How to adjust machine to make it stable?

Time：2024-09-10 08:19:07 / Popularity： / Source：

I often hear some bosses in industry complain:
①. Machine is unstable, resulting in a high scrap rate.
②. Your machine adjustment is not stable! Will it be possible to adjust machine?
In fact, whether injection molding production process is stable and whether yield rate is high is a systematic management process and a technical control process that cannot be fully controlled by an on-site operator.
Editor briefly explains: How to adjust machine to make it stable?
First explain what is machine adjustment?

1. For grassroots employees and laymen: adjusting machine is to press equipment control screen and enter numbers.

2. For on-site technicians and foremen, machine adjustment means:

2.1 Injection molding machine molding parameter input settings.
2.2 Upper mold content, material addition content, machine inspection content, and warehousing content.
2.3 Check and set safety settings before adjusting machine.
2.4 Manipulator adjustment and auxiliary equipment adjustment.
2.5 Open mold locking, ejection pin, core pulling, blowing and other demoulding parameters and mode settings.
2.6 Molding auxiliary action needle valve delay device, hot runner parameter setting.
2.7 Adjust shaping fixture and shear nozzle fixture.
2.8 Parameter settings such as injection base, melt glue, and barrel temperature of injection molding machine.
2.9 Clean mold before adjusting machine, perform maintenance actions, perform maintenance during production, handle minor abnormalities in mold and equipment.
2.10 Instruct and supervise operating movements of machine side operators.

3. For on-site supervisor, machine adjustment means: making product on time and with good quality, handing it over to next process, and providing good service. At the same time, site is beautiful, process is efficient, talent echelon is built, and training content is provided.

4. For director and vice president of injection molding factory, adjustment means: Boss, after receiving business order, design it, produce it efficiently, deliver goods, get money back, build a talent echelon, and provide training content.

5. For boss, machine adjustment means: adjusting all operations in factory to develop factory, make employees live better, and build a happy company.

First: If you want to adjust machine stably, you must design mold exhaust and water entry methods, and test mold for mass production to confirm.

Because of structure and function of product, customers will definitely confirm acceptance, so these abnormalities generally will not wait until production to solve them.
Customers only want products and will not pay too much attention to whether you have high losses and are difficult to produce.
At this time, manager or factory director will adjust your machine: design review, mold test to confirm corrections.
Without effort in design, production will be miserable. Remember, design and drawing are two different concepts in industry.
Drawing: Draw product and put it together as a set of molds, regardless of loss of injection molding production, let alone what efficient mass production is.
Many people can do it. They are just painters. Just like children draw eggs, a circle is an egg, which is also a picture.
Ghost painting talisman drawing mold ▼

Ghost painting talisman drawing mold ▼

Design: Draw product, use professional design concepts, injection molding knowledge, and mechanical knowledge to make mold for mass production with perfect efficiency.
Make mass production design mold▼

The two most important design factors that affect stability of machine adjustment must be controlled well: exhaust and water inlet.
It must be confirmed clearly during mold trial and mass production. Confirmation by injection molding supervisor shall prevail, and mold room will implement it accordingly.
Please think about it: Does 3D drawing of mold you designed have exhaust? Or during mold production, fitter master casually makes a cross to exhaust gas?

Second, if you want to adjust machine stably, it is most important to prepare material room well.

In the 1990s, there was a saying spread by injection molding masters in Hong Kong: If material room cannot be built well, building a machine room is a dream!
1. If there are foreign objects in material and injection nozzle is often stuck, how will machine be stable?
2. If mixing is not done according to work instructions: mixing time is not solidified, and diffusion auxiliary materials are not put in as required, how can we ensure that each shots has no mixed colors and no black spots, and how can machine be stable?
3. Nozzle is not clean, particles are of different sizes, and there is no uniform mixing. How can we ensure that melt density is consistent and how can machine be stable?
Yuanyang hotpot? ▼

Third, if you want to adjust machine stably, parameter settings are very important.

1. All injection molding machines must have back pressure.
Setting of back pressure should be determined according to material and production conditions at that time, usually 1bar ~ 20bar. You must not completely release back pressure, because this will cause screw to be sucked into air when it rotates and retreat too quickly, and quality of melt cannot be guaranteed. Quality of plastic products cannot be guaranteed.

2. Action parameters set cannot be extreme.

Parameters for building aircraft cannons▼
You set rate of fire to 1, please ask:
A, can your injection molding machine perform this action perfectly as you want?
B. Molten rubber has no heat loss, can it be in a constant temperature state, and can it advance at your firing rate of 1?
In the past few years, in some groups of consulting units, some fake masters posted some weird parameters: firing rate is 0 or 1, injection pressure is 175, or mold locking low pressure is 25, and high pressure is 30.
I just asked: Your parameter is 86,400 seconds a day. How many seconds does it take for normal mass production?
Banquet has died down, it is just more fun and showing off one's ignorance.
This kind of parameter is common in the hands of some fake masters. To a certain extent, it can temporarily solve problem of several beers, but it cannot be produced efficiently and is unstable.
Parameters must be set so that screw, opening and locking mold can move smoothly and forcefully, otherwise, production will be unstable.
Editor recommends that when setting action parameters, pressure value should be larger than speed, and data should be medium speed.
3. Injection action must be maintained with pressure.
Parameters of selling rice noodles▼

Injection action must be maintained with pressure, or there must be a suitable pressure at the end of injection, and speed is regarded as pressure maintenance. After it couldn't shoot to tail position, it suddenly stopped, pressure and speed returned to zero.
During injection, quality of melt will be different each time, and shrinkage of product will be slightly different each time, so there must be a feeding and enrichment stage.
Do you think molten material in barrel can be sold piece by piece like rice sausage?
This parameter is common among injection molding masters in some small factories who have not received professional training.

Fourth, if you want to adjust machine stably, 4-stage injection is the most reasonable.

The most reasonable parameters▼

In injection molding, 3~4 stages of injection + 1~2 stages of pressure holding is the best parameter setting method.

Gud Mould Industry Co., Ltd