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.  Both controllers have on board DeviceNet communications that make is easy to connect to an Allen-Bradley controller of any type.

 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.

 Injection Molding and the plastics industry is 2R Automation’s specialty but we also have experience with 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.

 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

 Hydroforming is the forming of metal with high pressure (30,000 PSI) water and can also be controlled with good hydraulic and good control systems.  Similar systems used in injection molding are used to control Hydroforming.