∆T control: profitable and sustainable

“∆T control” is the innovation for regulating the flow in temperature control units. REGLOPLAS has been the first manufacturer to offer temperature control units equipped with a frequency converter. The RT100 control compares the temperature of the inlet and the outlet and regulates the pump performance using a frequency converter in such a way that the difference between the two temperatures remains constant. Thus REGLOPLAS offers a technologically innovative product with which up to 50% of the previous energy consumption can be saved.

Temperature control units are standard equipment on die-casting and injection moulding machines. In both methods, the requirements for the components and the process control in the manufacturing of products are very high. Temperature management for tools and their moulding components is of the utmost importance for zero-defect production.

REGLOPLAS offers three different types of pump control, which are used depending on the application of the temperature control units: in addition to the existing flow control  and pump pressure control, there is a third option – ∆T control.

In flow control, flow monitoring and a variable pump speed ensure that the temperature control medium flows constantly. The constant flow and temperature permit precise temperature control. 

Traditionally, pump pressure control is used in bypass functions in which the pressure on the mould is limited. The speed of the pump is limited in such a manner that the outlet pressure does not rise above the maximum allowed. Therefore, energy no longer needs to be consumed by an overflow valve; instead, the excess energy – and thus money – can be saved. Pump pressure control is also used in multiple distributors: the constant pressure on the distributor enables precise control of each single distributor strand. The mutual influencing of the flow rates in the individual strands is minimised.

With its innovative control, REGLOPLAS has set a milestone for the entire industry. Until now, the ∆T value was used only in process monitoring. ∆T control automatically ensures the minimum necessary flow rate. The deviations are monitored and the correct operating point is independently regulated. In addition to the features generally expected of temperature control equipment – such as modern process management and ease of operation – energy consumption is coming more and more to the forefront. With our  technology for ∆T control, which regulates the pump performance to a constant ∆T, energy can definitely be saved. Thanks to the automatic monitoring and control, as little energy as possible is consumed. Flow measurement is unnecessary because a constant ∆T regulates the process.

The temperature difference between the time of entry and exit of the temperature control medium at the mould is dependent on the delivery rate, and therefore on the pressure and the flow rate generated. REGLOPLAS controls the temperature difference by adjusting the pump frequency. Customers no longer have to specify a flow setpoint; instead, they can directly enter the permitted ∆T. The flow then adjusts automatically according to the defined values.

This significantly simplifies process control for the customer, as flow measurement is no longer necessary. The pump speed is reduced if, for example, the required flow or pressure is low. As a result, the pump consumes less power. At a 20% reduction in speed, the pump consumes 50% less energy; at half the speed, it needs only 12.5% of the energy. Overall, the ∆T control – as part of the optimisation of a temperature control system – provides significantly greater cost savings than if the pump motors are merely switched to an efficiency class of IE3.

∆T control extends the range of options for pump control of the RT100 control system, as well as the new RT200 controller, to supplement pump pressure control and flow control. ∆T control can be configured for any temperature control unit.