PECS The Control System for Extrusion Blow Molding

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2 PECS The Control System for Extrusion Blow Molding The PECS control system for extrusion blow-moulding machines is based on advanced but proven technology and is easy to use. It enables flexible machine design and quick start-up. The system makes possible to design blow-moulding machines with unprecedented precision, minimal material use and the fastest production cycle. Due to the Mitsubishi advances in manufacturing technology and due to high production volumes, the Mitsubishi PLC s can meet or beat the price of many competitor systems. The PECS control system allows highly flexible configuration of hardware and software components. The PLC system is completely modular system, which could be optimized by the machine designer to reach the optimal price/performance level. The machine parameters and data are organized as recipes. Their use ensures fast and efficient set-up of the new machine without excessive time consumption to configure and to parameterize the control system from the scratch. On the other side, the product recipes are used to help the end user to change the production in the shortest possible time. The PECS control system can be used as a package for building new blow-moulding machines or as well as for retrofit machines. Advantages of the PECS control packages The human-machine interface (HMI) screens are already prepared and SPAC20 coprocessor modules are pre-programmed to execute the most demanding control algorithms. Everything is linked together by the PLC software to make the machine running in the shortest possible time. The user needs only to match the system to the specific configuration of the machine and to make final adjustments. Of course, one may make greater redesigns if necessary. 1

3 The main advantages of the system are:! Modular PLC system, which can fit to different requirements and price/performance levels! Standard PLC I/O modules support interfacing to all kind of control signals and to most of communication protocols.! High-speed intelligent co-processor modules take the control of fast blow-moulding tasks. Dedicated control algorithms are pre-programmed and easy to use.! Analog and digital I/O s are included in the co-processor modules for fast and effective control of wall thickness and hydraulic motions.! Powerful HMI terminal with color touch screen and function keyboard helps the operator to operate the machine in a user-friendly, efficient and safe way.! Three types of recipes are available: machine data, product data and complete data.! Several security access levels are possible.! Multi-language HMI supports with up to 4 languages and different types of fonts (Asian fonts as well) are available. Functions of the PECS Blow Moulding Control System Mitsubishi Electric offers complete blow-moulding solutions for:! Temperature control Auto-tuning temperature control with pretune.! Parison control Fast wall thickness control with simple profile programming.! Hydraulic control Accurate open-loop or closed- loop motion control.! Sequence control Standard ladder logic programming. Hydraulic Control The hydraulic motion control with smooth and precise control is one of the most important features of the blow-moulding machines. While closed-loop control provides the ultimate positioning accuracy, the open-loop control may also be used to realize less demanding and cost sensitive positioning solutions. 2

4 ! Motion control in open-loop or closed-loop for carriage, mould and blow-pin movements! Up to 16 channels possible to drive servo/proportional valves (using four SPAC20 PA4 modules)! Hydraulic motion control with high accuracy and repeatability! Simple calibration of the complete hydraulic system (including valve, cylinder and linear position sensor) Parison Control Wall thickness parison controller is available for continuous as well as for accumulator based machines. The touch screen technology enables fast and efficient design of the parison wall thickness profile.! Wall thickness control using profiles with up to 128 points and smooth interpolation between points! Control loop update in 80µs or 160µs 3

5 ! For continuous extrusion and for accumulator-based machines! Up to 16 channels available for multi-head machines (by using up to four SPAC20 PA4 modules. Axial wall thickness control possible.! Cycle time correction for time based systems and push-out time correction for accumulator based machines! Separate weight and profile adjustments Temperature Control Multi-loop temperature control is capable of accurate temperature control of different types of extruders and co-extruders. Intelligent pre-tune and auto-tune functions are built-in to enable simple automatic tuning of the control loops and to adapt control parameters to varying load conditions. User-friendly graphical screens and improved diagnostics make the control system easy to use and simple to maintain the heating/cooling elements. 4

6 ! Temperature control of up to 64 heating/cooling temperature zones! Suitable for different types of zone cooling: air, water or oil cooling! Automatic pre-tune cycle assures quality tuning and fast start-up of the machine.! Auto-tune control algorithm monitors control loops on-line and continuously retunes the control if necessary.! Automatic machine scheduling using time schedule for heating Sequence Control The MELSEC series is an extremely compact and very powerful generation of logic controllers from the Mitsubishi Electric. Besides the other convenient programming tools, the sequential programming can be done also with the powerful GX Developer featuring full online programming capability.! More than 60 different types of modules are available to interface with different kinds of control devices.! Up to 1024 I/O points are possible by using up to 7 extension racks.! High-speed ladder processing with instruction cycle as low as 0.075µs per logic instruction (Q2ASHCPU)! More than 700 instructions available! Standard PC-based programming with powerful ladder logic programming tools! Full on-line programming capability, which is especially useful during upgrading or maintenance of machines 5

7 System Configuration Three different powerful versions cover the overall range of applications of blow-molding technology: Basic, Standard and Professional. Maximum flexibility permits a very attractive price level. performance BASIC STANDARD PROFESSIONAL systems Specifications BASIC STANDARD PROFESSIONAL Temperature zones Parison and Hydraulic channels Continuous extrusion machine # # # Accumulator based machine - # # Hydraulic motion control - # # Specifications BASIC STANDARD PROFESSIONAL PLC CPU type A2SHCPU-S1 Q2ASHCPU Q2ASHCPU-S1 I/O points Instruction time µs Floating point math - # # Multiple programs - # # Co-processor module SPAC20 - # # Specifications BASIC STANDARD PROFESSIONAL HMI type MAC E700 REDIS 52 B REDIS 52 B Display type 320x240 color 640x480 color 640x480 color Display size Function keys Touch screen - # # Multi-language # # # Recipe size (values in recipe)

8 Example of the System Configuration Blow Molding Standard A1S61PN Q2ASHCP SPAC20PA4 SPAC20ATHC16 A1S68TD A1S68TD A1SJ71 QC24-R2 Main Base Unit Free Power Supply CPU Module Coprocessor Module: Parisonand Hydraulic Controller Coprocessor Module: Temperature and Analog I/O Thermocouple Module Thermocouple Module (RS232 Module) (Profibus Module) Extension Base Unit A1SX80 A1SX80 A1SX80 A1SY80 A1SY80 A1SY80 A1SY80 A1SY80 Inputs Inputs Inputs REDIS 52 B 7

9 PECS the control systems for extrusion blow moulding are the actual result of the partnership between Mitsubishi Electric, Inea and Resotec. Mitsubishi Electric is a recognized company as a Global Player among the worldwide leading companies of control technology, drives technology and robotics. Inea's business is control and management of industrial processes. Inea is a specialized firm, providing engineering solutions, services and equipment for control and management of industrial systems, known for its excellence in technology, quality and customer services. During the last ten years, Inea is present also in the field of automation control of the blowmolding machinery as a technology partner of Mitsubishi Electric and gives all necessary technical support worldwide. Resotec is recognized as a carrier of know-how in the field of automation for plastics processing machinery and a leader in visualization technology. MITSUBISHI ELECTRIC EUROPE B.V. Gothaer Straße 8 D Ratingen Phone Fax Hotline /-766 Faxback / [email protected] INEA d.o.o. Stegne 11 SI-1117 Ljubljana Phone Fax [email protected] Local distributor: RESOTEC Eisenstraße 7 D Baunatal Phone Fax [email protected] PECS Blow-Moulding Leaflet Print date: