INOVA Controller Architecture and Interface Overview
The HWAMDA SPV5 INOVA controller uses an ARM-based industrial computer running a real-time operating system with cycle time resolution of 1 millisecond. The 15.6-inch resistive touchscreen provides 6 primary navigation tabs: Injection (speed, pressure, and position profiles), Clamp (tonnage, speed, and position for mold open/close), Ejection (stroke, speed, and force profiles), Temperature (barrel zones, hot runner zones, mold temperature), Production (shot counter, cycle time, alarms), and Quality (weight monitoring, SPC charts, tolerance bands). Each injection cycle generates approximately 2,000 data points sampled at 1ms intervals, stored in a 50,000-shot circular buffer. Data export via USB or Ethernet allows offline analysis in CSV format. The controller supports up to 32 temperature zones (6 barrel zones plus 26 hot runner zones), adequate for the most complex multi-drop valve gate systems. Communication protocols include Euromap 67 for robot interface (SWITEK, Campetella, Yushin), Euromap 77 (OPC-UA) for MES integration, and Modbus TCP for auxiliary equipment control. Network connection via RJ45 Ethernet enables remote access for HWAMDA technical support when troubleshooting requires factory assistance.
Key Specs
- •The controller supports up to 32 temperature zones (6 barrel zones plus 26 hot runner zones), adequate for the most complex multi-drop valve gate systems.
High-speed injection unit with linear guides
Initial Machine Setup and Mold Installation Parameters
Systematic mold installation on the HWAMDA SPV5 follows a sequence that prevents mold damage and establishes safe operating parameters. Step 1: Enter mold dimensions in the INOVA controller -- mold thickness (minimum/maximum for the machine: 250-650mm on HMD 380M8-SPV), mold height, and mold weight for appropriate clamp speed calculation. Step 2: Set clamp force to the minimum required: calculate from projected part area (cm2) multiplied by maximum cavity pressure (MPa), with 15-20 percent safety factor. For an 8-cavity yogurt cup mold with 45 cm2 projected area per cavity, at 120 MPa cavity pressure: 45 x 8 x 120 x 1.2 = 51,840 kN = approximately 520 tons, appropriate for the HMD 600M8-SPV (6000 kN). Step 3: Program mold open/close positions: slow approach zone starts 10-15mm before mold touch, transition speed drops from 800-1200 mm/s to 50-100 mm/s to protect the mold. Mold protection zone activates in the final 5-10mm with force limited to 5-10 kN -- if resistance exceeds this threshold, the INOVA controller halts closing immediately to prevent damage from obstructions.
Injection Parameter Programming: Speed and Pressure Profiles
The INOVA controller's 10-stage injection profile provides granular control over the fill and pack phases. Programming sequence for an 8-cavity yogurt cup on the HMD 380M8-SPV: first determine the total shot volume (48g PP parts + 12g runner = 60g total, approximately 67 cm3 at PP melt density of 0.9 g/cm3). Set the shot size (dosing position) to deliver 67 cm3 plus a 10mm cushion, corresponding to approximately 35mm screw stroke on the 55mm screw. Program the speed profile: Position 35mm to 30mm (gate fill): 200 mm/s. Position 30mm to 12mm (wall fill): 368 mm/s. Position 12mm to 8mm (flow front deceleration): 250 mm/s. Transfer to pack at 8mm position (leaving 8mm cushion). Pack phase: Stage 1 at 85 MPa for 0.3s, Stage 2 at 70 MPa for 0.5s, Stage 3 at 55 MPa for 0.2s. Decompression: 5mm at 50 mm/s to prevent nozzle drool. The INOVA controller displays the injection pressure curve in real-time overlaid on the speed setpoint, enabling immediate verification that the machine is following the programmed profile. If pressure reaches the limit before speed is achieved, the pressure limit setting must be increased or the speed target reduced.
Key Specs
- •Set the shot size (dosing position) to deliver 67 cm3 plus a 10mm cushion, corresponding to approximately 35mm screw stroke on the 55mm screw.
- •Program the speed profile: Position 35mm to 30mm (gate fill): 200 mm/s.
- •Position 30mm to 12mm (wall fill): 368 mm/s.
