Moog DigiPack III J141-215 Maintance Manual

Download

MRJ06301 Rev. Orig.

DigiPack

Ⅲ

Parison Wall Thickness Controller

J141-215

INSTALLATION,

MAINTENANCE

AND

USER’S MANUAL

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

MRJ06301

RECORD OF CHANGES

Rev.

Page

Description

Prepared

Checked

Approved

Orig.

New Model Release(EOJ20210)

T. Kouda 15, Mar’19

T.Shimizu 15, Mar ‘19

K.Mashino 29,Mar’19

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

MRJ06301

MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND

This technical Document contains information that is proprietary to, and is the express property of Moog Inc., or Moog Inc. subsidiaries except as expressly granted by contract or by operation of law and is restricted to use by only Moog employees and other persons authorized in writing by Moog or as expressly granted by contract or by operation of law. No portion of this Data/Drawing/Document shall be reproduced or disclosed or copied or furnished in whole or in part to others or used by others for any purpose whatsoever except as specifically authorized in writing by Moog Inc.

NOTES TO USERS

(1) Description in this manual is subject to change without any obligation on the part of the Manufac-

turer. (2) Notice would be appreciated if you find any question, omission or error in this manual. (3) Disassembly, maintenance or repair, other than in accordance with the instruction herein or other

specific written instruction from MOOG will invalidate MOOG’s obligations under its warranty. Refer to MOOG warranty for complete previsions thereof.

SAFETY INSTRUCTION

Description in this manual is essential to the safety of life and property, therefore, before operating this equipment, you should first thoroughly read this manual, and this manual should be kept in accessible for when you have any questions.

WARNING

This symbol with the word “WARNING” is used to call attention to safety instructions

concerning a potential hazard to people. Failure to comply with these safety instructions can result in serious damage to health and can even prove fatal in extreme cases.

CAUTION

This symbol with the word “CAUTION” is used to call attention to instructions concerning

potential damage to the equipment or to the system as a whole.

NOTE

Notes contain useful information to the operator when starting up and operating the equipment or system.

MOOG JAPAN LTD.

1-8-37 NishiShindo, Hiratsuka, Japan 254-0019

Tel:+81-463-55-7141 Fax:+81-463-54-4709

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

III

MRJ06301

EN 61000-6-2:2005 IEC61000-4-2~6

Electromagnetic compatibility (EMC) - Part 6-2: Generic standards

- Immunity for industrial environments

EN61000-6-4:2007+A1:2011

Industrial, scientific and medical equipment - Radio-frequency disturbance characteristics - Limits and methods of measurement

About EMC Standard

1. Safety standard

Notes to certified of EC directive

J141-215 DigiPackⅢ is a device incorporated in customer's equipment (blow molding machine) and we are conducting EMC test against EC Directive within the scope of embedded equipment, but the J141-215 DigiPackⅢ use by itself is not compatible with the EC Directive.

When customer completes the equipment with J141-215 and use it within Europe or shipment to the area within European region as the final product, please be sure to check certified of EC Directive by customer self.

Applicable directive and relative standard.

J141-215 is conducting the EMC test conforming to the EC directive below. It shows directives and related standards.

EC Directive: EMC Directive 2014/30/EU Relative Standard:

2. Measures EMC

In order to applicable EMC directive, please takes suitable measure against EMC with a customer's blow molding machine.

And also, when include J141-215 in apparatus and it is used, please consider wire connection and grounding.

The cable used for each wire connection recommends use of a shielded cable. A shielded cable should be connected to the terminal of J141-215, and the length of skin wire processing

should be less than 100 mm.

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

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TABLE OF CONTENTS

1. DigiPackⅢ Manual, Installation and Maintenance .............................................................................. 1

1-1. CHANGES FROM J141-214A ......................................................................................................... 1

1-2. INTRODUCTION .............................................................................................................................. 2

1-2-1. GENERAL DESCRIPTION.............................................................................................. 2

1-2-2. WHO CAN INSTALL THE DigiPackⅢ ............................................................................. 5

1-2-3. INSTALLATION TIME ..................................................................................................... 6

1-2-4. SOFTWARE UPDATE .................................................................................................... 6

1-2-5. BACKUP BATTERY ........................................................................................................ 7

1-2-6. SCREEN DISPLAY PROTECTION (password) ............................................................... 7

1-2-7. DATA TRANSFER FROM DigiPackⅡ ............................................................................. 7

1-3. DigiPackⅢ SPECIFICATION .......................................................................................................... 8

1-4. CHECK LIST .................................................................................................................................... 9

1-4-1. INSTALLATION CHECK LIST ......................................................................................... 9

1-5. MECHANICAL INSTALLATION ..................................................................................................... 10

1-5-1. GENERAL .....................................................................................................................10

1-5-2. TOOLING ADJUSTMENT .............................................................................................. 11

1-5-3. MOOG DIE GAP TOOLING ACTUATORS .....................................................................12

1-5-4. CYLINDER INSTALLATION ...........................................................................................12

1-5-5. CUSTOMER SUPPLIED CYLINDER REQUIREMENTS ................................................13

1-5-6. TOOLING ADJUSTMENT ..............................................................................................14

1-5-7. ACCUMULATOR POSITION MEASUREMENT .............................................................14

1-5-8. THE IMPORTANCE OF FILTRATION ............................................................................15

1-5-9. FILTER INSTALLATION .................................................................................................15

1-5-10. HYDRAULIC POWER SUPPLY ...................................................................................16

1-5-11. HYDRAULIC POWER SUPPLY START UP INSTRUCTIONS ......................................16

1-5-12. CONTAMINATION CONTROL ..................................................................................... 17

1-6. ELECTRICAL INSTALLATION ....................................................................................................... 18

1-6-1. GENERAL .....................................................................................................................18

1-6-2. REAR CONNECTOR .....................................................................................................18

1-6-3. TB-1, TB-2 WIRING .......................................................................................................19

1-6-4. COMMUNICATION AND SSI SNSOR WIRING..............................................................19

1-6-5. TB-2 I/O CIRCUITRY ................................................................................................ .....25

1-6-6. TB-3: POWER SUPPLY .................................................................................................26

1-6-7. NOISE AND GROUND ISOLATION ...............................................................................26

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1-7. CALIBRATION OF TOUCH SCREEN ........................................................................................... 29

1-8. DigiPackⅢ front panel .................................................................................................................. 30

1-9. TOOLING SYSTEM SETUP .......................................................................................................... 32

1-9-1. GENERAL OF SETUP ................................................................................................ ...32

1-9-2. MACHINE SETTING ......................................................................................................32

1-9-3. SET UP PROCEDURE ..................................................................................................35

2. DigiPackⅢ Manual, User operation .................................................................................................. 43

2-1. INTRODUCTION ............................................................................................................................ 43

2-2. PARISON CONTROL..................................................................................................................... 44

2-2-1. HISTORY .......................................................................................................................44

2-2-2. PARISON PROGRAMMING BENEFITS ........................................................................44

2-2-3. CONTINUOUS EXTRUSION MACHINES .....................................................................44

2-2-4. ACCUMULATOR MACHINES ........................................................................................44

2-2-5. PARISON PROGRAMMING BENEFITS ........................................................................45

2-2-6. WITH ACCUMULATOR BLOW MOLDING MACHINES .................................................46

2-2-7. WITH CONTINUOUS BLOW MOLDING MACHINES ....................................................46

2-2-8. PARISON MOLD ALIGNMENT ......................................................................................47

2-3. MAN MACHINE INTERFACE ........................................................................................................ 48

2-3-1. OPERATOR CONTROL .................................................................................................48

2-3-2. INPUT FUNCTION .........................................................................................................48

2-3-3. FUNCTIONS ..................................................................................................................51

2-3-4. STATE MONITORING AREA .........................................................................................51

2-3-5. EDIT AREA ....................................................................................................................52

2-4. SCREENS OF EDIT AREA ............................................................................................................ 53

2-4-1. EDITING METHOD ........................................................................................................53

2-4-2. F1: Profile Mode ............................................................................................................54

2-4-3. F2: Marker Mode ...........................................................................................................59

2-4-4. F3: File Mode .................................................................................................................61

2-4-5. F4: Monitor Mode ...........................................................................................................65

2-4-6. F5: Data Display Mode ..................................................................................................66

2-4-7. SHIFT→F1: Set Up Mode ..............................................................................................67

2-4-8. SHIFT→F2: Analog monitor ...........................................................................................67

2-4-9. SHIFT→F3: File delete and Backup/Restore .................................................................68

2-4-10. SHIFT→F4: Machine Setup .........................................................................................69

2-4-11. SHIFT→F5: Communication Mode ...............................................................................70

2-5. COMMUNICATION PROTOCOL ................................................................................................... 71

2-5-1. EtherNET COMMUNICATION SPECIFICATION ............................................................71

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2-5-2. PROFILE .......................................................................................................................71

2-5-3. WAVE ............................................................................................................................73

2-5-4. MONITOR ......................................................................................................................73

2-5-5. INFORMATION DATA ....................................................................................................73

2-5-6. INTERFACE CONTROL ................................................................................................74

2-5-7. OTHER ..........................................................................................................................76

2-5-8. ERROR CODE ..............................................................................................................76

2-5-9. ADC/DAC CHANNEL ................................................................................................ .....76

2-6. PROFILE DATA LIST ..................................................................................................................... 77

2-7. SETTING UP .................................................................................................................................. 78

2-7-1. OBJECTIVE ................................ ................................................................ ...................78

2-7-2. DIE GAP TOOLING SETUP ...........................................................................................78

2-7-3. PRELIMINARY SET UP .................................................................................................79

2-7-4. INITIAL TRIALS .............................................................................................................80

Reference Drawings

CC70353 ---------- Installation CC70355---------- Customer Wiring

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

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Table of Figure

Figure 1-1 DigiPackⅢ appearance - - - - - - Page 2 Figure 1-2 Basic Continuous Blow Molding Machine Control Diagram- - - Page 3 Figure 1-3 Basic Accumulator Machine Control Diagram- - - - Page 4 Figure 1-4 Start up Display - - - - - - - Page 6 Figure 1-5 Die Gap Tooling Actuator Installation - - - - Page 10 Figure 1-6 Die Gap Tooling Actuator - - - - - - Page 10 Figure 1-7 Actuator – Die Gap Tooling Mechanical Adjustment - - - Page 11 Figure 1-8 Tooling Adjustment Mechanism - - - - - Page 11 Figure 1-9 Typical Cylinder Installation - - - - - Page 12 Figure 1-10 G631-XXX Servovalve - - - - - - Page 13 Figure 1-11 Typical Linear Potentiometer - - - - - Page 14 Figure 1-12 LWHxxx Potentiometer Installation- - - - - Page 14 Figure 1-13 High Pressure Filter - - - - - - Page 15 Figure 1-14 Hydraulic Power Supply - - - - - Page 16 Figure 1-15 Flow Pressure Filter - - - - - - Page 17 Figure 1-16 REAR CONNECTOR - - - - - - Page 18 Figure 1-17 DigiPackⅢ Installation Drawing - - - - - Page 20 Figure 1-18 ServoValve and Transducer Phasing- - - - - Page 21 Figure 1-19 TB-1 Connections - - - - - - Page 21 Figure 1-20 TB-1 Functions - - - - - - Page 22 Figure 1-21 TB-2 Connection - - - - - - Page 23 Figure 1-22 TB-2 Connection - - - - - - Page 23 Figure 1-23 TB-2 Functions - - - - - - Page 24 Figure 1-24 Input use external Power supply - - - - - Page 25 Figure 1-25 Input use internal Power supply - - - - - Page 25 Figure 1-26 Output use external Power supply - - - - Page 25 Figure 1-27 Output use internal Power supply- - - - - Page 25 Figure 1-28 Power supply Connections - - - - - Page 26 Figure 1-29 Accumulator Machine Timing chart - - - - Page 27 Figure 1-30 Continuous Machine Timing chart - - - - Page 28 Figure 1-31 Touch screen Calibration - - - - - Page 29 Figure 1-32 Touch screen calibration display - - - - - Page 29 Figure 1-33 DigiPackⅢ Flont panel - - - - - - Page 30 Figure 1-34 Machine setup display (SHIFT→F4) - - - - Page 33 Figure 1-35 Machine setting Functions - - - - - Page 33 Figure 1-36 Example of profile points change - - - - - Page 34 Figure 1-37 Setup screen - - - - - - - Page 35 Figure 1-38 Die Converge/Diverge Setup- - - - - - Page 35 Figure 1-39 Die Gap Setup - - - - - - - Page 36 Figure 1-40 DCDT Noise Filter - - - - - - Page 36 Figure 1-41 Die Gap Span Setting - - - - - - Page 37 Figure 1-42 Back - - - - - - - - Page 38 Figure 1-43 Gain select - - - - - - - Page 39 Figure 1-44 Gain setting - - - - - - - Page 39 Figure 1-45 Accumulator Setup - - - - - - Page 40 Figure 1-46 EMPTY Accumulator Set Up - - - - - Page 40 Figure 1-47 FULL Accumulator Set Up - - - - - Page 41 Figure 1-48 Extrusion Fixed- - - - - - - Page 41 Figure 1-49 Filling Fixed - - - - - - - Page 41 Figure 1-50 Accumulator setting (Back) - - - - - Page 42

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Figure 2-1 DigiPackⅢ appearance - - - - - - Page 43 Figure 2-2 Section of an Un-programmed Parison and the Resulting Container Walls Page 45 Figure 2-3 Section of a Programmed Parison and the Resulting Container Walls - Page 45 Figure 2-4 Poor Vertical Alignment Between the Parison and the Mold - - Page 47 Figure 2-5 Good Vertical Alignment Between the Parison and the Mold. - - Page 47 Figure 2-6 DigiPackⅢ Front panel - - - - - - Page 48 Figure 2-7 Ten key on the screen (1) - - - - - Page 49 Figure 2-8 Ten key on the screen (2) - - - - - Page 49 Figure 2-9 Status indicator - - - - - - - Page 52 Figure 2-10 F1: Profile mode Screen - - - - - Page 53 Figure 2-11 Profile Mode Screen - - - - - - Page 54 Figure 2-12 0%Weight Change - - - - - - Page 56 Figure 2-13 (-)23.3% Weight Change - - - - - Page 56 Figure 2-14 0% Range H - - - - - - - Page 57 Figure 2-15 (+)25.0% Range H Change - - - - - Page 57 Figure 2-16 0% Range L - - - - - - - Page 58 Figure 2-17 (-)20.0% Range L - - - - - - Page 58 Figure 2-18 Marker Mode Screen - - - - - - Page 59 Figure 2-19 Slope Timing - - - - - - - Page 60 Figure 2-20 File Mode Selection Screen - - - - - Page 61 Figure 2-21 Select SAVE - - - - - - - Page 61 Figure 2-22 File Description Data-Page 1 - - - - - Page 62 Figure 2-23 File Description Data-Page 2 - - - - - Page 62 Figure 2-24 File Description Data-Page 3 - - - - - Page 62 Figure 2-25 Edit File name - - - - - - - Page 63 Figure 2-26 Change File Number - - - - - - Page 63 Figure 2-27 Initial Load Screen - - - - - - Page 64 Figure 2-28 File Load - - - - - - - Page 64 Figure 2-29 F4: Monito screen - - - - - - Page 65 Figure 2-30 Data Display Screen A - - - - - - Page 66 Figure 2-31 Data Display Screen B - - - - - - Page 66 Figure 2-32 Data Display Screen C - - - - - - Page 66 Figure 2-33 [SHIFT]→[F1]: Setup Screen - - - - - Page 67 Figure 2-34 [SHIFT]→[F2]: Analog Monitor Screen- - - - - Page 67 Figure 2-35 [SHIFT]→[F3]: File delete and Backup - - - - Page 68 Figure 2-36 File Delete - - - - - - - Page 69 Figure 2-37 [SHIFT]→[F4]: Machine Setup Screen - - - - Page 69 Figure 2-38 [SHIFT]→[F5]: Communication Mode Screen - - - Page 70

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1. DigiPackⅢ Manual, Installation and Maintenance

1-1. CHANGES FROM J141-214A

The basic specifications of DigiPackⅢ (J141-215) are equivalent to conventional J141-214A.

There are the following major differences.



Changed from currnt VGA (480 x 640) to WXGA (1200 x 800) size In addition, with touch screen conversion, operation by the conventional push button switch and display by the LED are abolished, and it is changed to operation/display on the screen. (Excluding rotary knob and power supply confirmation LED)



Considering availability, change the external storage device to USB memory. (It is not attached to controller) The following USB memory has been tested for operation. The operation can not be guaranteed with USB memory other than these model numbers. We recommend that you select the same model number as below when purchasing.

  -HTU3A 16GBK

In addition, other than the above, you can refer to the list of USB memories being used without problems by customers at the following URL:

https://www.moog.co.jp/products/controllers-software/blow-molding-controllers/digipack3.html

 -tightened, and the terminal block was made detachable.

Mounting screw size is M3.5. Please use crimp terminal matching it. Also, since the terminal block is removable, rewiring is unnecessary when replacing the controller.



 Name change: DI 10 Servo OFF → Emergency. This signal is normally(under control) OFF, and

if input is ON, turns OFF the servo output. For details, refer to Figure 1-23 TB-2 Functions .

 Signal addition: DI 11 temperature up completion. This signal is normally(under control) OFF, and

if input is ON, turns OFF the servo output. (Please turn ON when the resin is sufficiently warmed up and it becomes operable.) Please refer to Figure 1-23 TB-2 Functions for details.



 serial communication function   

For other details, please check this manual in detail.

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

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1-2. INTRODUCTION

288.00 mm

LCD Touch screen 10.1 (WVGA)

青色画面時 (RGB: 183.221.232)

DigiPackⅢ

Parison Controller

MOOG

0% 25% 50% 75% 100%

100

File Name:1234567890123456

Point No.

