注塑机保养手册

嘉兴昌机械工业【注塑机保养手册】保养及检查MaintenanceandExamination日常保养及检查机器寿命是非常重要,预防重于治疗，然而对于机器而言，当然是保养重于修理了，射出成型机是一种高运转的机器，一天可能接近24小时操作，假设以一个月25个工作天而言，每一月累积600个操作小时，一年将达7200小时，几乎是一般工具机4-5倍长之操作时间。保持良好的保养是减少及防止机器发生故障的最有效途径。以下资料提供给用户,使用机器时必须仔细阅读,给机器定期检查保养及维护..Itisimportanttomaintainandexaminethemachineeveryday.Wearealwaystoldthatpreventionisbetterthancure,aswellasmachine,maintenanceisbetterthanrepair.Injectionmoldingmachineasakindofhighoperationmachines,mayworknear24hoursinoneday,ifitkeepworking25dayseverymonth,thenitwillaccumulate600operationhourswithinamonth,7200hoursinayear,whichis4-5timeslongerthangeneralmachine.Maintainingagoodmaintenanceisthemosteffectivewaytoreduceandpreventthemalfunctionofmachine.Thefollowinginformationisprovidedtouser,andpleasekeepscarefulreadingbeforeusingthemachineaswellasexaminesandmaintainsregularly.清洗Washing机器经过长时间使用后,所有滑动导杆、油缸的轴芯、滑面等会被沙尘等物质沾污,假设不及时清理,滑动导杆、油缸轴芯及滑面会容易磨损,尤其对油缸轴芯油封为甚。保持清洁可防止由杂物引起磨损、堵塞、水份引起的锈蚀和及早觉察漏油情况。所以经常要清洗机器。请勿使用酒清、挥发性油、汽油、石油等制品擦拭人机屏幕，必须使用一般家庭擦试玻璃用清洁剂擦拭。Afteralongtimeusing,alltheslidinglead-screw、axiscoreofoilcylinder、slidingsurfaceandsoonwillbestainedbythesandflyingintheair.Ifnotcleaningintime,thoseplacestalkedabovemaybeabradedeasily,especiallytheaxiscoreofoilcylinder.Keepingcleancanavoiddetritions 、pluggingcausingbysundriesandrustinesscausingbywater,andalsoeasytofindtheoilspill.Pleaseusethegeneralhouseholdglasscleaningagenttowipethehuman-computerscreen,butnotalcohol 、volatileoil 、gasoline、oilorotherproducts.润滑系统LubricationSystems有足够润滑可减少机件磨损,必须经常加注润滑油及油脂于机件如射台导杆、 锁模导杆及有润滑标识处..机台KS55C和KS55T的注油点如下列图所示：Ifthere'senoughlubrication, itcanreducemechanicaldetritions.Organlikeinjectionstagelead-screw、clampinglead-screwandlubricationidentificationmustbeoftenaddedoilorgrease..MachineoilinjectionpointofKS55CandKS55Tasshowninthefollowingfigure：注黄油I.'"MM-f版本比例00共页第页射台油缸射出组座台油缸关模油缸嘉兴昌机械润滑示意图KS25T普通机数量重量1:12KS25T-0001 530.132标记处数更改文件号签字日期设计标准隹化校对审定审核工艺日期 ；1014-06-26图样标记此处注入

滑油润此处注入润滑油部装、锁模部装isirFuw处注入滑油注入油此处润滑此润Z寸出用户必须注意以下几点:〔一〕润滑油之选择〔1〕耐高负载性〔2〕氧化稳定性〔3〕防锈性佳〔4〕适用30#~40#〔二〕每个工作班的操作者必须检查润滑油喉能否向摩擦零件部位供油,不允许供油喉塞、脱落。〔三〕检查油脂润滑摩擦外表的润滑油膜状况,不允许出现干摩擦,及时加注润滑脂。Usermustpayattentiontothefollowingpoint:〔一〕Choiceoflubricationoil〔1〕 Highloadresistance〔2〕Oxidationstability〔3〕Goodrustproofness〔4〕Applyto30#~40#〔二〕Eachworkshiftoperatormustchecktheoilthroatwhetheritsupplyoiltofrictionparts,withoutoilthroatplugorshed.〔三〕Checktheconditionoflubricationfilmonthegreaselubricatedsurface,anddryfrictionisnotallowed,fillinggreaseintime.液压系统Hydraulicpressuresystem液压油箱必须经常存有足够液压油,可从装置于油箱外之油尺检查油位,如果觉察油位低于要求,应及补充。Hydraulicfluidtankshouldbeoftenstoringwith enoughhydraulicoil,andoillevelcanbeexaminedbyusingthedipstickwhichisfixedoutsidetheoilbox.Iffindingthatoillevelislowerthanrequirement,itshouldbereplenishedintime.很多液压系统毛病起源于已污染之液压油,应采用高质素之液压油,液压油在摄氏30-50度,粘度在150-225SUS或动动粘度40-60厘澌最为适合。