Plastic Molding Module
Inject Mode
(Cat. No. 1771-QDC)
Page 1: ...Plastic Molding Module Inject Mode Cat No 1771 QDC...
Page 2: ...ion SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid...
Page 3: ...scribe the task 2 1 2 9 Reversed the order of chapters 3 and 4 to present the download procedure for the MCC block before the download procedure for the other data blocks Revised the download procedur...
Page 4: ...and Machine Interlocks 2 11 Configure the QDC Module s I O 3 1 Chapter Objectives 3 1 Use Worksheets to Select Module Parameters and I O Ranges 3 1 Determine Initial Sensor configuration Values 3 4 Do...
Page 5: ...ol Valves 7 12 Select the Type of PID Algorithm 7 14 Set Values for Expert Response CompensationE ERC 7 15 Determine Unselected Valve Set output Values 7 15 Set Your Acceleration Deceleration Ramp Rat...
Page 6: ...lve 9 25 Tune Your Machine for Producing Parts 10 1 Chapter Objectives 10 1 Closed loop Control 10 2 Tune Closed loop Pressure Control 10 2 Tune Closed loop Velocity Control 10 5 Tuning Considerations...
Page 7: ...remaining configuration procedures that you will perform throughout the remainder of this manual Chapter 4 Jog the ram screw This task requires jog setpoints to be configured along with jog pressure...
Page 8: ...by the QDC module s algorithms the selected valve Unselected Valves In multi valve systems depending on the configured profile the QDC module controls one valve and presets the remaining valves to pro...
Page 9: ...ack Hold Profile Block PRC Pre decompression Configuration Block PLC Plastication Configuration Block PPC Plastication Profile Block PSC Post decompression Configuration Block DYC Dynamic Command Bloc...
Page 10: ...for the successful application of the QDC module Publication Use this documentation To 1785 6 6 1 PLC 5 Family Programmable Controller Installation Manual Install the PLC processor and I O modules 62...
Page 11: ...C module If you purchased Pro Set 600 software you also need the following Publication Use this documentation To 6500 6 5 11 Pro Set 600 Software Designer s Guide Select the Pro Set 600 software that...
Page 12: ...e flexibility of the molded part To achieve uniform density you can release or increase pressure in steps according to cooling gradients across the mold Thus as the plastic cools unevenly the pack pro...
Page 13: ...peed The pattern of velocity or pressure variation during injection is called the injection profile The QDC module lets you chose from four different injection profiles velocity vs position pressure l...
Page 14: ...ocity setpoint the module returns to velocity control Example Benefits of Profiling an Injection Phase The injection phase should force the melt through the mold as fast as possible without flashing o...
Page 15: ...n boost velocity at segment 3 c where the resulting pressure is well below the flash point Segment pressures in part 4 are optimum for the velocity vs position profile in part 3 Figure 1 4 Flash Preve...
Page 16: ...the event You also may specify the zone of ram screw travel over which pressure transitions may or may not occur Pack Phase The QDC module controls the pack phase with a pressure vs time profile You...
Page 17: ...r pressure Pressure You can remedy this by decreasing the pack pressure with time so plastic can back out of the mold as shown in Figure 1 7 This is to alleviate gradations in density as the plastic c...
Page 18: ...nt if none is required and immediately starts the plastication phase or waits for a command from your PLC program to continue Pre decompression Movement You select a length of pullback for the ram scr...
Page 19: ...ressure or increasing screw RPM After completing the last segment of the Plastication phase the QDC module either immediately starts the Post decompression movement or waits for a command from your PL...
Page 20: ...per plugs and in chapter 4 to configure the module s inputs and outputs with software Circle or check the I O ranges on Worksheet 2 A Cross off I O not used Worksheet 2 A Record I O Ranges I O Connect...
Page 21: ...static work station when setting jumper plugs 1 Remove the label side cover plate by removing the four screws 2 Remove the circuit board from the module housing by removing the two screws located cent...
Page 22: ...uit Board E6 E7 E8 E9 E17 E13 E14 E10 E16 E11 E15 E12 E5 E1 TOP BOTTOM RIGHT LEFT 10908 I Important We define jumper plug positions as left right top and bottom This represents the position of the jum...
Page 23: ...ts Important If you select current output with jumper plugs E10 E14 E13 and or E17 then you must select the 4 to 20mA jumper position with E11 E12 E15 and or E16 ATTENTION If an output is unconnected...
Page 24: ...ing bands between the following terminal numbers labeled on the backplane connector of your I O chassis see Figure 2 2 between 20 and 22 between 26 and 28 Figure 2 2 Keying Positions 2 4 6 8 1 0 1 2 1...
Page 25: ...ifications to your PLC 5 application program will be necessary refer to your Pro Set 600 documentation for details 3 Do not force the module into its backplane connector Apply a firm and even pressure...
Page 26: ...sor Screw RPM Sensor Amplifier Valve 1 Amplifier Valve 2 Customer PS Earth Ground Input 1 Input 2 Input 3 To Valve 1 To Valve 2 Output 1 Output 2 Wiring Arm 1771 WF Amplifier Valve 4 To Valve 4 Output...
Page 27: ...Output common 09 08 Valve 2 Output 2 Output common 07 06 Valve 3 Output 3 Output common 05 04 Valve 4 Output 4 Output common 03 02 Not used 01 ATTENTION The QDC module has ESD protection to 20KV but...
Page 28: ...distances over 50 ft use 18 gage cable such as Belden 8760 or equivalent Ground the cable shield at one end only generally at the sensor or amplifier end not at the I O chassis see Figure 2 4 and Figu...
Page 29: ...separate grounded conduits in parallel runs separate the Class A and B conduit by at least 1 foot where conduit runs must cross cross them at right angles For additional grounding recommendations ref...
Page 30: ...nadvertent clamp closing with a safety gate in an open position In addition we strongly recommend that the electrical interlocks consist of redundant devices and that the control circuit be so arrange...
Page 31: ...ression network for 120V AC use Allen Bradley cat no 700 N24 for 220 240V AC use cat no 599 KA04 To minimize EMI generation you should connect a suppression network for 120V AC use Allen Bradley cat n...
Page 32: ...tion to move the ram screw complete your sensor configuration use optional sensor configurations Important You must properly configure the QDC module using procedures in this chapter before attempting...
Page 33: ...ddr B34 bit 543 542 541 540 539 538 537 536 535 534 533 532 531 530 529 528 Value 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 Example If you select Inject operation with English units MCC02 00000000 00001000 Select...
Page 34: ...3 3 3 Worksheet 3 B Select Input Ranges for your Sensors Control Word MCC03 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr B34 bit 559 558 557 556 555 554 553 552 551 550 549 54...
Page 35: ...560 0 009 99 sec 0 47 sec 00047 0 09999 psi 321 psi 00321 0 0999 9 Bar 222 Bar 2220 Table 3 A Determine Initial Sensor configuration Values for Worksheet 3 D Category If your Then Use a Value Equal to...
Page 36: ...ero 1 2 MCC10 N40 6 Maximum Screw Position Screw Axis Measured from zero 1 3 MCC11 N40 7 Analog Signal Min Screw Position Input Signal Range 2 4 MCC12 N40 8 Analog Signal Max Screw Position Input Sign...
Page 37: ...enter bit selections in words prefixed with file identifier B example B34 the PLC 5 processor automatically switches the radix to binary format so you can conveniently enter binary data Download MCC V...
Page 38: ...s an error the QDC module halts operation until you correct the error For a complete list of error codes to help you correct a programming error refer to Section 2 of the Plastic Molding Module Refere...
Page 39: ...value of zero in set output words N40 121 N40 124 does not necessarily correspond to zero pressure or flow If you configured jumper E11 E12 E15 and or E16 for bi directional valve operation an output...
Page 40: ...Pro Set 600 software so changes you make to output values are immediately implemented Complete the procedure for configuring the QDC module to match its sensors by spanning them over their intended r...
Page 41: ...2 8 MCC20 N40 16 Analog Signal Max Screw Pressure Input Signal Range 2 3 9 MCC51 N40 47 0 Minimum Screw RPM Rotational Speed 4 10 MCC52 N40 48 Maximum Screw RPM Rotational Speed 4 11 MCC53 N40 49 Ana...
Page 42: ...movement 3 Record this position value normally 0000 on line 1 for MCC09 on Worksheet 4 E 4 With your programming terminal read the signal level returned in SYS33 N40 185 from your position sensor You...
Page 43: ...re sensor in step 4 ATTENTION Use extreme caution during the next steps because you stress the hydraulic system to its maximum rated pressure Loose fittings or faulty components could fail causing pos...
Page 44: ...ost applications require no further spanning If your application requires greater accuracy follow the this procedure 1 Confirm that the screw is at rest not rotating 2 Record 0000 as the minimum RPM o...
Page 45: ...st damaging the nozzle assembly or seals Pressure Alarm Time Delay to warn of excessive pressure without nuisance alarms Digital Filter to compensate for noise on position inputs RPM Alarm Time Delay...
Page 46: ...DC module for SWTL as follows 1 Determine these SWTL values for ram screw travel with respect to the range of physical travel SWTL deadband Maximum SWTL Minimum SWTL 2 Record non zero SWTL values on W...
Page 47: ...re alarm setpoint time delay setpoint 2 Determine these values for screw RPM alarms RPM alarm setpoint time delay setpoint 3 Record non zero setpoints on Worksheet 3 G for the pressure alarms RPM alar...
Page 48: ...rt with a small value such as 00 01 and enter it into MCC16 N40 12 A value of zero disables the filter ATTENTION Increasing the value of the time constant decreases the QDC module s capability to resp...
Page 49: ...configuration changes or initiate machine actions Status Blocks the QDC module uses these blocks to send information to the PLC 5 processor about current operating status The configuration procedure d...
Page 50: ...achine setpoints and action commands Type Which Contain Examples Status Blocks Information about machine operation and operating status of the QDC module The molding machine is currently performing a...
Page 51: ...DC module offers many machine operation options to meet nearly any injection molding machine s requirements You must write PLC ladder logic to cycle the machine in the desired manner Chapter 6 3 Enter...
Page 52: ...Set 600 software forces the PLC 5 processor to download all command blocks to the QDC module when you switch the processor from PROGRAM to RUN or power it up Important The following procedure does NO...
Page 53: ...returns the ID in SYS61 Important If the value returned in SYS61 is NOT the ID number you entered you have an error in the MCC or DYC block If SYS61 has this value This block has errors Fix them as f...
