Modular Multi-Zone Temperature Controller

Abstract

A scalable temperature controller has a single human interface that is connected to a cabinet that contains a plurality of identical control modules. One of the control modules is the master of other control modules in the cabinet and can access all interconnected control modules and allow user control of parameters therein through the human interface. Each control module has a processor that receives temperature information and controls heating elements. The scalable controller can connect and control additional control modules by connecting additional modules or cabinets without the need for an additional human interface.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Provisional Application Ser. No. 63/455,606, filed Mar. 30, 2023, the disclosure of which is incorporated by reference.

BACKGROUND OF THE INVENTION

The present disclosure relates to temperature controllers for heating multiple zones, such as is used in hot runner injection molding processes. Currently, standalone controllers are used that can control multiple zones, but these controllers can only control the amount of zones that the controller and interface can handle. For complex operations, multiple standalone controllers may be required for a simple process. Further, if the process covers a large amount of space, multiple controllers may be required to reduce cable length and extensions. Monitoring, calibrating, and adjusting these separate controllers requires the technician to interact with multiple interfaces, where it is difficult or impossible to see the overall process.

Currently, modular controllers such as those available from others combine any combination of 1, 2, 5, 8, 9, 12, or 24 zone mainframes together to serve the total number of zones requiring temperature control. However, each module (zone) must be operated independently on the faceplate of each module and such systems do not offer the advanced temperature control technology as described above. Alternative, “advanced temperature controllers” that are currently available on the market offer single-HMI control of multiple zones but do not offer the range of expandability, portability, and flexible positioning of this invention. Therefore, an improved controller is needed.

SUMMARY OF THE INVENTION

The present disclosure describes a modular controller that controls multiple zones, namely 6-zone hot runner temperature controller modules in any combination within a 24-zone capacity cabinet that can be daisy-chained to other 24-zone capacity cabinets up to 192-zones while being operated by a single Human-Machine Interface (HMI) and allowing for flexible installation configurations, mounting positions, and portability to other installations.

One embodiment easily expands from 1-6 zones all the way up to 192 zones not previously possible in the marketplace using a single HMI with system-wide control of hot runner ramp-up, run, boost, idle or stop. Further, the device also supports advanced features such as energy conservation, thermocouple protection, recipe storage, auxiliary input-output signals, copy/paste set-points, hot runner diagnostics, multi-level security, VNC viewer HMI access, adaptive Proportional Integral Derivative (PID) logic, or zone slaving (automatic or manual).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram showing four interconnected cabinets powered from a transformer;

FIG. 2 is a block diagram showing the components internal to a single cabinet;

FIG. 3 is a block diagram of a single control module;

FIG. 4 is an isometric view of a single cabinet system;

FIG. 5 is an isometric view of a dual cabinet system; and

FIG. 6 is an isometric view of a four cabinet system on a cart with a transformer.

DESCRIPTION OF THE PREFERRED EMBODIMENT

An interconnected array 10 is shown in FIGS. 1 and 4-6 for monitoring temperature and controlling multi-zone heaters as part of an injection molding machine 16. The array 10 is made up of either a single cabinet 20 as shown in FIG. 4 or multiple interconnected individual cabinets 20, 21 as shown in FIGS. 5-6. As shown in FIG. 6, the cabinets 20 can be attached to a portable rack 12. The rack 12 may contain power conversion, such as a transformer 14, which can be used to convert higher voltage (such as 480V) to a voltage range useable by the array 10. The array 10 is typically connected to a hot runner system 16 (including nozzle heaters, manifold heaters, sprue heaters, or the like, along with all related thermocouples). Each cabinet 20 has four slots allowing it to hold up to four control modules 26, 27, and each control module 26 can control 6 zones. While the cabinet 20 in the embodiment herein has four slots, other numbers of slots are contemplated. The rack 12 can hold up to 4 cabinets, making each rack 12 capable of controlling 96 zones. Multiple racks 12 can be interconnected to further increase the number of zones. A human interface 40 can be attached to the cabinet 20 or remotely mounted. The human interface 40 can also be virtual, accessed through a communication connection to the cabinet 20, accessed using a custom API, VNC, or integrated into other equipment. The human interface 40 is used to change setpoints, monitor alarms, change recipes, and view data or control other aspects of the control modules 26, 27. Cabinets 20 can be standalone, on a cart, mounted via brackets, or integrated into the injection molding machine 16.

