Having a complete line of mold temperature controllers including water type temperature controller and oil type temperature controller.
Mold temperature controller units are widely used in a variety of industrial applications such as plastic injection, blow bottle and extrusion, die-casting and die casting, press machine laminated board, composite materials, and carbon fiber compose, reaction kettle chemical industry, pharmaceutical, industrial drying oven, roller film industry package printing, building industry mixing station.
Mold temperature controller units provide constant temperature with accurate temperature for the process, the temperature controlling stability can be ± 1℃.
Our mold temperature controller unit designed and have features for: high efficiency in heating up faster, harmless to your mold and more economical when it comes to operation and maintenance.
Each MTC unit controls the mold temperature to give perfect moldings with every shot automatically, by-pass pressure release loop for hot water with a customizable multi-point temperature control unit.
All temperature controlling units also featuring full protection devices such as oil/water shortage alarm, overheat protector, motor reverse protector, motor overload protector, auto-exhaust.
There are also some optional protection devices such as rs485 communication function for automated management, explosion-proof type, instant cooling return oil shut-down function and a microcomputer for PLC control.
Mold Temperature Controller Unit: The Complete Buying Guide
You will get all knowledge of mold temperature controller from below information, just hope this will helpful for your selecting the right temperature controlling machine for your industries.
The working principle of the mold temperature controller unit
The mold temperature controller unit is industrial water or oil heating device., can also be called mold temperature machine and temperature controller unit. It’s short for MTC and TCU.
The mold temperature controller is composed of a water tank or oil tank, a heating device and cooling system, a power transmission system, a liquid level control system, a temperature sensor, an injection port.
Mold Temperature Controller Working Principle
Typically, the pump from mold temperature controller in the power transmission system causes the hot fluid to reach the mold from the tank with the built-in heater and cooler, and then return from the mold to the tank.
The temperature sensor measures the temperature of the hot fluid and transmits the data to the control section. Controller; the controller regulates the temperature of the hot fluid to indirectly adjust the temperature of the mold.
If the temperature of the mold exceeds the set value of the controller during production, the controller opens the solenoid valve to open the inlet pipe until the temperature of the hot liquid, that is, the temperature of the mold returns to the set value.
If the mold temperature is lower than the set value, the controller turns on the heater.
Mold Temperature Controller for Injection Molding Machine
Types of mold temperature controller
There are many types of mold temperature controllers, mainly are water-type and oil-operated mold temperature controller.
The characteristics of the water type mold temperature controller:
- 1, the maximum use temperature of 40 ° C -120 ° C, accurate ± 1 ° C;
- 2. Microcomputer touch control operation is simple;
- 3, boot automatic exhaust;
- 4. Water and return water temperature display;
- 5, pipeline explosion-proof device;
- 6, mold return water function (optional);
- 7, OMRON, FUJI, temperature control parts;
- 8, stainless steel pipe, reduce pipe yin and rust;
- 9, fault display, maintenance without professional staff.
Oil-operate mold temperature controller features:
- 1. The temperature controller adopts Japanese and Italian (P.I.D.) touch mode for internal storage, automatic calculation, accurate and reliable control within ±2 °C, saving more than 35%;
- 2. Two sets of electric heating tubes can be used alone or together;
- 3, heating and cooling time is fast, the temperature is stable;
- 4. The electric heating cylinder is made of stainless steel material;
- 5. The safety protection and fault indication system is perfect;
- 6, Imported advanced components, long service life;
- 7, Perfect process system design, easy operation and maintenance.
Temperature controllers can also be divided into below types based on the application industries and temperature controlling ways:
high temperature-double temperature mold temperature controller, rubber/plastic mold temperature controller, die-casting mold temperature controller, high-light mold temperature controller.
Steam mold temperature controller, extrusion Mold temperature controller, double circuit mold temperature controller, calendering mold temperature controller, rubber mold temperature controller, dense mold temperature controller, tire mold temperature controller.
