Mold Channel Flow Testing: Blockage Detection, Leak Testing and Cleaning Records

DOUBLE EASY's Mold Channel Cleaning Machine includes functions for measuring mold-channel flow, identifying blockage, comparing flow before and after cleaning, and storing cleaning records.

Applicable machine configurations use a KEYENCE ultrasonic flowmeter to measure water flow. The operating interface displays the current system flow rate, and cleaning records can show changes in mold-channel flow before and after cleaning.

The equipment also provides individual-channel Flow Test functions, leak and pressure testing, cleaning-data storage, traceable maintenance records, MES system integration, and endoscopic visual inspection.

Why Mold Channels Can Become Restricted or Blocked

Calcium and magnesium ions in circulating water can precipitate and form hard mineral scale.

Other contaminants can include:

1. Rust particles

2. Production dust

3. Water impurities

4. Other contaminants

Over time, mold channels can become narrower, partially blocked, or locally completely blocked.

Deposits on internal channel walls can also create an insulating layer that reduces mold heat-transfer efficiency.

Flow-Rate Monitoring

Applicable DOUBLE EASY Mold Channel Cleaning Machine configurations use a KEYENCE ultrasonic flowmeter to measure water flow.

The operating interface displays the current system flow rate.

Cleaning records can also show changes in mold-channel flow rate before and after cleaning.

Individual Mold-Channel Flow Testing

The Mold Channel Cleaning Machine provides a dedicated Flow Test function.

Operators can:

1. Select an individual mold channel

2. Set a target reference flow value

3. Set the test duration

4. Start flow detection

5. View real-time flow changes

6. View the detected flow value after testing

7. Receive an advisory prompt when the detected value falls below the preset reference threshold

Target Reference Flow Setting

The Flow Test function allows an operator to set a target reference flow value for an individual mold channel.

After testing, the machine displays the detected flow value.

If the detected value falls below the preset reference threshold, the system can provide an advisory prompt.

Real-Time Flow Display

During individual-channel testing, the Flow Test function can display real-time flow changes.

After the test, the detected flow value can also be displayed.

Before-and-After Flow Comparison

Cleaning records can display changes in mold-channel flow rate before and after cleaning.

Before-and-after mold-channel flow comparison is also listed among the machine's digital maintenance functions.

A mold channel cleaning equipment demonstration can help operators understand the sequence before creating their own inspection record.

Leak and Pressure Testing Before Cleaning

The Mold Channel Cleaning Machine includes built-in leak and pressure testing.

Before cleaning, the machine can perform leak and pressure testing on the connected mold channel.

The test result can display:

1. Normal

2. Leak

3. Blockage

Blockage Detection

Blockage is one of the possible results displayed by the machine's leak and pressure test.

The individual-channel Flow Test also allows the detected flow value to be compared with a preset reference value. If the detected value falls below the preset reference threshold, the system can provide an advisory prompt.

Leak and Pressure Test Parameters

The leak-test interface includes:

1. Pressure-drop value

2. Pressure-holding time

3. System air pressure

4. Pressurization time

The operating procedure specifies a default leak and pressure test duration of approximately 50 seconds.

Cleaning-Data Storage

The Mold Channel Cleaning Machine supports:

1. Before-and-after mold-channel flow comparison

2. Cleaning-data storage

3. Traceable maintenance records

4. MES system integration

5. Endoscopic visual inspection

These functions are described as being intended for digital maintenance and quality-audit requirements in new-energy, medical, precision-electronics, and other high-precision manufacturing applications.

Traceable Mold-Maintenance Records

Traceable maintenance records are among the equipment's digital functions.

The same section also lists before-and-after flow comparison, cleaning-data storage, MES system integration, and endoscopic visual inspection.

MES System Integration

MES system integration is one of the Mold Channel Cleaning Machine's digital functions.

MES connectivity and traceable mold-maintenance data are part of the development toward intelligent and digital mold maintenance.

