The plastics machinery automation market surpassed 1 billion yuan in 2005, showing a year-on-year growth of 5.6%. Currently, the primary automation products used in plastic machinery include control systems, transmission control, motion control, human-machine interfaces, and sensors. Among these, transmission control, controllers, and low-voltage electrical appliances are the most significant components in the market. In 2005, their sales accounted for 48%, 23%, and 15% of the total press automation market, respectively.
In terms of automation product usage, controllers play a central role. China's plastic machinery primarily uses dedicated controllers and PLCs, with some low-end machines still relying on relay controls. The number of control points in domestically produced machines typically ranges up to 128 IO, while large-scale plastic film production lines may exceed 6,000 IO points, utilizing multiple PLCs and IPCs.
Different types of plastic machinery use different controller types. Injection molding machines and small blow molding machines mainly use embedded controllers, with some PLCs and relays. Extrusion equipment mostly relies on PLCs, while auxiliary equipment often uses PLCs and relays. Due to the relatively simple control requirements of standard machines, which are often operated individually, embedded controllers are widely used due to their cost-effectiveness and sufficient performance for basic operations.
However, as technology advances, controllers now need to handle more complex tasks, such as integrated control of melt temperature, injection pressure, speed, and cooling processes. While traditional embedded controllers were once sufficient, modern equipment increasingly requires faster response times and higher precision, leading to greater use of PLCs in new and large-scale equipment. In the next three years, PLCs will dominate high-end and large-scale machinery, while dedicated controllers will continue to be used in mid-to-low-end models.
Regarding drive systems, plastic machinery typically involves oil pump motors and screw extruder motors, with power ranging from 5.5 kW to 55 kW. Higher-power applications often use multiple motor setups. Energy efficiency is a growing concern, especially in injection molding machines, where frequency converters have been introduced to reduce energy loss during the hydraulic process. By adjusting the motor speed, frequency converters ensure that the oil pump provides the right amount of pressure at each stage, minimizing waste. Initially adopted by end-users and system integrators, frequency converters are now being integrated directly into machinery by manufacturers.
Motion control systems, particularly servo drives, are increasingly used in all-electric plastic machines to replace traditional hydraulic systems. These systems offer better precision, lower maintenance, and improved efficiency. However, despite these advantages, all-electric machines remain expensive, limiting their widespread adoption. Servo products are mainly found in high-end models, with limited use in the broader market. As a result, many manufacturers rely on external partnerships to develop suitable solutions.
Overall, the growth of the plastics machinery automation market is driven by the expansion of the plastics machinery industry itself, with increasing demand for efficient and intelligent automation solutions.
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