All-Electric Machine Debugging Guide
All-electric injection molding machines use servo motors to drive injection, plasticizing, clamping, and ejection actions. Compared with hydraulic machines, they provide faster response, higher repeatability, and cleaner operation.
Debugging focus: All-electric machines rely on accurate servo position, speed, and torque control. Confirm encoder feedback, mechanical zero points, and axis limits before high-speed operation.
1. Pre-Commissioning Checks
Before tuning, check the power supply, servo drive status, encoder cables, lubrication system, safety-door circuit, and emergency-stop circuit. Confirm that no axis is blocked mechanically.
Confirm Servo Status
Power on the control system and check that each servo drive reports ready status without alarms.
Confirm Mechanical Zero Points
Return each axis to its reference position and verify that the displayed position is consistent with the actual machine position.
Run Low-Speed Manual Actions
Operate mold opening, mold closing, injection, plasticizing, and ejection at low speed to confirm smooth motion.
2. Injection Axis Tuning
Injection performance is strongly affected by acceleration, V/P switching accuracy, and holding-pressure response. Start with conservative speeds and gradually increase to the target process window.
Increase acceleration gradually. If the pressure curve oscillates or the screw position overshoots, reduce acceleration or smooth the transition between injection stages.
3. Clamping and Mold Protection
All-electric clamping control is highly repeatable, but low-pressure mold protection must still be tuned carefully. Set mold-protection speed and force as low as possible while ensuring stable mold closing.
4. Common Issues
| Symptom | Possible Cause | Suggestion |
|---|---|---|
| Servo alarm during acceleration | Acceleration too high or mechanical resistance | Reduce acceleration and check guide rails or ball screws |
| Unstable V/P switching | Incorrect zero point or unstable material cushion | Recheck position calibration and stabilize plasticizing |
| High part-weight variation | Holding pressure/time mismatch | Tune holding pressure and check check-ring sealing |
| Abnormal noise during axis movement | Lubrication issue or mechanical interference | Stop and inspect lubrication and moving parts |
Never disable servo alarms or axis limits during debugging. If repeated servo alarms occur, identify the mechanical or electrical cause before continuing.