Injection molding machines typically consist of an injection system, a mold clamping system, a hydraulic transmission system, an electrical control system, a lubrication system, a heating and cooling system, and a safety monitoring system.
Structure and Function:
Composition of the Injection System: The injection system consists of a plasticizing device and a power transmission device. The plasticizing device of a screw-type injection molding machine mainly consists of a feeding device, a barrel, a screw, and an injection nozzle. The power transmission device includes an injection cylinder, an injection seat moving cylinder, and a screw drive device (melt motor).
(1) Function of the Injection System: The injection system is one of the most important components of an injection molding machine. It generally comes in three main forms: plunger type, screw type, and screw pre-plasticized plunger injection type. Currently, the screw type is the most widely used. Its function is to heat and plasticize a certain amount of plastic within a specified time during one cycle of the injection molding machine, and then inject the molten plastic into the mold cavity through the screw under certain pressure and speed.
(2) Mold Clamping System: The function of the mold clamping system is to ensure the mold closes, opens, and ejects the product. Simultaneously, after the mold closes, sufficient clamping force is supplied to resist the mold cavity pressure generated by the molten plastic entering the mold cavity, preventing mold opening and resulting in undesirable product conditions. The mold clamping system mainly consists of a mold clamping device, mold adjustment mechanism, ejection mechanism, front and rear fixed templates, moving template, mold clamping cylinder, and safety protection mechanism.
(3) Hydraulic System: The hydraulic transmission system provides power to realize the various actions required by the injection molding machine according to the process, and meets the pressure, speed, temperature, and other requirements of each part of the injection molding machine. It mainly consists of various hydraulic components and hydraulic auxiliary components, among which the oil pump and motor are the power source of the injection molding machine. Various valves control the oil pressure and flow rate, thereby meeting the various requirements of the injection molding process.
(4) Electrical Control System: The electrical control system, in reasonable coordination with the hydraulic system, can realize the process requirements (pressure, temperature, speed, time) and various programmed actions of the injection molding machine. It mainly consists of electrical and electronic components, instruments, heaters, sensors, etc. There are generally four control modes: manual, semi-automatic, fully automatic, and adjustable.
(5) Heating/Cooling System: The heating system heats the barrel and injection nozzle. Injection molding machine barrels typically use electric heating coils as heating devices, installed externally and monitored in sections by thermocouples. Heat is conducted through the barrel wall to provide a heat source for material plasticization. The cooling system primarily cools the oil temperature; excessively high oil temperatures can cause various malfunctions, so oil temperature must be controlled. Another area requiring cooling is near the material outlet of the feed tube to prevent the raw material from melting at the outlet, which could prevent normal material feeding.
(6) Lubrication System: The lubrication system provides lubrication for relatively moving parts of the injection molding machine, such as the moving platen, mold adjusting device, and connecting rod hinges, to reduce energy consumption and extend part life. Lubrication can be performed manually or automatically by an electric lubricator.
Classification
I. Vertical AC/DC Injection Molding Machine Series: This type of machine is mainly used for injection molding of connecting cables, various electronic and computer data cables, and power plugs. The precision requirements for injection molded products are not high, and PVC and PE plastics are the primary materials used. Suitable machine specifications for this product generally have clamping forces ranging from 15T to 35T. Since the specific mold capacity and configuration vary between manufacturers, it is essential to request the manufacturer to visit your factory to confirm the specific parameters and specifications before purchasing.
II. C-Type Injection Molding Machine Series: This machine features vertical clamping and horizontal injection. It is named for the "C" shape of the clamping part due to the absence of guide pillars. This machine has a complex structure and a very large injection volume. Because it has no guide pillars, the working area is wide, making it mainly suitable for injection molding various safety-compliant power plugs, such as French plugs, American plugs, and British plugs.
III. Vertical Single-Slide Injection Molding Machines and Double-Slide Injection Molding Machines: These machines are primarily designed for engineering plastics products with strict precision requirements. They are used for injection molding precision parts or small inserts, and are one of the most optimized molding solutions for inserts. This is because the machine features a fixed upper mold and a sliding lower mold. Double-slide machines have one upper mold and two lower molds, with alternating operation, making them suitable for inserting or removing precision metal parts. Some two-color molds can also be molded using double-slide injection molding. For general molding products such as precision electronic connectors, mobile phone connectors, and integrated circuit components, the disadvantage of double-slide machines is the increased labor costs due to the two working positions.
IV. Vertical Disc Injection Molding Machines (Rotary Series): Vertical disc injection molding machines (rotary series) are the optimal solution for precision part embedding and two-color molding. This is because the machine can be designed with one upper mold and two lower molds or multiple lower molds, offering advantages such as suitability for complex embedding and labor savings.
V. Vertical and Horizontal Injection Molding Machines: Vertical and horizontal injection molding machines are suitable for hardware overmolded inserts with large injection volumes that require a vertical mold structure. The vertical structure facilitates insert placement, while the horizontal structure allows for larger injection volumes, making it a product that meets market demand for a combination of vertical and horizontal structures.
Operating Procedures
1. Preparation
1.1 Check that all machine components and the electrical control box are in good working order.
1.2 Check the hydraulic oil level and ensure the oil level is sufficient. Start the motor and observe whether the axial piston valve is discharging oil normally.
1.3 Open the cooling water valve to connect the cooling water supply.
2. Operation
2.1 Mold Installation: Push the mold-moving mechanism to its highest position, install the plastic mold on the moving template, unscrew the fixed template, align the upper mold and fixed template, and tighten the screws. Secure the lower mold to the moving template, run the mold-moving mechanism, and check if the mold position is correct.
2.2 Barrel Heating: Turn on the heating switch in the electrical control box, add plastic to the barrel, and heat it thoroughly until the plastic melts.
2.3 Injection Operation: Turn on solenoid valve 8 to raise the mold-moving mechanism and close it with the plastic mold. Turn on solenoid valve 6 to press the injection plunger into the barrel for injection. After injection, turn on solenoid valve 6 to push the injection plunger out of the barrel. Turn on solenoid valve 8 to lower the mold-moving mechanism, and then the plastic mold can be opened for demolding.
3. Maintenance and Care
3.1 Check the hydraulic oil level. Replenish promptly if insufficient. Keep the oil clean at all times.
3.2 Lubricate the lubrication points regularly as specified, and clean the oil filter periodically.
3.3 Keep the area around the machine clean and prevent dirt from entering the oil tank.
3.4 After use, wipe the machine clean and apply oil to smooth surfaces.
3.5 Regularly inspect the electrical components, remove dirt, oil, and dust, keep electrical contacts clean, and frequently remove dirt and dust from the connectors.
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