Tempo osadzania się osadów pochodzenia mineralnego lub korozji zależy od wielu czynników, takich jak skład chemiczny medium chodzącego czy temperatura pracy. Także to w jaki sposób chłodzenie zostało zaprojektowane może mieć niemały wpływ na spadek wydajności chłodzenia. „Martwe” obszary generujące zerowe przepływy będą miejscami gdzie w naturalny sposób będą osadzały się złogi wytrącone z medium chłodzącego. Ważne jest, aby jeszcze na etapie projektowania chłodzenia formy symulować sposób płynięcia medium, tak aby unikać fundamentalnych błędów zwiększających ryzyko spadku wydajności chłodzenia. Niestety na etapie konstruowania formy temat spadku wydajności chłodzenia w wyniku zakamieniania układu wydaje się tak odległy, że rzadko kiedy brany jest pod uwagę.

This post Czynniki wpływające na spadek wydajności chłodzenia first appeared on Coolingcare.eu and is written by testadmin

During discussions with customers, we always try to convince them to test the device they are interested in. We believe that before deciding on an investment we should always verify the effectiveness of a given solution, all the more so when we are dealing not with a product that obviously increases the productivity of the company (such a product is, for example, another injection molding machine), but a device that indirectly 'frees up' productivity and minimizes production costs. Driving around different companies, it is not uncommon to come across competitors' equipment, which for some reason is not used and put away in a corner collecting dust. When asked why they don't use a particular solution, we usually hear that in practice the machine didn't work out and didn't perform as expected, either from the efficiency, operation or failure rate side.

The question then arises of its own accord as to how the buying process went and why the end users of this product were not actively involved in the decision, or at least in the opinion of the solution. Marketing departments of companies can be very creative and write things in brochures that are supposed to attract the attention of a specific target group. Often it turns out that some boisterously named feature turns out to be something completely trivial and obvious, or worse, XYZ device called automatic requires multiple operation of the service during the process. From our 7 years of experience, we know that a purchasing decision made solely on the basis of price, without taking into account the real needs of the enterprise, most often ends up with the purchased device ending up in the corner, unused, because it is a) ineffective, b) impractical from the operator's perspective.

Such a purchase is throwing money down the drain and, moreover, spoiling the market itself, because usually the possibility of buying a device with similar functionality again is no longer possible. Therefore, as a manufacturer of equipment, we urge you to test, compare and verify what you read and hear from traders. Remember, the most expensive machines are those we do not use, such an investment will never pay off. Verifying the effectiveness of a given solution in your production environment will allow you to truly evaluate the device from the standpoint of efficiency, ease of use and overall design consideration.

This post NAJDROŻSZA MASZYNA TO TA, Z KTÓREJ NIE KORZYSTASZ, BO NIGDY SIĘ NIE ZWRÓCI. NIE KUPUJ KOTA W WORKU first appeared on Coolingcare.eu and is written by testadmin

To minimize the risks associated with declining cooling performance, it is essential to include regular cooling duct cleaning in your mold service routine. Here are some best practices to help keep cooling channels clean and efficient:

1. Regular preventive cleaning: Set a cleaning schedule based on the frequency of mold use and the type of coolant circulating in the system. Regular diagnostics and short preventive cleaning sessions are effective in preventing the buildup of contaminants before they cause more serious problems that reflect on the process.
2. Flow monitoring: Implementing systems to monitor the flow of the cooling medium through the ducts allows early detection of decreases in flow or increases in delta T (the difference in inlet and outlet temperatures), which can indicate blockage or scale/rust buildup.
3. Documenting maintenance activities: Keep detailed records of all maintenance activities, including cleaning dates/times and recorded flow expenditures for individual channels. These records help track the decline in cooling performance over time and can guide future decisions on tool maintenance activities.
4. Selecting the right tool: Make sure the device dedicated to cleaning has features that will allow you to clean effectively and efficiently as well as monitor the performance of individual tool cooling circuits. It's a good idea if the device also has a function to save the data with the ability to play it back and refer to it in subsequent cleaning sessions. 

