APSX APSX-PIM User manual
APSX-PIM USER MANUAL
Full-Automatic Electric Desktop Plastic Injection Machine
APSX-PIM
User Manual V1.5
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This equipment manual is intended to provide information for safe operation and maintenance. APSX
reserves the right to make changes to equipment in an effort to continually improve the equipment,
features, and/or performance. These changes may result in different and/or additional safety measures
that are communicated to customers through bulletins as changes occur.
This document contains information which is the exclusive property of APSX LLC. Except for any rights
expressly granted by contract, no further publication or commercial use may be made of this document,
in whole or in part, without the prior written permission of APSX LLC.
Notwithstanding the foregoing, APSX LLC grants permission to its customers to reproduce this
document for limited internal use only.
Copyright © 2017, APSX LLC.
All Rights Reserved.
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General Information
Phone Support Number: 1-513-716-5992 (9AM-5PM EST Weekdays)
Please refer to www.apsx.com for the office locations.
Product Upgrades
Upgrades may be available that can improve your equipment. To see what upgrades are available for your
machine please visit www.apsx.com or call support number.
Spare Parts
All spare parts for APSX-PIM can be ordered online at www.apsx.com.
Unauthorized Modifications
Under no circumstances should any changes or modifications be made to the electrical circuits,
mechanical structures, or the safety devices to the machine and guarding on the mold without the prior,
written permission of APSX LLC.
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Table of Contents
Injection Molding Process ........................................................1
Processing Characteristics.......................................................1
Example for Polypropylene.............................................................1
Some Terms for Injection Molding............................................2
Safety Precautions...................................................................8
Thermal effects:..............................................................................8
Off-Gases Ventilation:.....................................................................8
Slipping Hazards:............................................................................8
Physical Hazards: ...........................................................................9
Electrical Hazards:..........................................................................9
Other Safeguards:...........................................................................9
APSX-PIM Injection Molding Machine....................................11
Plasticizing Section.......................................................................12
Pre-Plasticizing Section ................................................................12
Injection Section............................................................................12
Injection Valve Section..................................................................12
Clamping Section..........................................................................12
User Interface Section...................................................................12
Moving the APSX-PIM to Another Location............................ 13
APSX-PIM Injection Molding Process..................................... 14
Preparing the Machine..................................................................14
Powering the Machine...................................................................14
System ON....................................................................................14
Installing the Mold.........................................................................14
APSX-PIM MAGNETS, SWITCHES AND SENSORS: .................22
APSX-PIM CYCLE:.......................................................................23
Settings.........................................................................................24
APSX-PIM User Screen................................................................24
Filling the Hopper..........................................................................30
Start the Heat................................................................................30
Manually Controlling......................................................................30
Purging..........................................................................................30
Start RUN......................................................................................31
Stopping the Machine ...................................................................31
Cleaning the Machine ...................................................................31
Troubleshooting Guide........................................................... 32
Machine Specs.......................................................................34
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KEY FEATURES OF APSX-PIM...................................................34
TECHNICAL OVERVIEW .............................................................34
DESIGN ELEMENTS....................................................................35
SUPPORT.............................................................................. 37
SPARE PARTS.............................................................................37
LIMITED WARRANTY ..................................................................37
TRANSFERABILITY .....................................................................38
TOOLS AND ACCESSORIES................................................ 39
Kill-A-Watt.....................................................................................39
15/16” Wrench ..............................................................................39
7/16”, ½”, ¾” Wrenches ................................................................40
3/16”, ¼” and M4 Hex Keys ..........................................................40
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C H A P T E R : P R O C E S S I N G C H A R A C T E R I S T I C S
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Injection Molding Process
It is a science but is also kind of art.
he injection molding of thermoplastic resins is a well-known and widely
practiced application. It constitutes a major processing technique for
converting plastics into a variety of end-use products. Basically, the process
involves heating the solid pellets to melt, then transferring it to a mold and
holding it under pressure until it freezes, or solidifies.
