The fully electric injection molding machine replaces traditional hydraulic systems with electric drive, which has the advantages of energy saving, high efficiency, high precision, and low noise. However, its electrical control system is complex and requires higher maintenance and upkeep. The following are the maintenance points for fully electric injection molding machines, covering daily inspections, regular maintenance, key component maintenance, and safety precautions:
1、 Daily maintenance and inspection
Pre-start inspection
Electrical system: Check whether the connection wires of the control cabinet, operation panel, motor and sensor are loose, and ensure that there is no damage or aging.
Mechanical components: Confirm that the moving parts such as guide rails, screws, bearings, etc. are well lubricated and free of foreign objects.
Safety device: Test whether the safety functions such as safety door, emergency stop button, and grating protection are normal.
Environmental requirements: Ensure that there are no debris around the equipment, good ventilation, temperature between 5-40 ℃, and humidity ≤ 80%.
runtime monitoring
Temperature control: Regularly check whether the temperature of the barrel, mold, and heating coil is consistent with the set value, and adjust if the deviation exceeds ± 5 ℃.
Pressure and speed: Monitor injection pressure, holding pressure, mold opening and closing speed and other parameters through the operation panel. Abnormal fluctuations may indicate motor or driver failures.
Noise and vibration: If there is abnormal noise or vibration during equipment operation, immediately stop the machine and check the status of mechanical components or motors.
Cleaning after shutdown
Barrel cleaning: Before stopping the machine, clean the barrel with PP or PE material to prevent residual material from degrading and blocking the screw.
Mold cleaning: Wipe the parting surface of the mold with a soft cloth to remove oil stains or debris, and spray rust inhibitor (when not in use for a long time).
Equipment surface cleaning: Wipe the control cabinet, operation panel, and body with a dry cloth to prevent water or oil stains from entering electrical components.
2、 Regular maintenance (classified by cycle)
1. Weekly maintenance
Lubrication system inspection:
Confirm that the automatic lubrication device has sufficient oil and that the lubrication pipeline is not blocked.
Manually add lubricating grease to the guide rail, screw, bearings, and other parts (if automatic lubrication fails).
Electrical cabinet dust removal:
Use compressed air (pressure ≤ 0.2MPa) to blow away dust inside the control cabinet, with a focus on cleaning the cooling fan, power module, and wiring terminals.
Security function testing:
Simulate emergency stop, safety door closure and other scenarios to verify whether the safety circuit is triggered normally.
2. Monthly maintenance
Motor and driver inspection:
Check if the servo motor, stepper motor, and driver cooling fan are running smoothly without any abnormal noise.
Use an infrared thermometer to measure the surface temperature of the motor (normal ≤ 70 ℃). Overheating may indicate excessive load or poor heat dissipation.
Tightening of transmission components:
Check the tension and connecting bolts of transmission components such as belts, couplings, and gears, and adjust or replace them if necessary.
Hydraulic components (if there is an auxiliary hydraulic system):
Check the hydraulic oil level and quality, replace the filter element, and prevent impurities from entering the system.
3. Quarterly maintenance
Electrical component calibration:
Contact manufacturers or professionals to calibrate key components such as temperature sensors, pressure sensors, encoders, etc., to ensure accurate data.
Mechanical accuracy adjustment:
Check the parallelism of the mold opening and closing, the accuracy of the front and rear positions of the injection seat, and adjust them to the required range in the equipment manual.
Cooling system maintenance:
Clean the mold cooling water channel and material cylinder cooling ring to prevent scale blockage from affecting heat dissipation efficiency.
4. Annual maintenance
Comprehensive maintenance:
Disassemble and inspect the wear of the screw and barrel, and repair or replace them if necessary (if the chrome plating layer on the surface of the screw wears more than 0.1mm, it needs to be replaced).
Check the insulation resistance of the motor (should be ≥ 1M Ω), replace aging cables or wiring terminals.
System upgrade:
Upgrade the control software according to the manufacturer's recommendation, optimize operating parameters, and improve equipment performance.
3、 Key maintenance points for critical components
Servo motor and driver
Maintenance: Keep the surface of the motor clean and prevent metal shavings or oil stains from entering; Regularly check the connection wires of the motor encoder to prevent looseness and positional deviation.
Troubleshooting: If the motor overheats, vibrates, or reports an error, check the load, heat dissipation, and driver parameter settings.
Screw and barrel
Cleaning: Regularly use cleaning materials (such as screw cleaning agents) to remove residual materials from the barrel to prevent carbides from blocking the screw.
Replacement standard: When the straightness deviation of the screw exceeds 0.05mm/m or the wear of the inner diameter of the barrel exceeds 10% of the standard size, it needs to be replaced.
electric control system
Moisture prevention: Place desiccants inside the control cabinet and replace them regularly; Avoid using equipment in damp environments.
Anti interference: Keep away from interference sources such as high-power motors and frequency converters, and install filters if necessary.
Mold interface
Sealing: Check if there is any material or water leakage at the hot runner interface and cooling water interface of the mold, and replace the sealing ring in a timely manner.
Compatibility: When replacing the mold, confirm that its size, weight, and interface match the equipment to avoid overload operation.
4、 Common faults and preventive measures
Insufficient injection pressure
Reason: Screw wear, insufficient motor torque, or incorrect driver parameters.
Prevention: Regularly check the status of the screw, calibrate the driver parameters, and avoid long-term overload operation.
Abnormal noise or jamming during mold opening and closing
Reason: Insufficient lubrication of the guide rail, improper adjustment of mechanical balance, or excessive weight of the mold.
Prevention: Supplement lubricating grease periodically, adjust the parallelism of the opening and closing molds, and confirm that the mold weight is within the rated range of the equipment.
Temperature control malfunction
Reason: Damaged heating coil, poor contact of thermocouple, or malfunction of temperature control module.
Prevention: Regularly check the resistance of the heating coil (the normal value should be close to the nominal value), and replace the aging thermocouple.
Electrical faults (such as errors, crashes)
Reason: Power fluctuations, software conflicts, or hardware damage.
Prevention: Configure a regulated power supply, regularly backup control software, and avoid unauthorized personnel operations.
5、 Safety precautions
Power off operation: Before maintenance, be sure to cut off the power and hang a "Do not close" warning sign.
Protective equipment: When cleaning the material cylinder or replacing the screw, wear heat-resistant gloves, goggles, and dust masks.
Professional training: Non professionals are not allowed to disassemble electrical components or adjust driver parameters at will.
Compliant use: Strictly follow the equipment manual for operation, and prohibit over temperature, over pressure, or over speed operation.