  • Adaptive material viscosity changes.

When facing engineering plastics with strict cooling requirements for molding, the drive can fine-tune the ejection time without interrupting the workflow of the central controller.

8-16 times faster response speed

Response speed is a key indicator for high-throughput molding operations. Network communication speeds limit traditional centralized drives, and the response time is usually only tens of milliseconds. With discrete intelligent drives, servo controllers can bypass these delays, making the response speed 8 to 16 times faster than traditional settings. This fast response capability enables energy-saving injection molding machines to quickly switch between injection, holding, and pressure holding stages, thereby minimizing cycle time without sacrificing precision. For manufacturers, this means higher productivity and lower energy consumption per unit part because the motor idle time is reduced and production efficiency is higher. At the same time, the enhanced response speed improves the machine’s ability to maintain consistent melt buffer and back pressure, further stabilizing the injection quality.

Intelligent parameter latching to improve cycle efficiency

In discrete intelligent drive systems, parameter latching is key to efficient cycle execution. After the servo drive of the energy-saving injection molding machine receives the set parameters (such as speed segment, dwell time, and pressure set value), it stores these values ​​in its internal latch memory. In each reciprocating cycle, the drive instantly retrieves the latched parameters and dynamically generates the motor speed and torque curve. This eliminates the need for the upper controller to transmit data repeatedly in each cycle, reduces bus traffic, and allows the drive to focus on motion execution. The result is a more streamlined control architecture that speeds up each molding cycle and reduces energy waste associated with unnecessary communication overhead. By simplifying this process, discrete intelligent drives can improve all-electric injection molding machines’ overall availability and throughput.

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Bring sustainable production benefits.

Using discrete intelligent drive technology on energy-saving injection molding machines such as all-electric and electric injection molding machines can achieve higher precision, faster response time, and significant energy savings. By decentralizing the control logic and authorizing the servo drive to generate its motion profile based on latched parameters, plastic manufacturers can almost eliminate communication delays, increase cycle rates by up to 16 times, enhance the accuracy of position, speed, and pressure control, minimize energy waste, and improve operational efficiency.

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