INJECTION BLOW MOLDING BOTTLE TROUBLESHOOTING 中英文版

INJECTION BLOW MOLDING BOTTLE TROUBLESHOOTING

瓶子注吹问题的解决方法

The contents of this troubleshooting guide are meant only to give the leaders and machine operators something to refer to, when trying to correct a problem with a bottle on the injection blow molding. The below list is not all the possibility which may be become the cause of the problem, and indeed, the solution may be a combination of several things.

这个问题解决方法的内容只是为了在解决瓶子注吹问题时，给领班和机器操作员一些参考。以下的列表不是所有可能导致问题的原因，事实上，解决方法可能是几件事情的结合。

There are several important things to remember when trying a troubleshooting: 当式着解决一个问题时，有几件很重要的事需要记住：

1. THINK! Think about the problem and the possibility reason for it before you try anything.

思考！在你做出任何尝试之前思考出现的问题以及可能的原因。 2. Try only one change at a time. Don’t lose your perspective. 一次只试着改变一个变量！不要失去你的观点

3. Be patient! Give a change an opportunity to work before you go into something else. For example, a change in the barrel heat setting may take 15 to 20 minutes before its true effect will be noticed.

有耐心！在你得到一些结果之前给变量一个运作的机会。例如，在真实结果被发现之前滚筒的温度设置可能需要达到15到20分钟。

4. If one change doesn’t work, return that change to the original setting before trying something else.

如果一个改变没有起作用，在尝试其他改变时把这个改变回归到原来的设置。

5. Observe and learn from the incorrect changes have been made. For example, if you find that lowering the parison mold temperature will aggravate the situation, then raise the same temperature to see if improvement will be occurred.

对于做出的错误改变需要观察和学习。例如，如果你发现降低原型模具的温度会使问题更严重，那么，提高这一温度是否会改善这个问题呢？

6. After the problem can be solved, watch the machine for a while to be sure that something else will not become the side effect.

在问题得到解决后，观察一会机器直到确保不会产生其他方面的副作用。

7. Communicate with others in your team/ shift and to the other shift, so they can learn from your finding.

和你团队的成员/班次和班次之间进行交流，这样他们也可以从你发现的问题中学到一些东西。

8. Record the change on the set up sheet. Refer to change problem. 在设置单上记录下这一改变。指出改变的问题。

ABOUT DIMENSIONAL STABILITY 关于尺寸的稳定性

1. “ H “ Dimension “ H “尺寸

a. Move the parison and / or blow mold out ( add shim ) to increase “ H “ 把原型和/或注吹机（加薄垫片）移出来增加“ H “

b. Move the parison and / or blow mold in ( remove shim) to reduce “ H” 把原型和/或注吹机（加薄垫片）移入来减小“ H “

2. “ E”, “ I “ and “ T “ Dimension “ E”, “ I “ 和“ T “尺寸 a. To raise “ E”, “ I “ and “ T “ 提高“ E”, “ I “ and “ T “

(1) Lower parison mold neck temperature降低原型模具的瓶颈温度 (2) Add more injection time 增加注塑时间 (3) Add more stabilize time 增加稳定时间

(4) Lower blow mold neck temperature 降低注吹模具的瓶颈温度 (5) Add more core rod cooling ( internal)增加芯棒冷却（内部的）

b. To lower “ E”, “ I “ and “ T “ 降低 “ E”, “ I “ and “ T “

(1) Raise parison mold neck temperature提高原型模具的瓶颈温度 (2) Raise blow mold neck temperature提高注吹模具的瓶颈温度 (3) Reduce core rod cooling 减少芯棒冷却

(4) Hot line blow mold neck加热注吹模具瓶颈线

Note: In some cases, the opposite will happen when above steps is done when the “ E”, “ I “ or “ T “ is being blown out in the blow mold.

