Page 17 - MetalForming November 2017

These photos compare the wiring complexity of the old control cabinet (left) installed on the Verson press in Monterrey, and the new press control, which features off-the-shelf Allen-Bradley processors and I/O modules.
then adjusting the counterbalance to the proper upper die weight.”
Installed with Minimal Interruption
Ease of installation, with minimal press downtime and production interruption, played an important role in the Monterrey press upgrade. That press, says Turk, includes an eddy-current flywheel drive and magnetic clutch-brake system. “Integrating that drive with the new control was a
challenge, but the PLC-based setup, with its flexibility and efficient wiring design, helped streamline the installation process.”
While the Milan press project opened Turk’s eyes to the benefits of open-architecture controls, compared to a pro- prietary control, the more recent project in Monterrey delivers even more benefits. Says Turk, “This technology just continues to accelerate in terms of delivering new fea- tures and benefits.”
Among those benefits is the use of Helm’s FirstMate WebVIew browser-based production-reporting software, generating reports on fault history and press-cell up- and downtime. Taking data from through-the-stroke tonnage-monitoring (Helm’s Loadgard package) sensors and Helm’s Mariner sig- nature-analysis software, WebView generates real-time graph- ical waveforms for each production run and delivers them to remote PCs via Ethernet.
The Loadgard setup integrates force measurement with crank angle, providing detailed monitoring throughout each stroke. Users can set upper and lower limits and establish alarm setpoints, or even initiate press shutdown if necessary at any time during the machine cycle.
“Through-the-stroke tonnage monitoring and signature analysis,” Turk explains, “has really paid dividends. In par- ticular, on deep-drawn parts we can quickly identify when a part tears and trigger a press shutdown before we generate a lot of scrap. We also can use the tonnage signatures to identify dull or broken punches and avoid making bad parts. Other benefits include downtime tracking, monitoring of snapthrough forces and better control of die wear.”
Challenging Applications Require Close Monitoring
Dura and GAS plants manufacture a host of automotive products, including structural body products, seating
With the PLC-based control, human-machine interface (HMI) screens are completely customizable. Shown are the main screen (left) and the die-monitoring setup screen.
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