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LINK ELECTRIC & SAFETY CONTROL COMPANY OmniLink II Operating Manual

Press automation control, tonnage & analog signal monitor
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OmniLink II
Press Automation
Control
TONNAGE &
ANALOG SIGNAL MONITOR
OPERATING MANUAL
Version 1.01
R
Link Electric & Safety Control Co.
444 McNally Drive,
Nashville, TN 37211
PH (615) 833-4168 FAX (615) 834-1984

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Summary of Contents for LINK ELECTRIC & SAFETY CONTROL COMPANY OmniLink II

  • Page 1 OmniLink II Press Automation Control TONNAGE & ANALOG SIGNAL MONITOR OPERATING MANUAL Version 1.01 Link Electric & Safety Control Co. 444 McNally Drive, Nashville, TN 37211 PH (615) 833-4168 FAX (615) 834-1984...

  • Page 2: Table Of Contents

    Table of Contents Section 1 Introduction ............1.1 Section 1.1 Features .
  • Page 3 Section 4.2.3 Setting Additional Data Window Parameters ..... . . 4.8 Section 4.2.3.1 Turning Data Windows ON or OFF ......4.8 Section 4.2.3.2 Setting the Data Window “Start Angle”...
  • Page 4 Section 5.2 N/A ............. . 5.5 Section 5.2.1 N/A .
  • Page 5 April 27, 2004 Manual Version 1.01...

  • Page 6: Introduction

    Limits can be programmed manually, automatically calculated by the Tonnage and Analog Signal Monitor Module, or recalled along with all other OmniLink II settings through the use of job setups. Status messages for each channel indicate the first alarm condition that occurred during the stroke.
  • Page 7 April 27, 2004 Manual Version 1.01...

  • Page 8: Parameter Entry And Access Control

    Section 2.1 Parameter Entry Throughout the OmniLink II control, a fairly standard form of data entry is employed. When data entry is allowed, an “editing cursor” will appear on the screen. This cursor can typically be moved from parameter to parameter on the screen with the up, down, left, and right arrow keys. The topmost softkey is used to select the parameter for editing and can change description depending on the parameter selected.
  • Page 9 TEXT ENTRY ABORT EDIT CURSOR LEFT his is text to edit CURSOR Keys to select letter RIGHT Press ENT to save text ABCDEFGHIJKLMNOPQRSTUVWXYZ.+-=()%<>/ SPACE SELECT LETTER LOWER CASE UPPER CASE EXIT Figure 2.1: Example Text Entry c) The fist character of the text is highlighted with the text cursor. The CURSOR LEFT and CURSOR RIGHT softkeys will move this cursor.

  • Page 10: Access Control

    Section 2.2 Access Control The OmniLink control has several parameters or operations that have limited access. In regards to the tonnage monitor the ability to perform actions of turning bypass off and on, resetting faults, or changing limits must be restricted to certain personnel. The OmniLink control provides several means to limit access to these parameters or operations.

  • Page 11: Section 2.2.3 Password Only Mode

    The example above can be taken one additional step, if two press operators are given different user names and different passwords. One operator can be assigned the ability to change tonnage monitor limits in addition to the ability to reset tonnage monitor faults, while the other operator is not assigned the ability to change the tonnage monitor limits.

  • Page 12: Section 2.2.6.1 Run/Prog Key Switch Operation

    Section 2.2.6.1 RUN/PROG Key Switch Operation The RUN/PROG key switch is located on the lower right side of the operator terminal. This is a two position switch. The key is removable in the RUN position only. If the RUN/PROG key switch is being used as a means to access the restricted items, the switch must be turned to the PROG position.
  • Page 13 Step A: Select the restricted item. In the example shown in Figure 2.2 the restricted item is Channel 2 High Limit. Once the parameter is selected then Softkey # 1, the upper vertical softkey (Softkey # 1 is highlighted in Figure 2.2) , will display the legend “SELECT”. Step B: A list of users that have access to this restricted item will appear.

