SCHMIDT PressControl. Machine Control Units

Transcription

1 SCHMIDT PressControl Machine Control Units SCHMIDT PressControl 70, 600 and 5000 are control units of the latest generation, which allow the design of modern production processes from the single workstation to complete automation. You benefit from our competence in: Safety technology type-approved devices Process measurement technology simultaneous measuring during the process Process documentation SCHMIDT PressControl control units have the following features: Efficiency due to intuitive user interfaces Quick and secure process set-up e. g. thanks to the touchscreen and additional handwheel ram control function with SCHMIDT PressControl 600 and 5000 in combination with the ServoPress / TorquePress The integrated PLC allows programming of additional inputs / outputs or sensors / actuators and the application-specific design of the workstation or the line The integrated measurement data processing is insensitive against interferences (EMC). This results in a high measurement security of the entire system With integrated safety technology, the entire system becomes a type-approved single workstation Service functions such as "Firmware Update" ensure the user has the up-to-date version of the software Guaranteed complete process documentation with full traceability SCHMIDT PressControl 70 SCHMIDT PressControl 5000 RT SCHMIDT PressControl 600 SCHMIDT PressControl 5000 HMI Simply the best! 65

2 SCHMIDT PressControl 70 Compact PressControl With the new modular control conception of SCHMIDT Technology, control and safety technology are separately. Thereby the new control unit SCHMIDT PressControl 70 for the pneumatic and hydropneumatic SCHMIDT Presses has been designed very compactly and nevertheless multifunctionally. The result is strong. This control is space saving with a size of only 90 x 120 x 60 (hxwxd) and can be integrated into the work station very flexible by its optional magnet holder. In conjunction with the SCHMIDT SafetyModule a manual work place with two-hand release or light curtain can be realized as well as EC-type-approved safety technology. The connection to the SCHMIDT PressControl 70 is made by CANfieldbus. This control persuades also by its easy operation via 3 key pads together with a 5-digit 7-segments-display. A key switch is as well existing as a LED display for the system static supply voltage and stroke take-over. The following modes of operation and functions are directly selectable: Two-hand release Light curtain Workpiece control Sliding table activation Return stroke initiation with external signal Preselection counter Operation without SafetyModule (in conjunction with capsuled machines or safe tools) Further helpful functions are: set up mode piece counter BDC-dwell time All important settings on the SCHMIDT PressControl 70 can only be done with the key switch, this is for safety reasons. Technical Data Supply voltage 24 V DC Current < 3 A Operating temperature 0 40 C Protection class IP 54 Interfaces CANopen for SafetyModule I / O: 4 digital in- and outputs (preset for operation modes) Electrical connections All connections are pluggable Display LED 7-segments, with 5 digits LED for stroke takeover Key switch For all important alignments Operation 3 function keys Modes of operation Two-hand release with SafetyModule Light curtain with SafetyModule Start button for operation without SafetyModule Workpiece control activation of sliding table Return stroke initation with external signal Operating functions Piece- or preselection counter set up mode BDC dwell time Dimensions 90 x 120 x 60 (h x w x d) Mounting Fastening screws, optional magnet holder Accessory Magnet Holder, optional mountable on the side or behind 66 SCHMIDT Presses

