Press Release 19/2007

Debut at the K 2007: BOY sets new standards with the Procan ALPHA Control

During K 2007 BOY, the manufacturing specialist of injection molding machines with clamping forces below 1000 kN, will debut the Procan ALPHA control. The touch screen system sets new standards for speed, precision, and ease of operation. Procan ALPHA, which incorporates three patented components, has successfully completed the test and pilot phase and will now begin mass production.

In 1998 BOY was the first German injection molding machine manufacturer to introduce an easy to understand touch screen control. This type of control has subsequently become the industry standard. With the debut of the Procan ALPHA control during K 2007, BOY will once again prove itself as a technical pioneer.

"The Procan ALPHA will be a highlight during the K 2007 exhibition", says Bernd Fischer, Director Process Engineering and Service at BOY. "This new system will confirm the claim that BOY is one step ahead when machine controls are considered, which is supported by the numerous pilot companies that have put the Procan ALPHA control to the acid test for an extended period of time. Many of these pilot companies offered a number of suggested improvements that have been incorporated into the final version.

Easy and safe operation
Procan ALPHA features a patented 15" full touch screen display that is both intuitive and easy to use. These features enable a rapid and safe operation. A logical analogue configuration continuously displays the process sequence. The time needed for changes in set values and the selection of screen pages is extremely short.

The complete touch screen operation works entirely without customary keys. The entry key panel is displayed on the monitor, and even functions for machine operation and the selection of operating modes are accomplished via the touch screen. The operators identify themselves with their USB flash drive or their name and password. All changes of set values that are entered are automatically stored, and the name of the operator is recorded.

Screen pages are logically arranged and designed with clearly understandable symbols. The start page features all the important information at one glance and offers direct access to further pages. It contains a notepad where the operator can enter short messages via the entry keys or by writing on it. A graphics editor is available to rapidly and easily enter or modify the profiles of set values.

The tolerance range for an actual value curve can be individually defined and ensures that the desired tolerance limit is set. The operator can freely configure and arrange set and actual values on any screen page in just about any combination. Thus, a quick overview of the important parameters is available to the operator at all times.

The configuration page displays the machine cycle with all auxiliary functions including core pulls, unscrewing, and the freely programmable entries and exits. The programming of the auxiliary functions is directly accessible. The text and image of each recording can be stored on a "notepad".

The complete operation manual of the Procan ALPHA control is stored in the system, including the explanation of warning codes, a list of all alarms and causes, as well as trouble shooting information. When and if needed, the operator has immediate access to the required information.

A USB flash drive serves as an external means for entry and storage. Connections for printer (USB interface), Ethernet, and OPC are available as options. Temperature control units and hot runners can be controlled via a serial port.

High speed, shorter cycle times
The hardware is based upon a rapid UTX PC system. The patented hardware module, which is separate, is especially effective regarding the processing of analogous signals. It reacts without delay and frees the PC from all time-critical tasks. With this configuration, even shorter cycle times can be achieved.

Maximum precision, highly efficient production
The third of the patented solutions, the Iterative Learning Controller (ILC), ensures high precision, which markedly reduces time and cost. Due to the ILC, the actual values are rapidly attained in a stable state. The advantages include the reduction of start-up and set-up times, and the deviations during continuous operation are quickly and precisely controlled. The profiles of actual and set values are largely approximated, minimizing frequency peaks.

During each heating phase (five heat zones), the temperature control is adapted automatically and the nozzle and nozzle mounted heater bands are individually adjustable.  

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