ALFAMATIC PRESS-RIGHT User Manual
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ALFAMATIC PRESS-RIGHT User Manual

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USER MANUAL
P
-R
RESS
IGHT
•
User manual
Issue 2 - August 8, 2023

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  • Page 1 USER MANUAL RESS IGHT • User manual Issue 2 - August 8, 2023...

  • Page 3: Table Of Contents

    Control of the position-force curve .................... 5 Absolute and relative odds ......................5 Installation Press-Right ........................7 How to start ............................8 Press-Right user interface ......................8 First approach ........................... 8 Set the view ..........................9 The main menu ......................... 9 Jobs10 Create a new job ........................
  • Page 4 13.4 Tools recognition ........................31 14 Data storage ........................... 33 15 Password ............................34 16 Calibration ............................35 16.1 Force transducer calibration ....................35 16.2 Position transducer calibration ....................35 16.3 Encoder alignment ........................36 17 Connection to computer ......................... 38 17.1 Connection via USB port ......................

  • Page 5: General Informations

    The positions referred to the zero of the cylinder are called absolute positions. The positions referred to the contact position on the piece are called relative positions. The Press-Right can use both absolute and relative positions. The load cell is used to detect the contact position: when the force measured by the load cell exceeds a programmed value, the position values is set to zero.
  • Page 6 1) Top dead centre 2) Zero absolute position 3) Zero relative position Figure 1 The accuracy of the contact position detected with the load cell depends on the speed of the cylinder and above all on the type of piece to be machined. In inserting operations, the two pieces have rounded corners, consequently the contact position also varies with the variation of the bevel and the force used to position one part into the other.

  • Page 7: Installation Press-Right

    2 Installation Press-Right To install the instrument on the machine, consult the specific manual.

  • Page 8: How To Start

    3 How to start This chapter will walk you through the basics of programming and using the Press-Right instrument. To better illustrate the operations, it is advisable to carry out the tests in practice; to do this it is very useful to have an elastic support of adequate compliance to simulate repeated machining.

  • Page 9: Set The View

    Once the job has been created, indicate to the instrument when it has to stop the press by entering a stop value. The stop value can be a position value or a force value. The difference in usage is explained in chapter 5.

  • Page 10: Jobs10

    4 Jobs The Press-Right memorizes all the settings (parameters, tolerance range, limits and counters) relating to the various jobs in an internal memory. Each group of settings is called Job. Each job has its own name. JOBS LIST item is present in the main menu. Through this menu it is possible to choose a job among those present, create a new one, or delete the job in use.

  • Page 11: Selection Of A Job Via Fieldbus

    Selection of a job via fieldbus It is possible to select the job to be used via the fieldbus in three different ways: via the job name, via the identification code or via an index number. 4.6.1 Selection from fieldbus by name To select a job, first write the code of the desired job in the string buffer at the address 45, then write command 3 in the CONTROL_WORD_OUTPLC.

  • Page 12: Job Counters

    4.11 Job counters Each job has a piece counter. To access the counter options, select the menu EDIT JOB > SCHEDULING. In this menu it is possible to reset the piece counter or choose a maximum number of pieces to block the instrument.
  • Page 13 The phases will be performed automatically in sequence. If you want to carry out a phase individually out of sequence, select the Do not perform the phases in sequence option in the TOOLS > SETUP > JOBS SELECTION menu. In this case it is not possible to change the phase that will be performed from the menu. It is also possible to have a single phase repeat several times by activating the Phase repeat options in the TOOLS >...

  • Page 14: Parameters

    The first thing to do is tell the instrument when to stop the press. To set the stop values, use the EDIT JOB > STOP VALUES menu. The Press-Right can stop the press when the force reaches a certain value (Stop force) or when the press reaches a certain height (Stop position).
  • Page 15 5.1.2.1 Stop with mechanical stop. In most cases the press is used to carry out an insertion up to a mechanical stop. In this case the curve will be similar to that in next figure, i.e. the force will be zero for the entire approach stroke, once the piece has been reached (at the contact position) the force will begin to increase until the mechanical stop is reached where it will increase up to the maximum force value of the press (vertical part of the curve).

  • Page 16: Control Limits

    Control limits The control limits, together with the range, determine the outcome of the job. It is possible to set the limits of the reached force, the limits of the reached position, the limits of the contact position and the check points. Note: Control limits, set equal to zero, are not used.

  • Page 17: Checkpoints

    Limits with machining with mechanical stop When there is a mechanical stop, the press will always reach either the stop force. The maximum peak force limit can be used to ensure that the maximum force that the workpiece can withstand is never exceeded. In this type of work, to control the effective force required, the tolerance range or the checkpoints are necessarily used.