Page 54: ...al configuration procedures we recommend that you download the companion block after each subject block Otherwise the procedure to correct multiple errors becomes too complex 7 Complete the procedure...
Page 55: ...ard and backward Although the QDC module in inject mode may not be directly controlling your machine s clamp and ejector jogs your hydraulics may require that valves connected to your QDC module outpu...
Page 56: ...ut occurs 50 See Warning on next page Later in this chapter you modify them to obtain desired jog results setpoints for jog RPM and jog pressure alarms The QDC module sets an alarm any time ram screw...
Page 57: ...ate Jog JGC09 N40 65 Set Output Values Output 1 Signal Output 1 JGC10 N40 66 Output 2 Signal Output 1 JGC11 N40 67 Output 3 Signal Output 1 JGC12 N40 68 Output 4 Signal Output 1 Jog RPM and Pressure A...
Page 58: ...may also be designed such that zero volts signal input does not result in no flow or pressure Please consult your valve and amplifier specifications for more details 10 5 0 5 10 0 10 20 30 40 50 60 7...
Page 59: ...Description DYC01 B09 B34 393 Execute Screw Rotate Jog DYC01 B10 B34 394 Execute Inject Cylinder Jog Forward DYC01 B11 B34 395 Execute Inject Cylinder Jog Reverse Table 5 B Ram Screw Jog Status Bits...
Page 60: ...N JOG MOVE SCREW SCREW MANUAL ALLOWED FORWARD FWD JOG I 003 B11 B11 B34 05 1 8 394 Rung 6 3 CYCLE MANUAL DIRECTION DYC01 B11 CONTROL SCREW SOLENOIDS SELECTOR REVERSE ALIGNED TO EXECUTE A S M IN JOG MO...
Page 61: ...DC module s outputs to go to a certain position to assure proper clamp and or ejector jog functions The jog configuration block lets you set up these indirect jog values If your hydraulics require it...
Page 62: ...verse Jog JGC41 N40 97 Set Output Values Output 1 Signal Output 1 JGC42 N40 98 Output 2 Signal Output 1 JGC43 N40 99 Output 3 Signal Output 1 JGC44 N40 100 Output 4 Signal Output 1 Ejector Advance Jog...
Page 63: ...orward DYC01 B13 B34 397 Execute Clamp Jog Reverse DYC01 B14 B34 398 Execute Ejector Jog Advance DYC01 B15 B34 399 Execute Ejector Jog Retract Table 5 D Clamp and Eject Jog Status Bits Status Block Wo...
Page 64: ...CYCLE MANUAL DIRECTION DYC01 B15 CONTROL EJECTOR SOLENOIDS SELECTOR JOG ALIGNED TO EXECUTE A S M IN RETRACT RETRACT UNASSIGNED MANUAL ALLOWED EJECTOR 7 JOG I 003 B11 B11 B34 05 7 14 399 Do this only...
Page 65: ...according to your machine s sequencing requirements If you need to Refer to this table for required command and or status bits Execute phases of the Inject mode without interruption no additional lad...
Page 66: ...01 B11 SYS01 B11 Unassigned 4 Jog DYC01 B12 SYS01 B12 Unassigned 5 Jog DYC01 B13 SYS01 B13 Unassigned 6 Jog DYC01 B14 SYS01 B14 Unassigned 7 Jog DYC01 B15 SYS01 B15 Stop DYC02 B15 SYS02 B15 Table 6 B...
Page 67: ...ication profile end of pre decompression movement 1 stop and set output end of pre decompression movement HPC03 B09 0 start post decompression movement end of plastication profile 1 stop and set outpu...
Page 68: ...ssion movement complete 25 SYS02 B09 Busy Status no action outputs at zero 31 SYS02 B15 Miscellaneous Status cure timer timing 35 SYS03 B03 ram screw retracted 36 SYS03 B04 cure time complete 37 SYS03...
Page 69: ...s execute pack profile 405 DYC02 B05 execute hold profile 406 DYC02 B06 execute pre decompression movement 407 DYC02 B07 execute plastication profile 408 DYC02 B08 execute post decompression movement...
Page 70: ...re control limits set velocity control limits set screw RPM control limits set profile tuning constants and pressure alarm setpoints Then you determine initial values record values on worksheets enter...
Page 71: ...use them when spanning valves in chapter 9 We discuss their application in chapter 10 Take a moment now to browse through the worksheets Notice that each worksheet contains two parts control words for...
Page 72: ...Load Initial Configuration Values Chapter 7 7 3 This page is purposely blank so that the following 2 page worksheets will be on facing pages...
Page 73: ...loaded by Pro Set 600 0 or 1 Load Initial Configuration Values Chapter 7 7 4 Worksheet 7 A Injection Configuration Command Block INC Control Word INC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01...
Page 74: ...C41 N44 37 0 Pressure Minimum Control Limit Pressure 3 INC42 N44 38 Pressure Maximum Control Limit Pressure 3 INC43 N44 39 Selected Pressure Valve Output for Minimum Percent Signal Output 4 INC44 N44...
Page 75: ...equired initial value loaded by Pro Set 600 0 or 1 Load Initial Configuration Values Chapter 7 7 6 Worksheet 7 B Pack Configuration Command Block PKC Control Word PKC01 Bxx 15 14 13 12 11 10 09 08 07...
