注塑（成型）模具安装及调试

注塑（成型）模具安装及调试
Injection Mold Installing and Setup
注塑模具安装及调试
1. Purpose (⽬的)
To provide the general standard guideline for injection mold installing and setup.
Ensure consistent approach is used for each injection mold installing and setup processes.
提供⼀套标准注塑模具安装及调试⽅法。

确保每次注塑模具安装及调试⽅法⼀致。

2. Scope (应⽤)
This instruction applies to injection molding machine inside Grakon injection molding division.
本指引适⽤于所有Grakon注塑部注塑机。

3. Responsibilities (责任)
Injection Molding In-charge need to ensure all of the Injection Molding Foremen and operators are been trained and qualified for
injection mold installing and setup.
Production Engineering Manager delivers proper training to Project Engineers, Process Improvement Engineers and Technicians to ensure
that all the molding activities, tooling qualification and molding
parameter determination follow this guideline.
注塑部总负责⼈需确保所有注塑部领班和操作员有适当及充⾜模具安装及调试训练. 及后各⼈取得模具安装及调试资格。

⽣产⼯程经理培训⼯程师及技术员，确保所有模具安装及调试; 模具验证;
注塑记录调试遵照本指引进⾏。

4. Instruction (程序)
4.1Preparation Sizing and Inspection准备 - 依⼤⼩排列和
检验
A machine must be selected that is properly sized for the
specific mold being installed. After the machine is selected it
must be inspected to determine its status. This inspection
includes items such as:
机器选择时需注意模具要求及注塑机规格相配合。

在机器被选择以后, 需所作如下检查,决定机器状况为正常及可作⽣产. 检验项⽬包括:
Proper hydraulic oil level 确保压⼒油在正常⽔平
Heater bands in place and operating 炮筒发热圈适当安装及正常可连作
Mold temperature controllers operable 模具温度控制器可正常连作
Injection cylinder empty and screw forward 注射筒内⽆塑料及螺杆在最前⽅
Hopper shutoff closed and hopper wiped clean 蓄料⽃落料门关闭及擦⼲净蓄料⽃
Proper material available and dried 塑料是正确须要的及有适当乾燥
Granulator clean and available碎料机清洁及待⽤
Safety gates and mechanisms operating and in good condition 检视安全门及机械安全设备情况良好和正常操作
Vent hood(s) clean and operating 料⽃通风⼝清洁和正常连作?Heat exchanger clean and operating 热交换器清洁和正常连作?Machine lubricated or auto-lubrication working and filled 机器要有适当润滑及⾃动润滑油器正常操作，保持润滑油盅油量?Alarms and lights operable 警报器和操作指⽰灯正常连作
4.2Installation Procedure安装程序
After the machine inspection is completed, the mold can be
installed. The following steps should be taken, but they are
generic in nature and do not preclude the machine
manufacturers instructions. Always follow those
instructions first and foremost.
注塑机检验完成以后，模具可开始安装。

以下为标准安装步骤，详
细步骤可参照机器制造商机械⼿册。

4.2.1Make sure that the mold has a connecting strap
installed. This strap should connect the two halves
of the mold and keep them from coming apart during
transportation. Normally this is a metal strap mounted
across the "A" and "B" plate parting line. It is not
a safe or proper practice to install the mold as two
separated halves.
确保模模具安装⼀件锁模连接块。

锁模连接块作⽤防⽌前后模在运输及安装时分离。

通常这是横跨「A」和「B」模块装置的⼀根⾦属块。

不提议分开模具两半存放, 因运输上可能损坏模具及对操作⼈产⽣危险。

4.2.2Start the machine, make sure the injection sled is in
the full back position, and set the barrel heaters to
the proper temperatures. The profile should run from
a cool rear setting to a progressively hotter front
zone and nozzle as outlined on the setup sheet. Turn
on the feed throat cooling water.
开动机器，确保注射台在完全后退位置，设定注射筒的发热器到正确的温度。

