PRESS CONTROLS

MECHANICAL POWER PRESS CONTROL SYSTEMS

 

Each mechanical power press must be looked at as an individual system. This system consists of, but is not limited to, the frame, all mechanical parts, clutch and brake assemblies, electrical or electronic systems, hydraulic systems, pneumatic systems, tooling or dies (present and future), tool or die setup, safeguarding, material handling, maintenance requirements, size or configuration of workpiece, and most importantly, production requirements.

CONTROLS

Controls are furnished according to the type of press: full revolution or part revolution. Please see later pages detailing these requirements for further explanation.

PART-REVOLUTION CONTROL SYSTEMS

 A part-revolution control system consists of:

  1. A control box

  2. Individual components

  3. OR Component packages

We offer a variety of control boxes that can be furnished to meet your specific requirements. The SSC-1500 solid-state control box version is available as follows:

1. Standard clutch/brake control

2. Custom clutch/brake control which includes a fused disconnect switch and magnetic motor starter

3. Special clutch/brake control

4. Remote operator style

SELECTING A CONTROL SYSTEM

To order a complete control system which includes control reliability and brake monitoring, determine which style control box is required. A standard control box includes the clutch/brake control and transformer. The clutch/brake control can also be furnished in a plain-door enclosure, as a subpanel, or as a module kit. The plain-door control requires a remote operator station. Subpanels and module kits are furnished without the enclosure; module kits include the primary internal components of the control only. Subpanels and module kits must be installed into an existing enclosure by qualified personnel. The subpanel or module kit also requires a remote operator station or a keypad/display kit. A custom control box includes a main power disconnect switch and magnetic motor starter in the same enclosure as the clutch/brake control. A reversing ram-adjust motor starter may also be included. Special control boxes can include either a standard or custom clutch/ brake control that requires modification for any special requirements. This can be an interface of auxiliary equipment, such as a lube system, a light curtain interface for a non-Rockford light curtain, or components specified by the end user, such as NEMA starters and disconnects. Remote operator-style control boxes include the clutch/brake control and are designed to be mounted close to the operator. A control transformer must be supplied separately or the existing transformer must be reused.

STANDARD MODES OF OPERATION

  • Off

  • Two-hand inch (regular, timed, or top-stop)

  • Two-hand single stroke

  • Foot single stroke

  • Two-hand “walk-away” continuous

  • Continuous-on-demand

  • Automatic single stroke

  • Two-hand-maintained continuous

  • Foot-maintained continuous

  • One-hand or foot trip single stroke (use with light curtain or interlocked guard only)

PROGRAMMING

The SSC-1500 press control has eight (8) user-programmable inputs (6 static-type and 2 static- or cyclic-type inputs) that can be programmed for equipment monitoring or other user-defined functions. All inputs are 24-V DC selectable current-sinking or sourcing inputs. There are three parameters that can be programmed for the six statictype inputs, and five parameters that can be programmed for the two static- or cyclic-type inputs. The three parameters are input logic, stop type, and fault message; the five parameters are input logic, stop type, fault message, open angle, and close angle. They can be assigned to each input from the list below. When a fault condition is detected, the machine will top stop or emergency stop, and the assigned message will be displayed. This feature helps when troubleshooting common fault conditions.

 

FAULT MESSAGE LIST:

Clutch/Brake Air Fault

Counterbalance Air Fault

Dual Solenoid Fault

Clutch Valve Fault*

Brake Valve Fault*

Lube Fault

High Lube Pressure

Low Lube Pressure

Low Lube Level

Main Motor Overload

Ram-Adjust Motor Overload

Lube Motor Overload

Auxiliary Motor Overload

Guard Interlock Open

Front Guard Open

Rear Guard Open

Left Side Guard Open

Right Side Guard Open

Feeder Fault

Load Monitor Fault

Safety Block Interlock

Shut Height Fault

Variable Speed Drive Fault

Die Protection Fault**

Short Feed Fault**

Part Ejection Fault**

Stock Buckle Fault**

End of Stock Fault**

Pilot Pin Fault**

Part Input #1**

Part Input #2**

Part Input #3**

*Only used on machines that have a split clutch and brake, and two dual valves have been furnished.

**Messages typically used for die protection.

FEATURES

  •  Meets and exceeds OSHA 29 CFR 1910.217 and ANSI B11.1 and B11.19 

  • Provides two-hand control safeguarding device

  • Redundant/cross-checking microprocessors

  • Redundant microprocessor logic power supplies

  • Redundant solenoid relays

  • 4-line x 20-character LCD (liquid crystal display) with 20-key operator interface

  • Wide range of input power supply — 85-to 135-V AC

  • Absolute resolver/pulser with sync sensor for timing and motion detection

  • ime-based brake monitor with programmable warning and fault set points

  • Stop-time measurement test

  •  6 user-programmable 24-V DC static diagnostic inputs

  • Part-in-place 24-V DC input

  • 2 user-programmable 24-V DC static or cyclic die protection inputs

  • 7-digit stroke and batch counters with preset, and a 7-digit total counter

  • Automatic variable-speed top-stop adjustment (for continuous mode only)

  • Light curtain interface(s) with off/on selector

  • Light curtain mute during the nonhazardous portion of the stroke

  • 4 PLS (programmable limit switch) outputs—2 on/off angles, or 1 timed off, or 1 counted output per PLS (or 3 PLS outputs and 1 auxiliary output with 1 contact)

  • Information displayed when the machine is in operation: angle, speed, batch counter, stroke counter, mode of operation, and stop time

  • Display of text in English or Spanish

KEYPAD/DISPLAY

The keypad/display is used to enter setup information, monitor machine operation, and display messages to the user. The keypad/display has a 4-line x 20-character LCD (liquid crystal display) with 20 keys for entering information and programming. As standard, this keypad/display is mounted in the control box. For operator convenience, it can be furnished in a remote enclosure up to a maximum of 150’ from the SSC-1500 control module (see page 28). Information displayed during the machine run cycle includes:

• Angle                               • Stroke Counter

• Speed                              • Mode

• Batch Counter                  • Stop Time