Creating a Plastics Injection Molding Machine Control Solution
Contents
1. 1 meee 2 3 Hi 5 aes JE ap 3 ae 3 DeviceNet Network DeviceNet is the interface between the Logix system and the Bosch Rexroth Clamp and Inject Eject controllers DeviceNet triggers are sent to the inject eject and clamp cards predicated on the following a events and conditions programmed through ladder code b status from the hydraulic controllers These triggers indicate the sequence of block number s in the inject eject and or clamp hydraulic controller card Additional DeviceNet based hardware such as PanelViews Stacklights sensors etc could be placed on the DeviceNet network as well however keep in mind that since time critical triggers to the hydraulic controllers are sent via DeviceNet you want to maximize network and machine performance To that end it is not recommended that you place any device on the same DeviceNet network that will be continually polling the devices for large amounts of data 4 Injection Molding Machine This specific injection molding machine solution was integrated onto a Van Dorn 170 HT with a typical Van Dorn hydraulic circuit with 2 manifolds 1 of these supports both inject and eject and 3 proportional valves 1 pressure and 2 flow However the solution is not limited to this particular hydraulic circuit to this type or size of machine or by size of the application Rockwell Automation recommends you consult your local hydraulics expert or system integrator to review your hydraulic2. Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 Publication RA AP012A EN P September 2003 Copyright 2003 Rockwell Automation Inc All rights reserved Printed in USA
3. diagrams to ensure optimal performance of your system i e you want to make sure the hydraulics components have been properly sized for your application 5 Operator Interface Panel The existing universal RIO remote I O network and RediPanel used with the previously installed control system solutions SLC and PLC 5 were also used in this solution Although universal RIO is supported by the Logix platform RA recommends that you consider using a PanelView on EtherNet or DeviceNet for operator machine controls This provides you with a more open solution based on the NetLinx Integrated Architecture for more information on this topic contact your local RA distributor or Sales Representative 6 Machine HMI Interface For the purposes of this application the RSView32 project was developed on an Allen Bradley 6181 Industrial Computer in a Windows 2000 environment The data is served up to the RSView application through an OPC Server RSLinx Data is transmitted from the ControlLogix L63 controller over EtherNet and from the Bosch Rexroth Inject Eject and Clamp controllers via the DeviceNet scanner across the backplane to the EtherNet module out the EtherNet port to the HMI This demonstrates one of the key strengths of Rockwell Automation s Integrated Architecture Seamless bridging and routing Because the Bosch Rexroth hydraulic controllers sit 4 on DeviceNet one of Rockwell s core networks the user has the ability to explicit message to a
4. w Bosch Rexroth hydraulic controllers let s take a look at how the solution addresses each of the control challenges previously stated in this document Control Challenges 1 Increase overall production speed of the injection molding machine e High performance closed loop velocity and pressure regulation for both the inject and clamp control e High response ejector profile with multi stroke capability A comparison to the existing Pro Set 200 solution shows a marked difference as displayed in the table below Cycle Cycle Cycle Time Time Time Minimum Maximum Standard sec sec Deviation Pro Set 200 SLC based injection molding control Logix based Solution w Bosch Rexroth hydraulic controllers 2 Improve process repeatability and reduce scrap regrinds e High speed program scan in Logix controller improves control and repeatability e Control structure specifically designed for hydraulic axes makes control so repeatable that exact setup of the desired profile is possible without allowance for variation e Cutting edge performance of injection and clamp controllers is for both old and new injection molding machines This performance helps minimize scrap and makes the injection and clamp processes completely repeatable 3 Reduce cost and machine vibration e Reduce your hardware investment the injection ejection card DPQ can control up to 3 proportional valves simultaneously the clamp card DPC can control up to 2 p
5. 0V AC Output Module Wired to solenoids on molding machine 5 1756 OA16 17 point 120 240V AC Output Module Wired to solenoids and temperature outputs Interfaces to HMI programming terminals 6 1756 ENET Ethernet Communication Interface Module land upper level systems T 1756 L63 ControlLogix Controller Provides system controls 8 spare Interfaces to Bosch Rexroth Clamp and Inject 9 1756 DNB DeviceNet Interface Module Controllers spare H 11 1756 IB16 16 point 12 24V DC Input Module Hardwires to Inject Eject and Clamp Cards Hardwires to Inject Eject and Clamp Card 12 OB16l 16 point DC Isolated Output Module Enables and Autos Remember we re providing the above list of specific hardware and software products to help our customers understand this application solution but you are NOT limited to these hardware products One of the powers of this solution lies in its hardware independent nature Customers may pick and choose their hardware based on their particular application needs as well as their budget 2 EtherNet Network Ethernet networking was chosen to support communications between the HMI programming terminal s and upper level management systems For this application solution a small isolated Ethernet network was created as shown below Supervisor Station Programming PC 2 130 1 30 130 2 ControlLogix Chassis 6192 HMI Station 139 130 130 6 130 130 130 3 130 130 130 5 an LA SwitehiRouter
6. D_Permissive Local 9 0 D ata 0 19 M FJ In the ladder rung shown above you can see that the OTE instruction is mapped to the output Local 9 0 Data 0 19 and has a description of Screw Rotate This is a trigger to the DPQ 2X Bosch Rexroth Inject Eject controller to instruct the card to rotate the screw for recovery after a shot was fired This particular DPQ 2X DeviceNet product has 16 bytes of input data and 4 bytes of output data as shown in the following table 1 0 from Bosch Rexroth Inject Controller Descriptor 1 0 Type i Descriptor Transfer Achieved input 1 0 Inject Start output 1 0 Inject Card OK input 1 1 Eject Retract Manual output 1 6 Ejector Fully Retracted input 1 2 Manual Post Decompress output 1 7 Select Ejector Retract Position input 1 3 Clamp Movement output 2 8 End of Pressure Profile input 1 4 Eject Extend output 2 9 End of Decompress input 1 5 Jog Forward output 3 17 At Shot Size input 1 6 Jog Reverse output 3 18 At Ejector Extend input 1 7 Screw Rotate output 3 19 Inject Card Enable input 2 0 Pre Decompress output 3 22 Inject Cylinder Position Feedack input 3 6 Post Decompress output 3 23 System Injection Pressure input 7 10 Eject Forward Manual output 4 25 Ejector Position Feedback input 11 14 Eject Retract Manual output 4 26 Active Block in Inject Card input 15 16 Ejector Auto Full retract output 4 27 Ejector Auto Retrac
7. Technical Application Notes Fitomstion Creating a Plastics Injection Molding Machine Control Solution Using the Logix Platform DeviceNet and Bosch Rexroth High Speed Closed Loop Controllers Purpose of this Document This document will provide useful information for helping a Rockwell Automation customer with understanding the plastics injection molding solution using Logix based hardware in conjunction with Bosch Rexroth high speed closed loop controllers It is recommended that the user be familiar with RSLogix5000 and Logix hardware understand the injection molding process have basic hydraulic knowledge and be able to write and interpret ladder and function block code Additionally it would be beneficial to have some experience with DeviceNet This document should be used together with the appropriate Logix User Manual and DeviceNet interface module User Manual the DN 6 7 2 DeviceNet Cable Installation and Wiring Guide and the Bosch Rexroth Manuals for the specified hydraulic controllers Application Description Rockwell Automation has delivered injection molding control solutions based on the SLC and PLC 5 PLC product lines for many years This document will provide the injection molding machine user with a Logix based solution based on Rockwell Automation s newest control platform This document was developed in conjunction with Bosch Rexroth to provide a similar solution for new customers as well as existing customers who wan
8. allow smooth acceleration of the clamp e Position dependant braking technology is used so that even the most demanding systems can be decelerated in the shortest time possible smoothly and with superb repeatability e The DPC includes pressure limiting control that can be configured to work with 1 or 2 pressure transducers or a load cell e Advanced control techniques like Active Damping allow precise closed loop control of the most demanding low natural frequency systems e The velocity profile and pressure profiles may be controlled with one proportional directional type hydraulic flow control valve or using separate valves for flow and pressure e The DPC includes DeviceNet communications capability that allows access to all parameters directly from a PLC or computer All sequence triggers are transmitted to the DPC over DeviceNet Motion profile set points are normally transferred into the DPC from a PLC or computer The profile set points may also be entered into the card using RSNetworx for DeviceNet or Bosch Rexroth BODAC software The DPC is configured to control clamp type applications and all parameters are labeled to be recognizable in clamp applications There are however many other applications that could benefit from the quality of control afforded by the DPC Typical applications include e Mechanical handling devices Lift and Transfer machines Powder metal presses Angular position for rotary axis Shuttle and Transport ax
9. beled to be recognizable in injection molding applications There are however many other applications that could benefit from the quality of control afforded by the DPQ Typical applications include e Transfer molding Extrusion Broaching Rubber molding Accumulator head blow molding Software Components There are 4 Rockwell Automation RA software packages that were utilized for this project e RSLogix5000 software package used to program all sequential logic for stepping through the molding process and function block logic for temperature control e RSNetworx for DeviceNet software that lets you configure and monitor devices on DeviceNet networks e RSLinx a 32 bit product that links RA networks and devices to Microsoft Windows applications These range from device programming and configuration applications such as RSLogix and RSNetWorx to HMI applications such as RSView32 to your own data acquisition applications using Microsoft Office Web pages or Visual Basic e RSView 32 RA HMI package In addition to these products Bosch Rexroth provides their own proprietary Windows based software BODAC for the clamp inject and eject hydraulic control of the injection molding process This software provides another path to get online with the inject and clamp controllers in a quick and easy way through the serial ports located on the faceplate of the hardware The software which can be obtained directly from Bosch Rexroth Ind
10. e products Appendix A Major Differences in Logix PLC 5 and SLC Solutions The following table provides a comparison of many of the major differences in the Rockwell Automation hardware and software offerings for an injection molding solution A ProSet200 ProSet700 Logix Motion or process Loop Closure location Platform PLC 5 All Logix PLC 5 MicroLogix and SLC with DNet Comms Loop Closure time 10 msec 2 msec 2 msec or less Temperature Control 1746 BTM 1771 TCM Any Logix standard T C input HMI platform PanelView RSView ControlView Any View solution Integrated loop and discrete I O yes Processor scan time dependant yes o Aa loop closure parameters yes yes Actuals Available SLC processor I O controller card QDC Bosch Rexroth Hydraulic Controller Cards must calculate Appendix B Application Example and Results The following is a table displaying the operating parameters of a 700 ton injection molding machine before and after converting to Rockwell hardware in conjunction with the Bosch Rexroth hydraulic controllers This information was provided by JVH Engineering a Rockwell Automation System Solution Provider Notes The Decompression Repeatability measurement spec is dependent upon barrel size and the following information e This barrel had a shot capacity of 165 oz and 10 31cc mm of stroke e This measurement was taken at 75 decompress speed World Class 700 Ton After Characteristic 700 Ton Before Reb
11. elating to this particular application Let s Talk About Our Hardware and Network Components The following are the key components we utilized to build the control hardware network configuration of this system 1 ControlLogix The core of our system in this example is the ControlLogix chassis Within this chassis are all the modules required for sequential and process control network connectivity and I O interfaces to field devices As shown below a 13 slot ControlLogix chassis was used for this application other chassis sizes available 4 7 10 and 17 slot versions Scaleability of the Logix platform is a key feature for this solution therefore the spare slot shown below provides a buffer for potential future expansion with processing networking motion or I O capabilities ControlLogix Chassis The contents of the ControlLogix chassis used for our specific test case are described in the following table Module Description Function Returns temperature data from 4 J type T C ion different barrel locations as well as oil 0 1756 IT6l 6 Point Thermocouple Input Module temperature Data Highway Plus Remote I O Communication 1 1756 DHRIO Interface Module Interfaces to RediPanel on molding machine 2 1756 IA16 16 point 120V AC Input Module Wired to limit switches on molding machine 3 1756 IA16 16 point 120V AC Input Module Wired to limit switches on molding machine 4 1756 OA16 16 point 120 24
12. es Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this document www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa Rockwell Automation BrihlstraRe 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02
13. he moving platen from the stationery platen to open the mold e Eject During this phase the ejector plate in the mold advances the ejector pins to eject the part from the mold To understand more about how DeviceNet triggers to the inject eject and clamp hydraulic controllers are utilized to move through the process stages listed above reference the sequence charts provided in the Bosch Rexroth documentation for the DPQ 2X and DPC 1X products DeviceNet Interface to the Bosch Rexroth Hydraulic Controllers Rockwell Automation recognizes the strengths and benefits of DeviceNet as one of our core networks Because of this when we initiated a relationship with Bosch Rexroth in this development effort we mutually agreed to take their existing hydraulic controller technology and design next generation hydraulic controllers whose communications would be based on DeviceNet Today the resulting products DPC 1X clamp controller and DPQ 2xX inject eject controller are nearing final compliancy approval from ODVA and are marketed through their Sales and Distribution network with DeviceNet connectivity The trigger as discussed in previous sections of this document simply refers to an energized bit that is scanned in the ladder logic and sends a command to the specified DeviceNet target Let s look at an example to help you understand this a little better Inject Plastication Permit At Shot Size Screw Rotate B101 1 4 Local 9 1 Data 0 6 Inject LHAC
