Overview

This document presents the Dynamic Feed® system by Synventive, designed for online melt pressure control inside hot runner systems used in injection molding. It provides detailed information on components, operation principles, technical specifications, and integration with injection molding machines.

1. System Description and Application

• Purpose: Optimize filling of multi-gated parts, improve quality in multi-cavity molds, and balance runner systems in family and modular molds during production.
• Functionality: Dynamic Feed controls melt pressure by adjusting flow valve cross-section continuously, enabling individual pressure profiles per nozzle and optimal cavity filling.
• Key Components: Valve pin, pressure transducer, flow valve block, hydraulic actuator, connection box, pressure supply (via injection molding machine or mobile hydraulic power unit), and signal lines.

2. Flow Valve Modules

• Available for valve gate nozzles with flow bore diameters of 12 mm (Class 12 E), 16 mm (Class 16 E), and 22 mm (Class 22 E).
• Nozzle style: manifold nozzle with screw fit.
• Dimensions vary by nozzle series and type; detailed in Synventive Hot Runner Guide.
• Modules include flow valve block with valve pin and pressure transducer, plus hydraulic actuator with position sensors.

3. Hydraulic Actuator (HYC 4520M 01)

• Mounted on manifold with cooling plate to thermally isolate actuator from hot manifold.
• Features position sensors for precise control.
• Technical parameters:
  • Max operating pressure: 120 bar
  • Needle stroke: ±1.5 mm
  • Flow rate: 6 l/min
  • Closing/opening force: 14100 N at 120 bar
  • Cooling recommended post-production for 60 minutes at 30 °C to prevent overheating.

4. Connection Boxes (DF JB Series)

• Designed for hot runner systems equipped with Dynamic Feed.
• Available for 4, 8, 12, and 16 control zones, with combinations for larger zone counts.
• Dimensions approximately 1145 x 600 x 550 mm (varies by model).
• Screen options: internal, mounted on top, or remote wall-mounted.

5. Control Unit (DFC)

• Mobile PID control unit supporting up to 16 control zones.
• Operated via touch screen with flexible mounting options.
• Interfaces with injection molding machine, servo valves, and hot runner system for real-time pressure control.
• Technical environment: 110/230 V AC, 50/60 Hz, 10 A, operating temperature 5–40 °C, humidity 0–80% non-condensing.

6. Interface and Signal Lines

• Interface base and jumper allow operation with or without Dynamic Feed integration.
• Standard connection cables (7.5 m length) link:
  • Injection molding machine to control unit
  • Hot runner system to control unit
  • Servo valve block to control unit

7. Servo Valve Blocks (DF VB Series)

• Operate flow valves in hot runner systems with Dynamic Feed.
• Available for 2, 4, 8, and 12 control zones.
• Includes oil filter (DF HF 01).
• Can be mounted on injection molding machine or mobile hydraulic power unit.

8. Mobile Hydraulic Power Units (DF HPU Series)

• Supply hydraulic pressure to actuators in Dynamic Feed-equipped hot runner systems.
• Models available for 4, 8, 12, and 16 control zones.
• Technical data:
  • Power: 3-phase 400 V AC, 50/60 Hz, 3 x 16 A
  • Max pressure: 120 bar
  • Flow rate: 15 l/min (up to 8 zones), 26 l/min (more than 8 zones)
  • Connections: G3/4” and 1/2” BSP
  • Hydraulic oil: DIN 51524-2, HLP 32
  • Cooling: 15 l/min at max 20 °C
  • Weight: approx. 540 kg
  • Dimensions: approx. 1350 x 1180 x 770 mm (varies by model)
• Delivered with servo valve block and 6 m hydraulic hoses.

9. Hydraulic Lines and Fittings

• Hydraulic hoses (lengths 2 m and 6 m) connect servo valves to actuators.
• Includes quick couplings (socket and plug), retaining rings, seals, and fittings.

10. Contact and Support

• Global contact information provided for Synventive offices and representatives across multiple countries.
• For specific applications and detailed design guidance, users are advised to consult the Synventive Hot Runner Guide or contact Synventive directly.

Critical Information and Best Practices

• Ensure proper cooling of hydraulic actuators post-production to avoid overheating.
• Use correct nozzle sizes and types as per application requirements and refer to detailed nozzle data sheets.
• Maintain hydraulic oil quality and filtration to ensure system reliability.
• Follow recommended connection and interface setups for seamless integration with injection molding machines.
• Regularly monitor and adjust melt pressure profiles for optimal molding quality and system balance.