This document provides an overview of injection molding machines and their components and operation. It begins with defining injection molding as a process that uses heat and pressure to mold raw plastic materials into products within a reusable metal mold. It then describes the main parts of the machine including the clamping unit, injection unit, mold, and electric panel board. The document provides details on the injection and clamping processes, parameter settings, common product defects, and safety procedures. It also includes a section for maintenance technicians that covers the machine's energy flow, control system, key equipment, and safety checks.

1. Introduction to Injection
Molding Machine
Presented by :
Samir Ahmed
Deputy Director,
Electronics & Automation- ESM,
Walton Hi-Tech Industries PLC.

2. At a Glance
 What is injection molding Machine ?
 What is the process of Producing plastic product?
 How Machine function ?
 Main parts of machine.
 Some parameter setting.
 Basic troubleshooting (product).
 Safety .
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3. What is injection molding
machine?
 There are two principal methods for processing plastics.
 1. Extrusion
 2. Injection molding.
 A machine which is used to make different types of plastic product by
plasticizing row martial and Inject at high pressure into a reusable
interlocking metal frame (called mould) can define as injection
molding machine.
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4. 4
Clamping Unit Injection Unit
Mold Electric Panel board

5. Injection unit
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6. Injection Unit
6

7. Clamping Unit
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8. Clumping Unit
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9. Mould:  Mould or die are the common terms used to
describe the tool used to produce plastic parts in
molding.
 Type:
 cold runner, two plate mold
 cold runner, three plate mold
 hot runner mold
 insulated runner mold
 According to construction- Double Platte, Triple Plate etc
 According to runner type- Cold runner ,Hot runner .
 According to Cavity- 1, 2,3,4 ….N
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Useful website: http://www.custompartnet.com/wu/InjectionMolding

10. Mould:
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Different Parts of Mould:

11. Mould of Blow Molding Machine:
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12. Some row materials:
 Low Density Polyethylene (LDPE)
 High Density Polyethylene (HDPE)
 Polyethylene Terephtalate (PET)
 Polypropylene (PP)
 Polyvinyl Chloride (PVC)
 Polycarbonate (PC)
 Polystyrene (PS)
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13. Operation:
 Machine work according to the bellow Steps.
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Mold Close Injection
Holding
(optional)
Charging
Suck
Back(optional)
Cooling
Mold Opening
Core Open
(optional)
Ejector
Forward/&
Air Blast
4b
2 3 4a
1
6
7
8
Product drop
and Ejector
back
9
Core close
( optional)
10 4

14. Continue
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15. Injection unit & mold :
15

16. Injection Unit (SCREW)
16

17. Key Board and HMI
17

18. Parameter setting:
 Clamping setting :
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19. Continue:
 Injection:
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20. Continue:
 Charging:
20

21. Continue:
 Ejector:
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22. Continue:
 Air Blast:
22

23. Continue
 Core setting:
23

24. Continue
 Temperature setting:
24

25. Continue:
 Injection unit & adjust setting:
25

26. Continue:
Alarm:
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27. Continue:
Fast set:
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28. Common Plastic Product defects :
 Problems:
Short shot or short molded
Flash
Flow marks
Silver streaking
Sink marks
Burn marks/Black spot
Filler marks/White spot etc.
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Helpful apps for android phone: i-moulder
https://www.sabic.com/europe/en/products-
services/plastics/troubleshootingguide

29. Continue
Short shot or short molded
 Ⅰ. Description:
 A molded product that is incomplete because the mold cavity was not filled completely.
 Ⅱ. Causes :
 Insufficient injection-molding machine performance (shot capacity, plasticizing capacity,
etc.)
 Poor material flow ability
 Gate cross-section surface area is too small. Molded product thickness is too thin.
 Poor gas venting.
 Ⅲ. Countermeasures:
 <Molding equipment>
 Increase the amount of material feed. If material feed is still insufficient at maximum
material feed capacity, change to a larger capacity machine.
 Install a screw with a back-flow check valve.
 Increase injection pressure
 Raise the cylinder temperature setting. Raise the nozzle temperature, too.
 Make sure there are no severed lines to the heater.
 Make sure the nozzle is not clogged. If the nozzle clogs frequently, raise the mold
temperature or shorten the cycle time.
 Increase injection speed
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30. Continue
 <Mold>
 Raise the mold temperature.
 Increase the mold gas release.
 Increase gate cross section surface area.
 Increase the molded product thickness.
 Add ribs to the molded product design to improve flowability.
 <Materials>
 Choose a low-viscosity high flow material type.
 Apply surface lubricant. (Add 0.05-0.1% by weight.)
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31. Safety Check
 Mechanical Safety
 Hydraulic safety
 Front door safety limit
 Rear door safety limit
 Nozzle safety gate
 Nozzle safety gate limit
 Body Earth
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32.  Thanks
 The End
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33. PART -2
(Only for Maintenance Engineer & Technician)
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34. Energy Conversation
 Electric Energy
3 ,380V AC
 Main oil Pump motor
Mechanical energy
 Main oil Pump
Hydraulic oil Pressure
 Directional /Proportional valve
Hydraulic oil Pressure
 Cylinder/& Hydraulic motor
Mechanical energy
 Mechanical Movement
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Energy flow chart

