Rockwell Automation 1771-QDC, D17716.5.86 User Manual

Plastic Molding Module

(Cat. No. 1771QDC)

Inject and Clamp Mode

Important User Information

Because of the variety of uses for this product and because of the differences between solid state products and electromechanical products, those responsible for applying and using this product must satisfy themselves as to the acceptability of each application and use of this product. For more information, refer to publication SGI–1.1 (Safety Guidelines For The Application, Installation and Maintenance of Solid State Control).

The illustrations, charts, and layout examples shown in this manual are intended solely to illustrate the text of this manual. Because of the many variables and requirements associated with any particular installation, Allen–Bradley Company cannot assume responsibility or liability for actual use based upon the illustrative uses and applications.

No patent liability is assumed by Allen–Bradley Company with respect to use of information, circuits, equipment or software described in this text.

Reproduction of the contents of this manual, in whole or in part, without written permission of the Allen–Bradley Company is prohibited.

Throughout this manual we make notes to alert you to possible personal injury or damage to equipment under specific circumstances.

ATTENTION: Tells readers where people may be hurt, machinery may be damaged, or economic loss can occur if procedures are not followed properly.

ATTENTION helps you:

- identify a hazard

- avoid the hazard

- recognize the consequences

Important: Identifies information that is especially important for successful application and understanding of the product.

Important: We recommend you frequently backup your application programs on appropriate storage medium to avoid possible data loss.

PLC and ERC are registered trademarks of Allen-Bradley Company, Inc. Pro-Set, Expert Response Compensation, PanelView, and PanelBuider are trademarks of Allen-Bradley Company, Inc

Summary of Changes

We revised this publication to include changes due to upgrading the 1771-QDC/B module to a 1771-QDC/C.

For These Changes Refer to Page or Chapter

Lossofsensor detection input range changed back to 0.00 to 10V dc

Added the section, Record I/O Ranges.

Changed the title Ground the QDC Module to Ground and Shield Your I/O Devices to better describe the task.

Added data codes to configuration worksheets. Chapter 3 and Appendix A

Reversed the order of chapters 3 and 4 to present the download procedure for the MCC block before the download procedure for the other data blocks.

Revised the download procedure for the MCC block (chapter 3) and for other command blocks (chapter 4).

Changed the chapter title to better describe the task. Chapter 6

Added data codes to Configuration Block worksheets. Chapter 7 and Appendix A

Added data codes to Profile Block worksheets. Chapter 8 and Appendix A

Placed 2page worksheets on facing pages Chapters 7 and 8

35, 39 A2, 3

21

29

Chapters 3 and 4

Changed our recommendation on module calibration. 113

Added Block ID codes to blank worksheets. Appendix A

Minor corrections as found

To Help You Find Changes

To help you find these changes, we added change bars as shown to the left.

Summary of Changes 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using This Manual P1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual

Objectives Audience P2 Use Related

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of T

erms P2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Publications

Overview of Inject and Clamp Mode 11. . . . . . . . . . . . . . . . . .

P1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Inject and Clamp Mode Operation 11 Inject Control 12 Clamp Control 110

Objectives

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11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install the QDC Module 21. . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Record Set Module Jumper Plugs 22 Key Your I/O Chassis 25 Install Wire Ground and Shield Your I/O Devices 29 Plan for ESTOPs and Machine Interlocks 211

Configure the QDC Module'

Chapter Select Module Parameters and I/O Ranges 31 Determine Initial Sensorconfiguration Values 33 Download Use Setoutput Operation to Move the Ram (screw) and Clamp 37 Complete your Sensor Configuration 38 Select

Objectives

I/O Ranges

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the QDC Module

Objectives

MCC V

Optional Configurations

alues to the QDC Module

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s I/O

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21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31. . . . . . . . . . . . . . . . . . . .

31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35. . . . . . . . . . . . . . . . .

314. . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of Remaining Configuration Procedures 41. . . . . .

