Special Report: Latest hot-runner temperature controllers handle motions within tools

Gammaflux LP, Sterling, Va., has released its first integrated hot-runner temperature controller and sequential valve-gate controller and introduced and updated features for its G24. 

The new, integrated controller, the G24 SVGC, allows molders to selectively open or close valve-gate nozzles in sequence, to control material flow into the mold. The combination of temperature and valve-gate controls provides better coordination between the two sequences to optimize process adjustments, said Peter Reichel, European sales manager.

The G24 SVGC controls up to 48 zones. Advanced features include single and dual solenoids for valve-pin actuation; the ability to open or close a valve-gate pin within a millisecond; alarm functions that ensure accuracy and repeatability; and access to easy-to-read updates on the control screen. The unit can control valve gates that are driven hydraulically, pneumatically or electrically.

Users program the sequence of movements for each valve gate through the controller. Each valve gate can be opened and closed three times during the mold cycle, with four possible valve-gate movements. The controller can handle eight, 16 or 24 valve gates and can monitor each digital and analog input every millisecond. Gammaflux developed a start-up guide for the controller, composed of nine display screens, for monitoring and control of the sequential valve gates.

In addition to introducing the G24 SVGC, Gammaflux has extended the hot-runner leak-detection capability of the G24 unit beyond the monitoring of the nozzle and tip zones. It now signals when a leak is detected anywhere there is a large mass of metal, such as in the manifold. The G24 controller is connected to a plastic leak-detection system designed and manufactured by Airtect Plastic Leak Alarm System, Dublin. It collects data from the manifold and communicates it to the controller. The Airtect system is available in the U.S. through Plastixs LLC, Shrewsbury, Mass.

Gammaflux also updated the G24's Mold Wizard set-up and configuration tool to make it more user-friendly. Mold Wizard 2.0 takes advantage of key features built into the control to simplify setup and access to programming functions. The wizard guides the user through a seven-step process that is designed to be understood with just 5 minutes of training, Gammaflux said.

Introduced in 2012, the G24 uses Gammaflux's Triangulated Control Technology to measure temperatures up to 20 times per second. Proprietary control algorithms trigger an adjustment when the temperature deviates 0.03 degree Fahrenheit from the set point, while a second algorithm monitors the rate of temperature change.

MOLD-MASTERS

Mold-Masters Ltd., Georgetown, Ontario, a division of Milacron LLC, Cincinnati, Ohio, launched its M-AX Six Servo Axis hot-runner temperature controller, which is designed to control motions driven by servo or electric motors.

The M-AX unit controls the motions of valve stems, cores, coining plates, index plates, stripper plates and ejector plates. It also can control Mold-Masters' drive technologies, such as its E-Drive syncro plate and Single Electric Valve Gate (SeVG) technology.

The new M-AX controller incorporates Mold-Masters' Adaptive Process System (APS) technology, which makes the controller faster and more responsive. APS adapts to variations in material viscosity, shot size, pressure and power fluctuations, to maintain the temperature to within 0.1 degree Fahrenheit. APS also automatically controls the motor to maintain precise movements.

Mold-Masters also developed icon-based apps for its TempMaster M2 line of temperature controllers. The apps, to be installed on the TempMaster M2 as standard software this quarter, allow users to find and change parameters more quickly.

NEW IN VALVE-GATE CONTROL

HRSflow, San Polo di Piave, Italy, has developed a new servo-driven valve-gate control system for hot-runner nozzles. It functions as a stand-alone system without a control unit.

FLEXflow One allows users to set the stroke, position, velocity and profile for the needle of each nozzle of a multicavity, multidrop tool by controlling the electrical drives for each valve pin. Instead of a control unit, the settings are stored in a Driver Module that's attached to the hot-runner system and can be adjusted by an operator using a wired tablet known as an External Smart Interface.

The system is suited to applications with multiple gates or cavities, and offers a wider processing window compared to conventional hydraulically or pneumatically operated needle-valve nozzles. The wider processing window is due to FLEXflow One's ability to vary the stroke of an adjustable needle within an 18mm range. Also, with its ability to select the opening velocity of the valve pins, it offers optimized cavity filling.

The Driver Module receives a 24-volt signal from the injection press, which it uses to trigger valve-pin movement. Lubrication is not needed with the FLEXflow One, making it suitable for clean-room conditions.