  • Page 14: Definitions And Terminology

    Section 3 Definitions and Terminology This section will give some background and explain the meaning of various settings and readings in the tonnage monitor. It is strongly recommended that this section be read in order to use the tonnage monitor effectively! Section 3.1 Tonnage The tonnage monitor reads forming forces (“tonnage”) from strain gauges mounted on the machine...
  • Page 15 in Figure 3.2 shows the forces applied to the left and right sides of the machine frame along with the resulting total force. This process would result in the tonnage monitor displaying 100 tons for the left channel, 100 tons for the right channel, and 200 tons for the total. Figure 3.2: Tonnages From Example Die 1 When forces occur on the individual channels at different positions in the stroke (at different times), the total force depends on the amount of force exerted at any specific position.

  • Page 16: Section 3.1.3 Reverse Tonnage

    tons distributed to the right side of the machine frame and 40 tons distributed to the left. This process would result in the tonnage monitor displaying that the maximum tonnage measured on the left side of the machine frame was 60 tons, that the maximum tonnage measured on the right side of the machine frame was 60 tons, and that the maximum total tonnage exerted on the machine frame was 100 tons.

  • Page 17: Data Windows

    Section 3.2 Data Windows Peak tonnage monitors capture the maximum tonnage seen by each strain gauge over the stroke. This maximum tonnage is used for comparison to setpoints in determining if an alarm should be generated to stop the production process. While this is adequate for most applications, complex tooling can produce multiple peaks resulting in only the highest peak being checked against setpoints.

  • Page 18: Data Window Off Angle

    Section 3.2.2 Data Window Off Angle The Off Angle for a data window is the angle at which the setpoints for that data window stop being enforced. For example, in Figure 3.5, data window 1 has an off angle of 170 degrees. April 27, 2004 Manual Version 1.01...

  • Page 19: Limits

    Section 3.3 Limits The tonnage monitor can compare the tonnages it reads to limits set for each job. The following sections detail these limits. Section 3.3.1 Machine Rating Limit The machine rating limit, unlike low and high limits, is intended to protect the machine rather than the tooling.

  • Page 20: Total Tonnage Limit

    Section 3.3.5 Total Tonnage Limit There is only one limit that can be applied to the total tonnage. If so configured (see section 5.2 for details), the machine rating derate table will apply a limit to the total tonnage that varies with the crank angle (related to height off the bottom of the stroke).
  • Page 21 April 27, 2004 Manual Version 1.01...

  • Page 22: Operation

    Section 4 Operation Section 4.1 Main Operator Terminal Screen The Operator Terminal Main Menu shown in Figure 4.1 provides the current status of the tonnage monitor module directly beside the TONNAGE MONITOR softkey. Drive Order Counter OFF Speed Counter Stroke PC STATUS Stroke Mode Single Stroke...

  • Page 23: Main Tonnage Monitor Screen

    Section 4.2 Main Tonnage Monitor Screen The TONNAGE MONITOR softkey in the Main Menu provides access to the tonnage monitor module installed to operate with either two or four channels. This screen shows the maximum forward tonnages recorded during the last stroke, the description and status of each channel, the overall status of the tonnage monitor module, and limits that apply to the current view.
  • Page 24 c) Low Limit Value The low tonnage limit setting for this channel and view (peak, data window 1, data window 2, etc). d) Graphical Limit Bar This is a floating bar graph that graphically indicates where the tonnage for a channel is relative to the low and high setpoints for that channel.
  • Page 25 Figure 4.3 shows a four channel screen when viewing data window tonnages. Notice that the major difference between this screen and that of Figure 4.2 is the addition of three new parameters and the lack of a REVERSE TONNAGE softkey. Drive Order Counter OFF...

  • Page 26: Selecting A View

    Figure 4.4 shows a four channel screen when viewing reverse tonnages. Drive Order Counter OFF Speed Counter Stroke PC STATUS Stroke Mode Single Stroke READY TO STROKE Speed View Total TONNAGE Peak MONITOR Reverse Tonnage Tons CH1 - LEFT FRONT CH2 - RIGHT FRONT CHANGE 150%...

