In injection molding, stability has always been one of the most important pursuits for injection molding manufacturers.
However, the actual production environment is far from ideal - temperature fluctuations, changes in raw material batches
moldFactors such as thermal expansion and long-term wear of the machine continue to interfere, making it difficult to maintain the pressure, position, and other parameters of the machine within the set optimal range. The consequences are very specific: flying edge (cape), short shot, burning, material leakage, size deviation, and even shutdown in severe cases.
Ideal stability is not static stability that relies on fixed initial parameters, but dynamic stability that allows machines to perceive, judge, and correct themselves.
This is exactly the question that WINTEC fully closed-loop control wants to answer.
As a brand under ENGEL Group, WINTEC injection molding machines (t-win hydraulic two plate machine and e-win full)
electric motor）In a series of high-precision
sensorWith the support of, real-time monitoring of various stages of injection molding is carried out, and data is fed back to the control system to achieve dynamic parameter optimization, thereby ensuring high-precision repeatability and process stability throughout the entire process.
WINTEC's fully closed-loop control concept can be condensed into four aspects——There is input, detection, feedback, and adjustmentMachines are not just "executing" instructions, but continuously "reviewing" their execution results and comparing them with set values. Once deviations are detected, they are immediately corrected. This article will break down WINTECThe four core closed-loop systems of fully closed-loop control - locking force, mold thickness, injection, and displacementExplore how "fully closed-loop control" can be transformed into yield on your production line, thereby improving investment return.
Stability is never 'unchanging', but 'dynamic persistence'.
1Closed loop one: Full closed-loop control of locking force - eliminating flying edges
Locking force is the most easily forgotten parameter in injection molding process, but it is one of the variables that cannot be ignored.
After continuous operation of the machine for a period of time, due to environmental and machine changes, the actual clamping force may appear too high or too low. When the locking force is low, the mold cavity is slightly stretched open under the injection pressure ("mold breathing"). Melt overflows from the parting surface to form burrs; When the locking force is too high, it may cause burning, increased mold wear, and unnecessary energy consumption.
WINTEC integrates high-precision sensors in the mold clamping unit to monitor the deformation of the template in real time, convert it into the actual locking force value, and provide feedback to the control system. Once the detected value deviates from the set value, the control system will immediately adjust - at the moment of each the first mock examination, when it is high, it will fall down, and when it is low, it will rise up, so that the clamping force of each the first mock examination is kept within the setting window.
Value to you: You no longer need to rely on the experience of the experienced master to manually adjust the locking force, and there will be no quality fluctuations due to changing shifts or batches.
2Closed loop II: full closed loop control of die thickness - let dieAlways' in place '
Locking force is the most easily forgotten parameter in injection molding process, but it is one of the variables that cannot be ignored.
After continuous operation of the machine for a period of time, due to environmental and machine changes, the actual clamping force may appear too high or too low. When the locking force is low, the mold cavity is slightly stretched open under the injection pressure ("mold breathing"). Melt overflows from the parting surface to form burrs; When the locking force is too high, it may cause burning, increased mold wear, and unnecessary energy consumption.
WINTEC integrates high-precision sensors in the mold clamping unit to monitor the deformation of the template in real time, convert it into the actual locking force value, and provide feedback to the control system. Once the detected value deviates from the set value, the control system will immediately adjust - at the moment of each the first mock examination, when it is high, it will fall down, and when it is low, it will rise up, so that the clamping force of each the first mock examination is kept within the setting window.
Value to you: You no longer need to rely on the experience of the experienced master to manually adjust the locking force, and there will be no quality fluctuations due to changing shifts or batches.
3Closed loop III: injection full closed loop control - let each the first mock examinationThe material quantity is precise and consistent
The pressure and speed stability during the injection stage directly determine the weight, size, and appearance of the product.
The WINTEC injection unit is equipped with high-precision sensors to monitor injection pressure in real-time. After setting the injection pressure, if the actual pressure is too high or too low due to factors such as changes in melt viscosity or wear of the check valve, the sensor will transmit a deviation signal back to the controller, and the control system will adjust it to the set value immediately.
This mechanism is consistent with the closed loop principle of the clamping force, but the process is more refined - it ensures that the amount of melt injected into the cavity of each the first mock examination is highly consistent with the pressure curve.
