maintenance of injection mould machine

AuthorHaiflymachinery Date2010-1-21 20:16:09

In order to ensure the injection molding machine work normally,lower trouble

and prolong the using life of machine ,user must note to maintain the machine
during everyday use.

7.1 daily check

No.1:check to see if the button of emergency stop is normal:

No.2: check to see if there is abnormal noise during machine running :

No.3:check to see if the mechanical ,electrical and hydraulic safety device is

normal ,do the movement of clamping mold by operation style of manual
,semiautomatic and automatic separately,open the safety door to be 20-30mm
to test whether the movement of clamping mold can be stopped:

No.4:check to see if the oil position in hydraulic tank is over the middle position
in hydraulic pressure gauge and whether leak:

No.5:check to see if the grease/oil is enough on lubricating equipment and

lubricating spots,to see if the liquid position of lubricating pump is enough high

No.6:check to see if the work pressure of hydraulic system is too high

No.7:check to see if the oil temperature is increasing too fast and the water
supply for cooling is normal

No.8: check to see if the heating to screw barrel is normal and the running of
temperature-controller is normal

No.9:check to see if the injection mould installation is steady

No.10: check to see if the injection mould installation is steady

No.11:check to see if each parameter set of injecting is right

7.2 Periodic check

7.2.1 check weekly

1do routine check according to above 7.1

2check to see if the wire connection of each limit switch ,heater band and
thermocouple and screw is loosened or broken off .

3check to see if there is phenomena of leaking oil for the hydraulic cylinder
,joint ,flange and soft pipe, if that ,replace correlative airproof ring

Specification of bolt

Moment of forceskg*m

M3

0.23

M4

0.46

M5

0.92

M6

1.6

M8

3.9

M10

7.5

M12

13.0

M16

30.6

M18

43.0

M20

61.6

M24

80.4

7.2.2 check monthly

1do routine check according to above details

2check the tightening screw and nut of each structure to see whether it is
loosened, if that,tighten it ,as to details of tightening bolt:refer to the right
table shown

3check the net-shape filter to see if there is filament or other granule

jammed it ,clean off it if necessary

4check to see it is corrosive in the inner of cooler for oil and the external of
heat conductor pipeif supply water by city ,check it every six months ,then to
see if it need cleaning off

7.2.3 Check yearly

1do routine check according to above details

2check to see if the hydraulic oil is degeneration and polluted ,replace new
hydraulic oil if necessary
3check to see if the wire is aging and ossify ,if that ,replace them
4check the screw .screw collar .collar seat and mixing head to see if they are
worn
5check the charging motor to see if there is noise when the motor running ,if
the earing of rotation shaft has been damaged ,replace it
6clean off the whole machine ,clean off the oil dirt on the surface
7.3 maintenance of cooler for oil
This machine adopts cooler for oil with floating pipe style to cool the hydraulic
oil .the water for cooling to into the lids cavity for water entering-and-going
through the coming connection pipe,then flow along with the cooling pipe.the
flowing water absorbs the heat which is sent out by the hydraulic oil then to out
through the exit connection piperefer to the following drawing
The cooler for oil works for a long time .the water medium is accumulated
gradually on the wall of cooler ,which will decrease the performance of emitting
heat ,so it cant ensure to reach the requirement of oil cooling ,when you should
inspect and maintain the cooler for oil .
7.3.1 steps of inspection and maintenance of injection molding machine
No.1.close the valve of mouth of oil coming-and-going and water coming-andgoing .give out te left water in cooler ,then discharge it from machine
No.2.loose the screw on the lid for water entering-and-going,and discharge the
entering-and-going water lid.take down the airproof washer at the same time
No.3 loosen the screw on back lid ,discharge the back lid ,take down the airproof
ring at the same time ,draw out the cooling equipment from the end of position
hole
No.4 lead clear water througt soft pipe to lid for water entering-and going and
clean it,clean off accumulated dirt in back lid and inner wall of pipe for cooling
,wash inner wall of pipe for cooling with soft cloth.
No,5 use alkalescent wash which can be got from market ,wash the inner wall of
pipe for cooling again ,the washing pressure cant be over 5kgf/cm2,watching the
water flowing from the pipe during washing ,the cleaning work is finished until
clean water flowing out of pipe
No.6 as to the sandwich dirt which is difficult to clean,use weak muriatic acid
liquor dipping in it for 15-20minutes ,until the liquor flowing out is near same as
clean color;
Notice:

If using wash to clean it ,must clean it with clean water repeated to

avoid chemical substance in wash eroding it.

No.7 after clean it with clean water,blow to dry it by compressed air at last.
No.8 assemble the all parts in order ,there cant be phenomena of distorting for
each airproof ring when assembling .
No.9 do test of water pressure ,fill water fully to the place where the water for
cooling go by in cooler,then close the mouth of oil coming-and-going ,fill
compressed air 5kgf/cm from the mouth of ejecting air of oil side , when the
mouth of ejecting air of water side should be open state ,if there is leakage
phenomena,the water will overflow form the mouth of ejecting air of water side
No.10 after finish test ,assemble the machine as its origimal sample,and connect
pipeline well ,
7.3.2 Notice during using cooler for oil
1.medium for cooling is clean fresh water ,match water filter if the water
quality is bad explain to manufacturer if using seawater for cooling
2. in cold reason,must give out left oil and left water to avoid freezing if not use it
for a long time.
3.the temperature of water for cooling should be low and the flux of water should
be big in order to avoid forming water dirt ,if the water supply for cooling come
from under ground water or industrial water or other water with many salt-alkali
element.which will cause water dirt to from in cooler more fast
4.give out air periodically ,do periodic inspection and washing to the interior ,the
washing period is up to the water quality: the maintaining period is about six
months if water supply is from city,while the maintaining period is one month if
water supply is from water under ground or industrial water
5.Note the tempreature of oil coming or going when working ,adjust the
temperature of oil going through adjusting the coming flux of water for cooling so
that make it meet the requirement.
7.4 maintenance of net-shape filter
Net-shape filter has function of filtrating oil .the oil pump absorbs clean oil so
that the hydraulic system of machine can run normally, after the machine
running for a long time, the oil cycles continuously,the surface of net-shape filter
will adhere impurity in oil ,even be jammed by the impurity ,which will influence
the oil pump to work seriously .so it is very important to inspect and clean the
net-shape filter periodic.
In the first year using machine, inspect and clean it every six mouth,later
inspect and clean it every year when replace oil .
Steps of machine:
No.1 discharge the cover of oil tank ,give out the hydraulic oil in the oil tank
completely.screw off the net-shape filter from the pipe oil coming in oil tank
No.2 clean oil tank thoroughly
No.3 clean the filter with gasoline or coal oil ,and clean filament or thin granule
which is adhered on the surface of filter thoroughly

No.4 if find net-shape filter is damaged ,must replace a new one.

Notece:
1.
mustnt scrape the net on surface of filter with rigidity substance to avoid
damaging net
2.

when discharging the oil filter ,mustnt start motor of hydraulic pump

3.
after install the filter and when starting motor of hydraulic pump ,let the
motor of hydrculic pump run for ten minutes without loading ,check it to be
normal then it can work with loading
7.5 clean and inspect the screw and screw barrel
Adopt the way of exchanging plastic whose flowing performance is good to
clean screw barrel ,and should follow right operation steps when exchanging
plastic:master technical data such as the heat stability of plastic,forming
temperature range of plastic and consistency with other plastic,etc,if the forming
temperature of plastic with good flowing performance is much higher than
temperature of plastic in screw barrel.first,increase the temperature of screw
barrel and nozzl to be the lowest processing temperature of plastic with good
flowing performance ,then put plastic with good flowing performance into the
screw barrel ,and inject it for nothing continuously until clean out all after plastic
in screw barrel ,adjust the temperature to be normal to produce at last,if the
forming temperature of plastic with good flowing performance is much lower
than temperature of plastic in screw barrel , first ,increase the temperature of
screw barrel and nozzle to be the best flowing temperature ,then cut off electric
power for heating ,clean screw barrel using plastic with good flowiing
performance at the condition of lowering temperature ,if the forming
temperature of plastic with good flowing performance is hihh,and melting
mucosity is big ,moreover ,the plastic in screw barrel is material which is
sensitive to heatsuch as PVCyou should choose polystyrene with good
flowing performance and high heat-stability or polyethylene with low density as
transition material in order to avoid plastic be decomposed,
7.5.1 discharge the screw and screw barrel
The screw and screw barrel are important components of molding parts ,the
screw, screw barrel ,screw head and screw collar maybe will be worn or scraped
when the machine run for a long time or using reclaimed material often to mold,
so discharge the screw and screw barrel to check and clean if necessary ,and to
see the degree of wearing and scraping .
A: preparations befor dischanging
1
if the left plastic in screw barrel is material with high viscosity and
be sensitive to heat such as PVC,PCetc,the plastic will be stick in the surface
of screw and inner hole of screw barrel after it is cooled,when peel off it ,must be
care of maybe damage the metal surface ,must clean the screw barrel and screw
according to the way shown in above section 7.5 before discharging them.first
put plastic with good flowing performance into the screw barrel ,and inject it for
noting continuously until clean out all left plastic in screw barrel :
2

prepare flowing assistant tools or material :

a:four or five wooden stick or steel stickdiameterdiameter of screw,length

stork of injecting
b:four or five segment square-shape hardwood
c:clamp
d:several piece of waste cotton or waste cloth
e;one piece of waste cotton or waste cloth
f:fireproofing flux
g:brass stick or brass brush
3

moving position of whole injection base

NO. 1 start motor of oil pump

No.2 adjust the baffle for limit switch of base back to be max ,position
No.3 press the button of base back and make the injecting equipment back to
the bottom position
No.4 discharge the bolt between the base of injecting and base of flange for oil
cylinder which charges the whole movement of coming-and-going,make them
separate,
No.5 take out inner hexagon screw on front and back supporting of injecting
device .loosen the screw for adjecting
No,6 turn the whole injecting base at a angle .and push it to the direction of
operation,as shown in following drawing
B:steps of discharging screw
No.1 heat the nozzle of screw barrel and make its temperature to be the max
,value of melting temperature of plastic in screw barrel, then cut the heating
power supply
No.2 adjust each injecting pressure and injecting speed to be least value in
computer
No.3 start motor of oil pump ,make it to be manually-operation state,press the
putton of charging injecting piston back to limit position of stroke
No.4 discharge following parts in order:heater band for nozzlenozzlefront
body of screw barrel.as shown in following drawing
No.5 discharge following parts in order:screwhalf ringpull out end of
screwscrew for fixingpin.as shown in following drawing
No.6: take a segment of hardwood and put it at the end of screw ,clamp the
hardwood with clamp,start the motor of oil pump, make it to be manuallyoperation state, press the button of injectto push the hardwood and screw to
the front of screw barrel. When reach the limit position of injectig stroke,press
the button of

No,7 add second segment of hardwood,repeat the movement of above No6,so

that push out the screw from the front of screw barrel gradually.
Notice:
Mustnt push out the screw by hand directly because the screw hasnt cooled
at this time ,after discharge the screw ,put it on wood to avoid burr.
C:steps and way of discharging screw barrel
No.1 discharge all the heater bands and thermocouple on screw barrel
No.2 turn whole injecting base ,let it to be original position and tighten it with
screw
No.3 loosen and dischrge the notch nut which is fixesd the end of screw barrel
No.4 lift the screw barrel for the moment with lifting deviceNote the center of
gravityrefer to ollowing drawing
No.5 as shown on above drawing ,take a segment of hardwood and put it
between the base of charging and end of screw barrel ,clamp the hardwood with
clamp,start motor of oil pump ,press the utton of injecting plastic.make the
base of charging push the hardwood along with screw barrel out
No,6 back the base of charging ,use another hardwood to repeat the step above
No,5 until push screw barrel out of injecting base ,at the same time,concert the
movement of screw barrel with lifting so that make the screw barrel level
No,7after discharge the screw barrel .put away it on safety place
7.5.2 clean screw and screw barrel
A:clean and inspect screwas shown in following drawing
No.1 cover the screw handle on the end of screwside with key slotclamp the
screw head,rotate the screw out as shown on above drawing,screw head is leftrotating screw
No.2 wipe the main body of screw with waste cloth or cotton and clean off the
colopyony deposit on the surface
No.3 heat the surface of screw evenly with coal oil light ,then scrape it with
waste cloth or cotton ,clean off the deposit on surface of screw with brass
No.4 clean the components of screw head ,screw collar,collar seat and mixing
head according to above way of cleaning screw surfaceas shown in following
drawing
o.5 wipe off all oil dirt after cooling
Notice:
A :mustnt clean the deposit on screw by scraper ,grinding wheel or iron stick
forcibly to avoid damaging smooth surface of screw
B : when install screw head ,put some silicon oil or disulphide molybdenum
lubricate grease to avoid them joint,only thin layer is enough or will dirty plastic
product the grease is too much

No.6:check the inner or external screw thread of screw ,screw head and mixing
head to see if it is damaged .if that ,there will be trouble such as countercurrent
when injecting mold,or measurement fluctuating ,etc.
B:clean and nspect screw barrel
No.1 clean off the colophony deposit on surface of screw barrel when the screw
barrel remains some heat
No,2 slip waste cotton into the inner hole of screw barrel ,push the cotton comeand-go to clean the inner surface of screw barrel
No.3 heat the nozzle and front parts of screw barrel by coal oil light clean the
external surface .screw thread and each contact surfaceas shown in following
drawing
Notice:
Wipe each contace surface shown above drawing carefully to avoid burr or
scraping ,or scraping,or will cause leakage when molding
No,4 if there is left deposit on the inner surface of screw barre; ,use waste
cotton dipped with trichloro ethylene to clean it
No,5 finish clean work ,dry the surface ,check to see if the inner surface of screw
barrel is worn or scraped
7.6 elininate common problems
7.6.1 the motor of oil pump doesnt work
(1)if the motor of oil pump doesnt work ,and there is unusual noise ,check to see
if the fuse has broken or been fused,then check to see whether the three-phase
electric power supply is normal .
(2)if the motor stop suddenly ,to see if the air switch is in over condition ,close
the air switch after two minutes ,start motor of oil pump
(3)if having pressed the button of start motor,while the motor doesnt work ,to
see if the button has been damaged or the heat replay is breaking off ,at the
some time .check the emergency button or other correlative wire connection
(4)the oil pump is jammed so that the motor cant work ,when you shoule
discharge and clean the oil pump and take out of foreign substance ,then check
the rotation space of pumps vane
(5)the motor is burned ,then you should repair or replace the motor
7.6.2 the motor can work ,but it cant engender pressure
(1)the electromagnetic iron wire ring of presure proportion balve doesnt adsorb
or the core of valve is jammed by sundries ,when should discharge to clean it .at
the same time check the electromagnetic iron wire ring to see if it is burned or
the connection wire is loosened
(2)the hydraulic oil is not clean,leak oil because of motor wearing after the motor
was used for a long time ,repair of replace the oil pump

(3) the hydraulic oil is not clean ,the sundries is accumulated on the surface of
net-shape filter so that disturb the oil go into the oil pump.when you should clean
the filter and replace hydraulic oil
(4)to see if the motor is in reverse condition
(5) to see if the pressure gauge is bad,if that ,replace it .
Notice:
If the oil pump has been discharged to repair ,must assemble the
components in it according to their original position,otherwise the oil pump
maybe assembled at inverted direction ,if that,even if the rotation direction of
motor is right,pressure cant be engendered
7.6.3 the movement of clamping mold doesnt work
(1) to see if the safety door is closed,or the connection wire of limit switch on
safety door is loosened or is damaged
(2) to see the ejector mandril backing doest reach the required position or the
linear displacement transducer is no use ,adjust the set of ejector mandril
position or check the linear displacement transducer
(3) the wire of hydraulic valve for opening mold and clamping mold is burned or
maybe the core of valve is jammed by sundries ,clean or replace it
(4) the airproof of piston on clamp cylinder doesnt work
7.6.4 the movement of locking mold doesnt work
(1) to see if the position setting of linear displacement transducer used when
finish movement of clamping mold in low pressure and change to locking mold in
high pressure is right ,or reset the position
(2)to see if the force of locking mold is enough
(3)to see if the mold is adjusted too close ,if that ,increase thickness of holding
mold
7.6.5 Not inject
(1) to see if the wire of hydraulic valve for injecting is burned or the core of valve
is jammed by sundries ,clean or replace it
(2) to see if the heating temperature for screw barrel is too low. Note the alarm
from computer,check the heater band or fuse ,adjust the temperature setting in
computer
(3)check the allowed temperature tolerance of temperature setting in computer
(4)to see if the approach switch for injecting base forward isnt connected or the
connection wire is broken ,adjust the position of baffle and check the approach
switch
(5)to see if the limit switch of protecting cover for injecting head isnt connected.
7.6.6 the screw doesnt rotate

