SIJECT 16 / 16 DP Technical Details - Siemens molding machine.pdf · • 10 Step Profiles for Injection, Hold Pressure, Charging, Back Pressure • 16 Step Profile for Clamp Movement,

SIJECT - Workshop July 2001, ErlangenA&D MC PM1 / Version 07.2001

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A&D MC PM1

SIJECT 16 / 16 DPTechnical Details

Product Series forInjection Molding Control

A&D MC PM1

SIJECT 16 / 16 DPTechnical Details

Product Series forInjection Molding Control


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6LHPHQV

Cores:Controlled bydigital output

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Injection unit

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Proportional valves:Pressure and flow controlPump control

Temperature control:typical 5 to 8 zones

Closing unit:Position systemwith linear transducer

Ejector:Controlledwith linear transducer

Carriage:Position systemwith linear transducer

Injection:Position systemwith linear transducer

Õ Solution: SIJECT 16/16DPÕ Solution: SIJECT 16/16DP

Components of an Injection Molding MachineÍ typically controlled by micro controllerComponents of an Injection Molding MachineÍ typically controlled by micro controller


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6LHPHQV

n Hardware CI board

n Technology Software

n Hardware HMI

n Fully Electric Injection Molding Machine

ContentsContents


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6LHPHQVThe structure illustration of CIThe structure illustration of CI

Interfaces Outputs Inputs

Profibus(SIJECT 16DP)

P-Bus

RS 485

MPI

MMC-slot

Digital Inputs

Analog Inputs

Thermocouples

Digital Outputs

Relays

Analog Outputs


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6LHPHQVSIJECT, Hardware Features: CI BoardSIJECT, Hardware Features: CI Board

n Digital Inputsq all digital inputs optical isolated

n Digital Outputsq Short-circuit protection

n Analog Inputsq specified for Linear scales (1kOhm - 10 kOhm, 12 Bit)

n Analog Outputsq Prop. valve output (+/- 10V, 12 Bit)

or

q Prop. valve output with amplifier (+24 - 38V / 0,75 - 2A, 12 Bit)


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Input

Standard digital inputs: 31 / 31

High-speed digital input: 1- Screw speed -

Analog inputs (linear scales): 4 / 4- Position clamb unit -- Position screw -- Position ejector -- Position carriage -

Thermocouple Channels: 6 / 8- Sensor type: J or K -

Internal reference Temperaturecompensation: 1

Output

Digital outputs (Transistor): 24 / 24 - for solid state relays e.t.c -

Digital outputs (Relay): 8 / 8- for motor Control e.t.c. -

Digital outputs (Relay): 8 / 8- for Temperature actor ( Contractor, SSR )

Analog outputs: 2 / 4- for proportional valve amplifier orproportional valve: 2 / 4 amplifier

InterfaceMPIV24 (for OP 15)P-Bus (for extension with S7-300)Profibus (SIJECT 16 DP )Multimedia Card (MMC)

SIJECT 16/16DPCI board, Hardware and InterfacesSIJECT 16/16DPCI board, Hardware and Interfaces

PLC-Modules

CI16: S7 CPU 314CI 16 DP: S7 CPU 315 DP


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CI 16 int.Standard machines

❏ PLC >128k code

❏ 31 Inputs

❏ 1 Input counter (1 kHz)

❏ 24 Outputs 2A

❏ 8 Outputs relays

❏ 8x Relays for temp

❏ 4 x Analog inputs for linear scales

❏ 2 x Valve amp.

❏ 8x AI for TC

❏ CI 16 : L-price 1.588,00 EUR

❏ SIJECT 16 : L-price 2.403,00 EUR

CI 16DP int.Advanced machines

❏ PLC >128k code

❏ 31 Inputs

❏ 1 Input counter (1 kHz)

❏ 24 Outputs 2A

❏ 8 Outputs relays

❏ 8x Relays for temp

❏ 4 x Analog inputs for linear scales

❏ 4 x Valve amp.

