Situation
The plant moulds headlamp housings and reflectors on an 8-zone hot runner mould that ran on an imported controller. When one zone’s power stage failed, the whole unit went abroad for service; with no spare, the mould waited 2–3 weeks. Two faults a year meant roughly two weeks of lost production.
Solution
The mould was commissioned on an EHRTC-RM2, 8 zones:
- Each zone’s power stage sits on its own module, so the faulty module is removed and shipped while the other 7 zones keep running.
- Auto-Tune was run per zone at commissioning; manifold zones were split to respect the 3200 W limit.
- The deviation alarm was set to ±8 °C and the alarm relay wired to the moulding machine’s “temperature ready” input.
- Stand-By at 120 °C for weekend stops; Monday heat-ups use Soft-Start.
Result
No unplanned stops in six months of follow-up. In month three an SSR on one module was replaced; the module came back within 3 business days and the swap took 10 minutes between shifts. Zone temperatures stayed within ±1 °C and flash-related scrap disappeared from the quality log.
Note: This page represents a scenario typically observed with EHRTC-RM2 users; company name and measured values will be updated with customer approval.