注意：在某些情况中，当“ E”, “ I “ 或 “ T “在注吹模具里低时，完成上述步骤可能会有相反的情况发生。

3. “ S “ Dimension“S”尺寸 a. Move the parison and / or blow mold out ( add shim ) to increase “ S “ 把原型和/或注吹模具（加薄垫片）移出来增加“S”

b. Move the parison and / or blow mold in ( remove shim) to reduce “ S” 把原型和/或注吹模具（移除薄垫片）移入来减小”S”

4. Ovality of “ T “ and “ E “ Dimensions ”T” “E”的椭圆形尺寸 a. Caused by uneven shrinking – especially in oval bottles.由不均匀收缩导致―尤其是椭圆形瓶子。

(1) Raise temperature in shoulder / body area parison mold增加原型的瓶肩/瓶身部位的温度

(2) Lower temperature in neck of parison mold降低原型模具瓶颈的温度

(3) Lower blow mold neck temperature降低注吹模具瓶颈的温度 (4) Raise melt temperature提高熔化温度

(5) Check operation of temperature control unit检查温度控制器的操作

ABOUT FLASH (PARISON MOLD) 关于飞边（原型模具）

1. Neck Only 只是瓶颈部位 a. Lower temperature in parison mold neck rings降低原型模具瓶颈圈的温度 b. Increase injection time增加注塑时间 c. Increase stabilize time 增加稳定时间

d. Decrease high injection pressure 减少注塑高压 e. Decrease low injection pressure 减少注塑低压

f. Raise numbers of low injection pressure electrical set point ( bring low

pressure in sooner ) 提高低压注塑的电量设置（尽快产生低压） g. Decrease melt temperature 减小熔化温度

h. Balance nozzles for even fill 平衡管口均匀填充量 i. Check MTC operation 检验机器操作

j. Realign mold – blow mold alignment in relation to parison threads.重新

排列模具－关于原型螺纹的注吹合模准确

k. Remove plastic from part lines / neck rings / bottom plugs.从结合线/瓶

颈圈/底部堵塞处移除塑料

l. Shim parison mold neck rings在原型模具瓶颈圈加薄垫片

m. Check neck ring / core rod sealing surface 检查瓶颈圈/活塞密封表面 n. Platen tie rods loose 松开滚筒尖轨连接杆 o. Platen not aligned properly 滚筒排列不准确

p. Mold vents / parison mold too deep 模具通风/原型模具太深 q. Reduce back pressure 减小背压

r. Check neck ring part lines 检查瓶颈圈结合线 s. Bring in low pressure sooner尽快产生低压

2. Body 瓶身 a. Lower temperature in body of parison mold 降低原型模具的瓶身温度 b. Decrease high injection pressure 减少高压注塑 c. Decrease low injection pressure 减少低压注塑 d. Bring in low pressure sooner 尽快产生低压

e. Balance nozzles for even fill平衡管口均匀填充量 f. Check MTC operation检验机器操作

g. Remove plastic from part lines, neck rings, bottom plugs. 从结合线/瓶颈

圈/底部堵塞处移除塑料

h. Reduce back pressure减小背压 i. Shim cavity 薄垫片洞穴

j. Platen tie rods loose松开滚筒尖轨连接杆 k. Platen not aligned properly滚筒排列不准确 l. Check mold part lines检查模具结合线 m. Clamp tonnage exceeded夹具排水量超过

n. Change line ( re-zone hot water)改变线路（热水再分区）

3. Bottom 底部

a. b. c. d. e. f. g. h. Reseat nozzles 给管口换新的底座 Check nozzle seat 检查管口的座位

Check mold part lines 检查模具的结合线 Repair nozzle seat 修复管口座位 Change hose location 改变软管位置

Increase mold temperature at gate 增加模具口的温度 Increase stroke of relief 增加敲击 Move nozzles in 移入管口

ABOUT PINCH (BLOW MOLD) 关于收缩（注吹模具）

a. Increase / decrease cure time增加/减少治愈时间 b. Increase injection time增加注塑时间 c. Increase stabilize time 增加稳定时间

d. Realign molds – blow mold alignment in relation to parison threads. 重新排列模具－关于原型螺纹的注吹合模准确

ABOUT PROCESSING 关于处理

1. Sticking of parison to core rods ( core rod too hot ) 把原型粘在芯棒上（芯棒太烫）

a. Decrease cushion 减少衬垫

b. Lower melt temperature 降低熔化温度 c. Pack parison harder : 把原型包装结实

- Increase injection pressure 增加注塑压力 - Add more injection time 增加注塑时间

d. Reduce screw speed 减少螺旋速度

e. Add more stearate ( release agent ) 增加硬脂酸盐（减少隔离剂） f. Raise back pressure提高背压

g. Change core rod temperature – sometimes higher temperature is better

(less cooling) and sometimes cooler core rods are better ( more cooling). 改变芯棒温度－有时高温更好（较少冷却）有时冷却的芯棒较好（更加冷却） h. Check for proper MTC operation 检验机器操作是否正确 i. Check for folds in bottom “ I “ 检验底部折叠的”I” j. Increase internal air cooling 增加内部冷却的空气 k. Increase external air cooling 增加外界冷却的空气