❏ 8x AI for TC

❏ CI 16 DP : L-price 2.147,00 EUR

❏ SIJECT 16 DP : L-price 2.863,00 EUR

SIJECT SeriesOverviewSIJECT SeriesOverview


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6LHPHQVSIJECT 16, structure of the CI boardSIJECT 16, structure of the CI board

Periphery + RS 485 + MMC

I/O-Control

Data Block (DB1)

PLC320

MPI + P-Bus + PROFIBUS


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P-Bus extension

Extension of 16DP with standard S7-300 peripheriesExtension of 16DP with standard S7-300 peripheries

SIMATIC S7 extensions racks via IM361with digital and analogperipheries

MPI

OP 170 (1/4VGA b/w) +optionalOperatorPanel


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6LHPHQVSIJECT with PROFIBUS DPSIJECT with PROFIBUS DP

Profibus DP

MPI

T E

D I

H S

P

2

5

8

*

E

L

T

I

N

TP 270/TP370 (10“color) + optionalOperator Panel

SIJECT - CI Board

SIJECT PeripheryET 200 S / M / X / LMasterdriveSimodrive....


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6LHPHQV

n Hardware CI board


n Hardware HMI


ContentsContents


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SIJECT 16/16DPSoftware VersionsSIJECT 16/16DPSoftware Versions

n open loop program with OP 15 or OP170q STEP 7 sequence program (application example)

q HMI:q with OP15: fixed HMI functionality and screens

q with OP170: adaptable HMI functionality and screens with ProToolLite

n closed loop program with OP 170 or MP 270/370(in preparation)q STEP 7 sequence program (application example)

q technology function block TECH

q Temperature Control block TEMP

q HMI:q adaptable HMI functionality and screens with ProToolLite or ProToolPro for MP370 (MP

270 and OP 170 in preparation)


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6LHPHQVOpen Loop - Program StructureOpen Loop - Program Structure

Start

Ejector

Core in1,2,3

Moldclose

Carriageadvance

Injection Holding Charging Carriageretract

Coolingtime

Moldopen

Core out1,2,3

Air-blow1&2

One cyclefinished

Ejectoradvance

Cyclestart key

Closesafety-door

Sensor-full auto

Time-fullauto

Suckback

BasicPosition


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6LHPHQVOpen LoopOpen Loop

I / O - Function

• 4 Analog Input Scale with Reference Point• 2 direct output function with scaling factor and time ramp

• display of screw rotation

Technology - Function

• Open Loop - Controller

• 4 Step Profiles for Injection, Hold Pressure• 2 Step Profiles for Charging, Back Pressure• 3 Step Profile for Clamp Movement, 2 Step Profile for Ejector

• “Cut Off” Switch Logic with Time or Position• 3 Core, 2 Air-Blow and Carriage-Functions

Temperature Control Functions

• 8 Channel• P-Controller• Monitoring for Wire Break and Tolerances

I / O - Function

• 4 Analog Input Scale with Reference Point• 2 direct output function with scaling factor and time ramp

• display of screw rotation


• Open Loop - Controller

• 4 Step Profiles for Injection, Hold Pressure• 2 Step Profiles for Charging, Back Pressure• 3 Step Profile for Clamp Movement, 2 Step Profile for Ejector

• “Cut Off” Switch Logic with Time or Position• 3 Core, 2 Air-Blow and Carriage-Functions

Temperature Control Functions

• 8 Channel• P-Controller• Monitoring for Wire Break and Tolerances


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6LHPHQVClosed Loop - Program StructureClosed Loop - Program Structure

Start

Ejector

Core in1,2,3

Moldclose

Carriageadvance

Injection Holding Charging Carriageretract

Coolingtime

Moldopen

Core out1,2,3

Air-blow1&2

One cyclefinished

Ejectoradvance

Suckback

BasicPosition

TECH TEMP


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„TECH“

I / O - Function

• 16 Analog Input Scale with Reference Point• Calculation for screw rotation

• Calculation of speed for Injection and clamp• Different Valve Characteristics•16 direct output function with scaling factor and time ramp

Digital Function

• 9 channels position detection via cams• cam dependent manipulated output

• 16 limit switches


„„ TECHTECH““

I / O - Function

• 16 Analog Input Scale with Reference Point• Calculation for screw rotation

• Calculation of speed for Injection and clamp• Different Valve Characteristics•16 direct output function with scaling factor and time ramp