3 SCHMIDT PressControl 600 Press Control with integrated PLC & Process Data Management The SCHMIDT PressControl 600 with integrated PLC and process data management is made for intelligent process control of force / stroke monitored SCHMIDT ManualPress, (Hydro) PneumaticPress or ServoPress / TorquePress. Additional automation tasks around the press process can also be realized by the SCHMIDT PressControl 600. Control Unit All process integrated system elements and data are controlled and managed centrally by the SCHMIDT PressControl 600. The standard system configuration already includes a basic programming, special applications can be programmed as well. Features Processing of all process data in real time Process reliable production without further peripheral equipment Open communication with the peripherals: - CANopen - EtherNet TCP / IP - Profibus, PROFINET, Ethercat (optionally via external Gateway) Communication with other systems: - Master SPS - ERP - CAQ / Statistics System Multi-functional process control PLC for an individual design of process. Data are processed in real time by PLC, CNC (with SCHMIDT ServoPress / TorquePress) and process monitoring Integration of additional I / O s Process data acquisition and force / stroke monitoring with process monitored presses Connection to database server via Ethernet Integrated Operator Panel The integrated operator panel of SCHMIDT PressControl 600 with complete operating interface is made for parametrizing and operating the control as well as for visualization, administration, and documentation of process data (dataset management). Features User-friendly, intuitive menu navigation by touchscreen Individual design of user interface Keypad with integrated membrane for the input of numerical values and choice of functions Softkeys have different functions on different levels and simplify the handling Quality evaluation on the basis of force / stroke tolerances, and thus a reliable detection of NOK parts with process monitored presses Handwheel software for setup mode (SCHMIDT ServoPress / TorquePress), external handwheel as a handheld as an option (connection via SCHMIDT PRC Gateway) Industrial strength, even in harsh environments Protection class IP 54 Software Components The programming and projecting of the SCHMIDT Press- Control 600 as well as the data storing is done by software components. The software components can be installed on any Windows PC. The communication with the control unit is realized by Ethernet TCP / IP. Standard Software: SCHMIDT PRC Studio PLC editor Debugger SCHMIDT PRC Project Project Hardware set-up Dataset-management Optional Software: SCHMIDT PRC OPC OPC server, data exchange via the de facto standard of automation. SCHMIDT PRC DataBase Database software Export function for the process specifications / -results in different file formats, e.g. for quality management programs for Statistical Process Control (SPC) or Excel Q-DAS interface with certification Technical Data Industry PC with Integrated PLC Integrated CNC (by SCHMIDT ServoPress / TorquePress) Intelligent process control Diagnosis and service functions Linux operating system Drive Solid State Drive Field bus CANopen with possibility to connect: - 1 SCHMIDT ManualPress 3xx, 1 SCHMIDT (Hydro)Pneumatic Press (optionally with process monitoring) or 1 SCHMIDT ServoPress / TorquePress - SCHMIDT PRC Gateway - CANopen Compact box EtherNet TCP / IP PROFIBUS (optionally via external CANopen / PROFIBUS-Gateway) 16 Byte input / output data PROFInet (optionally via external CANopen / PROFInet-Gateway) 16 Byte input / output data EtherCAT (optionally via external CANopen / EtherCAT-Gateway) 16 Byte input / output data Interfaces EtherNet (10 / 100 MBit) 2 x USB Panel with Intuitive user interface Diagnosis and service functions Screen Integrated 7" widescreen TFT display (800 x 480) with touchscreen Power supply 24 V DC with integrated UPS Assembly Mech. adaption VESA 75 for optional table or wall fixture as well as fixture for housing Simply the best! 67

4 SCHMIDT PressControl 600 System Architecture SCHMIDT PressControl 600 does work as a system control and takes over the process monitoring. The hard- and software components forming a system concept with real time characteristics. This is guaranteed by a system architecture with CANopen fieldbus. SCHMIDT ManualPress with process monitoring or (Hydro-)PneumaticPress with / without process monitoring will be activated via fieldbus. The collected measuring data as well as in-/output data will be exchanged by the fieldbus. Communication with other systems can be realized via: CANopen EtherNet (OPC server) ProfIBUS (optional via external CANopen / PROFIBUS-Gateway) ProfINET (optional via external CANopen / PROFINET-Gateway) EtherCAT (optional via external CANopen / EtherCAT-Gateway) SCHMIDT PRC Gateway 2 CANopen connections for control (master) and PDA (Slave), with 24 V power supply 24 V interface with 16 inputs and 16 outputs Short-circuit-proof and overload-proof Status LED s for CAN bus and I / O s Encoder interface for external handwheel as handheld Supply voltage 24 V DC Top hat rail mounting 68 SCHMIDT Presses

5 SCHMIDT PressControl 5000 System Architecture SCHMIDT PressControl 5000 does work as a system control and takes over the process monitoring. The hard- and software components forming a system concept with real time characteristics. This is guaranteed by a system architecture with CANopen field bus. The SCHMIDT ServoPress- / TorquePress modules or other NC-axis will be controlled by the CANopen fieldbus and measuring data can be exchanged as well as I / O data. Furthermore, there is the possibility of connecting SCHMIDT PneumaticPress and SCHMIDT HydroPneumaticPress on safety technology SCHMIDT SafetyModule for CANopen. Communication with other systems can be realized via: CANopen EtherNet (OPC server) ProfIBUS ProfINET (optional via external CANopen / PROFINET-Gateway) EtherCAT (optional via external CANopen / EtherCAT-Gateway) External Handwheel as Handheld for SCHMIDT PressControl 600 and 5000 RT in conjunction with SCHMIDT ServoPress / TorquePress, connection via SCHMIDT PRC Gateway. CANopen Compact Box 16 digital combination inputs / outputs (8 inputs and 8 outputs), useable optionally as input and output (24 V) Plug 4-pins M8 screw type Simply the best! 69

