MACO IMPACT Process Control is a revolutionary, new form of injection process control technology. IMPACT adds auto-tuning, adaptive control, and expert process control to the industry standard closed-loop injection process control. IMPACT creates and continually updates a theoretical model of the injection molding process. The model is then used to auto-tune the injection, pack, hold, and recovery stages, shot after shot, to adjust for variations in both the machine and materials. IMPACT Process Control adaptive tuning monitors and compares machine performance against desired part setpoints and modifies key control parameters in order to achieve desired results. IMPACT improves shot-to-shot repeatability, improving part quality and reducing costs.

AUTO-tuned Injection Process Control:IMPACT Advanced Process Control significantly simplifies part setup and makes it possible for the molder, with little or no knowledge of process theory, to effectively set up the machine. With IMPACT, the machine operator no longer needs to spend time adjusting the machine's PID tuning constants in order to achieve desired control. Less setup time means more machine run time. IMPACT provides auto-tuning for the velocity, pack, hold, back pressure, and boost stages of the injection cycle. Patented control algorithms provide auto-tuned PID control for each of these critical stages of the injection molding process. Using IMPACT, machine operators need not have advanced process control expertise in order to make high quality parts.

Adaptive tuning for Automatic Shot-to-Shot Correction: IMPACT analyzes the tuning parameters and machine performance for each shot. The results are then used to adjust the tuning parameters for the next shot. With each successive shot the tuning parameters adapt to the most recent conditions of the machine and materials in order to ensure optimum machine control for each and every shot, which results in improved part quality and reduced scrap costs.

Injection Shot Control Modeling with Automatic Adjustment: IMPACT creates a theoretical model of the control system and uses the model to account for real world deadtime and lags in the injection machine barrel, providing superior control even with the most difficult shots.

Rule-based Expert System for Injection Shot Control: Transition is the most difficult phase of the injection molding process. With most controls, transition is marked either by a pressure spike (due to the transition from velocity to pressure control) or sluggish system response (a system undertuned in order to avoid the pressure spike). With IMPACT, an expert control algorithm monitors this key process area and, based on the desired results and embedded application knowledge about the transition period, adjusts control parameters to ensure repeatable, optimal control without pressure spikes.