The document summarizes the student's four month internship at SHIBAURA MACHINE PVT. LTD learning about injection molding machines. It describes the key components and processes of injection molding, including the hopper, barrel, screw system, temperature control, clamping unit, and mold. It also discusses the programmable logic controller (PLC) used to control the machine, the various input and output cards that interface with sensors and actuators, and the human-machine interface (HMI) used to operate the machine.
2. ABOUT INDUSTRY;
• We went to SHIBAURA MACHINE PVT.LTD For Industrial training for
the last four and a half months
• This our first phase of industrial training during my Diploma course
• We Worked in Electronics Lab in this Industry
3. INTRODUCTION:
• I am MOHAMED JAMEL.S studying in murugappa
polytechnic college,Avadi,Chennai.
• The industry produces “INJECTOIN MOULDIND
MACHINES”
• We worked on the controller and PLC (Programmable
Logic Control)
• The basic details of a Injection molding machines Are as
follows:
4. INJECTION MOULDING MACHINE;
• An injection molding machine is a complex piece of
machinery that creates one solid part by injecting molten
materials through a reciprocating screw system into a
mould. This machine is made of many components; it is
primarily consisted of a hopper, a barrel containing a
reciprocating screw, temperature control devices, a
clamping unit and the injection mould itself.
5. PROCESS OF MOLDING;
• The process begins with the creation of a mould. The mould is
created by the Toolmakers from the specifications given to
them from the designer or engineer via a 3D computer-
generated model. The mould is carefully constructed to allow
the two halves of the mould — the mould cavity and the
mould core — to separate along the parting line. This will
allow easy ejection from the injection moulding machine
when the part has cooled. If the mould is designed incorrectly
the part may catch on the mould, resulting in possible
damage.
6. WORKING;
• The specifications and components of the machine must be
carefully set up before the process of injection moulding can
begin. Temperatures and pressures will be programmed
according to the size and shape of the mould and the material
that the part is to be made from. Once the machine is set, the
cycle will begin, and the machine can be left unattended to
work its magic.
7. PLC;
• A PLC Consists of a CPU,INPUTS and OUTPUTS
• In our PLC we use separate cards for inputs and outputs
• The card that recieves INPUTS are named as “DIGITAL INPUT
CARD ,ANALOG INPUT CARD “
• The card that gives OUTPUTS are named as “DIGITAL OUTPUT
CARD ,ANALOG OUTPUT CARD”
8. POWERSUPPLYCARD;
•Power supply card convert 24v dc to 5v dc
supply.
•It provides 5v to processor of all cards.
•Back plane distributed 5v to all cards.
•It is 2amp fuse protected.
•Output 5v is isolated with 24v input.
•Input and output are connected with
ferrite bead to avoid noises.
9. DIGITALINPUTCARD;
•It reads 24v input form limit switch,Float
switch and Emergency switch.
•One card capable to read 32 inputs.
•24v is stepdown to 12v and given to
optocoupler.
•A decoder control 32 bit into 8 bit with 4
address bits.
•Controller side operating voltage is 5v.
•CPUreads there 8x4 bits inputs for every
cycle time.
•Limit switch, Float switch and Emergency
switch are mostly corrected to DI card.
10. DO CARD:
• Do card provides24v digital output.
• All outputs are short circuit protected.
• A separate regulator IC converts 24v to 5Vfor
ATMEL32A IC.
• CPU H05 writes in RAM IC.
• Atmel88 reads RAM IC and converts into serial
communication and gives to octocoupler.
• Optocoupler isolates field and processor side.
• Atmel32A reads serial communication from
optocoupler and separates 8x2 bit data’s and given
to driver IC.
11. ANALOG INPUT CARD:
• Analog input card reads 0v to 10v.
• It is used to read mould, ejector scerw
position.
• AI card provides 10v to the Lpot and gets
the feedback.
• The feedback voltage is depended upon
the position of platen /resistance of Lpot.
• The voltage is provided through the LPF to
avoid noise and given to TLC.
• TLC IC also makes the data into serial
communication and gives signal to AI card.
• ATMEL32A writes the data to RAM and CPU
reads the data from RAM.
12. HYBRID CARD:
• It is a multifunction card which controls DAC (digital to
analog conversion), RS 485 TCamp port, RS232 drive port.
• DAC we have four individual channels which provide -10v
to +10v.
• The output of DAC is given to drive which control the
motor.
• RS 485 port, it receives 8 bit serial data from TC AMP card.
• One hybrid card is capable to handle 5 TC amp card.
• RS 232 drive port, hybrid card receives a serial data from
drive such as motor speed & temperature.
• ATMEL324PA receives serial communication data, writesin
RAM IC and CPU H05 read from RAM IC.
13. TC AMP CARD:
• Thermocouple amplifier card, it reads milli volt from
thermocouple, amplifies the milli volt and converts into
serial communication.
• Maximum 5nos of TC amplifier is communicated with
each other and sends data to hybrid card
• A DIP switch is provided to know the TC amplifier
number position.
• It is working with ATMEL32A processor IC.
14. CT CARD:
• It provides milli volt proportionate to current taken by
the heater.
• CURRENT TRANSFORMER:
• Heater wires gets into current transformer coil, so that
the change in flux by heater induces the milli volt in coil.
• The induced milli volt is proportional to current taken by
the heater.
• Each CT card has 12 current transformer coil, so that
capable to read 12 heater current
15. CURRENT SENSING AMPLIFIER
CARD:
• It amplifies the induces voltage from CT coil.
• It multiplexes 12 channels into 1 channel through multiplexer IC’s.
• It provides +18v/0/-18v to AI, AO card through rectifier.
• 18/0/-18v is 1 amp fuse protected.
• It provides a 15v to back pressure card through 7815 regulator IC.
• Free wheeling diode is provided for this relay to prevent/dispute
reverse current.
• Three relay is housed in this card, which is used in motor power
circuit.
16. CONTROLLERS ;
• This is a semi automatic machine which can be controlled manually and
has a option of automatic
• The controller is a both reading and writing object that communicates
directly with the PLC
• The CPU Card of the PLC communicates with the controller
17. HMI;
• The abberivation of HMI is HUMAN MACHINE INTERFACE
• The HMI is used as the controller for the INJECTION MOULDING
MACHINES
• The controller was named as LNC6 and VCON in our industry
18. LNC6;
• This Injection molding machine is controlled by
this type of controller named LNC6
• The controller has some basic functions like
moving the piston , mould and the screws
