Fault patterns of injection molding machines

Research shows that the injection molding function or condition gradually decreases over time. Before many faults occur, there are some signs, which are called potential faults. The identifiable physical parameters indicate that a functional fault is about to occur, and a functional fault indicates that the injection molding machine has lost the specified performance standards.

The variation law of the failure rate of injection molding machines over time is often referred to as the bathtub curve. The failure rate of injection molding machines can be roughly divided into three stages over time: early failure period, occasional failure period, and wear and tear failure period.

1. Early failure period

The injection molding machine is in the early failure period, with a high initial failure rate, but the failure rate rapidly decreases over time. The early failure period is also known as the running in period for mechanical products. The duration of this period varies depending on the design and manufacturing quality of the product and system. The malfunctions that occurred during this period were mainly caused by design and manufacturing defects, or improper usage environments.

2. Occasional failure period

The injection molding machine enters an occasional failure period, and the failure rate is generally in a stable state, approaching a constant value. During this period, the occurrence of faults is random. During the occasional failure period, the failure rate of the injection molding machine is low and stable Therefore, it can be said that this is the optimal state period or normal working period of the injection molding machine. This section is called the effective lifespan.

Occasional failures are often caused by improper design, use, and inadequate maintenance. Therefore, by improving design quality, improving usage management, strengthening monitoring, diagnosis, and maintenance, the failure rate can be reduced to a lower level.

3. Loss and failure period

In the later stages of using injection molding machines, the failure rate begins to increase. This is caused by wear, fatigue, aging, corrosion, etc. of injection molding machine components. If major repairs are carried out at the turning point, which is the beginning of the wear and tear period, the failure rate can be economically and effectively reduced.

The three stages of the failure rate curve of injection molding machines reflect the law of the failure rate changes from running in, debugging, normal operation to major repairs or scrapping. Strengthening the daily management and maintenance of injection molding machines can extend the period of occasional failures. Accurately identifying the turning point can avoid excessive repair or expansion of repair scope, in order to achieve better investment benefits.

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