注射筒温度应该由后段(溶料区)到前段(射咀)逐渐变热,可参照相关注塑记录设定。

4.2.3Open the clamp to place the mold. Space is usually
equals a minimum of twice the height of the mold. This
may require re-setting the mold open limit switches
or control settings. Refer to the machine manual for
instructions.
打开机台板, 机台打开空间度通常⼤于或等于模具⾼度的两
倍。

这可需要重新设定注塑机开模限制位置或控制⾯板内开模位置设定。

请参照机器⼿册。

4.2.4Lower the mold from the top of the machine (or slide
it in from the side) using a chain fall, and bring the
mold up against the stationary platen, by hand. The
mold should rest against the platen without assistance.
This is accomplished by adjusting the location of the
chain fall towards the platen. It is a good idea to
have a thick metal plate placed across the lower tie
bars at this point. The plate will act as a safety catch
in case the chain fall breaks, or the connecting hook
opens.
使⽤吊环, 从机器的顶部降下模具，⾄注塑机定位板前。

调整模具吊环⾼度直⾄模具可平衡及贴紧注塑机定位板前。

提议在塑机底⽀承柱下⾯放置横铁板块，以防⽌当链条断裂或吊钩松脱时模具坠下。

4.2.5At this point the mold must be raised and lowered
slightly in an attempt to position it so the locating
ring on the mold will slip into the locating hole on
the platen. The chain fall should be connected such
that the mold tilts slightly at the top.
调整模具吊挂⾼度直⾄模具对准注塑机定位圈。

模具可略倾斜⽅便模具贴紧定位圈。

4.2.6The tilted mold should be placed slightly above the
locating hole of the stationary platen, and held
against that platen as the mold is slowly lowered. The
locating ring of the mold will automatically slip into
the locating hole of the platen as the mold is gently
lowered. A level can be placed across the top of the
mold to assist in aligning the mold so it fits squarely
on the platen. After leveling, the "A" half of the mold
is ready to clamp in place.
缓慢降低模具, 调整模具⽔平, 模具会⾃动接合注塑机定位
圈. 使⽤⽔平尺调整模具⽔平。

4.2.7Position clamps, adjust, and bolt the "A" half of the
mold to the stationary platen. The mold should be
mounted with at least 1 clamp in each of the 4 corners.
If the mold is very wide, additional clamps should be
placed along the long dimension. If the mold is very
small it may be possible to use only 2 clamps per mold
half, although this is not recommended and smaller,
specially built clamps may have to be utilized in order
to use 4 clamps per mold half.
装上码模夹，先收紧模具前模的＂A＂半。

模具应该在 4
个⾓装上⾄少⼀个码模夹。

如果模⼦阔度⼤，需多加额外
的码模夹。

如果模具太⼩,可每半模具装上码模夹两个，但
建议尽可能每半边模具⽤上4 个码模夹。

4.2.8The best thing to do is purposely adjust the heel of
the clamp away from the platen. This results in the
clamping force being directed toward the platen
through the toe of the clamp. The angle of direction
should be minimal and can be such that the clamp heel
is only 1/8" to 1/4" away from parallel.
码模夹最理想和塑机机板⽔平。

这时码模夹收紧⼒为最⼤。

码模夹和塑机机板⾓度应尽量⽔平, 最⼤差距不能和⽔平
距离多于1/8＂⾄1/4＂。

4.2.9The clamp is slotted for linear adjustment. The
adjustment allows the clamping bolt to be located as
close as possible to the mold because that, too, aids
in creating maximum clamping pressure on the mold
itself. The bolts should be tightened using a torque
wrench, with 5/8" bolts requiring approximately 150
ft-lb torques and 3/4" bolts requiring approximately
200 ft-lb torques.
码模夹在机板槽内可作调整。

