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Manuelles Verfahren

1. 14 Manual positioning eci aa 14 Manual registration 56 Measurement variables 30 Klee del le Le ett E 27 Motion uku ara 22 Parameter NC module 50 Password protection 58 98 1 PROMESS r wasa Pin assignment 72 PEC internate eege eech 79 Polling of the stations 56 POSIIONNG te ced 16 Power amplifier 70 Press to Force airline 17 Presso E Lee 19 Printer ete nen 40 PiiniGp Se bu 40 Printing graphics 41 Printing the CNC program 42 Profibus DB participant address 0 000n000n00aann 47 Program end uu uuu uu ee 23 Program parameters 43 46 Program pushbuttons 13 Beete EE 45 Programi Sara ann ann an 11 Program WINGOW a aan 12 FOG FAI re oi ana 15 FP USMDUTLOING eo c 18 Record measurement values eneee 30 Register new station 53 Register an NC module 53 Register measuring values
2. 81 20 5 Emergency Stop during standstill a 82 ZRO OY a Sono Cn RE 83 RRE eg program Bn Be el EE 84 2 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS 21 EUDrICaLION a dVi CE zer nee ck ek ee eee 85 ZN WSCA un MEO es aeons basta Ee 95 22 S ftWare Update ees ee ence 96 amp Tute TC nuyu 98 3 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 1 Introduction The UFM NC MODULE system is a powerful tool to rapidly setup alter optimize and adapt press and positioning tasks The basic element is the electro mechanical assembly unit from PROMESS consisting of e assembly unit with motor transducer and distance measuring device e motor power amplifier e NC module for NC control of the assembly program e programming and user software Several press units can be connected via a network and programmed from a single programming device The following figure shows a block schematic 4 Promess Montage und Prufsysteme GmbH Berlin UFM NC Module V3 1 1 Contents of supply Mechanical unit AC Servo motor Option e PC e Monitor e Keyboard Electro mechanical press unit SG amplifier in diecast aluminium housing SG Strain Gauge Power module NC module PLC interface
3. 27 Safety precautions 7 Save measurement values as ASCII data 31 Save measurement values in database 32 Save measurement values via bus systems 32 Screen settings 12 Serial communicationRS232 RS485 56 Serielle communikation Ethernetmodule 57 ISI RENE E 43 Set outputs 24 stalus iaee 25 SG ae 74 Signal description PLC interface 79 Signal flow cycle start 81 Signal flow during Emergency Stop during standstill E re u a ha a et 82 Signal flow Emergency Stop during a motion 81 Signal flow reference motion after start up 79 Signal flow reference motion without a request 80 Signal process of Emergency Stop during standstill EE 84 Software installation 10 Software Update 95 Start settings of 58 e Uleies suu uu re 49 SWILGHInO PTOQralY1S u u n u Umu aq Sa 54 Teach In strategy 16 Technical appendix 68 Technical features 69 Transducer c
4. ome me me m 7 1 E 1 Step 2 Startpozitba 104 025 Goal 12008 mm poziti 104 000 postion 112 451 mm M 0 000 kN 1 503 EE Stati Ho e mar R csr zz Mon bg GmbH 12082 Berlin cbermi na e ener Sr 52 30625572 D FraB 30625057269 41 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 13 3 Printing the CNC program m 3 PROMESS r wa Use the button Print or the file menu item Print to print out the CNC program 5 200 240 siti 1 NC modi b pogam 10 2430009E ADE ole 104 000mm 120 000mm 1000 000mm 1000 O00mm xt am 112 000mm 120 000mm 10 000 42 000 mm 1000 000mm Sr 100 000mm 1000 000mm e 1000 000mm Cue r baad It Cie rbad lim tt 17 07 H 17 05221 teztppg Hm adie ID Nam be DTTETTTES 15 Finrmma Konya Gmbh 20 Een Schr Si Sz r g 90 pAr o F 149 90 8230 7253 42 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 mm 3 PROMESS 14 Service 14 1 Program parameters The program parameters are retrieved via the menu Service 14 1 1 Standard settings Program parameter Station 1 Ka Program settings Analog input Program parameter Graphics Standard set
5. Every input has to be confirmed with OK The cycle stops until you confirm the input or if you have chosen Cycle stop until cycle start is set again 26 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS 10 Force Distance Development In order to register and monitor the force distance development of the press process please proceed as follows In the desired motion mode activate the following functions Position El Ei Position paramete Fosition og mm Ge Absolute Speed 5 mms Relative Acceleration n0 mm Brake rate o mm s Overload imit 0 INI Y Record data Position mm Force H Analog How many 100 Monitor Parameter Z Limit teachin Cycle stop Comments 10 1 Register measuring values All measuring values are registered for this motion if this option has been activated Under How many you should enter the number of supporting points The points are evenly dispersed over the entire distance An A is entered in the function list to earmark this step The development for this particular step is displayed in the graphics window in the form of a sub window 10 2 Monitoring When this function is activated the force distance development is monitored by means of limit curves The limit curves consist of a chain of connected straight lines 2
6. x V d TL Sec V DI 84 Schmierstellen A Nutschmierung B Nutschmlerung Spindelschmier ung D allagerschmierung E Radiallagerschmierung Ges f r Montage und XH D 12277 Berlin 10 05 Lechier Schmierm alichkeiten m 92 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS Ce PROMESS Gesellschaft f r produktions mmm techn Messen GmbH B C D A Schaffhausener Str 44 50 D 12099 Berlin Tel 030 628935 0 ER Fugeeinheit 40 60KN sd 180mm Hub 1 2 Schmierm glichkeiten Werkstoff Halbzeug 74040 74060 98500503 93 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 m 3 PROMESS r wasa 620 404 Schmierstellen A Nutschmierung B Nutschmierung C Spindelschmierung D Lagerschmierung Um die Spindel zu schmieren mu die Presse um ca 117 mm ausgefahren werden Dieser Wert kann um 3 mm variieren da der Naherungsschalter nicht bei jeder Presse an der gleichen Stelle vom Stempel bedampft wird mittel DIN 7168 Ges fur Montage und PROMESS Prufsysteme mbH Schaffhausener Str 52 D 12099 Berlin Telefon 030 628872 0 Bearb 06 11 0 Paulsen Ma
7. 0090000315 117 0701 17 07 01 171911 OS 1 170701 17 07 01 171917 mme 1170701 17 07 01 174921 _ a IO 170720 171825 a n 117020 17 07 01 17 19 21 D F 17 07 01 174337 m AT 171943 17 07 01 171943 n 0 174954 39 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 PROMESS Ce 13 Printing The following print options can be selected Printout station 1 Program listing Station Hardcopy e Curves report Printout of graphic with status messages for the displayed step e Program listing CNC program e Stations window Screenshot 13 1 Printer settings This menu item for configuring your printer can be reached from the file menu Drucker einrichten 21x m Drucker Name HP LaserJet 5 5M Verbessert Eigenschaften Status Standarddrucker Bereit Typ HP LaserJet 5 5M Verbessert Ort NT40_PDC HPLaser 5 Kommentar Papier Format Format Jad 210 x 297 mm Hochformat Zufuhr Fach 1 Mehrzweckfach Querformat Abbrechen 40 Promess und Prufsysteme GmbH Berlin UFM NC Module V3 mm 3 PROMESS r wasa 13 2 Printing graphics The graphic of the currently displayed curve together with the status of the press operation are available using the function Report in the file menu 17 07 01 17 04 49 Station 1 UFM 5 200 240 test ppg Pers ko too lt
8. RH PROMESS Jump to start of database e Database filters To display a reduced amount of data from a station or program you must define filters To define a database filter use the button in the top symbol bar or in the footer bar In the new Filter Cycle Data Gauging Jump to end of database window you can set filters to specific values in specific columns Table Filter Conditian s Elete Hour list Filter definition And Column name Dr to list Operator Value Cycle ID Prg ID Program name Aap Fiber Surpress Filter Cancel Station ID Station Date Time Status You can filter according to the following criteria Counter Cycle ID Program ID Program name Stations ID Station Date Time Status Identifier User 3 Promess Montage und Prufsysteme GmbH Berlin UFM NC Modul V3 Show curves NOK OK Force or signal too early No force or signal not reached Upper limit broken Lower limit broken Overload The filters can be linked with and or or conditions Example You want to define the NOK components for a specific program test2 ppg First define the following filter with the program name Activate the condition with the button Filter definitio Add to list Column name Operator Value Program name Jtest2 ppg Eiter Surpress Filter
9. link module Firmware Version of the Link serial Number Link Module Module Configuration Link Module Please choose here the function which you would like Input Outputs to assign to the respective E User input 0 1 User output 0 outputs and or inputs Version 2 022 ID 3 User input 2 Xx User output 2 fae oll le 10 no function 11 no function 11 no function 12 no function i no function Baudrate Link Module p 9600 Baud 19200 Baud Ce 38400 Baud v Link module memory active Cancel 10 function Please set here desired Baud rate between link module and NC module If this button is activated the compiled process programs are loaded during a program change from the link module and not from a possibly connected PC after they were loaded into the link module see 18 3 18 3 Link Module Sending and Loading of Programs To send a compiled program from the PC to the link module or to load the programs stored in the link module to toe PC you have to complete the following steps Open the item Program Pre select in the file menu Assign the set up programs to the program numbers This is performed by double clicking on the corresponding field in the column program name In the next window choose the file which you would like to allocate The sending PC gt link and reading link gt PC of the programs to the li
10. Yes 4 Send the program to the station for edit Nein Abbrechen If you want to switch programs via the PLC you first have to enter the programs in an allocation table because the program call via the PLC can only be performed binary code figures Program Pre selection You can reach allocation table via the file menu Select the menu item Program Pre selection or the respective button on the task bar Programm Auswahl Station 1 Fa Nae Progamm Pa aaa ppg C Promess 3 15439854101114 2 50 Chromesch 2 1543985410111 hella2ppo C Promess 3 1513985410111 ER Abbruch Hie The allocation is executed by a double click in the column Program Name Choose the desired program in the Explorer window that pops up ffnen 21x Dateiname ppg Dateityp Program ppg Abbrechen For the process for the program change the PLC see Chapter 20 7 Transfer of program number and or in the description of the used bus system 54 Promess Montage und Prufsysteme GmbH Berlin UFM NC Module V3 13 PROMESS r wasa 16 Error messages The following error messages may be displayed in a message window Overload Emergency stop Reference switch defective The following coded errors can be displayed in the status bar Comm active Step Ready T 61 U Overload R Refer
11. basic function Optional mounting plate for the installation of the control cabinet including Emergency Stop circuitry according to EN 4181 Stop Cat Dimensions H W D 773 492 300 mm Units gt 60 H W 1896 499 mm Connection cable confectioned Connection cable motor power amplifier power cable length 5 m Connection cable motor power unit resolver length 5 m Connection cable SG amplifier control unit length 5 m Connection cable proximity switch in OT SG amplifier length 2 m Interface cable RS 485 RS232 Optional PC with monitor keyboard 5 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 WH PROMESS 1 2 Transport The units are supplied packaged in standard cases The belt drive protection is not mounted to facilitate the use of lifting equipment when unpacking the unit Please follow the instructions below to remove the unit Use a broad double belt placed under the motor plate and around the mounting flange to unload the press unit ATTENTION Do not put any loads on the proximity and limit switches when attaching the lifting device There is also the possibility of using an eyebolt attached to the thread of the ball screw to unload the press unit After the unit has been unloaded inspect it for visible transport damages The press unit and related servo amplifier may only be installed in appropriate and
