Special designing for DISC molding.

Transcription

1 FORM No. OPERATION MANUAL OM1247A REGISTERD No. disc PRO SERIES (INJECTION MOLDING MACHINE) P A R T - 10 Special designing for DISC molding. APPROVED CHECKED DRAWN

2 ( ) 1 Interlock for Safety Door Detecting Injection Unit Swiveling out of Normal Position

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5 This machine is provided with an upgraded PLCS-10 (Special designing for DISC molding) control system for high precision parts molding with high productivity. The PLCS-10 controller (Special designing for DISC molding) is equipped with both 32-bit and 16-bit microcomputers for high speed processing, and it also features a TFT color LCD screen having a window and a touch panel for better communication between operators and the machine. Units for pressures, speeds, positions, ETC. can be chosen by unit setting on the screen. And the features render help to setting of the mold conditions, quality control of the molding products and up to maintenance of the machine. Copyright C Printed in Japan. No part of the contents in this manual may be duplicated without written permission from Toyo Machinery & Metal Co., Ltd. The appearance or specifications of this machine are subject to change without legal obligation on the part of Toyo Machinery & Metal Co., Ltd. 1

6 A F B C D E Part name Part name A Clamping unit F Control panel B Injection unit C Power box D Control box E Power control panel 2

7 (E ) Power source for printer Printer Output connector. Other device except printer must not be used. Depend on device, the noise may invade, causing malfunction of the communication. 3

8 ( ) Heater ON/OFF switch Motor ON/OFF switch Emergency key 10.4 inches TFT color LCD Screen changeover key Condition setting key Memory card slot Manual operation key Memory card slot is provided at the right side of the control panel. 4

9 1) Make sure everything is in order around the machine. 2) Check if safety doors, protection covers and other safety devices are fixed properly. 3) Check if cooling water valves for hopper throat and mold are opened. 1) Turn on the power switch in the factory. 2) Turn on the main power breaker on the power panel. 3) Turn on the heater circuit breaker on the power panel. 4) Turn on the control power breaker on the power panel, so that the screen is displayed. 5) Press MOTOR START ON/OFF button on the control panel for a few seconds, and the motor can be started. After pressing the MOTOR ON/OFF switch for a few seconds during the door is ON, the motor stops. However, it never stops when the machine is operated in auto-mode even the switch is kept pressing. 1) Double safety system(safety door limit switch and safety drop bar) The safety doors are linked with the following two safety devices: Safety door limit switch(electrical safety device) When the safety door is closed, the operator side safety door limit switch(lss1) is pressed(on) and the rear side safety door limit switch(lss2) is released(off). The mold can be closed in this condition. NoteThe buzzer sounds with the operator side safety door closed and rear side safety door opened. Safety drop bar(mechanical safety device) Check if the stopper works properly by repeating opening and closing of the safety door. 5

10 1) To turn on the heater, keep the HEATER ONOFF switch on the control panel for a few seconds pressing. And the HEATER ONOFF switch is kept pressing during the heater is ON, the heater gets OFF. However, when the machine is operated in auto-mode, the heater never gets OFF even the switch is kept pressing. Heater ONOFF switch 2) Confirm the setting up of the heat barrel temperature on TEMPERATURE SCREEN. Screen changeover key should be pressed. INJECTION or CHARGING operation can not be taken place unless 15 minutes have not passed (unless the cold-start protection interlock does not been released) after the heat barrel temperature reached up to the preset value 6

11 1) INTERLOCK FOR SAFETY DOOR. The mold open/close structure of this machine adopts such interlock system that functions as follows when the safety door is opened. It is therefore possible to have the effect upon the operational convenience of the conventional machine to a certain extent (a) When the machine being used for insert molding work in the semi-auto mode the safety door is once closed, after the product has been taken out by hand, and then carry out the insert work when the ejector has retracted. (The ejector does not retract while the safety door being left opened.) (b) During full auto operation, if the safety door is opened the mode becomes OFF. Therefore, when safety door is opened during injection, the trouble of short will occur, giving a bad effect to the mold. Be cautions for this point. MODE ITEM OPERATION MOLD CLOSE Halt MOLD OPEN Halt EJ ADVANCE Halt EJ RETRACT Halt GATE CUT IN Halt GATE CUT OUT Halt ARM UPWARD Halt ARM DOWNWARD Halt INJECTION Halt CHARGE(PLASTICATION) Halt SUCK BACK Halt SCREW ADVANCE SCREW RETRACT NOZZLE ADVANCE Halt NOZZLE RETRACT Operational MOLD ADVANCE MOLD RETRACT MOLD CLOSE Halt MOLD OPEN Halt EJ ADVANCE Halt EJ RETRACT Halt GATE CUT IN Halt GATE CUT OUT Halt ARM UPWARD ARM DOWNWARD 7

12 MODE ITEM OPERATION MODE ITEM OPERATION INJECTION MOLD CLOSE Halt M CHARGE(PLASTICA S MOLD OPEN Halt O H TION) E L E SUCK BACK M EJ ADVANCE Halt D I SCREW ADVANCE Halt I EJ RETRACT Halt G SCREW RETRACT Halt GATE CUT IN Halt H NOZZLE ADVANCE Halt GATE CUT OUT Halt T NOZZLE RETRACT Operational UNSCREWING OFF Halt MOLD ADVANCE Halt A ARM UPWARD Halt MOLD RETRACT Halt U ARM DOWNWARD Halt MOLD CLOSE OFF T INJECTION Halt MOLD OPEN OFF O CHARGE(PLASTICA Halt F U EJ ADVANCE OFF TION) SUCK BACK Halt EJ RETRACT OFF M SCREW ADVANCE L GATE CUT IN OFF O SCREW RETRACT L GATE CUT OUT OFF D NOZZLE ADVANCE Halt UNSCREWING OFF E NOZZLE RETRACT Operational A ARM UPWARD OFF MOLD ADVANCE U ARM DOWNWARD OFF MOLD RETRACT T INJECTION OFF O CHARGE(PLASTICA OFF TION) SUCK BACK OFF M SCREW ADVANCE O SCREW RETRACT D NOZZLE ADVANCE OFF E NOZZLE RETRACT OFF MOLD ADVANCE MOLD RETRACT 8

13 2) ALARM DEVICE FOR HEAT BARREL OVER-HEATING. In case the magnet or relay etc. of heater circuit get fused,the current is not cut and heat barrel temperature continues to rise even if "heater off" instruction is output from software. To prevent such situation,the device works to measure the current value during the time the "heater off" being controlled by software, and if the device judges the situation to be "abnormal" the device acts to cut the heater breaker with the alarm message displayed. (a) Alarm message. Due to abnormality in heater circuit, breaker has been shut off. (b) RESET method. Remove the cause of function etc. OFF key. Breaker reset. 9

14 3) Detecting Injection Unit Swiveling out of Normal Position. The injection unit is swiveled out of normal operating position when a screw is replaced, for instance. To eliminate hazards, a limit switch is provided to detect the injection unit position. And when the injection unit is out of normal position, only the Mold Height mode becomes available where every motion can be made at low pressure. (a) Specifications in detail (i) Location and status of limit switch Limit switch ON(Fig. 1) Injection unit is in the normal position. Limit switch OFF(Fig. 2) Injection unit is off the swiveled out position. (ii) With the limit switch ON Normal operation can be made. (iii) With the limit switch OFF Only operations in the Mold Height mode can be made. Neither Manual mode nor Auto mode is available. An alarm message is shown on the screen. (iv) Alarm and alarm resetting Input port: INJ SOL board LP18 Message:? Inj. Unit turned. Carry on machine operation in mold height mode.? Output: Signals for buzzer and flash light(red color)(optional) Reset method: Press OFF key. (v) Screw advancing speed in Mold Height mode When the injection unit is swiveled out, the screw advancing speed for screw pull-out is 13mm/sec. 10

15 Heater ON/OFF switch Motor ON/OFF switch Emergency key 10.4 inches TFT color LCD Screen changeover key Operation mode key Condition setting key Operation key Memory card slot Press this pushbutton when any emergency situation occurs, so that the machine instantly comes to stop and the motor is turned off. When pressed, the pushbutton is locked at the pressed position. Therefore, unlock the Emergency Stop pushbutton by turning its knob in an arrow direction before re-starting the motor. Otherwise, the motor cannot be turned on even if the Moter ON/OFF switch button is pressed 11

16 Screen changeover key When another screen is desired to call, press the desired screen key and a screen changes over to the desired one, and then the function key reverses in red. Example Screen changes over from INJ. CHG. SETUP screen to COPMPRESSION GATE-CUT screen. Now, INJ. CHG. SETUP screen is shown. Function key reverses in red. Press key () to changeover to COPMPRESSIONGATE-CUT screen. The screen changes over to COPMPRESSION GATE-CUT screen, and function key reverses in sky blue. 12

17 If LED(left, top part of the key) is being lighted, the OFF mode is kept continued(all actions are standing in OFF condition). Under OFF mode, the machine can not move at all. If LED condition to go on and off, it means that the machine is under ALARM condition, and the alarm message will be displayed at the top port of screen. To release the alarm, push key switch. LED will then lighted. Reset key switch is used to correct the data before setting process. key is touched during Press key, and data previously set appears. This key switch is for changing-over from the PREPARATION mode to the screw-draw-out mode. When mold is changed, this mode used for adjustment of each action. At the time of mold open/close, and screw advance/retract, this mode function at, low speed and low presser. Manual mode key switch. It is used when operating in manual made. Push this key switch so that semi-auto operation can be started. In semi-auto operation, one cycle is made to end with ejection completion. To start next cycle, open and shut the safety door on the operator side. Full auto key switch. Push this key switch twice so that automatic operation can be started. For both SEMI-AUTO and FULL AUTO operations, push the key switch twice for purpose of safety. If twice-push is forgotten, the message (16),(17) will be shown after 5 seconds. Message 16? Press FULL AUTO key again.? 17? Press SEMI-AUTO key again.? 2. To change-over FULL AUTO to SEMI-AUTO, push the key switch only one time. 3. In case the Motor Start Switch is off, LED of key switches of And the next message will be shown. 4 Motor is disconnected. Confirm emergency stop button SW. 13

18 0 9 Numeral keys. Use to input/alter the values. Use to input decimal point. Reset key. Use to release the setup on the way of operation, and to reset of the alarm. Depend on the alarms, some of them may not be able to reset. (See ALARM MESSAGE table in details.) Use to (, ON, SELECT)(, OFF) key. The functions of (, ONOFF, SELECT) are judged by the micro computer. To set up SELECT, move cursor (green) to the selecting item on the place shown in blue, and press keys, then the cursor changes in blue and the item is selected. To set up ONOFF, move cursor to the indicating ONOFF, place, and press to get OFF. keys to get ON and press To set up, press or key. And the set up value increases or decreases by one. (It is useful to fine adjustment.) And or are pressed, the set up value increases or decreases by 10. When (,) keys. or keys are pressed, the set up value gets 2 times or 1/2 times. Use to rough adjusting. When keys are pressed, the set up value becomes 4 times, 8 times at one time. 14

19 Enter key. The input value is confirmed in memory as the set up value. When setting up by numeral key is starts, the indication of cursor changes. This means the set up is under on the way. The value on this stage is still invalid. Press moves next. key, and the value gets effective. Then the cursor If key is pressed on the way of setting up, the input value up to that time will be cleared and returns to the previous indication before operation. If it takes over 5 minutes before pressing message will be shown. key, the following Message? Press ENTRY key.? Repeating facility When key is being pressed for longer than a second, the cursor on screen moves for the time length of the key being pressed. Similarly, when keys are pressed over a second, the set up value continuously increases or decreases by one. 15

20 While the operation key switch is being kept pushed, each action will be performed normally. During the actions are going on, LED at left, top is being lighted In manual mode This key switch is used to open the mold until complete position. When Eject being interlocked, Eject action takes place after completion of mold open. In preparation mode Up to the position of mold open completion, mold will open at low speed and low pressure. In manual mode This key switch is used to close the mold until complete position. In preparation mode Up to the position of mold close completion, mold will close at low speed and low pressure. In manual mode This key switch is used to retract the ejector. In preparation mode The key is used to retract ejector at low speed and low pressure. In manual mode The key is used to advance the ejector until the advance limit position. This action only can be done when the mold opens completely. In preparation mode In this mode, the ejector advances at low speed and low pressure. This action only can be done when the mold opens completely. In manual mode The key is used to return the gate cut. In preparation mode In this mode, the gate cut returns at low speed and low pressure. In manual mode The key is used to advance the gate cut up to the advance limit position. This action only can be done when the mold opens completely. In preparation mode In this mode, the gate cut advances at low speed and low pressure. This action only can be done when the mold opens completely. 16

21 In manual mode or preparation mode The movable side air can be actuated while this key is kept pushed. In manual mode or preparation mode The stationary side air can be actuated while this key is kept pushed. In manual mode If the nozzle stays at returned position, the screw can be advanced at low speed. In preparation mode In this mode, the screw can be advanced at low speed. In manual mode This key switch is used to rotate the screw. If being kept pushed for 0.5 second, the key can be held.1 The screw is acted the suck back from charge(metering) completed position. In preparation mode The screw will retract at low speed. In manual mode or preparation mode This key switch is used to advance the nozzle. In manual mode or preparation mode This key switch is used to retract the nozzle. In preparation mode This key switch is used to advance the clamping unit. In preparation mode This key switch is used to retract the clamping unit. Purge When this key is pressed during mold height mode, auto purge operation will be executed. Stamper change mode can be actuated in preparation mode. In preparation mode The movable ring can be retracted while this key is kept pushed. 17

22 1 : If the alarm message is being displayed, the operation key switch will be set free from holding-up. 18

23 3-2 Basic screen layout Sectional screen area layout No. Machine type Title DateTime Alarm message (Max. 4 lines.). Touch key Touch key To PLCS-10 control system, touch panel key is adopted on all screens. Cursor can be moved easily only touching desirable position to set up. Use condition set up key on the key-board panel to input numeral value. (Refer to ) ON/OFF set up. Function key Function key These keys are indicated on the lower part of screen (). These keys are used for screen changeover or indication of window (pop-up screen). Each screen can be call by just touching each function key on the screen. When the key is touched, letters part of the key change color. This means the screen is called out. Size Hemming Color Screen key Large Blue Reverse in sky blue Window key Small None Reverse in sky blue Auxiliary key Large None As to the screens of that setting up is prohibited and selection of indicating is OFF, they are not shown on this portion of the screen as function keys ONOFF set up When setting is ON, sign is shown, and if it is OFF, is shown on. () 19