Page 76: ...imum Control Limit Pressure 3 PKC43 N44 159 Selected Ram screw Pressure Valve Output for Minimum Percent Signal Output 4 PKC44 N44 160 Selected Ram screw Pressure Valve Output for Maximum Percent Sign...
Page 77: ...equired initial value loaded by Pro Set 600 0 or 1 Load Initial Configuration Values Chapter 7 7 8 Worksheet 7 C Hold Configuration Command Block HDC Control Word HDC01 Bxx 15 14 13 12 11 10 09 08 07...
Page 78: ...Set output Value at End of Profile Percent Signal Output 4 HDC41 N44 217 0 Ram screw Pressure Minimum Control Limit Pressure 3 HDC42 N44 218 Ram screw Pressure Maximum Control Limit Pressure 3 HDC43...
Page 79: ...ependent Gains 1 Independent Gains Load Initial Configuration Values Chapter 7 7 10 Worksheet 7 D Plastication Configuration Block PLC Control Word PLC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02...
Page 80: ...file Percent Signal Output 4 PLC34 N44 390 Output 2 Set output Value at End of Profile Percent Signal Output 4 PLC35 N44 391 Output 3 Set output Value at End of Profile Percent Signal Output 4 PLC36 N...
Page 81: ...Selected Control Valve for Injection Velocity INC02 The QDC module can control ram screw movement using a velocity vs position algorithm Since you can connect up to four valves to your QDC module you...
Page 82: ...s B06 B05 B04 Selects 0 0 0 Output 1 Used for Pressure Control 0 0 1 Output 2 Used for Pressure Control 0 1 0 Output 3 Used for Pressure Control 0 1 1 Output 4 Used for Pressure Control Record the app...
Page 83: ...onstants as follows Dependent Gains Constants Independent Gains Constants Controller Gain Kc dimensionless Proportional Gain Kp dimensionless Reset Term 1 Ti minutes per repeat Integral Gain Ki invers...
Page 84: ...r 10 For additional information refer to section 3 of the Plastic Molding Module Reference Manual publication 1771 6 5 88 Unselected Valve Set output Values INC09 12 PKC09 12 HDC09 12 and PLC09 12 Ear...
Page 85: ...Low flow 5000 to 2500 Flow Uni directional Direct acting Minimum flow 0 Flow Uni directional Reverse acting Maximum flow 0 Flow Uni directional Reverse acting Medium flow 2500 to 5000 Flow Uni direct...
Page 86: ...more details 10 8 6 4 2 0 2 4 6 8 10 0 10 20 30 40 50 60 70 80 90 100 Output Requested Output Voltage For additional information refer to section 3 of the Plastic Molding Module Reference Manual publ...
Page 87: ...on ramp rates We help you select the correct final values required by your application in chapter 10 For additional information refer to section 3 of the Plastic Molding Module Reference Manual public...
Page 88: ...pressure when setting the selected ram screw pressure valve to the percentage output you enter in word 44 Record an initial control limit equal to the maximum pressure available through the selected r...
Page 89: ...ng less than value in word 43 less than value in word 44 Record initial Output for Maximum values on corresponding worksheets Minimum Cavity Pressure Control Limit PKC45 and HDC45 The value in this wo...
Page 90: ...e Output for Maximum PKC48 and HDC48 The QDC module uses this word with Maximum Cavity Pressure Control Limit word 46 above Enter the signal output that the QDC module uses to drive the selected cavit...
Page 91: ...Minimum INC47 The QDC module uses this word with Minimum Velocity Control Limit INC45 above Enter the signal output that the QDC module uses to drive the selected velocity valve for minimum profile ve...
Page 92: ...ng on direction 0 0 for uni directional reverse acting valves If your selected velocity valve is Then the value in INC48 should be And during the profile the QDC module does NOT drive the valve with a...
Page 93: ...en setting the selected RPM valve to this percentage output Determine Output for Minimum values as follows 0 0 for uni directional direct acting valves 5000 50 for bi directional valves 9999 100 for u...
Page 94: ...D and VelFF algorithms QDC module algorithms are sensitive to changes in load not changes in setpoint because the QDC module must respond to a system that is undergoing constant load changes when hydr...
Page 95: ...ed by your application For additional information refer to section 3 of the Plastic Molding Module Reference Manual publication 1771 6 5 88 After you determine initial values and enter them on configu...
Page 96: ...o configure the QDC module with this profile block See this Worksheet On Page Injection Profile Command Block IPC 8 A 8 3 Pack Hold Profile Command Block HPC 8 B 8 10 Plastication Profile Command Bloc...
Page 97: ...ou determine other values in the text that follows Worksheet 8 A Injection Profile Command Block IPC Control Word IPC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr B38 bit 79...
Page 98: ...44 96 100 Segment 8 Time Setpoint Time 1 IPC41 N44 97 Segment 9 Velocity Setpoint Velocity 4 IPC42 N44 98 Segment 9 Pressure Setpoint Pressure 3 IPC43 N44 99 End of Segment 9 Position Setpoint Distanc...
Page 99: ...the direction of shift BIT 13 controls the direction of pressure profile offset 0 Pressure offset is positive more pressure 1 Pressure offset is negative less pressure We recorded B13 0 for positive...
Page 100: ...ns in IPC04 should be zero The valve spanning procedures in chapter 9 require these initial bit settings Where required we help you select correct final bit settings for your application in chapter 10...
