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How to choose a mold temperature controller suitable for thick-walled automotive products?

2025/07/19 By Topstar

Thick-walled plastic products in the automotive industry

When selecting the right mold temperature controller for thick-walled automotive parts, it’s essential to understand the performance requirements. In our experience, using a 120°C high-flow water-based mold temperature controller can reduce cycle times by 12% to 15% for parts with walls thicker than 20 mm. The controller features a high-pressure pump capable of delivering up to 25 L/min at 8 bar pressure, along with a 20 mm diameter cooling solenoid valve, which accelerates heat dissipation. This ensures even heat distribution throughout the mold by increasing flow and head pressure, thereby minimising thermal gradients.

Pump Capacity and Hydraulic Considerations for Mold Temperature Controller

The pump for a mold temperature controller must be able to handle the large volumes and significant back pressures required to circulate coolant through complex, thick-walled molds effectively. For example, a centrifugal pump rated for 25 L/min can ensure adequate coolant turnover even in large manifold systems, and its high-head design overcomes the resistance of narrow cooling channels and long pipe runs without causing cavitation. During testing, we verify pump performance using in-line flow meters and differential pressure gauges to confirm actual delivery under static and dynamic mold conditions. Additionally, an insulated pump housing reduces heat loss by 5%, thereby enhancing energy efficiency. By prioritising flow and head pressure, using a high-flow water mould temperature controller can maintain a rapid thermal response and a consistent mould temperature, thereby avoiding hot spots and warping in thick sections while optimising energy usage.

Heating Elements and Temperature Uniformity

To achieve precise control up to 120°C, we use heating elements and PID control algorithms in the mold temperature controller to ensure uniformity in all areas. During manufacturing, we install distributed cartridge heaters, each rated at 1 kW, placed every 300 mm along the dual heating loop to maintain uniform heat flux. At the same time, I developed an adaptive PID loop with an auto-tuning function to keep the set point within ±0.5°C, even under rapid load changes exceeding 20°C per minute. And we utilized a large surface area shell and tube heat exchanger to increase the speed of the heating and cooling phases by 30%. Additionally, the preset holding time stabilizes the temperature before injection, ensuring the material does not overheat. These design choices enable the mold temperature controller to rise from ambient temperature to 120°C in 10 minutes, reducing downtime in high-cycle automotive molding operations.

Nickel-plated copper heater

20 mm solenoid valve in the mold temperature controller

For thick-walled automotive parts that require a fast and reliable cooling phase, we installed a 20 mm diameter proportional solenoid valve in the 120°C high-flow water mould temperature controller. This modification increased the maximum coolant throughput by 25%, thereby achieving a faster cooling speed. At the same time, I integrated a high-speed valve driver that can adjust the opening according to real-time temperature feedback, achieving a cooling rate of up to 5°C per minute while maintaining an accuracy of ±1°C. Additionally, the dual-circuit cooling design allows for targeted heat dissipation, preventing thermal shock and uneven shrinkage. And we’ve programmed “burst” cooling sequences that instantly increase flow at critical mold stages, further reducing cycle times without compromising temperature control. This approach ensures your high-flow water-based mold temperature controllers meet the stringent requirements of thick-wall automotive part production.

mold temperature controller 10-10

Intelligent Control Features and User Interface

Advanced control features and connectivity are available in the mold temperature controllers, enabling optimised process management and enhanced traceability. In addition to a touchscreen that supports multi-touch gestures, the mold temperature controllers offer OPC UA and Modbus TCP interfaces, enabling seamless SCADA integration. Alarm thresholds for overheating, flow loss, and heater failure are configured to ensure immediate notification to the operator. In addition, embedded data logging records temperature, pump speed, and valve position at one-second intervals, generating trend graphs for SPC analysis. Automatic batch report generation simplifies compliance with automotive quality standards such as IATF 16949. By leveraging these advanced control features and user-centric interfaces, your production team can gain actionable insights into the performance of your mold temperature controllers, enhancing preventive maintenance and reducing scrap rates.

Mold Temperature System-10-3

Installation, Maintenance, and Lifecycle Costs

Implementing mold temperature controllers in automotive thick-wall parts also requires attention to proper installation, maintenance procedures, and total lifecycle costs. First, place the mold temperature controller within two meters of the mold block to minimize line losses and improve response time. Then, use flexible PFA-lined hoses rated for 150°C and 10 bar to accommodate tool movement without kinking. Meanwhile, it is recommended that you check the integrity of the pump impeller and valve seals quarterly, and it is recommended to replace the solenoid valve diaphragm annually to prevent leaks. Our high-flow, high-lift system reduces the total TCO by 18% compared to traditional 90°C units. Reliable installation practices, coupled with proactive maintenance and detailed cost analysis, can extend the life of the mold temperature controller and ensure the continued performance of thick-wall molds.

Ensure the reliable quality of thick-walled automotive parts.

The key to selecting a mold temperature controller for thick-walled automotive products is to choose one equipped with a high-lift pump, strategically distributed heating zones, and a 20mm proportional cooling solenoid valve. In the 120°C high-flow water mould temperature controller, I configured a large-capacity pump, installed a rugged cartridge heater, integrated a fast-response valve, and utilised an advanced HMI, ensuring tight thermal regulation, shorter cycle times, and excellent part quality.

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