6 SCHMIDT PressControl 5000 Compact System Control for intelligent Process Control SCHMIDT PressControl 5000 for SCHMIDT ServoPress / TorquePress is a compact, integrable system control with modular design for the operation of standardized individual workplaces up to complex, highly flexible automation lines with integrated joining modules. The realization and extension of assembly lines is considerably simplified by using SCHMIDT PressControl 5000 in conjunction with SCHMIDT ServoPress / TorquePress-modules. With this control it is also possible to integrate SCHMIDT PneumaticPress as well as SCHMIDT HydroPneumaticPress with SCHMIDT SafetyModule into the system concept via CANopen. Furthermore additional automation applications can be realized with SCHMIDT PressControl 5000 independently of the presses. Technical Data 5000 RT Industry PC with Integrated PLC Integrated CNC with all-digital drive control (integrated force-, position- and speed control loop) for up to 6 axis Intelligent process control Diagnosis and service functions Linux operating system Assembly on DIN rail (TS 35) according to EN (35 mm x 7.5 mm) Drive Integrated hard disk 30 GB Field bus CANopen with possibility to connect: - 6 SCHMIDT ServoPress- / TorquePressmodules or NC axis as well as SCHMIDT ManualPress 3xx and SCHMIDT (Hydro) PneumaticPress SCHMIDT PRC Gateway - more than 2000 I / O s EtherNet TCP / IP ProfiBUS: - PPROFIBUS Slave interface - 48 Byte input / output data PROFInet (optionally via external CANopen / PROFInet-Gateway) 16 Byte input / output data EtherCAT (optionally via external CANopen / EtherCAT-Gateway) 16 Byte input / output data Interfaces EtherNet (10 /100 Bit) 6 x USB 2 x RS 232 (COM 1/COM 2) for diagnosis purposes 4 digital inputs (24 V) galvanically isolated Steuerung 4 digital outputs (24 V) galvanically isolated Steuerung EMC 5000 Acc. to RT requirements of EMC law Power supply 24 V DC with integrated UPS Ambient temperature 0 40 C Control Unit 5000 RT All system elements and data involved in the process are centrally controlled and administrated by the control unit SCHMIDT PressControl 5000 RT. The integrated Profibus interface permits integration of the press system as an intelligent Profibus slave into existing Profibus networks. Parametrization, operation and programming will be effected by using software components which are installed on the operating panel SCHMIDT PressControl 5000 HMI or on a user PC. The standard system configuration already includes a basic programming for different operating profiles; special applications can be additionally programmed. Features Modular and can be networked Space-saving integrable in the switch cabinet Processing of all process data in real time Reliable production without further peripheral equipment Open communication with the peripherals: - CANopen - Profibus - PROFINET, EtherCAT (optionally via external gateway) - EtherNet Communication with other systems: - Master SPS - ERP - CAQ / statistic system Control of six SCHMIDT ServoPress / TorquePress modules or NC axis as well as capability of connecting SCHMIDT ManualPress with process control and SCHMIDT (Hydro) PneumaticPress via CANopen Multi-functional process control for an individual design of process. PLC, process data acquisition and CNC is in permanent dialog in real time Integration of more than 2000 I / O s Integrated process data acquisition and process monitoring Connection to database server via Ethernet Permanent use of the operating panel SCHMIDT PressControl 5000 HMI or temporary use of standard PC s (e.g. laptop) for parametrization, service, diagnosis during start-up and troubleshooting, as well as for process analyses and -optimizations (snap-shots or statistical parameters of the ongoing production) When used without HMI external handwheel as a handheld as an option (connection via SCHMIDT PRC Gateway) 70 SCHMIDT Presses