Plastic molding compounds represent a range of chemical types. Each type has its own
specific processing characteristics which must be considered and understood before it
can be successfully molded.
Processing Characteristics
The physical and chemical properties of a plastic dictate the way in which it must be
molded. Among these are:
Melting or softening temperature
Energy content (specific heat and latent heat)
Melt viscosity
Stability and behavior at melt temperatures
Freezing rate, crystallization rate, and cycle time
Shrinkage
Example for Polypropylene
For example the PP which is a frequently used plastic has physical,
mechanical, impact and thermal properties listed. Specific gravity,
mass flow rate, tensile strength, izod impact and deflection
temperature under load are some of the properties that make a
difference when processing for injection molding.
T
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Some Terms for Injection Molding
Alloy: A term used in the plastics industry to denote blends of polymers or copolymers
with other polymers or elastomers. - i.e. ABS/Polycarbonate.
Ambient Temperature: The temperature of a medium surrounding an object. The term
is often used to denote prevailing room temperature.
ANSI: Abbreviation for American National Standards Institute.
ASTM: Abbreviation for American Society for Testing and Materials.
Back Pressure: The resistance of the molten plastic material to forward flow. In
molding, back pressure increases the temperature of the melt, and contributes to better
mixing of colors and homogeneity of the material. However, as back pressure
increases, so does cycle time.
Barrel: The section of a molding machine that contains the feed screw, also the section
where resin heating and mixing occurs.
Blushing: The tendency of a plastic article to turn white or chalky in areas that are
highly stressed.
Bubbles: Air or gas pockets that have formed in the material of the component.
Bubbles may vary in size.
Burned: Showing evidence of excessive heating during processing or use of a plastic, as
evidenced by blistering, discoloration, distortion or destruction of the surface.
Cavity: A depression, or a set of matching depressions, in a plastics-forming mold
which forms the outer surfaces of the molded articles.
Charge: The amount of material used to load a mold at one time or during one cycle.
Clamp: The part of an injection molding machine incorporating the platens that
provides the force necessary to hold the mold closed during injection of the molten
resin and open the mold to eject the molded part.
Clamping Area: The largest rated molding area an injection press can hold closed under
full molding pressure.
Clamping Force: The force applied to the mold to keep it closed, in opposition to the
fluid pressure of the compressed molding material within the mold cavity and the
runner system.
Clamping Plate: A plate fitted to a mold and used to fasten the mold to a platen.
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Clamping Pressure: The pressure applied to the mold to keep it closed during the
molding cycle.
Closed-loop Control: System for monitoring and automatically adjusting injection
molding process conditions such as temperature, pressure and time. The automatic
changes keep part production within preset tolerances.
Cold Flow Lines: Imperfections within the part wall due to thickening or solidification
of resin prior to full cavity fill.
Compression Molding: A method of molding in which the molding material, generally
preheated, is placed in an open heated mold cavity, the mold is closed with a top force,
pressure is applied to force the material into contact with all mold areas.
Conversions (Commonly Used in Injection Molding)
MPa x 145 = psi
°C x 1.8 + 32 = °F
Liters/min x 0.2642 = Gal/min
Inches x 25.4 = mm
Flow rate = ((# of cavities) x (volume per cavity))/(injection time)
Cooling Channels: Channels located within the body of a mold through which a
cooling medium is circulated to control the mold surface temperature.
Cooling time: the elapsed time required for the melt to reach its Vicat softening
temperature.
Core: A protrusion, or set of matching protrusions, in a plastics forming mold which
forms the inner surfaces of the molded articles.
Creep: Due to its viscoelastic nature, a plastic subjected to a load for a period of time
tends to deform more than it would from the same load released immediately after
application, and the degree of this deformation is dependent of the load duration.
CSA: Abbreviation for the Canadian Standards Association.
Cure Cycle: The time periods at defined conditions to which a reacting thermosetting
material is processed to reach a desired property level.