应尽量贴近模具边缘，因这时码模⼒度最⼤。

螺丝应⽤扳钳收紧，5/8＂螺丝扭⼒约为150ft-lb; 3/4＂螺丝扭⼒约为 200 ft-lb。

4.2.10If ejector rods are required, place them in the mold
now. Then, slowly bring the clamp unit forward, under
low pressure, to prepare for clamping the "B" half of
the mold. This may require adjusting limit switches
or settings. Check the machine manual for this
information. Bring the moving platen up to within 1/4"
to 1/2" of the mold base and set limits for the 'high
pressure close" to activate at that point. Now,
continue moving the clamp unit forward until it
touches the mold base. Allow the press to build up
clamp pressure to the desired setting. This ensures
that the mold is fully closed.
如需推杆装置, 请安装推杆。

然后，缓慢地把注塑机后移动机板向前移动，在低压⼒下，收紧模具后模＂B＂半。

这可能需要调整限位制或控制⾯板闭合模位置设定。

可参照机器⼿册。

调整＂⾼压锁模＂在闭合位置1/4＂⾄1/2＂范围内。

接着，继续调整移动机板向前直⾄模具完全闭合。

允许锁模逐步增加到设定压⼒。

4.2.11Shut off the machine. Locate clamps, adjust, and bolt
the "B" half of the mold to the moving platen, making
sure to follow the procedure mentioned above.
关掉机器。

收紧模具后模的＂B＂码模夹，确保遵照上述提及收紧模具程序。

4.2.12Remove the chain fall hook, eyebolt, and connecting
strap from the mold. To avoid losing the connecting
strap, it may be desirable to keep it mounted but swung
out of the way and tightened down so it will not come
loose and cause mold damage.
移除吊排, 吊圜及吊模⽪带。

避免遗失锁模连接块，可把锁模连接块收回模具上。

4.2.13Recheck each and every clamp on both halves to make
sure they are all tight. Start the machine and SLOWLY
jog the clamp unit open under low pressure, watching
for any indication of the mold halves seizing or
binding together. Open the mold approximately 1/2" and
stop. Shut off the machine and fully check the mold
to make sure it is properly mounted.
检查所有码模夹, 确保全部收紧。

开动机器, 缓慢地使移动板在低速及低压⼒下打开，监视模⼦任何不正常现象。

打开模具约1/2＂后停⽌。

关掉机器和完全检查模具确保恰当收紧在注塑机上。

4.2.14Start the machine and continue to open the mold slowly
until the "B" half disengages fully from the "A" half.
Then stop the mold at the point described for fully
open. This would normally be a minimum of
approximately 2 times the depth of the part being
molded, to make sure the part will fall free after
ejection. It is acceptable to open the mold farther
than that rule-of-thumb, but it should not open
farther than necessary because of the additional time
required to do so. If there are slides, or other
actions, in the mold, make sure they are still properly
engaged upon full opening if at all possible. This will
minimize the potential for breakage. Check for broken
springs or other obvious damage.
开动机器和继续缓慢打开模具, 直⾄后模半边模具完全和前
模半边模具完全分离。

然后完全打开模具。

模具打开⾏程最少约为产品深度两倍，这可确保产品可完全顶出。

过长⾏程将使注塑周期时间加长。

如果模具有滑动块，或其它活动件，请检查及确保它们恰当地装置在模具上。

这可减少潜在模具损坏可能。

同时检查所有弹簧及其它有机会损坏部件。

4.2.15Adjust settings for proper ejection. Ejection should
NOT pulsate. One stroke should be adequate for part
removal. If this is not enough there is something wrong
and it should be corrected before continuing
production. The amount of ejection stroke should not
exceed 2-1 /2 times the depth of the part in the "B"
half of the mold (assuming ejection is located on the
"B" half). Ejection stroke should be kept to a minimum
and is only required to get that part of the plastic
that is molded in the "B" half freely out of the mold.
More than that only adds to the overall cycle time.
调整顶杆⾏程设定。

尽量减少顶出次数。

⼀次顶出为最理想设定。

如产品不能在⼀次顶出出模, 应检查模具是否有问题⽅可继续⽣产。

顶杆⾏程设定约为产品⾼度2-1/2倍。

过长⾏程将使注塑周期时间加长。

4.2.16Lubricate all moving components such as ejector guides,
leader pins, and slides. Wipe off all excess. Gently
clean the cavity surfaces. Close the mold and turn off
the machine.
所有活动组件加润滑油如顶杆导柱，滑块。

