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Bend Safety

02 | SETUP AND SAFETY

WORK
AREA

ATTENTION

EYE + HAND
PROTECTION

Always give the D.I.Wire plenty of room

to do its work. See the setup section for

details.

Do not leave the D.I.Wire unattended

during operation.

Always wear protective eyewear when

operating the D.I.Wire. Small bits of wire

can fly out unexpectedly when bending

or cutting the wire. Also, the edge of the

wire can be a sharp moving object, eye

protection is mandatory.

DO NOT
TAMPER WITH

OVERHEATING

EXPOSED
HARDWARE

DO NOT
REMOVE
PANELS

The D.I.Wire PRO needs sufficient air flow for

proper ventilation. See the Setting Up section

for instructions on how to select your work area.

Some hardware components are removable

but should not be removed unless instructed

by Pensa Labs, or the machine can be

rendered unusable. Refer to the service and

maintenance section for details.

Removing the covers, modifying the hardware,

electronics or switching the power supply can

damage the machine and be a potential source

for injury. Do not tamper with the machine.

It will void your warranty too!

Содержание D.I.Wire Pro

Страница 1: ...Version 19 4 16 1 ...

Страница 2: ...TableOfContents INTRODUCTION HARDWARE SETUP AND SAFETY BENDING SETTING UP WIREWARE PATH MODE SCRIPT MODE MATERIAL PROFILE MAINTAINANCE AND TROUBLESHOOTING 2 ...

Страница 3: ...Introduction SECTION 1 3 ...

Страница 4: ...THE D I WIRE PRO D I WIRE PRO AND ITS COMPONENTS GETTING TO KNOW THE D I WIRE PRO Introduction 01 INTRODUCTION 4 ...

Страница 5: ...s our newest desktop CNC wire bender offering the power speed precision and modularity that professionals need Bend any wire material between 0 027 0 7mm and 0 188 4 8mm bend strap and add a straightener and other accessories to optimize production 5 ...

Страница 6: ...qualified personnel only This manual contains valuable info about the operation care and service of your machine We recommend you keep it handy Note The instructions in this manual are not meant to cover every possible condition and situation that may occur Common sense and caution must be practiced when setting up operating and maintaining any equipment TheD I WirePro 01 INTRODUCTION 6 ...

Страница 7: ...KEY 5 32 HEX KEY RAMP GUIDES Guides are custom for each material diameter 45 0 1 CALIBRATION PLATE Used for creating Material Profiles and part inspection USB allows D I Wire to communicate with the computer SMALL TORQUE WRENCH SOCKET WRENCH LARGE TORQUE WRENCH CUTTERS For the Feed Wheels For the Bend Head D I WireProandItsComponents 01 INTRODUCTION THE MACHINE TOOLS AND ACCESSORIES Your set of to...

Страница 8: ...eed Wheels and Guides BEND HEAD Typically has two mandrels to form wire ACCESSORY MOUNTS 10 32 tapped holes for holding accessories such as a wedge CUT OFF SLOT Hole for inserting cutters Take a few minutes to get oriented to the D I Wire Pro TOP VIEW WIRE GUIDES Hold material in place as it is bent Interchangeable to accommodate specific material diameters DETAIL Gettingtoknowthe D I WirePro 01 I...

Страница 9: ...HardwareSetupAnd Safety SECTION 02 9 ...

Страница 10: ...GETTING SET UP D I WIRE ORIENTATION SAFETY AND PROTECTION DO S AND DON TS OF THE MACHINE HardwareSetupAnd Safety 02 SETUP AND SAFETY 10 ...

Страница 11: ...ce the machine on a sturdy table or work bench by itself The D I Wire is a heavy machine Make sure you place it on a hard flat and sturdy surface that can support the D I Wire s weight and remain flat Particle boards thin sheet metal or wire racks are not strong enough Make sure the work area is well illuminated and kept clean free of excessive dust debris and liquids GettingSetUp 02 SETUP AND SAF...

Страница 12: ...ng areas Back of the system for material loading front of the system for part bending and a dedicated area for the computer running WireWare D I Wire Orientation 02 SETUP AND SAFETY MATERIAL LOADING AREA BEND AREA Keep clear for parts to move freely during bending Caution Area 12 ...

