Both imported and domestic injection molding machines have the following characteristics:
1. The investment in fixed assets of injection molding machine is large, the production scale is large, the consumption of raw materials is high, the labor productivity is high, and the production value is large. It is a form of production organization with high labor efficiency.
2. The injection molding machine consists of mechanical, hydraulic, electrical, special accessory parts, etc., according to the needs of injection molding process technology, organically combined, high degree of automation, closely related to each other; injection molding machine can run continuously for 3 hours and 24 hours. If a component of the injection molding machine fails, it will cause a shutdown.
3. Although the injection molding machine is simple to operate and has few workers, the technical content of the injection molding machine for treatment and maintenance is high and the workload is large.
Therefore, to ensure that the injection molding machine is always in good condition, it is necessary to strengthen the injection molding machine management work and strictly control the failure of the injection molding machine. In order to achieve the purpose of reducing the failure rate, reducing the maintenance cost and extending the service life.
Failure of an injection molding machine generally refers to an event or phenomenon in which an injection molding machine or system loses or reduces its specified function during use. The injection molding machine is equipped by the company to meet the production process requirements of injection molding products. The function of the injection molding machine embodies its value in the production of injection molded products and the guarantee of injection molding production. In the modern injection molding machine production, due to the complex structure of the injection molding machine, the degree of automation is very high, the connection between hydraulics, electric control and machinery is very close, so the injection molding machine is faulty, even if it is a partial failure, the entire injection molding machine will be discontinued. Injection molding machine failures directly affect the number and quality of injection molded products. Injection molding machine faults are various and can be classified from different angles to facilitate the maintenance staff to quickly find out the cause of the fault and solve the fault.
1. According to the fault occurrence state, it can be divided into:
(1) A gradual failure. This is due to the gradual deterioration of the initial performance of the injection molding machine, and most of the failures of the injection molding machine belong to this type of failure. Such failures are closely related to the processes of electrical control, hydraulic mechanical components, wear, corrosion, fatigue and creep.
(2) Sudden failure. It is caused by a combination of various unfavorable factors and occasional external influences, which is beyond the limits of the injection molding machine. For example, the screw is broken due to the overload of the cylinder into the iron; the high voltage string further breaks down the electronic board of the injection molding machine. Such failures often occur suddenly and without any indication in advance.
Sudden failures often occur during the use of injection molding machines, often due to defects in design, manufacturing, assembly, and materials, or mishandling or illegal operations.
2. According to the nature of the fault, it can be divided into:
(1) Interruption failure. The injection molding machine loses some of its functions in a short period of time and can be recovered with a little repair and debugging, without the need to replace parts.
(2) Permanent failure. Some parts of the injection molding machine are damaged and need to be replaced or repaired to be used again.
3. According to the degree of impact of the fault, it can be divided into:
(1) Complete failure. This caused the injection molding machine to completely lose its function.
(2) Local failure. This causes some functions of the injection molding machine to be lost.
4. According to the cause of the failure, it can be divided into:
(1) Abrasion failure. Failure due to normal wear and tear of the injection molding machine.
(2) Misuse failure. Failure due to mishandling or improper maintenance.
(3) inherently weak faults. Due to the design problem, the injection molding machine has weak links and malfunctions during normal use.
5. According to the risk of failure, it can be divided into:
(1) Dangerous failure. For example, the safety protection system loses protection due to failure when it needs to act, causing personal injury and injection molding machine failure; failure caused by failure of hydraulic electronic control system.
(2) Security failure. For example, the safety protection system operates when no action is required; the failure that the injection molding machine cannot start when it is started.
6. According to the occurrence and development of the failure of the injection molding machine, it can be divided into;
(1) Random failure. The time at which the failure occurred is random.
(2) There is a rule failure. There are certain rules for the occurrence of faults.
Each type of fault has its main characteristics, the so-called fault mode, or the fault state. The fault status of various injection molding machines is quite complicated, but the following types can be recovered: abnormal vibration, mechanical wear, input signal can not be accepted by the computer, solenoid valve has no output signal, mechanical hydraulic components are broken, proportional linear imbalance, Hydraulic pressure drop, hydraulic leakage, oil pump failure, hydraulic noise, circuit aging, abnormal sound, oil quality deterioration, power supply voltage drop, no output of the amplifier board, temperature loss control and others. The proportion of various failure modes of different types of injection molding machines is different.
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