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How much power does an injection molding machine consume?

2024/04/10 By Topstar

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Injection molding machine are essential equipment in the injection molding process. Almost every purchaser will ask about their size and functions when consulting. Previous articles have shared these two questions. Today I will share another question when purchasing: How much power does an injection molding machine consume per hour? We will take Topstar’s TS series injection molding machine as an example to explain its hourly power consumption.

Factors affecting the hourly power consumption of injection molding machine

The hourly power consumption of Ts series injection molding machines ranges from 5kWh to 20.9kWh depending on the model, mainly affected by the size and clamping force. The chart shows that models with higher clamping force and larger injection capacity will consume more power. In addition, the design and construction of the injection molding machine, including the efficiency of the hydraulic system, electric motors, and heating elements, also affect overall energy consumption. The data in the figure is for reference only because the power consumption per hour will also be affected when different processing material types are used. Different materials have different viscosities, melt temperatures, and flow characteristics, which affect the energy required to heat and inject the material into the mold.

Hourly Power Consumption
Please note: The experimental data is for reference only; the actual data is determined by the product’s process parameters.

Machine type affects power consumption

Different types of injection molding machines also affect their hourly power consumption. Common types include hydraulic injection molding machines, electric injection molding machines, and hybrid injection molding machines, each with their own energy consumption characteristics. The Ts series mentioned in the article is a hydraulic injection molding machine that provides power for mold clamping, injection, and ejection mechanisms through the hydraulic system. The power consumption of these machines is usually a little higher than that of electric injection molding machines. If you use hydraulic technology such as servo hydraulic systems and variable speed pumps, the power consumption will not be so high.

TEII Series All Electric Injection Molding Machine(90T-460T)

TMII Servo-Driven Injection Molding Machine(90T-470T)

Electric injection molding machines use electric servo motors to power various machine parts. They are more energy efficient than hydraulic presses because they only consume electricity while running and can adjust motor speed and energy usage based on real-time needs. Hybrid injection molding machines combine hydraulic and electric technology, taking full advantage of both systems to be more energy efficient while maintaining performance and reliability.
Optimize energy use.

How to calculate the hourly power consumption of an injection molding machine?

How do we calculate the hourly power consumption of an injection molding machine? First, we will determine the power consumption of each component of the injection molding machine, including hydraulic systems, electric motors, injection molding robots auxiliary equipment, etc. Next, we determine the energy usage of each component during different stages of the injection molding process. For example, heating, injection, and cooling during the molding cycle. Once you know the power consumption of each component, you can calculate the total energy consumption of your injection molding machine over a given period of time (usually measured in hours). The best power consumption per hour is obtained by adding the power consumption of all components and multiplying it by the operating duration (power consumption (kWh) = power consumption rate (kW) x cycle time).

Reduce power consumption

Many manufacturers will also report to us that the power consumption of injection molding machines is too high, especially when injection molding large products. Traditionally, hydraulic systems have high energy consumption due to continuous pump operation and hydraulic fluid circulation. Therefore, we will add servo-driven hydraulic systems, variable frequency drives (VFD) for pumps and motors, energy recovery systems, and intelligent control algorithms to the injection molding machines. We can adjust power usage by adjusting motor speed and energy consumption to real-time demand, reducing hourly power consumption during operation.

Optimize energy use

No matter what type of injection molding machine you use, you need to optimize energy use, and part of that is process optimization. Fine-tuning processes such as injection speed, pressure, temperature, and cycle time can reduce energy consumption while maintaining product quality and production efficiency. Process optimization is another important component of energy optimization in injection molding. Fine-tuning process parameters such as injection speed, pressure, temperature, and cycle time can help minimize energy consumption while maintaining product quality and production efficiency. In addition, optimizing mold design, cooling systems, and material handling can improve overall efficiency and achieve energy savings by shortening cycle times.

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Reduce overall power consumption

The power consumption in the article is for your reference only and cannot be used as actual data. The type of injection molding machine will affect a certain amount of power consumption. Still, the material technology, injection speed, pressure, and other factors during our use directly lead to power consumption. The high and low quantity is because you must constantly optimize your injection molding parameters to make the machine more efficient.

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