A Rockwell, Allen Bradley MicroLogix 1400®
programmable logic controller provides the foundation of the
control. It handles functions such as single stroke, inch,
continuous modes, all hydraulic functions, press lube, optional die
clamping and status messages sent to SmartPAC2. It also monitors
safety circuit outputs from the Smart Guard 600 via hard wired
inputs and over the machine Ethernet network.
The speed and movement
of the press ram is controlled by the MicroLogix 1400 based on job
settings that are SAVED in the SmartPAC2 operator control. Hundreds
of jobs may be set up and saved for quick set up change over!
A Rockwell, Allen Bradley Smart Guard 600®
monitors all of the safety devices on the press. It monitors the
hard wired e-stop, light curtain guards, guard interlocks, die
blocks and safety contactor output for example.
A Rockwell, Allen
Bradley PanelView C600®
color touch screen
is the operator interface for starting the press motor, selecting
the press stroke mode, and operating the die clamping system. Why
pay for old fashioned control buttons when the touch screen can do
it for you? It uses much less panel space too. The press speed that
was selected with the job setup and saved in the SmartPAC2
is also displayed.
Many other functions
can be set up using the PanelView C600 depending on your needs. We
show an example of an optional maintenance screen that can be used
for checking and adjusting hydraulic pressure.
Are The Details:
The Wintriss SmartPac2
works like our
mechanical press system except that it has linear cams instead of
rotary cams. Now you can have the finest Wintriss
Die Protection and automation on your hydraulic presses that
thousands are familiar with on mechanical punch presses.
linear cams understand when the press is on the upstroke or down
stroke. You can easily set cams to turn on during the upstroke and
stay on to a point in the down stroke. All die protection cam
settings work this way as well.
cams AND die protection settings are adjustable while the press is
running. This makes fine tuning a job easy. The settings are saved
with the job. Jobs can be copied and renamed and backed up to a
laptop or networked computer.
SmartPac2 communicates with the MicroLogix 1400 over an RS232 half
duplex connection, allowing press control error and status messages
to be displayed on its color screen.
8 channel linear cam uses 6 channels for the press control. This
leaves 2 spares. The cams needed for the press control are:
DWELL ON BOTTOM
Cams that are not
needed can be re-assigned to, for example, additional speed
change or stock feeder control. Also, eight additional cams can
Cincinnati High Speed Hydraulic 175 ton Press has solenoids
for 3 different speeds for down stroke and 3 speeds for
upstroke. Speeds and change points are selected using SmartPac2
and saved with all the other job settings.
Press Operating Modes
All modes of
operation require the safety circuits to be closed and in a
normal run state. All downward movement of the ram requires
actuation of the two hand control buttons.
In single stroke the press cycles thru the stroke at the
selected speeds. A single stroke cycle must be started
at the top of the press stroke. The run buttons must be
held down through the bottom of the stroke. Once the
press reaches the bottom of the stroke, the run buttons
can be released and the ram will return to the top of
the stroke and stop.
In the inch operating mode the press will cycle at the
speeds that are selected. The press does not need to be
at the top of the stroke to start an inch cycle, and can
be jogged through the entire press cycle.
In continuous the press will cycle thru the stroke at
the selected speeds. Continuous operation must be
started at the top of the press stroke and a prior act
input must be made before starting the press. The run
buttons must be held down through the bottom of the
first continuous stroke. Once the ram reaches the
bottom of the stroke the run buttons can be released,
the press will continue to cycle until a stop input is
The die change operating mode will move the press ram
down at slow speed only. The ram does not need to be at
the top of the press stroke for a die change cycle to be
started. Once the press reaches the bottom of the
stroke the ram stops.
The manual return button is enabled in all four
operating modes. When pressed the ram will move up until
the button is released, or until the ram reaches the
absolute upper limit of the press. Pressing the manual
return button while the press is moving down will cause
the ram to reverse.
is achieved by a keyed selector switch labeled Supervisor. The
supervisor key must be in the on position to select the stroke
mode, start the press motor and unclamp the die. Once the press
is set up for operation the supervisor key can be switched to
off and removed. With the supervisor key off, no changes can be
made to press stroke mode or die clamps, the press motor can be
stopped but the supervisor key must be turned on before the
motor can be restarted. The supervisor key also takes the press
control out of lockout, by cycling the key from the off position
to the on position.
