Trumpf BendMaster 150 Operator'S Manual Download Page 41

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Residual risk

Dangerous point

Type of danger

Measure to be taken by
the operator

Electrical contact and
proximity to parts under
high voltage, electric
shock

■

Direct contact with nor-
mally live parts.

■

Indirect contact with
parts that are live due
to an error.

Risk of fatal injury

Maintenance/servicing/
repairs by specially
trained personnel.

Teleservice

Crushing, cutting, separat-
ing, impacting

Movements of the
machine

Risk of injury

Have Teleservice per-
formed only by persons
who have been trained by
TRUMPF.

Residual risks

Tab. 1-8

B579EN

2015-06-01

Overview of residual risks

‐

Summary of Contents for BendMaster 150

Page 1: ...Operator s manual BendMaster TruBend Cell 5000...

Page 2: ......

Page 3: ...Operator s manual BendMaster TruBend Cell 5000 Original operator s manual Edition 2015 06 01...

Page 4: ...TRUMPF Maschinen Austria GmbH Co KG Technische Redaktion Industriepark 24 A 4061 Pasching Fon 43 7221 603 0 Fax 43 7221 603 50 Internet http www at trumpf com E Mail tat at trumpf com For partly compl...

Page 5: ...d Cell 5000 bending cell for the automatic handling of sheets on the press brakes of the TruBend Series 5000 The machine documentation includes Spare parts catalog Circuit diagrams TruBend Series 5000...

Page 6: ...II Before you proceed 2015 06 01 B579EN...

Page 7: ...l productivity package 1 11 3 6 Dangers due to unexpected movements 1 12 3 7 Dangers due to Teleservice 1 12 4 Measures to be taken by the manufacturer 1 13 4 1 Danger zones and safeguarding device 1...

Page 8: ...2 11 2 5 Ambient conditions 2 11 3 Compressed air supply 2 13 4 Electrics 2 14 4 1 Electrical power supply 2 14 Connected loads 2 14 Connecting cables 2 15 4 2 Power supply 2 15 Residual current devic...

Page 9: ...9 Easy operation 3 10 3 10 Sensor gauge fingers at the TruBend Series 5000 3 11 4 axis sensor gauge finger 3 12 6 axis sensor gauge finger optional 3 13 Backstop resistor 3 14 4 Options 3 15 4 1 Exte...

Page 10: ...1 Portable manual control unit 4 6 Operating elements 4 6 Menus and submenus 4 7 1 2 Control panel 4 9 1 3 Stationary 19 screen 4 10 2 Operating the BendMaster 4 11 2 1 Safety information 4 11 2 2 St...

Page 11: ...hing off the BendMaster 4 46 4 1 Stopping BendMaster and TruBend in any emergency or after a malfunction 4 46 4 2 BendMaster switching off 4 46 5 Travel functions 4 48 5 1 Executing travel functions 4...

Page 12: ...ith the rough recognition 4 77 6 9 Defining stacks 4 78 6 10 Processing stacks 4 80 6 11 Creating a tooling plan 4 84 Checking the TruTops tooling plan 4 84 Selecting a separation method 4 85 Selectin...

Page 13: ...press brake without Bend Master 4 110 8 Errors and Messages 4 111 8 1 Displaying and acknowledging errors and messages 4 111 8 2 Troubleshoot an error 4 111 9 Error handling 4 113 9 1 Jumpering the se...

Page 14: ...er Z axis 5 11 Regripping station 5 12 Sheet removal station 5 13 Press brake sensor gauge finger 5 13 Gripper changing console option 5 14 BendMaster pivoted jaw gripper option 5 15 5 Electrical comp...

Page 15: ...components 5 24 7 1 Maintenance Instructions 5 24 Press brake compressed air supply 5 24 Maintenance Technical Service 1 Maintenance overview 6 2 Index B579EN 2015 06 01 Table of contents 0 9 Chapter...

Page 16: ...0 10 Table of contents 2015 06 01 B579EN...

Page 17: ...laser radiation 1 7 3 3 Dangers from magnetic fields 1 8 Mobile fanning magnet option 1 8 3 4 Hazards when dealing with workpieces 1 9 Sharp edged workpieces 1 9 Dangers due to floating loads 1 9 3 5...

Page 18: ...serving warnings and danger signs 1 20 5 2 Training and instructing operators 1 20 Measures applicable worldwide 1 20 5 3 Adhering to the duty of care when handling the machine 1 20 5 4 Pay attention...

Page 19: ...e and of the region USA and Canada TRUMPF also recommends compliance with the ANSI safety regulations for press brakes Observe the operator s manual for the press brake Certain operations can be a sou...

Page 20: ...regulations for the handling of heavy loads Never walk under a suspended load Use tested and appropriately sized tackle and means of transportation Employ qualified technicians to transport the machi...

Page 21: ...e machining cycle and then depending on the design version either set down at the loading or unloading position or transported onwards from the unloading position The following is not allowed Unauthor...

Page 22: ...ed TRUMPF assumes no liability for material damage or personal injury caused by gripper elements and peripheral equipment built by the user himself e g conveyor systems for the workpieces sheet thickn...

Page 23: ...ime at least 5 minutes Hot components Burns Keep switch cabinet closed Before opening the switch cabinet switch off the main switch and secure against being switched back on Wait for the correct cooli...

Page 24: ...ase of short exposure time up to 0 25 s as long as the beam is not observed through optical instruments magnifying glass lens telescope Addi tional radiation parts outside the wavelength spectrum of 4...

Page 25: ...heet metal stack in its retracted normal state Do not hold any heavy ferromagnetic parts sheets tools in your hands in the proximity of fanning magnets 1 m Keep watches and magnetic storage media disk...

Page 26: ...danger zone If there is a defect to the system outside the danger zone Eliminate the defect Deposit the suspended load on a pallet Do not move the BendMaster with suspended loads into the home positio...

Page 27: ...that the risk of workpiece loss is increased 3 5 Danger due to increased movement dynamics optional productivity package When the productivity package option is activated the movement dynamics of the...

Page 28: ...ecause the suction cup slat will start to move immediately 3 7 Dangers due to Teleservice Teleservice is used to establish a connection between the machine and Technical Service The service engineer c...