2. Sticking of parison to parison mold 把原型粘在原型模具上 a. Lower parison mold temperature in affected area 在受影响部位降低原型

模具的温度。

b. Add more “ screw “ time 增加“螺旋“时间

c. d. e. f. g.

Lower melt temperature 降低熔化温度

Purge barrel and manifold just before starting 在开始之前净化滚筒 Check for proper MTC operation 检查机器操作是否正确 Decrease injection pressure 减小注塑压力 Stearate 硬脂酸盐

3. Blow – Outs 吹出 a. Caused generally by parison mold temperature either too hot or too cold

in an area, but generally “ B “ & “ C “ are true一般由原型模具温度在某个部位温度太高或太低造成，但是一般“ B “ & “ C “是正确的

b. Blow – out in bottom – temperature in gate area – parison mold too hot

底部吹出－在门口部位的温度－原型模具太烫

c. Blow – out in shoulder or body – temperature in body of parison mold

too hot 肩部/瓶身吹出－瓶身原型模具太烫

d. Check for proper MTC operation. Rise of lower parison mold

temperature in effected area. 检查机器操作是否正确。在受影响的部位提高原型模具的温度。

e. Decreases melt temperature. 减小熔化温度

4. Parison Sag ( parison & blow mold part lines do not overlap)原型下陷（原型&注吹模具结合线不重叠）

a. Decrease melt temperature 减小熔化温度

b. Require better balance of parison mold cooling zones 要求原型模具冷却

区更好的平衡

c. Reduce inject / transfer portion of cycle 减小注塑/转移部分的周期 d. Pack parison tighter 包装原型更严密

e. Eliminate loops on parison mold cooling lines 除去原型模具冷却线上的环 f. Use low / high / low injectin to reduce core rod deflection 使用低/高/低

注塑来减少芯棒的偏移

g. Work with core rod temperature 合芯棒温度一起运作 h. Check for proper MTC operation 检查机器操作是否正确 i. Use lower melt flow polymer 使用较低的熔体流动聚合体 5. Parison wall thickness variation 原型瓶壁厚度变更

a. Increase nozzle orifice 增加管口孔

b. Increase melt temperature 增加熔化温度 c. Decrease injection speed 减小注塑速度 d. Check core rod alignment 检查芯棒排列

e. Raise parison mold body temperature 增加原型模具瓶身的温度 f. Reduce inject / transfer portion of cycle 减小注塑/转移份额的周期

g. Use low / high / low injectin to reduce core rod deflection 使用低/高/低

注塑来减小芯棒的偏移

h. Eliminate loops on parison mold cooling lines除去原型模具冷却线上的环 i. Pack parison tighter包装原型更严密

j. Balance nozzler for even fill 平衡管口的均匀填充量

k. Check and clean core rod blow air valve – all gaps must be the same 检

验并清理芯棒通气管的活瓣－所有间距都要相同

l. Check water lines in parison mold for scale 检查原型模具水位的范围 m. Check MTC operation 检验机器的操作

n. Increase/decrease cure time ( screw timer) 增加/减少治愈时间（螺旋时间） o. Check cartridge heaters 检验筒形加热器 p. Change core rod 换芯棒

q. Increase / decrease blow delay. 增加/减少注吹延迟

6. Nozzle freeze – off 管口冷冻－关闭

a. Clean nozzle –contaminated material 清洁管口－污染的材料 b. Raise gate MTC temperature 增加机器口的温度 c. Raise manifold temperature 增加各种温度 d. Raise melt temperature 增加熔化温度 e. Shorten cycle 缩短周期

f. Open nozzle orifice 打开管口孔

g. Check manifold heaters, fuses, wiring 检查多管加热器，保险丝，电线

7. Stripping difficulties 拆模难点

a. Increase stripping measure 增加拆模方法 b. Check core pins for burrs 检验中心销

c. Add external lubricant to polymer 对聚合体增加额外的润滑剂 d. Check stripper bar alignment 检查清理杆的排列 e. “ V “ groove too deep “ V “ 凹槽太深

