In the dynamic realm of plastics manufacturing, all-electric injection molding machines have emerged as a transformative force, setting new benchmarks for precision, energy efficiency, and environmental sustainability. As technological advancements continue to refine all-electric injection molding machines capabilities and prices become more competitive, their adoption is accelerating across a diverse spectrum of applications.
This buying guide for 2024 meticulously dissects the intricacies of all-electric injection molding machines technology, empowering you with the knowledge and expertise to make informed purchasing decisions. Embark on a journey that encompasses the fundamental principles of all-electric injection molding machines operation, cutting-edge market trends, and a strategic approach to identifying the machine perfectly aligned with your unique requirements.
In this article you will get the following content:
- What is an All-Electric Injection Molding Machine?
- How does Electric Injection Molding Work?
- What are the Components of an Electric Injection Molding Machine?
- What are the Benefits of Buying an Electric Injection Molding Machine?
- Should You Buy a New or Used Electric Injection Molding Machine?
- What is the Price of an Electric Injection Molding Machine?
- How to Choose the Right Electric Injection Molding Machine for Your Project?
- How to Find a Cheap Electric Injection Molding Machine?
- What are the Well-known Electric Injection Molding Machine Brands?
- Conclusion
1. What is an All-Electric Injection Molding Machine?
An all-electric injection molding machine is a process injection molding machine where all power is supplied by electricity. All electric injection molding machines do not have a central motor, but use individual motors designed for each function required by the entire machine, i.e. mold opening/closing, injection, recovery and ejection. This means that the motor can be left idle until its specific function is required. Unlike their traditional hydraulic counterparts, AEIMs harness the power of servo electric motors to orchestrate every aspect of the molding process, from injection to clamping and ejection. This meticulously controlled approach translates into a multitude of advantages, making AEIMs the preferred choice for a diverse range of applications, particularly in the production of high-precision, complex components.
2. How does Electric Injection Molding Work?
Electric injection molding machines (AEIMs) represent a paradigm shift in plastic manufacturing. Unlike their hydraulic counterparts, which rely on pressurized oil for actuation, AEIMs leverage the unparalleled precision and efficiency of servo-electric motors. This translates to a meticulously controlled process, yielding superior part quality, lower operating costs, and a more sustainable production environment.
1. Feeding and Heating
Plastic pellets are fed into a hopper and then conveyed into a heated barrel. Within the barrel, the plastic undergoes a transformation, melting and becoming a highly viscous liquid.
2. Plasticizing and Injection
A precisely controlled screw rotates inside the barrel. This screw not only mixes the molten plastic to ensure uniformity but also generates the necessary pressure. Once the plastic reaches the desired temperature and pressure, the servo motor driving the screw propels it forward, injecting the molten plastic into the precisely engineered mold cavity.
3. Clamping and Holding
A dedicated servo motor controls the clamping unit, which applies high and precisely controlled pressure to firmly hold the mold halves shut during the injection and holding phases. This ensures the molten plastic fills the cavity completely and takes its final, desired shape.
4. Cooling and Ejection
After the plastic cools and solidifies, another servo motor triggers the mold to open. The finished part is then meticulously ejected using an ejector pin mechanism.
5. Continuous Production
The mold swiftly closes again, and the cycle seamlessly restarts with the feeding of new plastic pellets.
3. What are the Components of an Electric Injection Molding Machine?
An electric injection molding machine (AEIM) is a complex piece of machinery composed of various components that work together to produce high-quality plastic parts. These components can be broadly categorized into three main systems: the injection unit, the clamping unit, and the control system.
1. Injection Unit
The injection unit stands as the heart of the AEIM, responsible for transforming raw plastic pellets into molten plastic and injecting it into the mold cavity.
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Hopper:The hopper serves as a reservoir for the plastic pellets or granules, which are the raw materials for the molding process.
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Barrel: The barrel houses the reciprocating screw, which is responsible for melting and plasticizing the plastic pellets.
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Nozzle: The nozzle acts as the gateway for the molten plastic, precisely guiding it from the barrel into the mold cavity.
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Screw Drive Motor: The screw drive motor powers the rotation and axial movement of the reciprocating screw, controlling the melting and injection process.
2. Clamping Unit
The clamping unit plays a pivotal role in the molding process, firmly holding the mold halves together during the injection and cooling phases.
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Clamping Platens: The clamping platens are the two large plates that hold the mold halves together during the injection and cooling phases.
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Clamping Cylinder or Tie Bars: The clamping cylinder or tie bars generate the clamping force that presses the clamping platens together.
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Clamping Force Motor: The clamping force motor powers the clamping cylinder or tie bars, controlling the clamping force applied to the mold.
3. Control System
The control system serves as the brain of the AEIM, meticulously coordinating the actions of all the components and ensuring seamless operation.
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PLC (Programmable Logic Controller): The PLC serves as the brain of the AEIM, controlling the overall operation of the machine, including the injection unit, clamping unit, and auxiliary systems.
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Servo Drives: Servo drives precisely control the movement of the servo motors in the injection unit and clamping unit, ensuring precise and repeatable operation.
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Human-Machine Interface (HMI): The HMI provides the operator with an interface to monitor and control the machine parameters, such as injection pressure, clamping force, and cycle time.
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Sensors: Various sensors provide feedback to the control system, such as position sensors for monitoring the movement of the injection unit and clamping unit, and pressure sensors for monitoring the injection pressure and clamping force.
In addition to these main components, AEIMs may also include various auxiliary systems, such as a cooling system to cool the molded parts, a lubrication system to lubricate moving parts, and a safety system to ensure safe operation.
The specific components and their configurations may vary depending on the size, capacity, and features of the AEIM. However, the essential components listed above form the foundation of any AEIM and play a crucial role in producing high-quality plastic parts efficiently and reliably.
