Installation

The installation of new machinery demands meticulous preparation to ensure a seamless and safe integration into the production line. Whether you are expanding your operations or upgrading to a new machine, these preparatory procedures are essential to streamline the installation process and minimize downtime. To guide you on the right path, let's explore the three key stages of installation: pre-installation, installation, and post-installation.

Why Proper Machinery Installation is Necessary?

The installation process directly impacts the machinery's performance and lifecycle cost. How a machine is installed determines how it will function in its operational environment. Proper installation helps align components correctly, optimize machine performance, and reduce the likelihood of breakdowns or malfunctions. It also ensures compliance with safety standards and regulations, safeguarding both equipment and personnel.

Pre-Installation Preparations

Before the machine arrives, it's crucial to prepare the installation site and ensure a safe working environment. Here are some essential procedures to consider:

Safety First: Injection molding machines are complex systems with high clamping force, high-speed moving parts, and high-temperature components. Prioritize safety measures to prevent accidents.
Clean Work Area: Keep the installation site clean and clutter-free to avoid potential hazards.
Environmental Considerations: Ensure the installation site is dry and well-lit. Do not expose the machine to rain or damp conditions.
Machine Maintenance: Follow manufacturer guidelines for injection machine maintenance, including hydraulic system maintenance, electrical system maintenance, and mechanical system maintenance.
Safety Measures: Disconnect the machine power supply before servicing or making adjustments. Always use proper personal protective equipment (PPE).

Machinery Installation Process

During installation, attention to detail is critical to ensure the machine is correctly positioned and assembled. Here’s a step-by-step guide:

The machine is positioned.
(The large injection molding machine is divided into four parts: a fixed platen, a moveable platen, a clamping unit base, and an injection unit base)
1. Install the anti-vibration pad under the clamping unit base, adjust its height to the lowest, fix it to the base, and then place it in the planned ground position.
2. Install the anti-vibration pad under the injection unit base, adjust the height of the anti-vibration pad to the lowest, fix it on the injection unit base, and then place it on the ground to install the injection seat above the injection unit base and lock all the screws.
3. Fix the fixed platen above the clamping unit base and lock all the screws.
4. Place the moveable platen above the clamping unit base and lock all the screws on the mold-adjusting platen.
5. Place the spirit level on the tie-bar to check if the machine is parallel to the front and rear. Then, place the spirit level below the barrel push rod to see if the machine is parallel to the left and right. Once the levels for front, rear, left, and right are all correct, secure all the anti-vibration pads’ fixing nuts.
6. Tighten all heat-resistant tubing.
When the motor starts, press and release it. After several times, the air in the motor will be discharged.
Test whether the pressure flow is normal.
Grease the tie-bar, adjust mold gear, slide plates, and fill all grease holes.
Fix all the shield (safety door) and test whether the opening of the safety door is smooth.
Measure whether the parallelism of the fixed and moveable platen is within the tolerance (within 10 bars of plus or minus).
Install and test all accessories.

Post-Installation Checks

After the machine is installed, perform thorough checks to ensure everything is in working order:

Place the machine on the planned ground position, adjust the machine level so it does not shake, apply anti-rust oil to the steel plates of the moving parts, clean the grease and foreign objects on the platen, replenish the grease of each moving part, and wipe off the excess grease.
Check whether the distribution valve of the toggle lubricating oil has a smooth action pressure and whether the lubricant quantity is sufficient and replenished. The hydraulic oil quantity must be sufficient, and the cooling water circuit must be properly connected.
Before connecting the power supply, it is necessary to check whether the electrical components and wires of the machine are loose and fall off due to the vibration of transportation. Only after confirmation can the power supply be connected. Connect the three contacts, R, S, and T of AC according to the local voltage of each country, and securely lock the power cord on the contacts. The diameter of the power cord should be selected according to the machine’s specifications.
Check the function of safety relief valve, when the safety door opens, the hydraulic oil can’t pass through the safety relief valve that machine can’t do the mold closing to protect the operator.
Check the function of the emergency button, when press the emergency button, the pump motor stops running.
Check the action program of manual, semi-automatic, and fully automatic modes, according to the control manual, to check whether the action is normal.