近幾年我(wo)國經濟持續(xu)發(fa)(fa)展，能(neng)源問(wen)(wen)題越來越來為(wei)各行業發(fa)(fa)展的(de)摯肘(zhou)。所以(yi)節能(neng)成為(wei)許多行業發(fa)(fa)展面臨的(de)主要問(wen)(wen)題，特別是一些(xie)能(neng)耗比較大的(de)行業如注塑(su)機(ji)的(de)行業等。
目前絕大多數(shu)的注塑機(ji)(ji)都屬于液壓傳(chuan)(chuan)動注塑機(ji)(ji)，液壓傳(chuan)(chuan)動系統中的動力由(you)電機(ji)(ji)帶(dai)動油(you)泵(beng)(beng)提供(gong)，其(qi)液壓油(you)泵(beng)(beng)為(wei)容積式油(you)泵(beng)(beng)，其(qi)供(gong)油(you)量與油(you)泵(beng)(beng)的轉速(su)(su)成正比，當油(you)泵(beng)(beng)馬達以50HZ恒速(su)(su)運轉時，油(you)泵(beng)(beng)的供(gong)油(you)量是不變(bian)的，所(suo)以稱為(wei)定量泵(beng)(beng)。
一般(ban)的(de)(de)(de)塑件的(de)(de)(de)生產過程(cheng)中有下面(mian)幾個環節(jie)：鎖(suo)模、射膠(jiao)、熔膠(jiao)、保壓(ya)、冷卻、開模。注(zhu)塑機在不同(tong)工(gong)序(xu)下需(xu)要的(de)(de)(de)流量(liang)(liang)(liang)和壓(ya)力不同(tong)，須(xu)依靠流量(liang)(liang)(liang)閥(fa)(fa)和壓(ya)力閥(fa)(fa)調節(jie)不同(tong)工(gong)序(xu)所(suo)須(xu)的(de)(de)(de)流量(liang)(liang)(liang)和壓(ya)力，當(dang)工(gong)作所(suo)需(xu)流量(liang)(liang)(liang)較小(xiao)時，油(you)泵供(gong)油(you)量(liang)(liang)(liang)大(da)于執行元件所(suo)需(xu)的(de)(de)(de)油(you)量(liang)(liang)(liang)，多(duo)余的(de)(de)(de)處于高壓(ya)狀態(tai)下的(de)(de)(de)液(ye)壓(ya)油(you)全(quan)部(bu)經溢流閥(fa)(fa)回(hui)流，大(da)量(liang)(liang)(liang)的(de)(de)(de)能(neng)(neng)量(liang)(liang)(liang)通過油(you)的(de)(de)(de)溫(wen)(wen)升消耗掉。這樣既加劇了各種閥(fa)(fa)門的(de)(de)(de)磨損，又造成油(you)溫(wen)(wen)過高，而且(qie)為了降低油(you)溫(wen)(wen)，往往還需(xu)要額外的(de)(de)(de)冷卻水(shui)循環，造成能(neng)(neng)量(liang)(liang)(liang)的(de)(de)(de)進一步(bu)浪費。
塑機節能改造原(yuan)理(li)：
①注(zhu)(zhu)(zhu)塑(su)機(ji)(ji)(ji)(ji)成(cheng)型(xing)的(de)(de)(de)(de)工(gong)藝(yi)(yi)過(guo)程注(zhu)(zhu)(zhu)塑(su)機(ji)(ji)(ji)(ji)主要用(yong)(yong)于熱塑(su)料(liao)的(de)(de)(de)(de)成(cheng)型(xing)加(jia)工(gong).注(zhu)(zhu)(zhu)塑(su)機(ji)(ji)(ji)(ji)成(cheng)型(xing)工(gong)藝(yi)(yi)是(shi)一個(ge)按照預(yu)定(ding)的(de)(de)(de)(de)周(zhou)期性動(dong)(dong)作(zuo)過(guo)程,即以合(he)模等—射(she)嘴前進—射(she)膠—保壓(ya)(ya)(ya)—溶膠,冷卻--開(kai)模—頂出(chu)制品(pin)(pin)—頂桿退回—合(he)模等加(jia)工(gong)工(gong)序(xu)達(da)到某件(jian)產品(pin)(pin)成(cheng)型(xing).注(zhu)(zhu)(zhu)塑(su)機(ji)(ji)(ji)(ji)通常(chang)采用(yong)(yong)減(jian)液(ye)(ye)壓(ya)(ya)(ya)傳(chuan)動(dong)(dong),其結構包含注(zhu)(zhu)(zhu)射(she)裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)(zhi),開(kai)合(he)模裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)(zhi),液(ye)(ye)壓(ya)(ya)(ya)傳(chuan)動(dong)(dong)裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)(zhi)和(he)電(dian)(dian)氣控(kong)制裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)(zhi),后(hou)者的(de)(de)(de)(de)作(zuo)用(yong)(yong)是(shi)保證注(zhu)(zhu)(zhu)塑(su)機(ji)(ji)(ji)(ji)按工(gong)藝(yi)(yi)過(guo)程以預(yu)完(wan)定(ding)每個(ge)工(gong)序(xu)的(de)(de)(de)(de)要求(壓(ya)(ya)(ya)力,速(su)度(du),溫度(du),時間,位置(zhi)(zhi)(zhi))和(he)動(dong)(dong)作(zuo)程序(xu)準確有效地工(gong)作(zuo).