Servo Injection Molding Machine For General Plastic Parts

This general-purpose servo hydraulic injection molding machine delivers high repeatability, low energy consumption, and long-term mechanical stability for general-purpose plastic part production. Built with a heavy-duty five-point double-toggle clamping system and an electro-hydraulic servo drive, it covers clamping forces from 700 kN (70 Tons) to 23,000 kN (2,300 Tons).

The closed-loop dynamic response system modulates motor speed and pump displacement according to real-time process demand. By eliminating standard hydraulic throttling, energy consumption during holding and cooling phases is reduced by 30% to 70% compared to fixed-displacement pump systems.

Designed for continuous 24/7 industrial manufacturing, this platform processes standard commodity resins (PP, PE, PS, ABS) as well as engineering plastics (PC, PA6/PA66, POM). It maintains shot-weight variance within +/- 0.3%.

The table below outlines technical parameters for standard frame sizes across the product series:

Closed-Loop Servo Drive Architecture: Integrates a high-response permanent magnet synchronous motor with an internal gear pump. System response time reaches maximum output in under 40 milliseconds.
Finite Element Analysis (FEA) Platen Design: Cast iron platens optimized via FEA minimize flexure under full clamping tonnage, protecting mold parting lines from flashing and preventing premature core pin wear.
High-Precision Injection Unit: Dual-injection cylinders maintain balanced axial forces on the screw during plasticization and injection, minimizing platen tilts and barrel misalignment.
Proportional Hydraulic Control for Ejection and Core Pulls: Offers programmable speed, position, and pressure profiles for multiple hydraulic core pulls and ejector pins.
Centralized Automatic Grease Lubrication: Automatically dispenses monitored doses of grease to tie-bar bushings and toggle linkages based on operational cycle counts, with pressure-sensor fault tracking.
Microprocessor Controller: Features a 10.4-inch color touchscreen supporting multi-language operations, heat zone PID control within +/- 1 degree C, cycle data logging, and EUROMAP 63/78 robot interfaces.

System Flow
[Servo Motor + Gear Pump] -> [Hydraulic Manifold Block] -> [Proportional Valves] -> [Actuators: Clamping / Injection / Ejection] -> [Rotary Encoder & Pressure Transducer] -> [10.4" PLC Touchscreen]
Injection Unit
Nitrided alloy steel screw and barrel (38CrMoAlA) treated with ion nitriding to achieve a hardness depth of 0.5 - 0.8 mm and surface hardness >= 900 HV.
PID-controlled ceramic heating bands divided into 4 - 6 independent heat zones with thermocouple monitoring.
Linear position transducers monitor injection position, holding position, and screw backpressure with 0.01 mm resolution.
Anti-cold-start protection locks plasticization until all barrel zones reach designated melt temperatures for a preset soak period.
Clamping Unit
Five-point double-toggle mechanical linkage engineered for rapid opening and closing with smooth acceleration-deceleration curves.
Hardened steel tie bars (42CrMo) with hard-chrome plating (0.03 - 0.05 mm depth) ensure resistance to tensile fatigue.
Automatic mold height adjustment powered by a hydraulic motor and sun gear assembly.
Low-pressure mold protection with adjustable sensitivity prevents mold damage from un-ejected parts or flash debris.
Hydraulic & Electrical Systems
Dynamic servo pump system tailored for high fluid displacement stability.
Premium hydraulic valves (Rexroth / Vickers) mounted on short-path manifold blocks reduce internal pressure drops and heat build-up.
Oil temperature monitoring with automatic alarm triggers if hydraulic oil exceeds 55 degrees C.
Electrical cabinet layout compliant with CE / UL safety standards, utilizing Schneider / Siemens low-voltage components and an isolated cooling ventilation loop.

Energy Efficiency Comparison
Traditional Fixed Pump: Full power output continuously. High energy loss during idle and cooling phases.
Servo Hydraulic System: Dynamic power matching. Output peaks during injection, drops during holding, and reaches near zero during cooling. Total energy reduction: 30% - 70%.
Core Technical Benefits
Thermal Management & Oil Longevity: Because the servo motor runs at near-zero speed during cooling and dwell phases, hydraulic oil heat generation is reduced. This cuts cooling water demand by up to 50% and preserves oil viscosity, extending hydraulic seal life and reducing oil degradation cycles.
Shot Weight Stability: Closed-loop pressure transductive feedback samples barrel pressure at 1 ms intervals. This level of real-time compensation limits shot-to-shot weight variations to +/- 0.3%, keeping tight-tolerance commercial parts compliant.
Structural Rigidity: Platen deflection is kept within 0.05 mm at maximum clamping force. This preserves uniform clamping force distribution across large multi-cavity molds, reducing flash and part wall thickness variance.
Low Noise Levels: Operating noise stays below 75 dB(A) under maximum hydraulic pressure loading, providing a safer, quieter shop floor environment compared to conventional hydraulic presses.

