All Gammaflux temperature controllers feature Triangulated Control Technology®. Using this unique technology, our controllers:
Sense – Twenty (20) times per second, Gammaflux controllers precisely measure the temperature.
Control – The proprietary self-optimizing Gammaflux PID2 control algorithm adjusts if the actual temperature deviates 0.03°F (0.014°C) from set point. The second derivative (PID2) monitors the actual temperature rate of change. As a result, the output to the heater is regulated in advance of the typical proportional band to limit or eliminate over and undershoot.
Actuate – Using phase angle fired output (0.1% resolution; 1,000 steps), the Gammaflux controller delivers smooth and exact power to each heater for the ultimate in temperature control.
Triangulating your process with a Gammaflux controller means achieving better temperature control, which could result in:
- Enhanced part quality
- Reduced scrap
- Improved part weight consistency
- Material savings
- Higher profit margins
"Low mass", or extremely small hot runner nozzles are a unique challenge to control. To smooth the power and the melt heat history, Gammaflux created Power Priority®. Power Priority® smoothes the power output to individual zones. Users have the option to manually apply a Power Priority® set point from 1 (light) to 4 (heavy), providing unparalleled control for applications where it is most needed.
Troubleshoot Your Mold
Mold Doctor® is an off-line (tool room), advanced troubleshooting tool consisting of four diagnostic tests:
Wiring Analysis: checks the wiring of the tool. The software clearly tells the user of miswired zones and how to fix them.
Fault Analysis: quickly identifies the following problems: thermocouple open, thermocouple reversed, thermocouple pinched, open fuse, heater short/wet, heater open, uncontrolled output and ground fault.
Thermodynamic Analysis: automatically heats all selected zones to 400° F (204° C) and cools to 330° F (165° C). During the heating and cooling process Mold Doctor® records critical information and reports to the user. Compare like zones against one another: major differences in the four key areas (resistance, power consumption, heating and cooling rates) will point you towards a solution. Once the tool is qualified, save a thermodynamic analysis as your known 'good parts' baseline. Future problems will be easy to diagnose using the historical mold performance tool.
Historical Mold Performance: allows the user to easily compare a known 'good' thermodynamic analysis baseline to the current 'suspect' thermodynamic analysis. Intuitively troubleshoot your mold with hard data.
Gammavision® chart recorder and statistical analysis software allows the user to record the control performance, print reports to the USB drive or watch databases of production runs on-screen with our playback mode. Pause live action on the line graph and manually or automatically place injection marks on the screen for in-depth analysis.
Actual Leak Detected With Alarm
This photo shows an actual leak that was detected early by the Gammaflux watt/leak alarm. As can be clearly seen, the material started leaking out the backside of the nozzle but did not make it to the wires. Once the wires are coated in plastic the mold must be shut down and removed from the machine and the heater, thermocouple or both will need to be replaced. Detecting leaks early not only saves money but also speeds the mold back into service.
Too Late - Example
Gammaflux temperature controllers can be calibrated in the field quickly, easily and without a technician. Calibration error can be calculated by establishing a thermocouple source equivalent to the controller; the difference between the calibrator value and the control screen is the calibration error. Gammaflux Calibration software corrects the error with an accuracy of +/- 0.2° F (+/-0.1° C).
I didn't believe that a controller change would make much difference... the change was amazing.