Related Manuals for Schmidt PressControl 3000
Summary of Contents for Schmidt PressControl 3000
- Page 1 Operator’s manual ® SCHMIDT PressControl 3000 ® SCHMIDT press system with force/stroke-monitoring and ® SCHMIDT PressControl 3000...
- Page 2 +41 (0)31 755 40 71 Fax. +41 (0)31 755 40 73 eMail infoCH@schmidttechnology.ch www.schmidttechnology.ch © 2007 SCHMIDT Technology GmbH All rights reserved. Printed in the Federal Republic of Germany. Version and revision date: Version 1.3 of August 2007 ® SCHMIDT PressControl 3000 – V1.3...
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Page 3: Table Of Contents
System outputs ...................24 Process data ..................24 Press processes..........25 Defining the press process ..............25 Press parameters................25 Return stroke criterion.................25 Stroke takeover (only two-hand control) ..........26 Optimisation of the press process ............27 Bend-Up (Yield Factor) ...............27 ® SCHMIDT PressControl 3000 – V1.3... - Page 4 Managing tolerances ................48 Move tolerance data................49 11 Maintenance and servicing......51 11.1 Setting the force offset ................51 11.2 Calibrating the force sensor ..............52 11.3 Adjusting the stroke offset..............54 12 Customer Service..........56 ® SCHMIDT PressControl 3000 – V1.3...
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Page 5: Documentation Structure
User Manual – SCHMIDT ControlTool - Teil 2 Optional • Fundamentals • PLC programming • Range of commands ® User Manual – SCHMIDT Optional • Structure and function • User interface • Practical operation ® SCHMIDT PressControl 3000 – V1.3... -
Page 6: Safety
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: •... -
Page 7: Organisational Measures Of The System Operator
Any work on the electrical system or equipment must be carried out only by trained electricians or by specially instructed persons under the control and supervision of a trained electrician and in accordance with the applicable electrical engineering rules and regulations. ® SCHMIDT PressControl 3000 – V1.3... -
Page 8: Safety Devices
1 Safety Safety devices Figure 1-1: PressControl 3000 Operational status indicator EMERGENCY STOP pushbutton Operational status indicator The operational status indicator is located on the display of the control unit. The status indicator is lit in green permanently when the press system has been switched on and is ready for operation. -
Page 9: Presscontrol 3000
® The SCHMIDT Press System with force/stroke monitoring and SCHMIDT PressControl 3000 operates according to the following principle: Sequence control The sequence control of the press process is done via a PLC program. The PLC program carries out the following functions: •... -
Page 10: Technical Data
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 ® SCHMIDT PressControl 3000 – V1.3... -
Page 11: Assembly And Startup
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. Transport Use the original packaging for further transport (service, repairs….). -
Page 12: Connecting The Control Unit
Installing the control unit The control unit is equipped ex works with a control unit holder for table or wall mounting. Insert the control unit in the table holder. Tighten the fastening screw (1). ® SCHMIDT PressControl 3000 – V1.3... - Page 13 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. ® SCHMIDT PressControl 3000 – V1.3...
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Page 14: Operation
4 Operation 4 Operation Operating elements ® The SCHMIDT PressControl 3000 press system is basically operated by means of the following operating elements: Figure 4-1: Operating elements LCD with touch screen On/Off pushbutton “Set contrast” key EMERGENCY STOP pushbutton Softkeys System function keys “Change operating level”... -
Page 15: Softkeys And Operating Levels
Softkeys and operating levels ® The SCHMIDT PressControl 3000 press system is provided with a PLC program having a large number of basic functions. They can be activated by means of softkeys on the touch screen. Softkeys The following table describes the softkeys included in the standard PLC program. -
Page 16: Switching On And Off
SafetyModule. Start the press system as described in chapter “3.4 Switching on and ® off” in the "Operating Manual – SCHMIDT SafetyModule". Dataset 1 P C - D E A C... - Page 17 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. ® SCHMIDT PressControl 3000 – V1.3...
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Page 18: Data Input
With increasing operating temperature, the contrast of the display diminishes. Since nothing can be seen any longer on the display, the user may think that the control is defective. CAUTION Check if the contrast is set correctly using the "Contrast setting" key. ® SCHMIDT PressControl 3000 – V1.3... - Page 19 2000 2000 Max. Stroke Res. Force Sensor Maximum Force Please refer to chapter “5.1 Press data” in the operating manual of the press to find out which force sensor is integrated in which press. ® SCHMIDT PressControl 3000 – V1.3...
- Page 20 UE470 address The CAN gateway address must be correctly set for the communication ® between the control unit and the SCHMIDT SafetyModule. The address “10“ is set by default in the CAN gateway and also in the control unit. Select the “System menu” system function key.
- Page 21 When the set alarm time is reached, a marker is activated in the PLC program. By querying this marker, you can initiate other actions. For further ® information, please see the "User manual - SCHMIDT ControlTool - Part 2". You can set the volume of the "key click" (acknowledgement when a key is Volume pressed) and the volume of the alarm functions.
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Page 22: Standard Parameters Overview
The following table describes the parameters included in the standard PLC program. Malfunctions of the press system Parameters 9 to 11 / 51 to 59 are adapted ex works to the respective press system and should only be changed after consultation with SCHMIDT Technology. CAUTION No. Parameter... - Page 23 (standard value 5 inc., i.e., every 5 increments one measuring point). The larger the value, the fewer measuring points are written. Aq. distance PDA stroke dto. Offset stroke The “Offset stroke” value is machine specific. The measured value for the activated machine is included in the test certificate. ® SCHMIDT PressControl 3000 – V1.3...
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Page 24: Text And System Outputs
. . . S e r v i c Figure 6-2: View “Output 2” The average values of the force tolerances or the passages of the stroke tolerances are displayed only for the defined tolerances. ® SCHMIDT PressControl 3000 – V1.3... -
Page 25: Press Processes
Select the "Mode: F=0, s=1, t=2, m=3" parameter. Enter the value "0". If in a press process the set force is not reached, but the set stroke is exceeded, the error message: "P2:RS stroke exceeded!" is displayed. ® SCHMIDT PressControl 3000 – V1.3... -
Page 26: Stroke Takeover (Only Two-Hand Control)
A dangerous closing movement is that part of the movement of closing tools that may cause injures. It is finished, when moving parts and fixed parts have approached each other to such an extent that no more injury is possible (6 mm). ® SCHMIDT PressControl 3000 – V1.3... -
Page 27: Optimisation Of The Press Process
Set the cylinder switch for the stroke takeover. For further information, please refer to chapter “3.7 Setting the press stroke takeover” of the “Operator's manual – SCHMIDT PneumaticPress”. Check if the control unit settings for the existing cylinder switch(es) are correct. - Page 28 Stroke difference ∆s = 2 mm Sample calculation: Force difference ∆F = 1,7 kN Deflection ∆s/∆F = 1,176 mm/kN Select the "Data Input" system function key. Enter deflection Select the "Bend up [mm/kN]" parameter. Enter the calculated value ® SCHMIDT PressControl 3000 – V1.3...
- Page 29 2 7 . 5 2 3 6 . 3 9 Figure 7-4: Stroke tolerance of the return stroke Overcompensation (increased factor of deflection constants in mm/kN) may lead to a shifting of s within the force curve. ® SCHMIDT PressControl 3000 – V1.3...
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Page 30: Idle-Stroke Monitoring
(s If in a press process the max. allowed force is reached, an error message will appear, and the press will move back to the TDC position. ® SCHMIDT PressControl 3000 – V1.3... -
Page 31: Block Limit Window
In the control unit, no window is displayed. The limits are monitored by the parameters only. Defining the limits Define the limits of the block limit window. To do so, enter the corresponding values for the following parameters: ® SCHMIDT PressControl 3000 – V1.3... -
Page 32: Acknowledging 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. -
Page 33: Acknowledging By Means Of The Reject Box
(Not OK box). Connect the sensor for the automatic acknowledgement of an incorrect ® pressing to the relevant input (see circuit diagram) of the SCHMIDT SafetyModule. Switching on the Select the "Data Input" system function key. -
Page 34: Pre-Selection Counter
P C T o n P C T o f f P C T - 0 - C N T - 0 - A C K Figure 7-7: View of "Output 1" with activated pre-selection counter ® SCHMIDT PressControl 3000 – V1.3... - Page 35 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 Locking reset. Select the "Data Input" system function key. Select the "Counter access" parameter. Enter the value "0". ® SCHMIDT PressControl 3000 – V1.3...
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Page 36: Further Integrated Functions
As-delivered, the control has been configured for operation without connection to an external PC. The note "PC-DEAC" in the left upper corner of the control display tells you that this operating mode is active. ® SCHMIDT PressControl 3000 – V1.3... - Page 37 ControlTool When operating the control on an external PC using SCHMIDT ControlTool software, a press stroke is only possible if the PressControl 3000 is connected to ControlTool. If there is no connection, the stroke will be blocked. Configuring the press Select the "Data Input"...
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Page 38: Taring The Force Value
However, this function can only be used if a additional sensor for parts inquiry is available. Connect the sensor for parts inquiry to the relevant input (see circuit ® diagram) of the SCHMIDT SafetyModule. ® SCHMIDT PressControl 3000 – V1.3... - Page 39 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 only be acknowledged after the workpiece has been removed. ® SCHMIDT PressControl 3000 – V1.3...
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Page 40: Dataset Management
The data contained in the system dataset is used to operate the press system. To achieve this, a user dataset is loaded to the system dataset. It can now be edited for the press system operation via the “Data Input”. ® SCHMIDT PressControl 3000 – V1.3... -
Page 41: Managing Multiple Datasets
Datasets created and saved earlier can be loaded when needed. Select the "Datasets" system function key. Select the "Load File" command. Using the "Up" / "Down" cursor keys, select one of the 20 memory locations and confirm by pressing "Enter". ® SCHMIDT PressControl 3000 – V1.3... -
Page 42: Renaming Dataset
Now you may select the further letters, as already described. Using the "Left" cursor key, you can again select the front letters. Exit the "Edit Filename" dialog with the "Enter" key. Afterwards, save the dataset at one of the 20 memory locations. ® SCHMIDT PressControl 3000 – V1.3... -
Page 43: Quality Monitoring
By default, when the curve output is called, only the last recorded curve is displayed (parameter "Output Diagram" = "Single"). Alternatively, you can also establish that the curves of the production process be displayed as a group. ® SCHMIDT PressControl 3000 – V1.3... -
Page 44: Enlarging Details
Z o o m A l l C t r O N C t r O F F ..S e r v i c Figure 10-3: "Zoom Diagram" menu ® SCHMIDT PressControl 3000 – V1.3... -
Page 45: Tolerances
Produce a workpiece and check whether it meets the quality requirements. Repeat the production process and the check until a Not O.K. part is produced. When compared to the recorded curves, this Not O.K. part exhibits an outlier in at least one place. ® SCHMIDT PressControl 3000 – V1.3... -
Page 46: Force Tolerances
Move the cursor using the cursor keys to the right, lower corner of the desired window and confirm the position by pressing the "Enter" key. In the curve output, the tolerance window created is displayed with the designation "F". The tolerances are numbered sequentially. ® SCHMIDT PressControl 3000 – V1.3... -
Page 47: Stroke Tolerances
"Enter" key. Move the cursor using the cursor keys to the right corner of the desired stroke tolerance and confirm the position by pressing the "Enter" key. ® SCHMIDT PressControl 3000 – V1.3... -
Page 48: Managing Tolerances
S t r o k e T o l e r a n c e C t r O N C t r O F F ..S e r v i c Figure 10-8: "Monitoring Data Numerical" menu ® SCHMIDT PressControl 3000 – V1.3... -
Page 49: Move Tolerance Data
"Move tolerance data" function. Define offset The offset is determined via the intersection of the reference curve with a stroke tolerance. reference curve offset curve offset Figure 10-10: Principle of the offset of the tolerance data ® SCHMIDT PressControl 3000 – V1.3... - Page 50 [ m m ] 0 . 0 1 6 . 5 1 2 0 . 1 8 2 3 . 8 5 2 7 . 5 0 Figure 10-11: Force curve with offset of the tolerance data ® SCHMIDT PressControl 3000 – V1.3...
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Page 51: Maintenance And Servicing
All spare parts must comply with the technical requirements established by SCHMIDT Technology. This is always guaranteed in the case of original spare parts. 11.1 Setting the force offset Each force sensor has a different output signal in the unloaded state. -
Page 52: Calibrating The Force Sensor
As specified by the DIN EN ISO 9000, a calibration of the system must be carried out at regular intervals. The calibration is also offered by SCHMIDT Technology as part of its customer service. Prerequisite A reference measuring system is needed for the calibrating of the force measuring system. - Page 53 If there are large calibration errors, you can reset the calibration value to "1". calibration value Select the "Calibration Init" command. When using the optional analog output 2 to measure quality-relevant dimensions, regular inspections or calibrations should be made. Proceed as described at "Analog input 1". ® SCHMIDT PressControl 3000 – V1.3...
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Page 54: Adjusting The Stroke Offset
5 9 9 . 5 5 8 m m C t r O N C t r O F F ..S e r v i c Figure 11-5: Enter the "Offset stroke" ® SCHMIDT PressControl 3000 – V1.3... - Page 55 11 Maintenance and servicing The position measuring system does not have to be calibrated due to the fact that it is a digital system. ® SCHMIDT PressControl 3000 – V1.3...
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Page 56: Customer Service
12 Customer Service Customer Service Please contact to the SCHMIDT Technology Customer Service department when you encounter difficulties with the press system or the software. Describing problem Note, if possible, the error message. in detail ® Inform the SCHMIDT Customer Service:...
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