SYNVENTIVE MOLDING SOLUTIONS

Synventive Molding Solutions, Peabody, Mass., introduced SVG+, its newest standard system for hydraulically or pneumatically driven sequential valve gating. SVG+ is primarily for use with Synventive hot runners and features several patented enhancements to improve the molding process.

The system can facilitate faster startups and tooling changes, increase machine utilization rates and yield better part quality, Robert Redzisz, regional sales manager for Eastern Europe, said at the K show.

Key components include a patent-pending, self-cooling, modular actuator that drives valve-gate movements. The actuator is designed to operate without water lines or cooling plates. Traditional actuators get hot when cooling water is turned off along with the hot-runner power.

The actuator incorporates the company's patent-pending SynCool3 design, which cools by using proprietary thermal conductors that contact the top clamp plate of the injection unit. The SynCool3 design eliminates the need for water lines and cooling plates to improve the temperature uniformity of the manifold. It allows for preheating of the mold without damage to the actuator or seal and facilitates quick mold changes by eliminating the need for cooling the hot runner first. The technology maintains the actuator within an acceptable temperature range. The thermally isolating design of the self-cooling actuator prevents overheating. Redzisz said the actuator is supplied as a plug-and-play system and allows for easy access to the valve-gate pin.

SVG+ consists of a junction box in which calibration data is stored. A position sensor sends signals to the junction box. Status lights on the box indicate whether the pins are in open, closed or intermediate position. Opening times for two selectable zones in the sequential valve-gate system can be displayed.

Synventive's valve-pin monitoring and diagnostic tool, VMI, can be incorporated into SVG+. It allows setup and troubleshooting outside the mold. With VMI installed, users can check that the movements of the valve pin and piston occurred as intended. They can also read the opening times of the actuator and ensure that the plumbing and the labeling of zones are correct. VMI displays the opening time of the valve-pin movement during the most recently completed cycle. Data-logging equipment can be connected to SVG+ to capture pin opening data.

Users can tie SVG+ to Synventive's activeGate line of valve-gate control technologies for increased valve-pin control and feedback.

PRIAMUS SYSTEM TECHNOLOGIES

Priamus System Technologies AG, Schaffhausen, Switzerland, said its FillControl Control V quality management system now can provide automatic valve-gate control for multicavity molds with hot-runner or cold-runner systems. FillControl Control V previously was used primarily to balance and control the filling phases of multicavity molds using cold-runner systems.

The ability to directly position and control the valve-gate pins opens up new possibilities for process control, Priamus said. 

FillControl Control V uses cavity-pressure sensors and related technology to automatically delay the opening of each valve-gate nozzle, resulting in the simultaneous filling of all cavities in the tool. By automatically detecting the melt front in every cavity, the system can determine filling times for each cavity.

When used with hot runners, the system calculates the optimized setting of the pin stroke for every cycle, based on the cavity-pressure readings it collects. The pin-stroke setting is transmitted via an interface to a system that controls the valve pins. In this way, the filling times in every cavity are automatically matched and balanced.

FillControl Control V can also be used as an automatic valve-gate control device, via a valve-gate control interface. Such an arrangement would bundle control over valve gates and temperature in one unit.

FillControl Control V opens the valve-gate nozzle when a trigger, such as the forward movement of the injection screw, is detected. It closes the nozzle when the cavity sensor detects the melt front.

HASCO

Hasco Hasenclever GmbH + Co KG, Ludenscheid, Germany, introduced a hot-runner control unit for central gating with a single nozzle, with separate heating for the nozzle head.

The H1250 unit is for use with one or two control zones. Features include self-optimizing control, and soft start for gentle drying of the heating unit. The unit also features an LED display of set point and temperature, functions such as boost and standby, and automatic monitoring of the sensor and heating. Error messages and an alarm-diagnosis function are standard functions. The 3,600-watt, 16-amp H1250 can control temperatures ranging from 86 degrees to 932 degrees Fahrenheit.

SISE SAS

SISE SAS, Oyonnax, France, introduced the third generation of its M-series multizone controller for hot-runner systems, designed for 24 to 500 zones.

The MV3 controller can govern hot-runner systems used in automotive, packaging, cosmetic and medical applications, said Philippe Monnet, export sales and marketing manager. It uses a redesigned version of the company's permanent, self-tuning control software that continuously calculates the most suitable control parameters for each zone, based on changes in the process.