12. Berlin UFM NC Module V3 13 PROMESS 9 3 Press to signal This function is very similar to the press on force block however in this case you press to an external signal that you can select from the signal source You can select between an external analog signal of a switch signal If you want to set the switch signal via the bus you can use the freely programmable inputs 1 and 2 Press to signal Press paramete jJ Position mm Signal saurce method EM mm Signal limit P l oo L J Pre positior 0 00 Absolute Relative Speed 0 00 Acceleration 0 00 mens Analog 1 mm press in poz 0 00 mm Press In speed 0 00 Overload 0 Extended gt gt Cancel If you do not set the switch signal via the bus but as a 24 VDC signal you must first select the option User I O in the standard settings under Program Parameter The reference input then becomes input PLC 1 and the start input becomes input PLC 2 The start and reference run can then only be executed via the bus system Program parameter x Program settings Analog input Program parameter Graphics Standard setting Analog Output Datastorage Profibus DP Manual standards Position increment 10 000 mm Speed 10 000 rms Acceleration 1000 000 Overload limit F 000 IN Decceleration 1 000 000 mraz IO Lonfiguratio Standard 12
13. Berlin Telefon 030 628872 0 Beat 09 02 06 Paulsen Ma stab cx 090208 teme Nom UFM 20 180 150 1 Werkstoff Halbzeug 74020 90 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 RH PROMESS r wasa Initiator ohne Lg Au mech Endschalter l Initiator mit i eee mech Endschalter A B Dv lt N I t LO W 38 LO LO LO LO Y Y Y SE a ES Ps PES Schmierstellen Si TR AX A Nutschmierung S En B Nutschmierung Te 2A i C Spindelschmierung iw D Lagerschmierung S Z Bs I w AX P m y D C e Ges fur Montage und Prufsysteme mbH Nunsdorfer Ring 29 D 12277 Berlin Telefon 030 628872 0 Bearb 09 02 06 Paulsen Ma stab amp 090208 Lechter Schmierm glichkeiten Nom DIN ISO PROMESS 2768 m EE UFM 30 180 230 1 5 Werkstoff Halbzeug 74021 91 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa i II P
14. E Ref Start Cycle Error NOK Force kN Position mm Analog Step Start Ref Stop EXIN 49 999 9 Q Q Q Stef Comand Parameter GEM 0 2 0 GVal3 0 GVal4 0 1 Position 104 000 mm y Pose 0 Pos3 0 Pos4 0 I i 2 Press to force 1 500 kN 000 Val 2 0 000 Val 3 0 000 Val 4 0 000 a Position 3 Position 50 000 mm 0 000 Yar 6 0 000 Yar 0 000 Var 8 0 000 lt En NE Force 0 145 Distance 107 089 TII s to Press to force M SA M E ee ee mE LED Lower absolute limit E x Upper absolute limit ga E eget a a ao ca a gf sp Sa sis ag a ss pe wer Upper limit Press to signal PAR ie Delay time Program end 103 104 105 106 107 108 109 110 111 112 113 Position mm Start position 104 028 mm Goal position 120 023 mm Min position 104 000 mm Max position 112 481 mm Min force 0 000 kN Max force 1 503 kN p e oe n information Upper limit violated Lower limit violated Force Signal early Force Signal limit not reached Monitor step 2 Step 1 5 Ready MCM 7 61 17 17 14 2 7 Screen settings Meas variable Variable Signal progress Status Various windows may be displayed on the screen The window
15. Help The following Baud rates are available e RS 232 19200 Baud e RS 485 max 38400 e Link Module 115kBaud 56 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS 17 1 1 Serial communication Ethernet module Please choose Ethernet for communication Configuration information Interface Com Com6 Ge Ethernet Baudrat f 9600 C 19200 38400 Com Com3 Com4 Comb 115k Manual The connected Ethernet modules are shown by clicking on the Find button Active modules are marked by the green LED Modules which have been connected are still shown but marked as inactive You can choose the stations you want to connect Only chosen modules are polled by the software If you want to delete a station please enter zero as IP address Pall the station f Automatically tram Statior 1E 1 Canco TCP IP settings Station Station text Station text Station texts Station text4 Station text Station textE Station text Station texta Station testa Station text 0 Station text 1 Station text 2 Station text 3 Station text 4 Station text15 Station text E The station text is entered in program parameter in the service menu chapter 14 1 1 address 192 168 000 091 192 165 000 092 192 165 000 093 192 168 000 097 000 000 000 000 000 000 000
16. Modul V3 mam PROMESS r wasa set the physical interface via analog type Enter also the nominal value and if necessary the offset of your analog source 14 1 4 Program parameters On the register card Program parameters you enter the offset value of the actual force during teach in The data entry is expressed as a percentage of the nominal load e Expansion parameter This is used to compensate for the expansion of the press frame caused by the force produced during the positioning process Input is based on the nominal load The value is stored related to the active part program so you can store different values for different part programs The compensation is linear 14 1 5 Graphics In this menu you can set the colors of the various curves that are going to be displayed Program parameter Program settings Analog input Program parameter Graphics Color desig Hel upper limit mnes Abs upper lirit mnes gt Active curve Histogramme E Lime Rel lower limit E Yellow zl Abs lower limit E Yellow zl Background color C3 white gt Axis labelling mp Black Bek pe 46 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS 14 1 6 Profibus DB participant address Enter the address you wish to assign to the station Program parameter Program settings Analog input Program parameter Graphics Standard setting Analog Output
17. V3 9 7 Conditional jump Use this function to program jumps in your program Jump cormarn when v ar 1 gt 23 then ga to STEP Comments 4 1 Cancel 9 8 Motion Control GE mam PROMESS r wasa This component makes it possible to keep the force or any other connected signal constant over a certain period of time This means the joining unit moves back and or forth within a range that has to be determined in order to eliminate the deviations from the control size This process is also monitored by a overload limit for the force to avoid destruction of components Motion control Press paramete Control source Tolerance Closed loop value Press in speed Acceleration Overload Min distance Max distance Commenta Position mrm gt 0 00 Imm 3 00 mms 500 00 mm 5 Ce Absolute Relative Force Analog 1 mm 1 00 mm 0 60 mm Duration DOO Cycle stop e Control Size First select the size to be controlled You can choose between the force input and the defined virtual analog inputs under Program Parameters Analog Inputs e Control Deviation Here you set how the unit should react to deviations from the control size 22 Promess Montage und Prufsysteme GmbH Berlin UFM NC Module V3 1 PROMESS A positive control deviation leads to a forward
18. movement of the spindle Example Control value 200 actual value 202 gt move forward actual value 199 gt move backward negative control deviation leads to a forward movement of the spindle Example Control value 200 actual value 202 gt move backward actual value 199 gt move forward e Control Speed Enter the speed by which the control deviation should be moved out e Acceleration Enter the acceleration by which the control deviation should be moved out e Overload This force monitors the control process e Min Control Position Max Control Position Enter here the range within which the control may be performed The entry can be made absolute or relative Basis of the relative way is the position at the entry into the control component I I If the permitted positioning range is exceeded the part is declared The program continues the cycle No reference run is requested e Duration Please enter here the time for which the control process should be performed The time starts with the first reaching of the control value e Cycle Stop Choose this option if the cycle should be stopped after this function has been executed 9 9 Program end With this function you can define the end of your program cycle Mandatory in program structures using conditional jumps This input is not necessary in simple cycles without conditional jumps The program returns to the first step and a
19. movement to the selected position is also monitored then the limit values are also written to the database e The data volume to be transmitted or saved can be influenced by using the following switches e Save measurement values The values recorded with the function are saved in the database e Save curves The curves recorded with the function Monitor are saved in the database e Always load curve from station The transmission of the curves from the station always occurs The switch Curves determines whether the curve is only displayed graphically or also saved in the database Only load curve from station in case of error The curves are only transmitted from the station if an NOK occurs If the database is activated the status data of the cycle are always saved Leave the window with OK lf a database is not present the following message appears Information Database doesn t exist create Abbrechen Reply with OK to create a database 12 1 4 Database maintenance The size of the database is generally limited to 650 MByte Further on you can limit the size by time and by number of entrees When a limit is reached a new database is produced The name is of the 33 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wa database is extended by a counter The data are always a stored in the datbase with the highest number Pl
20. ppg 0000000815 17 07 01 17 07 01 17 183 30 zBASOUSF 12 pog 000000315 17 07 01 7 07 01 175184 31 Dong pag 000000315 17 07 01 17 07 01 17 185 32 ZBAB USF lest pag 000000091 5 17 07 01 17 07 01 17 185 33 2BA80ISF test pog 00000008915 17 07 01 17 07 01 17180 34 2BASOOSF pog OOO 00087 5 17 07 00 17 07 01 17 18 35 28480097 best 0000000815 17 07 01 17 07 01 17191 Jb 28480097 fest pag 000000091 5 17 07 Dn 17 07 01 15151 37 2BASO0SF png 0000000315 17 07 01 17 07 01 17 192 38 28480097 1642 0000000915 17 07 01 17 07 01 15192 39 zHABDUSF lest ppg OOO D000 S 14 07 Dn T2027 01 15193 last 0000000815 17 07 17 07 01 17123 E od a gt Cycle Data Gauging Fite Show curves 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 The data from all connected stations are stored in the sequence of their occurrence in time The window that displays the measurement values only opens if you have used the function Measure in your program To update the values actuate the Cycle data button Use the Measure button to show all values that have been collected using the Measure function To navigate within the database you can either use the scroll bars on the side and at the bottom or use the navigator buttons arrow keys at the bottom of the PC screen Cycle data Previous record Next record Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3
21. press casing AMOUNT OF LUBRICANT FOR LUBRICATION POINT C Lubrication point C is located behind the seal cap M20 1 5 To re lubricate the ball screw nut complete the following steps Remove the cover flap manually move the spindle slowly downwards until you see the lubrication opening on the now open drill hole Please screw in the lubrication fitting UFM 3 12 M6 e Now you can be re lubricate with a lubrication press 85 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 PROMESS wa AMOUNT OF LUBRICANT FOR LUBRICATION POINT The thrust bearing especially on the units starting at 20KN nominal load must be lubricated very carefully As from the lubrication fitting to the rolling body running path also hollow spaces have to be filled the following lubricant amounts are necessary UFM 20 30 me Lubrication fitting behind the front cover Thread for lubrication fitting UFM 40 60 80 330 240 R UFM 100 330 200 Lubricant A high quality roll bearing lubricant must be used PROMESS recommends the following lubricant brands Kluber ISOFLEX NBU 15 Kluber ISOFLEX NCA 15 FAG ARCANOL and comparable types 86 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS emm 377 5 253 5 253 5 Schmierstellen A Nutschmierung B Nutschmierung
22. 0 User ld The fieldbus I O s 1 2 dont function when digital user 1 0 iz selected ca mm 19 Promess Montage und Prufsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wa Once you have selected one of the switch signals define the threshold or switching limit that should trigger the movement end using the signal limits On Stop when level is high Off Stop when level is low Enter the pre position speed acceleration and overload value for the force Also define the maximum position and the pressing speed e Extension Use this extension to configure the monitoring and if necessary a control once the switch off criteria are reached Press to signal Press paramete Position mm Signal source method Analog 1 an Signal limit gt ll EI a Pre position 0 00 mmn Absolute Relative Force Analog 1 mm Speed 000 Acceleration DOC mms press in poz DDD mm Fress in speed DOO mmz Overload Standard Hold signal level const ination 0 00 Mel Record data mani Monitoring Parameter Teach limit Cucle stop Comments Cancel e Hold signal If you select this point you can regulate the external input values i e the module changes its position so that the signal remains constant for the given time Teach in of limit curves A teach in curve for this function is es