Digital Function

• 9 channels position detection via cams• cam dependent manipulated output

• 16 limit switches

SIJECT 16Software Functions - closed loop - TECHSIJECT 16Software Functions - closed loop - TECH


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„TECH“• 10 Step Profiles for Injection, Hold Pressure, Charging, Back Pressure• 16 Step Profile for Clamp Movement, 4 Step Profile for Ejector• Open Loop or Close Loop with PID - Controller

• “Cut Off” Switch Logic with Time, Position or Pressure• Adaptation to reduce the “break down” of Hold Pressure in the “Cut Off” Point• Curves for Injection, Hold Pressure, Charging and Back Pressure

• Quality Function via Master Curve and Tolerance Band• Calculation of the Integral of Injection Pressure

• Process Value Monitoring


„„ TECHTECH““• 10 Step Profiles for Injection, Hold Pressure, Charging, Back Pressure• 16 Step Profile for Clamp Movement, 4 Step Profile for Ejector• Open Loop or Close Loop with PID - Controller

• “Cut Off” Switch Logic with Time, Position or Pressure• Adaptation to reduce the “break down” of Hold Pressure in the “Cut Off” Point• Curves for Injection, Hold Pressure, Charging and Back Pressure

• Quality Function via Master Curve and Tolerance Band• Calculation of the Integral of Injection Pressure

• Process Value Monitoring

SIJECT 16Software Functions - closed loop - TECHSIJECT 16Software Functions - closed loop - TECH


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“TEMP”

• 24 Channel, expandable up to 48 Channels

• PID Controller with Close Loop Zone

• Self Tuning• Parameter Adaptation during Process • separate Parameters for Heating and Cooling

• Monitoring for Wire Break, indirect Short Cut and Tolerances


““ TEMPTEMP””

• 24 Channel, expandable up to 48 Channels

• PID Controller with Close Loop Zone

• Self Tuning• Parameter Adaptation during Process • separate Parameters for Heating and Cooling

• Monitoring for Wire Break, indirect Short Cut and Tolerances

SIJECT 16Software Functions - closed loop - TEMPSIJECT 16Software Functions - closed loop - TEMP


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Siject 16Software Structure (closed loop)Siject 16Software Structure (closed loop)

PLC 320 OS

OB1 OB 100 OB40

PLC 320 OS

OB1 OB 100 OB40

Technology Block „ TemperatureTemperature Control“

Backgr. Init. Cycle

Technology Block „ InjectionInjection Molding“

Backgr. Init. Cycle

Communication Function Block

Data BlockCommands

Messages

User Cycle Program

Read / Write I / O

DataBlockI / O

Counts

Data BlockParameter

HMI

MPI


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6LHPHQV

n Hardware CI board


n Hardware HMI


ContentsContents


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• OP15 (240 x 128 dots LCD, 16 lines with 30 Latin Characters, 8 lines of 15 Chinese Characters, 64 Keys) fixed screens, only for “Open loop”

• OP 170 (1/4 VGA, b/w) with ProToolLite (Injection Molding Standard HMI/light) / optional with MSTT

• TP 270/370 (10” VGA, color) with ProToolPro (Injection Molding Standard HMI) + MSTT with Jog Shuttle

Operator Panels for SIJECTOperator Panels for SIJECT


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Function keys below display

Alarmmessages 1

MonitorScreen

Timer Function Input 1 Save/Load Information 1

Alarmmessages Temperature2

Temperature1

CounterInput 3

Output 1

Information 2

Output 3

Menu tree of OP15 (function keys)Menu tree of OP15 (function keys)


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Screen Call-outkeys

Mold Open

Ejector

Mold close

Carriage

Injection Holding

Charge

Core1

Core2

Air blow Core3

Moldadjustment

Lubrication/Purge

Menu tree of OP15 (screen call-out keys)Menu tree of OP15 (screen call-out keys)


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• Recipes• Curves• Text- and Graphic lists• Alarm and Machine mailfunktions• 3 Online Languages (20 Offline)• Foil Keyboard with LED´s• Password• Alphanumeric inputs• Alarm Clock• Compact Flash Card• and more.

