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SCHMIDT PressControl 3000
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1. Select the Access Code command Assign a new access code This code consists of a number with a maximum of 9 digits Select the access area which you would like to change Confirm the selection with the Enter key The setting is changed from Access to No access or visa versa Other features These settings are made in the System Options display mode Inthe System Options submenu select the Date Time selection Select the Date command and enter the date in the format DD MM YY Select the Time command and enter the date in the format HH MM SS You can define two alarm times Time Alarm 1 and Time Alarm 2 that trigger an alarm daily You further have the possibility to define an alarm time Time Alarm 3 that is only triggered on a certain date Date Alarm 3 Inthe System Options submenu select the Date Time selection Select the desired alarm in the Alarm menu Enter a time in format HH MM SS and the date in format DD MM YY When the set alarm time is reached a marker is activated in the PLC program By querying this marker you can initiate other actions For further information please see the User manual SCHMIDT ControlTool Part 2 You can set the volume of the key click acknowledgement when a key is pressed and the volume of the alarm functions You can enter values of 0 to 255 for both volumes Test the volumes under the usual background noi
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3. 1 Datasets 4 Data Input 2 System Options 5 Data Output 3 Curve Output In this display mode you have access to the commands for dataset management They include commands for creating saving renaming and loading datasets SCHMIDT PressControl 3000 V1 3 4 Operation System Options Curve Output Data Input Data Output Sofikeys Changing operating level SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology In this display mode you have access to the commands for the system settings of the control They include settings for time date alarms machine parameters interface definitions etc In this display mode you have access to the commands for displaying the recorded curve They include commands for zooming tolerance data input and for displaying the curve In this display mode you have access to the machine parameters for operating the press system They include parameters for the return stroke for process data acquisition or for quantities In this display mode the operator can view information on the state of the press system This information includes data on the system condition quantities incorrect pressings etc You can find detailed information concerning the most important menu commands in the following chapters Softkeys and operating levels The SCHMIDT PressControl 3000 press system is provided with a PLC program having a large number of basic functions They can be acti
4. SafetyModule PC DEAC Dataset 1 1 Control Off 1 CtrON CtrOFF ee Pee Servic Figure 4 3 Display after the self test Change to operating level 1 Select the CtrON softkey The system first carries out a self test and then automatically starts the delivered PLC program After the system has been switched on the status indicator is lit and the message Machine ok appears on the display 4 4 Reference run After switching on the control unit a reference run must be carried out This is shown by the Operate press lt Ref gt message on the display PC DEAC Dataset 1 1 Machine ok Operate press lt Ref gt 1 CtrON CtrOFF aes ie Servic Figure 4 4 Display after switching on SCHMIDT PressControl 3000 V1 3 4 Operation Manual reference run SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Carry out a working stroke After reaching the reference point the press moves automatically to the TDC position Re DERG Dataset 1 Machine ok 2 Hand Release Returnstroke at stroke Quantity ok Quantity nok Quantity Reached force Reached stroke 1 CtrON CtrOFF Figure 4 5 Display after the reference run 30 000 mm 000 mm 1 pcs pcs pcs N Servic In general you can always carry out a reference run manually During this operation the control unit must not be switched off Change to operating level 3 Select t
5. 1 1 Designated use The control unit may be operated on a SCHMIDT PneumaticPress or a SCHMIDT HydroPneumatic Press only in connection with the SCHMIDT SafetyModule The control unit may only be used together with the above mentioned components for the following press processes e Assembling e Forming e Riveting e Pressing e Crimping e Flaring e Bonding e Punching Using the system for purposes other than those described above is contrary to the designated use The manufacturer cannot be held liable for any damage resulting from such a use The risk lies entirely with the user Do not make any changes to the press system which could impair safety The manufacturer cannot be held liable for any damage resulting from such a use The risk lies entirely with the user Designated use also includes e compliance with the documentation e compliance with the inspection and maintenance measures SCHMIDT PressControl 3000 V1 3 1 Safety DANGER DANGER SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 1 2 Organisational measures of the system operator Use as safety component If the control has been delivered not ready for use with a Declaration of Conformity according to Annex II b of the Machinery Directive 98 37 EC the operator or the system manufacturer must ensure observance of the safety regulations Of the safety regulations observe in particular the Machinery Directive 98 37 EC and the standar
6. With the function switched on the tolerance windows will be offset in each press process automatically by the difference of the actual and target passages in the reference curve of stroke tolerance 1 This offset is displayed in the curve window at Demo 1 2 00f EikN 8806 1 50f 1 00 500 l s mm 0 0 76t51 20 18 23 85 27 50 Figure 10 11 Force curve with offset of the tolerance data SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 11 Maintenance and servicing 11 Maintenance and servicing Safety instructions The control unit may only be installed and serviced by setup engineers who have been commissioned and trained by the company CAUTION Any work on the electrical equipment of the press must be carried out only by trained electricians or by specially instructed persons under the control and supervision of a trained electrician and in accordance with the applicable electrical engineering rules and regulations All spare parts must comply with the technical requirements established by SCHMIDT Technology This is always guaranteed in the case of original spare parts 11 1 Setting the force offset Each force sensor has a different output signal in the unloaded state However this output signal must be in a defined range The force offset allows you to adjust the output signal Switch on conirol Switch the control unit on Select the Data Output system fu
7. and the check until a Not O K part is produced When compared to the recorded curves this Not O K part exhibits an outlier in at least one place 45 10 Quality monitoring Defining quality range 46 Creating force stroke window SCHMIDT Technology Figure 10 5 Reference data with outliers After having collected the reference data you can establish the valid quality range Find out which pressing curves come from O K parts Define the quality features of the O K part curves Define the force stroke tolerances as required Force tolerances The force tolerances are displayed as monitoring windows These windows limit the allowed minimal and maximum pressing force values within the defined pressing stroke The control system continually checks if the pressing process is running within this monitoring window The force curve must enter from the left vertical line of the window and leave the window by the right vertical line If during the working process force values occur that exceed fall under the defined tolerance limits the control unit will output a suitable optical and acoustic error signal A maximum of 8 monitoring windows can be defined which may overlap as desired Select the Curve Output system function key Press the Enter key Select the Input Monitoring Data command Select the Create Window command The display switches to the curve output and a cu
8. can hide tolerances they will not be taken into account by the quality evaluation without deleting the tolerances Move tolerance data The curve of the reference force curve shows a characteristic press process The length tolerances of the parts can offset the curve on the X axis in the positive or negative direction To be able to monitor press processes of this type efficiently the tolerances must be offset as a function of the length of the components This is done by the Move tolerance data function The offset is determined via the intersection of the reference curve with a stroke tolerance reference curve offset curve to iol f f A a s a T offset Figure 10 10 Principle of the offset of the tolerance data 49 10 Quality monitoring 50 Switching on off the offset Se SCHMIDT Technology Select the Data Input system function key Select the Move tolerance on off parameter Enter the value 0 Record the data of a reference curve Determine the target passage in a stroke tolerance This value can be read in the Desired range str tol1 line of the Data Output 2 Select the Data Input system function key Select the Desired range str tol1 parameter Enter the value for the target passage Select the Data Input system function key Select the Move tolerance on off parameter Enter the value 1 To switch the function off again enter the value 0