23. 000 O00 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 O00 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000 ID Station text Test 1 v Station Priiffeld 222 amp 9 W Station Pr ffeld 333 WM Station Station v Station W Station JW Station v Station v Station v Station v Station Iv Station v Station Station Station v Station Cancel 57 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 17 2 General Select the language for the UFM software here L onfiguration information Serial communication General Data settings Layout Language selecho Deutsch Ce English Amen Francais Swedish Spanish Window startup setting Marmal Minimized Masimized Password setting Program edit Old password Program save amp load TESTI Exit program Motion Ref Start Step Manual Password Validity 3 mir e In addition you can also specify the start settings of the window and the password settings 17 2 1 Password protection The following program functions can be password protected Edit program Load save program Quit program Start movement reference move start step manual moving 17 Call up the password settings in the file menu using Configuration Select the regis
24. 1 1 Save measurement values as ASCII data To save the ASCII data please activate the data export under Configuration file settings The data are saved in the selected directory under the following name on Programname Gn Sn Station number n Gn Measurement variable n The file is structured as follows Measurement T SPosition EPosition APosition UL AValue LL 1 33 00mm 34 00mm 33 42mm 2300N 2178N dA CMM Start position End position Actual position Upper limit Lower limit where the value is recorded 31 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 12 1 2 Save measurement values via Profibus DP CAN Open Interbus S The data within the Promess program are saved in Microsoft Access format and can be edited evaluated at any time with the Access program The values recorded using the function Measure can also be transmitted as measurement variables via the bus systems for further details see bus system manuals 12 1 3 Save measurement values in database The requirements for data storage are as follows Pentium class PC MS Access or DAO 3 5 3 6 driver installed available from Promess Data storage facility to hold the database or LAN network installed with relevant server At least one press module actively connected with the PC To store measurement values in the database you must activate data storage under the Service Program parameter in the regis
25. 7 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa Distance Mouse coordinates r Press to force _ Histogram tume LLLLIL Lower absolute limit Upper absolute limit Lower limit Upper limit ti Ber GE E EH Support points r 1 Upper limit curve m 1 1 1 1 ate t mm Actual curve Lower limit curve 24 25 Position mm lt 4 lt 1 E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I 1 4 1 lt 4 21 hea Teach in limit curve When this function is selected limit curves are recorded of the actual curve after the next step The number of supporting points may be determined the button Parameters Max 20 supporting points Monitoring parameter Paramete Ho of support points Cancel The distance of the limit curve during the learning process from the actual curve can be defined globally via the register card Program parameter in the service menu for all programs 28 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 mm 3 PROMESS 10 3 Edit limit curves Graphics Total view Optimal view zoom in zoom out Edit upper limit E dit lower lirit Resort points Add
26. C Spindelschmierung D Lagerschmierung mittel PROMESS Ges f r Montage und DIN 7168 Mmmm Pr fsysteme mbH Schaffhausener Str 52 D 12099 Berlin Telefon 030 6288 2 0 Bearb 12 02 04 Paulsen Ma stab amp 100208 teme Schmierm glichkeiten 1 5 bu UFM 05 200 74005 Werkstoff Halbzeug 8 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 1 PROMESS r wasa 418 Schmierstellen A Nutschmierung B Nutschmierung C Spindelschmierung D Lagerschmierung m 1 mittel PROMESS Ges f r Montage und DIN 7168 Mmmm Pr fsysteme mbH Schaffhausener Str 52 D 12099 Berlin Telefon 030 628872 0 Bearb 14 10 0 Paulsen Ma stab o 141093 eme Gchmierm glichkeiten 1 au UFM 12 200 74012 Werkstoff Halbzeug 88 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS r wasa Initiator ohne b mech Endschalter i gt Initiator mit i
27. Cancel mama PROMESS r wa In order to filter with the NOK component of the program test2 select the link and enter the condition NOK 1 You could also filter using OK 0 1 stands for the condition True while 0 stands for the condition Not true Table Filter L anditian s Pragram name teste ppg Delete from list Filter definition Add to list Ge And Column name Operator Value Cor NOK sl fil Apply Filter Surpress Filter Cancel Add the condition and then apply the filter All the NOK components in program test2 are displayed 38 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS T Data View Station CD n desl2 ppg 40 2BABD SF test ppg Je j pop e Show curves By activating the appropriate control button the database view also displays the curves and status information Solkwaae 1999 Fromas Montage GmbH View NUT IN CH UIN l GER ae Pat Re Y KEE mu 0000000315 1117 07 01 17 07 01 171843 100202020815 1170701 17 07 01 171850 o 0010020815 1 17 07 01 17 07 01 171855 0 E 0000093815 1 17 07 01 17 07 01 17 1201 D 0000099915 1 1707 01 17 07 01 17 1406 0
28. Data storage Profibus DP Profibus settings Station Number 3 Swap data word 2 3 e Exchange data words Data word 1 on the Profibus is exchanged with data word 3 14 1 7 CAN Open Enter the participant address and the timeout time for the bus Select the required baud rate Programm Parameter Programmeinstellungen Analogeingang Programmparameter Grafik Profibus DP Standardeinstellungen Analog Ausgang Datenspeicherung Open Profibus Einstellungen Teilnehmeradresse 0 BUS Timeout 0 ms D atenworte vertauscht 125K 250K 500K BDDK C 1M e Exchange data words Use this switch to exchange data word 1 transmitted to the bus with data word 3 14 1 8 Analog output 47 Promess Montage und Prufsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa The system has two analog outputs that can be used to output the following values Variables 1 4 Position Force Analog input Output analog Parameters Analog Output 0 000 Comment Val Val 2 Cancel Val4 Position Force Analog Define the nominal value or the physical output for the respective outputs Assign these using the function Analog output see Chapter 9 11 Analog output 48 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS 14 2 In outputs Use this menu to check the digital inputs and outp
29. E UFM60 175 150 UFM60 330 240 UFM80 330 24 UFM100 330 200 FM150 400 145 UFM100 330 200 Servo amplifier Unidrive 2402 Unidrive 2403 Unidrive 3401 Unidrive 3401 Unidrive 3401 Unidrive 3404 Construction 3 size Size 1 Nominal unit capacity JA _ 114 19 26 40 66 Max unit current during 4 sec A closed loop only 37 149 067 198 16 6 Unit output voltage 3 AC 0V U net Recommended mains fuse slow A 6 10 110 10 16 Losses W at 12 kHz frequency 70 90 100 150 1250 Ventilation integrated fan o Ab Weight 4 kg Protection class IP 40 Size 2 Weight 8 kg Protection class IP 40 Size 3 Unidrive Type 3401 3402 3403 3404 3405 Article number 9642 0131 0132 0133 0134 0135 Nominalunitcurent A 340 400 460 600 770 70 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 Max unit current during 60 sec A 510 60 0 1690 1900 11155 Recommended cable cross section mm 60 100 100 160 250 Cable connection M8 screws O Mains voltage 50 60 Hz Unit output voltage OV U net Recommended mains fuse slow A 35 50 60 170 180 integrated fan at 6 kHz frequency at 3 kHz frequency 71 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 19 5 Force measuring Force measuring is done using strain gauges integrated in the press unit Th
30. ID LIFE Iv PAGS MU STEP E JOG DT 4 STEP JOG_OUT CCE e outo JOG_IN ACT START JOG IN REF AR auras WU KBLOCK HU 05 cm NU ESTO Status Informatio Pakages per Sec 444 Variable level Profibus Service Dialog x OP Interface NE KISEHRl ll ex D 5GM T CST D_14 I D 5GM T CST 014 D 29 CMD I D 13 D 29 CHD2 rr D 28 CHD1 D 12 D 28 CHD1 D 27 CHDDN I 011 D 27 0 I Di m D 26 RE amp DA D10 D 25 READ D 1 D 25 WRITE D ns D 25 wRITE 009 D 24 SEL1 D 24 SEL 1 j D 23 J nur I D 23 F SELO nar D 22 IDx 7 Dm D 22 Uz DOE D 21 1056 005 E D 2j IDK 6 D 05 m p 20 1055 DIM D 20 IDK 5 D 04 m D 19 4 Dm gt D 19 pgs D_18 Iv IDx3 Du D 18 Eo D_17 IDN on D 17 in D DI j D 15 100 1 Dm D 16 101 D_15 050 D 15 51 Promess Montage und Prufsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 14 4 2 Link Module Inputs Outputs Here you can have the condition of the inputs and or outputs of the link module displayed If you want to set an output please click on the button Link Modul 170 Ausgange Eingange Bit 11 Bit 11 Bit 10 Bit 10 Bit 09 Bit 09 Bit 08 Bi
31. Iv Outp QUIT Inp Enable E wusqarm i E 1 Digital display force Channel 1 4 __ BEEG Channel 1 0 4000 Channel 2 Zero point 2000 Analog out 1 E wusqariq De Analog out 2 Interface 5 Digita Output 401 Iv Input EDO v Input ED1 Extended gt Adjust if necessary to the value 2000 with the potentiometer P2 zero point displacement See diagram of amplifier Change to manual travel F5 19 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa Before applying a load set the speed to a very low value e g 0 5 mm s Travel in small steps to ca 80 of the nominal load Keep an eye on the force display in the right half of the window Manual motion Station 1 Faramete Positionchange Position Speed 10 000 mrs Force PT Acceleration 1000 000 mm z Analog 0 00 mm Neg acceleration 1000 000 Overload limit 2000 Y Advance A e Y Kont Ausfahren A Kant Einfahren Close Warning If you reach the overload limit an Emergency Stop is triggered Adjust the amplifier using the potentiometer P1 amplification until the display of the press unit is the same as the display of the reference transducer Move the unit back Warning Please avoid staying in this position for too long at higher loads
32. Manual UFM NC module 1 PROMESS r wasa TABLE OF CONTENTS Ul Ia te UG COD aan 4 p Y 5 2 GOITtect Ee E 7 SEENEN e Tu EE 7 SA RISK analysis airline 9 4 Software 10 d ele LTE EE 11 SCILEEN E due E 12 5 Manual POS IE OI ln O we vw UU ME In meee UR SEIN ER NEIN 14 O PFOGFAMIMING ME 15 9 1 POSIUONING qaa Dit ra Ra 16 Se PIeSS ONG lt 17 Deo eso 02 19 hPl yI perce E T CA 21 O25 CO AUO ee ee 21 LO VAIO nee 21 S e toate xuxin Meier Eee 22 OG erter CONTON ee es densest ee 22 9 9 reg ein AR EE 23 SEENEN 24 STT EE 24 9 EE 25 Oe bo Dialog le ele e EC 25 TO Force Distance Development nein 27 10 1 Register measuring valles een 27 10 2 MONDOFINO uu t Ir 27 IOS Ed ik C EE EE 29 NES Tei graphitS ais uu vu sive ie een l u ERE eb sen Qf 29 PB ER 30 12 1 Record measurement values stein coti edu debe koci oda E Pu ask hk bv agus 30 12 1 1 Save measurement values as ASCII data 31 12 1 2 Save measurement values via Profibus DP CAN Open Interbus S 32 12 1 3 Save measurement value
33. ROMESS r wasa 20 2 Reference motion without a request Reference request j n Ack EE Reference motion gee e ew Description e The PLC sets the signal reference motion e The NC module confirms the signal by resetting the Ack signal and setting the signal reference request e The PLC resets the signal start reference motion when the signal reference request has been reset e The NC module confirms that the signal start reference motion has been reset by setting the Ack signal If the signal start reference motion is cancelled during execution of the command the PC stops the reference motion and the signal reference request remains set 80 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS 20 3 Cycle Description ER Home request 7 ig gt gt Life Bit Start ae I Ack OK 1 NOK Ue x TE e he PLC sets the start signal The NC module confirms the l by resetting the Ack signal and resetting OK or NOK e The PLC detects the cycle end through the signal OK or NOK e The NC module confirms the start signal reset by setting the Ack signal If the signal start is cancelled during the program cycle the NC module stops the motion and the signals Ack OK and NOK are set 20 4 Emergency Stop during a motion g