  • Page 18: Job Options

    The piece code can also be set via a barcode scanner. To use this option, it is necessary to activate the Part number management option in TOOLS > SETUP > VISIBLE OPTIONS menu. Contact Alfamatic to find out which barcode readers are compatible with the instrument. Save curves of pieces good Save the curves of the good pieces on the internal flash memory.
  • Page 19 If you only want to save some curves, with this parameter you can set every how many pieces you want the curve to be saved. Number of good pieces to be produced Number of pieces to produce. When the good parts counter reaches this value, a warning appears on the instrument screen.

  • Page 20: The Tolerance Range

    7 The tolerance range The tolerance rage is used to control the curve and consequently to control the quality of the piece. The tolerance rage consists of two lines called the upper border and the lower border. For the piece to be classified as good the points representing the curve cannot be above the upper edge, and cannot be below the lower edge.

  • Page 21: Remove The Tolerance Range

    Remove the tolerance range To eliminate the tolerance range use the EDIT JOB > TOLERANCE RANGE > DELETE menu.

  • Page 22: Rejected Pieces

    If the job has multiple phases, the Press-Right can request confirmation for the rejected. If the tolerance band is not reached by the curve and if the minimum quota limit is not present, the piece is signaled as reject due to the minimum quota not being reached.

  • Page 23: Rejected Management

    For example, it is possible to separate recoverable rejected from unrecoverable rejected. When there is a special reject the Press-Right activates the second reject signal and counts the piece separately. In this way it is possible to know, for example, how many pieces are rejects due to operator error.

  • Page 24: Codes Of The Job

    Codes of the job In this menu it is possible to indicate the job name, the selection index and which part of the barcode identifies the job code.

  • Page 25: Measured Values

    9 Measured values The Press-Right stores the displacement-force curve and measures some quantities that can be controlled thanks to the limits. The last curve can be analyzed with the analysis cursor. The quantities measured can be displayed at the end of each process.

  • Page 26: The Tools Menu

    10 The tools menu The Press-Right configuration is performed via the TOOLS menu. The detailed description of the single configuration options can be found in the following chapters. This menu contains the following submenus: DISPLAY OPTIONS Allows you to setup the main page.

  • Page 27: Instrument Configuration

    By activating this option, the Press-Right is blocked and enabled by the supervision system connected via fieldbus. Wait for computer connection By activating this option, the Press-Right does not allow the machining of the pieces if it is not connected to the WinScope program. Press with manual approach This option must be activated if the press controlled by the Press-Right has the piece approach lever and the automatic working stroke, for example the presses M-OP model.

  • Page 28: Job Selection

    Mechanical press This option must be activated if the press controlled by the Press-Right is completely mechanical. For example, toggle presses, rack and pinion presses... 11.2 Job selection These options modify the method used by the instrument to automatically select jobs and phases. The options are accessible from the TOOLS >...

  • Page 29: Diagnosis

    (outside the menus). 12.1 Firmware version The Press-Right has several microprocessors inside. To find out the version of the software contained in the microprocessors, it is possible to view the diagnosis window TOOLS > DIAGNOSIS.

  • Page 30: Special Configurations

    13 Special configurations The Press-Right tool is very versatile. Thanks to Alfamatic's years of experience in pressing, the instrument is set up to solve the most varied customer needs. In order not to unnecessarily complicate the use of the instrument, these functions are hidden and must be made visible manually in the instrument configuration.

  • Page 31: Management Of Supplementary Controls

    In practice, the outcome of the machining can be conditioned by the logic status of three inputs. This logical state can be checked at various times during the working. For additional control number 1, the Press-Right can also activate an output before carrying out the control and, after a pre-set time, read the state of the input.
  • Page 32 13.4.2 RFID tablet writing To write the identification number of the tool, access the TOOLS > SETUP > ELECTRICAL CONNECTIONS > TOOLS menu. 13.4.3 Select tool to use To indicate the tool that must be used for the operation, access the EDIT JOB > ROPERTIES AND OPTIONS >...

  • Page 33: Data Storage

    14 Data storage The Press-Right is able to memorize the production data in the internal memory. In practice, for each piece produced, a file is created which contains the following information: • The recorded force-displacement curve. • The job settings used when recording the curve.

  • Page 34: Password

    The admin user cannot be deleted and has full permissions. To change the password, you need to know the old password or, if it has been lost, you need to contact Alfamatic to send him the code that appears in the old password entry window. The default administrator password is 9724.

  • Page 35: Calibration

    16 Calibration The calibration operation must be performed by trained and qualified personnel. To calibrate the transducers connected to the Press-Right you need to access the TOOLS > DIAGNOSIS menu. For each transducer, the raw output value from the converter and the real value of the measured quantity are shown.

  • Page 36: Encoder Alignment

    16.2.2 Analog input The Press-Right has an analog input with a 12-bit analog-to-digital converter. The offset is the value that is subtracted from the output value of the analog-digital converter. The gain is the multiplication factor that adjusts the displayed value.
  • Page 37 Carry out a pressing cycle and check that, when the stem returns, the instrument displays a negative value of a few millimetres.