Expanding on the previous introduction of the main components, each cabinet 20 has a frame with a backplane 24 that can receive up to four control modules 26. The overall architecture of the array 10 is shown in the block diagram in FIG. 1. A single cabinet 20 is shown in FIG. 2, with four control modules 26, 27 installed. Each control module 26 is individually replaceable and can monitor and control 6 zones. Further, the control modules 26 are replaceable without the need for tools. In the embodiment shown herein, a full cabinet 20 can control 24 zones. The cabinet 20 contains a rear panel 28 that has connectors 29 for heaters, power, network, and interconnections to other cabinets. In FIG. 3, a single control module 26 is shown as connected to the cabinet 20. The control module 26 has mechanical relays 50, triacs or electronic relays 52, along with other electronic components. In addition, an onboard microcontroller or CPU 54 is used to manage communication, store recipes, manage APIs, monitor thermocouple temperatures and control heaters. An onboard diagnostic connector 56 provides troubleshooting access that is accessible without removing the control module 26 from the cabinet 20. Fuses on the control module 26 are replaceable in the event of an overload condition. A series of connections are located where the control module 26 mates to the backplane 24, such as power input, heater outputs, thermocouples, and communication. Power connectors 30 mate with complementary connectors 32 located on a power connection board 34. The power connection board 34 is attached to the backplane 24. As affixed to the cabinet 20, the power connection board 34 is electrically connected to the rear panel 28. In addition, the control module 26 includes a thermocouple connection 38 that mates to a complementary connector 42 on a thermocouple input connector 44. The control module 26 includes a communication connection 46 that connects to a complementary connector 48 on a communication board 36. The communication board 36 allows communication between control modules 26, human interface 40, and/or other cabinets. The communication board 36 has CAT5/CAT6, USB, and other standard communication capabilities. By interconnecting multiple cabinets 20, 21 via CAN or other network communications, the embodiment shown herein can control up to 192 zones.

As previously disclosed, the cabinet 20 can hold up to four control modules 26. As installed, the control modules are physically identical but one of the control modules 26 is the “master,” determined by its slot or position in the cabinet. Specifically, the communication board 36 identifies one slot as a master/controlling position and the other slots as slave/controlled positions. The control modules 26, 27 are identical and interchangeable, with their identity and role determined by the slot and cabinet in which they are installed. Each control module 26, 27 contains the same firmware. When the control module 26 is in the master slot, it takes the role of a master control module 26 and controls slave control modules 27 that are in the slave slots. Communication between the control modules 26, 27 occurs through the communication board 36. The first cabinet 20 in a chain of multiple cabinets 20, 21 is the master cabinet 20 with the others taking the role of slave cabinets 21, with communication between the cabinets occurring through the cabinet network cables 37. Further, when multiple cabinets 20, 21 are connected, the master control module 26 in the master cabinet 20 controls the master control module 26 in the slave cabinet 21, which then in turn controls the slave control modules 27 in the slave cabinet 21. In other words, the communication between the control modules 26, 27 cascades from master to slave at a cabinet and module level and is accomplished through a daisy chain structure using the communications boards 36 and cabinet network cables 37. As previously disclosed, each control module 26, 27 contains the same program, with different parts of the program in use, depending on the location of the control module. For example, regardless of position, the CPU 54 in each control module handles its own signal monitoring, thermocouple measurements, and PWM instructions for the electronic relays 52. Each control module 26, 27 runs own 6 zone controller, but may receive commands from and send data to a master control module 26. This architecture decentralizes the processing of information.

The control module 26, cabinet 20, and/or human interface 40 can store multiple recipes, heating profiles, and/or programs, which can be updated or changed through the human interface 40, USB, network, or remote access. The heating zones can be reassigned or set to master/slave automatically or manually, along with re-assignment of thermocouples in the event of a wiring error. PID control settings can be auto-tuned. The outputs on the control module 26 can be programmed to be staggered to reduce peak amperage on startup or during control events, maximum power limits, and diagnose and report connection and measurement issues. Firmware and programs are stored without the use of mechanical hard drives and can be transferred over USB or network connections.

The control modules 26 include active protection for thermocouples by detecting ground fault leakage. In the event any improper current is detected through the thermocouple wiring, through a partial short, worn wiring insulation, or other electrical anomaly, the relevant circuit is electrically disconnected. An automatic bake out (to remove residual moisture) can be programmed, along with soak time, to allow proper heat transfer and uniform heating of the relevant parts of the tool and/or runner system.

