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How energy-efficient is a mould temperature controller？

2024/06/19 By Topstar

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Mould temperature controller is used in many fields. In injection molding, they can achieve precise temperature control so that the injection molding machine can produce high-quality plastic parts. They play a vital role in maintaining the optimal temperature of the mold during the injection molding process, which directly affects the quality of the final product. Besides knowing their functional advantages for many users, the main thing is their energy-saving effect. Therefore, this article will also explain their energy-saving characteristics and benefits.

Mould temperature controller

This device is used to maintain the required temperature of the mold during the injection molding process. It is used for temperature regulation of plastic molding molds and extrusion molding. It usually consists of a heating and cooling unit, a temperature sensor, and a control unit. The temperature of the mold and the roller is controlled with high precision by the heating and cooling device. The main function of the controller is to circulate a heat transfer fluid (such as water or oil) through the mold to achieve the precise temperature required for molding.

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The energy-saving effect of the mould temperature controller can be attributed to various factors, including efficient heat transfer fluids and optimized system design. By maintaining specific technologies and functions to keep the mold temperature constant, these controllers minimize the need for frequent heating and cooling cycles, thereby reducing energy consumption and the energy required to achieve the molding temperature.

Energy saving of mould temperature controllers

Topstar’s mould temperature controllers can save more than 35% of electricity. There are two types in total. Suppose it is a water-type mold temperature controller. In that case, water is used as the heat transfer medium to achieve heat exchange in direct (low-temperature) or indirect cooling (high-temperature type). It has high heat conduction efficiency and less pollution. Suppose oil is used as the heat transfer medium. In that case, indirect cooling is used for heat exchange, which has the advantages of a comprehensive temperature control range and good thermal stability. In addition, it has functions such as PID automatic temperature control to further save energy.

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PID adjustment function

The PID adjustment function in the mold temperature controller is a control mechanism. After integration, the PID adjustment function provides a balanced and powerful temperature adjustment method. They continuously monitor the mold temperature and fine-tune the heating and cooling devices to maintain the set temperature. The best energy savings are achieved when PID parameters are correctly tuned. Accurate PID tuning results in uniform temperature distribution, shorter cycle times, and better product quality. It also minimizes thermal gradients, preventing defects such as warping, shrinkage, or incomplete filling. By maintaining consistent mold temperatures, PID tuning improves the molding process’s efficiency and reliability, increasing productivity and saving energy.

Efficient heat transfer fluids

Heat transfer fluids such as water and oil are commonly used in mold temperature controllers to transfer heat. The heat transfer efficiency of these two fluids directly affects the energy consumption of the mold temperature controller.

Water is one of the most efficient heat transfer fluids because it has a high specific heat capacity and thermal conductivity. Water can absorb and transfer a large amount of heat with minimal energy input, requiring energy to reach the desired mold temperature. Therefore, water-based mold temperature controllers are highly energy efficient. Oil-based mold temperature controllers are another commonly used heat transfer fluid. Still, they have the advantage of higher operating temperatures and lower viscosities and advances in heat transfer fluid technology have made it possible to minimize energy consumption.

Clever heat dissipation channel design

The mould temperature controller adopts the multi-channel heat dissipation structure design, and the coolant flows through multiple paths within the mold. This increases the surface area for heat exchange and improves heat dissipation efficiency. Topstar turbulence inducers are integrated into the channels to enhance the heat transfer rate. These inducers induce turbulence in the coolant flow, destroy the thermal boundary layer, and increase the convective heat transfer coefficient. In addition, a spiral channel design is used to extend the path length of the coolant in the mold. This extended flow path ensures more thorough heat exchange, reduces hot spots, and promotes uniform cooling. Most importantly, Topstar uses molds and water channels made of high thermal conductivity materials to ensure that heat can be conducted quickly, minimizing thermal lag to achieve energy-saving effects.

Essential equipment in the injection molding process

The mold temperature controller is essential in injection molding and can provide precise temperature control. In addition to its functional advantages, the mold temperature controller is also very energy-efficient. Its energy-saving performance is achieved through the PID adjustment function, efficient heat transfer fluid, etc., and the power-saving rate can reach more than 35%.

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