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Manual LaserCheck Hardware Installation, Software and Maintenance

1. ccccccceseeceeeseceeeeeeeeeees 76 Variable AOL cccccscsssssrencsssscrensrescassrencusnses 76 V height adjustment ccccccceseceeeeeeeeeenees 68 81 ViSUALISATION cceccccseseeccsesccceeesecseaeeeesaeeees 71 WING sons srcteiacstedubeyecculsne ted E EA 96 LaserCheck TT sisseanncsewhsicannnsnnnsannesbarncieaunataucehdueraens 69 V Width adjustMent cccccccssecceeeeeeeeeeees 68 80 Learnt DENG rena r N 29 W LEMO E a T ETA E 67 Longitudinal adjustment ccccesecceseeeeeees 68 84 Wiring Scheme M Amplifier N E EA EE E E E 10 AE ree a 37 Machine requirements for LaserCheck 6 6 LaserCheck 10 osiriciuccrriroicnrtiarsendrnnia i 62 MaintenentE scssicescincnncosnran er me oe 99 LaserCheck 11 cceecccccsssssecceceesseeeesaeeeeeeees 63 Material surface ssiccsancsdesacwnstapaawacanewstinseavarenciuieds 92 LaserCheck Oestacsncostereccestveroonsacssaerstensammneevernace 57 ME GSV EXE iteatsdadeaccetanieatcasnaiesaanaaieattantarasanasiic 14 16 LaserCheck 7 scnsissiissanaavaansiecauiiaciasteenoarinasoadesanceee 61 Mirror OptiOn esssessssssssssesrresreesreesrresrersressreese 67 77 Longitudinal Adjustment ccccceeeeeeeeeeeeees 86 ModEva Io uesirii a ea nee mere ne eevee nereane re 41 Sian GAUPE rnar 10 Mounting angle s sesseeensssereesssereesssreresssrerssseeee 21 Working distance ccccccsseeceseeseeeeeeeeeeees 20 21 Mounting of the Strain gauges
2. Page 43 LaserCheck Hardware Setup Gate n Configuring the Cybelec Control 1 6 7 Programming Machine Parameters MACHINE PARAMETERS ANGLE MEASUREMENT SYSTEM VERSION NLR DM ANGLE Sane cl A oo FORCE AT 0 FIXED DYNAMIC 202 Force detector 1 40 203 Force detector 2 A D 04 Minimum angle 205 Maximum angle 2U7 Threshold springback measurement 2U0 Measurement force 209 Compensation factor lz Max tire springback measurement 15 External detection end of springback 216 Cycle with N measures First stop 217 Delay before measures 216 Number of samples 220 Speed springback measurement Pi PRODUCT BEND CORRECTIONS ACTIONS EXECUTE Figure 34 Cybelec control Angle Meas System page Unless the bending force of the current bend already requires a very large pressure a bend including a spring back measurement procedure SBMP will be performed using the pressure specified by parameter 35c Min pressure if spring back measure If this parameter is left undefined the value of parameter 33 Pressure is used instead The goal is to guarantee enough pressure to lift the beam during SBMP Since a change in pressure at BDC might Cause unwanted perturbations this pressure is used throughout the entire bend not only during SBMP lifting e Parameter 33 and 35C must be high enough Begin with 100 and then diminish the value Typical values range between 35 and 50 Do not be afraid of overshooting e Input
3. lost spring back is larger than with large dies o Note 4 This of course only holds for small angles It is difficult to define small because it depends on a number of things including tool geometry hence we just say 5 6 degrees Note that the lines do not need to be linear throughout It suffices that it is reasonably linear in the range of the expected variation of spring back i e in the zone just before sheet release In some cases the amount of spring back is so large say 12 degrees so that we are outside the linear zone In these cases one must work with a manually predefined pre compensation in order to bring the work zone back inside the linear zone E g if you are sure that spring back ranges between 10 5 and 13 5 degrees you should enter a pre compensation of 10 degrees in order to have the measurement done near the final BDC If this range is also too large there is currently no other solution than completing multiple cycles of spring back measurement and compensation Copyright by data M Engineering GmbH Page 48 ete N LaserCheck Hardware Setup Gate en Configuring the Cybelec Control 1 6 9 Programming Bends The SPRING BACK page can be reached via the CORRECTION page but also via BEND NUM BEND 2D and BEND 3D Full control over the use of the AMD and SBMP is possible from here mainly on a bend to bend basis BEND 37 3cy__cr_ J PROGRAMMING CORRECTIONS BEND SECTION PRODUCT AIM Se
4. Correcting the Calibration 76 6 Real Time Measurement 78 6 1 General 78 6 2 Cybelec 78 7 Sensor V Adaption Control 81 7 1 Automatic V Width Adjustment 81 7 2 Automatic V Height Adjustment 82 7 3 V Adjustment for bending 84 7 4 Automatic Longitudinal Adjustment 85 7 4 1 Driver parameters for Lexium ILS1 86 7 4 2 Electrical installation 87 7 4 3 Working Principle 90 7 4 4 Parameters from LaserCheck par 91 7 4 5 Setting Up and Testing the Sensor for Longitudinal Adjustment 92 8 Material Surface Control 93 9 Automatic Write Protection EWF 95 10 Contents of the LaserCheck folder 96 11 Troubleshooting 97 12 Safety and Maintenance Instructions 98 12 1 Safety of Laser Devices 98 12 1 1 Safety Instructions 98 12 1 2 General Instructions 98 12 1 3 Laser Classes 99 12 1 4 Laser Devices of Class 1M Class 2 Class 2M and Class 3R 99 12 2 Daily Checks 100 12 3 Weekly Checks 100 13 General Specifications 101 Copyright by data M Engineering GmbH Page 3 Jata N LaserCheck Hardware Setup Gate en Introduction 1 Hardware Setup 1 1 Introduction This chapter covers the installation of the LaserCheck angle measurement system on the press brakes The installation procedure is divided into 4 steps Mounting of the force measurement system strain gauges Set up strain gauge force amplifier ranges Mounting of Laser sensors Configuring the press brake control a Sm ethernet eh wiwk Abe ethernet etherne
5. Permanent Regulation Must remain at 1 throughout the entire cycle and it must not drop Other pertinent parameters can be found on the ANGLE MEASUREMENT SYSTEM parameters page Values displayed at the bottom of the page form a reasonable starting point They must however be adapted to the situation by hand Each parameter will be described in more detail below 200 Measurement System Error This value will always be added to the measured angle in degrees If the sensor repeatedly displays systematic errors these can be corrected by entering a value into the respective field This correction can be overridden by programming a similar field on the SPRING BACK page on a bend to bend basis Copyright by data M Engineering GmbH Page 44 LaserCheck Hardware Setup Gate en Configuring the Cybelec Control 180 90 Common values for these fields are 100 for 180 and 3600 for 90 These fields are used to build a simple linear function In 907 enter the analogue value value received from the corresponding serial line on the NLR generated by the sensor when measuring an angle of 90 In 1807 enter the analogue sensor value representing 180 angles which is typically not 0 These values will be used to build an interpolation table of 4096 entries because analogue angle values are 12 bit values with 12 bit values because also transformed angle values are 12 bit values Analogue values obtained from the sensor
6. cccccsseeeeeeeeeeees 7 WINE Protecti susisiiensdinssneseii nnan 69 94 R Real Time measurement 0ccccceeeeeeeeeeeees 53 79 Copyright by data M Engineering GmbH Page 106 fatah LaserCheck General Specifications Gate ll Weekly Checks data M Engineering GmbH Am Marschallfeld 17 D 83626 Valley Germany Tel 49 8024 47028 0 Fax 49 8024 47028 25 e mail support datam eng de http www datam eng de Copyright by data M Engineering GmbH Page 107
7. 100 Test the connection with a ping command The default IP address of LaserCheck is 192 168 144 184 The default password for VNC is 7 Auto login The computer is set to auto login by default If you do change anything on the system for example the IP address it is possible that a password will be requested during the startup The password for the user LaserCheck is lasercheck The user LaserCheck is an administrator If any other user is logged in the standard password for LaserCheck will be deleted Copyright by data M Engineering GmbH Page 97 Jata N LaserCheck Safety and Maintenance Instructions Gate M roering Safety of Laser Devices 12 Safety and Maintenance Instructions e Do not look into the laser beam not even with optical instruments It may cause injuries to your eyes e The operator must be trained for working with the machine on which the angle measurement system is installed Improper use can cause heavy damage to the equipment and injuries to people e Modification of machine parameters can cause material damage or lead to irregularities in the quality of the product e The computer housing may only be removed by a qualified technician danger of electric shocks e Do not expose the control to excessive humidity so as to avoid any risk of electric shocks and any deterioration of the equipment e Make sure that the control is disconnected from the main power before carrying out any cleani
8. 104 D awi General Specifications gata M LaserCheck Weekly Checks INDEX A 220 Speed spring back measurement 47 222 Measurement dynamic offset 08 47 Amplifier cess ccate ivan ocean eceteneee sana 7 Angle measuring CeVICE ccccccesssssseeeeeeenes 50 Alignment with pressure method 066 17 Compensation factor ccccccsseseeeeeeeeeeeeeeeeees 51 Alignment with test bend cccccceseeeeeeeees 18 EAEE caste I EE A E E 51 Amplification level ccccccccccccessssssseeeeeeeenes 17 Measure TYPC cccsssecccessecceessccceessceceasecensnees 50 OC PING se corpse scalars case A E E T 17 N 50 Sg eae EE SSE E EE EE E EE E 13 E 2 EE EE E E EE EEE EEE E 50 GSV Threshold ccccccccsssssseeceeeeseeeseeeeeeeenes 19 RF100 RF X RFO ssssseecceeesssseeeeeeeeees 51 LOAGING TES arrn ES 16 DONS OF ciori i NE EE EE 50 EEA E S 14 16 SPINE WACK COM ciyiccirtnerwvertverdaternamcanntytodectieentne 51 Offset ec cecepcaecnteszsceraueursapssesanenecevanneeeoaseurenssassat 14 Tolerance Opened closed cerren 51 POI wind E E E 74 76 Area of Interest AOI cccccssssecccceesseeeceeeseees 74 eU ioa OCU A E E A T T 96 Decompression speed ssssessssessssesssrrsssresss 19 B DEIC iieo EA N R 28 Bending process parameters ccceecceseeeeeees 33 Bending length sesssssssensssssssreressssssreressssssrereesss 6 Controller SetUp sssees
9. Also see 1 6 11 Bends with Spring Back Measuring Variants on page 51 BEND C PROGRAMMING ANGLE 177 ANGLE 2 gt o 177 0 Y1 227 000 Y2 ae 227 000 ANGLE MEASURING DEVICE YES DISTANCE START MEASURE MEASURE TYPE CYCLE WITH N MEASURES N a N2 a ee J en 1 ACTIVE NO CORRECTION 2 NOT ACTIVE SAME ANGLE CORRECTION AS FOR BEND A SPRINGBACK CORR SAME DEPTH CORRECTION AS FOR BEND TOLERANCE OPENED BY MONITORING END OF ANGLE VARIATION ot COMPENSATION FACTOF BY MEAS ANGLE WITH RESIDUAL FORCE BY MEAS FORCE AFTER OPENING ANGLE BY j ANGLE ANGLE 2 ws pas wuss FORCE 1 FORCE 2 Y1 t t Y2 Ae Paur EN CORRECTION VAL ANGIE FO X SE US UF DEFTH a Si ie PEN prooucr BEND corrections ACTIONS SHUT OOWN Copyright by data M Engineering GmbH Page 80 vate Ll LaserCheck Sensor V Adaption Control Gate eenn Automatic V Width Adjustment 7 Sensor V Adaption Control The sensor adaption control moves the sensors according to the width and height of the current die The necessary information is sent from the control to the LaserCheck system before each bend For adjusting the sensors both the height and the width adjustment axes must be in their reference position 7 1 Automatic V Width Adjustment The sensors are calibrated for a constant distance to the sheet flange Changing the die different V width results in a modified position of the sheet flange with respect to the center plane of the machin
10. Also values for all other angles are interpolated from this line The way this is done can be chosen Spline or Polynom By choosing spline a linear correction is calculated as shown above If you choose polynom the program will calculate a function from those points and you will see a curve like the one in the picture below Also you can_ change the Exposure Time for every die individually by a certain percentage if you adjust the lower scrollbar The adjusted percentage only applies to the die that is currently chosen We recommend adjusting the exposure time under Options Correction Material for a die with a medium distance and then using this option to adjust the exposure time for all other dies if necessary Copyright by data M Engineering GmbH Page 77 Gi f n l LaserCheck Real Time Measurement for Delem and Cybelec Option 66 cate M roering General 6 Real Time Measurement for Delem and Cybelec Option 66 6 1 General The Real Time option can be activated in the window Options General Settings and by clicking on Real Time Support for Cyb Opt 66 and DM101RS Also the options Real Time with graphic output and Real Time with Force Measurement are available Real Time measurement means that the LaserCheck sensors constantly take pictures not only when triggered which are processed and sent to the control This type of measuring has the advantage that the bending process does not need to be stopped at any point The difference
11. LaserCheck 11 Sheet ist 6 pi CJ f a LaserCheck LaserCheck Software Cate M veering License 2 LaserCheck Software By default the LaserCheck computer is set up in such a way that the measurement program starts automatically as soon as the LaserCheck computer is powered up and the power switch is on The computer can run without mouse keyboard or monitor However it could be necessary that a mouse a keyboard as well as a monitor must be attached for adjusting the measuring device In that case the following screen should appear data W Angle Measuring Sensor 1 Program Options View Window Help Be pe e F amp W Sensor 1 Angle 137 25 Sensor 1 Off Left Front Live Angle 132 83 Sensor 2 Off Left Back NLR not ready Connection Online Sent O Received 0 16 11 07 Figure 46 Control window of the LaserCheck program 2 1 License If you only have a temporary license you will see the following dialog pop up during the start of the program indicating the number of days remaining LaserCheck Runtime amp License information Bh LaserCheck 7 Copyright 1995 2070 by data M Engineering Developed by Andreas Bachthaler and Or Thomas K Dietl The runtime license of this program ie limited While the ownership is reserved steamy eset time or date will terminate the runtime licence Remaining days E License Figure 47 LaserCheck License information Cop
12. O E if g Gee g Go DO led bd ing Laser Figure 41 Internal sensor interface Internal interface SV1 to SV5 are connected via a flat ribbon cable to the 9 Pin Sub D connectors at the backside Sensor 1 Table 8 Meaning of SV1 SV5 Copyright by data M Engineering GmbH Page 57 Nate N LaserCheck Hardware Setup Cete M eorn Wiring Schemes X1 24V Power supply PWR GND Ext ATX PWR Ext ATX PWR Table 9 Meaning of connector X1 The Ext ATX PWR connectors are used to shut down the system via an external contact Confirming this contact will shut down Windows Newer systems have a CF Card with writing protection on C and therefore do not need to be shut down X2 ATX PWR ATX PWR Table 10 Meaning of connector X2 X3 SELECT ee Input 1 PAPER OUT ee BUSY 4 input3 ACK Table 11 Meaning of connector X3 1 8 1 3 Connector pin assignment SENSOR PC Sub D 9 femala 8 Pin Header x6 Figure 42 Connection cable sensor PC Cybelec NLR Figure 43 Connection cable NLR card PC COM1 Copyright by data M Engineering GmbH Page 58 id a i LaserCheck Hardware Setup cate ML neering Wiring Schemes Plug Force Amplifier X1 v Internal Interface VI Strobe Auto Form Feed Initialize Computer internal power supply Bk we CNio 2 4 ATX Power SW JUKI 3711 Figure 44 Wiring of the control computer Stepping Motor Interface Schrittmotor GND b
13. Sensor C Sensor 2 Move sensor mm Endurance test cS 7 Absolut position fi 0 mm fo Set zero point C Sensor d ero point 10 mm Distance Reference Cancel Figure 71 Dialog to adjust the sensor height control units In this dialog you can adjust the kinetics of the sensor movement maximum speed acceleration start stop frequency If you install the software on the computer for the first time you must also calibrate the computer by pressing the Calibrate kinetics button You can move each sensor individually by first selecting the desired sensor then entering a value into the Distance field This is a relative distance A negative value moves the sensor downwards a positive value moves it upwards In order to start the movement press the Move sensor button When you adjust the sensors move the sensors to a position to their lower back stop Adjust the laser and the camera in such a way that the laser beam is centered Then save the zero point by pushing the Set zero point button From then on this point can be reached immediately by pressing CTRL S The zero position can be tested by pressing CTRL R The sensors will move synchronously inwards to their mechanical back stop position They will move for the duration corresponding to the distance of their maximum course Parameter 106 Remark If the sensors are not referenced correctly the angle measurement result will be erroneous as their position wi
14. a perturbation area 4 The next example shows 2 overlapping sheets On the left the segmentation option is activated The green marker in the centre of the image marks the end of the good part of the laser line The rest of the laser line is discarded On the right the image segmentation is not activated The real angle is erroneous because the laser line angle is determined as the average of both lines Figure 64 Zoom of 2 overlapping sheets Left with segmentation option right without 4 5 Short flange compensation If the option variable AOI is activated short flange compensation is automatically activated too In order for this function to work properly the laser line must be completely confined by the AOI for every angle The program can then artificially elongate the laser line in order to improve the measurement result If the variable AOI is deactivated this option is automatically deactivated too Copyright by data M Engineering GmbH Page 74 Jata N LaserCheck Variable AOI area of interest Gate un Die Definition 5 Variable AOI area of interest If you want to use LaserCheck 8 9 10 or 11 you need a variable AOI These sensor types are not adjustable in the V width and therefore the working distance constantly changes during a tool exchange You need the variable AOI in order to find the correct position of the sheet metal and to select the correct calibration data All dies needed must be defined and calibra
15. angle measurement system W Sensor Press Grake connection Figure 55 Toolbar with control connection Press brake connection icon Figure 46 shows camera pictures of 2 sensors The red rectangles indicate the maximum search area AOI within which the laser line is searched by the software Above every sensor image you find its corresponding status line zio x Live I Z Angle 89 76 Off Left Front ADI 1444 1837 1232 b627 MGADI 000 000 LL 000 000 Mal 1 vl H Aolttwhl 232 444 393 395 E fa ex fT oo r Mirror Ex Figure 56 Status line of sensor 1 On the left there is a check box with the title Live which activates the live picture mode In this mode the angle is permanently measured without transfer to the control The current laser angle measured by the sensor is displayed in the Angle field A value of 180 signifies an error In the next field you can find the assigned position of the corresponding sensor Also the current activation status On Off is displayed Next to it you can read the measurements of the AOI On the bottom left you can see the number of the current matrix with its width and height On the right you can see the Mirror option When using LaserCheck 10 or 11 you have to activate this option for sensors 2 and 4 Remarks 1 An individual sensor can be activated or deactivated in the LaserCheck dialogue Options Angle measurement In order to be active in ON state a sensor must be activate
16. by data M Engineering GmbH Page 75 Jate N LaserCheck Variable AOI area of interest Gate an Additions for LaserCheck 10 and 11 5 3 Additions for LaserCheck 10 and 11 When using LaserCheck 10 or 11 there are no left or right sensors as they all have the same hardware Thus sensor 2 and 4 back must be mirrored W Sensor Z E O x o Live Angle 180 00 Ort Lett Back Die 1 Width 0 0 Height55 0 MGA 000 000 LL 000 000 Maat 1 v 0 00 H 55 00 ADI tlh cng 411 405 406 Exp 15 00 Est oo i Miror Ex Figure 68 Sensor headline with activated mirror option If you want to change the AOI you have to deactivate the mirror option first 5 4 Correcting the Calibration After calibrating a tool you can click on correct in the Measurement Parameters window and the Angle Correction dialog opens Angle Correction X 2 0 Height 55 0 Die Mo zZ al k Update Unda Mesaured Real Delete Corr Width E i e ge fo fo M Sensor 1 jo jo IY Sensor 2 jo fo fo Spline C Polynom mes Figure 69 Angle Correction dialog Copyright by data M Engineering GmbH Page 76 LaserCheck Variable AOI area of interest Gate en Correcting the Calibration You can choose the die you want to correct by using the upper scrollbar Then you can enter the measured angle and the real angle for each sensor as corrections into the tables These values are shown by the black line after you click on Update
17. cables connecting the sensors with the control computer must be protected in cable carriers The control computer itself should be mounted in the electric cabinet with sufficient air conditioning and filtered air Vibrations on the computer housing should be avoided Remarks 1 Avoid plugging the sensors cables in or out while the LaserCheck computer is switched on and running 2 Switching off the main power plug of the LaserCheck computer does not switch off the 24V external power supply connected to the LaserCheck computer Copyright by data M Engineering GmbH Page 20 Jata N LaserCheck Hardware Setup cate M roering Mounting the Sensors 1 4 2 LaserCheck 6 Working distance 200 mm Height 260 5 mm Horizontal distance 111 5 mm Mounting angle 45 The required installation space is shown for a maximum course of the V width adjustment of 65mm The maximum V width supported is 120mm Please contact data M Engineering if you require a longer stroke top die OK Werkzeug N 109 1 229 5 N center die 2 Mitte Werkzeug pe i a i 163 G 248 5 Figure 14 Mounting of the sensors Side view Copyright by data M Engineering GmbH Page 21 ate N LaserCheck Hardware Setup Cete M eon Mounting the Sensors Note The difference between LC6 U and LC6 G is the length of the plugs Material V2A Oberfiache perigestrahit a ooo ie oe Gee data M Engineering Figure 16 Sensor mea