本司推荐使用46#液压油.Lotsoferrorsofhydraulicsystemoriginatefromthepollutedhydraulicoil,sohighqualityhydraulicoilisbetter.Thesuitablestateofthehydraulicoilisin30-50degree〔temperature〕、150-225SUS〔viscosity〕and40-60ls〔kinematicviscosity〕.Ourcompanyrecommends#46ofhydraulicoil.用户亦须定期检查液压油，假设果需要更换液压油，把原有液压油抽掉，清洗油箱后，再加注全新液压油于油箱内〔新旧液压油不能混合〕,同时清洗油筛。Usersalsoshouldcheckthehydraulicoilregularly.Ifitneedstorenewalthehydraulicoil,firstly,takeouttheoriginalhydraulicoilandwashthetank.Andtheninpourthenewhydraulicoil〔oilandnewhydraulicoilcannotbemixedtogether.〕,washtheoilscreenatthesametime.机器在正常运作时，液压系统温度不能超过摄氏55度。在超过情况下工作，液压系统会产生以下现象：Whenthemachineworksregularly,thetemperatureofhydraulicpressuresystemcannotovertake55degree.Ifitisexceeded,thehydraulicpressuresystemwillcomewiththefollowphenomenon:〔一〕液压油氧化加速，提前变质。Oxidationofhydraulicoilisaccelerated,anddeteriorateinadvance.〔二〕粘度降低导致油泵及其他阀体受损.Viscosityreducingcausedamagetopumpsandotherparts.〔三〕油封加快老化。Oilsealacceleratetoageing.假设觉察Iffindthat…〔一〕液压油出泡沫Ifhydraulicoilbubble,〔1〕应检查油泵吸油管的密封性。Checktheleak-tightnessoftheoilpumpsuctionpipe.〔2〕应检查液压油是否充足。Checkthehydraulicoilwhetheritissufficient.〔3〕应检查回油管是否沉入液压油内。Checkbacktheoiltubewhetheritissinkingintothehydraulicoil.〔二〕 液压油呈悬浮状态白色Ifhydraulicoilappearinwhitesuspendedstate,〔1〕应检查油箱密封性，可能由于空气潮湿，空气中水氛进入液压油内。Checktheleak-tightnessoftheoiltankwhetherliquidwatercontentintheairgetintothehydraulicoil.〔2〕应检查热闪换器水管是否损坏导致冷却水混入液压系统内。ChecktheHotFlashConverterwaterpipewhetheritisdamageresultingincoolingwatermixingintothehydraulicsystem.液压泵及液压阀Hydraulicpumpandhydraulicvalve由于液压泵及液压阀结构精密及复杂,维修保养必须由技术人员处理。装拆时，要加倍小心以免损坏零件。Duetotheprecisionandcomplexofhydraulicpumpandhydraulicvalve 'sstructures,maintenanceandrepairmustbedealtwithbythetechnicalstaff.Whenassembleanddisassemble,becarefulsoasnottodamagetheparts.油隔Greasetrap油隔功能是把液压油被油泵吸入前经过油隔而过滤异物。必须经常检查油隔，假设油隔严重受污染油泵吸油管产生真空导致油泵损坏。Thefunctionofthegreasetrapisthatfilterstheforeignmatterbeforehydraulicoilbeingsuckedbytheoilpump.Checkthegreasetrapusually,andifthegreasetrapispollutedseriously,theoilpumpsuctionpipewillemergevacuumcausingtheoilpumpdamaged.油封Greaseseal所有密封填充圈是装于油缸及阀体上,当密封圈损坏时,会影响机器工作性能,甚至泄油。需要时，应及早更换损坏之密填封圈。Allsealedfilledcirclesareinstalledontheoiltankandvalvebody,andwhenthesealedcirclesisdamaged,itwillaffecttheperformanceofthemachineandevenoildrainage.电路控制Circuitcontrol在正常运作时,防止水及其他杂物进入电箱,电箱门应紧密关闭.遇到电路故障时应由合资格的工作人员负责维修。台电部份联接螺丝应紧固，防止因松脱而导致危险。经常检查电箱温度不能太高，防止影响电子零件的正常运作。同时定期检查平安门电器互锁及行程咭掣以免发生意外。Innormaloperation,preventwaterandotherdebrisgettingintotheelectricboxandthedooroftheelectricboxshouldbeclosedtightly.Whenitencountersacircuitfault,eligiblestaffshouldberesponsibleformaintenance.电热Electricheat应经常检进电热.电热不正常会产生注塑总是导致产品质素低.Checktheelectricheatregularly.Abnormalelectricheatcanproduceplasticinjectionresultinginalowqualityofproduct.〔一〕检查积各段电热是否正常。Checkeachpartofelectricheatwhetheritisnormal.〔二〕检查温度控制状态。Checkthecontrolstatusofthetemperature.〔三〕检查控温线端与熔胶筒接触状况。Checkthecontactstatusbetweentemperaturecontrolterminalandmeltadhesivecylinder.熔胶筒及螺杆更换联结Meltadhesivecylinderandscrewreplacingthecouplingassembly〔一〕 对射咀进行撤除或移开，必须先浅放掉料管内部的塑料产生的压力。