During the long-term operation of injection molding machines, various common faults are prone to occur, affecting production efficiency and product quality. To help operators quickly troubleshoot and efficiently solve faults,DKM injection molding machine team has organized and compiled the following injection molding machine troubleshooting guidelines and corresponding solutions for injection molding machines, which we hope will be helpful to you.various common faults, their causes and corresponding solutions are sorted out as follows:
Fault Causes: Power supply fuse blown; poor contact of start button connector; overload relay tripped; main circuit line or component failure.
Solutions: Replace the fuse of matching specification; inspect the start button connector and replace it in time if contact is poor; reset the overload relay, investigate and handle the cause of overload; inspect or replace the relevant faulty components of the main circuit to ensure unobstructed circuit.
Fault Causes: Air leakage on the suction side of the oil pump, leading to air suction; clogged oil filter, affecting oil flow; wear of internal components of the oil pump, resulting in decreased performance; too low oil level in the fuel tank, making the oil pump unable to suck oil normally.
Solutions: Inspect and repair the connector on the suction side of the oil pump to eliminate air leakage; disassemble and clean the oil filter to remove blocked impurities; inspect the worn internal components of the oil pump and replace them in time if they cannot be repaired; add hydraulic oil of specified specification to the standard oil level.
Fault Causes: Main pressure valve failure, unable to adjust pressure normally; amplifier board damage, abnormal signal transmission; loose or damaged connecting flange between motor and oil pump; solenoid coil of servo valve falling off or poor contact.
Solutions: Disassemble and inspect the main pressure valve to repair the faulty part; inspect or replace the damaged amplifier board; inspect and fasten the connecting flange between the motor and the oil pump, and replace it in time if it is damaged; reinstall the solenoid coil of the servo valve to ensure firm connection.
Fault Causes: Ejector pin not retracted in place, triggering limit protection; safety door not fully closed, safety interlock device not unlocked; manipulator not sending mold clamping signal; abnormal or faulty position ruler data; mold clamping directional valve stuck and not acting.
Solutions: Check the retraction status of the ejector pin to ensure it retracts to the specified position; check the closing status of the safety door, inspect the safety door circuit, oil circuit and mechanical safety to ensure normal interlock; inspect the signal transmission of the manipulator to restore the output of the mold clamping signal; check the calibration of the position ruler, inspect or replace the faulty position ruler; check the power supply of the directional valve, disassemble and clean the valve core, and handle the stuck problem.
Fault Causes: Failure of the mold opening directional valve, unable to reverse normally; insufficient adjustment of mold opening pressure; mechanical jamming of the toggle mechanism; position ruler failure, abnormal signal feedback.
Solutions: Disassemble and inspect the mold opening directional valve, repair or replace the faulty valve body; adjust the mold opening pressure to a reasonable range; inspect the toggle mechanism, remove stuck foreign objects, and lubricate relevant components; inspect or replace the faulty position ruler and calibrate the signal.
Fault Causes: Injection molding machine Manipulator not sending ejection signal; mold opening action not completed, triggering ejection interlock protection; ejection solenoid valve failure, unable to act normally.
Solutions: Check the signal output of the manipulator, investigate and repair signal transmission faults; confirm that the mold opening action is completely completed to meet the ejection conditions; inspect the ejection solenoid valve, clean the valve core or replace the damaged valve body.
Fault Causes: Poor sealing and invalid adjustment of the pressure regulating valve; air mixed in the hydraulic cylinder, affecting pressure transmission; pressure regulating valve failure, unable to adjust pressure normally.
Solutions: Disassemble the pressure regulating valve, check the sealing condition and repair it, then readjust the pressure; perform exhaust operation on the hydraulic cylinder to ensure no air in the cylinder; inspect or replace the faulty pressure regulating valve.
Fault Causes: Poor operation of the injection solenoid valve, abnormal commutation; failure of the pressure regulating valve, insufficient pressure output; blocked injection nozzle, making the material liquid unable to flow out; too low temperature of the injection nozzle or the temperature of each section of the barrel not meeting the set requirements, resulting in poor plasticization of the material liquid.
Solutions: Check the injection solenoid valve and safety valve, repair or replace faulty components; check the injection nozzle and clean blocked impurities; check the temperature of each section of the barrel and the injection nozzle, adjust to the set standard to ensure qualified plasticization of the material liquid.
Fault Causes: Feeding solenoid valve failure; improper back pressure adjustment, affecting feeding action; abnormal barrel temperature, too high or too low viscosity of the material liquid; screw breakage, severe wear or slipping, unable to transport the material liquid normally.
