| Pump Failure, Preventative Plan, Damage Control and Fast Recovery |
Throughout the discussion we will provide samples of failed pumps, how they failed and discuss the filtration and other methods to prevent it from happening. Pumps, as the heart of every hydraulic press, are probably the most strategic components. Pump failures impose major downtime on production facilities. Possible options for prediction and prevention technologies as well as dealing with catastrophic failures are the prime concern of the maintenance department. When pumps fail, the earth shakes! Most often the machine is completely contaminated with debris. |
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| Pressure Measurement Technique and Analysis Methods |
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This is a hands-on session in which analyzers and pressure simulators are used to show how variations in the machine’s parameters affect the readout. Pressure measurement in hydro-mechanical presses is one of the main sensing indicators that is readily available and can be used easily for diagnostics and predictive maintenance planning. Pressure ripple, magnitude and rise rate are the main ingredients of a pressure signal correlating with the status of any operating function. In other words, reading the pressure is like taking the machine’s pulse, helping you to connect to a problem’s root cause. Measurement of transient signals requires a good understanding of signal processing and systems. |
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| Hydraulic Oil Technology, a Key to Machine Longevity |
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The basic principle of hydraulics, types of hydraulic media, fluid viscosity, lubricity, oxidation, water contamination, filtration and life expectancy along with types of tests and inspection intervals are discussed during the session. Oil is what does the work! Often forgotten in the whole game of reliability, the oil’s characteristics have a major effect on machine performance and repeatability. Choosing the right type of oil for machines has a direct impact on efficiency, energy consumption and machine reliability. Chemical stability of the hydraulic oil is one of the major factors in oil aging and the types of additives added have a great effect on maintaining the hydraulic oil performance. |
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| PID Controllers |
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A very commonly asked question is: “Should all process control systems be closed loop to achieve the performance?” We will touch on this question during this session along with basics of design, tuning and optimization of PID controllers. A sample of the PID control system will also be shown during the session. Closed loop process control systems are used in nearly every press in your factory. These controllers are used to maintain the process set point in a closed loop system. Heat control is a typical function using classical PID controllers. It is important to understand how PID controllers function and affect process control. |
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| Servo Valve Technology |
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During this session, the basics of servo controlled axis circuit design will be presented and discussed along with a simulation of a servo valve in a hydraulic circuit and the system dynamics affecting the axis control performance. What is a servo valve? What is a proportional valve? And how to select one? How to achieve speed, accuracy and repeatability, required for today’s injection molding of complex parts? This is a hands-on session in which the characteristics of a servo valve and its required filtration level will be reviewed. Hydraulically operated injection molding presses, especially the small presses, where the cycle time drops below 5 seconds are one of the most challenging systems to control. |
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| Injection Control Technology Upgrade |
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Turnkey injection control solutions and benchmarking methods will be discussed during this session. Is your injection control PLC obsolete? Do you have high scrap rates? Do you achieve the desired shot to shot repeatability? Are you limited to using digital valves to control the injection profile? Is it optimized? Do you need SPC to monitor your molding process? Are you able to run complex molded parts to maximize your profitability? Are your mold change and set up times excessive? Can you easily handle hundreds of mold recipes? Is the power consumption per kg of part higher than expected? Do you want to reduce your energy bill while increasing productivity? Rexroth IndraMotion for Plastics (IMPL) offers a unique and complete solution for injection molding machine controls. A combination of Rexroth IMPL with Rexroth pumps, valves and axis control card products can help upgrade your press system, safety and energy consumption to the latest technology in the market. |
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Contact : Payman Kianpour
Kepstrum Inc 416-904-2129
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