The standard heating and screw configuration processes non-corrosive thermoplastics up to 350 degrees C processing temperatures:

Polypropylene (PP) & Polyethylene (HDPE / LDPE): Excellent melt stability for large thin-wall containers, caps, and domestic items.

Acrylonitrile Butadiene Styrene (ABS) & Polystyrene (PS / HIPS): High surface finish fidelity for appliance covers, housings, and consumer goods.

Polyamides (PA6 / PA66) Unfilled: Fast recovery screws maintain precise dosage without drooling.

Polycarbonate (PC) & PC/ABS Blends: High-torque servo motors ensure uniform shear without thermal degradation.

Screw & Barrel Upgrades
Bimetallic Screw & Barrel: Tungsten carbide alloy coating for processing materials with up to 40% glass fiber reinforcement.
PVC / Corrosive Plastic Package: Hard chrome-plated screw with specialized flight profile, forced air barrel cooling fans, and nickel-plated platens.
Hydraulic & Control Upgrades
Multi-Loop Core Pulling: Up to 4 independent hydraulic core pulls controlled via proportional valves.
Integrated Hot Runner Control Modules: 4 to 16 temperature zones integrated directly into the main machine PLC display.
Valve Gate Control: Pneumatic or hydraulic valve gate interface for runnerless mold designs.
Energy Management: Infrared barrel heater bands that lower thermal power consumption by an additional 15% - 25%.

Process Workflow
Raw Component Inspection: CMM dimensional check and ultrasonic flaw detection on castings.
Precision Machining & Alignment: Stress-relief annealing followed by CNC milling and laser interferometry alignment.
Pre-Shipment Quality Testing: 48-hour continuous dry run and full-load thermal imaging scan.
Key Quality Standards
Machining & Stress Relieving: Platen castings undergo stress-relief annealing before precision CNC milling. Critical mounting faces are machined in a single setup to maintain strict parallelism tolerances (<0.08 mm across platen face).
Precision Alignment: Tie-bar alignment and platen parallelism are verified using laser interferometers and digital dial gauges.
Hydraulic Testing: Manifolds undergo pressure-drop and leak testing at 125% of rated system pressure (200 bar).
48-Hour Dry Run Quality Assurance: Every completed machine runs a continuous 48-hour automated factory test before dispatch. This includes full speed and full pressure clamping cycles, thermal imaging, and sensor calibration.

We support machinery distributors, system integrators, and OEM buyers with customized engineering capabilities:
Custom Mechanical Dimensions: Extended tie-bar clearance, enlarged mold opening stroke, and customized platen mounting hole patterns (ANSI, SPI, or EUROMAP standards).
Software Localization: Custom PLC software interface design, supporting localized languages, specific user permission levels, and custom data logging parameters.
System Integration: Customized robotic arm mounting interfaces, conveyor sync controls, and auxiliary equipment power outlets (e.g., granulators, mold temperature controllers, material dryers).
Brand Customization (OEM): Custom paint colors, brand labeling, custom safety warning plates, and tailored technical documentation.

To help us select the correct frame size, screw geometry, and hydraulic profile for your application, please provide the following technical details with your inquiry:
Part Information: Part dimensions, 3D file/drawing, wall thickness range, target weight, and projected surface area.
Resin Specifications: Exact polymer grade, manufacturer, shrink rate, and additive loading (e.g., glass fiber %, flame retardants).
Production Requirements: Desired cycle time, required annual unit volume, and mold layout details (number of cavities, drop layout).
Mold Data: Mold weight, core pull requirements (number of hydraulic/pneumatic cores), and hot runner details (zone counts, valve gate requirements).
Electrical & Regional Setup: Local factory operating voltage/frequency (e.g., 480V / 60Hz, 380V / 50Hz), ambient plant temperatures, and regional compliance standards (CE, UL, CSA).