Solutions: Inspect the injection molding machine feeding solenoid valve to ensure normal operation; readjust the back pressure to a reasonable range; check the injection molding machine barrel temperature and adjust to the plasticizing temperature suitable for the raw material; inspect the screw and replace it in time if it is severely worn or broken.
Fault Causes: Circuit breaker failure, unable to control the on-off of electric heating; damaged heating coil, unable to generate heat normally; damaged thermocouple, abnormal temperature detection; short circuit or grounding of the electric heating line, leading to circuit failure.
Solutions: Replace the damaged circuit breaker, heating coil and thermocouple; check the electric heating line, repair short circuit or grounding faults, and ensure safe and unobstructed line.
Fault Causes: Injection molding machine operating pressure exceeding the rated range; wear of internal components of the oil pump, decreased efficiency; hydraulic oil viscosity not meeting requirements, poor fluidity; insufficient oil volume in the fuel tank, poor heat dissipation; blocked cooler, poor heat dissipation effect; loose fixing screws of the oil cylinder, leading to oil leakage.
Solutions: Check the operation status of the oil pump, adjust the equipment operating pressure to the rated range; inspect or replace the worn oil pump components; replace the hydraulic oil of specified specification to ensure suitable viscosity; add hydraulic oil to the standard oil level; clean the cooler, remove blocked impurities, and restore the heat dissipation function; fasten the fixing screws of the oil cylinder, investigate and repair the oil leakage part.
Fault Causes: Improper pressure adjustment, excessive pressure fluctuation in the valve body; valve core stuck, unsmooth movement; aging and damage of the solenoid coil, insufficient electromagnetic force; loose coil wiring or abnormal voltage, leading to unstable operation.
Solutions: Readjust the pressure to ensure stable pressure in the valve body; disassemble and clean the valve core, remove stuck impurities, and lubricate relevant components; replace the aging and damaged solenoid coil; check the coil wiring and power supply voltage to ensure firm wiring and stable voltage.
Note: The above solutions need to be gradually investigated and standardized according to the actual on-site fault conditions. When Injection Molding Machine troubleshooting and handling faults, operators must strictly follow the equipment safety operation procedures and take good safety protection measures; if the fault is relatively complex and cannot be solved by themselves, it is recommended to contact professional maintenance personnel in time to avoid fault expansion, resulting in equipment damage or safety accidents. Welcome find DKM team, below is our online communication email: dakumar-serve@dakumar.com whatsapp: 008615067608197
During the long-term operation of injection molding machines, various common faults are prone to occur, affecting production efficiency and product quality. To help operators quickly troubleshoot and efficiently solve faults,DKM injection molding machine team has organized and compiled the following injection molding machine troubleshooting guidelines and corresponding solutions for injection molding machines, which we hope will be helpful to you.various common faults, their causes and corresponding solutions are sorted out as follows:
Fault Causes: Power supply fuse blown; poor contact of start button connector; overload relay tripped; main circuit line or component failure.
Solutions: Replace the fuse of matching specification; inspect the start button connector and replace it in time if contact is poor; reset the overload relay, investigate and handle the cause of overload; inspect or replace the relevant faulty components of the main circuit to ensure unobstructed circuit.
Fault Causes: Air leakage on the suction side of the oil pump, leading to air suction; clogged oil filter, affecting oil flow; wear of internal components of the oil pump, resulting in decreased performance; too low oil level in the fuel tank, making the oil pump unable to suck oil normally.
Solutions: Inspect and repair the connector on the suction side of the oil pump to eliminate air leakage; disassemble and clean the oil filter to remove blocked impurities; inspect the worn internal components of the oil pump and replace them in time if they cannot be repaired; add hydraulic oil of specified specification to the standard oil level.
Fault Causes: Main pressure valve failure, unable to adjust pressure normally; amplifier board damage, abnormal signal transmission; loose or damaged connecting flange between motor and oil pump; solenoid coil of servo valve falling off or poor contact.
Solutions: Disassemble and inspect the main pressure valve to repair the faulty part; inspect or replace the damaged amplifier board; inspect and fasten the connecting flange between the motor and the oil pump, and replace it in time if it is damaged; reinstall the solenoid coil of the servo valve to ensure firm connection.
Fault Causes: Ejector pin not retracted in place, triggering limit protection; safety door not fully closed, safety interlock device not unlocked; manipulator not sending mold clamping signal; abnormal or faulty position ruler data; mold clamping directional valve stuck and not acting.
Solutions: Check the retraction status of the ejector pin to ensure it retracts to the specified position; check the closing status of the safety door, inspect the safety door circuit, oil circuit and mechanical safety to ensure normal interlock; inspect the signal transmission of the manipulator to restore the output of the mold clamping signal; check the calibration of the position ruler, inspect or replace the faulty position ruler; check the power supply of the directional valve, disassemble and clean the valve core, and handle the stuck problem.
Fault Causes: Failure of the mold opening directional valve, unable to reverse normally; insufficient adjustment of mold opening pressure; mechanical jamming of the toggle mechanism; position ruler failure, abnormal signal feedback.
Solutions: Disassemble and inspect the mold opening directional valve, repair or replace the faulty valve body; adjust the mold opening pressure to a reasonable range; inspect the toggle mechanism, remove stuck foreign objects, and lubricate relevant components; inspect or replace the faulty position ruler and calibrate the signal.
Fault Causes: Injection molding machine Manipulator not sending ejection signal; mold opening action not completed, triggering ejection interlock protection; ejection solenoid valve failure, unable to act normally.
Solutions: Check the signal output of the manipulator, investigate and repair signal transmission faults; confirm that the mold opening action is completely completed to meet the ejection conditions; inspect the ejection solenoid valve, clean the valve core or replace the damaged valve body.
Fault Causes: Poor sealing and invalid adjustment of the pressure regulating valve; air mixed in the hydraulic cylinder, affecting pressure transmission; pressure regulating valve failure, unable to adjust pressure normally.
Solutions: Disassemble the pressure regulating valve, check the sealing condition and repair it, then readjust the pressure; perform exhaust operation on the hydraulic cylinder to ensure no air in the cylinder; inspect or replace the faulty pressure regulating valve.
Fault Causes: Poor operation of the injection solenoid valve, abnormal commutation; failure of the pressure regulating valve, insufficient pressure output; blocked injection nozzle, making the material liquid unable to flow out; too low temperature of the injection nozzle or the temperature of each section of the barrel not meeting the set requirements, resulting in poor plasticization of the material liquid.
Solutions: Check the injection solenoid valve and safety valve, repair or replace faulty components; check the injection nozzle and clean blocked impurities; check the temperature of each section of the barrel and the injection nozzle, adjust to the set standard to ensure qualified plasticization of the material liquid.
Fault Causes: Feeding solenoid valve failure; improper back pressure adjustment, affecting feeding action; abnormal barrel temperature, too high or too low viscosity of the material liquid; screw breakage, severe wear or slipping, unable to transport the material liquid normally.
Solutions: Inspect the injection molding machine feeding solenoid valve to ensure normal operation; readjust the back pressure to a reasonable range; check the injection molding machine barrel temperature and adjust to the plasticizing temperature suitable for the raw material; inspect the screw and replace it in time if it is severely worn or broken.
Fault Causes: Circuit breaker failure, unable to control the on-off of electric heating; damaged heating coil, unable to generate heat normally; damaged thermocouple, abnormal temperature detection; short circuit or grounding of the electric heating line, leading to circuit failure.
Solutions: Replace the damaged circuit breaker, heating coil and ther mocouple; check the electric heating line, repair short circuit or grounding faults, and ensure safe and unobstructed line.
Fault Causes: Injection molding machine operating pressure exceeding the rated range; wear of internal components of the oil pump, decreased efficiency; hydraulic oil viscosity not meeting requirements, poor fluidity; insufficient oil volume in the fuel tank, poor heat dissipation; blocked cooler, poor heat dissipation effect; loose fixing screws of the oil cylinder, leading to oil leakage.
Solutions: Check the operation status of the oil pump, adjust the equipment operating pressure to the rated range; inspect or replace the worn oil pump components; replace the hydraulic oil of specified specification to ensure suitable viscosity; add hydraulic oil to the standard oil level; clean the cooler, remove blocked impurities, and restore the heat dissipation function; fasten the fixing screws of the oil cylinder, investigate and repair the oil leakage part.
Fault Causes: Improper pressure adjustment, excessive pressure fluctuation in the valve body; valve core stuck, unsmooth movement; aging and damage of the solenoid coil, insufficient electromagnetic force; loose coil wiring or abnormal voltage, leading to unstable operation.
Solutions: Readjust the pressure to ensure stable pressure in the valve body; disassemble and clean the valve core, remove stuck impurities, and lubricate relevant components; replace the aging and damaged solenoid coil; check the coil wiring and power supply voltage to ensure firm wiring and stable voltage.
Note: The above solutions need to be gradually investigated and standardized according to the actual on-site fault conditions. When Injection Molding Machine troubleshooting and handling faults, operators must strictly follow the equipment safety operation procedures and take good safety protection measures; if the fault is relatively complex and cannot be solved by themselves, it is recommended to contact professional maintenance personnel in time to avoid fault expansion, resulting in equipment damage or safety accidents.
Welcome find DKM team, below is our online communication email: dakumar-serve@dakumar.com whatsapp: 008615067608197
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