plastic injection molding and manufacturing

Injection Molding

Injection moldingis amanufacturingprocess for producing parts by injecting material into a mold. Injection molding can be performed with metals,glasses, confections, andplastic thermoforming. Material for injection molding parts is fed into a heated barrel, mixed, and then forced into a mold cavity where it cools and hardens to the specifications of the cavity.

After an engineer designs a product, molds are made by a toolmaker from steel or aluminum. After the mold is made it is precision machined to form the features of the desired part. Injection molding is used for manufacturing a variety of parts, from small components to body panels for automobiles. Technology advances in3D printing using photo polymers can also be used for some simple injection molds. Photo polymers are used because they do not melt during the injection molding of some lower temperature plastic thermoforming processes.

Injection molding parts must be carefully designed to facilitate the molding process to prevent defective parts manufacturing. The material used for the part, shape, features, mold material, and the properties of the molding machine must all be taken into consideration. The versatility of injection molding is facilitated by this compass of design considerations and possibilities.

Injection molding uses a ram or screw type plunger to force molten plastic material into a mold cavity. The material then solidifies into a shape that has conformed to the design of the mold. Injection molding is most commonly used to process plastic thermoforming in terms of total annual material volumes processed. Plastic thermoforming is prevalent because its characteristics make them highly suitable for injection molding; such as the ease with which they may be recycled, versatility allowing them to be used in a wide variety of applications,and their ability to soften and flow upon heating. Plastic thermoforming is also much safer than thermosetting because if a thermosetting polymer is not ejected from the injection barrel in a timely manner,chemical crosslinkingmay occur causing the screw and check valves to quit performing and potentially damaging the injection molding machine.

All injection molding processes can produce flawed parts. Troubleshooting is performed by examining defective parts for specific defects and addressing these defects with the design of the mould or the mold characteristics. Tests are performed before full production cycles begin in an effort to predict defects and determine the appropriate specifications to use in the injection process.

Industrial Drives For Injection Molding

Industrial variable frequency drives (VFD’s) enable uncompromised productivity for allinjection molding processes.The ABB ACS880 drive is compatible with virtually all injection molding processes, automation systems, users and factory requirements. ABB ACS880 industrial drives are designed to simplify injection molding operation, optimize energy efficiency and help maximize production output. The ABB ACS880 series consists of single drives, multiple drives and drive modules.ABB general purpose industrial drives are designed for motor control and energy savings. ABB general purpose drives offer plug and play motor control convenience, straight from the box. ABB general purpose drives are a self-contained solution for injection molding applications. ABB general purpose drives and ABB ACS880 drives offer built in features to simplify drive selection, installation and use for injection molding.

For injection molding equipment repair and replacement quotes, contact Precision Electric. ForABB industrial drive repair and replacement quotes, contact Precision Electric.

Lenze Drive Repair

Precision Electric offers Lenze drive repair because manufacturers cannot afford downtime when equipment fails. Most Lenze drives are replaceable but Lenze drives that aren’t in stock have extensive lead times. Lenze drive repair is usually less expensive than Lenze drive replacement.Precision Electric offers free Lenze drive repair quotes to customers who have failed Lenze equipment. The following is a list of steps Precision Electric uses for each Lenze drive repair.

Checking connections is a step many people miss or do incorrectly during Lenze drive repair. Heat cycles and mechanical vibration can lead to substandard connections, as can standard preventative maintenance practices. Reusing torque screws is not a good idea, and further tightening an already tight connection, can ruin the connection. Bad connections eventually lead to arcing. Arcing at the drive input terminal can result in nuisance over voltage faults, clearing of input fuses, or damage to protective components. Arcing at the drive output terminal could result in over-current faults or even damage to the power components. Loose connections can cause erratic operation. For example, a loose START/STOP signal wire can cause uncontrollable drive starting and stopping. A loose speed reference wire can cause the drive speed to fluctuate, resulting in scrap, machine damage, or personnel injury.