Page 101: ...es The procedures in chapter 9 require that you use all 10 position setpoints Determine end of segment position setpoints for your velocity vs position injection profile for use in chapter 9 as follow...
Page 102: ...vs position profile IPC57 determines the ram screw pressure limit for the pressure limited velocity vs position profile You enter this limit in PSI or Bar IPC58 determines the position at which the QD...
Page 103: ...Use a position equal to or just beyond top of cushion position PPC61 measured from the mold end We recorded zero on Worksheet 8 A to inhibit a position transition IPC62 determines the ram screw pressu...
Page 104: ...determine initial values and record them on Worksheet 8 A you are ready to proceed 1 Enter all worksheet values into your PLC 5 data table Important Be sure that you have not altered any setpoints and...
Page 105: ...Hold Ram Press vs Time 11 Hold Cav Press vs Time Code Your value Required initial value loaded by Pro Set 600 0 or 1 Load Initial Profile Values Chapter 8 8 10 Worksheet 8 B Pack Hold Profile Command...
Page 106: ...k Profile Ram screw Pressure Offset Pressure 3 HPC26 N44 262 0 Hold Segment 1 Cavity Pressure Setpoint Pressure 2 HPC27 N44 263 Hold Segment 1 Ram screw Pressure Setpoint Pressure 3 HPC28 N44 264 100...
Page 107: ...rofile offset sign for pack cavity pressure 0 positive offset more pressure 1 negative offset less pressure We recorded these bits 0 for positive offset on Worksheet 8 B Logical Bridges HPC03 Logical...
Page 108: ...other process variables It compensates for abrupt upsets and long term deviations 0 Expert Response Compensation ON 1 Expert Response Compensation OFF We recorded these bits 1 ERC Off on worksheet 8 B...
Page 109: ...in chapter 9 require all five Record maximum injection pressure a value less than maximum system pressure on Worksheet 8 B for each of the 10 ram screw pressure setpoints listed above The valve spanni...
Page 110: ...timer when SYS58 999 9 seconds or when it sees a false to true transition of DYC03 B01 resets SYS58 to zero on a false to true transition of DYC03 B01 We recorded zero for this preset on Worksheet 8 B...
Page 111: ...etpoints for a backpressure vs position plastication profile The valve spanning procedures in chapter 9 require specific values We have already entered many values for you and help you determine other...
Page 112: ...d 2 PPC32 N44 448 100 Segment 6 Time Setpoint Time 1 PPC33 N44 449 Segment 7 RPM Setpoint RPM 5 PPC34 N44 450 Segment 7 Pressure Setpoint Pressure 3 PPC35 N44 451 End of Segment 7 Position Setpoint Di...
Page 113: ...ded B13 B12 0 for positive offset on Worksheet 8 C Logical Bridge PPC03 The logical bridge controls the action taken by the QDC module when it completes the plastication profile BIT 08 determines if t...
Page 114: ...ol on Worksheet 8 C Important All other bit selections in PPC04 should be zero The valve spanning procedures in chapter 9 require these initial bit settings Where required we help you select correct f...
Page 115: ...ent Position Setpoints PPC11 15 19 23 27 31 35 39 43 and 47 Use these words to configure either one of the following profiles backpressure vs position RPM vs position The procedures in chapter 9 requi...
Page 116: ...necessary PPC51 determines the offset for RPM profiles in rotations per minute PPC52 determines the offset for backpressure profiles in PSI or Bar We recorded zero no offset on Worksheet 8 C Cushion...
Page 117: ...values and record them on Worksheet 8 C you are ready to proceed 1 Enter all worksheet values into your PLC 5 data table Important Be sure that you have not altered any setpoints and that you have ent...
Page 118: ...locity valve pack hold pressure valve plastication pressure valve plastication screw RPM valve We also describe how to test valve linearity set profile pressure alarms The following table lists comman...
Page 119: ...isabled with zero ramp rates INC17 20 0 INC25 28 0 N44 13 16 N44 21 24 Pressure limits Minimum Pressure Control Limit Maximum Pressure Control Limit Selected Pressure Valve Output for Minimum Selected...
Page 120: ...est mold in the machine Programming errors configuration errors or hydraulic problems could lead to machine damage or injury to personnel ATTENTION Be sure all machine guards and shields are in place...
Page 121: ...ined the lowest possible pressure or the highest possible signal at zero pressure copy the pressure observed in SYS26 into INC41 N44 37 the Minimum Pressure Control Limit 7 While maintaining this mini...
Page 122: ...arm bits SYS07 B00 through SYS07 B05 are set no programming error codes exist in SYS61 and SYS62 4 The QDC module automatically runs injection pack and hold profiles in succession At completion observ...
Page 123: ...nal outputs Set Profile Pressure Alarms For Ram Screw Pressure After spanning your injection pressure valve set the maximum ram screw pressure alarm setpoint INC57 N44 53 for the injection profile Set...
Page 124: ...connected your flow control valve INC02 B02 B01 B00 your selection B38 16 17 18 Set output values for outputs to unselected valves INC09 12 your values N44 5 6 7 8 All ramping is disabled with zero ra...
Page 125: ...you must download INC first followed by IPC chapter 4 To download Set INC B21 7 IPC B21 8 Span Your Injection Velocity Valve Span your injection valve for smooth operation at the highest desired veloc...
