AUTOMEC CoastOne Original User Manual

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rev.190903

CoastOne Press Brake

original user manual

Coastone Oy

82 Calvary St

Waltham, MA 02453

PHONE: (781) 893-3403

FAX: (781) 899-5708

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Page 1 CoastOne Press Brake original user manual Coastone Oy rev.190903 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453 FAX: (781) 899-5708...
Page 2: Table Of Contents
INTRODUCTION ........................3 TECHNICAL DATA ....................... 4 SAFETY ..........................10 Warnings and ways to prevent accidents during normal operation ........10 Warning signs ......................... 11 Safety devices / functions....................12 General safety ........................12 Before starting to work .....................13 During working ........................ 13 Changing the tools ......................13 Basic maintenance......................14 Periodic inspection / tests after installation or major overhaul of the machine ....
Page 3: Introduction
CoastOne Oy machines and devices are realiable and safe to use, assuming they are used according instructions. This manual must be red carefully before starting to operate the machine to avoid injuries of personnel and damage of machine.
Page 4: Technical Data
2 TECHNICAL DATA Authorized compiler for technical file: Jukka Hakala Tuottajantie 27 A 1 60100 Seinäjoki Finland TECHNICAL DATA DIM. C9 X kN(US tons) 220(24) 220(24) Press tonnage Motor power Max. bending lenght (D) Distance between side frames Frame width (A) 1440 1440 Frame height (B)
Page 5 TECHNICAL DATA DIM. C12 X kN(US tons) 440(48) 440(48) Press tonnage Motor power Max. bending lenght (D) 1300 1300 Distance between side 1250 1250 frames Frame width (A) 1930 1930 Frame height (B) 2150 2450 Frame depth (C ) 1550 1550 Throat depth Table height...
Page 6 TECHNICAL DATA DIM. C15 X kN(US tons) 440(48) 440(48) Press tonnage Motor power Max. bending lenght (D) 1600 1600 Distance between side 1550 1550 frames Frame width (A) 2230 2230 Frame height (B) 2150 2450 Frame depth (C ) 1550 1550 Throat depth Table height...
Page 7 TECHNICAL DATA DIM. kN(US tons) 600(67) 800(89) Press tonnage Motor power Max. bending lenght (D) 2040 2550 Distance between side 2200 2700 frames Frame width (A) 2990 3500 Frame height (B) 2500 2650 Frame depth (C ) 1780 1780 Throat depth O-frame O-frame Table height...
Page 8 TECHNICAL DATA DIM. kN(US tons) 1000(111) 1500(166) Press tonnage Motor power Max. bending lenght (D) 3060 4080 Distance between side frames 3200 4200 Frame width (A) 4010 5030 Frame height (B) 2830 2950 Frame depth (C ) 1780 1780 Throat depth O-frame O-frame Table height...
Page 9 TECHNICAL DATA DIM. Bull 12 Bull 15 kN(US tons) 1000(110) 1500(160) Press tonnage Motor power Max. bending lenght (D) 1320 1620 Distance between side frames 1390 1690 Frame width (A) 2200 2500 Frame height (B) 2650 2950 Frame depth (C ) 1760 1760 Throat depth...
Page 10: Safety
3 SAFETY 3.1 Warnings and ways to prevent accidents during normal operation When using this machine, operator should be careful and exact, because this machine is classified as dangerous construction machine. Manufacturer does not take responsibility for the damage of machine or accidents, which are caused by the machine abuses. Warnings below are only used in this manual and are suggested to be taken in consideration when using the machine.
Page 11: Warning Signs
3.2 Warning signs From left to right, up to down: Warning sign in electric cabinet door for danger of electric shock Warning sign in front of machine for danger caused by deflection of protruding work-pieces Warning sign in front of machine for danger of getting crushed between bending tools Warning sign in front of machine for danger of getting crushed between work-piece and parts of machine 82 Calvary St...
Page 12: Safety Devices / Functions
3.3 Safety devices / functions light curtain, laser actuated AOPD, hold-to-run control or scanner system to stop the beam closing and hold it as stopped. When a safety device is being muted or access is prevented only by hold-to-run control, press brakes beams closing speed is limited to <=10mm/s.
Page 13: Before Starting To Work
Before starting to work � Make overall check, that machine is fit for duty. � Check that tools are in good shape, if you notice any damages, tools must be replaced immediately. � Make sure that your working area is clean, that will prevent tripping or slipping. Machine is recommended to be bolted on the floor.
Page 14: Basic Maintenance