High temperature mold temperature controller, water heater, oil heater, heating equipment instead of boiler, oil circulation temperature control machine, die-casting mold temperature controller, flower roll special mold temperature controller, rolling special oil heater reaction kettle oil heater, Mixer oil heater, vulcanization molding mold temperature controller, wind power blade mold temperature controller, printing roller mold temperature controller, textile printing and dyeing mold temperature controller, hot press molding mold temperature controller
Mold Temperature Controller
Applications of mold temperature controllers
With the development of the mold temperature machine technology, the mold temperature controller has been applied in many fields:
- Petroleum and chemical industries: polymerization, condensation, distillation, melting, dehydration, forced the insulation
- Oil industry: fatty acid distillation, oil decomposition, concentration, esterification, vacuum deodorization
- Synthetic fiber industry: polymerization, melting, spinning, stretching, drying
- Textile printing and dying work: heat setting, drying, heat capacity dyeing
- Non-woven industry: non-woven fabric
- Feed industry: drying
- Plastics and rubber industry: hot pressing, calendering, extrusion, vulcanization molding
- Paper industry: drying, corrugated paper processing
- Timber industry: plywood, fiberboard compression molding, wood drying
- Building materials work: gypsum board drying, asphalt heating, concrete component maintenance
- Machinery industry: painting, printing and drying
- Food industry: baking, heating
- Air conditioning industry: industrial plant and civil building heating
- Road construction industry: asphalt melting, insulation
- Pharmaceutical industry: drying
- Light industry: production of ink, washing powder
The function of the mold temperature controller for injection molding machine
The purpose of controlling the mold temperature and the influence of the mold temperature on the injection molded part In the injection molding process.
The main purpose of controlling the mold temperature is to heat the mold to the working temperature, and the second is to keep the mold temperature constant at the working temperature.
If the above two points are successful, the cycle time can be optimized to ensure the high quality of the injection molded parts.
Mold temperature affects surface quality, fluidity, shrinkage, injection cycle and deformation.
Excessive or insufficient mold temperature can have different effects on different materials. For thermoplastics, higher mold temperatures generally improve surface quality and flow.
But extend the cooling time and injection cycle times. A lower mold temperature will reduce the shrinkage in the mold, but will increase the shrinkage of the molded part after demolding.
Mold Temperature Controller for Injection Molding Machine
For thermoset plastics, a higher mold temperature typically reduces cycle time, and the time is determined by the time required to cool the part.
In addition, in the processing of plastics, a higher mold temperature will also reduce the plasticizing time and reduce the number of cycles.
The thermal balance of the injection mold controls the heat transfer of the injection molding machine and the mold is the key to the production of injection molded parts.
Inside the mold, heat from plastics (such as thermoplastics) is transferred to the steel of the material and the mold by heat radiation, and is transferred to the heat transfer fluid by convection.
In addition, heat is transferred to the atmosphere and the formwork by thermal radiation. The heat absorbed by the heat transfer fluid is carried away by the mold temperature machine.
Mold Temperature Controller Units
The heat balance of the mold can be described as: P = Pm – Ps. Where P is the heat taken away by the mold temperature machine; Pm is the heat introduced by the plastic; Ps is the heat that the mold emits to the atmosphere.
The pre-condition temperature control system for effectively controlling the mold temperature is composed of a mold, a mold temperature machine, and a heat transfer fluid.
In order to ensure that heat can be added to the mold or removed, the various parts of the system must meet the following conditions:
The first thing is inside the mold, the surface area of the cooling passage must be large enough, and the diameter of the flow path should match the pump capacity (pump pressure)
The temperature distribution in the cavity has a large influence on the deformation and internal pressure of the part. Properly setting the cooling channel reduces the internal pressure and improves the quality of the molded part. It also reduces cycle times and reduces production costs.
Secondly, the mold temperature machine must be able to keep the temperature of the heat transfer fluid constant within the range of 1 ° C – 3 ° C, depending on the quality requirements of the injection molded parts.
The third is that the heat transfer fluid must have good thermal conductivity and, most importantly, it must be able to introduce or derive a large amount of heat in a short period of time. From a thermodynamic point of view, water is significantly better than oil.
Mold Temperature Controller
Application of nylon 66 and glass fiber injection molded parts
Nylon 66 is widely used in the electromechanical industry due to its superior mechanical properties, heat resistance, wear resistance, self-lubrication, low-temperature resistance and flame retardancy.
In order to improve the mechanical properties of nylon 66, glass fiber is one of the same. Glass fiber is enhanced and toughened by various high-performance engineering plastics because of its high-cost performance.
Nylon 66/GF30 is a product of nylon 66 and 30% (mass fraction) glass fiber blending, extrusion, cooling, and granulation. It is mainly used for products with performance requirements such as strength, toughness and flame retardancy.
