In the Japan injection molding equipment market, considerable results and progress have been made in terms of the number of shipments or the AI-based equipment. According to statistics from the Plastics Machinery Association of Japan, the domestic production of injection molding equipment in Japan in 2017 was 15,264 units, which is an increase of nearly 20% compared to 2016.
The global plastic injection market has grown by more than 2 digits
As far as the global market is concerned, Japan as a whole is quite satisfactory to equipment manufacturers. In overseas markets outside of Japan, the United States and Mexico also have good sales growth. Among them, the purchase of large-scale injection molding equipment has made equipment manufacturers deeply aware of the investment intensity. The overall American market does not it has been adversely affected by the environment.
In Asia, the most eye-catching market is the China market. Although the current global automotive plastic composite materials account for less than 8%, the consumption is much lower than in other countries. However, with the increasing demand for lightweight automobiles, the coverage of automotive plastic products has become more extensive, and the demand for automotive plastics in the future will continue to expand.
It is not only the China market that shows strong market demand momentum. Indian factories have a large demand for injection molding equipment. In addition, Southeast Asia and Thailand have a large number of automobile manufacturing-related factories in the local area, so the demand for equipment is also It is gradually growing steadily. However, because the political stability of East Asia still has a certain degree of risk, injection molding equipment manufacturers still expect the United States to reduce tariffs to stimulate equipment investment.
In the European market, according to EUROMAP statistics, the overall market size reached 13,500 units in 2017, a growth rate of about 15% compared to the previous year. Therefore, from a global perspective, the injection molding equipment market still maintains a growth trend.
Automobile EV drives a large number of demands for plastic injection molding products
As for the other parts of the injection molding products, the downstream industry will affect the changes in the injection molding equipment market scale to a certain extent. Among them, the increase in the number of plastic products used will further expand the scale of the injection molding market. The downstream application industries of injection molding equipment mainly cover multiple fields such as automobiles, home appliances, and 3C industries.
Therefore, in addition to the needs of the traditional electronics industry, there is some unexpected demand for injection products. In the 3C industry of the emerging technology industry, the ultra-lightweight and flexible characteristics of plastics make it widely popular in the 3C industry. For example, the demand for plastic injection in electric vehicles is rapidly expanding, so delays in the delivery of injection molding equipment have begun. In Europe, for example, the delivery time of general-purpose equipment is more than half a year. As mentioned above, the EV of automobiles has driven the demand for a large number of plastic injection molded products, including the demand for connectors, housings, and lenses required for photographic lenses and sensors.
In the China market, according to statistics, in the first quarter of 2018, China's computer, communications, and other electronic equipment manufacturing industry's fixed-asset investment increased by 15.4% year-on-year. According to the forecast of the China Market Research Company, by 2020, China's total automotive plastic consumption will reach 8.32 million tons, with a compound growth rate of 37%. In the growth scale part of 2017, compared with 2016, the number of orders received has a growth rate of 34.5%. This growth rate has exceeded the market conditions before the Lehman Storm.
Use AI capabilities to predict failures of plastic injection molding equipment
In terms of technological evolution, as Industry 4.0 and artificial intelligence concepts continue to ferment around the world, the needs of injection molding machine users have gradually evolved from a single machine to additional molds, peripheral systems, and even the entire line or plant planning. The Physical System (CPS) achieves equipment automation, digitization, and networking, allowing users to have more sophisticated operations planning and effective resource allocation.
Through big data and artificial intelligence analysis, effective monitoring of reverse flow to prevent valve wear
Use deep learning technology in AI technology to achieve equipment prevention and preservation capabilities. It is through the analysis technology developed based on the deep learning of artificial intelligence, the waveform data obtained by the sensor can be learned and analyzed through the intelligent deep learning technology to record the wear status of the backflow prevention valve (Scoring), Then, from the worn record (Score), we can calculate how much mm wear has occurred for the once-new backflow prevention valve, and how long it can be used.
In the past, the reverse flow of the resin in the injection molding equipment must be observed and judged by the operator through changes in the waveform data, and the wear condition must be estimated, as well as the time when the reverse flow prevention valve must be replaced. However, if we can automate the observing of the wear of the backflow prevention valve through artificial intelligence mechanisms, the production operation can reach the best state, and the production of high-speed equipment will not be interrupted due to the loss of parts.
For the backflow prevention valve wear in injection molding equipment, there will be different problems or wear levels due to different conditions or variables such as materials, product specifications, and factory environment. But generally speaking, there is no way for the operator to remove the backflow prevention valve to check the wear status. However, in the past, skilled technicians can use a wealth of predictions. In addition, most of them have to wait until the material backflow occurs. It will be found to prevent serious wear of the valve and stop the operation for new product replacement, but this will cause the production line to stop and cause losses.
Injection molding factories have also introduced artificial intelligence by themselves
Not only equipment manufacturers are competing to introduce artificial intelligence functions, but even factories that use equipment have begun to add artificial intelligence functions to the equipment they use. Ishikawa Resin Industry, located in Kaga City, Ishikawa Prefecture, has also begun to implement artificial intelligence for the injection molding equipment currently used in the face of the AI trend. After collecting and integrating the production data of more than 30 kinds of existing injection molding equipment in the factory, and systematize it, carry out data analysis on a large number of processing, and transform the production technology that only relied on experienced technicians in the past into visible Production parameters to reduce production costs and reduce defective products. At the same time, began to provide customers with various best-customized production services.
In addition, because the specifications and types of products produced by each factory are quite different, they only rely on the injection molding equipment manufacturers to collect and analyze data, and finally, develop an artificial intelligence system that can be applied to the injection molding equipment. However, Japan's five major injection molding production equipment companies later worked together to cross the barriers of equipment types and technologies to develop data acquisition software to assist injection molding factories to introduce existing equipment into artificial intelligence.
The production data has been accumulated continuously and analyzed to obtain valuable production parameter data. Through these collection and analysis actions, plus, on the other hand, at the same time analyzing and researching the causes of defective products, it has been possible to reduce the proportion of defective products from the original 5% to 3% and optimize the allocation of operators. After improving the work efficiency of personnel, it can even increase the factory utilization rate of 50% to 60% by about 20%.
If artificial intelligence analysis and big data technology can be smoothly introduced into the production management part, then it will not only achieve the visualization of skilled technology, efficiency, and high quality of mass production but also reduce the workload of technicians on the production line and save time. Shift to the development of new technologies and new products. The big data formed by the accumulation of various production data is analyzed by artificial intelligence, and it is believed that the best production parameters can be further obtained. Finally, after the data classification of different plastic injection molding types, it can be further improved in external sales.
A dedicated sensor is placed inside the injection mold
In order to bring injection molding molds into the next generation of artificial intelligence data analysis applications, for general injection molding processing, a distance of 2 mm is sufficient for the application, but when facing higher precision mold control, detection is required. A sensor capable of measuring longer strokes. Furthermore, it can be equipped with a mold operation monitoring system and other sensors including pressure and temperature for more complete data statistics and analysis.