Beforedismantlingorremovingtheshootmouth,pressureproducedbytheplasticinsidethematerialpipeshouldbeunhandedlightly.因为有时温度会对封闭式料管内部的塑胶产生化学反响，并于料管内产爆炸性的压力。Becausethatsometimestemperaturecanleadtothatplastictakeplacechemicalreactionsandcauseaexplosivepressureinsidetheclosedmaterialtube.将料管的温度降下及降低内部的压力，按下松退键让螺杆向后退。Pressingtheloosebackkeyandmakingthescrewbackcanlowerthetemperatureandpressureinsidethematerialtube.〔二〕 塑胶于料管内加热时间太长是相当的危险的，因为长时间的对塑胶加温产生的毒的气体，并经由射嘴喷出来。Itisdangeroustoheattheplasticcementinsidethematerialtubetoolongtime.Becauseofthatlongtimeheatingtheplasticwillproducethetoxicgasesandsprayingoutfromtheshootmouth.〔三〕 料咀跑入异物时，不可以加高温度或高压力将体更挤出来。Ifthere'ssomeforeignmattercomefromthematerialmouth,donotriseupthetemperatureandpressuretosqueezeitoutstrongly.必须关掉电源并将漏斗内时，然后再将异物去除。Turnoffthepoweranduseafunneltocleartheforeignmatter.〔四〕 当硬物掉入送料漏斗时，，要取出时必须相当的小心。Ifthehardobjectsfalldownintothefeedfunnel,paymoreattentionwhentakeitout.〔五〕 拆下料管的护盖前必须先确认关闭总电源开关。Besurethemainpowerisoffbeforeremovingthematerialtube 'scover.〔六〕 严禁将润滑油涂抹于射出螺杆、料管、电热片上。Lubricantappliedtoinjectionscrew 、materialtube、electricflakeisforbidden.(七)清洗或更换零件时，必须撤除熔胶筒、螺杆及止逆阀等零件。先选择手动方式。Washorchangetheparts,mustdismantlemeltadhesivecylinder、screwandlockcheckgatefirst.Selectmanuallyfirst.按以下步骤更换熔胶筒：Replacingthemeltadhesivecylinderaccordingtothefollowingsteps:关闭料斗闸板，采用手动或自动清洗功能把剩余塑料从熔胶筒打出。Closethehoppergate,andchoosemanualorautomaticcleaningfunctiontowhipouttheremainingplasticfromthemeltadhesivecylinder.操作射台至最后位置。Transferoperationinjectionstagetofinalposition.关掉电源，撤除电热圈。Turnoffthepower,removaltheelectriccircle.松掉熔胶筒，锁紧螺母。Loosethemeltadhesivecylinder,andlockthenuttightly.松掉螺杆端与传动轴之联结组件。Loosethecouplingcomponentsbetweenscrewterminalanddriveshaft.采用车间行车把熔胶筒稳固吊着，后把熔胶筒从射台拉出。Useaworkshopbridgecranetohangthemeltadhesivecylinderstably,andthenpullitoutfromtheinjectionstage.按以下步骤更换螺杆：Replacingthescrewaccordingtothefollowingsteps:关闭料斗闸板，采用手动或自动清洗功能把剩余塑料从熔胶筒打出。Closethehoppergate,andchoosemanualorautomaticcleaningfunctiontowhipouttheremainingplasticfromthemeltadhesivecylinder.操作射出台至最后位置。Transferoperationinjectionstagetofinalposition.逆时针方向摇摆射台(先松掉或撤除有关之螺丝或另件)。Swingtheinjectionstageinacounterclockwisedirection(looseorremovetherelevantscrewsorothersfirst).松掉螺杆端与传动轴之联结。Loosethecouplingcomponentsbetweenscrewterminalanddriveshaft.撤除射咀及射咀法兰。Removetheshootingmouthandshootingmouthflange.操作螺杆“倒索“动作把螺杆端与传动轴脱离，必要时，用木方枕着螺杆端与传动轴之间。Usethe “fallcable〞movementoftheoperationscrewtoseparatethescrewterminalanddriveshaft.Ifnecessary,pillowwithasquaredtimberbetweenscrewterminalanddriveshaft.操作射胶动作把螺杆推出。Pullthescrewoutbytheoperationinjectionaction.注意:为平安起见,把射胶压力及速度数值调低,由于熔胶筒已被加热,撤除时小心被烫伤Note:forsecurity,lowerthenumericalofinjectionpressureandspeed.Asthemeltadhesivecylinderisheated,becarefulwhendismantle.本机螺杆前端装有标准型之止逆阀组件，止逆阀组件采用左牙螺纹与螺杆连接。当螺杆转动时不容易把止逆阀松出，松脱时请留意旋向.Thereisastandardlockcheckgatewhichisusethelefttoothscrewthreadtoconnectwithscrewonthismachine.Whenturningaroundthescrew,ifitisnoteasytoloosethelockcheckgate.Payattentiontotheturnwhendoffing.