MORE ABOUT 2R AUTOMATION
AND INJECTION MOLDING CONTROLS
Injection Molding and the
plastics industry is 2R Automation’s specialty but we also have experience
with Structural Foam, Reaction Injection Molding (RIM), thermoset and
thermoplastic injection processes, co-injection, insert molding, gas assist,
robot interfaces, thermoforming and extrusion control systems as well as
blow molding.
Bosch
Rexroth (BR) has two very good controllers
for injection molding machines: The DPC which controls the clamp and the DPQ
which controls both the injection and ejection motion. Both modules are based
on the same hardware platform and have special algorithms that allow them to
move the clamp faster, reducing cycle time and injecting plastic more
consistently shot after shot for better quality and less scrap.
Rockwell Automation (RA) has a relatively new
controller called the CompactLogix (1769) system which has built in Ethernet
communications, high speed processing and a very robust instruction set, all
at a very reasonable cost. RA also has a very robust Windows CE operator
interface which allows configuration of crisp readable screens without the
need for Uninterruptible Power Supplies. The Windows CE system allows for
immediate power down and virtually eliminates systems crashes. The most
common size that is used today is a 12” version but 15” and 17” units are
also available. Mold part storage can be accomplished to and from a USB
Memory stick, locally to the Operator interface or across a network.
High Speed Hydraulic Motion
is accomplished using special BR proportional valves and the appropriate BR
controller card. If the motion isn’t smooth, it can’t run fast and the BR
system allows for moving high mass clamps and shuttles at very high speeds
with smooth acceleration and deceleration. 2R Automation has experience
with moving 30,000 lb loads at 32 inches per second and doing it very
smoothly.
Sequential Valve Gate
(SVG) controls and complete units have been developed, built and
installed by 2R Automation. This system can open and close
SVG’s on position or pressure.
Gas Assist Systems
have been upgraded by 2R Automation to provide the best in Gas
Assist controls. The process is programmed using Time, Pressure
and Ramp Rate setpoints.
Blow Molding
controls have been developed by 2R Automation and Bosch
Rexroth. This new control system offers superior parison
control.
Supervisory Systems
have been developed by 2R Automation that allow remote access to
molding machines and plant video surveillance systems via any
internet connection. One customer runs molding machines all
weekend UNATTENDED with our supervisory system monitoring all
aspects of the machinery. In the event of an alarm, an on call
person is paged and he/she can remotely access the machine to
view and reset alarms.