SIJECT 16 / 16 DP Technical Details

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1 A&D MC PM1 SIJECT 16 / 16 DP Technical Details Product Series for Injection Molding Control Folie - Nr..: 1

2 Components of an Injection Molding Machine Í typically controlled by micro controller Cores: Controlled by digital output Ejector: Controlled with linear transducer 7RRO =RQHÃ+HDWLQJ Temperature control: typical 5 to 8 zones Injection unit 'RVLQJÃ6FUHZ Injection: Position system with linear transducer Carriage: Position system with linear transducer,qmhfwlrqã5dpv Closing unit: Position system with linear transducer Õ Solution: Solution: SIJECT SIJECT 16/16DP 16/16DP Proportional valves: Pressure and flow control Pump control Folie - Nr..: 2

3 Contents n Hardware CI board n Technology Software n Hardware HMI n Fully Electric Injection Molding Machine Folie - Nr..: 3

4 The structure illustration of CI Interfaces Outputs Inputs Profibus (SIJECT 16DP) Analog Outputs Digital Inputs P-Bus MPI Digital Outputs Analog Inputs RS 485 MMC-slot Relays Thermocouples Folie - Nr..: 4

5 SIJECT, Hardware Features: CI Board n Digital Inputs q all digital inputs optical isolated n Digital Outputs q Short-circuit protection n Analog Inputs q specified for Linear scales (1kOhm - 10 kohm, 12 Bit) n Analog Outputs q Prop. valve output (+/- 10V, 12 Bit) or q Prop. valve output with amplifier (+24-38V / 0,75-2A, 12 Bit) Folie - Nr..: 5

6 SIJECT 16/16DP CI board, Hardware and Interfaces Input Standard digital inputs: 31 / 31 High-speed digital input: 1 - Screw speed - Analog inputs (linear scales): 4 / 4 - Position clamb unit - - Position screw - - Position ejector - - Position carriage - Output Digital outputs (Transistor): 24 / 24 - for solid state relays e.t.c - Digital outputs (Relay): 8 / 8 - for motor Control e.t.c. - Digital outputs (Relay): 8 / 8 - for Temperature actor ( Contractor, SSR ) Thermocouple Channels: 6 / 8 - Sensor type: J or K - Analog outputs: 2 / 4 - for proportional valve amplifier or proportional valve: 2 / 4 amplifier Internal reference Temperature compensation: 1 Interface MPI V24 (for OP 15) P-Bus (for extension with S7-300) Profibus (SIJECT 16 DP ) Multimedia Card (MMC) PLC-Modules CI16: S7 CPU 314 CI 16 DP: S7 CPU 315 DP Folie - Nr..: 6

7 SIJECT Series Overview CI 16 int. Standard machines PLC >128k code 31 Inputs 1 Input counter (1 khz) CI 16DP int. Advanced machines PLC >128k code 31 Inputs 1 Input counter (1 khz) 24 Outputs 2A 8 Outputs relays 8x Relays for temp 24 Outputs 2A 8 Outputs relays 8x Relays for temp 4 x Analog inputs for linear scales 2 x Valve amp. 8x AI for TC 4 x Analog inputs for linear scales 4 x Valve amp. 8x AI for TC CI 16 : L-price 1.588,00 EUR SIJECT 16 : L-price 2.403,00 EUR CI 16 DP : L-price 2.147,00 EUR SIJECT 16 DP : L-price 2.863,00 EUR Folie - Nr..: 7

8 SIJECT 16, structure of the CI board MPI + P-Bus + PROFIBUS PLC320 Data Block (DB1) I/O-Control Periphery + RS MMC Folie - Nr..: 8

9 Extension of 16DP with standard S7-300 peripheries SIMATIC S7 extensions racks via IM361 with digital and analog peripheries MPI P-Bus extension OP 170 (1/4 VGA b/w) + optional Operator Panel Folie - Nr..: 9

* TE DI H S P 8 5 2 L T I E N SIJECT with PROFIBUS DP

10 * TE DI H S P L T I E N SIJECT with PROFIBUS DP Profibus DP MPI TP 270/TP370 (10 color) + optional Operator Panel SIJECT - CI Board SIJECT Periphery ET 200 S / M / X / L Masterdrive Simodrive... Folie - Nr..: 10

11 Contents n Hardware CI board n Technology Software n Hardware HMI n Fully Electric Injection Molding Machine Folie - Nr..: 11

12 SIJECT 16/16DP Software Versions n open loop program with OP 15 or OP170 q STEP 7 sequence program (application example) q HMI: q with OP15: fixed HMI functionality and screens q with OP170: adaptable HMI functionality and screens with ProToolLite n closed loop program with OP 170 or MP 270/370 (in preparation) q STEP 7 sequence program (application example) q technology function block TECH q Temperature Control block TEMP q HMI: q adaptable HMI functionality and screens with ProToolLite or ProToolPro for MP370 (MP 270 and OP 170 in preparation) Folie - Nr..: 12