OEM definable Machine keys

B/H/T: 240mm x 252mm x 45mm

OP170B - CE Operator PanelOP170B - CE Operator Panel


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i

Act. product counter 99999

Current Start-up 99999

Start time 20:45:15

Cycle time 999.9

Current pressure 100

Current flow 80

Information message

!

1 2 3

Production time 999.9

S

S

Manuallubrication

Purge setting

OP 170 B - Screen Sample (open loop)OP 170 B - Screen Sample (open loop)

Blue mode


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6LHPHQVMP 370 - CE Operator PanelMP 370 - CE Operator Panel

12" TFT LCD Display800 x 600 SVGA256 colors

Life expectancy ofbacklighting: 50,000 hrs

Smooth frontwithout cover,degree ofprotection IP65/Nema 4/12

Serial interface ofconfiguration com-puter and printer

Dimensions as TP27-10":- Front 335 x 275 -Mounting 310 x 248 x 65

6 MBconfiguration memory

PC/CF card slot

Ethernet (TCP/IP)interface

Temperature range0° to 50° C

USB-interface poss. for- keyboard- mouse- barcode reader


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6LHPHQVMP 370 - Screen Sample (closed loop)MP 370 - Screen Sample (closed loop)


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6LHPHQVSIJECT 16: HMI SoftwareSIJECT 16: HMI Software

n ProTool/Lite for OP 170q Configuration Software

q MLFB 6AV6580-3BX05-2AX0

q list price: 330.- Euro

q no run time license necessary

n ProTool/Pro for MP 270/370q Configuration Software

q MLFB 6AV6581-3BX05-2AX0

q list price : 930.- Euro

q run time software (2048 power tags)q MLFB: 6A6584-1AF05-2BX0



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6LHPHQV

n Hardware CI board


n Hardware HMI

n Fully Electric Injection Molding Machine(under preparation)(under preparation)

ContentsContents


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6LHPHQV

Fully ElectricalInjection Molding MachineFully ElectricalFully ElectricalInjection Molding MachineInjection Molding Machine


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❒ Higher accuracy

❒ Better repeatability 20-25 %

❒ Reduced energy consumption 30-50 %

❒ Clean room ability 100 %

❒ Decreased Noise ejection 60-70 %

❒ Smaller costs, for aim-off of lubricant, oil approx. 80 %

❒ Smaller disposal costs (Oil) approx. 80 %

Customer benefit,for a Fully Electrical Injection Molding MachineCustomer benefit,for a Fully Electrical Injection Molding Machine


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P-Bus

S7300S7300

IM361

SM335SM335

X 23 4

SM335

335-7H G01-0AB0

AI4/AO4 x 14 / 12 Bit

SM335SM335

X 23 4

SM335

335-7H G01-0AB0

AI4/AO4 x 14 / 12 Bit

SM335SM335

X 23 4

SM335

335-7H G01-0AB0

AI4/AO4 x 14 / 12 Bit

4X

4X4

&,��'3�

Cla

mp

Eje

ctor

Inje

ctio

n U

nit

Inje

ctio

n

MPI

611U611U

Clamp3,8 KW

Ejector3,0 KW

Injection UnitInjection9,5 KW

Dosing3,8 KW

Power

31 Input points 24VDC24 Output points 24VDC/2A16 Output points Relay 8 Thermocouple input points 4 Analog Linear Potentiometer inputs 0-10V 4 Analog Proportional Valve output 0-10V 4 Analog Proportional Valve driver output 0-10V 1 counter input

SM321

TechnologyInjectionInjection

TempTemp

Control Unit

OP37

2 x AOSpeed / Force

2 x AISpeed / Force

High End Solution withOP37 Color, CI16 DPHigh End Solution withOP37 Color, CI16 DP


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P-Bus

S7300S7300SM335SM335

X 23 4

IM361SM335

335-7H G01-0AB0

AI4/AO4 x 14 / 12 Bit

SM335SM335

X 23 4

SM335

335-7H G01-0AB0

AI4/AO4 x 14 / 12 Bit

CI16 DP, OP170BCI16 DP, OP170B

4X

4X4

&,��'3�

Cla

mp

Eje

ctor

Inje

ctio

n U

nit

Inje

ctio

n

MPI

611U611U

Clamp3,8 kW

Ejector3,0 kW

Injection UnitInjection9,5 kW

Dosing3,8 kW

Power

2 x AISpeed / Force

31 Input points 24VDC24 Output points 24VDC/2A16 Output points Relay 8 Thermocouple input points 4 Analog Linear Potentiometer inputs 0-10V 4 Analog Proportional Valve output 0-10V 4 Analog Proportional Valve driver output 0-10V 1 counter input