Page 126: ...l segments of the profile Record the highest reported velocity 5 With your programming terminal enter the highest velocity from step 4 into INC46 N44 42 the Maximum Velocity Control Limit 6 Change all...
Page 127: ...s position profile Do this by toggling DYC02 B04 B34 404 from 0 to 1 to 0 4 The QDC module automatically runs the injection pack and hold profiles in succession At completion observe the actual segmen...
Page 128: ...toggling DYC02 B04 B34 404 from 0 to 1 to 0 4 The QDC module automatically runs the injection pack and hold profiles in succession At completion observe the actual segment velocities reported by the...
Page 129: ...ls for linear control of the injection velocity valve in open loop control For this range limit When trying to obtain the velocity in The QDC module drives the selected velocity valve to output signal...
Page 130: ...to PKC41 44 and into HDC41 44 and skip to Test Valve Linearity Important If your machine controls cavity pressure during pack and hold follow the procedure for ram screw pressure and transfer the valu...
Page 131: ...Hold HPC03 B02 B00 0 for ram screw pressure B38 288 290 Logical bridge to stop and set outputs before pre decompression plastication HPC03 B08 1 HPC03 B09 1 B38 296 B38 297 Open loop control HPC04 B03...
Page 132: ...r pack and hold or substantially different hydraulic circuit during the profiles span the pack valve first Then repeat the procedure for the hold valve Important If PanelView is available use it to ob...
Page 133: ...e or the highest possible signal at zero pressure copy the actual pressure observed in SYS26 into the Minimum Pressure Control Limit PKC41 N44 157 for pack HDC41 N44 217 for hold 7 While maintaining t...
Page 134: ...to the QDC module For instructions refer to chapter 4 2 Check that the ram screw is still at the mold end position 3 Run the pressure vs time pack profile by toggling DYC02 B05 B35 405 from 0 to 1 to...
Page 135: ...Decrease in 5 steps Reverse Acting Increase in 5 steps To do this change PKC43 and or HDC43 download PKC and HDC followed by HPC with bits B21 9 10 11 and repeat steps 3 and 4 What You Have Accomplis...
Page 136: ...re Control Limits PKC42 and HDC42 Entering a value of zero disables these alarms For Cavity Pressure If using a cavity pressure sensor set the maximum cavity pressure alarm setpoints PKC58 N44 174 for...
Page 137: ...404 406 Set output values for unselected valves PLC09 12 your values N44 365 368 All ramping is disabled with zero ramp rates PLC17 20 0 PLC25 28 0 N44 373 376 N44 381 384 End of profile Set output va...
Page 138: ...sure Valve Span your plastication valve for smooth operation at the highest desired backpressure Do this by finding the optimum values for these words Minimum Pressure Control Limit PLC41 N44 397 Maxi...
Page 139: ...41 44 that corresponds to the ram plastication valve x Observed Pressure in SYS26 Important If your valve is reverse acting apply the algebraic sign of value b correctly when computing PLC44 in the eq...
Page 140: ...ty with a Plastication Backpressure Profile 1 Change backpressure setpoints to 1 2 PLC44 1 2 Max Control Limit in PPC10 14 18 22 26 30 34 38 42 46 and 50 in N44 426 430 434 438 442 446 450 454 458 462...
Page 141: ...LC44 Now for open loop plastication profiles the QDC module assumes a liner relationship between backpressure and signal output Set the Profile Pressure Alarm After spanning your plastication pressure...
Page 142: ...et output values for unselected valves PLC09 12 your values N44 365 368 All ramping is disabled with zero ramp rates PLC17 20 0 PLC25 28 0 N44 373 376 N44 381 384 End of profile Set output values PLC3...
Page 143: ...n Your Plastication RPM Valve Span your plastication RPM valve for smooth operation at the highest desired RPM Do this by finding the optimum values for these words Minimum RPM Control Limit PLC45 N44...
Page 144: ...et output value in DYC09 12 N40 121 124 that corresponds to the selected RPM valve and observe the actual screw RPM reported in SYS27 N40 179 For a bi directional valve with a spool offset If this RPM...
Page 145: ...B08 B34 392 to 0 12 Download your final values for PLC45 48 to the QDC module by downloading the PLC and PPC blocks Important If downloading from your programming terminal download PLC followed by PP...
Page 146: ...rease in 5 steps To do this change PLC48 download PLC followed by PPC with bits B21 13 and 14 and repeat steps 3 and 4 as necessary Important If downloading from your programming terminal download PLC...
Page 147: ...scuss the usage and effect of the QDC module s PID gain constants and procedures to determine proper gain settings for your plastic molding process If your application does not require closed loop ope...
Page 148: ...without an Oscilloscope Tune Pressure Loops with an Oscilloscope Repeat either one of these procedures as needed for tuning the pressure control loop of these profiles Injection Pressure vs Position o...
Page 149: ...in chapter 7 disabled ERC reset ERC values disabled ramping downloaded all setpoint changes to the QDC module 1 Enter an operational profile representative of the characteristics you desire for your p...
Page 150: ...ed operational profile for a production cycle 3 Run several profile cycles while observing the oscilloscope trace Ideally for each step of a multi step profile the oscilloscope trace should rise or fa...