4Closed loop four: fully closed-loop control of injection movement - preventing material leakage,Guarding continuous production
The injection loop is the most easily overlooked among the four loops, but it has the highest cost once a problem occurs.
The deviation of the nozzle position or nozzle contact force can directly cause material leakage between the nozzle and the mold gate. Leakage not only causes waste of raw materials, but also forms a solidified layer at the mold gate, affecting the appearance of the product and, in severe cases, causing downtime for cleaning - and the impact of downtime on mass production often far exceeds that of single piece defects.
WINTEC adopts dual sensing in shooting control:
Nozzle contact force sensor:
Through the compression deformation of the spring mechanism, the sensor detects the distance between the nozzle and the template, converts it into the actual nozzle contact force, and feeds it back to the control system, thereby closed-loop controlling whether the actual value of the nozzle top contact force is consistent with the set value.
Shooting electronic ruler:
Real time notification to the controller whether the current shooting position is consistent with the set value.
If any of the two sets of signals deviate, the controller will immediately make adjustments to pull the position of the nozzle back to the set value in contact with the nozzle.
For e-win full electric motors, WINTEC also offers an adjustable full electric nozzle contact force system designed specifically for cleanroom operations, ensuring high performance and sustainability while improving energy efficiency.
In industries such as healthcare, electronics, optics, and food that require extremely high levels of cleanliness and continuity, the closed-loop system is not just an added bonus, but a necessary bottom line.
Four major closed-loop collaboration: from single point control to system stability
Many defects may appear the same, but the reasons behind them are different. Many times it is the result of multiple aspects not being optimized. The advantage of WINTEC is that the four closed loops work together under the same C3 control system, comprehensively investigating all possible sources of problems and reducing the possibility of problems and defects:
The data collected from the four closed-loop systems are collected in the C3 control system for dynamic parameter optimization. This is also why Shandong Weihai Ruimu Precision Machinery has been able to achieve high-precision product repeatability within 0.1%, efficiency improvement of 15%, and energy consumption reduction of more than 20% compared to other brands of equipment previously used after deploying more than 20 WINTEC t-win machines. Dong De, Technical Director of Ruimu, commented on Wintec's fully closed-loop control: "WINTEC's injection molding machines have achieved true fully closed-loop control. Every parameter - speed, pressure, position, etc. - is monitored in real-time through high-precision sensors, achieving seamless human-machine collaboration. "
Value Conversion for Potential Users
If you are evaluating injection molding equipment, you may compare WINTEC's fully closed-loop control with the following dimensions:
Quality dimension
Significant reduction in defects such as flying edges, short shots, and burning
The weight repeatability accuracy of the product can reach 0.1% (tested in the Ruimu case)
Efficiency dimension
No need for repeated manual parameter adjustment, no quality fluctuations during shift/material changes
Ruimu case test shows a 15% increase in efficiency
Cost dimension
Reduce energy consumption by more than 20% compared to domestic substitute equipment (tested in the Ruimu case)
Reduced mold wear and maintenance costs
Low defect rate reduces raw material waste
Stable dimension
The core components such as templates and pull rods have undergone 3 million cycles of maximum locking force verification, and the customer's factory has maintained zero cases of core component failure to this day
Ruimu's first WINTEC in 2018 has been performing as well as ever
Finally, stability is a quantifiable and verifiable ability
The competition in injection molding ultimately boils down to a competition for stability. When your customers require delivery within 1-3 days, demand a defect rate below a certain ppm value, and require each batch of goods to be consistent with the first piece, "machine can run" and "machine can be stable" are two completely different levels of capability.
WINTEC's fully closed-loop control breaks down "stability" from a slogan into four verifiable technical loops - locking force, mold thickness, injection, and displacement. Each closed loop is monitored by sensors, corrected by control systems, and recorded with data. This is not only a manifestation of technology, but also a solemn commitment to your production continuity and investment return.
Whether you are in the fields of automotive and transportation, packaging, electronics, medical technology, or technical injection molding, WINTEC's t-win (4500-40000 kN hydraulic two plate machine) or e-win (1000-5000 kN full electric motor) product series can combine ENGEL's solid industry application experience to provide you with injection molding solutions that meet your needs and are precisely adapted.
Stability, not machine rigidity - WINTEC allows it to maintain every set value while changing.