18. control sends the programmed die number directly to the LaserCheck computer Before each new bending step this information will be updated The die height corresponding to the Delem die number must be programmed in the LaserCheck program If the number is not available a relative height of O is used The following parameters in the parameter file are used for the height control 67 1 1 System with 1 without 0 motorized V width control motorized V height control 115 100 max Range V Height in mm 118 80 Relative Height Position after Reference in mm Parameter 67 In order to activate the option Automatic height control both parameters 67 must be 1 Parameter 115 Max course of the sensors in vertical direction Parameter 118 Die height that is corresponding to the reference position The reference height is adjusted with the calibration unit The height of the shaft is the die height in reference position Copyright by data M Engineering GmbH Page 82 Jata N LaserCheck Sensor V Adaption Control Gate n Automatic V Height Adjustment Furthermore automatic V height adjustment and automatic V width adjustment must be activated in Options General Settings For the adjustment of the height control you can use the following dialog Sensor Height adjustment x Kinetics Maximum speed 10 0 mms Acceleration 200 mms Calibrate kinetics Start Stop Frequency fi n E Movement and traverse path calibration
19. e ANGLE Y1 Y2 ANGLE MEASURING DEVICE YES al MEASURE TYPE CYCLE WITH N MEASURES N N 3 s SENSOR ACTIVE 180 0 ERROR __ _ SPRINGBACK CORR BY MEAS ANGLE WITH RESIDUAL FORCE _ amp TOLERANCE OPENED O CLOSED COMPENSATION FACTOR RF 100 RF Z RF 0 ANGLE o 00 o o00 91 52 FORCE 1 o 0 Zi FORCE 2 o 0 o Y1 221 47 221 63 221 65 2 221 47 221 63 221 65 CORRECTION VAL ANGLE _ DEPTH PRODUCT CORRECTIONS Figure 35 Cybelec control programming ANGLE MEASURING DEVICE This is a general switch that specifies whether an AMD will be used It should also be used to temporarily bend without using the device in case of problems or unavailability MEASURE TYPE Here one can again select whether an AMD is in function and which method type is used to control beam motion The option NO MEASURES DEPTH is always available If option 60 is confirmed choose CYCLE WITH N STEPS N This field specifies how many intermediate stops are performed before reaching the first BDC The default value is 1 stop If O is entered into this field the NC will try to reach the first BDC with a single blind step This is useful only if a SBMP is performed afterwards In most cases 2 or 3 intermediate stops give the best results N2 This field specifies how many intermediate stops are performed during the compensatory upward motion to the second BDC and after SBMP The default value is 0 no st
20. e Place the resistor between clamp 2 and 4 if the voltage is positive or between 2 and 5 if the voltage is negative e The voltage must now be below 0 5 mV 4 Check the output signal with MEGSV exe The last digits of the signal must change and not stay at 0 0000 Copyright by data M Engineering GmbH Page 15 PTN LaserCheck Hardware Setup Gate en Mounting of the Strain Gauges 1 3 6 Loading Test The amplification range of the force sensor is adjusted with the help of the programmed force for each bend Hence the measured value for the strain of the side stands needs to be aligned with the actual bending force This is best done using test bends Alternatively e g for very large machines or if not enough suitable test sheets are available the strain can be estimated using a manometer During the tests you can track the measurements with the oscilloscope function of the ME GSV software The range limits must be adjusted individually for each press brake type Note Press brake controllers send the calculated bending force in t e g Cybelec or in KN e g Delem MEGs 2 1 Serial Number 07019345 1 1 4 ajx Configuration Stress analysis Advanced Sensor Recorder Administration x10 s Auto scaling E i Display currently measured data A time window j0 lt Measurement Average Figure 10 ME GSV Control program Recorder tab Before actually trying to measure a force you sho
21. for sensors and materials Five different materials have been programmed The names of the materials are defined in KALIB DAT they can however be changed by clicking on Name Also you can add as many new materials as you need by clicking on the button new For each material you can define a constant correction value for the left and the right sensor that is added to the measured value Copyright by data M Engineering GmbH Page 93 LaserCheck Material Surface Control Gate n Automatic Longitudinal Adjustment Exposure Time You can input different exposure times for up to 6 different angles Between these values the exposure times are interpolated Typical values are 5ms with direct reflection 90 and 20ms with indirect refection 0 and 180 as shown in the picture above Activate the changes with the Accept button If you want to use the current values for all materials you can do so by clicking on Accept for all Materials not recommended for special cases only You can deposit a table for each camera Otherwise you can set up a sensor and click on All Sensors as displayed The slide control allows for a simple proportional alteration of the exposure times of the camera The Manual Correction all Materials allows you to input individual correction values for up to 5 angles Between these angles the correction is interpolated This correction is valid for all materials and all dies lf you use a LaserCheck system with variable
22. in the dialog box force measurement in the LaserCheck program Modify the Sequencer according to the input number Figure 13 Connection of the threshold Note Using this option will require a low decompression speed of max 3 s As you input the decompression speed in mm s you have to convert the value according to sheet thickness and die opening Copyright by data M Engineering GmbH Page 19 Jata N LaserCheck Hardware Setup Gate en Mounting the Sensors 1 4 Mounting the Sensors 1 4 1 General The LaserCheck sensors must be mounted in pairs one in the front and one in the back For the correct sensor position refer to Figure 14 and following It is important to have e The correct working distance between the front face of the sensor and the sheet metal at 90 between 110mm and 200mm Please contact data M if you are not able to have this WD e the correct height between the top face of the die and the fixation screws e the correct horizontal distance between the center of the die and the fixation block e Take care that the front sensors in particular do not collide with the bending support Please refer to the following instructions and drawings for your system It is recommended to mount sensor 1 to the left front side sensor 2 to the left backside sensor 3 to the right front side and sensor 4 to the right backside All systems are shipped with these default settings The horizontal reference is the machine center pla
23. the LaserCheck system by measuring the spring back e Sub Bend Method 1 LaserCheck is only used for the first bending process The result will be saved and used the next time learnt bend is applied This method only works in Semi automatic mode Copyright by data M Engineering GmbH Page 31 LaserCheck Hardware Setup Gate en Configuring the Delem Control e Sub Bend Method 2 The system performs a bend without spring back calculation The spring back angle is entered for the bend Two further preliminary bending steps are performed before the final bend position is reached 1 5 9 2 Method 4 Learned Bend In order to accelerate the bending process of several bends of the same angle and in the same anisotropy of the sheet you can use option 4 in BM Bending method With the aid of a second parameter you have to refer to a bend step which has been performed before this bend and which has the same angle and sheet direction This method only works in Ssemi automatic mode The first measurement is a reference measurement with the angle measuring system We save the obtained y position and the spring back For all other bends having the same reference number we will either use the same y position or the same spring back angle as for the reference bend The 2 modes are controlled by the sub bend method of the reference bend e Reference bend with sub bend method 0 We use the y position of the reference bend for the actual y depth No an
24. uses a GigE camera The technical drawings apply for both sensors 1 4 5 LaserCheck 9 e Working distance 110 160 mm e Mounting angle 35 60 Copyright by data M Engineering GmbH Page 26 Jata N LaserCheck Hardware Setup Cete M eorn Mounting the Sensors 1 4 6 LaserCheck 10 11 e Working distance 50 150 mm e Mounting angle 35 55 The sensor thickness is 44mm for LC10 and 53mm for LC11 51 53 87 55 44 00 y N Figure 26 LC10 11 General mounting details Copyright by data M Engineering GmbH Page 27 LaserCheck Hardware Setup Gate en Configuring the Delem Control 1 5 Configuring the Delem Control 1 5 1 Controller Setup 1 Go to page 19 3 Auxiliary axes 2 Select next available axis and enable it 3 Choose axes Sensor 1 and Control Sensor If you are using 2 pairs of sensors also enable Sensor 2 4 Click on the change parameter soft key and select sensor numbers for the left 1 and right 2 sensors If you only use 1 pair of sensors set Sensor 2 to 0 The sensor type can be Analog or Encoder 5 When you now select bending mode 3 there should be a window in which you can see the number 1 and 25 default of the selected axis If the configuration was not successful a message saying no valid sensor will appear once you start the controller 1 5 2 Network Configuration 1 Change the IP address of the Delem controller to 192 168 144 184 2 Change the LaserCheck computer s IP
25. you find a way to fix this problem otherwise you will never be able to obtain stable results The main causes are The centre of mass changes so much when the beam moves that the sensors can register it This only happens with very heavy tools Perhaps try to install the sensors elsewhere Cylinders and pistons are possibly not well aligned and tension is created while in motion If the above has established that you can confidently work with your sensors check for linearity e Install an angle measurement sensor or two but do not connect them to the NC Just make sure you can read off the angles Repeat steps 1 to 5 from above up to the activation of the SemiAuto Sensitive mode Put a sheet of suitable thickness in position so that 1 4 of the max force is required Press pedal and reach BDC Keep the pedal pressed Read force sensors angle s and Y1 Y2 positions and record them Using the button not the lift the beam Make sure Y1 and Y2 move smoothly and correctly both reaching the same final position Copyright by data M Engineering GmbH Page 47 LaserCheck Hardware Setup Gate un Configuring the Cybelec Control e Ateach step read force angle s and Y1 and Y2 positions and record them e When you release the sheet stop and transfer the recorded data into an excel spreadsheet e Draw a scatter plot with force on the abscissa and angle s on the ordinate e Draw a second scatter plot with Y1 and Y2
26. AOI meaning LaserCheck 8 9 10 11 we recommend using the manual correction from the Angle Correction window You can access it by going to Options Angle Measurement and clicking on correct See 5 4 Correcting the Calibration on page 76 Copyright by data M Engineering GmbH Page 94 Nate N LaserCheck Automatic Write Protection EWF Gate un Automatic Longitudinal Adjustment 9 Automatic Write Protection EWF After inputting an unlimited license code the system will automatically activate a write protection on drive C of the CF card Therefore the system will reboot After the reboot it is still possible to save data onto the drive but it will be saved in a shadow ram that is lost during a new reboot If you would like to permanently install something on drive C you have to run the batch file D data M Engineering Plus unprotect bat After a reboot you can install or remove software or change registry items etc Afterwards you should run D idata M Engineering Plus protect bat and reboot the system in order to reactivate the write protection To check whether the write protection is active use D data M Engineering Plus status bat The protection is on when State is ENABLED With a write protection enabled you can switch off the computer without shut down Drive D contains all the LaserCheck data and is not protected LaserCheck parameters lasercheck par can be deleted It is highly recommended that you make an
27. Adaption CONTIOl ccccsseseeeeeeeeeeeeees 80 F Sequencer modifications ccccsseeeeeeeseeeeeeeees 29 Sheet thickness cccsssecccccsseeceeeeeseceeeeeeeeeeeees 19 FUSS aenn AE 29 Short flange compensation sseeeeeeseeeeeeeees 75 L Spring back measurement on Cybelec 52 SECA BAU CC sirisser rn Ta 7 ASE ROME CK 10 sierociniec 27 Strain gauge offset adjustment ccceeceeeeees 14 LaserCheck 11 cerca scoaducnssudnciueneienncaetabeassnasaanesnmacsen 27 Strain GAUGES cccccsseecccssseccesesecsessecsenseesseaeeees 15 Laser NECK O renia np TETE 21 LaserCheck 6 G seviseccsncscsinesccegsabsdupsauaaniueduasansadvaneae 22 j LaserCheck 6 Uorren 22 Tandem option for Cybelec csesceceeeeeees 56 69 LaserCheck 7 scaccassanvedeissdeedeoassvecaneseesisteevevandes 23 25 Technical drawings LaserChe ck 8 cccccccsseeccceeeecceesecseneecssaesessaeeess 25 LaserCheck 10 ccccccssseccesssecceesecseseeeseaees 27 LaserChe ck 9 ccccccssssccccsseeccesceceensecseesesseeeees 26 AS CV CINO CK e e E E A E ET 27 LaserCheck Software ssssssnesssesensssreressererssseeee 64 LaserCheck 6 isawssinunscunemesnscesuntivwennmeeevaussbearsanane 21 Angle measurement s ssssessssessssressressseere 70 LaserCheck 7 ccccccccssseccccceseecceeeeneeecesaeeeeeeees 23 PO exe segetaroetewads creas iaraaes deta asegece sus teees nearaen eee 74 LaSerChe cK 8 cccccsss
28. Cata M Engineering Manual for LaserCheck Hardware Installation Software and Maintenance Version 1 6 Copyright for data M Engineering Germany May 2014 data M Engineering GmbH Am Marschallfeld 17 D 83626 Valley Germany Tel 49 8024 47028 0 Fax 49 8024 47028 25 e mail support datam eng de http www datam eng de LaserCheck Hardware Setup Introduction Table of contents 1 Hardware Setup 1 1 Introduction 1 2 Requirements 1 3 Mounting of the Strain Gauges 1 3 1 Gluing 1 3 2 Wiring of the Amplifier 1 3 3 Function Test 1 3 4 Strain Gauge Offset Adjustment 1 3 5 Adjustment of the Strain Gauges 1 3 6 Loading Test 1 3 7 Connection of GSV threshold Mounting the Sensors 1 General 2 LaserCheck 6 3 LaserCheck 7 4 LaserCheck 7 8 5 LaserCheck 9 6 LaserCheck 10 11 onfiguring the Delem Control 1 Controller Setup 2 Network Configuration 3 Troubleshooting of Network Connection 4 UAP 5 Sequencer Modifications 6 Sequencer Flags 7 General Machine Parameters 8 9 1 1 1 1 1 O 1 4 Sensor Parameters Bending Methods 0 Spring Back Calculation 1 Monitoring LaserCheck Delem Operations 2 Four Sensor Option 4 4 4 4 4 4 C D 0 F o iS 5 D 5 J 0 D 5 5 13 LaserCheck Error Messages on Delem Control 5 C D nfiguring the Cybelec Control 1 Hardware Connection to the Cybelec 2 Configuring the Cybelec Software 3 Connection wit
29. Class 3R Precautionary measures are only necessary in order to avoid continuous direct looking into the laser beam for classes 1 2 and 2M a momentary 0 25 sec irradiation of a wave length range between 400 nm and 700 nm as it may occur when you accidentally look into the beam is not considered to be dangerous However you should not intentionally aim the laser beam at people The use of optical aids e g binoculars together with laser devices of the classes 1M class 2M and class 3R may increase the risk of harming your eyes Copyright by data M Engineering GmbH Page 99 NPAT tT on N LaserCheck Safety and Maintenance Instructions Gate M neering Daily Checks 12 2 Daily Checks The user must check the glass filters on the front side of the sensors at least on a daily basis In case they are not clean scratches oil grease dust etc use a special cleaning set for standard glasses or replace the filter Remark Whilst cleaning do not look directly into the laser beam with or without optical instruments as it might be dangerous for your eyes r r e lt lt lt FL a se ae me Clean daily Figure 84 Front view of the Lasercheck7 sensor 12 3 Weekly Checks e Clean the threaded bolt with petroleum Use a nylon brush and spray it with light resin free oil e Clean the guide ways and spray them with light resin free oil Figure 85 Guide ways and threaded bar of the LaserChec
30. Gauges 2 Brown Red Us Positive sensor source 3 NC 4 Green Up Positive differential input 5 Yellow White Ub Negative differential input 6 NC 7 White Black 3 Us Negative sensor source 8 NC 9 NC 10 NC 11 NC 12 T Tara Reset 13 Us Source 24V Power 14 Us Source 24V supply 15 GND Power Ground Table 1 ME GSV 2 Amplifier Connection scheme for Delem controls 15 pin Clamp 3 Values in brackets only valid for older sensor types Cybelec Clamp Colorof Connection Meaning Cybelec interface sensor cards cable Strain 1 GND Power ground strain gage shield Gages 2 Brown Us Positive sensor source Red 3 NC 4 Green Ub Positive differential input 5 Yellow Up Negative differential input White 6 NC 7 White Us Negative sensor source Black 3 8 NC Analogue 9 Coax Ua Analogue output 0 10V NLR Force signal Measurement 1 Pin8 10 Shield GND Ground NLR OV Reference Pin 5 11 NC Calibration 12 T Tara Reset NOT A B2 Synchro Control Pin 8 13 Us Source 24V Power 14 Us Source 24V supply 15 GND Power ground Table 2 ME GSV 2 Amplifier Connection scheme for Cybelec 15 pin Clamp Standard NLR input for force measurement has a range from 0 to 5V must be adjusted to 0 10V 2 9 pin Sub D Plug X5 of NLR card Values in brackets only valid for older sensor types All cable shields should be electrically connected to the housing Copyright by data M Engineering GmbH Page 11 Jata N LaserCheck Hardware Setup Cete M eon Mou
31. LE Y1 Y2 ANGLE MEASURING DEVICE YES MEASURE TYPE CYCLE WITH N MEASURES N 2 N2 2 2 SENSOR ACTIVE 180 0 ERROR ne SPRINGBACK CORR BY MEAS ANGLE WITH RESIDUAL FORCE 15 TOLERANCE OPENED ae en CLOSED ae COMPENSATION FACTOR 5 ee UNS PE RE M ANGLE et E T 122 49 FORCE 974 190 38 FORCE 2 1 0 0 Y 2 alo sp eS ee ae Y2 p JL Ls Eo e 210 24 CORRECTION WAL ANGLE 2 40 DEPTH a MENU PRODUCT CORRECTIONS ACTIONS EXECUTE Figure 39 Cybelec control Automatic page When SBMP is performed it results in a correction value for the nominal BDC target angle Both angle and corresponding depth correction are obtained These CORRECTION VALUES are displayed at the bottom of the page in the fields ANGLE and DEPTH They are updated every time a new SBMP is performed on this bend At the top of the page a small CORRECTIONS table is displayed Copyright by data M Engineering GmbH Page 54 sete N LaserCheck Hardware Setup Gate un Tandem Option for Cybelec 1 7 Tandem Option for Cybelec 1 7 1 General The tandem option for LaserCheck allows running two press brakes with Cybelec controls in tandem mode with angle and spring back measurement LaserCheck is synchronizing the sensor values of the two machines Compared to the standard system there are the following differences 1 The strain gauge amplifier for the force measurement are connected to the LaserCheck computer not the NLR card The LaserCheck software reads the amplifie
32. Machine Zero Figure 80 Coordinates for a system with 4 sensors Copyright by data M Engineering GmbH Page 91 Jata LaserCheck Sensor V Adaption Control Gete on Automatic Longitudinal Adjustment 7 4 5 Setting Up and Testing the Sensor for Longitudinal Adjustment The adjust and test dialog for the longitudinal adjustment can be opened in the menu Options Longitudinal Adjustment The following options are available Adjust and Test Sensor longitudinal adjustement E x Longitudinal lt positions mrm Motori 0 05 E ji Matar 3 Pen MOT mor Offset mm Offset mm OW Reference Reference Motor 2 0 05 FE Motor 4 re ror ror Offset 300 mm Offset mm Set position absolute Motor 1 0 05 mm Motor 3 mm oo Move To v Pos E Motor 2 0 05 mm Motor 4 Reference v Ref E mms o o Fark position Motor 1 blotar 3 0 mm Move To Motor 2 OQ mm Kotor 4 __Move To_ Parameter Sensor bending Position offset lo ror Hin Pros E mrm after each bend to park position Max Pos E mm Eror status CAN Error M1 CAN Error Me EAN Eror Ma EAN Error tig Motors off Stap Cancel Figure 81 Settings and test dialog for the longitudinal adjustment e The current sensor positions can be read from the Longitudinal Z positions mm field The offset values refer to the reference positions If you change this value you must reference the longitudinal adjustment again The check m
33. Measurement Camera E Acrivare wriFe Prakerin For fd Figure 49 Choosing where to get the license from Using this option you can start the software from any computer if a camera with valid license is connected Every camera needs an extra license 2 2 Program Start Only for LC6 and LC7 During the program start the connected sensors are referenced i e moved to their back stops No program input is possible during sensor movement This position defines the physical zero position Then the sensors are moved away from the machine again This position is defined during calibration As the program starts several background processes are started that enable 1 the connection with the Delem control and 2 the connection with the data M calibration computer LCAdjust Copyright by data M Engineering GmbH Page 64 aata LaserCheck LaserCheck Software Gate M veering Program Options Three different window types document types appear after the program start 1 Sensor windows 2 or 4 depending on the number of connected sensors If a sensor is not working correctly the corresponding sensor picture will not be opened Error check 2 Connection window Press brake UDP connection window or Cybelec connection 3 Connection window LCAdjust 2 3 Program Options The two connection windows are minimized only their main bars are visible in the lower left corner of the screen Figure 50 Minimized windows of LaserCheck prog