Endoscopic Visual Inspection

Endoscopic visual inspection is listed among the equipment's digital maintenance and inspection functions.

Integrated Monitoring and Testing Functions

Integrated machine functions include:

This overview of the mold waterway cleaning machine process and functions explains how cleaning, circulation and verification fit into one workflow.

1. Leak testing

2. Pressure monitoring

3. Flow recording

4. Touchscreen control

The system uses PLC and touchscreen control.

Multiple Mold-Channel Connections

The equipment comes with nearly ten sets of universal and specialized connectors and can support multiple mold channels simultaneously.

Depending on the machine model, connection configurations include:

1. 5 inlet / 5 outlet

2. 7 inlet / 7 outlet

3. 8 inlet / 8 outlet

The Flow Test function separately allows operators to select an individual channel for testing.

Cleaning Without Mold Disassembly

The Mold Channel Cleaning Machine supports cleaning without mold disassembly and without stopping production.

The mold does not need to be dismantled, and the cleaning process can be performed without interrupting factory production schedules.

The system is designed to reduce the time and production losses associated with traditional mold disassembly and cleaning.

Mold-Channel Testing and Record Functions

The machine provides the following functions:

1. Individual-channel flow testing

2. Target reference flow setting

3. Real-time flow display

4. Detected flow display

5. Before-and-after flow comparison

6. Leak and pressure testing before cleaning

7. Normal, Leak, and Blockage test results

8. Cleaning-data storage

9. Traceable maintenance records

10. MES system integration

11. Endoscopic visual inspection

From Reactive Maintenance to Preventive Maintenance

Mold-channel maintenance is shifting from repairs after defects or complete blockage toward routine preventive cleaning.

Periodic cleaning is increasingly being incorporated into standardized mold-maintenance programs.

Key developments in intelligent and digital maintenance include:

1. Automatic parameter adjustment

2. Before-and-after flow visualization

3. Cleaning-record storage

4. MES connectivity

5. Traceable mold-maintenance data

Blocked Mold Channels and Cooling Performance

Blocked mold channels can cause different areas of a mold to cool at different rates, producing:

1. Localized hot spots

2. Excessive temperature differences

When cooling performance deteriorates, manufacturers may need to extend mold cooling time and slow the production cycle.

Longer cycle times reduce production output under the same machine and working-hour conditions.

Deep mold-channel cleaning removes stubborn scale, rust, sludge, and biological deposits and restores channel flow.

FAQ

Can the DOUBLE EASY Mold Channel Cleaning Machine measure mold-channel flow?

Yes. Applicable configurations use a KEYENCE ultrasonic flowmeter to measure water flow, and the operating interface displays the current system flow rate.

Can individual mold channels be tested?

Yes. The Flow Test function allows an operator to select an individual channel, set a target reference flow value and test duration, start flow detection, and view real-time and detected flow values.

Can the machine detect blockage?

The built-in leak and pressure test can display Normal, Leak, or Blockage.

The Flow Test function can also provide an advisory prompt when the detected flow value falls below the preset reference threshold.

Can flow before and after cleaning be compared?

Yes. Cleaning records can display changes in mold-channel flow before and after cleaning, and before-and-after flow comparison is one of the equipment's digital functions.

Can cleaning records be stored?

Yes. The equipment supports cleaning-data storage and traceable maintenance records.

Does the machine support MES integration?

Yes. MES system integration is explicitly listed among the digital functions of the Mold Channel Cleaning Machine.

Can the machine perform leak and pressure testing before cleaning?

Yes. The machine can perform leak and pressure testing on the connected mold channel before cleaning.

Can mold channels be cleaned without disassembling the mold?

Yes. The Mold Channel Cleaning Machine supports cleaning without mold disassembly and without stopping production.

Related Product and Application Resources

Review Product information and machine models.

Explore Mold waterway cleaning solutions and application resources.

For a complete service record, use the mold cooling channel cleaning checklist to capture baseline conditions, cleaning details, and post-service checks.