Injection Molding Machine

Inspection Manual ver. 2.2

APRIL, 2013

SEMA Mould & Die Team

Research & Development
 Overview of Injection Molding
Machine Inspection Manual

What is Injection Molding Machine Inspection Manual?

Injection Molding Inspection Manual is a basic description of SEC

Digital Appliance Division about how to check the performance of
Injection molding machine under control of SEC subcontractors of mass
production.

Purpose and Object of Injection Molding Machine

Inspection Manual

Injection Molding Machine Inspection Manual presents SEC

subcontractors of mass production with a basic principle of injection
molding machines performance inspection which regulates the control
skill to maintain the original performance of injection molding machine,
eventually improves productivity and quality of the products.

Injection Molding Machine Inspection Manual instructs SEC

subcontractors of mass production how to inspect machines on the
basis of the criteria, introducing measuring method, measuring tools
and equipment, working procedure, and calculation method, eventually
make an inspector carry out his task with ease.
Contents

1. Check Items & Standard ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 4

1-1. Check Items∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 5

1-2. Inspection Criteria ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 7
1-3. Check Sheet ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 9
1-4. Measuring Tool∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 10
1-5. Affection on Products by Check Items∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 11

2. Inspection Method ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 12

2-1. Injection Pressure∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 13

2-2. Injection Speed∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 17
2-3. Clamping Force ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 22
2-4. Parallelism∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 28
2-5. Back Flow∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 32
2-6. Reproducibility∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 35
2-7. Barrel Temperature∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 38

3. Inspection Manual Revision History ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 40

 1. Check Items & Standard

Selects 7 items most relevant to the product quality among those from which you
can identify the current condition of injection molding machines and presents the
minimum criteria for each machine performance item to maintain the product quality.

1-1. Check Items

- Machine performance check items
- Machine performance check points
(Check item composition diagram)

1-2. Inspection Criteria

- Detailed criteria of machine performance
- Measures by machine performance grades

1-3. Check Sheet

- Usage of check sheet
- Example of check sheet

1-4. Measuring Tool

- When measuring tools are included in machines
- When you need additional measuring tools

1-5. Affection on Products by Check Items

- Examples of product defects by check items

-4-
1-1. Check Items
Injection Molding Machine Performance Check Items
Selects and measures 7 items most relevant to the product quality.

Check Items Details

The pressure imposed on melting materials on the edge of the

screw. It controls the molding resistant force inside a cavity to
Injection
determine the molding dimension and strength. Without a
Pressure
pressure sensor on the nozzle part, the hydraulic piston
pressure would take its place for measurement.

Injection The screw speed to fill the melting material in the cavity and
Speed determine the appearance grade of molded goods.

The max force to fasten the mould. It shall be stronger than the
Clamp Force resin pressure inside the mould to prevent the mould from
being open.

The degree of parallel between the fixed platen and the

Parallelism movable platen. It indicates how severely the machine level is
distorted, affecting wear of the mould directly.

The degree of melting resin spill, that is, the degree of screw
Backflow wear. It affects product shrinkage and reproducibility in the
event of backflow.

It is a judgment criteria for production uniformity and Injection

Reproducibility molding precision. It is also used to check the operation of
back pressure.

The temperature measured at the longitudinal hole of barrel.

Barrel It plays a decisive role in the stability of supply performance
Temperature and molded material transportation as it affects the resin
melting point.

-5-
 1-1. Check Items

Injection Molding Machine Performance Check Points

Clamp Force Injection Pressure

Parallelism
Reproducibility Injection Speed
Barrel Temp.
Backflow

[Check Item Composition Diagram]

-6-
 1-2. Inspection Criteria
Detailed Criteria of Machine Performance
• Provide Weight in proportion to the importance, dividing the size into Small &
Medium and Large.
• Repair is necessary for Grade C or under for each check point.
Inspection Criteria
Evaluation
Check Basis of Actual Value Result Machine
Actual Value Grade Weight (Full Mark :
Point Measurement Deviation Condition
Deviation (Small) 100)
(Medium & Large)
< 200 Ton
≥ 200 Ton
< 1% < 5% A (5P) 15 Good