34. Spring Back Measuring Variants LIST OF CHOICES NO CORRECTION SAME ANGLE CORRECTION AS FOR BEND SAME DEPTH CORRECTION AS FOR BEND BY MONITORING END OF ANGLE VARIATION BY MEAS ANGLE WITH RESIDUAL FORCE BY MEAS FORCE AFTER OPENING ANGLE BY 00 CANCEL Figure 37 Cybelec control bends with spring back measurement variants NO CORRECTION No SBMP will be performed The beam simply reaches the BDC target angle by using the angle sensor and then returns to the TDC However a user defined correction can be introduced using the CORRECTIONS table at the top of the page Note that if the sensor is NOT ACTIVE the BDC will be reached based exclusively on calculated or programmed Y axes values without using the AMD Copyright by data M Engineering GmbH Page 51 LaserCheck Hardware Setup Gate en Configuring the Cybelec Control SAME ANGLE CORRECTION AS FOR BEND This is the same as above however the target BDC angle is corrected in real time using the CORRECTION VAL ANGLE obtained in a previous bend reference bend where a SBMP was active When this choice is selected an additional field appears on the right where the user must enter the number index of the corresponding reference bend The reference bend should show the same target angle and tooling as this bend otherwise bad results have to be expected A particular trick can be used to find all correction values at once and apply them subsequently for quicker product
35. TS TEXTS ON REQUEST REASON FILE FILE TEXTS TEXTS ON REQUEST REASON FILE FILE TEXTS TEXTS ON REQUEST REASON FILE FILE TEXTS TEXTS 3 Pe pRopucT ben co Oh LO EXECUTE Figure 33 Cybelec control Angle Meas System page 1 6 6 Longitudinal Adjustment Control with DNC The cyb file must also contain the normal parameters but in binary code This option must also be enabled in the LaserCheck parameter file Parameter 84 V Width Material Max Pressure R502 lt 502 BIN32 gt CR LF Material R28 lt 28 BIN32 gt CR LF Max Pressure R94 lt 94 BINS2 gt CR LF In order to work with the data M LaserCheck the cyb file must contain additional parameters Auxiliary Function F10 for positioning mode selection R111 lt 111 BIN32 gt CR LF Copyright by data M Engineering GmbH Page 42 LaserCheck Hardware Setup Configuring the Cybelec Control For the 2 sensor movement options Bending length R64 lt 64 BIN32 gt CR LF or Z1 and Z2 back gauge position R88 lt 88 BIN32 gt CR LF R89 lt 89 BIN32 gt CR LF For the individual movement of 4 sensors Z1 and Z2 back gauge position R88 lt 88 BIN32 gt CR LF R89 lt 89 BIN32 gt CR LF Sensor Z1 Position R2790 lt 2790 BIN32 gt CR LF Sensor Z1 Position R2791 lt 2791 BIN32 gt CR LF Copyright by data M Engineering GmbH Engineering
36. Within the log file you can read the protocol of the communication with the press brake control The folder rdgb VC10 contains files for the remote debugger The Registry folder contains the file autologin reg Normally you should not execute this file It is used to create an automatic login for the standard user LaserCheck in case more than one user exists on the LaserCheck computer The file CANOpenStack dil file is used for every hardware communication except USB If this file is missing you cannot control the motors any more e g for LaserCheck 6 or when using longitudinal adjustment The file ewfapi dll is used for the EWF writing protection See page 95 The file Hardware par contains additional information for the CANOpenStack dll LaserCheck par contains parameters for LaserCheck Do not manipulate this file manually If you change any parameter e g exposure time the change is saved to this file The file MEGSV dIl is used for the communication with the force amplifier via a COM port The file PCAN_USB is used for the communication with the longitudinal adjustment The file res_english dll is the language file of the LaserCheck program If this file is missing the program will be in German The file USBDII dll is used for the communication with USB interface cards Copyright by data M Engineering GmbH Page 96 LaserCheck Troubleshooting Gate un Automatic Longitudinal Adjustment 11 Troubleshooting The ang
37. _def is REF The negative limit switch on the left side of the machine must be connected to 101 the positive limit switch to 100 and the reference switch to IOS SignEnabl must be set for all connected limit switches and SignLevel for signal inversion Generally all switches should be contact breakers SignLevel is deactivated for all inputs Define RefSWMod according to the reference direction Processing sequence during reference movement to REF BitO direction of movement withdrawal path 0 Withdrawal in positive direction 1 Withdrawal in negative direction Bit1 direction of movement safety distance 0 in positive direction 1 in negative direction Default value is 0 All changes you make via the Schneider program are only saved if you temporarily disconnect the 24V power supply after programming Define LaserCheck parameter 169 in LaserCheck par Start of referencing mode action object Write access triggers reference movement from 1 LIMP 2 LIMN 3 REF neg direction of rotation 4 REF pos direction of rotation 5 Index pulse neg sense of rotation 6 Index pulse pos sense of rotation Comments 5 and 6 only supported from drives with index pulse Copyright by data M Engineering GmbH Page 86 C zta N LaserCheck Sensor V Adaption Control cate M neering Automatic Longitudinal Adjustment 7 4 2 Electrical installation Figure 6 2 Overview of all connections Connection Assignment CN1 Supply voltag
38. able Instead the beam is lifted to the TDC This considerably shortens the overall bending cycle time Moreover if the estimated final outcome is already smaller than the lowest tolerance there is no point in pursuing compensation because the angle is already closed too far Also in this case the beam is lifted to the TDC while an error message is displayed ANGLE OPENED and CLOSED values are added to the bend s desired angle to obtain the tolerable limit values Default values are 0 3 and 0 3 respectively We recall the possibility of using Known pre compensation values which need to be entered into the ANGLE row of the CORRECTIONS table at the top of the page and are used for time optimization purposes in controlled production settings COMPENSATION FACTOR This value overrides the default value if any specified by parameter 209 Special settings on the CORRECTION page allow the software to calculate a compensation factor given practical results introduced by the operator The procedure goes as follows 1 On this bend a full SMBP cycle must have been performed with an initial tentative compensation factor e g 100 in Semi Automatic mode generating some angle and depth correction values 2 Onthe CORRECTIONS page in the table at the bottom of the page there is a row labeled ANGLE Enter the obtained manually measured angles into the appropriate fields e g under column BEND This angle probably differs fr
39. above mentioned parameters in future sessions you need to save them onto the hard disk using the menu Program Save Copyright by data M Engineering GmbH Page 70 Jata N LaserCheck Laser Line Detection Parameters Gate n General Settings 4 Laser Line Detection Parameters Parameters of the laser linie detection Search width for laseriine per row h0 Pe Max distance of points from laser line Boo Poel Min brightness of laser line points 1100 Min length of laser line W Pie Comection with Polynom E Segmentation Activate segmentation Min number of pixels segment Max gradient difference segment poly Max deviation points segment poly Max distance of 2 segments IV Activate tool detection Angle of the die Wid deg Offset for dynamic AQ adaptation Pixel Filter Misc E Autom Brightness 0 0 min E Hardware Trigger Software Trigger Camera Pixel Clack MHz 115 min F Exposure Time ms h15 8 ar i Frame Rate Hz 11 C Camera 3 Settings C Camera 4 Fo fe The laser line is not always perfect due to environmental influences or different degrees of reflection off the surface of the sheet metal Sometimes it is not even possible to measure the laser line This can be due to too short flanges or existing flanges hiding the camera Therefore you can adjust the laser line detection parameters Open this window with Options Image processing or by pressing F3 Figure 61 Laser
40. ach four sensors with 2 motors each or four sensors with 4 motors each The box Serial Force Request must be activated if you connect the force amplifier to a control that uses serial communication e g Delem lf Realtime Measurement is active a measurement is done whenever the camera takes a picture Otherwise a measurement is only done when the control requests it Copyright by data M Engineering GmbH Page 67 anally LaserCheck LaserCheck Software Gate M veering General Settings If you Activate Writing Protection for C the writing protection of the LaserCheck computers drive C is active Also see 9 Automatic Write Protection EWF on page 95 Variable AOI must be activated if you use a LaserCheck system with variable AOI meaning LaserCheck 8 9 10 11 Also see 5 Variable AOI area of interest on page 75 LC TT must be activated if you use LaserCheck TT With I O via LPT USB off you must set how the LaserCheck sensor is controlled You can choose LPT or the parallel port for LaserCheck 6 and 7 USB for LaserCheck 8 and 10 or off if you use a network connection LaserCheck 9 and 11 Communication via UDP TCP OPC File determines the way the controls with serial communication interact with the LaserCheck computer UDP is used for Delem TCP for ESA and Bystronic OPC for Siemens Simotion and File for other controls lf for some reason a sensor does not work LaserCheck will assume that both sensors measured the same angle If
41. address to 192 168 144 183 3 Start the LaserCheck program and open the Press brake UDP network connection window Go to Connection Settings and enter the Delem controller s IP address 4 Now go to Delem and change parameters 4 and 5 to the values shown at the bottom of the small window in the LaserCheck program You also have to enter port 4660 as parameter 6 5 Run the program SaveRegistry exe in the directory hard disk WCE Tools in order to save the new registry settings IP address Remark This window must always remain open in order to be able to connect with a Delem press break control 1 5 3 Troubleshooting of Network Connection 1 In order to check the communication between the Delem control and the Data M LaserCheck device you can enable the display of all messages exchanged between the two systems in the menu View Messages of the press brake connection window 2 Check if the network connection cable is connected correctly and try to ping the Delem Control 3 Do the IP address setting and the Delem IP address match Do they use the same port 1 5 4 UAP Go to D data M Engineering LaserCheck Delem 2 For DAXXW Proceed to folder CE5 and copy the UAP datam dll to the directory harddisk Delem Bin uaps of the Delem controller 3 For DAXXT Proceed to folder CE6 and and copy the UAP datam_uap_ CE6 UDP dll to the directory Configuration Delem UAP of the Delem controller 4 Execute the progra
42. al centre of the area of interest The parameter Number of measurements per sensor indicates how many measurements are executed before their average value is transmitted to the control The check box Visualisation enables disables the output of the results in every sensor window disabling increases the measuring speed Real Time Measurement allows an angle measurement triggered by the cameras The Timeout limits the process time needed for detecting an angle Sensor Positions The definition of the mounting position of the sensors must be set individually for each sensor By double clicking on the corresponding sensor entry Mounting position of the sensors Sensor OUneOtt LettRight Front Back Right 2 On Lett Back 4 Ut Right Front 4 Lett Figure 58 Sensor position the following dialog opens Position for Sensor 2 x on C oon i Ori Cancel 0 Left Right Front Back Figure 59 Definition of sensor position The individual radio buttons define the mounting position of the selected sensor If you only use 2 sensors both must be on the Left one in the back and one in the front If you have double definitions you will obtain the following type of error messages LaserCheck Windows Application x Error in Sensor position definition Check For double entries sensors 2 and 4 Figure 60 Error in case of double sensor position definition Important Notes If you want to reuse all of the
43. alue In contrast to the standard application this method also measures the bendingforces synchronizes them and sends them to the NLR For the tandem option 6 or 8 sensors are necessary When using 6 sensors the missing measurement values are calculated assuming that the two upper dies are at the same height Therefore the positions of the two missing sensors need to be calculated and reported to Cybelec When using 8 sensors the tangential deviations of the upper dies are calculated separately Besides the angle calculation it is also necessary to synchronize the sensor values This can be achieved through coordinated answers from both LaserCheck systems This ensures that both controls get an angle at the same time In order to get the average force the amplifier are not connected to the analog input of the NLR as usual but are read by LaserCheck via the GSVs serial output and are send to the NLR via an additional analog card after calculation Both machines can be operated separately when the tandem switch is deactivated 1 7 5 Hardware Two additional USB DA14 cards will be needed in order to use the tandem option Copyright by data M Engineering GmbH Page 55 ate N LaserCheck Hardware Setup Cete M eorn Wiring Schemes 1 8 Wiring Schemes 1 8 1 Wiring Scheme for LaserCheck 6 The following wiring schemes only show the parts that can be repaired by the end user Any other defects of the system will be dealt with by data M The conn
44. ample below Table 5 the pressure values were read off a manometer the values of the columns Range 1 to Range 4 were read off the force measurement dialog and the load was calculated from the pressure From this chart you can now obtain the limits for the different force ranges We have obtained the force limits 10 35 100 and 1 70t Copyright by data M Engineering GmbH Page 18 Jata N LaserCheck Hardware Setup Gate n Mounting of the Strain Gauges Load t _ Pressure bar _ Range1 Range2 Range3 Range 4 0 0 2 83333333 5 0 3800 10 2 18 0 4600 0 1200 14 1666667 25 0 7400 0 2000 17 30 0 2700 28 3333333 50 0 4920 39 6666667 70 0 7600 0 2530 56 6666667 100 0 3800 70 8333333 125 0 4700 85 150 0 5800 99 1666667 175 0 6800 113 333333 200 0 8100 0 2310 141 666667 250 0 2820 170 300 0 3400 Table 5 Sample chart for a sensitivity range determination You can now enter these values in the dialog of the LaserCheck program Do not forget to save the parameters 1 3 7 Connection of GSV threshold The threshold output of the amplifier can be used for Delem to detect the end of spring back This is an open collector output For example Use a free input on a DM10x module Connect clamp 11 SW1 to DM104 pin 5 Input Connect clamp 15 GND to DM104 0V Use a pull up resistor 1kOhm between the input and 24V Threshold output sensor parameter 16 of the Delem control needs to be set to 1 and the option with threshold must be set
45. arks of each motor indicate its error and reference state e After being referenced the system can be positioned by using Set position absolute and the Move To button The Fields v_Pos and v_Ref indicate the speeds for referencing and normal positioning e Inthe field Park position you define a position for the longitudinal adjustment to which the sensors will move when they are requested to move to their parking position e The Position offset value is added to or subtracted from the target positions sent from the press brake control lf a motor error is indicated you can obtain a detailed error message by pressing the according CAN Error Mx button Remark If you want to reuse changed parameters after the next program start you will need to save them Copyright by data M Engineering GmbH Page 92 Tr LaserCheck Material Surface Control Engineering Automatic Longitudinal Adjustment 8 Material Surface Control In the dialog Correction factors for materials and sensors Ctrl K you can enter individual correction values for all sensors In addition to that you can define various camera settings for as many material types as you like Correction values for Sensors and Materials x Maternal Correction Aluminium F Material Accept Accept for all Maternal Correction Yalues Exposure Time left jao0 tee E Senso Ange Exposure me right 0 00 deg Sensor Cancel Figure 82 Dialog for correction values
46. at the changeover point If the crowning is adjusted right at the pinch point verify that no additional deformations of the C frames due to the movement of the bending beam are introduced otherwise the spring back calculation will be incorrect Back gauge and ram mounting The back gauge must be mounted in such a way that it does not influence the force measurement during the movement The usual design with the guides mounted on the side frame requires careful adjustments and exact parallelism of the guides The cylinder guides must also be exactly parallel as the movement on distorted guides may affect the reference force Ambient light As the LaserCheck sensor is an optical system you should avoid disruptive ambient light such as spot lights direct sun light Rigidity of the C frame The softer the C frame the higher the deformations during the bending process and the better the results obtained for the force measurement Minimum sheet bending length The minimum bending length depends on various factors such as The rigidity of the C frame The design of the machine The material of the sheet metal The thickness of the sheet metal The V width of the die The following rules generally apply The minimum bending length becomes bigger e the bigger the machine e the larger the V angle at a lower force e the thinner the material e the lower the Young s modulus of the material a Positioning of the ram The precision of the ram posit
47. between Delem and Cybelec is that Cybelec requests an angle and thereupon receives the newest one Delem on the contrary has an open input to which angles are sent to continuously 6 2 Cybelec 6 2 1 Option 66 Activate option 66 on the Machine Parameters page by replacing the with a 02 CAD Interface page 52 Front sheet supports H3 H4 03 Communicetions LINK7000 3 Deflection compensetion 08 Message interpreter 30 Angle measuring device 55 External commands 32 3 points bending 57 Thickness meas by N2X MS1 MS2 58 PRESSURE 2 and F10 page 60 Angle measuring device 38 Back sheel supports H H2 39 Punch mounting Po 62 PL Presse 41 Schraegstellung 64 CAN 42 Bending assistance 65 Second angle measure 44 Thickness meas by serial port 67 Bending knowledge base 68 Force amp crowning calculet V2 0 46 Angle measure with LAC 69 Force sensor with variable gain 47 Punch changer 51 Die axes M1 M2 71 Swing axes MENU PRODUCT BEND CORREC THONS lf LaserCheck is continuously taking measurements the beam is lowered at a constant speed without any stops Starting from the distance which is set in parameter 206 final approach the machine moves slower The speed is lowered even further when the machine approaches the BDC adjustable in parameter 214 advanced stop When the machine reaches the BDC the spring back measurement is done The machine is released with the speed se
48. by data M Engineering GmbH Page 33 LaserCheck Hardware Setup Gate en Configuring the Delem Control e Steps for Overbend approaching 2 Once the spring back angle is determined the machine will approach the final angle in n steps Information collected during these steps is used for the target angle approach e Delay before measurement in ms 100 Measurements will be taken after a delay of n ms in order to reduce potential vibration effects e Spring back measurement lf you deactivate this switch no spring back calculation will be performed Instead the expected spring back angle will be used as the real spring back value e Minimum correction distance for y axis in 1 100mm 1 If the relative position value sent from LaserCheck to Delem is below this limit during the bending cycle the Delem control will terminate the bend cycle If a relative position value below this limit is calculated we send an error to Delem because positioning below this value is not possible e Limit of force ratio for spring back angle determination 0 1 0 3 lf the force measured during unloading release is below this limit of the maximum force spring back can be calculated Otherwise the program continues to release the upper tool until the force ratio has fallen below the limit If the parameter is too small the sheet can potentially move rotate inside the die The value 0 3 means that if the force is getting below 30 of the maximum force t
49. c hard drive Connect the USB GSV interface and install the USB driver from the CD Connect the NLR card to COM2 on the PC via a serial cable Start LaserCheck exe 1 6 5 Sensor Distance and Pressure Sensitivity Control with DNC The sensor distance and pressure sensitivity control options use information sent from the ENC via the NLR card to the LaserCheck The programmed pressure and the die width are used to adjust the strain gauge amplifier and the sensor positions respectively Every time a mode change occurs or a new bending step is being loaded these data points are transmitted In order to activate these options on the Cybelec control the following settings are necessary You need at least the Cybelec software DNC and ENC version W Go to the Welcome page and enter 0607 into the maintenance line not for ModEva Entries in Machine parameters Angle measurement system page 3 a Other Parameter Reason 02 b File D dataM cyb 4 Copy the file datam cyb to D le The contents of the datam cyb file should be V Width Material Max Pressure R502 lt 502 DEC gt CR LF Material R28 lt 28 DEC gt CR LF Max Pressure R94 lt 94 DEC gt CR HLF Copyright by data M Engineering GmbH Page 41 LaserCheck Hardware Setup Gate n Configuring the Cybelec Control MACHINE PARAMETERS ANGLE MEAS SYSTEM 3 ST EEE TRANSMIT REPLY OTHER PARAMETERS REASON 02 FILE D datam cyb FILE TEX