在傳(chuan)統的(de)(de)(de)(de)注(zhu)(zhu)(zhu)塑(su)機(ji)(ji)(ji)(ji)中,液(ye)(ye)壓(ya)(ya)(ya)傳(chuan)動(dong)(dong)裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)(zhi)主要出(chu)油(you)(you)(you)泵(beng),液(ye)(ye)壓(ya)(ya)(ya)控(kong)制,壓(ya)(ya)(ya)力電(dian)(dian)磁(ci)比例閥(fa),流(liu)量(liang)(liang)電(dian)(dian)磁(ci)比例閥(fa),各種不同(tong)的(de)(de)(de)(de)動(dong)(dong)作(zuo)油(you)(you)(you)缸,油(you)(you)(you)泵(beng)電(dian)(dian)機(ji)(ji)(ji)(ji)及(ji)其它液(ye)(ye)壓(ya)(ya)(ya)附件(jian)和(he)管道組成(cheng),其中,油(you)(you)(you)泵(beng)是(shi)定(ding)量(liang)(liang)油(you)(you)(you)泵(beng),電(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)(ji)通常(chang)提供額(e)定(ding)功率和(he)轉(zhuan)速(su),油(you)(you)(you)泵(beng)將電(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)(ji)所輸入的(de)(de)(de)(de)機(ji)(ji)(ji)(ji)械(xie)能(neng)轉(zhuan)變為(wei)壓(ya)(ya)(ya)力能(neng),然后(hou)向液(ye)(ye)壓(ya)(ya)(ya)系統的(de)(de)(de)(de)液(ye)(ye)壓(ya)(ya)(ya)元件(jian)輸送具有一定(ding)壓(ya)(ya)(ya)力和(he)流(liu)量(liang)(liang)的(de)(de)(de)(de)液(ye)(ye)壓(ya)(ya)(ya)油(you)(you)(you),滿(man)足液(ye)(ye)壓(ya)(ya)(ya)執(zhi)行機(ji)(ji)(ji)(ji)構驅動(dong)(dong)負載(zai)所需能(neng)量(liang)(liang)的(de)(de)(de)(de)要求.
②變(bian)(bian)頻(pin)器調速節能裝置的(de)(de)控制(zhi)系統根據注塑(su)機的(de)(de)工(gong)藝(yi)要求,利用注塑(su)機電腦的(de)(de)同(tong)步控制(zhi)信號及電氣控制(zhi),從注塑(su)機的(de)(de)壓力電磁(ci)比例閥(fa)和流(liu)量電磁(ci)比例閥(fa)分(fen)別取出0-1ADC的(de)(de)模擬電流(liu)信號,直接加在(zai)變(bian)(bian)頻(pin)器專用的(de)(de)輸(shu)入(ru)端,從而改變(bian)(bian)變(bian)(bian)頻(pin)器的(de)(de)輸(shu)出頻(pin)率(lv),即(ji)改變(bian)(bian)油(you)泵電機的(de)(de)轉速,來改變(bian)(bian)油(you)泵電機的(de)(de)輸(shu)出流(liu)量Q,滿足注塑(su)機在(zai)各(ge)個工(gong)序中所需的(de)(de)油(you)泵壓力大(da)小和流(liu)量速度,將傳(chuan)統的(de)(de)定量泵轉變(bian)(bian)為(wei)量泵.
調速節(jie)能裝(zhuang)置的節(jie)能原理：
①變頻(pin)節能由流(liu)(liu)(liu)體力學可(ke)知,P(功率)=H(壓力),流(liu)(liu)(liu)量Q與轉(zhuan)(zhuan)(zhuan)速(su)n的(de)(de)(de)一次方成(cheng)正(zheng)比(bi),壓力H與轉(zhuan)(zhuan)(zhuan)速(su)n的(de)(de)(de)平方成(cheng)正(zheng)比(bi),功率P與轉(zhuan)(zhuan)(zhuan)速(su)n的(de)(de)(de)立(li)方成(cheng)正(zheng)比(bi),Q/Q=n/n,H/H=n/n式中:Q-油(you)(you)泵(beng)(beng)的(de)(de)(de)額(e)定(ding)流(liu)(liu)(liu)量,H-油(you)(you)泵(beng)(beng)的(de)(de)(de)額(e)定(ding)壓力,P-油(you)(you)泵(beng)(beng)電(dian)(dian)機(ji)(ji)的(de)(de)(de)額(e)定(ding)功率,n油(you)(you)泵(beng)(beng)電(dian)(dian)機(ji)(ji)的(de)(de)(de)額(e)定(ding)轉(zhuan)(zhuan)(zhuan)速(su).由上述公式可(ke)知,如果油(you)(you)泵(beng)(beng)的(de)(de)(de)功率一定(ding),當要求調(diao)節流(liu)(liu)(liu)量Q下降(jiang)時(shi),轉(zhuan)(zhuan)(zhuan)速(su)n可(ke)成(cheng)比(bi)例下降(jiang),此時(shi)油(you)(you)泵(beng)(beng)的(de)(de)(de)軸輸出功率P是成(cheng)立(li)方關系下降(jiang),即油(you)(you)泵(beng)(beng)電(dian)(dian)機(ji)(ji)耗電(dian)(dian)功率P與其(qi)轉(zhuan)(zhuan)(zhuan)速(su)n近似成(cheng)立(li)方關系.例如:某注塑機(ji)(ji)油(you)(you)泵(beng)(beng)電(dian)(dian)機(ji)(ji)額(e)定(ding)功率為(wei)55KW,則當轉(zhuan)(zhuan)(zhuan)速(su)下降(jiang)到原轉(zhuan)(zhuan)(zhuan)速(su)的(de)(de)(de)4/5時(shi),其(qi)耗電(dian)(dian)量為(wei)28.16KW,省(sheng)電(dian)(dian)48.8%;當轉(zhuan)(zhuan)(zhuan)速(su)下降(jiang)到原轉(zhuan)(zhuan)(zhuan)速(su)的(de)(de)(de)1/2時(shi),其(qi)耗電(dian)(dian)量僅用6.875KW,省(sheng)電(dian)(dian)87.5%.
②動(dong)態功(gong)(gong)(gong)(gong)(gong)率(lv)(lv)因(yin)數補償節能無功(gong)(gong)(gong)(gong)(gong)率(lv)(lv)不但增加線(xian)損(sun)和設(she)備的(de)發(fa)熱,更主要的(de)是因(yin)為功(gong)(gong)(gong)(gong)(gong)率(lv)(lv)因(yin)數的(de)降低(di)導致電(dian)網的(de)有(you)(you)功(gong)(gong)(gong)(gong)(gong)功(gong)(gong)(gong)(gong)(gong)率(lv)(lv)的(de)降低(di).由(you)公式S=P+Q, Q=S*SINфP=S*COSф ,其中:S-視在功(gong)(gong)(gong)(gong)(gong)率(lv)(lv),Q-無功(gong)(gong)(gong)(gong)(gong)功(gong)(gong)(gong)(gong)(gong)率(lv)(lv),P-有(you)(you)功(gong)(gong)(gong)(gong)(gong)功(gong)(gong)(gong)(gong)(gong)率(lv)(lv),COSф功(gong)(gong)(gong)(gong)(gong)功(gong)(gong)(gong)(gong)(gong)率(lv)(lv)因(yin)數.可知.當COSф越大,有(you)(you)功(gong)(gong)(gong)(gong)(gong)功(gong)(gong)(gong)(gong)(gong)率(lv)(lv)P越大.普(pu)通定量泵注(zhu)塑機COSф值在0.6-0.8之間(jian),而(er)使用變頻(pin)器調速節能控制(zhi)裝置(zhi)后, 由(you)于變頻(pin)器內濾波電(dian)容的(de)作用,使得(de)COSф≈1,從而(er)減小(xiao)了無功(gong)(gong)(gong)(gong)(gong)損(sun)耗,增大了電(dian)網的(de)有(you)(you)功(gong)(gong)(gong)(gong)(gong)功(gong)(gong)(gong)(gong)(gong)率(lv)(lv).
③軟(ruan)啟(qi)(qi)(qi)動(dong)(dong)節(jie)能(neng)由于電(dian)(dian)機為直(zhi)接(jie)啟(qi)(qi)(qi)動(dong)(dong)或Y/D啟(qi)(qi)(qi)動(dong)(dong),啟(qi)(qi)(qi)動(dong)(dong)電(dian)(dian)流等(deng)于(3-7)倍額定(ding)電(dian)(dian)流,這樣會對電(dian)(dian)機設備和(he)(he)供電(dian)(dian)電(dian)(dian)網造(zao)成(cheng)嚴重的(de)(de)(de)沖擊,而且(qie)還會對電(dian)(dian)網量要求過(guo)高,啟(qi)(qi)(qi)動(dong)(dong)時(shi)產(chan)生的(de)(de)(de)大電(dian)(dian)流和(he)(he)震動(dong)(dong)時(shi)對設備的(de)(de)(de)使(shi)(shi)用(yong)壽(shou)命極為不利,而使(shi)(shi)用(yong)變(bian)頻(pin)器節(jie)能(neng)裝(zhuang)置后,利用(yong)變(bian)頻(pin)器的(de)(de)(de)軟(ruan)啟(qi)(qi)(qi)動(dong)(dong)功能(neng)將(jiang)使(shi)(shi)啟(qi)(qi)(qi)動(dong)(dong)電(dian)(dian)流從零(ling)開始,最大值(zhi)也不超過(guo)額定(ding)電(dian)(dian)流,減(jian)輕了對電(dian)(dian)網的(de)(de)(de)沖擊和(he)(he)對電(dian)(dian)容量的(de)(de)(de)要求,延長了設備和(he)(he)模具的(de)(de)(de)使(shi)(shi)用(yong)壽(shou)命.