  • Page 38: Connection To Computer

    17 Connection to computer The Press-Right can be connected to a computer. It is possible to connect the instrument to the computer via USB port or LAN (Ethernet) port. WinScope program is supplied together with the instrument, through which the potential of the instrument is extended.
  • Page 39 Choose the instrument you want to assign the IP address to from the list that appears. If the list is empty, check the Firewall status of your computer, if any. The Firewall can be disabled from the Windows Control Panel. If you can't tell which instrument to configure, just turn it off, redisplay the list, and see who's missing.

  • Page 40: Field Bus

    With the PROFINET and EtherNet/IP protocols, you have direct access to 11 read registers and 11 write registers. You can decide which registers should be accessible directly. To do this you need the Press-Right setup program. Access to a greater number of registers requires accessing through the address of the same.
  • Page 41 The default content of these words is as follows: 18.4.1 Access via address/data 18.4.1.1 Initialization Load the value 0x00 into CTRL_OUTPLC Wait for CTRL_INPLC to contain 0x00 18.4.1.2 Reading a 16-bit register Load the register address into INDEX_OUTPLC Load the value 0x40 into CTRL_OUTPLC Wait for CTRL_INPLC to contain 0x10 Read the value from PV_INPPLC Load the value 0x00 into CTRL_OUTPLC...

  • Page 42: Strings

    18.4.2 PROFINET interface notes To install the GSD file in the library, select tools > device description file management. In the library, it can be found under Additional field devices > PROFINET IO > General > Alfamatic > PressRight. The device name and address are set by TIA: Open the TIA, under "Online access"...

  • Page 43: Registry Organization

    19 Registry organization 19.1 Execution of commands By writing in the CONTROL_WORD_OUTPLC the press is commanded. The command must be written until the Command BUSY bit of STATUS_WORD_INPLC goes high; at this you can write zero in CONTROL_WORD_OUTPLC. Regardless of whether the command involves motion or not, as long as the command is present the Command BUSY bit of STATUS_WORD_INPLC will remain high.
  • Page 44 The PLC must make the cylinder go back and wait for the outcome of the cycle. Note: For best performance, a physical Press-Right output should be used instead of using this signal. Boosters This bit is useful with hydropneumatic cylinders for starting the cylinder booster.

  • Page 45: Register Table

    Not used Bits 5 Not used Bits 6 Not used Bits 7 Note: Siemens PLCs have the high and low byte positions reversed. 19.2 Register table Name Content pos. Access Dummy Status and Flags See chapter 19.1.2 UINT16 Read only PositionAct Current position of the cylinder INT32...
  • Page 46 PartNumber Queues STRING 28L Read only decimalsY Number of decimals digit of the force values UINT16 Read only UnitY Unit of measurement of the force values UINT16 Read only decimalsX Number of decimals digit of the position values UINT16 Read only UnitX Unit of measurement of the position values UINT16...
  • Page 47 CP2par5 Fifth value of check point 2 UINT16 1042 Write/read CP3par1 First value of checkpoints 3 UINT16 1043 Write/read CP3par2 Second value of check point 3 UINT16 1044 Write/read CP3par3 Third value of check point 3 UINT16 1045 Write/read CP3par4 Fourth value of check point 3 UINT16 1046...
  • Page 48 OrderNumber Order number STRING 24L 1212 Read only Operator Operator ID STRING 24L 1 2 3 Read only Issue A BIT0: STOP FROM USER INTERFACE UINT16 2000 Read only BIT1: STOP FROM INPUTS SIGNALS BIT2: TIME OUT BIT3: MAX PROBE BIT4: MIN PROBE BIT5: PROBE ERROR BIT6: HIGH SPEED...

  • Page 49: Description Of Check Point Logs

    19.3 Description of Check Point logs Checkpoints are described by five different parameters: CPxPar1, CPxPar2, CPxPar3, CPxPar4, CPxPar5. The function of these parameters varies according to the type of check point. Thank you, you have a check point, for each piece worked, the instrument measures one or two values. These values are available in registers CPxValueA and CPxValueB.

  • Page 50: Description Unit Of Measure

    CPxPar2 Setpoint 2 activation value Quote CPxPar3 Setpoint 3 activation value Quote 19.4 Description unit of measure The following table contains the correspondence between the contents of the register with the unit of measure and the unit of measure to be used: Index First name Unit...

  • Page 51: Technical Data

    All control parameters are stored in 250 independent and selectable jobs. Advanced management of users with passwords and personal authorizations. It is possible to connect the Press-Right to the computer and, thanks to the WinScope program, save the curves, modify the settings, carry out statistical analyses, print the data.
  • Page 52 This image indicates that this appliance cannot be disposed of with unsorted domestic waste but must be disposed of separately. At the end of use, please send the appliance to Alfamatic to reduce the waste of materials and resources.

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