Measure & Analyze MM Automatic Quality Control System (AQCS) 5881B... 1... 5 The AQCS is used in conjunction with quartz cavity pressure sensors for measuring cavity pressure on injection molding machines, and is used to monitor and control the injection molding process. Artificial intelligence has made it possible to detect the volumetric filling of a cavity during injection molding and to switch over automatically from the injection to the holding pressure phase. The measured values are digitized. The 2 thresholds, upper limit (UL), lower limit (LL) as well as the condition within the limits are monitored by software. The peak value of the pressure p ma and the pressure curve p inde integrated over time (adjustable integral limits) are shown on the display numerically as measurands and graphically as trends. The pressure curve is recorded and displayed as a graph for setting the injection molding machine. The AQCS can be connected via 8 digital inputs and 8 digital outputs to a machine control system, in order to switch automatically to holding pressure and to transmit various control commands (alarm, good/reject, operate etc.). Illuminated graphics (LCD) provide the display. The equipment complies with the safety requirements according to EN61010-1 and also the EMC standards EN50081-2 (interference emission) and EN50082-2 (interference immunity), and is thus in conformity with the CE. Inputs and outputs are protected by varistors against electrostatic discharges (ESD). Intelligent, automatically optimized switching Maimum pressure and pressure integral monitoring Curves and trends on graphic display Auto zoom of the curve trace Documentation via RS-232C interface For direct and indirect measurement behind a pin Selectable mechanical units («bar», «psi», «Mpa») Conforming to Technical Data * Analog channel inputs 1 Scanning frequency (channel) khz 1,1 Error (with calibration) %FS <±1 Repeating error %FS <0,1 measurement and protective ground V <20 Analog monitor outputs (2 mm sockets) - Measuring amplifier output 1 Output voltage V ±10 Error repetition %FS <±0,1 measurement and protective ground V <20 Digital inputs: (electrically isolated by optocouplers) 8 Logical input level High V >14 Logicial input level Low V <8 Input current at 24 V ma 5 Input Voltage V <±30 inputs and protective ground V rms <30 Digital outputs (System: Photo MOS-relay, 4 outputs 8 in each case connected on one side) Voltage V <±42 Current loading ma <100 Current loading, pulse Impulse <0,1s ma <300 Resistance when switched on Ω <50 outputs and protective ground V rms <30 Auiliary supply Non-stabilized, electrically isolated Voltage No-load voltage V 26 at rated mains voltage and 150 ma current V 24 Current ma <300 Source resistance Ω 15 Au., GND and protective ground V rms <20 * In all Kistler documents, the decimal sign is a comma on the line (ISO 31-0:1992).
2 RS-232C interface (without control lines, signal ground is connected to analog measuring ground) Voltage at receiver input V <±20 Baud rates 110, 150, 300, 600, 1200 2400, 4800, 9600 Data bits 7 oder 8 Stop bits 1 Parity (none, even, odd) General Operating temperature range C 0... 50 Suply voltage VAC 100... 240, ±10% Hz 50... 60 VA 22 Mains connection 2P+E, Protection Class I Type IEC 320C14 Dimensions without case, cassette per DIN 41494 Part 5 42TE 3HE with case (WHD) mm 236151255 Weight (incl. case) kg 5,2 Charge amplifier module Measuring range, switched in steps 1, 2, 5 pc ±500... ±200'000 Drift pc/s <±0,05 Zero transient (Reset-Operate) pc <±1 Error (after echange, without re-calibration) %FS <±3,5 Equipment construction The AQCS has a modular design and consists of: Channel card with an epansion slot for a channel module Channel module for quartz sensors Case (table-mounted case, Switchboard installation set or 19 cassette) Power supply Front panel with display and keyboard Channel module Single-channel charge amplifier for quartz sensors Measuring range (switchable) 20, 50, 100, 200, 500, 1000, 2000 bar Sensor sensitivity adjustable 1,00... 99,9 pc/bar Analog monitor output Block diagram Display Keyboard Piezoelectric sensor Channel card Machine control (SPS) Channel module A Module SL Supply Analog output RS-232C Printer 100-240V AC 50-60HZ 24V DC PC
3 Evaluation functions Monitoring of the upper and lower limits (UL, LL) is carried out using preset absolute values or in percentage values. Selection of monitoring mode Maimum cavity pressure Integral (cavity pressure over operate time) Choice of thresholds (SL, LL, UL) Manual entry or automatic calculation of limits Function Real Time On-Line SL LL Within Limits UL p ma p inde Trend p ma Trend p inde (Real Time = during the measuring cycle, On-Line = after the measuring cycle) Monitor screen Measurement screen Menu screen Mask screen Operation The AQCS is menu-driven via the keyboard and the illuminated graphic display. Up to 99 equipment settings can be stored in the nonvolatile memory and can be selected via the keyboard or via a SPC. Operating levels with protected access guarantee optimum security and ensure that only authorized personnel have access for changing the parameters. Application The AQCS is primarily intended for automatic switching from the injection to the holding pressure phase of injection molding machines as well as for process monitoring. It is ideally suitable for upgrading eisting machinery. The automatic learning phase integrated in the AQCS considerably simplifies the start-up of production and for optimizing new molds. (For learning phase description, see Operating Instructions). Attention Automatic switching is possible only by using the directly measured mold cavity pressure, since only this parameter constitutes a specific feature of the volumetric filling of the cavity. Neither the hydraulic pressure nor the nozzle pressure can be used for this. The mold cavity pressure must be measured by a sensor mounted close to the gate. The AQCS determines the optimum switching point from the change in gradient of the rise in pressure, which occurs when the cavity is volumetrically full. Fluctuations in temperature and viscosity of the melt are thus automatically compensated for. This ensures that switching takes place neither prematurely (distorted parts) nor too late (parts with high internal stresses). The AQCS determines the optimum switching point in real time, shot by shot. Process fluctuations are thus compensated for and the AQCS automatically changes the machine settings to achieve constant quality of the parts.