13 Open Loop - Program Structure Ejector Core in 1,2,3 Mold close Basic Position Start Time-full auto Close safetydoor Sensorfull auto One cycle finished Ejector advance Air-blow 1&2 Mold open Carriage advance Cycle start key Core out 1,2,3 Injection Holding Charging Suck back Carriage retract Cooling time Folie - Nr..: 13

14 Open Loop I I // O -- Function Function 4 Analog Analog Input Input Scale Scale with with Reference Reference Point Point 2 direct direct output output function function with with scaling scaling factor factor and and time time ramp ramp display display of of screw screw rotation rotation Technology Technology -- Function Function Open Open Loop Loop -- Controller Controller 4 Step Step Profiles Profiles for for Injection, Injection, Hold Hold Pressure Pressure 2 Step Step Profiles Profiles for for Charging, Charging, Back Back Pressure Pressure 3 Step Step Profile Profile for for Clamp Clamp Movement, Movement, 2 Step Step Profile Profile for for Ejector Ejector Cut Cut Off Off Switch Switch Logic Logic with with Time Time or or Position Position 3 Core, Core, 2 Air-Blow Air-Blow and and Carriage-Functions Carriage-Functions Temperature Temperature Control Control Functions Functions 8 Channel Channel P-Controller P-Controller Monitoring Monitoring for for Wire Wire Break Break and and Tolerances Tolerances Folie - Nr..: 14

15 Closed Loop - Program Structure Ejector Basic Position Ejector advance Core in 1,2,3 Air-blow 1&2 Mold close Start TECH TEMP One cycle finished Mold open Carriage advance Core out 1,2,3 Injection Holding Charging Suck back Carriage retract Cooling time Folie - Nr..: 15

16 SIJECT 16 Software Functions - closed loop - TECH Technology Technology -- Function Function TECH I I // O -- Function Function Analog Analog Input Input Scale Scale with with Reference Reference Point Point Calculation Calculation for for screw screw rotation rotation Calculation Calculation of of speed speed for for Injection Injection and and clamp clamp Different Different Valve Valve Characteristics Characteristics direct direct output output function function with with scaling scaling factor factor and and time time ramp ramp Digital Digital Function Function 9 channels channels position position detection detection via via cams cams cam cam dependent dependent manipulated manipulated output output limit limit switches switches Folie - Nr..: 16

17 SIJECT 16 Software Functions - closed loop - TECH Technology Technology -- Function Function TECH Step Step Profiles Profiles for for Injection, Injection, Hold Hold Pressure, Pressure, Charging, Charging, Back Back Pressure Pressure Step Step Profile Profile for for Clamp Clamp Movement, Movement, 4 Step Step Profile Profile for for Ejector Ejector Open Open Loop Loop or or Close Close Loop Loop with with PID PID -- Controller Controller Cut Cut Off Off Switch Switch Logic Logic with with Time, Time, Position Position or or Pressure Pressure Adaptation Adaptation to to reduce reduce the the break break down down of of Hold Hold Pressure Pressure in in the the Cut Cut Off Off Point Point Curves Curves for for Injection, Injection, Hold Hold Pressure, Pressure, Charging Charging and and Back Back Pressure Pressure Quality Quality Function Function via via Master Master Curve Curve and and Tolerance Tolerance Band Band Calculation Calculation of of the the Integral Integral of of Injection Injection Pressure Pressure Process Process Value Value Monitoring Monitoring Folie - Nr..: 17

18 SIJECT 16 Software Functions - closed loop - TEMP Technology Technology -- Function Function TEMP TEMP Channel, Channel, expandable expandable up up to to Channels Channels PID PID Controller Controller with with Close Close Loop Loop Zone Zone Self Self Tuning Tuning Parameter Parameter Adaptation Adaptation during during Process Process separate separate Parameters Parameters for for Heating Heating and and Cooling Cooling Monitoring Monitoring for for Wire Wire Break, Break, indirect indirect Short Short Cut Cut and and Tolerances Tolerances Folie - Nr..: 18

19 Siject 16 Software Structure (closed loop) HMI MPI PLC 320 OS PLC 320 OS OB1 OB 100 OB40 OB1 OB 100 OB40 User Cycle Program Communication Function Block Read / Write I / O Data Block Commands Messages Data Block I / O Counts Data Block Parameter Technology Block Temperature Control Backgr. Init. Cycle Technology Block Injection Molding Backgr. Init. Cycle Folie - Nr..: 19

