Mould temperature controller for injection machine

Types of Mould Temperature Controller for Injection Machine

A mould temperature controller for injection machine aims to maintain consistent and precise temperature control in injection moulds. The temperature controller for injection moulding comes in various types that suit different application requirements. Here are the top common types of temperature controllers for injection moulds.

• Type T Temperature Controller

  The Type T temperature controller is one of the most common temperature controllers designed to control the temperature of heated moulds and platens. It uses a thermocouple sensor as an input to a microprocessor-based controller for better accuracy and reliability. The thermocouple senses the temperature of the mould and sends a signal to the controller. Then, the controller processes the signal in milliseconds and determines the required heating or cooling to maintain the desired temperature setpoint. Finally, it sends a control signal to the heating or cooling device. Type T temperature controllers come in different models to offer specific features and functionality, such as auto-tuning, control algorithms, and alarm functions for safety.

• Water Cooled Temperature Controller

  A water-cooled temperature controller regulates mould temperature using water circulation. Typically, it has a chiller or heat exchanger that removes heat from the water, lowering the temperature. A pump then circulates the cooled water through the mould, absorbing heat and maintaining a constant temperature. Water-cooled controllers can cool the mould more quickly than air-cooled controllers, improving the temperature uniformity and reducing cycle time. They are ideal for high-volume, high-speed injection moulding applications.

• Air Mould Temperature Controller

  An air-cooled temperature controller uses airflow to regulate the temperature. It typically has a heat exchanger that transfers heat from the fluid inside the hose to the air. Then, a fan blows the processed air to cool down the mould. Air-cooled controllers are easier to install and maintain than water-cooled controllers because they do not require a water treatment system. They are ideal for applications where water is not readily available, but they may not cool the mould as quickly or evenly as water-cooled controllers.

Specification and Maintenance

Low-cost mould temperature controllers work on the principle of electrical heating. The heater is always in current contact with the fluid. Heating fluids usually feature either piping or an electrical jacket that a fluid passes through. The following specifications reveal more details about its plumbing attachments and fittings.

• Power Supply : Controllers with less than 9 kW usually use standard 240 V power supplies, which are easily accessible to the general public. Bigger ones use 400 V 3-phase power supplies. Higher voltage is more efficient in heating higher fluid volumes.
• Power Consumption: Power consumption describes the amount the controller uses to heat the fluid. This is generally less than court power usage, as the temperate controller must heat the fluid only, not the entire premises. Controllers with 9-15 kW outputs typically draw 6.7 kW.
• Pump Flow : The pump flow denotes the amount of fluid the controller pumps around the mould per hour. This figure affects the heating's efficiency. Lower pump flow such as 400 litres per hour may be sufficient for small moulds such as those used to construct. Higher flows of 750 litres per hour may be necessary to ensure maximum contact for medium-sized moulds used for heavier industrial parts. Very high flows may be necessary to prevent overheating in the compressor's vicinity, such as 3000 litres per hour.
• Pump Pressure: The pressure at which the controller pumps the fluid typically ranges from 1 to 3 bar. Higher pressure is required for more significant moulds to overcome more extended fluid tubing systems' resistance and to ensure maximum contact within the mould.

Proper maintenance of a mould temperature controller prolongs equipment lifespan, prevents downtime, and ensures consistent temperature control during the injection moulding process. Regular inspection of the temperature controller helps track any arising issues and ensures prompt rectification. The following routine maintenance tips, along with the service manuals, should ensure the machine remains in excellent condition.

• Check Fluid Level: Regularly check and top up the temperate control fluid to ensure it provides accurate heating and cooling. Use the recommended fluid to prevent damage and corrosion to the mould.
• Clean Filters: Clean and replace the pump's filters to ensure contaminants do not block the moulding pump's flow. This will extend the lifespan of the temperature controller.
• Inspect Hoses and Fittings: Inspect hoses and pump fittings weekly for leaks, cracks, or loose connections. Early detection of fittings and washer damages can prevent fluid leakage and reparation needs.
• Calibrate Thermostat: Check and recalibrate the temperature regularly to ensure the temperature readings are accurate. Follow the manufacturers' guidelines when performing this to ensure effective and prompt activity.
• Clean Condenser Coils: Cleaning the fan coils regularly helps remove dirt and debris that clog the coils, thereby affecting its cooling functions. Also, ensure the fan is working optimally to prevent overheating and environmental hazards.

Application Scenarios for Mould Temperature Controllers for Injection Machines

The injection temperature controller is versatile and can be used in industries where injection moulding is applicable. Here are some areas where it can be used:

• Plastic Industry

  The plastic industry comprises anything that has to do with plastics — from raw materials to final products. In this industry, the mould temperature controller is used to enhance product quality. This includes reducing the defects and improving the overall quality of plastic products.