ABOUT SHOT SIZE 关于批量

1. Inconsistent shot size批量不一致 a. Raise back pressure 增加背压

b. Check hydraulic injection pressure for variations. 检查水压注塑压力的变量 c. Add more screw recovery time 增加螺纹恢复的时间 d. Balance nozzle 平衡管口

e. Check for loose of bad thermocouples 检查坏的隔电偶的松动 f. Broken element in mixing nozzle 混淆管口的坏的元件 g. Check for proper MTC operation 检验机器的操作 h. Check screw rpm 检查螺丝的可靠性能测定

2. Short shots 缺料 a. Clean nozzle 清洁管口

b. Open nozzle orifice 打开管口孔

c. Increase high injection pressure 增加注塑高压 d. Increase packing pressure 增加包装压力

e. Have low pressure come in later 之后进行低压

f. g. h. i. j.

More injection time增加注塑时间 Raise melt temperature 提高熔化温度

Raise all parison mold temperature 提高所有原型模具的温度 Raise back pressure 提高背压

Longer screw recovery stroke – larger shot size 延长螺旋恢复敲击－更大的批量

k. Add time to screw timer ( lengthen cycle)对螺旋计时器加时（周期长度） l. Check & clean non return valve on end of extruder screw 在压出机螺杆的末尾检验&清洁单向阀

m. Check screw rpm 检验螺旋可靠性能测定 n. Increase screw speed 增加螺旋速度 o. Increase cushion 增加垫子

p. Clean out hopper and throat 清洁送料斗合管口

SURFACE APPEARANCE 表面－外观

1. Sunken panels 凹陷的嵌板 a. More blow air time 更多的吹气时间

b. Lower blow mold temperature降低的注吹温度

c. Shorten inject / transfer portion of cycle 缩短注塑/转移份额的周期 d. Reduce core rod cooling 减少芯棒冷却

e. Add sink correction to blow mold 对注吹模具加陷入修正 f. Check for proper MTC operation 检验机器操作的正确性

2. Seams缝合线 a. Add delay to blow air 延迟吹气 b. Align molds 排列模具

c. Check parting lines for damage – if yes, need to repair 对于损坏检验结合

线－如果是的，需要修复

d. Flash from parison mold 原型模具的飞边

e. Die set guide posts require checking / replacement 模具导柱需要检验/替

换

f. Plastic on parting line – neck rings – bottom plugs 结合线上的塑料－瓶颈

圈－底部堵塞

3. Weld lines – ( usually apparent in oval bottle as a line up the wide panel)焊接线－（一般出现在椭圆形瓶子上宽的面板上排列的一条线） a. Raise melt temperature提高熔化温度

b. Raise body and neck temperature in parison mold 提高原型模具瓶身合瓶

颈的温度

c. Increase cushion 增加垫子

d. Raise injection pressure 增加注塑压力

e. Increase nozzle orifice size 增加管口孔的尺寸 f. Add time to injection timer对注塑器增加时间

g. h. i. j.

Check for proper MTC operation 检验操作是否正确 Pack parison harder 对原型包装结实 Raise back pressure 提高背压

Change parison design 改变原型的设计

4. ( White or black ) marks on neck finish caused by gas burning 由气体燃烧引起的瓶颈的（白色或黑色）痕迹

a. Lower melt temperature较低的熔化温度 b. Slow injection speed 低注塑速度

c. Lower temperature in neck of parison mold 降低原型模具瓶颈部位温度 d. Vent ( relief ) neck ring of parison mold 原型模具瓶颈圈通风 e. Open nozzle orifice打开管口通风口

f. Check for proper MTC operation检查机器操作是否正确 g. Slower ram 储存器较慢

5. Water marks – Alligator skin – trapped air水印－鳄鱼皮－收集的气体

a. Raise blow mold temperature ( hotter ) 提高注吹模具温度（更烫） b. Check for leak in molds 检验模具是否泄漏

