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The new-generation mold temperature controller that meets customer needs

2024/09/27 By Topstar

mould temperature controller 60

As one of the main components of auxiliary equipment in injection molding, the mold temperature controller has global sales of US$520 million in 2023, accounting for about 32% of the entire auxiliary equipment market, according to the “In-depth Research and Future Trend Analysis Report on the Development of Global and Chinese Injection Molding Machine Auxiliary Equipment Industry from 2023 to 2029”. As essential auxiliary equipment, fast heating, stable temperature, and no leakage are its standard functions. In order to meet the needs of industry customers for intelligent and digital upgrades, solve the temperature control problems of injection molding production, and improve product yield, Topstar’s newly launched 4th-generation mold temperature controller is constantly evolving for precision injection molding functions.

We have collected the problems encountered by customers in production and shared them with our customers to discuss the performance and advantages of the 4th-generation mold temperature controller in practical applications.

Hardware precision of mold temperature controller

Problem 1 encountered by customers: poor water quality and pipe blockage affect the heating effect

Due to the high concentration of calcium and magnesium ions in the water, it is easy to block the water pipe. To solve this problem, the water quality must be purified.
To solve this problem, Topstar upgraded the water temperature machine with a copper heater, which makes the impurities in the water less likely to adhere to the copper surface and not easy to scale. This makes the copper material ductile and superior in thermal conductivity, increasing the life by 40% and the efficiency by 10%. You can commonly use the mold temperature machine even with poor water quality.

Nickel-plated copper heater

In addition, Topstar comes standard with a 50-mesh high-precision filter and an optional 30μm filtration grade precision filter. The filter aperture is about 0.03mm, which is equivalent to the diameter of a hair, and can effectively filter impurities to prevent mold clogging.

High precision filter

At the same time, we have also added a liquid-level detection function using a Teflon float (the float has a zero welding process, and there is no welding leakage problem). You can use this for pure water and various poor water qualities, such as oil and iron filings.

Problem 2 encountered by customers: Unstable water pressure, low water inlet pressure, affecting the yield rate

Water inlet pressure is crucial for precise temperature control. If the water pressure is insufficient, it is easy to dry-burn the pipeline. You can replace the water supply equipment or switch to other mold temperature machines.
For this problem, Topstar uses water pressure adaptive temperature regulation. The 120℃ standard water-type mold temperature controller includes a pressure detector, ensuring detection accuracy reaches 1%. You can adjust the upper limit of the operating temperature based on different water inlet pressures to maintain regular use of the mold temperature controller when the water inlet pressure is low.

Water pressure adaptive temperature regulation


The 160℃ and 180℃ mold temperature controllers use an indirect cooling sealed circulation mode and micro-boosting pump water replenishment to lower the water inlet pressure requirements. People commonly use them when the water inlet pressure exceeds 0.3 bar.

Problem 3 encountered by customers: Components such as water pumps, pipes, and solenoid valves are easily damaged

In the daily operation of the mold temperature controller, metal pipe parts will experience continuous heating and cooling cycles. This repeated temperature change can easily cause metal fatigue, resulting in structural damage to the pipe parts.
The Topstar high-temperature water-type mold temperature controller is equipped with a standard gas collecting tank, which can absorb the additional pressure caused by this expansion and contraction, effectively buffer the pressure fluctuations inside the system, and thus prevent component damage caused by pressure changes. At the same time, the gas dissolved in the water will be released. The space provided by the gas collecting tank can collect these gases to prevent them from flowing back into the system, reduce the formation of bubbles, and ensure stable operation of the equipment performance.

Intelligent system of mold temperature controller

Problem 4 encountered by customers: Inaccurate temperature control and low product yield

The large temperature fluctuation is due to the fact that the mold temperature machine’s temperature control accuracy cannot meet the actual production requirements, and a more accurate device is needed for temperature control.

First, we upgraded the software and hardware to make the temperature control more accurate. The accuracy of the Topstar 4th generation mold temperature machine is ±0.1℃. The latest PID temperature control algorithm improves temperature control efficiency by 10%, ensuring uniform temperature. At the same time, the hardware adopts solid-state relay temperature control with a response time of 0.1 seconds. With the dual protection of software and hardware, the system temperature fluctuation is controlled within ±0.1℃, ensuring high product yield.
In addition, the more advanced mold temperature controller includes 1MHz ultrasonic flow monitoring. This monitors the media flow in real time, can detect bubbles larger than 2mm, ensures that the water flow is liquid, and makes the temperature control stable and accurate.
It is also standard to use a gas-liquid separation device, which can quickly separate the gas in the medium to prevent uneven heating of the mold. These functions can prevent mold temperature fluctuations and reduce the defective rate by about 3%~5%.

Application Industry

Topstar’s 320℃ oil-type mold temperature controller for the die-casting industry has the characteristics of precise temperature control of the 4th-generation machine, rapid heating and cooling, and easy maintenance and operation. At the same time, to ensure safe use, we adopt an electrical box separation design to isolate the high-temperature conduction in the chassis and effectively protect the electrical components. In addition, the magnetic drive pump we use solves the problem of natural wear and leakage of the shaft seal. An over-temperature protection switch is standard on the motor coil to prevent overheating and burning, lower the failure rate, and reduce the risk of accidental touch.

The 120℃ mold temperature controller for the automotive industry uses a cooling solenoid valve with a diameter of 20mm. This valve has a faster cooling speed and a lower temperature control temperature and is more suitable for the temperature control of thick-walled products in the automotive industry.

Explore the value of the diverse applications of mold temperature controller

From the first to the fourth generation of mold temperature controllers, Topstar has achieved many breakthroughs in their research and development, including gas-liquid separation structures and fluid inlet and outlet connection devices.

Through the integration of hardware and software, and combined with the diverse application experience of 15,000 customers, the mold temperature controller can adapt to a broader range of working conditions, allowing auxiliary equipment and customer manufacturing to move towards intelligent upgrading.

Topstar’s 4th-generation mold temperature controller currently includes a water-type mold temperature controller (120℃-180℃), an oil-type mold temperature controller (200℃-320℃), heating power 8-36KW, water pump power 1-5HP, and single-stage and double-stage temperature control series to choose from, to meet customers’ different working conditions.

TTWB-1810
water-type mold temperature controller (120℃-180℃)
TTOP-3210
oil-type mold temperature controller (200℃-320℃)

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