抹掉所有多余润滑油。

清洁模⾯。

锁模及关上机器。

4.2.17Attach the hose lines from the mold temperature
control unit. Blow air through the cooling lines of
the mold to make sure they are not obstructed and to
observe the proper path for connecting hoses. Do not
loop the "A" half and "B" half together on a single
line, but attaches separate "In" and "Out" lines for
each half, and use separate control units for each half.
Make sure there are no kinks in the hoses and that they
will not be crushed or stretched when the mold closes
or opens. After inspecting for proper attachment,
activate the temperature control units and adjust for
the proper temperature setting.
接上冷却管⼦及冷却温度控制器。

⽤压缩⽓吹向喉管确保喉管通畅，为了及可检查喉管路径。

接驳连接喉管, 不要把「A」
半和「B」半连通，可按模具「出」和「⼊」位标志接驳。

确保没有在管⼦摺叠和当模具移动时喉管不会变形拉脱。

检查所有喉管正确安装后可启动温度控制器和调整正确温度设定。

4.2.18Recheck all clamps.
再次查看所有码模夹。

4.2.19Check to determine if the barrel is up to heat. This
normally takes 45 minutes to an hour to properly come
to preset temperatures and soak. Make sure all heater
bands are operable and properly connected.
检查注射筒加热系统。

加热时间通常需45 分钟⾄⼀⼩时。

确保发热带操作正常及正确连接。

4.2.20Ensure that the hopper feed gate is closed and the
hopper magnet is in position. Place fresh, dry
material in the hopper. A purging compound may be
required first, depending on what material was in the
barrel last.
检查蓄料⽃落料门关闭及感应器位置正确。

看炮筒有否余料,决定是否清洗炮筒, 后加进乾燥塑料材料。

4.2.21After the barrel is up to heat, and allowed to soak
for 10 to 15 minutes, open the feed gate on the hopper
and allow material to drop through the feed throat and
into the cylinder.
待注射筒到达设定温度后，再等待多 10 到 15 分钟，打开⽃落料门让塑料材料进⼊注射筒。

4.2.22Purge the machine as follows 清洗注射筒步骤如下:
The injection screw should have been left in the
forward position of the barrel when the last job was
shut down. It should stay in that position while
preparing material for air shots. Activate the screw
rotation until fresh material is brought to the front
of the barrel. This will be obvious because the screw
will spin freely to begin with but slow down
considerably as the fresh material is brought forward.
注射螺丝应停留在前段位置(通常每次关机也应停留在前段
位置)。

每次注射筒内⽆塑料材料射料时都应在此位置。

启
动螺杆旋转直⾄材料带到注塑筒前段。

当材料到达前段时,
可从实际看到螺杆明显旋转速度减慢。

Set the screw return limits to the desired point and
allow the screw to return to that point. The screw
rotation will stop once the screw returns to the set
point. Allow the material that was brought forward
enough time to absorb heat from the cylinder. This will
normally be only a minute or two.
设定螺杆回车限位位置及调整螺丝到达回车限位位置。

到达
回车限位位置后螺杆将停⽌转动。

让材料在注塑筒内停留⼀
⾄两分钟使材料有充⾜时间吸热。

With the sled still in the back position, take 3 air
shots. An air shot consists of injecting a full shot
of material into the air, under molding pressure, and
allowing it to accumulate on a special plate designed
to catch purging. Make sure that proper time is allowed
between these air shots to allow the upcoming material
to come to proper heat. This time usually amounts to
the total cycle time of the job that will be running
in production. Using a fast acting pyrometer with a
probe, measure the melt temperature of the material
injected during the air shots. This is the temperature
that must be controlled for proper molding. Adjust
settings as necessary. If a different material or color
is being used it may require 15 or 20 air shots to clear
the old material out.
注塑机台应往后离开注塑机前固定板，射胶 3 次(空射胶)。

