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Before you purchase or retrofit another injection molding machine, investigate the Allen-Bradley
Pro-Set 200 Injection Molding Control. Based on our widely used SLC Small Logic Controller,
this system provides complete control of the molding machine.
The Pro-Set 200 Injection Molding Control System offers you these
features and more.
Profiling lets you configure the operation of screw, clamp, and ejectors
for faster, smoother, molding cycles. We provide profiling screens
where you subdivide machine action into position segments, each
having a pressure or velocity setpoint. This lets you manipulate
hydraulic pressure and/or velocity of the injection ram, allowing you to
mold even the most complex parts with the most difficult of materials.
For example, you can divide the injection phase into 5 segments and
tailor the speed of the injection shot to the characteristics of your mold
and/or material.
Injection Profile
segment 4
segment 3
segment 2
segment 1
segment 5
Ram (screw)
Pos 4
Vel 5
xx.xx
Pos 3
Vel 4
xx.xx
Pos 2
Vel 3
xx.xx
Pos 1
Vel 2
xx.xx
Vel 1
xx.xx
xx.xx
xx.xx
xx.xx
xx.xx
psi 5
psi 4
psi 3
psi 2
psi 1
xxxx
xxxx
xxxx
xxxx
xxxx
Profiles Used in
the Molding Process
Any profile in the inject, clamp, and ejector phases can be controlled
by pressure or velocity to suit you molding machine. Here are the
default (pressure or velocity) control modes and number of segments
for all of the profiles that Pro-Set 200 uses in the molding process:
Control of Inject Phase
Profile:
Injection
Pack
Hold
Pre-Decompress
Plastication
Post-Decompress
Segments:
5
2
2
1
5
1
Default Mode:
Velocity
Pressure
Pressure
Velocity
Pressure
Velocity
Segments:
3
1
1
1
1
4
Default Mode:
Velocity
Pressure
Pressure
Pressure
Pressure
Velocity
We Do the Engineering
For You
Segments:
2
1
1
Default Mode:
Velocity
Velocity
Velocity
System Expansion to
Match Your Machine
Precise Temperature
Control
is easy to use
has resolution of "0.1 degree C / F
is optimized for your process
You would set up and monitor temperature control loops with this
PanelView screen, included in the set of Pro-Set 200 operator screens.
An Easy-to-use
Control System
Communication Networks
and Software to Gather
Process Data
Lower Cost
Pro-Set 200
PanelView Screens
Reserved
I/O Slot
PanelView 550 or 900
SLC 5/04P
Processor
Fast Analog
I/O Modules
Temperature
Control
Modules
Optional Modules
for other purposes
(ac, dc, relay)
Pro-Set 200
Ladder Logic
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Power
Supply
executes the sequence logic which controls the injection molding machine. Embedded within this
processor are the ERC2 algorithms which control the pressure and flow valves for the injection,
clamp, and ejector phases.
accepts position and pressure inputs and provide analog output signals to the proportional valves
which control velocity and pressure. You need a least one FIO4V or FIO4I module for each controlled
phase (pressure and position inputs and pressure and velocity outputs). To select these modules:
If your valves require and/or your sensors produce"10V dc signals, use FIO4V
if your valves require and/or your sensors produce 4-20mA signals, use FIO4I
To control all three phases (inject, clamp, eject) with pressure/position inputs and pressure/flow
outputs, you need at least three modules. More may be required for other I/O combinations.
provides temperature control for the barrel of the injection molding machine. These modules contain
specialized start-up and auto-tuning algorithms which have been optimized for barrel temperature
control. Each module controls four temperature loops using either J or K thermocouples (grounded or
ungrounded). The ladder logic and PanelView screens accommodate eight temperature loops.
Important: Separate output modules provide the time-proportioned (on/off) or analog outputs for the
temperature loops. BTM modules do not have outputs.
lets you enter and modify profile and temperature setpoints, see alarms, view production data, etc.
works with the ERC2 algorithms to control closed-loop hydraulic pressure and flow circuits of the
inject, clamp, and eject phases of machine operation. Also controls the machines sequential
operations. You may modify this logic to accommodate your specific machine.
lets you operate the machine (configure profiles, modify/monitor temperatures, save/restore recipes),
calibrate, and troubleshoot. You may modify or add screens for additional machine features.
accept limit-switch and pushbutton inputs; control heaters, directional valves, pilot lights, and manual
functions. You can use any of the 1746-type I/O modules in the SLC 500 product line.