9. configured for operation without connection to an external PC The note PC DEAC in the left upper corner of the control display tells you that this operating mode is active SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 8 Further integrated functions SCHMIDT ControlTool Configuring the press Establishing a connection Switching on the SPC SCHMIDT PressControl 3000 V1 3 pea Dataset 1 1 Machine ok 2 Hand Release Returnstroke at stroke 30 000 mm Quantity ok 17 pcs Quantity nok 4 pcs Quantity 21 pcs Reached force 2138 N Reached stroke 40 432 mm 1 CtrON CtrOFF Hees Fea Servic Figure 8 2 View of Output 1 including the note PC DEAC When operating the control on an external PC using SCHMIDT ControlTool software a press stroke is only possible if the PressControl 3000 is connected to ControlTool If there is no connection the stroke will be blocked Select the Data Input system function key Select the PC on off parameter Enter the value 1 To switch the function off again enter the value 0 As long as no connection has been established to the PC the stroke remains blocked In addition the control displays PC not ready TEC OER Dataset 1 1 PC not ready Returnstroke at stroke 30 000 mm Quantity ok 17 pcs Quantity nok 4 pcs Quantity 21 pcs Reached force 2138 N Reached stroke 40 432 mm 1 CtrON CtrOFF eee R Servi
10. electrician and in accordance with the applicable electrical engineering rules and regulations 1 Safety What to do in an emergency Start after Emergency Stop SCHMIDT Technology 1 4 Safety devices SCHMIDT PressContro 3000 Figure 1 1 PressControl 3000 1 Operational status indicator 2 EMERGENCY STOP pushbutton Operational status indicator The operational status indicator is located on the display of the control unit The status indicator is lit in green permanently when the press system has been switched on and is ready for operation Emergency Stop pushbutton There is an EMERGENCY STOP pushbutton on the control panel of the control unit Press the Emergency Stop pushbutton immediately in case of emergency The press system is taken to a safe operating state All moving machines are stopped immediately and the press system is depressurised Eliminate the error Unlock the Emergency Stop pushbutton by turning and pulling it Switch the press system on again at the control unit SCHMIDT PressControl 3000 V1 3 2 PressControl 3000 Sequence conirol SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 2 PressControl 3000 2 1 Function The SCHMIDT Press System with force stroke monitoring and SCHMIDT PressControl 3000 operates according to the following principle The sequence control of the press process is done via a PLC program The PLC program carr
11. the piece counter can be reset or not O disabled 1 enabled 6 Target count As soon as the set nominal piece number is reached an alarm will be output 7 Alarmtime quan reached Duration 0 to 10 sec for how long the alarm should sound when the number of pieces has been reached 8 Alarmtime press error Duration 0 to 30 sec for how long the alarm should sound in case of an incorrect pressing 9 BDC stroketakeover From this stroke the two hand button can be released as a result of which the stroke will be completely carried out The stroke has to be set in such a way that the dangerous closing movement is finished when the stroke has been reached 10 Servicetime In the Setting the time mode the two hand button has to be pressed for this time 0 to 20 sec After that the press is depressurised 11 Alarm time STO Duration 0 to 5 sec for how long the alarm should sound when the stroke signal in parameter 9 has been reached and the pressure switch is switched on 13 Block Limit Window This parameter defines whether the Block limit window function is active or not O active 1 inactive 14 min force limit If the Block limit window function is active this parameter defines the minimum force which must be reached 15 max force limit If the Block limit window function is active this parameter defines the maximum force which may be reached 16 min stroke limit If the Block limit window function is
12. the press moves to the BDC position The press remains in the BDC position until it is acknowledged by means of the external luminous button Then the press moves to the TDC position Select the Data Input system function key Select the Mode F 0 s 1 t 2 m 3 parameter Enter the value 3 Stroke takeover only two hand control The stroke takeover is the moment of the working stroke from which the closing movement of the working stroke is no longer interrupted upon releasing the two hand control This stroke takeover has to be set in such a way that the dangerous closing movement is finished upon reaching this switch A dangerous closing movement is that part of the movement of closing tools that may cause injures It is finished when moving parts and fixed parts have approached each other to such an extent that no more injury is possible 6 mm SCHMIDT PressControl 3000 V1 3 7 Press processes PneumaticPress HydroPneumaticPress SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology The stroke takeover is monitored in two channels by means of e a pressure switch which monitors the lower pressure chamber and e a cylinder switch in the bottom dead centre BDC The pressure switch has been set to a fixed value ex works and must not be adjusted Set the cylinder switch for the stroke takeover For further information please refer to chapter 3 7 Setting the press stroke takeov
13. the stroke tolerances are displayed only for the defined tolerances SCHMIDT PressControl 3000 V1 3 7 Press processes force return stroke criterion SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 7 Press processes 7 1 Defining the press process A press process is defined by the press parameters force and stroke and the selection of the return stroke criterion These parameters are entered in the Data Input display mode and are automatically linked to the PLC program These settings are made in the Data Input display mode Select the Data Input system function key Press parameters The definition of a press process always requires force and stroke to be entered Both parameters are monitored during the press process Select the Returnstroke Force parameter Enter the force that is not to be exceeded during the press process Select the Returnstroke Stroke parameter Enter the stroke that is not to be exceeded during the press process Return stroke criterion The return stroke criterion determines the order in which force and stroke are monitored When performing the press process with the force return stroke criterion primarily the Returnstroke Force parameter and secondarily the Returnstroke Stroke parameter are monitored Select the Data Input system function key Select the Mode F 0 s 1 t 2 m 3 par
14. 7 5 Different positions of Smax 1 Change from the working stroke to the return stroke Pressing 1 2 Change from the working stroke to the return stroke Pressing 2 Idle stroke monitoring This function allows you to monitor whether a max allowed force Fmax has not been reached or exceeded up to a certain stroke s If in a press process the max allowed force is reached an error message will appear and the press will move back to the TDC position SCHMIDT PressControl 3000 V1 3 7 Press processes Defining the limits Switching on Defining the limits SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Fmax Figure 7 7 Idle stroke monitoring principle Define the limits of idle stroke monitoring Enter the corresponding values for the following parameters e max force idle stroke e stroke for idle stroke Select the idle stroke monitoring parameter Enter the value 1 Enter value 0 to deactivate the function Block limit window This function allows you to monitor whether the reversal point of the force curve change from the working stroke to the return stroke is within certain limits If in a press process one of the determined limits has been reached an error message will appear indicating which limit has not been observed Figure 7 8 Block limit window principle In the control unit no window is displayed The limits are monitored by the p
15. SCHMIDT Technology Operator s manual SCHMIDT PressControl 3000 SCHMIDT press system with force stroke monitoring and SCHMIDT PressContro l 3000 General Germany USA Great Britain Switzerland SCHMIDT Technology Contact adresses SCHMIDT Technology GmbH Feldbergstr 1 D 78112 St Georgen Tel 49 7724 899 0 Fax 49 7724 899 101 eMail info schmidttechnology de www schmidttechnology de SCHMIDT Technology Corp Cranberry Corporate Center 280 Executive Drive USA Cranberry Twp PA 16066 Tel 1 724 772 46 00 Tel 1 800 959 12 18 Fax 1 724 772 46 88 eMail info schmidtpresses com www schmidtpresses com SCHMIDT Technology Ltd Unit 14 18 The Markham Centre UK Theale Reading Berks RG7 4PE Tel 44 118 9305 464 Fax 44 118 9305 440 eMail sales schmidttechnology co uk www schmidttechnology co uk SCHMIDT Technology GmbH Niederlassung Schweiz Gerbeackerstr 8 CH 3210 Kerzers Tel 41 0 31 755 40 71 Fax 41 0 31 755 40 73 eMail infoCH schmidttechnology ch www schmidttechnology ch 2007 SCHMIDT Technology GmbH All rights reserved Printed in the Federal Republic of Germany Version and revision date Version 1 3 of August 2007 SCHMIDT PressControl 3000 V1 3 General SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Table of Contents Documentation structure eeececeeeenneeeeeenneeeeeeaaeeeeeeaaeeeseeaaeeeseaeeeesenaeee
