The premonition of injection molding machine failure and failure law before occurrence

The study of injection molding machine performance or condition gradually decreases with the time of use. Many failures are preceded by several precursors, which are called potential failures, whose identifiable physical parameters indicate a functional failure is imminent, and functional failures indicate that the injection molding machine has lost the specified performance criteria.

The pattern of injection molding machine failure rates over time is often called the bath curve. The failure rate of an injection molding machine over time is divided into three general phases: the early failure period, the occasional failure period, and the depletion failure period.

1. Early failure period

Injection molding machine in the early failure period, the failure rate is high at the beginning, but the failure rate decreases rapidly over time, the early failure period for mechanical products is also known as the break-in period.

The length of this period varies with the design and manufacturing quality of the product and system. Failure occurs during this period, mainly due to design, manufacturing defects, or improper use of the environment caused.

2. Occasional failure period

Injection molding machine into the occasional failure period, the failure rate is roughly in a stable state, tends to a fixed value. During this period, the occurrence of failure is random. During the period of occasional failure, the failure rate of the injection molding machine is the lowest and stable. Therefore, it can be said that this is the best condition period or normal operation period of the injection molding machine. This period is called the effective life.

Failure in the period of occasional failure is mostly caused by improper design, use, and maintenance. Therefore, the failure rate can be reduced to the lowest level by improving the design quality, improving user management, strengthening the monitoring and diagnosis, and maintenance.

3. Wear and tear period

In the late stage of the use of injection molding machines, the failure rate begins to rise. This is due to the wear and tear, fatigue, aging, and corrosion of injection molding machine parts. If the overhaul is carried out at the inflection point, i.e. at the beginning of the wear and tear period, the failure rate can be reduced economically and effectively.

The three stages of the change in the failure rate curve of injection molding machines truly reflect the rule of change in the failure rate of injection molding machines from break-in, commissioning, normal operation to overhaul or scrapping. Strengthening the daily management and maintenance of injection molding machines can prolong the period of occasional failure. Accurate identification of the inflection point can avoid excess repair or repair scope expansion to obtain the best investment benefits.