The plastics machinery automation market surpassed 1 billion yuan in 2005, marking a 5.6% year-on-year growth. At present, the primary automation products used in this sector include control systems, transmission control units, motion control components, human-machine interfaces, and sensors. Among these, transmission control, controllers, and low-voltage electrical devices are the most critical segments. In 2005, they accounted for 48%, 23%, and 15% of the total size of the press automation market, respectively.
Automation products in the plastics industry serve various functions. Controllers, for instance, are widely used in different types of machinery. Most Chinese plastic machines rely on dedicated controllers or PLCs, with only a few using relay-based systems. The number of control points varies, with smaller machines typically having up to 128 IO points, while large-scale production lines may exceed 6,000 IO points, often utilizing multiple PLCs and industrial PCs.
Different types of machinery use distinct controller types. Injection molding and small blow molding machines mainly use embedded controllers, while extrusion equipment relies more on PLCs. Auxiliary equipment often uses PLCs and relays. Since many machines operate independently and have relatively simple control needs, embedded controllers are commonly preferred due to their cost-effectiveness and sufficient performance for basic tasks.
However, as technology advances, controllers are evolving beyond basic action control. They now integrate functions like melt temperature regulation, injection pressure, speed, and cooling process management. Many systems are transitioning from open-loop to closed-loop control, demanding faster response times and greater precision. This shift has led to increased use of PLCs in new and high-end equipment, while embedded controllers remain dominant in mid-to-low-end models.
In terms of drive systems, the main focus is on oil pump motors and screw extruder motors, typically ranging between 5.5 kW and 55 kW. Higher power applications often use multiple motor setups. Energy efficiency is a growing concern, especially in injection molding machines. Traditional hydraulic systems often waste energy by over-supplying oil, but frequency converters can optimize this by adjusting motor speed based on demand. Early adopters were end-users, but now more manufacturers are incorporating inverters into their machines. Although some users still opt for non-inverter models to reduce upfront costs, retrofitting is becoming increasingly common.
Motion control and servo systems are primarily used in all-electric injection molding machines, replacing traditional hydraulic systems. These systems offer better accuracy, lower maintenance, and improved environmental conditions. However, despite their advantages, all-electric machines remain expensive, limiting their widespread adoption. Servo systems are mostly found in high-end models and specialized applications, such as automotive and medical industries.
Overall, the plastics machinery automation market continues to grow, driven by the expansion of the plastics machinery industry itself. As technology evolves, the role of automation will become even more critical in improving efficiency, reducing costs, and meeting higher performance standards.
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