14. is Inject Controller DPQ 2X The DPQ is a digital platform industrial injection molding controller It optimizes the control of a hydraulic injection axis and or a hydraulic ejector axis Injection velocity profiles are controlled completely by use of closed loop position control An advanced position command profile is calculated automatically based on the operator input velocity profile Ejector profiles are controlled either open or closed loop depending on the hydraulic configuration Because the DPQ is a position control device it requires a position feedback transducer Both 0 to 10 VDC analog and SSI digital types are supported for the injection axis The DPQ includes injection pressure limiting control that can be configured to work with 1 or 2 pressure transducers or a load cell The injection velocity and pressure profiles may be controlled with one proportional directional type hydraulic flow control valve or using separate valves for flow and pressure The DPQ includes DeviceNet communications capability that allows access to all parameters directly from a PLC or computer All sequence triggers are transmitted to the DPQ over DeviceNet Motion profile set points are normally transferred into the DPQ from a PLC or computer The profile set points may also be entered into the card using RSNetworx for DeviceNet or Bosch Rexroth BODAC software The DPQ is configured to control injection molding type applications and all parameters are la
15. nd from the devices directly from the HMI which bypasses the ControlLogix L63 controller altogether This greatly reduces the overhead in the controller allowing for faster scan times and more communication bandwidth additionally it reduces the time commitment of the programmer Because a molding machine can be used to mold numerous parts the ability to store recipe information is critical To support this function an RSView32 extension called RecipePro is utilized This is a simple add on to the basic RSView32 package and makes the download and storage functions very easy Another advantage of using this utility to store your recipes is the conservation of memory space in your sequential controller For more information on how to use this RSView extension please refer to the following Rockwell Software manual 9399 RSVPROGR RecipePro Getting Results Guide 7 Bosch Hydraulic Controllers Clamp Controller DPC 1X The DPC is a digital platform industrial clamp controller It optimizes the control of a hydraulic axis for velocity and pressure control e Velocity profiles are controlled completely by use of closed loop position control An advanced position command profile is calculated automatically based on the operator input velocity profile e Because the DPC is a position control device it requires a position feedback transducer Both 0 to 10 VDC analog and SSI digital types are supported e The DPC uses constant acceleration type ramping to
16. oller to support any hydraulic circuit that uses directional type of proportional control valve 5 Improve overall process control e Setup in both clamp and injection ejection controllers allow enough profile options for total control of the most demanding application e True differential force control in the clamp allows the lowest possible mold protect force without affecting the velocity setting e Complete closed loop multi step open and close profiles for clamp velocity e Position dependent braking allows repeatable fast and smooth deceleration of toggle or hydraulic clamps e Multiple options for part ejector profile mold fill hold pressure and recovery pressure 10 Final Thoughts The ease of development for an injection molding application has been greatly improved by using the Logix based programming environment and hardware in conjunction with Bosch Rexroth Inject Eject and Clamp Hydraulic controllers From setting up the hardware to sequencing the machine processes to controlling the barrel temperature to configuring and integrating the Bosch Rexroth controllers the use of software and hardware components from Rockwell Automation a world class provider of industrial networks and control systems and Bosch Rexroth a world class provider of hydraulic control technology provides the molding machine OEMs integrators and end user with a world class injection molding solution that utilizes standard off the shelf hardware and softwar