(1)to see if the wire of hydraulic valve for controlling charge is burned or the core
of valve is jammed by sundries,clean or replace it
(2)the hydraulic temperature is too low the computer stops automatically and
alarms
(3) to see if motor for oil pump is over loading ,if that ,stop the movement of
charging immediately to avoid damage the screw ,and check to see jif the motor
is damaged
(4) there maybe be sundries going into the screw barrel when charging ,which
make the screw occlude screw barrel
(5) the position setting for stopping charging isnt suitable ,reset it
7.6.7 the screw can rotate,but not charging or the speed of charging is slow
(1)the screw barrel isnt connected with water for cooling or the water for cooling
isnt enough so that the temperature of fallen plastic go up ,which prevent the
plastic going so take out the agglomeration plastic which is melt
(2) to see if there isnt plastic in hopper
(3)the adjustment of adjusting valve for back pressure isnt suitable or there is
sundries to jam it in valve ,the back pressure is too high so that make the screw
back off slowly
(4)sundries go into the screw barrel so that it isnt smooth for plastic going
7.6.8 the screw rotates abnormality and quantity of injecting isnt stable when
injecting
(1)the injecting components ,especially the screw collar is damaged ,so that
make the melt plastic regurgitate ,which lead the screw rotate
(3)the screw barrel or screw has been damaged
7.6.9 movement of adjusting mold doesnt work
(1) to see if the select switch isnt in state of on(the indicating lamp isnt light)
(2)wire of electromagnetic commutating valve for adjusting mold is burned, or
there is sundries to jam it in valve.clean or replace electromagnetic valve
(3) to see if the parallet of molding platen meet the requirement ,see if the level
position of machine frame is wrong ,which will bargen the movement resistance
of molding platen
(4)to see if the motor of oil pump is damaged
(5)check the work pressure.
7.6.10 the movement of opening mould isnt sensitive or there it engender noise
(1) check to see if the position setting for finish opening mold is suitable
(2)wire of electromagnetic commutating valve for opening mold is burned, or
there is sundries to jam it in valve ,clean or replace electromagnetic valve

(3) check the work pressure ,increase the pressure suitable

(4)the position setting for finish opening mold isnt suitable ,which will make the
piston strike the back cover of oil cylinder ,reset the position to be suitable
7.6.11 the semiautomatic operation doesnt work
The semiautomatic operation is realized through electric signal which is sent by
computer controlling each electromagnetic valve.if each movement is normal in
manually-operation state.while the semiautomatic operation doesnt work
,whose reason mainly is electrical limit switch

Maintenance and fault analysis of the causes of vertical

injection molding machine maintenance
Date2015-3-25 9:40:51
First, the vertical injection molding machine failure category
Vertical injection molding machine failures are diverse, from different angles can its
category.
1. Press the failure state can be divided into:
(1) gradual onset fault. Vertical injection molding machine is due to the gradual
deterioration of the initial performance and generated most of the vertical injection molding
machine failures are part of such a failure. Such failures and electronically controlled,
hydraulic machinery yuan parts wear, corrosion, fatigue and creep processes are closely
related.
(2) sudden failure. Various unfavorable factors and occasional interaction outside influences
arising from this effect is beyond the vertical injection molding machine can withstand the
limit. For example: physical appearance due to barrel into the iron overload caused by broken
screw; and breakdown due to high pressure in series vertical injection molding machine
electronic board. Such failures often occur suddenly, without any prior warning.
Sudden failure occurred in the vertical injection molding machine application stage, often
due to the design, manufacture, assembly and material defects or operational errors, caused
by illegal operations.
2. Press the nature of the fault can be divided into:
(1) intermittent failures. Vertical injection molding machine in the short term loss of some
of its features, debugging can restore a little repair, no replacement parts.
(2) a permanent failure. Vertical injection molding machine has been damaged in some
parts need to be replaced or repaired to restore applications.
3. Failure impact can be divided into:
(1) complete failure. Resulting in a complete loss of function of vertical injection molding
machine.
(2) localized failure. Resulting in some loss of function vertical injection molding machine.
4. The cause is divided by the fault can be divided into:
(1) failure to wear. Due to normal wear and tear caused by vertical injection molding
machine failure.
(2) misuse of failure. Due to operator error, failure caused by improper maintenance.
(3) the inherent weakness of the fault. Because of design problems, make vertical injection

molding machine appear weak link, the fault generated during normal use.
5. Press the risk of dividing the fault can be divided into:
(1) the risk of failure. For example, the security system in action when needed due to failure
to lose the protective effect, causing bodily harm and vertical injection molding machine
malfunction; hydraulic electronic control system malfunction caused by failure.
(2) security failures. Security systems such as the action happens when the action is not
required; vertical injection molding machine can not be started when the start of the fault.
6. Press the vertical injection molding machine failure occurs, the law of development can
be divided into;
(1) random failures. Failure occurred is random.
(2) there is a fault rule. There are certain rules failures occur.
Each fault has its important characteristic, i.e., a so-called failure modes, or fault condition.
Fault status of various vertical injection molding machine is commensurate complicated, but
can be summarized in the following several kinds: abnormal vibration, mechanical wear and
tear, so that the computer can not accept the input signal, the solenoid valve is no output
signal, proportional hydraulics components rupture ,, linear imbalance hydraulic pressure
drop, hydraulic leaks, oil pump failure, hydraulic noise, circuit aging, abnormal sound, oil
deterioration, power drop, enlarged board has no output, thermal runaway and others. Various
failure modes of different types of vertical injection molding machine is different proportion.
Second, failure analysis and troubleshooting procedures
To ensure the failure analysis and troubleshooting of fast, effective, must follow certain
procedures, such a procedure is as follows.
Under the first step in maintaining symptom analysis site status
1. ask the operator
A fault what happened? In the current situation what happened? When did it happen?
Two vertical injection molding machine has already started the long run?
The first three failure there any anomalies? What sound or audible alarm signal? Presence
of smoke or odor? Whether or misuse (note inquiry method)?
4 control system is operating properly? Whether the change in operating procedures? When
the operation is extraordinary difficult or abnormal?
2. Observe the whole situation, the operating parameters
1 whether the apparent anomaly? Parts for jamming or injury? No loose or leaking
hydraulic system? Wires for cracks, scratches or burned?
What happens to two vertical injection molding machine operating parameters? Whether
the apparent interference signal? Without obvious damage to the signal?
3. Check the monitor indicating device
1 Check that all readings are normal, including pressure gauges and other instruments
readings, height status of the oil.
2 Check the filter, alarm and interlock operation output or display properly.
4. Jog vertical injection molding machine inspection (at agreed conditions)
Check the status of intermittent, lasting status, the status of the fast forward or slow forward
time to see whether these affect the output in the current situation, whether it may cause
damage or other hazards.
The second step to check vertical injection molding machine (including parts, components
and wiring)
1. Use the sensory examination (in-depth observation of the process of succession)
1 See: plug and socket without exception, operation of the motor or pump is normal, adjust
the position control accuracy, with or without signs of arcing or burning fuse is good or bad,
fluid leaks, lubricants and other road is smooth.
2 Touch: vertical injection molding machine vibration status, Yuan (Group) piece heat,

tubing temperature, state of the mechanical movement.

3: whether the abnormal sound.
4 sniffing: whether the burning smell, the smell of leaking other odors.
5 Charles: shape and position of the workpiece changes, changes in vertical injection
molding machine performance parameters, line error checking.
2. Evaluation of test results
Accurate assessment to determine whether the fault, the fault is found clues, the test results
are consistent.
The third step of determining the location of the fault
1. The difference between the system structure and to determine the test mode
Check vertical injection molding machine specification, vertical injection molding machine
is the difference between what a structure, conduct tests in what way, what test means
necessary, what test parameters or performance parameters may be obtained under what
operating conditions test, which must comply with safety measures, if required operating
licenses.
2. The system detected
Using the most suitable system architecture technology testing. At the appropriate test
points, depending on the input and feedback the results or performance of the normal
standard for comparison, to identify suspicious locations.
The fourth step repair or replacement
1. Repair
Finding the cause, for the vertical injection molding machine repair faults and take
precautions; check the relevant parts to prevent failures from spreading.
2. Replace
Accurate assembly debugging replacement parts, and pay attention to the relevant parts.
Repaired or replaced parts scrapped.
The fifth step for performance measurement
1. Start the vertical injection molding machine
After the commissioning start assembling parts vertical injection molding machine,
manually (or jog), then load and load measurement.
2. Adjust the load changes from low to high speed, small to large loads, the system pressure
may not exceed 140kg / cm2, measured according to the standard performance.
3. To expand the scope of the performance test
According to need, from the local to the system, and gradually expand the scope of the
performance test. Pay attention to non-fault zone system health. Performance requirements
are satisfied as to deliver applications such requirements are not satisfied with the redetermine the fault position.
The sixth step recording and feedback
1. collect valuable information and data, such as time vertical injection molding machine
failure, the failure phenomenon, downtime, when repairman, repair replacement parts, repair
effect, unresolved issues, settlement costs, according to the requirements exist into the
archives.
2. Statistical Analysis
Regular analysis of vertical injection molding machine application to record, analyze
downtime, revision notes directory to find measures to reduce maintenance operation point,
development failure mechanism, suggest improvements.
3. Press the program feedback about the failure to report the competent authorities, and
feedback to the vertical injection molding machine manufacturing units. Third, the failure to
start the program governance
Failure to do vertical injection molding machine control, we must grasp the reasons for

failure, often accumulate fat breakdown and typical breakdown of information and data, carry
out fault analysis, emphasis on fault law and failure mechanism of the development,
strengthening of routine maintenance, inspection and pre-repair . Expand the program failure
of governance in the following eight areas.
1. improving information and education, so that operation of the workers and maintenance
workers on the vertical injection molding machine consciously serious fault records,
statistics, analysis, rationalization proposals.
2. The close connection with the actual production of injection and vertical injection
molding machine status characteristics, divided by the vertical injection molding machine in
a, b, c three categories to determine the point of failure of governance.
3. The use of monitoring equipment, parts of the main points of the main points of vertical
injection molding machine in a planned monitoring, and found signs of failure and
degradation of information.
Generally vertical injection molding machine to go through the human senses and the
general detection tools for routine inspection, patrol inspection, periodic inspection (including
accuracy checking), good condition inspection focused grasp technological failure-prone
parts of the state, institutional and parts and anomalies information. The same time to develop
inspection standards to determine vertical injection molding machine normal, abnormal, fault
boundaries.
4. Conduct failure analysis, training, vertical injection molding machine repairman grasp
failure analysis methods.
5. Failure to achieve record vertical injection molding machine failures of governance
biography, but also for failure analysis, based on the original deal, the records must be
complete and accurate. After the vertical injection molding machine maintenance workers on
site inspection and troubleshooting, follow the "vertical injection molding machine
troubleshooting single" fill in the content, the workshop mechanic and submit monthly
statistical analysis of vertical injection molding machine control supervisor.
6. Workshop vertical injection molding machine maintenance staff in addition to routine
failure to grasp the current situation, but should be pooled month "troubleshooting list" and
maintenance records. Through statistical failure data, collation, analysis, calculate the
frequency of various types of vertical injection molding machine failure, the MTBF period,
failure analysis and dynamic elements Cause single vertical injection molding machine, find
Occurrence of failure, in order to highlight the main points to take countermeasures, fault
information analyzed with data feedback to the planning department to arrange for repair or
improvements preparedness plan, but also as a modified regular inspection intervals, check
the contents and standards based.
According to statistics collated data, statistical analysis charts can be drawn as a single
vertical injection molding machine malfunction dynamic statistical analysis table is the
maintenance team for failures and other visually effective way of governance, both for
management staff and maintenance workers to grasp each type vertical injection molding
machine failure status, but there are clear objectives when determining maintenance
countermeasures.
7. Adoption of the maintenance workers daily inspection tours and vertical injection
molding machine status check, made a sign of status and fault information, and relevant
records, analyze data, by vertical injection molding machine repair shop clerk or repair for all
types of vertical injection Leader Problems machine, timely arrangements for routine
maintenance, make full use of the production gap of time or holidays, so defensive front to
control and reduce failure. For some fault symptoms, risks, routine maintenance can not
afford, then back to the planning department plans to arrange repairs.
8. Failure to develop information management flowchart.

Fourth, the vertical injection molding machine fault law

R & D to develop a maintenance fault law of countermeasures, as well as to establish a
scientific system maintenance is very favorable. Vertical injection molding machine in the
application process, the application performance or status over time and gradually decline.
There will be a lot of failure before some omen, this is called a potential failure, physical
parameters which can indicate the difference between a functional failure is imminent, the
functional breakdown showed the loss of vertical injection molding machine specified
performance standards.
Vertical injection molding machine failure rate variation over time, often called the bathtub
curve. Vertical injection molding machine failure rate changes over time can roughly be
divided into three stages: early failure period, occasional failure and loss failure period.
1. Early failure period
Vertical injection molding machine in the early failure period, began a high failure rate, but
the passage of the failure rate decreased rapidly with time, early failure period for mechanical
products, also known as break-in period. The length of this period, due to the design and
manufacture of quality products, systems varies. Failure occurred during this period, it is
important that the design, manufacturing defects caused by or resulting from improper
application environment.
2. The occasional failure
Vertical injection molding machine into the occasional failure, the failure rate is about at the
steady state, tend to value. During this period, failure is random. The lowest failure rate in the
occasional failure period, vertical injection molding machine, and stable. Thus it can be said
that this is the best state to work on or called Vertical injection molding machine. This zone is
called the effective life.
Occasional failure fault, more due to the design, improper use and maintenance of the poor.
Therefore, by improving design quality, improve application management, diagnostics and
maintenance strengthen surveillance, etc., can be reduced to the lowest level in the failure
rate.
3. Failure of wear and tear
In the late vertical injection molding machine applications, the failure rate began to rise.
This is due to the vertical injection molding machine parts wear, fatigue, aging, corrosion
caused. If that is the turning point of the beginning of a major overhaul depletion fault, it can
be economical and effective way to reduce the failure rate.
Three stages of vertical injection molding machine failure rate curve, and a true reflection
of vertical injection molding machine from running, debugging, to work to overhaul or scrap
failure rate of change of the law, strengthen the daily management of vertical injection
molding machine and maintenance, You can extend the occasional failure. Correctly identify
the inflection point, to avoid excess expand the scope of repairs or repairs to get the best
return on investment.

Trouble Shooting for Injection Molding

Process
Black Spots, Brown streaks. Blisters (Air Entrapment). Brittleness.
Bubbles. Burn Marks, Dieseling. Cracking, Crazing. Delamination.
Discoloration. Excessive Flash. Flow, Halo, Blush Marks. Gate Stringing,
Drooling. Gels. Jetting. Material Leakage. Oversized Part. Part ticking.