Chapter Configuration Concepts 41 Special Command and Status Blocks 42 Overview of Remaining Configuration Procedures 43 Enter Data Table Values and Download Command Blocks 44

Objectives

41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contentsii

Jog Your Machine 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter About Jogging 51 Use These Worksheets 51 Determine Write Ladder Logic 55 Jog Your Ram (Screw) and Clamp 57 Configure Screwrotate and Ejector Jogs for Indirect Control 57 Write Ladder Logic to Assist with Screwrotate and Ejector Jogs 58 Jog the Ejector and Rotate the Screw 510

Objectives

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Initial Jog V

51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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alues 52. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Select Command and Status Bits to Sequence

Machine Operation 61. . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Assess Your Logic Requirements 61 Use Chapter Use These Worksheets 72 Procedure Determine

Select the T Determine Word Selections: Select ERC Values 731 Determine Unselected Valve Setoutput Values 731 Set Your Acceleration/Deceleration Ramp Rates 733 Determine Setoutput Values for End of Profiles 734 Set Pressure Control Limits 735 Set V Set Profile Gain Constants, PressureAlarm Setpoints,

Enter and Download your Worksheet Values 740

Objectives

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Command and Status Bit T

Objectives

to Determine and Enter Initial V

Bit Selections: Assign Module Outputs for

Your Control Valves 728. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ype of PID Algorithm

elocity Control Limits

and Watchdog Timer Presets 739

ables 62. . . . . . . . . . . . . . . . . . . . . .

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alues 728. . . . . . . . . . . . . .

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61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

729. . . . . . . . . . . . . . . . . . . . . . . . .

737. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load

Initial Profile V

Chapter Use These Worksheets 81 Determine and Enter Setpoints for Clamp Close Profile (CPC) 82 Determine Bit Selections for Worksheet 8A 84 Determine Word Values for NO TAG 86 Enter and Download Your Worksheet Values 88 Determine and Enter Setpoints for the Injection Profile (IPC) 89 Determine Bit Selections for Worksheet 8B 812 Determine Word Values for Worksheet 8B 813 Enter and Download your Worksheet Values 817 Determine and Enter Setpoints for the Pack/Hold Profile (HPC) 817 Determine Bit Selections for Worksheet 8C 820

Objectives

alues 81. . . . . . . . . . . . . . . . . . . . . . . . .

81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contents iii

Determine Word Values for Worksheet 8C 821. . . . . . . . . . . . . . . . . .

Enter and Download your Worksheet Values 822 Determine and Enter Setpoints for Plastication Profile (PPC) 823 Determine Bit Selections for Worksheet 8D 826 Determine Word Values for Worksheet 8D 827 Enter and Download your Worksheet Values 829 Determine and Enter Setpoints for Clamp Open Profile (OPC) 830 Determine Bit Selections for Worksheet 8E 832 Determine Word Values for Worksheet 8E 834 Enter and Download Your Worksheet Values 836

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Span Your V

Chapter Referenced Worksheets 92 Span Your Low Pressure Close Valve 93 Span Your Clamp Close Pressure Valve(s) 99 Span Your Clamp Close Velocity (Flow) Valve(s) 914 Span Your Injection Pressure Valve 919 Span Your Injection V Span Your Pack and Hold Pressure Valves 930 Span Your Plastication Pressure Valve 936 Span Your Clamp Open Pressure Valve(s) 941 Span Your Clamp Open Velocity (Flow) Valve(s) 947

alves 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Objectives

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elocity V

alve 924. . . . . . . . . . . . . . . . . . . . . . . .

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91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tune Your Machine 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Closedloop Control 102 Tune Closedloop Pressure Control 102 Tune Closedloop V Injection Tuning Considerations for Producing Parts 1010 Profile Requirements 1010 Cushion, Shot Size, and T Unselected Valve Setoutput Values 1015 Logical Bridges and Endofprofile Setoutput Values 1016 Decompression Pullback 1017 Acceleration and Deceleration Ramp Rates 1018 Watchdog T Pressure Pressurelimited V Expert Response Compensation 1023 Tuning Considerations for Clamp Operation 1024 Clampcontrol Profile Requirements 1025 Unselected Valve Setoutput Values 1028 Logical Bridges, and Endofprofile Setoutput Values 1029

Objectives

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elocity Control

imer and Profile Of

Alarm Setpoints

elocity vs. Position Injection

Objectives

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ransition Setpoints

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fsets 1020. . . . . . . . . . . . . . . . . . . . . . .

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101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106. . . . . . . . . . . . . . . . . . . . . . . .

1013. . . . . . . . . . . . . . . .

1020. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1021. . . . . . . . . . . . . . .

1024. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv

Acceleration and Deceleration Ramp Rates 1030. . . . . . . . . . . . . . . . .

Pressure Profile Watchdog Timer Presets 1033 Expert Response Compensation 1033

Alarm Setpoints

1032. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Troubleshoot with LEDs 111. . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Use LEDs to Troubleshoot Your QDC Module 111 Module

Objectives

Calibration

111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blank Worksheets A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using This Manual

Preface

Manual Objectives

Use this preface to familiarize yourself with this manual so you can use it effectively. This manual shows you how to apply the QDC module to your molding machine in a reasonable length of time.