The human interface 40 is a graphical interface touchscreen or virtual interface that allows the user to interact with any of the cabinets 20 and/or control modules 26 that are on the communication network. The graphical interface allows simultaneous viewing of 24 zones in the embodiment shown herein, but other viewing options are contemplated. The communication network can be through wireless (Wi-Fi), ethernet, USB, 4-Channel I/O, Optional OPC-UA or other industry standard protocol. Further, the interconnected array 10 can be accessed via VNC or other remote VPN access.

It is understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects. No specific limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. Modifications may be made to the disclosed subject matter as set forth in the following claims.

Claims

1. A multi-zone expandable temperature controller, comprising:

a plurality of identical control modules connected to a first cabinet, each said control module having a processor, a program, a plurality of power outputs, and a plurality of thermocouple inputs, said processor receiving temperature data from said thermocouple inputs and controlling said power outputs based on a program;

a first said control module is a master control module; and

a second said control module is in communication with said first control module, said processor in said first control module controlling said processor in said second control module.

2. The multi-zone expandable temperature controller in claim 1, further comprising a second cabinet, said first cabinet is connected to said second cabinet through a network connection.

3. The multi-zone expandable temperature controller in claim 2, wherein each said cabinet has a communication backplane, each said communication backplane for allowing communication between said first and second cabinets and communication between said control modules.

4. The multi-zone expandable temperature controller in claim 1, further comprising a human interface in communication with said master control module in said first cabinet, said human interface for communicating with each said control modules in communication with said master control module of said first cabinet.

5. The multi-zone expandable temperature controller in claim 1, wherein each said control module can independently monitor and control six heating zones.

6. The multi-zone expandable temperature controller in claim 1, wherein each said cabinet has four slots to receive up to four control modules, each said control module can independently monitor and control up to six heating zones.

7. A multi-zone expandable temperature controller, comprising:

a first cabinet having a plurality of slots, one of said slots is a master slot, a remainder of said slots are slave slots, said first cabinet for being connected to external heaters and thermocouples;

a plurality of identical control modules located in said slots, each said control module having a processor, a program, power outputs, and thermocouple inputs;

when one of said control modules is located in said master slot, said control module is a master control module and controls other said control modules in said cabinet; and

a second cabinet in communication with said first cabinet, said master control module in said first cabinet in in communication with and controls said master control module in said second cabinet.

8. The multi-zone expandable temperature controller in claim 7, wherein each said cabinet has a communication backplane for communication between said control modules and said cabinets.

9. The multi-zone expandable temperature controller in claim 7, wherein each said control module can independently monitor and control six heating zones.

10. The multi-zone expandable temperature controller in claim 7, wherein each said cabinet has four slots to monitor and control up to twenty-four heating zones.

11. The multi-zone expandable temperature controller in claim 7, further comprising a human interface in communication with said master control module in said first cabinet, said human interface for accessing each said control modules in communication with said master control module of said first cabinet.

12. The multi-zone expandable temperature controller in claim 7, wherein said communication connectors are located on a communication backplane, said communication backplane for allowing communication between said first and second cabinets and allowing communication between said control modules of any interconnected cabinets.

13. The multi-zone expandable temperature controller in claim 7, further comprising a mobile cart, said first and second cabinets affixed thereto.

14. A multi-zone expandable temperature controller, comprising:

a first cabinet having a plurality of slots, each said slot having a power connector and a communication connector, one of said slots is a master slot, a remainder of said slots are slave slots, said power connector for being connected to heaters external to said cabinet;

a plurality of control modules, each said control module having a processor, power outputs, and thermocouple inputs;

when one of said control modules is located in said master slot, said control module is a master control module and controls other said control modules in said cabinet; and

a human interface in communication with said master control module in said first cabinet, said human interface for communicating with each said control modules in communication with said master control module of said first cabinet.

15. The multi-zone expandable temperature controller in claim 14, further comprising a second cabinet in communication with said first cabinet, said master control module in said first cabinet controls said master control module in said second cabinet.

16. The multi-zone expandable temperature controller in claim 15, wherein each said cabinet has a communication backplane for communication between said control modules and said cabinets.

17. The multi-zone expandable temperature controller in claim 15, wherein each said control modules are connected to a communication backplane, said communication backplane for allowing communication between said first and second cabinets and allowing communication between said control modules.

18. The multi-zone expandable temperature controller in claim 14, wherein each said control module can independently monitor and control six heating zones.

19. The multi-zone expandable temperature controller in claim 14, wherein each said cabinet has four slots to monitor and control up to twenty-four heating zones.

20. The multi-zone expandable temperature controller in claim 14, wherein each said control module is identical and has an identical program.