定期检查Regularchecking〔一〕每天检查一次Checkitonceaday.〔1〕当机器运作时，检测电马达、油泵、油管及油阀发出声音及震动状况。Whenthemachineismoving,checkthesoundandvibrationconditionofelectricmotors、pump、oilpipeandoildischargevalve.〔2〕检查系统压力及油温，假设温度过高，检杳冷却系统部份。Checkthesystempressureandtemperature.Ifthetemperatureistoohigh,checkthecoolingsystem,too.〔3〕观察液压系统之管道接口、阀体、法兰等有否泄油。Observethe pipe'sinterfaces、valve、flangeofthehydraulicsystemifthere'saoilleakage.〔4〕观察冷却系统管道有否漏水。Observethecoolingsystemifthere 'sawaterleakage.〔5〕检查平安装置、紧急停止按扭及指示灯状况。Checkthesafetydevice 、emergencystopbuttonandpilotlamp.〔6〕检查螺丝、螺母等紧固状况。Checkthescrew 、nut.〔7〕检查润滑系统。Checkthelubricationsystems.〔二〕每星期检查一次Checkitonceaweek:〔1〕检查加注润滑点。Checkitlubricationpoints.〔2〕检查电路如电热圈、控热线、行程咭掣等按线状况。Checkthecircuit'swiringstate,likeelectricheatingloop、controlhotline、travelcardsforappliancesandsoon.〔3〕紧固可能松脱之螺丝、螺母及联结法兰。Fixturethosemayloosenedscrew 、nutandfittingflange.〔4〕清洗机器上所有滑动之机件，以免被沙尘覆盖容易受损。Washalltheslidingableorgansofthemachine,sothatitwillnotbeeasytodamagecausedbythedust.〔三〕每月检查一次Checkitonceamonth:〔1〕检查安装装置Checktheinstalldevice.〔2〕检查阀体之线圈是否松脱。Checkthecoilofthevalvewhetheritisloosened.〔3〕检查液压油是否保持良好质素。Checkthehydraulicfluidwhetheritkeepsagoodsituation.〔4〕更换已磨损之机件。Changethewearer.〔四〕每年检查一次Checkitonceayear:〔1〕 更换已磨损之机件。Changethewearer.〔2〕 检查系统压力，必要时重新调节。Checkthesystempressure,andadjustagainifnecessary.〔3〕 检查熔胶转动轴承状况，加注润滑油脂。Checktheconditionofmeltspinningbearings,andaddsomegreaselubricant.〔4〕 清洗热交换器。Washtheheatexchanger.机器的储存Keepofmachine如果机器长期不生产运作，请在检查机器之后用保护膜罩好，以防杂尘物进入。Ifthemachinedoesn'tworkforalongtime,pleaseuseaprotectivefirmcoverthemachinebeforechecking,incaseofthedustgoinginto.常见故障及排除方法CommonTroublesandExcludedSolutions2.1.报警及排除Alarmandexclude常见报警commonalarm原因及排除方法Causeandexcludedsolutions脱模失败Failtoknockout当顶针两个限们开关同时压合〔X013、x014同时亮：查看两个接线点处是否有短路S,行程开关们置是否松动或不恰当〕Whentwolimitswitchofthecentrepressatthesametime〔X013、x014lightsimultaneously:Checkwhetherthere'sashortcircuit Sattheconnection,andlimitswitchisloosedorimproper.机械手失败Failinmanipulator机械手操作中，机械手未能复位〔功能页面机械手选择使用〕Whenthemanipulatorisoperating,itfailedtoreset〔manipulatorselectfunctionpage〕射嘴护罩翻开Opentheinjectionmouthcover射胶平安门〔X514〕未关Injectionsafetydoors〔X514〕isclosed.熔胶未定时完成Meltadhesiveisnotscheduledtocomplete自动过程中，在熔胶计时内未能完成熔胶动作：熔胶时间、行程的设定是否正确，料筒时有无料，熔胶压力、流量是否够大Intheprocessofautomatically,failedtocompletethemeltinthemelttimingaction:whetherthemelttimeandtripsettingiscorrectandifthere 'smaterialinthebarrel;whethermeltpressureandflowislargeenough.开模未定时完成Openingmouldisnotscheduledtocomplete开锁模计时内，未能完成开模动作：开锁模时间设定是否正确，开模压力、流量是否够大，此时循环不能继续Failedtocompletetheopeningmouldactionintime:whetherthesettingtimeiscorrectandthepressure 、flowislargeenough;cyclingcannotcontinue关模未到定位Closingmoulddoesn'treachposition开模计时内，未能完成锁模动作：开锁模时间设定是否正确，锁模压力、流量是否够大Failedtocompletetheclosingmouldactionintime:whetherthesettingtimeiscorrectandthepressure 、flowislargeenough;cyclingcannotcontinue开模未到定位Openingmoulddoesn'treachposition作顶针动作时，开模终止行程〔开模二慢〕未到或限位咭制〔X013〕未压合Incentreaction,openingmouldendtherouteisnotreachorlimitcards〔X013〕arenotpressed.