Cure: The process of changing properties of polymer into a more stable and usable
condition. This is accomplished by the use of heat, radiation, or reaction with chemical
additives.
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Custom Molder: A firm specializing in the molding of items or components to the
specifications of another firm which handles the sale of distribution of the item, or
incorporates the custom molded components in one of its own products.
Cycle Time: The time required by an injection molding system to mold a part and
return to its original position/state.
Cycle: complete, repeating sequence of operations for injection molding a part.
Deflection Temperature: The measurement of temperature at which a specimen
deflects to a set point under a defined load.
Degassing: The momentary opening and closing of a mold during the early stages of
the cycle to permit the escape of air or gas from the heated compound.
Differential Cooling: occurs when one area of the part cools at a different rate or when
the mold surfaces are at different temperatures. Warping can result from differential
cooling.
Draft: A Slight taper in a mold wall designed to facilitate removal of the molded object
from the mold.
Drag Marks: A form of deep scratch or scratches on the surface of the component
usually caused by the ejection of the part.
Drooling: The extrudation or leakage of molten resin from nozzle or nozzle sprue
bushing area while filling or shooting the mold.
Dwell: A pause in the applied pressure to a mold during the injection cycle just before
the mold is completely closed. This dwell allows any gases formed or present to escape
from the molding material.
Ejection Pin Marks: A residual mark on the part caused by the profile of the ejection
pin.
Ejection Pin: A rod, pin or sleeve that pushes a molded part off of a core or out of a
cavity of a mold.
Ejector Rod: A bar that actuates the ejector assembly when the mold opens.
Family mold: A mold that produces non-identical parts simultaneously from multiple
cavities.
Fill pressure: the pressure required to fill the cavity.
Fill Time (also known as Injection): Time required to fill the cavity or mold.
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Fill: The packing of the cavity or cavities of the mold as required to give a complete
part or parts that are free of flash and porosity.
Flash: Any excess material that is formed with and attached to the component along a
seam or mold parting line.
Flow Rate: the volume of material passing a fixed point per unit time.
Gate: The channel through which the molten resin flows from the runner into the
cavity.
Hopper Loader: Auxiliary equipment for automatically loading resin pellets into
machine hopper.
Injection Molding Pressure: The pressure applied to the cross-sectional area of the
molding cylinder.
Injection Molding: The method of forming objects from granular or powdered plastics,
most often of the thermoplastic type, in which the materials is fed from a hopper to a
heated chamber in which it is softened, after which a ram or screw forces the material
into a mold. Pressure is maintained until the mass has hardened sufficiently for removal
from the mold.
Injection Pressure: The pressure on the face of the injection screw or ram when
injecting material into the mold, usually expressed in PSI.
Insert Molding: Insert molding is the process of molding plastic around preformed
metal inserts. This process is compatible with both thermoplastic and thermoset
materials.
Insert: a removable part of the mold imparting increased resistance to wear, heat
transferability, or changeable part shape to that area of the mold.
Machine Shot Capacity: Refers to the maximum volume of thermoplastic resin which
can be displaced or injected by the injection ram in a single stroke.
Material Safety Data Sheets: Documentation regarding the toxicity or hazards
associated with contact with some substances. The manufacturer of the plastic prepares
these data sheets.
Mechanical Property: Properties of plastics which are classified as mechanical include
abrasion resistance, creep, ductility, friction resistance, elasticity hardness, impact
resistance, stiffness and strength.
Melt Flow Rate: A measure of the molten viscosity of a polymer determined by the
weight of polymer extruded through an orifice under specified conditions of pressure
and temperature. Particular conditions are dependent upon the type of polymer being
tested.
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Melt Flow: Rate of extrusion of molten resin through a die of specified length and
diameter. The conditions of the test (e.g. temperature and load) should be given.
Frequently, however, the manufacturer's data lists only the value, not the condition as
well.