24 3-2-5 Calculator function Press CALC function key and the table calculator will be displayed on the screen. 1) The calculator function is available. When the function key said above is pressed, the calculator window) will be displayed on the screen. Data input and calculation can be done on this window. And the calculated result by this calculator can also input as the set up value. 2) Method to input the calculation results into the setup value. Move cursor to desired item to set up. Press CALC key. Then, the table calculation function will be displayed. Calculation is processed. When the result is displayed, press ENTER key again. The table calculator will disappear, and the cursor indicates calculated results under on the way of calculation. If the calculated result is OK, press the result is input as the set up value. key (condition set up key). Then 3) Method of inputting the set up value into the table calculator Move cursor to the position of desiring set up item. PressCALCkey, then the table calculator will be displayed. PressLOADkey. Then the setup value will be loaded to the table calculation function. And calculation function is available. 20

25 3-2-6 Print Print of the displayed screen. (Hard copy) 1) Printing method of the displayed screen. (a) Connect the printer to the machine with the printer cable. (b) Call the COMMUNICATION PORT screen, and select and set USE of SELECTION of printer. Refer to PRINTER screen in detail. (c) Select the printer to be used. (d) Call the desiring screen to print, and press PRINT function key. Then printing will take place and the message (No.239) will be shown. The printing is executed in monochrome. Message Hard copy now being displayed. 2) Suspension of printing (a) When press PRINT function key, the characters change STOP. Press STOP function key under the present condition. Then the message will be shown. Message Hard copy suspend signal received.standby 21

26 3-2-7 Scroll of screen On the screen as shown left, the right part of screen is off and can not be read. In such case, the scrolling of screen is useful. NOTEAt the edge of a screen, sky blue border line is indicated. The screen can not be moved beyond this line. Indication of key changes. To scroll the screen, use on the bottom right of the screen. (Function key) key 22

27 3-2-8 Window screen If window of the function key is pressed, a small screen (window) will be shown on the present screen, and it is possible to set up the function that is shown in window When window is shown, the character part of the window key will be colored (reversed in sky blue ). During the window is shown, cursor can be moved only within the window. ExampleOpening of INJ. SUB SETUP window of INJ. CHG. SETUP screen. When operation power is turned ON, TEMPERATURE screen comes appear. Characters of the function Screen changeover key is lit in color and indicates the window being shown. ( 1) Press key for screen changing over, the screen changes to INJ. CHG.SETUP screen and the characters of INJ. CHG. Is lit in color as same as TEMPERATURE screen. Touch AUX.INJ. key at the second from left of the bottom on this screen. right corner. Or press AUX.INJ. key again. The window will be shown as left and INJ. SUB SETUP characters will lit in color. The set up within the window is also available through To erase (close) the window, press the upper 23

28 3-2-9 Character input window Figures or English characters can be input in PRODUCT NAME column of the DATA MEMORY screen and PRODUCTION CONTROL screen. Get of the DATA MEMORY screen being displayed, move cursor to PRODUCT NAME column, and character window will be shown. As to PRODUCTION CONTROL screen, the procedure is same as above Character input method Move cursor to this part, and the window can be shown. Press desiring character and press ENTRY key, then the window disappears and input characters on the PRODUCT NAME will be shown. When key is pressed, the set up completes. If this operation is ignored, the characters input become invalid Press desiring character and then press ENTRY key. The window disappears and characters witch has been input onto PRODUCT NAME will be shown. And key is pressed, then the set up completes. When erasing or altering the input characters, press BACK key before press ENTRY key. And the characters will disappear, one by one, from the right end. The blank portion is equal to the space key. 24

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31 In, there are available 55 screens, but the necessary setup values for ordinary molding are arranged in the SETUP SCREEN. By using this SETUP SCREEN, the setup alteration of molding condition can easily be processed. Method to call the screen. (Screen changeover key 27

32 Select of screen. : Normal screen. : Graphic screen. (By / setup) : Monitor screen. (By / setup) : Spare, Fixed setup, Printer. (By / setup) 28

33 The screen regarding temperature is divided into 2 screens; one is temperature and the other one is PID setup. When the power source is turned ON, the following temperature screen will be displayed. When call up this screen, shifting from other screen, push key switch. Screen changeover PID setup screen is called by using PID SETUP function key on the temperature screen. If PID SETUP function key is touched, the screen will change to PID SETUP SCREEN as follows. 29

34 A B C D E When the power is turned ON, the following TEMPERATURE screen will be displayed, or press key (Screen changeover key), then the screen will be shown. A : Measured temperatures of each zone. B : Setting temperatures of each zone. C : Upper zone temperature allowance. In case actual temperature rises beyond this allowance, the auto operation stops, buzzer sounds and message (24) appears on the screen. D : Lower zone temperature allowance. In case actual temperature drops beyond this allowance, the auto operation stops, buzzer sounds and message (25) appears on the screen. E : ON/OFF setting of each zone. Move the cursor to any setting position, push ON key switch and ENTER key switch for ON setting. For OFF setting, push OFF key switch and then ENTER key switch. : Name of heater zone. When status become stabled, color changes to GRAY. : Indication of heater energization. When Heater is energized, color changes to RED. : Indication of cooling water flowing. When the cooling water is flowed, color changed to BLUE. : Indication of energization of heater and cooling water valve. The arrow mark of (Red) or (Blue) will be displayed by energy condition. 30

35 The numerical value in the frame shows the energizing rate. : ON/OFF setting of control of holding temperature. When setting is '', the heater is controlled by the temperature of. : Temperature setting under controlling of holding temperature : Indication of heater control condition During controlling of heater temperature holding, the indication of HOLDING is shown on screen. During other process than holding temperature control, the indication of CONTROL is shown on. 31

36 A B C D E F G H I J K Method to call the screen This screen can be inhibited to display by (OFF) setup the SPARE,FIXED DATA, UNIT INDICATION SCREEN on ACCESS SCREEN. (Screen changeover key) (FUNCTION KEY) Explanation of screen. A : P SETUP( or F) PID proportional control constant.(large gain by small value.) B : I SETUP(sec) PID integral control constant.(large gain by small value.) C : D SETUP(sec) PID derivative control constant.(large gain by large value.) D : SAMPLING PERIOD Control period of temperature. E : OFFSET Present PID control offset value will be displayed. 0 (Sampling period10). F : INTEGRAL VALUE Present PID control integral value will be displayed. 0PI/Sampling period. G : STEADY STATE JUDGE VALUE 32

37 Presently not been used. H : STABLE STATE JUDGE VALUE This is the constant to judge the stability of integral value variation F. When in stable state, the offset E will change. I : TEMPERATURE SLOPE CONSTANT When temperature rises, the slope command is issued, and over-shoot will be prevented. J : CONTROL COMMAND Control method of mold 1,2 or spare 1,2 will be ordered. In the case of (OFF) set. In the case of (ON) set. Cooling Heating control by heater. Cooling control by water. P I D PID control command. ON/OFF ON/OFF control command. Either one of these is to be set as (ON). K : COLD PREVENTION TIME 15min900sec.(This value must not be altered.) : MOLD COOLING WATER CONTROL It is displaying but it doesn't function. 33

38 Screen construction. 1) The number of screen consists of the following. 5screens : CompressionGate-cut, Airvacuum, 1Cycle Graph,Mold movement, Option. 3Functions : Cross-hair, Graph erase, Auxiliary function. 2) The method to call the COMPRESSIONGATE-CUT SCREEN. When the screen of COMPRESSIONGATE-CUT SETUP is displayed, 3) The method to call the screen by using the function key. function key When AIRVACUUM function key is touched, the screen will be changed to AIR VACUUM SCREEN. 34

39 When 1CYCLE GRAPH function key is touched, the screen will be changed to 1CYCLE GRAPHIC SCREEN When MOLD MOVEMENT function key is touched, the screen will be changed to MOLD MOVEMENT SETUP SCREEN. When OPTION function key is touched, the screen will be changed to OPTION SETUP SCREEN. 35

40 A B C D E F G H I 1 2 Method to call the screen. Push Screen changeover key switch. Explanation of INJ.COMPRESSION screen. A : Injection compression start width setting during injection process B : Position setting for speed control in injection compression Compression start position( = changeover position to high clamping force) Pressure control start position C : Speed setting for speed control This is a speed in the speed control process, and it also serves as a regulated speed during the pressure control process. Unless any trouble occurs in molding operation, set as high speed as possible for the third speed. (If too low, the motion in the pressure control process will not be smooth.) D: Clamping force setting in injection compression This setting regulates the maximum clamping force that occurs during the speed control process. To make the operation in the speed control process smooth, set as high force as possible unless any trouble occurs in molding operation. E : Time setting for 5-step pressure control in injection compression. F : Compression force setting for 5-step pressure control process. G: Slope-constant setting for 5-step pressure control process This constant sets the degree of the slope(force shifting per second) in compression force shifting. The higher the value is set, the faster the force shifting is made. H: Monitored mold position in mold open/close process 36

41 I : Monitored clamping force : Delay when changing from SPEED CONTROL to PRESSUER CONTROL. In a state of positioning while the timer is working. K: Compression mode selection VP mode: The changeover position to high clamping force in clamp force setup screen serves as the compression start position(stand-by position). OFF mode: The mold closing motion continues till the closing completion position. Timing chart of compression motion. Compression start position Position during injection process [Mold pen/close] Closing Compressing Opening Ejecting [Injection plastication] Injecting(Holding) Plasticating Inj.delay time Plastication delay time VP Mode(Speed Pressure Mode) The compression motion starts at a set point during the injection process, and the speed is controlled in one steps and pressure in five steps. Delay timer Speed control process Pressure control process 37

42 Explanation of GATE-CUT screen. A B C D E F G H I A : Position setting for gate-cutting retracting (retracted position): After the injection process, gate-cutting starts at this position. B : Speed setting for gate-cutting retracting. C : Position setting for gate-cutting advancing (advanced position). D : Speed setting for gate-cutting advancing. E : Driving force setting for gate-cutting advancing. F : Setting for Gate-cutting delay time. G : Gate-cutting ends when COOLING TIMER times up. +: Gate-cutting ends(retracts) at the preset time(+ figures setting) after COOLING TIMER has timed up. -: Gate-cutting ends(retracts) at the preset time(- figures setting) before COOLING TIMER times up. "In case of '0' time setting, gate-cutting starts retracting at the start of mold opening." H : Monitored position in gate-cutting process. I : Gate-cutting mode selection. OFF : Gate-cutting is not used. HOLD POSITION : Gate-cutting operation starts when injection holding process is start. Timing chart of gate-cutting motion. [Mold open/close] Closing Compressing Cooling timer Opening COOLING CMP. - + [Ejecting/gate-cutting] Gate-cut advance retract EJ advance EJ retract [Injection/plastication] Filling pressure Holding pressure Delay time Plasticating Operating time 38

43 Method to call the screen. Push Screen changeover key switch. And touch AIRVACUUM function key Explanation of AIRVACUUM screen. MOV. AIR A Movable mold side air +/- selection +Air blow on the movable mold side is made after cooling process. -Air blow on the movable mold side is started before the end of cooling process. B Air blow start timing setting C Air blowing time setting With "+" selection ina The COOLING CMP timer starts when cooling timer times up. Air blowing starts when COOLING CMP timer times up, and air blowing continues for the time set at OPERATION TIME timer. Machine cycle Injection Charge Mold open Cooling timer Air blowing 39

44 With "-" selection ina Air blowing starts before the end of cooling process. The COOLING CMP timer sets the time how long before the end of cooling process. If you set 3 seconds for Cooling time and 2 seconds for COOLING CMP timer, air blow starts one second(3 seconds - 2 seconds) after the start of cooling. Air blowing continues for the time set at OPRATION TIME timer. Machine cycle Injection Charge Mold open Cooling timer Air blowing STAT. AIR Stationary mold side air +/- selection +Air blow on the stationary mold side is made after cooling process. -Air blow on the stationary mold side is started before the end of cooling process. Air blow start timing setting Air blowing time setting With "+" selection in The COOLING CMP timer starts when cooling timer times up. Air blowing starts when COOLING CMP timer times up, and air blowing continues for the time set at OPERATION TIME timer. With "-" selection in Air blowing starts before the end of cooling process. The COOLING CMP timer sets the time how long before the end of cooling process. If you set 3 seconds for Cooling time and 2 seconds for COOLING CMP timer, air blow starts one second(3 seconds - 2 seconds) after the start of cooling. Air blowing continues for the time set at OPRATION TIME timer. START-UP Start-up mode of Movable mold side air and Stationary mold side air. Selection of start-up. At the start of automatic operation, air blowing is made in "start-up setting" mode for the number of cycles preset at the counter. Air blowing is made in standard setting mode. Notes Even before OPERATION TIME timer times up, air blowing stops when the mold starts closing in the next cycle. (This situation will occur when the setting time for OPERATION TIME is long.) If you set 0.00 seconds for COOLING COMP timer, air blowing starts at the time 40

45 when cooling process is finished. I Mold open monitor MOVABLE RING Cooling completion +/- selection + : The movable ring is retracted after the cooling timer times up. - : The movable ring is retracted before the cooling timer times up. Setting of Delay time 1 and Delay time 2 With "+" selection in The delay 1 timer starts when cooling process is finished. The movable ring starts to retract when the delay 1 timer times up, and the ring stays at retracted position for the time set at Delay 2 timer. Cooling timer Cooling time times up SOL for movable ring Movable ring retraction Delay 1 Delay 2 With "-" selection in The movable ring starts to retract before the cooling process is finished. The Delay 1 timer sets the time how long before the end of the cooling process. If you set 3 seconds for Cooling time and 2 seconds for Delay 1 time, the movable ring starts to retract one second(3 seconds - 2 seconds) after the start of cooling. The ring stays at the retracted position for the time set at Delay 2 timer. Cooling timer SOL for movable ring Movable ring retraction Delay 1 Delay 2 Note The movable ring advances with the solenoid valve OFF and retracts with ON. If you set 0.00 seconds for Delay 1 timer, the movable ring retracts at the time when cooling process is finished. 41

