Bob Tymcio Presentation

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Full Pathfinder Presentation.ppt/KDV/9Jun98
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Simply Smart Controls
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The Pathfinder Control Family

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Pathfinder Controls

• Original introduction in 1994
• Pathfinder 3000 5000 introduced in 1997
• Family of controls
• Modular, expandable control
• Technology aimed at ease-of-use
• Broad capability and flexibility
• State-of-the-art features
• Patented technology
• Precision
• Repeatability

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Hardware Platform

• Developed by Van Dorn Demag
• Designed Exclusively for IMM Control
• Ability to Modify and Customize Based on
  VDDC/Customer/Technology Needs
• Distributed Control Architecture
• Advanced Parallel Processing
• Multiple 32-bit Processors
• Based on Motorola VME Standard
• Manufactured by APSCO International

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Hardware Platform

• Reliable Hardware
• Multi-layer Surface Mount Boards
• Tested to IEC-801 Level 4 Noise Immunity
• Fiber Optic Communication
• Built-In Noise Suppression
• About 2,500 Controls Shipped to Date

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Hardware Platform

• Major Control Components
• Logic Processor
• Analog Processor
• Temperature Controller
• System Interface
• Communication Processor
• Operator Station
• PCMCIA Memory Card
• Display Varies by Model

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User Interface

• Intuitive Screen Layout
• Screens Designed by Function
• 1 or 2 Button Access to All Setup Screens
• Soft Key, Direct Key, Menu and Screen Number
  Access
• Window Concept for Lesser Used Data
• Data Visibility by Access Level
• Multi-Language and Metric Support
• Context-sensitive Help

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User Interface

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User Interface

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User Interface

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Pathfinder Family

• Pathfinder 1000 Introductory Control
• Pathfinder 3000 Adds Advanced Control
• Pathfinder 5000 Adds Advanced Analysis and
  Communications

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Pathfinder 1000 Control

• Monochrome LCD
• 25 Line by 80 Column Text Display
• Advantage simplicity

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Pathfinder 1000 Control

• Basic Injection Molding Machine Control
• Open-loop Control System
• Utilizes Feed Forward Positioning Control
• Profiled Injection, Hold and Back Pressure
• Barrel State Temperature Control

1000
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Pathfinder 3000 Control

• Electro-Luminescent Display
• Large10.4-inch Viewing Area
• Graphics

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Pathfinder 3000 Control

• Advanced Machine Control Features
• Pathfinder Scout (Guided Setup)
• Pathfinder Expert (Process Machine)
• Pathfinder Optimizer
• Auto-calibration
• Adaptive Process Control
• Preventive Maintenance Tracking
• Enhanced Production Monitoring
• Enhanced Process Monitoring

3000
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Pathfinder 5000 Control

• Active-matrix color LCD display
• 10.4-inch diagonal viewing area

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Pathfinder 5000 Control

• 10.4-inch active-matrix LCD color display
• Same advanced features of the 3000
• Pathfinder Scout (Guided Setup)
• Pathfinder Expert (Process Machine)
• Pathfinder Optimizer
• Preventive Maintenance Tracking
• Enhanced Production Monitoring
• Enhanced Process Monitoring and SPC
• Auxiliary and Host Communications

5000
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Feed Forward Motion Control

• Patented Technique to Accurately Control Machine
  Motions
• Reduces Event Response Time and Repeatability
  Error
• Advanced Digital Signal Processing Predicts
  Events in the Future
• Short-Term Predictions to Eliminate Latency and
  Jitter
• Long-Term Predictions for Control of Mass

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Feed Forward Motion Control

• How it Works
• Analog Information Sampled Each .25 Ms
• Multiple FIR Filters Applied to Signal Data
• Analog Processor Detects Approaching Event
• Sequencer Pre-Arms for Event
• Analog Processor Detects Actual Event
• Sequencer Outputs Pre-Armed Actions

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Feed Forward Motion Control Benefits

• Precise and Repeatable Machine Control
• Applied to All Machine Motions
• Decreased Cycle Times
• Accurate Response to Setup Changes
• Consistent Performance

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Barrel State Temperature Control

• Patented Technique for IMM Barrel Temperature
  Control
• Modern Control Techniques Modeled on
  Thermodynamics of Barrel
• Considers Flow of Heat Through Entire Barrel

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Barrel State Temperature Control

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Barrel State Temperature Control Benefits

• Faster Startup Times
• Improved Response to Disturbances
• Better Tracking of Desired Setpoints

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Barrel State Temperature Control Benefits

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The Optimizer

• Automatic Calibration
• Adaptive Process Control
• Included on Pathfinder 3000 5000 Controls

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Auto-calibration

• Separate function for each proportional valve
• Exercises valve with incremental voltages
• Sets span offset
• Measures response
• Sets gain, rate, reset (PID) FF value for
  adaptive process control

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Auto-cal Benefits

• Precisely calibrated to match specs
• Removes the human element
• Machine-to-machine consistency
• Enables setups to move between machines with
  consistency
• Enables ISO procedures

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Adaptive Process Control

• Combines three control loops
• Traditional PID closed-loop
• Predictive open-loop
• Adaptive load memory
• Revolutionary technology
• Patent applied for

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Adaptive Process Control

• Predictive open-loop
• Signals machine to begin profile changes in
  advance of the time required based on machine
  dynamics
• Adaptive load memory
• Stores data on mold process dynamics to correct
  future shots on a predictive basis
• Traditional PID closed-loop (reactive)
• Real-time correction of divergence from set
  profile using optimal gain, rate reset values

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Adaptive Process Control

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Adaptive Process Control
3) Traditional Closed Loop makes real-time
corrections
Typical Conventional Closed Loop Errors
2) Adaptive Load Memory learns and counters
effects of mold/process dynamics
Setpoint Profile
1) Predictive Open Loop eliminates delays
before profile changes
Actual Boost Profile
The Pathfinder Optimizers Adaptive Process
Control follows desired profiles more precisely
due to the three interacting control loops.