16. Zoom Zoom Record reference data SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology The recorded curves together with their respective tolerance limits are displayed in the curve output over the entire force and stroke range The recorded curves together with their respective tolerance limits are displayed in the curve output in the adapted form To enlarge a certain area Se Select the Zoom command The display switches to curve output and a cursor appears additionally Move the cursor using the cursor keys to the left upper corner of the desired detail and confirm the position with the Enter key Move the cursor using the cursor keys to the right lower corner of the desired detail and confirm the position with the Enter key The selected detail shown enlarged s mm 38 53 37 61 36 69 35178 Figure 10 4 Enlarged section This ends the enlarged display The display goes back to the last curve display 10 2 Tolerances Reference data With the help of the reference data the quality features can be defined for individual workpieces To be able to define the quality requirements for the individual workpieces you first have to record the reference data Se Set the Output Diagram parameter to Continuous to display all force curves as a group of curves Produce a workpiece and check whether it meets the quality requirements Repeat the production process
17. active this parameter defines the minimal stroke which must be reached 17 max stroke limit If the Block limit window function is active this parameter defines the maximum stroke which may be reached 22 SCHMIDT PressControl 3000 V1 3 5 Data Input SCHMIDT Technology No Parameter Description 25 idle stroke monitoring This parameter defines whether the idle stroke monitoring function is active or not O active 1 inactive 26 max force idle stroke If the idle stroke monitoring function is active this parameter defines the maximum allowed force which must not be reached 27 stroke for idle stroke If the idle stroke monitoring function is active this parameter defines the stroke which has be controlled 30 PC on off This parameter defines whether the control unit has to be connected to an external PC for operation 31 SPC on off This parameter determines whether the SPC has been switched on or not O off 1 o0n 40 Move tolerance on off This parameter defines whether the Offset of tolerance data function is active or not O active 1 inactive 41 Ref pos stroketol 1 This parameter defines the intersection of the reference curve with the stroke tolerance 1 42 Force tare on off The Force tare function is used to tare the force value after each stroke to the value 0 45 Part check on off This
18. ameter Enter the value 0 If in a press process the set force is not reached but the set stroke is exceeded the error message P2 RS stroke exceeded is displayed 25 7 Press processes stroke return stroke criterion time return stroke criterion manual return stroke criterion 26 SCHMIDT Technology When performing the press process with the stroke return stroke criterion primarily the Returnstroke Stroke parameter and secondarily the Returnstroke Force parameter are monitored Select the Data Input system function key Select the Mode F 0 s 1 t 2 m 3 parameter Enter the value 1 If in a press process the set stroke is not reached but the set force is exceeded the error message P1 RS force exceeded is displayed When performing the press process with the return stroke criterion time the press moves to the BDC position When the time set in parameter Returnstroke Time has expired the press moves to the TDC position Select the Data Input system function key Select the Returnstroke Time parameter Enter the time after which the return stroke has to be started Select the Mode F 0 s 1 t 2 m 3 parameter Enter the value 2 If in a press process the BDC position is not reached the error message BDC not reached gt ACK appears When the press process is performed with the return stroke criterion manual
19. arameters only Define the limits of the block limit window Todo so enter the corresponding values for the following parameters 31 7 Press processes Switching on Acknowledging via luminous button only 32 SCHMIDT Technology min force limit max force limit min stroke limit max stroke limit Select the Block Limit Window parameter Enter the value 1 Enter value 0 to deactivate the function 7 3 Acknowledging an incorrect pressing An incorrect pressing can be acknowledged by pressing the ACK softkey Change to operating level 2 Press the ACK softkey or Press the Acknowledge incorrect pressing key Acknowledging by means of external luminous button In addition to the options of acknowledging an error described above for severe production conditions an external luminous button can be used to acknowledge an incorrect pressing Connect the external luminous button for acknowledging incorrect pressing to the relevant input see circuit diagram of the SCHMIDT SafetyModule Now the error messages can also be acknowledged using the external luminous button If you want to acknowledge error messages exclusively by means of the external luminous button you have to switch on additionally the ACK n ok box on off parameter Select the Data Input system function key Select the ACK n ok box on off parameter Enter the value 1 T
20. c Figure 8 3 View of Output 1 including the note PC not ready Configure the press system in the SCHMIDT ControlTool software see section Define press unit in the User Manual SCHMIDT ControlTool Part 1 Establish the connection see chapter 4 1 Establishing a connection to the control in the User Manual SCHMIDT ControlTool Part 1 Select the Data Input system function key Select the SPC on off parameter 37 SCHMIDT Technology 8 Further integrated functions Switching on CAUTION 38 Prerequisite Enter the value 1 To switch the function off again enter the value 0 As long as the function SPC in ControlTool is not activated the stroke will be blocked In addition the control display will tell you SPC not ready ae eu Dataset 1 1 SPC not ready 2 Hand Release Returnstroke at stroke 30 000 mm Quantity ok 17 pes Quantity nok 4 pcs Quantity 21 pcs Reached force 2138 N Reached stroke 40 432 mm 1 CtrON CtrOFF mete ce Servic Figure 8 4 View of Output 1 including the note SPC not ready 8 3 Taring the force value By default the force value displayed in Data output 2 is tarred during the reference run i e when the system is switched on With the machine running it may happen that the force value changes In this case at no load of the ram the force value 0 is no longer displayed The Tare force value
21. d at Analog input 1 53 SCHMIDT Technology 11 Maintenance and servicing 11 3 Adjusting the stroke offset After work has been performed on the stroke sensors the reference marker on the scale are rarely at the original location This offset must be compensated You can set this value using the stroke offset When the ram is in the TDC position the Output 2 view of the data output must not exhibit a negative stroke The value 603 corresponds to the zero point in the control If therefore a value smaller than 603 is displayed it is considered a negative stroke A stroke offset of 1 to 1 5 mm is set ex works The system requires this value to be in the range between 0 and 3 mm If the value is outside this range the stroke offset must be set again and tolerances that have already been set may have to be adjusted Select the Data Input system function key Select parameter 59 Offset Stroke Using the Left and Right cursor keys you can jump from on block of 10 to the next Enter the value 0 as new stoke offset Select View 2 of the data output Dataset 1 2 Force ON Stroke 600 558 mm Increment force 0 inc Increment stroke 65278 inc Offset force 19 inc Average force wind F1 ON Average force wind F2 ON Average force wind F3 ON Average force wind F4 ON Desired range str tol1 000 mm Desired range str tol2 000 mm 1 CtrON CtrOFF ne ae Servic Figure 11 4 View of Output 2 W
22. dditionally Move the cursor using the cursor keys to the left corner of the tolerance to be deleted and confirm the position by pressing the Enter key The stroke tolerance that will be deleted is always the one whose left corner is closest to the cursor Managing tolerances After you have defined the tolerances using the cursor keys you can display the values of every single tolerance numerically and change them if necessary Select the Curve Output system function key Press the Enter key e Select the Monitoring Data Numeric command Monitoring Data Numerical Window 1 4 Window 5 8 Stroke Tolerance 1 CtrON CtrOFF ae tee Servic Figure 10 8 Monitoring Data Numerical menu SCHMIDT PressControl 3000 V1 3 10 Quality monitoring Define offset SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Select the desired tolerance Window 1 Window aktiv left 10 00 right 30 00 down 20 00 up 35 00 1 CtrON CtrOFF re Bee Servic Figure 10 9 Changing the tolerance numerically Enter the corrected values for the individual parameters In the case of force tolerances you have the possibility to set individual windows to not active In the case of stroke tolerances you have the possibility to transfer the tolerance from the Working Stroke to the Return Stroke or vice versa or to set the tolerance to not active By using the Not active setting you
23. ds DIN EN 349 DIN EN 292 and DIN EN 294 The operator must make sure that e the instructions contained in the operating manual concerning startup operation and maintenance are observed e the press system is properly operated tested and maintained and the responsibilities for these tasks are clearly set out e those persons responsible for activities on the press system have read this operating manual and in particular chapter 1 Safety before starting work This also applies to persons who work only occasionally e this operating manual is always kept within easy reach at the workplace 1 3 Risks The press system is constructed so as not to put any persons at risk when used in accordance with its designated use However certain parts of the press system cannot be protected without limiting its functionality and usability Thus despite constructional safety measures a residual danger remains Safe press operation requires the interaction of press control unit tools safety devices and conduct of the user in accordance with the safety measures Injuries or death caused by touching live parts During assembly and repair work you may come into contact with parts which carry dangerous voltage in operation Touching live parts may cause death Any work on the electrical system or equipment must be carried out only by trained electricians or by specially instructed persons under the control and supervision of a trained
24. dto 59 Offset stroke The Offset stroke value is machine specific The measured value for the activated machine is included in the test certificate SCHMIDT PressControl 3000 V1 3 23 6 Text and system outputs Activating data output Changing view 24 SCHMIDT Technology 6 Text and system outputs 6 1 System outputs Select the Data Output system function key Machine ok 2 Hand Release Quantity ok Quantity nok Quantity Reached force Reached stroke 1 CtrON CtrOFF Figure 6 1 View Output 1 PC BEAC Dataset 1 Returnstroke at stroke 40 432 mm 2138 N Servic In this display mode the operator can view information on the states of the press system This information includes system messages such as for example control on off piece numbers incorrect pressings etc 6 2 Process data In another view you can see the current process data of the sensors and the evaluation of the monitoring windows By pressing the Data Output system function key you can toggle between the two views Force Stroke Increment force Increment stroke Offset force Average force wind F1 Average force wind F2 Average force wind F3 Average force wind F4 Desired range str tol1 1 CtrON CtrOFF Figure 6 2 View Output 2 Dataset 1 Desired range str tol2 2 1 030 mm The average values of the force tolerances or the passages of
25. e counter By default this counter is always switched on in the control as delivered If for monitoring the quality tolerances have been set see chapter 10 2 Tolerances the counter will distinguish between OK parts and Not OK parts In addition the produced total number of pieces will be displayed PEDEN Dataset 1 1 Machine ok 2 Hand Release Returnstroke at stroke 30 000 mm Quantity ok 17 pcs Quantity nok 4 pcs Quantity 21 pcs Reached force 2138 N Reached stroke 40 432 mm 2 PCTon PCTof f PCT 0 CNT O ACK Figure 7 6 View of Output 1 with default piece counter 33 7 Press processes Incorrect pressing Reset Locking Setting Switching on 34 SCHMIDT Technology Acknowledge the incorrect pressing After that you will be able to continue the work f required change to operating level 2 When you want to reset the piece counter press the CNT 0 softkey You can lock this counter and prevent the piece counter from being reset Select the Data Input system function key Select the Counter access parameter Enter the value 0 Pre selection counter A pre selection counter is integrated into the control unit in case the lot batch sizes to be produced are always the same As soon as the set nominal piece number is reached an alarm sounds If for monitoring the quality tolerances have been set see chapter 10 2 Tolerances the counter will dist
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27. eeeeeeeaeeeeeeeeeeeeeanaeeeeeeeseeeedeeaeeeeeeeeneees 45 Force tolerances ccceccceceeeeeeeeeeaeeeeeeeeeeceeanaeeeeeeeeeeeeneeaeeeeeeeeneees 46 Stroke tolerances ces snccccvasi sca vvnded cadeauadaawesandceaeiaa Shgnvdseacevnedeadesadiaweuanes 47 Managing tolerances ccececeeeeeeeeeeeeeneeeeeeeeaeeeeeeaaeeeeneaaeeeeeeaaeeeeeeaas 48 Move tolerance Gata ccccccceceeeeeeeeececeeeeeeeseeanaeeeeeeeseeeenaneeeeeeetes 49 11 Maintenance and servicing secceee 51 11 1 Setting the force offset ec eee eee ceeeee cece eeseaeeeeeeeseeeeeeeessaeeseneeeeees 51 11 2 Calibrating the force sensor cccceeseeeeeeeeeeeeeeeeeeceeeeseeeesnaeeteneeteaes 52 11 3 Adjusting the stroke OffSet eee eeeeeeeeenneeeeeenaeeeeeenaeeeeeeaeeeeeeaaes 54 12 Customer ServiCe cccccceeecstseeeeeeseeeeeeeeeeeeees 56 SCHMIDT PressControl 3000 V1 3 General Optional Optional Optional SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Documentation structure The operators manual for the press system is divided into the following documentation modules Operator s Manual SCHMIDT Press e Structure and function e Assembly and startup e Maintenance and servicing Operator s Manual SCHMIDT SafetyModule e Structure and function e Mounting and startup e Maintenance and servicing Operator s Manual SCHMIDT PressControl 3000 e Structure and function e A
28. eft cursor key you can again select the front letters ee ee Exit the Edit Filename dialog with the Enter key Afterwards save the dataset at one of the 20 memory locations SCHMIDT PressControl 3000 V1 3 10 Quality monitoring Activating curve output Curve output SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 10 Quality monitoring 10 1 Curves The press system records the individual force and stroke data during the pressing process This data is then represented as a force curve in a force stroke diagram Select the Curve Output system function key s mm 27 52 36 69 Figure 10 1 Curve Output Curve display You can modify the display of the curves in the Curve Output display mode These settings are made in the Diagram selection menu Select the Curve Output system function key Press the Enter key Select the Diagram Mode command Diagram Selection Output Diagram Single Diagram Force Stroke Units Metric 1 CtrON CtrOFF T TA Servic Figure 10 2 Diagram Selection menu By default when the curve output is called only the last recorded curve is displayed parameter Output Diagram Single Alternatively you can also establish that the curves of the production process be displayed as a group 43 10 Quality monitoring Diagram type System of units 44 SCHMIDT Technology Select the Output Diagram pa
29. em function key In the System Options submenu select the Calibrate analog Inputs command Select the Analog Input 1 Enter the noted value in KN into the Value Machine parameter Enter the noted value in KN into the Value Reference parameter Select Calculate amp Save using the arrow key Confirm the entry by pressing the Enter key The control calculates the new calibration value from the two entered values and displays the result Force Calibration Calibration 1 0000 Value Machine 1 0000 Value Reference 1 0000 Calculate amp Save Calibration Init 1 CtrON CtrOFF Servic Figure 11 3 Force Calibration submenu Subject the force sensor again to a load Compare the measured value of the reference measuring system with the measured value of the machine Repeat the calibration process if the values do not coincide The calibration affects the value of the force offset ee Se After the calibration check whether the value has changed After a large change has taken place set the force offset again For more information on setting the force offset please see chapter 11 1 Setting the force offset If there are large calibration errors you can reset the calibration value to 1 ee Select the Calibration Init command When using the optional analog output 2 to measure quality relevant dimensions regular inspections or calibrations should be made Se Proceed as describe