Since this manual is task oriented, we recommend that you perform these tasks in the following order:

Perform this task: As discussed in this chapter:

Browse through the entire manual to become familiar with its contents.

Overview the inject and clamp process describes how the QDC module controls your injection molding system.

Install the QDC module. This includes such tasks as wiring and setting jumpers.

Configure the QDC module mode off operation to match your specific application, and configure its communication with its inputs and outputs.

Overview of remaining configuration procedures that you perform throughout the remainder of this manual.

Jog the ram (screw) and clamp. This task requires that you configure jog and pressure alarms setpoints.

Set up communications between your PLC5 processor and the QDC module. You select command and status bits that you use to write your ladder logic.

Prepare to run your machine in open loop. This task requires you to determine and enter initial values into the ram (screw) and clamp configuration blocks.

Prepare to run and tune your machine in open loop. This task requires you to determine and enter initial values into the ram (screw) and clamp profile blocks.

Span your ram (screw) and clamp valves. This is done using setoutput and openloop control.

Tune the machine for parts production. Chapter 10

Troubleshoot problems that may occur with QDC module. Chapter 11

Refer to this appendix for a blank copy of each worksheet contained in this manual.

All chapters

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7

Chapter 8

Chapter 9

Appendix A

P-1

Preface

Audience

Use

of T

erms

Before attempting to apply the QDC module to a molding machine we assume that you are:

an injection molding professional

an experienced PLCprogrammer (especially with the Allen-Bradley

PLC-5 family of processors)

an hydraulics designer or technician

We use these abbreviations:

Abbreviated Name: Title:

QDC module 1771QDC Plastic Molding Module

PLC5 processor PLC5 Programmable Controller

T47 or T50 terminal 1784T47 or 1784T50 Programming Terminal

ProSet 600 Software PanelView Terminal

6500PS600 ProSet 600 Injection Molding Operator Interface Software

2711KC1 PanelView Operator Interface Terminal

ERC

Expert Response Compensation

The next table presents other terms we commonly use in this manual:

Term: Definition:

Selected Valve In multivalve systems, depending on the configured profile, the QDC

module controls one valve and presets the setting of the remaining valves to produce moldingmachine profiles. We call the valve being controlled by the QDC modules algorithms the selected valve.

Unselected Valves In multivalve systems, depending on the configured profile, the QDC

module controls one valve and presets the setting of the remaining valves to produce moldingmachine profiles. We call the valves that are preset with an openloop percentage setpoint the unselected valves.

Profile A group of mold/part setpoints which define a given machine operation

to the QDC module.

Command Block Data blocks downloaded from the PLC5 data table to the QDC module

to make configuration changes or to initiate machine actions.

Status Block Data blocks used by the QDC module to relay information to the PLC5

processor about the QDC module's current operating status.

Profile Block Command block containing mold/part setpoints.

Configuration Block Command block containing machine setpoints.

Direct Acting Valve An analog control valve that delivers increasing velocity or pressure with

increasing signal input.

Reverse Acting Valve An analog control valve that delivers increasing velocity or pressure with

decreasing signal input.

P-2

Preface

Command Blocks

Command blocks provide the parameters that control machine operation. They are transferred from the PLC-5 processor to the QDC module by means of block transfer write (BTW) instructions in software ladder logic. Command block abbreviations are:

Acronym: Description:

MCC Module Configuration Block

JGC Jog Configuration Block

FCC First Clamp Close Configuration Block

SCC Second Clamp Close Configuration Block

TCC Third Clamp Close Configuration Block

LPC Clamp Low Pressure Close Configuration Block

CFC Clamp Close Profile Block

INC Injection Configuration Block

IPC Injection Profile Block

PKC Pack Configuration Block

HDC Hold Configuration Block

HPC Pack/Hold Profile Block

PRC Predecompression Configuration Block

PLC Plastication Configuration Block

PPC Plastication Profile Block

PSC Postdecompression Configuration Block

FOC First Clamp Open Configuration Block

SOC Second Clamp Open Configuration Block

TOC Third Clamp Open Configuration Block

OSC Clamp Open Slow Configuration Block

OPC Clamp Open Profile Block

DYC Dynamic Command Block

RLC Inject ERC Values Block

CLC Clamp and Eject ERC Values Block

P-3

Preface

Status Blocks

Status blocks report current status of molding-machine operation. They are returned from the QDC module to the PLC-5 processor by means of block transfer read (BTR) instructions in software ladder logic. Status block abbreviations are:

Acronym: Description:

SYS System Status Block

CPS Clamp Close Profile Status Block

IPS Injection Profile Status Block

HPS Pack/Hold Profile Status Block

PPS Plastication Profile Status Block

OPS Clamp Open Profile Status Block

RLS Inject ERC Values Status Block

CLS Clamp and Eject ERC Values Status Block

Word and bit Numbering

The QDC module stores data in command and status blocks. Each word location in a command or status block is identified by an alphanumeric code containing the block acronym and word number. For example, word 09 of the Module Configuration Command Block (MCC) is identified as MCC09.