46 Even before Delay 2 timer times up, the movable ring advances when the mold starts to close in the next cycle.(this situation will occur when the setting time for Delay 2 timer is long.) MOLD CLOSING SOL ON In automatic and manual operations in this mode, air pressure to the cavity ring is released in the mold closing process. (This mode is used when AXXICON mold is used.) Note Turn this setting ON()when AXXICON mold(s-mold) is used. Set this setting to OFF(X) when TECHNOPLAS mold is used. AIR MONITOR Air pressure is monitored. When air presser drops beyond this setting, Message '1254'is displayed. The next cycle is prohibited in automatic operation. At the start of automatic operation, Message '1246'is displayed, and automatic operation start is prohibited. 1246? Air pressure is low. Auto operation prohibited.? 1254? Air pressure is low. Confirm the air pressure.? Stamper sucking Measured value of stamper sucking ( ) Measured value of the inside vacuum degree or out side one is indicated when stamper sucking is being carried on. Setting value of stamper sucking ( ) This function is used to judge lowering of vacuum degree. Timer ( ) When vacuum sucking is carried on, the inside is sucked first, then the outside will be sucked after the timer ( ) timed up. Condition ( ) On this part, condition of vacuum sucking is shown on. Manual sucking ( ) Move cursor to this part, and ON/OFF mode of the vacuum sucking solenoid can be shifted every time when ON/SELECT key is pushed. (This is the same operation as stamper sucking key on the operation panel. 42

47 F A G B H C I D J E 1) Method to call the screen. Push Screen changeover key switch. Function key Touch 1CYCLE GRAPH function key switch. 2) Explanation of screen. This screen indicates each measured value of one cycle. The ordinate is indicated each measured item, and the abscissa is indicated time. A : Graphic indication of injection speed. B : Graphic indication of injection pressure. C : Graphic indication of mold movement speed. D : SPARE 1 E : SPARE 2 F,G,I,H,J : This value is equivalent to one scale of ordinate(upper scale). K,L,M,N,O: This value is equivalent to one scale of ordinate(lower scale). [Note] Time of abscissa; In the case of manual mode, the counter starts from 0.00sec at the moment of start of each action. 43

48 In the case of auto mode start time, the counter starts from 0.00sec at the moment of action start. In the case of next cycle in auto mode, the counter starts from 0.00sec at the moment of cycle start(at mold clamp start). c d a b 3) Explanation of graph function. SUB FUNCTION WINDOW(Touch SUB FUNC function key switch.) a : Selection of graphing. Either SINGLE or MULTI of graph is selected. SINGLE WRITING------The graph changes at each on cycle. MULTI WRITING The old data is kept staying, in different color (WHITE) on the graph, and the new data is graphically displayed over the old data. b : Selection of scale mode. AUTO-----At each one cycle, the scale size is automatically adjusted so that the actually measured value can be shown within the space of graph. SETUP----Simultaneously with the fixing of scale(f,g,h,i,j,k,l,m,n and O ), the setup becomes possible to alter according to the need. By fixing the scale, at the time when the setup has been altered during MULTI WRITE mode, the comparison of actioning status between the old data and new data can visually be confirmed that will make the 44

49 optimum determination of condition setup easy. c : Selection of the line color of graph can specifically be set by number. d : Setting of scale MIN. width. The scale MIN. width of each item is set here. If the scale mode has been set to AUTO mode, the scale itself will automatically be adjusted so that each measured value may be displayed within the space of graph. In this case, however, the least width of scale has been limited to prevent the auto-adjusted-scale width from becoming. GRAPH CLEAR(Touch GRPH CLR function key switch.) If this touch key is touched the graph will disappear. CROSS ON(Touch CROSS ON function key switch.) The cross-hairs functions take place. For details, see the paragraph of Cross-hairs function,

50 This function works to measure the distance between 2 points set on the graph. When CROSS ON function key is touched, the graphing work will stop, and the function-key will change-over as shown below. (MULTI mode will not be executed). Function key All while the cross-hairs function is working, the change-over to other screen is not possible. If CROSS OFF function-key is touched, the function-key returns to the preceding function-key, and the screen will be become changeable. If this function-key is touched, WINDOW will be displayed on the screen as shown below. In the case if the graph can not seen because the graph is behind the WINDOW, touch DATA CHANGE function-key, then the WINDOW moves in order as illustrated in the following figure. 46

51 The indication of a port will be changed-over. The indication is different according to each graphic screen. In the case of WINDOW shown left, the time(horizontal line) and speed(vertical line) of injection speed are being displayed. c This function-key is for moving the cross hair1 b, right and left. The cross-hair1 b will move along the wave-form. In the column of c, X coordinates of cross-hair1, and in d column Y coordinates will be displayed. In the figure, left, c means the time and d the speed. This function-key is for moving the cross-hair2 e, right and left. The X coordinates of cross-hair2 will be displayed in f column, and Y coordinates will be displayed in g column. In the column of h, the balance of X coordinates between the cross-hair1 and 2 will be displayed, and the balance of Y coordinates will be displayed in i column. The line color of cross-hair1&2 can be set by SUB FUNCTION. [The method to call SUB FUNCTION.] function key SUB FUNC function key 47

52 A B C D 1) Method to call the screen. Touch 1CYCLE GRAPH function key switch. Next touch ITEM SELECTION function key switch. 2) Explanation of screen. Items of 1 cycle graph can be designated in terms of selection, Order. A Setup of the selective item no. out of 1 cycle graph. B Contents of the selective item no. of 1 cycle graph. CIf O setup is done, the Spare 1 can indicate graphically the external volt input (0 10v).(Scale value = 10v). If the number of 1115 of Spare Item list is selectively set, the Spare 1 can indicate graphically the internal control data. 48

53 3) Setup method of 1 CYCLE GRAPH ITEM. The item that is desired to be shown graphically is selected out of the select items A (1 11), and set its designated No. at the ITEM SETUP B (15). Then, the item set will be displayed on the screen. D : Explanation of SELECT ITEM(SLAVE MPU) and SELECT ITEM(SCPU). No. ITEM Scale Value 1 (D/A 3) Output current of EH volt A 2 (D/A 4) Output current of EH speed A 3 (D/A 7) Output volt of mold clamp DFP V (DRIVE FIRST PROPORTIONAL VALVE) 4 (D/A 1) Command volt of charge speed V 5 (A/D 1) Input volt of mold clamp potentiometer V 6 (A/D 2) Input volt of EJ potentiometer V 7 (A/D 3) Input volt of pressure head V (MOLD INTERNAL PRESSURE) 8 (A/D 4) Input volt of motor CT V 9 (A/D 5) Input volt of charge TG V 10 (A/D 6) Input volt of servo torque V 11 (A/D 7) Input volt (SPARE 1) V 12 (A/D 8) Input volt (SPARE 2) V 13 (A/D 9) Input volt of pressure head(main PRESSURE) V 14 (A/D 10) Input volt of pressure head(acc PRESSURE) V 15 (A/D 11) Input volt of pressure head of EJ ACC pressure V 16 (A/D 12) Input volt of pressure head( ) V 1722 Omitted 23 Scanning time of control CPU ms 2430 Omitted 31 Item 1 of 1 CYCLE LOGIC GRAPH 256 ON,0 OFF 32 Item 2 of 1 CYCLE LOGIC GRAPH 256 ON,0 OFF 3349 Omitted 5069 Control value of feed back control ee----operation amount (PP) P-----P setup e-----deviation ei----integrating control value ed----derivative control value 70 Scanning time of injection control CPU 20001ms 71 (SCPU A/D1) Input volt of pressure head of injection pressure 72 (SCPU A/D2) Input volt of pressure head(spare) 73 (SCPU) Counter value of encoder, injection encoder 74 (SCPU D/A1) Output volt of injection DFP (DRIVE FIRST PROPORTIONAL VALVE) V V V 75 (SCPU D/A2) Output volt (spare) V Omitted 49

54 A B C D E L M N O P F G H I J K 1)Method to call the screen. PUSH function key Screen changeover key switch and push MOLD MOVEMENT 2) Explanation of screen. This screen is used to set mold opening/closing motion and ejector motion. If the mold requires special motions such as core, unscrewing and air blowing, OPTION SETUP screen is used in addition to this screen. The mold positions in opening A and closing C are indicated with the distance from the mold clamping completion position where position is regarded as 0 mm. Monitored position is indicated in cell K. The mold moving speeds in opening B and closing D are set in %,respectively as 100% with the full speed of the mold moving. Low pressure mold closing system. Never fail to set (on) the cell E. The position H is automatically set where mold closing pressure is shifted from low to high. This setting is made in the process of automatic clamping force setup.(in case of compression mode was selected as VP mode, the position of pressure shifting from low to high is not set automatically.) Time setting for low pressure mold protection is made at the cell F. The 50

55 timer starts when mold closing process enters low pressure stage. In case that any foreign object stays between mold halves preventing mold from further closing, an alarm is issued when the preset time is expired. Set the pressure for low pressure mold protection at cell G in the following manner. 1. After fixing a mold, close the mold in manual mode. 2. See the cell I to check what pressure(in %) was actually required in low pressure closing process. 3. Set the cell G at 2-3% higher figure than the pressure observed at the cell I. 4. In case that the pressure setting is too low, alarm will be issued even with no foreign object between mold halves. < Alarm message > 77? Low pressure mold closing alarm.? Clamping force.j Clamping power is shown on by using the load cell value. The ejector motion can be programmed depending on the mold. Ejector stroke is set at cells L. Ejector speed is set at cells M. Each setting can be made for ejector advancing and retracting respectively. The speed and pressure setting can be made in two steps for ejector advancing process. The present ejector position is indicated at the cell N. Ejector advancing delay time is set at cell O. This is a timing time for the convenience in removing products by hand or with a robot. Ejector holding time is set at the cell P. The ejector stays at the advanced position for the time set at the cell P. 51

56 3) Explanation of window function. SUB SETUP WINDOW(push AUX.CLP. ) A B C D E F A : Slope control of mold open speed.(only 3stages and 4stages) The A is set as (ON), then the mold open speed will become the slope control. POSITION [ mm ] [ inch ] SPEED [ % ] SLOPE CONTROL PRESSURE [ kgf ] [ psi ] SLOPE CONTROL Example Setup data of mold open. 60 % 30 % 10 % 10 % Opened [ mm ] Closed 0.4 [ inch ] Opening position The slope is controlled between SLOW-2 and OPENED. 52

57 B : Slope control of mold open pressure. The B is set as (ON), then the mold open pressure will become the slope control. POSITION [ mm ] SPEED PRESSURE [ % ] SLOPE CONTROL [ kgf ] SLOPE CONTROL ExampleSetup data of mold open. OPEN PRESS (kgf/cm2) 80kgf 170kgf 20kgf 10kgf Opened Closed C : Slope control of mold close speed. Opening position The slope is controlled between SLOW-2 and OPENED. POSITION [ mm ] SPEED [ %] SLOPE CONTROL PRESSURE [ kgf ] SLOPE CONTROL The C is set as (ON), then the mold open speed will become the slope control. ExampleSetup data of mold open. CLOSE SPEED (%) 60% 40% 30% 10% Opened Closed Closing position The slope is controlled in SLOW-1. 53

58 D : EXACT MOLD OPEN The D function is set as (ON), and by combining the mold open mechanical stopper in good order, the mold opening accuracy will firmly be maintained. E : EJECTION (times) The number of ejecting motion can be set at the cell E. The ejector repeats advancing and retracting for the times set at the cell E. This secures perfect ejection of products from the mold. The maximum settable number is 99. F : EJ ADV.POS.(Ejector re-advancing position) When the number of ejecting is set at more than twice, setup of this position becomes effective. For example, if the number of ejecting time is set at three (3), the retracting position of ejector until the second time is to be the value set at F, and the third(last) time, the ejector returns back up to 0 mm position. 54

59 C D E F G H A B L M I J K 1) Method to call the screen. This screen can be inhibited to display by (OFF) setup the SPARE, FIXED DATA,UNIT SCREEN INDICATION on ACCESS SCREEN. 2) Explanation of screen. A : The number of mold open half-way position(04) is set here. The item name will be indicated in M column according to the set numeral. B : The number of mold close half-way position(0 4) is set here. The item name will be indicated in L column according to the set numeral. C : The using number of air blow(04) is set here. In the standard specification, the output available for use of the air blow is only up to 2. D : The selection of either use or NO use of Ejection is set by /. E : The selection of either use or NO use of ON Way Ejection is set by /. While setting of this mode is (ON), ejecting will start when the setting time from the die open start has been passed. F : Start timing for On way ejection is set. (The ejector motion starts after this set timing passed from mold opening start.). G H : During Air blow is being operated, it can be forcibly completed by means of starting of mold close, or completion of injection. I : COMPLEX MOVEMENT CLOSE & INJ.: Crossing point of high pressure clamp and injection. While setting of this mode is (ON), injection will commence from the point 20mm ahead of mold clamp position in cylinder stroke. EJ R & CLOSE: Ejector retract and mold clamp. While setting of this mode is (ON), clamping will start from the setup position. 55

60 J a) EJ F WIDTH Setting of EJ advancement position for interface signal for improving of cycle time of ROBOT. (ROBOT should be modified to use this function.) b) NO MOLD FULL OPEN AT AUTO STOP Selection of mold open operation when automatic operation is stopped. : The mold opens to the maximum stroke. : The mold opens to the open-completion position. K : Air blow (Starting position of air blow control.) 0: Air control starts when mold open comes set position. 1: It starts when mold open completes. 2: It starts when charging completes. 3: It starts when mold close comes low pressure position. 4: It starts when before the end of cooling process. 5: It operates according to settings at the AIR VACUUM SETUP screen. (Standard) L : The half-way position of mold clamp is set here. M : The half-way position of mold open is set here. 56

61 The number of screen consists of the following. 4screens : Injection, Graphic, 1Cycle Graph, Spare setup. 3windows : Adjustment, Graphic, Auxiliary setup. 3Functions : Cross-hair, Graph erase, Auxiliary function. 3) The method to call the screen by using the function key. Function key This screen can be inhibited to display by INJECT (OFF)setup the SPARE,FIXED DATA,UNIT SCREEN INDICATION on ACCESS SCREEN. When INJ.GRAPHIC function key is touched, the screen will be changed to INJECTION GRAPHIC SCREEN. 57

