Instruction
Instruction
Layout
Monitor
Management
Paramenters
Communication
(One PC control 64 workstations by RS-422C communication)
Introduction
Because the cost of the automation for a single machine is going up lately, the automated factory is needful. For a factory to reach the automation, the jet controller system is necessary because it can support many PCs connection together. In other words, it can help a factory to integrate their computer manufacture and to reach an automatic operation.
DIH ZHOU TECHNOLOGY is not only one of the best companies on the controller systems area in the Taiwan but also its controller systems--research, design and manufacture all are produced from its own company. The text is mainly introduction its controller system products-EASY SERIES on their design, plan, manufacture concept. The systems are very easy to connect to network and to reach a goal-central integrated control for factories.
Commercial purpose
To develop jet controller systems, the purpose is to promote the added values of EASY-96000 and EASY-9000. End users can build and settle their own factories to become to an automatic operation via the controller interface.
System purpose
To develop a system has two connection commands—word format sample and word format database. End users can not only create their own connection programs conveniently via format sample but also develop the connection programs of EASY SERIES by themselves and know how to create a package easily. Format database provides EASY SERIES controller to be got and save data from outside PCs. (the internal signals for jet controller) and to save developers’ created time. This system is an integrated CIM application system and a communication interface of EASY SERIES. It is also to consider end users’ basic needs on the connection application.
Communication software has five functions and the statement is as below :
| A. Procedure guide | |||||
|---|---|---|---|---|---|
| B. Single machine monitor | B0 Active information | B1 Alarm detection | |||
| C. Production management | C0 Set connection objects | C1 Collect data detection | C2 Clear out database | ||
| D. Set parameters | D0 Set pressure | D1 Set speed | D2 Position coordinate | D3 Timer | D4 Counter |
| D5 Set temperature | D6 Operate parameters | D7 Statistic measures | D8 Workstations spaces | ||
| E. Set communication |
For the operation of plastic injection molding, the injection quality will be determined by a precision design mold, high lever injection raw material (epoxy material) and the five basis injection factors – temperature, pressure, speed, position & time. Another definition is: a set of procedure is “an assign mold combine with one set of injection factors”.
The purpose of procedure guide design is to let the far end PC to upload & download the injection parameters (which is called mould memory or procedure parameters) which are stored in the engineering controller. Include “upload” and “download” functions, refer to below screen, “upload”: send from PC to engineering controller, “download”: send from controller to PC, follow the indication of procedure code in the engineering controller and send all the parameters to PC. (Due to one set of injection molding machine can store 50 or 100 sets of procedure parameters matrix, so the download procedure parameters must be indicated clearly from which procedure code.)
There are two main functions (refer to following screen): 1. Dynamic information: To monitor and response the dynamic information of plastic injection molding machine during operation, such as running mode, temperature heating mode, oil temperature, screw stroke, ejector stroke, injector hydraulic sensor, production quantity. 2. Alarm log record: To collect the alarm log record of machine during operation.
When the plastic injection-molding machine is operated at auto mode, a product is produced when a procedure cycle (mould close -> injection -> holding pressure -> cooling time –> ejector) is completed. The product quality can be observed with the 10 information feedback from the operation, that is: 1. cycle time, 2. mould open end position, 3. injection speed time, 4. cushion position, 5. injection V-P position, 6. charge time, 7. RPM, 8. charge end posit, 9. nozzle and 10.oil temperature. Normally, for a stable operation machine, during the production, the standard deviation of the 10 information report data should approaching zero.
“The collected information data checking”(refer to following screen) provide a function to collect the above 10 items information data of each injection machine, meanwhile, it could also provide the simplify process data analysis, such as minimum value, maximum value, average figure and standard deviation, which could allow end user to follow up the whole process and check the variation of processes quality any time, this data will also use for process improvement referring & suggesting information.
According to “Procedure Guide”, the parameters setting are the all related settings before the process operation start. There are 9 items of information to be set (refer to following screen).
| 1. Proportional pressure control value command |
|---|
| 2. Proportional flow control value command |
| Under the operation of injection, holding pressure, cooling, ejector and core, to set the machine command value output between proportional pressure value and proportional flow value. |
| 3. Position meter |
| Use to set the position meter of machine during the clamp, core, ejector, charge, ejector and injection unit. |
| 4. Timer |
| Except apply in the engineering controller of injector machine, in other application field, according to the application, the timer is designed to 4 items listed as below: |
| 1）DELay：The stand by/transfer time between motion A and motion B; that means motion B will start to ON(OFF) until elapse “time T” after motion A “start” the action. Or motion B will start to ON (OFF) until elapse “time T” after motion A completed the action.For example, the delay air spray after ejector. |
| 2）PERiod：It means the continuous time (OFF) of one action(e.g. ON ->+T OFF -> ON) or showing the continuous time (ON) of one action(OFF -> +T ON ->OFF). Specify and describe the status of continuous time of “one” action. Such as the ejector continue time. |
| 3）MONitor：Action monitor time (To monitor one action must be completed under T time). For example, cycle monitor time. |
| 4）DISplay：To display the elapse time, for example, the display of running time for auto mode. |
| 5. Counter |
| To set the counter numbers of cleaning, machine lubricating cycle, ejector, unscrew etc. |
| 6. Temperature Setting |
| Indicate and set the temperature of hydraulic oil and to set the temperature & monitor value at each part of charge stroke. |
| 7. Parameters |
| Indicate the selected parameters of different process. |
| 8. Statistic Rules |
| To preset the related quantities of statistic number, there are 4 main information: |
| One mold cavity : To calculate one injection quantity. |
| Lot counter : To indicate the lot count, the system will alarm when it reach the lot count. |
| Good-shot counter : The system will alarm when it reach the good-shot count. |
| Reject-shot counter : When the injection is under the position control mode, if the injection speed time cannot reach V2P position in the specified time, or if cushion posit is not in the tolerance of V2P position, it will count as reject-shot. The maximum reject-shot count will be indicated into the system, the system will alarm when it reach the reject-shot count. |
| 9. Specification of Capacity |
| The parameters is to indicate the hardware parameters specification of machine, for example, high and low pressure of mould close or mould protected tons. |
To set the on line connecting communicate regulation between the server and injection machines. The COM port of server will be the existing RS232 COM port of PC. The on line connection will only success under the consistency regulation (e.g. 19200,N,8,2) between server and injection. The actual examples refer to following screen.