座退未到定位Seatbackdoesn'treachposition作滑模或转盘动作时，座退终止开关〔X007〕未压合Whendoslidingorturntableaction,seatbackendswitch〔X007〕isnotpressed.滑模未到定位Slidingmoulddoesn 'treachposition作锁模、顶针动作时，滑模终止开关〔X403X404〕未压合Whendoclosingmouldandcentreaction,slidingmouldendswitch〔X403、X404〕isnotpressed.顶退未到定位Driftdoesn'treachposition作锁模、滑模或转盘动作时，顶退终止开关〔X011、X013〕未压合Whendotheclosingmould、slidingmouldandturntableaction,driftendswitch 〔X011、X013〕isnotpressed.定位上未到定位Positionupdoesn'treachposition作锁模、顶针动作时，定位上终止开关〔X516〕未压合Whendotheclosingmouldandcentreaction,positionupendswitch 〔X516〕isnotpressed.定位下未到定位Positiondowndoesn'treachposition作滑模或转盘动作时，定位下终止开关〔X517〕未压合Whendotheslidingmouldandturntableaction,positiondownendswitch〔X517〕isnotpressed.开模总数已到Reachtheopeningmouldtotality实际开模次数到达时间页面内“开模限数〞的设定值Realopeningmouldtimesreachthesettingpointonthetimetable.润滑油位低Lowlubricationoillevel润滑油箱内的润滑油低于润滑油位开关〔X405〕Lubricationoilinthetankislowerthantheoillevelswitch〔X405〕料筒温度太高Materialbarrel'stemperatureistoohigh料筒的实际温度高于设定温度加上高温偏差Realtemperatureofmaterialbarrelishigherthanthedesigntemperaturepulsingthedeviation料筒温度太低Materialbarrel'stemperatureistoolow料筒的实际温度低于设定温度减去低温偏差，此时不能进行射胶、熔胶、抽胶动作Realtemperatureofmaterialbarrelislowerthanthedesigntemperaturecutting thedeviation, andnoinjection、meltingandtakingouttheglueactionthismoment.22故障及排除FailuresandTroubleExclude故障现象Faultsymptom原因及排除方法Causeandexcludedsolutions系统不上电Systemcannotreachthepower1、 检查开关电源保险管Checktheprotectortubeofpowerswitch2、 检查开关电源各路输出是否正常Checktheoutputlineofpowerswitch3、 检查主机板保险管Checktheprotectortubeofmainboard.l/Olwg出现不正常l/Olwgisnotnormal1、 检查各动作输出条作是否满足Checkwhetheralltheoutputactionisreachthecondition2、 检查外部相关行程开关是否有坏Checkwhetherrelevantrouteswitchoutsideisbroken.3、检查输入输出检测页面相应点是否输出，如有输出那么页面更改输入输出点，相应调换输入输出点Checkwhethertheinput/output detection page'scorrespondingpointsisoutput,ifoutput,thenchangetheoutputandinputpoint.4、 通知生产厂Informtheproducer.有背光无字Backlightwithoutwords1、 比照度是否调好，调比照度Contrastmightnotbeadjustingwell.2、 面板后盖的稳压管7805是否插好Voltage-stabilizing tubeofthepanel'sbackcover7805mightnotbepluggingwell.3、 程序是否插好Proceduremightnotbepluggingwell.4、 液晶模块与显示板的连线是否插好Thelinebetweenliquidcrystalmoduleanddisplaypanelmightnotbepluggingwell.5、 通知生产厂Informtheproducer.有字无背光Wordswithoutbacklight1、 连结线是否松动，把连结线螺丝旋紧Thelinemightbeloosed.Screwthescrewslightly.2、 电源问题，查看电源盒+12V,+24V1A是否正常Powerproblems.Checkthepowerbox+12V ，+24V1A3、 显示板与键盘板，液晶模块的背光线是否插好displaypanelandkeyboardpanel、thebacklightofliquidcrystalmodulemightnotbepluggingwell.4、 通知生产厂Informtheproducer.显示闪动Displayflashing1、 联结线是否松动，把联结线螺丝旋紧Thelinemightbeloosed.Screwthescrewslightly.2、电源问题，面板后盖的稳压管 7805没插好或坏Powerproblems.ChecktheVoltage-stabilizing tubeofthepanel'sbackcover7805.3、 外围供电电220VACA或380VAC低或不稳Checkwhethertheexternalpowersupply220VACA或380VACistooloworunstable.4、 通知生产厂Informtheproducer.