3.8 Basic maintenance Every two weeks: � Check the condition and tightness of belts � Grease ball screws and bearing � Grease linear bearings of linear guidings � Check that screws and nuts are tight. � Check cable conditions. Recommend grease is NLGI class 2. 3.9 Periodic inspection / tests after installation or major overhaul of the machine Once a year manufacturer or manufacturers dealer shall perform periodic inspection according...
Page 15: Transportation
3.11 Transportation � Before transporting the machine, make sure that the machine is disconnected from power. � Machine must be lifted up by a lifting belt or by chains with a forklift or a crane � Lifting points and centre of gravity are marked in following picture. �...
Page 16 C12 / C15 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453 FAX: (781) 899-5708...
Page 17 G20 – G40 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453 FAX: (781) 899-5708...
Page 18: Acting In Extremis
3.12 Acting in extremis When emergency situation happens, act by the rules of the general emergency rules. 3.13 Disposal Disposal of the machine will be taken care as the general rules require. 3.14 Manufacturer/ retail dealer duty � Manufacturer/ retail dealer responses the transportation of the machine to the client. �...
Page 19: Release Of Trapped Person
3.16 Release of trapped person 1. Turn power off from main switch Remove covers above Y axis servo motors. Cut the timing belts by using tools designed to cut metal, for example angle grinder, as timing belts have steel wires inside them. Force ram/upper tool up by using one of the following methods Manually rotate each Y axis timing pulley clock wise (while observing above) Force upper beam up with a hydraulic jack...
Page 20: Working With The Machine
4 WORKING WITH THE MACHINE 4.1 Basic operations 4.1.1 Startup Power is turned ON from the main switch located at the electric cabinet door. After this safety circuit must be reset from blue mechanical button. If machine has lazersafe safety device, back guard must be separately reset from mechanical blue button at the backside of electric cabinet, excluding model C9.
Page 21: Using The Control
4.2 Using the control Touch screen can be operated by pushing the functions gently by finger or corresponding soft, round-tipped object. When power has been switched on, it will take a moment, while system starts up. After a while main screen appears. 4.2.1 Main screen From here operation can be continued with the buttons in lower bar.
Page 22: Lower Bar
4.2.2 Lower bar Lower bar is visible on each page. Button above enables auto mode. Light/dark color in button indicates if auto mode is active and servo motors are ON. Half light / half dark color indicates semi-auto mode. Possible causes for this button being inactive: -machine is not referenced -machine has an alarm Button above enables manual mode.
Page 23: Manual Mode
Program menu. Upper tool can be lifted with this button while servo motors are ON. If servo motors are OFF this button is inactive. 4.2.3 Manual mode Manual mode can be entered with this button when machine is in normal stage (no alarm etc). Axis being jogged can be selected with above buttons.
Page 24 Z1/Z2-axis position means the distance from back gauge fingertip’s left edge to the left edge of die holder. S1/S2-axis position means the distance to the horizontal plane. Note! Some of the axis positions are proportional the currently selected tools and material thickness.
Page 25: Settings
4.2.4 Settings At above middle, settings page number is shown. Settings page can be changed with buttons on left/right. Page 1 Y-axis fast closing speed, if fast closing is enabled for the machine. Y-axis slow closing speed from speed change point to material surface, or whole stroke if fast closing is not enabled.
Page 26 If fast closing is not enabled, with selection “3”, Y-axis stops at material surface, and continues to bottom dead point with next push of pedal. If fast closing is enabled, with selection “2” Y-axis stops at speed change point, and with selection “3”...
Page 27 Page 2 Manual and auto mode speeds for back gauge axes. For S axes auto mode speed upwards is calculated automatically according tool info, bend angle etc. With this setting (arrow up) 100% means exactly that calculated speed. If it appears that sheet followers rise too fast or too slow, for a reason or another, increasing/decreasing this value this can be compensated.
Page 28 Page 3. Material table. Materials ultimate tensile strength (Kg / mm2) affects calculated bending force and frame deflection compensation. K-factor affects to X-axis outer dimension correction. 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453 FAX: (781) 899-5708...