Short Shot (Incomplete Filled Parts). Sink Marks. Splay Marks, Silver Streaks.
Sprue Sticking. Surface Finish (Low Gloss). Surface Finish (Scars, Wrinkles).
Undersized Part. Valve Pin Does Not Close. Voids. Warping, Part Distortion.
Weld Lines.
Black Spots, Brown streaks
Description
Black spots and brown streaks appear as dark spots or streaks in the molded
part and are usually caused by thermal damage to the melt.
Possible Solutions Check the material for contamination. Decrease the melt
temperature. Decrease the overall cycle time. Purge and/or clean the screw
and barrel. Decrease the screw speed. High screw speeds may cause the
material to degrade. Material may have too much regrind content. Material
may be overdried. Decrease drying time/temperature. Refer to drying
instructions provided by the material supplier.
Material may be prone to thermal degradation. It may be necessary to use a
more thermally stable material. Dead spots may be occurring, ensure that the
alignment between the machine nozzle and mold sprue is correct. Residence
time may be too long, or the shot size may be too small for the machine. It may
be necessary to move the mold to a machine with less injection capacity.
Blisters (Air Entrapment)
DescriptionBlisters are hollows created on or in the molded part. In contrast to a
void (vacuum) this entrapped gas can also appear near the walls.
Possible Solutions
Decrease melt temperature. decrease screw speed. Dry material. Increase
back pressure.
Increase mold temperature.
additional mold vents.

Ensure regrind is not too coarse.

Provide

Relocate gate.
Brittleness
DescriptionBrittleness is a condition where the part cracks or breaks at a much
lower stress level than would normally be expected based on the virgin material
properties.
Possible Solutions Check for material contamination. Decrease amount of
regrind use. Decrease back pressure. Decrease injection pressure.
Decrease screw speed. Increase melt temperature. Dry material. Refer to the
drying instructions provided by the material supplier.
Bubbles
Description
Bubbles are similar to blisters in that there is air entrapped in the molded part.
Possible Solutions

Decrease injection speed. Decrease injection temperature. Dry material

further. Increase injection pressure. Increase number and/or size of vents.
Increase shot size.
Burn Marks, Dieseling
Description
Burn Marks or Dieseling show up on the finish molded parts as charred or dark
plastic caused by trapped gas and is usually accompanied by a distinctive burnt
smell.
Note: If this problem is allowed to continue without fixing the root cause it will
very quickly cause damage to the molding surface.
Possible Solutions
Alter gate position and/or increase gate size. Check for heater malfunction.
Decrease booster time. Decrease injection pressure. Decrease injection
speed. Decrease melt and/or mold temperature. Improve mold cavity
venting. Vents may become smaller over time due to wear and they will need to
be brought back to their original depth. Reduce clamp force to improve
venting. Vents may become smaller because they are being crushed by the
clamping force. If it is possible to reduce the clamping force without causing flash
then this should be done. Note: This is always good practice to minimize wear on
the mold and machine. Improve venting at the burn location. Burn marks often
occur on deep ribs that have no venting. If possible it may be helpful to put an
ejector pin or sleeve at the burnt area to allow the trapped gas to escape to
atmosphere.
Cracking, Crazing
Description
Cracking or Crazing is caused by high internal molded in stress or by an external
force imposed upon the part. They can also be caused by an incompatible
external chemical being applied to the finished parts The cracks often don't
appear until days or weeks after the parts have been molded.
Possible Solutions
Decrease injection pressure. Dry material. Increase cylinder temperature.
Increase mold temperature. Increase nozzle temperature. Modify injection
speed. If the material is partially crystalline then it may help to reduce the
mold and/or melt temperature. If the material is amorphous then it may help to
increase the mold and/or melt temperature.
Delamination
Description
Delamination occurs when single surface layers start flaking off the molded part.
Possible Solutions
Adjust injection speed. Check for material contamination. Incompatible
resins or colorants may have been accidently mixed causing this condition to be

seen. Dry material. Increase melt temperature. Increase mold temperature.

Insufficient Blending. Check melt homogeneity and plasticizing performance.

Discoloration
Description
Discoloration is similar to burn marks or brown streaks but generally not as dark
or severe. It may cause the part to be a darker shade than the virgin pellets and
is often found nearest the gate area, however it can also appear as dark streaks
throughout the part.
Possible Solutions
Check hopper and feed zone for contamination. Decrease back pressure.
Decrease melt emperature. Decrease nozzle temperature. Move mold to
smaller shot-size press. Provide additional vents in mold. Purge heating
cylinder. Shorten overall cycle.
Excessive Flash
Description
Excessive Flash is often seen near sealing faces, out of vent grooves, or down
ejector pins. It appears as thin or sometimes thick sections of plastic where it
would not be on a normal part.
Note: Flash can very quickly (within a few cycles) damage the parting line
surfaces.
Possible Solutions
Decrease back pressure. Decrease cylinder temperature. Decrease
injection hold time. Decrease injection pressure. Decrease injection speed.
Decrease mold temperature. Increase clamp pressure. Check mold venting.
Vents may have been ground too deep for the material being used. Check
sealing surfaces to ensure that they seal off properly by "blueing" them in under
clamp tonnage. Check ejector pin bore diameter to pin diameter tolerances.
The tolerances may be too large allowing plastic to flash down the opening. The
tolerances may be too large for the material being used and can occur due to
wear over time.
Flow, Halo, Blush Marks
Description
Flow, Halo, Blush Marks are marks seen on the part due to flow of the molten
plastic across the molding surface.
Possible Solutions

Decrease injection speed. Increase cold slug area in size or number.

Increase injection pressure. Increase melt temperature. Increase mold
temperature. Increase nozzle temperature.Increase size of
sprue/runner/gate.Gate Stringing,
Drooling
Description
The part does not break cleanly from the gate area.
Possible Solutions
Insufficient cooling time during the cycle. Excessive heat in the gate area.
Check thermocouple in the nozzle or decrease the temperature of the hot runner
manifold and nozzle. Increase cooling at the gate area.Ensure that you have
controllable turbulent flow in the gate area.
Gels
Description
Gels are bubbles, or blisters seen on or in the part due to poor melt quality.
Possible Solutions
Change screw speed. Increase back pressure. Increase cylinder
temperature. Increase overall cycle time. Increase plasticating capacity of
machine or use machine with large plasticating capacity.
Jetting
Description
Jetting is caused by an undeveloped frontal flow of melt in the cavity. The
uninterrupted plastic flows or "snakes" into the cavity and cools off enough so
that it does not fuse homogeneously with the material that follows.
Possible Solutions
Decrease injection speed. Change the melt temperature, up or down. Use
higher compression screw. Increase the gate diameter. Move the gate so that
when the plastic first enters the cavity it hits an obstruction such as a rib or wall.
Material Leakage
Description
Material Leakage is usually caused by material forces overcoming the structural
strength of the mold. NOTE: One sign that indicates that material has leaked is
that the manifold reaches processing temperature very slowly.
Possible Solutions
Manifold locator is oversize. Processing temperature may be too low causing
increased pressure in the manifold. Manifold locator may be hobbed into the
mold. Decrease the force applied to the nozzle pad by the machine then repair
the damaged area, then check and if necessary replace the locator. Insufficient
number of mold assembly screws. Ensure that the quantity, type of screw, and

the location of the screws correspond to the general assembly drawing. Nozzle
may have overheated causing damage to the seal or gate. Check/replace the
thermocouple in the nozzle, then check and if necessary repair the nozzle well
area. Manifold may have overheated. Check and replace if necessary the
following components; nozzle well area, thermocouple, valve disks, sprue disks,
or pressure disks.
Oversized Part
Description
Part is too large when compared to the drawing specifications.
Possible Solutions Decrease booster time. Decrease cylinder temperature.
Decrease holding pressure. Decrease injection pressure. Decrease injection
speed. Decrease overall cycle time. Increase gate size and/or change gate
location. Increase mold temperature.
Part Sticking
Description
Part is getting not pulling out of the cavity and in rarer circumstances cannot be
ejected off the core.
Possible Solutions Check mold for undercuts and/or insufficient draft.
Decrease booster time.
Decrease cylinder and nozzle temperature. Decrease injection pressure.
Decrease injection-hold. Decrease mold cavity temperature. Increase clamp
pressure. Increase mold-close time. Texturing on part is too deep. The parts
may stick in the cavity if a new texture or a retexturing has been performed on
the cavity half of the mold. If possible add undercuts to the core to allow the
part to pull out of the cavity.
Short Shot (Incomplete Filled Parts)
Description
Short Shots occur when the part does not completely fill.
Possible Solutions Increase back pressure.
Increase injection speed.

Increase injection pressure.

Increase melt temperature. Increase mold temperature. Increase nozzle

temperature. Ensure that the manifold and nozzles have reached the set
temperature. Increase shot size and confirm cushion. Make sure mold is
vented correctly and vents are clear. Confirm that the non-return valve used is
not leaking excessively. Increase the switch over pressure, distance, or time
(whichever method is being used) point from fill to hold so the fill stage is used
longer. Change part design. Thin areas of the mold may not fill completely,
especially if there is a thick to thin transition, or there is a long rib that cannot be
vented very well. If the part design allows it, change in these areas can
improve the situation.
Sink Marks

Description
Sink Marks occur during the cooling process if certain areas of the part are not
cooled sufficiently causing them to contract.
Possible Solutions Decrease amount of regrind use. Decrease back pressure.
Confirm that the non-return valve being used is not leaking excessively.
Decrease melt temperature. Do this if the sink marks are near the gate or thick
walled areas. Decrease mold temperature. Do this if the sink marks are near
the gate or thick walled areas. Decrease injection rate. Do this if the sink marks
are near the gate or thick walled areas. Dry material. Increase injection
pressure. Do this if the sink marks are away from the gate or in thin walled areas.
Increase injection speed. Do this if the sink marks are away from the gate or in
thin walled areas. Increase mold temperature. Do this if the sink marks are
away from the gate or in thin walled areas. Increase injection-hold. Increase
shot size and confirm that the a cushion is being maintained. Increase size of
sprue and/or runners and/or gates. Relocate gates on or as near as possible to
thick sections. Increase cooling time. If possible change the mold design to
maintain an even wall thickness throughout the part.

Splay Marks, Silver Streaks

Description
Splay Marks, Silver Streaks are usually caused by water vapor blisters at the flow
front burst and freeze on the wall of the molding surface.
Possible Solutions Check for contamination. Decrease melt temperature.
Decrease nozzle temperature. Dry resin pellets before use. As per the
manufacturers recommendations. Incorrect storage of pellets. Moisture on the
pellets could be transferred into the melt, especially if the resin is not normally
pre-dried. Raise mold temperature. This will prevent condensation on the mold
walls from being carried into the melt. Ensure the mold is not leaking water
onto the cores or cavities. Again this will prevent condensation on the mold walls
from being carried into the melt. Relocate gates on or as near as possible to
thick sections. Shorten overall cycle.
Sprue Sticking
Description
Sprue Sticking generally occurs in a cold runner mold when the sprue is staying
in the mold.
Possible Solutions Check mold for undercuts and/or insufficient draft.
Decrease booster time.
Decrease injection pressure. Decrease injection speed. Decrease injectionhold. Decrease mold close time. Decrease nozzle temperature. Increase

core temperature. Open the gates.

tip for the material is being used.

Ensure that the correct design of nozzle

Surface Finish (Low Gloss)

Description
Surface Finish (Low Gloss). Gloss is the appearance of the surface of the molded
part when light is reflected off of it. Molds that are textured or resins that are
filled have an inherently reduced level of gloss when compared to highly polished
mold surfaces.
Possible Solutions Clean mold surface. If the part design allows increase the
polish of the molding surface. Increase cylinder temperature. This applies to
molds that have a polished surface. Increase injection pressure. This applies to
molds that have a polished surface. Increase injection speed. This applies to
molds that have a polished surface. Increase mold temperature. This applies to
molds that have a polished surface. Decrease cylinder temperature. This
applies to molds that have a textured surface. Decrease injection pressure.
This applies to molds that have a textured surface. Decrease injection speed.
This applies to molds that have a textured surface. Decrease mold
temperature. This applies to molds that have a textured surface. Increase melt
temperature. Make sure venting is adequate.
Surface Finish (Scars, Wrinkles)
Description
Surface Finish (Scars, Wrinkles). Is the appearance of the ripples or wrinkles on
the surface of the molded part.
Possible Solutions Decrease back pressure. Decrease nozzle temperature.
Increase booster time. Increase the melt temperature. Increase injection
pressure. Increase injection speed. Increase overall cycle time. Increase
shot size. Inspect mold for surface defects.
Undersized Part
Description
Part is too small when compared to the drawing specifications.
Possible Solutions Decrease mold temperature. Increase booster time.
Increase cylinder temperature. Increase hold-time. Increase holding pressure.
Increase injection pressure. Increase injection speed. Inspect mold for surface
defects.
Valve Pin Does Not Close
description
Valve pin does not close properly. This will leave the gate protruding from the
part. This may also occur if the valve pin is too hot, the material may stick to the
valve pin.
Possible Solutions Valve pin is too short. Check and replace if necessary.
Valve pin fit. Ensure that the valve pin is lapped to the gate steel when

appropriate. Damaged gate. Check if valve pin is too long, rework if necessary.
Also check to ensure that the valve pin is concentric with the gate, if not replace
it. Hydraulic / Pneumatic seals may be worn. Replace as necessary.
Insufficient pin/land area in the gate area of the mold. Increase the gate area
cooling, or increase the valve pin land contact. Insufficient hydraulic or air
pressure. Increase the pressure up to but not beyond the maximum rating of the
unit being used. Excessive hold time. Decrease the hold time.
Voids
Description
Voids are hollows created in the part. They are normally found in thick sectioned
parts caused by material being pulled away from the hot center section towards
cold mold walls leaving a void in the center.
Possible Solutions Clean vents. Decrease injection speed. Decrease melt
temperature. Dry material. Increase injection pressure. Increase injectionhold. Increase mold temperature. Increase shot length. Increase size of
gate. Increase size of sprue and/or runners and/or gates.
Warping, Part Distortion
Description
Warping, Part Distortion is shows up as parts being bowed, warped, bent or
twisted beyond the normal specification outlined on the drawing.
Possible Solutions Adjust melt Temperature (increase to relieve molded-in
stress, decrease to avoid overpacking). stress, decrease to avoid over packing).
stress, decrease to avoid over packing). Check gates for proper location and
adequate size. Check mold knockout mechanism for proper design and
operation. Equalize/balance mold temperature of both halves. Increase
injection-hold. Increase mold cooling time. Relocate gates on or as near as
possible to thick sections. Try increasing or decreasing injection pressure.
Weld Lines
Description Weld Lines are created when two or more melt flow fronts meet
possibly causing a cosmetically visible line. It can also create a weakened area in
the finished molded part especially with filled resins.
Possible Solutions Increase injection pressure. Increase injection speed.
Increase injection hold. Increase melt temperature. Increase mold
temperature. Make sure part contains no sharp variation in cross-sections.
Vent cavity in the weld area.

The the fault of the injection molding machine experience in

the maintenance talk about
Published on2013/5/7 15:34:12

KeywordInjection molding machine, PC, hydraulic, electrical, electronics, integrated circuits, switches,
injection molding technology, molding machine
IntroductionInjection molding machine is the crystallization of machinery, electronic control, hydraulic
integration, complex electrical, hydraulic pipe cross-lined controller varied,

Injection molding machine is the crystallization of machinery, electronic control, hydraulic

integration, complex electrical, hydraulic pipe cross-lined controller varied, from the 1980s to the
present, fault phenomenon is strange, of the same, especially imports of injection molding
machines, expensive, each about tens of thousands to hundreds of thousands of dollars. Large
injection molding machines and thousands of components, a component failure, it will cause
irregularities of the injection molding machine, wire connections, a little negligence will be a
problem, coupled with the large injection molding bulky machine, thermostatic injection workshop
conditions, the environmental impact can easily lead to failure. To this end, the imported injection
molding machine maintenance difficult "issue is placed in front of us.

Introduction of so many injection molding machines, and how you can quickly locate the fault,
hidden, and timely exclusion? How can repair these expensive equipment? I think that first of all
have a high sense of responsibility; Second, we must work hard to master the CNC hydraulic
technology, injection molding Management Technology Network. Ten years of maintenance
practice of injection molding machine of injection molding technology experts that you want to
see more, ask more in mind, more thinking, more training, and gradually improve their level of
technology and maintenance capability to adapt to a variety of more complex situation, to solve
the difficulties problem repaired injection molding machine.