34. Relieve the unit during the adjustment procedure Repeat this step until you are certain that the system is correctly calibrated Move the unit to the reference position Disengage the Emergency Stop and remove the reference transducer To calibrate the unit on a regular basis PROMESS recommends that a calibration program be created This program could appear as follows Program step Position just before reference transducer Press to block Application of specific force 1 2 3 Holding period 2 s Recording of applied force Return of unit Location of the adjustment potentiometer Amplification P1 _ Zero point displacement P2 ez 60 mm Output 76 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS 19 10 Wheight of toools The maximal allowable weight for the assembly units can be taken from the table below Artikelnr Bezeichnung Nennlast kN Gewicht kg 64002 UFMO1 1 74003 UFMO3 3 2 74005 UFMO5 5 5 74012 UFM12 12 8 7402X UFM20 20 20 7404X UFM40 40 20 7406X UFM60 60 50 7408X UFM80 80 80 741XX UFM100 100 and higher 100 If the weights are higher you have to to add a holding brake to the unit to avoid the bagging of the ram in case of lost power Stempel 77 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 WH PROMESS Ts 19 11 Integration of a holding break into the control The break must be integrated into t
35. Structure 34 Delay Hte unse 21 Dialog WING OW RT 25 Distance measuring 72 69 el 29 Error messages nun 55 Error messages Link Module 60 Ethernet Module 65 Expansion parameter 46 BIOS pb HC 37 Force distance development 27 Force measuring 72 Force transducer outside permissible offset 55 Force transducer outside the permitted offset area east asec Desa ee ades UU 35 Functions Linkmodule 60 giri I 73 General description and design 68 Graphics colours curves 46 Configuration ann aan ae 43 Jee eidel sense 49 Integration of a holding break into the control 78 Jade edel SE 4 IP address Ethernetmodule 66 Language ee 58 LED IET 13 Link Module Sending and Loading of Programs 63 Linking of NC Modules 60 EinK MOQUle en een user 60 Linkmodule Inputs Outputs 52 Lubrication advice 85 Malin WING OW EE 12 Manual operation
36. alibration 75 Transpo eR 6 Type of Memory Programs in the NC Module 44 Unidrive Parameter 11 V allablesSu entre a MeL tu 21 Weights Mechanics 69 ZOO ibis bci a seien 29 eine e alte 29 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3
37. alue lower limit 4 X value actual value 5 Y value actual value Force or signal too early i e the switch off force was exceeded during mam PROMESS r wasa This message means that the zero point of the force transducer was shifted by more than 10 This was probably caused by an overload The joining module cannot be loaded anymore to the nominal load Please perform an immediate re calibration of the transducer Bit 10 512 Maximum travel range exceeded Bit11 1024 Not used 12 2048 AD converter has reached maximum value 13 4096 Start signal was cancelled during the movement 14 8192 Not used Bit 15 16283 Not used Bit 16 32768 Status manual set 12 2 Call up saved measurement values To recall saved values select Data call in the File menu or actuate the corresponding button Measurement value Database call up Filter Cycle data The following database view is opened N Data View Station 1 Eu oa Ip station 24 00000061 5 1 17 07 01 Values from k Aj Eee PO Program name Ter the function 24 BADIS test 0000000815 17 07 01 17 07 01 17180 Measure 25 zBAS OUSE lez ppg 0000000315 17 07 01 17 07 01 17 181 Zb SBABDOSR lest pag HDODEEIEEL T5 14 0 1207 01 17161 2T DUU test pag 0000000915 17 07 01 17 07 01 17 162 28 2BAB UDSE lest 0000000315 17 07 00 17 07 01 17 1832 29 28480097 lest
38. astab Geor 06 11 0Bechler Schmierm glichkeiten Nom UFM 80 330 1 10 Werkstoff Halbzeug 74080 94 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS 21 1 Gear box oil For those press modules containing a gearbox the oil must be changed after 5 000 operating hours or at latest after 4 years MPS 0 UFM 20 180 150 Kl ber D68EP MPS 1 UFM 40 175 150 125 ml za Kl ber D68EP UFM 60 175 150 UFM 80 Kl ber D68EP UFM 100 95 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 1 PROMESS r wasa 22 Software Update If you update the software in the PC it will also be necessary to overwrite the firmware in the NC module with a newer version This will be necessary if the PC software displays the following message after restarting Error Station 1 Y 3 20000 P X NC Modul Sofware Version not compatible with Ehe PC program Please contact Promess For an update The firmware can only be updated using the RS 232 interface Com 1 4 If the PC and the module are connected the RS 485 you will also require connection the RS 232 Start the program UPDATE EXE in the installation directory UFM_NC EXE You will see the following start window Station Update 1 Promess Montage GmbH Zum Laden des Updates muB der PC mit einem RS232 Kabel mit der Montag
39. ata that is transferred in several sets can be buffered by the link module which accelerated the transfer as there are no waiting periods due to the slower communication with the NC module 60 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS The Baud rate selected in the PC is automatically recognized by the link module The following Baud rates link module PC are available 9600 Baud 19200 Baud 38400 Baud 57600 Baud 115200 Baud Max Baud Rate NC Module 38400 Baud e Program Storage The program storage serves as storage for a maximum of 123 NC programs for the UFM NC module which can be submitted by the superordinate control The assignment of the programs is performed via the allocation table which is stored in the link module Measurements and Terminal Assignment Pin Inputs Outputs A 61 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa Outputs Lirik Link Module PC Link Module NC Module Link Bee UD70 Lira d Para Hir it piang n Bp sl Luet Kul Kabel paang var dll RS 232 62 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS r wasa 18 2 Configuration Link Module Please select the respective item in the service menu for the configuration of the inputs outputs of the
40. ation Ethernet module nennen nnn 57 e een 58 17 271 Pasewoid seele een 58 17 3 FOCI DIE CX DOM Aether 59 17 4 Layout Display Error Messages use a oo 59 NI durer i es 60 TOT Funcions Onk Mod le cepit 60 18 2 Conhig urauon EIDK MOdUle uyum ee 62 To 2 Conhg rauonm Bue le EEN 63 18 3 Link Module Sending and Loading Of brograms enne 63 T EMONG nut een 65 10 41 IP Address Ethernetmodule ien dee aan 66 19 TEcHNICal ADD CMGI u u u a 68 19 1 General description and design 68 19 1 2 Weights Mechanics r u ale nei 69 19 2 Specifications and technical features nenne nenne nenne nennen 69 19 5 Te qan 69 194 e el le TEE 70 19 5 Force MeasUurnd anreisen 72 19 8 DISTANCE measuring uyu u uu een En ah el nai eet 72 19 7 Elecircal CONNECUONS sasea nat 73 19886 M HR 74 19 9 Transducer este iii 15 19 10 Wheiglit OF 8008 a ee ee 77 19 11 Integration of a holding break into the Control 78 20 ah dn u uu uuu u u ee ee ee en 79 20 1 Reference motion after start up 79 20 2 Reference motion without areouest nenne nenne nnns nan 80 SEENEN 81 20 4 Emergency Stop during a motion
41. e einrichtung verbunden sein Bitte die Not Aus Taste betatigen um den Antrieb Sp nnungsfrei zu schalten Soll der Update durchgefuhrt werden Promess Internet Updateseite Updates Schlie en Create the connection to the NC module by clicking on the Find button Once the program has found the station the UPDATE button is activated III Please shut down the UFM NC Module software or disconnect the station you want to update If you use the Ethernetmodule please choose the IP adress of the station you like to update Before continuing with Update please press the Emergency Stop button to disconnect the motor from the power component 96 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 m 1 PROMESS r wasa Station Update Promess Montage GmbH Zum Laden des Updates muB der PC mit einem RS232 Kabel mit der Montage einrichtung verbunden sein Bitte die Not Aus Taste betatigen um den Antrieb Spannungs rei zu schalten Soll der Update durchgef hrt werden Promess Internet Updateseite Select the file Node 1 in the following dialog box to download the firmware to the NC module NC Modul File Ed ES Suchen in E Uim nc zer J 0000000000 Mode 1 BFH J 0000000815 J 0000004711 3710412073 J prg version 1 06 1 00007 3 Promess Dateiname Dateityp UFM_NC_File bfh Abbrechen Once selected the software will initiate th
42. e advantage of this arrangement is that there are no moving cables and the connection cables can be placed outside of the operating area The nominal values of the force transducers may change due to the mounting conditions therefore each transducer is calibrated after assembly The calibration result is documented in a test protocol Technical data of the force transducer Input voltage 3 Bridge resistance 352 Q Reference temperature Nominal temperature 20 60 C range Limit load 150 Burst load 500 all percentages stated are related to the nominal load e Pin assignment Input voltage brown Input voltage Shield 19 6 Distance measuring Distance measured with resolver on motor The resolver transmits a sine formed signal which is transformed into an incremental signal in the power amplifier This signal is in turn output from the power amplifier in the form of a differential signal i e the usual tracks A B and C and their inverted signals are available Alternatively distance measuring may be done by means of an integrated scale magnetic or optical Resolution with resolver 2 5 um magnetic scale optical scale lt 72 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS 19 7 Electrical connections If you have acquired the press unit in the form of components without the mounting plate please refer to the use
43. e download of the system files or binary coded firmware Station Update __ Promess Montac zum Laden des Updates mu der PC mit einem 2 Kabel mit der Montage einrichtung verbunden sein Bitte die Notus Taste bet tigen um den Antrieb Spannungsirei zu schalten Soll der Update durchgefuhrt werden Promess Internat Upcatessite d Feder Weel ds Once download is successfully completed close the program After the successful update it is essential to back up your parameter set 97 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 Index Acknowledgement 79 Allee Bei DEE 14 u een 24 47 PNAIO GS IN e 45 ASCII data export data path 59 Baud rale ee 56 Cable cross section 73 loro EE 21 GANSODEN MT Tm 47 Conditional jump 22 C OMMOULAUON 56 Configuration 63 Contents of SUD ONY eege ee eege 5 Control of external signal 20 Correct usage 7 Cycle OA 83 SIOP ana nn 83 Database d ee 37 Database maintenance 33 Database
44. ease enter a zero to stop a creating databases by time or number Programm Parameter Station 3 Programmeinstellungen Analogeingang Programmparameter Grafik Standardeinstellungen Analog Ausgang Datenspeicherung Profibus DP Kalibrierung r Datenspeicherung Setup ODBC Yersion Access 97 Format ODBC Treiber DI v Messwerte abspeichern v Kurven speichern SPS ID abspeichern abspeichem Reverse ID r Daten Auswahl Ze Kurve immer von Station laden Kurve nur im Fehlerfall von Station laden Abbr Hilfe 12 1 5 Database Structure The database is divided into three tables 1 Data 2 Curves 3 Measurement Values The tables are linked by the cycle ID Cycle ID Autoline Frg ID Text Program name Text Statian ID Text Station Number Date Time Date Time Zahl Text Text Number Number Force or Signal early Number Force oder Signal Number Upper limit Fault Number Lower limit Fault Number Overload Number Datenbank Pflege Zeit Interva Woche 1 Tagle 0 Stundefn 0 Minute n 0 Datenbank grah Aktuelle Gro e 1 30 Gro e B25 E MB und Maximale Anzahl von Eintr gen 100000 Eintr ge Serial number NC Module Station number Ident number 34 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 m 3 PROMESS r cmm Gauging Requested position Acquir
45. ed position Requested position 2 Upper limit Actual analog Lower limit Position unit Force unit Status Curve Type Number Unit Mode Step Min Position Max Position Min Force Max Force Bit 1 1 Bit 4 8 Bit 5 16 Bit 6 32 Bit 7 64 Bit8 128 Bit9 256 Messwerte Name Dp O Auto Inc Number Text Number Date Time Date Time Number Number Number Number Number Number Number Text Text Number Text Serial number NG Module Station number Position start gauging Position end gauging internal use nat used Kurrendaten Auto Inc Number Text Number Date Time Date Time Number Number Text Text Number Number Number Number Number Number ar Text Not used Number XIW value of the curve and of oder Number signature Number Labeled by datatyp Number Number Number Number Number Number Serial number NC Madule Station number otatus binary codes Overload Bit 2 2 Bit 3 4 Reference Error the pre positioning No force and or signal within the set range Emergency off Upper limit of the envelope curve exceeded Lower limit of the envelope curve exceeded Tracking error Force transducer outside the permitted offset area 35 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 Data type 0 X value upper limit 1 Y value upper limit 2 X value lower limit 3 Y v