Identify bits in a word location by adding bit numbering to the abbreviated word location. For example:

Specific: MCC09-B15 General: MCCxx-Byy

where:

MCC = Module Configuration Command Block xx=word number (01-64) B = bit identifier yy = bit number (00-15)

P-4

Preface

Related Publications

The following table lists documentation necessary for the successful application of the QDC Module:

Publication Use this documentation: To:

17856.6.1 PLC5 Family Programmable

Controller Installation Manual

6200N8.001 6200 PLC5 Programming

Software Documentation Set

17714.10 Plastic Molding Module

Application Guide

17716.5.85 Plastic Molding Module User

Manual, Inject Mode

17716.5.87 Plastic Molding Module User

Manual, Clamp & Eject Mode

17716.5.88 Plastic Molding Module

Reference Manual

17716.5.93 Plastic Molding Module User

Manual, Inject, Clamp & Eject Mode

Install the PLC5 processor and I/O modules.

Select instructions and organize memory when writing ladder logic to run your machine.

Help select the module mode and match your QDC module to your hydraulic layout.

Configure, program, install, and operate your QDC module to control inject operations.

Configure, program, install, and operate your QDC module to control clamp and eject operations.

Program block transfers between PLC5 processor and QDC module. PLC5 data transfer logic.

Configure, program, install, and operate your QDC module to control inject, clamp, and eject operations.

Take time now to familiarize yourself with the Reference Manual (publication 1771-6.5.88). The four sections include:

a summary of each data block used by the QDC module

(abbreviated command and status blocks)

programming error codes returned by the QDC module for each data

block, and recommended procedures to correct these errors

detailed listing and explanation of each command word and bit used by,

and each status word and bit returned from, the QDC module

operational, electrical, and environmental specifications of your module

If you purchased the Pro-Set 600 software, you also need the following:

Publication Use this documentation: To:

65006.5.11 ProSet 600 Software

Designers Guide

65006.5.12 ProSet 600 Software

Assembly Manual

65006.5.13 ProSet 600 Software

Overlay Installation Manual

65006.5.14 ProSet 600 Software

Customization Manual

65006.5.15 ProSet 600 Software

Reference Manual

Select the ProSet 600 software that matches the requirements of your molding machine.

Transfer your ProSet 600 software from a floppy disk to your hard drive. Add Overlays into your PLC5 and PanelView application files.

Install ProSet 600 overlays into your application files.

Customize your ProSet 600 build for your machine control requirements.

Support customizing your software control system.

P-5

Chapter

Overview of Inject and Clamp Mode

Chapter Objectives

This chapter presents an overview of the 1771-QDC Plastic Molding Module in the inject and clamp mode. We present a summary of inject and clamp features followed by sample applications.

Important: This manual assumes you have already read your Plastic Molding Module Application Guide (publication 1771-4.10) and have chosen inject and clamp as your QDC module’s mode of operation.

Inject and Clamp Mode

When you select inject and clamp mode, you can use the following phases:

Operation

Table 1.A Glossary

Inject Phase: Description:

Injection The ram (screw) injects plastic into the mold. You can vary the velocity of the ram (screw), or the pressure

driving it, to fill areas of the mold cavity at different rates to achieve uniform quality of the molded part. This phase can be critical to part quality. The pattern of velocity or pressure variation during injection is called the injection profile.

Transition Detects when injection is complete.

Pack (optional) Packing pressurizes the plastic to a specified density which determines the flexibility of the molded part. To

achieve uniform density, you can release or increase pressure in steps according to cooling gradients across the mold. Thus, as the plastic cools unevenly, the pack profile can compress the plastic uniformly.

of Inject and Clamp Mode

Hold Holding lets the plastic cool and shrink slightly from the mold cavity in preparation for ejection. The effect is

similar to packing. You can hold at predetermined pressures for predetermined lengths of time throughout the hold phase.

Predecompression (optional) This single, backward movement of the ram (screw) separates plastic solidifying in the mold from molten

cushion remaining in the barrel prior to plastication. This phase is also called sprue break or suckback.