无显示无背光Nodisplayandnobacklight1、 联结松动，把联结线螺丝旋紧Thelinemightbeloosed.Screwthescrewslightly.2、电源问题，查看电源盒电源是否正常：板面后盖的稳压管7805是否插好,显示板灯是否亮Powerproblems.Checkthepowerbox:Voltage-stabilizingtubeofthepanel'sbackcover7805;whetherthelightofdisplaypanelislight.3、 通知生产厂Informtheproducer.记忆丧失Memoryloss1、 电池电压低(一般不能低于3V)换电池Lowvoltageofbattery(generallydon'tlessthan3V);changethebattery.2、 记忆块坏(256)坏Memoryblock(256)isbroken.3、 通知生产厂Informtheproducer.中文变英文ChangeChineseintoEnglish1、 电池电压低(一般不能低于3V),换电池Lowvoltageofbattery(generallydon'tlessthan3V);changethebattery.2、 换显示程序Changethedisplayroutine.3、 通知生产厂Informtheproducer.困难Problem可能原因Cause解决方法Solution1.小黑点Littleblackpoint熔胶筒败壁烧焦胶块脱落(PE较常见)Meltadhesive cylinder'sdefeatedwallcharandrubberisfalling off. (commonlyhappentoPE)清洗机筒内壁Cleantheendophragmofcylinder用较硬的塑料进入以擦净机筒壁面。Useahardishplastictoclearwallofcylinder防止胶料长时间受高温。SizingnounderthehightemperatureIong.2黑占J・八、、八、、Blackpoint空气带来肮脏物Dirtycomefromair.1.封盖料斗Cappingbunker.3.胶料亦要封闭好Sealwellthesizing.模空腔内有空气，引致焦化Airinthemoldcavity,resultingincoking.工模排气要改好。Mouldexhausttobechangingforthebetter.再设计工模或塑料.Redesignmouldorplastic.定浇口位置Gatelocation.增加或减少熔胶及工模温度，以改变胶料在模内的流动形态。Addorreducethetemperatureofmeltadhesiveandmould,andchangethemobilitypatternsofsizingintheintramembrane.减低射胶压力或速度Reducethepressorspeedofinjection.3.黑色条纹Blackstreak料筒或螺丝不乾净，原料不乾净利Dirtybarrelorscrewsanddirtyrawmaterial1.清理料筒及螺丝以后应小心处理.Cleanthebarrelorscrewsandtakecareafterwards.2.胶料勿令其污染.Don'tpollutethesizing..料筒内胶料局部过热.Sizing overheatlocality inthebarrel.使料筒的加热均匀.Heatingwell-distributed.冷胶粒互相磨擦或与机筒壁磨擦时烧焦.Coldprotomerescorchwhenrubbingmutuallyorrubwithcylinderwall.1、 参加有外润滑的塑胶.Addsomelubricatingplastic.2、 翻磨料参加润滑剂.Addsomelubricant intoabrasive.4、增加机筒后端温度.Addthetemperatureofcylindertrailingend.因柱塞与螺杆的中心有偏差，发生柱塞与机筒壁面磨擦，烧僬熔胶•Becauseofthe deviationbetween the pistons andscrew'scenter,pistonsandcylinder wall will rub,resulting burning charredmelt.•再次使柱塞疋位，柱塞与机筒壁有足够距离,使空气能顺利排出机筒外；Reorientehpistons.•防止用幼细磨料，因其位於柱塞与机筒壁面间.Don'tusethegrainofabrasive.射嘴过热,烧焦胶料Nozzleisoverheatingandburnsthesizingmaterial1.减低射嘴温主度reducethetemperatureofthenozzle射嘴温度范围大•Thetemperaturerangeofnozzleiswide1.不用[开关]式温度控制器，改用变压器Usetransformer displacethe[switch] type temperaturecontroller。4.黄点、黄线、棕色条纹Yellowpoint 、yellowline、brownstripes.熔胶筒全面或局部过热。Melt adhesive cylinderoverheatlocalityortotally.降低发热器温度.Reducetheheatingtemperature降低螺杆旋转速度.Reducethescrewspinspeed3•减少螺杆背压.Reducethescrew'sbackpressure.胶料粘机筒壁或射嘴，以致烧焦.Plastic material stickmachinecylinder wallorshooting mouth, resultingcharring.拆开射嘴进行清洁或拆开机筒和射嘴 ，一同清理Openingtheinjection nozzleforcleaningoropenthebarrelandshootingmouth,cleantogether.胶料在料筒内停留时间过长.Staytoolonginthebarrelofrubbercompound.缩短注塑周期.Shortenthemoldingcycle.料筒内存有死角.Barrelcontainsacorner.更换螺杆.Changethescrew.5.外表哑白Surfacemattwhite.料太湿.Materialistoowet.烘料至干.Bakedtodry.困 难Problems可能原因Cause解决方法Solution6.