17. ot limited to Logix based controllers alone it has also been successfully implemented with SLC and PLC 5 based controllers as well The following is a representation of the injection molding system Injection Molding Machine GALE LI Control Cabinet Development PC Logix Chassis HMI Station Bosch Controllers EtherNet Bus DeviceNet Bus The configuration for the System consists of the following DeviceNet Network DeviceNet Scanner DPC 1X Bosch Rexroth clamp controller DPQ 2X Bosch Rexroth inject eject controller EtherNet Network Ethernet Module HMI Station Development PC whatever quantity is required during integration process RIO Network DHRIO Module Redi_Panel Operator Interface Control Miscellaneous Various I O modules wired to field devices DPC and DPQ hydraulic controllers are wired to physical valves and sensors to control and read valve outputs pressures and positions within the hydraulic circuit Note This configuration was chosen for a number of reasons i e quickest integration with the existing set of hardware however the network could be re arranged to suit your application Your Operator Interface Control could be on DeviceNet ControlNet or EtherNet Your high level data acquisition system could be connected to the Ethernet backbone to gather and analyze real time data Now that you have an idea of what a typical injection molding system looks like let s get into some specifics r
18. perator interface device as well as RSLogix 5000 software For this application the Autotune function has already been performed To view the PID values for each heating zone go to the zone specific sheet in the FB routine and click the ellipsis button on the PIDE instruction PIDE Enhanced PID 218 58626 Nozzle_Temp D J Heat_Regulation_Percent_Nozzle Temp_HI_Nozzle 5 B2 ef Temp_Lo_Nozzle 5 B1 600 0 Temp_Hi_Limit O C PVHHLimit 300 0 Temp_Lo_Limit D C PVLLLimit ProgProgReq E ProgOperReq ProgCasRatReq ProgAutoReq c ProgManualReq c ProgOverrideReg E ProgHandReq AutotuneTag Then go to the Autotune tab to view Autotune data Parameters Tag Autotune Tag Name AT_Nozzle Tag Status lt not online gt Autotune Inputs Current Gains Process Type Temperature Proportional Integral P Change Limit 0 0 Derivative C Step Size 00 The application code performs the multi zone temperature control through function block routines and autotune functions For a more detailed explanation on how each of these tasks is accomplished please refer to the following KnowledgeBase Documents located on the www ab com website A22929290 ControlLogix Multi zone Temperature Control Plastics Industry A20456899 Performing a PIDE Autotune from Logic with the Embedded PIDE Autotune Summary To summarize the benefits of the Injection Molding Solution utilizing Logix based control
19. roportional valves simultaneously e Eliminate leaks due to hydraulic shock by precisely controlling the hydraulic conditions within the system e Eliminate vibration to injection molding machine and any peripherals such as your HMI due to smooth transitions in clamp movement acceleration deceleration and breaking functions 4 Increase flexibility and improve efficiency e Create a solution that can be used in SLC PLC 5 and Logix based injection molding applications e Simplify reusing this control strategy when integrating it into larger or smaller injection molding machines e Use multi language support in RSLogix 5000 software for closed loop temperature control of the injection molding barrel e Use of the ControlLogix backplane as a bridge device allows easy access to all control and configuration parameters via on board DeviceNet communications on both clamp and inject eject controllers without loading the Logix controller with extensive explicit messaging in ladder code Use off the shelf controllers I O and communications products and customize to your application specifications Use off the shelf front end HMI products and customize to your application specifications Simplify recipe changes by utilizing extensions to standard HMI products Configuration options on injection ejection controller to support any type of proportionally controlled hydraulic circuit including one or two valve injection circuits e Configuration options on clamp contr
20. t to migrate their plastics applications to Logix based control The power of the solution lies in the open network architecture and the various SLC PLC 5 and Logix hardware products available for control making the new solution very scaleable in terms of memory I O control and communications Control System Product Requirements The following list of hardware and software products is required for implementing the solution as described in this application note Any Logix controller DeviceNet interface module Various Logix input and output modules Bosch Rexroth Inject Controller DPQ 2X Bosch Rexroth Clamp Controller DPC 1X RSLogix 5000 software with Function Block activation RSLinx software RSNetworx for DeviceNet software Any Front End HMI software i e RSView32 ME or SE Control Challenges Reduce overall cycle time of injection molding process Improve process repeatability and flexibility Reduce vibration Reduce scrap and regrinds Simplify recipe changes Simplify reusing this control strategy when integrating it into larger or smaller machines Create a solution that can be used in Logix based injection molding applications as well as MicroLogix 1500 SLC and PLC 5 System Overview For the purposes of this application note we ll use a specific example that was implemented and installed on a machine in Rockwell Automation s development lab Keep in mind however that this solution is n