Plastication Phase The machine reloads by drawing plastic beads into the barrel containing the ram (screw). The mechanical

action of the rotating ram (screw) grinds and melts the beads. The longer it grinds, the hotter it melts. You can vary the backpressure on the ram (screw) causing it to remain longer in an area. Thus, you can induce any desired temperature gradient along the length of the shot by controlling ram (screw) backpressure.

Postdecompression (optional)

This single, backward movement of the ram (screw) guards against drooling molten plastic into the open mold during ejection prior to clamp close. This phase is also called melt pullback or suckback.

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Chapter 1

Overview of Inject and Clamp Mode

Clamp Phase:

1st Close 2nd Close 3rd Close

Low Pressure Close To guard against damaging the mold when the two mold surfaces make contact and to detect obstructions to mold

1st Open 2nd Open 3rd Open

Open Slow

Inject Control

Description:

You can program a singlestep clampclose profile and not use a second or third profile. Or, you can program up to three clampclose profiles that let you do the following at up to three different points in the clampclose phase:

• pick up a third mold plate

• set cores

• pick up or drop out pumps to change clamp speed or pressure

closure, you close the mold slowly with low pressure and closedloop or openloop control. Low Pressure Close can only be controlled through a pressure vs. position profile.

You can program a singlestep clampopen profile and not use a second or third profile. Or, you can program up to three clampopen profiles that let you do the following at up to three different points in the clampopen phase:

• drop out a third mold plate

• pull cores

• drop out or pick up pumps to change clamp speed or pressure

To decelerate the moving platen to accurately position it before ejecting the part.

You control inject operation with these phases:

injection transition pack hold pre-decompression plastication post-decompression

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Clamp & Eject Operation

Figure 1.1

Operation of a T

Inject

Injection Pack Hold

Transition to Pack or Hold

Post- PreDecompression Decompression

ypical Machine Cycle

Plastication

(Reload)

Chapter 1

Overview of Inject and Clamp Mode

Injection Phase

You can vary the velocity of the ram (screw), or the pressure driving it, so the leading edge of the melt moves through the mold cavity at the desired speed. The pattern of velocity or pressure variation during injection is called the injection profile. The QDC module lets you chose from four different injection profiles:

velocity vs. position pressure-limited velocity vs. position pressure vs. position pressure vs. time

Figure 1.2 Example

Injection Profile

11 10 9

Velocity or Pressure

87654321

Position or Time

You enter setpoints to create a profile. You can select from 1 to 11 segments of position or time. Segment numbers represent the order of operation. By convention the ram (screw) injects plastic by moving from right to left.

With this Profile: You Control Injection: With up to 11 Segments

Velocity vs. Position Speed Length of the shot

Pressurelimited1 Velocity vs. position

Speed with a maximum pressure

Distributed over the:

Length of the shot

Pressure vs. Position Pressure Length of the shot

Pressure vs. Time Pressure Time for a shot

Pressurelimited velocity vs. position profile differs from the velocity vs. position profile as follows: During any segment, if the pressure exceeds a preset limit, the module switches to PID pressure control with the pressure limit as the setpoint. Then if velocity exceeds the velocity setpoint, the module returns to velocity control.

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Chapter 1

Overview of Inject and Clamp Mode

Example Benefits of Profiling an Injection Phase

The injection phase should force the melt through the mold as fast as possible without flashing the mold or burning the melt at a mold gate. Here are two examples of how you can achieve this by profiling the injection phase:

Velocity Example - As the leading edge of the melt enters different mold cavities, the flow of plastic through the gate should increase or decrease accordingly to keep the melt front at maximum desired speed without flashing the mold. This reduces injection time and minimizes surface stress due to surface cooling. You achieve this by shaping the injection profile to suit the mold cavity (Figure 1.3).

Mold Cavity

54 3

Flow into mold

Figure 1.3 Velocity

Example

Gate

Mold End

Injection Profile

Position

Sequence of execution

Velocity

Back Point

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Chapter 1

Overview of Inject and Clamp Mode

Flash Prevention Example - With a velocity profile (Figure 1.4 part 1), the pressure may reach a peak and flash the mold at ram (screw) position segments that correspond to events such as:

the initial surge (2.a) when the melt front enters a constriction in the mold cavity (2.b)

You can remedy this (part 3) by decreasing the ram (screw) velocity at segments (3.a) and (3.b) that correspond to flash points. Conversely, you can boost velocity at segment (3.c) where the resulting pressure is well below the flash point.