Melt Index: The amount of a thermoplastic resin, measured in grams, which can be
forced through a specified orifice within ten minutes when subjected to a specified
force. (ASTM D-1238)
Mold (n): A hollow form or matrix into which a plastic material is placed and which
imparts to the material its final shape as a finished article.
Mold (v): To impart shape to a plastic mass by means of a confining cavity or matrix.
Mold Temperature: the temperature at which the mold is maintained. Often the most
important benefit of raising mold temperature is that it allows a slower injection rate
without the plastic getting too cold.
Multi-Cavity Mold: A mold having two or more impressions for forming finished
items in one machine cycle.
Nozzle: hollow metal hose screwed into the extrusion end of the heating cylinder of an
injection machine designed to form a seal under pressure between the cylinder and the
mold.
Overpack: melt will fill the easiest flow path first and will continue to pack this area
while material reaches the other areas. This is a cause of warping created by unbalanced
flow.
Packing: The filling of the mold cavity or cavities as full as possible without causing
undue stress on the molds or causing flash to appear on the finished parts. Over- or
under-packing results in less than optimum fill.
Parting line: mark on the part indicating where the two halves of the mold met in
closing.
Pellets: Tablets or granules of uniform size, consisting of resins or mixtures of resins
with compounding additives which have been prepared for molding operations by
extrusion and chopping into short segments.
Platens: The mounting plates of a press on which the mold halves are attached.
Prototype Tool: A preliminary mold built upon which the final mold will be based.
Purging: In extrusion or injection molding, the cleaning of one color or type of material
from the machine by forcing it out with the new color or material to be used in
subsequent production, or with another compatible purging material.
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Runner: In an injection mold, the feed channel, usually of circular cross section, which
connects the sprue with the cavity gate. The term is also used for the plastic piece
formed in this channel.
Shot Capacity: Generally based on polystyrene, this is the maximum weight of plastic
that can be displaced or injected by a single injection stroke. Generally expressed as
ounces of polystyrene.
Shrinkage Allowance: The dimensional allowance which must be made in molds to
compensate for shrinkage of the plastic compound on cooling.
Sink Mark: an indentation on the surface of the part as a result of significant local
change in wall section. The mark will occur in the thicker area.
Sprue: The feed opening provided in injection molding between the nozzle and cavity
or runner system.
Thermoset: A polymer that doesn't melt when heated. Thermoset polymers "set" into a
given shape when first made and afterwards do not flow or melt, but rather
decompose upon heating. They are often highly cross-linked polymers, with properties
similar to those of network covalent solids, i.e., hard and strong.
Tie-Bar Spacing: The space between the horizontal tie-bars on an injection molding
machine. Basically, this measurement limits the size of molds that can be placed
between the tie-bars and into the molding machine.
Tonnage: The measure by which injection molding machines are typically categorized,
representing the clamping force of the injection molding machine.
Tool: In injection molding, the term sometimes used to describe the mold.
Undercut: A protuberance or indentation that impedes withdrawal from a two-piece
rigid mold.
Vent: A shallow channel or opening cut in the cavity to allow air or gases to escape as
the melt fills the cavity.
Virgin Material: Any plastic compound or resin that has not been subjected to use or
processing other than that required for its original manufacture.
Warpage: Distortion caused by nonuniform internal stresses.
Weld Line: Where melted material flows together during molding to form a visible line
or lines on a finished part that may cause weakening or breaking of the component.
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Safety Precautions
APSX-PIM is a small and low pressure machine. However, the following safety
precautions should be taken before and during the machines use.
Thermal effects:
Skin contact with molten plastic can inflict severe burns. This could happen when
the machine under pressure ejects molten plastic through the nozzle.
To minimize the chance of an accident, potential hazards must be anticipated and
should be eliminated or guarded properly. Purging should be performed carefully
with the guard gates closed. The trapped gas in the cylinder may cause splattering
at the beginning of the purging process.
Molten plastic material can appear cool on the surface, but remain very hot
on the inside. Wear personal protective equipment when handling hot
plastic material.
ALWAYS ASSUME GAS AT HIGH PRESSURE COULD BE TRAPPED
BEHIND THE NOZZLE AND THAT IT COULD BE RELEASED
UNEXPECTEDLY.
A face shield or safety goggles, heat resistant protective gloves, safety shoes, non-
melting fiber pants and long sleeve shirts should be worn at all times.
In the event that molten polymer does contact the skin, cool the affected area
immediately with cold water or an ice pack and get medical attention for a thermal
burn. Do not attempt to peel the polymer from the skin.
The machine has multiple parts that have high temperature levels that the user
should never touch with bare hands. Those parts are electric motors, cylinder
barrel, mold structure and hopper assembly.
Off-Gases Ventilation:
During the molding some amount of gas is released. As a general principle, local
exhaust ventilation is recommended during the process of all plastic heating. Injection
molding normally releases substantially less volatile material so it requires less
ventilation. But during purging, volatile releases are similar to that in extrusion. Extra
care in avoiding the inhalation of fumes is recommended. Local exhaust ventilation
should be used to convey such fumes outside the workplace.
Slipping Hazards:
Pellets of plastics are a slipping hazard if spilled on the floor. They are cylindrical in
shape and have a low coefficient of friction. Any spills should be swept up or cleaned
immediately. There should be a vacuum cleaner available to collect spilled pellets from
the ground.
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Physical Hazards:
The machine has multiple moving mechanical parts under load. Placing hands in
between those moving parts such as springs, metal blocks, chains and cylinders can be
a cause to a serious injury. Never reach into the machine when it is going through its
injection cycle.
The machine is too heavy for one person to move or lift. Never try to move or lift the
machine without proper equipment. Do not exceed the rated capacity of the lifting
equipment.
Electrical Hazards:
The machine uses 115VAC power. Touching it to uncovered electrical control panel
parts can put you at risk of fatal injury.
NEVER UNPLUG THE MACHINE WHEN THE SPRING IS PRESSED
OR WHEN THE RED LIGHT IS ON UNDER ELECTRONICS COVER!
The quality, rating, and insulation of electrical power wires and cables have been
selected specifically for the requirements of this machine. Damaged cables must be
replaced immediately with the same or higher quality cables than those specified for the
machine.
Other Safeguards:
The machine should only be used for its intended purpose by an authorized and
trained individual as described in the manual.
Never leave the machine unattended without placing a warning sign around it for
others not authorized to use the device.
Make sure the machine is securely placed to a safe table or bench before operating.
During maintenance always shut the power off.
Never try to inject the plastic until it has reached proper operating temperature.
Never leave the heaters on for any extended length of time when the machine is not
being operated.
The maximum temperature set is set below the ignition point of the material being
processed.
Only original APSX parts should be used for replacement.
Regularly inspect all assemblies and screws connecting different sections and parts.
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Safety Alerts:
The DANGER safety alert indicates an imminently hazardous situation that if not
avoided, could result in death or serious injury.
The WARNING safety alert indicates a potentially hazardous situation that if not
avoided, could result in death or serious injury.
The CAUTION safety alert indicates a potentially hazardous situation that, if not
avoided, could result in property damage.
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APSX-PIM Injection Molding Machine
APSX-PIM is a fully automatic electric desktop injection molding machine. It runs
with 115VAC power with no water or hydraulic connection required. It can generate 5
tons of clamp force and can inject 30 cu-cm of plastic at a time up to 315 C degrees.
Standard mold size is 6” (H) by 4.8” (W).
APSX-PIM consists of multiple small sections. The machine is controlled by electric
motors and precise sensors. The user has touch screen PC attached to the machine for
setup and operational controls.
The main sections are listed below:
-Plasticizing section
-Pre-plasticizing section
-Injection section
-Injection valve section
-Clamping section
-User interface section
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Plasticizing Section
The plasticizing section melts plastic pellets and contains them at a set temperature for
the injection process. It has an electronically controlled/heated cylinder barrel,
thermocouple, heater and insulation parts. It touches to the injection, valve and pre-
plasticizing sections.