To see more
1. To see more of the injection molding machine electronic circuit

To see more, to understand the various injection molding machine electronic circuit system and
PC, features and functions of the PLC programmable logic controller; understand the injection
molding machine electronic circuit system alarm and trouble shooting; want to understand the
PC, PLC injection molding machine parameter settings meaning; to understand the PC, PLC
programming language; programming to understand the action of the injection molding machine;
to understand the operation of the injection molding machine control panel and menu, often a lot
of information, how do you see? I think that the main focus, to find out the ins and outs, the focus
is to thoroughly understand the basic composition and structure of the injection molding machine
controller, master block diagram. The rest of the "tour" and read through, but every part of the
contents must be focused to understand and master. Injection Molding Machine Controller
internal circuit diagram is quite complex, and manufacturers are not available. And therefore do
not have to find out in detail. Should focus on understanding the role of each part, each board
interface the whereabouts, LED lamp meaning. Injection molding machine controller model,
update, different manufacturers, different models are often very different. To understand its
commonness and individuality

2. To see more of the injection molding machine electrical diagrams, digestion injection molding
machine electrical diagrams
For each electrical components, such as: contactors, relays, time relays, etc. as well as PC, PLC
input, output, electrical diagrams specify one by one.

To see more of the hydraulic diagram, and in-depth digestion

Mechanical, hydraulic diagram of the injection molding machine to figure out its role and the ins
and outs. And in the drawings indicate, Clamping which solenoid valve action? The
corresponding PC, PLC output, input, which is a few? Stated in the chart, such a pole in the end,
with special mechanical, electrical close parts should focus on understanding from electrical to
mechanical action, injection molding machine with electro-hydraulic proportional technology
should focus on understanding its role and functions, in particular, adjusting method and adjusted
data, static and dynamic proportional valve current and the corresponding pump pressure, not
only understands power but also understands the machine, mechanical and electrical integration,
to master a variety of skills, so that problem-solving skills.

To ask
1. To ask the injection molding machine experts
If you are training opportunities to your plant installation and commissioning injection molding
machine or injection molding machine experts, you'd better have the opportunity to participate.
This is a best opportunity to learn, because to get a lot of first-hand information and injection
molding machine debugging methods and techniques, and do not know we should find out. By
this time, there will be a great harvest, be able to get a lot of inside information and manuals (the
user is confidential). When the injection molding machine into full production, it should always
maintain close contact with relevant experts of the injection molding machine. By FAX, E-Mall,

request further solutions to solve difficult problems of the injection molding machine and related
information, also be a special, special spare parts, it is very useful, controller agents
manufacturers should maintain good relationship, ask for more, but also the controller deep step
and timely information and related spare parts, but also have the opportunity to participate in the
controller thematic classes.

2. After a failure, would like injection molding machine operator asked whole process of fault, do
not ask, or casually ask enough, this is often not the correct field data will result in errors of
judgment, to complicate matters, , to ask, to ask more detailed understanding of the whole
process of injection molding machine failure (start, middle, end), resulting in what police
numbers, when operating any components, touched anything, to turn over what the external
environment, how? To fully investigate the scene first-hand material on the basis of the fault are
listed correctly, has actually solved half of the problem, and then analyze the solution for the
experienced and skilled injection molding machine operator, injection operating familiar the
processing procedures familiar with injection molding machine is very common understanding,
close cooperation with them, is very favorable for rapid troubleshooting.

3. To ask other maintenance personnel

When other maintenance personnel in maintenance of injection molding machines, and you did
not go, so they came back, also should ask, just what happened wrong? How he was excluded?
Asked him to introduce their exclusion. This is also a good opportunity to learn. Learn from
others to correct troubleshooting techniques and methods, especially to the experienced old
maintenance personnel to learn, Xue Daoshou their ability to improve their knowledge and level.

To remember
1. To record all relevant parameters
Key recorded in the various relevant parameters of the injection molding machine is adjusted,
such as the pressure of the injection molding machine parameters, the speed parameters of the
injection molding machine, injection molding machine motor current, voltage, speed and other
data. Also note the cabinet relays, contactors energized and formal processing status (pull or off)
as well as PC, PLC all input, output LED light-emitting diode state (light and dark, shining) or
record the screen on the PC, PLC status (input bit), (output bit) is 0 or 1, so recorded for later
analysis to determine fault benefits greatly.

2. To record the status of the hydraulic system

Also record the hydraulic system in the formal processing or processing various pressure gauge,
pull solenoid valve off state, which for adjusting the judgment was also very helpful, normal
pressure will directly affect the injection molding machine function is activated or not, the record
static, dynamic pressure is very important.

Carry a notebook failures every day, how to troubleshoot the process of recording down people's
mind for a long time easy to forget, a good memory as bad written, recorded great benefits. We
found that the injection molding machine failure often repeated, and always several faults, as
long as the check was how to solve a few minutes troubleshooting, fast and good.

To think
1. To think, to broaden their horizons
Often for repair of injection molding machine is cool enough, there is no analysis into a dead end.
We should list all alarm and fault conditions occur, through the outside to the inside,
Quweicunzhen comprehensive judgment and screening to predict the maximum likelihood of
failure, followed by exclusion. Every blind alley vista "to think, to point you in the direction.

2. To think, to know why

Often when troubleshooting injection molding machine, sometimes did not find the real cause of
the failure, after failure continued to occur.

3. To think, consider to be one step ahead

Failure frequency of occurrence, repeatability, the life of the machinery and electrical spare parts,
do a good job. This is to ensure that the injection molding machine for the normal operation of
the important work of non-do not. For some devices, with the postponement of time, out of the
market buy or purchase very expensive to be considered in advance, efforts to improve the
external environment of the injection molding machine, think of ways from the temperature, dust,
humidity and other aspects, installation of power regulator, the installation of the electrical cabinet
air-conditioned house measures so that the failure of the injection molding machine greatly
reduces.

Fifth, we should more practice, more practice:

1. To practice, to dare hands, good hands
For injection molding machine maintenance personnel, to be bold but cautious, to dare hands,
spoke only, no hands, bad repair injection molding machine. But cooked before you start, do not
blindly, otherwise it will expand the malfunction, causing the accident, the consequences could
be disastrous. At the same time, we must also be good hands, we must first be familiar with the
contents of the injection molding machine operator panel and menu on the machine, operate
freely. Should also make full use of the injection molding machine self-diagnostic technology to
quickly troubleshoot. Injection molding machine develops, the growing self-diagnosis ability.

2. To practice and develop their own ability and experimental skills

Sometimes injection molding machine failure looks fuzzy, can not tell the electrical failure or
mechanical failure, we have adopted a "separate", completely separate from the control of the
electrical part of the original circuit there are many other methods, such as "isolated",
"replacement", "contrast", "percussion method and other methods can be used as an effective
means to help us find troubleshooting.

3. To practice, learn to use the instrument

Such as oscilloscope, multimeter, line circuit tester, short circuit tester, computer programmer to
help us determine the specific circuit, check PLC programming, computers, skilled, and are free
to enter, the output injection molding machine parameters, online test state, the system
initialization. This analysis of failures, especially complex failure to solve the problem of great
help.

4. More practice, "piecemeal reform"

Often occur in normal operation of a component damage (such as switches, push buttons,
relays, etc.) No spare parts, do-it-yourself way possible bonding repair or use of temporary
special way, the normal function of the injection down , until the spare parts and then restored.

5. Be more practical, do-it-yourself repair board

In general injection molding machine circuit board reliability, the failure rate is very low, generally
to check the injection molding machine, do not doubt the issue of the board first. Can split pull
method, initialize, hot and cold start of the PLC trial can generally be ruled out. Indeed proved to
be the board to be repaired. Board (usually drawings) is expensive, so the injection molding
machine circuit board is good or bad is very important, once the damage to the circuit board
without spare parts, and sometimes not fix it, is bound to stop, seriously affecting production.
Sometimes tend to just a tiny circuit board failure, serious examination, it is not difficult to find the
problem, we have repeatedly found the individual capacitor leakage, the board Weld, short circuit
fault, some more complex circuit board failure, but as long as the time, instrument checks, or can
be repaired; But there are parts of the circuit board in serious condition, especially large-scale
integrated circuits, maintenance difficulties, together with the original device spare parts, only
early buy backup board or send out repair. It-yourself repair board, a great advantage, on the
one hand, the cost savings for enterprises to solve the pressing, on the other hand can analyze
and familiar with electronic circuit is very useful to develop their own analysis and judgment and
practical ability. (Xu-new)
Injection molding machine is the mechanical, electronic control, hydraulic integration of the crystallization of
complex electrical, hydraulic pipe cross * buildings, the controller wide variety of products from the 80's to the
present, symptoms are varied, different, especially the imported injection molding machines expensive, each of
about tens of thousands to hundreds of thousands of dollars. There are thousands of large injection molding
machine components only if one has a faulty component, can cause irregularities in the injection molding
machine, as well as wire connections, a little negligence will be a problem, coupled with the large injection bulky
machines, injection molding workshop in the absence of constant temperature conditions of use, the environment
can easily lead to failure. To this end, imported injection molding machines "maintenance difficult" to put the

issue before us.

The introduction of so many injection molding machines, how to quickly identify the fault, hidden, and
immediately removed the? How can these expensive equipment repaired? I think that first of all have a high
sense of responsibility; Second, we must strive to master the CNC hydraulic technology, injection molding
Management Technology Network (http://www.yxx.com.cn) ten years of technical experts injection molding
machine maintenance practices that should be more Look, ask, and more mind, more thinking, more training,
and gradually improve their technological level and repair capabilities, in order to adapt to a more complex
situation, to solve difficult problems, fix the injection molding machine.
To see more of a
1. To see more information on injection molding machines to see more of electronic circuits, a variety of injection
molding machines to understand the electronic circuit system and PC, PLC programmable logic controller of
features and functions; to understand the injection molding machine electronic circuit system alarm and trouble
shooting; to understand PC, PLC injection molding machine parameter setting means; to understand the PC,
PLC programming languages; to understand the programming method of injection molding machine action; to
understand the injection molding machine's control panel and the content of each menu, often a lot of
information, how watch? I think the key to focus, find out the whole story, focusing on thorough understanding of
the basic injection molding machine controller, the composition and structure, control block diagram. The rest of
the can "visit" and read, but each part must be focused to understand and master. Since the internal circuit
diagram injection molding machine controller is a complex and manufacturers are not available. Therefore, do
not have to figure out in detail. To focus on understanding the role of each part, the board's functions, the
whereabouts of the interface, LED lights and other means. Injection molding machine controller model is now
more updates soon, different manufacturers, different models are often very different. To understand the
generality and individuality
2. To see more of injection molding machine electrical diagrams, electrical plans for the injection molding
machine to digest every electrical components, such as: contactors, relays, time relays, etc. as well as PC, PLC
input and output, one by one to indicate the electrical diagram.
3, to see more of the hydraulic diagram, and a thorough digestion of the machinery for injection molding
machines, hydraulic diagram, to make clear its role and context. Indicated in the drawings one by one, such as
locking solenoid valve by which the action? Corresponding to PC, PLC output, input is few? Stated in the chart,
so from the electrical to the mechanical action of a pole in the end, but especially for mechanical, electrical and
close relationship of the part to focus on understanding, and now the proportion of injection molding machine
using electro-hydraulic technology, we should focus on understanding its role and functions, in particular
understand the adjustment method and adjustment data, static and dynamic current and the corresponding
proportional valve when the pressure of the pump, not only understands but also understands electrical
machines, mechanical and electrical integration, master various skills, such problem-solving skills on the larger.
Second, we must ask
1. Injection molding machine to ask an expert if you have training opportunities for experts to come to you, or
injection molding machine injection molding machine factory installation, you better have the opportunity to
participate. This is a the best learning opportunities for access to a large number of first-hand information, and
injection molding machine debugging methods and techniques, do not know will find out. By this time, there will
be a great harvest, access to many internal information and manual (the user is confidential.) When put into full
production after the injection molding machine, injection molding machine should be regularly and maintain close
ties with relevant experts. By FAX, E-MALL, ask resolved fault injection molding machine troubleshooting
solutions and further information can also be a special, special spare parts, which is very useful, while the
manufacturer of the controller of the agents should also maintain good relationship, ask for more, but also timely
information to the controller and the deep-step parts, but also the opportunity to attend special classes on the
controller.
2. Fails, ask the operator to the fault injection molding machine the whole process, do not ask, or feel free to ask
about good, so that field data are often not the correct result in wrong judgments, to complicate matters, so , to
ask, ask more detailed, understanding of injection molding machine fault is the whole process (beginning, middle,
end), resulting in what police numbers, what was operating components, touched something, to turn over what
the external environment, how? To fully investigate the scene on the basis of first-hand material, the failure to list
the issue correctly, in fact, half of the problem has been solved, and then analyze the solution, for injection
molding machine of skilled and experienced operators, their injection molding machines Operating familiar,
familiar processing, injection molding machine is very common understanding, close cooperation with them, very
favorable for rapid troubleshooting.
3. Other maintenance staff to ask if other maintenance personnel in maintenance of injection molding machine,
and you do not go, so they came back, it should be more than ask, just what happened wrong? How did he
exclude? Asked him to introduce the exclusion method. This is also a good opportunity to learn. The right of
others to learn skills and methods of troubleshooting, especially to veteran service personnel learn their skills
Xuedao Shou to increase their knowledge and level.
Third, we should remember more
1. Various parameters to focus on recording the records of all kinds of injection molding machine after adjusting
the parameters, such as injection molding machines pressure parameters, speed parameters of injection molding
machines, injection molding machine motor current, voltage, speed and other data. Also note the panel of relays,
contactors and other power and formal processing in the state (or pull-off) as well as PC, PLC all input and output
status LED light-emitting diode (light and dark, flashing) or record screen PC, PLC status (input bits), (output bit)