50. can be higher 3 Pre bend angle a default 10deg The machine stops 10 before reaching the target angle 1 5 8 Sensor Parameters Sensor parameters are accessible on Delem control via Page 19 3 1 2 default access code 32157 These parameters have to be considered machine parameters They only have to be adjusted once for each machine 1 UAP_prog_y_pos flag pre value in 1 1000 mm Standard value 5 Upon release the press control verifies every x ms whether the programmed position is reached If so the sequencer sets a stop flag In order to prevent the upper tool from entirely releasing the sheet we reduce the programmed y position by this value so that the stopping condition has been achieved before the intended y position is reached 2 wait n 20ms before sending a measurement request Standard value 10 3 waitn 20ms before changing from decompression to compression mode Standard value 0 4 5 IP Address in TCP IP s network byte order of the LaserCheck computer default setting is 192 168 144 184 IP 192 168 144 184 O0xb890 Oxa8c0 47248 43200 Calculation 1440 90 Make 2 byte groups going from the last to the first value B890 A8CO Convert these values into decimal values B890 47248 A8CO 43200 These values are calculated and displayed in the LaserCheck program See page 10 in the LaserCheck software manual 6 UAP Port number e g 4660 This value must match LaserCheck parameter 121 7 Number of steps in order to a
51. chieve an overbend angle Standard value 2 Once the spring back angle is determined the machine will move to the final angle in n steps Information collected during these steps is used for the target angle approach Copyright by data M Engineering GmbH Page 30 LaserCheck Hardware Setup Gate en Configuring the Delem Control 8 Minimal movement of y axis in 1 1000mm Standard value 10 If the relative position value sent from LaserCheck to the Delem control during the bending cycle is below this limit the bending cycle is terminated lf a relative position value below this limit is calculated it is sent to Delem control as positioning below this value is not possible 9 Minimum force ratio RFiim during spring back calculation in Standard value 30 lf the measured force during release is below X of the maximum force spring back can be calculated Otherwise the program continues to release the upper tool until the force ratio has fallen below this value If this value becomes too low the sheet can move rotate inside the die 10 Target Angle offset for approaching programmed angle in 1 100deg Standard value 200 In order to be able to perform a spring back calculation we must be in the region of the target angle In order to prevent the system from overbending we need to approach the target angle with a safety factor such as 90 2 11 Maximum allowed spring back angle in 1 100deg Standard value 1500 12 Overshoot bef
52. computer If you choose Camera you can use the camera with any computer Copyright by data M Engineering GmbH Page 68 Jata N LaserCheck Image Processing and Angle Measurement Gate n General Settings 3 Image Processing and Angle Measurement Once you have established the connection between the LaserCheck device and the Delem network card the system can start measuring the bending angle If you want to change the measuring parameters you can open the dialog box Angle Measuring Parameter in the menu Options Angle measurement F2 The input is divided into 3 parameter groups 1 Image processing 2 Plausibility of the measured angle 3 Mounting position of the sensors Measurement Parameters o i Area of interest Pixel Sensor Plausibility of measured angle index 1 8x 55 v Difference fin deg from nominal angle to oN Top 90 Bottom 0 5 00 rn Max Diference fn deg between angles 140 Restrain search area to nominal angle Width fin pix of the search area at the bottom load save Sensor l lv Force double sided measurement Left 575 Right 1950 WUD pi AE Top 416 Bottom 819 Sensor Calibration Mounting position of the sensors Sensor Measured Inner Angle Sensor On Off Left Right Front Back Mirror Number of Measurements lv Visualisation y n 1 C2 C3 7 NLR idle Meas Figure 57 Angle measurement parameters The following parameters can be set Area of interest Search a
53. d in the LaserCheck program 2 In addition to the interactive control of the sensors all attached sensors are looked up and tested automatically when the program starts If an attached sensor does not function correctly it is deactivated automatically OFF state and its respective window is not opened 3 If you are calibrating a sensor with the data M calibrator or if the system is operating with the press brake control the live mode of each sensor should be deactivated 4 If you are calibrating a sensor with the data M calibration unit it must be in the ON state otherwise a calibration is not possible The file LaserCheck par contains all adjustable parameters of the LaserCheck program Each modification in the input dialogs of the program must be stored in the menu Program Settings Save Otherwise the new adjustment will not be available after the next program start AN arming Do not edit the file LaserCheck par manually Copyright by data M Engineering GmbH Page 66 a115 l LaserCheck LaserCheck Software cate M veering General Settings 2 4 General Settings You can open this window by clicking on Options General Settings Global Settings Cybelec DNC Data C Binary ASCII automatic Width Adjustment automatic Height Adjustment Motor Control with C cef ESI l automatic Lomaitird tdiuishrns C Ide op No of Axes Cy lt 2 E4 License from License for IV Serial Force Request Computer E Realtime Measurement Came
54. e In order to compensate for this variation the sensors are equipped with stepping motors These are connected to the parallel port of the LaserCheck computer via a special cable and controlled by the LaserCheck program During motor operation all user inputs to the computer are blocked The press brake control sends the programmed V width information directly to the LaserCheck computer This information will be updated before each new bending step The following parameters in the parameter file control the distance 67 1 0 System with 1 without 0 motorized V width control motorized V height control 115 60 max Range V Width in mm Parameter 67 In order to activate the program option automatic distance control parameter 67 must be 1 Parameter 106 Max course of the sensors in horizontal direction Also automatic V width adjustment must be activated in Options General Settings For the adjustment of the distance control you can use the following dialog Sensor width adjustment x kinetics Maximum speed 10 0 mmg Acceleration 200 mimes Calibrate kinetics Start Stop Frequency fi i amis Movement and traverse path calibration Ob Geman A m Move sensor C Sensor 2 Position absolute Endurance test Sensor 3 Set zero point Sensor 4 Muce yt Ee rare ero 5 mm Traverse path factor 45 46 Reference Cancel Figure 70 Dialog to adjust the sensor distance control units Copyrig
55. e VDC CN2 Interface for PROFIBUS DP CN3 Interface for CAN or RS485 CN4 24 V signal interface CNS5 Interface for STO safety function CNG Jumper for disabling STO safety function Figure 6 6 Pin assignment supply voltage Signal Meaning Number VDC Supply voltage 1 OVDE Reference potential to YDE 2 1 Information relates to pre assembled cables Figure 75 Connectors of the CAN motor Copyright by data M Engineering GmbH Page 87 oo f n LaserCheck Sensor V Adaption Control cate M neering Automatic Longitudinal Adjustment 7 4 2 1 Configuration and Connection of a HS CAN Every device in the network is identified by a unique node address which can be set as desired The address and baud rate are adjusted via DIP switches Bit6 54 baud rate High address ON one oh T mT o mmm 1234 res OFF Bit3 210 terminating resistor Low address ON on res OFF Figure 6 12 Parameter switch Switch settings 1 and 2 1 2 1 3 1 4 2 1 2 2 2 3 2 4 Address bit 6 5 4 3 2 1 0 Fieldbus address 127 default 1 1 1 1 1 1 1 Fieldbus address 25 example 0 0 1 1 0 O0 1 Switch setting 54 Baud rate Kbaud 1 50 2 100 3 125 4 250 5 500 6 800 7 1000 Figure 76 Dip switches for CAN settings Copyright by data M Engineering GmbH Page 88 Jata N LaserCheck Sensor V Adaption Control Gete eon Automatic Longitudinal Adjustment Figure 6 13 Pin assignment of CAN fieldbus i
56. e connected if their intersection angle is lower than Max gradient difference segment New line segments are created when the distance of a point exceeds Max deviation points segment Max distance of 2 segments is the highest possible distance from the end point of the last segment to the sum of all segments already connected Now we have one long connected line potentially representing the true laser line reflection on the sheet flange Then we take all the points from the beginning to the end of the segment and make a linear regression If tool detection is active and we obtain an angle smaller than the angle of the die we can be sure that we have detected the reflection of the lower die lf we have detected the die at the bottom of the image we take the end of the detected line add the value of the Offset for the dynamic AOI adaptation Parameter 30 pixels and restart the line detection process 4 3 Additional Camera Settings The parameters Pixel Clock Exposure Time and Frame Rate change basic settings of the camera The maximum possible value for the pixel clock is limited by the transfer rate of the USB bus This can be tested with the program uEye Cockpit installed on the LaserCheck computer The exposure time controls the image brightness The frame rate determines the number of images transferred per second All values are dependent on each other e The pixel clock divided by the image size is the maximum frame rate e The
57. e override the default value specified by parameter 208 Values as low as 10 15 are used in favorable situations Recall that current usable limits are set to 2 65 Values outside this range are taken as their nearest limit Copyright by data M Engineering GmbH Page 52 sete N LaserCheck Hardware Setup Gate en Configuring the Cybelec Control BY MEASURING FORCE AFTER OPENING ANGLE BY This choice is only available if at least one force sensor is present When this choice is selected an additional field appears on the right where the operator can enter the angle value by which the beam is lifted before reading X force and angle The default value is 5 This SBMP variant is more interesting when using CYCLE WITH N MEASURES by which this value is transformed into mm by a function of nominal tools material and target angle In fact lifting the beam by a few mm can be quicker than monitoring the force sensor because the NC can use its usual Y based control algorithms although usually less exact When a SBMP variant has been selected in the SPRING BACK CORR field of this bend several other bend related fields appear 1 6 12 Bends without Spring Back Measuring Variants LIST OF CHOICES WO CORRECTION FIRED CORRECTION IN DEGREES RECTION AS PREVIOUS BEND O00 CANCEL Figure 38 Cybelec control bends without spring back measurement variants NO CORRECTIONS For the remaining bends no particular corrective action will be perfor
58. e protective plastic film only just before the assembly Do not touch the strain gauges Do not bring any adhesive onto the white sealing surface ne 5a e nn wr rg tow t HF Figure 3 Strain gauge with adhesive At first look for an appropriate place to mount the strain gauges Preferably this is on the outside of the sides near the lower radius Make sure that the strain gauges cannot be damaged by any component parts throughout the bending process Mark the spot and remove all paint Drill two tap holes and deburr Grind down the surface with sandpaper granulation 240 Degrease it with acetone For the cleaning of the surface use a cotton bud which you need to move across the surface in one direction whilst turning it The surface is only considered clean if the cotton bud remains clean Copyright by data M Engineering GmbH Page 7 m Jatah LaserCheck Hardware Setup Cete M eorn Mounting of the Strain Gauges Thereafter do not touch the application area again and keep it free of dirt and grease Remove the clip that separates the hardener from the resin Knead the pack until the resin and the hardener are evenly mixed and have a uniform color Pay attention to the corners of the pack during mixing Mixing takes about three minutes The adhesive remains workable for 30 to 60 minutes after mixing depending on ambient conditions Take the strain gauge out of its packaging and remove the protective wrapping Do
59. eaes 33 MANN E icesdtee vain E A E 56 Decompression distance esseere 30 Cybelec Parameter Decompression speed ceeccccceseeeeeeeeeeeeeeens 30 Closed loop cycle ad scacnsccanosecasestsotsataiisantadaknneaads 46 Delay before measurement senseseesees 34 Cybelec Parameters Expected spring back esseesssseseseeeserese 33 200 Measurement SyStemM sssssssseesressessersee 44 IP ACCIreSS cccccssecccsececececeneeceseeeeeeceeenceeeues 30 202 FORCE detector scctcisincastrundousncumieenteendonteeunes 45 Limit Of force ratio ce eeccessssteeeeeeeesesteees 34 204 Angle MiIN MaX ccccccccccccccesessesssssssteeeees 45 Maximum allowed spring back cccccceee 31 206 Final approach ceeceeeseeeeteeeesteeseeeeees 45 Maximum spring back ceeceeesseeeeteeeeees 34 207 Treshold spring back cccccesecceeeeeeeeees 45 Minimal movement Of y aXiS ccccceeeeeeeeeees 31 208 Measurement force cssccccccceesssssreeeeeees 46 Minimum correcion dIStance cccceeeee 34 209 Compensation factor cccccccsssseeeeeeeees 46 Minimum force ratio RF lim cccccssssseeeeeeeeenes 31 211 Spring back measurement cycle 46 Mute 2 as reference cccccceseccceseceeeeeeeeeeees 31 212 Max time sping back measurement 46 Overbend angle ccccsssssscccsessescecseesseceeseees 30 213 Spring back measurement tolerance 46 Overshoot before r
60. ec better than 0 1 Delem DA 65 DA 69 DA66W DA69W Cybelec DNC 1200 ESA kvara Amada Bystronic Modeva Simotion 2 or 4 sensors in parallel 100 000h 10 000h 2M 204 206 173 3 5 Page 101 LaserCheck General Specifications Weekly Checks LaserCheck 8 Sensors Length mm 120 Width mm 90 Height mm 40 Weight kg 0 6 LaserCheck 9 Sensors Length mm 120 Width mm 90 Height mm 40 Weight kg 0 6 LaserCheck 10 Sensors Length mm 105 Width mm 80 Height mm 45 Weight kg 0 6 LaserCheck 11 Sensors Length mm 105 Width mm 80 Height mm 55 Weight Kg 0 7 Control Computer Power Input voltage 24VDC input 9 26V max 60W Physical Size Length mm 229 Width mm 132 Height mm 64 Weight kg 1 7 Copyright by data M Engineering GmbH Engineering Page 102 GA f a LaserCheck General Specifications cate M neering Weekly Checks v S E 2 O i D x p W o ww Oe am O Gy S ca ma Os gt C aa oc gt o Ww W lt U pat D O 2 N Sot o Q o gt a5 ada fa gt T gt to i L gt i JACK Z 12V DC RS 232 serial ports power jack Figure 86 Back side view Copyright by data M Engineering GmbH Page 103 2111753 LaserCheck General Specifications cate M neering Weekly Checks USB ports HDD LED Power button Figure 87 Front side view Copyright by data M Engineering GmbH Page
61. ection of the USB cameras requires the following sequence USB Cameras gt Powered USB Hub gt Small USB Hub gt PC Remarks AN Maximum cable length between Cameras and USB Hub is 5m Maximum cable length between two USB Hubs is 5m Maximum cable length between USB Hub and PC is 5m 1 8 1 1 Stepping Motor Driver The stepping motor driver is located inside the sensor housing It controls the movement of the stepping motors and the status of the laser Note Please carefully check the position of the JP1 connector The mark 1 on the connector must match the 1 on the board Do not change the motor current with the potentiometer R7 It is adjusted to 1A phase In case of malfunction replace L297 L298 and T1 2101 O Otto LASER oto 50337 xs g 2K 0000000 m Figure 40 Stepping motor interface Copyright by data M Engineering GmbH Page 56 ate N LaserCheck Hardware Setup Cete M eorn Wiring Schemes Connection to LaserCheck computer JP1 Pin ed 1 5 Laser On OFF 5 24V_________ 6 PWRGND Ea Motor Enable 7 Motor CW CCW 5V__________ 8 Motor Clock Table 7 Connection to computer JP1 1 8 1 2 Internal sensor interface Inside the LaserCheck computer there is a sensor interface for the interaction between the parallel port of the computer and the stepping motor interface as well as with the amplification range settings of the GSV2 In case malfunction replace the drivers 74LS244
62. efault value of this field is 5 In degrees transformed into mm as a function of nominal tools thickness and target angle The purpose of this parameter is to determine the position of the first stop where the first angle measurement is taken 216b Step size The step size of this angle measurement cycle with stepwise approach can be modified Usually each intermediate step except the last one tries to cover half of the remaining distance to the target BDC There are various ways of influencing these steps The next step covers XX of the remaining distance e g each step covers 3 4 75 of the remaining distance 217 Delay before measures The default value of this field is 0 0s which is also the minimum value It has proven useful to wait a little while after the beam has been stopped before asking the sensor for a new measurement This allows the whole system to settle Sometimes vibrations in the sheet or other parts of the machine can affect the reading Waiting a little while can be the only way to overcome the problem albeit introducing further delays This parameter can also be adjusted in LaserCheck 218 Number of samples The default value of this field is 1 which is also the minimum value This parameter also applies to the step wise approach For the same reasons as explained for parameter 217 above it is sometimes necessary to ask for several subsequent measurements and use their average value This parameter specifies
63. elease ccccccesssseeeeeeeees 31 214 Advanced stop cceecccccessseeeeeeeeeeeeeeneees 46 Pre bend GIVE C esis sasracnncupsennsassieauncatassscciacasnaneee 30 215 External detection of spring back 47 Spring back measurement on sses 34 216 Cycle with N measurements c0cee 47 Steps for overbend approaching 34 216b Step SIZC eeeeeeecccccceeesseeeecesseseeseeeees 47 Switch Of MESSABES ccccccssssssseecccesseaesseeeees 31 217 Delay before measures cscceeeteeeeeteeees 47 Target angle for nominal approach 34 218 Number of Samples cccccccccceeessseeeeees 47 Target angle OffSet ccssssscccceseseesseeeeeeeenes 31 Copyright by data M Engineering GmbH Page 105 D awi General Specifications gata M LaserCheck Weekly Checks Target ratio for spring back calculation 34 Real Time MeasureMent ccccccsssccessssseeeeeens 68 Use treshold for spring back detection 31 FROM OU Cl a crea asians ice sesae E 69 E S Electromagnetic compatibility cccceeeeees 16 Bo ae ceca teen cues se E EEE E 97 AAE DEEE date ae cag EEE E ne beans oo E 16 Safety of laser CEVICES cccseseccccsssseeeeeeeeeeeeeees 97 Error messages ON Dele cccsseeeecseeeeeeeeeeees 35 Sensor MOUNTING icssdessccssacnaraassansarescenaceassesnaysanonant 20 Exposure TIME ssessssssessesseesersrrssesseesrrsreesesseesnee 93 Sensor V
64. emarks In order to ensure that good conditions for using force sensors are in place you should consider the following Install force sensors Prepare an excel list to record readings Program a typical task with typical tools and typical metal sheets Go to the page CORRECTIONS and look at the field SENSITIVITY Record this value Enter Semi Automatic Sensitive Mode see Note 0 Do not put in a sheet Press pedal and reach BDC Keep the pedal pressed Read force sensors and Y1 Y2 positions and record them Press the or button The upper beam should rise Make sure that both Y1 and Y2 have moved up by the same amount and reached the same final position If the beam does not rise try to determine why See Note 1 If possible you could also install two comparators dial gauges one on the left and one on the right to check for overshoots See Note 2 e Press the or button The upper beam should descend Make sure that both Y1 and Y2 have moved down by the same amount and have reached the same final position Also check for undershoots See Note 3 e Now using the and buttons move the beam up and down in order to check the entire work space between the pinch point and the lowest possible Y position The force sensor s readings must remain constant all along If you observe changes they must be negligible compared to the expected readings during operation lf they are not negligible it is crucial that
65. et value at suitable points during the cycle The value corresponding to the machine s maximum force is not known and not necessary However care must be taken that the force sensor does not saturate when higher forces are in action DYNAMIC When automatically determined by the system NLR the force sensor s ADC value corresponding to 0 force will be displayed here POS The current analogue value read from the force sensor s ADC 204 Angle minimum maximum The default values of these fields are 75 and 160 respectively Angles outside of these values are considered unreliable 207 Threshold spring back measurement The default value of this field is 0 3 In degrees transformed into mm as a function of nominal tools thickness and target angle when using step wise approach In order to linearize the measured values the tension on the sheet is reduced with this value e g when there is a strong stick slip effect This parameter specifies how far the beam needs to be lifted off from the BDC before the 100 force and angle can be measured Use very little values e g 0 0 to 0 3 208 Measurement force The default value of this field is 10 In one of the SBMP variants the beam will be lifted until the force falls below a certain fraction of the 100 value measured at the BDC At this point the beam will stop and a new correct measurement will be taken the X value This parameter specifies the default value for thi