Page 151: ...Response Compensation ERC Set IPC04 B11 B10 B09 B08 1 Reset ERC values to zero Set DYC05 B15 B34 463 1 The QDC module resets this bit to zero after resetting ERC values Important Tuning constants diff...
Page 152: ...portional term Excessive hammering and vibration is observed in the cylinder s hydraulic lines Decrease the proportional term Important Each time you change a gain constant you must download the chang...
Page 153: ...s quickly and then bounces or chatters around a voltage current Decrease the proportional term Excessive hammering and vibration is observed in the cylinder s hydraulic lines Decrease the proportional...
Page 154: ...se velocity setpoints only for the injection velocity vs position profile to control the fill rate of various mold cavities with repeatability Do not be concerned if the reported velocity in the first...
Page 155: ...ls in the mold For plastication use backpressure setpoints to control heating the plastic due to shearing as the rotating ram screw backs up the length of the shot against a backpressure determined by...
Page 156: ...ed by your end of segment position setpoints Each segment has its velocity pressure or RPM setpoint for controlling the ram screw Important Avoid multiple adjacent segments having the same velocity pr...
Page 157: ...PC26 or HPC27 N A Plastication Pressure vs Position None required N A N A PPC10 N A PPC61 and 62 Pressure vs Time N A None required N A PPC10 N A PPC61 and 62 RPM vs Position None required N A N A N A...
Page 158: ...end of hold position is approximately equal to cushion all cavities on the mold are being fully filled Cushion PPC62 Cushion measured from mold end is the length of molten plastic you want remaining...
Page 159: ...odule monitors this pressure setpoint along with the others you programmed to determine transition from injection to pack Choose a setpoint under the mold flash point The Minimum Position for Pressure...
Page 160: ...losed loop control consider this If your Selected valve controls And you observe Then Pressure Profile segment pressures substantially greater than setpoint Decrease the flow available during the prof...
Page 161: ...ed by your PLC 5 processor before continuing a molding cycle you may configure the QDC module to stop as completion of hold HPC03 B08 1 pre decompression HPC03 B09 1 plastication PPC03 B08 1 Then the...
Page 162: ...movements equal to the ram screw reverse jog set output values JGC25 28 from chapter 5 Enter end of movement set output values into PRC33 36 and PSC33 36 as required by your application The zero ramp...
Page 163: ...eady tuned all applicable pressure and velocity loops Ramp rates control selected and unselected valves Therefore even though you may be controlling velocity you can ramp ram screw pressure during an...
Page 164: ...basis and without regard to current machine mode or operational cycle Pressures are compared to profile pressure alarm setpoints configured in the respective configuration blocks refer to chapter 7 on...
Page 165: ...n pressure limit zone defined by IPC58 1 Freezes its outputs at current levels 2 Starts time delay IPC59 Freezes its outputs after ram pressure exceeds IPC57 during velocity control Time delay IPC59 e...
Page 166: ...ited Velocity Control This position defines the zone measured from mold end in which the QDC module allows a change from velocity to pressure control figure 10 4 Pressure limiting can occur after the...
Page 167: ...r pressure not position setpoints is required Do NOT use ERC when spanning your valves if using velocity feedforward Vel FF gain if using slow low value acceleration or deceleration ramp rates until y...
Page 168: ...iodes LEDs Use them for troubleshooting during integration or operation of the QDC module Each LED is a different color for easy identification Color of LED Identified as Green ACTIVE Red FAULT Yellow...
Page 169: ...ock received by the QDC module had a recognizable block ID Do nothing Green Off Off Software Error The QDC hardware and firmware are OK no pro gramming errors exist but the last command block received...
Page 170: ...Workshet 3 A Select Module Parameters Control Word MCC02 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr B34 bit 543 542 541 540 539 538 537 536 535 534 533 532 531 530 529 528 Va...
Page 171: ...orksheets Appendix A A 2 Worksheet 3 C Select Output Ranges for your Valves Control Word MCC04 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 B34 bit 575 574 573 572 571 570 569 568 5...
Page 172: ...2 8 MCC20 N40 16 Analog Signal Max Screw Pressure Input Signal Range 2 3 9 MCC51 N40 47 0 Minimum Screw RPM Rotational Speed 4 10 MCC52 N40 48 Maximum Screw RPM Rotational Speed 4 11 MCC53 N40 49 Ana...
Page 173: ...C20 N40 16 Analog Signal Max Screw Pressure Input Signal Range 2 3 9 MCC51 N40 47 0 Minimum Screw RPM Rotational Speed 4 10 MCC52 N40 48 Maximum Screw RPM Rotational Speed 4 11 MCC53 N40 49 Analog Sig...
Page 174: ...and Time delay Setpoints Control Word Pro Set 600 Addr Value Description Units MCC21 N40 17 Screw Pressure alarm Setpoint Ram screw Pressure 2 MCC22 N40 18 Screw pressure Time delay Setpoint Time Mea...
Page 175: ...es Output 1 Signal Output 1 JGC26 N40 82 Output 2 Signal Output 1 JGC27 N40 83 Output 3 Signal Output 1 JGC28 N40 84 Output 4 Signal Output 1 Screw Rotate Jog JGC09 N40 65 Set Output Values Output 1 S...
Page 176: ...verse Jog JGC41 N40 97 Set Output Values Output 1 Signal Output 1 JGC42 N40 98 Output 2 Signal Output 1 JGC43 N40 99 Output 3 Signal Output 1 JGC44 N40 100 Output 4 Signal Output 1 Ejector Advance Jog...