Pre-Plasticizing Section
The pre-plasticizing section allows the transfer of plastic pellets and moves them into
the cylinder barrel in the plasticizing assembly. It includes the hopper motor, hopper
and hopper feeder. It also prevents the backward flow of pellets to the hopper feeder
when the injection plunger injects the pellets into the mold cavity. The hopper feeder
with a screw in it can control the amount of metered plastic material to be transferred
from the hopper to the cylinder barrel. Hopper which is 5.44kg (12lbs) capacity can be
fed either manually or with an automatic feeder.
Injection Section
The injection section is secured to a movable structure that can move the plunger
horizontally. Injection assembly applies linear injection pressure onto the melted plastic
within the plasticizing assembly. It uses the spring, injection motor and plunger. The
plunger is connected to the spring by a precision ball screw. The injection motor
compresses the spring to push the plunger into the cylinder barrel. All actions of the
plunger and the spring compression are precisely controlled by linear motion control
sensors.
Injection Valve Section
The injection valve section controls the flow of the pressurized melted plastic into the
plastic mold cavity. It includes the valve pin and the valve motor. The injection valve
section is connected to the tip of plasticizing assembly with screws. The pressurized
hot plastic travels the cylinder barrel when the plunger pushes it within the cylinder
bore along a flow path into the mold cavity. The flow is adjustable for various plastics
by electronically controlling the degree of opening angle of the valve pin positioned in
a metal block. It can be controlled by the valve motor interconnected to the pin
through the sprocket mechanism.
Clamping Section
The clamping section holds the opposite injection pressure on the mold by applying
force against the injection force generated by the injection assembly. It has the
clamping motor and the cooling fan. The clamp force is adjusted electronically by using
a pressure sensor. There is also an ejector mechanism attached to the clamping section
that allows automatic ejection of the part from the mold.
User Interface Section
The user interface section provides full control to the user. Its two parts are the
electronics board panel and the touch screen tablet PC. It allows the user to set the
operational and material related parameters on screen within the pre-set ranges. The
115VAC power input from a regular wall outlet is also included in this section.
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Moving the APSX-PIM to Another Location
Please be aware of the following precautions when moving the APSX-PIM to another
location or carrying it out from the shipping crate.
1 –Always use the chain hook holes located on the clamp motor and injection motor
mounts. They are designed specifically for lifting. You can use a small size hydraulic lift
or a similar tool.
2 –Never use the cable rail as your carrying point since it is not designed to hold much
force. Also, it is very sensitive to bending and pushing movements because it carries
multiple sensors that control the machine.
3 –Never use the tablet holder as your carrying point. It is only for holding the tablet
PC.
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APSX-PIM Injection Molding Process
Preparing the Machine
The user must check if the machine hopper and hopper feeder pipes are cleaned and
there are no obstructions from the previous injection session. Otherwise the hopper
system may not be able to feed the barrel with enough plastic pellets.
Powering the Machine
The user powers the machine from a regular 115VAC wall outlet then connects the
USB cable to the tablet. Using a voltmeter display on the connection can help
monitoring voltage fluctuations to ensure your machine is operating within its specified
limits. When the machine has multiple motors and heaters are turned on, the VAC
value should not drop below 114VAC. Otherwise the machine would not have 100%
power and processes may take longer or may never be completed.
System ON
The user pushes the SYSTEM button to turn on the main components such as motors
and sensors.
Installing the Mold
In this step, the user places and secures the injection mold kit and adjusts the ejector pins on the mold for
a perfect ejection process if the automatic multi-injection mode is intended for use.
Press the “Engage Clamp”button on the tablet until the movable platen stops.
Disassemble and put aside the mold fan assembly by unscrewing the two nuts located
on the fixed platen at Block 4. Then start placing four mold clamp claws by using a
wrench.
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