"We've expanded functionality for the customer to do more process alarming on auxiliary equipment. Then, based on the performance of that auxiliary equipment, we can lock out the molding machine to prevent suspect product from getting away from the machine," Benedix said.

Another major development involves integration of SnapShot, Portrait and Panorama with enterprise resource-planning (ERP) software systems such as SAP, JD Edwards or Oracle for multiple process methods, he said. Each platform can send updates from the monitored system to the ERP system on every cycle of the machine, rather than gathering data and sending it in batches several times during a shift.

"We can now send it directly from the machine to ERP every single cycle, which is huge for ERP," said Benedix. "If you want to update your ERP that quickly, we can do it. It's essentially real-time ERP updates, if the system can handle it."

Besides its software packages, Syscon PlantStar also works with individual customers to help them address specific needs. For instance, the company has been developing a custom system for a medical molder facing a recall over parts made of resin that was not being dried long enough. The system is designed to confirm that the dryer is up to the correct temperature and drying long enough. However, if the monitor reaches set parameters, the system will send an input signal to the data-collection module. That would start an internal clock, and send an alert to have a person check the material. If no one comes within 5 minutes, the monitor is designed to switch the machine into manual mode to keep it from making any more product.

"It's in the final test mode," Benedix said. "We're confirming that everything's working the way it's supposed to work, and meets their needs for isolation of the suspect product. That's taking advantage of our data-collection module and all the functionality it has in expanding some of the software and writing some custom software."

Beckhoff Automation includes cloud connectivity for XMold systems

Beckhoff Automation has enhanced its XMold and eMold control systems for injection molding machines in the past 12 months to include connectivity to cloud services, said Daymon Thompson, automation specialist for North America.

"The newest development is IoT (Internet of Things), connecting systems to the cloud or analytics platforms and sending data across the enterprise or to cloud services," Thompson said. "It works across all our platforms, and supports IoT protocols that historically haven't been known in industrial applications, like MQTT and AMQP." The list also includes OPC UA. All three are commonly used connectivity protocols.

The upgrades allow the control system to connect to multiple cloud platforms, such as Microsoft Azure or Amazon Web Services, depending on what the end user or OEMs want to use for data analytics and storage, Thompson said.

"Even though OPC UA technology is something that's been around for quite a while, that's [a protocol] we see machine builders using to communicate to the end user's MES [Manufacturing Execution System] or data-collection system as well."

The purpose for this is high-precision monitoring of processes across multiple sites to track data and reduce raw material or energy use, Thompson said.

"In other parts of the world, manufacturers are really conscious of the energy usage of their machines, because energy use costs significantly more and there are different regulations to abide [by]. So it's really important for these manufacturers to collect consumption data and figure out why certain machines use more energy than others, or facilities that use more than others," he said.

The cloud-capable XMold system is also being offered with a larger, 19-inch HMI, as well as the standard 15-inch display.

Eurotherm enhances precision temperature control

Eurotherm by Schneider Electric will be releasing the EPC3000, a single-loop controller, by the end of the second quarter, product manager Ben Freckmann said. It is designed for temperature applications in extrusion processes. The measurement hardware is accurate within to 0.1 percent.

Freckmann said the controller's accuracy allows it to meet high quality standards.

The new controller also has enhanced cybersecurity, with an embedded Ethernet chip that defends against hacking and brute force attacks, he said.

"As things become more connected, cybersecurity becomes a major concern. These are things you have to protect against," Freckmann said. "It's going to be one of the most secure devices out there."

The EPC3000 also improves on communication through its Ethernet connection, he said. Previous controllers came with Modbus RTU serial communication via a two- or four-wire serial connection, and while the EPC3000 still includes this as standard, providing an Ethernet connection gives it greater connectivity to other devices. Having two options for communication also allows it to be used with existing products and controls, such as the 3208 and P304i.

"It's a scalable product that you can use in conjunction with other controls and other recording devices because of the connectivity feature," he said.

Eurotherm also has updated its Nanodac recorder/controller to automatically recognize and communicate with its P304c and P304i melt pressure indicators, simplifying data collection, he said. The update also applies to the 3200 series.

"As more and more people want to start recording their process in plastics, they want to start connecting their existing devices like the P304c or the P304i to recording devices, whether that's a [data-logging] Wonderware historian server or the Nanodac," Freckmann said. "It eliminates configuration time. There are default menus set up now."

Maco-sys develops Opti-Pak EM for extrusion processes

Maco-sys has developed a new version of its Opti-Pak II for extrusion processes, the Opti-Pak EM. This follows the Opti-Pak BM, released last year for blow molding processes.

"We took what we had done originally for injection molding. We enhanced that by putting the parison control into that for blow molding," President Dave Spahr said. "We made a derivative of the product on the software side for extrusion. Then, for the hardware, it's a little different because for extrusion you don't need digital I/O, but it typically requires pressure transducers unlike in injection and blow molding."

The Opti-Pak EM is meant for a smaller machinery setup as a flexible, cost-effective controller, similar to Maco-sys' products for blow molding and injection, he said.

The control was developed with several enhancements to make it easy to integrate.

"Ease of use is really what stands out about it," Spahr said. "You turn it on, set up the functions required, and it's configured for you."

Maco-sys also has enhanced its HMI offerings and created custom displays at higher resolutions, Spahr said.

"Most everything's going to be up to 1,024 by 768 [pixels]. It seems like that's the sweet spot at the moment," he said.

Maco-sys worked with Dongshin Hydraulics Co. Ltd., Busan, South Korea, supplying controls for its injection molding machines, with various HMI placement including unique design. The client wanted specific designs that would make the controls look and feel as if they were created as part of the final machine.

"It's been a lot of work together," Spahr said. "It depends on the size of the machine, and what goes into the machine to make it not look like an add-on, that it's ergonomically a part of the machine's design."

Some of that design is cosmetic, but it also affects operator functionality, both in terms of finding the appropriate space on machines of various sizes and finding the correct size of the HMI.

"Going from a range of a 50-ton machine to a 3,000-pound machine, you've got a lot more room to work with on one," he said. "On a smaller machine, space is more limited, so you have to be more creative with how you integrate it."

Maco-sys also offers new HMI sizes for its EM-3c control system, trending smaller. While the system has traditionally had a 12- or 15-inch screen, it is now available in 7- or 8-inch sizes, Spahr said.

"We've gone in that direction for the same reason [as the custom design]," he said. "On some of the smaller machines, space is a premium. Any reduction in size is helpful."

Kyle Brown, contributing writer

[email protected]

For more information

Beckhoff Automation LLC,Savage, Minn., 952-890-0000, www.beckhoffautomation.com

Eurotherm by Schneider Electric,Ashburn, Va., 703-724-7300, www.eurotherm.com

Maco-sys LLC,Rockford, Ill., 779-888-3263, www.maco-sys.com

Syscon PlantStar,South Bend, Ind., 574-232-3900, https://plantstar.org