It is also the appearance part of the product and requires high surface smoothness. However, in actual production, the material is dried, and the temperature of the injection plastic is 265-270 °C.
The fiber of the product is all floating on the surface, which is rough and loose. The user needs to manage surface treatment and use it. The effect is not good.
After nylon 66 is added to the glass fiber, the length, dispersion, content, coupling agent, lubricant and additives of the glass fiber will interact with the substrate, and the process conditions will affect the surface quality of the plastic part.
Temperature Controller Unit
When the blending temperature is too low, the combination of the glass fiber and the matrix is deteriorated, and the coating effect is not good; if the temperature is too high, the degradation of the nylon 66 affects the performance of the product, which is the cause of the glass fiber floating.
After many tests, the mold temperature is controlled by a mold temperature of 80 to 100 ° C, sometimes 110 ° C, while the moving mold is connected to the cooling water to maintain the temperature of 30 to 40 ° C.
The pressure and speed have been adjusted accordingly. The cooling time is extended by 6 to 10 s. The surface of the plastic parts is more nylon 66 resin. The corresponding fibers are less or go inside the cover. The surface quality of the plastic parts is good.
Higher temperatures improve the fluidity of the resin, which generally results in a smooth, shiny surface, especially for the surface aesthetics of glass-reinforced resin parts.
It also improves the strength and appearance of the weld line. Similar materials containing glass fiber can also improve the quality of the plastic parts by mold temperature.
The mold temperature machine controls the temperature in the reactor industry: the circulating pump converts the electric energy into mechanical energy to promote the liquid phase circulation of the heat transfer oil and transfers the heat to the reaction kettle.
The heat transfer oil exchanges heat with the materials in the reaction kettle and then returns to the reactor. The inside of the oil heater is again heated to the next cycle under the pressure of the pump.
After repeated cycles, heat transfer and delivery, heating, cooling or maintaining the temperature of the reactor to meet the temperature requirements of the production process.
Temperature control of mold temperature in the die casting industry: The most ideal heating method for temperature control of die casting mold is heat transfer oil heating.
The heat transfer oil flows continuously in the pipe in the mold for heat exchange, and the mold is uniformly heated to the use temperature. Another advantage of using heat transfer oil is that the temperature control accuracy is high.
Mold Temperature Controller for Die Casting Machine
Since the die-casting mold temperature machine itself has a cooling system, the heat transfer oil temperature can be accurately controlled within the set range.
This allows the temperature of the mold to be controlled within a very small margin of error, even in the event of production interruption.
The role of the mold temperature controller in each industrial process:
Why do you need a mold temperature controller for injection molding and other industrial processes?
Injection molding
When the plastic is injection molded, the melting temperature of the plastic in the material tube varies from one hundred degrees to more than three hundred degrees depending on the melting point of each plastic.
The mold should have an appropriate temperature (refer to the data in the table). The mold temperature control generally uses the mold temperature machine, the hot oil (water) runs in the cooling flow channel of the mold, and the mold temperature (cavity temperature) is controlled by the heat transfer.
Generally, the temperature of the injection molding cavity is 100 ° C, and the water temperature controller will control The set temperature of the water temperature machine is about 105-110 ° C, but if the oil temperature machine is used, the set temperature of the oil temperature may reach 130-150 ° C.
There is such a difference that the heat transfer coefficient of water is higher than that of oil. Double, so the heat transfer speed is fast and the temperature difference is small. Different molds may vary depending on the runner design.
The main key points are:
(1) Total heat transfer area of the runner in the mold
(2) distance between the flow path and the cavity
Traditionally, there is also a heater for heating the mold on the mold. Compared with the mold temperature controller, the temperature of the mold controlled by the mold temperature controller is stable, because the mold temperature controller provides a medium with a fixed temperature and continuously runs into the mold flow path.
The mold heated by the heater will be unstable, because the temperature of the heater may reach 300 ° C when heating, and the heat is not zero when it is not heated, so the precision and advanced products must use the mold temperature controller.
Advantages of using a temperature controller unit in the injection molding machine:
1, improve the molding efficiency of the product;
2, reduce the production of defective products;
3, improve the appearance of the product, inhibit product defects;
4. Speed up production, reduce energy consumption and save energy;
5, improve the life of the mold.
Zinc, aluminum, magnesium alloy die casting
The aluminum alloy has a point of more than 700, and the mold temperature is generally controlled at 200-300 ° C.