Conduct Diode and IGBT Tests – There are a number of methods to test the input and output power sections during Lenze drive repair, and this step is essential prior to applying power to the drive unit. If for any reason there is a short on the input side or output side of the drive, further damage can be caused to the unit if power is applied to it. For this reason, Precision Electric uses meters to properly test the input and output power sections of the drive prior to applying power to the actual unit. If a short is found, the unit can be disassembled and the cause of the short can be diagnosed and quoted for repair. If the repair is too costly, then a replacement is offered to the customer.

Power Up Unit – Before powering up the Lenze drive, programs and parametersthat can be salvaged from the drive should be backed up to a separate drive or computer. Then, if the input and output power sections test healthy during the Lenze drive repair, power is applied to the unit to perform amp reading and output frequency tests. Precision Electric prefers to slowly increase power voltage to the drive until the rated input voltage of the drive is achieved. Depending on whether or not the Lenze drive provides a display will determine what further action(s) will be taken. If display is unavailable, disassembly and diagnosis of the internal power supply of the control section of the drive is likely necessary to further evaluate cause of failure and establish cost and lead time for the repair.

Run A Motor – If the previous tests have passed during the Lenze drive repair process, then it is time to run a basic jog function of the drive with a simple template program. After the drive programs and parameters are backed up and saved, we either reset the adjustable speed drive to factory defaults and recommission a basic start, stop and job application or closed loop if an encoder is involved. If the motor will not run, it will be necessary to check the output voltages and current ratings going to the motor to see if the drive is functioning properly to rotate the motor.

Contact Customer – At this point we have determined the cause of failure, estimated lead time and cost of the parts that need replaced for the Lenze drive repair, and are ready to offer the customer our repair quote. If the drive performs perfectly during the entire repair process, then further underlying issues are communicated with the customer. This is when Precision Electric will gather application specific information from the customer to establish whether or not it may be some outside issue associated with the system; such as PLC communications, faulty I/O, bad wiring, bad cabling. There is no single way to do this step since it depends on a wide variety of variables.

Lenze drive repair should be taken with extreme caution. Drive repair should only be performed by technicians who have required training and experience to work with electrical equipment. Precision Electric strongly recommends consulting an expert in the field when repairing all industrial electrical equipment. Many drive controllers have an internal DC bus that retains a charge after power has been cut to the drive, as a result, it does not mean it’s safe to work with. Technicians working variable frequency drives and other electrical equipment must always take extra precautions to ensure proper safety measures are taken, or injury or even death may occur.

 

ForLenze drive repair quotes, contact Precision Electric.

Harmonic Distortion

Harmonic Distortion is any distorted voltage and current waveform that deviates from an ideal sinusoidal waveform. Harmonic distortion presents potential harm and equipment downtime to electrical components. Non-linearloads connected to the electrical supply in facilities cause harmonics (waveform distortions) on the power distribution system. Common non-linear loads include solid state motor soft starters, variable frequencydrives, computers, electronic lighting, welding supplies and uninterrupted power supplies.

The Institute of Electrical and Electronics Engineers (IEEE) has established a recommended practice – IEEE 519-2014- which sets limits for harmonic current and voltage distortion for electrical power systems.This recommended practice provides the foundation for evaluating the level of harmonic distortion in a power distribution system, and the level of action required to mitigate the risks.Industries such as water and waste water treatment, and HVAC, must meet local requirements to achieve low harmonic levels; this prevents disturbances to equipment in nearby residential properties and commercial buildings.Harmonic distortion can impact a system in many ways: it can cause distribution transformers to overheat, resulting in insulation breakdown and failure; electronic displays and lighting may flicker; nuisance tripping of circuit breakers is possible; and damage can occur to electronic equipment. Harmonic distortion effects are not limited to the facilities where electrical equipment is installed. This potentially impacts any residential and commercial areas, where electrical equipment is installed such as: pumping stations, waste water treatment plants, cooling towers and HVAC systems.

Harmonic Distortion Reduction

Professionals responsible for designing and maintaining electrical systems must be aware of the potential issues related to harmonic distortion of their power distribution systems; and know how to manage them in the most efficient and cost effective manner.Many factors and components impact the overall quality of a power distribution system. Variable frequency drives (VFD’s) are among the many electrical devices included in that group. Manufacturers of variablefrequency drives offer a variety of answers to the question of how to reduce the levelof distortion these devices produce. Most of these solutions involve adding large, costly components like specialty transformers to the variable frequency drive installation to reduce the level of harmonic distortion.