Standard features include two adjustable set-point values and a 10-inch color touch screen. The screen displays information such as percentage of power used and load current per zone, as well as indicates whether there is an inverted or broken thermocouple. Users can designate a zone, or zoom in on one or multiple temperature zones. Other features include a choice of four soft-start programs and real-time mold surveillance of variations in electrical data.

ORYCON CONTROL TECHNOLOGY INC.

Orycon Control Technology Inc., Ocean, N.J., unveiled its new T-500 touch-screen hot-runner temperature controller, ideal for clean rooms. The system operates on a Windows-based platform, which allows for the use of more graphics and icons that ease programming.

The intuitive touch-screen operator interface displays 14 diagnostic messages for startup and troubleshooting, eliminating guesswork. The system adjusts to changing conditions, recalculating control parameters and making quick revisions, if necessary. A self-compensation function allows the unit to continue running even if a thermocouple fails.

A built-in initial test cycle automatically determines the type of algorithm best suited to the control application. The control helps to minimize gate vestige and produce higher quality parts.

The T-500 employs static cooling with a low-velocity fan that reduces air-flow requirements to keep internal components cleaner and allows them to operate more accurately and reliably. Connectors to the mold, located in the back of the unit, can be supplied in a variety of styles and standards to meet the requirements of any molding facility.

The T-500 can control up to 36 temperature zones, with the possibility of expansion.

Orycon also introduced the T-700 sequential valve-gate controller, which provides 12 zones of control. It features a 10-inch touch screen and a Windows-based, graphical software control. Users can use touch and slide motions to enter or adjust each zone of control. Eight operations can be programmed or displayed per cycle. The T-700 can be integrated with the T-500.

PSG PLASTIC SERVICE GMBH

PSG Plastic Service GmbH, Viernheim, Germany, expanded the functionality and shrunk the size of its profiTEMP+ line of hot-runner controllers.

The system, which is available with two different types of housings, has a very small footprint, according to Dre Schulte, technical adviser at PSG in the Netherlands. ProfiTEMP+ can control six to 64 zones. Each zone handles 230 volts and 15 amps.

The 15-inch touch-screen control is more suited to the upgraded model, incorporating multi- touch gestures familiar to users of smartphones or tablets.

The company, represented in the U.S. by Thermal-Tech Systems Inc., West Chicago, Ill., also offers an app that allows users to monitor and diagnose the process remotely using a mobile device.

The unit has several new functions, including Smart Power Limitation, which prevents the required heating power from exceeding the available power. In addition, a Smart Peak function monitors the heating power, preventing power fluctuations, Schulte said.

ProfiTEMP+ analyzes temperatures, control and flow data and signals alarms at the first anomaly. It detects leaks early via process monitoring and algorithms in the software. Control cards can be accessed through the front of the unit. Data exchange, backup and tool settings can be uploaded or downloaded through the system's USB port.

HUSKY INJECTION MOLDING SYSTEMS LTD.

At the K show, Husky Injection Molding Systems Ltd., Bolton, Ontario, displayed an Altanium controller, which can control valve-stem motions, slides, unscrewing and core movements that have a servo power source. The customizable servo control allows users to achieve mold qualification more quickly with greater reliability and repeatability.

According to Husky, its Altanium line can handle from two to 254 zones. The units use Active Reasoning Technology (ART), which provides optimized control for greater repeatability and consistency, shot-to-shot and cavity-to-cavity. 

They also feature easy-to-use navigation on full-color screens and are available in a variety of configurations that can be implemented in any injection molding environment. The series includes the Neo2, Delta3 and Matrix2.

Mikell Knights, senior staff reporter

[email protected]

Contact:

Gammaflux LP, 703-471-5050, www.gammaflux.com

Hasco America Inc., 828-650-2600, www.hasco.com

HRSflow, 616-228-6900, www.hrsflow.com

Husky Injection Molding Systems Ltd., 905-951-5000, www.husky.co

Mold-Masters Injectioneering, 905-877-0185, www.milacron.com

Orycon Control Technology Inc., 732-922-2400, www.orycon.com

Priamus System Technologies LLC, 877-774-2687, www.priamus.com

SISE Plastics Control Systems Inc., 404-495-5968, www.sise-plastics.com 

Synventive Molding Solutions, 978-750-8065, www.synventive.com

Thermal-Tech Systems Inc., 630-639-5115, www.thermal-tech.com