Pr oc ess Contr ols

Process Controls

ACHIEVING OPTIMAL MOLDING

RESULTS WITH INJECTION PROCESS
CONTROLLERS, BUTTON SENSORS
AND SLIDE SENSORS

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Table of Contents

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Process Controls

62

Portable Cavity and Hydraulic Pressure Monitor and Controller

COMPACT AND SELF CONTAINED
PROVIDES DIGITAL DISPLAY READOUT OF HYDRAULIC AND
CAVITY PRESSURES
PROVIDES AMPLIFIED OUTPUT OF PRESSURE SIGNAL
1 AMP RELAY OUTPUT FOR CONTROL OF BOOSTER PUMP CUTOUT

Process Controls

Portable Cavity and Hydraulic Pressure Monitor and Controller

PROVIDES EASY CALIBRATION OF D-M-E CONSTANT

CALIBRATION SENSORS
The IPC-01-01 Injection Process Controller is a portable device
that provides an inexpensive means of controlling peak plastics
pressure in the mold. Peak pressure control is accomplished
using a mold pressure sensor and a single setpoint to control
lling and packing of the mold. By closely monitoring and
controlling cavity pressure the user will reduce cycle time,
reject rates and plastics usage. The controller operates the
booster pump for the absolute minimum time required to ll
and pack the cavities, signicantly reducing electrical power
consumption.
The IPC-01-01 controller uses a technique known as Dynamic
Pressure Control (DPC). DPC maintains a more constant peak
cavity pressure than machine timers and limit switches,
regardless of plastic viscosity changes. This is accomplished
by switching from High Volume (Fill) to Low Volume (Hold)
injection at a predetermined cavity pressure.
Because of a direct correlation between peak cavity pressure
and part weight (and therefore part size), accurate control of
peak cavity pressure means more consistent part production.
Because part weight range can be reduced by using DPC, the
average part weight can be reduced without occurrences of
short shots. This translates into potential reduction in material
usage. Increased repeatability in part weight also means less
scrap as a result of short shots, over packed and ashed parts.
Reducing these occurrences can also reduce associated wear
and damage to tooling.
The IPC offers the three most requested features in a pressure
monitor/controller:
1. Display of the pressure reading, including the peak pressure
that occurred.
2. Amplication of the pressure signal for use by other equipment.
3. A relay contact set for direct control of the molding
machines booster pump cutoff function.
The IPC uses an injection signal or other switch closure to arm
the holding of the peek pressure that occurred during the shot.
The peak pressure reading is held until the end of the injection
sequence.
A connector on the rear of the IPC provides the amplied
pressure signal. A zero to 1, 2, 5, or 10 VDC (or 4 to 20 mA DC)
signal directly corresponds to a zero to 20.000 PSI pressure.
This signal can be routed to strip chart recorders, plant wide
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monitors or other equipment. The signal can also be input into

molding machines offering closed loop pressure control but
that lack the necessary ampliers for the sensing equipment.
The IPC offers a one amp, form C (normally open, normally
closed) relay contact set for direct control of the machines
booster cutout function. The relay contacts are also gold plated
for switching of low level signals such as the potentiometers
used to set the machines injection velocity. Many control
relays are not capable of switching such sensitive signals.
The relay contacts carry a voltage rating of up to 120 VAC.
The IPC is designed for use with D-M-Es Constant Calibration
sensors but can be used with other manufacturers strain gage
based sensors as well.
FRONT PANEL CONTROLS AND INDICATORS
The IPC offers quick easy calibration of pressure sensors
via front panel adjustments. Calibration is quickly
performed by pressing a push button and then adjusting
the calibration setting.
A rotary switch allows for rapid selection of the pressure
sensor and ejector pin size. A second rotary switch allows
for selecting what is displayed: The pressure signal with
peak hold, the pressure signal without peak hold or the
DPC pressure setpoint.
A DPC light illuminates when the mold (or hydraulic)
pressure reaches setpoint. This is an indication that the
IPCs control relay has activated.
A toggle switch allows the user to override the control
function while allowing for continued monitoring of pressures.
A high accuracy ten-turn potentiometer allows for input of
the pressure setpoint for booster cutout.
A three and one-half digit display allows for direct readout
of pressures up to 19,990 PSI. This is displayed as pressure
(times 10) for mold pressure.
A UL, CSA, VDE approved power switch allows the user to
turn the IPC on and off from the front panel. Internal fuses
(not shown) protect the unit from both sides of the AC line
voltage. While the standard unit (IPC-01-01) is constructed
for 120 VAC use, an optional IPC-01-02 is available. The unit
is easily converted between 120 and 240 VAC operation.
The 120 VAC unit comes with a standard wall outlet plug.

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Process Controls

63

Portable Cavity and Hydraulic Pressure Monitor and Controller

REAR PANEL (LEFT TO RIGHT)

ORDERING INFORMATION

Accuracy:

Analog output and digital display: / 1%

full scale
Setpoint: 0.8% of full scale

Repeatability:

Analog output and digital display: / 0.5%

full scale
Setpoint: 0-25% of full scale

Recorder Output:

Proportional to cavity pressure.

Zero to 1, 2, 5 or 10 VDC (or 4 to 20 mA DC)
corresponds to zero to 20,000 PSI

Control Span Range:

Zero to 20,000 PSI

Temperature Range:

50 to 130F

Power Required:

115 VAC (105-125), 50-60Hz

Zero Drift, Analog Out:

Long Term: 0.1%/month, with temperature

0.1%/F

Control Relay:

1 amp, form C, 0-120 VAC, VDC

Injection Forward In:

normally open contact closure, less than

10 milliamps

Dimensions:

7.2 wide, 2.7 high, 8.6 deep

CONTROLLER
Includes 19 foot integral power cable, mating control and analog output
connectors and two spare fuses. Pressure sensors and extension cables
must be ordered separately.
Catalog Numbers: IPC-01-01 (120 VAC standard)
IPC-01-02 (240 VAC optional)
Fuse Requirement: (2) ABC-1 fuses
SLIDE MOLD PRESSURE SENSORS
Catalog Numbers: SS-405C
SS-406C

(500 pound)*
(2000 pound)*

BUTTON MOLD PRESSURE SENSORS

Catalog Numbers: BS-411C
BS-412C
BS-413C
Requires Extension: BSC-10

(125 pound)
(500 pound)*
(2000 pound)*
(10 foot cable)

EXTENSION CABLES
Catalog Numbers: SSC-10
BSC-10
SI-900

works with all sensors, 10

one reqd for button sensor
JIG box with 15 cable, works
with all sensors.

*NOTE: 500 pound sensors are recommended for use with ejector pins
from 1/16 to 3/16 inch diameters. 2000 pound sensors are recommended
for use with ejector pins from 3/16 to 1/2 inch diameters. The 125 pound
Sensor is recommended for 1/16 inch or less diameter pins.

DESIGNED, MANUFACTURED AND TESTED IN THE U.S.A.

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Canada 800-387-6600

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Portable Cavity and Hydraulic Pressure Monitor and Controller

IPC-01-01 SPECIFICATIONS:

Analog Output: is a standard 1/4 inch stereo headphone jack that

outputs an amplified pressure signal of zero to 1, 2, 5 or 10 VDC (or 4 to
20 mA DC) corresponding to zero to 20,000 PSI.
D-M-E Sensor: accepts a D-M-E slide, or button sensor or related
extension cable. Also accepts other sensors via a conversion cable.
Machine Interface: provides the injection forward and booster cutout
wiring connections to the molding machine.
Power Input: provides 120 VAC (standard) or 240 VAC (optional)
power for operation.