Setting Value < 3% < 10% B (4P) 12 Normal

Injection
10%,30%,50%, < 5% < 15% C (3P) 3 9
Pressure To be
80%,99% < 7% < 20% D (2P) 6
repaired
≥7% ≥20% E (1P) 3
< 1% < 5% A (5P) 15 Good
Setting Value < 3% < 10% B (4P) 12 Normal
Injection
10%,30%,50%, < 5% < 15% C (3P) 3 9
Speed To be
80%,99% < 7% < 20% D (2P) 6
repaired
≥7% ≥20% E (1P) 3
• Hydraulic Type < 5% < 5% A (5P) 15 Good
 Max Clamping < 10% < 10% B (4P) 12 Normal
Clamp Pressure
< 15% < 15% C (3P) 3 9
Force •Toggle Type To be
 Elongation < 20% < 20% D (2P) 6
repaired
Rate of 4 Tiebars ≥20% ≥20% E (1P) 3
After primary resin <1 <2 A (5P) 15 Good
compression in the <2 <4 B (4P) 12 Normal
barrel cylinder,
Backflow <3 <6 C (3P) 3 9
Pressure : 50% To be
Speed : 50% <4 <8 D (2P) 6
repaired
Fill Time : 5sec >5 >8 E (1P) 3
≤Tolerance ≤Tolerance A (5P) 15 Good
Tolerance+0.13 Tolerance+0.2 B (4P) 12 Normal
Parallel- On the basis of 4
Tolerance+0.17 Tolerance+0.4 C (3P) 3 9
ism Tiebars To be
< Tolerance+0.23 Tolerance+0.6 D (2P) 6
repaired
≥Tolerance+0.23 ≥Tolerance+0.6 E (1P) 3
Diving the weight 0.5% 1.0% A (5P) 15 Good
deviation of 5 shot 1% 1.5% B (4P) 12 Normal
Reprodu- by the average
1.5% 2.0% C (3P) 3 9
cibility weight, To be
Back Pressure 2% 2.5% D (2P) 6
repaired
over 15 f/ > 2% > 2.5% E (1P) 3
< 5℃ < 5℃ A (5P) 10 Good
< 8℃ < 8℃ B (4P) 8 Normal
Barrel Setting Value vs.
< 11 ℃ < 11 ℃ C (3P) 2 6
Temp. Actual Value To be
< 14 ℃ < 14 ℃ D (2P) 4
repaired
≥ 14 ℃ ≥ 14 ℃ E (1P) 2

※ See parallelism of judgment criteria for the parallelism tolerance.

※ The above performance criteria is the in-house standard of SEC Digital
Appliance Division with reference to the Injection molding machine manufacturer.
-7-
1-2. Inspection Criteria

Measures by Machine Performance Grades

• Sum the evaluation points of each performance item and check the
condition of machine with reference to the following table.

• If one of the 7 performance check items is graded less C,

points will be deducted from the sum though the sum exceeds 90 point.

※ C grade : - 10 points, D grade : -15 points E grade : -20 points

[ Grade Judgment Criteria ]

Performance
Point Range Judgment & Recommended Measure
Grade

A ≥ 90 Normal

B 80 ~ 89 Light Repair & Calibration

C 60 ~ 79 Heavy Repair

D 40 ~ 59 Remodeling

E < 40 Disposal & Sale

※ Light Repair : Machine Component Exchange and Repair of Consumables

※ Heavy Repair : Exchange and Repair of Main Components

(including Machine Level Control and Toggle Boring for Toggle)

※ Remodeling : Exchange of All Components except Machine Frame

(including Overhaul of Controller and Control Part)

※ Re-measure after reworking Nozzle R in the event of resin spill resulted from
nozzle wear and Replace pressure gauge in the case of gauge breakdown.

-8-
 1-3. Check Sheet
Usage of Check Sheet
• Check Sheet is so composed that it calculates the result automatically
once you input inspection data in the Sheet to avoid wrong calculation or error.
(Check Sheet (PC document) will be distributed to the users additionally.)
Example of Check Sheet Use
• Example of Medium & Large : Colored boxes will be filled by the inspector.
Measurement Sheet Use Others will be automatically calculated.
Vendor Machine No. Maker Tonnage 850 Result Measures
Year of Model Name Manufacturin Injection 500 Point 54
Manufacturing g Number Flow rate
Remodeling
Screw Dia. 80 Checked by Date of Clamping Toggle Grade D
Inspection Type
Check Point Max Standard Standard Actual Deviation Dev.(%) Avg. Dev.(%) Point Inspection Unit
(%) ( / ) ( / ) Result
10% 15 15 0 0.0%
30% 45 55 10 6.7%
Injection Pressure 150 50% 75 80 5 3.3% 2.9% 15 A /
80% 120 121 1 0.7%
99% 149 150 1.5 1.0%
Check Point Max Standard Standard Filling Finish Actual Dev.(%) Avg. Dev.(%) Point Inspection Unit
(%) ( /sec) Point( ) ( /sec) Result
99.5 10% 10 280 10.0 0.0%
Feeding 30% 30 240 30.0 0.1%
Stroke ( )
Injection Speed 300.0 50% 50 200 50.0 0.2% 13.9% 9 C /sec
Fill Time 80% 80 190 55.0 25.0%
(sec)
2.0 99% 99 190 55.0 44.2%

Check Point Clamping Standard (Max) & Actual Deviation Deviation (%) Point Inspection Unit
Type Measuring Point Result
Hydraulic /
Non- A 1.03
Operator↑
Clamp Force Operator↑ B 1.09
Toggle Non- 0.1 8.0% 12 B
Operator↓ C 1.07
Operator↓ D 1.12
Check Point Criteria Measure Actual Deviation Point Inspection Unit
Point Result
15 sec 70
Backflow Speed 50%, Pressure 50%, 3.0 12 B
Fill Time 30 sec
25 sec 67

