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Home / Common operating problems and solutions for several plastic injection machine

Common operating problems and solutions for several plastic injection machine

2024/02/20 By Topstar

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Plastic injection machine play a vital role in modern injection molding manufacturing processes. They are capable of producing a variety of plastic products. At the same time, operators will encounter many problems during their daily operations, and plastic injection machines are susceptible to various operational issues, disrupting production and affecting product quality. In this guide, we will give you some examples of standard operating problems encountered during the operation of injection molding machines and provide practical solutions to solve these problems.

Plastic injection machine nozzles and injection devices clogged

One of the common reasons plastic injection machines experience clogs in operation is the buildup of plastic residue or contaminants in the nozzle or injection device. This may result from inadequate cleaning procedures, poor-quality materials, or improper processing conditions. Regularly maintaining and cleaning injection equipment is crucial to solve this problem. Operators can clean the nozzles and injection devices using appropriate solvents or cleaners to remove accumulated residue and prevent clogs from forming.

Another possible reason is improper material selection or processing parameter settings. Using incompatible materials or not operating within the recommended temperature and pressure ranges can cause the injection molding material to degrade or overheat, causing the nozzle to clog. So, ensuring you’re using suitable materials and optimizing processing parameters for the specific material you’re processing can prevent clogging issues.

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Plastic injection machine mold cooling issues

Common problems with plastic injection machine molds are insufficient cooling channel design or cooling capacity. Poor cooling can lead to uneven temperature distribution within the mold, resulting in longer cycle times, increased risk of defects, and reduced product part quality. To solve this problem, we optimize the design of cooling channels while increasing cooling capacity to improve heat dissipation and achieve a more uniform temperature distribution throughout the mold.

Also, improper placement or configuration of cooling channels can cause mold cooling issues. If cooling channels are poorly located or have inconsistent channel diameters or spacing, uneven cooling or hot spots may occur. These problems can be solved by adjusting the layout and configuration of the cooling channels to ensure even coverage and adequate cooling of the entire mold cavity.

Injection pressure and temperature changes

One of the causes of unstable injection pressure in an injection molding machine is changes in material viscosity or melt flow behavior. Changes in material properties, such as temperature sensitivity or moisture content, can affect the material’s flow characteristics and cause fluctuations in injection pressure. Consistent material properties can be maintained by correctly storing and handling materials, monitoring material moisture content, and adjusting optimized processing parameters to address this issue.

In addition, the operator’s improper machine settings or operating conditions can also lead to unstable injection pressure. Suppose the injection pressure setting is not ideal. If the injection speed or pressure is too high, it can result in over- or under-packing of the mold cavity, resulting in part defects or inconsistencies. We then need to adjust the injection pressure settings to the optimal level based on material type, product shape, and mold design to reduce injection pressure variations.

plastic injection machine parts sticking and ejection problems

Plastic parts sticking is a common problem, and one of the contributing factors is insufficient or improper use of mold release agents. The proper release agent ensures even coverage, helps reduce sticking, and facilitates part removal. In addition, adhesion is minimized by optimizing mold surface finish and texture to reduce surface friction and promote easy release of molded parts. Ejection problems, such as incomplete or part deformation during ejection, will affect production efficiency and part quality. One of the common causes is insufficient ejection force or improper ejection pin design. We provide better support and prevent part deformation by increasing the ejection force or modifying the ejection pin shape.

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Machine failure due to hydraulic system problems

A common hydraulic system problem in plastic injection molding machines is oil leakage caused by worn seals, damaged hoses, or loose joints. To fix this problem, you must check the hydraulic system for signs of oil leakage, such as puddles or stains around hydraulic components. If damaged seals or hoses are found, tighten loose fittings and replace them promptly to prevent further leakage. Another hydraulic system problem is insufficient hydraulic pressure, which a failed pump, clogged valves, or contaminated fluid can cause. Identify deviations from standard operating pressure by checking hydraulic gauges and monitoring system performance. Periodically inspect hydraulic pumps, valves, and filters for wear or damage, and clean or replace components as needed to restore proper hydraulic pressure.

Electrical and control system failures

A typical electrical problem with plastic injection molding machines is power fluctuations or interruptions, which can disrupt machine operation and cause production delays. One can install protectors, voltage regulators, or uninterruptible power supply (UPS) systems to protect machines from voltage spikes, surges, or outages. Similar electrical wiring issues like loose connections, damaged wires, or short circuits can cause machine failure or shutdown. Operators must regularly inspect electrical wiring and connections, tighten open terminals, and replace damaged wires or connectors. In addition, control system failures can also affect machine performance and production quality. One must perform diagnostic testing using control system software or diagnostic tools to identify and resolve software or hardware-related issues.

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Improve plastic injection machine performance and reliability

Solving common operating problems of plastic injection machines is about improving their performance and reliability. In the article, we have listed several common issues and solutions. We hope users who read this guide can refer to our solutions to improve machine performance, reduce downtime, and improve product quality.

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