Dual proportional control (pressure + flow rate dual closed-loop electronic control) and dual electronic ruler control (mold clamping + injection dual position closed-loop) combine to achieve precise, stable, and efficient injection molding, representing the core configuration of high-end vertical injection molding machines.
I. Core Definitions and Principles
• Dual Proportional Control (Pressure + Flow Rate Proportional Control) The core is a dual proportional valve + proportional amplifier: one channel controls system pressure, and the other controls the execution flow rate, achieving stepless smooth switching between multiple pressure/speed stages, adapting to complex precision molding processes.
Advantages: Fast response, low impact, low energy consumption, and precise matching of dynamic requirements at each stage, including injection, pressure holding, and mold clamping.
• Dual Electronic Rulers (Dual Displacement Closed-Loop) Electronic rulers are linear displacement sensors that convert mechanical displacement into electrical signals for real-time feedback and closed-loop control of the mold clamping stroke and injection stroke.
Common Layout: The mold clamping electronic ruler measures the moving template position, and the injection electronic ruler measures the screw position; accuracy can reach ±0.01~0.02mm, ensuring accurate repeatability and measurement.
II. Collaborative Workflow (Closed-Loop Control Logic)
1. The controller issues position and pressure/flow commands for mold clamping/injection.
2. The dual proportional valves output the corresponding pressure and flow according to the commands, driving the hydraulic cylinder/screw to move.
3. Dual electronic scales collect position data in real time and feed it back to the controller.
4. The controller compares the command values with the feedback values, dynamically adjusting the proportional valve output until the target position is reached and the pressure stabilizes.
This closed-loop system ensures accurate positioning, stable pressure, and smooth speed, significantly improving yield and consistency.
III. Key Advantages (Comparison with Single-Scale/No Electronic Ruler)
• Precision: Position repeatability within ±0.02mm, yield rate up to 99.7%+, suitable for precision electronics and automotive small parts.
• Efficiency: Seamless switching between multiple processes, shorter mold change and molding cycles, increasing production capacity by approximately 15%.
• Stability: No pressure/speed impact, reducing mold and machine wear, extending lifespan.
• Energy Saving: On-demand pressure and oil supply, reducing energy consumption by approximately 18% compared to traditional models.
• Ease of Use: Supports multi-language interaction, and with PLC/touchscreen, machine setup and monitoring are more convenient.
IV. Typical Application Scenarios
• Precision Electronics: Connectors, sensor housings
• Automotive Components: Small clips, sensor bases
• Medical Consumables: Miniature connectors, plastic components
• Insert Molding: High-variety, low-batch production requiring rapid mold change and precise positioning. These scenarios all highly rely on precise and coordinated control of pressure and position.
Summary
The dual-proportion + dual-electronic-scale design marks a turning point for vertical injection molding machines, moving from simply "being able to do it" to "doing it well," making it particularly suitable for precision, multi-variety, and high-quality production. It represents both a hardware upgrade and an optimization of control logic, directly resulting in triple benefits in yield, efficiency, and energy consumption.