Die gap

Delay

Auto cycle

5.0

1.5

sec

Data

Weight

Range H

Range L

* 79.0

0.0

Start

Die gap

Continuous

Accumulator

Divergent

Convergent

End of filling

Point out End of

extrusion

F1 : Profile

F2 : Marker

F3 : File

F4 : Monitor

F5 : Data

Cursor

DEL S hift

X10 Set

2018/1/23 13:35:45

Cycle time 10.0 100% = 25.40

sec

Figure 1-1 DigiPackⅢ appearance

1-2-1. GENERAL DESCRIPTION

The J141-215 DigiPackⅢ is a user friendly, high performance 200 Point Digital Blow Molding Parison Wall Thickness controller producing lighter, stronger containers at increased production rates.

A properly installed and intelligently used system will deliver higher operating efficiency from your blow molding machine as a result of faster molding cycles, shorter change over times and reduced scrap.

The DigiPackⅢ adjusts the parison wall thickness by controlling the core position with the core actuator. The core position can be finely set up to 200 points maximum.

For an accumulator type blow molding machine, set the target core position with reference to the accumulator position. For a continuous blow molding machine, set the target core position based on time.

The core position control system with the above setting consists of four main components: DigiPackⅢ controller, servo valve, actuator for core and feedback detector for accumulator. The function of each component is as follows.

 Operator using DigiPackⅢ to set the core position (core die gap opening / closing amount) required

 DigiPackⅢ also functions as a digital interface with the PLC controller of the blow molding machine

 The servo valve adjusts the flow rate to the core actuator according to the flow (spool position) com-

 The actuator for the core, the core is fixed to the rod, and the rod (core) moves according to the flow

to obtain a product with the desired wall thickness (usually constant wall thickness). In addition, it outputs a flow (spool position) command to the servo valve so that the core follows the set core position.

and provides information such as the end of the program and the point status of sequential programs.

mand from DigiPackⅢ.

rate adjusted by the servo valve. Moving the core changes the gap through which the parison passes and controls the wall thickness of the parison.

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

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Hydraulics

Die Gap

PLC Controller

Servovalve

Actuator

DCDT

Core Position

Parison Cutoff Knife

 Accumulator feedback detector is used for accumulator type blow molding machine. The DigiPackⅢ

changes the target core position while monitoring the signal from this detector.

1.2.1.1. Continuous blow molding machines

Tooling

Figure 1-2 Basic Continuous Blow Molding Machine Control Diagram

When used with continuous blow molding machines, the DigiPackⅢ controls the parison wall thickness relative to the machine cycle time. The machine cycle starts when the start signal is input (when the parison cutting knife disconnects the parison). The cycle time can be determined by the following.

a) Fixed cycle time set by the operator (when [Auto cycle] is OFF) b) Automatic cycle time set by repeatedly measuring the time between start signals (when [AUTO CY-

CLE] is ON)

When using the fixed cycle time of a), it is necessary for the machine operation time to be negligible for reasons such as multiple die interlocking, or It is a premise that it is a machine that performs machine functions such as closing and moving molds within the cycle time

The shape of the parison wall profile is set digitally by the operator. The size of the die gap, measured by a die gap position transducer, is compared with the operators commanded position as set on the DigiPack

Ⅲ display. The error between the operators set position and the actual position causes the servovalve to flow oil to

the actuator to reduce the position error to a very small value. This feedback process ensures that the actual die gap follows the commanded die gap very accurately.

With a continuous blow molding machine, DigiPackⅢ operates / processes as follows. ① The operator sets the core position (core die gap opening / closing amount) necessary to obtain the

desired wall thickness (usually constant wall thickness) product on the DigiPackⅢ controller panel.

② When the start signal switches from OFF to ON, DigiPackⅢ controls the servo valve so that the core

follows the set position according to the cycle time.

③ The servo valve adjusts the flow rate to the core actuator according to the (flow rate) command from

DigiPackⅢ.

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

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Hydraulics

Die Gap Actuator

PLC Controller

Servovalve

Actuator

DCDT

Position

Accumulator Push Cylinder

Accumulator

Position

④ By controlling the actuator for the core, control the thickness of the parison at the core die gap portion. ⑤ During ② to ④, DigiPackⅢ functions as a digital interface with the PLC of the blow molding machine

and provides information such as the end of the program and the point status of the program sequentially.

1.2.1.2. Accumurator type molding machines

When used with accumulator machines, the DigiPackⅢ controls the parison wall thickness relative to the accumulator position as the plastic is being extruded.

As the total quantity or volume of plastic extruded is proportional to the accumulator position, then it follows that the resulting parison wall thickness at any given point on the length of the container must be related to the accumulator position. Given that the physical properties of the plastic and its temperature are constant from container to container, then each container’s weight and strength will be consistent.

Tooling

Figure 1-3 Basic Accumulator Machine Control Diagram

A potentiometer measures the accumulator position and controls the vertical axis of the program display. The operator can also set the accumulator operating stroke, shot size, and accumulator injection comple-

tion position (cushion). In addition, DigiPackⅢ also provides interface signals to the machine's PLC for these functions. After that, the operation of the accumulator is controlled by the PLC.

With an accumulator type blow molding machine, DigiPackⅢ operates / processes as follows. ① The operator sets the core position (core die gap opening / closing amount) necessary to obtain the

desired wall thickness (usually constant wall thickness) product on the DigiPackⅢ controller panel.

② When the start signal switches from OFF to ON, the DigiPackⅢ controls the servo valve so that the

core follows the set position according to the position of the accumulator.

③ The servo valve adjusts the flow rate to the core actuator according to the (flow rate) command from

DigiPackⅢ.

④ By controlling the actuator for the core, control the thickness of the parison at the core die gap portion.

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⑤ During ② to ④, DigiPackⅢ functions as a digital interface with the PLC of the blow molding machine

and provides information such as the end of the program and the point status of the program sequentially.

Successful performance of the DigiPackⅢ depends a great deal upon how well it is installed on the machine. By following the instructions contained idatan this manual it will be possible to easily install this system and obtain many years of trouble free operation.

1-2-2. WHO CAN INSTALL THE DigiPackⅢ

The installation of the DigiPackⅢ control system requires the installer to be familiar with electrical wiring, hydraulic plumbing and basic metal working. The calibration and start up of the finished system requires some understanding of the blow molding process and use of test instruments such as a digital voltmeter. The plumbing, wiring and bracketry should not be difficult. Most molding shop maintenance men who are familiar with blow molding machines will have little difficulty with the help of this manual.

The system can be satisfactorily calibrated to the machine and started up without assistance or special equipment by following the instructions in this manual.

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

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USB memory

Save

DIGIPK3.FMW

Software version

1-2-3. INSTALLATION TIME

The time to install a DigiPackⅢ varies with the type and size of machine, mechanical constraints such as the location of water lines and auxiliary equipment and the ability of the mechanic doing the installation.

Our experience has shown that typical maintenance men will require about 20 to 30 man hours. Smaller machines will require less time.

Of this time, the actual machine shut down time can be held to 6 hours or less.

1-2-4. SOFTWARE UPDATE

The software of this controller may be updated if a bug is found or the function is improved. Please check the software update status (latest version) from the MOOG website below. Also you can download the update file "DIGIPK3.FMW" from the website. How to update Please refer to the following description.

Update Process

1. Prepare the USB memory and turn off the power of DigiPackⅢ.

2. Save the "DIGIPK3.FWM" file to the USB memory using the computer.

3. Insert the USB memory into the DigiPackⅢ and turn ON the DigiPackⅢ.

4. Turn the rotary knob clockwise while turning on the power.

5. When "Updating firmware ..." appears on the display, the update process is in progress. ※ It takes about 30 seconds to update. If "Failed" is displayed on the screen, or if nothing happens

and screen changed to the startup screen, the upgrade fails. Please try again from process 1. If "Failed" is inevitably displayed and the upgrade is not successful, there is a possibility that the file is broken. Please download "DIGIPK3.FWM" again and try update again.

6. Then check the software version in the startup display (Figure 1-4).

7. Turn off the power and remove the USB memory.

Figure 1-4 Start up Display

USB memory is not included with DigiPackⅢ. Refer to section 1-1. for recommended USB. "DIGIPK3.FWM" can download the latest version from the MOOG website

https://www.moog.co.jp/products/controllers-software/blow-molding-controllers/digipack3.html

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1-2-5. BACKUP BATTERY

Since backup of an internal clock is using the ultra capacitor, there is no necessity for exchange. Backup time is about three weeks. A time display may be [----.--.-- --:--] when not turning on electricity the time of the power activation after purchase, and for a long period of time. In such a case, please set up the right time on F2 screen. (Reference 2-4-3. )

1-2-6. SCREEN DISPLAY PROTECTION (password)

The DigiPackⅢ has two types of screen configurations that the normal operation screen (F1 to F5) and the setting screen (SHIFT → F1 to F5) for making various settings. Each screen can be distinguished by the color of the background. The background color of the normal operation screen is light blue " " The background color of the setting screen is yellow " ". In this controller, the transition to the setting screen is limited by the password. When entering the setting screen, entering a password enables you to migrate.

* Once you enter the password, it is not necessary to enter the password until you restart the controller. Also, if password function is unnecessary, it is possible to invalidate password from SHIFT → F4 screen. See 1.9.2.1

Password: 6009 (Password is fixed and can not be changed)

Password input

After activating the controller, the password entry screen will be displayed when entering to the setup screen by first pressing “SHIFT” and then pressed Fx key. Once you enter 4-digit password, you will be able to switch to the setup screen without entering again the password. This will be retained until you restart DigiPackⅢ.

In addition, this password can be enabled / disabled on the machine setting screen (SHIFT→ F4) . Refer to Section 1.9.2.1 Machine Settings for details.

This level change does not indicate any notice on display. Please check the level is correctly changes or not by press SHIFT→F1, if the level “Low” should not goes to setup display

1-2-7. DATA TRANSFER FROM DigiPackⅡ

The saving data of DigiPackⅡcan be transferred to DigiPackⅢ due to following process. With the DIgiPackⅡsave the parameters file to SD Card and copy it to USB by using PC. Then, load

parameter file from USB to DigiPackⅢ. (Refer to 2-4-4. for save/load description) NOTE: New parameter like PURGE/TOOLING is not include.

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1-3. DigiPackⅢ SPECIFICATION

Model Number:

J141-215 DigiPackⅢ.

Function:

Max 200 points Single head blow molding Parison programmer

Application:

Accumulator Based or Continuous Extrusion Blow Molding Machines can be selected.

Profile Points:

10 to 200，Custom points. And Straight or Spline interpolation can be selected.

Tooling Type:

Divergent or convergent die gap tooling types can be selected.

Tooling Position Control:

Digital closed loop servo system with a 1m sec update time.

Tooling Position Monitor:

From Tooling Position Actuator’s DCDT  10 VDC.

Accumulator Position Monitor:

From Accumulator Potentiometer 0 to 10 VDC FS.

Programming Inputs:

By Rotaly knob and touch panel switches.

Display:

Color Display (LCD). 10.1 inch(WXGA) touch screen. English/Japanese/Chinese language selected by Parameter at Setup

screen.

Memory:

100 program profile patterns can be stored in a Flash RAM. And can be stored in USB memory.

※ Supports standard USB memory, up to 32G. (Refer to 1-1. ) ※ Data format: FAT32

Point Marker:

A marker output signal can be set maximum 10 program point.

Other Functions:

Shot Size, Delay, Cushion (for accumulator machines only), die gap, data saving, profile curve adjustment (Weight and Range H/L), adjustment of the tooling actuator stroke and the accumulator position transducer, backup for the system timer(by capacitor).

Output to Servovalve:

MFB type: ± 10, 20, 50, 100 mA or EFB type: ± 10 VDC

Servovalve Monitor:

± 100% Spool Stroke equals 4-20mA

I/O for Accumulator:

0 to 10 VDC transducer output and 10 V DC transducer excitation.

I/O for Tooling Position:

± 10 VDC DCDT output and ± 10 V DC DCDT excitation.

Common External Input:

Photo Coupler Isolated Customer Supplied 15 to 24 Vdc @ 10 mA /Channel

24 VDC External Outputs:

Photo MOS Relay Customer Supplied 15 to 24 Vdc @ 100mA /Channel Max. Accumulator type: End of Extrusion/Filling Relay Contacts: 250Vac @ 1 A/channel MAX.

Communication:

Data transfer with host computer by RS422 and Ethernet

Power Requirements:

24 VDC 0.5A min (MAX 3.0A depend on Servovalve Power required) No ripple requirement : Max +-10 %

Temperature/Humidity:

0 to 45ºC within 85% relative humidity

IP rating

Front side = IP20, Rear side = IP30

Dimensions:

288 (W) x 240 (H) x 55 (D) mm (not include terminal)

Weight:

3.6 kg

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1-4. CHECK LIST

*The instructions in this section are general installation procedures.

1-4-1. INSTALLATION CHECK LIST

Order parts for installation Identify component mounting locations and procure the necessary mounting brackets Install the DigiPackⅢ unit in the blow molding machine or optional enclosure Mount tooling servoactuator to machine or Mount servovalve manifold and or Mount DCDT to tooling actuator Mount servo actuator pressure filter Install hydraulic power supply Install main system filter Make hydraulic pressure and return connections and flush the hydraulic system, Mount accumulator position transducer, if required Install conduit and pull cables for the tooling servoactuator, transducers, filter differential pressure switch

and interface between the DigiPackⅢ control panel and the machine PLC Check the wiring Calibrate transducers Set up the control loop Connect the actuator to the die gap tooling and adjust the die gap end points.

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Figure 1-5 Die Gap Tooling Actuator Installa-

tion

Figure 1-6 Die Gap Tooling Actuator

Filter

Servovalve

DCDT

Tooling Actuator

1-5. MECHANICAL INSTALLATION

*The instructions in this section are general installation procedures.

1-5-1. GENERAL

Mounting provisions for the tooling servoactuator should include a stable mounting platform for the tooling actuator, a filter location which allows the filter element to be readily replaced and mechanical provisions allowing simple adjustment of the mechanical relationship between the actuator and the die gap. Figure 1-5 shows such as a well planned installation.

A tooling servoactuator provides a long lived solution to the problems caused by high temperatures and force levels. Low friction seals and strong bearings insure long term and good tooling die gap positioning performance. A built in position transducer provides mechanical isolation from shocks and climbing feet. A directly manifold servovalve is tightly coupled to the actuator. Figure 1-6 illustrates a packaged tooling actuator with provisions for pre-blow air.

Figure 1-5 shows a typical tooling actuator installation. A servovalve (upper right) is directly mounted on a manifold, which in turn is attached to a tooling actuator. Directly below is a DCDT position transducer measuring the actuator rod and die gap tooling motion. In addition, a high pressure filter mounted directly on the manifold provides clean oil to the servovalve. Tooling adjustment provisions are also shown.

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Figure 1-8 Tooling Adjustment Mechanism

Die Gap

Adjust-

ment

Lock

Figure 1-7 Actuator – Die Gap Tooling Mechanical Adjustment

1-5-2. TOOLING ADJUSTMENT

When a mold change is made, it is often necessary to change the die gap tooling assembly. Therefore the actuator installation must provide for simple adjustment of the die gap tooling position relative to the actuator position. Figure 1-7 shows two possible methods of adjusting the positional relationship between the tooling actuator and the die gap tooling’s closed position. Tooling motion stops may be required to limit the forces on the die gap tooling when the die and mandrel touch. Figure 1-8 is a typical installation.

Some actuators with an anti-rotation feature require the nut torque loads on the anti-rotation device to be limited by absorbing the tightening torque with a wrench on the actuator rod flats

Tooling stops are required to insure a die gap that cannot close on a continuous molding machine. An inadvertent closure of the die gap could cause very high pressures in the extruder barrel and extrusion head and result in their damage and/or failure.

The above comments must be considered for the proper installation of either a Moog supplied die gap tooling actuator or a customer supplied actuator.

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Core control Actuator (example: J085-139)

Servo Valve(G631-3004B)

DCDT Sensor

The actuator rod extends when the currents of the servo valve pins A, C are positive with respect to the currents of the pins B, D

Pin A

Pin B Pin C Pin D Pin E

+10V

-10V

+OUT

-OUT N/A

Pin C becomes positive with respect to pin D when retracting the actuator

Connector compatible with MS3106-14S-5S

Servovalve

DCDT Toolong Position Transducer

Tooling Acutuator

The extruder barrel and/or screw can be severely damaged if the die gap closes when the extruder is running. A mechanical motion stop must be installed which will not allow the die gap to close.

1-5-3. MOOG DIE GAP TOOLING ACTUATORS

The Die Gap Tooling Actuator is designed specifically to control the die gap motion in blow molding extrusion heads. Their design specification includes: Low friction, Long life piston and rod seals. Graphite flake cast iron rod bearings to absorb potential side loads and high temperatures. Provision for blow air through the piston rod, and pre adjusted position feedback transducer.

The mounting provisions for a die gap tooling actuator must include: a strong mounting structure, provisions for axial and parallel alignment of the tooling actuation rod (mandrel) with the die gap actuators rod,

provisions to allow the actuator stroke center and the tooling’s effective stroke center to coincide, tooling

motion stops to protect the tooling and/or extruder. Figure 1-6 illustrates a packaged tooling actuator.

1-5-4. CYLINDER INSTALLATION

Figure 1-9 shows an installation example of Moog's die gap core control actuator.

Figure 1-9 Typical Cylinder Installation

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Figure 1-10 G631-XXX Servo-

1-5-5. CUSTOMER SUPPLIED CYLINDER REQUIREMENTS

The customer supplied cylinder is required to control the die gap motion in blow molding extrusion heads. As such their purchase specification must include: Low friction, long life piston and rod seals; Robust rod bearings capable of absorbing large potential side loads and high temperatures. A quality cylinder must be purchased to meet these requirements.

The mounting provisions for the tooling actuator shall include: a strong mounting structure, provisions for axial and parallel alignment of the tooling actuation rod (mandrel) with the die gap actuators rod, provisions

to allow the actuator stroke center and the tooling’s effective stroke center to coincide, tooling motion stops

to protect the tooling and/or extruder.

Some actuators with an anti-rotation feature require the nut torque loads on the anti-rotation device to be limited by absorbing the tightening torque with a wrench on the actuator rod flats.

1.5.5.1. MANIFOLD

The manifold must be mounted using as close as possible to the cylinder. Ideal methods are to mount the manifold directly on the cylinder, sealing the ports with “O” rings or to use tubing between the cylinder and manifold.

The pressure and return connections should be straight thread fittings using an “O” ring as a seal. Tapered

thread fittings are not encouraged as they tend to leak and when they are torqued up to stop the leak, the servovalve mounting surface is distorted, causing leakage at the servovalve-manifold seal. Straight thread fittings using “O” rings do not leak or cause mounting surface distortion.

Should tapered thread fittings be used, ONLY Teflon tape can be used on the tapered threads as a sealant. The Teflon tape must not cover the last two threads at the smaller diameter portion of the thread. Any other material will cause eventual contamination problems.

Figure 1-7 shows two possible methods of adjusting the positional relationship between the tooling actuator and the tooling die gap closed position. Tooling motion stops may be required to limit the forces on the die gap tooling when the die and mandrel touch. “Figure 1-9” is a typical installation.

Tooling motion stops may also be required to insure a die gap opening on a continuous molding machine. An inadvertent closure of the die gap could cause very high pressures in the extruder barrel and extrusion head and result in their damage and/or failure. The above comments must be considered for the proper installation of either a Moog supplied die gap tooling actuator or a customer supplied actuator.

1.5.5.2. SERVOVALE MOUNTING

The servovalve is mounted to a manifold with four mounting

screws and using four “O” rings to seal the Pressure, Return

(Tank), and the two Cylinder hydraulic connections. The “O” ring seal between the servovalve and manifold depends

upon the servovalve mounting manifold surface flatness to insure that there are no oil leaks. This surface must be flat within

0.025mm and have a √32 RMS finish. Two servovalves mounting patterns are available: a Cetop 5, NG

10 or a Ø22,2mm, Moog 76 port circle.

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LWH

300

500

750

900

Electrical Data

Rated Stroke

300

500

750

900

Nominal Resistance

Kohm

5 5 10

Independent Linearity

0.07

0.05

Mechanical Data

Mechanical Stroke

312

515

769

922

Body Length

375

579

833

985

Mounting Feet Spacing

280.5

484.5

738.5

890.5

1-5-6. TOOLING ADJUSTMENT

The extruder barrel and/or screw can be severely damaged if the tooling die gap closes when the extruder is running. A mechanical motion stop must be installed which will not allow the die gap to close.

1-5-7. ACCUMULATOR POSITION MEASUREMENT

If the DigiPackⅢ is being installed on a continuous extrusion machine please go to the next section. Accumulator type blow molding machines require a position transducer to indicate the accumulator posi-

tion. The parison wall thickness pattern can then be programmed with direct reference to the accumulator stroke of Shot Size.

1.5.7.1. INSTALLATION REQUIREMENTS

The position transducer is required to operate in a high temperature and vibration environment. In addition the transducer must accommodate some mechanical miss-alignment without reduction of life and linearity.

The part of position sensor allows adjustment for interlocking the movable part of the potentiometer with the moving of the accumulator. and also has the following functions:

1) An accumulator driven bearing guided structure for the potentiometer drive arm

2) Mounting provisions for the potentiometer on the same bearing guided structure, provisions for adjustment to insure parallel motion of the potentiometer guide arm and potentiometer drive rod

3) And a rod end bearing between the potentiometer drive rod and the potentiometer guide arm

Figure 1-11 Typical Linear Potentiometer Figure 1-12 LWHxxx Potentiometer Installation

Installation Information

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1-5-8. THE IMPORTANCE OF FILTRATION

Figure 1-13 High Pressure Fil-

ter

Adequate contamination control in any hydraulic system is the key to a highly reliable system. Proper filter placement and selection insures long term trouble free operation of every hydraulic system component. There are three essentials:

1) a high pressure filter mounted directly at the tooling actuator

2) a re-circulating circuit providing continuous filtration and heat removal

3) proper control of the tank breathing and filling operations to prevent the ingression of contaminant

High pressure filter (β15»75, 15µ absolute) mounted directly with tubing at the tooling actuator provides protection against particles created by component failures.

The main contamination protection is provided by oil taken from one corner of the tank, flowing through the low pressure re-circulating filter back to the opposite corner of the tank. The re-circulation filter is a low pressure filter (β3»75, 3µ absolute) with an inexpensive replacement filter element. The re-circulation also incorporates a heat exchanger to maintain low oil temperature and insure adequate oil life.

Protection against ingression of contaminant during oil make up and normal breathing is provided with breather rated at 10µ.

Currently, MOOG does not sell filters. Please purchase directly from the filter manufacturer.

1-5-9. FILTER INSTALLATION

High pressure filter or equivalent, β15>75 rated, high pressure filter must be mounted as close as possible (50mm to 300mm) to the actuator or servovalve manifold. The location of the filter must allow an easy access to make a replacement of filter element easy and safety.

Filter Installation Information

The hydraulic connection between the filter and actuator must be tubing. Under no circumstances can hydraulic hose be used as the hose is a contaminant generator and this contaminant will go directly into the servovalve, eventually causing contamination problems.

The hydraulic connections used will be a straight thread “O” ring sealed boss into the servoactuator and high pressure filter with either flared or compression fittings used to connect the tubing to the straight thread fittings.

The use of tapered thread fittings with pipe dope will cause both contamination and leakage problems. Teflon tape may be used, but only if applied in such a manner as to keep the edge of the Teflon tape at least two threads away from the end of the fitting.

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1-5-10. HYDRAULIC POWER SUPPLY

Figure 1-14 Hydraulic Power Supply

The Hydraulic Power Supply provides clean oil to the die gap tooling actuator at a constant supply pressure. An accumulator provides the peak flows that may be required. A water heat exchanger ensures reasonable oil temperatures.

The Hydraulic Power Supply is normally used on first installations when the cleanliness condition of the blow molding machine’s hydraulic power supply is unknown or suspect.

A separate hydraulic power supply provides a reliable source of clean oil for trouble free long term operation. A bypass filter allows the oil to be continually cleaned and cooled.

The hydraulic power supply pressure output should be connected directly to the input port of the high pressure filter at the die gap tooling actuator or the servovalve manifold. The actuator or manifold return line goes to the hydraulic power supply return port.

1-5-11. HYDRAULIC POWER SUPPLY START UP INSTRUCTIONS

1) Check for any damage to the hydraulic power supply and its parts.

2) Fill the tank through the breather filter with Shell/Tellus 68 or equivalent fluid.

3) Check the nitrogen gas pressure in the accumulator bladder. The pressure should be 35 bar or 66% of the maximum system pressure, whichever is higher. Add nitrogen, if necessary.

4) Replace the filter elements with flushing elements. Store the original filter elements in a clean, very clean plastic bag.

5) Connect the pressure and return lines to and from the tooling actuator assembly

6) Check the motor name plate for the correct line voltages and connect the motor to power. Start the motor and check that it rotates in the proper direction.

7) Connect cooling water to the heat exchanger. The required water flow rate is 30 1/min at 2-3 bar.

8) Run the hydraulic power supply for at least 6 hours. Vary the flow rate and pressure to thoroughly flush all chips and dirt into the filters. Monitor for leaks and repair.

9) Replace the flushing filter elements with the elements removed in step 4.

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1-5-12. CONTAMINATION CONTROL

Figure 1-15 Flow Pressure Filter

Long term trouble free operation with a minimum of unplanned down time and adequate oil contamination control are linked very closely. It is very important to maintain adequate oil cleanliness. The addition of a system contamination control filter will control oil contamination levels at minimum expense.

The filter should be located such that the flow through the filter is relatively constant and at a low pressure. The junction of the return lines from the tooling actuator and the system relief valve is a suitable location.

Currently, MOOG does not sell filters. Please purchase directly from the filter manufacturer.

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Lock lever Please lock securely

when fixing the connector.

TB-3：Power connector (Screw diameter 3.0 mm,

tightening torque 0.6 Nm)

Reference wiring diagram

Ethernet Plug

TB-1：Base connector

Connector removal status (Screw diameter 3.5 mm,

tightening torque 1.0 Nm)

Release

Lock

TB-2 ： Connector installation state

Desorption

1-6. ELECTRICAL INSTALLATION

1-6-1. GENERAL

Electrical installation includes several phases of work:

A) mounting the DigiPackⅢ in a suitable location B) determining the correct phasing so the servovalve, tooling position transducer and, possibly,

accumulator position transducer may be connected to the DigiPackⅢ

C) determining the blow molding machine interface interaction with the DigiPackⅡand then

wiring the machine-DigiPackⅢ interface

D) connect the DigiPackⅢ to electrical power supply from the stable 24VDC

DigiPackⅢ MOUNTING

The DigiPackⅢ must be mounted in a location free of vibration, with protection from the environment and most important, located in a position allowing the operator and setup man easy visual and physical access. It is recommended that the mounting be on a swing out panel allowing easy access to the front and back sides of the DigiPack3.

Mounting information is shown in “Figure 1-17”. Brackets providing simple panel mounting are included.

All wiring from the DigiPackⅢ must be shielded. The shield is to be grounded to the DigiPackⅢ ground at the DigiPackⅢ only Any other ground paths may cause damage.

1-6-2. REAR CONNECTOR

The rear connector of DigiPackⅢ can be detached. When installing the connector, secure with the lock lever. See Figure 1-16.

Figure 1-16 REAR CONNECTOR

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Pin No.

Signal

Connection

TD+

2 TD-

3 RD+

6 RD-

1-6-3. TB-1, TB-2 WIRING

The wire size for TB-1 and TB-2 are able to use AWG26 - 16(Recommended AWG 19-18, 0.75 mm2), and required using O type or Y type crimp terminal. (Screw diameter 3.5 mm, tightening torque 1.0 Nm).

TB-1 provides the interface between the DigiPackⅢ and the servovavle, die gap sensor, accumulator position sensor. TB-1 also provides outputs to optional customer monitors MFB Valve current, EFB spool monitor, DCDT input voltage, Accumulator voltage, Position command, these signals can be select at setting display (See 2-4-8. ). A schematic of TB- 1 is shown as “Figure 1-19” and TB-1 functions are outlined in the table, “Figure 1-20”.

Phasing definitions for the servovalve, die gap position and accumulator position (if used) transducers are given in “Figure 1-18”.

Some connections to TB-1 are shown in parenthesis, (), in “Figure 1-19”. The parenthesis, (), indicate alternate connection possibilities result from particular directions of motion or phasing determined during the design of the mechanical installation. Phasing requires that a defined direction of motion of the tooling actuator will result from TB-1-1 being negative with respect to TB-1-2; that the output voltage of the die gap position transducer be positive or negative when the die gap is moving in a specific direction; and that the accumulator position transducer output voltage direction be defined when the accumulator is ejecting molten plastic into the die head. Terminal TB-2 is using the external power supply to isolate logic inputs, “Figure 1-21, Figure 1-22”, TB-2 functions are outlined in “Figure 1-23”.

1-6-4. COMMUNICATION AND SSI SNSOR WIRING

The DigiPackⅢ can be communicate with host computer by Ethernet. The connector is using RJ45

socket type for Ethernet (connector name label “Ethernet”). Please refer to Figure 1-17 for connector location. And connector pin assign see below list.

Ethernet connector RJ45 socket “Ethernet”

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Figure 1-17 DigiPackⅢ Installation Drawing

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57986104

Figure 1-18 ServoValve and Transducer Phasing Figure 1-19 TB-1 Connections

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Name IN/OUT Function Comments

1 -MFB Signal PinA or D, B to C, MEB Servo valve (MFB) Mechanical Feedback

2 +MFB Signal PinA or D, B to C, MEB Servo valve Connection A to D or D to A allow phase reversal

3 F GND(Cable Shield) Cable Shield ground, MFB Servo valve Do not ground the shield at the servovalve

4 F GND(Cable Shield) Cable Shield ground, EFB Servo valve Do not ground the shield at the servovalve

5 24V DC OUT Pin A, EFB Servo valve (EFB )Electrical Feedback Valve Power. Max 1.5A available

6 GND OUT Pin E or D, EFB Servo valve The polarity is reversed depending on the connection of pin D / E

Connection example

7 P GND Pin B, EFB Servo valve

8 EFB Signal OUT Pin D or E, EFB Servo valve EFB Signal : ±10V OUT

　MFB Servo valve

9 Valve Spool(-) Pin C, EFB Servo valve 1 A

10 Valve Spool(+) Pin F, EFB Servo valve 2 D

3 Shield

11 Monitor 1 Monitor Out 1 ±10 V DC OUT. Signal selectable

12 Monitor 2 Monitor Out 2 ±10 V DC OUT. Signal selectable

　EFB Servo valve

13 GND Monitor Ground Ground for Monitor 1 and 2 5 A

14 NOT USE 7 B

15 NOT USE 9 C

16 NOT USE 8 D

17 NOT USE 6 E

10 F

18 GND 4 Shield

19 DCDT IN (+) IN Pin C or D : DCDT Feedback signal (+) (DCDT) Parison core position feed back sensor

20 +10V DC OUT Pin A : DCDT Power voltage (+10V) The level of the feedback signal changes depending on the type of DCDT (maximum: ± 10 V)

　Core Position (DCDT)

21 DCDT IN (-) IN Pin D or C : DCDT Feedback signal (-) The polarity is reversed depending on the connection of pin C / D 20 A

22 -10V DC OUT Pin B : DCDT Power voltage (-10V) 22 B

23 F GND(Cable Shield) Cable Shield ground, DCDT Do not ground the shield at the Actuator or DCDT 19 C

21 D

24 ACC IN IN Pin 2, Potentiometer (ACC Pot) Accumulator position feed back sensor 23 Shield

25 ACC VLT OUT Pin 1 or 3, Potentiometer Available accumulator type: Internal resistance 1 kΩ or more

26 GND Pin 3 or 1, Potentiometer

　ACC Position (POT)

27 F GND(Cable Shield) Cable Shield ground, Accumulator Do not ground the shield at the Accumulator 25 1

24 2

28 Monitor 3 Monitor Out 3 ±10 V DC OUT. Signal selectable 26 3

29 Monitor 4 Monitor Out 4 ±10 V DC OUT. Signal selectable 27 Shield

30 GND Monitor Ground Ground for Monitor 3 and 4

31～40 NOT USE

OUT

TB-1: Analog I/O Terminals (Moog Production and Transducers)

Term No.

OUT 　±10, 20, 50, 100 mA

IN Spool Signal : 4-20mA

Figure 1-20 TB-1 Functions

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Figure 1-21 TB-2 Connection

with Internal Logic Supply

Figure 1-22 TB-2 Connection

with External Logic Supply

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※ Minimum acceptance time of digital input is 50msec or more

Name IN/OUT Function Comments (Refer Fig1-20, 1-21)

1 IN1 START IN Command for Cycle Start Enable machine cycle start.

2 IN2 DIE GAP IN Command to keep the tooling die gap It is valid at any time by continuous mode. Cycle is stops

at the set Die Gap value until IN1 START Accepted only at injection completion state (END EXT) at ACC mode

3 IN3 REBOOT IN Reboot switch for controller. Not accepted during machine cycle

4 IN4 STOP IN Command for Stop operation Cycle stop, hold at current position

5～8 NOT USE

9 IN9 START SLOPE IN

A command to move the core from the current position to the position of the first point

Maintain position until start after moving completes.

The movement speed is set on the screen. Not accepted during machine cycle

10 IN10 EMERGENCY IN Servo OFF command. (E-Stop)

When it is High, the servo valve signal is stopped.

Because it is an emergency stop, accept at any time

ON = Emergency state

11 IN11 TEMP. OK IN Temperature rise completion confirmation.

When this signal is High, the servo valve signal is stopped.

ON = Temp not rised

12 NOT USE

13 INPUT COM.

14 INPUT COM.

15 NOT USE

16 24V DC

17 P GND

18 END FLG. OUT

ON at End of Filling.

Maintain until it falls below the position of End Filling

With this signal, the filling of the accumulation is stopped

19 END EXT. OUT ON at End of Extrusion. With this signal, the injection of the accumulation is stopped

In Continuous mode: ON until the next start.

※ In the case of Accum mode 1% hysteresis (injection & filling)

In Accumulator mode: ON while the accumulation position is smaller than

the injection completion position

20 MARKER OUT OUT Marker output signal. Output at the specified marker point Pulse width 200 msec

21 NOT USE

22 END ST SLOPE OUT At start slope input, ON at movement completion, maintain until IN1 start input

23 READY OUT Turn on when the start condition is set When this signal is ON, controller can receive the start signal.

※ This is not an interlock. Just inform to the host controller

24 ALARM OUT When both IN10 and IN11 are High and output (OFF=alarm state)

25 NOT USE

26 OUTPUT COM. Common for Digital Output Both Sink/Source support. For details see manual page 25

27 NOT USE

28 EOF Relay COM END OF FILLING Relay Common

29 EOF Relay B END Relay Contact B (NC)

30 EOF Relay A END Relay Contact A (NO)

31 NOT USED

32 EOE Relay COM END OF EXTRUSION Relay Common

33 EOE Relay B END Relay Contact B (NC)

34 EOE Relay A END Relay Contact A (NO)

35～40 NOT USE

Common for Digital Input (Isolation)

Pin 13-14 is internally connected.

Both Sink/Source support. For details see manual page 25

Digital signal power supply for both IN/OUT

Maximum current out : 3.0A

Relay Relay output、AC250V、Maximum 1A

TB-2: General I/O Terminals

Term No.

