Page 18 - MetalForming November 2017

PLC-Based Controls
systems and closure hinges. In addition, the Milan plant performs some rather dramatic deep-draw operations, including forming a door threshold 3-ft. long by 20-in. wide, with a 10-in.-deep cavity, drawn in one hit. That’s the type of part Turk refers to when explaining how through-stroke tonnage monitoring and signature analysis can pay off.
“We find the Loadgard tonnage monitor to be very intu- itive and detailed in terms of the data it delivers,” Turk says. “We have it installed on nearly every press—the Milan plant houses 24 presses, from a 50-ton OBI to a 2000-ton transfer; Monterrey houses 14 presses, from 50- to 3000-ton capacity. We can store and recall signatures, and use it the data to generate SPC charts.”
Both control-upgrade projects also include Helm’s remote- access technical-support feature. “This allows us,” says Turk, “to provide Helm’s engineers with access to the controls, to expedite troubleshooting. They also can edit our programs, if needed, from remote locations. While we rarely have to use this feature, it eliminates the time and cost of travel for the Helm team, and it makes the troubleshooting process that much more efficient.”
Die Protection
On the press in Mexico, the control features 48 inputs for sensors. “If you run out of inputs,” says Turk, “you have
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to connect the sensors in series. We do not want to do that because it makes it harder to trace problems if a sensor fault occurs. So, we want to isolate the sensors, especially on a press that large, that includes automation. We have cam drivers on that press, and we want to monitor whether they are in or out, and whether a part is sitting in the die correctly, on each end. That means we can have six sensors in one station—cam-in and cam-out on each end, and part- in-place on each end.
“We also rely on the press control for brake monitoring,” he continues, “a very important safety feature. We can track the stopping time of the press, which lets the operator know if he needs to adjust the brakes.”
An added safety feature: use of programmable safety relays. This, according to Helm, enables control of multiple light-curtain functions including barrier guarding and e-stops.
Lastly, as temperature in the plant can impact press per- formance and reliability, Turk equipped the control setup to monitor operating temperature and ensure that bearing points remain adequately lubricated.
“Prior to the control upgrade, we had downtime inci- dences caused by excess temperature,” he says. “Now we use the press control to monitor temperature, ensuring that operators pay close attention to press lubrication; downtime has practically been eliminated.” MF
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16 MetalForming/November 2017
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