7 SCHMIDT PressControl 5000 Control Unit 5000 HMI SCHMIDT PressControl 5000 HMI can be parametrized and operated via operator panel SCHMIDT PressControl 5000 RT with its complete operating interface. Furthermore visualization, administration and documentation of process data (dataset management) can be effected as well by this instrument. Features Industrial PC with Microsoft Windows XP High-resolution process visualization by 19" TFT display for depiction of several processes Individual design of user interface, e.g. in conjunction with other system components Direct access to the process image User-friendly, intuitive menu navigation by touchscreen Operating modes: - Set-up mode via integrated, high-resolution handwheel function (mechanical) - Cycle mode by function key Integrated handwheel (for set-up mode): Switchable to any CNC axis with selectable resolution in order to simplify set-up of an operation. Press ram can be brought exactly to the required position or force by this handwheel. Keypad with integrated membrane for the input of numerical values and choice of functions Softkeys have different functions on different levels and simplify the handling Track ball takes over mouse -function and is also usable in rough working environment Industrial strength, even in harsh surroundings Protection class IP 54 Software Components Parametrization, operation and programming of the SCHMIDT PressControl 5000 RT will be effected by using software components. Moreover these software components are supporting project set-up, project visualization and data archiving. The software components can be installed on the operating panel SCHMIDT PressControl 5000 HMI or on a conventional Windows PC. The communication with the control unit is realized by Ethernet TCP / IP. Standard Software Package SCHMIDT PRC HMI User guidance Dataset management Process visualization Function keys Quality evaluation on the basis of force / stroke windows and stroke tolerances, and thus a reliable detection of NIO parts. SCHMIDT PRC Studio PLC-Editor CNC-Editor Debugger SCHMIDT PRC Project Project Hardware set-up Data Management Optional Software SCHMIDT PRC OPC OPC server, data exchange via the "de facto" standard of automation (see also page 79) SCHMIDT PRC DataBase Database software Export function for the process specifications / -results in different file formats, e. g. for quality management programs for Statistical Process Control (SPC) or Excel Q-DAS interface with certification Technical Data 5000 HMI Operating panel with Intuitive user interface Diagnosis and service functions Microsoft Windows XP operating system Screen Integrated 19" TFT display (SXGA resolution) with touchscreen Drive integrated hard disk 80 GB Interfaces 1 x PS / 2 keyboard 1 x VGA 3 x USB 1 x RS232 2 x Ethernet (10/100 MBit) EMC Acc. to requirements of EMC law Power supply 24 V DC Current consumption 4 A Ambient temperature 0 40 C Protection class IP 54 Weight Approx. 15 kg Simply the best! 71

8 User Interface for professional Assembly For PressControl 600 and 5000 The user interface for professional assembly is installed in the SCHMIDT PressControl 600 and The functionality has been developed especially for assembly operations with direct intervention in the process. The following functions are available Process visualization Process data management Development tool (PLC editor) SCHMIDT PRC DataBase as an option Features Easy and quick setup of the processes Definition of the data sets and operating profiles by parameters Process optimization due to switchover of the process display (F / s, F / t, s / t) Easy and quick definition and evaluation of the processes using the quality monitor Guaranteed detection of failed parts Unambiguous documentation and component assignment Software PLC for freely programming processes Service functions for diagnosis and system updates User Interface SCHMIDT PRC 600 User Interface SCHMIDT PRC SCHMIDT Presses

9 Visualization and Process Analysis For PressControl 600 and 5000 Visualized Display Force output and press stroke are important parameters for evaluating the quality of pressed assemblies. The data of these measurements are recorded during the process and displayed by the software as force / stroke behavior curve F / s, F / t or s / t. Freely definable tolerances the form of force/stroke windows and stroke tolerances are provided for quality assurance of the assembly process. With the help of these criteria, quality critical areas can be monitored selectively. If the tolerances in the monitored curve areas are not met, application-specific interventions can be carried out (e. g. selection measures). It is easy to create tolerance criteria and to display curve behaviors exactly. For an evaluation of the behavior, the working stroke and the return stroke are important. The high resolution of our measurement systems allows a large number of measuring points that are required for a process-safe evaluation. Zoom and measuring functions allowing detailed documentation about the assembly processes. Toleranzkriterien lassen sich sehr leicht erstellen und Verlaufsku Zooming area The Curve must pass the Window from Left to Right Measuring cursor Stroke Tolerance in Working Stroke Stroke Tolerance in Return Stroke Process Analysis Graphic Display Force over Stroke Process Analysis Graphic Display Force over Time Process Analysis Graphic Display Stroke over Time Simply the best! 73

10 Process Data Management For PressControl 600 and 5000 Press, quality and SPC parameters as well as system settings are menu-guided, extended and modified. This does not require programming knowledge. The parameters are defined within the data sets under customer defined identifications. Setting up additional data sets are simple via a menu driven wizard. Loading of a different data set can occur manually or via external, automated input. Data Management Entry of the Parameters via Dialog Fields 74 SCHMIDT Presses

11 Software Architecture For PressControl 600 and 5000 The function of the SCHMIDT Presses is based to a large extent on the control architecture. The combination of process entries, PLC, CNC and process data acquisition is the key to solving highly complex joining tasks precisely and efficiently. The force and stroke measuring systems with integrated signal amplification used in all monitoring based press systems by SCHMIDT Technology are evaluated in high resolution by the process data acquisition and transferred as ACTUAL values to the PLC for graphic or numeric output. The excellent control behavior of SCHMIDT PressControl 600 and 5000 is a direct result of the quick, bidirectional communication between PLC, CNC and drive of the servo axis. SCHMIDT PressControl 5000 SCHMIDT PressControl 600 Input and Output Mask Input and Output Mask PLC CNC Process Data Acquisition Measuring Data Process Simply the best! 75

