Page 19 - MetalForming April 2009

how technology improvements have expanded control capability. “When fully populated with 16 input units, the system can monitor 80 digital die-pro- tection inputs, and the control package can supply PLC-switch outputs from eight to 96 in groups of eight.”
With the increase in controls capac- ity comes an equally impressive increase in capability. Mascari recounts a few that Link has implemented.
“The automatic-setups module can automatically adjust shut height, coun- terbalance and as many as seven cush- ions,” he says. “The analog die-protec- tion module can perform in-die measurements and drive servo motors to make in die adjustments.”
In a nutshell, control manufacturers have in recent years developed smarts into their packages. One such illustra- tion comes from Link. Should condi- tions indicate presence of a bad or miss- ing part in one station of a transfer or progressive die, the bad or missing part can be tracked as it progresses through the die. This allows for methods to adapt to a missing part—for example, ignoring sensors in missing-part loca- tions—or ejection of a bad part at a later station in the die.
Work on Any-Sized Press, New or Used
Controls-technology improvements, besides improving flexibility and expandability in press lines, have enabled simplified implementation on presses and lines of varying sizes. The ability to provide a flexible controls solution across new or used, and small, medium and large presses was the driv- er for Toledo Integrated Systems, Hol- land, OH, in introducing its Press Pilot 150 press clutch-brake control.
“End users as well as OEMs and rebuilders have numerous applications and requirements for new machines as well as the need to retrofit outdated controls and provide communication with a variety of design platforms,” explains Dan Falcone, sales and mar- keting manager for Toledo Integrated Systems. “So we developed the Press Pilot 150 to be configured for use with
The ability to provide a flexible con- trols solution across new or used; and small, medium and large presses has driven controls development.
a resolver, encoder or cams. Further, it can be used as a stand-alone system or integrated with a PLC and other devices via Ethernet or discrete I/O for seamless integration.”
Another new feature, an adjustable clutch-engagement time, accounts for the fact that “some presses kick in slow while others engage very quickly,” says Falcone, “so it is important to have this flexibility.”
Simple applications for this control includes replacing outdated clutch brake controls in single-stroke hand-fed press- es, while more demanding applications include interfacing with input (die pro- tection) and output (programmable limit switch) devices as well as contin- uous on-demand or auto-single-stroke modes of operation. Custom or hybrid applications would include interfacing the press control with a PLC system, ideal for transfer presses, press lines, tandem lines and blanking operations that feature demanding tooling and automation.
Do More with Data
Of course, with press controls, acquiring the data is only half the bat- tle. What can you do with it? That is where Wintriss Controls Group of Hon- eywell, Acton, MA, has been focusing. Here’s a glimpse into the reporting capabilities now available for press con- trols, which speaks to the advancements made in data projection.
Wintriss developed reporting to take advantage of its SmartPAC 2 press con- trollers, which provide timing signals to the presses and ancillary equipment as well as monitor tonnage and die-pro-
tection and in-die-measurement sen- sors. Each controller has a built-in Eth- ernet port for simple networking.
The company has developed and expanded LETS (Line Efficiency Track Software), which collects production information directly from the Smart- PACs and sends it over the existing inhouse Ethernet to the LETS database. The information then is available in report form, or can be accessed using Factory Viewer, a built-in browser-based real-time interface. LETS also can col- lect from non-Wintriss-equipped equipment.
A LETS datalogger collects data from each control and places it into the data- base, courtesy of FactoryTalk Transac- tion Manager, an industry-standard data logger/transaction manager from Rockwell Automation, Milwaukee, WI, that can communicate from various standard and proprietary controls. The database stores production informa- tion and feeds the LETS Analyzer, the Report Server, and the Factory Viewer.
The analyzer allows report configu- ration by date range, shift, machine, tool/part and/or operator. For example, users can specify a report showing pro- duction data for four presses producing 10 specific parts, and being run by five selected operators on third shift. Once configured, settings can be saved as a new report. Since it runs on a server, several users can configure reports simultaneously. Reports can be sent to a printer, sent via e-mail to any recipi- ents that you chose, or posted on a net- work that can be viewed in a web brows- er by anyone with appropriate access.
The LETS Factory Viewer allows users to glance the status of the entire factory via web browsers. An overview screen shows the status of each machine as well as the parts count, current tool, and estimated time until job comple- tion. Clicking on the machine name accesses detailed job and downtime information. The viewer also lists tools and their status. MF
Don’t forget, new control products are on display in MetalForming’s Pressroom Tech- nology Show on the Web. Just click the show logo at www.metalformingmagazine.com.
www.metalformingmagazine.com
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