Speed without Haste EtherCAT for Injection Molding Systems. Chris Choi Director of Technology Husky Injection Molding Systems Ltd.

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1 EtherCAT for Injection Molding Systems Chris Choi Director of Technology Husky Injection Molding Systems Ltd.

2 Sales of US$860 million (fiscal 2005) 3000 employees Manufacturing campuses in North America, Europe and Asia Global, company-owned distribution network Technology leader Sales of US$935 million (fiscal 2006) 3rd International Chris Choi, October 4,

3 Injection Molding Equipment Suppliers Husky Engel Sumitomo Milacron **Krauss-Maffei **Demag Haitian Arburg Nissei JSW Toshiba **Netstal Mold Masters Hot runners / molds / mold components Machines $0 $100 $200 $300 $400 $500 $600 $700 $800 $900 Sales (millions of USD)* *Injection molding equipment sales estimates for year ending December 31, 2004 ** Part of MPM Includes machines, molds, hot runners, parts and service, robots and value-added services Source: Annual reports, Press reports, Husky estimates 3rd International Chris Choi, October 4,

4 Local Relationships - Worldwide 3rd International Chris Choi, October 4,

Hot Runners Hylectric 90-1000t 3rd International Chris

5 Hot Runners Hylectric t 3rd International Chris Choi, October 4, Quadloc t Polaris Control

6 Purpose and Core Values Core values have been the foundation of growth and success Make a contribution Proactive environmental responsibility Passion for excellence Bold goals Uncompromising honesty 3rd International Chris Choi, October 4,

7 3rd International Chris Choi, October 4,

8 3rd International Chris Choi, October 4,

9 Speed and Haste are not Synonymous Hasty actions do not produce speedy successes because hasty actions are not coordinated efforts. - Adapted from General George S. Patton Jr. Haste makes Wastes 3rd International Chris Choi, October 4,

10 Principle of Operation The Four E s Goal EXPLORE Variation Business BHAG EXECUTE CORE COMPETENCE EXPERIENCE Evolution Innovation EXPLOIT Selection Try a lot of stuff & keep what works. - J. Collins 3rd International Chris Choi, October 4,

11 Breaking the part cost barrier Thinner Wall Thickness Less Material Lower Cost What are the challenges? Cooling Lines Melt Front Frozen Layers Velocity Profile Thickness Fountain Flow 3rd International Chris Choi, October 4,

12 HyPAC - Purpose built for packaging 3rd International Chris Choi, October 4,

13 Benefits to Customer Material Savings Example (750 gram/ 24 oz) Part weight today (grams) 22 Part weight target (grams) 20 Cavitation 8 Annual parts 54,568,421 Annual PP savings (kg) 125,507 Annual savings ($US) $182,651 Reduces Part Weight 3rd International Chris Choi, October 4,

14 Hydro-Mechanical clamp, Reflex and SMC Central support, Speed, Efficiency, Mold Protection Force distribution Alignment and quick change 3rd International Chris Choi, October 4,

15 Hydro-Mechanical Clamp 3rd International Chris Choi, October 4,

Integrated manifold and cylinder head for low restriction hydraulic circuit.

16 Engineered for Performance With 30% more injection rate and plasticizing capability, HyPAC spans the performance of 2 conventional units. Integrated manifold and cylinder head for low restriction hydraulic circuit. Lighter parts. Less scrap. Faster cycle. 3rd International Chris Choi, October 4,

17 HyPAC +30% injection rate and plasticizing 3rd International Chris Choi, October 4,

18 Polaris Controls Network Server Husky Service Workstation Internet / Intranet 12 Husky HMI (High Resolution) CP Link Profibus Networking Industrial PC SERCOS Machine Control + Robot Control + HMI + Programming + Diagnostic + Web Enabled Machine Sensors and Actuators Robot Servo Drives 3rd International Chris Choi, October 4,