66. exposure time must be smaller than 1 frame rate 1000 Copyright by data M Engineering GmbH Page 72 achiev LaserCheck Laser Line Detection Parameters cate M reoring Detection Results 4 4 Detection Results The image below shows some characteristic items which the user of the angle measurement system should observe while bending 1 The green marker must be visible only when the segmentation option is activated in the sensor image If this is not the case the measurement is not taken due to the following reasons a Line is too short b Line angle is outside the limits c Laser line is too dark all points are below minimum brightness for line points 2 The blue lines show a V shaped region defined by the set angle given by the Delem control and by the upper and lower limits of the deviation from the set angle Parts of the laser line must be inside this region the rest of the line points are rejected Green marker Laserline Dynamic AOI adaptation Figure 62 Image of a detected laser line 3 In this example the image shows some perturbations at the bottom The AOI is automatically adapted to the top In this area 2 potential laser line segments are visible but they are rejected as either their angle is below the die limit angle or their length is too short Copyright by data M Engineering GmbH Page 73 Jata lV LaserCheck Laser Line Detection Parameters Gate un Short flange compensation Figure 63 Zoom of
67. ghly lasts for about 10 ms With insufficient values the sheet metal will oscillate when approaching BDC With excessive values it will take too long to reach the BDC Hence first try lower values and increase them until you have found a configuration which is stable for most bends 211 Spring back measurement cycle The default value of this field is 0 3s but we recommend 0 1s The NLR card continuously compares the current angle with an older one in order to determine when the angle ceases varying This parameter determines the time period between these angles Parameter 211 must be short for the lifting speed to be high it must be longer for lower speeds If the given time period is too big the risk of releasing the sheet will be higher If it is too short there is an increased risk that the software will be too late at detecting the slower change of the angle and hence it will stop too early Moreover the process can be influenced by random non repeatable incidents such a sensor noise or slip stick effects 213 Spring back measurement tolerance The default value of this field is 4 For technical reasons precision this parameter is given in digital angle values not in degrees Under continuous measures the NLR steadily compares the current angle value with an earlier older one to detect when the angle ceases varying This parameter determines by how much the angles must differ Common values are between 2 and 4 which typically corres
68. gle measurement system is used This is useful in cases where the geometry does not allow any usage of LaserCheck e Reference bend with sub bend method 3 We use the LaserCheck system without spring back calculation The spring back angle of the reference bend is directly applied The number of the reference must be lower than the current bend which will use this reference bend 1 5 10 Spring Back Calculation 1 5 10 1 Working Principle On the picture below we have an exampleof a bending cycle with spring back measurement 1 Steps 0 2 pre bend and nominal angle approach 2 Steps 3 4 unloading for spring back calculation 3 Steps 5 6 overbend angle approach 120 21 400 21 380 24 360 21 340 Position 1 100 mm Lr mm j Step Figure 27 Example of a sensor bending cycle Copyright by data M Engineering GmbH Page 32 LaserCheck Hardware Setup Engineering Configuring the Delem Control 1 5 10 2 Bending Process Parameters The bending process parameters can be accessed via the menu Options Bending process Function key F4 Bending Process Pararneters Expected springback angle 2 deg OK Compensation factor for springback angle 115 EA Cancel Left comection angle 0 deg Right comection angle o deg Steps for Overbend Approaching 2 Delay before measurement 100 ms i Springback measurement Minimum comection distance for y as i 1 100 mm Limit of force ratio for spr
69. gle measuring device 61 Diagnostic Bs Wey 41 Schraegstellung 65 Force amp crowning calculat v2 0 51 Die axes M1 M2 MENL PRODUCT BENCI CORRECTIONS EXECUTE Figure 31 Cybelec control Options page 1 6 3 Connection with Cybelec If you use a Cybelec control you have to adjust the control properly and then click on the Cybelec connection window go to Connection Cybelec Settings and choose the correct COM Port usually COM1 Settings of the Serial Interface Cybelec x COM Options Control Connection Timeout for Restart in z 20 Toggling of OTA and ATS Fort Baud Rate Data Bits Parity Stop Bits Flow OTR DSA M ATSACTS M 3ON40FF cence Figure 32 Serial connection interface settings If you can t establish a connection to the Cybelec control check the following 1 Did you choose the correct COM port 2 Are all cables connected up properly Copyright by data M Engineering GmbH Page 40 LaserCheck Hardware Setup Gate un Configuring the Cybelec Control 1 6 4 Installing LaserCheck Software on ModEva 15 For LaserCheck 8 9 10 and TT the LaserCheck software can be installed on the Cybelec PC You will need 2 USB ports to connect the sensors and one USB port for the interface to the GSV amplifier LaserCheck 9 and LaserCheck 11 require a free GigE connector Install the uEye driver from the LaserCheck CD Then copy the folder data M Engineering onto the Cybele
70. gs Attention Flags 7180 7199 must not be used elsewhere Flag 7180 I is used to stop the machine Flag 7181 I is adjusted after successful bend Flag 7182 I is the LaserCheck error flag Flag 7188 I is used to set the sequencer message indicating reset reference bends for learnt bending Flag 7184 O is used to reset the references of the learnt bends of the robot This flag is also used when the machine switches to Stop mode C_STOP flag Flag 7185 I indicates active sensor supported bending Flag 7186 O When set it prevents a reset of the reference from mode change to Stop mode Flag 7094 O Indicates Robot Mode Flag 7191 O Indicates that crowning is in position I Flag is set inside the UAP O Flag is set externally to check the UAP Copyright by data M Engineering GmbH Page 29 Jatah LaserCheck Hardware Setup Gate en Configuring the Delem Control 1 5 7 General Machine Parameters These parameters are accessible on Delem Control via Page 19 3 1 Sensor Parameters 1 Decompression speed default 3 mm s The decompression speed should not exceed 3 s Reduce the decompression speed according to the tool geometry if necessary 2 Decompression distance default 2mm During the spring back measurement the ram releases the sheet This parameter limits the maximum upward movement of the pressure cylinder For certain materials with high spring back angles or larger V openings this value
71. guring the Cybelec Control 1 6 10 Easy Use of Spring Back Measurement Pages A degree symbol appears in the top right corner of BEND NUM BEND 2D BEND 3D and SPRING BACK pages By clicking on it a dialog window is displayed whose purpose is to reach the SPRING BACK page quicker without first displaying the CORRECTIONS page This is achieved by simply clicking on DISPLAY SPRING BACK PAGE at the bottom of the window Also you can initialize SPRING BACK page fields for all bends following common user defined rules This is achieved by first programming the various fields and then clicking on INITIALIZE ACCORDING TO THESE PARAMETERS When appropriate the operator can use the SPRING BACK page to further refine the programming To simply quit the window with no other effect click on QUIT BEND 37 3CY__cR_J PROGRAMMING i SENSOR AND METHOD ANGLE MEASUREMENT GENERAL AUTHORIZATION NO STOPS BEFORE SPRINGBACK MEASUREMENT 1 STOPS AFTER SPRINGBACK MEASUREMENT 1 BENDS WITH SPRINGBACK MEASUREMENT ALL oz P MEASURE EVERY N PRODUCTS _ BENDS WITHOUT SPRINGBACK MEASUREMENT SA NO CORRECTION TO METHOD SPRINGBACK MEASUREMENT Cq RETURN AND STOP IF REMAINING FORCE BELOW 3 TOLERANCES ANGLES TOO OPEN F zar S A ANGLES TOO CLOSED s AS A COMPENSATION FACTOR a FO FO Y1 Y2 DISPLAY SPRINGBACK PAGE cq INITIALIZE ACCORDING TO THESE PARAMETERS QUIT Figure 36 Cybelec control Sensor and Method Angle measurement 1 6 11 Bends with
72. h Cybelec 4 Installing LaserCheck Software on ModEva 15 5 Sensor Distance and Pressure Sensitivity Control with DNC 6 Longitudinal Adjustment Control with DNC 7 Programming Machine Parameters 8 General Installation Remarks 9 Programming Bends 10 Easy Use of Spring Back Measurement Pages 11 Bends with Spring Back Measuring Variants 12 Bends without Spring Back Measuring Variants 13 Spring Back Measurement Results andem Option for Cybelec 1 General 2 Installation 7 3 Tandem Definitions 1 7 4 Mode of Operation 1 7 5 Hardware 1 8 Wiring Schemes SN ee ee ee ee ee a a oa a d 6 6 6 6 6 6 6 6 6 6 6 6 6 1 7 T vE ve 7 j j j Copyright by data M Engineering GmbH ata IM Gr Page 2 Engineering Jate N LaserCheck Hardware Setup Gate en Introduction 1 8 1 Wiring Scheme for LaserCheck 6 56 1 8 2 Wiring Scheme for LaserCheck 7 60 1 8 3 Wiring Scheme for LaserCheck 10 61 1 8 4 Wiring Scheme for LaserCheck 11 62 2 LaserCheck Software 63 2 1 License 63 2 2 Program Start 64 2 3 Program Options 65 2 4 General Settings 67 3 Image Processing and Angle Measurement 69 4 Laser Line Detection Parameters 71 4 1 Plausibility 72 4 2 Segmentation 72 4 3 Additional Camera Settings 72 4 4 Detection Results 73 4 5 Short flange compensation 74 5 Variable AOI area of interest 75 5 1 Die Definition 75 5 2 Switching the AOI 75 5 3 Additions for LaserCheck 10 and 11 76 5 4
73. he spring back angle can be calculated if the force is still above 30 the beam must be released more e Target Angle for nominal angle approach in deg 2 In order to be able to perform a spring back calculation we have to be in the region of the target angle To prevent the system from over bending we approach the target angle with a safety factor for example 90 2 e Maximum spring back angle in deg 15 lf the calculated spring back angle is above this limit an error is sent to the Delem control e Target ratio for spring back angle calculation 0 1 0 1 During the unloading process the system uses this value to extrapolate the final unloading position 0 1 means that the target force is 10 of the maximum force measured e Force limit points for overbend pos calculation 0 1 0 7 During loading only force points will be collected which have a force value above this limit e 1 step spring back cycle in deg 0 3 Opening angle before starting the spring back measurement This opening will take out some forces caused by friction between sheet and die A typical value is 0 3 Remarks 1 Every time the LaserCheck system is connected to the Delem control some of these parameters are sent from the Delem control to LaserCheck and are overwritten 2 If you want to change them permanently you must do so in the Delem control 1 5 11 Monitoring LaserCheck Delem Operations 1 Open the Delem window for messages exchanged be
74. hing according to this picture For the connection of the force amplifier see also 1 3 2 Wiring of the amplifier Sensor 2 USB Hub Sensor 1 NLR NOT LaserCheck computer DA40 Amplifier Cybelec GND COAX Cable Cybelec Tara DA40 lf you use LaserCheck without a computer you must connect everything according to this picture For the connection of the force amplifier see also 1 3 2 Wiring of the amplifier or on the next page USB Hub oT NOT PPY USB I O card COAX cable DA40 COAX cable anpii dii Copyright by data M Engineering GmbH Page 37 Cate lt lE ngineering LaserCheck Hardware Setup Configuring the Cybelec Control PJ AMP SUB D MALE CONNECTOR 3 2x0 259 1N4 p04 L a 2 E 2 af le _ i a034 8 Amplifier GSV 2 USB INPUT OUTPUT BOARD AO SO TO me ge a at gi a tL The J ae l i 5 a Amplification factor P Dimis GAENT 3 5 mW anal IO a USB Adapter GSU _ Bn Wh 17 12 2013 14 02 36 dE dE NOT A B1 Synchro Control Sheet 1 1 aa ee eS aS a ee ee ee eee Copyright by data M Engineering GmbH Page 38 LaserCheck Hardware Setup Gate en Configuring the Cybelec Control 1 6 2 Configuring the Cybelec Software In order to work with the data M LaserCheck parameters must be set up on the Cybelec control You need a Dongle to get the options Nr 60 and or 65 2 Goto Machine parameters gt Op
75. how many values are being read off This parameter can also be adjusted in LaserCheck 220 Speed spring back measurement This speed will be converted into mm sec as a function of BDC angle thickness and tools The beam will rise with this soeed during the spring back measurement cycle thus adapting to the bending conditions especially to the die opening This speed is limited to the maximum upward bending speed parameter 13 on BEAM page 222 Measurement dynamic offset This machine parameter defines whether the measurement of the force offset is done at TDC or at SP The measurement at TDC is done at the beginning of each cycle when the ram is at TDC The measurement at SP is done just after the ram passes the SP even if the downward motion is still active Remarks 1 Measurement force parameter 208 in machine parameters should be changed according to the material used e Alu 15 25 e Steel 10 20 e VA 5 10 Copyright by data M Engineering GmbH Page 46 sete N LaserCheck Hardware Setup Gate un Configuring the Cybelec Control 2 In Machine parameters go to page Angle measurement system The value 3600 for 90 corresponds to a minimum angle parameter 204 of 75 However if you would like to use a different minimum angle you must adapt the value for 90 3 You should also adapt the value for the speed of the spring back measurement Parameter 220 according to thickness of the metal sheet 1 6 8 General Installation R
76. ht by data M Engineering GmbH Page 81 LaserCheck Sensor V Adaption Control Gate n Automatic V Height Adjustment In this dialog you can adjust the kinetics of the sensor movement maximum speed acceleration start stop frequency If you install the software on the computer for the first time you must also calibrate the computer by pressing the Calibrate kinetics button You can move each sensor individually by first selecting the desired sensor then entering a value into the Distance field This is a relative distance A negative value moves the sensor to the machine center a positive value moves it in the opposite direction In order to start the movement press the Move sensor button When you adjust the sensors move the sensors to a position about 1 mm from their back stop Adjust the laser and the camera in such a way that the laser beam is centered Then save the zero point by pushing the Set zero point button From then on this point can be reached immediately by pressing CTRL S The zero position can be tested by pressing CTRL R The sensors will move synchronously inwards to their mechanical back stop position They will move for the duration corresponding to the distance of their maximum course Parameter 106 Remark If the sensors are not referenced correctly the angle measurement result will be erroneous as the sensor position with respect to the sheet will be wrong 7 2 Automatic V Height Adjustment The press brake
77. image of the CF card after finishing the setup We recommend using ghost Symantec to make this image For this open the LaserCheck computer s cover remove the CF card and put it in a CF card reader Copyright by data M Engineering GmbH Page 95 Jata N LaserCheck Contents of the LaserCheck folder Gate n Automatic Longitudinal Adjustment 10 Contents of the LaserCheck folder Since the folder D data M Engineering LaserCheck contains a lot of data here is a quick overview of the functions of some of the most important files The Calibration folder contains backup files of the Kalib dat data so that changes can be undone The Cybelec folder contains datam cyb You have to copy this file to the press brakes drive D Please also use the information given in 1 6 4 Installing LaserCheck Software on ModEva 15 on page 41 The Delem folder contains the folder CE5 with DATAM dil and the folder CE6 with DATAM_UAP_CE6_UDP dlil Please also use the information given in 1 5 4 UAP on page 28 The Data folder contains the Kalibmatrix files for each tool for each sensor These files are created when the sensor is calibrated while the option short flange compensation is active The Documentation folder contains the most recent version of the LaserCheck Manual The Driver folder contains lasercheck sys The Logs folder contains the log files You can create a log file by clicking on the connection window and then selecting Options Log file
78. ingback angle determination 0 3 Target angle for nominal angle approach 2 deg Maximum springback angle 15 deg Target ratio for springback angle calculation 0 1 0 03 deg Ist step springback cycle i Display and Measurement of last bend step Fe Measure after o S Figure 28 Dialog of the bending process parameters The first 4 parameters in this dialog must be adjusted for each bend in manual and automatic mode If you write a program you must adjust these parameters beforehand These parameters are sent to LaserCheck before each bend If the values are 0 the LaserCheck control will use its own default values e Expected spring back angle in deg 2 This value depends on the material and the V angle used If this value is too far away from the actual spring back angle the machine will perform more cycles in order to lift the upper tool until the Minimum force ratio RF has fallen below the limit RFiim Moreover the results become less precise the more cycles are performed e Compensation factor for spring back angle in 115 The calculated spring back angle will be altered by this compensation factor If value 100 no changes will be made If value gt 100 the angle decreases If value lt 100 the angle increases e Left correction angle in deg 0 e Right correction angle in deg 0 The following parameters are machine parameters which depend more on the machine than on the bend Copyright
79. ion 1 First one of the SBMP variants is selected for a certain bend say bend 1 while other bends serve as reference bend 2 Then the product is bent in one go generating some ANGLE and DEPTH correction values for bend 1 3 Finally the SPRING BACK CORR field is switched to SAME ANGLE CORRECTION AS FOR BEND and the number 1 is entered as a reference bend i e the bend now refers to itself The SBMP can now be switched on again in regular intervals in order to look for material discrepancies SAME DEPTH CORRECTION AS FOR BEND Similar to the above except the obtained DEPTH correction is used instead of the ANGLE No AMD is used This option is interesting because beam control using an AMD is usually slower than the familiar Y based beam motion control However it has to be considered as less robust than the previous choice as variations in the sheet characteristics cannot be taken into account The same observations concerning the reference bend and related tricks apply as with SAME ANGLE CORRECTION AS FOR BEND BY MONITORING END OF ANGLE VARIATION This method of spring back requires real time measurement but no force sensor is necessary If the upper tool is lifted slowly at constant speed the angle will initially open increase at a relatively high constant rate but subsequently it will cease changing and will remain constant until the sheet is released However it is possible to detect a point where the sheet is almo
80. ioning has an important influence on the overall bending result The ram must not overshoot and the minimum pressure of the hydraulic system must guarantee an upward movement decompression cycle Copyright by data M Engineering GmbH Page 6 Jata N LaserCheck Hardware Setup Cete M eorn Mounting of the Strain Gauges e Limitations due to the material e Optical properties no bright steel no brushed surfaces parallel to laser beam e No rusty surfaces as it results in high friction between sheet and die e High yield point due to friction the spring back measurement has a proportional error relative to the spring back angle The higher the spring back the lower the bending accuracy e Collision between LaserCheck sensor and sheet metal e Inthe case of a counter bend care must be taken to ensure that a collision between the LaserCheck sensor and the sheet is avoided e Hydraulic crowning In the case of hydraulic crowing it must be ensured that the hydraulic crowning is in position before the machine stops at the mute point otherwise the reference force measurement tends to be wrong 1 3 Mounting of the Strain Gauges Mounting the strain gauges consists of two main steps The first one is gluing the strain gauges onto the machine s C frame The second step is wiring the strain gauges to their amplifier and to the LaserCheck computer 1 3 1 Gluing Caution Do not take the strain gauges out of its packaging before mounting Remove th
81. k 6 sensor Check e that the mounting screws are tight e that the guide ways are parallel e the measured angles with a metal part of known angle e whether the connectors and cables are tight and not damaged lf necessary clean the control computer Carefully remove dirt and dust from inside the housing Copyright by data M Engineering GmbH Page 100 LaserCheck 13 General Specifications General Specifications Weekly Checks Engineering Remark Technical specifications are subject to changes without notice Environmental Characteristics Operating Ambient temperature Relative humidity Non condensing Vibration random RMS Non operating Ambient temperature Relative humidity Non condensing Vibration random RMS General System Computer Housing Operating system Image processing Laser Measuring frequency Precision per sensor Supported controls Number of sensors Sensors Laser Life Time At 0 C At 40 C Safety Laser class LaserCheck 6 Sensors Length mm for max course 65mm Width mm Height mm with mounting block Weight kg LaserCheck 7 Sensors Length mm Width mm Height mm Weight kg Copyright by data M Engineering GmbH 5 to 40 C 8 to 90 0 15G for horizontal 0 1G for vertical 10 to 50 C 5 to 80 0 5G rms XYZ Industrial PC with Atom D525 Mini chassis for wall mounting MS Windows XPE uEye USB Cameras 5mW Laser diode 5 6 measurements s