Figure 1-23 TB-2 Functions

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1-6-5. TB-2 I/O CIRCUITRY

Input _________________

Figure 1-24 Input use external Power supply Figure 1-25 Input use internal Power supply

All DigiPackⅢ I/O can be uses both POSITIVE/NEGATVIE LOGIC DigiPackⅢ can be used external and internal power supply. And provide isolated inputs.

The external power supply has an output 24VDC. The contacts used must have very low contact resistance over a long life time. Extreme care is required when wiring to insure that ground loops do not exist. Ground loops can cause

damage to the DigiPackⅢ and other electronic equipment. Ground loops can also cause erratic operation of the entire blow molding machine.

Output ___________________

Figure 1-26 Output use external Power supply Figure 1-27 Output use internal Power supply DigiPackⅢ’s output circuits use Photo MOS Relay to provide isolation from the external circuitry. The maximum voltage and current output to each load terminal (TB-2, 18, 19, 20, 22, 23 and 24) is 24VDC

and 100 mA MAX/each.

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Term No.

Name

Specification

DC24V

Power Supply 24V

24V DC Input 0.5A min – 3.0A max * Required install Fast blow Fuse. * No ripple required, Max +-10 %

P GND

Power Supply 0V

0V (for DC 24V)

F GND

Earth

1-6-6. TB-3: POWER SUPPLY

The wire size for TB-3 is able to use AWG17 – 16, 1.75 mm2, and required using O type or Y type crimp terminal. (Screw diameter 3.0 mm, tightening torque 0.6 Nm).

There is protection that does not break down with reverse wiring, but please be careful because input of high voltage will damage the circuit.

Figure 1-28 Power supply Connections

1-6-7. NOISE AND GROUND ISOLATION

In any location there is always the potential for electrical noise interference and multiple ground paths. Electrical noise can cause erratic system operation and is very difficult to find and isolate, ground loops also cause unexpected operation as well as burn out components. In addition, mains voltage stability can sometimes be questionable.

An isolation transformer between the mains and DigiPackⅢ can provide some relief from noise, ground loops and wandering mains.

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Figure 1-29 Accumulator Machine Timing chart

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Figure 1-30 Continuous Machine Timing chart

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1-7. CALIBRATION OF TOUCH SCREEN

Calibration of the touch screen has already been completed at the time of product shipment, so basically no user setting is necessary. Here is explain that the readjustment method when there is an error in the calibration of the touch screen by some reasons. (If there is an error in the calibration of the touch screen, the touch area corresponding to the display button will shift, so it will not react even if you touch the display button.)

If the readjustment becomes frequently necessary, it seems that some trouble has occurred on the touch screen. In that case we recommend that you submit it for repair.

Step 1: While DigiPackⅢ powered on, digital signal is continuously input for 3 seconds or longer to TB-

2-8 (this channel displayed as Do not use).

Step 2: DigiPackⅢ will be automatically restarted and the calibration screen as shown in Figure 1-31 will

be displayed. Touch the "Calibration" button. (At this time, since the calibration information is reset, "Calibration" button can be pressed)

Step 3: Since Figure 1-32 is displayed, touch all the "+" signs surrounded by the red frame square in the

corner. If you press the wrong place to push, the calibration will fail and the screen will stop responding. In that case, please turn on the power again, return to step 1 and try again.

Step 4: If the calibration is successful, display will return to Figure 1-31, Restart the controller and finish.

Figure 1-31 Touch screen Calibration

Figure 1-32 Touch screen calibration display

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1-8. DigiPackⅢ front panel

288.00 mm

LCD Touch screen 10.1 (WVGA)

青色画面時 (RGB: 183.221.232)

DigiPackⅢ

Parison Controller

MOOG

0% 25% 50% 75% 100%

100

File Name:1234567890123456

Point No.

Die gap

Delay

Auto cycle

5.0

1.5

sec

Data

Weight

Range H

Range L

* 79.0

0.0

Start

Die gap

Continuous

Accumulator

Divergent

Convergent

End of filling

Point out End of

extrusion

F1 : Profile

F2 : Marker

F3 : File

F4 : Monitor

F5 : Data

Cursor

DEL Shift

X10 Set

2018/1/23 13:35:45

Cycle time 10.0 100% = 25.40

sec

Rotaly Knob

Used to enter the value of various functions. Rotation in a clockwise

X10

Increases the sensitivity of the Rotaly Knob by a factor of 10

SET

Push to set value

DEL

Invalidates the set profile data and changes it to interpolation data.

Rotaly Knob

USB slot

Beep sound speaker

Edit area Switched by

F1 to F5

Other Switch

Power LED

State monitoring area

Figure 1-33 DigiPackⅢ Flont panel

OPERATIONS CONTROLS

The operator will setup and monitor the parison wall thickness program using the display switches and Rotaly knob on the DigiPackⅢ’s front panel, shown in “Figure 1-33”

Beep sound

A beep sounds when parameters and keys in the screen are selected. Also, if an error occurs at startup and normal startup can not be performed, A beep sounds ON/OFF is repeated continuously.

Power LED

It lights up with 24 VDC being supplied. Also, if an error occurs at startup and normal startup can not be performed, ON/OFF is repeated continuously.

All of the functions normally required to program the parison and machine are available on the front panel.

|INPUT FUNCTION SELECTION AND VALUE

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SHIFT

While pressing "SHIFT" is active, the screen called by the F1 to F5 switches becomes the setting screen. If you push this switch again or select one of F1 to F5 setting screen, "SHIFT" becomes inactive. *Refer to 1-2-6. for protection of setting screen transition

Cursor △▽

Used to scroll the items on the LCD in the direction indicated by the triangular shape

Start

Lights when the cycle Start signal is received.

Die Gap

Lights when the Die Gap signal is received and “DIE GAP” on the LCD is lit

Continuous

Lit when the “Continuous Extrusion” machine type is selected

Accumulator*

Lit when “Accumulator” machine type is selected

Divergent

Lit when “Divergent” die gap tooling is selected

Convergent

Lit when “Convergent” die gap tooling is selected

End of Filling

Lights at the end of the accumulator filling stroke

Point Out

Lights when each Marker point is reached

End of Extrusion*

Lights at the end of the accumulator extrusion stroke (Cushion)

F1 Profile

Controls the parison wall profile and other related functions. (When start up the controller, move to this screen first)

F2 Marker

Set the program point markers. And set the slope(Speed) that do to Die gap and start position. Internal clock time setting. PURGE/TOOLING core opening setting

F3 File

Controls the container wall thickness storage functions

F4 Monitor

Indicate the digital I/O, current value of servovalve input current and core position. Manual operation is also done on this screen.

F5 Data

Displays the profile point and related function data

SHIFT→F1

SET UP Mode - Provides die gap tooling and other machine related set up functions

SHIFT→F2

Signal assign to Monitor Analog output

SHIFT→F3

Delete and Backup/Restore the storage data.(Backup/Restore for data in USB memory)

SHIFT→F4

Machine setting setup

SHIFT→F5

Communication parameter setting of Ethernet.

Highlights are used to indicate the action function or its value to the operator. You can change the value of the highlighted parameter by turning the rotary knob or inputting from the numeric keypad. *The numeric keypad is displayed on the screen after touching the same parameter again or turning the rotary knob after specifying the parameter. For details, refer to section 23-2.

STATE MONITORING AREA

In the status monitoring area shown in Figure 1-33, it is used to indicate the status of the following functions.

SWITCH OF F1 TO F5

It is used to select the function screen displayed in the editing area shown in Figure 1-33. The contents of the function are as follows.

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1-9. TOOLING SYSTEM SETUP

1-9-1. GENERAL OF SETUP

The Mechanical and Electrical installation must be finished before the Dig Gap Tooling position control system can be set up. In addition the, hydraulic system must have been flushed for at least 24 hours.

The Die Gap Tooling position control system setup involves several steps:

1) The Machine setup in the DigiPackⅢ display (SHIFT→F4) must be set to match various options determined by the blow molding machine and tooling head type.

2) The correct tooling type selection, Convergent or Divergent, must be determined. This will be determined by which portion of the tooling moves, the die or mandrel, as well as its internal shape.

3) The DigiPackⅢ must know if the blow molding machine is a Accumulator or a Continuous molding machine.

4) The working Die Gap end positions, closed and maximum open, must be set.

5) The responsiveness of the Die Gap Tooling position control system is measured and optimized.

When finished with the Die Gap Tooling system setup, the blow molding machine will be ready to be programmed for production containers.

The hydraulic pressure must be lowered during the setup procedure or the die gap tooling may be damaged.

1-9-2. MACHINE SETTING

After confirming the mechanical and electrical connection completely, turn on the DigiPackⅢ. However, please do not apply hydraulic pressure yet here. The LCD of DigiPackⅢ gets brighter and [F1 Profile] is displayed via the startup screen. Next, press the

[SHIFT] → [F4] key in that order to reflect the machine settings such as language, servo valve type, con-

tinuous type machine or accumulator type machine.

1.9.2.1. MACHINE SETTINGS (SHIFT→F4)

At the DigiPackⅢ display “SHIFT -> F4” (“Figure 1-34”) is Setting for Machine setting. Set these parameters according to Machine type, these parameters should setting before start setting any parameter of tooling and accumulator. (Accumulator setting only accumulator machine)

The settings required now are:

1) Machine type - Either Continuous or Accumulator

2) Servovalve type - Either mechanical feedback, MFB, or electrical feedback, EFB

3) Valve current - If selected MFB type, this parameter can be selected current level

10, 20, 50 or 100 mA

Depending on the setting of MFB and EFB, the output terminal changes. (The output terminals of MFB/EFB are located in TB-1.) The Servovalve type that not set is fixed to "0" mA or "0" V, if no output signal and the actuator does not operate, Please review the machine setting.

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Function name

Setting

Profile points

10/20/30/50/100/200

Custom

Any value between 10-200

Profile interpolation

Straight

Spline

Language

English

Chinese

Japanese

Back light (min)

-- (no screen saver)

LCD

Contrast. Knob CCW : dark, Knob CW : bright

Memory

OFF

Password

OFF

Above 7 parameters are updated always

Machine Type

Continuous

Accumulator

Servovalve type

MFB

EFB

Valve current (mA)

100

-- (*Note)

Open command

Disable

Enable

The above 4 parameters are updated by pressing the switch in the order of [Reboot]->[SET], by being restarted

*Note) When [Servovalve type] is set to [EFB], it automatically becomes ± 10 V output.

Figure 1-34 Machine setup display (SHIFT→F4)

“Figure 1-35” defines all of the settings.

Figure 1-35 Machine setting Functions

It is necessary to execute Reboot whenever you change the setting. When moving to another screen without Reboot, the parameter returns to its original value. When you press [Reboot] →

[SET], DigiPackⅢ will be restarted. Do not apply hydraulic pressure when executing [Reboot].

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1.9.2.2. MACHINE SETTING (SHIFT → F4) FUNCTION

Profile points

It is possible to specify the number of set points in the profile display (F1) from [10/25/30/50/(*)100/200 / Custom]. When [Custom] is specified, it is possible to specify the number of profile points freely between 10 and 200 points.

Profile interpolation

Sets a interpolation (*)Straight or Spline on the profile display (F1)

Language

Language – ((*)English/ Chinese / Japanese) Sets the language used on the LCD Display

Back light (min)

Sets the timer of screen saver. 5, 10, (*)30 min or non screen saver.

LCD

Adjust the screen brightness. Knob CCW : dark, Knob CW : bright

Memory

Select actual feedback line indicated on profile display. (*)ON : Show, OFF : Not Show

Password

Sets to enable or disable of password protection at the migration of setting screen.

(*) ON: Enabled, OFF: Disable * When disabled, there is no protection for setting screen transition.

Machine Type

Machine type – Accumulator or (*)Continuous

Servovalve type

Servovalve type – EFB or (*)MFB

Valve current

Valve current of MFB type – 10, 20, 50 or (*)100 mA

Open command

Cursor move admission to Open command on Monitor display (F4) Enable or (*)Disable

Marked as (*) is initial setting with new DigiPackⅢ shipped.

When “Profile Points” is changed, if the value is not specified in the original profile at the final

point of the new profile (for example, 25th points of when specified 25 points) If it was interpolated value, the new 25th point in the profile is specified as the height "0". Also, when the number of profile points is increased (Example 100 to 200), the profile of the newly added part is specified as the height "0". See Figure 1-36

Figure 1-36 Example of profile points change

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1-9-3. SET UP PROCEDURE

To go to Set Up mode press “SHIFT” then press “F1”. The Set Up mode screen appears as shown in “Figure 1-37”.

Three words [DCDT], [Accumulator], and [Gain] are displayed on the left side of the screen. By selecting them, you can set DCDT, accumulator and gain value respectively. The highlighted word (in this case [DCDT]) indicates the setup screen that will transition when you press [SET]. However, [Accumulator] is displayed only when it is set to accumulator type mode at [Machine] setting ([SHIFT]→[F4]).

Note that the [DCDT], [Accumulator], and [Gain] screens have a button as "Back" under the setup parameters of the screen. If [Back] is highlighted and you press [SET] or directly touch [Back] on the screen, the display returns to the setup screen (Figure 1-37).

1.9.3.1. DCDT SETUP

To go to the [DCDT setupup] screen, press [SET] when [DCDT] is highlighted in Figure 1-37 or directly touch [DCDT] on the screen.

The screen shown in Figure 1-38 is displayed.

CONVERGE/DIVERGE SETTING

The selection between Converge and Diverge tooling designs implies that the selection between Converge and Diverge is a simple one. This is not necessarily true.

If the Converge or Diverge tooling uses a moving mandrel (inner part), then simply set Converge or Diverge as dictated by the tooling design.

However, if the Converge or Diverge tooling uses a moving die (outer part), then the other tooling type name must be used. For example, if the tooling design is Converge and the die is the moving part, the proper tooling selection for the DigiPackⅢ is Diverge. Example below.

Figure 1-37 Setup screen

Figure 1-38 Die Converge/Diverge Setup

Diverge Converge

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An alternate: if the tooling actuator moves in a downward

20 22

19 21

A B

C or D D or C

DCDT

RED

TB1

BLK

BLU

GRN

+10V

-10V

+INPUT

-INPUT

direction to make thicker parison walls, then select Diverge. If the tooling actuator moves in an upward direction to make thicker parison walls, select Converge as the tooling type selection.

CONVERGE/DIVERGE SELECT

At the [DCDT setup] screen with Converge highlighted. (Figure 1-38) Select DIVERGE or CONVERGE by rotating the ROTALY KNOB in a cw or ccw direction. When the selection is made, push Set.

Figure 1-39 Die Gap Setup

The currently set values and file values (Reference) for Figure 1-39 and Figure 1-38 are displayed. The value (Reference) of the file shows the setup value saved in DigiPackⅢ memory using [F3:File]. For machine protection, these data are not rewritten directly from the file as production data and are displayed as reference values (Reference).

CORE

In this screen, “Figure 1-39”, under the heading Zero/Span, Zero is highlighted. Zero is the Die Gap closed position. If the tooling installation includes a Tooling Motion Stop then it must be temporarily positioned so the stop does not interfere with the tooling motion.

Note that the Valve current (or spool monitor) indicator may show a Valve current (spool position) indication that is continuously and rapidly moving back and forth over a band of as much as 25% of the indicated range. If there is a continuously moving indication of more than 5% then the Die Gap transducer connection to TB-1 should be changed to conform to the schematic show in “Figure 1-40”.

Rotate the ROTALY knob to make the tooling move in the Die Gap closed direction (CCW). When the ROTALY Knob is turned, the Valve current indicator will move slightly and then return to zero or nearly zero when the ROTALY KNOB is stopped. The DCDT voltage indicator will indicate the changed Die Gap position.

Figure 1-40 DCDT Noise Filter

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ZERO

Continue to move the Die Gap towards its closed position (Rotaly knob CCW) while watching the Valve current indicator. At some point the Valve current indication will not return to zero, but will increase with further rotation of the ROTALY knob, while the Die Gap does not change position. Increasing Valve current without Die Gap motion indicates that the Die Gap has closed (or has run into a motion stop).

Then slowly rotate the ROTALY knob in the reverse (CW) direction while watching the Valve current indicator until the Valve current reaches Zero or the Die Gap indicator moves slightly.

Now turn the ROTALY knob in the original direction until the motion just stops and the Valve current indicator shows slightly increasing current. The Die Gap has just reached its closed position.

Push SET. The value of the current DCDT voltage is reflected as the position of [Zero] (0% position), and the highlight moves to [Span]. (Figure 1-41)

Figure 1-41 Die Gap Span Setting

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SPAN

When zero setting is completed, the highlight will indicate [Span] (Figure 1-41). [Span] is the maximum value of the die gap opening (100% on the profile). The die gap core designer checks the [DCDT voltage] indicator and turns the rotary knob clockwise (CW) to the value of the opening to be specified and set it. At this time, when the servo valve current starts to move greatly, it means that it has reached mechanical stop position. In that case, rotate the rotary knob in the opposite direction again and look for where the servo valve current returns to near the center.

When the required die gap maximum opening has been reached, press [SET] and finish setting the span. The highlight moves to [Unit].

If you do not do zero and span on the DCDT setting screen, do not move the cursor by touching the [SET] key. If [SET] is pressed while [Zero], [Span] is highlighted, the current DCDT position will be reflected to zero and span. To move highlighted parameter, please use the up / down (△▽) key or directly touch the desired parameter.

Unit and Stroke

When [Span] is highlighted, touch [SET] or the cursor down key, the cursor will move to [Unit] (% or mm). “%” Is set to 100% as the distance indicated in [Stroke] and displayed on the profile screen as reference. “mm”, set the profile directly in mm based on Span setting. Select the desired unit with the rotaly knob and press [SET]. The value of [Stroke] sets 0 to 100% stroke length of DCDT. Measure 0-100% movement amount with a ruler and input it. The value set here, 100% = Stroke (mm) is displayed on the profile screen as a reference for the die gap opening.

