Page 1 of 4 the Press Release: „Easier troubleshooting, reduced downtimes, improved productivity
Gammaflux: extensive software update for TTC hot runner temperature control systems“
Press Release
Easier troubleshooting, reduced downtimes, improved productivity
Gammaflux:extensive software update for
TTC hot runner temperature control systems
Wiesbaden/Germany, October2009. – Gammaflux, one of the world’s leading suppliers of hot runner temperature control systems, has integrated three new functions into the software of its line of TTC high-performance hot runner temperature controllers:
- Temperature monitoring and alarm function, e.g. for cooling water temperature or surface temperature in the mould cavity.
- A new “OK to Run” status screen, which indicates whether all monitored temperatures are within the given limits and, in the event of a malfunction, identifies the possible cause.
- An extended heat input monitoring and alarm function for detecting leakages of melt in the hot runner manifold.
These additional functions convert the TTC controller into a temperature monitoring system for the entire injection moulding process and considerably facilitate troubleshooting, especially in the case of hot runner moulds. They effectively help to reduce downtimes and hence improve productivity. All new TTC hot runner temperature controllers are already supplied with these extended software functions. Users of existing controllers are offered the extensions as an update. The TTC hot runner temperature controllers equipped with these new functions will be making their début at Fakuma (Friedrichshafen, 13th to 17th October 2009) on Gammaflux’s exhibition stand No. 7221 in Hall A7.
The benefits of the extended software functions to the user are explained by René Bertschi, Managing Director of Gammaflux Europe GmbH, Wiesbaden/Germany: “These improvements reduce downtimes in the injection moulding shop. The additional features help the operator to recognize malfunctions well before they can cause any damage to the mould and the hot runner system. The tried and tested features of our high-precision hot runner controllers – PID² control algorithm, phase angle control, detection of wiring faults and broken sensors, numerous status reports and graphics, diagnostics with Mold Monitor, malfunction elimination with Mold Doctor® – have been retained in their existing form.”
Monitoring of process temperatures with alarm function
Through the simple installation of a thermocouple, this useful additional function permits the effective monitoring of process temperatures. All the operator has to do is input the upper and/or lower temperature limits. If the temperature rises above or drops below the set limits, the hot runner controller can be put into stand-by or inhibited. Moreover, with the aid of the new “OK to Run” status screen it is possible to communicate the alarm to the injection moulding machine or its peripherals.
“This integrated temperature monitoring function ensures, for example, that the mould cooling system is working properly,” says Bertschi. “All users of hot runner systems can benefit from this safety function. During a machine stoppage, in the case of a malfunction or interrupted operation, for example, it prevents any hot runners that have not been switched off from overheating the mould or even the platens in the event that the mould cooling system is not operative – this overheating would cause damage to the nozzles, the runner system, the mould and/or the machine itself when starting up again.”
The new function also permits monitoring of the surface finish of the moulded parts. To this end, the mould is equipped with a thermocouple for the surface temperature of the mould cavity. If the TTC controller detects a temperature above or below the set limits, it will activate the malfunction alarm.
A further beneficial feature is the protection that can be given to the hot runner valve gate system. The monitoring system enables the user to ensure that the temperature of the hot runner manifold does not exceed the critical level, which is usually 80 °C. If the temperature is too high, the valve pins and the nozzles may sustain costly damage.
Status screen for monitoring readiness for operation
The new “OK to Run” status screen indicates whether all monitored temperatures are within the given upper and lower limits for safe and reliable operation. The screen with give the “OK to Run” signal if all unlocked monitor zones in the controller are ready for operation when the controller is switched on.
The screen tells the operator at a glance whether all zones are “OK to Run” or not. A “Status of OK to Run” button has been added to the bottom of each monitor zone’s alarm screen in order to allow the operator easy access to the screen.
If there is a problem in any monitor zone, the screen tells the operator exactly what the cause is. In addition, the red warning light at the top of the TTC control screen can be set with a simple command to flash whenever the controller is “Not OK to Run”. This feature enables the operator to recognize problems in good time and to reduce scrap to a minimum.
Modified heat output monitoring feature
This improvement to the TTC controller indicates leaks in the hot runner system. René Bertschi says: “This function recognizes material leaks in the hot runner system before they can spread any further within the system. While our controllers already had this feature, we have now modified it by making it more accurate and enabling the user to set up the alarm more easily.”
The new and more accurate algorithm calculates the average heat output of each monitor zone and compares it with the given alarm setpoints. The average is taken from 100 measurements. If the average output exceeds the alarm setpoint in four successive measuring periods (i.e. in 4 x 100 measurements), the alarm will go off.
This facility is of particular interest to those processors who use hot runner systems that are more prone to leakage, e.g. low mass systems with miniature nozzles. By detecting a leakage at its earliest stage, the controller can shut down the affected zone at the mould cavity, thus minimizing nozzle damage.
Gammaflux, based in Sterling/VA (U.S.A) and Wiesbaden/Germany, is a leading global manufacturer of hot runner temperature controllers for the plastics processing industry. The company has long been on record as a supplier of innovative control technology and became the industry's first manufacturer to develop controllers capable of anticipating temperature deviations, detecting wiring and heater problems, and averting severe mould damage through instant control response. Gammaflux control technology combines digital performance with high-precision analogue control action. Users benefit from a central control system enabling them to manage the injection moulding process and to extract data for performance analysis. Gammaflux serves a wide range of markets all over the world, from automotive to medical equipment manufacturers through to the packaging, electronics, household products and toolmaking industries.
Further information:
Benno Kippes, Gammaflux Europe GmbH
Bahnstraße 9a, D-65205 Wiesbaden
Phone: +49 (0) 6 11/9 73 43-0, Fax: +49 (0) 6 11/9 73 43-25
E-mail: , Internet:
Editorial contact and voucher copies:
Dr. Diether Burkhardt, KONSENSPublic Relations GmbH & Co. KG,
Hans-Kudlich-Straße 25, D-64823 Groß-Umstadt
Phone: +49 (0) 60 78/93 63-11, Fax: +49 (0) 60 78/93 63-20
E-mail: , Internet:
The screen for the temperature monitoring function indicates not only the hot runner monitor zones but also the actual and limiting temperatures for three cooling water circuits (right) and activates an alarm if the temperature rises above or drops below the set limits.
Photo 1: Gammaflux, Wiesbaden
The new “OK to Run” status window – shown here in alarm status – shows at a glance the monitor zones in which the problems have occurred
Photo 2: Gammaflux, Wiesbaden