PHOTO: Tempmaster M2 – Tempmaster M2 is designed for maximum flexibility. It can control up to 500 zones and can manage even the most challenging applications
TODAY’S demanding moulding applications require precise, reliable, user-friendly hot runner controllers where the focus is in thermal and pressure balance within cavities for achieving consistent part quality. Equipment size and level of integration have become an important factor when trying to maximize shop floor utilization and process optimisation.
One of the advantages of hot runner systems with individual tip control is that the temperature controller automatically compensates for subtle gate-to-gate variations by adjusting the amount of power each tip receives, maintaining a consistent set temperature.
However, when it comes to controlling high-wattage, low-mass hot runner nozzles, the range and choice of sufficiently advanced temperature controllers available is drastically reduced.
High-wattage, low-mass hot runner nozzles heat up and cool down very rapidly. Without a suitable high performance temperature controller, the hot runner nozzle experiences undesirable temperature swings, resulting in non-uniform solidification of material in the gate area and an unbalanced fill pattern. Because of the nozzle heater’s fast response, the controller’s logic needs to act faster than the nozzle to achieve a stable and consistent temperature.
State-of-the-art controllers are equipped to do just that. Through continuously optimized programming logics, the controller is able to identify the type of heater being controlled and automatically applies the correct algorithms to achieve precise, stable temperatures to the hot runner nozzles, so that they may achieve a more balanced fill of cavities.
The future of temperature and process control in injection moulding
New moulding processes require new technologies to keep pace with technical as well as economic challenges. SmartMold, from Mold-Masters, is one of these growing technologies, and is defined as a small, powerful and fully integrated PC with sensors in the hot runner, including the strain gauge, thermocouples and accelerometer. It also includes a data server with process setup storage, details on machine, hot runner, robot, thermolators, chillers, schematics, bill of materials, processing notes and so on. The system also continuously collects process data such as cycle time and cycle count.
SmartMold could be defined as a ‘Fitness and Activity Tracker’ as it provides a comprehensive look at all relevant parameters and their impact on the moulding process — and finally, part quality. Latest developments include configurable event servers where cycle count can trigger recommended preventive maintenance and operational extreme can be monitored for failures, such as over-temperature, over-tonnage, etc. The large scope and the central storage of mould setup data including machine, control and auxiliaries creates enormous potential for continuous manufacturing process improvement as well as cost savings due to preventive actions.
New developments from Mold-Masters include the TempmMaster M Series which feature adjustable, customisable control touchscreens including diagnostic technology that optimises hardware configuration and performance, intuitive programming, easy ‘plug and play’ set up and a user friendly interface. TempMasters are compatible with ANY hot-runner system. All TempMasters use an advanced proprietary algorithm, current control, group fault detection and power thermocouples.
Such total system and process control is required to ensure that application parameters are carefully monitored and measured. The selection of the correct temperature controller and ‘Smart Control’ is essential for producing perfect plastic parts. New user-friendly and highly integrated control solutions therefore provide moulders with the critical edge for today’s plastics.
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