VT-HACD-DPQ and DPCDigital Controllers for Injection Molding and Blow Molding Machines

New Intelligence for Drives

With new market and application specific control cards, Rexroth opens up additional machine design freedom through simple implementation of robust indus-trial controller technology in de-centralized control structures.

One Card, Two Applications

The separation between auto-mation and hydraulic axis control hardware reaches a new level of quality with the VT-HACD family.

Injection cylinder Screw motorClamping cylinder

Ejector Nozzle system

WRKE WRLE

VT-HACD-DPQVT-HACD-DPC

Bosch Rexroth has paved the way for increased productivity of injection molding machines with this new series of configurable digital controllers. Specific critical process movements in a plastics machine are controlled by Field-bus capable control cards: VT-HACD-DPQ for all injection phases and VT-HACD-DPC for clamp motion. Both use internal profiles that are totally inde-pendent of the scan times of the machine control.

The VT-HACD-DPC is used as an application specific solution for all the requirements of a clamp in a plastics machine. It is optimized for protection of the mold, repeat-ability, and exact control of force, as well as very accurate velocity control.

The VT-HACD-DPQ controls the injection process in injection molding machines with para-meterization of all of the process phases. Specific functions repeat-ability are exact dosage and correct injection velocity, as well as bumpless transfer from velocity control to pressure control.

Clamp Control — the VT-HACD-DPC Fast, Stable and Precise Large Mass Motion Control

Rexroth offers optimized digital closed loop control solutions for injection molding and blow mold-ing machines: The VT-HACD-DPC is configured for applications where characteristics and functions are specially tailored to the demand-ing control of closing movements, mold protection and breakaway forces. Using Active Damping technology ensures smooth, fast and accurate movement of large mass systems.

Reduced cycle times• Accurate and very responsive

velocity and pressure control• A special controller design takes

into consideration the require-ments of the hydraulics and attains maximum repetitive accuracy.

• Active damping technology permits smooth and swift motion sequences even with springy, low natural frequency clamping units.

Reduced costs• The flexibility of the program

structure allows easy adaptation to a wide range of hydraulic control concepts.

• First-class control for both old and new injection molding and blow molding machines mini-mizes waste and protects the mold, as a result of smooth motion sequences and highly repeatable accuracy.

• Leakage caused by hydraulic pressure spikes and shocks are eliminated.

Improved process control• Versatile profile and set-up

options for complete closed loop control, even in the most com-plex clamping applications

• True differential force control enables the machine to prevent damaging the mold without affecting the velocity profile.

• Position-dependent deceleration for repeatable, swift and smooth deceleration of toggle lever or fully-hydraulic clamping units

Greater flexibility• Adaptable to any machine control,

PLC or PC• Controls the complete clamping

process, including velocity and pressure

• Configuration options simplify adaptation to customer-specific requirements.

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Improved process monitoring• Field-bus interfaces permit access

to all parameters.• Acquisition and storage of criti-

cal process data during the oper-ating cycle for precision process monitoring and quality control

Simple set-up and adjustment of profile• Special closed loop control solu-

tions for hydraulic systems are more efficient than conventional machine controls and simplify set-up.

• Configurable parameters to define the characteristics of Rexroth valves make for easier commissioning.

• Powerful software tool with graphic real-time display reduces set-up time.

• Stored profiles reduce set-up time when changing molds.

Functionality: • Controlling the different

process phases: – Closing of the mold using velo-

city profiles, speed and pressure control with mold protect

– Closing pressure – Decompression – Open mold

• Configuration options support almost any hydraulic circuit that is equipped with proportional valves.

Alphanumeric display and pushbuttons• Display and modification of

parameters• Display of setpoints and actual

values• Diagnostics

LED’s:• Display of the digital inputs and

outputs

Serial interface (RS232) for com-munication with a PC containing interface software

Analog I/O• Six analog inputs, voltage (± 10 V,

0 – 10 V) or current (0 – 20 mA, 4 – 20 mA) configurable through software

• One analog output, voltage (± 10 V, 0 – 10 V) or current (0 – 20 mA, 4 – 20 mA) configurable through software

Visualization of the process steps and error messages is accom-plished using the digital outputs.

Digital position transducer:1 x SSI or 1 x INC

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Injection Control — the VT-HACD-DPQ Perfect Control and Precise Repeatability

With the VT-HACD-DPQ the cor-rect closed loop control electronics for the injection process are now available from Rexroth: perfect process control and the highest repetitive accuracy for maximum economic efficiency. As soon as both halves of the mold are closed, the most important part of the process begins – the injection of plastic. Not only volume, but also the accurate flow rate of the extruded plastic is essential for the quality of the molded parts.

Being able to define and guarantee material flow according to the design of the mold cavity so that the resulting control of the injec-tion speed is accurate and remains independent of all other process variables, demands the highest level of closed loop control tech-nology. Know-how in the develop-ment, design and application of control axes is based on decades of experience working on hydraulic axis controllers. Rexroth has applied this know-how to design critical

process steps, such as the transi-tion from velocity into pressure control (hold pressure) without variation and with repetitive accuracy. The VT-HACD-DPQ from Rexroth, now the most comprehensive control package in the field of plastics processing machinery, possesses this capa-bility.

Reduced cycle time• Efficient control of injection

velocity and pressure• Special controller design for

highly repeatable accuracy

Reduced costs • Controls the overall injection

process• High efficiency for old and new

molding machines minimizes waste thanks to repetitively accurate motion sequences.

• Leakage caused by hydraulic pressure spikes and shocks are eliminated.

Improved process control• Versatile profile and set-up

options permit complete closed loop control of complex motion sequences.

• Repeatable transition from injection-velocity profile to pressure profile based on cylinder position, pressure, mold pressure or external event

• Multiple steps for mold fill, hold, and back pressure profiles

• Control of recovery volume and screw decompression.

Increased flexibility• Adaptable to any machine control,

PLC or PC• Configuration options support

different types of proportionally controlled hydraulic circuits.

• Control the process using either an analog command profile, or store a complete injection profile “on board” and trigger indivi-dual sequences via either discreet signals or Field-bus

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Improved process monitoring• Field-bus interfaces permit access

to all parameters.• Acquisition and storage of

critical process data during the operating cycle improves process monitoring.

Simple set-up and adjustment of profile• Special closed loop control solu-

tions for hydraulic systems are more efficient than conventional machine controls and simplify set-up.

• Configurable parameters to define the characteristics of Rexroth valves make for easier commissioning.

• Powerful software tool with graphic real-time display reduces set-up-time.

Functionality: • Controlling the different

process phases: – Injection speed control with

pressure override – Back pressure – Decompression• Setpoint generation analog

(extern) or digital (intern)

Alphanumeric display and pushbuttons• Display and modification of

parameters• Display of setpoints and actual

values• Diagnostics

LED’s:• Display of the digital inputs and

outputs

Serial interface (RS232) for com-munication with a PC containing interface software

Analog I/O• Six analog inputs, voltage (± 10 V,

0 – 10 V) or current (0 – 20 mA, 4 – 20 mA) configurable through software

• One analog output, voltage (± 10 V, 0 – 10 V) or current (0 – 20 mA, 4 – 20 mA) configurable through software

The different phases of the process can be triggered with digital signals.

Visualization of the process steps and error messages is accom- plished using the digital outputs.

Digital position transducer:1 x SSI or 1 x INC

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Parameterization, Configuration and Diagnosis Made Easy — BODAC

Both VT-HACD-DPC and VT-HACD-DPQ were developed specifically for injection molding and blow molding machines. The machine control or a PC can be used to configure the process dependent data with the help of the interface program BODAC. For these applications, specific user-screens were developed that define the different phases of the process.

The BODAC interface software enables the user to configure, para-meterize and diagnose the card without having any programming knowledge. This user friendly software makes it easier to start-up and operate. The available menus and screens are tailored to the application.

Communication of BODAC with the VT-HACD is realized through the RS232 connection on the face-plate. Modification and display of parameters using the pushbuttons and the display on the faceplate is also possible. BODAC is available for download on the internet.

Alphanumeric display and pushbuttons: • Display and

modification of parameters

• Display of setpoints and actual values

Serial interface (RS232) for communication with a PC con-taining interface software

Testjacks Diagnose LEDs:• Display of the

digital inputs and outputs

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With BODAC, application specific configurations are available that contain user-screens tailored to that specific application. This allows for easy configuration and set-up for many different automa-tion levels. The application specific user screens allow for easy and fast parameterization. All relevant pro-cess parameters can be modified from here.

The parameters used for the injec-tion process are available through multiple input locations on the screen:• Time• Position• Velocity• PressureThe parameters can be entered as absolute values in sec, mm, mm/sec and bar.

VT-HACD multiplot screenThe integrated oscilloscope func-tionality of the multiplot screen enables the user to monitor im-portant process signals. Recording of signals for an extended period of time is another included benefit.

Did this ever happen to you? The mechanical integrity of your machine is still in perfect condi-tion and does not show any signs of failing components; however the cycle times and quality of the pro-ducts dictated by the market and or products are getting harder and harder to achieve. Ineffective pro-duction, increased rework and increasing scrap rates are the result. Another factor that does not help the situation is that replacement parts or components are harder to find. Now what?

Rexroth will be your competent partner in assisting of upgrading your existing installation. Please contact our specialists so you will benefit from:• Improved accuracy• Reduction of downtime• Easy operation and parameter-

ization• Improved diagnostics• Better repeatability

Upgrade of Existing Installations

Use the many advantages the VT-HACD-DPQ and VT-HACD-DPC bring to

the table to upgrade your machines to the newest

available technology.

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The Drive & Control CompanyRexroth is unique. No other brand on the world market can offer all drive and control technologies, both on a specialized and inte-grated basis. With approximately 28,000 employees in more than 80 countries around the world, Rexroth has an infrastructure designed with partnership and customer proximity in mind. Over 500,000 customers worldwide utilize the know-how of the tech-nology leader.

Intelligent Hydraulics in New DimensionsWhether it’s a case of raising or lowering loads smoothly, undertaking linear or rotational movements, achieving even acceleration or accurate posi-tioning, maintaining preset speeds, transmitting power or linking motion sequences – in fact, wherever economical power is required, this is where hydraulics comes into its own.

Using hydraulic drive and control technology from Rexroth will help you become more competi-tive than ever.

Printed in GermanyRE 09945/09.06

Bosch Rexroth AGHydraulicsZum Eisengießer 197816 Lohr, GermanyPhone: +49(0)9352/18-0Fax: +49(0)9352/18-16 38info.bri@boschrexroth.dewww.boschrexroth.com