PT ZONE: All Electric vs Hybrids

Why Use All Electric Injection Molding Machines? Why Use All Electric Injection Molding Machines?
All electric injection molding machines turn injection molding into a predictable, robotic operation. More (+)
PT Article A History of All-Electric Injection Molding Machines
As a leader in all-electric injection molding machines since their invention, Milacron Plastics Machinery today continues to build on its proven expertise in this powerful technology. More (+)


MOST RECENT CONTENT: All Electric vs Hybrids

All-Electric Injection Molding Machines vs. Hybrids

Seeking the energy-saving benefits of electrics and the power of hydraulics, molders are increasingly turning to hydraulic-electric hybrid injection molding machines.

Markets & Applications for All-Electric Injection Molding

The precision and repeatability of all-electric injection molding machines make them ideally suited to high speed, thin-wall parts common in the following markets and applications: Medical: Syringes, petri dishes and more Food & Beverage: Caps, closures, containers, cutlery Industrial: Buckets and Pails Consumer goods: High volume packaging Automotive Communications: Smart phones Electronics: Connectors

What Matters in All-Electric Injection Molding Controls

Exacting computer controls have always been at the heart of the speed and precision of all-electric injection molding machines.

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OVERVIEW:
All Electric vs Hybrids


All Electric vs Hybrids

Seeking the energy-saving benefits of electrics and the power of hydraulics, molders are increasingly turning to hydraulic-electric hybrid injection molding machines. However, these machines often fall somewhat short of energy-efficiency goals.

The reason is that, while the typical hybrid machine has an electric screw drive, three of the four axes are hydraulic – meaning that nearly all of those hoses, valves and pumps associated with a hydraulic system are still part of the machine. Along the way, energy is lost as it is in all hydraulic systems.

A simple comparison of comparable tonnage machines, a typical hybrid and an all-electric, shows the major differences:
 

Typical Hybrid 550

 All-Electric 550

Hydraulic Clamp
 
 4 Pulleys
 

Hydraulic injection
 

Hydraulic eject
 

2 Rollerscrews
 

1 rack/pinion
 

1-2 Motors
 
 5 motors
 
85 Power Factor
 
 95 Power Factor
 
Motor/Drive creates harmonics
 
Low harmonics
 
Hydraulic HP does not decrease to keep
same injection rate and clamp speed
HP decreases when not needed
 


A New Kind of Hydraulic-Electric Hybrid

Unlike the typical hybrid, a new electric-based hybrid injection molding machine for the first time delivers electric efficiency along with hydraulic force.

The new system uses a hydraulic accumulator to provide the force that would otherwise require an all-hydraulic machine. The rest of the machine is electric-driven, maximizing the energy savings.

In other words, molders using the new hybrid configuration, available on Milacron POWERPAK®™ machines, get all the benefits of an electric machine, but with injection rates up to 300+ cubic inches per second (compared to all-electric machines, which top out around 100).

These rates are necessary especially for applications with thin-walled parts with high length over thickness (L/T) ratios, in which the material must fill the entire part before setting in the thinnest areas.


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