46. en ac Press to signal ox 1 4 amp b 1 L I 5 0 5 10 15 20 25 30 35 Delay time Position mm Start position 0 00 mm Goal position 0 00 mm Min position 0 00 mm position 0 00 mm Min force 0 00 N force 0 00 Error statu Q Upper limit violated Lower limit violated Monitor step 2 Monitor step 3 Monitor step Com not active Step 8 Modified NCS IMCM 7 No communication Proceed to configure the communication via the menu option Configuration in the menu File please refer to Chapter 13 Configuration e Select the COM port number of the interface you are using baud rate 19200 Baud e Polling error Check if you have selected the proper COM port 15 1 Register a new station This is only active if you use the RS232 or RS485 Using the Ethernet module you have to register the module under configuration 17 1 1 and 18 4 1 Open this point in the menu File Select the station number you want to open or select Auto Poll Station selection Station auto polling U Cancel 53 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 15 2 Switching Programs The programs in the NC module can be switched manually via the PC or via the PLC If you use the PC please open the program which you would like to send to the NC module and confirm it in the following window with
47. ence error F Force or signal too early i e the switch off force was exceeded during the pre positioning N No force or signal within the set path window E Emergency Stop UL Upper limit of generating curve exceeded LL Lower limit of generating curve exceeded FE Contouring error T Force transducer outside permissible offset range This message means that the zero point of the force transducer is displaced by more than 10 This is probably due to an overload The press module can no longer be loaded up to the nominal load The transducer should be recalibrated immediately These messages will also be output via any connected bus systems or the Link Module 55 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wa 17 Configuration 17 1 Serial communication RS232 RS485 You can set the COM port and baud rate used on your PC here e Polling of the stations You can also determine whether the stations connected should be automatically registered to the PC during the program start or if you want to carry out the registration manually Enter the numbers of the stations which will be automatically registered in the corresponding fields in the registry card Configuration information serial communication General Data settings Layout Baudrat 9600 c 19200 38400 C 55k 115k Poll the stations f Manual Automatically fram Statior 1 bis 31 Cancel
48. he control due to the function The holding break should only be used when heavy tools are needed for the assembly operation Tools with extreme weight might cause the ram to move downwards in case the axis is not in control loop disabled Precaution The holding break cannot be used to reach higher safety demands e g due to EN954 1 cat 4 In these cases a mechanical safety break with integrated monitoring functions must be used When must the break be activated The break must hold the ram of the assembly unit in position when e The emergency circuit is opened e g when the protecting door with safety switches is opened or the red emergency button is pressed down e The drive is disabled or switched off e The drive has an internal fault and is disabled control loop is off PROMESS provides a PROFIBUS output for these cases DRIVE DISABLE When this output is set the break can be activated Technical data of the break The break is a permanently exitated single disk break which is operated with direct current Nominal current 0 75A Protecting circuit Due toe the inductivity of the break voltage preaks will be occur when the break is disactivated current is switched off The voltage can reach 1000 V To avoid these peaks a protecting circuit should be used PROMESS recommends to use a Varistor R type 069 X3022 Switching contact Precaution As holding break is permanent magnet break the right pola
49. ive or absolute mode e Speed Speed up until the force level is reached e Acceleration Positioning acceleration e Max press in position This is the max position of the press ram 17 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa Press in speed feed Speed at the beginning of the force level With increasing force the speed is reduced to 10 of the press force entered The change of speed is executed via a brake ramp of 1000 mme Add limit force to the current force at pre position If this function is activiated the switch off criterion from the force at reaching the pre position plus the value entered under force is determined Up to the pre position the movement with the nominal load is monitored for collision Signal source Please choose the input for monitoring Recording of values The force way course is recorded for the movement Enter the desired number of reading points maximum 200 Teach in of limit curves A teach in curve for this function is established when the next teach in cycle is started Existing limit curves are overwritten The distance of the limit curves relative to the actual curve may be set in the service menu under configuration gt control parameters gt parameters in field teach in strategy Cycle stop Select this point if you want to stop the cycle after having executed the active function 18 Promess Montage und Pr fsysteme GmbH
50. l motion curve can be registered but in addition also the force distance development can be monitored see monitoring It is also possible to position according to any variable value Working with variables please refer to the chapter Variable Click the button Positioning in the drop down menu Function The following window is opened Enter the values required in the following fields Position eee 31 xl Position paramete Position mm Position Do Absolute Saat Ie op Relative Ge IN Current force Acceleration 0 00 zl mm Brake rate 0 00 mms Analog 1 mm Overloa Current position 4 Current value of an Force Analog Analog 2 Analog Temm additional analogue sensor Overload limit 0 00 Signal source methad Force Record data How many 2 Monitor Parameter Limit teachin Cycle stop Comments e Position positions may be reached in either relative or absolute mode e Speed e Acceleration e Brake ramp e Overload limit Please choose the input for overload e Signal source Please choose the input for monitoring e Limit curve teach in A teach in curve for this function is established when the next teach in cycle is started Existing limit curves are overwritten The distance of the limit curves relative the actual curve may be set in the service menu under configuration gt control parameters gt parame
51. ly disconnected from any electrical power supply before any service repair work or problem solving can start Proceed as follows Set main switch to OFF position f necessary pull out the power plug IMPORTANT The switch in the 0 or OFF position must be marked with a sign WARNING UNIT UNDER MAINTENANCE REPAIR OR SERVICE DO NOT SWITCH ON If the unit has to be disassembled you must first undo all electrical connections The PROMESS electro mechanical press unit can harm the operator if used incorrectly Please comply with the following directions 1 Do NOT attempt to undertake any internal system configurations without prior consultation with PROMESS Do NOT keep your hands in the working area The safety chain must be closed when operating the press unit Do NOT operate the unit in areas for which it was not designed DN Only authorised personnel may operate press unit 8 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS 3 1 Risk analysis Risk estimation Frequency of exposure Accident probability seldom often great small Possible injuries 1123 1 2 3 Countermeasures Category 1 Minor injuries crushing of the hand and fingers Category 2 Major injuries loss of fingers severe crushing of the hand Category 3 Death Severe crushing of the head Dangers through mechanical malfunction
52. m PROMESS r wa e Analog inputs The values for force distance and the external analog signal are displayed here Force H Position mm External mm e Status line Status of communication between the PC and NC module ul 113 Step counter Status Error messages 8 Manual positioning You will find the item Manual positioning in the service menu Use this window to control the axis in manual mode Enter the values required for position speed acceleration and excessive load limit Manual motion Station 1 Faramete Position change Position 0 001 mm Speed 10 000 mms Force Acceleration 1000 000 ms Analog mm acceleration 1000 000 8 Overload limi 2000 IN Y Advance w Kont Ausfahren Kont Einfahren Close Jogging press and hold down the respective button to move the axis in the direction desired at the speed programmed As soon as you let go of the button the axis stops Continuous motion the axis is positioned the equivalent distance you have entered The axis moves along the programmed distance If the button is released the press will stop To continue moving along the distance press the button again 14 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 mm 3 PROMESS 9 Programming To generate a new program first select New from the drop down
53. mber of decimal places to display force distance and additional analog input values Program parameter Standard setting Analog Output Data storage Profibus DP Program settings Analog input Program parameter Graphics Data entry parameter in position max position in speed max speed In acceleration max acceleration in brake rate max brake rate max force Decimal places Force 3 Decimal places analog Decimal places position 3 14 1 3 Analog Input Program parameter Station 1 P X Standard setting Analog Output Data storage Profibus OP Calibration 15 5tat Program settings Analog input Program parameter Graphics Analog input 1 Display ext measuring device shown Select analog channel Ext analog signal 1 Analog Type 20 4m amp Pt Reference value 1000 00 Offset 0 00 Unit nm m Analog input Display ext measuring device shown Select analog channel Ext analog signal 1 Analog Type Reference value 100 00 Offset 0 00 Unit mm Mm m In this register card you can define additional virtual analog inputs which you can use in the function Join upon Signal and in the control component You can choose between external analog input 1 external analog input 2 the power input an incremental transducer and the engine power You can 45 Promess Montage und Prufsysteme GmbH Berlin UFM NC
54. mech Endschalter x P SCH tO LO Lo tO tO LO LO N N Y Y S 7o Joe Schmierstellen ER s 2 Nutschmierung o B Nutschmierung GER recs C Spindelschmierung ho de D Lagerschmierung Ges fur Montage und DIN ISO OM T 2768 m PROMESS Prufsysteme mbH Nunsdorfer Ring 29 D 12277 Berlin Telefon 030 628872 0 Beat 03 0305 Paulsen M Ma stab c mmm Leme Schmierm glichkeiten 1 5 T UFM 20 350 230 Werkstoff Halbzeug 74023 Ma Ao Ay 74023 89 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa Initiator ohne p mech Endschalter Initiator mit mech Endschalter A gt H 524 LO 9 X LO LO LO LO gt Y Y Y Patr esce REC qe Schmierstellen S mc x A Nutschmierung gt Nutschmierung d C Spindelschmierung X E 4 D Lagerschmierung P d D C Ges f r Montage und DIN ISO OM 2768 m PROMESS Prufsysteme mbH Nunsdorfer Ring 29 D 12277
55. menu File or click on the corresponding button in the toolbar Select the function required before you start generating your press program All functions for the generation can also be selected with the right mouse button if you click in the step list With the help of the right mouse button it is also possible to copy and paste program steps Press to signal N ies Delay time Program end Motion control All generation functions can also be called up via the right mouse button if you click within the step list is also possible using the right mouse button to copy and insert program steps Insert step Erase step Copy Step Insert copied step Menu by clicking the right mouse button Position Press En Force Press to signal Memory requirement of the individual program steps Delay time see Program parameter Standard parameter page Pragram end 48 Motion control Conditional jump Tare Variable Measurement Set status Dialog window Set output Analog output 15 Promess Montage und Prufsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa Saved programs can be reopened under Open Program If you want to delete a program please click with the right mouse button on the chosen program and on the menu that is opened then on the function Delete 9 1 Positioning This function block is used to move the press ram to any position both in absolute and relative mode The actua
