Proper maintenance of injection moulding machine is crucial for their longevity and efficient operation. Neglecting regular upkeep can lead to costly downtime and reduced productivity. This article outlines seven essential maintenance tasks to ensure your injection moulding machine runs smoothly and reliably.
1. Injection Moulding Machine and Mould Protection
Before shutting down the injection moulding machine, it’s important to open the mould to a 5-10mm distance. This position ensures that the mould clamping mechanism, specifically the hinge (curved arm) mechanism, remains in a half-extension state. By doing so, the injection moulding machine’s hinge mechanism is not under stress, providing better protection for both the mould and the mould clamping system.
2. Cylinder Emptying
To prevent damage and contamination, the barrel should be thoroughly cleaned before the machine is stopped. Use one of the following plastics: PP, PS, or PE to purge the residual plastic from the barrel. Once cleaned, loosen the screw stroke back to a large stroke. This step prevents the screw head from burning out during the next warm-up. For colored, VO fireproof grade, corrosive, or glass fiber plastics, use PP, PS, or PE for cleaning. After cleaning, you can close the material tube temperature.
3. Draining Mould, Barrel Cooler, and Hydraulic Oil Cooler
Proper drainage is essential to avoid rust and oxidation inside the cooling systems. Here’s how to do it:
- Hydraulic Oil Cooler: Close the inlet and outlet water valves, remove the water pipe joints, and use an air compressor air gun to blow out all residual water. Clean the oil cooler inlet pipe filter.
- Mould Cooler: Similarly, close the mould’s inlet and outlet water valves, remove the water pipe joints, and blow out all residual water with an air compressor air gun. This prevents rusting inside the mould’s core.
4. Lubrication Maintenance
Regular lubrication of the machine’s moving parts is critical for smooth operation:
- Mould Adjusting Mechanism: Lubricate with molybdenum difluoride as per maintenance requirements.
- Hinge Mechanism: Use Sinopec Great Wall guide oil L-G150 for lubrication. Clean the electric lubrication pump, the oil pump suction port screen, and check for any damage to connecting tubes. Perform a manual lubrication test to ensure all distributor spools pop-up and reset correctly and that there are no fractures in lubricant pipes.
- Shooting Table Plates and Drive Shaft: Use lithium grease (3#) for lubricating the front and back plates of the shooting table and the melting drive shaft.
5. Maintenance of Bypass Filter and Oil Suction Filter
Filters play a crucial role in maintaining the cleanliness and efficiency of the machine:
- Bypass Filter: Monitor the pressure gauge. If the needle points towards the red area, replace the bypass filter cartridge immediately.
- Oil Suction Filter: Similarly, if the pressure gauge needle points towards the red zone, clean the filter cartridge promptly. If the hydraulic oil is excessively dirty, replace it to prevent contamination.
6. Maintenance of Motor Cooling Fan
A well-functioning cooling system is essential to prevent overheating:
- Cooling Fan: Remove the motor sealing plate to inspect the fan’s operation. If the fan is not functioning, replace it immediately. Use an air compressor air gun to clean the dust off the motor cooling fan and heat sink surface. Always turn off the power before performing these tasks.
7. Maintenance of the Electrical Box
Ensuring the electrical components are in good condition is vital for the machine’s safety and performance:
- Exhaust Fan: Check if the exhaust fan in the electric box is running properly. If it’s not functioning or making noise, replace it immediately.
- Cleaning: Use an air pressure gun to clean the cooling fan screen and air intake screen. Turn off the main power switch and use a hoover to clean the dust inside the electrical box. This prevents dust buildup, ensuring the electronic board and components operate correctly. Additionally, store mothballs in the electrical box to deter rodents from damaging the wiring, and ensure the electrical box door is closed securely.
Additional Maintenance Tips
- Debris Removal: Keep the machine table free from debris and glue.
- Oil Return Port: Ensure the oil return bin’s oil return port under the clamping frame is open.
- Rodent Prevention: Place mothballs in the electrical box to prevent rodents from chewing on electrical wiring.
Wrapping Up
Regular maintenance of injection moulding machines is not just about preventing breakdowns but also about ensuring the machine operates at its highest efficiency. By following these seven routine maintenance tasks, you can extend the life of your injection mold machine and avoid unexpected downtime. Remember, a well-maintained machine not only enhances productivity but also ensures the quality of the products being manufactured.
