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Analysis of common problems of hot runner systems and solutions

Table of Contents

1. The thermal manifold cannot reach the set temperature  

Cause: Poor contact or failure of thermocouple, broken heating wire, heating wire wiring is too loose or too short. 

Solution: Check whether the thermocouple contact is normal wiring is correct check the heating wire circuit.

2. Thermal manifold heating up too slow  

Cause: A heating wire break or wiring is too loose, insufficient air gap in the thermal manifold, excessive cooling on the thermal insulation gasket, and poor thermocouple contact. 

Solution: Check all heating wires, increase air gap, require at least 10mm, or use heat insulation plate, add heat insulation plate on fixed die fixing plate (bottom plate) or lower the cooling on lower fixed die fixing plate, check whether the thermocouple is good. 

3. Thermal manifold temperature instability 

Cause: Poor thermocouple contact

Solution: Check the thermocouple

4. Metal fragments in the melt  

Cause: Debris on the injection molding machine screw, metal fragments in the injection material.

Solution: Remove the metal fragments to repair the impurities in the screw-filtered plastic.

5. Leakage of material on the combination surface of thermal manifold and thermal nozzle  

Reason: Incorrect calculation of expansion amount, inconsistent processing height of W surface, fixed mold fixing plate (bottom plate) material is too soft, the temperature of the hot manifold is too high for a short period, and the installation of the “O” seal is problematic. 

Solution: Recalculate and check the expansion amount, check the height of the correct W surface, replace the fixed plate (base plate) with the appropriate hardness, and replace the damaged parts and the “O” seal ring.

6. Hot manifold compensation plug leaking rubber 

Cause: No gasket

Solution: Install the gasket.

7. Oil (gas) cylinder does not work  

Cause: No air / hydraulic oil into the cylinder, pneumatic/hydraulic cylinder system stuck, the system pressure is not enough.  

Solution: Check whether the pipeline, pump leakage, blockage, check the cylinder and piston with check whether the feeding pipeline is excessively bent, the piston and valve needle are flexible. 

8. Cylinder system is seized  

Cause: Cylinder body, hot manifold, hot nozzle, etc. are not centered, fixed die fixed plate (bottom plate) accumulate too much heat. 

Solution: Adjust the cylinder body, manifold, and hot nozzle concentricity around the cylinder body to increase cooling.

9. Cylinder block overheating and stuck  

Cause: Cylinder body, hot manifold, hot nozzle, etc. are not concentric, fixed die fixing plate (bottom plate) too much heat accumulation gasket and valve pin fixing nut friction.  

Solution: Adjust the concentricity of the cylinder body, hot manifold, and hot nozzle, increase cooling around the cylinder body, adjust the gasket and valve pin fixing nut.

10. Leakage around the valve needle bushing  

Cause: The valve needle bushing on the hot manifold is too loose.  

Solution: Check the diameter and height of the hole of the hot manifold, and valve needle bushing.

11. Valve needle head sticky material  

Cause: Too much heat is not emitted from the valve needle.  

Solution: Reduce the temperature of the hot nozzle and the gate and increase the cooling time.

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