56. nd position you have to program these step always just before the movement you want to gauge the value Gauging at position Gauging variable 1 Force Force N Value type Behind position WI I I II WI Position mode Absolute f Relative Position mm Analog 1 rm Start position 0 200 mm lt End position 0 000 mm Limit Monitoring Upper Limit 50 Lower Limit 40 H Comment The recorded measurement variables can be monitored using upper and lower limit values The OK or NOK evaluation occurs independently of any limit curve monitoring In the case the display of the measurement variable has an orange background 30 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS r wasa The values are if the step is monitored saved together with the relevant limits from the limit curve You can transmit the values as follows Position mm Gauging at pozitio Gauging variable Force Value type Maximum walle Position mode Ce Absolute Relative Start position 0 mm lt End position 7 4 mm Limit Monitoring Upper Limit 2500 N Force N Analog Lower Limit 2000 M Comment e InanASCll text file the values are overwritten after every cycle e the fieldbus system Profibus DP CAN Open Interbus 5 In the program internal database 12
57. nk module or from the link module is performed via the respective buttons 63 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 To delete a program please mark it and activate the button to delete the program 44 Deleting of programs Loading the programs from the link module the link module Program Selection Station 1 x Program path Remark CarstenU0 ppg C Promess B iania ppq Pramess 3 429 c 4 PC Link Link gt PC Cancel Help Sending the programs to mam PROMESS r wa If you edit a program on the PC it is crucial that you re enter it into the allocation table 64 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS 18 4 Ethernet Module Functions e Networking of NC modules e 12 In 12 Outputs in preparation e Storage of NC programs in preparation power supply Pin 1 0 VDC Pin 2 24 VDC 104 165 RS 232 connection to RS 485 to NC Module PC Ethernet connection to LAN 65 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 PROMESS CH 18 4 1 IP Address Ethernet module To enter the IP address please load the utility Chip Tool that was delivered by PROMESS b IPC CHIP Tool Bl gt File BIOS CHIP Info Find Ctrl F IP config Ctrl I To
58. nly be used to perform the operations it is intended for The use in other operations or for other purposes may lead to operator injuries and damages to the unit If you have acquired the unit as components without the optional mounting plate you are responsible for the installation of the Emergency Stop chain according to EN 418 Cat 1 PROMESS is not liable for damages resulting from incorrect installation The power amplifier may only be connected and operated by competent personnel It is strictly forbidden to disconnect bridge or remove any safety equipment The belt protection may only be removed once the unit is completely electrically disconnected from the power amplifier If it is not possible to start the unit because of a technical disturbance or functional problem of the protective equipment then the faulty part or equipment must be repaired or exchanged It is strictly forbidden to operate the press unit without the proper function of the safety equipment e g through manipulation of the safety devices The press unit may only be operated by personnel who have been fully instructed in its proper operation If problems occur during normal operation and they can not be resolved through known and recommended strategies specialist personnel from the responsible department must be informed 7 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa The press unit must be complete
59. pid traverse Vmax 150 240 mm s Time that reference force is kept gt at least 5s under constant load lt 0 010 mm Play free ball screw Springing of the press ram under nominal load omits stick slip and reduces load peaks 50 80 um Spring stiffness 150 N um 250 N um Capacity of the screw spindle and the Cay 2 5 3 nominal load thrust bearing Ostat 5 6 nominal load Useful life At least 25000 operating hours Verification through a spindle life calculation is supplied on request Safety standard Certificate of compliance EMC immunity Motor choking coil net filter Axis control The unit is equipped with a resolver and resolver interface the amplifier delivers the usual incremental signals for NC axis controls with the 3 lines A B Z Force measuring otrain gauges integrated in the press unit Precision 0 5 Drive unit 19 3 The drive AC servo motor with resolver digital servo amplifier with 380 480 VAC 48 62 Hz Capacity reserves through ample system dimensioning 69 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 19 4 Power amplifier NAME UFM01 100 400 UFM03 100 150 UFM05 200 240 UFM12 200 240 UFM20 180 150 UFM20 350 230 UFM40 175 150 UFM40 330 240 Servo amplifier Unidrive 1401 Unidrive 1402 Unidrive 1403 Unidrive 1405 Unidrive 1404 Unidrive 1405 Unidrive 2402 Unidrive 2402 Construction size NAM
60. points to upper limit Add points to lower limit Right click in the graphics to edit the path of the force distance curve You can also open the menu Graphics and select one of the edit functions from the drop down menu If you want to edit an existing support point you must first select the upper or lower limit curve Then click with the cursor on the point you want to edit Press and hold down the left mouse button and pull the point to the new position In a similar way click on either the upper or lower limit curve if you want to add or delete support points Subsequently with the cursor on the point where you want to add a support point click the left mouse button Press and hold down the left mouse button and pull the point to the position where you want to insert a new point Existing points in between will be deleted 11 Zoom graphics There are several options to zoom graphics the buttons m ex j optimal view enlarae reduce e via menu Graphics or right clicking in the araphics window Scaling to nominal values Graphics Total view _ Reduce curve view Optimal view zoom in Runa s oom aut crease curve view Edit upper limit E dit lower limit Resort points Add points to upper limit Add points to lower limit e by using the mouse Press and keep the shift button pressed then with the left mouse button pressed draw a rectangle corresponding to the view required 29 Promess Mon
61. r manual of the Unidrive power supply for data on the electrical connections The optionally supplied connection cable set must be connected according to the numbering key Preferably install the motor cable in a conduit separated from the data cables Input voltage 380 480 VAC 48 62 Hz Fuses Press modules Fuse Cable cross section UFM 01 100 400 6A K 1 5 mm UFM 05 200 240 10A K 2 5 mm UFM 20 180 150 10A K 2 5 mm UFM 40 175 150 20A K 4 mm UFM 60 175 150 20A K 4 mm UFM 80 330 240 35 A K 6 mm UFM 150 400 245 35A K 6 mm Connection 220 VAC Fuse 4A Cable cross section 1 5 mm 73 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 19 8 SG pre amplifier The force transducer is driven by an analog SG pre amplifier Technical data Signal output Temperature coefficient PY of the zero point of the amplification Power supply Voltage range 19 28 VDC Current consumption Operating temperature range Pin assignment Force Transducer 1 Supply ye 2 Supply br not used 4 Bridge gr 5 Bridge wt 6 not used description of contact pins VK S Offset G3 Gain 0 604 V 1 Supply OV wt o2 Supply 24V gr 2 3 not used o 4 Out 20mA br 5 Out OmA ye Output Supply Voltage 74 Promess Montage
62. rity has to be regarded when the break is wired 78 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS 20 PLC Interface 1 Remarks The interface is designed to ensure a complete handshake so that times do not have to be programmed or considered for the signal transmission 2 Acknowledgement The output signal Ack is used to confirm System ready and to acknowledge the detection of a PLC signal 3 Signal description Signal Function Meaning Start of reference motion Cycle start Cycle start Output Part OK and cycle end 20 1 Reference motion after start up Reference request Ack Reference motion start mm i Description After a start up of the NC module the reference request Ack are set The PLC sets the signal reference motion e The NC module acknowledges the signal by resetting the Ack signal e The PLC resets the signal start reference motion when the signal reference request has been reset by the NC module e The NC module confirms that the signal start reference motion has been reset by setting the Ack signal If the signal start reference motion is cancelled during execution of the command the PC stops the reference motion and the signal reference request remains set 79 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam P
63. s mern of malfunction Possible Countermeasures injuries aiiis A wear blocking after being None damaged Thrust E wear damage A None Broken drive belt 1 Category 1 and 10 fold safety level against rupture 2 under normal working conditions No brake function after the belt is ruptured Cog belt coupling loosened Category 1 and The couplings are self retaining loose 2 screws can only result in the coupling loosening itself when the press unit is exerted to extremely strong vibrations or shocks Slippage of the cog wheel on the None axle wrong positioning force exceeded Transducer destroyed through excessive load Cable breakage force transducer a BEE Cable breakage limit switches None Cable breakage motorresolver I Cable breakage power cable None ooo 9 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 4 Software installation Place the disk or CD ROM in the appropriate drive Go to the Windows start button bottom far left select Execute and then type Setup Follow the on screen instructions to install the program Connect your PC with the press unit NC module via the serial interface RS 232 or RS 485 a separate board is needed in your PC If you connect via RS 485 you must bridge pins 4 and 9 e Position of the NC module in the power amplifier RS232 Port 5485 Por
64. s can easily be opened closed or toggled so that any combination is possible The windows can be selected or de selected via the menu View View Graph Command Steps Editar Strg E Chart Gauging Variables Statusintormation Gauging Cycle Data Filter 12 Promess Montage und Prufsysteme GmbH Berlin UFM NC Module V3 m 13 PROMESS LEDs The LEDs show the status of the I Os of the PLC interface basic function The following conditions are displayed Start reference positioning 1 Start 1 Confirmation Ref Error reference request O OK O Ref Start Cycle Eror OF e Pushbuttons NC module E Stop Stop Step Start The buttons are used to initiate the following functions E Stop The program can only be resumed after a reference positioning Stop The program execution is interrupted Resume with Start Step The next step in the program cycle is executed Start The complete program cycle is started Ref A reference positioning is executed e Program pushbuttons Send program to Graphics NC module zoom out New program Save Program Preset Graphics zoom in Open database z Br ri SFIS EE s a AAN IN program SS step Arrange stations Get program from NC module 13 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 ma
65. s in database ener nne nennen nnns 32 12 4 Database Maintenance usc nee 33 121o Database SIUE Os uisi oii zuo to satiate Bee 34 12 2 Call up saved measurement values 36 TS PrIntUBQ0uu ects pt 40 E ee a ipte a een a u cfi Ue 40 19 2 Pining ee aa 41 5 DIOg am see ee 42 14 SEVICE EE 43 14 1 Program EE 43 1 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul 141 1 Standard Ende E 43 1 1 2 Program EE 45 141 3 Analog NPU see buys lan Dean ca A Fade dip Se uo Fu da 45 141A Program parameters he ee E AE ON 46 5616 er EE 46 14 1 6 Protibus DB partieipantaddress ea rule 47 ee M E 47 12 158 ANOJ QUEUE m nu ys 47 EE 49 14 2 Change station address riesaa ee ee ee 49 14 4 Parameter NC module uu L uu u pu 50 14 4 1 Service Window Bus Systems a 51 14 4 2 Link Module Inputs Outputs 52 15 Register an NC module to the uuu uu uuu u u una 53 IS Register new an u mau ae a 53 19 2 PIOOQLalTIS dose ae en 54 NCS SAG EEN 55 17 ee ed Le E en WEE 56 17 1 Serial communication RS232 RS483 a a sese 56 17 1 1 Serial communic