This post Najlepsze praktyki w zakresie skutecznego czyszczenia kanałów chłodzących first appeared on Coolingcare.eu and is written by testadmin

Neglecting to regularly clean cooling channels can have serious consequences for both the mold and the production process. As contaminants accumulate, water flow is reduced, which lowers the cooling system's capacity. Lower heat removal capacity as a result of a layer of insulation with low thermal conductivity, combined with throttled flow, can cause localized overheating in the mold (known as hot spots), leading to uneven cooling and unstable part quality. As a result, the percentage of defective parts increases, production costs rise, and more frequent mold repairs or even mold replacement becomes necessary. In critical cases, cooling channels can become completely clogged, forcing mold downtime, the need to dismantle the mold and mechanically reaming out the blockage, which generates huge costs. This not only increases operating costs, but also negatively affects the ability to meet production deadlines. At a time when customers' quality requirements are so exorbitant, maintaining stable molding quality with the shortest possible cycle time is crucial.

Potential problems arising from tool thermal disturbances:

1. Extended cycle times: Clogged cooling channels result in slower heat transfer, which means the mold takes longer to cool. This leads to longer production cycles, reducing overall process efficiency and increasing operating costs.
2. Disadvantages of molding: Uneven cooling can affect part quality. Defects such as deformations, sink marks and dimensional deviations become more common, leading to more rejections by the quality control department. In addition, the uneven cooling process of the workpiece can lead to stresses, reduced product strength and cracking under load.
3. Faster mold wear: Low cooling efficiency forces the mold to operate at higher temperatures for longer periods, accelerating wear on mold components. This can shorten tool life and require more frequent repairs and reconditioning.
4. Higher energy consumption: An inefficient cooling system requires more energy to maintain the proper mold temperature, leading to increased energy costs and greater environmental impact.

This post Konsekwencje zaniedbania czyszczenia kanałów chłodzących first appeared on Coolingcare.eu and is written by testadmin

Mineral deposits originally consist of calcium and magnesium carbonates. Carbonates, which are generally insoluble, are precipitated by heating water containing soluble calcium and magnesium bicarbonates. Bicarbonates are thermally unstable and break down to form carbonates and thus scale when heated.

Factors affecting scale deposition:

• The higher the (temporary) hardness of the water, the more scale will precipitate.
• The higher the pH (alkaline pH) of the water, the greater the tendency to scaling
• The higher the temperature to which the water is heated, the more scale will precipitate.

Scale precipitation and deposition on sewer walls increases dramatically when water temperatures exceed 60 degrees Celsius. It also depends on the hardness of the water, so in some areas the problems caused by scale are greater than others. To counter scale problems, most injection molding plants use some form of water treatment to minimize the risk of deposits based on minerals such as calcium or magnesium.w

For descaling of calcium and magnesium deposits, it is advisable to use DS2 cleaner.

Another type of deposits is formed during the corrosion process. These can be solid, water-insoluble deposits (such as encrustations during the microbial corrosion process) or scale - a layer of solid corrosion products or hard iron oxides. Like other deposits, they are dangerous to the ducts, restricting flow and reducing the efficiency of heat extraction.

Scale in water-cooled mold ducts will usually have a high concentration of iron oxides/corrosion by-products. This is mainly because companies use "closed loop" water supply systems where the concentration of iron oxide is up to seven times higher than in ordinary tap water. Another reason for the formation of deposits as a result of the corrosion process may be water left in the sewers after the cleaning process. Oxygen dissolved in the water reacts with the steel, causing corrosion.

To remove scale with a high concentration of iron oxides, it is advisable to use DS1 cleaner.

This post Rodzaje osadów i typy kamienia first appeared on Coolingcare.eu and is written by testadmin