20 Contents n Hardware CI board n Technology Software n Hardware HMI n Fully Electric Injection Molding Machine Folie - Nr..: 20

21 Operator Panels for SIJECT OP15 (240 x 128 dots LCD, 16 lines with 30 Latin Characters, 8 lines of 15 Chinese Characters, 64 Keys) fixed screens, only for Open loop OP 170 (1/4 VGA, b/w) with ProToolLite (Injection Molding Standard HMI/light) / optional with MSTT TP 270/370 (10 VGA, color) with ProToolPro (Injection Molding Standard HMI) + MSTT with Jog Shuttle Folie - Nr..: 21

22 Menu tree of OP15 (function keys) Function keys below display Alarm messages 1 Monitor Screen Temperature1 Timer Function Input 1 Save/Load Information 1 Alarm messages Temperature2 Counter Input 3 Information 2 Output 1 Output 3 Folie - Nr..: 22

23 Menu tree of OP15 (screen call-out keys) Mold Open Mold close Ejector Carriage Injection Holding Charge Core1 Core2 Air blow Core3 Screen Call-out keys Mold adjustment Lubrication/ Purge Folie - Nr..: 23

with LED s Password Alphanumeric inputs Alarm Clock Compact Flash Card

24 OP170B - CE Operator Panel Recipes Curves Text- and Graphic lists Alarm and Machine mailfunktions 3 Online Languages (20 Offline) Foil Keyboard with LED s Password Alphanumeric inputs Alarm Clock Compact Flash Card and more. OEM definable Machine keys B/H/T: 240mm x 252mm x 45mm Folie - Nr..: 24

25 OP 170 B - Screen Sample (open loop)! i Blue mode Act. product counter Current Start-up Start time 20:45:15 Cycle time S Current pressure 100 Current flow 80 Production time S Information message Manual lubrication Purge setting Folie - Nr..: 25

MP 370 - CE Operator Panel 12" TFT LCD Display 800 x 600 SVGA 256 colors Smooth front without cover, degree of

expectancy of backlighting: 50,000 hrs Dimensions as TP27-10": - Front 335 x 275 - Mounting 310 x 248 x 65 6 MB

26 MP CE Operator Panel 12" TFT LCD Display 800 x 600 SVGA 256 colors Smooth front without cover, degree of protection IP65/ Nema 4/12 Temperature range 0 to 50 C Serial interface of configuration computer and printer Life expectancy of backlighting: 50,000 hrs Dimensions as TP27-10": - Front 335 x Mounting 310 x 248 x 65 6 MB configuration memory PC/CF card slot Ethernet (TCP/IP) interface USB-interface poss. for - keyboard - mouse - barcode reader Folie - Nr..: 26

27 MP Screen Sample (closed loop) Folie - Nr..: 27

SIJECT 16: HMI Software n ProTool/Lite for OP 170 q Configuration Software q MLFB 6AV6580-3BX05-2AX0 q list price: 330.

28 SIJECT 16: HMI Software n ProTool/Lite for OP 170 q Configuration Software q MLFB 6AV6580-3BX05-2AX0 q list price: Euro q no run time license necessary n ProTool/Pro for MP 270/370 q Configuration Software q MLFB 6AV6581-3BX05-2AX0 q list price : Euro q run time software (2048 power tags) q MLFB: 6A6584-1AF05-2BX0 q list price: Euro Folie - Nr..: 28

29 Contents n Hardware CI board n Technology Software n Hardware HMI n Fully Electric Injection Molding Machine (under preparation) Folie - Nr..: 29

30 Fully Electrical Injection Molding Machine Folie - Nr..: 30

31 Customer benefit, for a Fully Electrical Injection Molding Machine Higher accuracy Better repeatability % Reduced energy consumption % Clean room ability 100 % Decreased Noise ejection % Smaller costs, for aim-off of lubricant, oil approx. 80 % Smaller disposal costs (Oil) approx. 80 % Folie - Nr..: 31

32 High End Solution with OP37 Color, CI16 DP 31 Input points 24VDC 24 Output points 24VDC/2A 16 Output points Relay 8 Thermocouple input points 4 Analog Linear Potentiometer inputs 0-10V 4 Analog Proportional Valve output 0-10V 4 Analog Proportional Valve driver output 0-10V 1 counter input OP37 SM335 S7300 SM335 SM335 MPI &,Ã'3Ã P-Bus IM361 SM335 AI4/AO4 x 14 / 12 Bit SM335 AI4/AO4 x 14 / 12 Bit SM335 AI4/AO4 x 14 / 12 Bit X X X HG01-0AB HG01-0AB HG01-0AB0 SM321 Technology Injection Temp Injection Unit Injection Ejector Clamp 2 x AO Speed / Force Power 2 x AI Speed / Force 611U Control Unit Dosing 3,8 KW Ejector 3,0 KW Clamp 3,8 KW Injection 9,5 KW Injection Unit Folie - Nr..: 32 4 X 4 X

