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Hydraulic Pressure Drops
Meaning
Hydraulic resistance results in a loss of fluid energy as oil or melt travels through the various channels of a molding system. Measuring hydraulic pressure drops is required for sizing the pumps and motors that drive the injection unit and the clamp. If the pressure loss is too high, the machine may not be able to reach the required injection speed or maintain the necessary holding force.
Flow Resistance
Friction between the fluid and the walls of the pipes or hoses creates a drag that consumes energy. This effect is more pronounced in long runs of narrow tubing or in systems with many sharp bends and restrictive valves. Maintaining a smooth and unobstructed path for the hydraulic fluid helps to maximize the efficiency of the power transmission and reduces the heat generated by the system.
Thermal Consequence
Energy lost to pressure drops is converted into heat, which can degrade the hydraulic oil and damage the seals. Cooling systems must be sized to handle this additional thermal load to prevent the oil from thinning and losing its lubricating properties. Monitoring the temperature of the fluid at various points in the circuit helps to identify areas where the resistance is excessive and where the system may be failing.
System Limit
Maximum pressure capability of the machine provides a hard ceiling on how much drop the process can tolerate. When the combined resistance of the machine and the mold exceeds the pump output, the process becomes unstable and parts may show defects like short shots or sink marks. Engineers use these measurements to determine when a system requires an upgrade or a redesign to handle more demanding materials.