空射胶步骤包括:把注塑筒内材料射出，在设定注塑压⼒，⽤
盘⼦放在射出胶料上⽅便清理。

确保有⾜够时间让材料在注塑
筒达到正确的温度。

空射胶时间约为此产品射胶时间。

使⽤反
应快速温度计量度射出胶料温度。

此温度应为此胶料控制熔胶
温度。

如塑料为有颜⾊材料可能需 15 ⾄ 20 次空射胶来清洗
筒内材料。

4.2.23Start to setup molding parameter.
开始设定注塑参数。

4.3Setup Molding Parameter 设定注塑参数
In general, injection molding parameters shall be calibrated as the following procedures:⼀般⽽⾔，注射成型参数如以下程序调校：
4.3.1Verify the material melt temperature specification
provided by the resin suppliers; ensure the barrel
temperature set to the mean value of the temperature
range.
检查树脂供应商提供的熔胶温度规格；确保注射筒内温度在提
议平均温度范围内。

4.3.2Estimate the shot size. Adjust the machine's shot
volume to about 2/3 of the actual shot size. Regulate
the melt decompress stroke. The position of changeover
should be set with at least 2.5mm above the bottom of
injection.
估计射胶量。

先⽤约 2/3射胶量作调整。

调整熔胶位置。

注射终⽌位置应该⾄少离注射筒尽头有2.5 毫⽶距离。

4.3.3Estimate and adjust the 2nd injection time. Set the
2nd injection pressure to zero.
估计和调整第 2 注射时间。

设定第 2 注射压⼒到零。

4.3.4Set the 1st injection pressure to the 50% of maximum
machine capacity. (If collapsible core is employed,
1st injection pressure can be applied to 100% of its
requirement).
设定第 1 段注射压⼒到 50%是注塑机器最⼤注射压⼒。

（如果可折叠的核⼼被使⽤，第 1 注射压⼒可设定为 100%）。

4.3.5Set the injection speed to the maximum.
设定到最⼤注射速度。

4.3.6Predict and set the cooling time.
预测和设定冷却时间。

4.3.7Adjust the back pressure per resin supplier’s
recommendation. (Usually, 3.5 bar is applied to most
of the resin)
根据调树脂供应商建议,调整背压。

（通常⼤部分树脂为 3.5 Bar ）
4.3.8If hot runner system is used, please refer to the
corresponding guideline.
如果热流道系统被使⽤，请参考对应指导说明书。

4.3.9Purge out the degraded material inside the cylinder.
把注射筒内降解的材料射出。

4.3.10Prepare a full charge of material for the first shot.
Bring the injection sled forward until the nozzle
seats against the sprue bushing of the closed mold.
The mold must be closed to absorb the force of the
injection sled against the sprue bushing. If the mold
is open at this point the "A" half will be pushed off
the platen. Lock the sled control in place.
注塑筒加满⾜够材料准备注塑。

把注塑台对准模具浇⼝套移前直⾄喷嘴贴紧。

模具应在合模状态,因喷嘴贴紧时压⼒很⼤。

锁紧注塑台位置。

4.3.11Close the safety gate to initiate the first cycle.
关上安全门启动⼀个周期。

4.3.12Operate the machine with semi-auto mode. Observe the
motion of injection screw during the injection
process.
以半⾃动操作。

在注射过程期间观察注射螺丝的运动。

4.3.13Adjust the injection speed and pressure if necessary.
If short and rapid filling time is needed, injection
pressure can be increased. There will be a changeover
before the mould cavity is fully filled. Thus, the
filling pressure can be adjusted to 100% of the 1st
injection pressure. Adjust and set sufficient
pressure so that the maximum injection speed is not
restricted by injection pressure. Adjust injection
pressure if flashing is found.
如果需要调整注射速度和压⼒。

如果需短注塑时间和快速注塑速度时，注射压⼒可加⼤。

在模腔完全注满前, 注塑参数会适当调整。

因此，第1段注射压⼒可设为 100%。

调整和设定最⼤注射速度使其不会影响注射压⼒设定。

调整注射压⼒如果产品出现溢边。

4.3.14Observe for a cycle and adjust the shot size and
changeover point. Let the 1st injection stage can
achieve the cavity filling to 95-98%.
观察⼀个注射周期和调整射胶量及注射终⽌位置。