SM321


TempTemp

2 x AOSpeed / Force

Control Unit

SM321


TempTemp


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6LHPHQVApplikation BasisextruderApplikation Basisextruder

ET200 B

AE AA

Expansion ofperiphery,

drives, sensorswith

PROFIBUS-OP

MPIPROCESS FIELD BUS

TEMP

SIJECTCI 16 DP

MASTER-DRIVES VC15-250 kW

P-Bus

Cheap and fastconnection tostandard S7-

Periphery


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6LHPHQV

Back up sheets


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6LHPHQV

n Start-up & Service


n Hardware HMI


ContentsContents


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6LHPHQVStart-up & serviceStart-up & service

n Start-up and Toolsq Open Loop

q Step7 (min. Step7 mini-Version)

q Local Teleservice

q MMC-Card

q Close Loopq Step7 (min. Step7 mini-Version) & MMC-Card

q Local Teleservice & MMC-Card

q MMC-Card

q Close Loop Technology TECH +TEMPq MMC-Card

n Start-up and Toolsq Open Loop

q Step7 (min. Step7 mini-Version)

q Local Teleservice

q MMC-Card

q Close Loopq Step7 (min. Step7 mini-Version) & MMC-Card

q Local Teleservice & MMC-Card

q MMC-Card

q Close Loop Technology TECH +TEMPq MMC-Card


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6LHPHQVSoftware & ToolsSoftware & Tools

F irmware:IO

Memory CardCommunication

PLC Application

CI16

Bootlult Program(DOS )

S IJECT Loader(Windows)

S IMAT IC Manager(Windows)

RS 485

MPI

RS 485

Code

Code

DB1 (DPRAM)Data exchange

OP15F irmware

Menu


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6LHPHQVS IJECT 15/16 AdapterS IJECT 15/16 Adapter

T o OP15RS 485

T o CI15/16RS 485

Reset CI15/16 orOP15

S elect Connection:PC to OP15

or PC to CI15/16

T o PCRS 232

OP CI

Boot Reset CI/OP

ActivateBootstrap Loader


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6LHPHQVHandling Multi Media Card (MMC)Handling Multi Media Card (MMC)

7654321

24,0 mm

32 m

m 1. Recipes:

the MMC 50 can store up to 50 recipes

the SIJECT 30 can store up to 30 recipes

2. PLC - Controlprogram

3. Technology Software (TECH + TEMP)

4. Start page for OP 15Standard Memory Card (8 - 128 Mbyte)Fully compliant with industry standardsMiniature postage stamp sizeLow power consumption to conserve battery life


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6LHPHQVSIJECT 16: S7 Software PackagesSIJECT 16: S7 Software Packages

n For S7 - Program: SIMATIC S7, STEP7-MINI V5.0

q S7-300, 5 Languages, CD, with electr.documentation, WINDOWS 95/98/NT,single license

q limitation: no CP‘s + FM‘s

q MLFB: ES7 810-03CC04-0YX0



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6LHPHQVSIJECT OP37SIJECT OP37

n CPU: Pentium 100 Mhz, heatpipe

n Display: 10.4” STN, 640x480, VGA

n 50 Keys, 32 System-, 8 Soft keys

n Interfacesq IF1A, RS232/TTY (act/pass)

q IF2, RS232/TTY (act/pass)

q IF1B, RS422/RS485

q IF3, TTY(pass.)/RS422/RS485

n Printer Port

n External MF2 keyboard

n Jeida/PCMCIA cards type I, II, III

n Power Supply, 18 to 30 V D, max. 2A

n 340 mm x 550 mm x 150 mm (H x W x D)

Documents

SIJECT 16 / 16 DP Technical Details - Siemens molding machine.pdf · • 10 Step Profiles for Injection, Hold Pressure, Charging, Back Pressure • 16 Step Profile for Clamp Movement,