1、 Hydraulic system malfunction

1. Hydraulic oil leakage
   • Fault phenomenonHydraulic oil leaks from the cylinder, oil pipe, joint and other parts, causing a decrease in system pressure and affecting the normal operation of the injection machine.
   • Possible reasonsSeal aging or damage, oil pipe rupture or loose joints.
   • solutionReplace seals, repair or replace oil pipes, and tighten joints.
2. Unstable hydraulic system pressure
   • Fault phenomenonThe injection pressure fluctuates greatly, affecting the quality of the product.
   • Possible reasonsWear of hydraulic pump, malfunction of relief valve, and blockage of oil circuit.
   • solutionReplace the hydraulic pump, inspect or replace the relief valve, and clean the oil circuit.
3. Hydraulic pump has loud noise
   • Fault phenomenonAbnormal noise is generated during the operation of the hydraulic pump.
   • Possible reasonsInternal wear and tear of hydraulic pump, oil contamination, and intake of air.
   • solutionReplace the hydraulic pump, replace the hydraulic oil, and check and eliminate the air in the oil circuit.

2、 Electrical system malfunction

1. Control system unresponsive
   • Fault phenomenonThe operation button or touch screen is unresponsive, and the device cannot be started.
   • Possible reasonsPower failure, open circuit in control circuit, PLC or controller failure.
   • solutionCheck the power connection, repair the control circuit, and replace the PLC or controller.
2. Abnormal sensor signal
   • Fault phenomenonTemperature, pressure and other sensors have inaccurate readings or no display.
   • Possible reasonsSensor damage, poor circuit contact, signal interference.
   • solutionReplace sensors, check and repair circuits, and add shielding or filtering measures.
3. Motor overheating or unable to start
   • Fault phenomenonThe motor temperature is too high or cannot start normally.
   • Possible reasonsMotor overload, unstable power supply voltage, short circuit in motor winding.
   • solutionReduce load, stabilize power supply voltage, and repair or replace the motor.

3、 Mechanical component failure

1. Screw stuck or difficult to rotate
   • Fault phenomenonThe screw cannot rotate normally, resulting in the inability to perform injection.
   • Possible reasonsThere are foreign objects in the barrel, the gap between the screw and the barrel is too small, and the screw is worn.
   • solutionClean the material cylinder, adjust the gap between the screw and the material cylinder, and replace the screw.
2. Mold closing mechanism malfunction
   • Fault phenomenonThe mold is not tightly closed or cannot be closed, which affects the molding of the product.
   • Possible reasonsLeakage of the clamping oil cylinder, wear of the clamping mechanism, and improper installation of the mold.
   • solutionReplace the sealing components of the clamping cylinder, repair or replace the clamping mechanism, and reinstall the mold.
3. The injection seat does not move smoothly
   • Fault phenomenonStuck or abnormal noise when the injection seat moves.
   • Possible reasonsWear and tear of the guide rail, insufficient lubrication, and malfunction of the drive mechanism.
   • solutionReplace the guide rail, increase lubrication, inspect or replace the drive mechanism.

4、 Heating and temperature control system malfunction

1. Uneven temperature of the material cylinder
   • Fault phenomenonThe temperature difference between each section of the barrel is large, which affects the plasticizing effect of the rubber.
   • Possible reasonsHeater damage, thermocouple malfunction, improper temperature control system parameter settings.
   • solutionReplace the heater, replace the thermocouple, and adjust the temperature control system parameters.
2. Temperature out of control
   • Fault phenomenonThe temperature of the material barrel is too high or too low to stabilize at the set value.
   • Possible reasonsTemperature controller malfunction, damaged solid-state relay, poor heat dissipation.
   • solutionReplace the temperature controller, replace the solid-state relay, and improve the heat dissipation conditions.

5、 Injection and pressure maintenance system malfunction

1. Unstable injection volume
   • Fault phenomenonThe amount of rubber injected each time is inconsistent, which affects the weight of the product.
   • Possible reasonsUnstable back pressure of the screw, leakage of the injection cylinder, and inaccurate measurement.
   • solutionAdjust screw back pressure, replace injection cylinder seals, calibrate measuring devices.
2. Insufficient holding pressure
   • Fault phenomenonThe product shrinks or deforms during the pressure holding stage.
   • Possible reasonsInsufficient pressure in the holding cylinder, short holding time setting, and poor mold exhaust.
   • solutionAdjust the pressure of the holding cylinder, extend the holding time, and improve the exhaust of the mold.

6、 Safety and protection system malfunction

1. Security door failure
   • Fault phenomenonWhen the safety door is opened, the equipment continues to operate, posing a safety hazard.
   • Possible reasonsDamaged safety door switch, circuit malfunction, and safety relay failure.
   • solutionReplace the safety door switch, repair the circuit, and replace the safety relay.
2. Emergency stop button malfunction
   • Fault phenomenonThe device cannot stop immediately after pressing the emergency stop button.
   • Possible reasonsThe emergency stop button is damaged, the emergency stop circuit is open, and the controller is faulty.
   • solutionReplace the emergency stop button, repair the emergency stop circuit, inspect or replace the controller.