33 CI16 DP, OP170B 31 Input points 24VDC 24 Output points 24VDC/2A 16 Output points Relay 8 Thermocouple input points 4 Analog Linear Potentiometer inputs 0-10V 4 Analog Proportional Valve output 0-10V 4 Analog Proportional Valve driver output 0-10V 1 counter input S7300 SM335 SM335 MPI &,Ã'3Ã P-Bus IM361 SM335 AI4/AO4 x 14 / 12 Bit SM335 AI4/AO4 x 14 / 12 Bit X X HG01-0AB HG01-0AB0 2 x AO Speed / Force 2 x AI Speed / Force SM321 Technology SM321 Technology Injection Injection Temp Temp Injection Unit Injection Ejector Clamp 611U Power Control Unit Dosing 3,8 kw Ejector 3,0 kw Clamp 3,8 kw Injection 9,5 kw Injection Unit Folie - Nr..: 33 4 X 4 X

sensors with PROFIBUS-OP AE AA Cheap and fast connection to

34 Applikation Basisextruder MPI SIJECT CI 16 DP P-Bus TEMP ET200 B PROCESS FIELD BUS Expansion of periphery, drives, sensors with PROFIBUS-OP AE AA Cheap and fast connection to standard S7- Periphery MASTER- DRIVES VC kw Folie - Nr..: 34

35 Back up sheets Folie - Nr..: 35

36 Contents n Start-up & Service n Technology Software n Hardware HMI n Fully Electric Injection Molding Machine Folie - Nr..: 36

37 Start-up & service n Start-up and Tools q Open Loop q Step7 (min. Step7 mini-version) q Local Teleservice q MMC-Card q Close Loop q Step7 (min. Step7 mini-version) & MMC-Card q Local Teleservice & MMC-Card q MMC-Card q Close Loop Technology TECH +TEMP q MMC-Card Folie - Nr..: 37

38 Software & Tools Bootlult Program (DOS ) RS485 OP 15 Firmware Menu SIJECT Loader (Windows ) RS485 Firmware: IO Memory Card Communication CI16 Code SIMATIC Manager (Windows ) MP I DB1 (DPR AM) Data exchange PLC Application Code Folie - Nr..: 38

39 S IJE CT 15/16 Adapter Activate Bootstrap Loader Res et CI15/16 or OP 15 S elect Connection: PC to OP15 or PC to CI15/16 B oot Reset CI/OP To PC RS 232 OP CI To OP15 RS485 To CI15/16 RS485 Folie - Nr..: 39

32 mm Handling Multi Media Card (MMC) 1 2 3 4 5 6 7 1. Recipes: the MMC 50 can store up to 50 recipes the SIJECT 30 can store up to 30 recipes 24,0 mm 2. PLC - Controlprogram 3.

40 32 mm Handling Multi Media Card (MMC) Recipes: the MMC 50 can store up to 50 recipes the SIJECT 30 can store up to 30 recipes 24,0 mm 2. PLC - Controlprogram 3. Technology Software (TECH + TEMP) Standard Memory Card (8-128 Mbyte) Fully compliant with industry standards Miniature postage stamp size Low power consumption to conserve battery life 4. Start page for OP 15 Folie - Nr..: 40

41 SIJECT 16: S7 Software Packages n For S7 - Program: SIMATIC S7, STEP 7-MINI V5.0 q S7-300, 5 Languages, CD, with electr. documentation, WINDOWS 95/98/NT, single license q limitation: no CP s + FM s q MLFB: ES CC04-0YX0 q list price: Euro Folie - Nr..: 41

IF2, RS232/TTY (act/pass) q IF1B, RS422/RS485 q IF3, TTY(pass.

42 SIJECT OP37 n CPU: Pentium 100 Mhz, heatpipe n Display: 10.4 STN, 640x480, VGA n 50 Keys, 32 System-, 8 Soft keys n Interfaces q IF1A, RS232/TTY (act/pass) q IF2, RS232/TTY (act/pass) q IF1B, RS422/RS485 q IF3, TTY(pass.)/RS422/RS485 n Printer Port n External MF2 keyboard n Jeida/PCMCIA cards type I, II, III n Power Supply, 18 to 30 V D, max. 2A n 340 mm x 550 mm x 150 mm (H x W x D) Folie - Nr..: 42

SIJECT 16i Operation Manual Software Version 1

SIJECT 16i Operation Manual Software Version 1 User Manual 11.2003 Edition User Documentation SIJECT 16i Document Structure General Documentation: Catalog Short Start-Up User Documentation: Operation Manual