82. lack Stepping motor Figure 45 Wiring of the sensor Copyright by data M Engineering GmbH Page 59 Jata N LaserCheck Hardware Setup Geta eon Wiring Schemes 1 8 2 Wiring Scheme for LaserCheck 7 There is a module on the inside of the sensor which controls the stepping motor o Motor PEE Laser TMCM 110 R5232 USB Connector 1 a 7 Black 2 4 7 f White Green USE female con a 1 diat Ried 4 Z oree F White J 22 10 2010 11 31 86 Sheet 1 2 a Copyright by data M Engineering GmbH Page 60 Jata N LaserCheck Hardware Setup Ceta M onn Wiring Schemes 1 8 3 Wiring Scheme for LaserCheck 10 LAS EF 5 Digitaler Output i Camera UL 1548LE M ee ee es ee E Sig ont I Collector _ 3 Enim cl oA A Ma Sensor Connector 4p LaserCheck 18 HM H8 2810 11 15 46 Sheet 1 1 Lo 6 ni i R Datai i Datai 5 GMD BK O aa ae ee ees Copyright by data M Engineering GmbH Page 61 LaserCheck Hardware Setup Wiring Schemes 1 8 4 Wiring Scheme for LaserCheck 11 ae ee oes Sig T tate Jie ur i ry amp Wine 12 V 160 mA 24 V 90 mA Vin GND U 1542LE M Einbaustecker 4p 1 A Z a B ii C ey eee eee eee eee eee eee or Gata lM Engineering Copyright by data M Engineering GmbH Page 62 Al Aang 1 a d Awad 5 Stecker iat TTT Wael E inteme erbindung Sensori M12 Einbaubuchse
83. le is wrong If you bend an incorrect angle check if the problem is LaserCheck or the press brake Take a sheet metal with a known angle and see if LaserCheck shows the correct angle If therefore the problem is at the press brake please create a log file and send it to support datam eng de You can find the standard log files in D data M Engineering LaserCheck logs They are named mess 0 log to mess 100 log Every time you activate the option Log file F7 a new file will be created If you deactivate the option Log file the log file will be closed Spring back measurement is wrong Test the positioning of Y1 and Y2 Make sure that there is no overswinging of the computed target position Otherwise these valueswill be missing in the SB calculation Test the positioning accuracy of the beam It must not exceed 0 01 mm The monitor does not start The chipsets Intel 82852 82855 will deactivate the external monitor if the system has already been booted once without a monitor connected The standard hot key for activating the monitor is lt CTRL gt lt ALT gt F1 Make sure that the keyboard is working otherwise reboot the system with monitor mouse and keyboard connected Use the PS 2 connectors as USB mouses and USB keyboards are not Supported by some of our older systems No connection with VNC If you connect a laptop to LaserCheck with a network cable and there is no DNS in the network set the TCP IP address of the laptop to 192 168 144
84. line detection Copyright by data M Engineering GmbH Page 71 sete N LaserCheck Laser Line Detection Parameters Gate an Plausibility 4 1 Plausibility The following parameters test the plausibility of the obtained result Search width for Laserline per row indicates the maximum range of values n pixel around the brightest point of a line If several brightest points are found in a line then the left most point is stored The tolerance indicates how many pixels a brightest point can be away from the laser line without being rejected Max distance of points from laser line With the help of linear regressions we calculate the average laser line only taking points into account which are separated by fewer pixels than the indicated value Min brightness of laser line points In each line we search for the brightest point having at least the minimum brightness The value varies from 0 for a black point to 255 for white one Min length of laser line If the detected line is shorter than this value it will be rejected Correction with polynom or polygon Short flange compensation is automatically active for sensors with AOI It is used to measure short flanges with a minimum error 4 2 Segmentation First we try to detect anything that looks like a laser line The result is a list of non continuous line segments The number of segments is controlled by Minimum number of pixels per line segment Segments can b
85. m SaveRegistry exe in the directory nard disk WCE Tools in order to save the new registry settings IP address Copyright by data M Engineering GmbH Page 28 LaserCheck Hardware Setup Gate un Configuring the Delem Control 1 5 5 Sequencer Modifications The Delem sequencer txt or seq_inp txt must be modified In order to do so and hence stop the machine the Y_T flag must be defined Flag 7180 is used to stop the machine via the tandem flag Examples With robot Tandem LaserCheck uses Flags 7180 and 8039 flag to monitor programmed y postion Flag 7185 Sensor bending is active skkkkkkkkkkkkkkkkkkkk 1150 Y_T 8039 SRFF 7089 C_STOP 7092 7095 DN 7180 UP Y_MUTE1 7185 UP 7180 7 094 UP Y_MUTE1 Y_MUTE2 UP Y_PINCH 7185 Y_BP or standard machine sample skkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxk LaserCheck skkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxk J Clear Sensor bending in UDP 900 7185 SRFF UP Y_UDP 7185 Tandem LaserCheck uses Flags 7180 and 8039 flag to monitor programmed y position Flag 7185 Sensor bending is active 901 Y_T 8039 SRFF C_STOP DN 7180 UP Y_MUTE1 7185 UP 7180 skkkkkkkkkkkkkkkkkkkk With GSV threshold 901 7187 102 05 7187 is used to stop the machine when threshold is off 902 Y_T 8039 SRFF C_STOP DN 7180 UP Y_MUTE1 7185 UP 7180 7185 Y_STAT5 7187 1 5 6 Sequencer Fla
86. med The AMD will be used to approach the uncorrected nominal angle at BDC However it is expected that the user will modify the situation by entering special corrective values pre compensation values on the SPRING BACK page FIXED CORRECTION IN DEGREES When this option is selected an additional field will appear on the right where the user can enter the desired correction in degrees The CORRECTION VAL ANGLE field will initialize each bend with this value The SPRING BACK CORR field will be initialized together with SAME ANGLE CORRECTION AS FOR BEND The bend itself is taken as the reference bend SAME BDC CORRECTION AS PREVIOUS REFERENCE BEND The depth correction value of the corresponding reference bend will be reused The SPRING BACK CORR field will be initialized together with SAME DEPTH CORRECTION AS FOR BEND For bends which are not compatible with the reference bend NO CORRECTION will be displayed SAME ANGLE CORRECTION AS PREVIOUS REFERENCE BEND The angle correction value of the corresponding reference bend will be reused The SPRING BACK CORR field will be initialized together with SAME ANGLE CORRECTION AS FOR BEND For bends which are not compatible with the reference bend NO CORRECTION will be displayed Copyright by data M Engineering GmbH Page 53 LaserCheck Hardware Setup Cete M eorn Configuring the Cybelec Control 1 6 13 Spring Back Measurement Results BEND E ey AUTOMATIC CORRECTIONS ANG
87. n Delem control e ERROR Angle and Force measurement Error with force and angle measurement e ERROR Force measurement Check for possible overload force limits in LaserCheck programmed force bending length e ERROR Angle measurement Check visibility and quality of laser beam 1 5 14 Tools LaserCheck reads the tool width and radius directly from the Delem control The tool height can only be read indirectly via the tool name Therefore the tools used by Delem must be saved in the LaserCheck parameters if either an automatic height adjustment is used or the option Var AOI is activated when using LaserCheck 8 9 10 or 11 That is the reason for the LaserCheck par extension Die definitions for Height Adjustment 300 0 Selected Die 301 OZU 053 55 302 OZU 045 55 303 OZU 051 55 304 OZU 063 55 305 OZU 351 100 306 OZU 352 100 307 OZU 353 100 308 OZU 354 100 In line 300 is the index of the active tool starting with line 301 there are first the tool names like the Delem control uses them and second the tool height You can save as many tools as you want Copyright by data M Engineering GmbH Page 36 Ge fe M LaserCheck Hardware Setup an uini Configuring the Cybelec Control 1 6 Configuring the Cybelec Control 1 6 1 Hardware Connection to the Cybelec An NLR Card must be installed in the Cybelec control If you use a LaserCheck computer you must connect everyt
88. ne The front and back sensors must be symmetrical to this plane The horizontal movement is done by the stepping motors of the LaserCheck sensors The movement is proportional to the V width of the die LC6 7 The vertical reference for the mounting of the sensors is the height of the die If you intend to use different die heights you must foresee a sensor height adjustment or use the option VarAOIl LaserCheck 8 11 The best solution is having pre selectable heights which are defined by bolts An automatic height adjustment is also available as an option The height of the sensor must be adjusted in such a way that the front edge of the die is not visible in the camera window The lateral movement of the sensors can be carried out by guide rails mounted onto the machine These guide rails must be aligned parallel to the machine s center plane and to the tool table with a deviation of not more than 0 05 mm For instance the sensors can be mounted onto the rails for bending support It is also possible to mount the sensors onto a fixed position This however reduces the flexibility of the system as now the bending always has to take place at the same point on the machine An automatic longitudinal adjustment is also available as an option All sensors without a motorized distance adjustment can be mounted on a variable die The calibration must be done externally Ensure that the calibration will copy the mounting situation exactly All
89. ng Do not use liquids based on alcohol or ammoniac e Inthe case of a malfunction of the control call a technician e Do not expose the control to direct solar radiation or to any other heat source e Do not place the control close to any magnetic equipment such as transformers motors or devices which generate interferences welding machines etc e Replace fan filters in regular intervals so as to avoid overheating 12 1 Safety of Laser Devices 12 1 1 Safety Instructions The work space in which the laser is mounted has to be flagged in accordance with the legal requirements in order to avoid any inadvertent damage of third parties The optical path should be kept clear of mirrors as dangerous reflections may occur In the case of a malfunction the device has to be shut down immediately 12 1 2 General Instructions Safety instructions serve for occupational safety and avoidance of accidents They must be followed In order to prevent you and your colleagues from injuries YOUR co operation is also required Please always work with care and be aware that dangers are often not obvious In order to ensure a safe operation the operator has to make sure that people working with or around the device have been informed about the potential dangers associated with laser radiation You can protect yourself from avoidable damages if you are familiar with the following national cooperative regulations for the prevention of industrial accide
90. nges that are set by the LaserCheck computer Turn on the press brake 24 V for the strain gauge amplifier Move the upper tool to the top dead center Check the supply voltage between clamp 14 and 15 12 28V Copyright by data M Engineering GmbH Page 13 GA f a l LaserCheck Hardware Setup cete Mi neering Mounting of the Strain Gauges 1 3 4 Strain Gauge Offset Adjustment Normally these adjustments are already set by data M This procedure is used to compensate initial deformations of the strain gauges Verify that the serial connection between your computer and the force amplifier has been established Apply the following procedure 1 Raise the beam to its upper dead center and mount the upper tools 2 Run ME GSV exe and select the Advanced tab 3 Click on Load Settings Select the manufacturer 4 Click on Offset adjustment 5 Set gain to x1 6 Set the data frequency to 100 Hz 7 Click on Save and save as User 1 User 1 corresponds to configuration 2 in the LaserCheck program 8 Close the program and switch off the 24V power supply of the force amplifier The new settings of the measurement amplifier have now been saved MSGs 2 1 Serial Number 07019345 1 1 4 7 x Configuration Stress analysis Advanced Sensor Recorder Administration Intertace Select mterface com Find mterface Settings Load Save Bipolar mode f Adiust ents Offset adjustment ero adjustment Unipolar m
91. not touch the strain gauge Using a spatula or similar tool carefully apply adhesive to only the SG Place the strain gauge onto the processed area and screw it down at once Gradually tighten the screws until the strain gauge sits flat on the surface Do not loosen the screws from here on since this could damage the SG Attention You must not move the SG once it has been in contact with the machine If you cannot mount the screws lift the SG then put the screws through the holes of the SG and screw them into the threads without the SG touching the machine surface Use the screws to pull the SG to the machine surface The hardening of the resin may take about 12h to 72h or even more depending on ambient air temperature During this hardening period you must neither move the machine nor the SG Moreover you should always keep a sample of the resin to check if the hardening is correct At ambient temperatures below 20 C the sensor should be warmed up e g with a hair dryer to max 70 C during the hardening process of the resin The sensor can be loaded after the adhesive resin in the bag has hardened Figure 5 Strain gauge DA 40 mounting example Copyright by data M Engineering GmbH Page 8 Jata N LaserCheck Hardware Setup Cete M eon Mounting of the Strain Gauges Do not move the strain gauge once it has been in contact with the resin The adhesive is only applied to the strain gauge Figure 6 Pictures of the strain ga
92. nter this value into the Max Pressure field Click on Set Perform a bend without any angle measurement and note the value of the maximum pressure shown by the control unit Calculate a new limit at which a value of 0 75mV V will be shown and enter this as the first force limit Check this limit by performing a test bend with a value a little below this one If necessary correct the force limit As force limit 2 enter a value about three times as big as force limit 1 and perform another test bend a little below this limit Correct force limit 2 appropriately in order to reach 0 5mV V Repeat these steps for the other force limits Force measurement x x Force sensor parameters COM Port come Amplification Factor JP 2 Offset f Configuration 2 Y Force Sensor tests Seral number M odel5 11354389 Port Actual value 00238 Offset ero Save Threshold Output Threshold ON fo Accept Threshold OFF fo C ON C OFF Use Threshold Cancel Figure 12 Dialog for the force measurement In addition to the force ranges mentioned above defined in the amplifier force measurement dialog the overall sensitivity can be influenced by amplification factors 0 low sensitivity to 3 high sensitivity in the force measurement dialog You can enter this window via Options Force Measurement If you change this setting and wish to save it you should click on the Save button In the ex
93. nterface Pin Signal Meaning SUB D 3 CAN H CAN interface i 6 CAN L CAN interface 2 2 CAN OV Internally connected to CH1 OvDC 3 Figure 77 CAN bus connector in IFS1 GND o CAN L GAN H GND MC gt mvc 5 V optional P o C we not connected Figure 2 Pin assignment HS C AN iview onto a male connector of the PCAN PCI card Figure 78 CAN bus connector at PEAK USB adapter Copyright by data M Engineering GmbH Page 89 Jata N LaserCheck Sensor V Adaption Control Gate n Automatic Longitudinal Adjustment 7 4 2 2 Pin assignment of the 24V signal interface Figure 6 1 Pin assignment of the 24V signal interface Pin Signal Meaning I O 1 24VDC_ ouT The 24V signal supply may be used to supply O the sensor system e g limit switches 2 I02 Freely usable input output I O a I00 Freely usable input output iO 4 OVDC Internally connected to cN1 OvDC 5 103 Freely usable input output I O 6 Tol Freely usable input output VO Figure 79 Connector for the limit switches 7 4 3 Working Principle The LaserCheck system communicates with the press brake control and receives position information for the longitudinal adjustment of the sensors The LaserCheck longitudinal adjustment control processes this information offsets and calculates the new sensor positions The system starts the positioning procedure automatically when the press brake control demands an angle from the LaserCheck device and
94. nting of the Strain Gauges O B k x2 4 tei 2 E 3 AD 4 gia 5 aji 6 7 he 8 AR A 9 NO D 3 11 3 i D2 h04 mT iN4b04 Oimvv 0 3a5mvVl 1mvV 35mVN ae eee eee 2 2 GND GSV2 15 pin clamp NLR Force Measurement Bn NOT A B2 Synchro Control ME GSU Cyubelec 6 29 03 2007 18 36 16 Sheet 1 1 o BD Copyright by data M Engineering GmbH Page 12 Jata N LaserCheck Hardware Setup Gate en Mounting of the Strain Gauges 1 3 3 Function Test For the functional test of the strain measurement system the ME GSV 2 amplifier needs to be connected to the serial port of the LaserCheck PC via a serial cable You can now run the program ME GSV Control which is already installed on the LaserCheck PC This connection is later used to track the actual strains force of the press brake GSV Clamp pin connector A GND GND Shite Bo RX TK Yellow Co X RK Green Table 3 Serial connector of force sensor ME GSV 2 Amplifier to PC COM1 The main functions can be inspected even before the adhesive has fully hardened by connecting the supply voltage Us red black and measuring the zero signal at the output Up green white The signal should not exceed 3 mV V If it does exceed this value the sensor requires compensation See also the table on chapter 1 3 5 The real functions however must be checked using a mechanical load on the press brake The amplifier with option VX has 4 input sensitivity ra
95. nts UVV Electrical installations and equipment BGV A2 VBG 4 UVV Laser radiation BGV B2 VBG 93 Copyright by data M Engineering GmbH Page 98 Jata N LaserCheck Safety and Maintenance Instructions Gate M neering Safety of Laser Devices UVV Safety labelling at work BGV A8 VBG 125 You can get the documents from your occupation co operative or you can download them e g at www hvbg de These documents refer to the regulations in Germany Additionally there is a reference to the norm EN 60825 1 VDE or VDE 0837 as of November 2001 Safety of laser devices Attention should especially be paid to paragraph three guidelines for users The norm is available at the publishing company Beuth GmbH Burggrafenstrasse 6 10787 Berlin Germany In countries other than Germany you have to follow the regulations that correspond to the German UVVs and norms 12 1 3 Laser Classes The laser class is given on the yellow or black white red USA warning label which can be found on every laser or on it s tightly screwed dimming cap Never remove this warning label It is absolutely necessary that the safety measures corresponding to the respective laser class are complied with see UVVs and norms An extract from the EN 60825 1 safety of laser devices Chap 12 5 Laser devices in laboratories and at the place of work p 48 is here for your information In analogy to EM 60825 1 safety of laser devices table D F Summary of the precauvhon
96. ode f Sensitivity Calibration Scaling Unknown i Display Channel jo gt Range Urit Gair Normalize 2 02080 mv l x1 os er Hz Digits le gt Switching points window Or Tet 2nd Adjust 2 1219 F 2 1219 mA Mode Logger Test output Averaging filter D Ml asimum Maximum Event P Linearization B Low pass filter D Sth Order Filter T Auta Zero eo Hase Eut offs pity Measurement Average 0 00015 mv 7 E xi Data frequency programmed Figure 9 ME GSV Control program Advanced tab Copyright by data M Engineering GmbH Page 14 Jata N LaserCheck Hardware Setup Gate en Mounting of the Strain Gauges 1 3 5 Adjustment of the Strain Gauges lf the amplification of higher values 0 1mV V or 0 35mV V does not work and the GSV does not produce a value the bridge might already be under load and the zero offset is failing In this case it is necessary to compensate the bridge with an additional resistor Solving this problem 1 Open the cover of the amplifier 2 Measure the voltage between clamps 4 5 3 If this voltage is higher than 0 5 mV e Choose the resistor from the table 219 146 109 No O1 0 90 0 5 1 00 1 25 1 50 1 75 D NI 00 oO N N iN D OO u oo 0 25 050 075 10 p 125 150 175 ee N AIAIAJA NI 01 DO O1 O1 O ee O1 NO O1 ll s Table 4 Compensation resistors
97. om the desired angle The difference is called the compensation error 3 We can now see the new compensation factor on the SPRING BACK page The new value has been calculated with the aim to reduce the compensation error to virtually 0 The underlying idea is that if the compensation error was positive obtained angle too big then the compensation factor was insufficient and must be increased On the contrary if the compensation error was negative obtained angle too small it was excessive and must be decreased 4 The procedure can be reiterated albeit a single trial usually suffices RF 100 RF X RFO Here RF stands for measured at Residual Force At the end of each SBMP a set of useful values is displayed here Column RF 100 displays the angle forces sensor 1 and 2 and beam position Y1 and Y2 measured at BDC or slightly above before starting SBMP beam lifting Column RF X displays the same information as measured when SBMP beam lifting is stopped Column RF 0 is different Row ANGLE displays the estimated final outcome assuming the sheet has been released Rows Y1 and Y2 display the estimated beam position at which the sheet is released Rows FORCE 1 and FORCE 2 display the current DYNAMIC force offset i e sensor reading at zero force see parameters 202 and 203 These values are also recorded in the LOG Copyright by data M Engineering GmbH Page 50 Jata N LaserCheck Hardware Setup Cete M eorn Confi
