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1 Safety 

SCHMIDT

®

 PressControl 3000 – V1.3 

6

 

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 

•

  it is not used in accordance with its designated use, 

•

  it is operated by untrained personnel, 

•

  it is modified or converted incorrectly or 

•

  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. 

 

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: 

•

 Assembling 

•

 Riveting 

•

 Crimping 

•

 Bonding 

•

 Forming 

•

 Pressing 

•

 Flaring 

•

 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: 

•

  compliance with the documentation 

•

  compliance with the inspection and maintenance measures 

 

Содержание PressControl 3000

Страница 1: ...Operator s manual SCHMIDT PressControl 3000 SCHMIDT press system with force stroke monitoring and SCHMIDT PressControl 3000 ...

Страница 2: ...hmidtpresses 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 schmidttech...

Страница 3: ...nnecting the control unit 12 3 3 Installing the control unit 12 4 Operation 14 4 1 Operating elements 14 4 2 User interface 14 System functions 14 Softkeys and operating levels 15 4 3 Switching on and off 16 4 4 Reference run 16 5 Data Input 18 5 1 Default settings 18 5 2 Standard parameters overview 22 6 Text and system outputs 24 6 1 System outputs 24 6 2 Process data 24 7 Press processes 25 7 1...

Страница 4: ... 36 8 3 Taring the force value 38 8 4 Parts inquiry 38 9 Dataset management 40 9 1 Principle of the dataset management 40 9 2 Managing multiple datasets 41 Creating and storing datasets 41 Load dataset 41 Renaming dataset 42 10 Quality monitoring 43 10 1 Curves 43 Curve display 43 Enlarging details 44 10 2 Tolerances 45 Reference data 45 Force tolerances 46 Stroke tolerances 47 Managing tolerances...

Страница 5: ...ructure and function Assembly and startup User interface Practical operation 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 ControlTool Teil 1 Installation User interface Project and dataset manage...

Страница 6: ...nd accident prevention regulations provided by law apply 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 Assembling Riveting Crimping Bonding Forming Pressing Flaring Punch...

Страница 7: ... starting work This also applies to persons who work only occasionally 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 constr...

Страница 8: ...witched 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 pushbutt...

Страница 9: ...ontrol of the press process is done via a PLC program The PLC program carries out the following functions Control of the process data acquisition sequence Monitoring of the press process on the basis of the set quality parameters 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 Figure 2 1 Block c...

Страница 10: ...nes 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 V or 2 5 A 24 V Weight 5 5 kg incl external power supply unit Ambient temperature 0 up to 40 C Air humidity up to max 95 relative non condensing Protection type IP 54 Dimensio...

Страница 11: ...d 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 Ens...

Страница 12: ...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 Sa...

Страница 13: ...ation 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 1 2 Setting the inclination ...

Страница 14: ...n 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 Figure 4 1 System function keys 1 Datasets 4 Data Input 2 System Options 5 Data Output 3 Curve Output In this display mode you have access to the com...

Страница 15: ...IDT PressControl 3000 press system is provided with a PLC program having a large number of basic functions They can be activated 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 ...

Страница 16: ...le Servic CtrOFF CtrON 1 Control Off PC DEAC Dataset 1 1 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 t...

Страница 17: ...ce 0 pcs 0 pcs 0 pcs Quantity Quantity nok Quantity ok 30 000 mm Returnstroke at stroke 2 Hand Release Machine ok PC DEAC Dataset 1 1 Figure 4 5 Display after the reference run 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 the Ref softkey Perform the reference run as described above Ma...

Страница 18: ...ey 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 ...

Страница 19: ... submenu select the Machine Parameter selection 1 CtrON CtrOFF Servic Graphic init 10 Maximum Force kN 400 Res Force Sensor I kN 100 Max Stroke mm 2000 Res Stroke Sensor I mm 10 Machine Parameter 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...

Страница 20: ... System Options menu 1 CtrON CtrOFF Servic Adress UE470 10 Ident Service 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 numbe...

Страница 21: ...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 In the 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 ...

Страница 22: ...ount 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 re...

Страница 23: ...n off This parameter defines whether a part has fallen into an optionally mounted reject box or not 0 active 1 inactive 50 Bend up mm kN The measured bending constant eliminates the elastic properties of the overall system 51 BDC signal I1 3 exist This parameter defines whether the press is provided with a cylinder switch or not 0 not provided 1 provided 52 TDC signal I1 4 exist dto 54 Sensor type...

Страница 24: ...ff 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 Servic CtrOFF CtrON 1 000 mm Desired range str tol2 000 mm Desired range str tol1 0 N Average force wind F4 0 N Average force wind F3 0 N Averag...

Страница 25: ...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 criter...

Страница 26: ...rocess the BDC position is not reached the error message BDC not reached ACK appears When the press process is performed with the return stroke criterion manual 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 ...

Страница 27: ...and of 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 ...

Страница 28: ...e 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 2 00 1 50 1 00 500 0 0 F kN s mm 10 00 20 00 30 00 40 00 Figure 7 2 Calculate deflection Calculate the deflection Sample calculation Stroke difference s 2 mm Force difference F 1 7 kN Deflection s F 1 176 mm kN Select the Data Input syst...

Страница 29: ...f 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 thro...

Страница 30: ...e 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 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...

Страница 31: ...tor 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 parameters only ...

Страница 32: ...rror 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 ...

Страница 33: ...n 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...

Страница 34: ...es the counter will distinguish 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 s...

Страница 35: ...u 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 off 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 Resetting Switching off Incorrect press...

Страница 36: ... 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 Servic CtrOFF CtrON 1 40 432 mm 2138 N Reached stroke Reached force 21 pcs 4 pcs 17 pcs Quantity Quantity nok Quantity ok 30 000 mm Returnstroke at stroke SET UP Machine ok PC DEAC Dataset 1 1 Figure 8 1 View Output 1 displaying the word SET UP Cha...

Страница 37: ...nction 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 Servic CtrOFF CtrON 1 40 432 mm 2138 N Reached stroke Reached force 21 pcs 4 pcs 17 pcs Quantity Quantity nok Quantity ok 30 000 mm Returnstroke at stroke PC not ready SPC OFF PC OFF Dataset 1 1 Figure 8 3 View of Output 1 including the...

Страница 38: ...rce value changes In this case at no load of the ram the force value 0 is no longer displayed The Tare force value 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...

Страница 39: ...her a part is available on an optionally mounted workpiece fixture If no part is in the fixture the message Part insert appears The hand lever will remain locked until the input transmits a signal After inserting a part the message will disappear After the press process the message Part remove will appear The message will disappear as soon as the part is removed A possible incorrect pressing can o...

Страница 40: ...ve 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 Figure 9 1 Principle of dataset management ...

Страница 41: ...ss 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 1 CtrON CtrOFF Servic 10 Dataset 10 9 Dataset 9 8 Dataset 8 7 Dataset 7 6 Dataset 6 5 Dataset 5 4 Dataset ...

Страница 42: ...t upper corner of the display The currently loaded dataset can be renamed A total of 21 characters can be used for a dataset name Select the Datasets system function key Select the Filename command The cursor blinks below the first letter of the dataset name to be edited 1 CtrON CtrOFF Servic Dataset 1 Edit Filename Figure 9 4 Renaming dataset Select the desired letter using the Up Down cursor key...

Страница 43: ...odify 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 1 CtrON CtrOFF Servic Diagram Selection Output Diagram Single Diagram Force Stroke Units Metric Figure 10 2 Diagram Selection menu By default when the curve output is called only the la...

Страница 44: ...meter 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 lbs and inch By pressing the Enter key again you can reset the parameter to Metric Enlarging details To make...

Страница 45: ...lower corner of the desired detail and confirm the position with the Enter key The selected detail shown enlarged 1 95 1 85 1 75 F kN s mm 35 78 36 69 37 61 38 53 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 ...

Страница 46: ...he 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 Selec...

Страница 47: ... If a value falls below the minimum or exceeds the maximum 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 Select the Curve Output system function key Press the Enter key Selec...

Страница 48: ...ars additionally 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 numerica...

Страница 49: ...ive By using the Not active setting you 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 t...

Страница 50: ...ameter 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 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 ...

Страница 51: ...n a defined range The force offset allows you to adjust the output signal Switch the control unit on Select the Data Output system function 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 Servic CtrOFF CtrON 1 000 mm Desi...

Страница 52: ...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 measuri...

Страница 53: ...it 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 After the calibration check whether the value has changed After a large change has taken place set the ...

Страница 54: ...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 Servic CtrOFF CtrON 1 0 N 000 mm 000 mm 0 N 0 N 0 N 600 558 mm 0 inc 65278 inc 19 inc 0 N Desired range str tol2 Desired range str tol1 Average force wind F4 Average force wind F3 Average...

Страница 55: ...11 Maintenance and servicing SCHMIDT PressControl 3000 V1 3 55 The position measuring system does not have to be calibrated due to the fact that it is a digital system ...

Страница 56: ...error message Inform the SCHMIDT Customer Service When and how often has the problem occurred and what changes has been made recently 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 function key Select the System Options menu In th...

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