Page 177: ...itial value loaded by Pro Set 600 0 or 1 Blank Worksheets Appendix A A 8 Worksheet 7 A Injection Configuration Block INC Control Word INC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set...
Page 178: ...Pressure Minimum Control Limit Pressure 3 INC42 N44 38 Pressure Maximum Control Limit Pressure 3 INC43 N44 39 Selected Pressure Valve Output for Minimum Percent Signal Output 4 INC44 N44 40 Selected...
Page 179: ...Your value Required initial value loaded by Pro Set 600 0 or 1 Blank Worksheets Appendix A A 10 Worksheet 7 B Pack Configuration Block PKC Control Word PKC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03...
Page 180: ...Limit Pressure 3 PKC43 N44 159 Selected Ram screw Pressure Valve Output for Minimum Percent Signal Output 4 PKC44 N44 160 Selected Ram screw Pressure Valve Output for Maximum Percent Signal Output 4...
Page 181: ...Your value Required initial value loaded by Pro Set 600 0 or 1 Blank Worksheets Appendix A A 12 Worksheet 7 C Hold Configuration Block HDC Control Word HDC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03...
Page 182: ...Value at End of Profile Percent Signal Output 4 HDC41 N44 217 0 Ram screw Pressure Minimum Control Limit Pressure 3 HDC42 N44 218 Ram screw Pressure Maximum Control Limit Pressure 3 HDC43 N44 219 Sele...
Page 183: ...ithm 0 Dependent Gains 1 Independent Gains Blank Worksheets Appendix A A 14 Worksheet 7 D Plastication Configuration Block PLC Control Word PLC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pr...
Page 184: ...cent Signal Output 4 PLC34 N44 390 Output 2 Set output Value at End of Profile Percent Signal Output 4 PLC35 N44 391 Output 3 Set output Value at End of Profile Percent Signal Output 4 PLC36 N44 392 O...
Page 185: ...Ramp Rate during Movement Percent Signal Output per Second 5 PRC20 N44 316 Output 4 Accel Ramp Rate during Movement Percent Signal Output per Second 5 PRC25 N44 321 Output 1 Decel Ramp Rate during Mo...
Page 186: ...6 Output 4 Accel Ramp Rate during Movement Percent Signal Output per Second 5 PSC25 N44 501 Output 1 Decel Ramp Rate during Movement Percent Signal Output per Second 5 PSC26 N44 502 Output 2 Decel Ram...
Page 187: ...PC01 Bxx 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Pro Set 600 Addr B38 bit 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 Value 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 Control Word IPC03 Bxx 15 14 13...
Page 188: ...6 100 Segment 8 Time Setpoint Time 1 IPC41 N44 97 Segment 9 Velocity Setpoint Velocity 4 IPC42 N44 98 Segment 9 Pressure Setpoint Pressure 3 IPC43 N44 99 End of Segment 9 Position Setpoint Distance fr...
Page 189: ...Time 10 Hold Ram Press vs Time 11 Hold Cav Press vs Time Code Your value Required initial value loaded by Pro Set 600 0 or 1 Blank Worksheets Appendix A A 20 Worksheet 8 B Pack Hold Profile Block HPC...
Page 190: ...Ram screw Pressure Offset Pressure 3 HPC26 N44 262 0 Hold Segment 1 Cavity Pressure Setpoint Pressure 2 HPC27 N44 263 Hold Segment 1 Ram screw Pressure Setpoint Pressure 3 HPC28 N44 264 100 Hold Segm...
Page 191: ...it 13 for Pressure Profile Code Your value Required initial value loaded by Pro Set 600 0 or 1 Blank Worksheets Appendix A A 22 Worksheet 8 C Plastication Profile Block PPC Control Word PPC01 Bxx 15 1...
Page 192: ...PC32 N44 448 100 Segment 6 Time Setpoint Time 1 PPC33 N44 449 Segment 7 RPM Setpoint RPM 5 PPC34 N44 450 Segment 7 Pressure Setpoint Pressure 3 PPC35 N44 451 End of Segment 7 Position Setpoint Distanc...
Page 193: ...values 8 15 IPC profile values 8 9 jog initial values 5 4 PPC profile values 8 22 QDC module config values 3 6 E E Stop 2 11 end of segment setpoints 8 6 8 20 tuning 10 10 ERC tuning considerations 10...
Page 194: ...s 7 25 ramp rates for accel decel 7 17 set output values end of profile 7 18 unselected valve 7 15 velocity control limit 7 22 watchdog timer presets 7 26 worksheets for 7 2 load initial HPC profile v...
Page 195: ...ack and hold pressure 9 19 plastication backpressure 9 24 Q QDC module calibration 11 2 inputs and outputs 2 8 3 1 set jumper plugs 2 2 troubleshooting 11 1 QH module record I O ranges 2 1 R ram press...
Page 196: ...on backpressure 9 23 valve spanning procedures for injection pressure 9 2 injection velocity 9 7 pack and hold pressure 9 13 plastication pressure 9 20 plastication screw RPM 9 25 velocity control lim...
Page 197: ...iland The Netherlands Turkey United Arab Emirates United Kingdom United States Uruguay Venezuela Yugoslavia World Headquarters Allen Bradley 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 3...