62 When 1CYCLE GRAPH function key is touched, the screen will be changed to 1CYCLE GRAPHIC SCREEN When SPARE function key is touched, the screen will be changed to INJECTION CHARGE SPARE SETUP SCREEN. 58

63 A B C D F G K L E I J H M 1) Method to call the screen. N Push Screen changeover key switch. 2) Explanation of screen. A : Change-over position for injection speed(1st10th). B : The setting of injection speed. C : The screw stroke measured value. D : The injection speed measured value. E : The injection pressure measured value. F : The setting of packing pressure(2nd10th). G : The setting of packing pressure action time(2nd 10th). H : The setting of 1st INJECTION ACTION or BACK UP timer. The 1st injection action time is subject to change depend on the selection of 2nd pressure change-over mode. In TIME mode, when this timer timed up, the 2nd injection pressure starts getting into packing stage(2nd pressure). In STROKE mode, this timer works as a back-up timer or a timer to monitor an 1st injection pressure time. I : The injection packing pressure measured value. J : The action time of injection packing pressure measured value. K : Pressure holding range This setting (control value) is used to stabilize the position of injection completion by means of holding pressure. (In case of its setting is at 1.00 mm, the maximum stroke of 59

64 screw advance during pressure holding process becomes 1.00 mm.) L : Injection delay time Delaying time up to the point of injection start. M : Cooling timer This setting is the same as one on TIMERCOUNTERPRINTER screen. (Refer to TIMERCOUNTERPRINTER screen.) N : Monitoring items Measured value of each item such as stated below is indicated on this portion H. Items : Maximum pressure Injection stroke 1 st injection time Maximum injection stroke in pressure holding mode Charge time Cushion volume Cycle time Completion position of charge 3) Explanation of window function key. SUB SETUP WINDOW(AUX.INJ. AUX.INJ.) A B C D E A 1 st pressure Setting of 1 st injection pressure B 1 st timer Backup timer of 1 st injection pressure in the DISC molding machine. C Pressure monitoring and time monitoring of 1 st injection pressure (See st Injection pressure monitoring function.) D Control mode See Injection slope control. E Suck back after injection completion Setting of width and speed of Suck back after injection completion. 60

65 4) ADJUST WINDOW(ADJUST ADJUST) a): : Cushion volume adjustment. This function is used, when forming the molding condition, to increase the cushion volume or to decrease the cushion volume, little by little. After the adjustment width has been set at a, the cushion volume can be increased or decreased by the value preset at a by means of selective setting of b, (Increase) or (Decrease). [Example] In the case the cushion volume is increase by 3mm (0.3in). Push ADJUST function key. Then, the ADJUSTMENT WINDOW SCREEN will be displayed. 3mm (0.3in) is set at a. Touch the position that to be adjusted, and push ON, ENTER condition setting key switch. All position of Charge change-over and Injection change-over will be increase by 3mm (0.3in) simultaneously with the charge start. When the setup is altered, the message (10) will be displayed, and b is changed-over OFF 61

66 increased b): : Plastication(CHAGE) adjustment. This function is used, when forming the molding condition, to increase the plastication completion position, little by little. After the adjustment width has been set at c d, the change-over position can be increased or decreased by the value preset at c by means of selective setting of d, (increase) or (decrease). [Example] In the case the plastication volume is increased by 3mm. Push ADJUST function key. Then, the ADJUSTMENT WINDOW SCREEN will be displayed. 3mm is set at c. Touch the position that to be adjusted, and push ON, ENTER condition setting key switch. All position of change-over will be increased by 3mm simultaneously with the charge start. When the setup is altered, the message (11) will be displayed, and d is changed-over OFF. Message 62

67 C D B E A F H G 1) Method to call the screen. Spare, Half-fixed, Unit screen indication of the setup inhibition screen is to be set as (ON) beforehand. 2) Explanation of screen. The setup value and measured value of injection speed/pressure is displayed on the graph screen. The stability of injection position, speed and pressure can be judged by watching this graph screen. This facilitates that the judgment as to what condition is INADEQUATE for stable molding of quality product can be established instantly. A : The horizontal ax is shows Stroke, and the vertical ax is Pressure & Speed. The center line on graph screen means the screw position is 0mm (advance limit). The rightmost end injection start position. B : The horizontal ax is shows Hold press. time after changing-over to 2nd pressure, and the vertical ax is Pressure & Speed. The center line of graph screen means that when 2nd pressure started, the leftmost end shows hold pressure completion. C : Indicates the scale of injection pressure. D : Indicates the scale of injection speed. E : Indicates the scale of hold pressure time. 63

68 F : Indicates the scale of screw position. G : Indicates the screw position. H : Indicates the No. of times of multi-writing. 3) Explanation of window function. : SUB FUNC WINDOW(PUSH SUB FUNC ) a b c d e a : Selection of Graphing. Selection, either SINGLE WRITE or MULTIPLE WRITE of graph is decided. SINGEL WRITE----At each action of injection per shot, the graph varies. MULTI WRITE-----The old data is kept being displayed in different color, and new data will be graphically displayed over the old data. b : Scale mode selection. Selection of graph scale, either auto or manual setting, is effected. AUTO At each shot, the scale size is adjusted automatically to make the measured value of injection speed, pressure indicated ON the graph. SETUP Simultaneously with the fixture of scale for pressure, speed time and stroke(graphic SCREEN C,D,E AND F ), the setup alteration becomes possible. By fixing the scale, under mode of MULTI WRITE, it is possible to compare the old data against the new data, when the setup has been altered, and such comparison will be of a great help to locate the proper setup condition without difficulty. 64

69 c : GRAPH SETUP On screen, the graph indication of measured value, setup value can freely bee set by selection of (ON)/(OFF). : STROKE, : TIME d : COLOR The line color of graph can be set specifically by numeral. Light color (lighter color of the one in the above table is shown). e : Setting of scale minimum width. The scale minimum width of STROKR, TIME, SPEED and PRESSURE is set here. Do not change this data according to user s own way. : Graph erasepush GRPH CLR. If pushed this key, Graph is erased. : CROSS-HAIR ONPUSH CROSS ON. Following cross-hairs function will take place. Injection speed. (time - speed) Injection speed. (position - speed) Injection pressure. (time - pressure) Injection pressure. (position - pressure) For details, see the description of

70 1) Method to call the screen. The SUB SETUP WINDOW is shown on INJECTION SCREEN. a b 2) Explanation of slope control function. a : SPEED SLOP CONTROL(2nd9th) By means of setting at ON( ), 2nd 9th speed goes the SLOPE CONTROL mode. b : PRESSURE SLOP CONTRL(2nd10th) By means of setting at ON( ), 2nd 10th speed goes under the SLOPE CONTROL mode. 3) Example of slope control setting. Set the SPEED or PRESSURE at (ON). When the injection speed is set as follows, the speed is controlled in the way as illustrated below. 50 % SPEED(%) 20 % 10 % (mm) (in) 66

71 Effect: 1. By a smooth control of injection speed, the cavity flow is made stable and the inclusion of weld and/or gas is prevented. 2. Effective for an even distribution of stress of plastic product. 3. Effective for preventing deformation and/or warp on product. When the injection pressure is set as follows, the pressure is controlled in the way as illustrated below PRESS(kgf/cm2) (psi) Effect: This mode is effective for an improvement of dimensional accuracy and for a relaxation of residual stress. 67

72 A 1) ) Purpose In the event that the nozzle or mold gate is clogged, abnormal pressure is generated during first injection process. This monitor checks if the first injection pressure exceeds the tolerable level or not. 2) (ON) setting of 1ST PRESS = AUTO STOP in SPECIAL MODE SETUP screen(see ) The setting of tolerable pressure can be set automatically at the cell A in INJECTION SUB SETUP window screen can. The pressure is set at 20kgf/cm 2 higher than the setting pressure for first injection pressure. If the automatic setting is not appropriate, manual setting can also be made. The motion in ON setting is described in (3). (OFF) setting of 1ST PRESS = AUTO STOP When the first injection pressure exceeds the tolerable pressure which is set at the cell A the injection process is shifted to holding pressure stage, and an alarm message (47) is issued. Operation continues; however, check if products have short shot problem or not. 68

73 3) Motion If the first injection pressure exceeds the tolerable pressure which is set at the cell A, for the time period which is preset, operation stops immediately, and an alarm is issued.(refer to the graph below.) 1 First injection pressure monitoring time: The monitor system also monitors if the peak pressure exceeding tolerable Level continues beyond a preset time or not. This function tells abnormal situation such as nozzle clogging from normal situation such as peak pressure right before shifting to holding pressure. If the time is set at 0 seconds, machine stop or shifting to holding pressure is made upon as soon as the injection pressure exceeds the tolerable level. 46? Primary injection pressure is abnormal. Foreign matter remains, confirm.? 47? Primary press. Monitoring system worked, and changed over to 2ndary press.? 69

74 1) Screen construction. The number of screen consists of the following. 3 Screens : Measuring, Measure graphic, Plasticizing measuring. 1 window : Adjustment. 3 Function : Cross-hair ON, Graph erase and Auxiliary function. 2) The method to call the CHARGE SCREEN. When the screen of measuring screen is displayed. push Screen changeover key switch. And push function key switch. 3) The method to call screen by using the function key. Function key When GRAPH function key is touched, the screen will be charged to CHARGE GRAPHIC SCREEN. 70

75 When PLASTICIZING function key is touched, the screen will be charged to INJCTION CHAGE SPARE SETUP SCREEN. This screen can be inhibited to display by (OFF) setup the SPARE,FIXED DATA, UNIT SCREEN INDICATION on SECRET SCREEN. 71

76 D L A B C 1) Method of to call the MEASURING SCREEN. G H I J K E F Push Screen changeover key switch. And push function key switch. 2) Explanation of screen. Following settings are for plastication(charging). A : Plastication(charging) completion position can be set. B : Screw revolution can be set. C : Melt pressure at screw tip can be set. Following settings and an indication are for the SRC- control (Refer to for the SRC-control system.) D : The SRC- time can be set. E : The SRC- pressure can set. F : Monitored screw position is indicated when the SRC- control is finished. (This position is recognized as a starting position of injection.) L : Setting of the position range in order to stabilize the screw movement by SRC- controlling of 2 nd step pressure. Following settings and an indication are for suckback. G : Suckback stroke can be set. Indication for monitored data. H : Screw position is indicated. I : Screw revolution is indicated. J : Melt pressure at screw tip is indicated. K : Aggregated number of screw revolution during plastication is indicated. 72

77 Nozzle movement setup U P M N O Q T S R V W X Y Y Setting of Nozzle touch forwarding force in manual mode and also in preparation mode. The nozzle is pressed against mold by this force set here at the step in auto mode. The nozzle is pressed against mold by this force set here at the charge step in auto mode. The nozzle is pressed against mold by this force set here for the time between die and the next injection start in auto mode. Setting of nozzle touch speed. Setting of nozzle retracting stroke in auto mode. Setting of nozzle retracting stroke in semi-auto mode. Setting of nozzle retracting force at nozzle retract step. Setting of nozzle retracting speed at nozzle retract step. Indication of the nozzle condition. Setting of holding (waiting) time up to nozzle retract start. Indication of the nozzle (Injection unit) position. Setting of holding (waiting) time up to the time point of charge start after injection completion. Setting the range of suck back whensuck back action is carried on before mode to other from auto mode. Monitor data Measure completion position, cushion volume and measure time will be measured and displayed. These items can be watched without changing over from the measure screen to the monitor screen. 73

78 A B C D A B C D A B C D F G E 1) Method to call the screen. Push Screen changeover key switch. And touch function key switch. Explanation of screen. Both the setup value actually measured value of plastication(charge) revolution number and the melt pressure at screw tip during plastication will be displayed on the graph screen. At the same time, the actually measured value of screw retract speed will be displayed as well. The axis of abscissa shows the plastication(charge) stroke, and the axis of ordinate the melt pressure at the screw tip during plastication, revolution number and speed. The leftmost end means the 0mm(0 in) position of plastication(charge) stroke, and rightmost end the position of metering(charge) completion. A : Shows the scale of the melt pressure at screw tip during plastication. B : Shows the scale of the load torque at motor during plastication. C : Shows the scale of revolution number. D : Shows the scale of speed. E : Shows the scale of screw position. F : Shows the number of multi writing. G : Shows the screw position. 74

79 3) Explanation of graphic window. : SUB FUNCTION WINDOW(Push SUB FUNC function key) c d e a b a : Selection of graphing Either Single writing or Multi writing of graph is selected. SINGLE WRITING ---- At each shot, the graph changes in accordance with injection action. MULTI WRITING ----The old data is kept staying, in different color on the graph, and the new data is graphically displayed over the old data. b : Scale mode selection. Either Auto or Manual setting of graph scale can be selected. AUTO------At each shot, the scale size is automatically adjusted so that the actually measured value of charge revolution number, the melt pressure at screw tip during plastication and screw retract speed can be shown within the space of graph. SETUP-----Simultaneously with the fixing of scale of stroke, charge revolution number, the melt pressure at screw tip during plastication, screw retract speed and load torque (Graph screen : A,B,C & ), the setup becomes possible to alter according to the need. By fixing the scale, at the time when the setup has been altered during MULTI Write mode, the comparison of auctioning status between the data and new data can visually be confirmed that will make the optimum determination of condition setup easy. 75

80 c : GRAPH SETUP The graph indication of measured value setup value can be selected on the screen via (ON)/(OFF) setting. d : COLOR The line color of graph can be set specifically by numeral. Light color (lighter ( color of the one in the above table e is shown). e : SETTING OF MIN SCALE The scale min. width of stroke, measure speed, revolution number, and the melt pressure at screw tip during plastication is set here. If the scale mode has been set to Auto mode, the scale itself will automatically be adjusted so that each measured value may be displayed within the space of graph. In this case, however, the least width of scale has been limited to prevent the auto-adjusted- scale width from becoming too small. : GRAPH CLEAR(push GRPH CLR key) If this key is pushed the graph will disappear. : CROSS-HAIR ON(push CROSS ON key) The following cross-hairs functions take place. Measure speed (position speed) Revolution number (position revolution NO.) The melt pressure at screw tip during plastication (position pressure) Load torque (position torque) For details, see the description of Cross-hairs function. (4-3-4) 76

81 A Q R B C D E F G I J K L M N O P S H Method of to call the SCREEN. Push Screen changeover key switch. And touch, function key. 2) Explanation of screen No pressure at manual charge (under nozzle retract condition) (A ) If this setting is (ON), the resin pressure becomes none even it has been set on CHARGE SETUP SCREEN when manual charge is carried on under nozzle condition. Charging(Metering) FF factor By setting this factor properly, post-charging melt pressure can be released to 0 without using suck-back function. If setting of FF length is too long, charging(metering) cannot be finished. NOTE NOTEWhen using this function, set "0.00(S)" to CARGING-OFF DELAY. When this function is not used, set t original figures(usually, 0.3S) to CHARGING-OFF DELAY. 77

82 Setting for FF control B : FF WIDTH: Area where FF control is made. C : FINAL PRESS: Melt pressure after charging(metering). Setting of Suck backspeed (D ), Torque (E ), Delay time (F ) until suck back start and Delay time (G )until suck back start after injection completion. Setting of the charge process order (H ) Setting of ON/OFF selection and the acting order of Charge, Check openand Nozzle retract. If an item is set at zero (0), setup of the item gets OFF. Selection of Reverse rotation during SRC carried on, /. (I ) If this setting is (ON), the screw can be rotated reversely during SRC- controlling. CAUTION Do not set this at (ON). Speed (J ) Setting of reverse rotating of the screw during SRC- controlling. Number of reverse turn(k ) The number of reverse rotating of the screw during SRC- controlling is to be set. * When SRC- control is completed, the reverse rotating of the screw will be stopped and the process goes forward even if the number of reverse rotating does not reach up to setup value. Check ring protection : ( L ) The check ring is protected by means of making the revolution no start up slowly at the start of measuring. The timer covers the time needed up the Max rpm. 78

83 Galling prevention It is for prevention of galling on screw. a) No resin detection. If, in the time space that was set at ( N ), the screw retract speed went below ( M ) the situation is judged as No Resin. In the case the proximity switch is OFF in the process of nozzle back etc. the No Resin judgment is given at the time when ( N ) set time became double. b) When no resin exists. When no resin judgment is given under a) the system functions at the preset speed ( O ) the melt pressure ( P ). Items related to AUTO PURGE The pressure at AUTO PURGE end is set at (Q ).At AUTO PURGE end, the back-pressure is lowered to this setting with which CHARGE is completed. The standard charging frequency in AUTO PURGE is set at (R ). The standard charging frequency set at (R ) is restored whenever any auto-purge operation is finished. (relation setting:4-6-5auto PURGE) PRESS RELEASE The PRESS RELEASE mode is selected at (S ). OFF: no processing. INJ. AXIS FREE: The screw axis is made free, during after charging. (During "CHARGE DELAY", The screw axis is controlled by V-CONTROL mode.) V-CONTROL (Standard): During "CHARGE DELAY" and after charging, the screw is operated with the following setting. PRESS RELEASE SPEED: Screw retracting speed in pressure releasing process. PRESS-OUT PRESS: Pressure in pressure releasing process. TAGET PRESS: Target pressure in pressure releasing. 79

84 Because SRC- metering control is made in one step different from the former multi-step charge control, so thecondition setup is simple and this contributes to stabilize the plasticized density of metered resin and also to the quality of molded products. a b c e d f h i Plasticization Resin pressure of screw head is controlled to be c by screw revolution speed b,and the screw goes back up to a position as same as the conventional metering control. Metering (2 steps) The screw stops rotating for the time d and the resin pressure of screw head is controlled to e. Then the process gets into the second step after the first metering step completion, the screw head pressure is to be controlled at i for the time h. Stabilization of plasitisized resin density can be done by doing above. The screw position will be shown at f when the time d and h has passed. 80

85 1) Screen construction. The number of screen consists of the following. 4 Screens : Mold height, Data memory, Setup screen 1, Setup screen 2. 2) Method to call the MOLD SETUP MODE SCREEN. Push Screen changeover key switch. 3) Method to call the screen by function key. When DATA MEMORY function key is touched, the screen will be charged to DATA MEMORY SCREEN. When SETUP SCREEN 1 function key is touched, the screen will be charged to SETUP SCREEN 1. 81

86 When SETUP SCREEN 2 function key is touched, the screen will be charged to SETUP SCREEN 2. 82

87 B C D E H A F I J K L M N O G 1) Method to call the MOLD HEIGHT SCREEN. Push Screen changeover key switch. Explanation of screen. A : Actually measured value of STROKE: mold position. HIGHT: mold height. FORCE: mold clamping force. B Setup values of Auto clamp force setup. CLAMP FORCE TOLERANCE(±): Mold clamping force allowance. Setting of allowance against mold clamping force for auto clamping force adjustment. C : MOLD HEIGHT MOVE WIDTH Setting of total length of mold height adjusting length and its width when the mold height operation is executed. D : STAMPER EXCHANGE POSITION Setting of the position of exchanging stamper. E : Setup values of MOLD ADJUSTMENT. FORCE: Setting of clamping force with MOLD ADJUSTMENT. NUMBER: Number of which clamping operation is iterated. F : Settings of auto purge. G : ON/OFF setting of control of holding temperature. 83

88 AUTO MODE: Starting of each auto mode in preparation mode. The operation starts when START key is pushed twice after touching each key. H : CLAMP FOCE SETUP Settings are B. See I : ZERO ADJUSTMENT Auto zero(0) setup mode of the mold, ejecter and screw position. See J : MOLD HEIGHT MOVE Setting is C. See This mode is used before installing the mold on die plate. K : AUTO PURGE Settings are C. See This mode is used when carrying out color-change of resin or purge-out. L : STAMPER EXCHANGE. See M : MOLD ADJUSTMENT Settings are E. See N : M.H. PERMISSON The following operations are restricted with setting. The manual operation of Mold height advance/retract motion is prohibited in the preparation mode. (With setting, manual operation can be made.) Unless clamping force setup is completed, automatic start is prohibited. (With setting, automatic start can be made.) Unless stamper sucking is completed, automatic start is prohibited. (With setting, automatic start can be made.) O :ROBOT ADJ. MODE This is a mode in which position adjustment of ROBOT can be made easily. The alarm message "Now in Robot adjustment mode." is displayed during operation in ROBOT ADJ. MODE. In Semi-automatic operation, one cycle stops before EJ advancing process, where the mode is shifted to MANUAL. In ROBOT ADJ. MODE, one cycle operation is completed with the mold opened to its opening completion position, but not to the maximum opening stroke. 84

89 H B 1) Explanation of AUTO CLAMPING FORCE ADJUSTMENT. This mode is required when the machine is installed the mold. The clamping force is automatically set by using this mode. Also in this mode, both the mold open/close and the screw retract/advance action are made with low pressure and low speed. Explanation of starting the auto clamping force adjustment. Push Screen changeover key switch, so that the SETUP MODE SCREEN is shown on the screen. Set the necessary clamp force at () position. Push ENTER condition setting key switch. Move the cursor to CLAMP FORCE SETUP () position. Push START function key switch, twice so that auto clamping force adjustment can be started. When the operation is completed, the message(105) is shown on the screen. Push OFF key switch. Message 105! Clamping force setup completed.! 85

90 3) Explanation of the auto clamping force action. ZERO POINT SEACH ---- Repeat mold open/close and mold height retract, and, after having determined the enough clearance of mold, carry out mold height advance under condition that the mold close is completed, and the sensor is detected that the face to face of the mold has touched, then mold height advance is stopped. The mold height at this moment is measured and memorized. CLAMP FORCE The mold is opened, and the clamping-force-volume that has been preset against basic clamp force is calculated by computer, and then the mold height goes advancing until calculated value. HIGH PRESSURE ---- The mold is closed at low pressure, and set stop position CHANGE-OVER POSITION SETTING OF MOLD CLOSE as the high pressure change-over position. (In case of compression mode was selected as VP mode, automatic setting of high pressure changeover position is not done.) If auto clamping force has been carried out right after reading of molding condition out of memory card (or internal memory) the measured mold height is compared with the reset value, and if any difference is present between the mold and molding condition the message(110) will be displayed. 106? Mold open / close motion suspended.? 107? Mold height motor slipped.? 108? Mold too thin.? 109? Mold too thick.? 110? Mold height is net corresponding. Please confirm the leaded molded condition.? 111? Extra-clamp constant corrected, but actual clamping force still not proper.? 112? Abnormal clamping force worked.? 113? Extra-clamping force did not work.? 86

91 1) Explanation of AUTO ZERO ADJUSTMENT An origin position (0 point) is set for each axis of injection, mold opening/closing and ejecting. 2) Method of starting the auto zero adjustment. Raise the heat barrel temperature to preset temperature so that the screw cold start prevention interlock can be released. Push Screen changeover key. Move cursor to ZERO ADJUSTMENT (I ) position. Push condition setting key. Push START function key, twice. Nozzle retracts and zero adjustment starts. When the process is over, the message(123) is shown on the screen. Push OFF key Caution CautionNever fail to remove the mold before starting AUTO ZERO ADJUSTMENT of mold open/close and ejection. 87

92 J 1) Explanation of the mold height movement. If this mode is used before fitting the mold on to die plate, the automatically moves as much as the using mold height MOLD HEIHGT MOVE + WIDTH. Expl Explanation of starting the mold height movement. Read the molding condition out of the internal memory or memory card. Push Screen changeover key switch. Set up the MOLD HEIGHT MOVE + WIDTH. touch MOLD HIGHT MOVE (J ) position. Push START function key switch twice so that the mold height movement can be started. When the operation is completed, the message(115) is shown on the screen. Push OFF key switch. Message 115! Auto mold height move completed.! 3) Explanation of the auto mold height movement action. Mold open Move as much as MOLD HEIGHT + MOLD HEIGHT MOVE + WIDTH completed(message 115) Move the mold up to the position including MOLD HEIGHT MOVE + WIDTH with mold height which is memorized through mold height advance /retract action. 88

93 K a b c d e f g j i h k 1) Explanation of the auto purge function. This mode is required when purge out all materials or change the color of material. a : Setting of injection speed during auto purge. b : Setting of injection pressure during auto purge. c : Setting of charge completion position during auto purge. d : Setting of charge revolution speed during auto purge. e : Setting of pressure during auto purge. f : Setting number of charging during auto purge. g : Setting of screw retract position during auto purge. h : Setting of screw retract speed during auto purge. i : Setting of screw retract pressure during auto purge. j : Setting of number of screw-retraction during auto purge. k : Actually measured value during auto purge. 2) Explanation of starting the auto purge. Push Screen changeover key switch. Set auto purge condition. Move cursor to AUTO PURGE (K ) position. Push START function key switch twice so that the purging can be started. (Action of the process include issuing a message is quite same as when actuating on screen.) When all the operation is completed, the message(116) is shown on the screen. Push OFF key switch. Message 116! Auto purge completed.! 89

94 3) Explanation of the auto purge action. Starting method of auto purge on MOLD SETUP SCREEN 1. Change screen to Preparation mode, and MOLD SETUP SCREENwill be shown. Push MOLD HEIGHT key switch. Push RESET key switch. Move cursor to K AUTO PURGE position. Push START key switch twice. Nozzle retract for 5 seconds. When times did you set for purge at f position? Charge is done. Injection is done. Purge counter counts up by one. Not yet finished. Count up What times did you set for free purge at j position. Screw retract. Injection is done. Dry shot counter counts up by one. Not yet finished. Charge + Suckback Automatic purge completed. Metering and suck back action are executed once in accordance with the setting condition on CHARGE SETUP screen. 90

95 Other settings related to AUTO PURGE, There is 'AUTO PURGE FINAL PRESS' and 'AUTO PURGE BASIS CHG. No.'. Please refer When CHARGE key is pressed during auto-purging process, the purging process gets into finishing motion regardless of the preset frequency. 91

96 1) Starting method on screen Change screen to Preparation mode, and MOLD SETUP SCREENwill be shown. Input the required stroke to exchange the stamper. Move the cursor to the position of stamper exchange, and push START key twice. Process of stamper exchange CAUTION When stamper exchange mode is actuated, Process (A) above shown is executed usually. However, if it is started under the condition below stated (), the will proceed in accordance with Process (B) above illustrated. ( Unusual condition : Die height position Target position under die-open condition.) Target position Stamper exchange position Die open full stroke Die thickness in the memory. 92

97 93

98 a b 1) MOLD ADJUSTMENT Aligning of movable and stationary mold halves can be made by repeating mold open/close action for the preset number of times at (b ) with the clamping force preset at (a ). 2) Explanation of the auto purge function MOLD ADJUSTMENT FORCEIt is setting of clamping force with MOLD ADJUSTMENT. MOLD ADJUSTMENT NUMBERFrequency by which clamping operation is iterated 3) Operation sequence Shifting of mold Mold height Mold clamps with Mold opens. Mold clamping is Completion height position. The position is sought advances until slipping occurs. preset clamping force. (a ) (Clamping force becomes 0.) completed with the force preset at of operation based on the actual a. mold thickness and the preset force at a. Mold open/close motion is repeated for the number of times preset at "b ". 94

99 C D A B 1) Screen construction. The number of screen consists. 10 Screens : Internal memory 1, Internal memory 2, Memory card 1, Memory card 2, Memory card 3, Memory card 4, Memory card 5, Memory card 6, Memory card 7, Memory card 8. 1 Function : Auxiliary. 2) Method to call the DATA MEMORY. Push Screen changeover key switch and touch the DATA MEMORY function key on the panel. The 1 page of INTERNAL MEMORY 1 is shown on the screen. The other page is called by function key. The function key line is shown INTER1 INTER2 CARD1 CARD2 and CARD3. The other function keys of CARD4 CARD8 are changed over by pushing function key switch. MEMORY OF MOLDING CONDITION SCREEN INETER 1 INTER 2 CARD 1 CARD 2 CARD 3 MEMORY OF MOLDING CONDITION SCREEN CARD 4 CARD 5 CARD 6 CARD 7 CARD 8 95