30. enenaes 5 ge 6 een eer ee ee ene eer 6 1 1 Designated USC ae zcceisasccearsssecanes deccechiis tenevssadchartaitedevd A 6 1 2 Organisational measures of the system OperatOl cccceeeeeeeeeees 7 13 RISKS E E eee eocnes eet ade ee 7 1 4 Safety devices rinitin aiaiai iiaa 8 Operational status indicator ccccceecceceeeceeeeeeeeeeeceeeeeeeeesaeeeeeeeeenees 8 Emergency Stop puSNbUutton ccccceececeeeeeeeeeeeeeeseeeeseeeeseaeeseneeeeaes 8 2 PressSControl 3000 cccceeeeeeeeeeeeeeeeeeeeeeeeeeeees 9 2l PUMCHOMi c Give steep slit eerie cenit ee asi eee 9 22 Technical Data cci0i ces edle ts deen eevee enn ea tienes 10 3 Assembly and Startup ceseeeseeeeeeeeeeees 11 3 1 Transport and Storage iiss seeccceeseecucktie exetevancenelesneweertanvenelaneedstenceegttaa es 11 3 2 Connecting the Control unit 00 cece eee eeceeeeeeeeeeeeeeeeeeeeseaeeeeaeeneneeeeaes 12 33 Installing the control Umit i sssrinin inkaa 12 4 Operation ssssssssssnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnna 14 4 1 Operating CleMent ceccccceeeeeeeeeeeeeeeneeeeeaeeeeaeeseeeeeeueesseaeeseeeeeaes 14 4 2 User interface ee ececcccceeescceeeeneeceeeenseceeesneeeeesneeeeesnnnaeeesnneaeensnnaees 14 System FUNCTIONS vrienn aa aaa aaa aaa AAE 14 Softkeys and operating levelS ccccccecceeeeeseeeeeeeceeeeeeeaeseeaeeseeeeeees 15 4 3 Switching on and Off ee cec ce cceeeeeeee cece ee eeeeeeeaeeeeeeeseeeeseeeesaees
31. er of the Operator s manual SCHMIDT PneumaticPress Check if the control unit settings for the existing cylinder switch es are correct f necessary adapt the BDC signal 11 3 exist parameter and the TDC signal 11 4 exist The stroke takeover is monitored in two channels by means of e a pressure switch which recognises the switchover from rapid approach stroke to power stroke and of e the BDC stroketakeover parameter in the Press Control 3000 control unit The pressure switch has been set to a fixed value ex works and must not be adjusted The BDC stroketakeover parameter has to be set in such a way that the dangerous closing movement is finished upon reaching this position 7 2 Optimisation of the press process Bend Up Yield Factor Every press system has a force dependent deflection This results from the elastic deflection of the machine the tool and the workpiece For stroke dependent press operations without a positive stop freely positioned possible bend up may lead to positioning errors due to dispersion of the press forces Positioning accuracy in the range of 0 01 mm are practically impossible to attain without compensation of the deflection constants The drive control calculates the axis specific and application specific deflection constant in real time The representation of the deflection in the following figure is strongly exaggerated 27 7 Press p
32. f You can lock this counter and prevent the pre seletion counter from being reset Select the Data Input system function key Select the Counter access parameter Enter the value 0 35 SCHMIDT Technology 8 Further integrated functions Switching on the setup mode Leaving the setup mode 36 8 Further integrated functions 8 1 Setup mode for tool change For a simple setup of the press e g change of heavy upper tools the setup mode is available In the setup mode the press moves to the BDC position After the time set in the Setup time parameter has expired the control unit is switched of and the press is depressurised Select the Data Input system function key Select the Servicetime parameter amp Enter the time after which the control unit is to be switched off and the press to be depressurised Change to operating level 1 Press the Servic softkey This operating mode is indicated by the word SET UP in output 1 PE DEAC Dataset 1 1 MENIRE Clis kkkk Returnstroke at stroke 30 000 mm Quantity ok 17 pcs Quantity nok 4 pcs Quantity 21 pcs Reached force 2138 N Reached stroke 40 432 mm 1 CtrONn CtrOFF Servic Figure 8 1 View Output 1 displaying the word SET UP Change to operating level 1 Press the CtrOn softkey 8 2 Operation with ControlTool As delivered the control has been
33. function is used to tare the force value before each stroke Select the Data Input system function key Select the Force tare on off parameter Enter the value 1 To switch the function off again enter the value 0 Production of defective parts If this function is permanently switched on a possible defect on the force sensor may not be detected in time This may result in defective parts being produced that are not detected as defective Switch off the function as soon as the function is no longer needed 8 4 Parts inquiry A function for parts inquiry is included in the scope of delivery of the PLC program However this function can only be used if a additional sensor for parts inquiry is available Connect the sensor for parts inquiry to the relevant input see circuit diagram of the SCHMIDT SafetyModule SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 8 Further integrated functions Switching on the parts inquiry SCHMIDT PressControl 3000 V1 3 Select the Data Input system function key Select the Part check on off parameter Enter the value 1 To switch the function off again enter the value 0 As soon as the function is switched on the input is queried as to whether a part is available on an optionally mounted workpiece fixture If no part is in the fixture the message gt Part insert gt appears The hand lever will remain locked until the in
34. he Ref softkey Perform the reference run as described above 17 5 Data Input Calling data input CAUTION 18 Scrolling SCHMIDT Technology 5 Data Input Various parameters data input system options etc can be input directly at the control unit Select the Data Input system function key Input Dataset 1 0 Mode F 0 s 1 t 2 m 3 1 1 Returnstroke Force 1500 N 2 Returnstroke Stroke 30 000 mm 3 Returnstroke Time 2 0 sec 4 Start Stop PDA 5 000 mm 5 Counter access 1 6 Target count 20 7 Alarmtime quan reached 3 0 sec 8 Alarmtime press error 3 0 sec 9 BDC stroketakeover 20 000 mm 1 CtrON CtrOFF obs TE Servic Figure 5 1 Data input Mark the desired parameter The selected line is given a dark background Press the Enter key The previously set value is deleted and the cursor blinks at the input position Enter the desired value using the numeric keys Input errors can be corrected by means of the Left cursor key Confirm the entry by pressing the Enter key 10 input parameters can be displayed simultaneously on the display of the control unit You can move from one parameter to the next by using the Up Down cursor keys With the Left and Right cursor keys you can jump from on block of 10 to the next 5 1 Default settings Contrast The display is blank With increasing operating temperature the contrast of the display diminishes Si
35. he control The data contained in the system dataset is used to operate the press system To achieve this a user dataset is loaded to the system dataset It can now be edited for the press system operation via the Data Input SCHMIDT PressControl 3000 V1 3 9 Dataset management SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Parameter changes in the system dataset have an immediate effect only upon the next press process but not upon the original dataset If you wish to retain the changes you need to save the changed system dataset as a user dataset For this a total of 20 storage locations for user datasets is available 9 2 Managing multiple datasets Creating and storing datasets In the control unit 20 datasets can be stored in the respective memory locations Define the press parameter as described in chapter 7 1 Defining the press process Define the tolerance data as described in chapter 10 2 Tolerances Select the Datasets system function key Select the Save File command Using the Up Down cursor keys select one of the 20 memory locations and confirm with Enter Save File Dataset 1 Dataset 2 Dataset 3 Dataset 4 Dataset 5 Dataset 6 Dataset 7 Dataset 8 Dataset 9 Dataset 10 SOONDOARWNY Sy 1 CtrON CtrOFF Roar See Servic Figure 9 2 Save dataset Load dataset Datasets created and saved earlier can be loaded when needed Select
36. he control unit is equipped ex works with a control unit holder for table or wall mounting Insert the control unit in the table holder Tighten the fastening screw 1 SCHMIDT PressControl 3000 V1 3 3 Assembly and startup Setting the inclination SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Figure 3 2 Control unit holder 1 Fastening screw hidden in the figure 2 Screw for inclination adjustment on both sides The holder adapter in the control unit must not be removed The holder allows the control unit to be swivelled by 70 Loosen the screw connections for the inclination adjustment 2 Set the desired control unit inclination Tighten the screw connections for the inclination adjustment 2 again 13 4 Operation 14 Datasets SCHMIDT Technology 4 Operation 4 1 Operating elements The SCHMIDT PressControl 3000 press system is basically operated by means of the following operating elements Figure 4 1 Operating elements 1 LCD with touch screen 6 On Off pushbutton 2 Set contrast key 7 EMERGENCY STOP pushbutton 3 Softkeys 8 System function keys 4 Change operating level key 9 Cursor keys 5 Numeric keys 10 Acknowledge incorrect pressing key 4 2 User interface System functions Using the system function keys you can directly access the most important display modes having system functions wa Figure 4 1 System function keys