is 0 or 1, so that recorded for later analysis to determine the benefits of a great failure.
2. The state of the hydraulic system to record the same in the official records of the hydraulic system processing
or not processing all kinds of pressure gauge, the suction valve off state, which for the adjustment, is also a great
help to determine the pressure directly affects the injection molding machine function is activated normal or not,
record the static and dynamic when the pressure is very important. 3. Carry with them a notebook, the daily
failures, how to record each and every process of elimination, the human mind a long time, easy to forget, "a
good memory, not as bad written," the benefits of a great record. We found some fault injection molding machine
will be repeated often, and always these failures, as long as the check was how to solve, and a few minutes
troubleshooting, fast and good.
Fourth, we must think more
1. To much thinking, to broaden our horizons often for not repairing injection molding machines cool, is not well
analyzed, into a dead end. We should put the alarm occurred, the failure to list all cases, by outside to the inside,
Quweicunzhen, comprehensive screening to determine and predict the possibility of failure of the largest,
followed by exclusion. "Dead end crows," to think, to give you the direction.
2. To much thinking, we want to know why they are often excluded from injection molding machine failure, and
sometimes did not find the real cause of failure, after the failure and continue to occur.
3. To much thinking, considering the lead according to the frequency of failure, repetitive, mechanical electrical
life, do a good job of spare parts work. This is to ensure a continuous injection molding machine, the normal
operation of the important work of non-do not. For some devices the same time, as time delay, phase out, the
market has been unable to buy or buy very expensive, should be considered in advance, efforts to improve the
external environment for injection molding machine, from temperature, dust, humidity, and several other areas to
find ways to Power regulator with the installation, the installation of electrical cabinet air-conditioning and other
measures of small houses, so that the fault injection molding machine greatly reduced.
Fifth, to more training, the more practice:
1. Be more practical, to dare to get involved, be good at hands-on maintenance personnel for the injection
molding machine, it should be bold but cautious, to dare to get involved, would only say, no hands, bad repair
injection molding machine. However, the situation should be cooked before you start, do not blindly, otherwise it
will expand the malfunction, causing the accident, the consequences could be disastrous. At the same time we
have good hands, we must first know the injection molding machine on the machine control panel and the
content of each menu, operating freely. Must also make full use of the injection molding machine self-diagnostic
technology to quickly deal with troubleshooting. Injection molding machine is now more developed, the selfdiagnostic capability is growing.
2. To more practice, develop their own ability and skills to master the experimental injection molding machine
failure is sometimes seem vague, hard to tell that an electrical fault or mechanical failure, we have adopted a
"separate Act," part of the control and the original electrical circuit completely There are many other separation
methods, such as "time out", "Replacement," "contrast method", "percussion" and other methods can be used as
an effective means to help us find, troubleshooting.
3. More practice to learn to use the equipment such as oscilloscope, multimeter, circuit tester line, short-circuit
tester, computer, programming, etc. will help us determine the specific circuit, checking, especially PLC
programmer, computer, to skillfully use, free input and output parameters of injection molding machines, online
test on the state, system initialization and so on. This analysis of failures, especially complex failure of great help
to solve the problem.
4. More practical to carry out a "piecemeal reform"
Often occur during normal operation of a component is damaged (such as selector switches, push buttons,
relays, etc.) and no spare parts, stick yourself with legal and other measures as possible to repair or use of
temporary special measures, the injection function to work down , wait until after the spare parts to restore.
5. Be more practical to repair the board yourself injection molding machine circuit boards in general can be *
good, very low failure rate, usually to check the injection molding machine, do not question the first suspect the
board. Pull through the demolition method, initialization, hot and cold start PLC and other methods of trial
generally can be ruled out. If it does prove is that the circuit board problem, to be repaired. These plates (usually
without drawings) is expensive, so mechanical and electrical circuit board is good or bad injection is extremely
important, once the circuit board without damage to spare parts, and at another bad repair, is bound to stop,
seriously affecting production. It is sometimes just a tiny circuit board failure, as long as serious examination, not
difficult to find, we have repeatedly found that the individual capacitor leakage, the board cold solder joint, short
circuit fault, and some more complex circuit board failure, but as long as the aging time, through the Check with
the equipment, or can be repaired; but there are some circuit board in serious condition, particularly large-scale
integrated circuits, maintenance difficulties, coupled with the original device no spare parts, advance purchase
only by the board or send out repair. Board repair yourself, there are significant benefits, while cost savings for
enterprises to address the urgent needs, on the other hand can "dissect Sparrow" familiar with the electronic
circuit, develop their own analytical judgments and practical ability is very useful.
Injection Management Technology Network (http://www.yxx.com.cn) ten years of technical experts injection
molding machine maintenance practices, are imported injection molding machines, injection molding machine in
particular, large-scale is not perfect, there exist many problems and defects. Through our injection molding
machine learning, deepening, find out where the problem is boldly to improve on some issues, and achieved
good results. Although the injection molding machine fault complex, ever-changing, if we take seriously and train
high-quality mechanical and electrical integration of the maintenance team, through to look at, ask, more thinking,

more training, accumulated experience, master repair techniques, together, we will be able to main by * their own
strength, the injection molding machine repaired, with good manage.

ENGINEERING BASICS
for INJECTION MOULDING MACHINE.
ENERGY
Energy is capacity to do work.
Work is done when a force moves its point of application in the direction of force . = force x distance moved.
Power is rate of doing work. Power = force x (distance/time). This also called energy.
Energy can neither be created nor destroyed but only transformed from one form to
others.
MACHINE
A machine is a device that makes the work easier.

This can happen by application smaller force (lever principle) to get bigger
force to do the work or

Changing line of action of force.

Machine can not create energy by it self. Therefore, machine requires a prime
mover. In most of the machines prime mover is an Electrical motor - 3 phase squirrel
cage Induction motor in case of Injection Moulding Machine. In this machine
electrical energy is converted to mechanical energy through hydraulics.
PRIM-MOVER
Electric motor is coupled to hydraulic pump. Pump has flow rating -say 100 liters per
min. or 25 gpm. Pump delivers oil flow in the system. Oil flow meets resistance
causing resultant pressure in the system. The hydraulic system includes Relief
Valves for pressure limit, Flow control Valves for speed and Directional valves for
directing oil to Actuators - Cylinder for linear movement and Hydromotor for rotary
movement. For each to and fro movement there must be one cylinder as actuator.
Therefore there are cylinders for mould open/ close, injection unit forward / retract,
Injection / retract. And Hydro-motor for screw rotation,
PUMP
Pump delivers oil flow in the system at rated flow rate till the resistance reaches say
150 bar. Thereafter further increase in load pressure decreases the flow rate. Many

in the moulding shop floor wrongly believe that pump creates pressure. Pump
creates flow rate not pressure. Therefore, hydraulic system pressure is not allowed
to go beyond 150 bar by Main Relief Valve in the system.

PRESSURE
The melt is pushed by the screw tip through nozzle in to the mould. As the melt
moves inside the mould, resistance to flow builds up and hence melt pressure at
screw tip increases. This is reflected at the hydraulic pressure gauge at injection
hydraulic cylinder.
Here, Ps As = Ph Ah
Ps is pressure at screw tip in barrel and Ph is hydraulic pressure at injection hydraulic
cylinder.
As is cross section area of screw and Ah is cross section area of piston of injection
hydraulic cylinder
Therefore pressure at hydraulic cylinder would be P h = (As/ Ah) Ps .
Since (As/ Ah) is less than one, Ph would indicate lower value of pressure than P s.
Similarly Ps can be determined = (Ah / As) Ph.
(Ah / As) is called Intensification Ratio.
It should be noted that melt pressure is

Directly proportional to viscosity. (it varies with temperature pvT diagram),

Directly proportional to length of flow,

Inversly proportional to wall thickness of flow.

SPEED
Injection rate = As V cc/sec. Injection rate is available in the spec table Here velocity
V of screw is same as velocity of hydraulic piston of injection cylinder.
On hydraulic side AhV = oil flow rate at hydraulic cylinder.
Ah is normally does not appear in the machine specification table. However, Max
pressure rating (say 1400 bar) at screw is available under Injection Unit spec. Most
of the hydraulic system pressure is recommended to limit at 150 bar. Therefore 150
bar can be considered as max hydraulic pressure corresponding to max melt
pressure. Now it is possible to compute diameter or area of injection piston if
required.
POWER
POWER= F V =(F/A) (AV) =P Q
F is force and Q is flow rate
Max Work that can be done by the machine with out accumulator =
=(max. melt pressure) x (max injection rate)
It means for a given screw diameter, higher injection rate means higher power and
hence higher hp of electric motor.
In injection moulding power consumption is not constant but it is cyclic. Pressure
peak occurs for a short duration. Moreover during peak load after switchover point,

flow rates are lower. Therefore, machine manufacturer may use slightly lower hp
electric motor, which can sustain short peak load.
Thin walled injection moulding demand higher injection rate at higher pressure.
Therefore power consumption has to be higher than that of medium or thicker walled
moulding.
Clamp unit of the machine does not required full connected power. However clamp
unit looks bigger than injection unit. Actually injection unit consumes more power.
Therefore comparing the prices of the machine purely based onclamp unit is not fair.
Price comparison should be made on the basis of specification (max- pressure and
injection rate for a given screw diameter)of injection unit and connected load.
EFFICIENCY
Efficiency of the machine is defined as the ratio of work output to wok input. It can
not be one. It has to be lower than one to account for power losses due to friction
and other causes. Efficiency of various types of hydraulic circuit is discussed in the
book " A Guide to Injection Moulding of Plastics".
UNDERSTANDING OF "PRESSURE",

To check the understanding of "pressure", consider fig 1 and answer the following
questions.

What is the pressure gauge reading when throttle valve is fully

open?

What happens when throttle is being closed to fully closed

position?

Since there is no relief valve, what can happen to the hydraulic

system powered by Induction Motor?

Now consider fig 2. A relief valve 1 is added to the circuit and it is set for 150 bar
pressure.

What is the pressure gauge reading when throttle valve is fully

closed?

Now consider fig 3. Another relief valve 2 is added to the circuit and it is set at 80
bar. Relief valve 1 is set at 150 bar.

What is the pressure gauge reading when throttle valve is fully

closed?

What happens when the pressure setting of relief valve1 is

reduced to 50 bar?

MYTH in INJECTION MOULDING OF PLASTICS

From " A Guide to Injection Moulding of Plastics" by Prabodh C. Bolur

ISSUE

MYTH- General belief

prevailing in the
industry.

TRUTH

Role of the
machine.

Machine should solve all

the quality-related
problems.

Role of the machine is to provide good

homogeneous melt and provide
consistent reproduction of set
parameters all the time during

production run. Machine should not

break down often. Energy efficiency can
be the merit of machine design.

Connected
load of the
machine

Connected load of the

machine depends on
Clamp unit specification.

Connected load of the machine is

decided by the specification of injection
unit. - Injection rate and maximum
injection pressure.

Energy
efficiency

Lower connected load is

the indication of energy
efficiency.

Amount of power required to carry out

a work can not be different in different
machines. It is the reduction or
elimination of power wastage in a given
machine that makes it energy efficient.

ISSUE

MYTH- General
belief prevailing
in the industry.

TRUTH

Comparison of
POWER in
injection unit

Lower connected Lower connected load will have lower

load will consume injection rate for a given screw diameter
less power.
and L/D ratio.
Higher connected load will have higher
injection rate for a given screw diameter
and L/D ratio.
Lower connected load will give lower
capability of spreading melt (lower flow
ratio) in the mould.
Higher connected load will give higher
capability of spreading melt (higher flow
ratio) in the mould.
It means that thinner and bigger part (high
flow ratio) can be moulded with higher
connected load machine.

Mouldability.

Any shape / part

geometry is
mouldable.

Perfection in mouldability depends on

balanced melt flow, balanced heat exchange
in mould and uniform freezing of moulding
in the mould.

What is
responsible for the
filling of melt in
the space between
clamped mould?

Pressure

Speed (injection rate) component of

Injection power. Injection power is product
of injection rate and actual pressure during
filling phase. Injection power is product of
injection rate and set pressure during
follow-up pressure phase.

Maximum shot
weight

Any part having

lower weight than
the maximum
shot weight of the
machine can be
moulded.

To mould the biggest possible part of

highest flow ratio requires higher injection
rate for a given size of screw.

ISSUE

MYTH- General
belief prevailing
in the industry.

TRUTH

Quality problemssink marks,

warpage,
shrinkage,
dimensional
inaccuracies.

Quality problemssink marks,

warpage,
dimensional
inaccuracy, can
only be corrected
by machine
parameters.

Part design and mould design should take

care of the moulding process constrains like
sink mark, warpage, dimensional
inaccuracy etc. Therefore part and mould
design are more responsible for quality of
moulded parts. Machine parameters should
lie in the middle of possible parameter
range. So that the influence of any minor
swing in the parameter on either side of the
set value still remains with in the tolerance
band.

Injection speed
profile and;mp;
pressure profile.

It improves
quality.

For uniform surface quality of moulded

part, it is necessary that skin development
while spreading melt in the mould should

Therefore bigger moulding (with in the

maximum shot weight) is possible only with
the machine having larger injection rate.

be uniform. That is possible only when melt

moves with uniform velocity in the complex
shape of part. Therefore the object of
injection profile setting is to achieve
uniform melt front velocity. By trial and
error method it is not easy at all. CAE
software can establish quickly best possible
profile for injection speed and follow-up
pressure.

RESIDENCE
TIME

Soak time significance is not

known, therefore
mistakes while
selecting the
screw size or
machine capacity.

Lack of sufficient residence time increases

the cycle time particularly in fast cycling
thin walled disposable mouldings. This
demands lower utilisation shot capacity (in
higher screw size) of machine to increase
residence time.

What is
responsible for the
filling of melt in
the space between
clamped mould?

Pressure

Speed (injection rate) component of

Injection power. Injection power is product
of injection rate and actual pressure during
filling phase. Injection power is product of
injection rate and set pressure during
follow-up pressure phase.

http://www.pitfallsinmolding.com/myth1.
html
Things to Know about Injection Moulding Machine
Whileselectinginjectionmouldingmachinethefollowingspecificationsare
requiredtobeevaluated.
INJECTIONUNIT

Tounderstand

Maximumsweptvolumecc/max.shotweightgr. calculationofmax.shotweightfora
material.

Maximummeteringstrokeinmm.

dependanceofqualityofmeltfor
consistancyofmoulding.

Maximuminjectionspeedg/sorcc/s

howitensursmelttospreadthroughout
wheninfluidconditionbeforeitfreezes.
Itsrelationshipwithfreezingtime.

MaximuminjectionpressureKg/cm2

howitovercomesresistancetoflow
duringfillingand;pressurephaseon
accountofflowratioand;viscosity.

MaximumInjectionPower.Kgcm/sec.

howittakescareofdifficultyinfiilingfor
thinerwalledandhighflowratioparts.

Plasticizingrateg/sorKg/hr.

howitinfluencescycletime.

CLAMPINGUNIT

Tounderstand

ClearancebetweenTiebarsandplatensizemmx
mm

howitaccomodatesmould.

Maximumdaylightmmandmouldopenstroke
mm

itssignificanceforejectionofdeepparts.

Minimummouldheight

itsrelationshipwithmouldopenstroke
anddaylight.

Clampingforce

itsdependanceoncavitypressureand
methodtocomputecavitypressure.

HYDROMOTOR

Tounderstand

TorqueKgmandrpm

torquerequirementforviscosityofmelt.

DRIVEPOWER

Powersupplyfrquency60or50Hz.

itsinfluenceonspeeds.

Pumpmotorrating.kW

CONTROLS

NOLOADCYCLETIME

tomatchtheapplicationusageof
machine.

Conventional/Proportionaland
CartridgevalveHydraulicControls

Electrical/solidstate/
microprocessorcontrols

Openlooporclosedloopcontrols

Itindicatesthetimefornonprocessing
partofthecycletime

GLOSSARY OF BASIC TECHNICAL TERMS - Physics

Acceleration: The acceleration of an object is its change in velocity per unit time
in the direction of change. It is a vector with direction and magnitude. Unit is m
/sec.2
Conduction: It is the transfer of heat energy from one region to another region
through a substance with out the movement of the substance as a whole is known
as conduction. It is the transfer of heat from particle to particle in a substance.
Some materials are good conductor and some are bad conductor of heat.
Convection: It is the transfer of heat by the substance moving en bloc. Heated
substance (gas or liquid) loses density and therefore rises (moves) to cooler region
in the substance. Heated substance looses density, therefore moves from hot region
to cooler region and colder substance (with higher density) move to towards the
source of heat. Hence a convection current is set up.
Creep: A time dependent strain of solid resulting from stress.
Density: It is mass per unit volume. Unit is gr/cc or kg / m 3 .
Efficiency: It is defined as the ratio of work got out to work put in. It is important
to cut down the energy wasted so that the useful work obtained from a machine is
as high as possible.

Energy: A body capable of doing work is said to posses energy. See also Work. A
body may be capable of doing work because it is moving or because of its state or
position. Unit is kg. .m or Nm. Since there are many different ways in which a
body may be capable of doing work, there are different forms of energy like
Mechanical energy, Electrical energy, Chemical energy, Heat energy, Nuclear
energy, etc.
Fatigue: Weakness in metal caused by repeated stress in metal is known as fatigue.
Flexural Strength: It is the measurement of resistance of the material to fracture
during bending.
Force: Force is not visible but its effect is visible. Force is rate of change of
momentum.Momentum is product of mass and velocity.
Force = mass x acceleration. It has a direction and a magnitude. Unit is kg.m/sec 2 .
1 kg = 10N.
Heat: It is a form of energy. Its unit is Calorie. It is related to temperature by
Heat = mass x specific heat x temperature difference.
Hydraulic Pressure: Pressure exerted in the hydraulic system. Hydraulic injection
pressure is not same as pressure on melt at screw tip. Hydraulic pressure is
required to be multiplied with intensification ratio to get pressure on melt at screw
tip.
Integrated Circuit: It is a complete miniaturised electronic circuit that has been
etched in to a small silicon wafer or chip.
Isotropic: It means that the material is having same properties regardless of the
direction of measurement.
Isothermal: When the temperature is kept constant during the change in pressure
and volume by adding or removing heat energy from the system, it is called
isothermal process.
Similarly when heat content of the system is kept constant therefore temperature
alone is altered with out entry or exit of heat, then the process is called adiabatic.
Latent Heat: When a substance changes fri4om one state to another energy is
either absorbed or liberated. This heat energy is called the Latent heat. The specific
latent heat is the energy required to change the state of 1kg of the substance. The
specific latent heat of fusion is the heat energy required to change 1 kg of material
in the solid state at its melting point to 1kg of the material in its liquid state, and
that released when 1kg of the liquid changed to 1kg of solid.

