1. Injection molding machine fixed asset investment, large-scale production, consumption of raw materials and more labor productivity, a large production value. Is a labor-efficient production organization form. 2. Injection molding machine by the mechanical, hydraulic, electrical, special accessories, etc., in accordance with the needs of injection molding process technology, organic together, high degree of automation, closely linked to each other; injection molding machine can be 24h continuous operation. If an injection molding machine failure of a component, will result in downtime. 3, although the injection molding machine is simple, less workers, but the injection molding machine management and maintenance of high technical content, workload is also large. Therefore, to ensure that the injection molding machine is often in good condition, we must strengthen the management of injection molding machine, strict control of the failure of the injection molding machine. In order to achieve the purpose of reducing the failure rate, reducing the maintenance cost and prolonging the service life. Injection molding machine failure, generally refers to the injection molding machine or system in use to reduce or reduce the function of the event or phenomenon. Injection molding machine is equipped to meet the requirements of the production process of injection products. The function of the injection molding machine reflects its value in the injection molding production activities and the degree of assurance of the injection molding production. In the production of modern injection molding machine, due to the complicated structure of the injection molding machine, the high degree of automation, hydraulic, electrical control and mechanical contact is very close, so the injection molding machine failure, even if it is partial failure, will result in the shutdown of the entire injection molding machine. Injection molding machine failure directly affects the quantity and quality of injection products. First, the classification of injection molding machine failure Injection molding machine failure is diverse, you can classify them from different angles. 1. According to the occurrence of the state, can be divided into: (1) progressive failure. Is due to the gradual deterioration of the initial performance of the injection molding machine, most of the failure of the injection molding machine belongs to such failures. Such failures and electronic control, hydraulic machinery parts wear, corrosion, fatigue and creep process is closely related. (2) sudden failure. Is a result of a combination of unfavorable factors and accidental external influences that go beyond what injection molding machines can afford. For example: due to the cartridge into the iron overload caused by the screw broken; due to high-voltage stringing and breakdown injection molding machine electronic board. Such failures are often sudden, without any prior warning. Sudden failures occur in the use of injection molding machines, often due to design, manufacture, assembly and material defects, or operational errors, illegal operations caused. 2. According to the nature of the breakdown, can be divided into: (1) intermittent failure. Injection molding machine in the short term to lose some of its functions, a little repair can be restored without the need to replace parts. (2) permanent fault. Some parts of the injection molding machine have been damaged, need to be replaced or repaired to resume use. Divided by the extent of the impact of failure, can be divided into: (1) complete failure. Cause the injection molding machine completely lost its function. (2) local failure. Lead to some loss of injection molding machine. 4. According to the cause of the breakdown, can be divided into: (1) wear failure. Due to the normal wear and tear caused by the failure of the injection molding machine. (2) misuse fault. Due to operational errors, maintenance failures caused by improper. (3) inherent weakness fault. Due to design issues, the injection molding machine appears weak links, failures arising in normal use. 5. According to the risk of failure, can be divided into: (1) dangerous fault. For example, if the safety protection system loses its protective function due to a malfunction when it is in need of action, it will cause personal injury and failure of the injection molding machine; and malfunction caused by failure of the hydraulic electronic control system. (2) safety fault. For example, the safety protection system does not need to move when the action; injection molding machine can not start when the failure. 