After completing the setting, move the cursor to [Back] as shown in Figure 1-42 and press [SET] or directly touch [Back] on the screen to move up one screen.

Figure 1-42 Back

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1.9.3.2. GAIN SETUP

Use Up / Down cursor to move to [Gain] (Figure 1-43) and press [SET] or touch [Gain] on the screen directly, the screen will shift to Figure 1-44 screen. In [Gain], adjust the speed and stability of die gap core control actuator. At this point, it is necessary to increase the hydraulic pressure to the correct value.

At Figure 1-44 use the up and down cursor on the screen to move to [Move] or touch [Move] on screen directly to select. Turn the rotaly knob left or right and observe the DCDT voltage indicator. If it is normal, the indicator will move right and left smoothly according to the movement of the rotaly knob. If the movement is awkward (poor tracking), return to the setting of the gain, increase [Gain] by about 25% and check the operation again by [Move]. If noise behavior is seen, move to [Gain], reduce it by about 25%, and confirm the operation with [Move] again. Repeat this until the response becomes good, move the cursor to [Back], press [SET] or directly touch [Back] on the screen to move to the previous screen.

Figure 1-43 Gain select

* The [Gain] parameter reflects the value in real time according to the rotation of the rotary knob. Therefore, the numeric keypad is not displayed. Also, [SET] for confirmation is unnecessary.

* When an oscilloscope is available, monitor the movement of the core with [MOVE] while monitoring between 19 of TB-1 and 21 of TB-1.

This completes the setup of the continuous blow molding machine.

A NOTE REGARDING CORE STROKE AND ZERO

The value displayed in [Reference] is the value saved on the F3 screen. Because the reference numerical value directly affects the specification of the machine, it does not reflect as it is at the time of file loading (there is a possibility that the machine may break down). These numbers are displayed as Reference in order to see how they were set in the loaded configuration file. This will be displayed to allow customers to switch products quickly while minimizing the switching time from the end of production to the start of the next new production

Figure 1-44 Gain setting

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1.9.3.3. ACCUMULATOR MACHINE SETUP

The setup of the accumulator type blow machine is almost same as the setup procedure of the continuous blow machine. The difference is where there is a calibration of the accumulator position detector.

To shift to accumulator setup screen Move to [Accumulator] with up/down key and press [SET] or directly touch [Accumulator] on the screen. The setup screen as shown in Figure 1-46 is displayed.

* When selected continuous type machine, this parameter is not displayed.

When starting accumulator setup, it is necessary to complete setting of DCDT zero/span position, gain, and so on.

When shifting to Figure 1-46, some of the function switches on the right side of the screen will change as follows. (Red frame part)

 DEL → PURGE  SHIFT → TOOLING

This is a function to smoothly set up the accumulator. Please check the setting of EMPTY/SPAN for details.

Figure 1-45 Accumulator Setup

Empty

Push the “PURGE” switch located at the lower right of the screen (Figure 1-46) to set the core to the open state (purge position) so that the resin can be easily discharged. The core opening position by PURGE is set on the F2 marker screen. (*When the core reaches the purge position, the PURGE key will return from yellow to white.If you press the PURGE key again while moving to the purge position, the PURGE key will return to white and the core will stop) Next, move the accumulator to the empty position using the host controller. When Empty is highlighted, press the [SET] key when the accumulator is in the extrusion position (empty position). The empty position is saved, and the [End of Extrusion] of the status monitoring area lights up. The highlight moves to Full (Figure 1-47).

Figure 1-46 EMPTY Accumulator Set Up

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Full

Next, press “TOOLONG” located at the lower right of the screen to set the core to the closed state (Tooling position). Set the core position by TOOLING on the F2 screen. (*When the core reaches the tooling position, the TOOLING key will return from yellow to white.If you press the TOOLING key again while moving to the tooling position, the TOOLING key will return to white and the core stops) Fill the accumulator using the host controller. Move the accumulator to the fully filled position (the state where the molten plastic is stored in the maximum amount). This is the [Full] position. While Full is highlighted, press the [SET] key when the accumulator is in the full fill position. The filling position is saved and [End of Filling] in the status monitoring area lights up. Highlight moves to [Filling Type].

Figure 1-47 FULL Accumulator Set Up

The Empty and Full value cannot set same value, it is automatically set 0.2V space, if set same value e.g, Empty=5V and Full=5V, then automatically Empty set 4.8V.

And these two values can set only 0 to 10V. If set both 0V, value of “Full” change to 0.2V. And, if set both 10V, value of “Empty” change to 9.8V automatically.

Filling type

Next, decide Filling Type. Filling Type is the relationship between "Empty" and "Full" positions when the vertical axis (Profile Points number) on the profile data is set to "shot size" (refer to 2-4-2. F1: Profile mode) .

Extrusion

Plastic extrusion to the container mold starts at the filled Accumulator position determined by the sum of Cushion, Shot size and Delay when Filling type - Extrusion is selected. End of extrusion is the Cushion position. “Fig- ure 1-48” End of filling position is the Shot size stroke plus Delay stroke plus the Cushion strok

Figure 1-48 Extrusion Fixed

Filling

Plastic extrusion to the container mold starts at the Accumulator filled position (End of Filling) when FILLING FIXED is selected. The length of stroke is determined by the sum of SHOT SIZE plus DELAY. (Figure 1-49)

Select either EXTRUSION FIXED or FILLING FIXED and press SET

Figure 1-49 Filling Fixed

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Unit

Two UNITs are available, % or MM. The Unit selected will be applied to the following parameters: on the F1 screen:

 SHOT SIZE  DIE GAP  DELAY  CUSHION

Select either % or MM and press SET

Full Stroke

Use the Rotaly Knob or Ten Key to indicate the length of accumulator Linearpot.

Full Stroke is set as Linearpot full stroke length. (ex, 010V=500 mm, Full stroke set to 500.0). The Stroke will automatically calculate from Empty/Full setting. Which mean 100%=Stroke(mm) showing Accumulator position reference on display.

Move the cursor to [Back] and press [SET] or directly touch [Back] on the screen to go to the setup screen.

The Accumulator blow molding machine set up process is now complete.

Figure 1-50 Accumulator setting (Back)

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2. DigiPackⅢ Manual, User operation

288.00 mm

LCD Touch screen 10.1 (WVGA)

青色画面時 (RGB: 183.221.232)

DigiPackⅢ

Parison Controller

MOOG

0% 25% 50% 75% 100%

100

File Name:1234567890123456

Point No.

Die gap

Delay

Auto cycle

5.0

1.5

sec

Data

Weight

Range H

Range L

* 79.0

0.0

Start

Die gap

Continuous

Accumulator

Divergent

Convergent

End of filling

Point out End of

extrusion

F1 : Profile

F2 : Marker

F3 : File

F4 : Monitor

F5 : Data

Cursor

DEL Shift

X10 Set

2018/1/23 13:35:45

Cycle time 10.0 100% = 25.40

sec

2-1. INTRODUCTION

How do you program the DigiPackⅢ Parison Programmer? Its job is to allow you to easily program a plastic container that will meet your customer specifications for weight and strength.

This manual will provide information about the DigiPackⅢ’s container wall thickness program setup procedure, its controls and information provided available on the front panel.

After a short learning period, you will be able to readily setup your blow molding machine to mold containers to their required specification.

Figure 2-1 DigiPackⅢ appearance

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Un-programmed

parison

2-2. PARISON CONTROL

2-2-1. HISTORY

Many different products are produced by the Blow Molding process. Any food, drug or toy store is filled with items using blow molded products. Many automobiles use blow molded windshield cleaning fluid. From a small beginning many years ago, the blow molding process has grown to a major industry.

The value of parison wall thickness control was recognized when the industry was young. Some of the early machines used two position hydraulic control of the die-mandrel gap. Others used heavy cams in strong structures to withstand the large forces involved. The first electro-hydraulic blow molding system replaced the heavy cams with light cams that were easy to modify. This was quickly followed by a readily adjustable electronic master cam used to determine the correct cam shape. Electronic interpolation then eliminated the cam. Today’s parison programming systems provide reliable programming of parison wall thickness and in addition, may provide control of mold motion; screw speed; injection barrel heater temperatures, etc. or the capability to control all machine functions.

2-2-2. PARISON PROGRAMMING BENEFITS

Parison programming provides improved container quality, higher production rates and increased profits. Control of parison wall thickness as a function of parison length results in constant container wall thickness

after the parison is blown to conform to the mold. Quality tests determine the ability of a container to withstand drop tests without bursting or leakage of its

contents. Parison programming provides constant wall thickness throughout the container, insuring improved mechanical endurance at minimum weight.

Container wall thickness control reduces the container weight, eliminates the hot spots, resulting in de-

creased parison cooling time. The parison programmed blow molding machine’s shorter cycle time results

in increased production rates, combining with the decrease in material cost to ensure higher profits.

2-2-3. CONTINUOUS EXTRUSION MACHINES

A continuously rotating extruder screw pressurizes the granular plastic material, driving it through a heated tubular barrel. The resulting molten plastic is then extruded through the mandrel die gap, forming a continuous tubular parison.

As the parison never stops being formed, multiple molds are required to receive the parison in turn. One mold is in the cooling position, where the plastic cools until the container can stand alone when the mold is opened. The open mold has been moved to a position surrounding the parison, and when the parison is long enough, the mold is closed. The parison is then pressurized with air through the blow pin, causing it to expand and take the shape of the mold walls, after which the mold is moved to its cooling position. The other mold is now open and is moved to the position where it surrounds the parison and the cycle repeats.

The machine and parison program cycle is started by the knife cutting the parison. Program start Delay time may be used to properly position the programmed parison profile relative to the mold profile to insure constant wall thickness.

2-2-4. ACCUMULATOR MACHINES

Accumulator blow molding machines are normally used to make large containers. Plastic is extruded into an accumulator until the amount required (Shot Size) to make the container is available. When the mold is positioned to receive the parison the accumulator piston moves, extruding the plastic through the programmable die gap to form the parison.

A position transducer measures the accumulator piston motion and causes the parison profile to be controlled as a function of the volume of plastic extruded through the die gap. During filling, the transducer also causes the accumulator to stop filling when Shot Size is achieved.

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2-2-5. PARISON PROGRAMMING BENEFITS

Container Wall Profile

Programmed

parison

If the die mandrel gap is constant, the extruded parison wall thickness is constant. When the parison is expanded by air pressure, it is stretched and made thinner. The resulting container walls contain thick and thin portions depending upon the amount of parison stretching occurring during the inflation of the container.(Figure 2-2)

When this container is filled with a test fluid and dropped, it is likely to split in the heavy wall areas upon impact, due to reduced material strength resulting from uneven cooling stress. The entire container must be made thicker or more uniform to provide even cooling and improved strength.

Figure 2-2 Section of an Unprogrammed Parison and the Resulting Container Walls

As a result the container walls will be heavier throughout the container, require a long cooling time, material cost will increase and container production rates will decrease.

If the parison container thickness can be programmed as it is extruded by varying the die mandrel gap width, the resulting container will have constant thickness walls.(Figure 2-3)

Figure 2-3 Section of a Programmed Parison and the Resulting Container Walls

This container will pass the drop test with less material as there are no heavy spots. On average, the wall thickness will be less requiring shorter time to cool the container. The container will have constant thickness walls. Programmed parison wall thickness control therefore results in higher container production rates using

less material per container and higher profits.

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2-2-6. WITH ACCUMULATOR BLOW MOLDING MACHINES

When used with accumulator machines, the DigiPackⅢ controls the parison wall thickness relative to the accumulator position as the plastic is being extruded. In this case the displays (LCD) vertical axis is accumulator position and the horizontal axis is die gap opening.

The total quantity or volume of plastic extruded is proportional to the accumulator position, then the resulting parison wall thickness at any given point on the length f the container is related to the accumulator position when that point on the parison was extruded through the die gap.

A potentiometer measures the accumulator position and controls the vertical axis of the program display. The desired shape of the parison wall profile is commanded digitally by the operator using the display. The

size of the tooling opening or die gap, as measured by a die gap position transducer, is compared with the operators commanded die gap opening as set on the DigiPackⅢ display.

The error between the operators commanded die gap opening and the actual position causes the servovalve to control the oil flow to the actuator and reduce the difference between the commanded and the actual die gap opening (position error) to a very small value. This feedback process ensures that the actual die gap opening follows the commanded die gap opening very accurately.

The operator can also set the accumulator working stroke, Shot Size, and the desired position at the end of the accumulator push out, Cushion, the DigiPackⅢ also provides interfacing signals for these functions with the machines PLC, which then controls the motions of the accumulator.

2-2-7. WITH CONTINUOUS BLOW MOLDING MACHINES

When used in a continuous blow molding machine, DigiPackⅢ controls parison wall thickness by relative value to the time required for one machine cycle. The vertical axis of the LCD display is time and the horizontal axis is the die gap opening amount. The cycle begins, for example, when the parison cutting knife cuts the parison (actually when the start signal is input). The end of the cycle can be determined by one of the following:

a) Fixed cycle time set by operator b) Automatic cycle time (cycle time is controlled by the blow molding machine) set by repeatedly meas-

uring the time between cuts by the parison cutting knife (the time until the next start is input)

c) Detect a fixed time cycle and activate machine functions such as closing the core (cycle time is con-

trolled by DigiPackⅢ)

The desired shape of the parison wall profile is commanded digitally by the operator using the display. The size of the tooling opening or die gap, as measured by a die gap position transducer, is compared with the

operators commanded position as set on the DigiPackⅢ display. The error between the operator commanded position and the actual position caused the servovalve to

control the oil flow to the actuator and reduce the difference between the commanded and actual die gap opening (position error) to a very small value. This feedback process ensures that the actual die gap opening follows the commanded die gap opening very accurately.

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Figure 2-4 Poor Vertical Alignment Between the

Parison and the Mold

Figure 2-5 Good Vertical Alignment Between the

Parison and the Mold.

2-2-8. PARISON MOLD ALIGNMENT

Alignment lines are reference lines that are displayed when cross-sectioning the positional relationship between the parison wall thickness and the product wall thickness generated after molding by blow molding.

On the alignment line shown above in Figure 2-5, the parison wall thickness is relatively thick and the core gap is large. Once the parison has been blown and molded, the wall thickness of the molded product measured on the alignment line will be nearly constant with respect to the wall thickness measured in other parts of the product.

However, if the vertical alignment relative to the mold of the parison is not accurate, the wall thickness will not be constant throughout the product and the product will have to be discarded. (Figure 2-4)

Figure 2-4 and Figure 2-5 show the parison wall thickness and the relative vertical position of the mold. When parison wall thickness is stretched by blow air pressure, the amount of drawing will change depending on the size of the inner circumference of the core. By programming the parison it is possible to produce a product with the desired constant wall thickness by aligning the thick part and the largest part of the mold inner part.

In the state shown in Figure 2-4, the parison position is higher against the position of the mold. The wall thickness profile of the parison is the same as in Figure 2-5, but there is no alignment line position for the mold. The product wall thickness on the top and bottom alignment lines is too large and the middle alignment line thickness is too small.

Lowering the position of the parison against the mold, improves the consistency of the wall thickness of the entire blow molded product and ultimately produces the correct result. However, if the parison wall thickness is further changed here, the wall thickness control will become defective again.

Please note that the horizontal alignment line is displayed as a tool showing the vertical alignment requirements of the parison and the mold. The actual movement accompanying plastic blow molding and drawing is more complicated.

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2-3. MAN MACHINE INTERFACE

288.00 mm

LCD Touch screen 10.1 (WVGA)

青色画面時 (RGB: 183.221.232)

DigiPackⅢ

Parison Controller

MOOG

0% 25% 50% 75% 100%

100

File Name:1234567890123456

Point No.

Die gap

Delay

Auto cycle

5.0

1.5

sec

Data

Weight

Range H

Range L

* 79.0

0.0

Start

Die gap

Continuous

Accumulator

Divergent

Convergent

End of filling

Point out End of

extrusion

F1 : Profile

F2 : Marker

F3 : File

F4 : Monitor

F5 : Data

Cursor

DEL Shift

X10 Set

2018/1/23 13:35:45

Cycle time 10.0 100% = 25.40

sec

Rotaly Knob

USB slot

Beep sound speaker

Edit area Switched by

F1 to F5

Other Switches

Power LED

State monitoring area

Function Switches

Figure 2-6 DigiPackⅢ Front panel

2-3-1. OPERATOR CONTROL

The operator sets and monitors the parison thickness program using the display (editing area, status monitoring area, function switch, other switches) and rotaly knobs on the DigiPackⅢ front panel shown in Figure 2-6.

All functions normally required for parison and machine programming can be used on the front panel.

2-3-2. INPUT FUNCTION

Rotaly knob (numerical input) ： It is used to input values of various functions, turning clockwise increases the value of the function, turning

counterclockwise decreases the value. When the "X10" key on the screen is active (inverted to yellow), the sensitivity when the input knob is rotated is multiplied by 10.

Setting value by ten key (10 key) : In addition to the method by pressing [SET] after increasing / decreasing the value by the rotaly knob, you

can input with the numeric keypad displayed on the screen to set the value. If you select a parameter and rotate the rotaly knob, the selected parameter value will be enlarged as shown in Figure 2-7. This value increases or decreases following the rotation of the rotary knob. Also, if you touch the selected parameter again, the numeric keypad will be displayed. In this case, the numeric keypad becomes active from the beginning as shown in Figure 2-8.

If you press "ESC" or touch anything other than the numeric keypad area, the screen returns to Figure 2-6 without changing the value. Press the "SET" key to update the value and return to Figure 2-6.

