1. Regularly check and lubricate all moving parts
Detailed description:
Injection molding machines have many high-frequency moving parts, such as guide pillars, sliders, templates, and connecting rods (especially in mechanical toggle structures). These parts will wear out due to friction after long-term operation. If they are not lubricated in time, they will cause unsmooth movement, or even jamming or damage.
Use lubricating oil or grease recommended by the manufacturer, and ensure that the lubrication pipeline is unobstructed.
A visual inspection can be carried out every shift, and inspection and oiling maintenance can be carried out every week or month.
Check whether the automatic oil supply of the lubrication system is normal, especially the pressure gauge, filter and oil level indicator of the centralized lubrication system.
If the movement is not smooth, the noise is abnormal, or the lubrication position is dry, it needs to be checked and repaired immediately.
2. Maintain the cleanliness and stability of the hydraulic system
Detailed description:
The hydraulic system is the key power source for the injection molding machine to perform mold opening, mold clamping, injection, pressure holding and other actions. The cleanliness, pressure and temperature of the hydraulic oil have a great impact on the life of the system.
Regularly check the hydraulic oil level, color and viscosity. Replace it in time when it changes color, has a strange smell, or is mixed with bubbles/impurities.
It is generally recommended to replace the hydraulic oil and the filter every 6,000 working hours or 12 months.
Check the system for leaks, especially the hose joints and seals.
Control the hydraulic oil temperature within the recommended range (usually 40°C ~ 50°C) to avoid high temperature aging or low temperature affecting the viscosity.
Check the pressure gauge, the sound of the pump and the response of the reversing valve to ensure the efficient operation of the hydraulic system.
3. Clean the heating system, barrel and screw regularly
Detailed description:
The barrel and screw are the core components for completing the melting and mixing of plastics. If carbon deposits or residues are not cleaned in time, it may cause material degradation, color pollution, and even block the system, affecting the quality of injection molding.
When changing different materials or colors, the screw should be cleaned (cleaning materials or idling + screw reversal operation can be used).
Thorough cleaning and maintenance can be carried out at regular working hours (such as every month), especially when processing corrosive materials such as glass fiber and flame retardants.
Check whether the heating ring, thermocouple and heating belt are intact to prevent the quality fluctuation of melt glue due to uneven heating.
Use temperature probe to calibrate the temperature control system regularly to ensure that the set temperature is consistent with the actual temperature.
Pay attention to whether there is a "dead corner" or carbon deposition in the screw segment, which will seriously affect the discharge and product performance.
4. Check the operation status of the electrical and control system
Detailed description:
Modern injection molding machines generally use servo control, electrical proportional valves, PLC controllers and a variety of sensors. Keeping these systems running stably is crucial for equipment accuracy and reliability.
Regularly check whether there is dust, water vapor or debris inside the electrical cabinet, and use dry air to blow if necessary.
Check whether the terminal is loose and whether the cable has wear, aging or rat bite marks.
Test whether the limit switch, proximity sensor, photoelectric element, etc. are sensitive to response, and replace the failed device in time.
Check whether the touch screen, operation panel, emergency stop button, etc. are working properly to avoid downtime due to misoperation.
Verifying the accuracy of encoders, displacement sensors and pressure sensors helps to maintain the consistency of the injection molding process.
5. Establish a detailed maintenance log and regular maintenance plan
Detailed description:
Maintenance logs and plans can help the team manage equipment status in an orderly manner, track potential problems, and avoid repeated failures.
Use a digital maintenance system or Excel spreadsheet to record the time, content, person in charge, and problems found for each maintenance.
Establish a regular inspection system (such as daily inspection, weekly minor maintenance, monthly mid-term maintenance, and annual overhaul).
For equipment failures, recording the failure phenomenon, treatment method, and recovery time will help form an experience library.
Use standard operating procedures (SOPs) uniformly during maintenance to improve operational standardization and safety.
Perform a comprehensive inspection at least once a year (including mechanical, electrical, and hydraulic systems), and contact the original manufacturer or third-party technical support for precision inspection and adjustment when necessary.
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