Check Point Measuring Point Actual( ) Deviation Tol. (Dev. - Inspection

Tolerance) Point Result Unit
Non-Operator ↑ A 1.02
Operator Side ↑ B 1.82
Parallelism 0.8 0.3 0.5 9 C
Non-Operator ↓ C 1.14
Operator Side ↓ D 1.37
Check Point Criteria Shot Actual (g) Deviation Deviation (%) Point Inspection Unit
Number Result
1shot 500
2shots 499
Reproducibility Back Pressure over 3shots 499 1 0.2% 15 A g
15 f/
4shots 500
5shots 500
Check Point Measuring Criteria Heater Setting Actual Deviation Max. Point Inspection Unit
Zone (deg.C) (deg.C) Deviation Result
Nozzle 260 221 1
H1 220 222 2
Check the max deviation
in the Heater Zone H2 225 226 1
Barrel Temperature 30 2 E deg.C
vs H3 230 200 30
the setting value. H4 235 236 1
H5 240 241 1
-9-
 1 - 4. Measuring Tool
You need the following measuring tools to measure the performance of 7
check items.

When measuring tools are included in the machine

Injection Pressure Injection Speed / Backflow Barrel Temperature

Pressure Gauge, Encoder Thermocouple

Pressure Sensor

When you need additional measuring tools

Parallelism Clamping Force Reproducibility

Electronic Scale
Interval : 0.1g

Jig
Toggle Type Height : 2500㎜

Dial Indicator
Measuring
Range : 30㎜
Toggle Type Interval : 0.01㎜

Tubular inside micrometer

Measuring Range : 100 ~ 2,000㎜
Interval : 0.01㎜ Hydraulic Type
Measurement Tolerance : 400㎜ ±12 μm
-10-
1-5. Affection on Products by Check Items
Examples of Product Defects by Check Items

Shrinkage Jetting
Injection Pressure

Injection Speed
Gate Mark
Weld Line

Clamping Force

Flash
Flow Mark

Parallelism

Short Shot Stress Crack

Backflow

Reproducibility
Whitening Mould Wear

Barrel Temperature

-11-
 2. Inspection Method

Injection Molding Machine Performance shall be measured according to

Manual, paying attention to the inspection procedure, method, calculation
formula, and notices.

2-1. Injection Pressure

2-2. Injection Speed

2-3. Clamping Force

2-4. Parallelism

2-5. Backflow

2-6. Reproducibility

2-7. Barrel Temperature

※ The Judgment Criteria in this Manual was based on a hydraulic

open-loop machine. Therefore, it may change subject to the
machine maker.

※ Prior to the inspection of injection pressure and speed, it is

recommended the machine maker calibrate or tune machine in order to
put the machine in optimum condition.

※ It is safety activity to turn off motor and open safety door in operator and
non-operator side when the part of body is put between movable and fixed
platen.

-12-
2-1. Injection Pressure

2-1
Details Remark

Injection Pressure
Check Point Calibration, Pump, Hydraulic Valve, Controller

Judgment Criteria Linearity versus Spec. and Zero Pressure

Pressure Gauge and Pressure Sensor in

Measuring Tool
Injection Molding Machine

Affecting Element Dimension, Shrinkage, Strength

Trouble by
Abnormal Short Shot, Flash, Over-packing, Shrinkage
Condition

Effect of Normal Reduced molding deviation

Condition  Reduced product defect

- Medium, Large (above 200 ton) :

Pressure Deviation less than 5%,
Spec. in Scope
- Small (below 200 ton) :
Pressure Deviation less than 1%

Check and Repair Logic Valve, Proportional

Measure
Valve, Solenoid Valve, Pump, and Controller

-13-
 2-1. Injection Pressure
Inspection Procedure
※ Prior to the inspection of injection pressure, it is recommended the 2-1
machine maker calibrate or tune the machine for the normal setup of the basic
function.

Injection Pressure
1. Close the hopper and mould
Hopper cooling water.
Make the melt purge out.

2. Check if the relief valve of the

Relief proportional valve is fully open.
valve

※ If the relief valve is tight, the

zero pressure will be raised.

3. Shift to the Manual Mode and make the screw position at 0mm.

4. Set the packing pressure speed to over 50%.

(※ A closed-loop has no space available to input the packing speed.)
5. Set the Injection Time to 10 ~ 20 sec to read pressure gauge.
6. Set Packing Pressure to 10%.
(※ Note the unit. In case of ㎏f/㎠ unit, multiply the Max by 0.1.)
1st Pack 3rd Fill 2nd Fill 1st Fill
1st time 10.0% Pack Injection T
00.0 00.0 00.0 %
00.0sec 2nd Pack Speed 20.0sec
2nd time 10.0% 4th 3rd 2nd 1st
50.0% 000.0
00.0sec 3rd Pack Speed Speed Speed speed
10.0% 00.0 00.0 00.0 00.0
Cooling T
V/P 00.0sec
3rdShift 2ndShift 1stShift
FS : Feeding Speed switch
000.0 000.0 000.0 000.0
BP : Back Pressure 000.0