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Selected value zoomed

At this stage the numeric keypad is still translucent and can not be entered

Active numeric keypad

10 key switch

Figure 2-7 Ten key on the screen (1)

Figure 2-8 Ten key on the screen (2)

If you press the "10 Keys" switch from the state shown in Figure 2-7, or touch the selected parameter again from the state of Figure 2-6, the numeric keypad becomes active as shown in Figure 2-8. You can enter a value with the numeric keypad. When you use the numeric keypad, the original value is cleared. For example, pressing "1" changes the value to 1. After that, when you use the rotary knob, the value increases or decreases based on that value.

If you press "ESC" or touch anything other than the numeric keypad area, the screen will return to Figure 2-6 without changing the value. Press the "SET" key to update the value and return to Figure 2-6. Also, when the numeric keypad is active, pressing the [C] key clears the input contents and can re-enter. I will explain the rules for entering 10 keys on the next page.

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1) Numeric keys (1) In the case of a parameter having a decimal point unit: The input value is shifted from the right

and input. Example) 0.0 → "1 input" → 0.1 → "2 input" → 1.2 → "3 input" → 12.3 (2) In the case of integer parameter: The input value is input shifted from the right. Example) 0 → "1 input" → 1 → "2 input" → 12 → "3 input" → 123

2) minus key (-) (1) When the parameter input range is minus: +/- toggles. The key is always valid. Example) -16.5 → "- input" → 16.5 → "- input" → -16.5 (2) When the parameter input range does not reach minus: minus key is invalid (no minus display) Example) 3.2 → "Input" → 3.2 → "- input" → 3.2

3) ESC key Returns the input value before change and returns to the normal screen.

4) C key Clear to 0 which is currently input.

5) SET key It reflects the input value and returns to the normal screen.

6) MAX / MIN indication Displayable range of the specified parameter is displayed.

[X10] ： Increase the sensitivity of the rotaly knob by 10 times. The color of the switch changes from white to yellow

while active. Press again to deactivate and switch to white. [SET] ： If you press the [SET] key while it is shown in green, the setting item value is confirmed. When the value

is changed with the rotaly knob or the numeric keypad, the color of the [SET] key changes from white to green. At that time, press the [SET] key to confirm the set value. [ESC] or cancels the change with touch other than the numeric keypad, without pressing [SET], the selection parameters are changed back to original valueand and the [SET] switch returns to white.

Cursor(△▽)： Move the selection parameter on the LCD in the direction indicated by triangle. [DEL] ： In the [F1] profile edit screen, invalidate the set thickness point. When you tap [DEL] on the set point, the

[DEL] switch turns green. If you tap again the [DEL] switch, [DEL] is executed to invalidate the thickness point and it becomes interpolation data between specified points before and after.

* When setting the accumulator, this switch changes to the [PURGE] function. [SHIFT] ： While this switch is pressed and "SHIFT" is in the active state (switch is yellow), the screen called by the

F1 to F5 switches becomes the setting screen. If you press this switch again or select one of the setting screens of F1 to F5, "SHIFT" becomes inactive (switch is white). * Please refer to 1-2-6 for the protection of setting screen transition

* When setting the accumulator, this switch changes to the [TOOLING] function.

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F1 Profile

Controls the parison wall profile and other related functions (When start up the controller, first move to this screen)

F2 Marker

Set program point marker. Slope setting for die gap and start slope. Time setting of internal clock. PURGE / TOOLING target position setting

F3 File

Allows storage and retrieval of 100 container wall thickness programs and related functions

F4 Monitor

Display status of digital signal and current value of servo valve current and die gap position. Manual operation is also done on this screen.

F5 Data

Displays the profile point and related function data

SHIFT→F1

Set Up Mode – Provides die gap tooling and other machine related set up functions

SHIFT→F2

Analog monitor assignment to monitor channels.

SHIFT→F3

Delete and Backup/Restore the storage data. (Backup/Restore for data in USB)

SHIFT→F4

Machine primary setting setup

SHIFT→F5

Communication parameter setting RS422 and Ethernet. And Inter clock time setting

Start

Lights when the cycle Start signal is received

Die Gap

Lights when the Die Gap signal is received and “DIE GAP” on the LCD is back lit

Continuous

Lit when the “Continuous Extrusion” machine type is selected

Accumulator

Lit when “Accumulator” machine type is selected

Divergent

Lit when “Divergent” die gap tooling is selected

Convergent

Lit when “Convergent” die gap tooling is selected

End of filling

Lights when the accumulator completes its charging stroke

Point Out

Lights when each Marker point is reached

End of extrusion

Lights when the accumulator completes its empty stroke

2-3-3. FUNCTIONS

It is used to select the function screen displayed in the editing area shown in Figure 2-6. The contents of the function are as follows.

2-3-4. STATE MONITORING AREA

In the status monitoring area shown in Figure 2-6, it is used to indicate the state of the function as shown below.

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Running or Ready

Die gap and Delay are not highlighted

Die gap

Die gap is highlighted

Delay

Delay is highlighted

Status indicator

STATUS INDICATORS

There are two status indicators on the [F1] profile page (Figure 2-9). The status can be checked as follows depending on the status of the indicator.

Status Condition

Running or Ready:

1) When the mode is changed from MANUAL to AUTO

2) When the power is turned on or the DigPackⅢ is reboot

3) When the STOP signal is input

4) End of movement of the Delay to until Diegap signal ON.

Die gap:

From DieGap signal and while core on the Die gap position

Delay:

From Start signal and while Delay running

Figure 2-9 Status indicator

2-3-5. EDIT AREA

In the edit area shown in Figure 2-6, the detail screen when the specific function key [F1-F5] selected is displayed.

Selection of the individual Function Items is done by the Cursor or touch directly. In Figure 2-9, the value of the Item Cycle time, 10.0 sec, is highlighted and therefore Cycle time is selected. Turning the Rotaly Knob will increase (CW) or decrease (CCW) the Cycle time value. To make this Cycle time change permanent, SET must be pressed. If do not press SET and press ESC or move the cursor here, the value of Cycle time will be restored. * For details of value input method, please refer to section 2-3-2.

Selection of other Function Items is done by repeatedly pressing the Up or Down Cursor until the desired Item is reached or touch the item directly. In this manner, all of the individual Function Items may be selected. The value of any Function Item will not be changed when moving between Function Items unless SET is pressed.

This input procedure applies to all Function screens.

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2-4. SCREENS OF EDIT AREA

Container Identification

100 Program Point = Parison Top

First Program Point = Parison Bottom

Programmed Parison Wall Thickness or Die Gap Opening

Indicate actual line from DCDT feed Back. And Indicate process of running.

Selectable indication ON or OFF at setup display (SHIFT→F4). See 1.9.2.1

Program setting Point Indicator

Explanation here is given (profile point = 100 points).

Figure 2-10 F1: Profile mode Screen

2-4-1. EDITING METHOD

The Cursor key (up/down) is used to move the cursor to each displayed parameter item. And also select items by touching directly.The Cursor will indicate its location by light green on LCD display. If the cursor put on to Point No. the cursor in Profile graph will move by rotating the Rotaly Knob (Clockwise to up, Counterclockwise to down; X10 key makes the Rotaly Knob faster) to obtain the desired value, then confirm the value by pressing the SET key. And, If the cursor put on to Data, the cursor in Profile graph will move by rotating the Rotaly Knob (Clockwise to increase, Counterclockwise to decrease; X10 key makes the Rotaly Knob faster) to obtain the desired value, then confirm the value by pressing the SET key.

If change the item value but press ESC without confirmation with the SET key, that value returns. (Some parameters are excluded)

If set values are modified, changes take effect during the next machine cycle.

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2-4-2. F1: Profile Mode

Mode obtained by pressing the F1 Key. Display condition:

Normally displayed when manufacturing containers.

Profile Mode Function Items

Please refer to Figure 2-11 and description below for further definition information.

Die Gap Opening Profile

The profile uses 10 to 200 separate points to define the desired parison wall thickness profile. The horizontal axis of the LCD display is the programmed tooling die gap or parison wall thickness. The points along the vertical axis of the LCD display are Shot Size, either cycle time or accumulator stroke.

Linear or Spline interpolation can be set at machine setup display (SHIFT→F4) is used to define the profile between the operator set points. *Figure 2-11 showing Spline type.

Figure 2-11 Profile Mode Screen

Each profile point may be set to a value between 0% to 100% of the maximum tooling die gap opening by rotating the Rotaly Knob and pressing SET. (For definition of 0-100% see 1.9.3.1)

As shown in Figure 2-11 Profile Mode Screen, the active profile point on the display is indicated by a inverse video bar. Its value is shown on the upper right hand corner of the LCD display as “Data %”(77.1% on Figure 2-11). Points displayed as “*” are interpolated values. If the value not displayed “*” its settled program point, you can also see setting point with purple color line mark on profile left side as shown Figure 2-11.

If “-“ is being displayed as a point value of left side of profile, that value has been set using F2: Marker Mode.

To cancel entered profile points, turn the Rotaly Knob counterclockwise until the display in the upper right hand corner of the LCD display indicates “Data: ---.-“ and press the SET Key or move to the point where you want to cancel the green bar and delete the setting with the [DEL] key.

After deletion, it will be changed to interpolation value. The scale of the profile display will automatically change between 25%, 50%, 75% and 100% as required. The following Function Items are found in the area of the LCD display arround the parison profile.

Point No.

If the cursor placed on this value, the profile bar in the graph can be moved up and down by turn the

Rotaly Knob, CW to move up and CCW to move down. Once decided cursor point on profile graph press SET key, and cursor move to Data value.

Data

If the cursor placed on this value, the profile thickness can be adjust increase and decrease by turn the Rotaly Knob, CW to increase and CCW to decrease. Once decided profile thickness on this profile point, press SET key, and cursor move back to Point No. value. * The profile adjustment affected to next start cycle.

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Shot Size Shot Size sets the quantity of plastic used during one machine cycle to produce a container. The setting

type is different depending on the accumulator or continuous machine type. Accumulator Machines – the amount of plastic extruded by the accumulator or accumulator stroke. Shot

Size is shown as a percentage (or mm) of the accumulator stroke and its value may only be set between 1% and 100%.

Continuous Extrusion Machines – the length of time for one machine cycle in seconds. Cycle Time may only be set between 0.1 and 999.9 seconds. This time is started by machine event, such as the motion of the knife cutting the parison.

An additional feature is Auto Shot which automatically sets Shot Size to be equal to the time interval between sequential knife cuts. If Auto Shot is ON then Shot Size automatically update each cycle interval, and Shot Size is no effect on the cycle time.

Die Gap

This parameter is the core gap target position when the die gap digital signal (TB-2-2) is input. Set the core die gap opening amount on the cycle between the end of the program profile (point 200) and the start of the next cycle. The setting range can be set between 0 and 100% with respect to the maximum value of the core die gap opening amount. Also, if this parameter is changed while the [Die gap] status ([Die gap] status indicator is green), the core gap changes at the speed of [Die gap slope] setting when pressing the [SET] key Move to a setting position. In general, [die gap] is used to control the thickness of the parison in a continuous blow molding machine (for example, resin cutting etc.), in the accumulator molding machine to close the core gap and prevent resin drooping during filling.

Delay Delay delays the start of the programmed profile after the machine cycle is started. During this Delay the

tooling die gap is maintained at the gap programmed by profile point 1. Delay may be set from 0% to

999.9% of the Shot Size in ACC mode. If Continuous Extrusion mode, Delay may be set from 0sec to

999.9sec Delay is often used to synchronize the position of the initial programmed portion (bottom) of the parison with the bottom of the container mold.

Cushion Cushion applies to Accumulator Machines and when filling type selected to Extrusion only. Cushion is the point where the accumulator stopped with pushed out. Cushion is often set to leave a

small amount of material in the accumulator at the end of the push out to insure that the accumulator does not bottom out before all of the plastic required for programmed portion of the parison is extruded. As the total accumulator stroke has been made equal to a Shot Size setting of 100%, the total of the equation

Shot Size + Shot Size x Delay + Shot Size x Cushion must be equal to or less than 100% of the actual maximum accumulator stroke.

Auto Cycle

Applicable only with continuous extrusion machines. It is not displayed on the accumulator type machine. This parameter automatically sets [cycle time] to a value equal to the time interval between successive start signals (TB-2-1). When [Auto cycle] is set to ON, [Cycle time] is automatically updated every interval of each cycle.

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Weight Weight is a constant value added to each profile point

and when varied, has the effect of changing container weight roughly in proportion to the amount of weight change.

As used on the DigiPackⅢ, Weight produces a change proportional to the average thickness of the parison. For a given Weight change, the amount of change at each program point is related to the initial value of that point. The effect is to provide a container weight change with a minimal effect on the container wall thickness distribution.

Weight is expressed as a percentage of the thickest point on the profile. Weight can vary from minus 100% to pluse 100%. Weight reduction can occur until the value of one of the 200 profile points reaches zero.

* If the profile over 100%, Weight still can be increase continuously up to 100%, however actual profile command is 100% maximum.

Figure 2-12 0%Weight Change

Figure 2-13 (-)23.3% Weight Change

Use the Rotaly Knob and Set to change the Weight setting. The percentage Weight change will remain displayed after being Set. When the Rotaly Knob is turned again the new Weight entry will start at zero us- ing the current display as reference. If the Rotaly Knob is accidentally moved and the displayed Weight value changed, it will revert to its former value if SET is not pressed and the Cursor used.

When you start to generate the profile for a container for the first time, the Weight displayed will equal zero. After a Weight change has occurred, the Weight displayed will indicate the percentage Weight change.

Figure 2-13 shows the effect of a Weight reduction of

-23.3% from the Weight value of 0% in Figure 2-12. To make the change easier to visualize, reference lines drawn between the figures starting at four different parison wall thickness program points have been included. The Weight change will be same from minimum to maximum parison wall thickness program point.

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Range H

The lowest thickness will be fix

Range H changes the value of all profile points by a

percentage of the difference between the thickness and thinnest points. The value of the thinnest profile point remains constant during a Range H change. Range H can vary between –100% and non limit + side (3276.7%).

* If the profile over 100%, Range H still can be increase continuously, however actual profile command is 100% maximum.

Use the Rotaly Knob and SET to change the Range H setting. The percentage Range H change will remain displayed after being Set. When the Rotaly Knob is turned again the new Range H entry will start at zero using the current display as a reference. If the Rotaly

Knob is accidentally moved and the displayed Range H value changed, it will revert to its former value if SET

is not pressed and the Cursor used.

Figure 2-14 0% Range H

Figure 2-15 (+)25.0% Range H Change

Range H has the effect of allowing container weight changes while retaining the containers minimum wall thickness distribution pattern.

Figure 2-15 shows the effect of a Range H increase of +25.0% from the Range H value of 0% in Figure 2-14. To make the change easier to visualize, reference lines drawn between the figures starting at four different parison wall thickness program points have been included.

Range H will use the thinnest parison wall thickness program point as a reference and will not change its thickness. The Range H change will be largest at the maximum parison wall thickness point, and proportionately less at the intermediate parison wall thickness poins.

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Range L

The highest thickness will be fix

Range L changes the value of all profile points by a

percentage of the difference between the thickest and thinnest points. The value of the thickest profile point remains constant during a Range L change. Range L can vary between –3276.7% and +100%. Range L may be changed until the thinnest profile point reaches zero. Use the Rotaly Knob and SET to change the Range L setting. The percentage Range L change will remain displayed after being Set. When the Entry Knob is turned again the new Range L entry will start at zero using the current display as a reference. If the

Rotaly Knob is accidentally moved and the displayed Range L value changed, it will revert to its former value if SET is not pressed and the Cursor used.

Range L has the effect of allowing container weight

changes while retaining the containers maximum wall thickness distribution pattern.

Figure 2-16 0% Range L

Figure 2-17 (-)20.0% Range L

Figure 2-17 shows the effect of a Range L decrease of –20.0% from the Range L value of 0% in Figure 2-16. To make the change easier to visualize, reference lines drawn between the figures starting at four different parison wall thickness program points have been included.

Range L will use the thickness parison wall thickness program point as a reference and will not change its thickness. The Range L change will be largest at the minimum parison wall thickness point, and proportionately less at the intermediate parison wall thickness points.

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2-4-3. F2: Marker Mode

File Name

Current CursorPosition

Year : Month : Day

Die Gap Slope

Start Slope

Time: Minute

Purge/Tooling Setting position

Figure 2-18 Marker Mode Screen

Mode is obtained by pushing the F2 Key.

Display

Available when manufacturing containers.

Point No.

Set the profile point marker up to 10 points on the profile. To set these conditions, move from point to point using the Cursor Key and set point number with the Rotaly Knob or Ten key and press SET Key to confirm. The value can be set from 0 to 200, and If set point number to “0”, this mean not set this marker point.

Use

May be used to provide a pulse output (200msec)(TB-2-20) occurring at a selectable point in the DigiPackⅢ cycle to control and/or synchronize machine functions or for other uses.

Die gap slope

The slope or velocity of the motion to the “Die Gap” setting position, when the Die Gap signal is given. Setting range is 0.1 to 999.9%/sec. Please refer to Figure 2-19 for the timing.

Start slope

The slope or velocity of motion to Point 1 position, when the Start Slope signal is given. Setting range is

0.1 to 999.9%/sec. Valid only when the “Filling” status is indicated. When the start position is reached by the start slope, the start slope end signal (TB-2-22) is output. Please refer to Figure 2-19 for the timing.

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Figure 2-19 Slope Timing

PURGE GAP

With this parameter, set the core movement target position (PURGE opening) by the [PURGE] switch located at the following two places. Setting range 0 to 100% (Initial value 100%) (For definition of 0 to 100% see 1.9.3.1)

· F4: Monitor screen: PURGE switch can be pushed in the manual mode.

· Accumulator setting screen: The PURGE key is displayed when accumulator initial setting page is indicating. (DEL key changes to PURGE key)

TOOLING GAP

With this parameter, set the core movement target position (TOOLING closing) by the [TOOLING] switch located in the following two places. Setting range 0 to 100% (Initial value 0%) (For definition of 0 to 100% see 1.9.3.1)

· F4: Monitor screen: TOOLING switch can be pushed in the manual mode..

