TOX -Controls. TOX -Process Monitoring TOX software

Transcription

1 TOX -Controls TOX -Controls TOX -Process Monitoring TOX software 1

2 TOX -Controls NETWORK TOX software Ethernet Interbus / ProfiNet / Profibus PLC TOX -Controls a modular system Pneumatic 2-hand controls console Safety valve pneumatic or electric From simple, pneumatic basic controls, or electro-pneumatic controls, all the way to complex, custom programmable controls with nearly unlimited possibilities, all controls needs can be fulfilled. All TOX -Controls meet the latest technical safety norms and guidelines from the German Occupational Safety and Health Administration as well as European Directive EN for pneumatic presses. With TOX -Controls, you are always on the safe side, as only high-quality, tried and tested safety components and valves are mounted. 2-hand safety controls console A pneumatic air servicing unit is included with each TOX -Control System 2

3 TOX -Monitoring The process at a glance Control units for monitoring of clinching and pressing processes The evaluation device can be selected according to each requirement. From 1- to 12-channel clinch monitoring all the way to continuous measuring in force-travel-pressing monitoring. Various evaluation methods allow for different analysis of your processes. Diverse communication-interfaces allow for simple and quick data transfer to the data storage. We provide: --customer optimized total solutions --single components --high quality sensors --shielded cables --user defined evaluation software --everything from one source, one system TOX -Clinching Monitor CEP 400 / 400T --Force monitoring of clinching processes --Trend monitoring --Process sequencing --Network capability over Ethernet TCP / IP --Expandable to user defined processes --With and without display KN Control dimension X (mm) Shown: 8-channel version TOX -Pressing Monitor EPW 400 The TOX -Pressing Monitor EPW checks continuously the pressing operation providing quality control during production: --monitors pressing- and forming processes, as force-travel function --controls windows: threading, progression, block measure / block force --64 different component part types in 64 measuring programs --provides most important data about process status Interfaces: --CAN-Interface --Integrated Ethernet- Interface --USB Optional: --Profibus --Analog output 0 10 V TOX software This specially developed software from TOX PRESSOTECHNIK integrates all appropriately equipped TOX -Products. Programming, visualization, networking and archiving, all this can be done using a common platform. 3

4 Scope of the TOX -Controls Signals from pneumatic controls for: --Pressure switch --Safety valves --Jog/ sequencing valves --Other valves Further supplies: / 230 V AC --24 V DC for connected process monitoring units Supply and main switch Basic components of the TOX -Controls Process specific signals from the press for: --Top and bottom end position --Power stroke --Parts presence --Oil level --Oil pressure Junction box Lift guards Rolling guards Process monitoring Light curtains Integration of optional machine components Other options per customer requirements 4

5 TOX -Controls The modular controls system for presses, machine and robotic units Straight pneumatic controls 2-Hand Controls STP Simple basic controls to drive pneumatic and pneumohydraulic cylinders and presses without additional functions. For presses with a tool opening 6 mm. 2-Hand Safety Controls STP Control module according to EN 574 III C with main directional valve to drive pneumatic and pneumohydraulic cylinders and presses. Pulse Controls External Pulse Controls STE Main directional valve and required accessories (flow controls, air servicing unit, etc.), pneumatic components only, cycle initiation to be provided by customer using an external input from their controls. Foot Pedal Controls with Operator Safety Module STE STE STE Safe cycle initiation of pneumatic and pneumohydraulic cylinders by a foot pedal including an operator safety module to provide guarding. Electric Controls 2-Hand Safety Controls STE Simple cycle initiation of pneumohydraulic cylinders with establis hed, limited additional functions. 2-Hand Safety Controls STE From simple cycle initiation of pneumohydraulic cylinders to complex, standardized, programmable controls with established, limited additional functions. Hand Safety Controls with PLC STE STE Variable and customizable cycle initiation of pneumatic and pneumohydraulic cylinders and presses. The process sequence can be customized to meet customer requirements. Jog mode is available as an option. 5