Anti Tie Down / Anti Repeat
Four MicroLogix 1400
inputs, one normally closed and one normally open on each run
button, are used for the anti tie down / anti repeat
circuit. For the MicroLogix to process a valid run input the
following steps must occur in this order:
buttons must be released.
must be stopped at the top of the stroke.
must be in a ready to run state (no E-Stop, light
curtain faults etc.)
buttons must be pressed within two seconds of one
buttons must be held down thru the bottom of the stroke.
buttons must be released before another press cycle can
If one run button
is held down for more than two seconds, then both run buttons
must be released to reset the anti tie down timers. As soon
as the press starts, the anti tie down timers are placed in a
forced expired state, preventing the press from being jogged
with one hand within the two second palm time window. After the
press stroke is completed a no run input must be present before
another press cycle can be started. Additionally, one run
button is wired to sinking inputs of the MicroLogix while the
other run button is wired to sourcing inputs of the MicroLogix,
to prevent an attempt by the end user to defeat two hand
Continuous Prior Act
operation will be installed, the press must have OSHA compliant
light curtains, electrically interlocked hard guards, or a
combination of both. It is the end users responsibility to
insure all hazards are properly guarded.
before the press can be started in continuous a prior act button
must be pressed. The following steps must be followed to
produce a valid prior act signal:
The press must
be stopped at the top of the stroke.
The run buttons
must be released.
The prior act
button must be released.
The prior act
button must be pressed and released.
A valid run
input must be seen within six seconds of a valid prior act
The run buttons
must be held down thru the bottom of the first continuous
After the first
continuous stroke is completed the press will cycle
continuously until a top stop is opened, or until a safety
circuit is opened.
If the prior act
button is held for longer than two seconds, then the valid prior
act signal will be canceled until the prior act is released and
the prior act process is restarted. As soon as the press is
started the prior act timers are placed in a forced expired
state, preventing the press from being started more than one
time per prior act input. An indicator lamp on the prior act
push button stays lit while the prior act timers are enabled.
The Smart Guard 600
safety controller is approved and certified for use in safety
applications per IEC 61508 and ISO 13849-1, providing a Safety
Integrity Level (SIL) 3, and Category (CAT) 4 safety control.
Each safety circuit uses dual test voltage sourcing inputs,
where one input seeks test voltage 0 and the other input seeks
test voltage 1. The test voltages are outputted from the Smart
Guard 600 at 24 VDC, however each test voltage is pulsed at
different frequencies. If the wrong test voltage or pure 24 VDC
is applied to a safety input the Smart Guard goes into a fault
condition. Safety circuits wired to the Smart Guard include,
emergency stop push buttons, hard guard safety interlock
switches, front and rear light curtains, and a die safety block
receptacle. Each safety circuit has two inputs as stated above,
if the state of the dual circuits disagree, then the safety
controller goes into a fault condition. Internal logic in the
Smart Guard 600 controller activates a safety rated output for
each safety circuit input. Each safety output is wired to
inputs of the MicroLogix controller for safety circuit status.
Two safety contactors are also wired to two of the safety
outputs of the Smart Guard 600. All safety circuits must be
closed and in a normal run condition for the safety contactors
to turn on. The state of each safety contactor is monitored and
can never disagree. All of the ram motion solenoids power is
passed thru normally open contacts of the two safety
contactors. The main ram down and main ram up solenoids are
also wired to safety outputs of the Smart Guard 600. If voltage
is present at any of the safety outputs while they are in an off
state the Smart Guard goes into a fault condition. Any time
that the Smart Guard is faulted the press control goes into a
LET'S MAKE YOUR
HYDRAULIC PRESS BETTER THAN EVER!
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Crane Production Systems. All rights reserved.
August 15, 2014