Figure 1.4

Prevention Example

Flash

1. Initial Velocity Profile

Velocity

bca

Position Position

3. Final Velocity Profile

Velocity

b ca

Position

2. Resulting Pressure Profile

4. Resulting Pressure Profile

Position

Flash Point

Pressure

Flash Point

Pressure

Optionally, you may select pressure limited velocity versus position as your method of injection control. With your pressure limit setpoint just below the flash point, the module switches over to pressure control prior to flashing the mold.

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Chapter 1

Overview of Inject and Clamp Mode

Injectiontopack Transition

The QDC module ends the injection phase and automatically starts the pack or hold phase when it detects the first of up to three events occurred:

Ram (screw) position exceeds a preset limit Ram (screw) pressure exceeds a preset limit Injection phase elapsed time exceeds a preset limit

You select which of these events you want monitored for transition by entering the appropriate setpoint, or zero for ignoring the event. You also may specify the zone of ram (screw) travel over which the QDC module inhibits or allows a pressure transition.

Pack Phase

The QDC module controls the pack phase with a pressure vs. time profile. You create the profile based on controlling the hydraulic pressure against the ram (screw). The pressure can be controlled using up to five segments. By convention, events occur from right to left on the time axis (Figure 1.5). You determine the pressure setpoints and time durations for the pack profile based on molding requirements. The pack phase is optional.

Figure 1.5

Phase Example

Pack

Pressure

Time

123

1-6

Lower density (last zone filled)

Chapter 1

Overview of Inject and Clamp Mode

Example Benefit of Profiling the Pack Phase

Molten plastic may cool unevenly in the mold causing variations in density with the end result of warpage and distortion as shown in Figure 1.6.

Figure 1.6 Uneven

Density in Mold Cavity

Cooling in Pack Phase

Pack Profile

Higher density (gate zone, greater pressure)

Gate

Pressure

You can remedy this by decreasing the pack pressure with time so plastic can back out of the mold as shown in Figure 1.7. This is to alleviate gradations in density as the plastic cools from the low-density end of the mold (last zone filled) to the high-density end of the mold cavity (gate zone where pressure is greater).

Figure 1.7

Cooling in Pack Phase

Even

Constant Pressure over entire Mold Cavity

Density in Mold Cavity

Gate

Pack Profile

Time

234

Pressure

234

After completing the last segment of the pack phase, the QDC module automatically starts the hold phase.

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Chapter 1

Overview of Inject and Clamp Mode

Hold Phase

The QDC module controls the hold phase with a pressure vs. time profile. You create the profile based on controlling the hydraulic pressure against the ram (screw). The pressure can be controlled using up to five segments. You determine the pressure setpoints and time durations for the hold profile based on molding requirements.

After completing the last segment of the hold phase, the QDC module either immediately starts the optional pre-decompression movement, skips the pre-decompression movement if none is required and immediately starts the plastication phase, or waits for a command from your PLC-5 program to continue.

Predecompression Movement

You select a length of pullback for the ram (screw) prior to the plastication phase to separate plastic solidifying in the sprue from molten cushion remaining in the barrel.

After completing the pre-decompression movement, the QDC module either immediately starts the plastication phase or waits for a command from your PLC-5 program to continue.

Plastication Phase

The plastication phase lets you achieve a melt temperature gradient in the barrel containing the ram (screw). To program the desired temperatures, you consult backup rate (backpressure) vs. temperature tables. You can create the profile with up to 11 segments of position or time (figure 1.8).

You chose from two plastication profiles:

Backpressure vs. position Backpressure vs. time

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Chapter 1

Overview of Inject and Clamp Mode

Figure 1.8 Plastication

BackPressure

Mold End

Phase Example

12 345

Position or Time

hotter

Temperature Gradient

Barrel Containing the Melt

7891011

cooler

Back Point

Example Benefits of Profiling a Plastication Phase

The higher the backpressure during plastication, the slower the backup rate and higher the resultant temperature of the melt. You can achieve the desired temperature gradient by lowering ram (screw) backpressure to accelerate the backup rate and decrease the temperature of the melt along the length of the barrel.

After completing the last segment of the plastication phase, the QDC module either immediately starts the post-decompression movement or waits for a command from your PLC-5 program to continue.

Postdecompression Movement

You select a length of pullback of the ram (screw) after the plastication phase to guard against drooling molten plastic into the open mold during ejection. The QDC module notifies your PLC-5 program when the post-decompression movement is complete.