When the mold is not warmed when the machine is turned off, the mold is too cold, the melt is solidified at the inlet, and the melt does not enter the mold, even if it runs in.
Because the cooling rate is too fast, it is easy to cause products such as shrinkage, cracking, surface oxidation, bending, and dimensional deformation.
When the mold is opened, the mold opening force is very large. (Because the product shrinks and encloses the mold), the mold life is reduced by 1/3, and the metal die-casting molds are all high unit price, so the general precision die-casting such as automobile parts, computer parts or mobile phones For the outer casing, etc., the temperature should be controlled by the oil temperature controller.
The wheel temperature control
Plastic extrusion molding, such as extrusion of plastic flat plate, plastic from the mold out of the temperature of 230 ° C (ABS) and through three rollers, cooling, size, and the three rollers each temperature is different, you must control the temperature, and The oil temperature controlling machine also has a water temperature controller.
Another example is a plastic film on a stainless steel plate, or a plastic printer, such as a printed poster. The stainless steel plate passes through the roller, and the PE film is transmitted from the other roller.
Both of them are attached together by the temperature roller, so the temperature control of the roller is also performed by the mold temperature controller.
Besides the above applications, temperature controllers are also used in: Plastic Injection molding, light guide plates, connectors, DVD discs, magnesium-aluminum alloy die-casting, chemical, printing and dyeing, wheel heating, reactors, tires, extrusion, extrusion die and other industries have been widely used.
Advantages and disadvantages of the mold temperature controller:
There is no doubt that the comprehensive economy and technology are considered in many aspects, and we can find a mold temperature controller that matches your needs in the market.
But how to choose a suitable temperature controlling machine from a variety of brands and multiple series is not an easy task.
In addition to considering the cost, we must understand:
the timeliness of product supply, the quality of after-sales service, whether the machine can be expanded, and so on.
In fact, the most important thing for you is to obtain the technical parameters of the mold temperature machine that suits your needs, so as to measure the availability to you.
Some tips for choosing the right mold temperature controller
The thermal medium as the first standard
First, decide to use heat transfer oil or water. In the allowable temperature control range, based on the good thermal conductivity of water, water is preferred.
Water mold temperature controller
When the temperature requirement of the mold does not exceed 95 °C, the working mode of the mold temperature machine is non-closed;
when it is higher than 95 °C, the closed working mode must be selected to ensure a certain pressure inside the system to avoid evaporation of the heat transfer medium.
When the mold is at a high temperature, such as: thermoplastic material in the injection molding process, accurate and rapid heat transfer is necessary.
This is a worrying product for products with high precision requirements. Based on the limited internal space of the hot runner of the general model, the hot water mold temperature machine is more suitable than the oil mold temperature machine.
When the temperature reaches 200 ° C and the pressure is 16 Bar, the superiority of the water mold temperature machine is more prominent.
The temperature control range of the water mold temperature machine is: 5 °C ~ 200 °C.
Water Temperature Controller
Oil mold temperature controller
The temperature control range of the oil mold temperature machine is 45 ° C ~ 350 ° C.
The temperature of the non-closed oil mold temperature controller can be up to 200 degrees. Considering that some heat transfer media will undergo pyrolysis at 200 °C.
Therefore, the pyrolysis reaction humidity of the heat transfer medium selected by the series of mold temperature machines is higher than 200 ° C, so that the pyrolysis reaction will cause the decomposed carbon to be attached to the surface of the heat medium, thus reducing the thermal conductivity of the medium, and finally the mold The humidity is not well controlled.
Based on the pyrolysis reaction of oil at high temperature, safety measures should be taken to avoid the pyrolysis reaction when the oil temperature is higher than 200 °C.
If necessary, check the flow rate of the heat transfer medium. If the flow rate is too low, the system should have an automatic Shutdown function.
In addition, the oxidation of the heat transfer medium should be avoided. Oxidation increases the viscosity of the medium and reduces the thermal conductivity of the medium, which also affects the temperature control of the mold.
Therefore, when pouring oil into the fuel tank, the oil should be poured slowly and the medium temperature should be set at about 100 °C.
Oil Mold Temperature Controller
When choosing a machine, you also need to pay attention to the cooling method of the heat transfer medium. The cooling method is divided into direct and indirect.
