Industrial Internet of Things Module for Real-time Data Collection and Analysis

Product Specification

1. Deep intelligent integration to achieve digital management and control of the entire process • Real-time tracking and analysis of production data: Equipped with an Industrial Internet of Things (IIoT) module, it can collect key production data (such as injection pressure, mold temperature, product weight, molding cycle) in real time, and generate visual reports (such as "hourly qualified rate trend chart" and "energy consumption fluctuation curve") through the cloud platform. For example, when the qualified rate of a batch of products suddenly drops by 5%, the system can automatically trace back the previous 10 minutes of data, locate abnormal points (such as barrel temperature fluctuations exceeding ±5℃), and push warnings to the manager's mobile phone (response time ≤1 minute) to avoid batch scrapping (traditional manual inspections take more than 30 minutes to find problems). • Adaptive process adjustment function: Through the "AI process model" (trained based on historical production data), it can automatically adapt to the differences in raw material batches (such as fluctuations in the melt index of different batches of PP materials) - when the fluidity of the raw material is detected to decrease, the system will automatically increase the injection temperature (such as from 200℃ to 205℃) and extend the holding time (such as from 2 seconds to 2.5 seconds) to ensure that the product weight deviation is controlled within ±1% (manual adjustment requires repeated mold trials, which takes 1-2 hours).

2. Molding optimization capability for special materials • Adaptation for high viscosity/low fluidity materials: For high viscosity materials (such as PETG, PPSU, commonly used in baby bottles and medical containers), the injection blow molding machine can fully plasticize the material (plasticization uniformity ≥ 95%) through the "special screw wing design" (such as gradual pitch, the pitch gradually decreases from the feeding section to the metering section) and "high-pressure injection molding system" (injection molding pressure can reach 150-200MPa), avoiding bubbles and material shortages on the product surface caused by insufficient plasticization. • Increased proportion of recycled materials and guaranteed performance: Supports the molding of high proportion of recycled materials (such as recycled PP and recycled PE) - by adding a "twin-screw compounding module", recycled materials and new materials can be mixed in a ratio of 7:3 (the maximum ratio of traditional equipment is 5:5), and impurities (such as metal debris and fibers) in the recycled materials can be removed through an "online filtration system" (filter screen accuracy 50-100 mesh) to ensure that the mechanical properties of the products (such as impact strength) are only ≤5% lower than those of pure new materials (the traditional process can reduce by 10%-15%), which not only reduces the cost of raw materials, but also meets environmental protection requirements.

3. Flexible adaptation for small batch and multi-variety production • Quick mold change and parameter reuse: By adopting the “mold rapid positioning system” (such as magnetic mold locking + electronic alignment sensor), the mold change time can be shortened to 15-20 minutes (traditional mechanical mold locking takes 40-60 minutes); at the same time, the equipment has a built-in “process parameter database” that can store 1000+ sets of molding parameters for different products (such as 50ml medicine bottles, 100ml cosmetic bottles). When changing products, historical parameters can be directly called, and the number of mold trials is reduced from the traditional 5-8 times to 1-2 times, greatly reducing the changeover cost of small batch production (especially suitable for e-commerce customized packaging, medical small batch reagent bottles and other scenarios). • Compatibility of single-mode multi-cavity and single-cavity multi-specifications: The same device can flexibly switch between "single-mode multi-cavity" (such as molding 8 10ml vials at one time, suitable for mass production) and "single-cavity multi-specifications" (by replacing the mold cavity inserts, producing 5ml, 10ml, and 15ml specifications on the basis of the same mold without replacing the entire mold), meeting the "multi-variety, small batch" order requirements (such as cosmetic sample packaging, a single batch quantity of only 10,000-20,000 pieces).