Страница 13: ...57Kg 125 lb UNPACKING THE DIWIRE 2 PLUG IN 3 POWER CORD USB CORD WHAT S NEEDED ADDITIONAL ELEMENTS Computer D I Wire Pro USB Cord Power Cord The D I Wire weights 57 Kg 125 lb Be safe Seek assistance to pick it up from its case and to carry it to its assigned work area 57Kg 125 lb Only use the only provided power supply Using other power supplies may damage your machine 13 ...

Страница 14: ... Button MOVING PARTS NEVER touch the Bend Pins or Feed Wheels during bending Allow the D I Wire to finish bending before reaching into the top plate STOP Your safety and the safety of others is very important to us so we have provided the following safety section and other safety related messages along the manual Always read and follow all safety messages NEVER TOUCH MOVING PARTS AVOID WATER The D...

Страница 15: ...ection is mandatory DO NOT TAMPER WITH OVERHEATING EXPOSED HARDWARE DO NOT REMOVE PANELS TheD I WirePROneedssufficientairflowfor properventilation SeetheSettingUpsection forinstructionsonhowtoselectyourworkarea Some hardware components are removable but should not be removed unless instructed by Pensa Labs or the machine can be rendered unusable Refer to the service and maintenance section for det...

Страница 16: ...2x R25 55 2x R7 95 170 70 Bending SECTION 03 16 ...

Страница 17: ...LOADING MATERIAL CLAMPING AND ALIGNMENT Bending 03 BENDING 17 ...

Страница 18: ...eed Wheels with the Preset Torque Wrench LOAD MATERIAL 1 2 3 Loosen the Feed Wheels with the Preset Torque Wrench Load the wire through the Wire Guides 1 into the Feed Wheels 2 and toward the Bend Head 3 HOME BUTTON HOMING SEQUENCE The machine must be homed when turning on the machine or restarting or if it has lost position Before bending the D I Wire needs to go through the homing sequence to en...

Страница 19: ... get a feel for variation in how different materials should be clamped Record clamp force in each Material Profile WHAT S NEEDED If your application needs higher clamping force email us at support pensalabs com TORQUE WRENCH 1 4 HEX BIT CLAMP ADJUSTMENT 2 PREPARATIONS Torque wrench uses a stepped 5 32 to 1 4 hex bit 1 You received a pre set torque wrench that has been selected for your specific ap...

Страница 20: ...SettingUpWireWare SECTION 04 20 ...

Страница 21: ...DOWNLOAD WIREWARE PATH MODE SCRIPT MODE MATERIAL PROFILE MODE SettingUpWireWare 04 SOFTWARE 21 ...

Страница 22: ...ownload or installation of WireWare please contact us WINDOWS MAC EMAIL PHONE Choose either Windows or Mac version of WireWare to install on the computer support pensalabs com 1 844 434 9473 CONTACT US 2 INSTALL WIREWARE Download WireWare Download WireWare software to run the D I Wire Pro WireWare prepares your files for bending on the D I Wire 04 SOFTWARE 1 22 ...

Страница 23: ...PathMode SECTION 04 23 ...

Страница 24: ...pare them for bending It has been designed to provide basic manipulation and adjustments to bend points and line segments and to manage multiple paths on the work area 04 SOFTWARE OVERVIEW GETTING STARTED PATH WORKSPACE INFO TOOLBAR MATERIAL PROFILE SELECTION ACTION LIST CONTROL JOG BAR ARROW KEY CONTROLS OTHER FEATURES 24 ...

Страница 25: ...PATH INFO WORKSPACE TOOLBAR GRID TOOLS SELECTED MATERIAL PROFILE INFO CONTROL JOG ACTION LIST ScreenOverview 04 PATH MODE 25 ...

Страница 26: ...to view and manipulate the new set of segments and bend points The path is a series of bend angles and line segments These bend angles and line segments can be manipulated using the tools on the following pages IMPORT A FILE CREATE A SHAPE WORKSPACE Go to File Open to open a saved SVG file from your computer Add Bend B and Feed F points to the Action List to start creating a new part GettingStarte...

Страница 27: ... path The estimated total wire length needed for the part Bend points and line segments will snap to the ghosted imported path as they are moved around on the workspace Shows the minimum distance between bend points on a path Enter a small segment length value to get a smoother curve with many bend points 8 25 209mm of extra wire is needed in addition to the path length so that the feed wheels are...

Страница 28: ...g Move around the viewable area of the workspace by clicking and dragging ADD A PAUSE POINT Select a Bend Point where the machine will pause before the bending at that location CTRL U CTRL SHIFT U Undo previous action on the Workspace Redo previous action on the Workspace Zoom tools help you to navigate around your workspace Select Tool allows you to click on line segments and bend points and move...

Страница 29: ...s and Bend Head In order to modify or create new material profiles go to Material Profile Mode Always make sure to select the proper material profile of the wire you are bending Using other profiles will make Wireware calculate the wrong compensation angles Selecting the Material Profile that matches the wire in use ensures accurate bending of the Path A Material Profile is needed to bend from Pat...

Страница 30: ... and manipulate the new set of segments and bend points The Plus icon adds Feed and Bend Points to the list Clicking the Plus will add a bend and feed after the last segment of a shape If a file is imported into the Path Mode workspace WireWare breaks the shape up into Feed and Bend actions Action List values can be changed on the list and the Path will update on the workspace Add Bend B and Feed ...

Страница 31: ...he machine must be homed when turning on the machine or restarting or if it has lost its location Starts bending the active path Controls the feed of the wire measured in the units in use inches or mm Immediately stops moving the machine axes Jog controls the machine with simple movements set in the numerical fields for each moving part of the machine HOME BEND STOP JOG Control JogBar The Control ...

Страница 32: ...ise 1 SHIFT CMD CTRL SHIFT CMD CTRL Moves the Bend Pin incrementally 0 5 per move Moves the material incrementally 0 20 0 5 mm per move Moves the Bend Ring up and down incrementally 0 047 1 mm per move CTRL CMD SHIFT 2 CTRL CMD LEFT RIGHT ARROW UP DOWN ARROW INCREMENTAL MOVES CMD CTRL SHIFT CMD CTRL CMD CTRL LESS THAN 2 CTRL CMD GREATER THAN GREATER THAN LESS THAN 3 RAISE LOWER BEND RING Z AXIS 2 ...

Страница 33: ...ve to the path size Hides Shows the ghosted silhouette of the imported SVG Selects the next Path in order of creation if Workspace has multiple Paths Deletes selected Bend Point Use these tools to modify the imported Path Paths must be modified to accomodate Bend Head geometry and minimum segment lengths e g a 160 bend angle into two 80 Bend Points This allows easier manipulation of larger angles ...

Страница 34: ...ScriptMode SECTION 05 34 ...

Страница 35: ...se shapes using written WireWare script commands or G Code commands to control the D I Wire These allow for a higher level of control over the output OVERVIEW GETTING STARTED MATERIAL PROFILE SELECTION CONTROL JOG BAR ARROW KEY CONTROLS 35 ...

Страница 36: ...FILE INFO SELECTED MATERIAL PROFILE INFO SCRIPT MODE GLOSSARY CONTROL JOG BAR G CODE GLOSSARY SCRIPT WINDOW ScreenOverview 05 SCRIPT MODE 36 ...

Страница 37: ...dow to type in commands or copy and paste text SCRIPT WINDOW Paths can be saved as G Code from Path Mode and opened in Script Mode Refer to the Reference section at the end of this manual for a complete glossary of terms and other available commands SCRIPT MODE GLOSSARY IMPORT A FILE Use the file menu to open a saved file from your computer This is a glossary of WireWare Script and G Code commands...

Страница 38: ...Material Profile you will also be able to view its associated information The Drop down menu lets you select among saved Material Profiles in your Library Bend Velocity is measured in degress minute Feed Velocity is measured in mm minute in min For more information see the References section MaterialProfile Selection 05 SRIPT MODE When using the WireWare script select a Material Profile to compens...

Страница 39: ...e units in use inches or mm Controls the height of the Bend Pin in relation to the top shape 0 to 12 mm Immediately stops moving the machine axes Jog controls the machine with simple movements set in the numerical fields for each moving part of the machine HOME BEND STOP JOG Control JogBar The Control Bar and Jog Bar at the bottom of the workspace can be found in every mode These controls are Home...

Страница 40: ...0 20 0 5 mm per move Moves the Bend Ring up and down incrementally 0 047 1 mm per move CTRL CMD SHIFT 2 CTRL CMD LEFT RIGHT ARROW UP DOWN ARROW INCREMENTAL MOVES CMD CTRL SHIFT CMD CTRL CMD CTRL LESS THAN 2 CTRL CMD GREATER THAN GREATER THAN LESS THAN 3 RAISE LOWER BEND RING Z AXIS 2 MOVE BEND PIN A AXIS FEED MATERIAL X AXIS 2 CTRL CMD Moves the Bend Ring up Z0 Moves the Bend Ring down Z 9 max Use...

Страница 41: ...MaterialProfileMode SECTION 06 41 ...

Страница 42: ... wire used in the D I Wire Material Profile data is used to compensate for wire spring back during a bend A Material Profile is needed to bend from Path Mode or Run WireWare Script commands in Script Mode WireWare comes pre loaded with Material Profiles for wire sold on Pensalabs com 42 ...

Страница 43: ... the results into a table It is necessary to complete all three Datasets 0 Whatisa MaterialProfile HARDWARE DEFINITION DATASET MEASUREMENTS Whatisa MaterialProfile When creating a Material Profile the D I Wire learns how much to compensate for wire spring back Material Profiles consist of Hardware Definition information and Dataset measurements The Hardware Definition is information about the Bend...

Страница 44: ...al Profile Library is a collection of wire materials that have been calibrated for the D I Wire 06 MATERIAL PROFILE MODE MENU BAR CREATE NEW PROFILE EDIT EXISTING PROFILE IMPORT EXPORT EXISTING PROFILE DELETE EXISTING PROFILE 44 ...

Страница 45: ... Library Screen CREATE NEW PROFILE Fill in the information about the wire and the D I Wire hardware setup and click BEGIN when ready to move on PROFILE DEFINITION Red fields are required others are optional CreatingaMaterialProfile 2 1 3 ClampTorqueaffectstheMaterialProfile Usethepresettorquewrenchorrecordtorqueusingadigital torquewrench To determine the Bend and Feed Velocities for the material b...

Страница 46: ...s and into the Bend Head HOME BUTTON Commands the D I Wire to locate and rest at Home machine position zero The machine must be homed when booted or if it has lost its location Click BEND to bend your first datapoint Use the cutting tool to remove the bent wire from the D I Wire The BEND button will bend the angle of the active data field CreatingaMaterialProfile 06 MATERIAL PROFILE MODE 5 4 6 46 ...

Страница 47: ... press the ENTER key to move down to the next datapoint INPUT SAVE EXIT CANCEL Click the Save Exit button to save a completed or in progress Material Profile Click the Cancel button to exit without saving the file The file will not show up in the Materal Profile drop down lists until all three datasets are complete CreatingaMaterialProfile 06 MATERIAL PROFILE MODE 7 9 8 47 ...

Страница 48: ...e linked to this information Make any needed changes to the Material Profile Definition and click BEGIN Click the EDIT icon next to the datapoint that needs to be edited In the Material Profile Library select the Material Profile to be edited and click the EDIT button EDIT PROFILE INITIATE EDITING EDIT DEFINITION 2 1 3 EditingaMaterialProfile 06 MATERIAL PROFILE MODE 48 ...

Страница 49: ... is entered press the ENTER key to move down Save and Exit the Material Profile at anytime if needed However this file will not appear in a Material Profile drop down list until all 3 Datasets are complete EDIT DATAPOINT SAVE EXIT 5 4 EditingaMaterialProfile 06 MATERIAL PROFILE MODE 49 ...

Страница 50: ...SECTION 07 Maintenance Troubleshooting 50 ...

Страница 51: ...HOW TO CARE FOR YOUR MACHINE REPLACING BENDING COMPONENTS TROUBLESHOOTING Maintenanceand Troubleshooting 07 MAINTENANCE AND TROUBLESHOOTING 51 ...

Страница 52: ...pensalabs contact info for help for troubleshooting Or contact your local distributor were here to help SECTION 07 HowToCareFor YourMachine 52 ...

Страница 53: ...ss Using a fine tip syringe is helpful when applying lubricant to these tight areas Apply once a month or every 50hr of accumulated use CleaningAndLubrication 07 MAINTENANCE AND TROUBLESHOOTING Clean any dust or debris from under the feed wheels The preferred method is by using a vacuum cleaner but compressed air can also be used Just make sure to not blow particles into the bearings 53 ...

Страница 54: ...00 to 200 clamping cycles open close Unscrew the clamping screw completely until fully removed Inspect the state of the threads and wipe clean with a shop rag or paper towel Also do a quick inspection of the threads in the nut We normally apply a small amount of Moly Graph 2 grease to the first few threads of the screw and reinsert 54 ...

Страница 55: ...SECTION 07 ReplacingYourBending Components 55 ...

Страница 56: ...ngYourBending Components 07 MAINTENANCE AND TROUBLESHOOTING REPLACING YOUR BEND RING AND BEND HEAD REPLACING YOUR FEED WHEELS REPLACING YOUR WIRE GUIDES CONFIGURE YOUR D I WIRE PRO FOR A DIFFERENT WIRE SIZE 56 ...

Страница 57: ... this section and you ll be ready to continue bending in no time The Bend Head Bend Ring and Wire Guides also need to be changed if you are reconfiguring your machine for a different wire size Just follow the same process as for replacing the bending cmoponents but use your desired size configuration instead of a replacement kit Note If your components wore out but you don t have replacement parts...

Страница 58: ...SECTION 07 ReplacingThe BendHead 58 ...

Страница 59: ...ND HEAD For Bend Ramp 1 8 HEX KEY For Bend Ring 5 32 HEX KEY SOCKET WRENCH MAGNET ALIGNMENT PLATE TORQUE WRENCH For the Bend Head not provided TOOLS REQUIRED ReplacingTheBendHead 07 MAINTENANCE AND TROUBLESHOOTING 59 ...

Страница 60: ...07 MAINTENANCE AND TROUBLESHOOTING 1 2 TOOLS TOOLS 1 8 Hex Key 5 32 Hex Key Remove the ramp guides by unscrewing all the 10 flathead screws Prepare Bend Ring for removal by taking out the 4 10 bolts that hold it in place 60 ...

Страница 61: ...Ring to access the Bend Head Once the Bend Ring is removed you will have access to the Bend Head Different Bend Heads will look different but all are installed the same way We did not provide the magnet It is possible to remove the Bend Ring without a magnet but the magnet makes the process easier 61 ...

Страница 62: ... AND TROUBLESHOOTING 4 5 TOOLS Bend Head Torque Wrench 30mm Socket Wrench The Bend Head is held by an ER20 collet Start by loosening the collet nut but don t remove it completely Once the collet nut is loosened pull the Bend Head out 62 ...

Страница 63: ...NANCE AND TROUBLESHOOTING 6 7 TOOLS Replacement Bend Head Insert the Replacement Bend Head and ensure it is sitting all the way down If Bend Head is not able to be all the way down loosen the collet nut a bit more with your hand 63 ...

Страница 64: ...d the plate over the Bend Ring area and orient the center with Bend Head Apply downwards pressure to the top of the Bend Head with one hand as you tighten the collet nut with the other Most Bend Heads cue the same Alignment Tool but some may need a different one If your Bend Head needs a special Alignment Tool we will send it when we ship the Bend Head 64 ...

Страница 65: ...ck the Bend Ring and mare sure the flats on the tool engage with the flats on the Bend Head Command your D I Wire to go to the 0 position by either Run the Homing cycle by pressing home Run the following script G90 G1 A0 or PINA 0 Type 0 on the jog box for axis A and hit the go to button Verify the Alignment Tool remains fully engaged with the flats on the Bend Head The process makes sure the Bend...

Страница 66: ...Fasten the bend ring into place by reinstalling and tightening the 4 10 screws Do not use excessive force when tightening the screws 10 lb in is sufficient If you don t have a way to measure the force go to hand tight plus a quarter turn Make sure the dowel pins align and gently press down until the Ring is fully seated 66 ...

Страница 67: ...SECTION 07 ChangingTheFeed Wheels 67 ...

Страница 68: ...For Feed Wheel Fasterners 3 16 HEX KEY 1 8 HEX KEY For Ramp SMALL TORQUE WRENCH For the Feed Wheels TOOLS REQUIRED 07 MAINTENANCE AND TROUBLESHOOTING ChangingTheFeedWheels 68 ...

Страница 69: ...AND TROUBLESHOOTING 1 2 TOOLS 1 8 Hex Key Loosen the fasteners for the ramp Remove the ramp from the system TOOLS Feed Wheel Torque Wrench Start by clamping the Feed Wheels together by tightening the clamp screw with your Torque Wrench 69 ...

Страница 70: ...OTING 3 4 TOOLS TOOLS 3 16 Hex Key Feed Wheel Torque Wrench Feed Wheel Torque Wrench With the feed wheels pushed together loosen and remove the feed wheel fasteners Loosen and fully open the feed wheel carriage to allow the removal of the feed wheels 70 ...

Страница 71: ...d Wheels from the D I Wire by pulling them out of their shafts Insert new Feed Wheels into the D I Wire Align the keyway on the wheels to the keys on the shafts Ensure they are fully seated If the Wheels are too tight use the help of a strong magnet to pull them out 5 6 71 ...

Страница 72: ...gingTheFeedWheels 07 MAINTENANCE AND TROUBLESHOOTING 7 8 TOOLS TOOLS Feed Wheel Torque Wrench 3 16 Hex Key Tighten the feed carriage With the feed wheels pushed together tighten the feed wheel fasteners 72 ...

Страница 73: ...ChangingTheFeedWheels 07 MAINTENANCE AND TROUBLESHOOTING 9 10 TOOLS 1 8 Hex Key Place the ramp back onto the system Tighten the fasteners for the ramp 73 ...

Страница 74: ...SECTION 07 ChangingTheGuides 74 ...

Страница 75: ...1 8 HEX KEY For Ramp REPLACEMENT GUIDES Guides are custom for each material diameter ChangingTheGuides 07 MAINTENANCE AND TROUBLESHOOTING TOOLS REQUIRED 75 ...

Страница 76: ...ChangingTheGuides 07 MAINTENANCE AND TROUBLESHOOTING 1 2 TOOLS 1 8 Hex Key Loosen the fasteners for the ramp Remove the ramp from the system 76 ...

Страница 77: ...and remove the guides by pulling them out Insert the new guides into the ramp Make sure they are fully seated This section describes the process for our most common type of wire guides If your guides look different and need some help send us an email to support pensalabs com 77 ...

Страница 78: ...ChangingTheGuides 07 MAINTENANCE AND TROUBLESHOOTING 5 6 TOOLS 1 8 Hex Key Place the ramp back onto the system Tighten the fasteners for the ramp 78 ...

Страница 79: ...ave found on the field but we cannot cover every imaginable scenario If you can t find your issue in the following tables or the solution proposed is not solving it for you feel free to give us a call or shoot us an email at support pensalabs com and we will be more than happy to help 79 ...

Страница 80: ...to your system available Be prepared to work with the machine as many issues will require live troubleshooting Check the basic settings of the computer you use to operate the D I Wire such as the operating system and version e g MacOS X Windows 10 A description of the issue the more detailed the better Troubleshooting 07 MAINTENANCE AND TROUBLESHOOTING Technical support phone number Email Technica...

Страница 81: ...SECTION 08 References 81 ...

Страница 82: ...or negative backwards Uses the feed speed defined in the Material Profile BENDa Moves the Bend Ring an a amount in degrees The a value can be either positive Clockwise or negative counterclockwise Uses the bend speed defined in the Material Profile REPEATn END A loop that repeats the code between REPEAT and END an n number of times Very useful when bending many copies of the same part or bump bend...

Страница 83: ...Undo ConnecttoapluggedinD I Wire OpenafileineitherPathorScriptMode QuitsWireWare SwitchtoMaterialProfileMode SwitchtoScriptMode SwitchtoPathMode SavesshapeinPathModeWorkspace OpensSaveAsdialogforpathinWorkspace UndolastactioninWorkspace RedolastactioninWorkspace SwitchtothenextpathwhentherearemultiplepathsontheWorkspace inorderofcreation SwitchtothepreviouspathwhentherearemultiplepathsontheWorkspa...

Страница 84: ...http www pensalabs com support pensalabs com 84 ...

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