High Speed Servo Injection Molding Machine

This high-speed servo injection molding machine combines an accumulator-assisted injection unit with a high-response closed-loop servo system. Engineered for thin-wall packaging, medical consumables, and fast-cycle industrial parts, the system achieves injection speeds up to 500 mm/s and dry cycle times under 1.5 seconds.
By integrating a dual-pump hydraulic layout with a rigid five-point toggle clamping unit, the platform maintains stable tie-bar parallelism (within 0.05 mm) under continuous full-tonnage operation. The energy-efficient servo drive reduces power consumption by 30% to 70% compared to standard hydraulic systems, delivering precise shot-to-shot repeatability (+/- 0.3%) across multi-cavity production runs.

High-Response Servo-Hydraulic Drive: Permanent magnet synchronous motors paired with internal gear pumps yield response times of 30 ms from zero to maximum flow.
Nitride-Hardened Bimetallic Screw & Barrel: Standard SACM 645 steel with bimetallic lining provides resistance to abrasive fillers (up to 30% glass fiber) and corrosive resins.
Nitrogen Accumulator Injection Circuit: Dedicated hydraulic accumulators supply peak flow rates during the injection phase, enabling ultra-fast cavity filling without overloading the main pumps.
High-Rigidity Platen Structure: Finite Element Analysis (FEA)-optimized box-type platens minimize platen deflection under clamping pressure, preventing mold flash and parting-line wear.
Closed-Loop Temperature & Pressure Control: Multi-zone PID barrel heating combined with linear transducer feedback on clamping, injection, and ejection positions ensures operational accuracy within +/- 0.1 mm.

Centralized Automatic Oil Lubrication: Microprocessor-controlled volumetric gear pumps deliver metered lubrication to toggle pins and bushings based on stroke count, preventing localized wear.

[Servo Motor + Gear Pump] ---> [Hydraulic Accumulator] ---> [High-Speed Injection Unit]

|

v

[Mold Closed & Locked] <--- [5-Point Toggle Clamp] <--- [Multi-Cavity Mold Cavity]

Clamping Unit: A high-tensile 5-point mechanical toggle mechanism generates structural clamping force. Linear optical encoders provide position feedback to regulate high-speed closing, mold protection zones, and final high-pressure lockup.

Injection Unit: A twin-cylinder injection structure maintains balanced axial forces on the screw shaft during acceleration. The nitrogen accumulator discharges into the injection line during the filling phase to reach high peak velocities.

Hydraulic & Servo Loop: The system reads oil pressure via pressure transducers and position via linear scales. The main controller adjusts motor RPM via a high-frequency inverter every 0.5 ms, matching pressure and flow demands in real time.

Dynamic Response and Velocity Control
Standard hydraulic machines struggle to reach speeds above 150 mm/s due to pump flow limits. This machine uses a high-flow proportional directional valve coupled with an accumulator circuit, accelerating the injection screw to 450+ mm/s within 25 ms. This fast filling prevents premature freeze-off in thin-wall sections under 0.4 mm.
Thermal and Dimensional Consistency
Direct-drive servo motors eliminate continuous hydraulic bypass heating. Oil temperatures remain below 45 degrees C without requiring high cooling water volumes. Lower thermal drift directly translates to melt density control, keeping individual part weight variation within a +/- 0.2% tolerance over 24-hour continuous production cycles.
Platen Parallelism and Mold Protection
Heavy platen structures guided by linear guide bearings (optional) or hardened frame ways maintain parallel alignment between moving and stationary platens. The dynamic mold protection monitoring system checks torque variations during the low-pressure closing segment, interrupting stroke within 10 ms if foreign matter or stuck parts are detected.