No Flow Temperature: No flow temperature is the temperature at which the

viscosity of the melt is so high that it effectively can not be made to flow.
Power: It is rate of doing work. The rate at which energy is used. The ratio of work
done to the time taken. Unit is Watt. 1 watt = 1 joule per sec. Or kg.m / sec.
Pressure: It is the normal (perpendicular) force acting on unit area. Unit is
kg/cm2 (Bar) or N/m2 (Pascal).
Pressure Drop: Pressure drop is the loss of pressure that occurs when the melt is
pushed into a section of the mould during the filling phase.
Radiation: Heat transfer by Radiation takes place in the form of electromagnetic
wave. These waves do not need medium for transfer. Heat radiation has a range of
wave length. Heat from Sun reaches the earth by radiation.
Rheology: Rheology is defined as a science concerned with the laws of
deformation of various materials.
Shrinkage: It is the deviation of dimensions of the moulded part from the
dimensions of cavity when measured on moulded part after certain hours.
Compressibility, thermal expansion and pvT characteristics influence the
dimensions of moulded part.
Specific Heat: Temperature is measure of heat energy level whereas heat is a
measure of total internal energy contained in a body. When the same quantity of
heat is given to equal masses of different substances, they do not result in the same
rise in temperature. The specific heat is defined as the quantity of heat energy
which will rise the temperature of unit mass (1kg) of a substance by 1 0C. Heat =
mass x specific heat x Temperature rise.
Specific Volume: It is inverse of density. It is volume per unit weight. Unit is cc/gr.
Temperature: Temperature is measure of heat energy level whereas heat is a
measure of total internal energy contained in a body. Unit is 0C.
Thermal Properties: Thermal properties describe how a given polymer will
behave during the exchange of heat. They are important factor in determining how
succeptible a material is to shear heating; they also characterise how quickly a
given polymer will cool down.
Thermal Stability: It is polymers thermal characteristic. It is the time interval for
which polymer remains stable at certain temperature. Beyond that time if the
polymer is exposed to longer duration for a given temperature, it degrades.

Thermal Conductivity: It is defined as the rate of flow of heat between two

surfaces of unit area sepated by unit distance when the temperature difference
between them is 10 C.
Tolerance: The amount of variation in a dimension that may be permitted without
impairing the functional fitness of the part. The maximum and minimum
dimensions defining the boundaries of the tolerance zone is known as limits.
Velocity: The velocy of an object is its displacement per unit time. In the direction
of displacement. It has a direction and a magnitude. Unit is m / sec. Or cm / sec.
Viscosity: Viscosity is a way to describe how much resistance a melted polymer
exhibits when an attempt is made to make it flow. High viscosity means the melt is
thick and resistance to flow is high. Low viscosity means resistance flow is less.
It is the internal resistance to flow existing between two liquid layers when they are
moved relative to each other. This internal resistance is a result of interaction
between liquid molecules in motion.
Warpage: Uneven bending, Twisting etc on account of differential cooling,
differential shrinkage, or non uniform freezing of melt in the mould can cause
these conditions in the moulded part.
Work Done: Work is said to be done if an unbalanced force moves its point of
application through a distance measured in the direction of force. Work = Force x
Distance.
SHEAR
When forces act parallel to the surface area of the matter, internal stress (force / surface area)
between adjacent layers of surface resist the relative movement of layers.
SHEAR and SHEAR RATE:(Figure 6-01)

With the application of force, if a layer moves with velocity V at a distance of r

then

Shear rate = V / r
VISCOSITY:
Viscosity is a way to describe how much resistance a fluid - melted
polymer - exhibits when an attempt is made to make it flow. High
viscosity means the melt is thick and resistance to flow is high. Low
viscosity means resistance flow is less.
Just as solid surfaces in contact exert frictional force on each other,
the relative motion of layers of liquid is also restricted by friction. This
internal resistance to flow existing between two liquid layers when
they are moved relative to each other is called viscosity.
Consider the flow of liquid through a pipe and imagine that liquid
moves in layers. The liquid moves when there exists the pressure
difference between the pipe ends. The liquid in the center of pipe
would be moving with higher velocity than the liquid layer at the
internal wall of the pipe. This is because the frictional forces act
between the layers of liquid. Therefore there exists a velocity gradient
between pipe wall and center of pipe. Such motion of liquid is known
as laminar flow. The velocity of particles at a given distance from the
center of motion is constant. If the layers intermix we get turbulent
flow.

A streamline is a curve whose tangent always lies along the direction

of motion of fluid at that point. The streamlines never cross and in
laminar flow they do not change with time.
It is observed that frictional force is directly proportional to the
product of velocity gradient and cross sectional area.
F= A x velocity gradient = A x dv/dr

 = coefficient of viscisity. A = cross sectional area. dv/dr= velocity

gradient.

Tangential stresses
Shear stress
= ------------------------------ = -------------------Velocity gradient
Shear rate
Force
distance
Units is ------------- x ------------------ = Pascal sec.= Pa s.
Area
distance / sec.

Viscosity varies with temperature.

Fluid

Viscosity

Fluid

Pas at 200C

Viscosity
Pas at 200C

Air

1.8 x 10-5

Blood

3 - 4 x 10-3

Glycerol

8.3 x 10-1

Water

1 x 10-3

Castsor Oil

2.42

Mercury

1.5 x 10-3

SHEAR STRESS / SHEAR RATE CURVE: (Figure 6-02)

From the above plastic flow curve it is observed that the viscosity reduces as the
shear rate increases. Different polymers will exhibit different curve of the same
nature.
SHEAR THINING at compression zone of SCREW

Shearing in Nozzle

Things to Know about Injection Moulding Machine

Whileselectinginjectionmouldingmachinethefollowingspecificationsare
requiredtobeevaluated.
INJECTIONUNIT

Tounderstand

Maximumsweptvolumecc/max.shotweightgr. calculationofmax.shotweightfora
material.
Maximummeteringstrokeinmm.

dependanceofqualityofmeltfor

consistancyofmoulding.
Maximuminjectionspeedg/sorcc/s

howitensursmelttospreadthroughout
wheninfluidconditionbeforeitfreezes.
Itsrelationshipwithfreezingtime.

MaximuminjectionpressureKg/cm2

howitovercomesresistancetoflow
duringfillingand;pressurephaseon
accountofflowratioand;viscosity.

MaximumInjectionPower.Kgcm/sec.

howittakescareofdifficultyinfiilingfor
thinerwalledandhighflowratioparts.

Plasticizingrateg/sorKg/hr.

howitinfluencescycletime.

CLAMPINGUNIT

Tounderstand

ClearancebetweenTiebarsandplatensizemmx
mm

howitaccomodatesmould.

Maximumdaylightmmandmouldopenstroke
mm

itssignificanceforejectionofdeepparts.

Minimummouldheight

itsrelationshipwithmouldopenstroke
anddaylight.

Clampingforce

itsdependanceoncavitypressureand
methodtocomputecavitypressure.

HYDROMOTOR

Tounderstand

TorqueKgmandrpm

torquerequirementforviscosityofmelt.

DRIVEPOWER

Powersupplyfrquency60or50Hz.

itsinfluenceonspeeds.

Pumpmotorrating.kW

CONTROLS

NOLOADCYCLETIME

tomatchtheapplicationusageof
machine.

Conventional/Proportionaland
CartridgevalveHydraulicControls

Electrical/solidstate/
microprocessorcontrols

Openlooporclosedloopcontrols

Itindicatesthetimefornonprocessing
partofthecycletime

INJECTION MOULDING PROCESS

The process involves
Filling phase,
Switchover point, peak pressure occur after slight delay.
Pressure phase,
Cooling phase.
Sequence in the process
It is desirable to have highest possible filling speed (Injection
Rate) during filling phase.
Filling speed is normally limited by limitation of shearing in
engineering polymers. Highly thermally stable material commodity polymers- can be filled at high filling rate with out any
fear of degradation of polymers melt.
Filling phase covers 85 to 98% of total injection stroke.

 High speed filling is terminated at Switch-over point and low

speed Pressure phase commences.
Due to relaxation of compression (10-15%) of melt during
injection stroke, melt expands and fills up remaining empty space
in the mould. It overfills to raise the cavity pressure as
relaxation completes.
If we don't leave any space for relaxation of melt then,
tremendous amount of pressure generated. This can damage the
mould.
Since mould surface is maintained at lower temperature (than
that of melt), melt cools and hence tries to lower its volume as
per the pvT characteristics.
At this point the compensation for shrinkage is supplied at lower
speed. Since less than 10% of space is to be filled, it does not
require high speed filling. The cavity pressure is just to be
maintained in such a manner to compensate for void created by
the shrinking melt on account of falling melt temperature. The
pressure phase has to be maintained till the melt transfer stops.
There after the melt has to be cooled further, below heat
defection temperature of material. This would prevent
deformation of moulding during ejection.
Important note
During filling phase, pressure value should be set 15-25 bar above the
actual pressure encountered in the cavity. This is because if the relief
valve is actuated during the filling phase, oil would drain and you loss
control over the speed. In case of doubt, it is ok to set value at about
80% of maximum pressure for the machine through out the filling
phase. The value of maximum hydraulic system pressure is
recommended in the manual. To maintain the constant melt front
velocity, it is required to adjust the injection speed in stroke
dependent multiple steps.

During pressure phase, the filling speed is low and constant through
out the pressure phase and pressure can be adjusted in time dependent
multiple steps to avoid moulded-in stress.
SETTING POSITION SPEED AND PRESSURE

PRINCIPLE for SETTING OF INJECTION SPEED, PRESSURE AND

POSITION

FILLING PHASE
Also known as
Speed phase.

Also known as
Speed phase.

POSITION

SPEED

PRESSURE

Select end of 1st

step and; start of
2nd step.

Set SPEED 1

Only one pressure

setting is required
during FILLING
PHASE.

Select end of 2nd

step and; start of
3rd step

There may be no.

of steps available
on machine.

Steps are position

controlled.

Select end of 3rd

step and; start of
SWITCH OVER
POINT. This
point is at around
80-95% of the
injection stroke.

Try to set high.

Set SPEED 2
Lower speed for
crossing narrow
passage / gate

Set SPEED 3
Reduce to lower
sink mark /
increase to shift
weld line.

Pressure Setting should

be more than actual
filling pressure. as relief
valve should not be
actuated. If it is
actuated, then speed
control will be lost.
Filling pressure depends
on resistance to move
the melt. It depends on
flow ratio and viscosity
of melt.

PRESSURE
PHASEHolding phase.
There may be no.
of steps available
on machine.

Steps are timers

controlled.

Timer controls
the Holding
pressure steps if
available on
machine.
Holding pressure
time for step 1 is
set on a timer,

Holding pressure
time for step 2 is
set on a timer,

Holding pressure
time for step 3 is
set on a timer,

Set SPEED low

value say up to
35% not more.

Holding pressure 1 set

just enough to fill cavity
without overpacking.

This can be one

step of speed for
different Holding
steps.
Speed set is low,
as there is less or
no space to move
the melt.

Holding pressure 2 set

just enough to fill cavity
without overpacking.

Holding pressure 3 set

just enough to fill cavity
without overpacking.

pvT DIAGRAM

Referring to the cavity pressure profile and PVT-diagram it is observed that

The polymer melt at A in the diagram is at 230 C and 1 bar pressure. Between A
and; B about 90 % of mould filling takes place by injection speed resulting in
pressure build up at more or less constant melt temperature.

At B injection speed is terminated and switch over to follow-up pressure takes

place after a slight delay on account of switching delay and response time of
hydraulic valves.

At C peak cavity pressure is reached during the pressure control phase of

moulding.

CD describes the constant follow up pressure applied on melt. The specific

volume of melt is decreased between C and; D resulting in void / shrinkage which
is filled up by further transfer of melt from nozzle.

The melt is cooled between D and; E. Specific volume of melt remains constant
and the cavity pressure drops to 1 bar. E is the point on 1 bar curve. At this
point the moulded part can be ejected.

After demoulding the moulded part is further cooled up to room temperature

out side the mould.

Let us understand the factors influencing quality consistency in processing and

quality in performance
Let us understand moulding problems.
Let us see the analysis of plastic part failurs carried out by RAPRA.

PROCESSING LIMITATIONS FOR VARIOUS POLYMERS- GUIDELINES

Polymer

Density

Process
temp.

Room
Temp.

Density
process
temp

degree
c

%age
injection
utilisa-tion
capacity

ABS

1.05

220-260

0.96

40 - 80

CA

1.29

170-250

1.10

50 - 80

POM

1.42

192-215

1.16

30 - 80

Permissible
residence
time - min.

Max-flow
ratio for
1mm wall
thickness

Screw
cushion

Shrinkage
%

mm

Output
ratio
related
to

Screw
rpm
related
to

Ps

Ps

100-140

4-6

0.4 - 0.7

0.83

0.83

5- 8

300

0.4 - 0.7

NA

NA

15

100-230

2-6

NA

NA

PMMA

1.18

220-260

1.09

35 - 80

4- 8

100-130

2-6

0.4 - 0.8

0.94

0.74

PPO

1.06

250-290

NA

30 - 80

100-140

3-4

0.4 - 0.7

NA

NA

PA6 /6

1.14

220-280

0.95

40 - 80

100-230

2-4

NA

0.58

0.50

PC

1.22

280-310

1.08

50 - 80

2- 3

60-100

0.7 - 0.8

0.67

0.57

PES

1.37

330-400

NA

NA

NA

60- 120

4- 5

0.6

0.95

0.83

PBT

1.31

220-270

NA

40 - 80

3- 4

125-185

NA

NA

NA

PPS

1.5 - 2.1

300-360

NA

50-80

2- 4

120-150

4-6

0.2

NA

NA

PETP

1.38

260-300

1.2

50 - 80

2- 4

50-90

1.3 - 1.5

0.8

0.74

PS

1.05

220-270

0.95

25 - 90

2-4

150-200

0.45

1.00

1.00

HDPE

0.95

220-280

0.74

10 -85

170

2-6

1.5 - 2

0.73

0.94

LDPE

0.92

180-280

0.74

10 - 95

200

2-6

NA

0.82

1.05

PP

0.91

250-275

0.73

10 - 85

170

1.2 - 2.2

0.63

0.86

RPVC

1.3 - 1.6

170-190

NA

25 - 80

20

60

0.5 - 0.2

NA

NA

SPVC

1.1 1.14

180-200

NA

20 - 80

15

180

1 .2

NA

NA

SAN

1.08

240-270

0.99

40 - 80

5- 6

140-180

0.5

0.96

1.12

TPU

1.20

180-225

NA

40 - 80

30

50

1 - 1.15

NA

NA

A TYPICAL BARREL TEMPERATURE SETTINGS(appro.) Ascending profile

Polymer

Melt

Feed

Rear

Middle

Front

Nozzle

Temp

Throat

220

35

150

180

210

222

260

40

180

230

280

280

170

40

135

140

165

185

165

185

200

200

ABS

CA

PMMA

PPO

195

30

150

180

190

195

245

40

180

200

215

215

220

50

135

185

200

200

260

60

180

200

250

250

250

40

190

230

250

240

240

270

290

275

265

260

280

280

290

PA6/6

Melt

Feed

Rear

Middle

Front

Nozzle

Temp

Throat

260

60

240

245

250

250

280

80

250

255

260

260

220

20

150

180

210

220

270

30

200

230

260

280

220

20

160

200

220

210

280

30

230

260

280

270

180

20

120

180

200

210

280

30

200

260

280

270

250

20

150

210

240

240

270

30

210

250

290

300

170

30

135

165

180

180

250

POM

Polymer

220

60

PETP

PS

HDPE

LDPE

PP

RPVC

40

PC

PES

250

80

260

70

235

285

305

310

310

80

270

310

350

350

330

NA

320

350

360

360

390

410

430

420

320

250

260

255

260

270

275

270

290

300

310

305

310

320

360

320

400

PBT

240

NA

275

PPS

300
360

NA

190

SPVC

180

40

200

SAN

240

NA

270

TPU

180
225

NA

205
160

180

210

125

150

160

150

150

175

200

200

150

200

210

210

200

250

260

250

150

170

180

190

190

200

210

220

PLASTICATING
Plasticating refers to conversion of plastic granuals to flow-able melt. It
happens inside the screw barrel assembly of the injection unit in the Injection
Moulding Machine.