21. t to Tip Stroke output 4 28 Inject Card Initialize output 4 31 The same trigger mechanism is applicable to the Bosch Rexroth clamp controller As shown in the table below the Bosch Rexroth clamp controller supports 12 bytes of input data and 4 bytes of output data all of which are utilized in the sequencing of the injection molding process 1 0 from Bosch Rexroth Clamp Controller Input Descriptor Input Descriptor Transfer Achieved input 1 0 Start Close output 1 0 Clamp Card OK input 1 1 Decompress output 1 7 At Open Position input 1 3 Start Open output 2 8 At Tonnage input 1 4 Clamp Open output 3 16 At Closing Force input 1 5 Clamp Close output 3 17 At Decompress Pressure input 1 6 Clamp Card Initialize output 4 31 Clamp Permissive for Ejector input 1 7 Clamp Card Enable input 2 0 Clamp Position Feedback input 3 6 Clamp Pressure input 7 10 Active Block in Clamp input 11 12 Function Block Setup for Temperature Control One of the benefits of using the Logix platform as the foundation for this application is the addition of Function Block FB programming capability Along with a discrete output module and 6 channel thermocouple module 1756 IT6I FB provided the basis for barrel temperature control For this specific application heat only zones were utilized so only 4 outputs were required to drive the heater contactors As shown in the Controller Organizer in
22. the example below there are 2 function block routines that were created for the temperature control of our machine OOE Read_write_Compare Solenoid _Outputs Zone_TPO E ED Temperature _Control A Zone_Temp_Control Program Tags ER Tune_Int zones The first Zone_TPO is called unconditionally from the MainRoutine There are 4 sheets in this FB routine 1 for each heating zone of the barrel The SRTP instruction takes the 0 100 output of a PIDE loop in the Zones FB routine in the Temperature_Control task and drives the output contacts via a digital pulse As shown below in the FBD for the Nozzle heating zone the contactors are not energized until two additional inputs to a BAND instruction are high as well SRTP_O1 SRTP A Split Range Time Proportional 100 0 Heat_Regulation_Percent_Nozzle O c In HeatOut o HeatTimePercent D BAND_01 BAND Fal Boolean And Nozzle Heat a Local 5 0 Data 9 Barrel Heat On Light 0 Redi_Panel 0 Data 1 10 a r Control Power On 1 Local 2 1 Data 1 a A second FB routine Zones is unconditionally called from the Atune_Interlock routine and uses enhanced PID instructions to allow the programmer to set up control setpoint and alarming values for each heating zone on the barrel Additionally the RSLogix 5000 PIDE provides an open loop autotuner built into the PIDE instruction You can autotune from the PanelView terminal or any other o
23. uild Machine Rebuild Hydraulic Response sec 1000 psi Failed Pressure never settled 0 200 0 145 Speed Linearity 28 28 10 00 8 41 Load Compensation kpsi 88 10 lt 3 0 610 Clamp Repeatability mm Clamp Speed Control 7 188 2 540 1 676 3 Stage Capability Velocity Pack Cavity Pressure Transfer Not capable Capable Capable Ejector Repeatability mm 1 78 2 54 0 254 Decompression Repeatability cc Not repeatable lt 25cc 9 940 Injection Speed cc sec 700 n a 900 11 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www ab com manuals gi describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this document are included solely for illustrative purpos
24. ustrial Hydraulics Division has the following functionality setup troubleshooting upload and download parameters tuning parameter monitoring real time graphing and module diagnostics Ladder Code Setup The code that was developed for this application was designed to control the most standard injection molding sequences The code interfaces with the Bosch Rexroth clamp and inject eject controllers through DeviceNet triggers and hardwired connections Additionally it includes barrel temperature control machine modes standard clamp inject eject sequences alarms etc For this specific application the ladder code was developed in conjunction with clamp and inject eject sequence charts provided through Bosch Rexroth technical manuals for DPQ 2X and DPC 1X which follow the four main phases of the injection molding process e Clamp close During this phase the clamping cylinder pushes the moving platen towards the stationery platen e Inject During this phase the injection ram advances to shoot molten plastic into the mold cavity pressurizes it to fill any voids pack and holds that pressure as the part cools the injection ram screw then rotates to reload plastic for the next shot The screw forces the plastic down the screw flights in front of the screw tip As this occurs the ram is forced to retract Plastication The distance the ram retracts designates the shot size e Clamp open During this phase the clamping cylinder pulls t
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