100 3) Explanation of screen. A Basic data of molding condition and additional condition of ST50. B Basic data of molding condition and additional condition of ST50 with the teaching position data of the extractor. 4) Method of memory to store. In, fooling 2 memories are available for storage. Memory Memory volume Internal memory(page1,2) 32 Memory card(page310) 64 INTER1 INTER 2 CARD 1 5) Method memory to internal or card. Use the function key to select the memory for storage. Input the mold number into C position. CARD 2 CARD 3 Input the mold comment into D position. Regarding character input method, see ). Select the condition to be stored from A or B and Push ON/SELECT + ENTRY key. Move cursor to the line number that is desired to store. (Mold data can not be stored on No.16 area, because the data is successive on two areas.) Push STORE function key switch, twice. When writing is finished the message(861 or 862) will be shown, and the mold number, machine type name, data and comment will be displayed in the line that has been selected. NOTE NOTE Because the condition 1 1 and condition 2 2 (condition 2 2 with the extractor position) is required as the data of one mold condition, so, the data is stored successively on two areas in one time. 96

101 6) Method to memory back from internal or card. c Select the memory page that is desired to read out by using the function key. (Set the cursor to condition 1 to load the mold data which stored on two areas successively.) Move cursor to the line number from which the molding condition is desired to read out. Push LOAD function key, twice. When reading out is finished the message(859 or 860) will be shown, and the mold number and comment containing the conditions that have been processed for reading out will be shown at C, D. When the reading out of molding conditions is finished, the cold start condition becomes active, and injection as well as change actions become inhibited. NOTE NOTESet the cursor to condition 1to 1 load l the mold data which stored on two areas successively. To load the mold data stored by the former specifications, the data condition 1 and condition 2 2 (condition 2 with extractor position) should be loaded separately. In this case, the message or (868) be shown. Message 209! setups read completed.! 210! setups write completed.! 858! Setups (2) "Read-Out" completed.! 859! Setups (1),(2) (Robot positioning) "Read-Out" completed.! 860! Setups (1),(2) "Read-Out" completed.! 861! Setups (1),(2) "Write" completed.! 862! Setups (1),(2) (Robot positioning) "Write" completed.! 868! Setups (Robot positioning) "Read-Out" completed.! 97

102 1) Kind of Memory Cards. IC memory card : JEIDA for personal computer. IC memory card (Ver. 4) Kind of memory : SRAM. Capacity : 256K byte. 2) Method of setting the memory card. Set the memory card in place. Set the memory card to card slot at the right side of operation panel. Pay attention to the card direction. IN Method to call the screen. Push Screen changeover key switch and touch the DATA MEMORY function key on the panel. Select the memory page that is desired to read out or storage by using the function key 98

103 The message(228) will be shown. The display on the screen will change to the PAGE 3, and when the message has gone, the Mold information(mold No., DATE and PRODUCY NAME) will be shown on the screen.(16 mold's information) 3) When replacing memory card. Take out the memory card. Insert the intended memory card. Change over either to Internal(1) or Internal(2) (Condition Storage Screen), or to other screen. Once again press the DATA MEMORY function key switch, and then touch CARD 4 CARD 8 function Key. The above message(228) will then be displayed, and the screen indication changes from 3 page memory card(1) (10) to memory card(8). When the message disappears, the mold data(mold no. and date, comment etc.) covering 16 molds will be displayed. [Caution] If, without processing, operations, Load or Save operation is processed to the newly replaced card, the message(233) will be displayed, and automatically changed over to "Internal(1)" screen. If this happened, get Card(1) (8) screens, and execute the required processing all over again. 99

104 4) Kind and content of Error Message. When changed over to Card (1) (8) screens(page) this message is shown, and this message disappears when the mold data for 16 molds (mold no., date, comment has been read from the memory card). When the processing of Load, Save or Print etc. is commenced into the memory card, either one of the above three messages will be displayed, and when Processing is over, the message disappears. During,, messages shown above are being displayed, if a new processing (Load, Save etc.) has been executed into the memory card, this message will be displayed, and the Processing is cancel(become ineffective ). In such a case press key, and when,, message disappear, repeat the operation all over again. This message will be shown if the operation(load, Save etc.) is executed after memory card has been changed, or without changing over the screen when replaced, or without changing over the page. After this message has been displayed, the screen is automatically changed over to Internal(1), therefore press the Function Key to get the card (1) (8) for change over of screen, and then repeat the operation all over again. 100

105 In the case when failed to execute correct exchange between the memory card and data, the above message, will be shown. Press key, and execute the changing over to Internal(1) screen, or to other screen. After that, get Card (1) (8) screen out of the condition storage page, and then execute the operation all over again. Other Error Message. PAGE WRITE LOAD 208? Insert memory card in memory card slot.? 209! setups read completed.! 210! setups write completed.! 216? During auto operation, no reading possible.? 217? No read possible. Machine type is wrong.? 218? Wrong read-in. Heater zone NO. is different.? 219? No data available.? 220? Abnormality happened during data transmission. ( Re-operate again. )? 221? No write permitted. Confirm data memory switch.? 229? Memory card battery volt dropped. This card now useless.? 230? Memory card battery must be replaced.? 858! Setups (2) "Read-Out" completed.! 859! Setups (1),(2) (Robot positioning) "Read-Out" completed.! 860! Setups (1),(2) "Read-Out" completed.! 861! Setups (1),(2) "Write" completed.! 862! Setups (1),(2) (Robot positioning) "Write" completed.! 868! Setups (Robot positioning) "Read-Out" completed.! 869? Setups (1) or (2) data not available.? [Note] 1.When the message(220) is displayed, the board is suspicious to have been abnormal. 2.When the message(229) is displayed, the contents of memory card go off. 3.When the battery b of memory card became almost consumed, the message(230) is shown. Promptly replace the battery. As to the method of replacement, see the Instruction Book attached to the memory card. 101

106 1) Method to call the sub function. Push function key on the panel. Screen changeover key switch and touch the DATA MEMORY Next push SUB FUNC function key switch. Then, the item of function key is changed over to AUXILIARY FUNCTION OF MOLDING CONDITION. 2) Explanation of auxiliary function. COPY The data is copied among the memories. MOVE DELETE RETURN The data is moved among the memories. The stored data is deleted. The data deleted by mistake is restored. SORT OUT The ordering is re-listed in order of mold number, machine type name or date. END After completion of condition setup, touch END function-key then the processing will start. When setup has been completed if this key is touched successively the key tile will change as follows. END EXECUTE SURE? The processing starts. SUSPEND If SUSPEND key is touched before start of processing, the title of function key goes back to the preceding process. 102

107 COPY AUXILIARY FUNCTION OF MOLDING CONDITION is released, and the item is changed over to the original function key item. 3) Explanation of WINDOW SCREEN. 3-1) If COPY key is touched, the window page is displayed, and if PROCESS MODE item is selected on the window, the display will change as follows. PAGE All data stored on the page screen is copy-processed onto the other page. A B A : Set the previous page of the copying origin. B : Set the next following page of copying. DATA The designated number stored on the page screen is copying-processedto the particular number of the designated page screen. A B C D A : Set the previous page of the copying origin. B : Set the next following page of copying. C : Selectively set the designated number of the copying-origin. D : Set the head number of the next following page of copying. 103

108 TOTAL All data of internal memory is copy-processed into the memory card. A B A : Set the page No. of copy-processing location(memory CARD). B : Set the head No. of copy-processing location(memory CARD). 3-2) If MOVE key is touched, the window page is displayed. The page configuration is same as COPY processing. 3-3) If DELET key is touched, the window page is displayed, and if PROCESS MODE item is selected on the window, the display will change as follows. PAGE All data stored in page screen is deleted. A A : Set the page No. of deletion. DATA Data of designated No. stored in page screen is deleted. A B A : Set the deleting page No.. B : Selectively set the designated No. of deletion. 104

109 TOTAL All data of INTERNAL MEMORY or MEMORY CARD is deleted. A B A : The all internal memory is deleted. B : The all memory card is deleted. 3-4) If RETURN key is touched, the window page is displayed. In the case the stored data has been deleted by mistake do Return processing, then the deleted data returns. The page configuration is same as DELET processing. 3-5) If SORT OUT key is touched, the window page is displayed, and if PROCESS MODE item is selected on the window, the display will change as follows. PAGE The ordering stored in page screen is arranged. E F A B D C A : Set the page No. of arrange process B : The arrangement is processed in order of mold number. C : The arrangement is processed in order of machine model. D : The arrangement is processed in order of date. E : MOLD No.-----The arrangement is processed in order of small number. MACHINE -----The arrangement is processed in order of small class. DATE -----The arrangement is processed in order of old date. F : MOLD No.-----The arrangement is processed in order of big number. MACHINE -----The arrangement is processed in order of big class. DATE -----The arrangement is processed in order of young date. 105

110 DATA The ordering stored in page screen is arranged within the designated range. A E F G B D C A : Set the page No. of arrange process B : The arrangement is processed in order of mold number. C : The arrangement is processed in order of machine model. D : The arrangement is processed in order of date. E : MOLD No.-----The arrangement is processed in order of small number. MODEL -----The arrangement is processed in order of small class. DATE -----The arrangement is processed in order of old date. F : MOLD No.-----The arrangement is processed in order of big number. MODEL -----The arrangement is processed in order of big class. DATE -----The arrangement is processed in order of young date. G : Set the designated range. TOTAL The ordering stored in INTERNAL MEMORY or MEMORY CARD is arranged. F G A B C E D A : All data in the internal memory is arranged. B : All data in the memory card is arranged. C : The arrangement is processed in order of mold number. D : The arrangement is processed in order of machine model. E : The arrangement is processed in order of date. F : MOLD No.-----The arrangement is processed in order of small number. MACHINE -----The arrangement is processed in order of small class. DATE -----The arrangement is processed in order of old date. 106

111 G : MOLD No.-----The arrangement is processed in order of big number. MACHINE -----The arrangement is processed in order of big class. DATE -----The arrangement is processed in order of young date. 107

112 4) Method of setting. Push DATA MEMORY key switch. Select the desired Process Function function key. COPY & MOVE processing. 108

113 109 DELET & RETURN processing.

114 110

115 1) Method to call the MOLDING CONDITION SETUP SCREEN1. Push Screen changeover key switch. When SETUP SCREEN 1 function key is touched, the screen will be charged to SETUP SCREEN 1. 2) Explanation of the screen. In the screen, the setting of heater temperature, injection, charge, cooling timer and interval timer can be done. 111

116 1) Method to call the MOLDING CONDITION SETUP SCREEN2. When SETUP SCREEN 2 function key is touched, the screen will be charged to SETUP SCREEN 2. 2) Explanation of the screen. In the screen, the setting of open/close, ejection, inj.compression, gate-cut, and air can be done. 112

117 1) Screen construction. 2 Screens : TIMERCOUNTERPRINTER, COMMUNICATION PORT. 2 Function : HEATER ON, OUTPUT COMMAND. 2) The method to call the TIMERCOUNTER COUNTERPRINTER SCREEN. Push Screen changeover key switch. 3) The method to call screen by using the function key. function key When COMMUNICATION P function key is touched, the screen will be changed CONMMUNICATION PORT SCREEN. [NOTE] : If Spare, Fixed, Unit screen display is set at (OFF) on the setup inhibition screen the COMMUNICATION PORT SCREEN can not be called. 113

118 A C B D F H J L M E G I K O N 1) Method to call the TIMERCOUNTER FUNCTION. Push Screen changeover key switch. 2) Explanation of the timercounter function. A : CYCLE TIME SETTING If one cycle takes longer time than preset time in auto operation the cycle time times up, and display will show alarm message(83), sound buzzer. B : Setting of cooling time In auto operation, when holding time counted over, the mold open will start after the cooling time has timed up. But if the charging time is longer than the cooling time, the open will start after charge completed. C : Setting of interval time In auto operation, when eject is completed, the mold clamp will start after the interval time has timed up. D : It counts the cycle number in auto operation. E : Setting of DIVIDED LOT NO. This counter issues a signal and a message(86) when DIVIDED LOT NO. reached the preset value. The counter counts the only cycle in which the monitored parameter is the MAX and MIN set-up range on MONITOR SCREEN. When the counter has counted over, the counter starts from the beginning again while the machine keep on running. F : Setting of LOT NUMBER. When this counter counts over, the message(84) is shown on the screen, and the machine comes to stop. This counter counts only the cycle in which the monitored parameter is 114

119 within the MAX and MIN set-up range on MONITOR SCREEN. G : Setting of FINISH NOTICE 115 This counter is a setting of remaining cycle number before finish of LOT NUMBER. When this counter works, buzzer sounds and the message(85) is shown on the screen. The auto driving dose not stop. [EXAMPLE] LOT NUMBER : 50 FINISH NOTICE : 5 When the LOT NUMBER counter reached 45, alarm sounds. H : Setting of START REJECT At the job start stage, a reject signal is kept issued from SIF BOARD while this counter works. When the reject signal is sent to the pick-up robot(optional), the robot will put the product into the box for the out-of-spec products. I : Setting of CONTINUOUS REJECT This counter counts when an out-of-spec or reject signal is given (When the monitored parameter is exceed the MAX and MIN set-up range). And when this counter has counted through the preset number, the machine comes to stop and the message(87) is shown on the screen. If the machine produced an in-spec product, this counter is automatically reset. J : Setting of DISK TAKE-OUT FAILURE The number of miss takeout of DISK is counted while this timer is set at (ON). K : Setting of SPRUE TAKE-OUT FAILURE The number of miss takeout of sprue runner is counted while this timer is set at (ON). L : Setting of IMM ABNORMAL The number of emergency stop of the machine in is counted while this timer is set at (ON). M : RECORD COUNTER This counter record all the cycle since the machine started up. This counter cannot be reset. Message 83? Cycle timer is over.? 84! Molding No. counted out.! 86! Repeat-lot completed.! 87? Continuous rejects happened.? START UP MODE If / selection is set at (ON);