98. ome LaserCheck machine parameters must be set up before using the system 150 1 1 Width control of longitudinal adjustment Number of CAN Axes 151 0 0 Max moving distance mm axes 1 and 2 152 0 1 0 1 0 1 0 1 Tolerences of positions mm axes 153 222 3 222 3 222 3 222 3 Encoder increments Incs mm axes 154 400 100 Moving and reference speed m s fur longitudinal adjustment 155 290 490 4170 3400 Zero point offset mm axes 156 0 500 4000 3400 Parking position mm axes 157 0 Calculation Modes for positioning 0 1 2 use 2 Sensors like 4 Sensors 1 don t swap left and right angles 1 158 0 300 Machine center and positioning offset mm 159 0 4000 Min and max sensor position mm for positioning 160 0 Counter fur Timeout in 5ms cycles 161 0 Move sensors to park position after each bend 162 192 Input mask 163 300 Min sensor distance mm 164 0 0 Reference left 0 or right 1 axes 1 and 2 165 290 490 290 490 Min position of axes 166 4170 3400 4170 3400 Max position of axes 167 222 3 222 3 222 3 222 3 Motor increments Incs mm axes 168 20 Timeout s longitudinal adjustment 169 3 3 3 3 Reference mode axes 1 LIMP 2 LIMN 3 REF neg 4 REF pos The coordinate system for the longitudinal adjustment is the same as the machine coordinate system Ref Pr Uffset 2 Ref I Home 1 Machine OF rsSek d gt 7 center z 0
99. on the ordinate e Plots should reasonably resemble straight lines thus validating the linearity of the relationship See note 4 o Note 0 In order to reach the SemiAuto Sensitive mode the machine must be in automatic mode In addition to that the inputs AUTOMATIC and REGULATION must be 0 o Note 1 Typically there is not enough pressure Manually change the force value on the BEND NUM page Then report this value as a of max force in parameter 35C on machine parameter page PRESSURE AND CROWNING In some cases Permanent Regulation is the problem This value must remain at 1 throughout the entire cycle It must never drop to 0 o Note 2 Very slight overshoots are acceptable if they are small compared to the SENSITIVITY Otherwise you risk releasing the metal sheet during the spring back measurement cycle o Note 3 Undershoots should be as small as possible in particular with small dies Recall that this can be a major cause for faulty spring back in fact our current algorithms assume that BDC was reached without undershoot Compare the amount of undershoot with the SENSITIVITY if you have 0 01 mm undershoot which is usually considered acceptable you will have lost knowledge of about 0 01 0 0435 0 2 degrees of elastic return This is still acceptable however higher values are not A compensation factor typically 115 can help coping with this but it is not adaptable to different situations in fact with small dies the
100. ops Better results are achieved with 1 or 2 stops N and N2 fields can be changed on each bend However usually the same values are used for all bends SENSOR On each bend the angle sensor can be either NON ACTIVE off ACTIVE or in AUTODETECTION mode For sensors in AUTODETECTION MODE the system will only accept angles between minimum and maximum values parameter 204 Ultimately however the angle value must be between 1 and 179 Copyright by data M Engineering GmbH Page 49 LaserCheck Hardware Setup Gate n Configuring the Cybelec Control ERROR This field can be used to correct systematic angle errors probably caused by tools or other factors but not by the sensor alone The value entered into this field is added to the measured angle value before using it in any algorithm This correction will override the one specified in parameter 200 For systematic errors stemming exclusively from the sensor we recommend using parameter 200 SPRING BACK CORR When a SBMP variant has been selected in the SPRING BACK CORR field of this bend several other bend related fields appear TOLERANCE OPENED CLOSED During SBMP the system estimates the final resulting angle assuming the sheet has been released If the estimated final outcome is within the tolerances desired angle CLOSED and desired angle OPENED specified by these fields no compensatory descent is performed at all because the angle is considered accept
101. ore release decompression in 1 1000mm Standard value 15 13 Target value of force ratio for spring back calculation in Standard value 10 14 Period for communication timeout in 200ms Standard value 10 2s lf LaserCheck does not respond within this time period up to 3 more requests will be sent Should these requests also remain unanswered an error will be indicated Using longitudinal adjustment requires a longer timeout The timeout must be longer than the time needed for the longest stroke moving the sensors 15 Use mute point 2 for force reference 1 or mute point 1 0 16 Use the Threshold Output for End of spring back detection 1 or not 0 17 Switch off Messages 1 0 or not 0 0 18 Correction of y_mean for learnt bend in 1 1000 mm 19 Reserved should be 0 20 Used to indicate DAxxT Touch 1 or DAxxW 0 only for CE6 UAP Remarks Every time the LaserCheck system is connected to Delem these parameters are sent from the Delem control to the LaserCheck system Parameters 7 9 10 11 and 13 can be changed afterwards in the LaserCheck program for the current work session If you want to change them permanently you must do so in the Delem control All other parameters can only be changed in the Delem control 1 5 9 Bending Methods 1 5 9 1 Method 3 Sensor Bending This method uses the angle measuring system for bending We can choose between 3 sub bend methods e Sub Bend Method 0 or 3 Each bend is done with
102. ositions Moreover if you enable the switch Individual spring back calculation for both axes an individual spring back value is calculated for the Y1 and Y2 correction if the system does not calculate an average spring back angle Important Note The origin of the machine s coordinate system must be located on the left side of the machine and not in its center 1 5 13 LaserCheck Error Messages on Delem Control e ERROR Calibration Problem with strain gauge amplifier e ERROR Max course sensors V width Die V opening is too large e ERROR Press brake control Positioning Check maximum decompression distance DC in Delem control or Y axes positioning parameters e ERROR Reference force Problem with strain gauge amplifier e ERROR Y_set Y_actual But not yet in final bending state Measured spring back too small problem with spring back calculation measured bending forces too low e ERROR Number of REPETITIONS gt 5 Check estimated spring back angle and maximum measured force bending forces too low Copyright by data M Engineering GmbH Page 35 Jatah LaserCheck Hardware Setup Gate un Configuring the Delem Control e ERROR Number of RELEASE Steps gt 10 Check estimated spring back angle and maximum measured force bending forces too low e ERROR Overbend position Calculated spring back too high Problem with spring back calculation Check angles and forces e ERROR 1st Stop position too low Check pre bend angle Pa i
103. ponds to about 0 1 Too large values might cause the lifting to be terminated when the elastic spring back has not yet sufficiently expressed itself The resulting spring back angle would be underestimated Values which are too small can be unreliable due to the presence of noise not only at the sensors but also due to slip stick effect which might occasionally cause the procedure to stop in a random unrepeatable fashion Moreover the risk of releasing the sheet is higher 214 Advanced stop The default value of this field is 0 1mm Transformed into degrees as a function of nominal tools thickness and target angle The speed below this distance is set to the regulation speed the slowest possible speed whilst being measured continuously Corrective displacements of plus or minus 1 Y encoder unit are possible 220 Speed spring back measurement This speed will be converted into mm sec as a function of BDC angle thickness and tools The beam will rise with this soeed during the spring back measurement cycle thus adapting to the bending conditions especially to the die opening This speed is limited to the maximum upward bending speed parameter 13 on BEAM page Copyright by data M Engineering GmbH Page 79 Jata N LaserCheck Real Time Measurement for Delem and Cybelec Option 66 cate M neering Cybelec If you want to bend using continuous measurements you have to choose the spring back method by monitoring end of angle variation
104. r for the CANOpen interface to function the CANOpenStack dll Hardware par and the pcan_usb dll need to be in the LaserCheck folder Copyright by data M Engineering GmbH Page 85 LaserCheck Sensor V Adaption Control Gate n Automatic Longitudinal Adjustment 7 4 1 Driver parameters for Lexium ILS1 The general setup of each motor must be done by the commissioning software Lexium CT by Schneider Electric Download this software from www schneider electric com Within this installation you will also find the manuals for this motor Normally the motors are set up by data M If there are any problems follow these steps 1 DY Set up the CAN address for each motor via the dib switches 1 front left 2 back left 3 front right 4 back right The CAN addresses should match the sensor numbers and the motor numbers Sensor 1 should have motor 1 with CAN adress 1 Set the baud rate to 250KB for all motors this is the default setting Start the Lexium CT program Define the direction of rotation invertDir All motors must reference themselves to the negative limit switch on the left Changing the direction of rotation is only implemented after the power has been switched off and the motors have been restarted Define the phase currents for still _ acc _const _ stop Default values are _still 70 _acc _ const and _ stop 100 Configure the I Os Standard values IO0_def Input LIMP 101_ def Input LIMN IO3
105. r values calculates an average value and sends the result to the NLR card via an analog output 2 Both LaserCheck computers are connected via the network The measurement results are exchanged via a Master Slave configuration 1 7 2 Installation Perform the following procedure 1 Set up the separate LaserCheck systems mechanically and electrically at each machine 2 Connect the amplifiers to the correct COM port COM2 at the LaserCheck computers via serial interface Connect the LaserCheck computers analog output to the NLR card Connect the tandem switch to the TTL input Define Master and Slave machine in the parameter files Test the machines separately Test the tandem mode ole 1 7 3 Tandem Definitions Master Left machine with four connected sensors On this machine the server configuration for the LaserCheck tandem option has to be installed Set LaserCheck parameter 92 to 2 Slave Right machine with two connected sensors This is the client configuration Set LaserCheck parameter 92 to 1 All z coordinates start from the left side They are counted independently for each machine The z positions are required for all sensors The left sensors on the right machine Slave must be programmed to be at z 0 position 1 7 4 Mode of Operation The tandem option synchronizes the angle measurements of two machines All measured values are incorporated in the calculations to ensure that the upper dies are positioned on the same Y v
106. ra mie Activate Write Protection for C gi Language IV Variable AOI C German LcTT I O via C LPT USB off English Communication with Gu Cie fo a Do not swap left and right angles Test Mode Simple serial connection no NLR Vv uEye output for switching laser alter fio 0 Waiting time ms om Minimize at Program Start Real Time with graphic output Metric lV extended Errormessages aa Seve Setings oe Binary ASCII is the type of encryption the LaserCheck computer uses for the communication with the Cybelec control This option is only available if you use a Cybelec control Automatic V Width Adjustment must be selected if you use an automatic V Width adjustment If you want to use this also see 7 1 Automatic V Width Adjustment on page 81 Automatic Height Adjustment must be selected if you use an automatic height adjustment lf you want to use this also see 7 2 Automatic V Height Adjustment on page 82 If you either use an automatic height or V Width adjustment the buttons Motor Control with will become available You can choose between two methods of communication Pulse Dir and RS232 If you have the appropriate license the option Automatic Longitudinal Adjustment becomes available You can choose the type of motor you want to use Icla or Lexium The No of Axes is equivalent to the number of motors It is used for the longitudinal adjustment You can move two sensors with 1 motor two sensors with one motor e
107. ram Individual menus are assigned to each window type If a window is closed and it should be opened again the following toolbar is available Rt oS P Figure 51 Toolbar of LaserCheck Program A mouse click on the first icon opens the following dialog in which the desired sensor image can be opened LaserCheck Bending Angle Measurement Cybelec Conn Program Connection Options View Window Help Live Angle 180 00 Sensor 1 Off Right Front ae Figure 52 Toolbar of LaserCheck program with sensor image icon Open Sensor Image a Cancel Figure 53 Sensor Selection dialog box If the camera diagnostic module determines an error during the opening of the sensor the appropriate window is not opened In this case check the connection of the sensor with the LaserCheck computer With the help of the next icon the calibration connection window is opened If this window is not opened no LCAdjust computer can be connected via the TCP IP interface GE PF m 3 Figure 54 Toolbar with calibration connection LCAdjust icon Copyright by data M Engineering GmbH Page 65 pi CJ f a l LaserCheck LaserCheck Software cate M veering Program Options The third icon opens the Press brake connection window or the Cybelec connection window If this window is not opened no connection with the bending press control can be established via the serial interface and consequently no bend can be performed using the
108. rea of the laser line in pixels for each sensor The values define a rectangle inside which the LaserCheck program searches for the laser beam For Variable AOI see 5 Variable AOI area of interest on page 75 Plausibility of measured angle For checking the plausibility a nominal angle is transmitted from the Delem control The difference between these angles must not exceed the difference between Top and the Bottom value Additionally the maximum acceptable asymmetry of the front and back angle can be limited Max Difference between angles In the case that the plausibility check fails an error angle of 180 is sent The enabled switch Force double sided measurement only prevents single sided measurements Even if an angle is fine an error is generated Normally the flange angles are non symmetrical therefore a single side measurement is not precise and distorts the bending solution significantly This option can also be activated via parameter 59 in the parameter file Copyright by data M Engineering GmbH Page 69 Jata N LaserCheck Image Processing and Angle Measurement Gete eon General Settings The search area of the laser beam can be limited by a V shaped area around the nominal angle by activating the option Restrain search area to nominal angle The area is defined by the upper and lower limits of the deviation from the nominal angle and by the value Width of the search area at the bottom which is located around the horizont
109. ries you can use one of two methods Amplifier Force Measurement Mas Pressure 44 26 kN Cancel Set Apply e Output Fore i Output Force 2 I switch Wx Amplification setting P Force lirit 1 jo Force limit 2 fiso o Force limit 3 J0 Force limit 4 00 Number of measurements i Delay between measurements f ol ma Delay after tara i ogi ma Figure 11 Dialog for controlling the max pressure Delem version 1 Alignment using the pressure method 1 Start loading the press brake gradually from 0 to 100 load and record the values you can read in ME GSV program The values vary between 0 and 1 05mV V Also record the corresponding pressure values indicated on the press brake control 2 When you read a value above 0 75 change the current Max Pressure setting to the next range Press the Set button Different check marks should now appear in the Output Force 1 and Output Force 2 boxes When you change the amplification range a significant change in the force readings should be observed 3 Continue loading the machine When a value above 0 75 is reached you should switch to the next range by entering a higher Max Pressure value Copyright by data M Engineering GmbH Page 17 rel LaserCheck Hardware Setup Gate yi Engineering Mounting of the Strain Gauges 2 Alignment using test bends 1 2 Program a test bend with a calculated force value of roughly half the size of the first force limit and e
110. s are transformed into angles by interpolation in the table Analogue values below the value entered in field 180 will always give 180 Care must be taken that there is no overflow for angles below 90 i e values above 4096 Typically we should have about 30 analogue values per degree POS This field displays the last analogue value obtained by the sensor 202 Force detector 1 A D 203 Force detector 2 A D YES NO This selects wich force detector is used Both can be used If both are used the software will use an average value However it will not be the average of the analogue ADC Analog to Digital Converter values but the average of the X force values MIN The minimum reliable force at BDC When the forces are very small it is difficult to obtain stable results During the calculation of the total spring back we also check the force measured at the BDC If it is below a certain minimum threshold it is considered unreliable Moreover we expect that the sheet would be released when the beam is raised Therefore the difference of the measured angle matches the total spring back i e we take the residual force as 0 FIXED This is the force sensor s analogue ADC value when no force is applied also known as force offset or 0 force value If a value is entered here this offset can be seen as fixed and does not change with time If no value is entered then the system will try to determine this offs
111. s stopping threshold For every new bend it can be overridden by entering a new value on the SPRING BACK page Programmed values above 65 will be taken as 65 Programmed values below 2 will be taken as 2 Copyright by data M Engineering GmbH Page 45 sete N LaserCheck Hardware Setup Gate en Configuring the Cybelec Control 209 Compensation factor The default value of this field is 115 During SBMP the software extrapolates the expected spring back angle This parameter specifies how much must be compensated for this angle A common value is 115 but it is heavily dependent on the system including in particular how underestimating the SBMP is 212 Max time spring back measurement The default value of this field is 10s During SBMP the beam is lifted until one of several conditions is met However this condition must be met within the given time otherwise SBMP is aborted 215 External detection of spring back The default value of this field is NO This requires a special NLR version and external hardware If programmed to YES this parameter informs the NC that an external device exists which is able to detect the point where the sheet is released during the upward lifting of SBMP In this case a corresponding additional choice BY MEAS ANGLE AFTER EXTERNAL TRIGGER is displayed among others in the selection list of the SPRING BACK CORR field on the SPRING BACK page 216 Cycle with N measurements first stop The d
112. s users should take Requirements Class _ Class 1M Class 2M_ Class 3R Class 3B Laser safety officer Not required but recommended tor Not required Required apphecations which demand a direct for visible look into the laser beam emissions Interlock operatable Mot required To be connected by remote control to room or door cecuits key switch Not required Pull out key f device 5 not operating Beam reducer Not required Avoeds unintenhonal exposure fo beams when operating Beam indication Not required Indicates when the Indicates d the laser laser 1s operahng 5 operating with invisible radiahon Loser warning labels Not required Follow the indications on See labels on the laser the warning labels Nlo required for laser classes land 2 The beam has to Measures as for 3R 38 finish at the end of as expedsent wedly Mirroring reflection Mot required for laser classes land 2 Unintended reflections are to be For 1M 2M Measures as for 3R 3B avoided Eye protection Hot required Required d constructive oi organisational measures are not workable ov if permitted m x radion is exceeded Protective clothing Hot required Schooling Not required Required for operational and maintenance stoff t Trainmmag courses are offered eg by the TUV Akademe Rheinland in Koln Tel 022 1 806 3055 Fax 022 1 806 1534 Figure 83 Safety of laser devices in analogy to EN 60825 1 12 1 4 Laser Devices of Class 1M Class 2 Class 2M and
113. ssccccceseecceceeeseeeesaeeeeeeees 25 Camera settings ccccccsssecccssececeeseeseeeeesees 73 LaserCheck Forerio teia 26 Exposure TiMe sssssesssesssssssersssrsssressressreserees 78 Trinamic stepper motor modules sssssseesesssss 23 Force double sided measurement 66 70 Troublesshooting sseccccesseecceeececseeseeseeeseesees 96 General Settings ccccssecccsssseeceeseeeeeeeesees 68 U Image processing sssseessssssesrrsrssessreresreseeseee 70 Laser Line detection parameters 0006 72 CALI scaaieecrtcaeaia taucciaaniteai a A 28 LIVE MOG Ecossaise A 67 UOP ics testa an aaatee p pote eae iaanieageaterteapaanataremaeneasnaeies 28 Material SUN TACE assins 92 V Mirror option esssssssesssessessssssesressessessrresesseeseee 67 Mounting position of the SENsOrs 8 71 V Adaption ccccccsescccssseccceeeecccesceeseseeseeeseesaes 80 PIGUSIDINILY wssisvssdcovenchevessonbsesesneesosncsesscteanssenorseen 73 Variable AOl ois canetcte se var oneeaustecnteassneseewesanaeesetacomee 76 Plausibility of measured angle 0ccccceeee 70 Calibration Correction ccscccccssseeceeeeeeeees 77 Segmentation siscicocsnansansraccetnddoaninaceiesvanseaniamdons 73 Die dehnt ON sorsana 76 Short flange compensation sssseseeeereeeesssss 75 LaserCheck 10 11 esssrrrrrrrrrrrrrrrrrrrrrrrrrrrrreee 77 Short flange COMPENSATION cecccceeeeeeeeeees 73 Switching the AOI