6 Scope of the TOX -Controls Ordering description Size variants STP /4" 1/2" STP /2" 1/4" STE /4" 1/2" 3/4" 1" STE /2" STE STE STE STE STE STE /4" 1/2" 3/4" 1" 1/4" 1/2" 3/4" 1" STE /4" 1/2" STE /4" 1" Controls Straight pneumatic External signal Electric Functionality 2-hand controls to drive main directional valves. 2-hand safety controls. Basic function, approach / return strokes actuated by push buttons. (Enclosure per EN 574). Main directional valve with required accessories, requires customer supplied signal for cycle initiation, only for automated lines. Foot pedal controls. Requires mechanical guarding of work area prior to start of cylinder cycle. (See TOX -Presses catalog for type CLX). 2-hand safety controls series 600. Cycle initiation by push buttons, with basic functions 2-hand controls series 600. Cycle initiation by push buttons, from simple to complex program sequencing (STE 336 with basic PLC). 2-hand safety controls with PLC. Comprehensive, flexible and customizable controls. Signal for approach stroke Push buttons 2-hand c. Push buttons 2-hand controls External signal Foot pedal Push buttons 2-hand controls Push buttons 2-hand controls Push buttons 2-hand controls Signal for return stroke Push buttons 2-hand c. Push buttons 2-hand controls External signal from pressure switch Pressure switch Pressure switch Pressure switch Pressure switch Safety functions Safety valve with CLX All Controls includes: Air servicing unit and speed flow controls Glossary: Locking function: Jog mode: Scope of delivery: Electric: Pneumatic: Stand-alone: When the cylinder has switched into the power stroke, and the sensor signaling tool closed has been met, the push buttons can be released. The cylinder develops the preset pressure and then retracts. Used for setup of the machine. Momentary activation of the 2-hand buttons results in a movement of the piston with reduced speed. The cylinder can be stopped at any desired position. All required electric components, emergency reset, in-feed, function keys etc. are included. Includes all required valves as well as an air servicing unit, as well as flow controls for approach and return speed. Controls ordered without a press will be delivered with 3 meter long hoses and wiring. 6

7 Jog/setup mode Sequencing mode Interface CEP 400 / EPW 400 possible Peak load oil press. switch Locking function power stroke Inclusive Additional functions (optional) In-feed and main switch in separate enclosure Electric controls in 2-hand enclosure Enclosure for electric components Pneumatic mounting plate without enclosure 2-hand controls Optional enclosure 2-hand controls 340x x380 x x x380 x210 Foot pedal, CLX, automatic- and setup ZDA Foot pedal, CLX, automatic mode Foot pedal,clx 2-hand controls 1) 10), 16) incl. ZDA 340x x600 x x380 x210 2-hand controls 1) 11), 13), 15), 16) 340x x380 x210 2-hand controls 1) 16) 340x340 Additional functions for approach resp. connection 380x380 x x x800 x210 1) External input signal 2) Additional retract signal for external input 3) Proximity switch 4) Foot pedal 5) Push buttons 6) Oil level monitoring 7) Counter 8) Preset counter 9) Safety light curtain 10) Manually operated protective grid (swivel-mounted) 11) Pneumatic operated lift guarding; travel: 250 mm / width: 400 mm 12) Remote access for Siemens S7 13) End position feedback and separate control possibility 14) Interface for monitoring unit 8 E/A 15) Interface for monitoring unit 3 E/1A 16) External release Ordering example: STE /4" + Description of additional functions Size of pneumatic supply Ordering description 7

8 Additional Information on the TOX -Controls Basic operation of the electric TOX -2-hand Controls when used with TOX - Presses The cycle is initiated using the two push buttons on the 2-hand safety control. Both sensing devices must be activated within 0.5 seconds. The working rod will advance through the fast approach stroke until it meets resistance. This resistance will shift the sequence valve and initiate the power stroke. The TOX - Powerpackage remains pressurized as long as the push buttons are activated. Once the preset oil pressure is reached, the pressure switch sends a signal to the directional valve to retract the working rod. Controls with the self locking function initiate the return stroke automatically regardless of whether the safety push buttons are still activated. The working rod will retract as soon as the preset oil pressure has been reached. If any or both of the push buttons are released prematurely, the TOX - Powerpackage will retract immediately. After completing a cycle, a new one can only be initiated after the 2-hand safety buttons have been released during the return stroke of the previous cycle. Depending on the type of controls, additional signals can be used, such as parts presence sensors. Complete process sequencing can be realized using our PLC controls. Safety: Activating the integrated emergency reset button will introduce the return stroke immediately in any operating mode. In case of a loss in air pressure, the working rod will not retract and could drift down slowly. Standard version of the TOX -Safety Control Flow control valves to regulate speed during approach and return strokes, air servicing unit, oil pressure switch to signal return stroke (not included with straight pneumatic controls) For machines without a base or for orders without a PC press, the control elements will be supplied separately including 3 m of connecting power lines. This applies also to controls which are ordered with a TOX -Powerpackage and are to be mounted by the customer. All controls are supplied according to TOX PRESSOTECHNIK specifications. The buyer must ensure that any presses and controls supplied by TOX PRESSOTECHNIK conform to all applicable national and local Occupational Safety Hazard Guidelines. TOX PRESSOTECHNIK shall not be held liable for any damage or injuries resulting from neglect or misapplication. The buyer guarantees to TOX PRESSOTECHNIK that they will comply with all applicable national and local safety regulations prior to use of the equipment. By definition, any pinch points along the return stroke of the tooling area must be properly guarded. Safety recommendations for press controls with self locking function For presses with 2-hand safety controls and using tools with an opening > 6 mm, a sensor for tool closed must be installed (see operating manual) according to the guidelines provided in the DIN EN standards. The sensor must be installed in such a way that it will provide a signal once the tooling is closed. If the tool opening is 6 mm or the tooling area is guarded (e. g. perimeter guarding), then this sensor is not required. The sensor serves as a fail safe method of the command for the self locking function. 8

9 TOX -Monitoring Monitoring units CEP 400 / 400T for clinching processes 1- to 12-channel units CEP 400.x01 / x02 Panel mount unit Installation housing Wall mount unit Wall housing IP54 Advantages: + + Reduced programming costs + + Optimum price / performance ratio + + User friendly + + Many optional interfaces + + Comprehensive product family CEP , 1-channel version CEP , 2-channel version CEP , 1-channel version CEP , 2-channel version CEP 400T.x04 x12 Panel mount unit Installation housing CEP 400T.004, 4-channel version CEP 400T.008, 8-channel version CEP 400T.012, 12-channel version Wall mount unit Wall housing IP54 CEP 400T.204, 4-channel version CEP 400T.208, 8-channel version CEP 400T.212, 12-channel version Ordering example: CEP 400.xxx 1- / 2-channel 4- / 8- / 12-channel Version 0 = Panel mount unit 2 = Wall mount unit IP54 Type 400 = Membrane keyboard (only 1- / 2-channel units) 400T = Touch-Display (only 4- / 8- / 12-channel units) Function of the CEP 400 / 400T Monitors clinching and joining processes Provides important data about process status Special clinching monitoring using window technique Up to 64 check programs can be selected Real names for program memory, up to 40 characters 64 sensor configurations per channel 4 password levels: operator, setup technician, integrator, end user 8 digital I/O s Status indicator menu of digital I/O ports Stores up to 100 values with time stamp Includes TOX software for parameterization and data recording Display of control dimension X (absolute value) Choice of panel mount unit or wall mount unit IP54 Backlit display Membrane keyboard with password protection for up to 2 channel units TFT, transmissive, graphics capability, 5,7" TFT LCD VGA (640 x 480) at 4- / 8- / 12-channel units RS 232 for parameterization Ethernet interface allows unlimited monitoring channels via network Optional expansion: PROFIBUS DP interface CANopen Gateway for implementation of all standard Bus systems, Interbus, ProfiNet, Process sequence control for TOX -Clinching Processes Service modules such as --Remote maintenance --Test control unit to check measuring cycle Analog output 0 10 V Evaluation unit for bench top presses TOX -FinePress 9

10 TOX -Pressing Monitor EPW 400 The safety window for the production process The windows to be passed through by the work process, are determined and defined according to the requirements of the customer. It is possible to define up to 10 windows for each check program. Main menu Configuration menu The TOX -Pressing Monitor EPW checks continuously your pressing operation providing quality control during production. Application: The pressing monitor EPW 400 checks processes where a precisely defined functional correlation between force and distance must be checked. The EPW is used widely to monitor joining, riveting, pressfit and staking processes. The EPW can be used in fully automated production lines, as well as in manual processes such as acceptance sampling in shipping and receiving. With EPW 400 rapid part type program exchanges become real. Up to 64 component part specific parameter settings are available and can be controlled by PLC or by menu. Due to the coloured touch display and the simple, self-explanatory icons of the menu guidance, it is very easy to adapt the measures to the specificrequirements of customers. 10 Submenu Several password levels are available in the user administration and also the required language can be selected there. Data EPW 400 Monitors clinching and joining processes Provides important data about process status Special clinching monitoring using window technique Up to 64 check programs can be selected Real names for program memory, up to 40 characters Stores last 10 measured curves 4 password levels: operator, setup technician, integrator, end user Includes TOX software for parameterization and data recording Display of control dimension X (absolute value,optional) Choice of mounting style or wall mount unit IP54 LCD color touch display TOX -Force Sensors Built-in sensors DMS Strain sensors 0 10 V TOX -Oil Pressure sensors bar / 0 10 V TOX -Travel Sensors Travel sensor ZKW integrated in the TOX -Powerpackage External travel sensors 16 digital inputs and 8 outputs Status indicator menu of digital I/O ports Interfaces on board: CAN, Ethernet, USB Optional expansion: PROFIBUS DP interface Subprint card for implementation of all standard Bus systems, Interbus, ProfiNet, Process sequence control for TOX clinching processes Service modules such as --Remote modem access --Test control unit to check measuring cycle Analog output 0 10 V Evaluation unit for bench top presses TOX -FinePress Ordering description: EPW 400

11 TOX software Overview of the process network The TOX software is delivered with the CEP/EPW 400 process monitoring systems as well as the electric servo systems TOX -ElectricDrive. The TOX software allows to parameterize, handle, save and evaluate processes in a simple, user friendly manner. Pressing Monitor EPW 400 Clinching Monitor CEP 400 / 400T TOX -Servo Controller TCP / IP TOX software Data backup Internet Parameterization Profibus Interbus Digital I/O Signal processing The TOX software is organized as follows: Project overview to visualize and parameterize clinching processes. Status report provides a clear display of primary parameters for one or several processes. Process overview for parameterization of individual processes. A separate force sensor can be defined for each process (e. g. for change of TOX -Tools or for TOX -Clinching Units with different parameters). End value overview for a quick control of the last 100 clinch points. These values can be recalled and exported at any time with help of the TOX software. Server archiving for continuous and complete archiving of all clinch data via Ethernet connection. The data is saved as a CSV file and can be easily evaluated using MS-Excel, for example. Project assistant The WORX-Module has pre-configured, ready to use process function blocks which can be customized to the individual application. A dialog based project-wizard will aid in the initial setup and assist in the project layout. Projects can be saved and copied as templates for future use. 11

12 TOX -Accessory, electrical Precision limit switch ZWE, Position transducer ZWW Precision limit switch ZWE for monitoring of control dimension X Technical data: Operating voltage: V DC Switching current min. at 1 mv: 1 ma Operating point accuracy: ± 0.01 mm Mechanical life: 10 million Actuating force: 10 N Mounting position: optional Connection: M12 round plug Protection: IP54 This precision limit switch can be used to monitor electrically the control dimension X for clinching applications. 2,5 Operating point 0,8 Differential travel 0,5 End position Wire colors: PIN 1 + excitation PIN 4 switching signal Ordering example: ZWE Variant Type Description Other position / travel measuring systems from other manufacturers and other measuring methods (such as inductive, capacitive, resistance, incremental) can be also implemented. Ø15,8 M14x1 Ø6 Dome plunger R M12x1 Wiring diagram External, analog absolute value position transducer ZWW for installation in die sets The displacement transducer indicates the absolute instantaneous position of the working rod or ram, even during power failure. The measurement system is almost wear-free, and it is not sensitive to dirt or interference. The sensor is mounted externally in a die set or on the working rod. Order no. Measuring range A B C D ZWW mm ZWW mm ZWW mm ZWW mm Technical data: Repeatability: ± 0.01 mm Operating voltage: 10 V DC Resistance: 1 Ω 5 Ω Linearity: % full scale Connection: plug, 5 pin, Binder Protection: IP54 Scope: Sensor Plug Bracket Ø clearance for travel A B C D Caution A means of connecting to the ram is required. Wire colors: PIN 1 excitation PIN 2 + output signal PIN 3 + excitation Ordering example: ZWW Variant Travel 100 mm Description Ø4 18 M Wiring diagram 22 12

13 TOX -Accessory, electrical Rod End Load Cell ZPS directly mounted on the working rod of the TOX -Powerpackage Technical data: Rated output: 1.1 mv / V Temperature range: -10 to +65 C Zero balance: ± 2 % Supply voltage: 10 V DC (max. 15 V) Insulation resistance: 1 G Ω Nominal impedance: 760 Ω Electric connection: System Fischer Combined error: < ± 0.5 % Overload: 115 % Protection class: IP54 The rod end load cell ZPS can be mounted directly on the working rod of the TOX -Powerpackage cylinder. D C G Press forces can be measured in both press and pull directions. Note: reduced retraction forces! It is sealed against dirt and moisture. The load cells are available in various sizes to fit each TOX -Powerpackage. The sensor should be applied with an antirotation device, to avoid damage of the connection cable. B ØA SW H I ZPS 001 / ZPS 002 J B ØA1 To avoid the damage of the sensor the clamping range (Ø A) must be considered. E D C G Advantages: + + highly precise + + robust + + compact ØA ØB ZPS 004 ZPS 200 ØFg6 H I J B SW ØA1 Order no. press force max. kn Please order accessories separately Information on the accessories, like the suitable antirotation device ZPSV, can be found in data sheet TOX -Powerpackage or on the internet website. for TOX - Powerpackage Ø A Ø A1 B C D E Ø F g6 G SW H I J retracting force max. kn ZPS S 1 / K M12x ZPS S 2 / K M16x ZPS S 4 / K M22x ZPS S 8 / K M30x ZPS S 15 / K M30x ZPS S 30 / K M39x ZPS S 50 / K M42x ZPS S 75 / K 75 S 100 / K M64x ZPS S 200 / K M80x

14 ØD1 F M H ØC ØK I TOX -Accessory, electrical Press Force Sensors CKN, ZKNW TOX -Press Force Sensor CKN, In-Die sensor for TOX -Punch or TOX -Die +0,07 +0,05 +0,02 (D) 5,05-0,02 L +0,07 +0,05 P ØA -0,1 ØC +0,15 +0,1 Guide length = min. 0.4 x (TOX tool length) Pressure plate Force sensor mounting plate 2 Ø3 4 Requirements: --press force + 20 % < rated capacity of the sensor --mounting guidelines (drawing) --included 5 pin connector --cable 2 m long --sensor must be installed in such a way that no side-, torsion-, or pre-loads are present This force transducer specially developed by TOX PRESSOTECHNIK allows measurement of relatively high forces under critical space requirements. Technical data: Rated output: 8 mv at 12 ma excitation Temperature range: +10 C to 65 C Zero balance: ± 3 % Excitation current: 12 ma Insulation resistance: >5x10 Ω Nominal impedance: 350 Ω Combined error: ± 2 % Overload: 120 % Protection: IP54 Order no. Rated Sensor dimensions Mounting dimensions capacity kn Ø A mm Ø B mm L mm Ø C mm D mm P mm CKN CKN CKN CKN CKN CKN CKN CKN CKN Wire colors: black + excitation red excitation white + signal output green signal output Ordering example: CKN Version Rated capacity (40 kn) Description TOX -Press Force Sensor ZKNW, miniature sensor for use in die sets ØD2 A Example: sensor under TOX -Die Extremely compact sensor for universal use. Technical data: Rated output: 1.5 mv / V Temperature range: +10 C to 65 C Zero balance: ± 1 % Recommended 3 V DC excitation voltage: (max. 5 V DC) Insulation resistance: >10 Ω Nominal impedance: 350 Ω Combined error: ± 0.5 % Overload: 150 % Protection: IP54 Order no. Measuring range Dimensions in [mm] [% FS] Ø D1 Ø D2 F A H I Ø C Ø K M ZKNW kn ZKNW kn ZKNW kn ZKNW kn ZKNW kn ZKNW kn ZKNW kn Wire colors: white + excitation brown excitation yellow + signal output green signal output Ordering example: ZKNW Version Rated capacity (10 kn) Description 14

15 TOX -Accessory, electrical Strain Sensor ZKN, bolt-on type 13,6 6, ,5 Ø6,6 92, Mounting recommendations: The strain sensor must be mounted on a machined surface with a minimum ISO surface finish of N9 and a maximum flatness tolerance of 0.05 mm. The tightening torque should be Nm. Use mounting screws M6 x 25 with a grade of 10.9 or higher. The surface sensor measures the strain between two bolted locations. The measured signal is proportional to the elongation of the structure. The sensor can measure elongation and compression, and provides the respective signal. Wire colors: Standard passive (pull and press): brown + excitation green excitation yellow + signal output white signal output Technical data: Standard passive: Rated output: 1.25 mv / V (250 µe) Temperature range: + 10 C to 65 C Zero balance: Excitation voltage: ± 100 % possible 5 V DC (max. 10 V DC) Insulation resistance: >10 MΩ Nominal impedance: 350 Ω Combined error: ± 2 % Overload: 120 % Standard cable length: Protection: 2 m IP67 Standard active: Rated output: 10 V (250 µe) Temperature range: + 10 C to 65 C Zero balance: ± 100 % possible Excitation voltage: max. 24 V DC 30 ma Insulation resistance: >10 MΩ Combined error: ± 2 % Overload: 120 % Standard cable 2 m length: Protection: IP67 Ordering example: ZKN 103.xxx.200 Cable length Sensor type upon request Description Other force sensors from different manufacturers are available on request. Please contact us. 15

16 Product Range TOX -Powerpackage TOX -ElectricDrive TOX -PowerKurver Our Worldwide Sales and Service Network TOX -FinePress TOX -Presses TOX -Tongs TOX -Controls TOX -Monitoring TOX -Joining- Systems TOX -Punching TOX -Coining TOX GmbH & PRESSOTECHNIK Co. KG Riedstrasse 4 D Weingarten Tel (0) 751 / Fax + 49 (0) 751 / info@tox-de.com TOX -Press-Fitting TOX -Production Systems Subject to technical modifications