Machine
Setpoints
Position Inputs
Production
Data
DH
Communications
Data
Table
Pressure Inputs
Raw
Pressure
STI
File
ERC2
Algorithms
scaled
position
Pressure
Valve
Fast Analog
I/O Module
scaled
pressure
Pressure
Output
scaled
position
3. ERC2 algorithms
use scaled position
and pressure inputs
to compute velocity
and pressure outputs.
scaled
pressure
Data
Table
Output to
Pressure Valve
Flow
Valve
Velocity
Output
velocity, pressure
output values
velocity, pressure
output values
Direct
Outputs
Output to
Flow Valve
Main
Ladder Logic
File
Directional
Valves
Pilot Lights
Data
Table
I/O
Update
Pumps
Heaters
Direct
Inputs
Operating
System
Pushbuttons
Limit
Switches
Pro-Set 200
Inputs and Outputs
Ladder logic for Pro-Set 200 software includes the following inputs
and outputs:
Inputs
Outputs
Malfunction Lamp
Qty:
Catalog Number:
1747-L542P
1-3
1746-BTM
1-3
1746-FIO4I or 1746-FIO4V
1746-P4
I/O Chassis
1746-A10
6500-PS2LBL
6500-PS210
Feature Specifications:
program memory size 32K
high-speed performance 0.90 ms/K typical
control of up to 960 local I/O
online programming (includes runtime editing)
built-in DH+ channel, supporting:
high-speed SLC 5/04P to SLC 5/04P communication
messaging capability between PLCsR and SLCs
built-in RS-232 channel, supporting:
DF1 Full-Duplex for remote or point-to-point communication,
General Specifications
Power Supply Loading at 5V dc
Clock/Calendar Accuracy
Noise Immunity
Vibration
ba
Shock (operating)
Humidity
Agency Certification
(when product or packaging is marked)
10
Communication Options
The processor supports the following types of communication options.
Data Highway Plus (DH+) channel offers:
Electrical Specifications
Backplane current consumption
Backplane power consumption
110 mA at 5V dc
85 mA at 24V dc
0.6W maximum (0.55W @ 5V dc, 2W @ 24V dc)
Number of channels
sigma-delta modulation
Input filtering
greater than 50 dB at 50 Hz
greater than 60 dB at 60 Hz
greater than 120 dB at 50/60 Hz
(with 1K ohm imbalance)
8 Hz
Calibration
Isolation
Environmental Specifications
Operating temperature
Storage temperature
Relative humidity
Agency Certification
(when product or packaging is marked)
11
Physical Specifications
LED indicators
Module ID code
10223
Recommended cable:
for thermocouple inputs
for mV inputs
Maximum wire size
Terminal strip
Overall accuracy
Overall accuracy includes variances in cold-junction compensation,
calibration, non-linearity, and resolution.
Input
Type
Maximum Error
@ 25C
Maximum Error
@ 77F
Temperature Drift
(0C60C)
1.06C
1.91F
0.0193C/C, F/F
1.72C
3.10F
0.0328C/C, F/F
50 mV
30 mV
30 mV
100 mV
30 mV
30 mV
Input Specifications
Thermocouple linearization
Input impedance
Temperature scale
0.1C or 0.1F
DC millivolt scale
0.01 mV
20 nA typical
Display resolution
0.1C/step or 0.1F/step
upscale
12
Specifications for
Fast Analog Modules
(Cat. No. 1746-FIO4I or
1746-FIO4V)
General Specifications
Catalog
1746-
ID
Code
Input Channels
per Module
Output Channels
per Module
Backplane Current
5V
24V
FIO4I
3224
2 current output
55 mA
150 mA
FIO4V
3218
2 differential,
select V or I per channel
2 differential,
select V or I per channel
2 voltage outputs
55 mA
120 mA
Input and output channels are isolated from the backplane but not from each other.
SLC Communication Format
500K ohms
Impedance, Channel-to-channel
1M ohms
500V dc (continuous)
Cable
Wire Size
removable
Installation
Calibration
factory calibrated
Noise Immunity
Environmental Conditions
Operating Temperature
Storage Temperature
Relative Humidity
0-60C (32-140F)
40 to 85C (40 to 185F)
5-95% (noncondensing)
Agency Certification
(when product or packaging is marked)
100 sec
Converter Resolution
12-bit
Conversion Method
successive approximation
Nonlinearity
0-20V dc (max)
n/a
n/a
Channel Bandwidth
0FFF
1.5 s (nominal)
Conversion Time
Module Throughput Delay
1.10 ms (max
Worst case throughput occurs when the module just misses seeing an event occur.
13
20 mA
Input Range
Input Impedance
Resolution
2 LSB (typical)
4 LSB
0.14 LSB/C (max )
Overvoltage Protection
10V dc
Input Range
0-10V dc 1 LSB
Input Impedance
1M ohms (nominal)
Resolution
14
Output Specifications
Full Scale
Output Range
Output Coding
Output Resolution
Converter Resolution
Location of LSB in I/O Image Word
Nonlinearity
Conversion Method
Step Response
Load Range
Load Current
Load Reactance
Over-range Capability
10V dc
10 to +10V 1 LSB (normal)
32,768 to +32,764 for -10 to +10V dc
1.22070 mV per LSB
14-bit
0000 0000 0000 01XX
0.05% of full scale
R2R ladder
2.5 ms (normal)
1K to ohms
10 mA (max)
1 F (max)
n/a
Pro-Set 200, ERC2, PanelView, and SLC are trademarks of Allen-Bradley Company, Inc.
16
Allen-Bradley, a Rockwell Automation Business, has been helping its customers improve
productivity and quality for more than 90 years. We design, manufacture and support a broad
range of automation products worldwide. They include logic processors, power and motion
control devices, Operator Interfaces, sensors and a variety of software. Rockwell is one of the
worlds leading technology companies.
Worldwide representation.
Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444