Longsheng

4. Smart Monitoring and cost optimization solution

• The sensor network monitors mold temperature and pressure data in real time, using artificial intelligence algorithms to predict the wear cycle of key components for preventive maintenance.
• Application examples show that predictive maintenance can reduce unplanned downtime of household appliance mold by 60% and extend its service life by 20%.
• Whole life cycle cost model: Comprehensive evaluation of R&D, production losses, operation maintenance, etc., to avoid deviating from a single initial investment decision.

• Comparison:

5. Balance Strategy Summary Table

JS Company Practice Case:

• Car dashboard die: Made with H13 steel and hot runner system, it has a service life of 800,000 cycles and annual maintenance cost of less than $2,000.
• Consumer electronics shell mold: Pre-hardened steel+modular design with 300,000 times service life and no more than 15 minutes of mold change time.
• Medical silicone mold: Special alloy steel + corrosionresistant coating with a service life of 500,000 times and a failure rate of less than 0.01%.

How do the core components of an injection molding machine work together in terms of their respective functions?

Division of functions among core components

1.Injection unit

Function: Heat and melt solid plastic particles and inject mold cavity under high pressure (50-200MPa).

Key technologies:

• Screw drive: Plasticized and measured by screw rotation and propulsion (e.g. JS's servo motor drive system, injection accuracy ±0.5%).
• Temperature control: Segmented heating coils ensures uniform melt temperature (e.g. nylon material requires constant temperature of 260-280°C).
• Performance indicators: Injection speed up to 80mm/s, suitable for thin-walled packaging, thick-walled auto parts and other requirements.

2.Mold closing system

Function: Provide sufficient locking force (such as JS model up to 1200 tons) to prevent injection molds from cracking under pressure and complete opening and closing action of injection molds.

Key technologies:

• Hydraulic drive: Adjust oil pressure through proportional valve to achieve accurate locking force control (error less than 5%).
• Mold adjustment mechanism: Mold thickness can be adjusted automatically according to different production specifications (e.g. JS electric mold adjustment system, mold adjustment accuracy ±0.01mm).
• Performance indicators: Support multiple mold sizes (minimum 50×50mm, maximum 1500×1500mm).

3.Control system

Function: Coordinate the timing and sequence of injection molding, compression, cooling, mold opening, etc. to ensure the stability of process parameters.

Key technologies:

• PLC Programming: Supports customization of production processes (e.g. multistage injection molding, delayed mold opening).
• Data collection: Real-time monitoring of parameters such as pressure, temperature and location (system sampling frequency up to 1000Hz in JS system).
• Performance indicators: Circulation time can be shortened to 1.5 seconds (high speed model) with a yield ≥98%.

Collaboration of the three main components

1.Mold closing stage

• The mold closing system shuts down the die and the hydraulic cylinder exerts locking force (200 tons of locking force is required, for example, for the mold of the cell phone case).
• The control system detects the closing state of the die and triggers the injection signal.

2.Injection stage

• The injection unit screw is pushed forward and molten plastic is injected into the mold (e.g. PET preforms 120MPa) at a set pressure.
• The control system adjusts the screw speed (segmented acceleration) and retention time (e.g.10 seconds for car parts).

3.Cooling and mold opening

• The cooling water circuit carries heat through the mold and the control system monitors the mold temperature (e.g. ±1℃  fluctuation).
• When the pre-set cooling time is reached, the mold closing system opens and the ejection mechanism pushes out the finished product.

How can JS material database help customers shorten the material selection cycle?

1.Intelligent screening and matching

• Parameterized query: Supports rapid filtration by material type (e.g. ABS, PA66, liquid silicone), mechanical properties, processing process (injection temperature, mold steel adaptability), etc.
• Case matching: Based on project history data, successful material solutions are directly recommended for similar situations.

2.Performance visualization comparison

• Material comparison matrix: Detailed parameters such as shrinkage rate, thermal deformation temperature and impact strength of 50+ plastic materials, 20+ silica and composite materials are compared by graph.
• Real-time simulation feedback: linked to mold flow analysis software to predict material flow behavior and cooling efficiency in a particular die.

3.Industry certification and compliance

• Standardized labeling: Indicates whether the material complies with FDA, RoHS, UL, and other certification requirements (such as biocompatibility certification for medical-grade silicone), reducing customer self verification time.
• Eco-friendly materials exhibition area: Concentrated display green materials such as biodegradable plastics (PLA) and recycled PET to support sustainable development needs.

4.Advantages of JS Material Database

Summary

Injection molding realizes efficient transformation of plastic particles into complex components, and its technical value is reflected not only in the ultimate exploration of material properties, but also in the deep fusion of molding design and injection-molding processes. Through intelligent parameter control, modular mold development and digital production process, injection molding not only reduces the cost, but also endows the product with higher accuracy and reliability. In the future, with the improvement of algorithm optimization and automation level, injection molding technology will continue to push the boundaries and become a key force driving product innovation and industrial upgrading.

isenção de responsabilidade

O conteúdo desta página é apenas para fins informativos. Não se deve inferir que os parâmetros de desempenho, tolerâncias geométricas, recursos específicos de design, qualidade e tipo de material ou mão de obra que o fornecedor ou fabricante de terceiros fornecerá através da rede Jusheng. Esta é a responsabilidade do comprador peça uma cotação para peças para determinar os requisitos específicos para essas partes.

JS Team

JS é uma empresa líder do setor Focus em soluções de fabricação personalizadas. Com mais de 20 anos de experiência atendendo a mais de 5.000 clientes, nos concentramos em alta precisão usinagem cnc , Fabrication impressão 3D , Moldagem de injeção , , , , metal Serviços. Fornecemos soluções de fabricação rápidas, eficientes e de alta qualidade para os clientes em mais de 150 países em todo o mundo. Seja a produção de baixo volume ou a personalização em massa, podemos atender às suas necessidades com a entrega mais rápida em 24 horas. Escolha JS Technology Significa escolher eficiência, qualidade e profissionalismo. href = "https://jsrpm.com/"> jsrpm.com

FAQs

1.How important is mold design?

Mold design directly influences the shape, dimension accuracy and surface quality of the product. Good design can reduce shrinkage and deformation and improve production efficiency.

2.How to choose the right plastic material?

Materials such as ABS (durable) and silicone (soft) for sealing ring are selected according to product usage. Material performance determines processing temperature and finished product performance.

3.How do injection molding machines work?

The injection molding machine melts plastic particles by heating them and then injects them into the mold at high pressure. Once cooled, open the mould and remove the finished product. Its core components include injection unit, mold clamping system and control system.

4.How to reduce pollution during injection molding process?

Plastic injection molding can be effectively reduced by adopting recycled plastics (e.g. PCR materials), optimizing process parameters, reducing waste, installing exhaust gas filtration devices, adopting heat flow systems and reducing raw material losses.

Resources

Thermoplastic

Silicone rubber

Injection moulding

GloriaJS

Prototipagem rápida e especialista em fabricação rápida

Especialize -se em usinagem CNC, impressão 3D, fundição de uretano, ferramentas rápidas, moldagem por injeção, fundição de metal, chapa metal e extrusão.

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