19 Controls Architecture - Testing Vehicle CP Link Panel IPC PROFIBUS DP PCI Card KL Terminal I/O 611U Screw Drive One additional NIC for TCP/IP (New) Temposonic EtherCAT I/O for Injection (New) TC Plug 3rd International Chris Choi, October 4,

20 Mapping wastes Control System Resource Fieldbus system generates physical process image Mapping to logical process image(s) is often required logical process images Control System, e.g. IPC Feldbus Scanner/ Data n PLC Data NC Data Mapping DPRAM node 1 node 2 node 3 node 4 Master node 1 node 2 node 3 node 4 Source: EtherCAT Technology Group 3rd International Chris Choi, October 4,

21 .... DVI Distributed Mapping IPC 2 32 Telegram Structure logical process image: up to 4 GByte Data n PLC Data NC Data 0 Ethernet HDR HDR 1 PLC Data HDR 2 NC Data HDR n Data n CRC Sub- Telegram 1 Sub- Telegram 2 Sub- Telegram n Distributing the mapping process releases the Control System Data transmission is application specific and is extremely fast, flexibly and efficiently Source: EtherCAT Technology Group 3rd International Chris Choi, October 4,

22 Process on the Fly Slave Device Slave Device EtherCAT Slave Controller EtherCAT Slave Controller Process data is extracted and inserted on the fly Process data size per slave almost unlimited Compilation of process data can change every cycle Support event triggered asynchronous communication Source: EtherCAT Technology Group 3rd International Chris Choi, October 4,

directly to PC RAM by DMA: CPU is relieved Enables higher Performance PC Control with EtherCAT NIC card, DMA

23 Direct Memory Access saves Time Fieldbus Cards: waste up to 30% of CPU s time to copy data PC Control with Fieldbus Cards PC RAM Scanner card, DP RAM PCI bus CPU Control task memcopy EtherCAT: NIC is PCI Bus Master, moves data directly to PC RAM by DMA: CPU is relieved Enables higher Performance PC Control with EtherCAT NIC card, DMA transfer CPU PCI DMA bus PC RAM Control task Source: EtherCAT Technology Group 3rd International Chris Choi, October 4,

EtherCAT has Built for Speed Leveraging the Fast Ethernet 100Mbit/s Communication completely in hardware Standard NIC hardware save CPU resource Pass-through telegram

24 EtherCAT has Built for Speed Leveraging the Fast Ethernet 100Mbit/s Communication completely in hardware Standard NIC hardware save CPU resource Pass-through telegram without buffering Built with well-thought-out Plan A fast train with pre-assigned seats High bandwidth with contingency and capacity 3rd International Chris Choi, October 4,

25 Real Time CPU Loading 40 Measured by Husky Real Time CPU Loading (%) Profibus (2 ms) EtherCAT (2 ms) Profibus (1 ms) EtherCAT (1 ms) Fieldbus (Control Scan Time) 3rd International Chris Choi, October 4,

26 Transition Position Repeatability Control Cycle Time mm/s Position 2 ms 2.00 mm 250 µs 0.25 mm Volume 2.00 % 0.25 % 80 Speed (mm/s) Speed at Transition = 1000 mm/s Velocity PV Position PV Position (mm) Fill to Hold Transition Time (s) 3rd International Chris Choi, October 4,

27 Transition Pressure Control 2500 Pressure (psi) Pressure SP 2 ms 250 µs Time (s) 3rd International Chris Choi, October 4,

28 Injection Hold Pressure Control 2 ms control cycle 250 µs control cycle Pressure (psi) Pressure SP Pressure PV 2 ms Time (s) Pressure (psi) Pressure SP Pressure PV 250 µs Time (s) Better performances with faster control cycle time? What are the constraints? Hints: Time constant of the process; rise time; bandwidth. 3rd International Chris Choi, October 4,

29 Summary of Performance Improvements Better injection repeatability Improved injection profile control Less melt degradation Better melt homogeneity Higher packing pressure Less energy consumption Lower maintenance Reduced noise level Part s Weight Variations 0.3% 3rd International Chris Choi, October 4,

30 Thank You! 3rd International Chris Choi, October 4,

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