6. According to the occurrence of injection molding machine failure, the development of the law can be divided into; (1) random failure. The time of the failure is random. (2) a rule of failure. There is a certain law of failure. Each type of fault has its main characteristics, the so-called fault mode, or fault status. Various injection molding machine fault state is quite complicated, but can be summarized in the following categories: abnormal vibration, mechanical wear, the input signal can not be accepted by the computer, the solenoid valve does not output signal, mechanical and hydraulic components rupture, the proportion of linear imbalance, hydraulic Pressure drop, hydraulic leakage, pump failure, hydraulic noise, circuit aging, abnormal sound, oil deterioration, power supply voltage drop, amplifier board no output, temperature control and other. Different types of injection molding machine failure modes of the proportion of different. Second, failure analysis and troubleshooting procedures To ensure failure analysis and elimination of the fast and effective, we must follow certain procedures, such procedures are as follows. The first step to maintain the case of the scene for symptom analysis 1. Asked the operator (1) What happened? Under what circumstances? When did it happen? (2) how long has the injection molding machine been running? (3) before the failure without any abnormal phenomenon? Any sound or sound and light alarm signal? Is there any smoke or smell? Have correct operation (note the inquiry method)? (4) control system operation is normal? Is there any change in operating procedures? Are there any special difficulties or abnormalities in operation? 2. Observe the whole machine condition, each operating parameter (1) is there any obvious abnormal phenomenon? Is there any jamming or damage to parts? Is the hydraulic system loose or leaky? Is the wire broken, scratched or burned? (2) injection molding machine operating parameters What changes? Is there any obvious interference signal? Is there any obvious damage signal? 3. Check the monitoring indicator (1) Check all readings are normal, including the pressure gauge and other meter readings, the oil level. (2) Check the filter, alarm and interlock, the action output or the monitor is normal. 4. Jog the machine to check (when allowed) for intermittent, long-term, fast-forward or slow-moving conditions to see if output is affected under these conditions and whether damage or other hazards may result. The second step to check the injection molding machine (including parts, components and wiring) 1. The use of sensory inspection (continue the process of further observation) 1 to see: plug and socket without exception, the motor or pump is functioning properly control the adjustment position is correct, Whether there is arcing or scorching marks, fuse is good or bad, liquid leaks, whether the smooth flow of oil and so on. 2 touch: vibration injection molding machine, yuan (group) pieces of heat, tubing temperature, the state of mechanical movement. 3 Listen: Is there any abnormal sound? 4 sniff: with or without burnt smell, leak smell, other smell. 5 check: the shape of the workpiece and position changes, changes in injection molding machine performance parameters, line abnormalities check. 2. Assessment test results to determine the fault is correct, fault clues are found, the test results are the same. The third step to determine the location of the fault 1. Identify the structure of the system and determine the test method Check the injection molding machine manual to identify what kind of injection molding machine structure, what method of testing, what testing tools may be obtained what test parameters or performance parameters, Under what operating conditions should the test be conducted, what safety measures must be followed and whether an operating permit is required. 2. System testing using the most suitable technology testing of the system structure. At the appropriate test points, the results of the inputs and feedback are compared with normal values ​​or performance criteria to identify suspicious locations. The fourth step repair or replacement 1. Repair Find the cause of the malfunction, repair the fault for the injection molding machine and take preventive measures; check the relevant parts to prevent the proliferation of the fault. 2. Replace the correct assembly and commissioning replacement parts, and pay attention to the relevant components. Replacement parts for repair or scrapped. The fifth step to determine the performance 1. Start injection molding machine parts assembly start debugging injection molding machine, the first manual (or jog), and then no-load and load measurements. 2. Adjust the load change speed from low to high, the load from small to large, the system pressure can not exceed 140kg / cm2, according to the provisions of the standard determination of performance. 3. Expand the range of performance test According to the need, from the local to the system to gradually expand the scope of performance testing. Pay attention to the health of the system in the non-fault zone. Such as the performance to meet the requirements of the delivery, if not meet the requirements are re-determine the fault site. Sixth step record and feedback 1. Collect valuable information and data, such as injection molding machine failure occurred time, breakdown, downtime, repair workers, repair parts, repair, to be solved, settlement costs, etc., according to The required requirements into the file. 2. Statistical analysis Regularly analyze the use of injection molding machine records, analysis of downtime losses, the revision of the memorandum directory to find the focus of measures to reduce maintenance operations, study the fault mechanism, propose improvements. 3. Press the program