Process Controls

OPERATION
The user plugs the IPC into a standard wall outlet. If machine control or automatic hold of the peak pressure signal is desired,
a normally open relay contact is attached via the rear panel connector. If control of the machine is desired, the IPCs control
relay is wired back to the machine via the same connector. A D-M-E pressure sensor is then attached via the rear panel and
the unit is set to the appropriate pin size calibration. The pressure offset value is adjusted to zero with the front panel ZERO
adjustment. The CAL push-button is pressed in and the CAL adjustment is then set for 8900 PSI. The user then sets IPC to
the actual pin size being used and the IPC is ready to run. With the IPC set to MONITOR, the user notes and records the peak
pressure obtained during acceptable part production. The SETPOINT is adjusted to 50 to 80% of the recorded peak. The user
then places the IPC into the CONTROL mode and adjusts the SETPOINT until the desired peak pressure is achieved. It will be
necessary to add time or distance to the machines booster setting for the IPC to take control. The amplied signal output can
be connected to process recording equipment or a molding machines pressure signal input.

Process Controls

64

Button Mold Pressure Sensors

Permanently Installed
Minimizes damage due to mishandling of sensors.
Temperature Compensated
Special ampliers that compensate for temperature changes
are avoided.
Constant Output
Because each sensor is electrically identical, each sensor
has the same output. This similarity practically eliminates
the need to recalibrate the readout system when sensors are
exchanged. Only a slight readjustment of the zero setting of
the readout system may be required when exchanging sensors.
D-M-E Button Mold Pressure Sensors are used for
measuring pressures in conjunction with auxiliary recording and Therefore errors in calibration are non-existent and operators
control equipment in injection, die cast and transfer molds. They will spend less time setting up control systems and recorders.
provide a full-scale output of 2 millivolts per volt of excitation.
Small Size
Suitable for small molds or molds where water lines,
Three Models
support pillars, etc., inhibit the use of slide sensors.
Available in 125, 500 and 2000 pounds force.
Installation
Hermetically Sealed
The Button Sensor is usually installed under an ejector
Allows sensor to be used where moisture is present.
pin and the shielded lead wire is run to the outside of
the mold for mounting. To accommodate the button
NIST TRACEABLE
sensor, a slot and counterbored hole is machined into the
SUPPLIED WITH CERTIFICATE OF CALIBRATION
ejector plate. See installation information for details.
.500
DIA.
.495

1.35
MAX

.105 DIA.

Female
D-M-ECOMPANY

.938
SQ

Button Mold Pressure Sensors

Both Models Available in 12, 24 and 36 inch lengths

Process Controls

.585 DIA. MAX

A

.719
SQ

BUTTON SENSOR BS-412 & BS-413-C

.375
.372

.120
DIA. HOLE
(#4)

.128 .004

Male

10 FEET
BUTTON SENSOR CABLE BSC-10

CABLE IS REQUIRED TO
INTERFACE WITH IPC-01-01

BUTTON SENSOR
EXTENSION CABLE*

BUTTON MOLD PRESSURE SENSORS

Supplied with soldered on ush mount connector Amphenol PT02A10-6S
(Mating connector Amphenol PT06A10-6P(SR) not supplied).
FORCE
POUNDS
125

MEASURES PRESSURE
ON PINS FROM:

ITEM NUMBER

A LENGTH

BSC-10

6 LEADS

12 LEADS

18 LEADS 24 LEADS

32 Thru 332 (1 Thru 3mm) dia.

BS411C6

BS411C12

BS411C18

BS411C24

16 Thru 316 (2 Thru 6mm) dia.

BS412C12

BS412C24

BS412C36

16 Thru 2 (6 Thru 16mm) dia.

BS413C12

BS413C24

BS413C36

500

2000

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36 LEADS

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LENGTH
10 FEET

*Mates with connector on

button sensors above. Amphenol
PT06A10-6P(SR) on each end.
Use where required for monitoring
and control equipment

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Button Mold Pressure Sensors

INSTALLATION INFORMATION
FLUSH MOUNTED CONNECTOR
E

REF.

CBORE 1/16 GREATER THAN EJECTOR

PIN HEAD DIA. FOR CLEARANCE

INSTALL BUTTON SENSOR

AND CONNECTOR IN MOLD AS
SHOWN FOR FLUSH MOUNTING.
SLOT CAN BE WIDENED
TO ACCOMODATE EXCESS
LEAD WIRE. HOLD DOWN WITH
COVER PLATE TO SUIT.

