Optimizing injection molding machine maintenance strategy: Scientific method to reduce failure rate and cost
In the manufacturing industry, injection molding machine is the key production equipment, and its stability and efficiency are directly related to the smooth operation of the production line. However, the maintenance cost and failure rate of injection molding machines have always been the focus of attention of enterprises. How to reduce the maintenance cost and failure rate of injection molding machine through scientific methods has become a key issue to improve production efficiency and reduce operating costs.
The maintenance cost of injection molding machine mainly includes daily maintenance, regular maintenance, parts replacement and other costs. The failure rate refers to the frequency of equipment failure in a certain period of time. The level of these two indicators directly affects the production cost and production efficiency of enterprises. Therefore, reducing the maintenance cost and failure rate of injection molding machine can not only improve the efficiency of the use of equipment, but also save a lot of operating costs for enterprises.
First of all, we need to understand the working principle and common faults of the injection molding machine. Injection molding machine is mainly composed of hydraulic system, electrical control system, mechanical structure and other parts. Among them, the hydraulic system is the core part of the injection molding machine, and its main function is to drive the mold to open and close by the pressure of hydraulic oil. The electrical control system is responsible for controlling the working pressure and flow of the hydraulic system, as well as the temperature of the mold and other parameters. The mechanical structure is the basic part that supports the whole injection molding machine, including the body, the mold mounting plate, the guide rail and other components.
The common faults of injection molding machine mainly include hydraulic system fault, electrical control system fault and mechanical structure fault. The failure of hydraulic system is mainly manifested as unstable hydraulic oil pressure and high oil temperature. The failure of electrical control system mainly manifests as controller failure, sensor failure, etc. Mechanical structure faults are mainly manifested as rail wear, mold mounting plate deformation and so on.
In response to the above faults, we can take the following measures to reduce the maintenance cost and failure rate of the injection molding machine:
Check and maintain the hydraulic system regularly. Hydraulic system is the core part of injection molding machine, and its working state directly affects the stability and efficiency of injection molding machine. Therefore, we need to regularly check the pressure and temperature of the hydraulic oil to ensure that it is within the normal range. At the same time, it is also necessary to regularly replace the hydraulic oil and filter element to prevent failures caused by oil pollution.
Strengthen the maintenance of electrical control system. Electrical control system is an important part of injection molding machine, and its stability directly affects the working efficiency of injection molding machine. Therefore, we need to regularly check the working status of the electrical control system, and timely find and deal with problems such as controller failure and sensor failure. At the same time, it is also necessary to clean the electrical control cabinet regularly to prevent dust and moisture from causing damage to the electrical components.
Strengthen the maintenance of mechanical structure. Mechanical structure is the basic part of the injection molding machine, and its stability directly affects the accuracy and life of the injection molding machine. Therefore, we need to regularly check the working status of the mechanical structure, timely find and deal with problems such as rail wear and mold mounting plate deformation. At the same time, it is also necessary to regularly lubricate the mechanical structure to reduce wear and extend service life.
Establish a sound maintenance system. In addition to the above technical measures, we also need to establish a sound maintenance system to ensure the stable operation of the injection molding machine. This includes developing detailed maintenance plans, training professional maintenance personnel, and establishing fault reporting and handling mechanisms.
In general, reducing the maintenance cost and failure rate of injection molding machine requires us to start from many aspects, including regular inspection and maintenance of the hydraulic system, strengthening the maintenance of the electrical control system, strengthening the maintenance of the mechanical structure and establishing a sound maintenance system. Only in this way can we ensure the stable operation of the injection molding machine, improve production efficiency and reduce operating costs.