4 Connector pin assignments Digital-Inputs Pin Digital-Outputs Pin (DSUB-26P, high density) Measure (+) 2 Ready 7 ( ) 1 Hardcopy (+) 11 Alarm 17 ( ) 10 Hand / Auto (+) 20 SL 8 ( ) 19 Read config. no. (+) 4 LL 18 ( ) 3 Common Digital Output 1-4 9 Digital-Input 5 (+) 13 Within 16 ( ) 12 Digital-Input 6 (+) 22 UL 23 ( ) 21 Digital-Input 7 p ma or p inde (+) 6 UL Kombi outside the limits ( ) 5 24 Digital-Input 8 (+) 15 not used 25 ( ) 14 Common Digital Output 5-8 26 Konfig Nr. Auiliary voltage +24VDC unstabilized (Round connector Binder Series 681, 4-pole) Function Pin Au. +24V 1 Au. GND 2 3 4 RS-232C interface (DSUB-25S) Function Pin Receiver RD 3 Transmitter TD 2 Signal ground 7 Screen/Protective ground 1 3 4 2 1 Ordering key for the Automatic Quality Control System AQCS Type 5881B v v without case 00 with case Type 5749A1 10 with Switchboard installation set 20 The basic unit comprises: Channel card equipped with single-channel charge amplifier Keyboard and display Power module RS-232C Interface Menu language selectable: English/German 19" cassette housing 42TE/3HE per DIN 41494 Eample for ordering 1 AQCS with keyboard, with single-channel charge amplifier for 230 V AC mains and built into housing Type 5749A1. The correct ordering code is 1 AQCS Type 5881B10 Safety notes and notes on product liability are included in the Operating Instructions. Accessories Type Printer cable RS-232C 3 m DB-25P/DB-25P 1467A3 Cable adapter DB-9P/DB-25S 1469 Connecting cable for digital inputs Type 1471A5 and outputs Adapter for testing the digital inputs Type Z16126 and outputs Connecting cable for auiliary supply 1473A5 AQCS - PC connecting cable 1465A3 Intermediate adapter with test sockets for digital input/output Z16126 Simulator incl. cable Z15822 Spare key for equipment operation 5.331.044 RS-232C cable with HARD WIRED HANDSHAKE 1475A3 Scope of delivery Power cord Type 1507/1508/1509 D-SUB-26 cable connector Art. No. 7.640.052 2 mm connector with fleible leads, black Art. No. 5.590.096 2 mm connector with fleible leads, red Art. No. 5.590.097 Cable connector 4-pole IP 40 Art. No. 5.510.228 (for auiliary supply AUX. +24 V)
5 Automatic detection of the switch-over point as soon as cavity is volumetrically filled. p p t Find the optimal switch-over point based on the cavity pressure: Traditional: Optimizing by hand 1 Set holding pressure to zero. 2 Set injection speed. 3 Choose intentionally a too low switch-over pressure (e. g. 50 bar). 4 Make a trial shot and determine the degree of volumetric filling. 5 Increase switch-over pressure, e. g. to 70 bar. 6 Make again a trial shot and determine the degree of volumetric filling. 7 Repeat steps 5 and 6 until the complete volumetric filling of the cavity is reached. Today: Molding with AQCS 1 Select a sufficiently large dosage (Melt cushion min.10 mm) 2 Holding pressure: about 2/3 of the epected holding pressure 3 Optimize remaining parameters as usual 4 Production: The AQCS switches over automatically when the mold is volumetrically full, i.e. at the optimum moment. The optimum switchover therefore also takes place when other parameters have also changed (e.g. the injection speed or melt temperature) or when parameters such as the viscosity of the melt change during production. 8 When the switch-over pressure for complete volumetric filling has been established (e. g. 112 bar), the switch-over point is optimized and only now the holding pressure can be set. 9 Each time a parameter (e. g. the injection speed or the melt temperature) is changed, the whole optimization must be redone, starting again with step 1 and whenever a parameter such as the viscosity of the melt varies during production, the quality of the parts is affected!