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Use mould temperature controller to improve injection molding yield

2024/07/19 By Topstar

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In the injection molding industry, the actual temperature delivered by the mould temperature controller of many users is different from the temperature displayed by the mold temperature controller. There is a significant deviation, resulting in a low yield rate. In communicating with users, we often encounter similar problems, and the yield rate is not high for various reasons. Therefore, we have sorted out the Topstar mould temperature controller functions to improve the yield rate and will share them with you in this guide.

Temperature control accuracy of mould temperature controller

Topstar’s mould temperature controller is based on the temperature PID algorithm, which allows the temperature control accuracy to reach ±0.1℃. It can ensure temperature uniformity and also has an over-temperature protection mechanism. By preventing temperature fluctuations, these controllers help minimize defects such as warping, dents and incomplete filling, thereby increasing the overall yield of the molding process. In addition, the machine’s system will automatically record the equipment operation status and alarm log to reduce the fault promotion response time. It not only guarantees productivity but also guarantees the yield rate.

Use mould temperature controller to optimize cycle time

In injection molding, cycle time is also a key factor that directly affects productivity and output. The mould temperature controller helps keep the mold at an ideal temperature, ensuring the material solidifies quickly without affecting quality. By shortening the cooling time, the enhanced cooling phase enables manufacturers to produce more parts faster. Faster cooling speeds up the solidification of the plastic, which reduces the overall cycle time. This increase in output can meet high production demands and ensure a good yield. In addition, shorter cycle times can reduce energy consumption.

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Blowing and water return function

The blowing function of the Topstar mould temperature controller helps to speed up mold cooling by introducing controlled airflow into the mold. By directing air to specific areas of the mould, blowing can supplement the cooling effect provided by traditional water-based systems. Achieve a more uniform and faster cooling process. The blowing function also greatly reduces cooling inconsistencies, directly translating into higher yields. The water return function ensures that the cooling water circulates efficiently and constantly throughout the mold. It helps to maintain a stable mold temperature, and constant temperature control minimizes thermal changes that may cause defects, thereby improving the yield rate. The two are combined with each other, using the targeted cooling enhancement provided by the blowing function, and the water return function ensures overall temperature stability to make parts more efficient and less defective.

Dual-circuit temperature detection

In mould temperature controllers, dual-circuit temperature detection uses two independent temperature sensors and control circuits to monitor and regulate the temperature of the mold. Enabling each circuit to operate independently allows for precise and continuous temperature measurement and control at different points within the mold. This ensures a more accurate and reliable thermal management system. By monitoring multiple points within the mold, they can detect and correct temperature deviations in a timely manner. This precise control can reduce temperature fluctuations that cause defects such as warping and shrinkage of moulded parts. Using dual-circuit temperature detection minimises temperature changes, resulting in more consistent product quality and better yields.

Wider temperature range

The mould temperature controller series is divided into water-type mold temperature controllers (120℃-180℃) and oil-type mold temperature controllers (200℃-320℃), with heating power ranging from 8-48KW and water pump power ranging from 1-5HP. Mold temperature controllers with a wide temperature range can meet the temperature requirements of different plastics such as PEEK, POM, PP or PE. Ensure that the appropriate temperature is maintained for each material type. This versatility reduces the risk of heat-related defects, thereby improving overall yields. Proper temperature control over a wide temperature range can improve the surface finish, dimensional stability, and strength of molded parts.

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Impact on injection molding yield

Topstar’s mould temperature controllers can improve product quality, reduce energy consumption, and minimize downtime and maintenance by providing precise temperature control, optimizing cycle time, and optimizing air-blowing and water return functions. Their advanced features and best practices further enhance their ability to increase production and yield.

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