让第 1段射胶阶段能够达到 95-98%总产品体积。

4.3.15When the shot size, injection position, speed and
pressure have been calibrated for 1st stage injection,
the setting for 2nd stage of packing pressure can be
calibrated.
当第 1段射胶的射胶量，注射位置，速度和压⼒调校后，可开始调整第 2 段射胶。

4.3.16Fine-tune the packing pressure and avoid of
over-packing.
调整保压压⼒避免保压压⼒太⼤。

4.3.17Ensure the level of cushion material.
确保胶料有适当预留。

4.3.18Adjust the ram speed to ensure that the material
feeding has completed before next injection cycle.
调整螺杆回料速度要在注射周期前完成。

4.3.19Observe the injection process. Determine the
injection steps single step molding is recommended
in general. Multi injection steps would be required
to improve the gate jetting, flow mark etc…visual
appearance.
观察注射过程。

决定注射段数 - 单⼀注射段数为⾸选。

多段
数注射可改进喷痕，放射纹及其它外观问题。

4.3.20Fine tune forward speed and pressure, packing pressure,
injection steps positions, back pressure, cushion
distance, cooling time, mold open and close settings,
and others until a properly molded part is produced.
This should be done over a long period of time (15 to
20 shots or more) and not hurried. Review the overall
part dimensions and appearance and continue if
acceptable. Injection technician or foreman put the
defect sample into the red box during set up injection
machine; not allow putting them on operator's work
station. After set up injection machine well,
re-check operator's work station, count the defective
samples, fill in MRB and sign off in MRB and enhance
all the defect samples were purged thoroughly, and
operator also re-checked operator's work station for
enhance the defect samples were purged thoroughly
before startup production;
调教速度，压⼒，保压压⼒，注射段数，背压，衬垫距离，冷却时间，模具打开及闭合设定，和其它直⾄产品吕品质合格。

这应需要多次试射调整（15 到 20 注塑次数或更多。

审核产
品尺⼨及外观直⾄可接受.在调机过程中注塑技术员或领班将
不良品放⼊红⾊胶箱内，不允许在⼯作台上放置不良品，机台调试好后，需要清点不良品，填写MRB和在MRB单上签名，确保不良品被彻底清除，在⽣产前，作业员再次确认⼯作台⽆不良品。

4.3.21All molding parameters must be confirmed by PE in
pre-launch, and then record the confirmed parameter
into IMR and control it. In production, the parameter
only allows 10% variation of controlled IMR；if the
change over the range, the new parameters need to get
Engineering reviewed and approved with full PPA passed
result or certain dimensions assigned by Engineering
compliance with the print when the full PPA is not
available in short time. Otherwise the production will
be stopped.
Pre-launch时所有的注塑参数必须由PE确认，PE确认后
记录到IMR并受控。

在⽣产过程中，参数调整不能超过受
控参数的10%，如果超过10%，新的参数必须依据全尺⼨PPA
报告或⼯程指定的尺⼨符合图纸要求，由⼯程批准，否则
停⽌⽣产。

4.3.22Record the molding parameter into IMR.
记录到 IMR(注塑参数记录)。

4.4Purge out degraded material after stopping machine停机后
排除料处理
If the injection machine stops during the production, the
barrel must shoot empty. Make following standard for each of
material.
如果在⽣产过程中注塑机出现停机的情况，注射筒必须被射空。

针对不同的物料，制定如下标准。

4.4.1If the injection machine downtime over the specified time during the production. Purge out the degraded material inside the barrel with 5 ~ 6 shots.
Each of material downtime as below the form:
如果在⽣产过程中注塑机停机时间超过规定的时间，必须要把注射
筒内降解的材料射出5⾄6啤。

每种材料规定的停机时间如下表所⽰：
5. Records (记录)
Training Record 训练记录
IMR 注塑参数记录。