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How to ensure uniform temperature distribution with a mold temperature controller?

2024/08/21 By Topstar

mold temperature controller(2)

Temperature changes in the mould during injection moulding can lead to part defects, such as warping, dents, and dimensional inconsistencies that compromise the integrity of the final product. Mold temperature controllers, as injection molding auxiliary equipment, are indispensable devices in a complete production line. This ensures that the mold maintains the desired temperature throughout the production process, thereby maintaining temperature uniformity and reducing the risk of defects. Topstar’s mold temperature controllers are based on a temperature PID algorithm with a temperature control accuracy of up to ±0.1°C, ensuring temperature uniformity and having an over-temperature protection mechanism, which is a good solution to the problem of uneven temperature during operation of the mold temperature controller. Below, we will briefly introduce how they achieve uniform temperature distribution.

The role of mold temperature controller

Mold temperature controllers regulate the mold temperature by circulating a heat transfer fluid (usually water or oil) through the mold cooling channel, helping keep the mold surface temperature consistent. Their main function is to minimize temperature fluctuations due to changes in the surrounding environment, differences in material thermal properties, or differences in mold design. By providing precise temperature control, mold temperature controllers help ensure that the mold remains within the required temperature range, ensuring that the parts produced have consistent quality and dimensional consistency. Typically, they will be equipped with sensors and control systems that monitor the temperature of the heat transfer fluid and adjust the heating or cooling output as needed to maintain the target temperature.

Key factors affecting mold temperature distribution

Achieving uniform temperature distribution in the mold is affected by several key factors, one of which is the design of the mold itself. The structural design of the Topstar mold temperature controller is more sophisticated, which can better improve space utilization, and the design of the heat dissipation channel can more effectively protect the electronic components to achieve a more uniform temperature distribution.

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Another key factor is the thermal conductivity of the mold material. The stainless steel casting used in the frame structure of the mold temperature controller has high thermal conductivity, which can achieve rapid heat transfer and more uniform temperature distribution. In addition, the type of heat transfer fluid used also plays an important role in temperature distribution. Water and oil are the most commonly used fluids, each offering its own advantages and limitations. Water is generally ideal for applications that require rapid cooling due to its high thermal conductivity and rapid heat transfer capabilities. On the other hand, you can use oil in applications that require higher temperatures because it has a higher boiling point. Still, its thermal conductivity is lower than that of water, which affects temperature distribution.

Maintaining uniform temperature through temperature PID algorithm

Topstar’s mold temperature controller has more uniform and accurate temperature control based on temperature PID algorithm control, which can achieve a temperature control accuracy of ±0.1℃, ensuring temperature uniformity, and also has an over-temperature protection mechanism to ensure the yield of plastic products. The PID algorithm dynamically adjusts the heating and cooling process by continuously monitoring the mold temperature and making real-time corrections. Balancing these adjustments minimizes temperature fluctuations and ensures mold operates within a narrow range. This precise control is essential for producing high-quality molded products with consistent performance, reducing defects and improving overall production efficiency.

The mold temperature control system is more intelligent.

The open communication interface of the mold temperature controller can realize interconnection with other equipment, which can improve the collaborative efficiency of the entire production process and optimize staffing to the greatest extent. At the same time, the system automatically records the equipment operation status and alarm log, improves fault response speed and maintenance efficiency, and reduces downtime. The 7-inch touch screen on the front of the mold temperature controller makes the display more intuitive, allowing operators to operate through the screen and better control the temperature parameters to make the temperature more uniform. Through real-time data collection and analysis, they can autonomously predict temperature changes and make precise adjustments. This self-control capability continuously optimizes to ensure the system maintains the mold temperature at the desired set point.

The mold temperature control system is more intelligent.

The impact of uniform temperature distribution on product quality

If the temperature changes in the mold, a series of defects and inconsistencies will occur, damaging the integrity, appearance and performance of the molded parts. One of the most common defects is warping. Warping occurs when different areas of the part cool at different rates, and the material shrinks unevenly. This distorts the shape of the part, making it difficult to fit or assemble with other parts. Another defect may also occur. When the part’s surface cools and solidifies faster than the material below, dents will appear, causing the surface to sink inward, forming unsightly depressions and affecting its appearance and structural integrity.

Warping and denting of plastic products

Inconsistent temperature distribution can also cause changes in the mechanical properties of the part. Different areas of the part may cool and solidify at different rates, resulting in changes in the crystallinity and molecular structure of the material. The final product’s appearance will also be affected by temperature changes in the mold. Inconsistent temperatures can lead to color variations, surface defects, and poor texture.

Achieve uniform temperature distribution.

Topstar’s mold temperature controller can achieve uniform temperature distribution through the PID algorithm and intelligent system settings. In addition, manufacturers can improve temperature uniformity and overall production efficiency by solving common challenges such as ambient temperature fluctuations, material thermal properties, and flow rate imbalance.

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