Z tego typu podłączeniami będziemy mieć do czynienia najczęściej w większych formach, które posiadają dużą liczbę kanałów chłodzących. Podłączanie chłodzenia do każdego z kanałów oddzielnie jest niepraktyczne, dlatego są one zazwyczaj spinane w jeden duży kolektor zasilający, którego celem jest doprowadzenie medium chłodzącego do poszczególnych obiegów w formie. Z tego typu podłączeniami będziemy mieć do czynienia najczęściej w większych formach, które posiadają dużą liczbę kanałów chłodzących. Podłączanie chłodzenia do każdego z kanałów oddzielnie jest niepraktyczne, dlatego są one zazwyczaj spinane w jeden duży kolektor zasilający, którego celem jest doprowadzenie medium chłodzącego do poszczególnych obiegów w formie. Tego typu rozwiązanie nie jest oczywiście idealne. Musimy pamiętać, że równoległe łączenie obiegów generujących różne spadki ciśnień (spadki te wynikać mogą z dużej dysproporcji w średnicach, długości, czy też odległości kanałów od siebie, wymuszających łączenie ich z kolektorem wężami o różnej długości) będzie przekładało się na nierównomierne rozprowadzanie cieczy chłodzącej do poszczególnych obiegów, nawet jeśli zastosowany

będzie kolektor o odpowiedniej objętości bilansujący ciśnienie. Takie rozwiązanie należy traktować jako kompromis i starać się podłączać obieg i w taki sposób, aby ryzyko nierównomiernego rozkładu cieczy chłodzącej było jak najmniejsze. W sytuacji kiedy jeden z obiegów jest przykładowo częściowo lub całkowicie zapchany, podłączenie równoległe spowoduje że ciecz czyszcząca nie będzie w stanie nawet dotrzeć do tego kanału, ponieważ popłynie zawsze tam, gdzie opory płynięcia będą najmniejsze.

Należy pamiętać jednak, że proces czyszczenia kanałów nie jest procesem ich chłodzenia. Jest to częsty, błędny skrót myślowy który stosują użytkownicy mostkujący obiegi do czyszczenia, argumentując że forma na produkcji podpięta jest w identyczny sposób. Chcąc efektywnie czyścić obiegi podłączone ze sobą za pomocą kolektora, musimy zastosować pompę podającą o znacznie większym wydatku, będącą w stanie pokonać spadki ciśnień generowane przez układ, zachowując jednocześnie odpowiednią dynamikę, która zagwarantuje skuteczność czyszczenia w jak najkrótszym czasie. Skuteczność urządzeń wyposażonych w pojedyncze pompy o większym wydatku zależy przede wszystkim na ilości litrów przepompowanej cieczy w zadanym czasie, co nigdy nie jest najbardziej efektywnym rozwiązaniem. Dlatego warto szukać rozwiązań wykorzystujących układy hybrydowe, takie jak chociażby opatentowany, dwuetapowy proces czyszczenia chemiczno-mechanicznego w maszynach CoolingCare, w którym zastosowano dwie współpracujące ze sobą pompy dla każdego z obiegów. Takie podejście daje dużo większą elastyczność i w znacznym stopniu skraca czas czyszczenia.

This post O podłączeniach równoległych słów kilka… first appeared on Coolingcare.eu and is written by testadmin

The task of an efficient mold cooling system is to guarantee an even temperature distribution across the individual cavities, which translates into appropriate dimensional tolerances and molded part quality.

Any temperature deviations caused by flow disturbances and/or the inability of the channels to effectively receive heat will, over time, translate into the quality of the manufactured product The walking medium circulating in the mold cooling system removes heat from the mold, ensuring an even temperature distribution, which in turn translates into adequate quality, meeting dimensional tolerances or cycle times.

Corrosion products, lime deposits and other deposits deposited on duct walls are a silent killer of our cooling system's performance. Deposits in the ducts reduce the cooling system's efficiency by reducing the duct diameter. To make matters worse, due to its very low thermal conductivity, even a thin layer of scale acts as an insulator, hindering the reception of heat from the molding cavity. Scale never deposits evenly, which can quickly lead to mold thermal disruption and quality problems. That's why it's worthwhile to regularly monitor the cooling performance in our molds and act preventively.

Note that the issue of cleaning channels and maintaining high cooling performance over the life of the tool applies not only to those made with incremental technologies, but also to classic drilled cooling channels. The only difference is that the complexity of the channel geometry and the small diameters of conformal-cooled channels make cleaning more difficult and require appropriate tools and methods. This does not mean, however, that classic designs with drilled channels are free from problems of decreased cooling performance or clogging. This is a very common phenomenon and, worst of all, it goes unnoticed.

This post Czy kontrolujesz wydajność w Twoich formach wtryskowych? first appeared on Coolingcare.eu and is written by testadmin