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Home / How do injection molding machine manufacturer deal with high precision requirements?

How do injection molding machine manufacturer deal with high precision requirements?

2024/11/13 By Topstar

High precision injection molding(1)

In pursuit of higher precision, electric injection molding machines have gradually replaced hydraulic presses, but traditional electric injection molding machines still have a communication delay of several milliseconds. This will lead to uneven quality control when pursuing precision injection molding products. This is a problem that many customers involved in the precision industry need help with, and they are also looking for injection molding machine manufacturers that can provide precision injection molding solutions. As an injection molding machine manufacturer with three core technologies, Topstar relies on the concept of integrated injection molding process and discrete intelligent drive to launch TE ll electric injection molding machine, making control more precise and injection molding iteration more thoughtful, making customers’ intelligent upgrades and precision management easier.

Discrete intelligent drive used by injection molding machine manufacturer

We use discrete intelligent drive communication as an injection molding machine manufacturer with a self-developed team and core technology. This principle solves the problem of product stability caused by control system communication delay, reduces the feedback cycle, and makes the mechanism movement more precise. In addition, this intelligent drive control mode minimizes the impact of communication delay on the high-speed operation of the servo motor, realizes real-time control of the servo motor, improves the accuracy of position, speed, and pressure control, and increases the response speed by 8-16 times.

injection molding machine manufacturer 5-1

When the servo drive receives the setting parameters from the HMI, it can save these parameters in the internal latch without waiting to receive the control speed from the upper controller during every cycle, making the execution process more efficient. At the same time, it also solves the problem that the operator of the traditional injection molding machine cannot intuitively understand the working conditions of the machine, improves the human-machine interaction, and makes the injection molding equipment more intelligent to reduce the number of debugging times for the production line operator.

Injection molding machine manufacturer use high-precision mold design.

The precision of the injection molding process lies not only in the system control but also in the design and production of the mold. Our mold designers will use high-quality steel and alloys to make durable, wear-resistant molds. They can withstand high pressure and temperature during the injection molding process, as well as CNC machining and EDM technology to produce molds with micron-level precision. These technologies can enable molds to achieve complex geometries. Topstar can create molds that handle tight tolerances and produce components with high dimensional accuracy to meet the precision requirements of industries such as medical equipment, automobiles, and electronics.

Dedicated integrated injection unit

The integrated injection unit has higher rigidity, stable structure, and more precise control, which can accurately control the injection volume, speed, and pressure. These units are calibrated to ensure that molten plastic is injected into the mold at the optimal rate and pressure, eliminating problems such as warping, shrinkage, or incomplete filling. For industries that require micro-molding or micro-components, the injection units are specially modified to handle micro-amounts of material without sacrificing control. They are carefully designed to achieve the precision needed for small parts and meet the high electronics, medical devices, and aerospace industry standards. In addition, the enhanced rigidity of the one-piece injection unit reduces mechanical wear, helping to extend machine life and maintain stable performance. By reducing the number of joints and potential weak points, the unit minimizes maintenance requirements and reduces operating costs, bringing long-term value to manufacturers.

Integrated injection unit,

Using linear guide rail

Linear guide rails have low damping, are more sensitive to pressure detection, and have more precise pressure control. Traditional guides react slowly to small changes in pressure, but linear guide rails detect even small fluctuations quickly. This high sensitivity allows real-time adjustments, which can significantly improve product quality by minimizing the risk of defects due to inconsistent pressure, such as warping or inadequate filling. With linear guide rails, electric injection molding machines can detect the smallest changes in pressure and make corresponding adjustments. In addition, linear guide rails improve pressure control accuracy, which is a key factor in molding complex designs or micro parts. By controlling pressure more accurately, manufacturers can achieve consistency, which is particularly important in electronics, automobiles, and medical devices.

Linear guides

Strengthen control of mold temperature controller

Accurate temperature control is also important for precision injection molding, especially for high-precision applications. In many cases, large temperature fluctuations occur because the temperature control accuracy of the mold temperature controller cannot meet actual production requirements. Plastic viscosity changes with temperature, affecting the mold’s flow and filling. Using the mold temperature controller with the latest PID temperature control algorithm can improve the temperature control efficiency by 10%, ensuring temperature uniformity, keeping the plastic at an ideal consistency, and ensuring uniform filling of complex mold geometries. In addition, the 1MHz ultrasonic flow monitoring monitors the flow in time, can detect bubbles larger than 2mm, ensures that the water flow is liquid, and provides stable and accurate temperature control.

mould-temperaturecontroller-(1)

Bring you higher precision management

We use discrete intelligent drive technology, precise mold design, and mold temperature controllers to meet strict standards. As an injection molding machine manufacturer, we provide plastic product companies with the injection molding equipment they need to achieve high-quality production, from precise temperature control to dedicated injection units.

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