The indirect cooling method uses a cooling circuit separate from the main circuit. The heat transfer medium used in this cooling method is generally oil type.
The heat of the cooling medium is absorbed by the heat medium and directly enters the exchange valve. The indirect cooling method is only used on the oil mold temperature machine.
Because the cooling capacity of this kind of cooling method is not strong, the cooling water must be cleaned when using this cooling method, so as to prevent the impurities from clogging the pipeline and affecting the temperature control performance of the machine.
Mold Temperature Controller
Advantages of direct cooling:
Disadvantages of indirect cooling: heat is lost in the heat exchanger. Therefore, when the actual temperature of the medium deviates significantly from the set value, we use a direct cooling method with large cooling capacity.
When direct cooling is used, the cooling water enters the circuit directly without the need for a heat exchanger. By using this cooling method, the cooling capacity of the system can be greatly improved, and the heat transfer medium can be quickly cooled.
An electric valve or multi-segment solenoid valve control can be used to increase the control accuracy of the system. The premise of using the direct cooling method is: closed circuit; the heat transfer medium needs to use clean water.
Mold Temperature Controllers
Single loop, dual loop, multi-loop control system, third selection standard
First, we need to distinguish between single-loop, dual-loop and multi-loop control systems.
The single loop control system is compact and small in size. There are several series according to its temperature control range.
The two-loop control system is used when the temperature required for the mold and the fixed template is different.
The temperature of the two circuits is controlled according to the difference in temperature requirements of the two templates and the flow rate of the pump is adjusted.
At the same time, the power supply of the cooling water is connected to the main power supply in the same junction box, so that the size of the whole machine is reduced.
The multi-loop control system contains multiple separate circuits, each of which is used to control different temperatures required during the molding phase of the product.
Therefore, the mold temperature controlling system can achieve perfect results for controlling products with complicated structures, complicated molds, and special process technical products.
The above is a series of knowledge about the working principle, type, function, advantages and disadvantages and selection points of the mold temperature machine.
In one sentence, the working principle of the mold temperature machine is introduced: heating the heat transfer oil or water through the electric heating tube, and then passing the mold temperature.
An oil pump or water pump inside the mold controlling unit causes the medium to circulate between the mold temperature machine and the heated equipment (object).
Mold Temperature Controller
As a leader in mold temperature controller unit manufacturing, TopChiller has been manufacturing molding temperature controller for almost 20 years.
TopChiller is a professional mold temperature supplier with a good reputation in the market for high quality and stable performance of our mold temperature controller unit.
Temperature Controller Unit
Mold temperature controller maintenance
1. Purchase a new mold temperature controller, check the cooling water before use to prevent damage to the mold temperature due to insufficient cooling water.
We must keep the working environment of the mold temperature controller clean and avoid dust, which can greatly extend the service life of the electrical components of the mold temperature controller.
2. For the new mold temperature controller, we have to make different maintenance measures according to the heat transfer medium used.
For the medium is water, we must keep the water source clean, so it is not easy to scale, and it can prevent the pipeline from clogging.
For the medium is oil, we have to replace it regularly according to the temperature of use. For 200 °C or above, we have to replace it once a month or two, and below 200 °C, we can replace it once a quarter or so. Avoid the problem that the temperature cannot be added.
3. In terms of piping, we need to judge whether the pipeline is clogged according to the relationship between pump and pressure.
If the pressure is too small, we can take out the heating pipe and clean it with tools, especially the filter mesh of the system inlet. The cover is best cleaned once a month.
4. Regularly check the mold temperature pump and oil pump for oil leakage. If necessary, the pump shaft seal can also be replaced regularly.
5. On the electrical components, we can replace them according to the service life of the components and test them regularly to ensure safety.
Features of the Mold temperature controller from TopChiller
Temperature controller units designed and manufactured by TopChiller having some features as below:
- Explosion-proof heating pipe device
- 304 metal forming an integrated pipe which can reduce pipe resistance and rust scale, improve the service life
- Microcomputer biped PID temperature control table, touch internal storage, automatic calculation
- Energy saving more than 35%
- Automatic air-discharging function to improve the speed of the machine, saving time
- Fully safety protection devices with fault display
- Easy maintenance and operation
- Up to 18 months warranty time for all temperature controller units
How Can we Help Your Business Today?
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Or perhaps you are unsure of what size temperature controller is required for your business process?
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Please contact us to customize your mold temperature controller unit.