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What factors can cause delays in the injection molding process of plastic molding machine?

2024/12/13 By Topstar

plastic molding machine 6-1

Injection molding is a fast, efficient, and economical manufacturing process for producing large quantities of complex plastic parts. Many factors can cause delays in plastic molding machines, affecting the efficiency of the entire production line. These factors include the machine’s insufficient intelligence, inadequate material handling, and more. Below, we will explore the various factors that cause delays in the injection molding process and how the plastic molding machine provided by Topstar can improve efficiency and prevent these delays.

Inadequate material handling and quality issues in plastic molding machine

First, let’s start with the material. Changes in material properties such as viscosity, moisture content, or particle size can affect the injection molding process. When moisture in plastic particles causes poor flow, surface defects such as speckles or bubbles will appear on the finished part. If operators do not dry the material correctly before injection, they will cause delays in the molding cycle, require additional drying time, or create waste due to part defects. The temperature of the material also plays a vital role. Operators will achieve consistent flow if they preheat the material to the proper temperature before injection, slowing the entire cycle time. Topstar’s plastic molding machines can integrate a drying and dehumidifying System, in which the double-layer insulated drying barrel adopts a down-blowing air duct design to prevent heat loss. Improving material drying efficiency can ensure optimal processing conditions, reducing delays caused by improper material drying.

drying and dehumidifying System

Plastic molding machine need more intelligence.

Intelligence is the key to reducing delays and improving production efficiency. Lack of intelligence in the injection molding process will lead to flexibility, slower cycles, increased labor costs, and unstable quality. Suppose the system does not integrate with the surrounding injection molding auxiliary equipment to improve intelligence and perform tasks such as part removal, material handling, and quality control. In that case, the equipment may experience repeated delays due to the inability to communicate between people and equipment. The automatic compensation function of the mold opening position is standard in Topstar’s plastic molding machine series. This function ensures that the robot can accurately grasp and place parts, solving problems such as delays in removal failure and equipment alarm shutdown due to ejection position deviation and inconsistent suction time.

Injection molding unit 1-2

Cooling System Problems and Extended Cycle Times

Cooling time accounts for a large portion of the total cycle time. If the cooling system is not operating correctly, it may result in extended cycle times, delayed part production, and affected part quality. In some cases, problems such as inefficient cooling or insufficient coolant flow may cause uneven cooling, which may cause part warping or cracking. In addition, if the cooling system cannot handle the required heat dissipation, it will cause excessive cycle times, slowing overall production.

Auto Cooling System

Topstar’s plastic molding machines use an automatic cooling system. The entire machine uses a fully computerized temperature controller, which is simple to operate and can accurately control the water temperature between 5-35°C. At the same time, current overload protection, high and low voltage control, and electronic time delay safety devices are also used. When a fault occurs, an alarm will be issued in time to display the cause of the fault, reducing the possibility of delays caused by inefficient cooling systems.

Inaccurate machine settings and calibration issues

Inaccurate machine settings can cause severe delays in the injection molding process. Operators must carefully calibrate injection pressure, speed, mold temperature, and cooling time to achieve the best results. If they set any of these parameters incorrectly, they can cause defects in the molded part, such as warpage, flash, or poor surface finish.

In addition, incorrect calibration can cause machine inefficiencies, such as uneven injection pressure, inconsistent part quality, or extended cycle times. The in-house control system used in our plastic molding machine series enables manufacturers to fine-tune all necessary parameters through a computer screen, ensuring that each injection cycle is optimized for speed and accuracy. Real-time monitoring and automatic adjustments can help prevent delays caused by incorrect machine settings, ensuring smooth and efficient production.

Delays caused by maintenance and repair issues

Planned and unplanned maintenance and repair downtime is another significant factor that causes delays in the injection molding process. Plastic molding machines are complex systems that require regular maintenance to keep them running smoothly. In addition, unforeseen repair issues can be even more detrimental, resulting in extended downtime between ordering parts and completing repairs. Topstar designs its plastic molding machines with reliability in mind, using high-quality components and durable systems to minimize the need for repairs. In addition, Topstar’s machines feature automatic diagnostics and preventive maintenance alerts to help identify potential issues before they cause unplanned downtime, reducing the risk of delays due to repair and maintenance issues.

Increase Efficiency and Reduce Delays

Delays in the injection molding can lead to lost time, increased costs, and reduced product quality. However, with features such as automatic mold compensation, state-of-the-art cooling systems, and automated control systems, Topstar’s injection molding machines are designed to reduce downtime, prevent delays, and increase the overall efficiency of the molding process.

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