Page 29: ...mpact button 4 EMERGENCY STOP impact button on the outside at posts 1 to 4 5 TruBend 5000 6 BendMaster 7 EMERGENCY STOP impact button on the inside on post 4 8 Safety fence 9 Main switch Danger zones...

Page 30: ...falling out of the system The safety doors are monitored and enable controlled access to the system The work area of the robot is restricted at the individual motion axes of the robot using soft and h...

Page 31: ...ors is interrupted The 24 V control voltage is maintained Vacuum remains In manual mode the enable key on the portable manual control unit is pressed into the neutral position in order that the axes c...

Page 32: ...reduced speed The ENABLE KEY on the portable manual control unit must be pressed the whole time Automatic mode All axes move at the programmed speed The program is started using the START button on th...

Page 33: ...or 3 Sheet sensor 4 BendMaster switch cabinet 5 Motors between A B and Z axes 6 BendMaster 150 Under the cover of the Z axis Danger signs BendMaster Fig 59196 B579EN 2015 06 01 Measures to be taken by...

Page 34: ...2 Danger due to laser radiation Caution radiation light emitting diodes class 2M Do not look into the beam or view directly with optical instru ments when the cover is opened 2 Danger due to laser rad...

Page 35: ...ge BendMaster switch cabinet 5 Danger due to hot surfaces 6 Danger due to electrical voltage Under cover Z axis BendMas ter 150 7 Freeing of clamped persons 8 Only trained personnel are per mitted to...

Page 36: ...et ting work and service Require that personnel read the technical documentation of the machine Recommendation obtain written confirmation from the personnel For fault diagnosis and error correction a...

Page 37: ...rformance occurring in the machine to the oper ator The machine must be checked for externally visible defects and damage at least once per shift The machine must be checked for externally visible def...

Page 38: ...n by TRUMPF may be installed TRUMPF is not liable for damage if external parts and accessories are used or if spare parts and accessories approved by TRUMPF are not installed or replaced properly TRUM...

Page 39: ...Waste code with prescribed disposal method for the operat ing materials Note Safety data sheets can be obtained from the manufacturers of the respective operating materials B579EN 2015 06 01 Organizat...

Page 40: ...ufficient dis tance from moving assem blies BendMaster press beam backgauge It is forbidden to go beneath the BendMaster or between the BendMaster and the bending machine Crushing hitting shearing Fal...

Page 41: ...ve parts Indirect contact with parts that are live due to an error Risk of fatal injury Maintenance servicing repairs by specially trained personnel Teleservice Crushing cutting separat ing impacting...

Page 42: ...nents under pressure e g compressed air line Wait at least an hour to allow any residual voltage in the machine to dissipate and hot components to cool down All assemblies components can then be touch...

Page 43: ...nd storage positions over a wide area Use suitable lifting gear See installation conditions Fasten assemblies above the center of gravity as far as pos sible B579EN 2015 06 01 Disassembly and disposal...

Page 44: ...1 28 Disassembly and disposal 2015 06 01 B579EN...

Page 45: ...6 2 1 Space requirements 2 6 2 2 Floor requirements 2 6 Surface 2 6 Floor quality 2 8 2 3 Weight load 2 10 2 4 Stress due to vibration 2 11 2 5 Ambient conditions 2 11 3 Compressed air supply 2 13 4 E...

Page 46: ...Network link 2 17 5 Transport 2 18 5 1 Preparing transport 2 18 Transport dimensions 2 18 5 2 Permitted auxiliary tools 2 18 5 3 Checking unloading and transporting the machine 2 20 On delivery check...

Page 47: ...machine may only be switched on by Technical Service The machine is put into service by Technical Service Start up includes Installing aligning leveling and securing the machine Connecting the machin...

Page 48: ...e Exposure to sunlight Purity of the ambient air Check transport route e g Gateway openings Header heights Cable rack heights Shunting areas around corners At least 8 weeks Installation plan Confirm t...

Page 49: ...feedback to confirm that the requirements of the installation conditions have been implemented During installation and start up Electrical installation At the start of the installation process have t...

Page 50: ...TruBend Cell 5000 with BendMaster 60 at least 4000 mm at least 157 in TruBend Cell 5000 with BendMaster 150 at least 5000 mm at least 197 in 2 2 Floor requirements The quality of the prepared parts c...

Page 51: ...ng examples Tab 2 2 Measuring procedure The straight edge is placed on the high points of the surface and determines the depth gauge at the lowest point For the selected measuring point distance the d...

Page 52: ...ent the arrangement of the expansion joints must be paid attention to A Joint arrangement permissible B Joint arrangement not permissible Expansion joints top view Fig 58390 Floor quality Note The flo...

Page 53: ...5085 X 5085 SX 5130 X 5170 X 5170 SX 5230 X 5230 SX 5320 X Top lengthwise xsi cm2 m 3 20 3 20 3 24 3 62 6 55 4 90 7 18 7 94 Top transverse eta cm2 m 3 20 3 20 3 20 3 20 3 20 3 20 3 80 4 20 Below leng...

Page 54: ...by the following meas ures Use Sylomer mats to isolate the machine thickness 12 mm 0 47 in quality SR 1200 violet color base plate to the sub surface and on the side Structure of the floor from the b...

Page 55: ...16 m floor lane 630 in 3264 kg 7196 lb Tab 2 5 2 4 Stress due to vibration In the immediate area around the system external influences can lead to vibration loads Vibration loads can effect the quali...

Page 56: ...ily but non condensing Ambient conditions for the control system Tab 2 7 Bright light impairs the sheet sensor of the BendMaster The sheet sensor may not be exposed to direct sunshine No halogen lamps...

Page 57: ...r of the sup ply line 13 mm 1 2 Min nominal diameter of the main line 13 mm 1 2 Length of the connecting line No limit Supply lines compressed air supply Tab 2 9 Property Requirement Quality class1 Re...

Page 58: ...ormance A voltage stabilizer is necessary Otherwise a regulated isolating trans former can be used Before shipping the system is set to the power supply voltage and frequency specified by the customer...

Page 59: ...ature of 90 C 194 F No aluminum cables may be used to connect the machine Cable cross section The cable cross section must comply with NEC 670 4 a The cable cross section must be designed for at least...

Page 60: ...ve Selective Sensitive to all types of current resistant to current surges 5 kA Sensitive to all types of current resistant to current surges 5 kA Sensitive to all types of current resistant to curren...

Page 61: ...if the machine is connected to an IT network TRUMPF recommends surge diverters from the following manu facturers Phoenix Contact GmbH Co KG Flachsmarktstra e 8 D 32825 Blomberg E mail info phoenixcont...

Page 62: ...he following including auxiliary tools and means of transporta tion 5 1 Preparing transport Before the machine is delivered check the following Is there sufficient space for transport to the installat...

Page 63: ...weight According to the machine weight Lifting belt According to the machine weight According to the machine weight Permitted auxiliary tools Tab 2 16 When transporting the machine with a crane use t...

Page 64: ...PF within six days Unloading and transporting the machine Suspended load Falling loads could lead to severe bodily injury or even death Observe safety regulations for the handling of heavy loads Never...

Page 65: ...mportant assemblies 3 6 3 1 Nameplate 3 6 3 2 Floor lane 3 7 3 3 Arm 3 7 3 4 BendMaster switch cabinet 3 7 3 5 Sheet sensor 3 8 3 6 Rotational transformer 3 9 3 7 Safety fencing 3 9 3 8 Control panel...

Page 66: ...er 3 19 Pivoted jaw gripper and pivoted jaw grip per with turning axis 3 20 4 4 Sheet removal station 3 21 4 5 Double sheet recognition and double sheet separation 3 22 Double sheet recognition 3 23 D...

Page 67: ...end Very high flexibility due to the option of configuring the load ing and unloading positions the length of the floor lane grip per changes and the regripping unit as desired as well as due to a she...

Page 68: ...Bend mm 1270 TruBend 5050 to 5130 1230 TruBend 5170 to 5320 1650 Weight kg 620 784 Floor lane m 4 Extendable up to 14 m in steps of 2 m 6 Extendable up to 16 m in steps of 2 m Floor lane weight per 2...

Page 69: ...ga drive A axis Rail interpolation for arm movement Drive via synchronous motor eccentric gear B axis Rail interpolation for arm movement Drive via synchronous motor eccentric gear C axis Rail interpo...

Page 70: ...6 TruBend press brake 7 BendMaster arm 8 BendMaster switch cabinet with nameplate 9 Floor lane The most important assemblies Fig 58810 3 1 Nameplate The nameplate with the CE marking is located on the...

Page 71: ...ess brake during the bending process The loading and unloading area may also be positioned next to the press brake In this case the arm also faces the brake press during loading and unloading A BendMa...

Page 72: ...ed for in the recorded image and the position of the work piece is determined if the pattern is found This position data is used to bring the sensor head into the right position for height measurement...

Page 73: ...r transfers compressed air vacuum AS i bus signals and 24 V DC for the vacuum gripper It is driven by an attached servomotor 3 7 Safety fencing The safety fencing prevents access of persons in automat...

Page 74: ...ntrol unit Press the following keys simultaneously Robot menu Position menu V The control panel also contains the visualization computer and the control cabinet of the BendMaster The main switch is on...

Page 75: ...ies 5000 If the BendMaster is used the standard equipment of the Tru Bend Series 5000 includes sensor gauge fingers The sensors recognize automatically when the sheet is up against or on gauge fingers...

Page 76: ...support and can be pressed in The BendMaster presses the workpiece to be bent against the sensor gauge finger The control releases the press beam for bending only once the workpiece rests properly ag...

Page 77: ...transferred to the control system The control system releases the press beam for bending only once the workpiece rests properly against the sensor finger The stop block for small parts is screwed on...

Page 78: ...backstop resistor Backstop resistor is cut in Thick workpieces must overcome the spring force of the sen sor gauge and the magnetic force of the backstop resistor when stopping This ensures that the w...

Page 79: ...changing console is present then a change of grip per can be carried out automatically see Automatic gripper change option pg 4 28 Vacuum gripper Vacuum grippers are operated with vacuum They are suit...

Page 80: ...1 Suction cup 2 Base plate 3 Gripper quick change adapter Fig 41774 1 Pneumatic cylinder for sheet separation 2 AS i module Fig 41775 3 16 Options 2015 06 01 B579EN...

Page 81: ...y can each of the four inner and outer suction cups be adjusted on the multigripper the arms with the suction cups can also be moved to the left and right Their individual activation allows individual...

Page 82: ...ual suction cup circuits can be switched on or off separately due to the individual suction cup activation Gripper construction kit The gripper construction kit is a modular system which consists of v...

Page 83: ...cesses or which are made of perforated sheets can still be reli ably gripped Fig 58424 Linear gripper The linear gripper is a vacuum gripper used preferably for profile parts Excess regripping is prev...

Page 84: ...switches Traverse path between the end positions 316 mm Note For operation see the supplement to the BendMaster operator s manual Linear Gripper Option Pivoted jaw gripper and pivoted jaw gripper with...

Page 85: ...ter Many different parts geometries can be machined with different gripper jaws A pneumatically driven turning axis option can rotate the grip per through 180 The number of regripping operations can t...

Page 86: ...n and if required dou ble sheet separation can be carried out The sheet removal station prepares the next sheet during Bend Master operation Note For operation see Supplement to the BendMaster Operato...

Page 87: ...dMaster systems which do not have the integrated double sheet recognition option Pallet scales for double sheet recognition Fig 38423 Double sheet recognition is carried out using pallet scales When a...

Page 88: ...e within the elastic range This bending process exerts a force on the two workpieces resulting in a peeling movement 4 6 Regripping station The regripping station is used if it is not possible to re g...

Page 89: ...be deposited inside Modular extension of up to four gripper changing consoles is possible 1 Upper gripper deposit station with gripper 2 Lower gripper deposit station Gripper changing console Fig 5301...

Page 90: ...y increase is achieved via synchronized travel motions and optimized continuous path control of the robot Axes control optimization Torque pre control exact pre calculation of the necessary drive torq...

Page 91: ...tal stack There it creates several magnetic poles which repel each other This effect causes to the separation of the sheets that have become stuck together 1 Sheet metal stack to be sepa rated 2 Setti...

Page 92: ...equipment for the BendMaster Fig 61948 Note For operation see Operator s manual for transport equipment 4 12 Store connection The TruBend Cell 5000 can be linked to a storage system The interface wit...

Page 93: ...e option 4 13 TruTops Bend TruTops Bend is the programming system for the bending tech nology There is an additional module for TruToPs Bend which can be used to program the BendMaster This allows two...

Page 94: ...d operating mode The BendMaster must be in home position when operating the bending cell manually All doors must be closed The operator is locked in within the safety fencing Some of the options of th...

Page 95: ...4 9 1 3 Stationary 19 screen 4 10 2 Operating the BendMaster 4 11 2 1 Safety information 4 11 2 2 Status display 4 11 2 3 Software versions view 4 13 2 4 User settings 4 13 Changing settings 4 13 Crea...

Page 96: ...ster 4 39 Referencing the Z A B C Z1 Z2 axes 4 40 Referencing the D axis 4 41 3 3 Referencing TruBend 4 42 4 Switching off the BendMaster 4 46 4 1 Stopping BendMaster and TruBend in any emergency or a...

Page 97: ...s 4 76 Intermediate layer searching for 4 77 Procedure in the event of problems with the rough recognition 4 77 6 9 Defining stacks 4 78 6 10 Processing stacks 4 80 6 11 Creating a tooling plan 4 84 C...

Page 98: ...in automatic mode 4 108 7 Working at the press brake without Bend Master 4 110 7 1 Working at the press brake without Bend Master 4 110 8 Errors and Messages 4 111 8 1 Displaying and acknowledging er...

Page 99: ...10 3 Problem part interference contour recognized 4 130 Solution interference contour recognized 4 131 B579EN 2015 06 01 Operation 4 5...

Page 100: ...elements Button array for various functions PULSE TRIGGER SWITCH EMERGENCY STOP impact button 1 Pulse trigger switch 2 Red LED for indication of error messages 3 Green LED Ready for opera tion 4 Butto...

Page 101: ...Select double sheet recognition and the separation method Bending parameters from software version 5 0 and higher Setting of parame ters for the bending support for the backgauge sensor system for app...

Page 102: ...ipping station User key 3 Press 1x Display of the speed in mm s Press twice the acceleration is indicated in mm s2 Press 3 x the jerk is indicated in mm s3 the smaller it is the smoother the accelerat...

Page 103: ...t button 6 BendMaster main switch Control panel with 19 screen mouse and keyboard Fig 41798 On the control panel Main switch On the support of the portable manual control unit Operating mode key switc...

Page 104: ...1 3 Stationary 19 screen The same user interface is used on the stationary 19 screen option as for the portable manual control unit A keyboard and mouse are available for operation Only the user inte...

Page 105: ...cause the blank could be released from the gripper Workpiece is suspended from the suction cup of the BendMaster The workpiece may fall down if the vacuum is reduced If the warning signal is emitted e...

Page 106: ...square job execution has been stopped Yellow double line execution of program is inter rupted Name of loaded job Single job SO Single Order mode Default process ing mode Is activated as soon as a job...

Page 107: ...ion software are both div ided into system software and application software Fig 39914 2 Double click on the desired software area The software ver sions are displayed 2 4 User settings Changing setti...

Page 108: ...sers pg 4 15 6 Press Release write permission The write permissions for the operating unit used are deactivated The operating units which can be used are the portable man ual control unit and the opti...

Page 109: ...irec tory C xChange BIO as a ZIP file The file name consists of the date and time of creation BIO files no longer required should be deleted Creating and modifying users 1 In the menu select Service U...

Page 110: ...The User configuration mask appears 10 Confirm the query 2 5 Operating modes The BendMaster has four different operating modes Automatic mode In automatic mode the BendMaster is controlled automatica...

Page 111: ...portable manual control unit On the support for the portable manual control unit On all posts of the safety fencing TruBend CONTROL key switch is set to ON Press beam not in sloping position Rear pro...

Page 112: ...sed All lift gates are closed The GREEN button on the mounting device of the portable manual control unit has been pressed once BendMaster is ready for operation Notes Lift gates can be opened only wh...

Page 113: ...ss once Deactivation of the catch is reported The RED button flashes slowly The current workpiece is finished 2 Press the START button on the portable manual control unit once BendMaster is moved into...

Page 114: ...ng cell To reset the deactivation of the 30 second catch Press the GREEN button in the mounting device of the portable manual control unit for at least 3 seconds or Press any EMERGENCY STOP button and...

Page 115: ...etizing protected field GREEN button on post 1 has been pressed The catch is activated The green key lights up Notes Lift gates can be opened only when the safety doors are released Deactivate the cat...

Page 116: ...he operator may be within the safety fencing If the compressed air fails an acoustic warning signal is emitted in manual mode and a cyclic error message is displayed at the HMI The BendMaster stops an...

Page 117: ...The move coordinate system currently set is displayed in the header There are six different move coordinate systems which can be used to move the BendMaster axes see Tab 4 4 pg 4 26 2 Set coordinate...

Page 118: ...1 to 100 in steps of 1 at continuous pressure in steps of 5 and then in steps of 10 4 With write permission press the speed window as required Manual speed is switched to automatic speed or vice versa...

Page 119: ...is D Movement of the D axis Cartesian CART X Towards or away from the press brake R Upwards or downwards Z To the right or left on the floor lane a Reorientation around the tool cen ter point the cent...

Page 120: ...r to the left Tab 4 4 The two other coordinate systems are tool coordinate systems Tool coordinate system TOOL Coordinate system for the respective tool position Corre sponds to the Cartesian coordina...

Page 121: ...dinate system Press the DISPLAYED COORDINATE SYSTEM button on the portable manual control unit The coordinate system is changed each time the button is pressed or Under Coordinate system press Select...

Page 122: ...pper In manual mode press and hold manual mode Press the middle Arrow or In automatic mode lock the safety fencing Press the middle Arrow The board is gripped or deposited with the gripper 8 Press the...

Page 123: ...operation the GREEN button was pressed and the BendMaster icon is green Gripper deposit station is occupied The gripper has a name Fig 52484 1 Select Robot Gripper deposit station menu Note A job mus...

Page 124: ...n not taught Deposit station occupied gripper unknown Deposit station occupied gripper known Deposit station free Status of gripper changing console deposit station Tab 4 5 5 Select Ok The BendMaster...

Page 125: ...Master icon is green A free deposit place is available at the gripper changing con sole The gripper is loaded at the BendMaster 1 Select Robot Gripper deposit station menu 2 Select Lay down gripper 3...

Page 126: ...trigger switch on the portable manual control unit has been pressed BendMaster icon is green Automatic mode BendMaster is ready for operation the GREEN button was pressed and the BendMaster icon is gr...

Page 127: ...t Position Position 2 Select the AUX move coordinate system Note The regripping station is integrated in TruTops If no regrip ping station is used the regripping consoles must be dis mounted Fig 51842...

Page 128: ...rms onto the regripping con soles 1 Angle setting 2 Length setting Regripping station Fig 41347 5 Set the position of the gripper arms according to the tooling plan with the help of the angle scale an...

Page 129: ...per to activate or deactivate the vacuum I O 1 vacuum on I O 0 vacuum off Removing the regripping station 1 Move the regripping station into the parking position with the Regripping unit in park posit...

Page 130: ...gardless of the program The backstop resistor can be set at the programmer user level see Fig 51840 pg 4 15 or higher regardless of the pro grams and jobs Condition Backstop resistors have been activa...

Page 131: ...ctive with a checkmark The backstop resistor is active while the backgauge with draws from the workpiece The function corresponds to When moving if the back stop resistor is set for a single program s...

Page 132: ...xisting users edited in the Service User configuration menu see Creating and mod ifying users pg 4 15 4 Set the CONTROL ON key switch at the TruBend to 1 5 Turn the BendMaster key switch on the mounti...

Page 133: ...after switching on and then referenced NRef in the header of the speed window status of the drive unknown e g after restarting the con trol N drive not referenced 1 Indication in the header in the sp...

Page 134: ...ady for operation pulse trigger switch on the portable manual control unit has been pressed BendMaster icon is green 1 Select the Position Position menu on the portable manual control unit 2 Press Ref...

Page 135: ...e run of the regripping station to the right hand reference switch at the parking position is started Referencing the D axis Conditions Manual operating mode is active No error messages i e green LED...

Page 136: ...axis until the reference marks are in alignment with each other or BendMaster 150 Press the blue D button on the portable manual control unit A reference trip of the D axis is carried out until the i...

Page 137: ...l unit has been pressed BendMaster icon is green or In automatic mode BendMaster is ready for operation the GREEN button was pressed and the BendMaster icon is green 1 Press the Press Press servicing...

Page 138: ...ol clamp 6 Clamp release lower tool clamp 7 Approach upper dead point 8 Approach mute point in auto matic mode only 9 Approach clamping point 10 Approach lower dead point Fig 46148 3 Press Up 4 Press...

Page 139: ...onnection The TruBend user interface is shown on the visualization PC Tip If a VNC connection already exists you can press Alt Tab to switch to the VPC connection B579EN 2015 06 01 Switching on and re...

Page 140: ...the portable manual control unit 4 2 BendMaster switching off Condition The control is in the Position Automatic menu 1 Press Stop to stop the program 2 If there is a blank on the BendMaster move into...

Page 141: ...off the main switch of the BendMaster Note The TruBend has its own main switch To switch off the Tru Bend see the Operator s manual for TruBend 5000 Series B579EN 2015 06 01 Switching off the BendMast...

Page 142: ...een LED on the portable manual control unit lights up acknowledge error if red LED is on In manual mode The BendMaster is ready for operation pulse trigger switch on the portable manual control unit h...

Page 143: ...off Robot in parking position Moves the BendMaster into the parking position The BendMaster is extended The parking position is approached For pallet change in automatic mode For the store connection...

Page 144: ...t movement so that this procedure is taken into consideration during the collision check For the procedure refer to the TruTops Bend software manual version 3 chapter 8 section Moving the cantilever p...

Page 145: ...of the robot speed pg 4 52 2 Adjust the parameters to the weight of the workpiece When doing this make sure that the center of gravity of the work piece is in the center of the suction cup arrangement...

Page 146: ...the TruTops program or select a job which has already been created Set job details such as fine recognition height measurement and error strategy Select areas where the BendMaster picks up workpieces...

Page 147: ...are displayed in the Selected Order window 5 Mark the job to be executed in Selected Order The selected job is opened and graphically displayed The name of the selected job is displayed in the Order...

Page 148: ...r the customer name or job number 15 Press OK The current project status is displayed under Status Symbol Description No job selected or error Job selected without errors Stacks have been defined Job...

Page 149: ...the calculation of the stack height Material The material programmed in TruTops Bend is displayed Unprocessed material or intermediate layer part Tab 4 9 Name Description Material ID store ID number o...

Page 150: ...and window The orders in the backup directory are dis played in the right hand window 2 Mark the orders to be archived in the left hand window 3 Press The marked orders are noted for archiving in the...

Page 151: ...d 3 Press The marked orders to be restored are noted 4 If the order is already in the control confirm the correspond ing query with OK 5 Press OK The marked orders are restored Deleting a job 1 Press...

Page 152: ...is stored in the control and is displayed again when the system is next accessed 1 Press Job File away Fig 76903 The orders saved on the BendMaster are displayed in the left hand window The orders in...

Page 153: ...h are defined in the job details are stored in the respective job and apply to all loading and unloading areas The settings for individual areas can be modified in the Area details mask Defining expos...

Page 154: ...recognition is carried out at defined intervals in the stack Period number of blanks after which a height measurement takes place If for example 3 pieces are entered a height measurement is carried o...

Page 155: ...ried out with each additional sheet If the fine recognition does not find any more blanks then the stack is marked as being empty through height measurement Once the quantity of 0 is reached a height...

Page 156: ...48245 Areas that cannot be changed Lines and areas Description Lines orange Fixed contours e g bending cell or press brake Dotted area white Working areas unloading areas Thin lines green Possible se...

Page 157: ...a cyan Unloading areas for blanks in case of area type Unload Precise Area white Unloading area for blanks with Deposit quality area type The periods for depositing for quality assur ance are entered...

Page 158: ...ress Continue or Press Set up Job details The job is loaded see Fig 48245 pg 4 62 Adjusting an area 1 Select the area to be changed Mark the area to be changed in the Active Areas list This area is di...

Page 159: ...direction is only possible by changing the starting point However it may be the case that the BendMaster can no longer approach the unload ing positions If the sheets of the loading stack are larger t...

Page 160: ...es which are joined to form an overall image varies depending on the size of the area The position of the intermediate layer in the overall image is determined by means of the rough recognition proces...

Page 161: ...agram 2 Press Area Copy The values of the selected area are adopted as proposal The following mask appears Fig 35718 3 Enter name Tip Use descriptive names 4 Enter the Z and X coordinates of the area...

Page 162: ...2 Press Area Approach laser position 3 Confirm the query with OK The area positions are approached 4 Press user key 2 to switch on the laser The point opposite the starting point of the selected area...

Page 163: ...ch on the laser The point opposite the starting point of the selected area is displayed X at the HMI user interface Fig 49446 5 Position the pallet 6 The opposite point of the starting point of the se...

Page 164: ...active if by layers has been selected in the Stack execution mode field Can only be defined for loading areas 3 Enter the height tolerance Maximum difference in height between the stacks which is stil...

Page 165: ...t mode As with job setting default value the job is resumed with the programmed settings No height measurement no additional rough recognition is carried out Determination of the minimum quantity of s...

Page 166: ...be viewed in order that the rough recognition process does not have to be repeated when searching for two or more loading stacks 13 Press Apply The graphic is displayed again 6 8 Performing the rough...

Page 167: ...image recording is reset from the currently zoomed in section to the previous image detail The function can be repeated until the original size is established Zoom 100 image recording size is reset t...

Page 168: ...search area the com plete blank must be within the displayed search area 5 Press Find stack 6 Enter the approximate stack height 50 mm stack height only without transport medium 7 Press OK The height...

Page 169: ...d out both in a defined search area and in the complete search area For a rough recognition in a search area the blank may protrude beyond the displayed search area in the X direction see Fig 39926 pg...

Page 170: ...he Stack layout mask appears Searching for further loading stacks Condition The rough recognition process is carried out 1 Switch to the Run in Area menu 2 Press Display Images of approximate search 3...

Page 171: ...properly Stack is not entirely in the search area 2 Use Search within area 3 Search for several stacks with separate individual loading areas 4 Reduce the size of the loading area if possible 5 Search...

Page 172: ...ncorrect in the Set upAreas menu 9 In the Set up menu press Apply areas 6 9 Defining stacks Switching over to Stack layout user interface is performed either automatically after the find stack process...

Page 173: ...de is displayed Note The coordinates of the starting point of the marked stack are displayed at the coordinate arrows for the X and Z directions Loading stack Stack mode Color L stack active Blue L he...

Page 174: ...collision free position e g zero position Loading or unloading stacks no longer used can be deleted Active stacks must first be deactivated before they can be deleted 1 Press Process Delete stack or P...

Page 175: ...ly one loading and unloading stack can be active at a time If a loading stack is in L coordinate OK stack mode sheets can be picked up since the BendMaster automatically measures the height 7 Press Pr...

Page 176: ...up as programmed in TruTops Number of layers Number of layers of the stack Current number of sheets Number of sheets of sheets in the loading stack Calculated on the basis of the stack height Can be c...

Page 177: ...n the unloading stack until A stack full is established The maximum number of finished parts comes from TruTops and depends on the simulated unloading stack It can only be reduced not increased Detail...

Page 178: ...ut mask Press Continue or press Set up Tooling plan 2 Press Setup plan The setup plan created in TruTops Bend is displayed Fig 39936 3 Load the bending machine according to the tooling plan 4 To displ...

Page 179: ...4 Set the suction and blow off times Timeout suction Delay until the vacuum switch is actuated Blow off time period during which the sheet is blasted when deposited Blowing clean time Period after dep...

Page 180: ...nt see Tab 4 24 pg 4 87 Name Description Separating time Duration of the peeling movements Delay time Time between two peeling movements Cycles Number of peeling movements Separation at gripper Tab 4...

Page 181: ...dless of the fine recognition set 8 Set a checkmark at Separate before measuring if a peeling cycle is to be carried out prior to the double sheet measure ment Note Only peeling is possible at the gri...

Page 182: ...recognizing that a double sheet has been picked up The execution of the program is resumed after successfully separating the double sheet Integrated system A double sheet recognition is performed wit...

Page 183: ...even after crossing Opening bending parameters 1 On the Separation method screenPress Continue or press Set up Bending parameters Fig 49448 Note The Backstop resistor field is displayed only for acti...

Page 184: ...a greater extent and the movements proceed more gently The delay time of the BendMaster compared to the bending part becomes even longer High The TruBend position settings are filtered to the maxi mu...

Page 185: ...The right sensor is active in the Z direction Setting the approach strategy The travel motion of the press beam during bending in combina tion with the search movement of the backgauge is set in the A...

Page 186: ...trength of the backstop resistor between 0 and 100 Left actuation of the left backstop resistor Right actuation of the right backstop resistor 5 Press For all bendings if the backstop resistor setting...

Page 187: ...SELECT TrumpfRobot Program reserves a robot The robot can no longer be used by any other program START_ORDER The robot gets ready for processing the selected job CHECK_PRESSTOOL Starts the bending mac...

Page 188: ...f a program is to be executed only up to a specific program point Interrupt the program at the portable manual control unit using the red STOP key Press Stepping Mark the program point at which the pr...

Page 189: ...d position of the marked point is approached manually and saved as a new position To edit a point the position is changed by changing the coor dinates manually in the respective coordinate system In a...

Page 190: ...sing the red STOP key 2 Approach the point to be taught step by step 3 Approach the new position manually make sure the correct coordinate system is used 4 Mark the program point to be taught This pro...

Page 191: ...ion is moved along a path The speed of the tool center point remains constant PTP Point to point path The movement from the starting position to the end position is as quick as possible regardless of...

Page 192: ...system mPos 1 Second coordinate axis in the right hand standard coordinate system mPos 2 Third coordinate axis in the right hand standard coor dinate system Position regripping station Z3 Position of...

Page 193: ...here the main run indicator is to be set 3 Select Operation Set PC Fig 39943 4 Press the green START key on the portable manual control unit The automatic program is resumed at the marked line Deletin...

Page 194: ...ve been referenced see Referencing the Bend Master pg 4 39 The program has been run in The system is ready for operation in automatic mode No error messages i e green LED on the portable manual contro...

Page 195: ...al lamp on the safety fencing is switched on The number of available free deposit places below which a warn ing information is issued can be programmed 8 Enter the corresponding quantity in the Advanc...

Page 196: ...part and the quantity as to how often it is to be produced In addition the speed can also be set Creating or modifying a production plan Conditions It must be possible to use the tool setup plan for T...

Page 197: ...ment is removed from the produc tion plan on the left 12 Highlight the element to be modified in the production plan 13 Press to move the element up or Press to move the element down 14 Highlight the...

Page 198: ...list production package or job in the window on the left 2 Press Save 3 Press Apply 4 According to the selected element press Check job Check package or Check job list A check is made to determine whe...

Page 199: ...height must not exceed the permissible maximum value when returning processed parts to storage Defining parts data 1 Press Set up Job menu 2 Enter the parameters lot size etc 3 Press Parts data 4 In t...

Page 200: ...rage management software Intermediate layer search automatic If present a rough recognition process is performed at the beginning of each intermediate layer stack and the stack is then completely exec...

Page 201: ...e The pallet ID must be know to the storage management soft ware Sequence Request a pallet BendMaster automatically moves into parking position The lift gate opens The storage cart enters with the req...

Page 202: ...ally see Production planning pg 4 102 If a job or production plan is started the control checks whether the required raw material is in the production cell The control also checks whether the finished...

Page 203: ...ton was pressed and the BendMaster icon is green 1 Press Display Details 2 Select a storage station from the drop down menu 3 Set the checkmark at Activate deactivate automatic mode All storage trips...

Page 204: ...standing on or storing parts on it Damage to the floor lane Do not step on the covering Do not deposit any workpieces on the covering 3 Close all safety doors if the operator is inside the bending ce...

Page 205: ...go on if there is an error at the BendMaster 1 Press Diagnostics Existing messages Fig 39953 2 Press Alarms Errors messages to display each message type individually 3 Press Alarms All to display all...

Page 206: ...3 Press Effect to display the possible effects of the error 4 Eliminate the cause of the error or the message 5 Acknowledging faults 4 112 Errors and Messages 2015 06 01 B579EN...

Page 207: ...matically 5 Press the green START button on the portable manual con trol unit The execution of the program is resumed 9 2 Image processing diagnostics Two CCD cameras Charge Coupled Device are used fo...

Page 208: ...0 nm blue 760 nm red The aim of the approximate position is to define the position of the individual part stacks This is done with the coarse position recognition process and the camera pictures used...

Page 209: ...to ensure the precise position recognition takes effect Four flashes which are activated separately are used to record the fine position image They are arranged at an angle of 90 to each other and in...

Page 210: ...image is of good quality as the following layer recognition process relies on this A good image quality is indicated by the fact that the edges of the parts are clearly identifiable in the recorded i...

Page 211: ...process The current position of metal Since the model is used for position recognition in the recorded images the contour of the CAD data must match the contour of the parts to be identified as precis...

Page 212: ...ur of the fine position model at this point in the recorded image Red lines indicate that the contour has not been found Yellow lines indicate that the contour has been partially found Fig 52330 The r...

Page 213: ...ndow only contains closed inner con tours the best result can always be applied If parts on the stack are then displaced the parts further down are concealed Examples for sorting by quality with sheet...

Page 214: ...user interface with Alt Tab 2 Press TRUMPF Logo at the TOS user interface 3 Press MMI 4 Press BV diagnostics The Vision Diagnostics tool is started or If the diagnostics tool is already open press Alt...

Page 215: ...d no connection to the image processing software The search results are not displayed in the diagnostic program Edit mode Run mode is not active Parameters can be changed Run mode Run mode is active T...

Page 216: ...mitting elements Save settings Saves the user defined settings for the currently loaded position recognition model The saved settings are available again if this model is reloaded for the next positio...

Page 217: ...by influences such as machining tolerances burrs on edges working distances etc Typical fine position values 0 3 Typical approximate position values 3 4 Ignore Polarity During position recognition it...

Page 218: ...ot activate X Activate 0 X Both options Simple contour Average contour Complex contour Inner contour Acceptance Elasticity Polarity ignoring 0 0 X 0 X X Sorting according to position X X X 0 Tab 4 30...

Page 219: ...he program 1 Diagnostics menu press BV diagnostics 2 Press BV restart The image processing software is restarted 9 3 Teleservice 1 Change to the TOS user interface with Alt Tab 2 Press MMI 3 Press Tel...

Page 220: ...the BendMaster when recording the image The entire selected search contour is on the recorded image The distance between the sheet surface and the upper edge of the BendMaster s covering hood is exac...

Page 221: ...identified Increase the position recognition tolerance two options 1 Set Pre defined settings to Complex contour The elasticity is increased and the acceptance threshold is reduced The part position i...

Page 222: ...a quality of 98 Position recognition by Ignore Polarity Fig 52492 10 2 Problem Part underneath detected Not the highest part but a part below it is identified 4 128 Solving problems and troubleshootin...

Page 223: ...ent quality for the highest part with an acceptance of 80 The part under neath it was found with sufficient quality Solution part underneath detected Increase the position recognition tolerance Increa...

Page 224: ...on by increasing the Elasticity to 2 0 Fig 52494 10 3 Problem part interference contour recognized An existing interference contour on the surface of the part not the part itself is recognized 4 130 S...

Page 225: ...s have to be sorted by their position see Fig 52331 pg 4 119 the innermost result in this case the scratch on the blank is always selected Solution interference contour recognized Reduce the position...

Page 226: ...position of the topmost part is recognized with a quality of 99 The scratch is no longer recognized The highest part was identified Fig 52496 4 132 Solving problems and troubleshooting 2015 06 01 B57...

Page 227: ...3 2 Maintenance Instructions 5 7 BendMaster Z slide 5 7 Regripping station option 5 8 4 Mechanical elements 5 10 4 1 Maintenance Instructions 5 10 Safety fencing 5 10 Lift gate 5 10 Transport equipmen...

Page 228: ...enance Instructions 5 17 BendMaster control cabinet 5 17 BendMaster switch cabinet 5 18 BendMaster fan in the C arm 5 20 BendMaster fan Z slide 5 21 6 Optical components 5 22 6 1 Overview 5 22 6 2 Mai...

Page 229: ...an ing wool kerosene or benzene Do not mix synthetic lubricating oils with mineral oils or syn thetic oils from other manufacturers even if the synthetic oil in question has equivalent properties Disp...

Page 230: ...tasks in accordance with DGUV Vorschrift 3 previous number was BGV A3 Furthermore the regulations of the relevant country are also applicable 5 4 General guidelines 2015 06 01 B579EN...

Page 231: ...bonate windows for dam age 5 10 Every 6 months Safety fencing Cleaning the polycarbonate panes 5 10 Every 6 months Lift gate Checking the lift gate without store inter face 5 10 Every 6 months Lift ga...

Page 232: ...Linear bearing on the other regripping station 2 Linear bearing at the Z slide guide carriage Fig 71106 Maintenance interval Read the maintenance instructions Lubricate with a grease gun Tab 5 1 5 6 L...

Page 233: ...ation rack INNOTEC Ceramic Grease Spray Material no 0816642 KP2N 30 NLGI 2 Lubricants Tab 5 2 3 2 Maintenance Instructions BendMaster Z slide see Overview pg 5 6 Maintenance interval 1000 operating ho...

Page 234: ...he grease gun Regripping station option see Overview pg 5 6 Maintenance interval Every 6 months 1 Release gripper 2 Move the BendMaster into home position 3 Shut down the machine properly secure the M...

Page 235: ...107 Maintenance interval Every 6 months 1 Shut down the machine properly secure the MAIN SWITCH and secure with a padlock 2 Check the rack for damage 3 In case necessary lubricate the rack B579EN 2015...

Page 236: ...de 3 Check the control unit of the lift gate of the upper end posi tion Correct display Eo 4 Manually close the lift gate in manual mode 5 Check the safety bar for proper function The lift gate has to...

Page 237: ...the system is deactivated 9 Carry out steps 1 to 8 on all lift gates Transport equipment option transport belt Maintenance interval Every 6 months Condition Manual operating mode is active 1 Manually...

Page 238: ...correct after cleaning the muffler must be replaced 1 Silencer Regripping station suction cup Fig 71049 1 Shut down the machine properly secure the MAIN SWITCH and secure with a padlock 2 Screw out th...

Page 239: ...active 1 Check the sensor gauge finger for damage 2 At the HMI user interface open Press Press sensor sys tem The ON OFF checkbox must be activated 3 Enter 20 in both fields Backstop resistor Left and...

Page 240: ...Tab 5 3 2 Manually remove all grippers from all gripper changing con soles All symbols must change to the Deposit station free status 3 Manually place the gripper in the deposit station 1 of gripper...

Page 241: ...pper option Risk of crushing Before starting set up or maintenance work close the shut off valve on the pivoted jaw gripper Take special care when you open the shut off valve because the suction cup s...

Page 242: ...5 Electrical components 5 1 Overview 1 Fan at rear side of the BendMaster control cabinet Fig 51884 5 16 Electrical components 2015 06 01 B579EN...

Page 243: ...l cabinet see Overview pg 5 16 Maintenance interval 1000 operating hours Depending of the machine configuration the fans are arranged differently Means Tools Materials 4x filter mat 120x120 mat no 177...

Page 244: ...r 4 Replace all four filters if they are very dirty 5 Reinstall the cover 6 Switch on the system again in manual mode 7 Check whether airflows can be felt BendMaster switch cabinet see Overview pg 5 1...

Page 245: ...id on the front side of the device 3 Blow out the air inflow and air outflow openings with com pressed air 4 Switch on the system again in manual mode 5 Check whether the inner and outer airflows can...

Page 246: ...ne properly secure the MAIN SWITCH and secure with a padlock 3 Remove the four screws from the fan mounting device 4 Pull out the fan mounting device 5 Blow out the fan with compressed air 6 Refit the...

Page 247: ...ttal In countries where there are higher ambient temperatures an optional second Peltier cooling unit is available Fig 71112 1 Check whether an airflow can be felt on the rear side of the switch cabin...

Page 248: ...dMaster sheet sensor see Overview pg 5 22 Maintenance interval As needed Means Tools Materials Glass cleaner 1000 ml mat no 1637606 Spray bottle 1000 ml with atomizer mat no 1733721 Cloth for cleaning...

Page 249: ...manual gripper change posi tion 2 Rotate the C axis in such a way that the sheet sensor can be cleaned 3 Shut down the machine properly secure the MAIN SWITCH and secure with a padlock 4 Clean the sh...

Page 250: ...he air supply to the TruBend Note Turning off the compressed air in the switch cabinet for options does not lead to a warning signal 1 Close the compressed air shut off valve under the press brake s s...

Page 251: ...Chapter 6 Maintenance Technical Service 1 Maintenance overview 6 2 B579EN 2015 06 01 Maintenance Technical Service 6 1...

Page 252: ...ore enter ing the safety cabin BendMaster brakes Check the brakes for proper function visual inspection The BendMaster must not drop 1 2 3 Every year Air conditioning unit Check the function of the ai...

Page 253: ...ng 4 70 4 71 Automatic gripper change 4 28 Automatic mode 4 18 AUX 4 26 4 32 4 33 Auxiliary tools 2 18 Average 4 123 4 124 Average contour 4 123 Axes 3 5 4 25 B B axis 3 5 4 25 Backgauge and Y movemen...

Page 254: ...supply 2 14 Electrics 2 14 Empty all unloading areas 4 82 Empty unloading area 4 82 4 101 Enable key 4 8 Enabling conditions Automatic mode 4 18 Manual mode 4 17 Manual press 4 20 Entire search area...

Page 255: ...ction 4 17 L L coordinate OK 4 79 L height OK 4 79 4 81 L stack active 4 79 4 81 L stack blocked 4 79 L stack empty 4 79 L coordinate OK 4 80 L no coordinate 4 80 Language 4 14 Lay down gripper 4 31 L...

Page 256: ...3 18 Handling equipment 3 27 Integrated double sheet recognition 3 23 Mobile fanning magnet 3 27 Multi gripper 3 17 Multiple circuit suction cups 3 17 Pivoted jaw gripper 3 20 Productivity package 3 2...

Page 257: ...bot 4 93 Selected Order 4 53 Selection 4 75 Sensor gauge finger 5 5 Sensor gauge fingers 3 11 Sensors for press 4 36 Separate before measuring 4 87 Separating time 4 86 Separation at the gripper 4 86...

Page 258: ...ripper 4 86 Travel point 4 97 Troubleshooting 4 126 TruTops Bend 3 29 U Unload Precise 4 66 UNLOAD_SHEET 4 94 Unloading stack 4 83 Unprocessed material 4 54 Update 4 54 Use Pattern Settings 4 122 User...

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