12 Software Development Tools For PressControl 600 and 5000 PLC Process Control The PLC processes signals or values. Apart from this basic function provided with standard PLC systems, our control also carries out a large number of tasks and decisions that influence the process. Features Easy troubleshooting due to cyclical and static debugger Easy overview due to separate debug window Commonly used operands (inputs/outputs, words, flags, etc.) are listed Useful search function Function-oriented programming Resources Editor A resources editor is provided as programming interface, which supports the easy and structured creation of instruction sets. The description of the operands by user-defined symbols facilitates an easy overview. In addition, many pre-defined functions simplify programming. Unlimited Design of the User Interface Process output window, clear and unambiguous interface for the user with dynamical and static text and graphic display Clear instructions for the user to intervene in the process, e. g. by pressing a function key Unrestricted definition and labeling of function keys Individually designable text output (e. g. as supplement to the process output for the administrator) and parameter entry 76 SCHMIDT Presses

13 Database Software SCHMIDT PRC DataBase For PressControl 600 and 5000 SCHMIDT PRC DataBase is an optional software for the modular control system SCHMIDT PressControl 5000 or SCHMIDT PressControl 600. The database software is used for storing and analyzing the data of the control system - process specifications and process results - particularly under quality assurance aspects. SCHMIDT PRC DataBase differentiates between productive and archive database and is equipped with a data export function. The target systems which are relevant for the data export, e.g. quality management programs for Statistical Process Control or Excel, will be operated via data interface. The exported data will be stored in a format which is compatible with the target application. The choices are the CSV format as well as the Q-DAS format including certification. Then the file will be read and processed by the target application. The automated data export happens time-controlled, periodically. The procedure of this periodical action will be done under control of the Windows task schedule. SCHMIDT PRC DataBase is interesting for customers which have to archive the production data for several years, e.g. for safety relevant parts. Furthermore it can be used to demonstrate the process capability. The data evaluation is done by customer s existing quality management systems. The software can be used for single workstations as well as for multiple workstations, i. e. the front end can be installed and used on several Windows computers. The service will be installed only on one computer. An easy-to-use professional product for data analysis and quality assurance is available for the users now. Documentation Analysis Quality assurance Traceability Data export in CSV format Q-DAS interface with certification Simply the best! 77

14 SCHMIDT MoveTol Patented Offset of Tolerance, Data Software for PressControl 600 and 5000 Assembled parts are subject to certain manufacturing tolerances. Altitude deviations of the parts result in an offset of the curves in the curve window. The curves of the parts with higher tolerance deviations may then be situated outside of the defined tolerance limits and are classified as failed part. Using the function Offset of tolerance data, the altitude tolerances of parts can be taken into account. The defined tolerance windows and stroke tolerances are offset by the distance of a reference position. After that, the pass / fail evaluation is carried out. Offset of Tolerance Data in Relation to freely selectable Reference SCHMIDT Interface Software / Hardware The communication with co-ordinated control system is realized via a standardized interface program with SCHMIDT Press- Control. All relevant system states as well as failed productions are transferred from one control to another via a simple signal transfer. The production data stored in datasets are recallable via the SPS program. If e. g. tools are equipped with an explicit identification code, the production data automatically adapt themselves to the specific process. All standard physical interfaces, such as I / O interface CANopen EtherNet PROFIBUS PROFINET (via CANopen / PROFINET-Gateway) EtherCAT (via CANopen / EtherCAT-Gateway) USB can be used for signal transfer with the automation environment. 78 SCHMIDT Presses

15 SCHMIDT PRC OPC Data Exchange via the de facto Automation Standard In the field of automation, the data communication, using co-ordinated systems and the reference level, is becoming increasingly important. OPC defines a manufacturer-independent interface. All parties participating in the communication must only support this interface. The OPC-capable components can be combined just like elements of a construction kit. Example: Process Data Evaluation by means of MS Office Application With OPC, a direct transfer of production-specific data to MS Office applications, such as Microsoft Excel or Microsoft Access, is possible. Example: Process Visualization OPC connects all production machines (with industry PC-based control [IPC]) of a production area to a process visualization. This achieves impressive outcomes: Centralization of fault and operating messages Unique message system for all machines Individual user interface design Example - Linked Production Line The following possibilities result from the central control of a production line: Central operation of the entire production line Integration of all production machines in overall transport systems (lifting bars, conveyors, etc.) Transfer of all relevant data, such as workpiece type, processing state, etc., from one machine to another Production results influence the process of the following machine Measurement results correct tool wear of preceding machines Simply the best! 79