35. Data sheet of 380T M/C
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36. Control system
36 Control System
HMI
Controller( Techmation/KEBA)
Digital Input Digital Output Temperature
Input
Analog
Input/output
1.Mold close valve
2.Mold close fast valve
3.Mold open valve
4.Injection valve
5.Suck back valve
6.Charge valve
7.Nozle forward valve
8.Nozel backward
9.Mold adjust forward
10.Mold adjust backward
11.Core in/out
12.Air valve 1 &2
13.Motor on/off
14.Heater on/off
15.Oil cool on /off
16 .Ejector forward
/backward
17.Lubrication on
18.Heat 1-10 on/off
1.Noizzle safety limit
2. Carries forward end
limit
3.Clamping limit
4.Ejector back limit/sensor
5.Hydrolic safety limit
6.Front door safety limit
7.Rear door safety limit
8.Screw sensor
9.Mold adjust sensor
10.State of oil filter
11.Oil level check
12.Enough lubrication
pressure
13.Core In/Out limit, and
So on.
1.Screw Position
2.Mould Position
3.Ejector Position
4.System Pressure
sensor
5.System Pressure
6.System Flow
7.Back Pressure
1. Barrel Temperature 1
2. Barrel Temperature 2
3. Barrel Temperature 3
4. Barrel Temperature 4
5. Barrel Temperature5
6. Barrel Temperature6
7. Barrel Temperature7
8 Barrel Temperature8
9. Barrel Temperature9
10. Oil temperature

37. Some Equipments of IMM :
1.Directional Valve
2.Hydraulic cylinder
37
3.Linier Position
transducer

38. Continue…
 4.Heat Exchanger
 5.Hydrolic Motor
38

39. Continue
 6.Limit Switch
 Type:
 According to connection:
 1) 1 NO 1 NC Option
 2) 2 NC option
 3) 2 NO Potion
 According to
 Horizontal , vertical etc.
 7. Screw:
Screw Tip,
Non return Valve,
Mixing Zone,
L/D ratio,
Pitch
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40. Continue:
 8.Solenoied Coil for Hydraulic valve
 24 VDC
 9.Grease Pump
 3 Phase, 380VAC
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41. Continue
 10. Sensor (All area):
a) Proximity sensor:
Size: Cylinder type ,Rectangular
Type: 3 Wire PNP NO 0-30 VDC
3 Wire PNP NC 0-30 VDC
3 Wire NPN NO 0-30 VDC
3 Wire NPN NC 0-30 VDC
b) Photo sensor (all area):
3 Wire PNP NO 0-30 VDC
3 Wire PNP NC 0-30 VDC
3 Wire NPN NO 0-30 VDC
3 Wire NPN NC 0-30 VDC
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42. Continue
11. Emergency Switch:
Press to stop all operation at
Emergency situation.
12.Hydrolic Pump:
Max. Pressure(Mpa)
Capacity (cc/rev)
RPM
13. Servo Motor:
42

43. Continue
 13 B. Teflon Coupling
Use for coupling motor and pump
14 . Hydraulic Hose Pipe:
Use to transmit hydraulic oil pressere
43

44. Continue
15. Motor Frequency Drive (inverter):
Use to control and drive servo motor according
to the required pressure and flow setting
 Controller:
Techmation, KEBA…..Etc
Pressure Flow control card
Temperature control card
Digital input output card
CPU card
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45. Continue
 16.Solid state relay:
Contract Channel : 1 (220 VAC)
Control : 3-32 VDC
Use at IMM: Heater circuit
17. Magnetic contractor:
Channel: 3 Line(Phase),380 V AC
Control: 220VAC (Coil)
Use at IMM : Motor circuit
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46. Continue
18.Air Solenoid valve:
2 Way, 24 V DC.
Also use 2 Way 220 VAC
It has some other types.
19. Cooling Fan :
Single Phase, 220 V AC
Size: 4”, 6” & 8” etc.
Use at IMM: Electric Panel
box cooling.
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47. Continue
20. Fuse:
Glass fuse,
Ceramics fuse
Use at IMM : Heater Circuit
21.Circuit Breaker:
MCB, MCCB, EMCB
SPMCB, DP MCB, TP MCB
Rating: 2 ,6,10,16,32, 63,80, 100A ……
( picture contain other equipment also)
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48. Continue
 22.Pressure Gauge :
 23. Ball Bearing :
48

49. Continue
 24. Heater:
 220V AC.
 Different size and watt
25. Y-Ring:
Example size: 44 x 55 x 7
Use at cylinder
26. Dust seal:
Example size: 44 x 55 x 7
Use at cylinder
49

50. Continue:
27. Current & volt meter :
Use at IMM: Measure flow voltage & Pressure Current
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51. Safety Check
 Mechanical Safety
 Hydraulic safety
 Front door safety limit
 Rear door safety limit
 Nozzle safety gate
 Nozzle safety gate limit
 Body Earth
51

52. Nozzle safety guard
 Check guard
 Check Limit condition
 Check Transparent sheet of guard
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53.  Thanks
 The End
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