  • Page 27: Section 4.2.1.1 Viewing The Peak And Data Window Tonnages And Settings

    Section 4.2.1.1 Viewing the Peak and Data Window Tonnages and Settings The CHANGE VIEW softkey allows the operator to select which set of tonnages and settings are shown on the tonnage monitor screen. The view can be the maximum forward tonnage that occurred anywhere during the last stroke (Peak) or the maximum tonnage that occurred during a particular data window (Data Window 1 through Data Window 4).

  • Page 28: Section 4.2.2.3 Setting Reverse Limits

    uppermost vertical softkey) should read “CHANGE LOW LIMIT”. Press this softkey to enter numeric entry mode. Enter the new limit with the numeric keypad and press the ENT key to set the limit. The low limit MUST be less than the high limit for that channel and view! Note that setting this value to zero effectively disables it.

  • Page 29: Section 4.2.2.5 Turning Low Limits On Or Off

    Section 4.2.2.5 Turning Low Limits ON or OFF Pressing the LOW LIMITS ON/OFF softkey will toggle all low limits (including those in all data windows) ON or OFF. This key is only available when viewing forward tonnage (as in Figure 4.2 and Figure 4.3).

  • Page 30: Bypassing The Tonnage Monitor

    (“m” in Figure 4.3). Softkey 1 (The uppermost vertical softkey) should read “CHANGE END ANGLE”. Press this softkey to enter numeric entry mode. Enter the new value with the numeric keypad and press the ENT key to set the angle. The end angle can be entered with a resolution of .5 degrees and MUST be greater than the start angle for that data window! Section 4.2.4 Bypassing the Tonnage Monitor...

  • Page 31: Tonnage Alarms/Stop Conditions

    Section 4.3 Tonnage Alarms/Stop Conditions The Main Tonnage Monitor screen provides a status indication for each channel. This message indicates any tonnage alarm or error condition that has occurred and under normal operating conditions should show "Status: OK". If a tonnage alarm occurs, the message will change to reflect the FIRST alarm detected on that channel during the stroke.

  • Page 32: High Data Window Alarm

    The Module Status in the bottom of the Main Tonnage Monitor screen will indicate "Tonnage Alarm". The Present Running Status in the Press Control screen will indicate "Tonnage Top Stop" or "Tonnage Cycle Stop". Section 4.3.3 High Data Window Alarm One of the messages listed below in the Channel Status indicates that the maximum tonnage recorded during the last stroke exceeded the High Limit setting in one of the data windows.

  • Page 33: Machine Rating Alarm

    Section 4.3.5 Machine Rating Alarm A Channel Status message "Machine Rating" indicates that the maximum forward tonnage recorded during the last stroke exceeded 125 % of channel rating. When the condition is detected on any channel, a Cycle Stop is provided to the press control. This stop signal remains in effect and further stroking prevented until the alarm is RESET.

  • Page 34: Error Conditions

    Section 4.4.1 Setpoint Errors When power is applied to the OmniLink II or when a limit has changed and the RUN/PROG keyed selector switch is in the RUN position, the tonnage monitor module performs a series of calculations based on the present limit settings. If an invalid condition is found to exist either due to an incorrect setting or an internal fault, an error message is generated in the Module Status and a Top Stop provided to the press control.

  • Page 35: Resetting Errors

    return, connect the strain gauges one at a time to determine which gauge causes the shorted condition or verify that the resistance of each gauge (Vref to Gnd) is approximately 350 ohms. If the problem remains, it indicates a failure on the tonnage monitor analog board.

  • Page 36: The Tonnage Monitor Graph Screen

    Section 4.5 The Tonnage Monitor Graph Screen The GRAPH OPERATIONS softkey in the main tonnage monitor screen provides the operator or die setter more detailed analysis of machine forces by displaying tonnage versus crankshaft angle curves. The screen in Figure 4.5 shows an example screen when viewing peak tonnage information. Figure 4.6 shows the same example graph when viewing data window 2 information.
  • Page 37 c) Reverse Limit Bar This line (in red) graphically shows where the reverse limit is set with respect to the tonnage waveform. For a “good” hit, no part of the tonnage waveform should extend below this line. The “R” to the right of the line is for “Reverse”.
  • Page 38 end angle of a data window. Note that the ending angle may not always be exactly the value entered for this parameter but is calculated by the tonnage monitor due to the way it handles the waveform. k) Number of Points The tonnage monitor module indicates the number of sample points taken during the last stroke in the upper right hand part of the screen.
  • Page 39 Figure 4.6 shows an example tonnage monitor graph screen when viewing a data window. For the most part, the screen is the same as when viewing peak tonnages. Use the keys to move the graph cursor Use the keys to move the parameter cursor CHANNEL 1 TONS - DW 2 SETPOINTS 100.0 Points: 1085...

  • Page 40: Viewing The Graph

    p) Low Limit Bar This line (in blue) graphically shows where the low limit is set with respect to the tonnage waveform. Notice that the line only exists where the data window is active. For a “good” hit, some part of the tonnage waveform between the data window start angle and the data window end angle should extend above this line.

  • Page 41: Section 4.5.1.3 Entering Pan-Zoom Mode

    Section 4.5.1.3 Pan - Zoom Mode Pressing the soft key “Enter Pan Zoom Mode” brings up a set of keys which allow the user to custom tailor the scale and position of the waveform shown on the screen for optimum viewing. The graph scale is the percent of channel rating (or machine rating when viewing the total) displayed on the y-axis of the graph.

  • Page 42: N/A

    and down arrow keys to place the editing cursor (not the measuring cursor) on the parameter to change. Assuming the operator has access (via RUN/PROG key or access code), the numeric keypad can be used to key in a new value or the decrement (m) and increment (l) keys can be used to decrement or increment the value.

  • Page 43: Section 4.5.3.3 N/A

    Section 4.5.3.3 Section 4.5.3.4 Section 4.5.3.5 4.22 April 27, 2004 Manual Version 1.01...

  • Page 44: N/A

    Section 4.5.4 4.23 April 27, 2004 Manual Version 1.01...
  • Page 45 4.24 April 27, 2004 Manual Version 1.01...

  • Page 46: Configuration

    Section 5 Configuration The configuration menus of the tonnage monitor module are accessed by selecting the CONFIGURE TON MON softkey in the Main Tonnage Monitor Screen with the RUN/PROG keyed selector switch in the PROG position. The operator terminal will request entry of the configuration access code and upon correct entry will provide the configuration menu shown in Figure 5.1.

  • Page 47: Section 5.1.1 High Peak Alarm Stop

    (see OmniLink II press control manual). This feature provides benefit only if the outputs (OR 2/3) control a mechanism that releases the hydraulic fluid in the overload system quickly.

  • Page 48: Section 5.1.4 Channel Configuration

    If this setting is changed from the way it was shipped from the factory, the OmniLink II power must be turned OFF and back ON. The channel configuration is examined only at power up.

  • Page 49: Section 5.1.7 Start Sample Window Angle

    crankshaft angle at which it occurred in order to display the tonnage vs. crankshaft angle curve. This parameter defines the rate at which tonnage samples are stored for use in displaying this tonnage curve. It has no effect on the determination of peak tonnage (sampled at 200 microseconds). Machines with speeds greater than about 20 strokes per minutes should be set to store at 200 microseconds.

  • Page 50: N/A

    Section 5.2 Machine Rating This selection displays the screen shown in Figure 5.3. Changes are made with the RUN/PROG keyed selector switch in the PROG position by positioning the cursor onto the desired parameter with the arrow keys, using the numeric keypad to set a new value, and pressing the ENT key or through the softkeys provided.
  • Page 51 order to position each region. Figure 5.4 shows the tonnage curve for a 12 inch stroke press with a 30 inch connecting rod. Rated tonnage is specified at .25 inch off bottom. In the example, the limits are placed approximately 10% beyond the rating. Figure 5.3 shows the table of 16 angle regions and % of machine rating for that angle region approximated from the curve.

  • Page 52: Calibration Screens

    Section 5.3 Calibration Screens Section 5.3.1 Dynamic Calibration This selection displays the screen shown in Figure 5.5. Changes are made to the tonnage monitor calibration numbers (gain) with the RUN/PROG keyed selector switch in the PROG position by positioning the editing cursor onto the desired calibration number with the up, down, left, and right arrow keys as necessary.

  • Page 53: Reset Alarm Counters

    Section 5.4 Reset Alarm Counters This selection displays the screen shown in Figure 5.6. Counters are reset with the softkeys shown. April 27, 2004 Manual Version 1.01...

  • Page 54: Job Setups

    Tonnage Monitor Module. If a tonnage monitor module is installed after an OmniLink II has been in operation and job setups have been stored in the press control, the jobs will not exist in the tonnage monitor module. If a job is recalled, the tonnage monitor will detect that the setup does not exist and the operator terminal will display the message "No Tonnage Monitor Settings".
  • Page 55 Low Limits will be automatically disabled in Inch or Timed Inch modes. After the correct tonnage monitor settings are established for the die, along all other OmniLink II settings, the present settings should be stored under a job number and description for recall later.

  • Page 56: Installation

    Section 7.1 Tonnage and Analog Signal Module Installation The OmniLink II Press Automation Control Tonnage and Analog Signal module can be used with the OmniLink II Press Automation Control system or with the OmniLink 5000 Press Control system. This is illustrated in Figure 3.1. The Tonnage and Analog Signal module connects to either system via the high speed serial bus.
  • Page 57 The OmniLink II Press Automation Control Tonnage and Analog Signal module can be mounted in the April 27, 2004...
  • Page 58 In selecting the mounting location for the OmniLink II Press Automation Control Tonage and Analog Setup module, the wiring connections for the unit should be considered. After the mounting location has been determined, the card rack assembly can be secured with four screws.

  • Page 59: Strain Gauge Locations

    Section 7.2 Strain Gauge Locations Section 7.2.1 "C" Frame Machines Machines with "C" frame configurations, such as OBI and GAP frame presses, should be installed with one strain gauge mounted to each side frame member and the tonnage monitor module configured for 2 channel operation.
  • Page 60 although ease of installation usually dictates mounting the strain gauges on the uprights. On solid frame straight side machines, the uprights are also the best strain gauge locations. The best strain gauge locations are below gibs and at least 12 inches above where the upright joins the machine bed.
  • Page 61 Figure 7.4 shows areas to avoid on uprights of straight side machines of tie rod construction. The cross- hatched areas should be avoided. Figure 7.4: Areas to Avoid on Straight Side Machines (Do Not Mount in Cross- Hatched Areas) April 27, 2004 Manual Version 1.01...
  • Page 62 On solid frame straight side machines, the preferred strain gauge mounting location is inside the "windows" under the ends of the crankshaft. A strain gauge should be mounted on the inside face of each column forming the "windows" as shown in Figure 7.5. Figure 7.5: Strain Gage Mounting on Solid Frame Straight Side Machines April 27, 2004...

  • Page 63: Strain Gauge Mounting

    Section 7.3 Strain Gauge Mounting Strain gauges may be bolted directly to the machine or bolted to intermediate pads welded or adhered to the machine. Section 7.3.1 Direct Machine Mounting Select the desired mounting locations for the strain gauges. Remove paint, oil, grease, etc., to obtain a bare metal surface slightly larger than the LST-1000 strain gauge.

  • Page 64: Section 7.3.2 Intermediate Weld Pad Mounting

    Section 7.3.2 Intermediate Weld Pad Mounting Select the desired mounting locations for the strain gauges. Remove paint, oil, grease, etc., to obtain a bare metal surface slightly larger than the LST-1000 strain gauge. Clean the mounting surface with a solvent, removing all contaminants. Assemble the intermediate pads to the alignment/clamping fixture using the 1/4 x 28 bolts provided, as shown in Figure 7.8.

  • Page 65: Strain Gauge Wiring

    Strain Gauge Wiring Run flexible or rigid conduit from the strain gauge protective boxes to the control enclosure that contains the OmniLink II card rack. Entry into the control enclosure should be as close as possible to the tonnage monitor module.

  • Page 66: Installation Procedure

    OFF, write down the present machine rating and cal #'s. In addition to moving the strain gauge wires to the OmniLink II, the stop signal from the tonnage monitor must be removed and jumped out at the control.
  • Page 67 Exit back to the Tonnage Monitor Screen and enter high limits and low limits (for Peak Tonnage and all Data Windows). Enter reverse limits. The tonnage monitor is shipped from the factory with low, high, and reverse limits programmed. If the installation procedure required the machine rating to be changed, these limits may no longer be acceptable and could generate an error condition.

  • Page 68: Configuring Control

    Section 7.6 Configuring Control The OmniLink II press control must be configured to allow the tonnage monitor module option. The installation procedure is as follows: From the Main Menu screen, select the PRESS CONTROL softkey. Switch the RUN/PROG keyed selector switch to the PROG position.
  • Page 69 7.14 April 27, 2004 Manual Version 1.01...

  • Page 70: Calibration

    Section 8 Calibration Calibration of an OmniLink II Tonnage Monitor Module consists of achieving a known load on the machine and adjusting the installed monitor so that the known load is displayed correctly. The known load used during calibration should be at least 50% of rated machine load and preferably 100% of rated machine load.
  • Page 71 CAUTION! Extreme care should be used in calibration procedures for tonnage monitors. Severe damage to the machine being calibrated or the calibration equipment can result from incorrect shut height adjustments. Injury to personnel calibrating the machine or to others in the machine area can result from poorly implemented load cell or hydraulic jack stacks that fly out of the machine under load.

  • Page 72: Dynamic Calibration With Load Cells

    If error conditions relating to setpoint limits occur, correct the invalid conditions and press the RESET ERROR softkey. d) Set the high setpoint for each channel of the installed OmniLink II Tonnage Monitor Module to about 10% greater than the tonnage expected on each channel when the machine is loaded at rated tonnage.
  • Page 73 “g” of this calibration procedure. i) Turn on the power to the machine and bypass (see Section 4.2.4) the OmniLink II Tonnage Monitor Module. Return the slide to the top of stroke position.
  • Page 74 RUN/PROG keyed selector switch to the PROG position and enter cal. #s for all channels until all four channel tonnages of the OmniLink II tonnage monitor module are within one or two percent of one-fourth (1/4) the sum of the load cell readings April 27, 2004 Manual Version 1.01...

  • Page 75: N/A

    Reduce the load gradually, and verify that the tonnages displayed by the OmniLink II tonnage monitor module "track" within one or two percent of those of displayed on the load cells. Failure of this indicates a non-linearity which could be due to incorrect strain gauge location, improper strain gauge mounting, or incorrect tie rod tension (in frames of this construction).

  • Page 76: Replacing System 1000/1100

    The calibration number for a System 1000 or System 1100 Tonnage Monitor is proportional to gain but not equal to it. This means that transferring the cal. number from a System 1000/1100 to a OmniLink II requires that the number be multiplied by a constant (constant=1.11).
  • Page 77 April 27, 2004 Manual Version 1.01...

  • Page 78: Troubleshooting

    MAIN SCREEN softkey and check if the Present Running Status of the OmniLink II control indicates that there is a fault. If so, verify that power is applied to each of the the OmniLink II modules (check the power supply LEDs). If power appears correct, check the wiring of the five wire cable from the operator terminal to the power connector module on the card rack.
  • Page 79 April 27, 2004 Manual Version 1.01...

  • Page 80: Section 10

    The Clear Stroke Counter/Memory Code used to clear memory in the tonnage monitor is the same Clear Stroke Counter/Memory Code as used by the OmniLink II press control. These codes are described in the OmniLink II Press Control manual, provided to customer supervisory personnel, and are not defined in this manual.
  • Page 81 10.2 April 27, 2004 Manual Version 1.01...

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