Packaging & Containers
Thin-Wall Food Containers: 500 ml to 1,000 ml PP tubs, ice cream tubs, and deli lids (wall thickness: 0.35 mm - 0.6 mm).
Closures & Caps: High-cavity beverage caps, flip-top dispense closures, and tamper-evident bands requiring fast cycle times under 3.5 seconds.
Medical Consumables
Laboratory & Diagnostic Ware: Pipette tips, Petri dishes, centrifuge tubes, and test cuvettes molded in ISO Class 7/8 cleanroom environments.
Syringe Barrels & Hubs: Multi-cavity molds requiring zero flash and tight dimensional tolerances for leak-free assembly.
Technical & Electronic Parts
Light-Guide Plates & Connectors: Fine-pitch electronic connectors and optical components requiring high injection pressure to eliminate sink marks and internal stress.

To match machine capacity with your production requirements, evaluate these core parameters:
Clamping Force Calculation
Calculate total projected area including runners:
Required Force (kN) = Total Projected Area (cm2) x Cavity Pressure (bar) / 100
Thin-wall packaging: Requires high cavity pressures (600 - 800 bar).
Standard parts: Requires lower cavity pressures (300 - 500 bar).
Shot Size and Screw Selection
Screw A (Small): Highest pressure capability (> 2,200 bar); ideal for thin-wall engineering resins.
Screw B (Standard): Balanced volume and pressure for general packaging and medical applications.
Screw C (Large): Higher volumetric capacity; recommended for polyolefins with lower pressure limits.
Factory Configurable Packages
High-Speed Packaging Package: Includes accumulator expansion, pneumatic core pulls, air-blow valves, and synchronized ejection during mold opening.
Cleanroom / Medical Package: Chrome-plated tie bars, non-paint nickel-plated platens, food-grade NSF-H1 hydraulic oil, and HEPA filter hood integration.
Abrasive Resin Package: Fully hardened bimetallic barrel, carbide-coated screw flight tips, and heavy-duty drive couplings.

[Raw Castings Inspection] ---> [5-Axis Machining Center] ---> [CMM & Laser Interferometry]
|
v
[72-Hour Load Testing] <--- [Dry Cycle Calibration] <--- [Assembly & Wiring]

Machining Precision: Platen mounting surfaces and tie-bar guide holes are machined on 5-axis horizontal CNC centers in a single setup to maintain perpendicularity and flatness within 0.02 mm.
Tie-Bar Stress Alignment: Tie bars undergo high-frequency induction hardening and chrome plating (0.03 - 0.05 mm layer thickness). Ultrasonic flaw detectors verify the absence of internal micro-cracks prior to assembly.
Hydraulic System Flushing: All hydraulic manifolds are flushed in a closed loop to ISO 4406 cleanliness standard 16/14/11 before component mounting.
Factory Acceptance Testing (FAT): Every unit runs a mandatory 72-hour continuous dry-cycle test followed by full-tonnage strain gauge checks on all four tie bars to verify balanced load distribution.

We support tailor-made equipment configurations based on specific mold tooling and factory automation requirements:
Custom Platen Drilling Pattern: SPI, Euromap 2, or custom threaded hole layouts to integrate directly with existing mold bases.
Core Pull & Pneumatic Circuits: Up to 4 hydraulic core pulls and 6 pneumatic air valves configured directly within the controller software.
Automation Interface: Full Euromap 67 or Euromap 73 interfaces for pick-and-place side-entry or top-entry robots, IML (In-Mold Labeling) systems, and downstream conveyors.
Extended Daylight / Stroke: Custom frame extensions for high-stack molds or long core-pull medical applications.

To receive an accurate technical proposal and commercial quotation within 24 hours, submit the following details:
Part Drawings / Samples: 3D CAD files (.STEP or .IGES) including wall thickness profiles and net weight.
Resin Specifications: Material grade, melt flow index (MFI), and filler percentages (e.g., glass fiber, mineral powder).
Mold Details: Cavity count, total mold dimensions (L x W x H), hot runner layout, and core-pull logic.
Target Output: Desired cycle time and annual production volume requirements.
Regional Utilities: Factory operating voltage (V), frequency (Hz, e.g., 480V/60Hz or 400V/50Hz), and ambient operating temperature.

Hot Tags: high speed servo injection molding machine, China high speed servo injection molding machine manufacturers, suppliers, factory