1 MIN.

LOCATE EJECTOR PIN FOR BUTTON

SENSOR UNDER MOLDED PATH OR RUNNER

FOR MULTIPLE
MOUNTING

1 MIN.

1/4 CENTRAL
3/8 CENTRAL

SECTION A-A

.812 010
000
8

.359

.510 DIA.
1/2

EJECTOR RETAINER PLATE

.050 MINIMUM
DEPTH CBORE

DRILL AND TAP FOR

#4 SCREW 4 PLACES .25 DEEP
LOCATE CENTRAL
.578 005
000
WITH .578 DIM.

EJECTOR PIN OR
DUMMY PIN
.010 MIN.
CLEARANCE

.719
.359

EJECTOR
PLATE

.719

1 MIN. TYP. TO EDGE

OF CUT-OUT
1 MIN. FOR
CLEARANCE WHEN
INSTALLING CONNECTOR

MIN. SLOT FOR LEAD WIRE.

BREAK ALL SHARP CORNERS

.375  .005
.000

EJECTOR PLATE

1 MIN
LOCATE SENSOR SLOTS
TO AVOID INTERFERENCE
WITH OTHER PINS OR
MOLD COMPONENTS.

SECTION E-E

EJECTOR RETAINER
PLATE

NOTE: When dummy pin installation

is made. Altering mounting
dimensions and location as required

OUTSIDE BOX MOUNTED

INSTALL BUTTON UNDER

PIN AS SHOWN
DRILL AND TAP
MOLD FOR #10
SCREW - 4 PLACES

DRILL 7/8 DIAMETER

HOLE IN BOX AND MOUNT
GROMMET. LOCATE
HOLE TO SUIT.

MOUNT BOX TO MOLD

AS SHOWN

Process Controls

NOTE: When ejector plate is thicker than 1 connector

may be centered on plate thickness. Altering mounting
dimensions as required slot for lead wire should be
depended as it approaches connector end as required.

BUTTON SEAT MUST BE PARALLEL

WITH TOP OF EJECTOR PLATE WITHIN .003

NOTE: When installing button sensor

in mold pass button through hole
in cover and Hole in box before
incorporating into mold under pin
excess wire may be left in box.

BUTTON SENSOR
INSTALLED UNDER PIN.

EJECTOR PIN
MOUNTED IN MOLD
UNDER MOLDED
PART OR RUNNER
DRILL 5/8 DIAMETER
CLEARANCE HOLE IN
COVER FOR MOUNTING
CONNECTOR

SPECIFICATIONS

WIRING INFORMATION
350

(red)

(white)

B
D
E

(black)
(green)
(shield)

350
350
350

POWER
POWER
SIGNAL
SIGNAL
GROUND

A
B
C
D
E

(red)
(black)
(white)
(green)
(shield)

WARNING:
DO NOT REMOVE CONNECTOR FROM SENSOR
CABLE. CALIBRATION
WILL BE ALTERED.

NOTE: MATING CONNECTOR IS AMPHENOL PT06A10-6P(SR).

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PRESSURE MEASUREMENT RANGE.......................................... 0 to 20,000 psi

(FOR RECOMMENDED PIN DIAMETERS)
FORCE RANGE
Ib.
kg.
ITEM NO. BS-411C .....................................................................125
60
ITEM NO. BS-412C .....................................................................500
225
ITEM NO. BS-413C ...................................................................2000
900
MAXIMUM LOAD.................................................................. 150% FULL SCALE
TEMPERATURE RANGE.................................................................. 0F T0 450F
TEMPERATURE COMPENSATION ............................................. 2% FULL SCALE
INPUT ..................................................................................................12V MAX.
OUTPUT ............................................................................2.0 mV/V FULL SCALE
ACCURACY............................................................................... % FULL SCALE
REPEATABILITY....................................................... 0.1% FULL RANGE OUTPUT
FULL RANGE DEFLECTION ................................................... LESS THAN .0008
CIRCUIT ......................................................................4-ARM 350 OHM BRIDGE
CONNECTOR ...............................................................AMPHENOL PT02A10-6S
MATES WITH AMPHENOL PT06A10-6P (SR)

Canada 800-387-6600

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www.dme.net

Button Mold Pressure Sensors

DRILL AND TAP

MOLD FOR #4
SCREW - 4 PLACES

Process Controls

66

Slide Mold Pressure Sensors

D-M-E Slide Mold Pressure Sensors are used for

measuring pressures in conjunction with auxiliary recording
and control equipment in injection and transfer molds. They
provide a constant, full-scale output of 2 millivolts per volt.
Because each sensor is electrically identical, the need for
recalibration of control systems or recorders when a sensor
is replaced is virtually eliminated. This means that errors in
calibration are non-existent and operating personnel will now
have an easier time setting up and operating control systems
and recorders.
Constant Output
All sensors have the same output. This eliminates the need to
recalibrate the readout system when sensors are exchanged.

Process Controls

Two Models
Covers ejector pin sizes from 1/16 to 1/2 diameter,
eliminating the need for stocking several different load ranges.
Installation
The sensing element is housed in a rectangular slide that
plugs into a 3/8 deep by 1/2 wide slot, machined from the
edge of the ejector plate to an ejector pin (slot machined in
support plate when using a dummy pin). When fully inserted,
the sensing element of the slide is under the head of the pin.
See installation information for details.

Temperature Compensated
Special ampliers are eliminated to compensate for
temperature changes.

NIST TRACEABLE
SUPPLIED WITH CERTIFICATE OF CALIBRATION

.492 REF.

SPRING LOADED
BALL DETENTS (2)

Slide Mold Pressure Sensors

Hermetically Sealed
Allows the sensor to be used at low temperatures where
moisture is a problem.

Easily Removed
Allows user to take sensor from one mold and place in another.

.375 .000
.003

SIDE VIEW

REF.

.358 REF.
SLIDE EXTENSION

MALE CONN.

.375 .005
.005 .000
.005

D-M-E
COMPANY

10 FT

SLIDE SEMSOR SS-405-C & SS-406-C

10

FEMALE CONN.

MALE CONN.
D-M-E
COMPANY

10 FT
SLIDE SENSOR CABLE SSC-10

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Canada 800-387-6600

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Process Controls

67

Slide Mold Pressure Sensors

SLIDE MOLD PRESSURE SENSORS

INSTALLATION INFORMATION

MEASURES PRESSURES
ON PINS FROM:

ITEM NUMBER
CBORE 1/16 GREATER THAN EJECTOR
PIN HEAD DIA. CLEARANCE
510

SS-405C

16 THRU 316 (2 THRU 6mm) Dia.

SS-406C

16 THRU 12 (6 THRU 16mm) Dia.

 .005
.000

SIDE EXTENSION

250 R

SECTION A-A

ITEM NUMBER

LENGTH

SSE-418

712

SENSOR BLANK
EJECTOR
RETAINER PLATE

EJECTOR PIN OR
DUMMY PIN

.002
.377  000

ITEM NUMBER

LENGTH

SSB-419

12

.010 CLEARANCE

.375

EJECTOR PLATE

1/16 X 45 CHAM ON HEAD

OF PIN (1/32 CHAM WHEN
HEAD DIA. UNDER 3/8)

SLIDE SENSOR EXTENSION CABLE**

ITEM NUMBER

LENGTH

SSC-10

10 ft.

**Mates with connector on slide sensors above. Has Amphenol

connector No. PT01A10-6S(SR) on one end and Amphenol connector
No. PT06A10-6P(SR) on the other end. Use where required for
monitoring and control equipment.

TAP No 10 24 HOLE TO
PULL OUT BLANK

WIRING INFORMATION
A

(red)

(white)

B
D
E

(black)
(green)
(shield)

350
350
350

POWER
POWER
SIGNAL
SIGNAL
GROUND

A
B
C
D
E

(red)
(black)
(white)
(green)
(shield)

WARNING:
DO NOT REMOVE CONNECTOR FROM SENSOR
CABLE. CALIBRATION
WILL BE ALTERED.

U.S. 800-626-6653

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SPECIFICATIONS
PRESSURE MEASUREMENT RANGE.......................................... 0 to 20,000 psi
(FOR RECOMMENDED PIN DIAMETERS)
FORCE RANGE...................................................................................Ib.
kg.
ITEM NO. SS-405C .....................................................................500
225
ITEM NO. SS-406C ...................................................................2000
900
MAXIMUM LOAD.................................................................. 150% FULL SCALE
TEMPERATURE RANGE.................................................................. 0F T0 450F
TEMPERATURE COMPENSATION .................................. 2% FULL SCALE/100F
INPUT ..................................................................................................12V MAX.
OUTPUT ............................................................................2.0 mV/V FULL SCALE
ACCURACY............................................................................... % FULL SCALE
REPEATABILITY....................................................... 0.1% FULL RANGE OUTPUT
FULL RANGE DEFLECTION ................................................... LESS THAN .0008
CIRCUIT ......................................................................4-ARM 350 OHM BRIDGE
CABLE LENGTH ...................................................................................... 10 FEET
CONNECTOR ........................................................ AMPHENOL PT06A10-6P(SR)
MATES WITH AMPHENOL PT01A10-6S(SR)

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Slide Mold Pressure Sensors

INSTALL SLIDE MOLD PRESSURE SENSOR

BLANK ITEM NO SSB 419 10 SUPPORT PIN
AND PLUG SLOT WHEN SENSOR IS NOT
IN USE CUT TO SIZE AND FASTEN TO SUIT

350

Process Controls

.050 MIN.
DEPTH CBORE

Process Controls

68

Using Process Controls and Monitoring

to Achieve Optimal Molding Results

D-M-E button sensors, slide sensors and injection process controllers

can be used for a number of applications. Assuming one is using newer
injection molding machine technology with 3-stage control, managing the
peak cavity pressure during pack (2nd stage) will guarantee consistent
part quality. Peak cavity pressure determines how much plastic is injected
into the part. Having consistent peak pressure during injection, shot after
shot, guarantees that all parts in production are of the same size. This is
referred to as process control.

Using Process Controls and Monitoring to Achieve Optimal Molding Results

Ensuring part quality

everytime.

Another application is that of process monitoring. By placing an ejector

pin and a sensor at the last location in the part to ll, the sensor can be
used to determine whether a short shot occurred. By determining the
minimum pressure that denes a lled part, monitoring the process can
determine whether a short shot has occurred. Many molders have used
this method to scrap a suspected bad part because they would rather risk
scrapping a good part than supplying a defective part to their customer.
This is a fairly common practice for molders supplying certain industries,
including automotive.
Many customers use D-M-E sensors in conjunction with plant-wide
monitoring systems to automatically control conveyors. If a specic range
of cavity pressure is not realized during ejection, the part is automatically
scrapped. Again, this practice of scrapping a potentially good part rather
than supplying a bad part to a customer ensures that part quality remains
consistently good.

Process Controls

The D-M-E Injection Process Controller (IPC) can operate in a couple

different ways. It can act as an amplier to supply zero to one, zero to
ve, or zero to 10 volts DC. It can also output a four to 20 milliamp signal.
If the molding machine has cavity pressure control but no strain gauge
amplier, the IPC can be used to ll the void. The IPC can also accept
a relay contact closure indicating that injection forward is occurring. It
can then use a pressure setpoint to trigger a relay contact to inform the
molding machine that a specic cavity pressure has occurred. This action
instructs the molding machine to go into a hold (3rd stage) state. Since
there is a slight delay in triggering the machine, a slightly lower setpoint
is used than the peak pressure.
The injection signal into the IPC also triggers a peak hold circuit so that
peak cavity pressure is maintained on the display of the IPC until the end
of injection.
For more information about setting up process control and monitoring
applications, visit www.dme.net.

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