Thermal Performance Analysis of Integrated Energy Management System for Mold Cooling/Heat Pump/Material Preheating of Injection-Molding Machine

The material in the mold of the injection-molding machine releases significant latent heat of solidification during the cooling process. The efficient recovery and utilization of this waste heat is crucial for improving energy efficiency. A novel integrated energy management system for mold cooling/heat pump/material preheating is proposed in this paper. Taking the symmetrical thermodynamic performance of the heat pump components as the basis and optimizing the system configurations, four system configurations were investigated: MC/BHP/MPCC, MC/RHP/MPCC, MC/HP/MP-IEMS, and MC/DCHP/MP-IEMS, utilizing EBSILON software. The performance of the systems was evaluated through the coefficient of performance (COP) and whole cycle energy efficiency (η). The T-q, T-s, and P-h diagrams were analyzed. It was found that, under comparative operating conditions, both the MC/HP/MP-IEMS and MC/DCHP/MP-IEMS systems exhibited significantly higher COP and η than the MC/BHP/MPCC and MC/RHP/MPCC systems. MC/HP/MP-IEMS achieves a COP of 13.66 and η of 22.09. Similarly, MC/DCHP/MP-IEMS achieves a COP of 14.00 and η of 22.53. The paper optimizes the other three systems using MC/BHP/MPCC as the comparison condition. Optimal cycle performances are achieved with COP and η values of 9, 16, 16, and 9, 26, 25, respectively. A comparison of the thermodynamic performance of five different refrigerants revealed that R123 and R245fa have superior overall performance. This study provides theoretical support for the engineering implementation of integrated energy management systems for injection-molding machines.