ABB offers a broad range of Ultra Low Harmonic drive solutions. ABB ULH drives have built-in components to reduce harmonic distortion. ABB ULH drive solutions provide the best combination of harmonic reduction, package size, weight and range of features.The ABB Ultra-low Harmonic drive solution provides the best overall management of harmonic distortion of all solutions tested. Not only are the current and voltage distortions minimized, but the power factor is controlled to operate at unity (1.0), minimizing the total current used by the drive. ABBULH drives are the ideal solution for those drive installations where low harmonic content is desired or mandated. Its footprint is generally smaller than com parable stand-alone installations that use additional bolt-on harmonic reduction means. Its performance and simplicity of installation make it suitable for the water and wastewater industry, which includes applications such as: pumps, blowers, and compressors.

For more information about harmonic distortion or for variable frequency drive repair and replacement quotes, contact Precision Electric.

 

Altivar VFD

The Altivar VFD Plus enclosed drives feature the Altivar 61 and Altivar 71 power converters. The Altivar VFD Plus enclosed drives provide a packaged adjustable speed drive solution for commercial, industrial, and municipal applications. The Altivar VFD Plus drives combine the reliability and ease of use of the Altivar drives family with proven, validated, and tested drive system designs. Altivar Plus enclosed drives are pre-engineered, ready to use solutions in highly efficient designs. Altivar VFD Plus enclosed drives are tested and validated before shipment to ensure smooth installation. Altivar VFD Plus enclosed drives are modular and compact to maximize space utilizationand easy to set up and commission with intuitive operator interface. Altivar VFD Plus enclosed drives are available from 125 hp to 2500 hp in 460 Volt and 600 Volt. The low voltage Altivar VFD Plus series engineered drives provide a high level of performance focusing on higher horsepower ratings in a Nema Type 12 enclosure.

Altivar VFD, CPD Series

For municipal and industrial pumping applications, the Altivar VFD, CPD Series drive is an 18-Pulse enclosed drive controller features the new Telemecanique brand Altivar 61 and 71 power converters. Schneider Electrics experience and expertise in power distribution and power quality measurement are combined with solid state motor control. The Altivar VFD, CPD series drive is a robust, packaged, adjustable speed drive with clean power. Altivar CPD Series 18-Pulse drives are ideal for installations specifying clean power low- harmonic content in compliance with IEEE 519 guidelines for harmonic mitigation. Altivar VFD, CPD Series 18-Pulse drives are UL508 listed and feature a heavy-duty industrial disconnect handle with lock-out/tag-out provisions. Altivar VFD, CPD Series 18-Pulse enclosed drive controllers are low voltage products and are available in 40 horsepower through 450 horsepower in 460 Volt.

Altivar VFD, M-Flex

The Altivar VFD, M-Flex series enclosed drive features either the Altivar 61 or Altivar 71 power converters. The Altivar VFD, M-Flex series drives are either within a Type 1 general purpose or Type 12/12K drip/dust proof enclosure with an integrated or barrier design. Altivar VFD, M-Flex series drives offer a platform of standard, engineered and special features to meet the varied needs of commercial, industrial and municipal process applications where high functionality of features is required. M-Flex enclosed drive controllers are low voltage products available in ratings from 1hp through 450 hp, 460 Volt, and 1hp to 40 hp, 208/230 Volt. Altivar VFD, M-Flex series drives for variable torque (Light duty, 110% current limit) are available in ratings from 1hp to 500 hp, 460 Volt, and 1hp to 50 hp, 208/230 Volt. Integrated enclosures can be wall or floor mounted, depending on size. They provide a circuit breaker disconnect and enough room for power peripherals, including isolation and bypass contactors, all within the same enclosure. Barrier enclosure Altivar VFD M-Flex series drives separate power and control circuits, such as bypass, from the drive control. The separate compartments allow for maximum flexibility if servicing a drive in bypass operation.

To learn more about Altivar VFD drives, please visit the Altivar Website. For Altivar VFD Repair and Replacement quotes, call Precision Electric.

