เครื่องประมาณการการใช้พลังงาน
Quickly estimate machine energy use (kWh) and electricity cost from heater power, cycle time and operation hours.
Calculate NowUse this tool for production cost estimation, bid pricing, and energy-saving retrofit evaluation in thermoforming processes.
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Calculations & Formulas
1) Instantaneous average power during operation (kW)
P_avg = P_heater × D + P_standby + P_other
2) Energy consumption per hour (kWh)
E_hour = P_avg (kW) × 1 hour = P_avg kWh
3) Energy per day (kWh/day)
E_day = P_avg × H
4) Electricity cost
Cost_hour = E_hour × Price
Cost_day = E_day × Price
5) Energy per cycle (kWh/cycle)
E_cycle = P_avg × (T_c / 3600)
6) Cost per unit (if units_per_cycle provided)
Cost_per_unit = (E_cycle × Price) / units_per_cycle
Heater power = 30 kW
Duty cycle = 80% → D = 0.8
Standby = 0.5 kW
Other loads = 2 kW (vacuum pump)
Operation hours H = 8 h/day
Electricity price = $0.12/kWh
Cycle time = 12 s, Units per cycle = 4
Common Industry Scenarios
Thin-Gauge Thermoforming
High-speed production with multiple heaters and quick cycle times.
Thick-Gauge Thermoforming
Longer cycle times with higher heater power requirements.
Twin-Sheet Forming
Dual heating systems with additional vacuum requirements.
Energy Saving Tips
Optimize Heater Control
Implement PID controllers to maintain precise temperature with minimal overshoot, reducing duty cycle by 10-20%.
Standby Power Reduction
Use smart power management to reduce standby consumption during breaks by up to 80%.
Improve Insulation
Upgrading oven insulation can reduce heat loss by 15-30%, directly lowering heater power requirements.
คำถามที่พบบ่อย
The duty cycle represents the percentage of time heaters are actually powered during a cycle. For precise measurement, use a power logger. For estimation: timed observation (e.g., heaters are on 45s of a 60s cycle = 75% duty) or consult machine specifications.
Include vacuum pumps, hydraulics, drives, and control systems in "Other loads". Typical values: vacuum pumps 1.5-5 kW, hydraulic pumps 2-7 kW, servo drives 0.5-3 kW. Check motor nameplates or power supply ratings for exact values.
Shorter cycles increase hourly energy use (more cycles/hour) but may reduce per-unit energy if heaters can maintain temperature efficiently. Optimal cycle time balances production rate with thermal efficiency.
Need a Custom Energy Analysis?
Our engineers can perform a detailed assessment of your production line and identify specific energy-saving opportunities.