Injection molding CONTROLS, Structural foam

Injection Molding and Structural Foam controls and hydraulics for the plastics industry is 2R Automation’s specialty. Our system utilizes the Bosch Rexroth DPQ controller for injection control which provides the best injection process control on the market today. The repeatability of the injection profile is the reason that this controller outperforms any other. The DPQ module allows for configuring up to five (5) segments of injection control, five (5) segments of pack control, and two (2) segments of backpressure control. We also use the Bosch Rexroth DPC controller for the best clamp control on the market. The clamp controller controls a high mass clamp so well that the cycle time can usually be reduced because the clamp profiling can be done faster without causing jerky motion or abrupt stops.

Both of these Bosch Rexroth controllers communicate via DeviceNet so any Allen-Bradley controller can be used to sequence the injection or structural foam molding machine. 2R Automation normally uses the CompactLogix (1769 or 1768) line of controller with a twelve or fifteen (12 or 15) inch PanelView Plus CE operator interface.

Our standard color configuration, as shown in the included Human Machine Interface (HMI) screens, utilizes light blue for setpoints and red for actual values. We start with our base screen set and adapt it to meet the configuration of the plastic molding machine on which it is being installed. Most basic controller upgrades can be accomplished in one to two weeks from start to finish. 2R Automation can provide a turn-key upgrade or work with your maintenance or local contractor for installation. 2R Automation provides a completely documented ladder program, the runtime operator interface and a complete set of electrical and hydraulic prints upon completion of every project. Please contact us for a quotation on your particular machine.

Structural Foam Systems Standard Features: 

  • Allen-Bradley CompactLogix PLC with Flex Inputs and Outputs (I/O) for remotely located I/O.
  • Complete temperature control including extruder heats, extruder cooling, accumulator heats, melt relief heats, fill pipe heats, diverter heats, inlet tube heats, extension heats, manifold heats, and nozzle heats,
  • Controls replacement includes updating to current ANSI/SPI safety rules.
  • Complete controls replacement including prints, hardware, software, operator interface and startup.
  • We stay onsite until your process people verify that the machine is processing to the best of its capabilities.

Structural Foam Systems OPTIONS: 

  • Replace Mercury contactors with Solid State Relays.
  • Replace Injection valves with new, higher flow valves that have on board electronics.
  • Replace amplifier cards for the clamp and back pressure with valve amplifier plugs.
  • Replace all pressure transducers.
  • Replace clamp and injection position transducers with new digital position transducers.
  • Replace nozzle bank manifolds with new nozzle manifolds with individual nozzle circuits and control.
  • Add nozzle heat zones to equal number of nozzle valves.
  • Add clamp full flow blocking valves to meet ANSI/SPI Safety Section 5 for new machinery (not mandatory).
  • Replace all hydraulic pumps at time of upgrade.
  • Separate and add manifold extension heat zones for individual control.
  • Supply spare I/O Cards (One of each type).
  • Add electrical breaker for nozzle heats to allow lockout of nozzle heats during pattern change.
  • Replace Gas, Head, and Tonnage pressure transducers and cables.