Case Studies

Challenge An automotive parts manufacturer needed a batch of non-standard rotary machines whose specification differed considerably from the standard model. Machine TFV-55R2 vertical rotary table injection molding machine, 55 tons clamping force, V35 injection unit. Solution Ø26 mm screw with a dedicated bimetallic barrel assembly for PPS+40% glass fiber; Ø810 mm rotary table driven by an Inovance servo; servo-controlled main motor; independent ejector with dual proportional control of pressure and flow; touch-screen controller with I/O expanded to 54 groups; minimum mold height 230 mm; an added top ejector; a modified bottom ejector without the Ø20 mm rod and with adjustable ejection speed; electronic back-pressure adjustment; and an upper-mold hydraulic clamping system (clamps supplied by the customer). Result The machines were built to all of the above requirements and passed the customer's acceptance.

Challenge A customer planning to purchase more than 60 machines for automotive parts production visited Taifu to assess its capability. The requirement was an ultra-low worktable rotary machine with 120 tons clamping force, specific worktable requirements and a completely different mold design. Machine Taifu ultra-low worktable rotary table injection molding machine, 120 tons. Solution A bimetallic screw and barrel assembly for PPS and reinforced nylon, with temperature control accurate to within 1 °C. The main structure combines quality steel and aluminum alloy, with stress-relieved welded parts and a steel base for good vibration damping. The machine stands on four feet, each with an anti-vibration pad of at least 80 mm diameter, so there is no noticeable shaking at high speed. Result Taifu confirmed it could meet every requirement and wrote them into the contract; the customer selected Taifu's ultra-low worktable rotary machines.

Challenge Connector components inside automotive gearboxes are small overmolded parts in a special material, requiring high injection speed and a barrel made for that material. Machine Taifu vertical rotary table injection molding machine with high-speed injection. Solution Injection speed of 218 mm/s (higher on request) and a Ø28 mm screw with a custom-made barrel for the special material; otherwise the machine is standard. The mold uses a hot runner plate, with thermocouples embedded in both the fixed and moving mold bases to monitor mold temperature continuously so the water temperature can be adjusted. Result Keeping the mold within the right temperature range improves part quality and extends mold life.

Challenge Growing demand for automotive parts called for a dedicated rotary machine to produce automotive horns. Machine Taifu custom vertical rotary table injection molding machine (in-house design). Solution Taifu-designed direct-lock clamping with the clamp cylinder mounted above the upper platen; a rotary table fixing plate built from two stacked plates, saving material while meeting strength requirements; an extra-large 1,800 mm rotary table with 900 × 500 mm mold space; and a semi-closed-loop power system that monitors and controls output pressure and flow in real time. Result The machine saves more than 50% of the power used by a conventional injection molding machine, while delivering precise, efficient production.

Challenge With demand for phone and computer data cables growing rapidly, a data-cable manufacturer in Jiangxi needed high-volume, stable overmolding capacity for cable connectors and plugs. Machine Taifu fixed-table vertical injection molding machines, 25–35 tons clamping force. Solution More than 20 fixed-table vertical machines were supplied in 2019. The lower mold is fixed and the upper mold moves, suiting insert molding. Machines feature multi-zone barrel temperature control, proportional hydraulic control, a Taiwanese bimetallic barrel with high-torque hydraulic motor, direct-pressure clamping with high-speed, low-pressure mold close, a liftable injection unit for easy mold and material changes, safety light curtains with automatic fault display and stop, and low-pressure mold protection. Result Stable production with a reported finished-part yield of up to 99.8%.

Taifu designs and builds liquid silicone (LSR) injection molding machines with an integrated machine design and a range of configurations to choose from. Features High-precision metering and injection for multi-purpose LSR molding Fixed upper mold with alternating double sliding lower molds Choice of hydraulic circuits, including semi-closed-loop and closed-loop injection Direct-pressure hydraulic clamping LSR-specific pneumatic, self-sealing, water-cooled shut-off nozzle to prevent leakage Two lower molds make loading and unloading easier: the operator loads, unloads and cleans one mold during the cure time of the other Injection hydraulics designed for LSR for accurate dosing Options Micro-injection system (high-precision) All-electric injection system (high-precision) High-precision pneumatic nozzle (prevents leakage and premature curing) Applications Phone accessories, diving products, medical products, automotive and electronic parts, keyboard covers and keypads.

Taifu high-speed vertical injection molding machines are used to produce plugs, earphone components and connectors. Direct-pressure clamping with vertical injection Simple structure, small footprint and easy part removal Multi-purpose molding, especially metal insert overmolding Choice of hydraulic systems — semi-closed-loop, servo or high-speed injection — to suit customer requirements

Taifu rotary vertical machines can process a wide range of thermoplastics, including nylon (PA), PC, PC/ABS, POM, PMMA, PET, PPO, PPS, ABS, PE, LCP, PVC, PS, PBT, PP, PU, acrylic and melamine. Applications Baby toys and toys, toothbrush handles, jewelry and badges, buttons, golf balls, antennas, chargers and electrical parts, stationery and pens, lamp shades, instrument housings, furniture parts, sporting goods, gears, tableware, decorative items, automotive and instrument parts, electronic components, connectors, plugs, sockets, switches, key rings, bag buckles, bottle and cosmetic-bottle connectors, and color plaques.

Apart from the way the mold is mounted, vertical and horizontal silicone machines work on the same principles. Vertical silicone machines make automation easy, and LSR offers several advantages: Excellent insulation, suitable for high-quality electronic plugs Insulating, mechanical and physical properties are maintained from 200 °C down to −40 °C Resistance to oxidation and aging, suitable for outdoor use Oil resistance Vertical LSR machines are available with single and double sliding tables for demanding LSR parts. Thanks to their clamping and sliding-table structure, vertical machines are better suited to manual demolding and insert parts. Horizontal LSR machines suit parts that can be ejected automatically, with short mold-open intervals and high efficiency in automatic demolding.