5/31/2021

Delta’s Vertical Injection Molding Machine Solution Offers High Repeatability and Thin-wall Plastic Production

The convenience of our daily lives depends on a variety of plastic products, and the popularity of these products results in a high demand for relevant manufacturing equipment. One example is plastic injection molding machines, which are used to shape and process plastic materials. Injection molding machines are usually either horizontal or vertical. Although the former is more common, the vertical types are better fit for products with plug-ins, and therefore more suitable for electronic gadgets, home appliances, and packaging industries. All types use a screw or plunger to inject molten plastic material into a closed cavity for curing.



Today, as thin-walled plastic products such as sensor connectors, SD cards and stator injective hulls, gain increasing prevalence, the level of precision in temperature and injection speed control has become an important point to consider. Higher injection speeds, in addition to providing higher repeatability and stability, can reduce flow resistance to prevent the mold from cooling the plastic material for a thinner wall.



As traditional injection molding machines can no longer fulfill these needs, Delta developed a vertical injection molding machine solution for a client in Southern China. The solution implements a distributed architecture for faster response and utilizes a hybrid electric system to utilize the advantages of both hydraulic and electric servo systems. The electric servo system, enabling faster injection speeds, serves to control injection, material storage and tray rotation. The hydraulic servo system provides a larger clamping force, and is the perfect fit for mold opening and closing, as well as the movement of the ejector pin and the injection unit.



The solution adopts Delta’s PC-based Host Motion Controller PAC-MH1 Series for precise temperature control. The AC Servo System ASDA-A2 Series drives the injection unit forward for injecting, performs pressure holding, and then moves the unit backward for feeding. After cooling, the hydraulic system opens the mold and retrieves the products from the turntable. The injection pin removes the final product.



The Integration of the Hybrid Energy Saving System HES Series allows a faster response, controlling the motor to rotate at various speeds for different pressure levels. As the motor does not always operate at high speeds like traditional injection molding machines, it avoids unnecessary energy consumption and rising temperatures and extends the equipment life.



Delta’s vertical injection molding machine brings the following benefits to the client:


  • • Customized integration provides higher flexibility


Delta’s PC-Based Host Motion Controller PAC-MH1 Series is combined with the Motion Control Card DMCNET Series to provide reliable high-speed motion control communication. The whole production process, including closed-loop control, can be adjusted flexibly in real time. Customizable integration of the operation interface, programs and motion control makes operation easier.

 

  • • Electric servo system controls plastic injection for thinner walls


The AC Servo System ASDA-A2 Series has a built-in injection axis motion curve to reduce the dependence on bus bandwidth. Through servo control of injection and material storage, flow resistance can be reduced for higher repeatability and thinner walls.

 

  • • Integrated drives, motors and hydraulic technologies reduce energy waste by high pressure throttling


With excellent performance in pressure and flow control, Delta’s Hybrid Energy Saving System HES Series cools down oil temperature at the stages of pressure holding and cooling to reduce oil consumption and required tank capacity. The system, compared with common dosing pump hydraulic systems, saves more energy while providing higher capacity and precision.



Delta’s vertical injection molding machine solution integrates the PC-Based Host Motion Controller PAC-MH1 Series with servo systems. This hybrid electric system solution enables high injection speed and flexibility, and is applicable to various industries that manufacture lightweight products with high repeatability, including automobiles and electronics.

News Source:IABG MKT Dept.