By the time you notice that your injection molding machine is acting up, repeatability has already been compromised and it’s only a matter of time before action needs to be taken. Chances are, you’ve owned this machine for quite some time and it’s always been a consistent workhorse. But you know these injection molding machines don’t last forever and now you’re left wondering if it’s time to consider upgrading the controls or hydraulic components, what costs are involved, and how long it will extend the lifespan of your machine.
Sometimes the issues you run into are obvious, like a control screen that suddenly goes black. Other times, there are things that occur over time like a repeatability issue that worsens, creating more scrap with each passing day. When the inevitable occurs, what’s your first line of defense? Most people contact the Original Equipment Manufacturer (OEM) or a local service provider and a service person is dispatched to diagnose the issue. Sometimes it can be tuning or a component replacement while other times you find out that the control system is obsolete and needs to be replaced. Control replacements themselves are an investment and can range anywhere from $50,000 to $350,000, depending on the machine size and complexity. With smaller equipment it often makes more economic sense to replace the machine completely. In the case of larger machines, you could save significant costs and extend the lifespan by an average of 15 years by simply replacing the control system.
Customers often wonder exactly what the upgrade process looks like. Many questions are met with decisions that need to be made in regards to the lifespan of the machine, costs involved, and the amount of downtime necessary to make the fix. We’ve laid the process out in three simple steps, so you know exactly what you’re getting:
Step 1: Gather information and create the scope of work
In order to quote a controls upgrade, we’ll need a set of the current machine’s electrical and hydraulic prints. We’ll also need pictures and dimensions of the control panel, as well as placement and size of the major components within the electrical enclosure.
Once the necessary prints and information are gathered, our engineers will get to work determining what components will be used and how they’ll fit into the existing space within the electrical enclosure. The system components will be priced and engineering, installation, programming, and startup time will be estimated to arrive at the final machine upgrade estimate.
This is also a great time to discuss additional interface options like data collection, quality control, robots, gas assist, hot runner, operator safety, and security. We’re also going to look at other ways we can save time and money, yet not compromise quality, by rebuilding things like hydraulic pumps, proportional valves, motors, and other electrical power components. In some cases, hydraulic power units can be replaced in order to speed up clamp and reduce the cycle time. Additional processing capabilities can also be included in an upgraded system. We can achieve better injection, hold, and back pressure control by updating injection valves or replacing manifolds.
Step 2: PO is issued and the upgrade begins
Once we discuss all viable options, a final scope of work is created, machine downtime is planned, and a purchase order is issued. Typical upgrades take one to six weeks for installation, power up, programming, debugging, and startup. The overall project timing varies according to the size of the machine and the options chosen by the customer.
Next up, solution design is completed, prints are generated, and materials are ordered. This step typically takes four to twelve weeks depending on machine complexity and options chosen as part of the upgrade. Controls-only upgrades traditionally take less time to complete, while hydraulic components typically take six to twelve weeks to ship.
Once the installation date arrives, the machine is taken out of production. Numbers on the existing wiring are verified and the wires are removed from the existing controller. Then existing control components are removed and the new components are mounted in the panel. Finally, the existing wiring is re-terminated on the new control system.
Once all the wiring is complete, the system will be powered up, software loaded, Inputs and Outputs (I/O) verified, and the machine commissioning will begin. At this time, all safety components and functions will be verified as well. Pump pressures and settings are verified and every manual function is tested and then the startup engineers can begin dry cycling the clamp and injection unit. Operating pressures and speeds are then tuned, plastic is introduced, and the first parts start coming out of the machine. During these first few days when you begin producing parts, the machine is fine-tuned and repeatability is verified. At this point you’ll be ready for full production to begin! As an added quality-control check and to ensure that you understand all the new features and how to properly use the system, our engineers will stay on-site until full production has been reached and all cycle times and machine performance criteria have been verified.
Step 3: Upgrade is complete and production resumes
The last step in the process is for the prints to get updated as there are typically minor changes required because of discoveries that were made during the installation. At this point you should be up and running like new and we consider your upgrade project a completed success.
FAQs about an injection molding machine upgrade
As you begin considering your options there are a number of questions you should discuss before making any decisions. Following are a few of the most common topics that we go over with potential customers:
Should I contact the original equipment manufacturer (OEM) first?
The OEM is a potential starting point, but we often find that they’re not the quickest or most cost effective at upgrading controls because they’re more inclined to build new machines, not work on old ones. In addition, the OEM will often quote their proprietary control system. You may want to consider an Allen Bradley control system because you can purchase replacement parts from your local distributor. At 2R Automation, we’re an Allen Bradley Systems Integrator and have been upgrading controls and hydraulics on plastics machinery for over thirty-two years. We have a thorough understanding of how molding machines operate and the process involved in repairing them.
What type of replacement parts am I getting?
It’s important to think long term here and not just look at the immediate future. This is a hefty investment and you want to make sure your machine is with you for the long haul. We’ll explain what version of Allen Bradley controller we recommend and why, how long it’s been on the market, the expected lifespan, and potential costs down the road.
Who is the manufacturer of the new system?
2R Automation is the company providing the service with off the shelf components by well-known names like Allen Bradley, Balluff, Dynisco, Lynch, and Bosch Rexroth. 2R stands behind the system and works with the parts manufacturers in the rare event that warranty replacement is needed.
How flexible is the new system?
Before we begin the quote, we’ll ask the right questions to provide you with a system that will offer just what you need as far as features, ease of use, adding new features down the road, and whether the system has alarms that clearly explain how to resolve the issue. All of our solutions are open and flexible for adding future features.
What about safety?
Safety is of the utmost importance. We’ll talk to you beforehand about whether your safety components will be changed or replaced during the upgrade, and whether they will meet current ANSI/SPI safety levels. 2R Automation, LLC has a certified TUV engineer on staff to assist with a risk assessment and make sure the new control system meets current safety standards.
Is there a warranty?
We provide a one year warranty on our work after the start of production. While there is a manufacturer warranty on the new hardware that you would be receiving in your upgraded equipment, we’re still available to support our customers every step of the way.
I have an issue…now what?
In most cases we have the ability to remotely connect to the machine to diagnose any potential issues – just give us a call if you have any problems.
Let’s get started
To gain a better understanding of the issues you’re facing and to see if upgrading your control system is the best choice, get in touch with 2R Automation today. In order to gain the most out of our conversation, it’s helpful if you have the current electrical and hydraulic prints of the machine in question. Our team of qualified engineers will be happy to answer any questions you may have and help you come up with a solution that will offer the best possible outcome for your business, both today and in the years to come.