c. Not water, but trapped air – sandblast blow molds没有水，只有收集的气

体－喷沙注吹模具

d. Clean blow mold vents 清洁注吹模具通气口

e. Use low / high blow system 使用低/高的注吹系统

6. Contamination ( Material ) 污染（材料） a. Check material source for contaminate 对于污染检查材料源 b. Too much stearate 太多的硬脂酸盐

c. Damaged screw or screw tip 螺丝或蜗杆梢损坏 d. Lower melt temperature 降低熔化温度 e. Purge净化

f. Mixing nozzle required cleaning and sandblast 混合喷嘴需要清洁和喷沙 g. Broken element in mixing nozzle 在混合喷嘴处打破成分

h. Burn in manifold – remove end plugs and purge多方面烧伤－移除塞子尾

并清洁

i. Melt too high融化太高。

7. Contamination ( Oil / grease on bottle )污染（瓶子上有油/油脂） a. Wash parison and blow molds with solvent – especially in neck rings –

also wash core rods.用溶剂清洗原型并吹干模具－尤其在瓶颈部位－同样清洗芯棒

b. Dirty blowing air (clean filter) 注吹脏的气体（清洁过滤器） c. Bottle rubbing machine tie rods 瓶子摩擦机器的传输杆

d. Replace “ O “ rings between molds在模具间重新放置一个O环

8. Nicks刻痕

a. Damaged blow mold注吹模具损坏

b. Plastic or dirt in blow mold cavity – wash out在模具洞穴里有塑料或脏物

－清洗干净

c. Damaged parison mold原型模具损坏 d. Damage core rod芯棒损坏 e. Strings from nozzles管口有线

f. Check parting lines for burns – parison and blow molds检验结合线的烧

伤－原型和注吹模具

g. Check parting lines for damage – parison and blow molds检验结合线的

损坏－原型和注吹模具

h. Wash out vents in blow mold清洁注吹模具的通风口 i. Turn off water, stop condensation关闭水阀，停止浓缩 j. Sandblast blow mold喷沙注吹模具 k. Reset mold in die set重新设置模具

SHOULDER AND BOTTOM FOLDS瓶肩和底部折合处

Defect description: one or more of the containers has a groove around the base of the neck finish.不良描述：一个或多于一个的容器在瓶颈底座周围有凹槽。

Probable cause: 可能的原因： a. Neck area of parison mold or neck area of core rod too cold原型模具的瓶颈周围或芯棒的瓶颈周围太冷

b. Material heat too low, melt is cold材料热度太低，融化冷却

c. d. e. f. g. Cycle too long 周期太长

Excessive injection pressure注塑压力太大

Neck end of core rod too hot芯棒的瓶颈底部太热

Neck end of blow mold too cold注吹模具的瓶颈底部太冷 Tip of core rod too hot芯棒尖部太烫

Corrective action : 纠正措施 a. Increase temperature of mold heating unit in neck end of parison cut down on core rod cooling timer提高模具的加热温度直到原型颈部末端减少了芯棒冷却的时间。

b. Raise manifold, nozzle, any cylinder front zone heats a few degrees at a time to try and improve on melt temperature一次提高几度管口，任一圆筒前的区域的加热温度来试着提高熔化温度。

c. Try shortening time on either the injection or mold delay timers or both.试着缩短注塑或模具延长的时间，或者同时缩短两个时间

d. Parison cavities are filling much too fast and plastic is setting up before blowing decrease pressure原型洞穴的填充太快，塑料的设置低于注吹压力

e. Increase time on core rod cooling time or core rod cooling air pressure.增加芯棒冷却时间或芯棒冷却的气压

f. Add warm water line to neck end of blow mold在注吹模具颈部末端加热水线 g. Increase cooling on tip of core rod在芯棒的尖端增加冷却

ROCKER BOTTOMS底部摇晃

Defect description: The bottom area of the container / bottle, extend below the lower rim of the bottle不良描述：容器/瓶子的底部区域，延生到瓶子较低的边缘。

Probable cause : 可能的原因

a. Core rod plugged with plastic芯棒塞住了塑料

b. Material laying too heavy in the bottom of container容器底部的材料放置

的太紧。

c. Blow air timer set for too much time吹气时间设置的太久 d. Bottom plug running too hot塞子底部太烫

e. Blow mold cavity is running too hot注吹模具的洞穴太烫 f. Slug form nozzle too long管口金属片的形状太长。