4. What are the Benefits of Buying an Electric Injection Molding Machine?
1. Higher injection Speed and Pressure
All-electric injection molding machines typically reach pressures of 300-400Mpa, significantly surpassing the 120-150Mpa of hydraulic machines.
For injection speed, electric machines can achieve 300-1000mm/s, while hydraulic machines hover around 100mm/s, with high-speed hydraulic models reaching 150-200mm/s.
2. Enhanced Manufacturing Accuracy
Utilizing servo motors for driving various components, these machines offer more precise control. This results in improved quality and consistency in the final products.
These machines use electric servo motors with a 0.1mm +/- rotation to actuate their movements. This type of movement allows the process to completely negate the fluctuations and inaccuracies of movements actuated by hydraulic pressure and their unavoidable pressure curves.
3. Superior Energy Efficiency
Servo motors make these machines more energy-efficient compared to traditional hydraulic counterparts. They consume energy only when necessary, leading to electricity savings of 50-70%.
4. Lower Lubrication and Noise Levels
The electric drive nature of these machines means they require less lubrication than hydraulic ones and operate with considerably less noise.
In a typical hydraulic injection molding machine, a hydraulic pump is constantly on when the machine is running. It has to keep running to circulate oil and is generating heat as long as the machine is running. On the other hand, an electric injection molding machine only consumes electricity as a servo motor turns to actuate movement, so much of the production cycle is spent idling, this is especially so in case of the cooling phase of cycle.
5. Should You Buy a New or Used Electric Injection Molding Machine?
Opting for a new AEIM presents a compelling opportunity to harness the latest advancements in injection molding technology. These machines boast peak performance, incorporating the most recent innovations in servo electric motors, control systems, and Industry 4.0 capabilities. However, the allure of new technology comes at a premium. The upfront cost of a new AEIM can be significantly higher than that of a used machine, requiring a substantial investment. Additionally, the lead time for new AEIMs can be longer, potentially impacting production timelines.
Used AEIMs offer an attractive alternative for budget-conscious manufacturers seeking a balance between cost and performance. These machines, often sourced from reputable dealers or previous owners.
The decision between a new or used AEIM is not a one-size-fits-all proposition. Manufacturers must carefully evaluate their specific needs, budget, and risk tolerance to make an informed choice.
6. What is the Price of an Electric Injection Molding Machine?
The price of all-electric injection molding machines (AEIMs) varies significantly due to factors like machine size, clamping force, injection speed, features, brand reputation, and warranty. Expect to pay anywhere from $5,600 for a desktop micro machine to $100,000+ for a large-tonnage AEIM.
It is important to get quotes from multiple manufacturers before purchasing an AEIM. This will help you ensure that you are getting the best possible price for the machine that meets your needs.
7. How to Choose the Right Electric Injection Molding Machine for Your Project?
Selecting the right AEIM involves meticulous analysis of part dimensions and complexity to determine machine size and precision requirements. Anticipating production volumes and cycle times helps align machine capabilities with throughput demands, while focusing on advanced features like data monitoring and automation enhances productivity. Choosing a reputable manufacturer with strong support and Industry 4.0 capabilities ensures reliability and future compatibility. Evaluating costs and ROI considerations completes the process, ensuring an AEIM investment that optimizes performance and supports long-term business success.
8. How to Find a Cheap Electric Injection Molding Machine?
1. Define Your Requirements with Precision
Before embarking on your search for an AEIM, meticulously define the specific requirements for your application. This entails carefully considering factors such as clamping force, injection speed, shot size, and precision tolerances. Clearly articulated requirements will guide your search towards AEIMs that align seamlessly with your production needs, eliminating the need for overspending on features that exceed your actual demands.
2. Explore the Landscape of Reputable Manufacturers
Dedicate time to researching and evaluating various AEIM manufacturers. Delve into their industry reputation, customer reviews, product warranties, and after-sales support. Reputable manufacturers prioritize quality, ensuring that their machines are built to last and backed by reliable support services.
3. Embrace the Potential of Used AEIMs
Consider purchasing a pre-owned AEIM as a means to significantly reduce upfront costs. However, exercise caution and conduct thorough inspections to ascertain the machine's condition. Evaluate factors such as operational history, maintenance records, and any visible signs of wear and tear. Engage a qualified technician to perform a comprehensive assessment if necessary.
4. Partner with Renowned Dealers
Purchasing from a reputable dealer offers several advantages. Dealers often provide extended warranties, installation support, and access to genuine spare parts. Additionally, they may offer financing options to align with your budget constraints.
9. What are the Well-known Electric Injection Molding Machine Brands?
The realm of all-electric injection molding machines is marked by the presence of both prominent domestic and global manufacturers, each bringing their own expertise and innovations to the field.
Haitian: One of China’s largest manufacturers, Haitian is renowned for its efficient and reliable machinery.
Welltec: Welltec has carved a niche for itself with its high-performance all-electric injection molding machines.
LKIMM: A key player in the Chinese market, known for their advanced technology in all-electric machines.
Chen Hsong: With a long history in the industry, Chen Hsong is recognized for its durable and precise machines.
Toshiba Machine: Toshiba Machine is a Japanese leader known for its robust and efficient all-electric machines.
Sodick: Specializing in precision molding, Sodick offers advanced all-electric injection molding machines.
Arburg: Based in Germany, Arburg is a key figure in the European market, renowned for its high-quality all-electric machines.
Conclusion
In conclusion, all-electric injection molding machines have emerged as a game-changer in the plastics industry, offering a compelling blend of precision, efficiency, sustainability, and versatility. As technology advances and costs decline, AEs are poised to revolutionize manufacturing processes and redefine quality standards across diverse industries.
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