66. scan for connected Ethernet modules please call Find at the menu Chip Scan for IPC CHIP s on the network Bl x REL Cs 7 0057 SC 12 132 158 0 3 205 255 255 0 0 0 0 0 ODS5E 5812 0 132 158 0 31 255 255 255 0 0 0 0 0 DE 21 sCl2 0 132 158 0 32 255 255 255 0 0 0 0 0 UE 025 ss a c 132 158 0 33 255 255 255 0 0 0 0 0 serial number Ethernet chip Use ping Please note the serial numbers Now please call IP config in menu Chip and enter the serial number of the Ethernet chip IP address and the net mask 66 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS IPconfigSnr EDZ3 132 158 0 33 25 2939 Ac l 67 Promess Montage und Prufsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS 19 Technical appendix 19 1 General description and design The mechanical parts Determining features are e robust construction designed for a long life even under the most severe operational conditions e simple design through the realization of the principle transparent engineering The following figure shows the design of the unit Cog belt drive Force transducer AC servo motor Ball screw Press ram 68 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 PROMESS r wasa 19 1 2 Weights Mechanics 395 19 2 Specifications and technical features Specification Ra
67. stem or the expansion module The PLC resets the start signal Setting the start signal again continues the cycle The outputs OK or NOK plus Quit are reset 83 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 20 7 Transfer of program number E Start E Reference start E Prog Bit 1 E Prog Bit 2 A Prog Bit 1 A Prog Bit 2 A Prog Bit n A Strobe Prog ta gt 10ms ty gt 20ms Program load time Description Assignment of binary coded program number Set strobe for transfer Reflection of program number Strobe acknowledgement after program loaded Reset strobe of PLC and NC module 84 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS 21 Lubrication advice Preliminary Remarks All electro mechanical presses from PROMESS must be re lubricated Over lubrication should be avoided however damage to the bearings due to overheating caused by over lubrication is not to be expected Over lubrication as no negative consequences Lubrication Points The following components are lubricated ex works The gliding guides Lubrication Points A and B The ball screw Lubrication Point C The thrust bearing Lubrication Point D AMOUNT OF LUBRICANT FOR LUBRICATION POINTS A AND B Approx 1 sq cm The lubrication points A and B consist of two opposite lubrication fittings in the centre of the
68. suitable locations In particular please observe all protection regulations Should you require information concerning requirements about the admissible locations please contact the manufacturer After the installation of the press unit please make sure you comply with the manufacturer s specific measures before operation Mount the belt protection prior to connecting the power cable Only use the power cables supplied Assemble the power amplifier with the supplied filters and choking coils according to the power amplifier manual instructions Make sure all cables are correctly installed Avoid laying power and data cables next to each other 6 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 1 PROMESS 2 Correct usage The press unit is designed and built for assembly operation tasks e g for pressing in bearings absorbers and shafts or to press in and caulk seals Operations other than the above may not be performed on the machine The permissible loads are determined by the performance data of the unit and must not be exceeded by any larger extent Avoid the following situations in particular Abrupt loads at high positioning velocities collisions Forces under normal operations that exceed the nominal load by more than 110 Excessive loads through unpredicted operational conditions exceeding the nominal load by 100 3 Safety precautions The press unit may o
69. t Female Male 10 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 mm 3 PROMESS r wasa 5 Program start Start the program with the help of the icon installed During start up the program scans the whole system to determine which modules are connected This scanning takes place provided the option automatic has been selected under polling of the stations new or substitute modules are always supplied with the station number 31 set The station number desired must be entered in parameter 20 29 of the Unidrive For details on how to enter parameters please see the Unidrive manual page 5 5 parameterisation If you only want to establish a connection to a specific station you should select manual Once a station has been detected the following station window is opened T UFM Software c 1999 Promess Montage GmbH Station 1 10 x T File Edit View Graph Command Service Window Help x a Force kN Position mm Ref Start Cycle Ener NOK OK 9 Step Start Ref Stop Parameter Steg Comand Parameter ig u Position Press to GYal 1 0 GYal 2 0 GVal3 GYal d 0 0 Pos2 0 Pos 0 4 0 0 000 Val 2 0 000 Val 3 0 000 Val 4 0 000 Var 5 0 000 Var B 0 000 Var 7 0 000 Var 8 0 000 D Force 3 604 Distance 200 636 force Diagramm Acti
70. t Pes P 2222 Emergency Stop g Ack Start Ref request Description In the case of an Emergency Stop the Emergency Stop chain is opened The press unit reacts by stopping the motion The PLC resets the start signal when an Emergency Stop situation is detected After clearing the Emergency Stop situation the PC confirms the flank change of the Emergency Stop signal after the start signal has been reset 81 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 20 5 Emergency Stop during standstill Emergency Stop Ack Description case of an Emergency Stop the Emergency Stop chain is opened e The NC module confirms by resetting the Ack e Closing of the Emergency Stop chain is responded to by setting the Ack 82 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 Ref request m 3 PROMESS 20 6 Cycle Stop L Bit Start Quit OK NOK 777777777 p EE Cycle stop t gt 10ms t gt 20ms Duration of program step to cycle stop ts Save data in database Description The PLC sets the start signal when live bits are present and no reference request is present The NC module acknowledges the signal by resetting the acknowledgement The PLC recognizes the cycle stop from the OK or NOK signal plus Quit or from the signal cycle stop This signal is only available via the bus sy
71. t 08 Bit 07 Bit OF Bit 06 Bit DE Bit 05 Bit 05 Bit 04 Bit 04 Bit 03 Bit 03 Bit 02 Bit 02 Eit 01 Bit 01 Bit D Bit DU m m G r m r m r r r r m m m m m m im 52 Promess Montage und Prufsysteme GmbH Berlin UFM NC Module V3 13 PROMESS 15 Register an NC module to the PC When started the program scans to determine which modules are connected This scanning takes place provided the option Automatic has been selected under Polling of the stations New or substitute modules are always supplied with station number 31 If you only want to establish a communication with a single station you should select Manual in stead of Automatic When a station has been detected the following station window is opened The program stored in the NC module is automatically loaded and displayed 10021002100 Test Mon ppg tep Comand Parameter Var 1 0 Var 2 0 Var 3 Var 4 0 assign variable Varl Y Coordinate 13 42 M Doordinate 124 36 L Position 40 00 mm Position Position 0 00 mm Position 120 Histogram curve Delay 4000 ms Lower absolute limit i i I 100 Upper absolute limit i i H assign variable 80 Lowattimit 4 peas aie EN Te 4 gt gt DS i Press to Position 5 00 mm 60 ome 3 Ee le s EN 1 i force Conditional jump When Var 1 lt 10 000 th
72. tablished when the next teach in cycle is started Existing limit curves are overwritten The distance of the limit curves relative the actual curve may be set in the service menu under configuration gt control parameters gt parameters in field teach in strategy e Cycle stop Select this point if you want to stop the cycle after having executed the active function 20 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 RH PROMESS r wasa 9 4 Delay time Programming of delay times during the execution of the program cycle The delay time is entered in milliseconds Delay Parameter Delay time FOO ms Comment 9 5 Calibration This function is used to calibrate the input of force or additional analog input values Select the input desired by using the arrow Tare Station 1 Position mm Force H Analog Comments 9 6 Variables There are 12 variables available in the process By the use of this function you can assign a numerical value or the value of an external sensor via the analog input to a variable of your choice In addition you can execute calculations by means of the variable Edit var able Variable assignment and calculation Variable fi gt uum 0 A Comments Variable 1 Yanable 2 Variable 3 Variable A Uk L Position Force Analog 21 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul
73. tage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wa 12 Data 12 1 Record measurement values Use this function to record and monitor force measurement values or external signals at any position required In addition the max value min value or middle value between specific positions can be determined Up to a maximum of 4 measurement variables can be saved It is also possible record a variable relative to the end of a movement Gauging at position Position mm Gauging variable 1 Force Force H Value type Current Position WIIII UCII Position mode Single value Average Start positions M asimum value aiti mm Minimum value Limit Monitoring Behind er Limi 0 0 I Analog 1 mm Lower Limit 0 0 I Comment Select the variable and the required type of measurement value recording Then define the required position or start and end point of the measurement value recording The measurement values can be recorded as absolute or relative If relative measurement value recording is selected the reference measurement is taken as the position the press module is located in when the function is called To record a value relative to the end of a movement please choose Behind position Enter the distance as a positive relative number When the end of the next movement is reached the value will be recorded relative to the postion of these step If you choose Behi
74. ter card Data storage Program parameter Station 3 Program settings Analog input Program parameter Graphics Standard setting Analog Output Data storage Profibus DP Calibration Data storage setup ODBC Version Access d Format ODBC Driver lw Data storage enabled Data path E sPromess v3 49 Ethemet 333333333 stationdata mdb SSC of data pa Store Gauging to Database JW Store Curves to Store 5 5 ID Save Variables Reverse ID Data Selection Always load station curve Load station curves on error only SN OF Cancel Help 32 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS r wasa The data path for the data to be stored can be set using the buttons This gives you the choice of saving the data locally or decentrally in a network LAN For decentralised data storage the connected PC must have the relevant network card It can also be specified at this point whether each station if more than one present should write to a central file or to an individual database It must be noted however that the data may be stored and distributed across the local hard drive and than one must save several files The database itself offers the opportunity of being used by many stations simultaneously The measurement values are saved with the data time actual position force value or signal value If the
75. ter card General Default delivery password is Bach Under validity period enter the period in minutes for which the protected functions are enabled after the password is entered Once this period is expired the password must be entered again 58 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 17 3 ASCII Data export e File settings Data path for ASCII data export Define the file path of the ASCII data export via the RS232 in the register card File settings using the File Configuration menu If a warning before the overwriting of data you have to activate the respective button Konfigurationsinformationen 17 4 Layout Display Error Messages Here you can minimize the display of the error messages if you are bothered by the pop ups Error messages are then only displayed in the status line Konfigurationsinformationen 59 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 EN 71 PROMESS CH 18 Link Module 18 1 Functions Link Module e 12 Inputs 12 Outputs DC separated max Switching capacity of the outputs 50mA e Storage for 128 NC Programs e Connectivity of Joining Modules II The link module cannot be used at the same as a bus system e Inputs Outputs Function Outputs The following functionalities can be assigned to the e 8 freely defined outputs 12 inputs and outputs A maximum of 8 freeliy 7 inputs for the