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Chapter 1

Overview of Inject and Clamp Mode

Clamp Control

Ejector retract

Ejector advance

You control clamp operation with these phases:

clamp close low pressure close clamp open open slow

Figure 1.9 Clamp

1st Close

Open Slow

Portion of a T

ypical Machine Cycle

2nd Close

3rd Open

3rd Close

2nd Open

Low Pressure Close

1st Open

Clamp Close

Inject

Three separate clamp close profiles may be configured:

first close second close third close

You may select from these control modes:

velocity vs. position pressure vs. position

Use clamp close to move the platen from the fully open position (L) to some position X at a relatively high velocity or pressure. X is a position relatively close to the stationary platen yet far enough away to allow deceleration into low pressure close. This prevents the platens from coming together at a high velocity (Figure 1.10).

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Chapter 1

Overview of Inject and Clamp Mode

Clamp Cylinder

Moving Platen

Figure 1.10 Example

Clamp Close

Stationary Platen

Velocity

1st Close Profile

2nd

Profile

Position

3rd

Profile

You may start these operations between the three clamp close profiles:

pick up the 3rd plate of a mold (on a floating 3-plate mold) or set cores program other events for all valves automatically bridge between profiles, or let ladder logic decide when to

begin the next profile

Each of the clamp close profiles can be subdivided into three position segments (Figure 1.11). You can change clamp velocity or pressure up to three times in each profile, or up to nine times for the entire clamp close phase.

Clamp Cylinder

Moving Platen

Figure 1.11 Example

Clamp Close Position Segments

Stationary Platen

1st Close Profile

Velocity

Segments

2nd Profile

Position

3rd

Profile

Important: You may use as many or as few profiles and/or segments within profiles as needed for your molding application. If using a single close fast motion, use the first segment of the 1st close profile. The low pressure close profile must follow.

After completing the last segment in each profile, the QDC module either switches immediately to the next programmed segment of the next programmed profile or waits for a command from your PLC-5 program to continue.

After completing the last configured close profile, the QDC module either switches immediately to the first programmed segment of low pressure close, or waits for a command from your PLC-5 program to continue.

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Chapter 1

Overview of Inject and Clamp Mode

Low Pressure Close

Use the low pressure close profile to decelerate closing motion to guard against damaging the mold halves and detect for part obstructions. The pressure setpoint(s) that you select to control low pressure close should prohibit the mold from fully closing if there is an obstruction. Up to two low pressure close profile segments may be used (Figure 1.12).

You will use pressure vs. position for low pressure close.

Clamp Cylinder

Figure 1.12 Example

Low Pressure Close

Moving Platen

Stationary Platen

Low Pressure Close

Segments

Pressure

Position

Important: If you need only one low pressure close segment, configure the 1st segment of the low pressure close profile.

The QDC notifies your PLC-5 program when this profile is complete and automatically uses set-output values at the end of low pressure close to build tonnage (hydraulic machine) or lockup your toggle (toggle machine).

Clamp Open

1-12

You can open the mold fast with three profiles of the clamp open phase:

first open second open third open

You may select from these control modes:

velocity vs. position pressure vs. position

Use clamp open to move the platen from the fully closed position (0) to some position Y at a relatively high velocity or pressure (Figure 1.13). Y is close to your fully open position (L), yet far enough away for deceleration into the open slow profile. This aids positioning accuracy at the full open position (L).

Chapter 1

Overview of Inject and Clamp Mode

Clamp Cylinder

Moving Platen

Figure 1.13 Example

Clamp Open

Stationary Platen

You may start these operations between the three clamp open profiles:

drop the third plate of a mold (on a floating 3-plate mold) or pull cores program other events for all valves automatically bridge between profiles, or let ladder logic decide when to

begin the next profile.

Each of the clamp open profiles can be subdivided into three position segments (Figure 1.14). You can change clamp velocity or pressure up to three times in each profile, or up to nine times for the entire clamp open phase.

Velocity

3rd

Open

Profile

2nd

Open

Profile

Position

1st Open Profile

Clamp Cylinder

Moving Platen

Figure 1.14 Example

Clamp Open Position Segments

Stationary Platen

Velocity

3rd Open Profile

Segments

2nd Open Profile

Position

1st Open Profile

Important: You may use as many or as few profiles and/or segments within profiles as needed. If using a single open motion, use the first segment of the 1st open profile. The open slow profile must follow.

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Chapter 1

Overview of Inject and Clamp Mode

After completing the last configured open profile, the QDC module either switches immediately to the first programmed segment of the open slow profile, or waits for a command from your PLC-5 program to continue.

