A 74 kW Power Boost by All World
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All World designed a custom Hydraulic Power System for an
injection molding machine producing large plastic automotive parts. Engineers designed
a 74 KW CorePULL® hydraulic power system, consisting of dual 37 kW units. This
achieved a flow rate of 158 gallons per minute and pressures up to 4,000 PSI,
meeting the mold’s operating requirements. Engineering Manager Frank Grube
described it as a highly advanced system with two inverter control systems
operating in tandem.
Seeking Efficient Hydraulic Power
In spring 2020, a Midwest plastics manufacturer
came to All World with a unique project requiring unconventionally high
pressure and flow rates. All World engineers successfully combined two 37 kW
Daikin inverted hydraulic units, providing a remarkable 74 kW of power. This
surpassed the standard capacity of smaller CorePULL units by 15 times.
“The typical CorePULL units handle around 10-20 gallons per
minute," explained Sr. Director of Manufacturing Kyle Crull. "This
system will generate 160 gallons per minute. It was like upgrading from a
riding lawnmower to a Formula One race car."
An Almost Perfect Solution
Since its launch in 2008, CorePULL has been a game-changer
for plastic manufacturers by providing a specialized hydraulic power solution
for plastic injection molding, catering to high-force and high-volume needs.
Powered by Daikin's SUT pumps, renowned for handling large
volumes and moderate pressures, CorePULL units stand out for their compact
size, energy efficiency, low noise levels, and low temperature operation. With digital
user-settable pressure and flow settings, CorePULL adapts easily to various
machines and applications.
Featuring user-friendly controls for swift adjustments and
equipped with manifolds supporting up to 12 stations with individual valve
stacks tailored to project requirements, CorePULL's advanced onboard system
reacts promptly to pressure demands by integrating fixed-displacement pumps and
a variable-speed electric drive into an energy-efficient setup that reduces energy
consumption by up to 63%.
2 Is Even Better Than 1
All World engineers knew CorePULL would be a perfect fit,
but it required higher flow rates than a standard CorePULL could deliver. They
set to work designing a new system, consisting of two 37 kW inverted units, sharing
one 120-gallon tank, providing the power needed while saving space.
“Both units were integrated with one tank and operated
jointly, achieving an impressive output of up to 158 gallons per minute,” Grube
said.
Equipped with an inverter controller, operators can monitor
motor temperature, inverter temperature, motor RPM, and access alarm history
for system anomalies. The controller allows for analog control of pressure and
flow rate. Engineers added a water cooler, in case additional cooling is
required.
A Challenging Build
All World custom-built every aspect of the project,
including the skid, tank, electrical control setup, valves, and hoses. The
components were larger than standard sizes, which made sourcing a challenge.
"Our main obstacle was ensuring a good fit. We
prioritized easy maintenance and accessibility. All components are exposed and
readily accessible," Grube said.
During the initial testing, the pumps were at equal pressure.
One pump was observed rotating in reverse. To counter act this effect, check
valves were added to each pump.
Despite facing numerous challenges, the twin units were
successfully constructed and dispatched within just 12 weeks. Engineers were
delighted by the motor's gentle ramp-up sound, finding it significantly quieter
than a hydraulic system of similar size.
“It sounds like a jet engine, but taxied on the runway,”
Grube said.
The system, initially used at 2,800 psi by the manufacturer,
is easily adaptable for various injection molding applications with minimal
adjustments.
"It can serve a broad spectrum of plastic injection
molding tasks through simple modifications," Grube added.