The plastic granules move inside the screw channel when screw is
rotated.

The screw has three sections. FEED ZONE, COMPRESSION ZONE

and METERING ZONE.

 In the compression zone the material is gradually compressed. It

therefore rubs against the barrel wall. This sets up shearing
forces on the material.

Plastic material under shear changes its viscosity. This is SHEAR

THINING characteristic of plastics.

Melt is then homogenised in metering zone.

At the tip of the screw, non-return valve is fitted. It allows the melt to flow
ahead through this valve while screw is rotated.
Non return valve does not allow the melt to slip back through it to the screw
channel.

GLOSSARY OF TECHNICAL TERMS - Polymer Process

Amorphous Polymer: Amorphous means irregular, having no discernible order or
shape. In the context of solids, the molecules are randomly arranged, as in glass,

rather than periodically arranged as in a crystalline material. Amorphous polymer

has a glass like structure with tangled chain and no long range order.
Cavity Pressure: Pressure on the melt in side the space between core and cavity as
the melt moves to fill the mould.
Change over- Fill/Pack: Switch over point fill to pack: The point on injection
stroke at which filling phase with speed profile ends and pack or pressure phase
with pressure profile starts.
Clamp Force: It is force applied by the machines clamping unit to the mould
during filling, packing and holding phases of moulding cycle. Unit is Tons or kN.
Cooling Channels: It is the channels through which coolant is flown to remove
heat from the mould. The channels are to be located thoughtfully in the core and
cavity so that the temperature distribution over the mould surface is constant with
little acceptable variation.
Co-polymer: Polymers that are derived from more than one species of monomers.
Cross linking: A process in which bonds are formed joining adjacent molecules.
At low density, these bonds add to the elasticity of the polymer and at high density
eventualy produce rigidity in the polymer.
Crystalline: It is the structure of polymer where the molecules are arranged in a
very regular repeating lattice structure.
Cure: The process of changing property of polymer into a more stable and usable
condition. This is accompolished by the use of heat, radiation or reaction with
chemical addition.
Cushion: It is the a small amount of melt that is left in the barrel at the end of
injection, follow up pressure. The cushion prevents the screw tip from making
contact to the head of
barrel.
Cycle Time; A sequence of operation that is repeated regularly, the time it takes
for one such operation. It is the time required to complete one moulding cycle.
Dosing Stroke: Metering stroke: It is stroke of screw that determines the quantity
of melt to be injected to the mould.

EUROMAP: Euromap is the non profit organisation of the national association of

machinery manufacturers for plastics and rubber industries in Austria, France,
Germany, Italy, Luxembourg, Netherlands, Spain, Switzerland, and U.K. It
represents 600 companies. It's Technical Commission deals with mechanical and
electrical sandardisation, the communication protocol, and interface for various
types of processing machinery and safety standards. It's technical work started in
early seventies describe recommendations for functional and specification, testing
of machines etc.
FAQ: Frequently Asked Questions.
Feed System: It is the main connecting channel between the machine nozzle and
the part cavities of the mould.
Feedback: Feedback in a closed loop system represents the return signal or
response of the system to input instruction.
Fill Pattern: It is a visual history of how a mould fills under a specific set of
moulding conditions.
Fill Time: Fill time is the time in seconds that it takes to just fill the mould with
melt during the filling phase (up to switchover point) of the moulding cycle.
Flow Balancing: Flow balancing is the process of choosing a mould design
strategy, which promotes even filling of mould. First, a gating strategy is selected
which will promote ease of filling. Second, a runner layout is developed to feed
material to the gates. Finally runner dimensions are identified which will cause all
of the flow paths to fill at the same time. Even wall thickness can be manipulated
by flow leader or flow deflectors.
Flow path: A flow path describes the route that is traveled by a melt front as melt
fills a section of a mould.
Flow Rate: Flow rate is a way of describing how much material goes through or
past a specific point in a fixed period of time. If nozzle tip is used as reference,
flow rate can be described how much melt is flowing out of the machine per
second during injection.
Flow Length: Flow length is the total distance that melt must travel from the
machine nozzle along a particular flow path in order to fill a section of the mould.
Follow up Pressure: It is pressure on melt after the switch over point in the
moulding process.

Fountain Effect: The fountain effect describes how the melt front behaves during
the filling of the mould. The leading melt front swells into the shape of a bubble; it
behaves in much the same way as water flowing from a fountain.
Frozen Layer / skin: The frozen layer is a skin of solid melt that forms next to the
mould surface during the filling phase of the moulding cycle.
Gating Strategy: It is the approach you use to choose the number, dimension and
location of gates in a mould.
Glass Transition Temperature: It is the point at which the polymer hardens into
an amorphous solid.
Hold on Pressure: Follow up pressure: It is pressure on melt after the switch
over point in the moulding process.
Homo polymer: A polymer that is constructed of identical monomers.
Injection Rate: It is the flow rate of melt (cc/sec) coming out of nozzle. Melt
comes out in the form of jet. Then it spreads inside the mould in shape of the space
between the core and cavity.
Injection Speed / velocity profile: Before the switch over point the set pressure
remains constant but set injection speed is varied with stroke position. After switch
over point injection speed should remain at lower value and pressure is changed
with time till the mould is just filled with out over packing. The variations in the
set speed through out the injection stroke is called Injection speed profile.
Injection Pressure Profile: Before the switch over point the set pressure remains
constant but set injection speed is varied with stroke position. After switch over
point injection speed should remain at lower value and pressure is changed with
time till the mould is just filled with out over packing. This set pressure for filling
stage and follow up / hold on pressure change with respect to time is called
Injection pressure profile.
Maximum Shot Capacity of Machine: In machine specification it is given in
terms of weight for PS. For other polymers the density of polymers at moulding
temperature should be multiplied to the maximum swept volume of the machine
barrel to get the weight for the given polymer.
Metering stroke: It is stroke of screw that determines the quantity of melt to be
injected to the mould.

Melt expansion: During the injection stroke melt is compressed by about 5 to

15%. After melt enters the mould it gets the chance to relax and expand.
Melt Front: As the mould is filling, the melt at the leading edge of flow is called
the melt front or stream.
Melt Front Velocity: It is not same as injection piston (screw velocity) velocity.
As melt enters mould it spreads in all direction depending on the resistance to flow
in each direction. Melt front velocity is determined by the area of flow, which does
not remain constant with time.
Melt Temperature: Melt temperature is the actual temperature of the melt during
processing. The melt temperature is constantly changing. It varies with time and
will not be the same at different locations in the mould.
MFI: It stands for Melt Flow Index. It is the weight of polymer melt in grams
extruded in 10 minutes through a standard nozzle or die under standard load
condition at a certain temperature.
Mould Cooling: Mould cooling describes the process by which the melt
temperature is reduced to the point where part can be removed from the mould.
Mould Packing / Follow up pressure / Hold on phase: Mould packing is the
process of delivering an additional amount of melt to the mould, to compensate for
the shrinkage after filling.
Mould Temperature: It refers to temperature of mould surface in contact with
melt. It varies from point to point on surface if cooling design does not provide
uniform heat extraction. It also fluctuates if heat is not balanced.
Moulding Cycle: The moulding cycle is the series of steps that result in the
machine producing a part. The cycle is usually described by breaking down into
four separate phases. The amount of time that it takes to complete one cycle is
called cycle time.
No Flow Temperature: No flow temperature is the temperature at which the
viscosity of the melt is so high that it effectively can not be made to flow.
Orientation: Orientation is the change in shape that polymer molecules can
undergo when they are made to flow.
Parting line: Contour line on the part separating core and cavity.

Polymer: Long chains of covalently bonded atoms.

Pressure Drop: Pressure drop is the loss of pressure that occures when the melt is
pushed into a section of the mould during the filling phase.
Pressure Profile: After switch over point injection speed should remain at lower
value and pressure is changed with time till the mould is just filled with out over
packing. This follow up / hold on pressure change with respect to time is called
Injection pressure profile.
pvT diagram: Polymer Melt follows law similar to famous gas law (Boyel's law).
It is the relation ship between pressure, volume and temperature for plastic melt.
RAPRA: RAPRA technology Ltd., (UK,) is a leading rubber and plastics
consultancy firm with over 75 years of experience. They offer conduct training
courses in Rubber and Plastics.
Repeatability: Repeatability is closeness of agreement of a tool movement
position from one part to another when cutting several copies of the same part.
Residence Time: Residence time is the length of time that the material is held at
melt range temperatures in the barrel.
Residual Stress / Moulded-in Stress: Residual stress is a term that describes the
level and pattern of stress, which is left in the part after it is removed from the
machine. It can be due to unbalanced flow, non uniform freezing of melt and over
packing.
Runner Layout: It is the channels used to get the melt from the machine nozzle to
the gates.
Shear Heating: Shear heating is due to friction caused by flow of melt through
narrow passages in the mould during filling phase.
Shear Rate: Shear rate is a way to describe how quickly the velocity of the melt
changes from the mould surface to the center of flow for a given cross section. The
size of the shear rate gives an indication of the shape of the velocity profile for a
given situation.
Shear stress: Shear stress is the result of the force that is generated in a melt to
overcome its resistance to a particular flow situation. Shear stress is the product of
a material and shear rate.

Shear Thinning: Shear thinning is a the description for the physical effects of
orientation and affect the flow behavior of the polymer. Shear thinning causes the
melts viscosity to drop when it is made to flow within a certain shear rate range.
Shot Composition: The shot size setting and the switch over point give the
machine information about how the melt has to be injected into the mould. The
stroke positions correspond to volumes of melt that play a role in different portions
of the moulding cycle. While the settings relate to the machine barrel, they
correspond with the actual events that happen during the cycle.
Shot size Setting: Shot size setting is control setting which limit how far back the
screw will travel as it rotates in the cooling phase of the cycle. The shot size setting
is measured as a distance from the front of the barrel.
Shrinkage: It is the deviation of dimensions of the moulded part from the
dimensions of cavity when measured on moulded part after certain hours.
Compressibility, thermal expansion and pvT characteristics influence the
dimensions of moulded part.
Sink Mark: A depression on the surface of moulded part caused by differential
shrinkage.
Specific Heat: Temperature is measure of heat energy level whereas heat is a
measure of total internal energy contained in a body. When the same quantity of
heat is given to equal masses of different substances, they do not result in the same
rise in temperature. The specific heat is defined as the quantity of heat energy
which will rise the temperature of unit mass (1kg) of a substance by 1 0C. Heat =
mass x specific heat x Temperature rise.
Specific Volume: It is inverse of density. It is volume per unit weight. Unit is cc/gr.
Speed profile: Injection speed set up with respect to stroke positions for the filling
phase so that melt front speed remains near constant during filling phase.
Split Points: Split points are locations in the a mould cavity where a melt front
will split up and advance in more than one direction at the same time. It is also
refered as flow junctions, branch points, or nodes.
Stress Cracking: A crack, either external / internal, in a plastic part caused by
tensile stress less than its short time mechanical strength.
The moulded-in stress left in the moulded part - due to unbalanced filling, over
packing or non uniform freezing - can fail in service condition. The service

environment can have objectionable temperature or contact with aggressive

chemicals causing the plastic part to fail. Avoiding or minimising moulded-in stress
in plastic part can increase the performance of part even under adverse condition.
Switch over point fill to pack: The point on injection stroke at which filling phase
with speed profile ends and pack or pressure phase with pressure profile starts.
Thermal Stability: It is polymers thermal characteristic. It is the time interval for
which polymer remains stable at certain temperature. Beyond that time if the
polymer is exposed to longer duration for a given temperature, it degrades.
Thermoplastic: Linear plastics of finite molecular weight that can be fabricated in
a complex shape by melting and injection moulding.
Thermoset: A type of plastics that must be cured, forming network like structures
that do not soften at high temperature.
Valcanisation: A process by which a network of cross linking is introduced in to
an elastomer to strengthen it.
Viscosity response: The viscosity response is a way of describing how the
viscosity of a particular polymer responds to the changes in temperature and shear
rate.
Warpage: Uneven bending, Twisting etc on account of differential cooling,
differential shrinkage, or non uniform freezing of melt in the mould can cause
these conditions in the moulded part.
Weld Lines: Weld lines are locations in the moulded part where two met fronts
meet.
Wireframe: It is a geometric model that describes 3D geometry by outlining its
edges.
Work Done: Work is said to be done if an unbalanced force moves its point of
application through a distance measured in the direction of force. Work = Force x
Distance

Injection molding machine service maintenance and breakdown

origin analysis

Post date: 2009/5/11 11:53:41 From:

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No matter is the import or the domestically produced injection molding machine

has the following characteristic:
1. the injection molding machine investment in the fixed assets is big, the scale of
production is big, consumption raw material are many, the labor productivity is high, creates
the output value to be big. Is one kind of labor efficiency high Production organization form.
2. the injection molding machine by the machinery, the hydraulic pressure, the electric
appliance, special-purpose matches the suite and so on, according to the injection molding
processing processing technology's need, organically combines, the automaticity is together
high, is connected closely; The injection molding machine may 3 class of 24h continuous
working. If injection molding machine's some part breaks down, will cause the engine off.
3rd, although on the injection molding machine the simplicity of operator, the worker are
few, but the injection molding machine management and the service technique content is
high, the work load is also big.
Must therefore guarantee that the injection molding machine is at the sound condition
frequently, must strengthen the injection molding machine supervisory work, strict control
injection molding machine's breakdown occurrence. Achieves cuts the failure rate, reduces
the maintenance cost, the extension service life goal.
The injection molding machine breakdown, is generally refers to the injection molding
machine either the system loses or reduces its stipulation function in the use the event or the
phenomenon. The injection molding machine is the enterprise to satisfy the injection molding
product technique of production request to provide. Injection molding machine's function is
manifesting it exists in the injection molding product production activity the value which and
to casts the production the guarantee {Today Hot} the degree. In modernized injection
molding machine production, because the injection molding machine structure is complex,
the automaticity is very high, the hydraulic pressure, the electric control and machinery's
relation is close, thus the injection molding machine presents the breakdown, that feared that
is the partial malfunction, can create the entire injection molding machine's production

suspension. Injection molding machine breakdown immediate influence injection molding

product quantity and quality.
First, injection molding machine breakdown classified <dnt> </dnt> <dnt> </dnt>

The

injection molding machine breakdown is many and varied, may carry on the classification
from the different angle to it.
1. presses the breakdown to have the condition, may divide into:
(1) gradually sends the sex breakdown. Is because the injection molding machine initial
performance deteriorates gradually produces, the majority of injection molding machine's
breakdown belongs to this kind of breakdown. This kind of breakdown and the electric
control, the hydraulic machinery Yuan fitting's attrition, the corrosion, weary and processes
and so on slow change have the close relationship.
(2) burst characteristics breakdown. Is each kind of disadvantage factor as well as the
accidental outside influences combined action produces, this kind of function has surpassed
the limit which the injection molding machine can withstand. For example: Because the
material tube enters the iron to present the excess load to cause the screw rod to break off;
Because the high-pressured string enters penetrates the injection molding machine electron
board. This kind of breakdown often is occurs suddenly, does not have any indication
beforehand.
The burst characteristics breakdown occurs much in the injection molding machine
operational phase, often is because designs, flaws and so on manufacture, assembly as well
as material quality, or the operate miss, violates regulations the work to create.
2. presses the breakdown nature division, may divide into:
(1) discontinual breakdown. The injection molding machine loses its certain functions in
a short time, repairs the debugging to be able slightly to restore, does not need to replace the
spare part.
(2) permanent breakdown. Injection molding machine certain spare parts have
damaged, needs to replace or the repair can resume the use.
3. presses the breakdown influence division, may divide into:
(1) complete breakdown. Causes the injection molding machine to lose the function
completely. {HotTag}
(2) topicality breakdown. Causes injection molding machine certain functions to lose.
4. presses the breakdown to have the reason division, may divide into:

 (1) wearability breakdown. Because the injection molding machine normal wear creates
breakdown.
(2) wrong uses the sex breakdown. Because the operation mistake, maintains the
breakdown which creates improper.
(3) inherent weak sex breakdown. As a result of the design question, causes the
injection molding machine to present the weak link, when normal use produces breakdown.
5. presses the breakdown the risk division, may divide into:
(1) risky breakdown. For example safety system when needs to act, because the
breakdown loses the protective function, creates the personal injuries and the injection
molding machine breakdown; The hydraulic pressure electrically controlled system
malfunction creates breakdown and so on.
(2) secure breakdown. For example safety system when does not need to act has the
movement; The injection molding machine cannot start when starts breakdown.
6. presses the injection molding machine breakdown the occurrence, the law of
development division, may divide into;
(1) random fault. The breakdown occurs the time is stochastic.
(2) has the regular breakdown. The breakdown occurrence has certain rule.
Each kind of breakdown has its chief feature, namely so-called fault mode, or
malfunction. Each kind of injection molding machine's malfunction is quite numerous and
diverse, but may induce the following several kinds: The unusual vibration, the machinery
wear, the input signal to be unable to let the computer accept, the solenoid valve output
signal, the mechanical hydraulic element not to burst, proportion linearity being out of
balance, the hydraulic pressure pressure drop, the hydraulic pressure leakage, the oil pump
breakdown, the hydraulic pressure noise, the electric circuit to get older, the unusual sound,
the oil material deterioration, the power source pressure drop, to put the doltish to relief, the
temperature out of control and other. The different type injection molding machine's each kind
of fault mode accounts for the proportion to differ from.
Second, fault analysis and trouble shooting procedure
In order to guarantee that fault analysis and elimination quickly, effective, must follow
certain procedure, this kind of procedure is approximately as follows.
First step maintains the scene in the situation carries on the symptom analysis
1. inquiry operators what (has 1) broken down? Occurs what situation in? When

occurs?
How long (2) did the injection molding machine sixth branch after move?
whether there is (does before 3) the breakdown have, any abnormal phenomenon? Has
what sound or the acousto-optics alarm? Whether there is haze or unusual smell? Whether
there is misoperation (attention interrogation mode)?
(4) the control system operates whether normally? Whether there does the operation
sequence change? Whether to have during the operation special difficult or exceptionally?
2. observation complete machine condition, each operational factor
(1) whether there is obvious abnormal phenomenon? Components whether there is card
anti- or damage? The hydraulic system whether or not becomes less crowded or divulging?
Whether there does the electric wire burst, the abrasion or the overburning?
(2) the injection molding machine operational factor has what change? Whether there is
obvious unwanted signal? Whether there is obvious damage signal?
3. inspection monitor indicating device
(1) inspects all reading value to be whether normal, including pressure gauge and other
instrument reading, fuel head situation.
(2) inspects the filter, the alarm apparatus and the interlocking device, the movement
output or the monitor to be whether normal.
4. the point moves the injection molding machine inspection (under permission
condition)
The inspection intermittence situation, the lasting situation, enter or enters when slowly
the situation quickly, looked that in these situations whether to affect the output, whether
possibly to cause damages or other dangers.
Second step inspection injection molding machine (including components, part and line)
1. (continues process which using the sense organ inspection observes thoroughly)
1 looked: Plug and plug whether there is exceptionally, electrical machinery or pump's
revolution to be whether normal, the control positioning is whether correct, whether there is to
have the arc or the air burn trace, the fuse quality, the liquid whether there is to divulge,
lubrication oil duct whether unimpeded and so on.
2 trace: Injection molding machine vibration situation, Yuan (group) heat degree, drill
tubing temperature, mechanical movement condition.
3 tins: Whether there is unusual sound.

4 smell: Whether there does the burnt smell, leak the smell, other unusual smells.
5 look up: Work piece shape and position variation, injection molding machine
performance parameter change, line follow-up for anomaly.
2. evaluation check result
The evaluation breakdown judges whether correctly, breakdown clue whether to find,
each check result is whether consistent.
Third step fault location determination
1. recognition system structure and determination test method
Does the consult injection molding machine instruction booklet, which one kind of
structure distinguish the injection molding machine is, carries on the test with any method,
needs any test method, possibly obtains any test parameter or the performance parameter,
carries on the test under any operating condition, which security measures can observe,
whether needs to operate the permit.
2. system examination
Uses most suits in the system structure technical examination. In the appropriate test
point, carries on the comparison according to the input and the feedback obtained result and
the normal value or the performance standard, finds out the suspicious position.
The fourth step repair or replacement
1. repair
The trouble shoot reason, carries on view of the injection molding machine breakdown
repairs and takes the preventive measure; Inspects the related components, prevents the
breakdown proliferation.
2. replacement
The correct assembly debugging replacement components, and pay attention to the
related part. Changes the components carry on the repair or the abandonment.
Fifth step carries on the performance to determine
1. starts the injection molding machine
After spare part assembly debugging, starts the injection molding machine, first manual
(or spot moves), then carries on the idling and the load determination.
2. the adjustment variation of load speed, the load from small to big, the system
pressure is from low to high highest cannot surpass 140kg/cm2, according to stipulation
standard determination performance.

3. expansion performance test scope

According to need, from part to system gradual growth performance test scope. Pays
attention to the non-breakdown area systems operation condition. If the performance
satisfies the request to be available, if does not satisfy the request again fault location.
The sixth step record and feeds back
1. collects the valuable material and the data, like the injection molding machine
breakdown occurs when time, breakdown phenomenon, down time, dresser, repairs trades
the question which, the settlement expense the components, the repair effect, remains
unresolved and so on, stores the file according to the stipulation request.
2. statistical analysis
The periodic analysis injection molding machine note for use, analyzes the engine off to
lose, the revision prepares forgets the table of contents, seeks for the reduced service work
the key measure, the research breakdown mechanism, proposes the corrective measure.
3. presses the procedure feedback related breakdown to report the Department
responsible for the work, and feeds back gives the injection molding machine manufacture
unit.
Third, fault management expansion process
Must complete the injection molding machine fault management, must grasp has the
breakdown reason, the accumulation often sends the breakdown and the typical breakdown
material and the data, the development fault analysis, takes the breakdown rule and the
breakdown mechanism's research, strengthens the routine maintenance, the inspection and
the preventive maintenance. Fault management's expansion process has the following 8
aspects.
1. completes the public education work, causes to operate the worker and to service the
worker on own initiative to carry on the earnest record, the statistics, the analysis to the
injection molding machine breakdown, proposes the rationalization proposal.
2. the close union injection molding production is practical and the injection molding
machine condition characteristic, is using the injection molding machine to divide into A, B,
the C three kinds, by determines the fault management the key point.
3. uses monitors the instrument, carries on to the key injection molding machine's key
spot has the plan monitor, by prompt discovery breakdown indication and deteriorated
information.

Generally the injection molding machine must and examines the tool through person's
sense organ to carry on the daily inspection, the tour inspection, the periodic inspection
generally (including curacy checking), the sound condition inspection and so on, grasps the
spot which, the organization and the components technical condition and the abnormal
phenomenon information emphatically easy to crash. Simultaneously must draw up the
inspection standard, definite injection molding machine normal, unusual, breakdown
boundary.
4. the development fault analysis, trains the injection molding machine maintenance
worker to master the fault analysis method.
5. the faulty recording realizes the injection molding machine fault management basic
data, is also carries on the fault analysis, the processing primitive basis, the record must
complete correct. The injection molding machine services the worker carries on the
inspection and the breakdown repair after the scene, should defer to the injection molding
machine breakdown repair bill the content fills in earnestly, the workshop mechanic monthly
the statistical analysis and sends the injection molding machine to manage the manager.
6. the workshop injection molding machine maintenance man besides keeps abreast of the
breakdown situation daily, should collect the breakdown repair bill monthly and the
maintenance records. Through to the breakdown data's statistics, the reorganization, the
analysis, calculates each kind of injection molding machine's breakdown frequency, the
average breakdown plastochrone, analyzes the single Taiwan injection molding machine's
breakdown dynamic and the key breakdown reason, discovers the breakdown the
occurrence rule, so that the target key points takes the countermeasure, feeds back the
breakdown information reorganization analyze data to the Project division, with the aim of
arranging the preventive repairing or the improvement measure plan, but may also take the
revision periodic inspection plastochrone, the inspection content and the standard basis.
According to statistical processing's material, may draw the statistical analysis graph, if
the single Taiwan injection molding machine breakdown dynamic statistics analytical table is
services the teams and groups and other carries on the visual management to the
breakdown the efficacious device, both are advantageous for the administrative personnels
and services the worker to grasp various types injection molding machine to have the
breakdown situation promptly, and can when the determination service countermeasure has
the explicit goal.

7. through services worker's daily tour inspection and the injection molding machine
condition check, obtains the status messages and the breakdown indication, as well as the
related record, the analyze data, or repair group leader by the workshop injection molding
machine maintenance man in view of various types injection molding machine's existence
question, the prompt arrangement daily maintenance, uses the production crevice time or the
holiday fully, achieves the prevention before, controls and the reduced breakdown
occurrence. To certain breakdown indication, the hidden danger, the daily maintenance
undertakes incapable, then feeds back for the Project division arranges the plan repair.
8. making breakdown information management flow chart.
Fourth, injection molding machine breakdown rule
The research breakdown rule to formulates the service countermeasure, down to the
establishment science's service system is very advantageous. Injection molding machine in
use process, its performance or condition along with period of revolution passage, but drops
gradually. Before many breakdowns will occur, will have some omens, this will be the socalled incipient fault, its may distinguish the physical parameter indicated that one kind of
functionality breakdown will soon occur, the functionality breakdown indicated that the
injection molding machine has lost the stipulation performance standard.
The injection molding machine failure rate along with the time change rule, is often
called the bathtub curve. Injection molding machine's failure rate is divided three stages
approximately along with the time change: Incipient failure time, sporadic fault time and
wearout fault time.
1. incipient failure time
The injection molding machine is in the incipient failure time, starts the failure rate to be
very high, but drops rapidly along with the time passage failure rate, the incipient failure time
is called the running-in period regarding the engineering products. This period of time length,
because of product, system's design and manufacture quality, but different. This period
occurs the breakdown, is mainly by in the design, the manufacture flaw result, perhaps use
environment not, when creates.
2. sporadic fault time
The injection molding machine enters the person sporadic fault time, the failure rate is at
the steady state approximately, the tending to definite value. , The breakdown occurs is
stochastic. In the sporadic fault time, injection molding machine's failure rate is lowest,

moreover is stable. Therefore may say that this is injection molding machine's optimum
condition time or calls the normal work time. This sector is called the effective life.
The sporadic fault time's breakdown, is attributed to the design, to use much improper
and does not service the strength. Therefore through the enhancement design quality, the
improvement use management, strengthens the surveillance maintenance work and so on to
diagnose and to maintain, may cause the failure rate to reduce to the lowest level.
3. wearout fault time The later period which uses in the injection molding machine, the
failure rate starts to rise. This is because the injection molding machine spare part's attrition,
weary, the aging, the corrosion and so on create. If is the wearout fault time starts carries on
the overhaul when the inflection point, but economy but cuts the failure rate effectively.
The injection molding machine failure rate curve change's three stages, reflected really
the injection molding machine from wearing, the debugging, the normal work to the overhaul
or the abandonment failure rate change's rule, strengthens injection molding machine's
current management and the maintenance maintenance, may lengthen the sporadic fault
time. Discovers the inflection point accurately, may avoid too much repairing or repair range
extension, obtains the best investment benefit.
Injection molding machine hydraulic system failure diagnosis is often limited by site conditions, and eliminate as
soon as possible after a failure, so as not to affect the production schedule. Site commonly used injection
molding machine hydraulic system fault diagnosis methods:
1. Visual inspection method for the failure of some of the more simple, you can watch, Shoumo, ears, and sniffing
and other means of parts to be checked.
For example, can be found by visual inspection, such as rupture, leakage, loose and deformation, such as failure
to imagine, which can repair or replace parts in a timely manner; hand holding the pipe (especially hose), when
there will be pressure oil flow out of date vibration to feel, without the oil flow or pressure is too low, no such
phenomenon. In addition, the hand touch can also be used with mechanical transmission parts to determine the
hydraulic components of lubrication is good, hand feel the temperature changing component case, if the shell
components overheating, then the poor lubrication; ears can determine the mechanical parts damage caused by
the failure point and the extent of damage, such as air suction pump, relief valve open, and other components
stuck fault is issued by the sound of the impact of water or "water hammer noise" and other abnormal noise;
some parts due to overheating, poor lubrication and gas erosion and other reasons, the odor by sniffing the point
of failure can be judged.
2. For diagnosis of lack of diagnostic equipment in the maintenance field or the more sophisticated components
should not be checked when opened, should use this method. First suspected component failure to remove and
replace with new parts or other machine working properly, test the components of the same model to see
whether the failure to make a diagnosis of exclusion. Injection molding machine such as a hydraulic system
pressure did not work, based on experience is the main safety valve out of the suspected fault, ordered to the
scene on the same type of injection molding machine with the main valve of the safety valve for, test machine
working properly, confirmed that suspicion is correct. Check with the fault diagnosis on the exchange, despite the
structure, site or demolition reserve components inconvenience factors, may also be cumbersome to operate, but
for such as valve, relief valve, check valve and the like are small in size easy disassembly of the components,
using this method is more convenient. For diagnosis of avoidable blindness due to demolition of hydraulic
components resulting performance degradation. The failure of the law if they did not check on the exchange, and
direct the main valve and remove the suspicious its dismantling, if the device no problem, after re-installation may
affect its performance.
3. Measuring instrument measuring instrument inspection method is to test for the various parts of the hydraulic
system with hydraulic oil pressure, flow and oil temperature measurements to determine the system's fault. Field

testing in general, due to the failure of hydraulic system pressure is often manifested in lack of easily perceptible;
and traffic detection is more difficult, flow can only be the size of the speed of movement through the
implementation of the components to make the wrong strategic judgments. Therefore, in the field test, the more
pressure detection system using the method.
Failure of a phenomenon of injection molding machines melt pressure is low. Testing found that when the
hydraulic motor when the pressure is 5MPa screw fixed, that the motor does not rotate, that speaks more serious
leak inside the motor. Dismantling the motor that, with Vice-wear plate and plunger are very serious, that judge is
correct. Grinding valve plate \ assembly after the test machine everything back to normal.
4. Principles of reasoning injection molding machine hydraulic system is the use of different basic principles of
hydraulic components, in accordance with the combination of matching circuit hydraulic system formed, when the
failure to analyze the phenomenon whereby inference can be preliminarily determine the location and cause of
failure, the right **** quickly be ruled out.
For on-site hydraulic system failure, according to the hydraulic system works, in accordance with the power
control element element element implementation of the order of forward reasoning in the system diagram of
the problem. Pressure drop or flow rate decreases the possibility of factors: First, the fuel ****, such as in oil, oil
filter clogging, air vents are not smooth; the second is leakage of hydraulic pump; third is the main pressure
regulator valve or the drain is too low serious; Fourth, and serious leakage of the hydraulic cylinder. Considering
these factors, according to the existing test results to exclude certain factors, narrowing the scope of failure, until
you find the trouble spots and to be excluded.
On-site fault diagnosis of hydraulic system, the system works, to have some law or common sense; one of fault
or mutation process is gradual, if it is gradual, generally due to the wear and tear lead to changes in the original
size and with the loss of the original function; if is a mutation, often sudden damage caused by spare parts, if
spring break, seals damaged, moving parts or dirt stuck blockage. The second is to distinguish between a
consumable or non-wearing parts, or in the moving parts under high-frequency overload, or as prone to failure of
hydraulic components. And in the low, light or basic components of relatively static, the less prone to failure, such
as valve, sequence valve, slide valve to less prone to failure. Master these rules, the failure to quickly determine
the location can play a positive role.