· Accumulator setting screen: The TOOLING key is displayed when accumulator initial setting page is indicating.. (SHIFT key changes to TOOLING key)

* PURGE / TOOLING is the core forced opening and closing function. This function is effective when replacing resin or when performing initial setting (zero-span) of the accumulator.

* The speed of the core moved by the PURGE / TOOLING switch is the speed set by “Die gap slope”. * Refer to Section 1.9.3.3 Accumulator setup for the purge / tooling function during accumulator setting.

Time set

A time setup of an internal timer is performed. When there is no time correctly by an initial state or no long-term turning on electricity, time is set up on

this screen.

Date

A date is inputted.

Time

Time is set up.

SET

After inputting a date and time, a timer is set up by SET and a count is started.

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2-4-4. F3: File Mode

Mode is obtained by pressing the F3 Key. Display

Available when manufacturing containers.

Function

This mode combines the profile, marker data and setup files and stores them in a Flash RAM or USB Memory for future use. To Flash RAM 100 files can be stored, and SD card can be saved data depend on the size of USB Memory. The data stored with identifying name of up to 32 characters, date and time.

Commands

When F3: File Mode is selected a choice Load, Load USB, Save or Save USB, is displayed (Figure 2-20). Load, Load USB, Save or Save USB can be selected, using the Cursor and Set or directly touch the applicable item.

Figure 2-20 File Mode Selection Screen

For USB memory writing or reading, USB memory must be inserted in the slot. If it is not inserted, the following message will be displayed and file management can not be continued.

“USB is not insert or format is not correct” ※ The maximum usable USB size is 32GB, the data format format is FAT32. Please note that if you select [Load] or [Load USB], the current product data will be automatically over-

written. Please save the current product data, before load the data.

Save or Save USB Save or Save USB combines the profile data, function item

data and point markers in one file and stores this file in the Flash RAM or USB Memory.

Use the Up/Down cursor to select Save or Save USB and press the SET Key or directly touch them. (Figure 2-20)

The prompt ‘Please edit file name Yes/No” is displayed.

(Figure 1-21) If you select “YES”: then go to Page 63. If you select “NO” then go to Page 62.

Figure 2-21 Select SAVE

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“Please edit file name Yes/No” If you select “No” then follow the instructions below..

The LCD display (Figure 2-22,Figure 2-23,Figure 2-24) shows the description of the file data, press SET at “Next” to see each display one by one.

To save the file, move cursor to “Save” with Rotaly Knob and press SET Key or directly touch “Save”. If you select “Save”, the DigiPackⅢ saves the data in the Flash RAM (or to the USB Memory if you

selected Save USB) and displays the save data in the Profile mode. (F1: Profile). If you select “Quit” the first screen of the F3 File mode is displayed and no data is saved.

The data will automatically be saved in the same “FILE Number” file shown in the LCD display even if data is already stored there. In this case, the previously stored data will be lost.

Figure 2-22 File Description

Data-Page 1

Figure 2-23 File Description

Data-Page 2

Figure 2-24 File Description

Data-Page 3

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“Please edit file name Yes/No” If you select “Yes” follow the instructions below…. The LCD display changes to the Edit screen (Figure 2-25)

and prompts ‘File name”. Use the Rotaly Knob or directly touch to input the name of file (32 characters maximum).

The Rotaly Knob moves the display cursor from character to character. The SET Key enters the individual characters of the file name.

Special Characters

The “←” and “→” symbols are used to move the display cur-

sor within the file name. The last character in the list inserts a blank space in the

name.

The “END” character is necessary for entry completion. “END” must be inserted at the end of editing or the new file

will not be renamed. (If not change the name, skip to Figure 2-22)

Figure 2-25 Edit File name

The LCD display changes to the File No. select screen (Figure 2-26) and prompts ‘File No.” Move to the desired file number by using the Rotaly Knob (selects in increments of

1) and the Cursor Key (selects in increments of 20). Press SET to enter. Or touch specified number frame, specify the desired file number, and press [SET].

After select file number, the LCD display changes to a description of the entry data (Figure 2-22,Figure 2-23,Figure 2-24) with the “Quit or Save or Next” prompt displayed. If you select “Save”, the DigiPackⅢ saves the data and dis- plays file name in F1 Profile Mode. If you select “Quit”, you are returned to the first screen of the F3 File Mode and no data is saved.

If another data is already stored in the location of the specified file number, the data is saved in that location. In that case, previously saved data will be lost.

Figure 2-26 Change File Number

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Load or Load SD

If you select “Load or Load USB” (Figure 2-20). The file list is displayed, starting at “No. 0 Initial file” (Figure 2-27). In

this mode, files 0 to 100 are displayed in blocks of 5. You can find the required file by using the Rotaly Knob (the dis- play cursor moves through the files in order) and the Cursor (jumps files in blocks of 20) to find the desired file. Then press the SET Key. or Touch the file you need directly and press the [SET] key.

Figure 2-28 is displayed at the bottom of the LCD display.

Select “Quit” or “Load” or “Next” with the Rotaly Knob and SET Key or touch the item directly.

If “Load” is selected the file loads and is displayed in F1 Profile Mode. If you select “Quit”, the initial F3 File Mode,

Figure 2-20, screen is displayed and no file is loaded. If “Next” is selected, described other parameters.

Figure 2-27 Initial Load Screen

Setup data (for example GAIN, DCDT Zero/Span, etc.) will be loaded only for reference because of the machine safety.

Initialize data

For the initialization method, select "0. INITIAL FILE" and execute [Load]. As a result, all parameters return to their initial values (factory-set values).

※ Machine setting parameters are not changed.

Figure 2-28 File Load

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2-4-5. F4: Monitor Mode

Mode obtained by pressing the F4 key. Display

Available at all times. But not available to change manual mode when profile is running.

Manual Mode is used to display and/or control the positions of the tooling actuator (DCDT) and the value of the servovalve input current as well as the Output ON/OFF functions. Auto Mode ONLY displays the above information.

Commands

The Cursor is used (or directly touch) to move to the various commands only in MANUAL mode. The SET Key is inactive. The displayed values reflect the actual positions or servovalve current. (or Spool position in EFB mode)

Output

There are 6 output commands which may be changed with the Rotaly Knob. Counter-clockwise rotation produces a 0 (OFF) and Clockwise rotation a 1 (ON).

Figure 2-29 F4: Monito screen

The functions controlled are: (1) End of Filling; (2) End of Extrusion; (3) Point out; (4) End of Start slope; (5) Ready; (6) Alarm.

Input

There are 7 input commands to monitoring the following functions: (1) Start, (2) Die gap; (3) Reset; (4) Stop; (9) Start Slope, (10) Emergency, (11) Temp OK. (not use 5 to 8)

Core check

When the display Cursor points to “Core check”, it is possible to control the tooling position in closed loop using the Rotaly Knob between 0 to over 3276.7%. (100% = Span position) *This parameter can not be changed with 10 key.

Open command

When the display Cursor points to “Open command”, it is possible to control the value of the servovalve input current with the Rotaly Knob. *This parameter can not be changed with 10 key.

USE OF “Open command” MAY RESULT IN DAMAGE TO THE TOOLING.

When the servovalve input is equal to any value other than those in the Zero range, servovalve oil flow will cause the tooling cylinder to move. The tooling actuator will stop only when the servovalve input current is within a very narrow band in the Zero current range. If the tooling actuator stops due to contact with the die and mandrel, very high forces may be exerted on the tooling, possibly causing damage. It is highly recommended that the hydraulic pressure be reduced to a low value to prevent possible damage.

To prevent inadvertent damage, setting the Open command to “Disable” in Machine setup display ([SHIFT]→[F4]) will disable this function.

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PURGE

With this switch, the core moves to the position set by the movement target position "PURGE GAP (F2 screen)".

By switching to the manual mode, the PURGE switch becomes effective (background white). When it is disabled, it becomes a gray background. In addition, the switch turns yellow while moving to the purge position.

TOOLING

With this switch, the core moves to the position set by the movement target position "TOOLING GAP (F2 screen)".

By switching to the manual mode, the TOOLING switch becomes effective (background white). When it is disabled, it becomes a gray background. In addition, the switch turns yellow while moving to the tooling position.

* PURGE / TOOLING is the core forced opening and closing function. This function is effective when replacing resin or when performing initial setting (zero-span) of the accumulator.

2-4-6. F5: Data Display Mode

Figure 2-30 Data Display

Screen A

Figure 2-31 Data Display

Screen B

Figure 2-32 Data Display

Screen C

Mode is displayed by pushing the F5 Key

Display

Available when manufacturing containers.

Function

To display the conditions, parameters and profile data for the container currently being made. Select to “Next” see other page one by one. This screen mode is display only, parameter editing is not possible.

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2-4-7. SHIFT→F1: Set Up Mode

The mode to shift by pressing [SHIFT] and pressing the [F1] key with the [SHIFT] key active.

Display

Not available when manufacturing containers. And Production can not be started while this screen is displayed.

Function

Set Up is used to set up the conditions and parameters required for proper operation when the container and/or die gap tooling are changed.

Commands

Set Up Mode is covered in detail in the DigiPackⅢ Installation manual at 1-9-3. SET UP PROCEDURE.

Figure 2-33 [SHIFT]→[F1]: Setup Screen

2-4-8. SHIFT→F2: Analog monitor

The mode to shift by pressing [SHIFT] and pressing the [F2] key with the [SHIFT] key active.

Display

Not Available while manufacturing containers. And Production can not be started while this screen is displayed.

Function

Internal signal assign to analog monitor channels 1 to 4. (TB1, 11, 12, 28 and 29). See 1-6-3. for details.

Commands

Change the displayed parameter using the SET Key or directly touch the parameter, revise the value with the Entry Knob (or ten key) and confirm with the SET Key.

Figure 2-34 [SHIFT]→[F2]: Analog Monitor Screen

Signal

The following signals can be set in “signal”. After that, each channel is monitored by the monitoring channel

on TB1.

00h : MFB valve current -> Monitored MFB Servovalve Current (Set at SHIT→F4) with +-10V. 01h : EFB spool monitor -> Monitored Spool position (4-20mA) with +-10V if EFB mode. 02h : DCDT input voltage -> Monitored DCDT Position (0-100%) with 0-10V.

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03h : Accumulator voltage -> Monitored Accumulator Position (0-100%) with 0-10V. 04h : Position command -> Monitored Parison command signal with 0-10V.

Offset

Add this value to output signal of monitor channel.

Gain

Set gain function for output signal. Ex) if Gain=2.00 then 50% is 10V output.

2-4-9. SHIFT→F3: File delete and Backup/Restore

The mode to shift by pressing [SHIFT] and pressing the [F3] key with the [SHIFT] key active.

Display

Not Available while manufacturing containers. And Production can not be started while this screen is displayed.

Function

Data file delete and all data backup to USB Memory and Restore from USB Memory

Commands Select the required function “Delete”, ”Backup” or “Re- store” using the Entry Knob and confirm with the SET Key

or directly touch to the desired command.

Delete

Delete the existing file which saved in Flash RAM. (F3: File mode). If select the “Delete”, Display indicate as Figure 2-36. And select file name using Rotaly Knob or touch then press SET. It will be delete the selected file.

Figure 2-35 [SHIFT]→[F3]: File delete and Backup

Backup If Select “Backup”, all Flash RAM data in DigiPackⅢ is copied in to USB Memory.

Restore

If Select “Restore”, all backup file in USB Memory restore to Flash RAM of DigiPackⅢ.

NOTE: [Backup] / [Restore] does not include executing files. Only files saved in F3 are covered.

When execute the Restore, all Flash RAM data in DigiPackⅢ are erased and write again data from USB Memory. If the save data in Flash RAM is different from USB Memory, all data in Flash RAM will lost.

And When the Backup or Restore executed, USB Memory needs to insert USB slot. If USB Memory is not in slot, below message occurred and can not continue Backup/Restore.

“ USB is not insert or format is not correct ”

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Figure 2-36 File Delete

2-4-10. SHIFT→F4: Machine Setup

The mode to shift by pressing [SHIFT] and pressing the [F4] key with the [SHIFT] key active.

Display

Not available when manufacturing containers. And Production can not be started while this screen is displayed.

Function

Machine setup is used to set up the conditions and parameters required for proper operation when install the most

beginning to machine or change machine mode. Commands

Machine setup is covered in detail in the DigiPackⅢ Installation manual at 1.9.2.1 Machine settings.

Figure 2-37 [SHIFT]→[F4]: Machine Setup Screen

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2-4-11. SHIFT→F5: Communication Mode

DHCP

ON or OFF

IP address

If DHCP is ON, automatically set this parameter.

Net mask

If DHCP is ON, automatically set this parameter.

Gate way

If DHCP is ON, automatically set this parameter.

Port No.

0 – 65535

The mode to shift by pressing [SHIFT] and pressing the [F4] key with the [SHIFT] key active.

Display

Not available when manufacturing containers.

Function

Provides RS422 and Ethernet communication with a host computer, using the parameters shown on the LCD display. And also can be set internal clock in this display.

Ethernet Communication Setup

Figure 2-38 [SHIFT]→[F5]: Communica- tion Mode Screen

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Type

TCP/IP (EtherNET)

Communication character ASCII code 20h～7Fh (Capital letter and control code)

[STX](02h)、[ETX](03h)

Numerical data is 2 and 4 ,8 characters of hexadecimal number

Capital letter (A,B,C,D,E,F)

Maximum packet length

Data：1024[Byte] + control：2[Byte]

Endianness

Big endian

[STX]

[Data]

[ETX]

Command:[Command Code][Command Data] / Response:[Command Code][Error Code][Response Data]

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 … … … … 796 797 798 799 800 801 802 803 P 0

0 1 2 3 P 0

Profile point 199

DigiPackⅢ→PC

Error

file No 0 = F1 Screen profile data

Nothing Profile data "FFFF”

PC→DigiPackⅢ

file No

Profile point 1

Profile point 2

Profile point 3

…

Profile point 200

file No 1～100 = F3 file (internal profile data)

0 1 2 3 P 1

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 … … … … 796 797 798 799 800 801 802 803 P 1

PC→DigiPackⅢ

file No

DigiPackⅢ→PC

Error

Profile point 1

Profile point 2

Profile point 3

Profile point 200

…

Profile point 199

Nothing Profile data "FFFF”

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 P 2

0 1 2 3 P 2

PC→DigiPackⅢ

file No

P-addr

Data

…

P-addr : Refer to Section 2-6

DigiPackⅢ→PC

Error

0 1 2 3 4 5 6 7 8 9

P 3 "n" can be omitted, in that case 1

0 1 2 3 4 5 6 7 8 9 10 11 P 3

PC→DigiPackⅢ

file No

P-addr

DigiPackⅢ→PC

Error

Data

…

2-5. COMMUNICATION PROTOCOL

2-5-1. EtherNET COMMUNICATION SPECIFICATION

Packet

[STX] --- Single-byte character of ASCII code 02h. Represents the start of a packet. [ETX] --- Single-byte character of ASCII code 03h. Represents the end of a packet. [Command Code] --- 2-byte character string from the head of [data] used for command classification. For details [Command data][Error code][response data], see the next section.

2-5-2. PROFILE

Please refer to the 2-6. profile data list.

