Injection moulding machine components
2 month ago
Product details
Injection Molding Machine Parts - Proportional Valve (Detailed Introduction)
I. Core Functions
Proportional valves precisely control the flow, pressure, or direction of hydraulic systems via electrical signals (e.g., current or voltage), enabling dynamic adjustments for critical injection molding machine operations:
1. Injection Phase: Regulates the injection speed and pressure of molten plastic to ensure uniform filling.
2. Packing Phase: Maintains pressure in the mold cavity to prevent product shrinkage or sink marks.
3. Mold Opening/Closing Phase: Adjusts the speed and force of mold movement to protect molds and enhance efficiency.
4. Ejection Phase: Controls the speed and force of ejector pins for smooth product demolding.
II. Leading Brands and Technical Features
1. Bosch Rexroth
• Model Examples: 4WRA, 4WREE, 4WRKE Series
• Technical Advantages:
• High-precision closed-loop control with ultra-fast response times (≤10ms).
• Strong resistance to contamination, suitable for complex hydraulic environments.
• Integrated electronic amplifiers simplify system commissioning.
• Application Cases:
• Used in Haitian injection molding machines for precise matching of injection speed and pressure.
2. Moog
• Model Examples: D661, D68X Series
• Technical Advantages:
• Direct-drive spool design for extremely fast dynamic response (≤5ms).
• Low-leakage design reduces hydraulic oil consumption and energy waste.
• Simulation-optimized spool structure for high-speed injection molding.
• Application Cases:
• Sumitomo Demag’s El-Exis series employs Moog D68X valves to shorten cycle times and improve repeatability.
3. YUKEN
• Model Examples: EFBG, EDG Series
• Technical Advantages:
• Cost-effective, ideal for small-to-medium-sized injection molding machines.
• Compact structure for easy installation and maintenance.
• Explosion-proof designs available for special working conditions.
• Application Cases:
• Standard equipment for domestic manufacturers like Chen Hsong and L.K. Technology, balancing performance and cost.
III. Key Selection Parameters
1. Flow Range: Choose based on machine tonnage (e.g., small machines: 10–50 L/min; large machines: 100–300 L/min).
2. Pressure Rating: Must meet the machine’s maximum operating pressure (e.g., 350 bar).
3. Response Time: High-speed molding requires ≤10ms; standard machines can tolerate ≤20ms.
4. Control Method:
• Analog control (4–20mA/0–10V): Low cost, suitable for simple systems.
• Digital control (CANopen, EtherCAT): High noise immunity, supports multi-axis synchronization.
5. Environmental Adaptability:
• Dust/water resistance (e.g., IP65) for high-temperature, oil-contaminated workshops.
• Corrosion-resistant materials (e.g., stainless steel valves) for special plastic processing.
IV. Industry Application Trends
1. Energy Efficiency:
• Low-leakage spool designs reduce hydraulic system energy consumption (e.g., Moog valves cut oil usage by 15%).
• Integrated servo drives enable on-demand oil supply, further saving 30%+ energy.
2. Smart Integration:
• IoT-enabled real-time monitoring of valve status (e.g., pressure fluctuations, temperature anomalies) for predictive maintenance.
• Digital twin technology optimizes valve parameters, shortening commissioning time.
3. Modularization:
• Proportional valves integrated with sensors and controllers into modular units (e.g., Bosch Rexroth’s "Smart Function Kit") simplify system design.
V. Maintenance and Troubleshooting
1. Routine Inspections
• Monitor hydraulic oil cleanliness (NAS 1638 standard ≤ Grade 7) to prevent spool sticking.
• Check electrical connections for looseness to avoid signal interference.
2. Common Failures
• Sluggish Response: Worn spool or contaminated oil; clean or replace the spool.
• Pressure Fluctuations: Amplifier failure or unstable power supply; inspect circuits and power quality.
• Leakage: Aged seals; replace O-rings or composite gaskets.
3. Maintenance Recommendations
• Replace hydraulic oil regularly (every 2,000 operating hours or annually).
• Use genuine spare parts to avoid compatibility issues.
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