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What is the energy consumption of an injection molding robot?

2024/06/13 By 兰兹

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What is the energy consumption of an injection molding robot?

As the manufacturing industry becomes more and more automated, injection molding robot is also constantly improving the efficiency and quality of injection molding under the influence of automation. Well, many manufacturers or purchasers will pay attention to the energy consumption of these robots and whether they can reduce energy consumption. Therefore, in this guide, we will discuss the energy consumption of injection molding robots with examples.

Energy Consumption of Injection Molding Robots

Regarding the energy consumption of injection molding robots, several factors affect their energy consumption, including the type of robot, its operating parameters, and specific applications. Take the Tosda EU series injection molding robots as an example. They are suitable for injection molding machines with a 30-450T tonnage range and a maximum power consumption range of 2.1-2.8KW. Like all automated equipment, the energy consumption of injection molding robots is mainly used for movement, control systems, and auxiliary functions. The main components that generate energy consumption include servo motors, control units, and other equipment such as EOAT.

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Factors affecting the energy consumption of injection molding robot

From a technical perspective, injection molding robots equipped with advanced servo motors consume less energy than robots equipped with standard electric motors because they are more efficient and precise in motion control. In terms of the type of drive system, electric drives are more energy-efficient than hydraulic drive systems. The self-developed control system used by Tosda can optimize the robot’s movement and reduce unnecessary power consumption by adapting to different load conditions.

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In addition, efficient communication and synchronization between them and the injection molding machine can reduce idle time and energy waste. In addition, shortening the molding cycle time will also directly affect the robot’s energy consumption. Consuming less power occurs with shorter cycles and running times. From an operational perspective, the energy they require is proportional to the weight of the material they handle. Overloading or continuously running at maximum capacity will also lead to higher energy consumption and reduced efficiency.

Energy-saving technology used

To better reduce the electricity costs of plastic manufacturers, we have adopted energy-saving technology in injection molding robots. The lightweight and high-strength A6061 material is used on the robot’s arm, which reduces 20 structural components of the whole machine and reduces the weight by 20%, improving the overall operating performance and reducing energy consumption during operation. In addition, the standard DC bus technology saves 10% of energy and reduces the overall electricity cost by 10%. The added automatic OFF function can stop the servo motor from being powered on when in standby mode, so there will be no standby operation, thus saving 10% of electricity. In addition, our Topstar link application platform can remotely monitor the operation of the machine in real time and can be adjusted according to different situations to improve the energy efficiency of the injection molding robot.

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Best practices for reducing energy consumption

Although we have adopted a series of energy-saving technologies, we still need to make certain maintenance and corresponding correct operations in daily use. Regular maintenance in daily use can ensure that all components of the injection molding robot are operating in optimal condition. Worn parts, improper lubrication, or misalignment will increase friction and resistance, resulting in higher energy consumption. Shortening the cycle time of the injection molding process can significantly reduce energy consumption. Accurate calibration of servo motors and sensors can ensure they operate within their optimal parameters. If there are misaligned components, it will put additional pressure on the system, resulting in inefficient energy use.

Future Trends

Improving energy efficiency will be a significant trend in industrial automation. In the future, AI and machine learning (ML) can be integrated into injection molding robots. AI algorithms can analyze large amounts of data to identify patterns and predict the most energy-efficient operating conditions. Machine learning models can continuously improve their predictions and suggestions based on historical performance and real-time data, making robot operations more innovative and efficient. The shift to hybrid and all-electric drive systems is another significant trend.

Energy saving in the manufacturing industry

The maximum energy consumption of injection molding robots is between 2.1-2.8KW, although other robots may be lower or higher. For manufacturers seeking to reduce costs and improve performance, significant energy savings and improved overall operational efficiency can be achieved by selecting energy-saving models and adopting best practices.

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