76. ters in field teach in strategy 16 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS e Cycle stop Select this point when you want to stop the cycle after having executed the active function 9 2 Press to Force This function block is used to press to a given force the distance may be expressed as absolute or relative values The actual motion curve can be registered but in addition also the force distance development can be monitored see monitoring Click the button Press on block in the drop down menu Function The following window is opened x Press paramete Force mE N Absolut Position mm Pre position oo mm Relative Ee IN Pre position speed oo mms Kurrent force Acceleration oo mm Analog 1 mm press in pos oo mm Current position Current value of an Pressin feed T Ims ko Zong additional analogue sensor Add force to force at prepos Signal source meth Force Record data How many 2 A Monitor Parameter Combine the curves at black posil Limit teachin Cucle stop Comments In the following fields enter the values needed e Force the required switch off force can be entered directly or via a variable Pre position Up to this position positioning is done at the speed value entered the position can be reached in relat
77. the stored status Set Status S Latus Status Comment k Cancel 9 13 Dialog window With the help of this function you can generate a user dialog The following inputs are possible Dialog Message Dialog definitio Message Please enter ID Input data Acknowledge Y Single exec Cycle stop Variable 04 arable 05 e Acknowledge Choose this if you only want to display a message the user has to confirm The message can consist of max 30 characters DB Ident Number Input of the Ident number to store to part in the database e DB User Input of the username to store in the database e Variable 1 12 Input of the value for a variable via the keyboard 25 Promess Montage und Prufsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa Dialog Message Dialog detinitia Message Please enter ID Input data DE ID NUMBER Single exec Cycle stop Cancel Single execution With this switch you decide whether the window is opened in every cycle or only once When the switch is not set the window pops up every cycle When the switch is set the window pops up once after loading a part program or homing up every cycle Cycle Stop If you choose this switch the unit has to be started again when you have finished the dialog When you run the cycle the following window pops up Please enter ID
78. the values on floppy disk Use the Host gt NC button to send saved values to the module after the power unit is changed It is possible to load parameter sets for download to the NC module using the Import button Parameter Backup 2 x Suchen in E wingman D cl Dateiname par Dateityp Parameter files par m Abbrechen 50 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS 14 4 1 Service Window Bus Systems Use this window to check the entered bits or the output bits that are transmitted via the Profibus Depending on the levels selected by the PLC either I O or variable information is displayed For further information regarding the Profibus module please refer to the Profibus manual I O level Profibus Service Dialog Station 2 gt DP Interface OP Interface Hui jg et IN 04 CSTI C NU DUT 03 CMD STALST IN 03 NU OUT 02 CMD1 STA IN 02 Mu OUT 01 CMD STA RES IM 01 NU nur oo MT STALL CTRL Iv IN D Mu PRGS PRGS PAGS PAGE PRG4 5 PRG PRAGA PRG PRG3 5 PAGE i PAGS FRAGE m PRG STA REF STA Ma I PRG Mu m PRG OL STA T PRG NU PRGO QUIT PRGO Mu m PRGS
79. ting Analog Output Data storage Profibus DP Calibration Position increment 0 00 Speed 0 10 mmz Acceleration 1000 00 mm s Overload limit 0 00 kN Decceleration 1000 00 mmr HandwheelInc mrn 200 122 Configuratio f Standard 170 User 20 The fieldbus 1 0 1 2 dont function when digital user 1 0 is selected Memory type of the NC f Permanent Memor Moduls limited program size Memory NC Moduls Must be downloaded at power up Etherne Ethernet Module T ext Test 1 Manual Motion The standard values for manual mode can be set here You can also decide whether inputs outputs 1 and 2 should be used as standard inputs or as freely definable inputs outputs This selection is only useful if the module is controlled via the Profibus Inputs and outputs 1 and 2 are then no longer available in Profibus Input Start Reference run Freely prog input 11 Input Cycle Start Freely prog input I2 Output OK Freely prog output 01 Output NOK Freely prog output O2 43 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wa You have different options to save the program in the NC module 1 In the non volatile storage fixed digit storage The programs remain stored after the power is switched off Storage size 154 Words 2 Inthe volatile storage The programs are lost after the power is switched off and have
80. to be reloaded from the PC or the link module after system is switched back on storage size 22 words Required storage of the individual program steps Words Words PrestoFoce 003 8 1 Deia Period 2 ProgamEnd 1 y Variable 2 e Conditional Jump 2 Tain IL 1 JoiingonSigal 9 1 Measuring LL Position Position X Output 2 Input 2 4 2 y Analog Output 2 Stts J 1 every point of the upper lower envelope curve needs one additional word e Ethernet module text To describe a station please enter the text here This text is shown in the respective station window Ethernet module text T UFM Sottware 1999 Promess Montage GmbH 1111111111 Station 1 UFM 12kN 200mm 240mm s Untitled ppa T Fie Edit Wiew Graph Command Service Window Help DAs BR HAA E m Z Em Ref Start Cycle Emer NOK OK Force kN Position mm O K Step Start Ref Stop Station Test 1 Sef ID nio Force 381 Distance 10 44 1 Position 20 00 mm 2 Position 30 00 mm AM 3 Position 0 00 mm 44 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS r wasa 14 1 2 Program settings Use this register card to set the press unit nominal values for position acceleration speed and force You can also determine the nu
81. transfer of a maximum of 128 program programable inputs and or outputs for controlling the numbers process within programs for the UFM NC module e Transfer interval receipt program No Strobe Cycle end and the transfer of process specific messages tothe Cycle stop superordinate control Life Connection PC NC Modul OK Function Inputs ae e Quit 8 freely defined inputs e Overload limit exceeded overloaded Inputs for the transfer of a maximum e Reference run not successful E reference program numbers e Block force before block window E force early e Transfer interval program No Strobe e force not reached no force Reference run Emergency off E EmergencyOff Start e Upper envelope curve or upper limit measurement e Writing variable exceeded E U limit Stop e Lower envelope curve or lower limit measurement Move stamp out variable exceeded L O limit Jog Move stamp back e Nominal force of the joining unit exceeded E force error PC key lock e Fuel set outside the permitted range of 10 E sensor error e Route exceeded the max permitted position E Max position e Axis is being adjusted Being adjusted e Linking of NC Modules The link module can speed up the communication when several terminals are connected to a PC because the connection to the PC can be run at a higher Baud rate than the connection PC NC module Furthermore d
82. und Pr fsysteme GmbH Berlin UFM NC Module V3 mm 3 PROMESS 19 9 Transducer calibration The integrated SG transducer can be calibrated in various ways You can use a reference transducer or a spring with known and constant spring characteristics You can calibrate the electronics using a calibration resistor connected to the system Sequence of operations to calibrate the system Note The hints concerning the calibration are kept very general and must be understood as an aid only The sequence of operations described may cause damage to the press unit the adapters or parts depending on the offset of the reference point the type of tool and part adapters used PROMESS accepts no responsibility for damages occurring during calibration Press the Emergency Stop Install the reference transducer in the adapter Ensure that the nominal load of the reference unit corresponds to the permissible load of the press unit Release the Emergency Stop Make a reference positioning Select the register card Sensor input in the system configuration to verify the permissible load Exit from the menu and select the manual mode of the press unit F5 Position the unit close to the reference transducer Verify the zero point of the analog signal To do this toggle to the service menu and select the point Inputs Outputs Interface 24V utp REF REQ Inp ENDSEH Dutp DK Inp REF utp NOK Inp START
83. uts as well as the analog inputs Interface 23 Inp ENDSCH WM Dun Dk Inp REF Outp Nok Inn START Channel 1 H Channel 2 st Iv Outp QUIT ep Enable EEE Input 1 utube Analog out 1 Input 2 output Ez Analog out 2 Interface Sy Digita Output AD Iv Input EDO Input ED i Help Extended gt 14 3 Change station address If you do not know the station address of the connected unit you can search for it using the buttons 31 1 Once you have entered the new station address you can implement changes using the button Change station address from n to m Status From addresse 1 found To addresse 0 Change station address Horn 1 to 33 x 49 Promess Montage und Prufsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wasa 14 4 Parameter NC module Once the press module is successfully installed we recommend that the parameter sets of the unit be backed up To do this open the item Unidrive parameter in the service menu then click on the button NC gt Host in the new window to load the NC module values onto the PC Parameter Backup Station 1 Parameter Parameter Value Import 102 00000000 103 00000000 104 00000000 105 00000032 106 000000 10 00000780 108 00000001 109 00000000 110 00000001 111 00000001 11 00000000 4 F Then back up
84. ve curve Histogram curve Lower absolute limit Upper absolute limit Press to 10 4 4 Ee SOS d Uppet limit on nm cn GA N signal gal Delay time Program end Motion control 0 20 40 60 80 100 120 140 160 180 200 Rel Position mm Start position 0 000 mm Goal position 0 000 mm Min position 0 000 mm Max position 0 000 mm Min force 0 000 kN Max force 0 000 kN x 8 Comm active Step 1 E E ese Stop 12 11 12 The program stored in the NC module is automatically loaded and displayed If there are any communication problems check the configuration of the interface first II Before you start the unit for the first time please check whether the calibration factor is correct To do this open program parameter in the menu service and check under calibration You will find the right calibration factor in the Proprietary Calibration Certificate you have got with the UFM and on the mechanical unit 11 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wa 6 Program window The main window Editor Step list Status line Histogram On Off T UFM Software 1999 Promess Montage GmbH Station 1 UFM 1172007240 EISE T File Edit View Graph Command Service Window Help ERAl Br wx
85. waits a new Start after the last step has been executed 23 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Modul V3 mam PROMESS r wa 9 10 Set outputs Using Profibus DP you can set or reset 8 freely programmable outputs in the program process When program control is implemented via the Profibus it is possible to define 2 standard inputs and outputs as freely programmable outputs Outputs or inputs 1 and 2 are then no longer available in the Profibus Definitio Output fo Of A Comment On 1 Yarable 2 3 Varable A Marable 1 2 m The outputs can be set directly or linked with variables In the above example output 2 is set when the value of variable 1 is greater than 200 9 11 Analog output It is possible using this function to output the value of a variable the actual position the actual force or the actual analog input signal via the two analog outputs Output analog Parameter Analog Output 0 000 Comment 9 D gt Cancel You must first define the analog output see Chapter 14 1 8 Analog output 24 Promess Montage und Pr fsysteme GmbH Berlin UFM NC Module V3 13 PROMESS 9 12 Set status With the help of these function you can influence the total status if necassary To characterize the manipulatet status in the database the bit 15 16384 is set in

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