114. sseeesssseeeesssreresssrerssseree 28 Bending with Cybele c cccccccssssccccsesseeeeeeeeeeees 50 Error M SSAGES eariad ner ina EREE NER 35 c EE e A E E E E E 29 Four sensor Option sesssssssssssessessessrrssessesseesee 35 Calibration correction ssssssssssesseresssrereesseereeses 77 LOC TIE en E E 34 Correction Material ccccssscccccsssseceeseeseeseeseees 92 Machine parameters cccccccccssseeceeeeeeeeeeees 30 COS OG rca E E E E E E E T 37 KENO erre n E E TEE 31 TE I EENE E AEAT AE E 37 Method 4 Learned bend ccccceessseeeeeees 32 PCI CIN Ss acca eeaneieeucasets E esa eens 50 Network configuration ccccccssseeeeeeeeeeeeeees 28 Connection to the NLR ccccccesssssseeeeeeeeees 40 Sensor parameters scecscusnacssueeenasbeavettiounetaeniveceee 30 Installing Force SENSOFSS ccccsssesseeeeeeeeeeeeeees 48 Sequencer modifications sssseseessssssseeeesse 29 Machine parameters ccccccccsssceesseeceneeeeeeees 44 TOO ee E E 36 MOdeva Ioe E ere ne rere 41 UAP oei E E 28 NLRC ar O senasis nran 39 40 Delem Parameters cccceccsccsecesseesenseesceseeseeeses 30 Programming bendS s ssosssossseressressressrersrererens 50 Communication timeout s sesssessessresressersees 31 Real Time MeasureMeNt cesccceeseeeesteeeees 79 Compensation factor cceeseeesseeeesteeees 33 Spring back measurement eere 52 Correction ANGIE cccccessseceeesssteeeeess
115. st but not yet released and to use this angle as an immediate estimation of the final outcome In reality a kind of gentle knee is formed In this region the angle only opens a little bit with a relatively large upward displacement of the beam Hence if the beam can be stopped here the sheet is still held rather firmly while the spring back angle has practically been completely unrolled Our system detects this knee as follows While the beam is being lifted the current angle value is steadily compared with the one measured 0 3s earlier parameter 211 As soon as the difference falls below approximately 0 1 parameter 213 the lifting will be stopped The corresponding SBMP goes as follows 1 At first the BDC or slightly above angle is measured 2 The beam is lifted and the angle is monitored until it ceases varying 3 The beam is stopped and at rest the angle is measured again This angle would have been considered the final outcome had the beam been lifted until TDC Albeit being highly attractive as it makes force sensors redundant this procedure by its proper nature only offers the necessary robustness and reliability in very constant and optimal environments BY MEASURING ANGLE WITH RESIDUAL FORCE This choice is only available if at least one force sensor is present This is by far the most commonly used model When this choice is selected an additional field appears on the right Threshold values entered her
116. surements LC6 U Copyright by data M Engineering GmbH Page 22 GA f a l LaserCheck Hardware Setup cete Mi neering Mounting the Sensors 1 4 3 LaserCheck 7 e Working distance 80 140 mm e Mounting angle 35 60 1 4 3 1 Setup of the Trinamic Stepper Motor Modules LaserCheck 7 uses intelligent Trinamic stepper modules for width positioning The Trinamic modules must be configured if a stepper motor module must be replaced or at the start of operation Each module needs an address and a reply address The address is the same as the sensor number the reply address must be twice the sensor number Reply Address ee Table 6 Definition of addresses The default addresses are 1 and 2 Connect only one sensor to the computer terminate LaserCheck exe and start TMCL exe Please disconnect the power supply before you unplug the connectors Select Setup Options and input the correct COM port under the Connections tab Cs x Eee EERE EERE EE EERE OREO EEE FREER EERE EERE EERE ERE E EE EH Type R5232 AS54385 COM port RAS232 7 R5485 7 Fort co M3 S Baud 3600 X Address fi Search OK Cancel Figure 17 Connection data for the COM port Default baud rate is 9600 Select Search Module Press Start The program should now find a module and represents this with a message box F3 Search Module x Trying address 1 Start Figure 18 Search Module dialog box Copyright b
117. t SERS sia a Airai gauges LAG Wy AMP DATA M DELEM Figure 1 Schematic diagram of the angle measurement system with Delem control Copyright by data M Engineering GmbH Page 4 Jata N LaserCheck Hardware Setup Gete eon Introduction LaserCheck PC ModEva 12 Sensor NLR card NOT card Analog strain gauge Cybelec ane neeeeaneensensinenesnnadanennenns See eeeeeeeeeeeeee eee e eee ee eee eee ee eee Figure 2 Schematic diagram of the angle measurement system with Cybelec control Copyright by data M Engineering GmbH Page 5 LaserCheck Hardware Setup Gate M roering Requirements 1 2 Requirements V angle of the die The V angle of the die must be considerably smaller than the smallest bend angle that should be formed with this tool The maximum V angle can be no bigger than the minimum bend angle minus the maximum expected spring back minus additional 5 degrees Example For a bend angle of 90 deg and a spring back angle of 7 deg gt Maximum V angle 78 deg Die type Do not use multi V dies or block dies The V angles of these are generally too big in order to bend 90 deg angles 86deg V angle The overall die width is too large especially for the small V widths Thus the minimum flange width increases with the overall V width Crowning The crowning must be kept constant throughout the entire bending process The bending process starts with the calibration of the strain gauges
118. t in parameter 220 until the angle change in s is lower than parameter 213 Then the spring back is measured we overbend and the piece is finished Copyright by data M Engineering GmbH Page 78 LaserCheck Real Time Measurement for Delem and Cybelec Option 66 Gate un Cybelec 6 2 2 Parameters for continuous measurement 206 Final approach The default value of this field is 1 5mm Transformed into degrees as a function of nominal tools thickness and target angle This value will be used instead of the normal one parameter 03 on BEAM page when using an AMD under CONTINUOUS MEASURES It is wise to use a relatively wide final step which is performed at a lower speed thus reducing the danger of overshooting If the final step is too wide it will slow down the bending process considerably 210 Closed loop cycle The default value of this field is 10 When the upper tool whilst being measured continuously is just in front of the lower dead centre see parameter 214 the NLR gives the instruction to correct the beam s downward position in steps of 1 Y encoder unit until the target BDC angle is reached These orders overlap and interfere with the usual bending process hence they cannot be given too frequently However if they are given too scarcely it will take too long to reach the target angle For technical reasons precision the time between orders is given in internal NLR cycle counts not in seconds One cycle rou
119. ted individually The option Var AOI must be selected in the General Settings Dialog Box 5 1 Die Definition We need the data of every tool that is going to be used in production later on as all of these tools must be calibrated Important is only the tool s V Width and height and also its radius if there is one Select Options Measurement or press F2 to open the Measurement Parameters dialog box Measurement Parameters Area of interest Pixel Sensor f Bl et rd _ dee oma save Sensor z 5 Rot fm 5 o Bottom fos Figure 65 Measurement Parameters Dialog Box d g j Select new A New Die dialog box opens newn x Width poo Height Bs Radius eo interpolate Canel Figure 66 New Die Dialog Box Input width height and shoulder radius In order to save this tool you have to click on accept Enter all tools following these steps Take care not to list any tool more than once 5 2 Switching the AOI Just like with LaserCheck 6 and 7 the AOI has to be adjusted according to the laser line As soon as a die is chosen by the control or the LCAdjust program this die is shown in the headline of the LaserCheck program 5 x W Sensor 2 M ire Angle 180 00 Off Left Back Die 1 V Width 0 0 Height 55 0 MGAOI 000 000 LL 000 000 Mat 1 yvi 0 00 H 55 00 DI tuLw h 254 411 405 408 Exp 15 00 Est oor Miror Ex Figure 67 Sensor headline Copyright
120. th respect to the flange will be wrong Copyright by data M Engineering GmbH Page 83 LaserCheck leh Wy Sensor V Adaption Control Gata M V Adjustment for bending Engineering i o M Figure 72 LaserCheck with height adjustment 7 3 V Adjustment for bending The press brake control sends the programmed V geometry information directly to the LaserCheck computer Before each new bending step this information is updated You can check the current V parameters in the following dialog Geometry of the die Width Cancel Adjust 1 mm Height fo PL Parameters Adjust Figure 73 Dialog to adjust the sensors according to the current die geometry Copyright by data M Engineering GmbH Page 84 a f a LaserCheck Sensor V Adaption Control cate M roering Automatic Longitudinal Adjustment Additional parameters for the height adjustment can be set by pressing the Parameters button The following dialog will be opened Die height definitions X Zero position by ext Signal Cancel Starting From rel height 100 mm Die a bd Number So Height oo mm Height at Ref 0 mm Mew Clear ar i Figure 74 Dialog to define new die heights For adding a new die push the New button and enter the corresponding die number 1 99 and the corresponding die height Pushing the Clear button will delete the current die settings from the list Once you have changed the parameters you must push the Appl
121. the actual sensor position differs from the desired position Optionally the sensors can move back to their parking position as soon as the bending process is finished We can operate 1 or 2 sensors with different positioning modes If the Delem bending method 3 is used the parameters of the sensor positions Z1 and Z2 are used to position the sensors LaserCheck parameter 157 and the sub method 3 define the positioning mode e Mode 0 Move to positions when new Delem data is received e Mode 1 The sensors either move to the positive right sensor or the negative left sensors offset position when new Delem data is received When the Delem REQUEST BENDANGLE command is received sensors are automatically moved to their positions without an offset Copyright by data M Engineering GmbH Page 90 Jata N LaserCheck Sensor V Adaption Control Gate n Automatic Longitudinal Adjustment Mode 2 Sensors either move to the positive right sensors or the negative left sensors offset position when new Delem data is received Subbend method 3 or mode 3 Move to the position when a Delem REQUEST for BENDANGLE data is received If subbend method 3 is received the LaserCheck parameter 157 will be ignored lf Parameter 161 is 1 the sensors will move back to their home position after the last step of the current bending cycle otherwise the sensor will stay at their current position 7 4 4 Parameters from LaserCheck par Depending on the machine s
122. tions page Change into for either angle measurement Nr 60 or angle measurement on both sides Nr 65 3 Goto the Welcome page and enter 0607 into the service line not for ModEva 4 New parameter pages should be available for the Angle measurement system 3 5 Adjust parameters in DNC the same way it was done on the Angle measurement system page 6 Activate angle measurement for individual bends on Correction spring back A NLR Card must be installed in the Cybelec control The following figures should help you to configure a Cybelec control for the use with a LaserCheck angle measurement system WELCOME TeA0S 0e MACHINE N 101 USER ORIGIN CYBELEC CH SOF PAARE VERSION SPEEL nm s DNC SSAFFWS ENC SHAPAW LENGTH Tort NIC 9600 aDA Nex FBS NLR DM ORECH FORCE man MEMORY CAPACITY TOTAL FREE FORCELENGIH Tonm DNC PROGRAM 1O360680 KB be 94 SIGMA Kg mm IN INTERNAL 2U966352 KB TUmSUUS VWYEIGHT Ton BEAR eerie 0B LANGUAGE GB ACTIVE PERIPHERALS MACHINE INTERNAL PRODUCTS INTERNAL PUNCHES INTERNAL DIES INTERNAL COMPLEMENTS INTERNAL KEY SERIAL N ye e EENE OPTIONS IN KEY De E SERWICE 06l TOTAL BENDS REALIZED ae SINCE 9 10 03 MENL PRODUCT BEND CORRECTIONS AC TIONS a RENEE Figure 30 Cybelec control Welcome page Copyright by data M Engineering GmbH Page 39 LaserCheck Hardware Setup Cete M eorn Configuring the Cybelec Control MACHINE PARAMETERS OPTIONS ne 55 External commands 6U An
123. tween LaserCheck and Deleml Measurement results and bending process data appear in the window 2 If you select the menu item Options Process results Function key F7 for Elastic Recovery Results you can see the bending process results 3 Activate Log file option CTRL L A log file is written in the program directory D data M Engineering LaserCheck Logs messX log Copyright by data M Engineering GmbH Page 34 a f a LaserCheck Hardware Setup cate M roering Configuring the Delem Control 1 5 12 Four Sensor Option If your system is equipped with 4 sensors the Y1 and Y2 positions of your ram are calculated independently In the Delem control you have to enable both sensor pairs and provide the position values of the LaserCheck sensors Of course you can still use only one pair of sensors which you must specify in the input dialog for the angle measurement system of the Delem control The control sends all information including the length between the cylinders and the total machine length to LaserCheck Using the supplied data the system determines the correct Y1 and Y2 positions for the spring_back correction Delem 4 Sensor Option x OF Position Left sensor mm 500 Cancel Position Fight Sensor mm a500 ance Length between the cylinders rmm jo Total machine length mnm jo Sensor couple Left C Rigt Both Individual spring back calculation Delay before measurements ma f OU Figure 29 Sensor p
124. uge DA 40 mounting surface treatment cotton bud strain gauge protection Epoxy resin Epoxy resin on the strain gauge fixation of the strain gauge final mountings Copyright by data M Engineering GmbH Page 9 m Jatah LaserCheck Hardware Setup Cete M eorn Mounting of the Strain Gauges 1 3 2 Wiring of the Amplifier This process consists of the connection of the strain gauges to the amplifier GSV 2 and its connection to the LaserCheck computer and to the Delem Cybelec control Figure 7 Size of the amplifier housing Figure 8 Amplifier GSV 2 The amplifier already has two cables for the connection to the LaserCheck computer AMP and COM1 Via AMP the amplifier is supplied with power and the amplification levels are switched The amplifier communicates with the computer via COM port With Delem systems COM port 1 is used With Cybelec COM port 2 is used because COM1 is already used for a serial cable to the NLR At first connect the two strain gauges in parallel to the clamps 1 2 4 5 and 7 Copyright by data M Engineering GmbH Page 10 LaserCheck Hardware Setup Gate en Mounting of the Strain Gauges The only external connections of the strain gauge amplifier are the power supply clamp 14 on 24V and clamp 15 on OV The strain gauge amplifier connections can be summarized in the following figure Table 1 Delem Clamp Color of sensor Connection Meaning cable Strain 1 GND Power ground strain gauge shield
125. uld check the electromagnetic compatibility EMC can cause electrical noise in the force signal This will result in wrong spring back measuring results for smaller forces Select the Recorder tab to check the EMC Set the Y zoom to 1000 The signal displayed must not exceed 1 2 when all servo drives and the pump are running and the amplifier is set to its highest amplification level Reduce electrical noise with Use of shielded wires for all motors Separate linear power supply for the amplifier Careful grounding Separate cable channels for power lines and signal lines Avoiding spare wires antennas in the cable channels EMC filters for servo drives Copyright by data M Engineering GmbH Page 16 a f a LaserCheck Hardware Setup cate M roering Mounting of the Strain Gauges If the EMC values are okay you can perform the following test procedure Open the Options Force Measurement dialog in the LaserCheck program Estimate the amplification levels by entering the maximum force of the machine as the Force limit 4 and by each dividing the next smallest values by 3 Insert a value smaller than the first limiting value into the Max Pressure field e g 0 Click on the Set button Check marks should appear in the Output Force 1 and Output Force 2 fields depending on the respective amplification level The limiting value that has been inserted is already part of the next highest amplification level In order to test the force bounda
126. y button Setting the checkbox Zero position by ext Signal moves the sensor down to its zero position if the current height is bigger than the limit indicated in the Starting from rel height field The value Height at Ref is the corresponding die height at the reference position You can use your Calibrated height as the reference height Input the height of the shaft Measure this height in the same way you measured the height of the tool Don t forget to save the parameters 7 4 Automatic Longitudinal Adjustment Options for longitudinal adjustments are 1 One motor driving two sensors Front and back sensor are moved by one motor 2 Two motors are driving two sensors Front and back sensors are moved separately 3 Two motors are driving four sensors Front and back sensors are coupled with one motor 4 Four motors are driving four sensors Each motor is moved separately General Remarks Longitudinal adjustment is designed to move the sensors on robotized press brakes out of the collision area of the robot It can also be used to take measurements on the left and the right using a pair of sensors in order to get 2 angle values for a bend There are 2 types of motors available e The intelligent stepper motor Schneider Lexium ILS1 with a CANOpen interface e The servo motors Schneider BSH BDH with a servo controller Lexium32 Both types of motors are controlled by LaserCheck via a CAN Interface tyoe PEAKCAN USB or PEAK PCI In orde
127. y data M Engineering GmbH Page 23 leh Wy LaserCheck Hardware Setup cate ML neering Mounting the Sensors Information x i TMCM 110 module has been Found on target address 1 Figure 19 Message box for a successful scan e Program anew module address and reply address in Setup Configure Module according to the address table Confirm the new addresses with Apply EI xX R5232 7 R5485 CAN Drivers TMCM 301 Microstepping Graph Microstepp f gt Module Address 2 ut Reply Address 4 Baud Rate 9600 bd Telegram pause time fo Apply Hint Set telegram pause time to 0 for RS232 and to 15 20 for AS485 with R5232 AS485 converters Figure 20 Configure a Mdule dialog box e Verify the modification with Search Module The Module must now be found at the newly programmed address e Repeat this procedure for all modules Copyright by data M Engineering GmbH Page 24 Jata N LaserCheck Hardware Setup Gete eon Mounting the Sensors 1 4 4 LaserCheck 7 8 75 mm min Die Heigt A XMS Machine Center View A Figure 22 General sensor measurements of LaserCheck 7 8 Copyright by data M Engineering GmbH Page 25 GA f a LaserCheck Hardware Setup Cate Mi neering Mounting the Sensors Figure 23 General mounting details for LC7 8 Figure 24 LaserCheck 8 sensor case LaserCheck 7 and 8 have the same sensor case but different connectors since LaserCheck 8
128. you do not want this activate Do not swap left and right angles Simple serial connection no NLR must be activated if you want to use a serial communication system other than Cybelec uEye output for switching laser shuts the laser down have been inactive for a time period exceeding the one set in this window There is also a Waiting time after the laser has been started again because it first of all has to adjust its brightness The Option left right with one Sensor is used for the longitudinal adjustment It means that the sensor will move to the left side take a measurement then move to the right side and take another measurement there You can also use the option Roboter if you want to use one In this case the sensor will move to a parking position after measuring The option Analogue Out with USB DAAD is used for the Tandem mode Also see 1 7 Tandem Option for Cybelec on page 55 If you want to Minimize at Program Start use this option Real Time with graphic output also displays the sensor picture whilst being in real time mode If Metric is active you can enter numbers with one decimal place If this option is inactive you can enter numbers with three decimal places lf Extended Errormessages is active it will also display all error messages from the uEye driver which is used to control the cameras License from Camera Computer determines on which device the license is saved If you choose Computer you can connect any sensor to this
129. yright by data M Engineering GmbH Page 63 anally LaserCheck LaserCheck Software Gate M veering Program Start If your license has expired or if you do not have a license yet the program will not start You will need to obtain a new license First press the License button then the following dialog will open where you can read your individual program key By indicating this key you can obtain a new License code from data M A temporary license expires if you change date and time by more than two hours Program Key amp License Code wales gh LaserCheck Copyright 1995 2077 by data M Engineering Programmed by Andreas Bachthaler and Dr Thomas K Dietl Pleage enter your license code fou will obtain this code from your manufacturer by indicating the programm key Frogramm key 04D SO 3CB 0 0 License code oso 304 C21 04C0B 53080 4 Cancel Figure 48 LaserCheck Program Key and License Code dialog In Windows XP Embedded the program will request you to restart the computer after you have entered an unlimited license code Afterwards the automatic writing protection is activated on the CF card The license code is saved to the registry and uses a network adapter s MAC address as a key Starting with Software Version 4 5 licensing the cameras is supported too Go to Options General Settings and activate the camera as the license type Ho of Axes fie eee tee License From M Serial Force Request sores Realtime

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