Energy Consumption of Die-casting Machine

The energy consumption of a die-casting machine is mainly affected by many factors such as its working principle, equipment type, production process, and production scale. The die-casting machine is usually used for high-speed casting of metals such as aluminum, zinc, and magnesium, and its energy consumption includes electrical energy, hydraulic energy, and heating energy. 

Specifically, the energy consumption of a die-casting machine can be divided into the following parts:

1. Electric Energy Consumption

This is one of the main energy consumption of die-casting machines. Die-casting machine drives various moving parts through electric motors, such as injection devices, clamping devices, mold opening and closing, cooling, and other operations. Its electric energy consumption includes:

Injection action: 

A large amount of electricity is required when injecting metals such as aluminum and zinc quickly.

Mold opening and closing: 

An electric system is used to control the position of the mold.

Cooling system: 

The pump and fan in the cooling system also consume a certain amount of electricity.

2. Hydraulic Energy Consumption

The hydraulic system in the die-casting machine is widely used for mold locking, metal injection during injection, and some other mechanical actions. The consumption of hydraulic energy mainly comes from:

Hydraulic pump: 

Provides power for the hydraulic system, adjusts the pressure of the mold, and other actions.

Heating and circulation of hydraulic oil: 

Additional energy is required to maintain the temperature of the hydraulic system.

3. Heating Energy Consumption

During die casting, the metal usually needs to be heated to a certain melting temperature (for example, the melting temperature of aluminum is about 660°C). The energy consumption of the heating process can be calculated in the following ways:

Furnace heating: 

A heating furnace is required to heat the metal to a molten state, and this process consumes a lot of heat energy.

Insulation system: 

To keep the metal temperature constant or prevent it from cooling rapidly, additional heat energy is required.

4. Mold Cooling

Mold cooling is also an important part of the energy consumption of the die-casting machine. After each injection, the mold needs to be cooled quickly to ensure the quality and demolding of the casting, usually by water cooling or oil cooling, and this process requires a certain amount of cooling energy.

5. Other Factors

Production cycle time:

The shorter the production cycle, the higher the energy consumption per unit product; but if the production cycle is long, the energy consumption of each die-casting machine is relatively low.

Production batch: 

Batch production is usually more energy-efficient than small batch production because the utilization rate of equipment and molds is higher in large batch production.

Type of die-casting machine: 

Different types of die-casting machines (such as hot chamber die-casting machines and cold chamber die-casting machines) also have differences in energy consumption. Usually, cold chamber die-casting machines require more energy to drive metal injection.

Energy-Saving Optimization Measures

To reduce the energy consumption of die-casting machines, some energy-saving optimization measures can be taken:

Use frequency converter speed regulation: 

Adjust the speed of the motor through the frequency converter to avoid energy waste caused by frequent starting and stopping.

Optimize the hydraulic system: 

Use efficient hydraulic systems and energy-saving hydraulic oil to reduce the loss of hydraulic energy.

Improve thermal efficiency: 

Use an efficient heating furnace and heat recovery system to reduce the waste of heating energy.

Optimize the cooling system: 

Reasonably design the mold cooling route, improve cooling efficiency, and reduce cooling energy consumption.

Accurately control the production process: 

Monitor and adjust the working status of the die-casting machine in real time through the intelligent control system to ensure that the equipment operates in the best way.

In summary, the energy consumption of the die-casting machine is multifaceted and the influencing factors are complex. By optimizing the design and improving the production process, its energy consumption can be effectively reduced, and production efficiency and economic benefits can be improved.

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