+86 17727725162 jqj014950@topstarltd.com

Home / How do I prevent scaling and corrosion in mould temperature controller?

How do I prevent scaling and corrosion in mould temperature controller?

2024/11/18 By Topstar

mould-temperaturecontroller-1-5

A mould temperature controller is essential equipment in injection moulding, helping to maintain consistent mould temperature to ensure part quality and operating efficiency. Most products are injected using water-type mould temperature controllers, often the most prone to common problems such as scaling and corrosion when used. It affects the performance of the equipment, resulting in poor water quality, low efficiency, easy downtime and increased maintenance. Therefore, in this article, we will share with you how to solve this problem in the Topstar fourth-generation mould temperature controller and reduce the occurrence of scaling and corrosion.

Causes of scaling and corrosion in mould temperature controller

Scaling and corrosion are common problems with many mould temperature controllers. Scaling refers to the precipitation of minerals from the water or heat transfer fluid used in the mould temperature controller. These deposits accumulate on the internal surface, reducing heat transfer efficiency and blocking the flow channel. Corrosion is the chemical reaction that deteriorates the metal parts inside, usually caused by oxygen, low pH or incompatible fluids. Poor water quality, improper maintenance, incorrect heat transfer fluids, and hardware issues can cause both problems. For example, untreated hard water is the main cause of scaling, while high temperatures and chemical contaminants exacerbate corrosion.

metal-failure-modes-1

Improving water quality in preventing scaling and corrosion

Water quality plays a key role in preventing scaling and corrosion of mould temperature controllers. Topstar’s mould temperature controller series will have a dedicated pure water series that can come with its water tank. It will use pure water as a circulating medium and a closed circulation system to prevent metal ions from corroding the mould and scale from clogging it. Reduce the requirements for water quality, in addition to avoiding scaling and corrosion, using pure water as a circulating medium has many advantages. Pure water can maintain consistent heat transfer performance without interference from dissolved minerals or suspended particles, improving the system’s thermal efficiency. This allows for more precise temperature control, essential for achieving consistent product quality in applications that require precision, such as the automotive, medical, and electronics industries.

mould-temperature-controller-1-6

Reduce damage to components such as water pumps, pipes, solenoid valves, etc.

In the daily operation of the mould temperature controller, the temperature changes that occur when metal pipe parts undergo continuous heating and cooling cycles can easily lead to metal fatigue, resulting in structural damage to the pipe parts. Topstar installs a gas collector in the mould temperature controller to mitigate these damages. They play a dual role in protecting system components. First, it acts as a buffer, absorbing the additional pressure generated by the thermal expansion and contraction of the water in the system. By balancing pressure fluctuations, the gas collector prevents sudden pressure peaks that could otherwise strain and damage sensitive components such as water pumps and solenoid valves.

Second, the gas collector also solves another problem in the mould temperature controller: accumulating dissolved gases in the circulating water. During the heating process, the gases naturally dissolved in the water are released, forming bubbles, which can cause cavitation in the pump and other flow interruptions in the pipeline. The gas collector provides a designated space for these released gases to accumulate, preventing them from recirculating into the system.

Solve the problem of a mould temperature controller and mould rust

Residual media inside the mould usually causes rust or pipe blockage and reduces product yield. The mould temperature controller uses heat medium recovery technology to completely replace the residual press in the mould with high-pressure gas, thereby preventing mould damage and improving product yield. Replacing the media after each cycle can significantly reduce the risk of corrosion and blockage. This process ensures no stagnant liquid in the mould, which could otherwise become a breeding ground for rust or cause certain compounds to crystallize.

Mold Temperature Controller Fouling and Corrosion

At the same time, it prevents rust, which can weaken metal structures and cause premature wear. This can lead to fewer mould changes and lower maintenance costs. In addition, this method not only cleans the mould but also prevents contamination of the circulating medium in the mould temperature controller.

Real-time monitoring of mould temperature controller parameters

Maintaining correct operating conditions is important to prevent mould temperature controller scaling and corrosion. Key parameters that need to be monitored include temperature, pressure and pH. Extreme temperatures accelerate scaling and corrosion, while pressure fluctuations stress system components. pH control is particularly important because acidic or alkaline conditions can exacerbate corrosion. Using pH-neutral heat transfer fluids and regularly testing the pH of the liquid can help maintain a stable environment within the MTC. In Topstar’s injection moulding system, a monitoring system that provides real-time data allows users to make adjustments immediately to prevent damage.

Better prevention of scaling and rusting

Scaling and corrosion are common challenges for mould temperature controllers, but they can be effectively managed through proactive measures. By maintaining water quality, heat recovery technology, etc., users can protect the mould temperature controller from damage and ensure consistent performance.

Prev: How is the screw design of a all electric injection molding machine different from that of other machines?

Next: Three types of injection molding machines that meet the needs of most companies

TRENDING POSTS

HOT TOPIC

Get A Quick Quote