120 The molding is carried on following other setup condition for the setting number of shot cycle during full auto operation. During semi-auto operation, the molding conditions follows other setup conditions without any relation to the setting number of shot cycle. Suck back action in manual mode or in auto purge mode follows the setup condition. at selection. If / selection is set at (OFF), each startup mode of marked item can not be used. O :CYCLE DELAY When CYCLE DELAY signal is received, COOLING time is increased by the setting time at (O ). Setting of COOLING timer is not changed. When CYCLE DELAY signal is received during automatic operation, the message Now in cycle delay modeis indicated. When Cycle time monitor is utilized during CYCLE DELAY mode, maximum cycle time is increased by the delay time(o ). cycle cycle G.C G.C Mold close Injction Charging (Metering) Mold open Mold close Injction Charging (Metering) Mold open Cooing timer Now, CYCLE DELAY signal is received. Cooing timer Cycle DELAY signal is cut at this point. Cycle in CYCLE DELAY mode. 116

121 1) ) Method to call the PRINTER FUNCTION. X Y Z Push Screen changeover key switch. 2) Explanation of the printer function. X : Selection of printer, either USE or NOT USE. Move cursor to the item desired, and push ENTER key switch. Then the item set as above will be colored in blue. NOT USE : Monitor data or hard copy printing is not processed. In the case the printer not being connected, be sure to set at NOT USE. USE : Monitor data or hard copy printing is processed. The only monitor item that has been selected on the monitor screen is printed. Maximum extent of monitor item printing is different depend on the type of printer. In the printer of 130 digits, 31 items can be printed. Printing means the max. monitor items, in 1 row, of one cycle. Y : In this mode, specified items for two pages can be printed out, and also each single page only can be printed. Only for the first page. Only for the second page. Z : If screen No. is set, its screen is printed. At one time, Max.10 screens can be designated. 3) Method of printer operation. Select USE. Push ENTER key switch. During auto driving, the monitor data is printed. If The screen is printed, move cursor to the position of each item of Y or Z. Push PRINT function key. The message(239) will be shown, and the printing starts. 117

122 1) Printer message. 235? Printer not ready to work. ( or,power source is off )? 236? Printer form all gone. ( or,unit not conected yet )? 239 << Hard copy now being displayed. >> 2) Cause of message(235) and return method. Following 2 reasons are considered. Printer is not in On Line condition. Push ON LINE or SEL switch on printer. Printer power source is OFF. Turn on the printer power source. At the same time, do not forget to prepare the paper setting. 3) Cause of message(236) and return method. Following 2 reasons are considered. Paper is not set for printer. Prepare paper and put the printer in ON LINE condition. If it is NEC make printer, after setting the paper, once turn off, power source, and then turn on again. Cable is disconnected. Once turn off power source of printer, and connect the cable then turn on again. This message(236) comes appear when outputted the printer printing while the cable has been in disconnection status. In the case printer not being used, set the printer selection on the TIMER COUNTERPRINTER SCREEN at NOT USE position. 4) Caution when removing printer. After monitor printing or printing of statistics process has been executed by printer, if the printer is removed, it is important to set Printer selection on TIMERCOUNTERPRINTER SCREEN at NOT USE position. [NOTE] Read well the instruction book of the printer that being used. 118

123 1) Explanation of window function. AUTO HT. Setting of heater auto turning-on. A : ON/OFF setting of heater auto turning-on. B : Setting of Day of the Week for heater-on. C : Setting of Time of heater-on. D : Setting of Day of the Week for heater-off. will be OFF at the fixed time, everyday. E : Setting of OFF time of heater. 2) Explanation of operation. Stop the pump motor. All while the pump motor being working, AUTO HT. CONTROL function becomes ineffective. The heater power and the operation power to be kept ON. 3) Example of setting. Example 1 : In the case of ON or OFF at the fixed time, everyday. At 7:00 in the morning, Heater is ON. At 8:00 in the evening, Heater is OFF. Heater Only the using column of setup is set at ON (). Heater ON time is set at 07:00. Heater OFF time is set at 20:

124 [NOTE] The timer not in use must be set at (OFF). The Day of the Week of ON time and OFF time must be set in all cases. If is set at Day of the week, the heater works as 24H timer, and becomes ON or OFF at the fixed timer, everyday. Such setting as overlapping the heater ON time must not be done. [Example] Mon.07:00 Mon.18:00 Heater ON Mon.06:00 Mon.17:00 Heater ON Timer-1 Timer-2 If such overlapping setup is done as above the heater becomes ON at 6:00 Mon. and OFF at 18:00 Mon.. Heater In the case ON time and OFF time fall on the same Day of the Week. The setting of ON time must be done in such a manner that ON time comes earlier than OFF time. If the setting of ON time has been set at the later time than OFF time the heater will be in a condition of Always ON. [Abnormal setting] Such setting is absolutely invalid. 120

125 A B C D E 1) Explanation of the COMMUNICATION SCREEN. Push Screen changeover key switch. Touch COMMUNICATION P function witch. 2) Explanation of the screen Setup of RS-232C communication port.( A ) The connection can be done to cover from No.1 machine to No.3 machine together. Touch the respective connecting machine from No.1 to No.3, and push, key switch for selective setting. 121

126 Selection of printer type.( B ) Select the printer type according to the maker that you intend to use. [Example] In the case EPSON printer is used in monochrome by using the paper of 136-digit width, you can select EPSON Monochrome 136. [Note] In some kinds of PRINTER, the hard copy can not be made. COMMUNICATION PORT COUNTER.( C ) D : The number of communication (transmitting/receiving) and the number of error occurred is indicated on this portion, and the communication condition can be checked if it is normal or not by using this counter. E : Move a cursor to the position E, and push ON key ENTRY key, then the counter can be reset. 3) Explanation of window function. Push Screen changeover key switch. When touch the COMMUNICATION P function switch, the function switch is chance. Touch OUTPUT function switch. OUTPUT DESIGNATION WINDOW a : OUTPUT FORMAT PART 6 FORMAT-----As from RS-232C, the monitor data of same format as PART 6(G2 series) can be output. PART 9 FORMAT-----As from RS-232C, the monitor data, alarm code & mode code can be output after having been converted into 122

127 PART 6 format. As it is the same data output as RS-232C of PART 6 (G2 series), the software of same control-in-group can be used. However, the software of control-in-group has not yet been developed for the machines for overseas markets. [Note] Presently, PART 9 FORMAT has not yet been programmed in. b : LF Setting of LF(Line Field) when outputting can be done. c : START REJECT At the initial ejection, the reject data in made to show 2. d : ALARM RESET OUTPUT When alarm is reset, the information of alarm is reset is issued. 123

128 1) Screen construction. The number of screen consists. 7 Screens : Monitor 1, Monitor 2, Monitor 3, Monitor 4, Monitor 5, Monitor display and Monitor spare. 3 Functions : Statistics calculation, Weight data and auxiliary setup. 2) Method to call the MONITOR SCREEN. When push Screen changeover key switch, the MONITOR 1 SCREEN is shown. 3) Method to call screen by using function key. function key [Note] : Unless Monitor Screen Indication of SECRET SCREEN is (ON) the displays are ineffective as following. When MONITOR2 function key is touched, the screen will be changed to MONITOR 2 SCREEN. When MONITOR3 function key is touched, the screen will be changed to MONITOR 3 SCREEN. When MONITOR4 function key is touched, the screen will be changed to MONITOR 4 SCREEN. 124

129 When MONITOR5 function key is touched, the screen will be changed to MONITOR 5 SCREEN. When MONITOR DISPLAY function key is touched, the screen will be changed to MONITOR DATA SCREEN. When MONITOR SPARE function key is touched, the screen will be changed to MONITOR SPARE SETUP SCREEN. 125

130 F A B C D E G H 1) Method call to the MONITOR 1 SCREEN. Push Screen changeover key switch. 2) Explanation of screen. A : Monitored parameters. B : Setting of lower upper of morning parameters. C : Setting of lower limit of morning parameters. D : Counters for cycle in which reject or out-of-spec signal is issued, and the counter counts up every time such a signal is issued. To reset the counter, touch the cell of the counter and press RESET key switch and then ENTER key switch, so that the counter may show 0. The other way to reset the counter is pressing key and then ENTER key switch. E : ON/OFF setting keys for monitoring. These Keys also serve as ON/OFF setting for printed items onto the printer. [NOTE]: 1. The out-of-spec or reject signal does not make the machine stop. The signal is output from IN/OUT BOARD. 126

131 F : Monitoring items on position. INJECTION HOLD It monitors change-over position from 1st to 2nd pressure. CUSHION It monitors cushion volume when holding pressure timer timed up. CHARGE It monitors charge complete position. OPENED It monitors mold open complete position. 127

132 G : Monitoring items on time. CYCLE 1ST INJECT It monitors time of 1st injection pressure. CHARGE It monitors charging time. Product (extraction wait.) It monitors the time-length from one cycle completion to the inputting of signal of extract completion sent from the drop confirmation device or extractor etc. MOLD OPEN It monitors total times of actions of mold open. MOLD CLOSE It monitors total times of actions of mold close. H : Injection stroke monitor HOLD 128

133 INJECTION END MAX TOTAL REV Aggregated number of screw revolution. FORCE Clamping force. 129

134 1) Method to call the screen. This screen can be inhibited to display by (OFF) setup the Monitor screen selection on ACCESS SCREEN. Push Screen changeover key switch Touch MONITOR2 function key switch. 2) Explanation of screen. See paragraph of , MONITOR SCREEN. Monitoring Items on temperature. HEAT It monitors nozzle heater temperature. HEAT It monitors front heater temperature. HEAT It monitors center heater temperature. HEAT It monitors rear heater temperature. HEAT It monitors EX-rear heater temperature. HOPPER It monitors hopper temperature. MOLD It monitors mold 1 temperature(option). MOLD It monitors mold 2 temperature(option). Spare(option). Spare(option). 130

135 1) Method to call the screen. This screen can be inhibited to display by (OFF) setup the Monitor screen selection on ACCESS SCREEN. Push Screen changeover key switch Touch MONITOR3 function key switch. 2) Explanation of screen. See paragraph of , MONITOR SCREEN. Monitoring Items of injection speed. 1ST V-----It monitors 1st injection speed. 2ND V-----It monitors 2nd injection speed. 3RD V-----It monitors 3rd injection speed. 4TH V-----It monitors 4th injection speed. 5TH V-----It monitors 5th injection speed. 6TH V-----It monitors 6th injection speed. 7TH V-----It monitors 7th injection speed. 8TH V-----It monitors 8th injection speed. 9TH V-----It monitors 9th injection speed. 10TH V-----It monitors 10th injection speed. Regarding the Stage No. of pressure, speed, only the items meeting the stage No. preset are displayed. Speed over Speed low 131

136 B : Monitoring of injection pressure at speed change-over point. C : Monitoring Items on injection pressure. 1ST P It monitors 1st injection pressure. 2ND P It monitors 2nd injection pressure. 3RD P It monitors 3rd injection pressure. 132

137 4TH P It monitors 4th injection pressure. 5TH P It monitors 5th injection pressure. 133

138 A B 1) Method to call the screen. This screen can be inhibited to display by (OFF) setup the Monitor screen selection on ACCESS SCREEN. Push Screen changeover key switch. Touch MONITOR4 function key switch. 2) Explanation of screen. See paragraph of , MONITOR SCREEN. A : SCREW REVOLUTION [rpm] It monitors screw revolution. B : PLASTICIZATION PRESSURE [kg/cm 2 ] It monitors plasticization pressure. 134

139 B D C E A F G 1) Method to call the screen. This screen can be inhibited to display by (OFF) setup the Monitor screen selection on ACCESS SCREEN. Push Screen changeover key switch Touch MONITOR4 function key switch. 2) Explanation of screen. See paragraph of , MONITOR SCREEN. 135

140 A : Monitoring of pressure/speed by position or timer. Monitoring of pressure/speed by screw position. It monitors injection pressure and speed at designated positions of B and C. Monitoring of pressure/speed by timer. It monitors injection pressure and speed at designated time of D and E. 136

141 F : MONITORING OF PRESSURE RISE-UP TIME It monitors time length from injection start to reach of preset at G. 137

142 1) Good or Bad of product is affected mostly by parameter of injection setup data. Therefore, the monitor data is controlled between injection complete of previous cycle and injection complete of next cycle. At the same time of injection completed in the next cycle, check if the monitoring data is in between MAX and MIN, and if any abnormality found, the reject signal is output. 2) When next cycle injection is complete, following processing is performed. 1. Lot counter, repeat lot counter processing. 2. Monitor data print start. 3. Continuous reject counter processing. 4. Reject signal processing. 5. Shot no. +1. Mold machine one cycle Monitoring cycle Reject signal CONTINUOUS REJECT COUNTER During molding, if reject continuously occurs, alarm message is shown, and machine is stopped. The case reject setting is 3. At here, the counter is initialized because reject has being changed to good. 138

143 1) Method to call the screen. This screen can be inhibited to display by (OFF) setup the Monitor screen selection on ACCESS SCREEN. Push Screen changeover key switch Touch MONITOR DISPLAY function key switch. 2) Explanation of screen. See paragraph of , MONITOR SCREEN. Monitor data is indicated on the screen. When the monitor function(for statistical calculation or monitor function) is set at OFF, the monitor data remains on screen. The number of page for storage of monitor data is 5 pages. In the case of 6 pages or over, the old data is erased as from the first page, and new data is indicated. INDICATION OPERATION for Function Key. PAGE UP Previous page is indicated. PAGE DOWN Next page is indicated. 139

144 B C H A E D F G 1) Method to call the screen. This screen can be inhibited to display by (OFF) setup the Monitor screen selection on ACCESS SCREEN. Push Screen changeover key switch. Touch MONITOR SPARE function key switch. Explanation of screen. :MONITOR SUB SETUP A : Setting of monitoring interval NO USE Monitored data is not printed out. Even when printer being not connected, set at No. monitor. EVERY CYCLE --Printer is connected. Select the desired item to monitor. The monitored data is printed at each shot. For 80 digits printer, max. 16 items and for 130 digits printer, max. 31 items can be printed. 140

145 REJECT ONLY-----Out of the whole monitored items, only shot which when outside MAX. or MIN. range is printed. CYCLE At each shot set, monitor printing is performed. (Reject shot is also printed). [Example] B : MONITOR PRONTING MODE During monitor printing, the printing manner of reject shot can be selected as follows. 1. NORMAL on left side of reject shot no. and reject item, asterisk mark ( * ) is printed. 2. UNDER LINE---Reject shot no. is underlined. 3. COLOR When the color printer was connected, reject shot is printed in red color. 4. GRAPH This function is not supported. Note If this item was selected, monitor printing is not performed. C : Selection of time unit. Time unit of monitor printing can be selected. mm : ss ----Minute : Second hh : mm ----Hour : Minute [Example] The case when hh : mm was selected. 141

146 D : Printing of reason of auto operation stop. During this item being set ON(),if auto operation stops the relating message is printed. [Example] *** The case of automatic stop. *** FEB 28,1998 (SUN) 18:00:07? Nozzle touch not performed. Manually conduct nozzle touch.? E : Monitor title setup value printing. During this item being set ON( ), the corresponding setup value to monitoring item is printed. a line is not printed in OFF() setting. [Example] a Note If no corresponding setup value to monitoring item is available, is printed. F : MONI. DATA PRINT With this setting on(o), monitored data can be printed. How to set to print the monitored data. Choose printout items by setting on each item on the MONITOR screens. Choose INTERVAL on the MONITOR SPARE SETUP screen. Set MONI. DATA PRINT on() on the MONITOR SPARE SETUP screen. Choose your printer model on COMMUNICATION PORT screen. Set "USE" on TIMER, COUNTER, PRINTER screen. Now, printer setting is completed. G : PROCESSING MODE In this mode, proper use of monitoring capability can be selected. If this mode is changed over, the title of monitor 1 to monitor 5 screen is changed. 142

147 Absolute value monitor: The tolerance is set at MAX or MIN on MONITOR SCREEN. If exceeded this range, reject occurs. RELATIVE VALUE MONITOR Monitor s range is set by range(tolerance VALUE) at basic value.(central value). Title of bottle of monitor printing and screen changes in the following way. max. BASIC VALUE min. RANGE The range of good product is between range of basic value. [Example] In the case that standard value of INJ-HOLD is 0.35mm, and range is 0.10mm, the range of good product is between mm. (Regarding the standard value setting method, see the paragraph H ). H : STANDARD VALUE SELECTION The manner to take basic value is selected. This manner is effective only when relative value monitor was selected by the paragraph G. BASIC VALUE INPUT Basic value can be set directly.(value of green color & blue color). 143

148 SETUP VALUE LINKAGE After injection completed, the setup value of molding condition is used as basic value. If this item was selected the value of molding condition is transferred to the basic value after injection. If standard value was changed the following message(262) is shown. 262? Basic value of monitor judge (criterion) has been altered.? As to basic value, the value of blue color only is changed automatically. MONITOR VALUE LINKAGE After injection completed, the latest monitor data is transferred to the standard value. At this time, the following message(263) is shown. 263? Basic value of all monitor judge (criterion) has been altered.? 144

149 K L M N O K : STATISTICS MODE SELECTION. No STATISTICS CALCULATION -- Statistical calculation is not carried out. ONE TIME CALCULATION Statistical calculation is carried out one time only for the shots that were set at L, and its results are shown on Monitor Screen or printed out by printer. When calculation is over, the mode changes over to No statistical calculation. [Example] In the case the statistical calculation was set at 5 shots. 145

150 CONTINUOUS CALCULATION --- Continuous calculation is carried out, and its results are shown on MONITOR SCREEN or printed out to printer. [Example] In the case the statistical calculation was set at 5 shots. MONITOR ADJUSTMENT --- Adjustment of monitoring extent (MAX, MIN, RANGE) is automatically performed. When adjustment is over, the mode changes over to OFF (No STATISTICS). CONTAIN S ADJ The operation of is repeated. L : STATISTICAL CALCULATION SHOT NUMBER Statistical calculation is carried out at every shot-numbers set at L against various modes of statistical calculation. (one-time-calculation, continuous calculation, monitor adjustment). M : ADJUSTMENT METHOD SELECRION(MONITOR RANGE) This mode is used for monitor adjustment. R (Magnification) Magnification coefficient value(.). [Method of calculation] In the case of MAX, MIN(on monitor screen). R : R = max.min Basic value = (max.min)/2 MAX = Basic value(rcoefficient)/2. MIN = Basic value(rcoefficient)/2. In the case of RANGE(on monitor screen). R : R(Coefficient)/2 146

151 3 (Magnification) Magnification coefficient value (.). [Method of calculation] In the case of MAX, MIN(on monitor screen). 3 : Adjustment value = 3(Deviation)(Coefficient)/2 Basic value = R/2 MAX = Basic valueadjustment value. MIN = Basic valueadjustment value. In the case of RANGE(on monitor screen). 3 : 3(Deviation)(Coefficient)/2 N : SHOT No. CLEAR FUNCTION This function works only when statistical mode was selected at one-time calculation during auto operation. If the mode was set (ON) the shot no. is counted at each shot starting from commencement of statistical calculation. When the shot no. reached the value set at Statistical Shot No. the mode is automatically changed-over to (OFF). If this function is used, it can be confirmed at a glance that from which shot to which shot the statistical calculation was carried out. Note Note This function does not work at the start of auto operation nor during initial ejections. [Example] In the case SHOT No. CLEAR FUNCTION was set (OFF). 147

152 In the case SHOT No. CLEAR FUNCTION was set (ON). O : Continuous calculation even after auto operation stop. When machine stops, statistical calculation also stops at the same time. However, if Continuous calculation function was set (ON) the calculation resumes successively following the data taken before the stoppage of machine simultaneously with the restart of auto operation. 148

153 1) Processing contents. During auto operation(full/semi-auto), if the mode was set at the statistical calculation (other the OFF mode ) the statistical processing is carried out. (Calculation ofx, x, max and min) During processing, statistical calculation counting is displayed. (Right side of b ). L When counting reached the statistical calculation no. preset the calculation of R, x,, R/x, 3/x is carried out, and its results are shown on the screen, or printed on the printer. If the mode was one-time-calculation, the mode is changed over to statistical calculation OFF. In the case of adjustment mode, the MAX and MIN setting of each monitoring item is changed using the calculated results and magnification(r or 3). If auto operation stops during statistical calculation the calculated results up to operation-stop are shown on the screen or printed on the printer. The statistical calculation mode remains unchanged. (Even in the case of one-time-calculation, the mode does not become OFF). If mode is changed over to OFF during statistical calculation, the calculation processing is stopped. If continuous calculation mode was set the calculation starts again after the results so for calculated have been printed. If calculated results exceeded the extent of calculation processing **** mark is printed. The initial shot when auto operation started is not included in the statistical calculation. Shots during initial ejections are not included in the statistical calculation. 2) Items of statistical calculation. max ----Max. value min ----Min. value R=max-min ----Irregular ( x = x) / n ----Average value 2 2 = { ( x) / n}/( n 1) ----Irregular(standard deviation) x R / X = R / x* 100 [%] ----Irregular rates ( R ) 3 / X = 3 / x * 100 [%] ----Irregular rates ( 3 ) 149

154 3) The using method of monitor adjustment mode. When setting MAX and MIN of each monitor item, if this mode is used under the condition of good product being processed, the setup of MAX and MIN is changed automatically. Note Note Cautions when using the statistical calculation values data mode. The monitor data is limited in displaying digits(printing digits no.) and there is the causes of error in calculated results. In particular, in the case of below decimal point smaller values that are actually ly displayed or printed are also being calculated that causes error. [Example] In case of temperature monitor. a. Temp. unit xxx (F) b. Temp. unit xxx.x (F) MAX 101 MAX MIN 99 MIN 99.6 MAX - MIN = R 1 MAX - MIN = R 1.4 In the case of a, the difference between MAX and MIN( MAX-MIN = R ) is 1 not 2. In the case of b, between MAX and MIN( MAX-MIN = R ) is 1.4. This is because that actual calculation is carried out by ***.* (F). 150

155 1) By setting Print mode on the counter screen, the monitor data printing can be done.(see F MONI.DATA PRINT ) The printer is connected to the control board and turn on the power. The page position of printer paper must be set in correct manner. 2) setting of (ON)/ (OFF) of each monitor item is common for selection of print-out items. 3) Max items of printing is 16. If exceeds 16, the 16th item of higher priority is printed. In the case of printer of 130 digits (15inch), up to 31 items can be printed. 4) Title, MAX setup data, MIN setup data, shot no. And time are also printed. If shot no. (TIMER COUNTER SCREEN) is set (ON), the monitor data analysis becomes easier. If monitor item setup has been changed on the way, Title is changed at next data first available. 5) Monitor data printing is performed when injection is completed. So, the time of injection completion is printed at the end(minute & second). Note 1 1 Time unit can be selected by setting on MONITOR SPARE SCREEN, ) As a result of monitor judgment, if reject comes out. (the case monitor data went outside the MAX or MIN bound), * mark(reject mark) is printed at the head of monitor data. (Underline is also drawn). 7) In printing of monitor data, following 3 method are available. EACH SHOT------Printing at each shot. REJECT Printing only when reject V. Intermittent------By setting shot no., printing is performed at the shot preset. However, printing is performed including the case of reject data appeared on the way. Note 2 2 These selection setups can be carried out on MONITOR SPARE SCREEN, Note 3 3 Although monitor data is within the monitoring extent(within MAX and MIN bounds), * mark (reject ect mark) is sometime printed. This is because the smaller values than printing digits in calculation processing (internal microcomputer) are judged internally that causes error against printing data. [Example] Heater 1 MAX 220(F) 220.0(F) MIN 210(F) 210.0(F) DATA * 220(F) 220.8(F) 151

156 8) Priority of printer output The priority is established in the order of importance for molding. Priority Name Priority Name 1 1st Injection pressure 49 Melted Resin press2 2 Changeover pos. of 2nd P 50 Melted Resin press3 3 1st Injection time 51 Melted Resin press4 4 Cushion position 52 Melted Resin press5 5 Stroke monitor(max) 53 Melted Resin press6 6 Charge complete position 54 CHARGE CHANGEPOS. 1 7 Charging time 55 CHARGE CHANGEPOS. 2 8 Clamp force 56 CHARGE CHANGEPOS. 3 9 Cycle time 57 CHARGE CHANGEPOS nd Injection pressure 58 CHARGE CHANGEPOS rd Injection pressure 59 CHARGE CHANGEPOS th Injection pressure 60 REV th Injection pressure 61 REV th Injection pressure 62 REV th Injection pressure 63 REV th Injection pressure 64 REV th Injection pressure 65 REV th Injection pressure 66 Temperature of Heater 1 19 Time of mold close 67 Temperature of Heater st Injection speed 68 Temperature of Heater nd Injection speed 69 Temperature of Heater rd Injection speed 70 Temperature of Heater th Injection speed 71 Temperature of Heater th Injection speed 72 Temperature of Hopper 25 6th Injection speed 73 Temperature of Mold th Injection speed 74 Temperature of Mold th Injection speed 75 Temperature of thermo 28 9th Injection speed 76 Tmp. of cooling water 29 10th Injection speed 77 Tmp. of Heat CLY st VP 78 Tmp. of Heat CLY nd VP 79 Temperature of spare rd VP 80 Temperature of spare th VP 81 Mold open complete position 34 5th VP 82 Time of product extraction 35 6th VP 83 Time of mold open 36 7th VP 84 Highest pressure 37 8th VP 85 Lowest pressure 38 9th VP 86 Highest speed 39 Pressure1 by position 87 Lowest speed 40 Speed1 by position 88 Power capacity of 1 cycle 41 Pressure2 by position 89 Weight of product 42 Speed2 by position 90 Time of ACC. charge 43 Pressure3 by time 91 2ndary close position 44 Speed3 by time 92 Open vol. 45 Pressure4 by time 93 2ndary close time 46 Speed4 by time 94 Total revolution 47 Rise-up time 95 Stroke monitor(hold) 48 Melted Resin press 96 Stroke monitor(inj. end) 152

157 1) Screen construction. The number of screen consists of the following. 13 Screens : PERIODICAL CHECKUP, ALARM HISTORY, 1 CYCLE LOGC, CLOCK SET UP, CALIBRATION SCREEN, ACCESS SCREEN, SETUP VALUE HISTORY, FIXED DATA, FIXED DATA2, CHECK, CHECK SCREEN 2, SPECIAL MODE SETUP, SPECIAL MODE2. 2) Method to call the MOLD SETUP MODE SCREEN. Push Screen changeover key switch. 3) Method to call the screen by function key. When ALARM HISTORY function key is touched, the screen will be charged to ALARM HISTORY SCREEN. 153

158 When 1CYCLE LOGIC function key is touched, the screen will be charged to 1CYCLE LOGIC SCREEN. When CLOCK SETUP function key is touched, the screen will be charged to CLOCK SETUP SCREEN. When ACCESS SCREEN function key is touched, the screen will be charged to ACCESS SCREEN. 154

159 When SETUP VALUE HISTRY function key is touched, the screen will be charged to STUP VALUE HISTRY. Touch function key switch. The function screen will be changed. When FIXED DATA Function key is touched, the screen will be charged to FIXED DATA SCREEN. Touch function key switch. The function screen will be changed. 155

160 When CHECK MODE Function key is touched, the screen will be charged to CHECK MODE SCREEN. When OPTION Function key is touched, the screen will be charged to SPECIAL MODE SCREEN. When OPTION 2 Function key is touched, the screen will be charged to SPECIAL MODE SCREEN. 156

161 C D E H I J K A G B F L O P M N 2) Explanation of screen. 157

162 158

163 159

164 160

165 161

166 162 A B

167 163

168 A B C D E 164

169 [Note] Depend on the machine type, the symbol and name are different. 165

170 A B C D 1) Method to call the screen. Push Screen changeover key switch. Touch CLOCK SETUP function key switch. 2) Explanation of screen. A : Present data and time are indicated. B : Present data and time are set. C : Data indication format is selected. D : Summer Time time indication is selected. ON ()------Summer Time indication. OFF()------Standard Time indication. 3) Setting method of Data and Time. Push OFF key switch. Data and Time to be set at B. Touch the SET position. Push ON key switch. The time indication of A changes to the indication that has been set. 166

171 E F G 4) Method of 30 sec. Adjustment. Push OFF key switch. Move cursor to ADJUST position. Push ON key switch. Time is made to advance or retract up to 00 sec from the boundary of 30 sec. [Example] 18:50:40 18:51:00 18:50:20 18:50:00 H J L I K 5) Setting method of Data indication format. E and H (Mon) G and I Heisei (Mon) E and J (Mon) F and K FEB 03,1998 (Mon) E and L () 167