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Plastic injection molding machine intelligent whole factory case

2024/10/08 By Topstar

plastic injection molding machine 1-7

“We hope that the yield rate and aesthetics of the products will be professionally improved and enhanced, the cost of quality inspection will be reduced, and we hope to place more machines in a limited workshop.” Zhejiang DERXIN Connector Co., Ltd. (from now on referred to as DERXIN) is a professional company specializing in the production of various specifications of wire and cable connectors (cable connectors and their accessories). It is an experienced, comprehensive enterprise that integrates R&D and production.

derxin

In the past five years, DERXIN’s sales have increased by 25%, and it has reached cooperation with many Fortune 500 companies. To further enhance product competitiveness and optimize the factory environment. DERXIN solves product precision and space problems by adopting Topstar’s intelligent whole-plant solution with injection molding machines as the core.

Plastic injection molding machine whole-plant planning

“We used to produce in an old factory building. The lack of standardization and professional design in the workshop layout resulted in low yield and affected appearance. The old equipment does not operate systematically, which easily causes after-sales service problems. Additionally, the workshop’s aesthetics and space utilization require improvement. This is what the head of DERXIN’s marketing department told us about the company’s problems during its expansion.

Injection molding whole plant solution

After a detailed survey of the old and new factories, Topstar equipped DERXIN with an intelligent energy management system, a central feeding management system, TM II injection molding machines and an MES digital management system based on the integration of the control system communication interface. These measures, from intelligent environment to digital management, have comprehensively improved the efficiency of DERXIN’s entire plant workshop, making it more efficient and tidy.
Therefore, through systematic and standardized design and transformation, the workshop space utilization rate has increased by nearly 30%, effectively solving the production environment problems caused by poor space management and chaotic raw material management.

Injection molding Whole plant solution（9）

Intelligent equipment such as plastic injection molding machines has increased the yield rate by about 25%

For the quality of products, Topstar not only requires the functionality of the products but also has strict requirements for the aesthetics of the product molding appearance. Production must guarantee the accuracy of the size and surface. According to the characteristics of raw materials, Topstar configures the TM II injection molding machine for DERXIN, and the main machine coordinates the peripheral injection molding robot, mold temperature controller and other auxiliary machines to dry the process parameters such as time, temperature and pressure. We thoroughly dry the raw materials before production to reduce defects such as bubbles, silver streaks, and splashes during the molding process.

Injection molding whole plant solution

Topstar has equipped the machine with a new generation of plastic injection molding machine control solutions, which adopt a distributed control method and reasonably distribute the equipment according to the production process to achieve local control and monitoring. This can shorten the data transmission distance, thereby increasing the data transmission speed, making the communication speed fast and having strong anti-interference ability. Simple wiring can reduce line failure points and maintenance difficulty, reduce failure rate, and thus improve equipment utilization to increase production capacity.

Features of TM ll series  injection molding machine

The TM ll series plastic injection molding machine, equipped with a Topstar injection molding robot, automatically compensates for the mold opening position. In the high-speed mold opening operation, it can realize accurate grasping and placement, and the production is more stable and efficient.

TM170II-Injection-Molding-Machine

New oblique hinge layout: can realize ultra-long stroke mold opening, mold opening position accuracy <±1mm, and template movement is fast and stable.

The oil circuit system is fully upgraded: safe, stable, full-featured, differential clamping and fast operation speed.

New mold adjustment structure: Automatic and precise mold adjustment can be achieved with one click, thus reducing manual intervention.
The overall servo power is increased by 20%, the shooting speed is increased by 20%, the melt speed is increased by 10%, and the overall efficiency is increased by 15%.

Fourth-generation mold temperature controller

The fourth generation of mold temperature controllers is suitable for whole-plant solutions. The newly upgraded copper heater is not easy to scale. The copper material offers excellent ductility and thermal conductivity, increasing life by 40% and efficiency by 10% while allowing the mold temperature controller to function effectively even with poor water quality.

Mold Temperature Control System 11

High-precision filter: The standard configuration is a 50-mesh high-precision filter, and the optional configuration is a 30μm filtration grade precision filter. In addition, the filter aperture is about 0.03mm, which can effectively filter impurities and prevent mold clogging.

High precision filter

Liquid level detection function: Teflon float is suitable for pure water, has a float zero welding process, and has no welding leakage problem.

Water pressure adaptive temperature adjustment: The 120℃ standard mold temperature machine includes a pressure detector that achieves 1% detection accuracy, and you can adjust the upper limit of the usage temperature according to different water inlet pressures to ensure proper operation when the water inlet pressure is low.

Water pressure adaptive temperature regulation

More accurate temperature control: The temperature control accuracy of the fourth-generation mold temperature controller reaches ±0.1℃. The latest PID temperature control algorithm improves the temperature control efficiency by 10%. At the same time, the hardware part adopts solid-state relay temperature control with a response time of 0.1s. The dual guarantee of software and hardware better ensures the product yield.

 

Make injection molding smarter and simpler.

“The new factory has been in operation for a month, and the yield rate has increased by about 25%, reducing the waste of raw material costs. The professionalism and tolerance of the products are in line with expectations, which will save a lot of energy for product quality inspection and subsequent sales.” ——-Feedback from DERXIN’s head

DERXIN plans to continuously increase its market share to 50% in the next five years. Topstar hopes to provide more companies with a series of more competitive solutions with its own experience and services in intelligent whole plants.

 

 

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