Open Slow

Use the open slow profile to accurately position the clamp for ejecting the part(s). You may decelerate clamp motion twice with this profile using up to two profile segments (Figure 1.15).

You may select from these control modes:

velocity vs. position pressure vs. position

Figure 1.15 Example

Clamp Cylinder

Open Slow

Moving Platen

L0Y

Stationary Platen

Open Slow

Segments

Velocity

Position

Important: If you need only one open slow motion, configure only the 1st segment of the open slow profile.

1-14

Chapter

Install the QDC Module

Chapter

Objectives

Record I/O Ranges

This chapter guides you through the following procedures:

record I/O ranges set module jumper plugs key your I/O chassis install the QDC module wire the QDC module ground your system plan for E-STOPs and machine interlocks

To match your QDC module to your I/O devices, record the I/O ranges of your I/O devices on Worksheet 2-A. You will use this information in this chapter for hardware configuration (setting jumper plugs) and in chapter 4 to configure the module’s inputs and outputs with software.

Circle or check the I/O ranges on Worksheet 2-A. Cross off I/O not used.

Worksheet 2A

I/O Ranges

Record

I/O Connection: Voltage 1: Voltage 2: Current:

Input 1 (Screw position) 0 to 10 Vdc 1 to 5 Vdc 4 to 20 mA

Input 2 (Screw pressure) 0 to 10 Vdc 1 to 5 Vdc 4 to 20 mA

Input 3 (Clamp position) 0 to 10 Vdc 1 to 5 Vdc 4 to 20 mA

Input 4 (Clamp pressure) 0 to 10 Vdc 1 to 5 Vdc 4 to 20 mA

Output 1 10 to 10 Vdc 0 to 10 Vdc 4 to 20 mA

Output 2 10 to 10 Vdc 0 to 10 Vdc 4 to 20 mA

Output 3 10 to 10 Vdc 0 to 10 Vdc 4 to 20 mA

Output 4 10 to 10 Vdc 0 to 10 Vdc 4 to 20 mA

2-1

Chapter 2

Install the QDC Module

Set Module Jumper Plugs

Before installing the QDC module, you must select with jumper plugs the I/O ranges that you recorded on Worksheet 2-A.

Access and Position the Jumpers

Access the jumpers and set them as follows:

ATTENTION: To avoid damage to internal circuits, observe handling precautions and rid yourself of any electrostatic charge. Use an anti-static work station when setting jumper plugs.

1. Remove the label-side cover plate by removing the four screws.

2. Remove the circuit board from the module housing by removing the

two screws located center-front at the swingarm catch.

3. Carefully turn over the circuit board so it is oriented as in figure 2.1.

Handle it by the edges to avoid touching conductors or components.

4. Use figure 2.1 to locate the jumper plugs.

5. Set the jumper plugs (Table 2.A) using a small needle-nose pliers.

6. After setting the jumper plugs, re-assemble the module.

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Chapter 2

Install the QDC Module

Figure 2.1 Jumper

LEFT

Locations on the QDC Module'

TOP

s Circuit Board

RIGHT

E10

E11

E12

E15

E16

E14

E13

E17

BOTTOM

10908I

Important: We define jumper plug positions as left, right, top, and bottom. This represents the position of the jumper plug on the 3-pin connector as relative to the sides of the circuit board shown above.

2-3

Chapter 2

Install the QDC Module

Table 2.A Jumper

Settings

Jumper: Function: Setting:

E1 Run/Calibrate Calibrate = right

E5 I/O Density Standard = top

E6 E7 E8 E9

E10 E14 E13 E17

E11 E12 E15 E16

Factory Defaults

Input 1 (Screw position) Input 2 (Screw pressure) Input 3 (Clamp position) Input 4 (Clamp pressure)

Output 1 (Valve 1) Output 2 (Valve 2) Output 3 (Valve 3) Output 4 (Valve 4)

Run = left

Do not use bottom position

Voltage = right Current = left

Current = top Voltage = bottom

-10 to +10 Vdc = top 0 to +10 Vdc or

4 to 20mA = bottom

Important: If you select current output with jumper plugs E10, E14, E13, and/or E17, then you must select the 4 to 20mA jumper position with E11, E12, E15, and/or E16.

ATTENTION: If an output is unconnected, set the jumper (E11, E12, E15, and/or E16) that corresponds to that output to 0 - 10 Vdc (bottom position). Setting the jumpers for –10 to +10 Vdc and later configuring the output as “unconnected” causes the QDC module to output –10 Vdc on that channel when a system reset occurs and all outputs are forced to 0% (i.e. 0% output equals –10 Vdc).

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