2nd FS
1st FS 50.0 2nd Suck
1st Suck 50.0 Back
back
50.0 1st BP 2nd BP 3rd BP
50.0 50.0 50.0 50.0

Feeding 2nd Feeding 3rd Feeding Feeding Suck Back

Start Shift Shift Finish Finish
000.0 000.0 000.0
00.0 100.0
-14-
 2-1. Injection Pressure

Inspection Procedure
2-1
7. After injection, use the pressure gauge

Injection Pressure
to compare the pressure with the actual
value. (Setting Value vs Actual Value)
※ Operating mode (manual, semi-auto, auto) is
depend on machine maker during checking.

Pressure Gauge

※ Why do you have to use packing pressure to

measure the injection pressure? : Because you can
check the injection pressure both Open-loop and
Closed-loop. (Open-loop : hard to check the
pressure during the filling stage)

8. Set Packing Pressure to 30%, 50%,

80%, and 99% in sequence and repeat
Procedure 7 above.
※ Measurement at 10 % : To check
the Zero Pressure

Remark) The inside of the graduation plate of a

pressure gauge is filled with oil by over 90%. If the oil
level is low, check if the indicator is in normal
condition.

9. Draw setting values and actual values on the graph.

180

160

140

120 Deviated
(㎏f/㎠)m

100
S etting Values
80 A ctualValues
60
Deviated
40

20

0
0 20 40 60 80 100 120
(% )
-15-
2-1. Injection Pressure

Calculation Method
2-1
Measure the deviation between the setting value and the actual value.

Injection Pressure
Example of Pressure
Deviation Calculation Method [Max. Hydraulic Pressure of 140 ㎏f/㎠]
Setting Value Actual
Deviation Deviation
No. Value Remark
% f/ f/ (%)
f/
1 10 14 17 3 2.1

2 30 42 39 3 2.1

3 50 70 80 10 7.1

4 80 112 105 7 5

5 99.9 140 125 15 10.7

Average Pressure Deviation (%) 5.4

※ The actual value, 10% is used to measure the zero pressure

and it will be excluded from actual calculation accordingly.

Deviation(%) Formula = Deviation ( f/ ) / Max. Hydraulic Pressure

No. 1.  3/140 * 100 = 2.1% (Check the zero pressure.)

No. 2.  3/140 * 100 = 2.1%

No. 3.  10/140 * 100 = 7.1%

No. 4.  7/140 * 100 = 5.0%

No. 5.  15/140 * 100 = 10.7%

Inspection Criteria

• As for Medium & Large (over 200 ton), the deviation shall be less than 5%.
• As for Small (below 200 ton), it shall be also less than 1%.
• As for closed–loop machines, the Small criteria will prevail at all times.

-16-
2-2. Injection Speed

Details Remark

Check Point Calibration, Pump, Hydraulic Valve, Controller

2-2

Injection Speed
Judgment Criteria Speed Linearity versus Spec.

Measuring Tool Machine Controller (Encoder, Liner Scale)

Affecting Element Part Appearance

Trouble by Reduced Surface Polishing,

Abnormal
Condition Weld line, Flow mark

Effect of Normal
Appearance Quality Upgrade
Condition

Medium & Large (above 200 ton) :

Speed Deviation less than 5%
Spec. in Scope
Small (below 200 ton) :
Speed Deviation less than 1%

Check and Repair Logic Valve, Proportional

Measure
Valve, Solenoid Valve, Pump, and Controller.

-17-
 2-2. Injection Speed

Inspection Procedure

※ Prior to the inspection of injection speed, it is recommended the machine

maker calibrate or tune the machine for the normal setup of the basic function.

1. Use the injection flow rate and screw diameter to measure the max
injection speed.
Max Injection Speed = 2-2
1,000*Injection flow Rate / (π*0.25*Screw Diameter2)

Injection Speed
Unit  Injection Speed : ㎜/sec, Injection flow Rate : ㎤/sec, Screw Diameter :㎜

2. Close the hopper, make the melt purge out and the barrel empty.
Set the operation mode manual.

3. Use the Suck Back commandment to move the screw backward by more
than 2/3 of the max Injection stroke.
※ During this process, Feeding is unavailable because the barrel is empty
without resin.

4. Set the Packing Pressure to 0.

Set the Injection Time to 3 sec. (or 1.5 ~ 2sec in case of fast Injection Speed)
Set the Injection Pressure to over 50%.
(Raise the pressure up to 100% if the Injection Speed does not reach your expectation. )

Set the Injection Speed to 10%.

After Injection, check the screw position.
※ Operating mode (manual, semi-auto, auto) is depend on machine maker during checking.

1st Pack 3rd Fill 2nd Fill 1st Fill

1st time 0.0% Pack Injection T
50.0 50.0 50.0 %
00.0sec 2nd Pack Speed 3.0sec
2nd time 0.0% 4th 3rd 2nd 1st
0.0% 000.0
00.0sec 3rd Pack Speed Speed Speed speed
0.0% 10.0 10.0 10.0 10.0
Cooling T
V/P 00.0sec
3rdShift 2ndShift 1stShift
FS : Feeding Speed switch 000.0
000.0 000.0 000.0
000.0
BP : Back Pressure
2nd FS
1st FS 50.0 2nd Suck
1st Suck 50.0 Back
back
50.0 1st BP 2nd BP 3rd BP
50.0 50.0 50.0 50.0%

Feeding 2nd Feeding 3rd Feeding Feeding Suck Back

Start Shift Shift Finish Finish
000.0 000.0 300.0
00.0 300.0

-18-
2-2. Injection Speed

Inspection Procedure

5. Actual Injection Speed Calculation Method

2-2

Injection Speed
Final Screw Original Screw
Position Position

Actual Injection Speed =

(Original Screw Position – Final Screw Position) / Injection Time

Unit  Screw Position : ㎜, Injection molding Time : sec

6. Set the Injection speed to 30%, 50%, 80%, and 99% in sequence
and repeat Procedure 5.
※ If expressed in % : Open-loop Control

7. If the speed is expressed in %, use the maximum Injection speed to

calculate each setting value.

Reference data

If the machine is worked with Inverter or 50Hz motor, the motor rpm is
reduced, therefore pump flow rate is also reduced.
As the result the max. injection speed is 20% smaller than 60 Hz motor.
If using inverter and 50 Hz motor, it will be taken a caution to apply the
spec. of injection flow rate to injection machine check sheet.

-19-
 2-2. Injection Speed

Inspection Procedure

8. Draw the setting value vs. actual value on a graph.

※ Use a graph to check the condition.

Actual Value :
Setting Value :
2-2
※ Proportional Valve : Speed,

Injection Speed
Pressure, Back Pressure
[Case 1] [Case 2]

• When abnormal condition

• Distorted Calibration continues after calibration,
Trouble with Logic,
• Min. and Max Values were Proportional valve, Solenoid
set high. valve, Low Controller
Performance
• Min. and Max Values
were set low.

[Case 3] •Distorted Calibration [Case 4]

•Trouble with Logic,

Proportional valve, •Distorted Calibration
Solenoid Valve
Low Controller •Trouble with Logic,
Performance Proportional, Solenoid Valve
Low Controller Performance

[Case 5] [Case 6]

• Hydraulic oil volume rate

•Distorted Calibration low due to low pump loading

-20-
2-2. Injection Speed

Calculation Method

Measure the deviation between the setting value and the actual value.

Example of Speed Deviation

Calculation Method [Max Injection Speed of 130 ㎜/sec] 2-2
Setting Value Actual
Deviation Deviation
No. Value Remark

Injection Speed
% /sec /sec (%)
/sec
1 10 10 12 2 1.5

2 30 39 42 3 2.3

3 50 65 60 5 3.8

4 80 104 98 6 4.6

5 99.9 130 132 2 1.5

Average Speed Deviation (%) 2.74

Deviation(%) Formula = Deviation( /sec) / Max Injection Speed *100

No. 1.  2/130 * 100 = 1.5%

No. 2.  3/130 * 100 = 2.3%

No. 3.  5/130 * 100 = 3.8%

No. 4.  6/130 * 100 = 4.6%

No. 5.  2/130 * 100 = 1.5%

Inspection Criteria

• As for Medium & Large (over 200 ton), the deviation shall be less than 5%.
• As for Small (below 200 ton), it shall be also less than 1%.
• As for closed–loop machines, the Small criteria will prevail at all times.

-21-
2-3. Clamping Force

Details Remark

Check Point Tiebar Condition and Pump

Toggle Type : Tiebar Elongation

Judgment Criteria Hydraulic Type : Actual Value vs 2-3
Max. Clamping Pressure

Clamping Force
Toggle Type : Dial Gauge, Magnetic Support Jig is
Measuring Tool
Hydraulic Type : Pressure Gauge necessary

Affecting Element Part Gap, Mould Wear

Trouble by
Abnormal Parting flash
Condition

Effect of Normal
Reduced Labor Cost, Extended Tiebar Life
Condition

Toggle Type : Tiebar Elongation Deviation

less than 5%
Spec. in Scope
Hydraulic Type : Clamping Pressure
Deviation less than 5%

Toggle Type : Tiebar bush, Toggle pin

Measure Hydraulic Type : Repair after Pump
Inspection

-22-
2-3. Clamping Force

Inspection Procedure (Hydraulic Type)

1. Shift to the Manual Mode.

2. Close the clamping pressure relief valve as tightly as possible.

※ As for an old model, use a relief valve to control the clamping pressure.
As for an new model, use a controller to control the clamping pressure.

2-3

Clamping Force
Clamping Pressure Gauge

Relief valve

3. Make the mould high clamped.

4. Compare the maximum clamping pressure with the actual value

measured by an pressure gauge.

-23-
 2-3. Clamping Force

Calculation Method (Hydraulic Type)

Measure the deviation of the actual value from the setting value.

Example of Clamping Pressure

Deviation Calculation Method [Max. Clamping Pressure of 175 ㎏f/㎠]

Setting Value Actual

Deviation Deviation
No. Value Remark
( ㎏f/㎠ ) (%)
% ( ㎏f/㎠ ) ( ㎏f/㎠ )

2-3
1 100 175 168 7 4.0

Clamping Force
Deviation (%) Formula =
Deviation (㎏f/㎠ )/ Max. Clamping Pressure *100

No. 1.  7/175 * 100 = 1.5%

Inspection Criteria (Hydraulic Type)

• As for Medium & Large (over 200 ton), the deviation shall be less than 5%.
• As for Small (below 200 ton), it shall be also less than 5%.

-24-
2-3. Clamping Force

Inspection Procedure (Toggle Type)

1. Shift to the Manual Mode after loading the mould into the machine.
Worn mould may cause poor measurement accuracy.
- The inspection should be performed with No flash, No slide and
below 1-year mould.

2. Remove the rear cover of the machine.

Machine Cover
2-3

Clamping Force
3. Use a soft cloth to wipe out grease on the measuring point.

4. Put up the jig as high as the tiebar.

-25-
 2-3. Clamping Force

Inspection Procedure (Toggle Type)

5. Attach a dial gauge to Magnetic Stand and fix it to a jig.

Dial Gauge

2-3
Magnetic Stand

Clamping Force
6. Use the dial gauge to measure the elongation of 4 tiebars at 8 position
of end of tiebars at the same time after high pressure clamping.
Do not make the jig touch the machine during measuring.
(to avoid the impact from machine vibration)

Movable Platen Fixed Platen

Tiebar Tiebar
Non operator side

Non operator side

Operator side
Operator side

A point B point E point F point

C point D point G point H point

Movable platen Fixed platen

※ When the tiebar elongation deviation is excessive, bore the toggle and
use the test block recommended by the machine manufacturer
to control the deviation. Some machine measure points are only 4 points.
-26-
 2-3. Clamping Force
-(Counter Clock wise) + (clock wise)
Calculation Method (Toggle Type)
A,B E,F
Measure the elongation
deviation.

C,D G,H

[ Example of Elongation Deviation Calculation Method ]

Movable Platen Fixed Platen
Side Side
Actual value Difference Difference
Measur Measur (mm) (mm) (%)
2-3
Actual Actual
e e
(mm) (mm)
point point

Clamping Force
A point +0.80 E point -0.11 A-E=0.80+(-0.11) = 0.69
= Difference (mm) /
B point +0.78 F point -0.07 B-F=0.78+(-0.07) = 0.71 Max – Min
= 0.92-0.69 Max(actual)*100
C point +0.90 G point +0.01 C-G=0.90+(+0.01) = 0.91 = 0.23
= 0.23/0.92*100
D point +0.87 H point +0.05 D-H=0.87+(+0.05) = 0.92

Tiebar elongation deviation (%) 25%

Inspection Criteria (Toggle Type)

The elongation deviation shall be less than 5% without

regard to the tonnage.

Reference Data
Elongation Tolerance at the time of machine delivery
Tonnage (Ton) Tolerance ( )
~25 0.01
26~110 0.02
111~170 0.03
171~220 0.04
221~280 0.05
281~380 0.06
381~480 0.07
481~680 0.08
681~880 0.09

-27-
2-4. Parallelism

Details Remark

Check Point Machine Level Balance

Deviation of Fixed and Movable Platens

Judgment Criteria
Parallelism

Measuring Tool Extension tubular inside micrometer

2-4

Parallelism
Affecting Element Parting Flash, Machine Operation

Trouble by
Parting Flash, Mould Damage and Wear,
Abnormal
Machine Malfunctioning
Condition

Effect of Normal
Protection of Mold
Condition

Medium & Large (above 200 ton) :

Tolerance by Tonnages
Spec. in Scope
Small (below 200 ton) :
Tolerance by Tonnages

Countermeasure Re-measure and control the machine level.

-28-
 2-4. Parallelism

Inspection Procedure

1. Use a soft cloth to clean the part of the platens to be measured.

2-4
Soft Cloth

Parallelism
2. Open as wide as the point when the mould guide pin escapes from the
guide bush completely.
If the mold weight is heavy comparing with the Injection molding tonnage,
put down the mold from the machine and measure it on the basis of the
minimum mould thickness.

Guide Pin Guide Bush

-29-
 2-4. Parallelism

Inspection Procedure

3. Measure the platens parallel according to the following figure.

Tiebar

20mm x4
Measuring
Point

100mm x 4

Common machine Tiebarless machine 2-4

Parallelism
Movable Platen Side

Fixed Platen Side

Fixed

Search the
minimum point,
drawing a cross.