2.5.2.1. WRITE PROFILE DATA (ALL PROFILE POINT)

2.5.2.2. READ PROFILE DATA (ALL PROFILE POINT)

2.5.2.3. WRITE PROFILE DATA (EACH DATA OR BLOCK DATA)

2.5.2.4. READ PROFILE DATA (EACH DATA OR BLOCK DATA)

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2.5.2.5. WRITE ALL PROFILE DATA (INCLUDE PARAMETER)

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 … 35 File name length is fixed at 32 characters P 4

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

y y / m m / d d h h : m m : s s

53 54 55 56 … … … … 849 850 851 852 853 854 855 856 … … … … 889 890 891 892

893 894 895 896 897 898 899 900 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916

917 918 919 920 921 922 923 924 925 926 927 928 929 930 931 932 933 934 935 936 937 938 939 940

941 942 943 944 945 946 947 948 949 950 951 952 953 954 955 956 957 958 959 960

0 1 2 3 Nothing Profile data "FFFF” P 4 An error occurs if there is a file with the same name as another file number

Profile point 1

Profile point xx

Profile point 200

Marker point 1

Marker point x

Marker point 10

PC→DigiPackⅢ

file No

File name

Fill in margins with spaces

Space = 20h

Spline

Core stroke

Accum. stroke

DCDT Zero

DCDT Span

Accum. Empty

Shot size

Die gap

Delay

Cushion

Die gap slope

Start slope

DigiPackⅢ→PC

Error

Accum. Full

Type set

Gain

PURGE gap

TOOLING gap

0 1 2 3 P 5

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 … 35 File name length is fixed at 32 characters P 5

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

y y / m m / d d h h : m m : s s

53 54 55 56 … … … … 849 850 851 852 853 854 855 856 … … … … 889 890 891 892

893 894 895 896 897 898 899 900 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916

917 918 919 920 921 922 923 924 925 926 927 928 929 930 931 932 933 934 935 936 937 938 939 940

941 942 943 944 945 946 947 948 949 950 951 952 953 954 955 956

PC→DigiPackⅢ

file No

Profile point 1

Profile point xx

Profile point 200

Marker point 1

Marker point x

DigiPackⅢ→PC

Error

File name

Fill in margins with spaces

Spline

Core stroke

Accum. stroke

DCDT Zero

DCDT Span

Accum. Empty

Marker point 10

Shot size

Die gap

Delay

Cushion

Die gap slope

Start slope

Accum. Full

Type set

Gain

PURGE gap

TOOLING gap

Nothing Profile data "FFFF”

Space = 20h

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 … 35 File name length is fixed at 32 characters P 6

0 1 2 3 P 6

An error occurs if there is a file with the same name as another file number

PC→DigiPackⅢ

file No

File name

Fill in margins with spaces

DigiPackⅢ→PC

Error

Error, accessing unregistered file

Space = 20h

0 1 2 3 File name length is fixed at 32 characters P 7

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 … 35 P 7

DigiPackⅢ→PC

Error

File name

PC→DigiPackⅢ

file No

Fill in margins with spaces

Space = 20h

Error, accessing unregistered file

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Date and time data are handled in P 8 y y / m m / d d h h

m m

s s decimal character string

Error, accessing unregistered file 0 1 2 3 P 8

PC→DigiPackⅢ

file No

DigiPackⅢ→PC

Error

Month

Day

Hour

Minits

Sec

Year

0 1 2 3 P 9

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Date and time data are handled in P 9 y y / m m / d d h h : m m : s s decimal character string

Error, accessing unregistered file

PC→DigiPackⅢ

file No

DigiPackⅢ→PC

Error

2.5.2.6. READ ALL PROFILE DATA (INCLUDE PARAMETER)

2.5.2.7. WRITE FILE NAME

2.5.2.8. READ FILE NAME

2.5.2.9. WRITE TIME

2.5.2.10. READ TIME

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2-5-3. WAVE

0 1 2 3 4 5 6 7 T 0

"n" : max 255 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 T 0

DigiPackⅢ→PC

Error

Data1

Data2

…

The memory unset point is set to "FFFF"

PC→DigiPackⅢ

Address

Address : 0～495

"n" can be omitted, in that case 1

0 1 2 3 4 5

M 0 "n" can be omitted, in that case 1

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

M 0

ch : the ADC channel number

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

Data1

Data2

…

0 1 2 3 4 5

M 1 "n" can be omitted, in that case 1

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

M 1

ch : the DAC channel number

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

Data1

Data2

…

0 1 2 3 4 5

M 2 0 0 "n" can be omitted, in that case 1

0 1 2 3 4 5 6 7

M 2

DigiPackⅢ→PC

Error

Data1

PC→DigiPackⅢ

0 1 2 3 4 5

M 3 0 0 "n" can be omitted, in that case 1

0 1 2 3 4 5 6 7

M 3

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

Data1

0 1 2 3 L S 0 0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 L S D I G I P A C K 3 Variable length character data

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

0 1 2 3 L S 0 1

0 1 2 3 4 5 6 L S 1 2 3 Variable length character data

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

For channels from "ch" to "n" "ch" see 2-5-9. AD / DA list

"n" is the number For the configuration of Data1, see 2.5.6 Interface Control Reference

For channels from "ch" to "n" "ch" see 2-5-9. AD / DA list

"n" is the number For the configuration of Data1, see 2.5.6 Interface Control Reference

2.5.3.1. READ WAVE. WAVE MEMORY OF REAL OPERATION

2-5-4. MONITOR

2.5.4.1. A/D CONVERT CHANNEL

2.5.4.2. D/A CONVERT CHANNEL

2.5.4.3. DIGITAL INPUT

2.5.4.4. DIGITAL OUTPUT

2-5-5. INFORMATION DATA

2.5.5.1. DEVICE NAME

2.5.5.2. SERIAL NUMBER

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2.5.5.3. PRODUCTION DATA

0 1 2 3 L S 0 2

0 1 2 3 4 5 6 7 8 9 10 11 L S 2 0 1 0 / 4 / 1 Variable length character data

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

0 1 2 3 L S 0 3

0 1 2 3 4 5 6 7 L S V 1

0 Variable length character data

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

0 1 2 3 L S 0 4

0 1 2 3 4 5 6 7 L S V 1

0 Variable length character data

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

0 1 2 3 L S 1 0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 L S 0 0

0 9 : C C : 1 0

x x : x x Character data

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

0 1

I G

※Interface data: 32 bit hexadecimal number

※Refer to Section 2.5.6.3 for the composition of interface data

0 1 2 3 4 5 6 7 8 9 10 11

I G

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

Data

0 1 2 3 4 5 6 7 8 9

I S

0 1 2 3

※Interface data: 32 bit hexadecimal number

I S

※Refer to Section 2.5.6.3 for the composition of interface data

PC→DigiPackⅢ

Data

DigiPackⅢ→PC

Error

2.5.5.4. HARDWARE VERSION

2.5.5.5. SOFTWARE VERSION

2.5.5.6. MAC ADDRESS

2-5-6. INTERFACE CONTROL

2.5.6.1. ACQUIRING INTERFACE DATA

2.5.6.2. INTERFACE DATA SETTING

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

MRJ06301

2.5.6.3. INTERFACE DATA STRUCTURE (32 bits)

31 30 29 28 27 26 25 24 23 22 21 20

↑ ↑

↑

※Writing to bits that can only be acquired is ignored.

171615141

Communication virtual input pattern (10bits)

Actual digital Input pattern (10bits, only acquisition possible)

Actual digital Output pattern (10bits, only acquisition possible)

Communication virtual input function 0 ... invalid / 1 ... Valid

765432131211109819

Digital output mode 0 ... AUTO / 1 ... MANUAL ※ Setting on the F4 Monitor screen (Acquisition only possible)

Communication virtual & actual digital input pattern 0 ... open / 1 ... Close

Actual digital output pattern 0 ... open / 1 ... Close

bit 9

E-Stop Signal input

bit 9

End of extrusion Relay status

bit 7

(No assignment)

bit 7

End of extrusion Signal output

bit 8

Start slope Signal input

bit 8

End of filling Relay status

bit 5

（No assignment）

bit 5

(No assignment)

bit 6

(No assignment)

bit 6

End of filling 信号出力

bit 3

Stop Signal input

bit 3

Ready Signal output

bit 4

Temp-OK Signal input

bit 4

Alarm Signal output

bit 1

Die gap Signal input

bit 1

(No assignment)

bit 2

Reset Signal input (Do not reset by communication setting)

bit 2

End of Start slope Signal output

bit 0

Start Signal input

bit 0

Maker out Signal output

0 1 2 3 I X

PC→DigiPackⅢ

bit

DigiPackⅢ→PC

Error

0 1 2 3 4 5

I X

0 1 2 3

I X

PC→DigiPackⅢ

bit

DigiPackⅢ→PC

Error

Level

Actual digital I/O is the state of the rear terminal block. When the communication virtual input function is invalid, the communication virtual input pattern is ignored and it operates only with the actual digital input. When the communication virtual input function is enabled, it is the logical sum (OR) of the close state between the communication virtual input and the actual digital input. Please note that it will be recognized as closed if either one is closed.

2.5.6.4. INTERFACE DATA SETTING (Edge setting)

bit ... 2 Hexadecimal digits. Specify the operation target bit with 00 to 09. Bits other than the operation target bit do not change. The number is as shown in the table of input in 2.5.6.3.

This “IX” command enables the communication virtual input function and indirectly manipulates the bit. After edge operation, the bit for communication virtual input is set to 0.

※The operation when an “IS” command or “IX” command is executed on the same bit within 2 [ms] after

edge setting with the “IX” command is undefined. To set them consecutively, leave at least 2 [msec] interval. (It is not necessary when manipulating another

bit with the “IX” command.)

2.5.6.5. INTERFACE DATA SETTING (Level setting)

bit ... 2 Hexadecimal digits. Specify the operation target bit with 00 to 09. Bits other than the operation target bit do not change. The number is as shown in the table of input in 2.5.6.3.

Level ... 2 hexadecimal digits. 00 = Open, Other than 00 = Closed.

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

MRJ06301

2-5-7. OTHER

USE

AD/DA channel

IN/OUT Specification

Reso-

lution

Core position voltage（DCDT）

ADC#0

-10V～10V

30802

EFB spool current

ADC#1

4～20mA、Center：12mA

26214

（Unimplemented）

ADC#2 ― ―

Accumulator position voltage

ADC#3

0～10V

30802

（Unimplemented）

ADC#4 ― ―

MFB current

ADC#5

-100～100mA

28836

2.5V A Internal voltage

ADC#6

Unused

―

2.5V B Internal voltage

ADC#7

Unused

―

0.0V A Internal voltage

ADC#8

Unused

―

0.0V B Internal voltage

ADC#9

Unused

―

Monitor 0～3 voltage

DAC#0～#3

-10V～10V

32767

EFB voltage

DAC#4-EFB Selected

-10V～10V

32767

MFB current DAC#4-MFB 10mA Selected

-10mA～+10mA

32767

DAC#4-MFB 20mA Selected

-20mA～+20mA

32767

DAC#4-MFB 50mA Selected

-50mA～+50mA

32767

DAC#4-MFB100mA Selected

-100mA～+100mA

32767

0 1 2 3

R S 0 0

0 1 2 3

R S

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R T 0 0 y y / m m / d d h h : m m : s s

Set RTC. 0 1 2 3 It is reflected at the time of transmission. R T

PC→DigiPackⅢ

DigiPackⅢ→PC

Error

Error of time format error becomes "data value range error".

0 1 2 3

R T 0 1

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

R T y y / m m / d d h h

m m

s s

DigiPackⅢ→PC

Error

PC→DigiPackⅢ

0 1

Command part of ※ 1

2 3

Number and Data part of ※ 1

4 5 6

P 2

↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑

｜｜｜｜｜｜

Data: write value, read value

｜｜

Number: other than command and data (address, file number, command extension number)

Command: the first two characters

No Error

Successful completion

Command Code Error

Corresponding command code does not exist

※1

Define area of command string

Number specification error

Value other than specified value for number specification

Number part of ※ 1

Data value range error

Data value is outside the specified range

Data part of ※ 1

Command Length Error

The command is not in the specified format

Overall length of ※ 1

Numeric string error

Number specification or data value is not a correct numeric string (hexadecimal / decimal)

file No

P-addr

Data

…

No File Error

Accessed an unregistered file

Flash memory Error

Failed to write to Flash memory

2.5.7.1. RESET COMMAND

2.5.7.2. SET RTC

2.5.7.3. GET RTC

2-5-8. ERROR CODE

2-5-9. ADC/DAC CHANNEL

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

MRJ06301

2-6. PROFILE DATA LIST

Prpfile Data address and data form

address

name

range

screen

content

File no

1～100

"0" is F1 screen profile data

File name

F1,F2,F3,F5

max 32 characters

Date

yy/mm/dd hh:mm:ss 17 characters

Shot size/Cycle time

1 ～ 9999

Shot size[0.1%]/Cycle time[0.1sec]

Die gap

0 ～ 1000

[0.1%]

Delay

0 ～ 9999

[0.1%] 7 03

Cushion

0 ～ 9999

[0.1%] 8 04

Die gap slope

1 ～ 9999

[0.1%/sec]

Start slope

1 ～ 9999

[0.1%/sec]

Spline 0=invalid

SHIFT→F4 1=valid

Core stroke

1 ～ 9999

SHIFT→F1

unit 0.01mm Tooling length

Accum. stroke

1 ～ 9999

SHIFT→F1

unit 0.1mm

DCDT zero

-1000 ～ 1000

SHIFT→F1

set voltage : unit [0.01V]

DCDT span

-1000 ～ 1000

SHIFT→F1

set voltage : unit [0.01V]

Accum. Empty

0 ～ 1000

SHIFT→F1

set voltage : unit [0.01V]

Accum. Full

0 ～ 1000

SHIFT→F1

set voltage : unit [0.01V]

Type set

bit0: 0 = Divergent, 1= Convergent

SHIFT→F1

（Core type)

bit1: 0 = %, 1 = mm

（Core stroke unit）

bit2: 0 = %, 1 = mm

(Accumulator stroke unit）

bit3: 0 = Extrusion fixed, 1 = Filling fixed

（Accumulator type only）

bit4: 0 = OFF, 1 = ON

（Auto cycle）

Gain

1～32767

SHIFT→F1

[0.01]

Marker point 1

0～200

Profile point 1～200 （"0" is not output）

Marker point 2

0～200

Marker point 3

0～200

Marker point 4

0～200

Marker point 5

0～200

Marker point 6

0～200

Marker point 7

0～200

Marker point 8

0～200

Marker point 9

0～200

Marker point 10

0～200

Profile point 1

-1 ～ 1000

[0.1%]

Profile point 2

-1 ～ 1000

[0.1%]

～

～～～

～

228

147

Profile point 200

-1 ～ 1000

[0.1%]

229

148

PURGE gap

0～1000

[F2]

[0.1%]

230

149

TOOLING gap

0～1000

[F2]

[0.1%]

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

MRJ06301

2-7. SETTING UP

2-7-1. OBJECTIVE

The container produced by the blow molding process must meet the customer’s specification. Customer’s specifications normally involve standards for appearance, weight and physical characteristics such as strength, endurance and dimensional accuracy.

The container design process will determine the material to be used, the shape of the mold and required special features as well as the size and shape of the die gap tooling.

The task of the set up man is to use the above information with the DigiPackⅢ to control the parison wall thickness and placement in the mold to produce the container to its design specification.

The setup man must become familiar with the contents and definitions contained in Section 1-5.

2-7-2. DIE GAP TOOLING SETUP

A feature of the DigiPackⅢ is its ability to store the programmed parison wall thickness profile and other settings required to produce a particular container. Up to 100 container files may be stored. The stored container files in the DigiPackⅢ easily allow the change from one container to another. ※ USB memory is used for external data storage.

The stored information for a particular container contains the closed tooling die gap position and the relationship between the programmed wall thickness or die gap opening and the actual tooling die gap opening produced by the desired wall thickness. In other words, the relationship between the programmed die gap opening and the actual die gap opening has been calibrated. For example, a commanded die gap opening of 37% could be calibrated to cause an actual die gap opening of 6.7mm. The tooling die gap calibration information is contained in the container file.

In order to quickly change the blow molding machine production from one container to another with minimum change over time, the tooling die gap calibration must be accurately established.

The DigiPackⅢ Installation and Maintenance Manual contains a tooling die gap calibration procedure in Section 1-9-3. , DIE GAP TOOLING SETUP. To achieve the minimum change over time it is essential that this procedure be followed and the requested information recorded.

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

MRJ06301

2-7-3. PRELIMINARY SET UP

SHOT SIZE

Shot Size basically determines the amount of plastic to be extruded through the die gap to make the container. In an accumulator machine it is the extrusion stroke of the accumulator, in a continuous machine it is determined by the time required to extrude the plastic volume or weight required by the container and tail, and also by the cooling capacity of the mold. This time or stroke was probably determined when the particular blow molding machine was selected to produce the container.

DIE GAP

Die Gap will probably be set to 0% for an accumulator machine to eliminate drool. In a continuous extrusion machine, the Die Gap must be used to set a minimum die gap opening (may also have mechanically set minimum opening) to prevent damage to the extruder and/or tooling due to excessive pressure or to a larger opening consistent with the parison tail requirements at the top of the container.

DELAY

Delay will initially be determined by the required tail length at the bottom of the container. Delay would be equal to the tail length divided by the length of the mold.

AUTO SHOT Auto Shot does not apply to accumulator machines,.

Auto Shot would be ON if the DigiPackⅢ is only controlling the parison wall thickness and its cycle time

is determined only by the interval between the machine controlled knife cuts. Auto Shot would be OFF if the machine timing is partially or totally controlled by the DigiPackⅢ. For

example, if the mold closure timing is controlled by a DigiPackⅢ marker pulse, then the time from the knife cut to mold closure is set by the DigiPackⅢ’s Shot Size; the time from the marker pulse to the knife cut is controlled by the machine’s controller.

WEIGHT, RANGE H and RANGE L Weight, Range H and Range L are set by default to zero at the beginning of setup. DIE GAP OPENING Die Gap Opening is determined by the Die Gap Opening required to extrude the required parison weight

for the container and is part of the initial selection of extruder speed and the specific tooling used. This average opening is set at program point 1 and program point 200 and the resulting die gap program will be a constant die gap opening between points 1 and 200.

This document is subject to MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND . The details are on page II.

MRJ06301

2-7-4. INITIAL TRIALS

After the heater bands have brought the extruder barrel and extrusion head to the desired temperature, some trial containers are blown. The blow molding machine timing and motions are adjusted to obtain a sealed container. Adjustments to the constant die gap program, Shot Size, Die Gap and Delay may have to be made before a sealed container is obtained. At this time, the die gap tooling opening is fixed and the operator would follow the same logic he would use if the tooling was mechanically fixed in position to obtain a sealed container.

Once a sealed container is obtained, it should be sliced open along the axis parallel to the parison length. If the containers plastic material is translucent, then thick and thin areas can be found by visual observation In any case, container wall thickness measurements should be made along the cut edge and compared with the target wall thickness. The wall thickness or die gap opening program is then changed based upon the differences with the target thickness.

More containers are then blown, cut open and the die gap opening changed as required. After two or three trials it would be helpful to know the location of the programmed portion of the parison in the mold.

One method is to reduce the programmed thickness at one point and determine where that reduced wall thickness ring is located in the container wall. Often, the reduced thickness point can be clearly seen. Further trials with a single reduced thickness point at different locations along the container will help to determine the position of the programmed points along the length of the actual container.

Do not run tests with more than one reduced thickness point. Reducing the wall thickness at a point will change the distribution of plastic along the parison length and the use of more than one reduced thickness point will lead to improper assessment of the results.

A second method to determine the program point distribution on the container is to mark the parison wall at or as near as possible to the place where the parison leaves the die gap tooling. The marks may be applied manually or it may be possible to use marker pulses to operate an ink jet. This method marks the program points on the parison without distorting the parison or container.

When program points 1 and 200 are marked, the position of the programmed portion of the parison in the mold may be determined and adjusted.

A constant thickness container wall will be probably obtained before the correct weight. Adjustment of Weight, Range H or Range L will then allow both the correct container weight and wall thickness to be obtained with minimum requirement for the operator to change the value of any individual programmed die gap opening points.

Moog DigiPack III J141-215 Maintance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual