Hot Runner System Optimization

 

The advantages of hot runner

In short, hot runner system is the extension of injection molding machine nozzle, its biggest advantages are:

Reduce the waste of raw materials;
Reduce the cooling time;
Reduce the pressure loss;
Less molding pressure are required;
Beautiful gate of molding products;
Expansion of the mold design application;

 

 

 

Hot Runner Applications

As a common component of mold system, hot runner system can effectively improve the quality of plastic products and improve production efficiency, to make the investment get higher returns.

 

Nowadays, insert molding technology, total and multi-component injection molding technique and can not work well without hot runner system. The amount of parts such as automobile bumpers can only be used for molding with hot runner molds because of restrictions in the flow path, the ratio of wall thickness and weld seam problems. In injection molding, hot runner system plays an increasingly important role.
Despite the hot runner and injection mold as a whole, its role and function is completely different with the mold itself. For the independent unit of the system, its installation, connection and operation all has special high-precision position requirements. For these reasons, the assembly of hot runner system can be a bottleneck. Therefore, to avoid errors during the hot runner system installation, simplify the system connection and save assembly time have become very important issues.

 

Technology optimization between integrated hot runner system and the mold

Hot runner system derived from the injection molding machine nozzle feeding system. Usually the nozzle is not always installed in the manifold block, it can also be installed in the mold flange, but such systems require a fixed plate to keep the system’s unity. For most plastics processing, because the molding temperature is about 200℃, so the hot runner and mold exits temperature difference. In addition, the system connected to the mold plate will rise the temperature and increase heat loss, the increase of the mold temperature will result in the increase of power consumption. Therefore, the design and assembly technology is very important.

 

When repairing, the hot runner must be completely removed from the mold. For the nozzles are not connected to on the plate, the electrical and hydraulic lines must be completely open, and they must be connected after maintenance.

 

In the modular hot runner systems, nozzles, manifolds, pneumatic or hydraulic systems and electrical systems, etc. form an integrated unit. Plastic melt flow from the manifold directly into the nozzle, and thus it will not produce bias and dead space. The nozzle is embedded into the manifold through screw thread, eliminating leakage between the nozzle and the manifold block. The traditional bushing system design will generate thermal expansion, and this modular system is particularly effective on the elimination of such leaks.

 

Modular hot runner system is located in the center of the mold but with little connection to the mold. The manufacturing material does not need a high thermal conductivity and setting the clamp and the mold piece pre-tension. This minimum connection provides a high accuracy and stable temperature profile, so the energy consumption is much lower than conventional hot runner system.

 

Modular hot runner system can directly install the hydraulic lines independent from the mold. The valve directly drove by hydraulic device can also be directly installed on the system, so the traditional control valves on the machine can be avoid and make injection molding more flexible. In addition, electrical and hydraulic lines can be configured according to customer requirements. Because the system will experience electrical, temperature, hydraulic or air pressure test before delivery, customers will receive a pre-installed system description or an appearance of the installation manual, which can help the customers easily install in the mold and immediately put into production.
When the mold or the system needs routine maintenance, modular hot runner system can be removed from the mold by the same simple steps; thereby it can be repaired and tested independently.

 

Usually, modular hot runner system reduces maintenance costs. Based on modular design and pre-configured installation, the heater or thermocouple wire will be removed during the assembly process. The wires connect the heater and the distribution box is placed in a specially designed junction box, which is very convenient to the demolition of the mold or hot runner system. At the same time, integrated hot runner system can be routinely maintained free from removal, which can save time and reduce the rate of assembly errors.

 

Selection of hot runner

Pay attention to the following aspects when choose a hot runner system!

 

Quality

hot runner system is very popular in foreign countries. The main considerations of foreign hot runners are application and promotion of new technologies. The domestic hot runner manufacturers have been improved rapidly. But compared to foreign countries, domestic manufactures are lacking of experience.

 

Service

the manufacturers with the ability to provide the fastest and best services and are eager to solve problem must be welcomed. In fact, no manufacturers can guarantee their hot runner will not have any problems (related to many factors). It will cause great losses when the problems can not be solved in time.

 

High cost-efficiency

Any products and markets has a cost-effective. Nothing for nothing and very little for a half penny” is absolutely justified. Doesn’t excellent quality and reasonable price exist? Yes. The competition of similar goods made the users become the biggest beneficiaries. Price can not unilaterally take into account for hot runner is not an ordinary commodity; many considerations need to be taken before you can get the satisfactory products and technologies

 

Structure

select the proper structure according to injection molding requirements and cost of products – open system (pin pouring, sprue), valve system (cylinder / hydro-cylinder drove), as well as other factors other special needs.

 

Accessory

the strength of manufacturers is an important factor when choosing hot runners. Nowadays most hot runners are modular, a great loss will be brought to the customers if damaged parts can not be replaced in time.

 

Popularity

every customer who have used hot runner knows that each manufacturer has its own supported hot runner temperature control systems. The change of manufactures will surely lead to an increase in cost. Usually the temperature controllers are sold in groups with a minimum of two control card. The popularity of hot runner temperature controller can to some extent enlarge the range of applications!

 

Communication

The difference between professional and non-professional is experience! So without strong technical communication, many problems may be rise and unnecessary losses can not be avoided. Therefore, the strength hot runner manufacturers, service and parts commonality must be taken into consideration before one make the decision.