※ If the deviation is bigger than expected, unload the mould,

make the clamping distance minimum and check it again.

-30-
2-4. Parallelism

Inspection Criteria

[Parallel Tolerance by Tons]

Tonnage (Ton) Tolerance ( )

100 ~ 350 0.2

351 ~ 500 0.25

501 ~ 900 0.3

901 ~ 1200 0.35

2-4
1201 ~ 1500 0.4

Parallelism
1501 ~ 1800 0.45

1801 ~ 3200 0.5

3201 ~ 4000 0.55

4001 ~ 5500 0.6

≥ 5501 0.85

-31-
2-5. Backflow

Details Remark

Check Point Wear of Screw Assembly and Barrel

Screw Position Deviation at the time of

Judgment Criteria
Injection following Nozzle block

Encoder (Linear Scale) included in the

Measuring Tool
machine

Affecting Element Part Dimension, Short shot

2-5

Backflow
Trouble by
Abnormal Dimension deviation, Short shot
Condition

Effect of Normal
Reduced Product Defect
Condition

Medium & Large : Screw Position Deviation

Spec. in Scope below 2
Small : Screw Position Deviation below 1

After unscrewing, check the wearing condition

Countermeasure of screw assembly and heating cylinder inside
and replace them if necessary.

-32-
 2-5. Backflow

Inspection Procedure

1. Close up the nozzle end.

1) Solidify resin at the end of the mould sprue.

(※ With sufficient back pressure, resin will enter the sprue end to be solidified.)

2) If you fail in Procedure 1, do not pull out any product after shot out.
3) As for Hot Runner, close air with the heater turned off.
High
Pressure Nozzle Touching
Clamping

Check Ring
Nozzle
Blocking

2. Set speed to 50%, pressure 50%, and injection time to 30 sec.

Set the feeding stroke to 20~50% of max feeding stroke.
2-5
3. Set operating mode semi-auto. If the screw position is rapidly

Backflow
reduced, set operating mode manual and check the melt drooling.

1st Pack 3rd Fill 2nd Fill 1st Fill

1st time 0.0% Pack Injection T
50.0 50.0 50.0 %
00.0sec 2nd Pack Speed 5.0sec
2nd time 0.0% 4th 3rd 2nd 1st
0.0% 000.0
00.0sec 3rdPack Speed Speed Speed speed
0.0% 50.0 50.0 50.0 50.0%
FS : Feeding Speed Cooling T
V/P 00.0sec
BP : Back Pressure 3rdShift 2ndShift 1stShift
switch 000.0
000.0 000.0 000.0
000.0

2nd FS
1st FS 50.0 2nd Suck
1st Suck 50.0 Back
back
50.0 1st BP 2nd BP 3rd BP
50.0 50.0 50.0 50.0%

Feeding 2nd Feeding 3rd Feeding Feeding Suck Back

Start Shift Shift Finish Finish
000.0 000.0 000.0
00.0 100.0

-33-
 2-5. Backflow

Inspection Procedure

3. Start Injection after nozzle touching and high pressure clamping

if the operation mode is manual.
※ Otherwise, the mould may be shocked.

4. The first stage is the primary resin compression which is about

15 sec. The second stage is checking screw position at 15 sec and
25 sec. As the result screw position difference of 5 sec is backflow 2-5
calculation.

Backflow
[Example of Backflow Calculation]
Injection Time Screw Position
Ref.
(sec) (mm)
0 300
15 290
20 288.7
25 288.1

Max. deviation Max(15 sec)-Min(25 sec) = 1.9 mm

Inspection Criteria

Medium & Large (above 200 ton) : Max Deviation less than 2㎜
Small (below 200 ton) : Max Deviation less than 1㎜
-34-
2-6. Reproducibility

Details Remark

Check Point Back Pressure, Feeding Pressure

Judgment Criteria Deviation of Resin Plasticization Weight

Measuring Tool Electronic Scale (Min. Resolvability : 0.1g)

Affecting Element Part Dimension

Trouble by
Increased Dimension Deviation and
Abnormal
Defect Rate
Condition

Effect of Normal
Stabilized Product Dimension
Condition
2-6
Reproducibility

Medium, Large : Weight Deviation below 1%

Spec. in Scope
Small : Weight Deviation below 0.5%

Check Wear of Barrel, Screw Assembly.

Countermeasure Check the hydraulic valve of back pressure.
Check and Repair Position Sensor.

-35-
2-6. Reproducibility

Inspection Procedure

1. Set the back pressure to 15 ㎏f/㎠ or higher.

( 5 ~ 10 ㎏f/㎠ is better depending on the resin type. )
※ If back pressure is lower, reproducibility is also lower.
Set the feeding stroke 1/3 ~ 2/3 of Max. feeding stroke.
(Overpressure will prevent screw backward. Be careful.)

1st Pack 3rd Fill 2nd Fill 1st Fill

1st time 0.0% Pack Injection T
nd
50.0 50.0 50.0 %
00.0sec 2 Pack Speed 5.0sec
2nd time 0.0% 4th 3rd 2nd 1st
0.0% 000.0
00.0sec 3rd Pack Speed Speed Speed speed
0.0% 50.0 50.0 50.0 50.0%
Cooling T
V/P 00.0sec
FS : Feeding Speed 3rd Shift 2nd Shift 1st Shift
switch 000.0
BP : Back Pressure 000.0 000.0 000.0
000.0

2nd FS
1st FS 50.0 2nd Suck
1st Suck 50.0 Back
back
50.0 1st BP 2nd BP 3rd BP
50.0 50.0 50.0 50.0%

Feeding 2nd Feeding 3rd Feeding Feeding Suck Back

Start Shift Shift Finish Finish
000.0 000.0 000.0
00.0 300.0

2. Feeding after Nozzle Touch

2-6
Reproducibility

3. Purge Out after Nozzle Backward

-36-
2-6. Reproducibility

Inspection Procedure

4. Repeat above 2 and 3 to make 7

shots.

※ Check if feeding time is uniform.

If not, the screw assembly and
cylinder inside may be worn.

5. Measure weight to determine

the maximum deviation.
[Example]
Shot No. Shot Weight (g) Ref
1 500
2 500
3 505 Max. exclusion
4 499
5 499
6 500
7 496 Min. exclusion
Max. Diff (500-499) / 500 * 100 = 0.2 %

(Both extreme values will be

excluded from the calculation.)
Inspection Criteria

Medium & Large (above 200 ton) : The weight deviation shall be less than 1%.
Small (Below 200 ton) : The weight deviation shall be less than 0.5%.
2-6

Reference
Reproducibility

※ If the weight deviation from the above procedure is excessive, check

the product weight for 50 shots in the running machine and measure
their weight deviation to see if each one is within 1% of the weight
average.

※ If deviated by more than 1%, request the machine manufacturer for

A/S because the machine is in trouble with its reproducibility.

-37-
2-7. Barrel Temperature

Details Remark

Check Point Band Heater, Thermocouple

Real Value Deviation from Temperature

Judgment Criteria
Setting

Measuring Tool Thermocouple, Controller Screen

Affecting Element Melting Temperature

Weld Line, Pressure Loss in Mould, Stress,

Countermeasure
Bending, Gas Trap

Effect of Normal Reduced Product Quality Deviation from

Condition Even Quality of Melting Material

Spec. in Scope Within 5℃ of Setting Value

2-7
Barrel Temperature

Thermocouple Cut, Thermocouple Ground,

Check Point Temperature Power Source,
Temperature Circuit

-38-
2-7. Barrel Temperature

Inspection Procedure

1. Check if the real temperature shown in the Controller Temperature

Setup Screen is within the deviation of ±5 ℃ of the value set by Heater
Zone.
Normal Deviated by ±5 ℃ or Less
Condition

Abnormal Condition Deviated by ±14 ℃ or More

No Heater Band

Corrosion of
Thermocouple 2-7
Barrel Temperature

-39-
 Inspection Manual Revision History

- All revision contents should be recorded below table after issued date 21 July, 2006
- After finishing the revision, the manual should be distributed to the vendors.

Ver. page Contents date

21 July,
V1.0 - First edition issued
2006
V2.0 8 Before : If one of the 7 performance check items is graded less C, June, ‘07
7 points will be deducted from the sum though the sum exceeds 90 point.

After : If one of the 7 performance check items is graded less C,

points will be deducted from the sum though the sum exceeds 90 point.
※ C grade : - 10 points, D grade : -15 points E grade : -20 points

9 Before : Inspection Result (Normal, To be repaired)

After : Inspection Result (A,B,C,D,E )

10 The figures of toggle clamping force are replaced.

12 Addition : Safety comment

14 Before : Set the Injection Time to Max.

After : Set the Injection Time to 10 ~ 20 sec to read pressure gauge.

15,18 Addition : Operating mode (manual, semi-auto, auto) is depend on machine maker
during checking.

18 Addition : Close the hopper, make the melt purge out and the barrel empty.
Set the operation mode manual.

19 Addition : the reference data for 50Hz motor & inverter

23 Addition : As for an new model, use a controller to control the clamping pressure.

25 Addition : The mould status in checking

26 Totally revised (measurement points)

27 Totally revised (calculation method)

30 Addition : If the deviation is bigger than expected, unload the mould,

make the clamping distance minimum and check it again.

33, 34 Totally revised (measurement method of semi-auto mode )

36 Before : Set the back pressure to 15 f/ or higher.

After : 5 ~ 10 f/ is better depending on the resin type.

37 -40-
Addition : Calculation example Reproducibility
Injection Molding Machine Inspection Manual

Issued by : Halim Bin Hassan, Mechanical Engineer

Samsung Electronics (M)

Issued on : 21 May, 2013

Note) This book is a property of SEC. No part of this book may be

copied without prior written permission of SEC.

The machine grade standard used in this book is the internal

standard of SEC Digital Appliance Division only.