• Automotive Industry

  The automotive industry refers to the sector that manufactures vehicles and car parts. This area uses the mould temperature controller to ensure precise temperature control when moulding automotive components.

  Such components include interior and exterior trims, dashboards, bumpers, and lighting housings, to name a few. Mould temperature control helps maintain consistent dimensions and reliable fit for automotive parts.

• Medical Field

  Medical devices are made with high-precision, high-tech plastic materials. Examples include housings, syringes, connectors, and surgical instruments. The controller is responsible for maintaining the temperature of the moulding for these devices.

  Using a mould temperature controller improves the mechanical and optical properties of medical devices. It also helps the production of devices with complex geometries and ensures that production meets strict regulations and standards.

• Consumer Electronics

  Consumer electronics includes daily personal use tools that make living easy. Things like mobile phones, tablets, and smartwatches all use mould controllers when the components are being made.

  A precise temperature is crucial for achieving the intricate details and thin walls typical of consumer electronic devices.

• Construction Industry

  When building or constructing structures, materials with temperature control help with the consistency of product quality. In the construction industry, temperature controllers are used to mould construction components like pipes, fittings, and structural elements.

  The durability and dimensional accuracy of construction materials are incredibly essential — especially those under pressure.

• Food Packaging

  Food packaging refers to all the materials used to contain food. This often establishes a protective barrier between the packaging and the contents. With a mould temperature controller, packers can ensure temperature consistency and rapid temperature control, which are vital to producing food packaging materials with reliable barrier properties.

  Examples include bottles, containers, and protective trays made of plastics.

• Aerospace and Defence

  Mould temperature controllers help enhance the quality of the engineered materials that are often used in the aerospace and defence industries.

  These include materials like carbon fibre and polycarbonate, which are known for their strength and clarity. The precision control offered by the mould controller ensures high consistency and reliability for all moulded components.

• Textile Industry

  In the textile industry, the mould temperature controller is used to produce textile machinery parts with high precision and durability, such as pump housings, gear boxes, and shuttles.

  It's important that these parts are highly resistant to wear.

How to choose a mould temperature controller for injection machine

When choosing a mould temperature controller for an injection machine, several factors should be considered to ensure the proper functioning of the equipment and the quality of the injected parts.

• Control and regulation system: It is essential to choose a temperature controller that has a precise control and regulation system. This will ensure that the temperature of the mould is maintained at optimal levels for the injection process, which in turn will improve the quality of the parts and reduce production times.
• Heating and cooling capacity: The heating and cooling capacity of the temperature controller must be adequate for the size and capacity of the injection mould. This will ensure that the temperature of the mould can be adjusted quickly and efficiently during the injection process.
• Energy source: The energy source of the temperature controller must be compatible with the production facilities. This will prevent the need for unnecessary adaptations and ensure a constant and reliable energy supply.
• Size and weight: The dimensions and weight of the temperature controller must be appropriate for the injection machine to which it will be fitted. This will ensure proper installation and integration of the equipment.
• Materials and construction: The materials and construction of the temperature controller must be resistant and durable to ensure a prolonged service life and low maintenance cost. In addition, the equipment must be easily cleaned and maintained to ensure optimal and safe operation at all times.
• Operating environment: The temperature controller must be able to operate in the environmental conditions where the injection machines are located. This includes resistance to humidity, dust, vibrations and other factors that could affect the proper functioning of the equipment.
• Compatibility with refrigerants and heating fluids: The temperature controller must be compatible with the refrigerants used in the cooling circuits and the heating fluids used in the heating circuits. This will ensure proper operation and avoid chemical reactions that could damage the equipment.

Mould temperature controller for injection machine Q & A

Q1. How do temperature controllers work?

A1. Mould temperature controllers regulate temperature using electrical sensors. They then send a signal to the heater or cooler to activate it until the desired temperature is achieved.

Q2. Why is temperature control important in injection moulding?

A2. Maintaining the proper temperature during injection moulding is crucial for consistent product quality. Furthermore, effective temperature control can shorten cycle times and reduce energy consumption.

Q3. What are the different types of temperature controllers?

A3. The different types of temperature controllers include on/off controllers, proportional-integral-derivative (PID) controllers, programmable controllers and pressure controllers among others.

Q4. What is the mould temperature control?

A4. Mould temperature control involves adjusting the temperature of moulds used in various manufacturing processes to improve product quality and production efficiency.

Q5. What are the benefits of the temperature controller?

A5. The temperature controller benefits include enhanced product quality, improved mechanical efficiency, energy conservation, reduced production costs and extended equipment lifespan among others.