What follows is a brief listing of the main algorithms used in our products, The list is divided by functionality:

Operational modes

Automatic

The simplest and safest way of working

This is the default operational mode: the thermoregulator powers the heaters so as to reach and maintain a programmed temperature. Sicem modules add the DS-p function that avoids unnecessary power peaks during warm up and the Adat-plus function to limit those harmful power peaks during normal operation and that that induce needless strains in the mould components.

 

Manual

To work without thermocouples

Controllers can operate also without thermocouples: in this case modules output a programmed percentage of power.

If the module is operating in manual mode, but there is a thermocouple available, the temperature can still be read in the display.

 

Manual stabilized

Stabilizes power output regardless of variations in the mains

Power output is voltage stabilized and normalized at 230V. This means that:

• Power output is not dependant of mains voltage variations.
• Tensions applied to heaters will never be higher than 230V: heaters will never operate over their nominal rating, regardless of voltage variations.
• The 230V limitation is always active, even when the controller is operating in automatic mode.

 

Thermometric

To keep an any on parts of the mould not directly under the control of the thermoregulator

Controllers only monitor the temperature of one thermocouple without any power output. Useful when there is the need to check a temperature outside the regulation system. The Off-limits function allows to have a single integrated alarm system for the whole mould.

 

 

 

Regulations

Smart-PDI

Smart-PDI provides differential power to the heaters based on the mass of the controlled objects.

This algorithm provides several functionalities:

• Controllers self adjusts to the characteristics of the controlled object: this feature guarantees perfect regulations in the most complex applications.
• Controllers self adjust to the specific load and mass of the controlled object.
• Regulating cycles are a mere 100ms, important when the regulated object has a small mass, like micro nozzles.

 

Dynamic Set-Point

To avoid deformations in the controlled objects.

During the warm up phase, Sicem controllers power the mould so that all the controlled object reach the programmed temperature at the same time. In this way, dangerous strains due to different dilatation levels are avoided.

 

µCARE

µCARE limits dilatations and contractions in micro nozzles

During the warm up phase iSicem controllers output power in such a way as to limit as much as possible the deformations likely to happen in micro nozzles.

This function is also beneficial when controlling nozzles with a very high length to diameter ratio.

 

Adat-plus

Adat-plus reduces the stress to which the heaters are subjected

Sicem controllers find the best compromise between regulating speed and precision, trying to minimize heaters stress. Heaters life span is greatly increased doe to the absence power peaks.

 

 

 

Heaters handling

• All thermoregulators issue a warning when the load is disconnected because of a severed cable or a broken heater, when there is only one.
  Power MH 3600 and Cluster MC 3800 controllers also react when one or more heaters, in a group of heaters connected in parallel becomes disconnected or breaks altogether.
  
  
• The temperature reached by a heater depends on the amount of power it receives from the controller and by its effective strength (a 1500W heater powered by 30% power output gives 450W output power)
  Standard thermoregulators only deal with power percentages, without taking into consideration the real load they are connected to.
  Power MH 3600  and Cluster MC 3800 controllers constantly monitor the installed load and vary their power output according to the obtained value.
  
  

Q-Watt

Q-Watt measures the power of the heaters

Controllers measure the real load they control, and in normal conditions the value should match the declared values for the heater, plu/minus the declared tolerances. This function allows to:

• Visualize the real power output in Watts. The sum of all the values in the thermoregulator gives a good indication of the whole control system energy consumption.
• Intervene promptly when there is an anomalous variation in the load. The HPM function deals with sudden variations in the effective load and issues the programmed warning or alarms.

 

HPM

HPM keeps under control the heaters

Controllers can be programmed to issue an alarm when the connected load varies abruptly. Usually this happens as a consequence of heaters disconnection or failure. This function is very useful in the following cases:

• Nozzles connected in parallel. If the connected load diminishes abruptly it is a sign that a nozzle has stopped working: if this nozzle is the one used as the reference for the whole group, the temperatures in the other heaters will rise dangerously. HPM solves this problem.
• Hot runners In critical applications or when handling demanding materials. When hot runners are warmed up by several heaters connected in parallel, usually the failure of a single one will still allow the system to function. But a broken heater inevitably causes an imbalance in the other heaters that must compensate for the missing one, and the heat distribution inside the hot runner will not be balanced. HPM monitors the connected load and in cases like this, issues a warning.

 

 

 

Thermocouples handling

Auto-Swap

Protects the mould if a thermocouple fails

Controllers can be programmed to switch from Automatic ti Manual mode of operation if a thermocouple stops operating properly. Power output will be based on a statistical calculation that takes into account injection cycles demands.

 

LPW: power limitation

To limit the maximum power a heater can get

A common mishap is a shorted thermocouple. In this case the thermocouple gives a wrong reading, usually room temperature. In this case, standard controllers, attempting to bring the temperature of the controlled object to the programmed temperature, will increase power output, with grave dangers to the whole mould.

Sicem controllers can be programmed to never go over a certain amount of power output. If this limit is choose properly, the temperature will only rise slightly and production output will not suffer.

 

Off-Limits

Global control of the workings of a mould

Some times temperatures can be altered by causes outside the controllers sphere of influence. In these, cases Off-limits alarms can help to enforce tolerance limits independently of the origin of the alterations, in the whole system.