Eaton Cutler Hammer Drive Repair

Eaton Cutler Hammer drive repair is an asset to manufacturers because Eaton usually recommends replacing failed drives instead of repairing them.Eaton Cutler Hammer drive repair is quicker and less expensive than Eaton drive replacement.

Checking connections is a step many people miss or do incorrectly during an Eaton Cutler Hammer drive repair. Heat cycles and mechanical vibration can lead to sub-standard connections, as can standard preventative maintenance practices. Reusing torque screws is not a good Idea, and further tightening an already tight connection, can ruin the connection. Bad connections eventually lead to arcing. Arcing at the drive input terminal can result in nuisance over voltage faults, clearing of input fuses, or damage to protective components. Arcing at the drive output terminal could result in over-current faults or even damage to the power components.Loose connections can cause erratic operation. For example, a loose START/STOP signal wire can cause uncontrollable drive starting and stopping. A loose speed reference wire can cause the drive speed to fluctuate, resulting in scrap, machine damage, or personnel injury.

Conduct Diode and IGBT Tests
There are a number of methods to test the input and output power sections during an Eaton Cutler Hammer drive repair, and this step is essential prior to applying power to the drive unit. If for any reason there is a short on the input side or output side of the drive, further damage can be caused to the unit if power is applied to it.For this reason, Precision Electric uses meters to properly test the input and output power sections of the drive prior to applying power to the actual unit. If a short is found, the unit can be disassembled and the cause of the short can be diagnosed and quoted for repair. If the repair is too costly, then a replacement is offered to the customer.

Power Up Unit
If the input and output power sections test healthy during the Eaton Cutler Hammer drive repairprocess, Precision Electric will power the unit and perform amp reading and output frequency tests. Precision Electric prefers to slowly increase power voltage to the unit until the rated input voltage of the drive is achieved. Depending on whether or not the Eaton Cutler Hammer drive provides a display will determine what further action(s) will be taken. If display is unavailable, disassembly and diagnosis of the internal power supply of the control section of the drive is likely necessary to further evaluate cause of failure and establish cost and lead time for the repair.

Run A Motor
If the previous three tests have passed during an Eaton Cutler Hammerdrive repair process, then it is time to run a basic jog function of the drive with a simple template program. Often when a drive comes into our facility, we make sure to backup all existing programs stored in the drive prior to inputting a template program and running a test procedure. This ensure we have a backup copy of the program.The best method for backing up depends on the brand of drive, but after it has been backed up, we either reset the adjustbale speed drive to factory defaults through the keypad and recommission a basic start, stop and job application or closed loop if an encoder is involved. If the motor will not run, it will be necessary to check the output voltages and current ratings going to the motor to see if the drive is functioning properly to rotate the motor.

Contact Customer
At this point we have determined the cause of failure, estimated lead time and cost of the parts that need replaced for the Eaton Cutler Hammer drive repair, and are ready to offer the customer our repair quote. If the drive has tested good entirely, then further underlying issues are communicated with the customer. This is when Precision Electric will gather application specific information from the customer to establish whether or not it may be some outside issue associated with the system including, but not limited to, PLC communications, faulty I/O, bad wiring or even bad cabling. There is no single way to do this step since it depends on a wide variety of variables.

Routine Maintenance
Most Eaton Cutler Hammer drive repaircan be prevented with routine maintenance. Drive repair cost and lead times can also be reduced with routine maintenance. Eaton Cutler Hammerdrive repair can be expensive and also cost manufacturers production downtime during the repair process. Most manufacturers keep spare drives in stock to prevent production downtime when their equipment repairs are in process.

Eaton Cutler Hammerdrive repair should be taken with extreme caution. Drive repair should only be performed by technicians who have required training and experience to work with electrical equipment. Precision Electric strongly recommends to consult an expert in the field when repairing all industrial electrical equipment. Many drive controllers have an internal DC bus that retains a charge after power has been cut to the drive, as a result, it does not mean it’s safe to work with. Technicians working variable frequency drives and other electrical equipmentmust always take extra precautions to ensure proper safety measures are taken, or injury or even death may occur.

Call Precision Electric today forEaton Cutler Hammer drive repair quotes.