With the rapid development of China's market economy and the gradual disappearance of the demographic dividend in recent years, die-casting products have entered an era of meager profits. The current national conditions of our country indicate that it is an inevitable trend to move from the era of high profits to the era of low profits. Reducing costs, ensuring quality and developing new products are the only ways to win the market in the era of thin profits

How to enhance production efficiency and product quality is related to the competitive strength of an enterprise. Through energy-saving renovations, the problems of high energy consumption, high temperature, high noise and high pollution in the traditional die-casting industry can be effectively solved.

The design is unreasonable and the energy consumption of the die-casting machine is too high

The design is unreasonable and the energy consumption of the die-casting machine is too high

Although China's die-casting machine industry started late, it has developed rapidly. The tonnage of die-casting machines has developed from a maximum of 500 tons to 4,000 tons today. The weight of die-castings has increased from a few grams in the past to over 50 kilograms. The hydraulic transmission control technology has also changed the previous situation where die-casting machines using real-time control were completely dependent on imported complete machines. However, there are significant drawbacks in the design and manufacture of the power structure of die-casting machines. At present, the power structure of die-casting machines with high market share is composed of three-phase asynchronous motors and vane pumps, resulting in excessive power and current losses, as well as significant reactive power waste.

Furthermore, for the die-casting industry, the stability of casting quality directly determines its market position. The development towards high-end die-casting products is also an inevitable trend, which inevitably puts forward higher requirements for the stability of casting quality. The energy-saving transformation of die-casting machines has once again been placed on the "agenda" of enterprises. The energy conservation of Chinese die-casting machines has basically gone through several stages, including PLC segmented control according to the process, dual pump control of high and low pressure in the system, proportional control of system pressure and flow, variable frequency energy-saving control, and servo drive control. Moreover, with the maturation of servo technology and the reduction of costs in recent years, equipping high-performance servo systems has become the preferred choice for the transformation of die-casting machines.

Innovative technology infuses new vitality into servo systems

The servo system adopts closed-loop speed control, featuring high repeatability accuracy of the injection running position. The products produced have high precision and good consistency, overcoming the drawback of the common asynchronous motor quantitative pump system where changes in grid voltage, frequency, etc. cause speed variations, which in turn lead to flow rate changes and reduce the product yield. At the same time, combined with an excellent intelligent control system, it can effectively enhance the production efficiency of enterprises and improve the working environment. After system optimization and transformation, the power-saving effect of the fixed or variable pump die-casting machine driven by hydraulic power can reach 25% to 60%.

In this era of meager profits, technological innovation is the driving force and guarantee for the continuous development of enterprises. Although there is still a considerable gap between China's die-casting equipment, especially large-scale die-casting equipment, and developed countries in terms of design methods, manufacturing processes, work efficiency, energy consumption, and reliability, the continuous application and promotion of servo technology have provided more flexible space for die-casting enterprises.