Page 29: Program Menu
4.2.5 Program menu. Bending program menu can be entered with this button. Program listing/storage can be selected for USB. Also returns to the root in the directory tree. USB stick, which is always provided with the machine, is the default storage media of the machine.
Page 30 Programs and tools can be freely copied from USB to another, or into office PC, by means of backup for example. With above button program listing can be switched into FTP server. Also returns to the root for FTP. FTP server is located in the touch screen and can be configured to be seen as external network location at a PC, which enables direct program transfer between machine and the PC.
Page 31 New sub folder can be created. Program search function. Programs will be searched only from the current folder of USB. When button is pressed keyboard appears. Programs can be searched with any amount of starting letters/numbers. Note that capital letters do make a difference. 2D programming/simulation can be entered with this button.
Page 32 Bend length basic value. When creating bend steps this will be the bend length automatically. Also when program is created in 2D each step will have bend length according this. Comment field. Operator can write program specific notes etc. This function must be enabled from commissioning settings.
Page 33: Punch Menu
4.2.6 Punch menu Opens punch list from USB. New punch can be created. Punch can be deleted. Button must be pressed briefly. Current punch can be selected into the program. Note that if page is changed with one of the lower bar buttons, punch is not selected into the program.
Page 34: Die Menu
Punch angle. Max allowed bending force. 4.2.7 Die menu Same buttons and functions in upper bar like in punch menu. Die height. Extremely important to have correct value to make machine work properly. Die V opening. Extremely important to have correct value to make machine work properly. 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453...
Page 35 Die safety distance. According this value back gauge avoids collision with the die. It is recommended to add 2mm to the measured distance from middle of the die to the back gauge side edge of the die. Die V opening radius. Extremely important to have correct value to make machine work properly.
Page 36: Multitool Function
This function must be enabled from commissioning settings. Also USB\2D FILES folder must have prober die holder files, which are available from CoastOne Oy and local dealers. Die holder files must be named as follows; First, the basic one must be “Die holder.xaml”.
Page 37 Up to 2 additional punches and dies can be used in single bending program. This function must be enabled from commissioning settings. When additional tools are required, desired tools must be “reserved” for given program as shown in picture above. After a tool is opened from USB, reserve slot can be selected (top right on tool info page).
Page 38: Bend Info
When additional tools are being reserved, punches and dies can be selected separately for each bend step by pushing the image of punch or die in bend info page as shown above. Some notes; These images are not shown in bend info page if there are no tools reserved for active program.
Page 39 Bend step delete. Bend step copy. Works like a copy-paste. When button is pushed to bottom bend step to be copied is stored, and when pushed again (button is released) stored bend step is copied to the current step number. Bend angle in degrees.
Page 40 Bend length. Bend position proportional to the lower beam. When bend length is entered, bend position is calculated into the middle of machine, but this can be changed if necessary. With this value Z1- Z2 positions are calculated automatically, also required bend force for separate Y axes. This function must be enabled from commissioning settings.
Page 41 R-axis position. Z1-Z2 axis positions. Delta X position. Sheet followers 1 and 2 can be selected separately for each step to support the sheet during bend. Surface of the back gauge fingertip where sheet will be positioned. According the selection X axis position is calculated automatically.
Page 42 By double clicking angle correction icon repeat icon appears as shown above. In this mode entered angle correction is added to each step of the program. Bull15 and G series machines crowning can be adjusted if necessary. X-axis correction. Pneumatic/hydraulic hemming die. When this is on it will lift the die up and when pedal is pressed, the die is released on the sheet.
Page 43: Radius Bend
4.2.10 Radius bend Total angle of the radius bend. Like in symbol, radius bend total angle is given as complement angle, unlike normal bend angle with cone TC15 2D control. Thus, it is natural to enter large angles of 180-360degrees. Radius of the radius bend.
Page 44 Radius bend selection can be cancelled, bend step is returned as normal step with basic values. Only possible in programming mode. Return to auto mode page. Only visible in auto mode. Radius bend step number. If radius bend has for example 4 steps, there will be 5 angles according the following example.
Page 45 In auto mode total complementary angle what should have reached at current point is shown. Actual angle correction which is added to each single step. When above mentioned measured angle function is used this value is automatically calculated. This is not complementary angle, it works similarly as normal angle correction.
Page 46 4.2.11 In 2D page bending program can be created and simulated graphically. 2D page can be entered with the 2D button in program menu page and in bend info page, when program is opened or created. If new program is created, a drawing grid awaits at 2D page. With it, the desired profile can be sketched.
Page 47 In next step profile is scaled to fill the screen and bend order is automatically calculated. Now actual angles and flange dimensions can be entered. Note that angle has to have – or + to specify the direction, clockwise or counterclockwise. With these buttons view can be toggled to show bend angles or bend order number.
Page 48 Bending order can be manually changed if required by entering the bending order numbers. When angles, dimensions and bending order is desired, with this button simulation step can be started. 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453 FAX: (781) 899-5708...
Page 49 If tools were not selected before entering 2D, first tools in the punch/die lists are selected. In simulation step in program mode punch and die can be browsed by pushing to punch/die. With this button profile dimensions, angles and bending order can be re-adjusted. With these buttons simulation and be toggled forward/backwards.
Page 50: Alarms And Warnings
4.2.12 Alarms and warnings Alarms and warnings page can be entered with above button. Emergency stop button pressed/safety circuit is not reset. Safety circuit can be reset from blue mechanical button, when cause of emergency stop is removed. Foot pedal is pressed into position 3. Pedal must be released with the mechanical button in the pedal.
Page 51 Notification for periodic greasing of machine linear components. Bend force limit of the active punch is exceeded. Bend force limit of the active die is exceeded. 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453 FAX: (781) 899-5708...
Page 52: Adjusting The Reference Values
4.2.13 Adjusting the reference values Before reference values can be adjusted properly, machine must be referenced, there has to be active program with real tool values, material thickness and machine has to have those tools fixed into it. Notification! Hemming tools with sprigs or pneumatics cannot be used for reference adjustment! Idea of the reference adjustment is that each axis is teached where actual 0.00 position should be.
Page 53 When selected axis is moved to correct position below shown point of the screen must be pressed briefly. After a while below shown button appear. When it is pushed briefly reference value is adjusted and axis position in upper bar should be 0.00 / 400.0. 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453...
Page 54: Lazersafe
4.2.14 Lazersafe After machine has been referenced lazersafe guards will be turned ON. IRIS/IRIS plus will also perform final tool alignment automatically at this point. When proper program with proper tools are selected and corresponding tools are fixed to the machine, vertical position of the guards must be confirmed and adjusted if needed.
Page 55 Adjustment tool with LZS-2. Adjustment with IRIS. 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453 FAX: (781) 899-5708...
Page 56 Adjustment tool with IRIS plus. For LZS-004-HS, place the tip of the punch to the point of 14mm in the scale. For LZS-2 place the tip of the punch to the point marked as “Tool tip”. For IRIS place the tip of the punch to the point marked as “Tool tip”. For IRIS plus place the tip of the punch to the point of 0mm (marked also as IRIS) in the scale.
Page 57 After final adjustment if middle led is green adjustment is completed successfully and machine is ready for operation. If upper led is red receiver should be adjusted upwards little bit, if lower led is red receiver should be adjusted downwards etc. Push tool align button again. If both upper and lower led are red, it might be caused by poor initial adjustment of transmitter and receiver, or by an obstruction.
Page 58 With this button tray mode can be selected. In tray mode closing stroke stops when a flange is detected, but with second press of pedal after this fast closing can continue of the middle sensor of the receiver is clear. Incase machine has two separate pedals connected to the PCSS operator can choose one pedal mode and two pedal mode with above button.
Page 59 For LZS-2 place the point of “Tool tip” to the tip of the punch. For IRIS place the point of “Tool tip” to the tip of the punch. 82 Calvary St PHONE: (781) 893-3403 Waltham, MA 02453 FAX: (781) 899-5708...
Page 60 For IRIS plus place the tip of the punch to the point of 0mm (marked also as IRIS) in the scale. Pay extra care to do this as accurately as possible as well as place the adjustment tools perpendicularly to the vertical axis as accurately as possible. 3.
Page 61: Ftp Server
4.2.15 FTP server The touch screen of TC15 2D control can be used as FTP server to transfer bending programs with an office computer etc. inside a factory network or with direct connection to single PC. Ethernet cable and correct network settings are required for this. To set correct settings follow the next steps 1.
Page 62 5. At PC side add network location with right clicking on the “computer” and select “choose a custom network location”, click next Syntax for FTP address according the example would be “FTP://192.168.0.251/”, adjust according if using another IP. Choose to enter username which must be “cone”. You can name this network location as you wish.
Page 63: Iris Plus Angle Measurement System
4.2.16 IRIS plus angle measurement system All functions related to IRIS plus are located on a separate page. Page can be entered from settings or bend info, button has the following IRIS plus icon Besides normal height adjustment and alignment of IRIS transmitter and receiver, which are explained in chapter 4.2.14, IRIS plus system requires reference image to be taken every 4 hour and system calibration minimum once a day.
Page 64 After successful reference image system calibration can be performed. To do that calibration tool shown below is required. Calibration tool is always provided with the machine. If angle of the punch is <70 degrees, calibration tool should be fixed to the punch according left picture, otherwise according right picture.
Page 65 Below are the functions and provided info from IRIS plus. Angle measurement ON/OFF, selection is stored to the given bend step. It might be necessary to turn measurement OFF in some cases where IRIS plus system won’t be able to measure the angle reliably, like for example too short flange.
Page 66 Above shown field is informative, the programmed target angle. Above shown field is the current measured angle. On bottom right is shown the measurement quality, which can be 100%, 75% or 50%. 0% quality means that the angle cannot be measured, in which case normal bend cycle is executed without measurement.
Page 67 Other points to take into account There are few parameters which are automatically tuned during operation. In operator point of view this means that the very first part of new program will take few seconds longer, but after few cycles the relevant parameters are tuned for faster operation. Parameters are adjusted only in full auto mode.
Page 68 Measurement accuracy Theoretical angle measurement accuracy is +/- 0.25 degrees at 100% measurement quality. Measurement quality can be 100%, 75% or 50%. 0% means that angle can’t be measured. Below are factors which might decrease measurement quality. 1. extreme conditions such as -direct sunlight -exposure to the outside elements (e.g.
Page 69: Trouble Shooting
6. Exposed limb length, meaning the part of sheet coming over the die edges on both sides. Minimum 20mm for 100% quality, minimum 10mm for 50% quality. 7. Part profile, with closed profile only 75% or 50% can be achieved. Always set the Lazersafe tray mode ON if part has a closed profile bend.
Page 70 Reference run or manual jog does not work � Try to jog each axis into both directions in manual mode, and before reference run try to jog axes away from the reference limit switch. � Check the torques of axes while jogging manually. Torques should never exceed 100%. �...
Page 71 Notifications and warnings � ”Y pos < 0.00”, Y axis position is negative. Check tool info and/or manually lift Y axis. � Punch image and question mark, check punch info. � Die image and question mark, check die info. � Thickness symbol and question mark check the thickness in the program. �...