The motion CONTROL SD is EWIKON's touchscreen-operated controller for electrically driven needle shut-off systems in hot runner injection molding. It manages the precise linear movement of valve gate pins — controlling both the timing and the physical position of each pin throughout the injection cycle — and supports single-drive and synchronous-plate actuator configurations across mold-mounted linear servo motors.

How does sequential gating with multiple valve pin positions work?

The SD controller supports up to six programmable valve pin positions per injection cycle, enabling sequential gating patterns that go beyond simple open/close timing. Each pin can be partially opened to a defined intermediate position — controlling melt flow rate into specific cavity regions — before reaching full open. This is particularly valuable for large-surface-area parts and multi-gated components where uncontrolled flow fronts would create weld lines, gas traps, or uneven filling. The position of every pin is monitored with continuous high-precision feedback, so deviations from the commanded position trigger an immediate alert.

What connectivity options does the SD controller provide?

OPC UA is integrated as a standard communication interface, allowing the SD controller to connect directly to MES, SCADA, or plant-wide monitoring systems without protocol converters or middleware. For daily operation, the touchscreen interface provides local control, while the built-in VNC server allows operators and process engineers to access the full controller interface remotely from a tablet — adjusting setpoints, reviewing alarm logs, or monitoring pin positions from anywhere on the production floor without walking to the control cabinet.

How are single-drive and synchronous-plate systems configured differently?

The SD controller supports two distinct actuator architectures. In single-drive mode, each linear servo drive operates independently with its own hybrid motor cable and signal cable — used when individual valve pins need independent timing and positioning. In synchronous-plate mode, multiple linear actuators are mounted on a common actuator plate and share motion — suitable for multi-drop gating where all pins on the plate open and close simultaneously. The controller automatically adapts its output configuration and monitoring logic to the selected architecture.

Frequently Asked Questions

Can the SD controller be integrated with existing injection molding machine controls?

Yes. The SD controller accepts digital and analog input signals for basic cycle synchronization (start-of-cycle trigger, injection-forward, screw-recovery) from the injection molding machine control. For deeper integration, OPC UA enables bidirectional data exchange with machine controllers that support the protocol, allowing the injection molder to read valve pin status and the SD controller to respond to machine-state transitions beyond simple contact closures.

What happens if a valve pin deviates from its commanded position?

The SD controller continuously monitors the actual position of each valve pin via the servo drive's feedback loop. If a pin fails to reach its commanded position — due to a jammed pin, excessive melt pressure, or drive fault — the controller triggers an alarm that can be routed to the injection molding machine's reject circuit or to a plant-wide monitoring system via OPC UA. The specific alarm response (warning only, automatic reject, or machine stop) is user-configurable per zone.