气泡airbubble模腔料缺乏，由於：Diecavitymaterialisnotenough,because:制品切面厚，模腔壁上有突盘和突起线条•Productscutisthick,cavitywallhasbothridiumlineandprotuberaneeline注射压力太低.Injection pressureistoolow.注射时间太短Injectiontimeistooshort入料缺乏.Materialisnotenough再设计工模.designthejigagain增加注射压力.Increaseinjectionpressure增加注射时间.Increaseinjectiontime增加进料速度.Increasethefeedingspeed.5增加浇口阔度.Increasethespruewide胶粒潮湿Colloidalparticleiswet模塑前先枯燥胶粒，模塑前胶粒要防止受过大的温度变化Beforemolded,shoulddrythecolloidalparticle, thecolloidal particle shouldavoidexcessivetemperaturechange工模温度不均匀.Themouldtemperatureisasymmetry重新排列模内入水管位置 ，使用权工模温度一致.Rearrangetheconduit position inintramode, usethemouldtemperatureconsistent.7.破裂或黾裂BrokenorMengcracked填模太实.Fillinthemoldistooreal减少入料速度.Reducespeedoffeedstock减少注射压力.Reduceinjectionpressure.减少注射时间.Reduceinjectiontime.工模温度太低。Thetemperatureofjigistoolow提高模温。Improvethemouldtemperature不适当的脱模设计如角度斜位及倒扣位InadequatestrippingdesignsuchasAngleloxosisandtheplaceofbackoff修改工模。Modifythemould再用废料。reoccupywaste少用或不用废料。Lessorwithoutusingwaste8.胶品尺寸性改变Rubberproductsizesexchange模塑情况不稳定.Molding condition isnotstable.调整操作情况，直至最大之平稳操作.Adjusttheoperatingconditionsuntilthemaximumstableoperating注胶工人视乎各情况而决定注塑时间长短TheguleworkercanDependingonthesituation todecidethetimelengthofinjectionmolding今次注塑与上次情况不同Thistimeinjectionmoldingisdifferentthanthelasttime改正跟上次不同之处.Correctthedifferenee betweenthelasttime.检查胶料温度、胶料压力、工模温度、模塑周期时间、入料、电压、温度调节表、压力系统和放入料斗时材料温度Checkthemelttemperature,meltpressure,themouldtemperature,moldingcycletime,and enters the material, voltage,temperaturereconciliation, pressuresystemandintohoppermaterialtemperature在检杳塑件时，周围的空气温度不固定。WhenCheckinplasticparts,the surrounding airtemperatureisnotfixed.1.保持周围空气温度固定。Keeptheambientairtemperaturefixed.2在中午及午夜换班时关闭窗户.Closethewindowwhenchangeshiftsinthenoonandmidnight3.电风扇安放的位置以不能吹到注塑机为佳.Thebestplaceofplacingtheelectricfanistheonewhichwillnotblowtotheinjectionmoldingmachine9.开模时射嘴滴胶•Nozzledroprubberwhendiesinking胶料太热•Sizingmaterialistoohot降低料筒温度当模后退时，小心把料筒内胶料清除Reducefeedtubetemperaturewhendieback,becarefulthematerialinthecylinderclearplasticmaterial10不稳疋周期unstableperiod开模时间长短不一•Timeisdifferentinopeningmould.用计时器确定工模的开关时间Usetimertodeterminetheswitchtimeofmold.不稳定压力Unstablepressure射胶压力要足够及稳定.Injectionpressuremustbefullenoughandstable.模塑周期间，熔胶温度不稳定•Duringthetimeofmouldmaking,meltingtemperatureisunstable.1.检查温度控制器是否正常.Checkthetemperaturecontrollerwhetheritisnormal.2..用最好的温度控制器.Usethebesttemperaturecontroller.检查电压是否稳定.Checkthevoltagewhetheritisstable.看发热圈是否损坏.Whetherthere'sdamagetotheheatingring.塑料入料斗前后其温有没有变化.Whetherthetemperatureischangebeforeandaftertheplasticmaterial joiningintothefunnel.泵心机柱塞头的胶料量保持固定.Keepthequantityofplasticmaterialinthecentrifugalmachineplugstable.注射机操作要稳定，不可经常扭动调制.Keeptheinjection machineoperationstably, anddonotoften rotatemodulation.检查由窗户或风扇吹来的空气流动情况.Checktheairflowingsituationofwindoworfan.工模温度不均匀Unevenmoldtemperature用工模温度控制器.Useamoldtemperaturecontroller.调整工模内的入水管.Adjustthepipeofwaterentranceinthemould.