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Innovative technologies and concepts provided by leading injection molding machine manufacturer

2024/10/28 By Topstar

injection molding machine manufacturer 1

Topstar is an injection molding machine manufacturer with industrial robots, injection molding machines, CNC, and auxiliary equipment as its core. We have three core technologies, control, servo, and vision, to create an intelligent hardware platform driven by core technologies, providing smart factory overall solutions for different manufacturing companies. On this basis, to make injection molding simpler, we proposed the concept of an “integrated process machine.” We adopted it on injection molding machines like the TM and TE ll series. The machine has the characteristics of openness, compatibility, continuous upgrading, and hardware iteration.

Injection molding machine manufacturer is adopting the concept of a “process all-in-one machine.”

In traditional injection molding, injection molding equipment cannot achieve communication integration, which is inconvenient for production management, and cannot achieve compatibility between equipment. The concept of “process all-in-one machine” is to achieve the integration of the main machine, auxiliary machine, and automatic control through an integrated open system, thereby significantly improving the efficiency of the production cycle. We incorporate various links into one system to achieve technical coordination between injection molding machines and peripheral auxiliary equipment, reduce the number of times operators debug the equipment, and make the effect more apparent, especially for those industries with clean production requirements. In this way, the “integrated process machine” of each injection molding unit is an injection molding automation workstation, and the automation level of the production line will be significantly improved.

Electric injection molding machine(10)

Process-integrated injection molding equipment can facilitate the intercommunication and sharing of production data and better help traditional manufacturing factories implement digital transformation.

With a more intelligent control system

Topstar’s second-generation electric injection molding machine uses a new control method to solve the product stability problem caused by delays in communication with the control system. One of the core principles is to send the injection molding process data to the servo drive through the central controller of the upper controller, and the servo drive generates the operation curve by itself. This intelligent drive control mode reduces 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. When the servo drive receives the setting parameters of the HMI, it saves these parameters in the internal latch to directly produce the motor speed curve to execute the corresponding process during each cycle reciprocating operation, making the execution process more efficient.

all electric injection molding machine 2-5

Make temperature control more accurate—mold temperature controller.

The significant temperature fluctuation of the mold temperature controller in injection molding is because the temperature control accuracy cannot meet the actual production requirements. Topstar’s fourth-generation mold temperature controller can improve the temperature control efficiency by 10% and ensure temperature uniformity through the latest PID temperature control algorithm. In addition, solid-state relays are used for temperature control in the hardware part, and the response time can reach 0.1s. We ensure that the temperature fluctuates within ±0.1℃ through the dual guarantee of software and hardware to ensure the product yield. At the same time, 1MHz ultrasonic flow monitoring is also used to monitor the media flow at all times, which can detect bubbles that are larger than 2mm, ensure that the water flow is liquid, and ensure stable and accurate temperature control.

More intelligent injection molding robot

We upgraded and updated the software under Topstar’s self-developed control system. It can support the injection molding machine in calling the robot’s signal, realizing integrated linkage, and controlling more accurately. It also has a built-in dual system so customers can choose freely and program actions for special requirements. Under the fully self-developed five-in-one servo drive system, the injection molding robot has powerful algorithm capabilities, making it more precise, energy-efficient, intelligent, and functional with solid scalability. It can add back-end automation processes according to customer needs. At the same time, advanced manipulator motion control technology is also used to ensure smooth and precise movement according to the predetermined contour when executing complex trajectories or paths, improving the workshop’s production quality and production efficiency.

Injection molding robot (1)

Injection molding machine manufacturer with MES module capabilities for data management

As an injection molding machine manufacturer with global capabilities, I provide more than just a single injection molding equipment. I position myself not as an equipment manufacturer but as one that offers a complete solution for intelligent injection molding. The innovative manufacturing technology used facilitates seamless communication between machines and MES. This integration simplifies workflows, automates repetitive processes, and promotes team collaboration. For example, MES can provide real-time visibility into production indicators, enabling managers to make informed decisions about resource allocation and production scheduling. As a result, manufacturers can respond quickly to changing market demands and optimize their operations for maximum efficiency. By adopting the concept of intelligent whole-field manufacturing and leveraging MES functions as an injection molding machine manufacturer, we can help customers improve productivity, reduce operating costs, and maintain a competitive advantage in a rapidly evolving industry.

More possibilities through technological innovation

Through innovative concepts such as control systems, drive systems, and “integrated process machines,” manufacturers can improve operational efficiency, improve product quality, and achieve the goal of digital development. Leveraging cutting-edge technology’s capabilities is crucial for maintaining competitiveness in the evolving industry and adapting to ever-changing market needs.

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