IoT Solution for Centralized Monitoring of Energy Consumption in Injection Molding Machines

Injection molding machines are the primary equipment used to manufacture various shapes of plastic products from thermoplastic (thermosetting) plastics using plastic molding dies.

 The operational energy consumption of injection molding machines mainly stems from power drives, barrel heating, and plastic drying heating. Given the low unit price of products, injection molding machines often operate continuously to ensure sufficient profits, leading to significant energy consumption costs that impact corporate operating efficiency. Therefore, energy conservation and cost reduction have become key focuses for the sustainable development of the injection molding machine industry.

Solution Overview

Smart electricity meters have been installed on injection molding machines in the workshop, which are connected to a centralized electric control cabinet.

 By deploying the WideIoT industrial smart gateway within the electric control cabinet and connecting it to multiple smart meters via RS485 serial ports, one-to-many electricity meter data acquisition can be achieved. Subsequently, by configuring device models, networking methods, upload frequencies, and alarm rules, energy consumption data can be transmitted to the factory's energy management platform via 5G/4G/WIFI/Ethernet, enabling functions such as remote monitoring, over-limit alarms, online management, and energy-saving analysis. This facilitates the timely identification of abnormal energy consumption and the implementation of measures to enhance energy utilization efficiency and management levels.

Achieved Functions

1. Real-time Monitoring: The system can monitor the energy consumption of injection molding machines during production in real-time, including electricity usage time and quantity, and generate visual data reports to ensure data accuracy and completeness.

2. Data Analysis: The collected energy consumption data is analyzed in-depth to uncover underlying patterns and trends, aiding enterprises in achieving energy conservation, emission reduction, and cost reduction goals.

3. Alarm Notifications: The system can set energy consumption thresholds and automatically send alarm messages when energy consumption is abnormal or exceeds set limits, prompting operators to take timely measures to ensure production stability and safety.

4. Remote Access: Operators can view the energy consumption data and production status of injection molding machines, as well as the operational status of individual electricity meters, in real-time via computers or mobile devices.

5. Detailed Reporting: Various detailed energy consumption reports can be generated as needed, including hourly, daily, monthly, and yearly energy consumption values and comparisons of energy consumption indicators, facilitating the submission of energy consumption reports to relevant departments or internal analysis.

6. Data Integration: The collected data can be uploaded to existing MES (Manufacturing Execution System) or ERP (Enterprise Resource Planning) systems within the enterprise, enabling data sharing and integration. This supports comprehensive digital management of the production process, enhancing production efficiency and product quality.