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How to improve the stability of horizontal injection molding machine?

2024/11/06 By Topstar

horizontal injection molding machine 1

Horizontal injection molding machine is one of the core equipment of many injection molding factories. Different types of horizontal injection molding machines will bring different precision and efficiency. When using some traditional injection molding machines, you may face the situation of the injection molding process not being stable enough and having a high defective rate. Stability is essential to achieve high-quality product output and extend the service life of the machine. Therefore, based on Topstar’s technical core and product philosophy, this guide will tell you how we use different technologies to improve the stability of the injection molding process and bring higher product quality.

Upgrade to a new horizontal injection molding machine control system

Due to communication delays in the control system, there will be problems with unstable product quality on traditional horizontal injection molding machines. This situation often occurs on electric injection molding machines. In response to this, Topstar sends the molding process data to the servo drive through the upper controller central controller, and the servo drive generates the operation curve by itself to form an intelligent drive control mode. This mode reduces the impact of communication delay on the high-speed operation of the servo motor and realizes real-time control of the servo motor. Therefore, the accuracy and stability of position, speed, and pressure control are improved, and the response speed is increased by 8-16 times.

High stability template

Wide support feet, stable dynamic support, smooth mold opening and closing, and better protection of molds and machines. Regarding software, we have upgraded to use a self-developed control system. In terms of hardware, the core of the stability of the horizontal injection molding machine is the use of a high-stability template. Especially in electric injection molding machines, high-stability pressure plates can ensure smooth, reliable, and safe operation, especially during high-speed mold opening and closing cycles. The pressure plate adopts a sturdy and wide support foot design to enhance dynamic support, minimizing vibration and ensuring uniform load distribution throughout the machine. This stability reduces the possibility of mechanical stress and ultimately extends the life of the mold and the machine itself. Through smooth mold opening and closing, the pressure plate helps prevent misalignment or uneven pressure that reduces the quality of molded parts, thereby improving production consistency and reducing defects.

Wide support feet

Comprehensive upgrade of the oil circuit system of horizontal injection molding machines

For horizontal hydraulic injection molding machines, the comprehensive upgrade of the oil circuit system has achieved a major leap in operational safety, stability, and performance. The enhanced oil circuit makes the machine more fluid-dynamically efficient, which means smoother transitions and more controlled movements in each cycle. Therefore, it can ensure that the high-pressure clamping and injection processes are handled precisely, reducing the risk of hydraulic fluctuations.

With faster and more sensitive clamping, the machine can switch between clamping states efficiently, significantly reducing cycle time. This differential speed control optimizes productivity and minimizes energy consumption by adjusting the flow rate at any time according to the machine’s specific needs. In addition, the upgraded oil circuit system also integrates a full-featured hydraulic control device, enhancing the machine’s versatility and stability.

The concept of a process-integrated injection molding machine

We have mentioned this concept in many articles and guides in the past. Traditional horizontal injection molding machines cannot achieve the interconnection between every device in the entire injection molding system because it will cause unstable molding. Therefore, Topstar defines the process-integrated injection molding machine as a fusion of software and hardware and continuously improves the intelligence of the equipment through communication, control, optimization, and perception. Today, the control interface links multiple devices to optimize the entire injection molding process, covering injection material pretreatment, plasticization, molding control, and removal process coordination. Through system integration, combining main and auxiliary machines, and using sensor technology, operators control key injection molding factors like temperature, speed, position, pressure, and time, ensuring a highly stable molding process.

Highly integrated with auxiliary systems

Optimize temperature control to achieve stability

Temperature control is a critical factor in maintaining the stability of horizontal injection molding machines. Temperature fluctuations can cause inconsistent material flow, resulting in changes in part quality and excessive stress on machine components. Stable temperature settings ensure that material viscosity remains constant, resulting in a smooth and predictable injection cycle. To improve temperature stability, Topstar’s mold temperature controller is based on temperature PID algorithm control, with a temperature control accuracy of ±0.1℃, ensuring temperature uniformity, and has an over-temperature protection mechanism to ensure the yield of plastic products. Meanwhile, Topstar uses stainless steel casting and welding in hardware for the main pipeline to reduce leakage. They can also select water quality filters to minimize pipeline blockages and shutdown failures caused by water quality issues, thus ensuring continuous production.

mould-temperaturecontroller-61

Bring you a more stable injection molding process

Comprehensive measures are needed to improve the stability of horizontal injection molding machines, including independent research and development of control systems, temperature control, and intelligent upgrades of software and hardware. Therefore, by targeting these factors, the stability of the machine can be gradually improved, downtime can be reduced, and product quality can be improved.

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