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What kind of positioning accuracy can an all electric injection molding machine achieve?

2025/07/14 By Topstar

All electric injection molding machines are a more suitable solution for the injection molding of ultra-precision plastic parts. According to our customer feedback, electric drives can reduce position deviations by up to 40% compared to hydraulic systems under the same load. The intelligent servo drive architecture on the Topstar all electric injection molding machine reduces communication delays and enables real-time control of the injection, clamping, and ejection axes. The real-time servo control of the all-electric injection molding machine improves response time by 8 to 16 times, with repeatability of less than 0.1 mm, and the integrated rigid injection unit ensures mechanical stability with positioning accuracy of ±0.1mm.

Controlling the all electric injection molding machine with a servo drive

The high-speed servo drive system of the all electric injection molding machine ensures real-time monitoring and adjustment of each axis. Unlike injection molding machines that rely on proportional valves and are affected by fluid compressibility, servo motors communicate via a high-bandwidth bus that can transmit position commands and encoder feedback within 1 millisecond. First, the servo drive controller issues torque and position targets. Then, encoder feedback allows for instant correction. At the same time, the servo drive parameters are finely tuned, which can be adjusted according to the inertia and load of each axis, making the response time 8 to 16 times faster than that of traditional hydraulic drives. In addition, feedforward compensation predicts dynamic loads and reduces overshoot by 70%. This real-time control almost eliminates stabilization time and ensures consistent injection weight and dimensional consistency over tens of thousands of cycles on any injection molding machine production line.

High-rigidity integrated injection unit

Precision mechanical stability demands led us to integrate a high-rigidity injection seat into our all electric injection molding machine. Under sufficient stress analysis, we reinforced the injection frame to reduce the deflection under peak pressure by 60%; in addition, the beam reinforcement ribs and optimized wall thickness can suppress vibrations up to 150 Hz. At the same time, during the manufacturing process, our engineers verified the frame stiffness through modal testing to ensure that the first-order natural frequency is much higher than the working bandwidth. The direct-drive injection screw mounted on this rigid platform maintains precise screw positioning and melt control, converting electronic instruction fidelity into material consistency. These design choices maintain position accuracy and prevent minute fluctuations that can cause flash or undershot, even at high injection speeds of 200 mm/s.

Low-damping injection seat

Shorter feedback cycles, higher precision

Hydraulic systems rely on feedback cycles of 10 to 20 milliseconds. However, our all electric injection molding machine reduces latency to less than 1 millisecond by sending a synchronization signal containing the servo motor’s working conditions to the upper controller under a self-developed system. Following a shortened cycle means that the system can detect and correct position drift before errors accumulate; as a result, positioning is maintained within ±0.5 mm, even during rapid acceleration. In addition, I implemented proprietary firmware that synchronizes sensor readings with actuator commands every 500 microseconds, reducing total control loop latency by 94%. Real-time metrics from each axis are fed into a deterministic scheduler that prioritizes critical motion tasks, ensuring that clamping, injection, and ejection phases proceed seamlessly without noticeable delays at transition points.

Accurate speed and pressure control

In addition to positioning, accurate speed and pressure regulation directly affect part quality, filling consistency, and mechanical stress. Driven by a servo, the injection screw achieves a speed accuracy of ±0.1%, enabling a smooth lift curve that reduces shear and improves melt uniformity; in addition, an integrated high-frequency pressure sensor samples at 5 kHz to ensure that the holding and holding pressures are within ±0.5 bar. At the same time, I designed a cascade control loop that tightly combines position, speed, and pressure to ensure a seamless transition from high-speed injection to low-speed holding without overshoot. This coordination prevents defects such as sink marks and internal stresses, achieving repeatable cycle-to-cycle consistency that hydraulic systems cannot match.

Shorter feedback cycles, higher precision

Bringing Smart Integration and Data Collection to All Electric Injection Molding Machine

Topstar’s all electric injection molding machines go beyond mere mechanical performance by embedding innovative hardware for real-time data collection and adaptive control. In addition, onboard IoT modules collect vibration, temperature, and torque data, enabling AI-driven analysis to predict maintenance needs before accuracy degrades. I oversee the implementation of servers that transmit high-resolution sensor data to the MES system to provide actionable insights into the injection molding machine. Machine learning algorithms dynamically adjust parameters to compensate for thermal expansion and wear, maintaining ±0.5mm accuracy over thousands of hours of operation. This overall intelligence ensures that the machine not only performs precise cycles but also maintains optimal performance with minimal human intervention.

Bringing ±0.1mm positioning accuracy

Topstar’s all electric injection molding machine uses real-time servo drives, high-rigidity mechanical design, ultra-short feedback cycles, precision speeds, and intelligent data integration to enable ±0.01mm repeatability, 8 to 16 times faster response speeds than hydraulic systems, and seamless connectivity for predictive maintenance. These features translate into shorter cycle times, lower scrap rates, and consistent part quality.

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