克定工模的排气情况正常.Checktheexhaustsituation ofmouldwhetheritiswell.检查工模的各入水管.Checkthemouldofthepipeofwaterentrance.入料不稳定.Feedinginstability.检查进料系统.Checkthefeedsystem.困难Problems可能原因Cause解决方法Solution11漏胶Droppedgum胶料过热.Compoundisoverheating.降低胶料温度.Reducethemelttemperature.降低工模温度.Reducethemouldtemperature.减少螺杆旋转速度或螺杆背压.Reducescrewrotationspeedorscrewbackpressure.注射压力过高Thepressureofinjectionistoohigh.降低压力Reducepressure.减少枕压时间.Reducethepillowpresstime.入料过多.Panfeedingistoomuch.减少入料Reducepanfeeding.入料不稳定.Panfeedingisinstability.泵心机要保持定量胶料落入柱塞前头Pumpshouldkeepthesizingmaterialdropintheheadofplungerquantify.工模的凸凹两面接触线不良 .Lineof contact inthe再次打磨凸凹遗的接触线..Shouldpolishthelineofcontactintheconvex-concaveagain.convex-concavetwosidesofthemouldcontactunwell.模塑周期不稳定.Moldingcycleisnotstable.用计时表，保持整个模塑周期时间固定 .Usestopwatch,keepthemoldingcycletimefixed.锁模力不够.Theclampingforceisnotenough.增大锁模力Increasetheclampingforce.用锁模力较大的注塑机..Useinjectionmachineswiththelargeclampingforce.射嘴不适合.Nozzleisnotsuitable.更换适宜的射嘴.Replacetherightshotmouth.12.流纹和塑面起波纹Flowlines andmodel facecrimped胶料不够熟.Sizingmaterialisnotenoughhot.增加胶料温度Increasemelttemperature.工模不够热.Themouldisn'thotenough.增加工模温度Increasethemouldtemperature.注射压力太低.Injectionpressureistoolow.提高注射压力.Improvetheinjectionpressure.注射速度太低Injectionspeedistoolow.提咼注射速度Improveinjectionspeed.浇口太小，引致胶料在模腔内有喷射现象Sprueistoosmallsoitcausesizingmaterialhasjetphenomenonindiecavity.扩大浇口和降低注射压力Expandthesprueandreduceinjectionpressure.塑品切面厚薄不均匀.Thethicknessofplasticsectionisasymmetry.在设计塑件,使用切面厚薄均一.Usetheuniformthicknesssectionwhendesigntheplastic.去除塑品上的突盘和凸起的线条.Removethebothridiumandraisedlineofplasticproduction.排气缺乏.Exhaustisinsufficient.增加排气..Increasetheexhaust.13.塑料胶在浇口成层状.Plasticinthegatelayer胶料过冷。Thematerialistoocold提高熔胶筒温度。Increasethemeltplastictubetemperature工模过冷。Thejigistoocold提高模温.Increasethetemperatureofthemold射胶速度太慢.Theinjection speedoftheistooslowly增加射模速度。Increasetheinjectionspeed.射胶压力缺乏。Theinjection pressureofisnotenough增加压力。Increasepressure射胶时间过长。Thetime减少注射时间。Reducetheinjectiontime胶料污染。Plastic material is1.清洁熔胶筒.Cleanthemeltplastictube.polluted.2.防止混入其它不同胶料.Avoidinterfuseotherdifferentmaterial工模润滑剂过多•Thelubricantofthejigistoomuch清洁模壁，用小量润滑剂.Cleanthediewall,usealittlelubricant水口太大或太小Thewaterentrancetoobigortoosmall调节水口大小使得有良好.压力控制。Changethesizeofwaterentranceandmakeithasbetterpressurecontrol.工模过热〔特别在直浇道的水口〕Thejigtoohot〔especiallyinthe在工模过热部份增加冷却.Increasecoolinginthehotpartofjig困难Problems可能原因Cause解决方法Solution14.水口四周有条纹Around thewaterripple料温过高•Material'stemperatureisoverhigh1.降低注塑温度.Reducetheinjectiontemperature.15注塑周期需时过长Injectioncycletaketoolong胶料温过高•material'stemperatureisoverhigh降低温度.Reducethetemperature.减少螺杆旋转速成度或背压.Reducethescrewspinspeedorbackpressure.工模温度过高•Jip'stemperatureistoohigh降低模温Reducethemouldtemperature.模塑时间不稳定modeling'stimeisinstable用计时表，管制工模开合时间.Usegauge,gontrolthemouldopening-closingtime.供热量不够.heatsuppliedisnotenough改换较大注塑机或将塑胶料预热.Changeabigger injection machineorpreheat.塑料较厚处冷却缺乏.plasticwheretherei