Corrective action :纠正措施

a. Remove core rod and clean or replace移走芯棒并清洁或重新换一个 b. Reset timer重新设置时间

c. Check refrigerated water line to this area to be sure if it is on or isn’t plugged检验这个区域的冷却水线，确保是否塞紧。

d. Check refrigerated water temperature and be sure the water is on检验冷却水的温度，确保有水。

e. Move nozzle in把管口塞入

BOTTOM PUSH UP底部推进

Defect description: The container have too much push up or wavy bottom.不良描述：容器推进太多或底部不稳

Probable cause: 可能的原因

a. Bottom plugs running too hot, allowing excessive shrinkage.底部塞子太烫，导致过度收缩

b. Parison mold running cold in this area then pulling the material down into the bottom这个部位的原型模具太冷，把材料拉到了底部

c. Core rod cooling is not too long pulling material down to the bottom冷却芯棒不够长，不能把材料拉到底部

d. Bottom wavy due to wall thickness, thin area in center of bottom 由于瓶壁厚度导致底部不稳，底部中心薄

Corrective action: 纠正措施

a. Check the refrigerated water line to this area to be sure it is on or is not plugged. 检验这个区域的冷却水线，确保是否塞紧

b. Increase the temperature of mold heating unit in the nozzle at the end of parison mold增加模具加热的温度直到原型模具管口末端

c. Reduce core rod cooling time or air pressure减少芯棒冷却时间或气压

d. Moves nozzles back in seats, far away from parison to make the bottom thickness even on the surface when blew the container.把管口移回位置，远离原型，当注吹容器时，使底部厚度表面平整。

DISTORTED ON SHOULDER肩部变形

Defect description: The container has distorted on shoulder不良描述：容器肩部变形

Probable cause:可能的原因

a. Distortion shoulder due to low blow air pressure肩部变形由于注吹气压低 b. Not enough blow air time注吹时间部够 c. Air trapped气体受限制

d. Parison mold running cold in this area这个区域的原型模具运作冷却

e. Cycle time too long , it causing the material need to be set up in this area

循环时间太长，导致这个部位的材料需要设立 f. Core rod plugged芯棒被塞紧

g. Stripper digging into shoulder剥离器钻到肩部

Corrective action :纠正措施 a. Increase air pressure增加气压

b. Increase time on blow air timer 增加注吹时间

c. Clean blow mold vents or blow mold need sand blasting清洁注吹模具通风口或者注吹模具需要撒沙爆破

d. Increase the temperature of mold heating unit in this area of the parison mold增加加热模具的温度直到达到这一部位原型模具的温度。

e. Decrease the cycle time or run a hot line under the shoulder of blow mold降低周期时间或在注吹模具的肩部运行一条热线

f. Remove core rod and clean or replace移走芯棒并清洁或替换

g. Reset stripper if it out of center or replace with the proper one.如果剥离器部在中心，重新设置或者替换一个好的。

BOTTLE WARPAGE OR DISTORTION瓶子扭曲或变形

Defect description: The container is warpage or distortion ( out of shape)不良描述：容器扭曲或变形（超出原形）

Probable cause:可能的原因：

a. Bottles are banana shaped. Material is not distributed evenly around the

bottle due to bend core or stack height set improperly瓶子成香蕉状。由于芯棒弯曲或堆叠的高度设置部当，导致瓶子周围材料分布不均。

b. Panel warpage due to low blow air pressure, blow mold running hot,

parison mold heating unit off of set point, not enough blow air time由于注吹气压低导致面板变形，注吹模具运作烫，原型模具加热到设置点，注吹时间不够。

c. Material running too hot材料运作才烫

d. Cycle too fast to allow proper cooling in mold周期太快以至于模具不能适

当冷却

e. Blow mold vents plugged with dirt注吹模具通风口有脏物堵塞。

Corrective action:纠正措施 a. Replace core rod and / or check stack height换芯棒和/或检验堆叠高度

b. Raise air blow pressure, check the refrigerated water to be sure it is on, return parison mold heating unit to set point, increase time on blow air timer提高吹气压力，检验冷却水保证其供有，把模具的热度归为设置点，在注吹时间器上增加时间。

c. Lower temperature on plastic melt降低材料融化温度 d. Lengthen cycle加长周期

e. Stop press and wash out vents.按停止按钮并清洁通风口。