BCSE-48V Battery Capacity Monitoring Discharge Equipment Selection Manual
From the known heat dissipation required per cycle, we can easily calculate the required coolant volume flow rate, and then derive the correct cooling capacity. Most mold temperature controller manufacturers provide formulas for calculating the minimum pump flow rate. Table 4.1 is useful when selecting a pump, as it accurately lists the heat dissipation capacity of different plastics.
The following rule of thumb determines the minimum flow rate required from the pump:
If the temperature difference across the mold cavity surface is 5°C,
0.75gal/min/kW @5°C temperature difference or
3.4151/min/kW @5°C temperature difference
If the temperature difference across the mold cavity surface is 1°C, the required minimum flow rate needs to be multiplied by five, i.e., 3.75gal/min/kW or 17.031/min/kW. To ensure product quality stability, many injection molding companies should control the mold cavity surface temperature difference within 1-2°C. However, in practice, many injection molding manufacturers may not know the importance of this temperature difference or believe that the optimal range is 5-8°C.
To calculate the required coolant volume flow rate, use the following procedure:
1. First calculate the heat to be removed from a plastic/mold combination: If
Taking the aforementioned PC cup mold as an example, the actual heat to be dissipated is:
Gross weight per part (g) / Cooling time (s) = 208/12 = 17.333g/s
The heat dissipation rate of PC is = 368J/g or 368kJ/kg
So the heat to be dissipated per cycle = 368×17.33/1,000 = 6.377kW
2. Then calculate the required volume flow rate for cooling:
According to the above rule of thumb, if the temperature difference across the mold cavity surface is 5°C, flow rate = 6.377×0.75 = 4.78gal/min or = 6.377×3.41 = 21.751/min. If the temperature difference across the mold cavity surface is 1°C, then flow rate = 4.78×5 = 23.9gal/min or = 21.75×5 = 108.731/min
3. Pump flow rate specification
For good heat dissipation, the pump flow capacity should be at least 10% greater than the calculated result, so a pump of 27gal/min or 120/min is required.
4. Pump pressure specification;
Generally, the operating pressure of mold temperature controllers is 2-5bar (29-72.5psi). Since insufficient pressure can affect the coolant volume flow rate (flow resistance causes pressure losspressure loss), the higher the pump pressure, the more stable the flow rate.
For molds with very small cooling channels, such as a pipe diameter of 6mm/0.236in, the pump pressure needs to be 10bar (145psi) to provide sufficient cooling rate (i.e., coolant velocity).
Generally, the higher the required coolant volume flow rate and the smaller the pipe diameter, the greater the required pumpoutput pressure. Therefore, in general applications, the pressure of the mold temperature controller should exceed 3bar (43.5psi). B. Heating capacity
Figure 4.8 is a typical heating calculation table, providing the heating required for the mold weight. The calculation method for Figure 4.8 is as follows:
1. The vertical axis represents the mold weight.
2. The horizontal axis represents the heat required to raise the mold to the desired temperature, in kW/hr.
3. The temperature slope lines from 37°C to 121°C provide the relationship between mold weight and the heating capacity of the mold temperature controller at corresponding temperatures.
For example, we can find from the figure:
1. The heating capacity required to raise a 500kg mold to 50°C is 3.3kW/hr.
2. ...
