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How to analyze the causes of horizontal injection molding machine failures?

2025/05/26 By Topstar

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Over time, horizontal injection molding machines will experience production interruptions due to mechanical, hydraulic, electrical, or process-related problems. Identifying horizontal injection molding machine failures requires a systematic approach that includes identifying failure symptoms and collecting data to identify the root cause. We will summarize several failure issues, including mechanical components, hydraulic systems, electrical controls, process parameters, etc., to provide plastic product manufacturers with practical insights to help maximize uptime, reduce scrap, and optimize overall equipment efficiency.

Wear and misalignment of the mechanical components of the horizontal injection molding machine

Mechanical failures often stem from wear or misalignment of key components of horizontal injection molding machines – tie rods, plate guides, elbows, and ball screws are subject to repeated load cycles that cause fatigue or corrosion over time. Symptoms include abnormal vibration, uneven clamping force, mold wear patterns, and increased cycle times. Therefore, we can use precision alignment tools to measure plate parallelism and detect shaft clearance using laser trackers, micrometers, and feeler gauges. At the same time, the clearance of the toggle joint and pivot pin is checked, combined with lubrication audit and hardness testing of wear surfaces to identify hot spots before failure occurs. High-strength steel tie rods and high-rigidity linear guide surfaces are used in Topstar’s horizontal injection molding machines. Combined with regular vibration analysis and grease sampling, mechanical performance degradation can be minimized.

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Hydraulic system failure of a horizontal injection molding machine

Hydraulic problems are another common failure problem of horizontal injection molding machines. Seal leakage, filter blockage, or proportional valve failure usually manifests as slow clamping, inconsistent injection speed, or complete pressure loss. Therefore, the operator may notice unstable platen movement, pressure fluctuations on the digital instrument, or a sudden increase in oil temperature. Thus, a hydraulic audit is required, and fluid analysis is necessary to check viscosity, particle contamination, and water content to determine whether deterioration requires fluid replacement. Next, technicians must check the hydraulic pump for cavitation, verify the safety valve setting, and clean or replace the clogged suction filter. Topstar’s hydraulic design has high-response servo valves, high-efficiency multi-stage filtration, and condition-based maintenance alarms to provide stable pressure control and minimal downtime. Regular hydraulic maintenance can maintain accurate clamping and injection curves.

Hydraulic system failure of horizontal injection molding machine 1

Electrical Control and Sensor Failure

Horizontal injection molding machines rely on an electrical system PLC, HMI, servo drive, and sensors to control every movement and process parameter. Any sensor or wiring harness failure may interrupt the injection cycle or affect safe operation. Alarms such as “no charge,” “position error,” or overcurrent indication usually indicate encoder failure, limit switch misalignment, or abnormal servo drive voltage. Therefore, we can conduct a step-by-step troubleshooting electrical diagnosis, which includes verifying power supply voltage, checking grounding and shielding integrity, and testing sensor output and signal quality with a multimeter or oscilloscope. If conditions permit, you can upgrade to shielded industrial-grade cables and implement strong cable management to prevent interference and wear.

Electrical Control and Sensor Failure 2

Process Parameter Deviation

Even if the hardware is perfect, wrong process parameters can cause apparent failures in horizontal injection molding machines. When the melt temperature is too high, it will cause polymer degradation and nozzle clogging. Insufficient back pressure will cause poor melt mixing and lack of material, and improper injection speed or holding time will trigger pressure alarms or incomplete filling. Therefore, operators must regularly verify parameter settings against recommendations and record any deviations. Data logging systems can record real-time injection pressure, screw position, barrel temperature profiles, and cycle times for historical trend analysis. In addition, a solid commissioning protocol for each new mold should include test runs, plotting optimal temperature profiles, and locking settings to prevent out-of-tolerance conditions.

Material and moisture-related issues

Inconsistencies in raw materials often masquerade as mechanical or hydraulic failures in horizontal injection molding machines. For example, wet, hygroscopic resins can bubble in the barrel, causing erratic pressure readings, erratic screw recovery, and poor part quality. We can perform comprehensive material audits, including verification of batch traceability, pellet shape, and moisture content through infrared analyzers or moisture meters. Topstar ensure consistent melt quality by integrating precise drying systems, hopper dehumidifiers, and automatic gravimetric feeders. In addition, our barrel and screw designs mitigate moisture-related defects. Regular material handling, such as hopper cleaning, can further reduce the risk of contamination. By strictly controlling material handling and pre-drying, you can avoid erratic injection behavior and extend the life of the screw and barrel on horizontal injection molding machines.

Holistic Failure Analysis Approach

Diagnosing and preventing horizontal injection molding machine failures covers checking mechanical integrity, hydraulic system health, electrical reliability, process optimization, material quality, and more. By systematically auditing each injection molding machine component and leveraging real-time monitoring data, plastic product manufacturers can minimize unplanned downtime, reduce scrap rates, and ensure the reliability of their horizontal injection molding machines.

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