Energy costs are considered a fixed operational expenditure by many molders, yet energy inefficiencies are extremely difficult to track and identify in a production facility, says Husky Injection Molding Systems Ltd., Bolton, Ontario (NPE Booth W2117). Reducing expenses by reducing energy inefficiency is possible if costs can be attributed to a particular device, says Curt Norby, product manager for Shotscope NX.
Husky last year launched its new energy monitoring module for use with Shotscope NX that measures power on any type of equipment.
"It is not limited to injection molding machines. Measurements can be taken from individual devices on the machine to a work cell, department or the entire factory," says Norby.
The energy module takes the energy consumption data being measured and relates it to material consumption. The module processes real-time energy data through an algorithm to determine the specific energy consumption of a task.
"You get a ratio of energy consumption to material consumption, based on a formula of kilowatt hours per kilogram of material processed," says Norby.
ENERGY INSIGHT
Users get an insight into identifying optimal conditions to run a job. This not only includes ideal energy consumption levels for each device in a molding cell, but molders can determine which specific molding press in their facility processes a particular job best.
"You'll find out the optimal machine to run a job based on energy consumption, one of the biggest concerns for any business," says Norby. The molder can also ascertain which products it makes with the least amount of energy consumption.
The energy module is a production monitoring tool for the molder to measure its overall equipment effectiveness (OEE), says Norby. OEE can be a metric to evaluate what areas in the process are performing well or not, and can precisely target a problem device based on its energy profile. Inconsistencies in equipment operation and consumption during startup and shutdown procedures can be recognized and classified.
A range of reports and charts can be generated for analysis of energy data. Energy data can help to establish energy-saving initiatives, or it can be combined with financial expenditures tied to the production of specific parts. Energy throughput per production run can be measured and saved as a standard metric, says Norby.
The energy monitoring module is scalable, where the user can measure a host of data points, such as screw position, cavity pressure or hydraulic pressures. "We monitor energy, energy usage and how it relates to power factor. Power consumption can be measured at an interval selected by the user," he says.
The system is designed to appeal to small- to medium-sized molders looking to take advantage of the capabilities, features and benefits of monitoring software without having to dedicate a staff or resources to maintaining the system when scaling up or looking to measure new devices. The energy module was beta-tested with a small injection molder in Germany. The company had several different machines and was in the process of expanding its line with new machine models. Development of the energy module helped the molder end its indecision regarding the purchase of a monitoring system.
"The molder has a better understanding as to which jobs will stay on existing machines and which jobs will move to other presses," says Norby.
OTHER DEVELOPMENTS
Shotscope NX now has the ability to signal if a molding cavity is blocked off. The system can gather data on the downtime and its cause, and can provide an accurate production count based on the number of active cavities.
Shotscope NX can be installed on non-Husky units either via an Ethernet connection (it is a PC web-based platform) or through Husky's own data-acquisition hardware device that can be mounted on the machine.
Mikell Knights, senior correspondent
Husky Injection Molding Systems Ltd.,
905-951-5000, www.husky.co
