Hotline
When a malfunction occurs in an injection molding machine, in order to ensure quick and effective troubleshooting, a certain procedure must be followed, which is roughly as follows.
The first step is to conduct symptom analysis while maintaining the scene
1. Inquire with the operator
(1) What malfunction has occurred? Under what circumstances did it happen? When did it happen?
(2) How long has the injection molding machine been running?
(3) Is there any abnormal phenomenon before the malfunction occurred? What sound or light alarm signals are there? Is there any smoke or odor? Is there any error in operation, pay attention to the inquiry method?
(4) Is the operation of the control system normal? Is there any change in the operating procedure? Are there any special difficulties or abnormalities during operation?
2. Observe the condition of the entire machine and various operating parameters
(1) Is there any obvious abnormal phenomenon? Are there any jamming or damage to the parts? Is there any looseness or leakage in the hydraulic system? Are there any cracks, scratches, or burns on the wires?
(2) What are the changes in the operating parameters of the injection molding machine? Is there any obvious interference signal? Is there any obvious damage signal?
3. Check the monitoring and indication device
(1) Check if all readings are normal, including pressure gauge and other instrument readings, as well as oil level conditions.
(2) Check if the filters, alarms, interlocking devices, action outputs, or displays are functioning properly.
4. Inching injection molding machine inspection (under allowable conditions)
Check for intermittent, persistent, fast forward, or slow forward conditions to see if they affect output and if they may cause damage or other hazards.
Step 2: Check the injection molding machine (including parts, components, and wiring)
1. Utilize sensory examination (continue the process of in-depth observation)
1. Check if there are any abnormalities in the plugs and sockets, whether the motor or pump operates normally, whether the control adjustment position is correct, whether there are any signs of arcing or burning, whether the fuse is good or bad, whether there is any leakage of liquid, whether the lubricating oil circuit is smooth, etc.
2 touch: Vibration situation of injection molding machine, heat of components, temperature of oil pipe, and mechanical motion status.
3 Listen: Is there any abnormal sound.
4 Nose: Check for burnt, leaking, or other odors.
5. Check: Changes in the shape and position of the workpiece, changes in the performance parameters of the injection molding machine, and abnormal circuit inspection.
2. Evaluation of inspection results
Assess whether the fault diagnosis is correct, whether the fault clues have been found, and whether the results of various inspections are consistent.
Step 3: Determination of Fault Location
1. Identify system structure and determine testing methods
Refer to the instruction manual of the injection molding machine, identify which structure the injection molding machine is, what methods are used for testing, what testing methods are required, what testing parameters or performance parameters may be obtained, under what operating conditions testing must be carried out, what safety measures must be followed, and whether an operating license is required.
2. System detection
Using technology suitable for system structure detection. At appropriate testing points, compare the results obtained from input and feedback with normal values or performance standards to identify suspicious locations.
Step 4: Repair or replace accessories
1. Repair
Identify the cause of the malfunction, repair the injection molding machine malfunction, and take preventive measures; Check the relevant parts to prevent the spread of faults.
2. Replace accessories
Properly assemble, debug and replace parts, and pay attention to relevant components. Repair or scrap the replaced parts.
Step 5: Conduct performance testing
1. Start the injection molding machine
After assembling and debugging the components, start the injection molding machine manually (or jog), and then perform no-load and load measurements.
2. Adjust the speed of load change from low to high, the load from small to large, and the system pressure should not exceed 140kg/cm2. Measure the performance according to the specified standards.
3. Expand the scope of performance testing
As needed, gradually expand the scope of performance testing from local to system. Pay attention to the operation status of the non fault zone system. If the performance meets the requirements, it will be delivered for use. If it does not meet the requirements, the fault location will be re determined.
Step 6: Record and provide feedback
1. Collect valuable information and data, such as the time of occurrence of injection molding machine faults, fault phenomena, downtime, repair hours, parts replacement, repair effects, unresolved issues, settlement costs, etc., and store them in the archives according to the prescribed requirements.
2. Statistical analysis
Regularly analyze the usage records of injection molding machines, analyze downtime losses, revise memo directories, identify key measures to reduce maintenance operations, study fault mechanisms, and propose improvement measures.
3. Report relevant faults to the competent department according to the program feedback, and provide feedback to the injection molding machine manufacturing unit or the injection molding machine equipment maintenance contractor.
No.16-1 Youyi North Road, Boyi Industrial Park, Zouqu Town, Zhonglou District, Changzhou City