Servo-hydraulic drive system with energy recovery
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Temperature Control Configuration
Temperature setup on the INOVA controller covers barrel zones, nozzle, and hot runner integration. Barrel temperature configuration for PP thin-wall: Zone 1 (feed) 190-200 degrees C, Zone 2 200-215 degrees C, Zone 3 215-230 degrees C, Zone 4 230-245 degrees C, Zone 5 (front) 235-250 degrees C, Nozzle 240-255 degrees C. The INOVA PID controller auto-tunes each zone during initial startup -- press the auto-tune button for each zone and allow 10-15 minutes for the algorithm to determine optimal P, I, and D values. Typical PID values for a 2.5 kW barrel heater band: P = 5-8, I = 30-60s, D = 5-10s. Temperature alarm bands should be set at plus or minus 5 degrees C (warning) and plus or minus 10 degrees C (fault/stop). Hot runner temperature integration: the INOVA controller communicates with YUDO/Synventive hot runner controllers via Euromap 82 protocol, displaying all hot runner zone temperatures on the machine screen for unified monitoring. For setups without Euromap 82, analog signal input (4-20mA or 0-10V) from the hot runner controller provides basic temperature monitoring on up to 16 zones.
Quality Monitoring and SPC Integration
The INOVA controller's quality module transforms raw cycle data into actionable process monitoring. Configure the quality monitoring system by selecting 3-5 key process indicators (KPIs): peak injection pressure (target: consistent within plus or minus 3 percent), fill time (target: plus or minus 0.02s), cushion position (target: plus or minus 0.5mm), plasticizing time (target: plus or minus 0.1s), and cycle time (target: plus or minus 0.05s). Set upper and lower specification limits based on the qualified process range, and control limits at plus or minus 3 sigma calculated from a 50-shot capability study. The SPC module displays X-bar and R charts updated in real-time. When a parameter drifts outside control limits, the controller issues a visual and audible alarm. Optional automated quality sorting: the INOVA controller sends a digital signal to the SWITEK robot to divert suspect shots to a reject bin based on any KPI exceeding its tolerance band. This reject-on-parameter capability catches defective parts before they reach the packaging line, with false rejection rates below 2 percent when tolerances are properly set. Export SPC data to PDF reports for customer quality documentation.
Key Specs
- •Configure the quality monitoring system by selecting 3-5 key process indicators (KPIs): peak injection pressure (target: consistent within plus or minus 3 percent), fill time (target: plus or minus 0.02s), cushion position (target: plus or minus 0.5mm), plasticizing time (target: plus or minus 0.1s), and cycle time (target: plus or minus 0.05s).
Toggle clamping unit — high rigidity for thin-wall molding
Recipe Management and Production Changeover
The INOVA controller stores up to 500 mold-specific recipes, each containing the complete set of machine parameters required to reproduce a qualified process. Recipe data includes: all injection speed/pressure/position stages, all temperature setpoints, clamp force and positions, ejection parameters, robot interface timing, cooling timer, and quality monitoring limits. Changeover procedure for switching from an 8-cavity yogurt cup mold to a 4-cavity food container mold on the HMD 380M8-SPV: load the stored recipe (10 seconds), adjust physical mold mounting (20-40 minutes with quick-change clamping), heat the barrel to new setpoints (5-15 minutes if temperature change exceeds 10 degrees C), run 20-30 warmup shots to purge the previous material/color and stabilize the process. Total changeover time: 30-60 minutes versus 90-120 minutes without stored recipes. Password-protected recipe access prevents unauthorized parameter changes: operator level allows monitoring and minor adjustments (plus or minus 5 percent from setpoint), supervisor level allows full parameter editing, and service level allows machine configuration changes. Recipe backup to USB drive should be performed weekly and after any qualified process change.
Frequently Asked Questions
The HWAMDA SPV5 INOVA controller supports 10-stage injection speed profiling, programmed by screw position. Each stage defines a speed (0-422 mm/s) and the position at which it activates. For thin-wall yogurt cups, typically 4-5 stages are used: slow gate fill, maximum wall fill speed, deceleration zone, and transfer to pack. The controller displays real-time speed versus position overlaid with the pressure curve at 1ms sampling resolution.
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