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Process Technologies SK 7, Operating Manual

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10/04

Technical details are subject to change without prior notice.©  Kopka GmbH

Operating Manual

Process Monitoring System

for Cold Forming Machines

SK 7

SK 7

Process Technologies Group, Inc.

30W106 Butterfield Road

Warrenville, IL 60555

Phone: (630) 393-4777 Fax: (630) 393-4680

Web: www.impaxptg.com   E-mail: [email protected]

Summary of Contents for SK 7

Page 1: ...notice Schwer Kopka GmbH Operating Manual Process Monitoring System for Cold Forming Machines SK 7 SK 7 Process Technologies Group Inc 30W106 Butterfield Road Warrenville IL 60555 Phone 630 393 4777 F...

Page 2: ...on modes 6 Sorting control idle stroke adjustment 26 sorting function 26 Envelope monitoring force 7 how to set the sorting parameters 27 envelope display 7 idle stroke adjustment 27 machine stop with...

Page 3: ...4 VDC T S N V A s c h w e r k o p k a CE s c h w e r k o p k a 24 VDC 4 A SK 4 C S1 D O 1 I1 24VDC Abmasse 200 B x 250 H x 160 T Raster Befestigungsl cher 160 B 272 H Sensor Box schwer kopka Machine I...

Page 4: ...schwer kopka SK 7 SK 7 10 4 12 1 SK7 15 Display Panel Front Panel 1 12 1 LCD colour screen TFT with Touch Screen Surface 2 Function keys Symbol keys touch elements 1 2 SK 7 V5 2 E 10 04 SK7 03...

Page 5: ...32 3 Connecting socket for Sensor Cable S1 7 Serial number plate 4 Connecting socket for Interface Cable I1 8 Rear panel lock T S N V A s c h w e r k o p k a s c h w e r k o p k a 24 VDC 4 A SK 4 C 6...

Page 6: ...10 belonging to the desired symbol in order to start the respective function For numerical entries please use the number keys on the front panel Screen layout Many features and operational steps are s...

Page 7: ...imits force and acoustic envelopes are dynamically updated and matched with the process variation Count ing of good parts made starts also Every impermissible deviation of the process curve signal wil...

Page 8: ...y Channel selection from one sensor to another is made by simply pressing the number of the channel you wish to see Changing from multiple to single curve presentation and vice versa is initiated by p...

Page 9: ...setup and establishing ineffective control limits Once this has been done one of the fol lowing procedures should be performed The system switches from adjusting mode yellow beam MAN Mode into AUTO Mo...

Page 10: ...displayed The optional SKProfilemaster software see page 27 provides a segmented envelope profile around the force curves tight where needed loose where necessary The Tolerance Tol setting determines...

Page 11: ...SKAutomaster software routines will in addition assure that the envelope band is properly adjusted While running in MAN mode the system will use a timing which is set overly wide to make sure that the...

Page 12: ...more sensitive settings depending upon what the current process will al low it to be This procedure ensures that the monitoring system always works with the best possi ble monitoring accuracy for the...

Page 13: ...r settings modification and erasing of profile zones The example below shows a profiled envelope band 2 zones with different upper and lower Sensitivity settings per zone The SKProfilemaster envelope...

Page 14: ...pe profile band The 3 zone setting allows for an even closer match between curve segment variation and adopted profiles How to set the SKProfilemaster band touch SKProfilmaster box in the single force...

Page 15: ...stops in between The trending screens can be accessed as follows 1 Press the M function key then select Trend press key 1 or 2 From the single force curve screen press the Cursor key to go to the tre...

Page 16: ...Adjusting the trend limits The trend limits can be adjusted independently for each monitored channel Press the Trend Limits function key A windows will come up on the left side of the screen giving y...

Page 17: ...off Working with relative trend limits has the advantage that the limits can remain active even when you change the machine over to another product which typically would mean totally different actual...

Page 18: ...etting the trend limits is identical to the procedure explained previously on page 20 NOTE Single stroke trending is based on individual parts and not on the average over many parts This means of cour...

Page 19: ...tter indicating the high degree of repeatability Such a process can be monitored very closely with tight envelope curves A separate Q factor is being calculated for every sensor channel and is shown a...

Page 20: ...ow stabilizes the force signal by automatically compensating left right bouncing of the wave form This allows you to run the usual tight envelopes or envelope profiles and it significantly minimizes n...

Page 21: ...anges to blue Enter the new quantity check the display to be sure you have typed in the correct number and confirm with the E key The made count automatically resets to zero and the green percentage b...

Page 22: ...he display indicates how many containers are filled already and to what percentage the current container is filled The remaining run time shows how much time is needed to fill all containers Touch the...

Page 23: ...a part with the least amount of pressure possible Low pressures are generally considered to be better for the machine and the tooling In addition the shape of the forming force curves will tell you th...

Page 24: ...ustments worked the wrong way when we assume that lower forces are better for machine and tooling The procedure described here can help to improve the machine set up step by step new curve blue showin...

Page 25: ...the M function key and entry of an access code Setting the sorting parameters Touch the numbered key to select the desired function The related data field on the right side turns dark Enter the desir...

Page 26: ...se potentially suspicious parts can all be sorted Press cursor key to get to idle stroke setting Idle stroke adjustment Some machines tend to occasionally run idle stokes due to problems in feeding bl...

Page 27: ...erated consecutive idle strokes before the machine is switched off example above 500 strokes During this time the optional warning lamp will flash to alert the machine operator of an unproductive mach...

Page 28: ...ffers as an option the possibility to memorize machine running data over a period of time and to provide some statistics from that data This function is accessible via the first page of the Menu secti...

Page 29: ...etails Sort list by time of error press 1 by type of error press 2 or by channel press 3 Use the cursor keys to scroll the blue bar to the desired position the related error curve will automatically i...

Page 30: ...in the diagram are either based upon the SK bbx s internal scale directly asso ciated with the strength of the incoming sensor signal or they can be actual tonnage kN readings in case you use calibrat...

Page 31: ...asking whether or not you really wish to make that entry SELECT PART YES NO When you picked an existing part number without data in memory or when you entered a new part number LOAD PARAMETERS YES NO...

Page 32: ...m old and new peak loads in comparison optional function To see the target force curves versus your current forces press the TOOL function key The graph shows channel by channel or in multi channel pr...

Page 33: ...r Stop relays 3 and 6 will switch every time the process monitor goes into stop Relay 4 Emergency Stop will be switched in addition with a delay of about 1 minute when a stop signal is given during AU...

Page 34: ...f Stop Connection towards machine controls Standard configuration Relay 1 Sorting Relay 2 Batching Relay 3 Motor Stop Relay 4 Emergency Stop Relay 6 parallel with 3 Motor Stop Relais 6 Relais 5 Relais...

Page 35: ...ng Connection Interface Machine Controls Power filter 6 free Power supply 85 260VAC 50 60 Hz The leads 1 2 and PE can also be used to supply general AC power from machine controls if permitted by elec...

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