37. he parameters by pressing the Graphic init key UE470 address The CAN gateway address must be correctly set for the communication between the control unit and the SCHMIDT SafetyModule The address 10 is set by default in the CAN gateway and also in the control unit Select the System menu system function key Select the Service submenu in the System Options menu Service Ident Adress UE470 10 1 CtrON CtrOFF ee MA Servic Figure 5 4 UE470 address The address is set in the CAN gateway by means of two rotary switches Access Assigning an access code and privilege level The control is delivered ex works with complete access rights and with the access code 0 Limit access to the individual areas Assign a new access code This code consists of a number with a maximum of 9 digits These settings are made in the System Options display mode Select the System Options system function key Select the Access Codes menu Enter the access code default setting 0 SCHMIDT PressControl 3000 V1 3 5 Data Input Changing access code Changing access authorization Date time Alarms Volume SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Access Codes User Data Access Monitoring Data Access System Options Access Com Port Access Access Code 0 1 CtrON CtrOFF Bene mee Servic Figure 5 2 Access Codes submenu
38. ies out the following functions e Control of the process data acquisition sequence e Monitoring of the press process on the basis of the set quality parameters e Plain text output on the display Additional functions e g feeds workpiece detection sorting of OK and Not OK parts etc are effected via the PLC program Key pad Display USB 4 freely programmable Process computer digital outputs PLC 8 freely programmable digital inputs PDA lt q CAN Bus gt SafetyModule t t j j a Key swich pa 6s S PP 5 i553 Operating mode Bs yasgses SES Les Ega oot tree aad FEES SSS gop eoSSBRecR SES Light curtain qgagqwa L LTL EEE Fo gt gt oostzaawna Electronic signal amplifier F S Press U An Pneumatic safety unit Sensors integrated in the press Figure 2 1 Block circuit diagram SCHMIDT Technology 2 PressControl 3000 2 2 Technical Data Dimensions 290 80 io N m l Figure 2 2 Dimensions of the control unit Technical Data Display Liquid crystal display 128 x 240 pixels with background illumination 16 lines of 40 columns each with touch screen functions Keypad Touch screen Interfaces USB Mains connection 100 up to V AC 50 up to 60 Hz max back up fuse 16 A Supply voltage 24 V DC Current consumption 350 mA 230 V or 700 mA 110 Vor 2 5A 24V Weight 5 5 kg incl external power supply unit Ambient temperature 0 u
39. inguish between OK parts and Not OK parts The nominal piece number and or the duration of the alarm can be set in the data input depending on the privilege level Select the Data Input system function key Select the Target count parameter Enter the desired piece number Select the Alarmtime quan reached parameter Enter the desired duration of alarm in seconds After you have set the pre selection counter you can switch the pre selection counter on f required change to operating level 1 Press the PCTon softkey pe SDERe Dataset 1 1 Machine ok 2 Hand Release Returnstroke at stroke 30 000 mm Preselect target count 20 pcs Preselect count 18 pcs Quantity nok actual 1 pcs Reached force 2138 N Reached stroke 40 432 mm 2 PCTon PCToff PCT 0 CNT O ACK Figure 7 7 View of Output 1 with activated pre selection counter SCHMIDT PressControl 3000 V1 3 7 Press processes Incorrect pressing Resetting Switching off Locking SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Acknowledge the incorrect pressing After that you will be able to continue the work As soon as the set number of pieces has been reached an alarm sounds If you want to continue to produce you need to reset the pre selection counter to zero Press the PCT 0 softkey Press the PCToff softkey when you want to switch the pre selection counter of
40. kaging of the components if they must remain unused for longer periods Store the control unit in upright position do not place on the display Store the control unit in such a way that it is not subject to large fluctuations in temperature Otherwise the resulting condensed moisture may cause corrosion on critical press or control unit components Please observe the information on the ambient conditions in chapter 2 2 Technical Data 11 3 Assembly and startup CAUTION 12 Communication Power supply SCHMIDT Technology 3 2 Connecting the control unit The back of the control unit housing contains the following connections 4 Figure 3 1 Connections 1 not used only ManualPress 5 Inputs outputs 2 Supply voltage 6 Service 3 Force stroke sensors 7 USB 4 CAN Damage to the force stroke sensors The cables may only be connected in the de energized state This applies especially to the connection of the force stroke sensors Connect the control unit in the order described below The communication between the control unit and the press or the force stroke sensors takes place via two connections Connect the control unit to the press using the cable for the force stroke sensors 12 pin plug Connect the control unit to the SafetyModule using the CAN cable 5 pin plug Connect the control unit to the 24V power supply of the SafetyModule 3 3 Installing the control unit T
41. m value of this stroke tolerance a suitable error message is sent to the control unit When defining the stroke tolerances a distinction is made between a tolerance in the working stroke and a tolerance in the return stroke A maximum of four stroke tolerances can be defined Se ee Se Se Select the Curve Output system function key Press the Enter key Select the Stroke Tolerance in xxx command By pressing repeatedly the Enter key you can select the desired stroke tolerance Select the Create Stroke Tolerance command when you want to create a stroke tolerance in the working stroke Move the cursor using the cursor keys to the left corner of the desired stroke tolerance and confirm the position by pressing the Enter key Move the cursor using the cursor keys to the right corner of the desired stroke tolerance and confirm the position by pressing the Enter key 47 10 Quality monitoring Deleting stroke tolerance 48 Se SCHMIDT Technology The stroke tolerance created is displayed in the curve output with the designation WA WR The tolerances are numbered sequentially 2 00f FLKN 1 50 1 00 500 R2 WA 27 52 Figure 10 7 Defined stroke tolerances Select the Curve Output system function key Press the Enter key Select the Input Monitoring Data command Select the Delete Stroke Tolerance command The display switches to the curve output and a cursor appears a
42. nce nothing can be seen any longer on the display the user may think that the control is defective Check if the contrast is set correctly using the Contrast setting key SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 5 Data Input t Figure 5 1 Contrast setting keys 1 Contrast setting keys Machine parameters Wrong evaluation of the quality parameters The sensitivity of the sensors of the connected press is set by the machine parameters The set parameters have been tested and should only be CAUTION changed by experts Select the System Options system function key In the System Options submenu select the Machine Parameter selection Machine Parameter Res Stroke Sensor I mm 10 2000 Max Stroke mm 100 Res Force Sensor I kN 400 Maximum Force kN 10 Graphic init 1 CtrON CtrOFF aoe aes Servic Figure 5 3 Machine parameters Modify the corresponding parameters according to the sensor type Parameter 5 kN 20 kN 100 kN 160 kN Res Stroke Sensor 2000 2000 2000 2000 Max Stroke 100 100 100 100 Res Force Sensor 400 100 20 16 Maximum Force 10 20 100 125 Please refer to chapter 5 1 Press data in the operating manual of the press to find out which force sensor is integrated in which press SCHMIDT PressControl 3000 V1 3 19 5 Data Input CAUTION 20 SCHMIDT Technology Confirm the entry of t
43. nction key Press the Data Output system function key again Now the current process data of the sensors and the evaluation of the monitoring windows will be displayed The Offset force parameter will show the currently set force offset Dataset 1 2 Force ON Stroke 1 030 mm Increment force O inc Increment stroke 112 inc Offset force 19 inc Average force wind F1 ON Average force wind F2 ON Average force wind F3 ON Average force wind F4 ON Desired range str tol1 000 mm Desired range str tol2 000 mm 1 CtrON CtrOFF AE ee Servic Figure 11 1 View of Output 2 Setting the force offset The force offset can be set at the amplifier board via a potentiometer Set the force offset to a value of about 50 To increase the force offset turn the screw on the potentiometer to the left To decrease the force offset turn the screw on the potentiometer to the right SCHMIDT PressControl 3000 V1 3 51 SCHMIDT Technology 11 Maintenance and servicing Prerequisite Preparing press system 52 Recording measured values Figure 11 2 Amplifier board 1 Potentiometer for the force offset 2 Potentiometer for the amplification If you turn the screw on the potentiometer but the value in the Offset force does not change Switch the control unit off Switch the control unit on again Try again to set the force offset 11 2 Calibrating the force sensor Since the force mea
44. o switch the function off again enter the value 0 SCHMIDT PressControl 3000 V1 3 7 Press processes Prerequisite Switching on the rejects box SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Acknowledging by means of the reject box A function for the automatic acknowledgement of incorrect pressings is included in the scope of delivery of the PLC program However this function can only be used if a additional sensor is available This sensor will detect whether the part of an incorrect pressing has fallen into a rejects box Not OK box Connect the sensor for the automatic acknowledgement of an incorrect pressing to the relevant input see circuit diagram of the SCHMIDT SafetyModule Select the Data Input system function key Select the ACK n ok box on off parameter Enter the value 1 To switch the function off again enter the value 0 As soon as the function is switched on the input is queried as to whether a part of an incorrect pressing has fallen into a connected rejects box n ok box This ensures that a Not OK part cannot continue the production process The message Press error ACK is acknowledged automatically as soon as the input transmits a signal If the function Acknowledging by means of the reject box is used the incorrect pressing can no longer be acknowledged by pressing the ACK softkey or the Acknowledge incorrect pressing key 7 4 Counter Piec
45. p to 40 C Air humidity up to max 95 relative non condensing Protection type IP 54 10 SCHMIDT PressControl 3000 V1 3 3 Assembly and startup CAUTION Delivery Transport Storage SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 3 Assembly and startup Safety instructions The control unit may only be installed and serviced by setup engineers who have been commissioned and trained by the company Any work on the electrical equipment of the press must be carried out only by trained electricians or by specially instructed persons under the control and supervision of a trained electrician and in accordance with the applicable electrical engineering rules and regulations Check the control unit accessories and all supply lines for possible damage prior to each startup Switch off a defective press immediately or depressurise the pneumatic system immediately and have the malfunctions repaired as soon as possible 3 1 Transport and storage Check the delivered press system components for visible transport damage Report any transport damage immediately to the following authorities the forwarding agent the dispatch department of SCHMIDT Technology Keep the original packaging for later transport and or for further storage Use the original packaging for further transport Service repairs Ensure proper packaging of the components Ensure proper pac
46. parameter defines whether a part is available on an optionally mounted workpiece fixture or not O active 1 inactive 47 ACK n ok box on off This parameter defines whether a part has fallen into an optionally mounted reject box or not O active 1 inactive 50 Bend up mm kN The measured bending constant eliminates the elastic properties of the overall system 51 BDC signal 11 3 exist This parameter defines whether the press is provided with a cylinder switch or not O not provided 1 provided 52 TDC signal 11 4 exist dto 54 Sensor type Enter the sensor type 5 kN 20 kN 100 kN or 160 KN according to the activated press type 55 Adm offsetdrift pos The allowed offset drift is set by default to 50 increments If the value of the force measuring system exceeds the nominal value or drops below it by 50 increments when the control unit is switched on the error message Error force measuring system appears on the display This error message indicates a possible defect of the force measuring system e g sensor deformed The force measuring system should be immediately checked and calibrated again 56 Adm offsetdrift neg dto 57 Aq distance PDA force The increment of the process data acquisition determines the frequency of the written measuring points standard value 5 inc i e every 5 increments one measuring point The larger the value the fewer measuring points are written 58 Aq distance PDA stroke
47. put transmits a signal After inserting a part the message will disappear After the press process the message lt Part remove lt will appear The message will disappear as soon as the part is removed A possible incorrect pressing can only be acknowledged after the workpiece has been removed 39 9 Dataset management What is a dataset CAUTION 40 Principle SCHMIDT Technology 9 Dataset management A dataset is used for the parameterization of the press system to adapt it for example to the production of different parts A dataset includes all e Working parameters user data input e Monitoring parameters 8 tolerance windows 4 stroke tolerances e Setting of the process data acquisition zoom window type of representation etc 9 1 Principle of the dataset management Loss of the dataset due to replacement or defect of the control The parameters and settings mentioned above can be stored for 20 datasets in 20 memory locations of an EPROM in the control In the case of control replacement i e changing location or a defect in the control the datasets can get lost Make note of the most important settings after having set up the working process Use the optional SCHMIDT ControlTool software for dataset management on a computer System dataset Parameters Se e Ee Tolerances save load copy copy User datasets Figure 9 1 Principle of dataset management in t
48. rameter Press the Enter key The parameter is set with the value Continuous By pressing the Enter key again you can reset the parameter to Single By default when the curve output is called the force stroke diagram of the pressing process is displayed Alternatively you can have the press curves displayed in a force time or stroke time diagram This allows individual process sequences to be visualized which can then be used for optimizing further pressing processes Select the Diagram parameter Select the desired diagram type by pressing the Enter key several times By default the diagram is displayed in the metric system of units mm KN Select the Units parameter Press the Enter key The parameter is assigned the value Imperial US Now the diagram will be displayed in the units Ibs and inch By pressing the Enter key again you can reset the parameter to Metric Enlarging details To make detailed examinations you have the possibility to enlarge individual details of the curve zoom functions These settings are made in the Zoom diagram menu Select the Curve Output system function key Press the Enter key Select the Zoom Functions command Zoom Diagram Zoom Zoom Zoom Fit Zoom All 1 CtrON CtrOFF area Aes Servic Figure 10 3 Zoom Diagram menu SCHMIDT PressControl 3000 V1 3 10 Quality monitoring Zoom All Zoom Fit
49. rite down the stroke displayed e g 600 558 mm Subtract the value 1 from this value e g 600 558 1 599 558 Enter the calculated value in parameter 59 Offset stroke Input Dataset 1 50 Bend up mm KN 000 51 BDC signal 11 3 pres 0 ee TDC signal 11 4 pres 0 54 Sensor type 5 KN 55 Adm offsetdrift pos 50 inc 56 Adm offsetdrift neg 50 inc 57 Aq distance PDA force 1 inc 58 Aq distance PDA stroke 1 inc 59 Offset stroke 599 558 mm 1 CtrON CtrOFF A wee Servic Figure 11 5 Enter the Offset stroke 54 SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 11 Maintenance and servicing The position measuring system does not have to be calibrated due to the fact that it is a digital system SCHMIDT PressControl 3000 V1 3 55 SCHMIDT Technology 12 Customer Service 12 Customer Service Please contact to the SCHMIDT Technology Customer Service department when you encounter difficulties with the press system or the software Describing problem Note if possible the error message in detail Inform the SCHMIDT Customer Service When and how often has the problem occurred and what changes has been made recently System identification When making contact with the SCHMIDT Customer Service by phone we need information concerning the control unit software This information can be seen in the System Options display mode Select the System Options system func
50. rocesses 28 Calculate deflection Enter deflection SCHMIDT Technology Figure 7 1 Positioning error due to deflection or compression 1 2 Deflection Compression After you have completely set up the press system with tools you can calculate the deflection This can be done based upon a normal press sequence Select the Curve Output system function key Press a workpiece and record the force stroke curve Enlarge the curve section so that the press start and press end are visible Figure 7 2 Calculate deflection Calculate the deflection Sample calculation Stroke difference AS 2mm Force difference AF 1 7 kN Deflection As AF 1 176 mm kN Select the Data Input system function key Select the Bend up mm kN parameter Enter the calculated value SCHMIDT PressControl 3000 V1 3 7 Press processes Before After ATTENTION Overcompensation SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology Press another workpiece and record the force stroke curve again en s mm 30 00 40 00 0 0 46 00 20 00 Figure 7 3 Force curve before and after deflection compensation After deflection compensation is performed the elastic properties of the entire system machine tool workpiece will be eliminated in each press operation in real time Wrong parts evaluation The maximum stroke Smax
51. rsor appears additionally Move the cursor using the cursor keys to the left upper corner of the desired window and confirm the position by pressing the Enter key Move the cursor using the cursor keys to the right lower corner of the desired window and confirm the position by pressing the Enter key In the curve output the tolerance window created is displayed with the designation F The tolerances are numbered sequentially SCHMIDT PressControl 3000 V1 3 10 Quality monitoring Deleting force stroke window Selecting stroke tolerance Creating stroke tolerance SCHMIDT PressControl 3000 V1 3 e Se SCHMIDT Technology Figure 10 6 Defined force tolerance Select the Curve Output system function key Press the Enter key Select the Input Monitoring Data command Select the Delete Window command The display switches to the curve output and a cursor appears additionally Move the cursor using the cursor keys to the left upper corner of the tolerance to be deleted and confirm the position by pressing the Enter key That tolerance window will always be deleted whose left upper corner lies closest to the cursor Stroke tolerances The stroke tolerance defines a section in which an expected change in force occurs the slope of the curve changes upon contact between two workpieces e g socket gt pin If a value falls below the minimum or exceeds the maximu
52. se conditions to check if the alarm can be heard during normal production operations 21 5 Data Input SCHMIDT Technology In the System Options submenu select the Speaker Volumes selection Select the Volume Keyclick command and enter the desired value Select the Volume Alarm command and enter the desired value 5 2 Standard parameters overview A total of 60 input parameters can be defined by means of the PLC program The following table describes the parameters included in the standard PLC program Malfunctions of the press system Parameters 9 to 11 51 to 59 are adapted ex works to the respective press system and should only be changed after consultation with SCHMIDT CAUTION Technology No Parameter Description 0 Mode F 0 s 1 t 2 m 3 This parameter determines according to which criterion the return stroke is to be started 0 force 1 stroke 2 time 3 manual 1 Returnstroke Force Force at which the return stroke is to be started 2 Returnstroke Stroke Stroke at which the return stroke is to be started 3 Returnstroke Time This parameter can be used to set a dwell time for the return stroke function of the press 0 to 600 sec Only after this time has expired will the return stroke be started 4 Start Stop PDA Stroke from which the process data acquisition begins is stopped return stroke 5 Counter access This parameter defines whether
53. separates the working stroke from the return stroke An overcompensation can result in a shift of Smax within the force curve If a return stroke tolerance in the diagram is above Smax it is by definition part of the working stroke Consequently the measured value will not pass correctly through the tolerance window so that O K parts will be identified as Not O K parts Avoid an overcompensation Make sure to place the tolerance in a safe area in which the measured value will pass correctly through the tolerance window in any case By definition the return stroke begins after reaching of Smax 18 34 Smax Figure 7 4 Stroke tolerance of the return stroke Overcompensation increased factor of deflection constants in mm kN may lead to a shifting of Smax within the force curve 29 7 Press processes 30 SCHMIDT Technology 2 007 FIKN 1 507 1 007 a 500 s mm 0 0 9 77 18 34 27 54 36 39 Smax Figure 7 4 Stroke tolerance in working stroke with overcompensation If the return stroke tolerance in the diagram is set above Smax it is by definition in the working stroke Consequently OK parts will be interpreted as Not OK parts and assigned accordingly Since the working stroke will change to the return stroke very rarely at a fixed position it may be difficult to find a suitable position for a tolerance in the return stroke Figure
54. ssembly and startup e User interface e Practical operation e Maintenance and servicing Technical documentation SCHMIDT press system Circuit diagram and pneumatic plan Manufacturer s Declaration or Declaration of Conformity Spare part lists Test certificates Description of special functions User Manual SCHMIDT Contro Tool Teil 1 Installation User interface Project and dataset management Quality monitoring Update and service User Manual SCHMIDT ControlTool Teil 2 e Fundamentals e PLC programming e Range of commands User Manual SCHMIDT SPC e Structure and function e User interface e Practical operation 1 Safety SCHMIDT Technology 1 Safety The press system has been built manufactured and tested ex works for its function and safety in accordance with current safety regulations and state of the art methods This guarantees its operational safety Nevertheless the press system can involve risks if e itis not used in accordance with its designated use e itis operated by untrained personnel e itis modified or converted incorrectly or e the safety regulations are not observed The press system may only be used if it is in technically perfect condition All required safety devices must be in place and fully functional Apart from the instructions listed in this operating manual the current country specific safety and accident prevention regulations provided by law apply
55. suring system is usually used for measuring quality relevant specifications it should be inspected and if necessary calibrated at reasonable intervals established by the user As specified by the DIN EN ISO 9000 a calibration of the system must be carried out at regular intervals The calibration is also offered by SCHMIDT Technology as part of its customer service A reference measuring system is needed for the calibrating of the force measuring system A calibration value is calculated using the measured value of the reference measuring system and the measured value of the machine SCHMIDT Technology optionally offers the SCHMIDT LoadCheck reference measuring system for the calibration of your system Select the Data Output system function key Press the Data Output system function key again to display the Data Output 2 Place the force sensor of the reference measuring system beneath the ram Subject the force sensor to the nominal pressing force Read the reference measured value on the display module display in kN and the measured value of the press system SCHMIDT PressControl 3000 V1 3 SCHMIDT Technology 11 Maintenance and servicing Entering measured values Calculating calibration value Checking calibration Resetting calibration value SCHMIDT PressControl 3000 V1 3 Make a note of both values Start the return stroke Select the System Options syst
56. the Datasets system function key Select the Load File command Using the Up Down cursor keys select one of the 20 memory locations and confirm by pressing Enter 41 9 Dataset management 42 SCHMIDT Technology Load File Dataset 1 Dataset 2 Dataset 3 Dataset 4 Dataset 5 Dataset 6 Dataset 7 Dataset 8 Dataset 9 Dataset 10 SOONDORWNY Ss 1 CtrON CtrOFF noes a Bee Servic Figure 9 3 Load dataset In this dialog the memory locations of the datasets are listed At the first startup of the control unit all datasets receive identical values and are numbered sequentially from 1 to 20 Renaming dataset The name of the dataset is displayed in the system functions Data Input Data Output and in the Curve Output in the right upper corner of the display The currently loaded dataset can be renamed A total of 21 characters can be used for a dataset name ee ee Select the Datasets system function key Select the Filename command The cursor blinks below the first letter of the dataset name to be edited Edit Filename Dataset 1 1 CtrON CtrOFF Reus eee Servic Figure 9 4 Renaming dataset Select the desired letter using the Up Down cursor keys The letters a to z A to Z and a few special characters are available Move to the next letter with the Right cursor key Now you may select the further letters as already described Using the L
57. tion key Select the System Options menu Inthe Service submenu select the Ident command 56 SCHMIDT PressControl 3000 V1 3
58. vated by means of softkeys on the touch screen The following table describes the softkeys included in the standard PLC program Operating level Softkey Description 1 CtrON Switch on control unit CtrOFF Switch off control unit Servic Setup operating mode switch press to airless mode 2 PCTon Switch pre selection counter on PCToff Switch pre selection counter off PCT 0 Set pre selection counter to zero CNT 0 Set piece counter to zero ACK Acknowledge fault 3 Ref Carry out a reference run The control starts automatically with operating level 1 Press the Change operating level key see Figure 4 1 This is how you switch to the next higher lower operating level All softkeys labelled with asterisk have not been assigned The assignment of the softkeys and their allocation to an operating level is done by the PLC program For further information concerning the programming of additional softkeys please see the User Manual SCHMIDT ControlTool Part 2 15 4 Operation 16 SCHMIDT Technology 4 3 Switching on and off After all mounting and installation tasks are complete the press system can be started As the control unit is supplied with voltage from the SafetyModule it can also be switched on or off by means of the main switch of the SafetyModule Start the press system as described in chapter 3 4 Switching on and off in the Operating Manual SCHMIDT
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