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Actual Closed-loop Results

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Actual Adaptive Process Control Results

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Adaptive Process Control Benefits

• Precise and repeatable following of profile
• Easy to use
• on or off
• no tuning required
• one button for optimizing

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Pathfinder Scout

• Guided Setup Feature
• Three Inputs
• Material Database
• Machine Specifications
• Part Characteristics
• Recommends Setpoints
• Step-by-step
• Load or Save

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Pathfinder Scout

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Pathfinder Scout

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Pathfinder Scout

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Pathfinder Expert

• Process Troubleshooting
• Machine Problem Troubleshooting
• Logic
• Select problem from list
• Control recommends solution based on material and
  conditions
• When appropriate, shows setpoints to be changed

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Pathfinder Expert

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Preventive Maintenance System

• Track Scheduled Maintenance at Machine
• Select from 24 Pre-Configured Tasks
• Add and Customize Tasks
• Maintenance Due Alarming
• Pre and Post Due Alarms
• Configurable Alarm Processing
• Maintenance Reporting
• Assist in ISO-9000 Verification

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Preventive Maintenance System

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Production Data System

• Complete Production Summary
• Current and Total Summaries
• Tracks Parts Completed, Production Efficiency,
  Reject Rates,
• Cumulative and Shift-based Summaries
• Integrated with Alarm Reject Function
• Downtime Tracking

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Production Data System

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Process Monitoring and Control

• Components of Monitoring and Control
• Gathering, Storing and Displaying Data
• Interpreting and Analyzing Data (SPC Tools)
• Implementing Knowledge Gained from Charts
• Two Systems
• Process Monitoring for Real-time Monitoring
  Shot-to-Shot
• Statistical Process Control (SPC) for Long-term
  Analysis

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Process Monitor

• Gathering Data
• Simultaneous Monitoring of up to 32 Parameters
  (Pathfinder 5000 control)
• Select from List of gt75 Process Variables
• Storing Data
• Saves Last 256 Cycles for Each Parameter
• Log to Printer, File or Host Computer
• Displaying Data
• Graphical and Tabular Display of Cycle Data

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Process Monitor

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Process Monitoring and Control

• Interpreting and Analyzing Data (SPC)
• Select up to 16 Process Monitor Parameters for
  Additional Analysis
• Select Sample Sub-groups from 1 to 25
• Select Sampling by Time or Cycle Count
• 192 Sample Groups Saved for Each Parameter
• Log Data to Printer, File or Host Computer

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Process Monitoring and Control

• Charting Data
• Choice of X-Bar/R, X-Bar/s and X/MR Charts
• Individual Subgroup Statistics
• Multi-Chart Viewing
• Automatic and Manual Scaling (Zoom)
• Tabulated Values of Means and Variation

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Process Monitoring and Control

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Process Monitoring and Control

• Process Capability Charting
• Histogram Chart
• Capability Indices (Cpk)
• Correlation Analysis
• Scatter Plot Diagram
• Correlation Coefficient

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Process Monitoring and Control

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Process Monitoring and Control

• Implementing Knowledge
• SPC Alarming
• Process Capability, Trend, Control Limit
• Configurable Alarm Functions
• Select Any Parameter to Sound Alarm, Fire Quality
  Outputs, Stop Cycle, Count Reject,...

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Communications

• Standard on Pathfinder 5000
• Available on Pathfinder 3000
• SPI Auxiliary Device Network
• SPI Host Network

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Communications

• SPI Auxiliary Device Network
• Integrated Setup and Monitoring of up to 16
  Auxiliary Devices
• Built-in Support for MTCs, Chillers, Dryers,
  Loaders, Blenders, Hot Runners (128 Zones)
• Built-in Support for Standard and Optional Device
  Commands
• Integrated Mold Setup
• Configurable Device Alarms

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Communications

• SPI Host Computer Network
• Support of Current SPI HostNet Protocol
• Support of All Defined IMM Commands
• Mold Setup File Upload / Download
• Access to All Control System Data
• Standard Protocol
• For Use with Third Party Networks that Use the
  SPI Protocol

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Pathfinder Controls
Summary of Benefits

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Summary of Benefits

• Long-term Cost Savings
• Reduced training costs
• ease of use
• consistency
• built-in help
• Reliability, reduced cost of maintenance
• Decreased downtime
• Reduced scrap
• Time-saving features
• Flexibility and breadth can replace other systems

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Summary of Benefits

• Increased Part Quality and Consistency Due to
  Performance, Precision Repeatability
• Optimizers Adaptive Process Control
• Feed Forward Motion Control
• State Temperature Control
• Optimizers Auto-calibration
• Control System Architecture

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Summary of Benefits

• Molding Management Tools
• Process monitoring and control
• Maintenance scheduling and tracking
• Production monitoring
• Expert systems for troubleshooting
• Help systems
• History systems
• Printing and data gathering

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Full Pathfinder Presentation.ppt/KDV/9Jun98