Allen-Bradley Press Automation & Control - Integrated W/ Our Press Pilot 150 Clutch/Brake Controller and PanelView HMI
Toledo Integrated Systems has been providing Allen Bradley solutions to the metal forming industry for over 13
years. In that time we have worked with all of the Allen Bradley hardware platforms including PLC5, SLC, MicroLogix,
CompactLogix and ControlLogix. Our AB Maximizer TPC has many standard control and automation features but allows
for easy customization and expandability.
The Max TPC is built to order with all the functionality and integration
that the customer requires. This gives the customer complete control of the equipment using standard "off-the-shelf"
hardware. The HMI is also selectable. Along with the standard Allen Bradley offerings for the HMI, we are capable of
providing an industrial PC or a screen from a different vendor (if you have standardized on a certain screen).
Allen-Bradley - Press Pilot 150 - HMI Communications
Below is a list of the standard features and options for the AB Max TPC. The options don't stop there. The true
advantage with a PLC system is that it can be expanded and customized to the customer's exact needs.
All supplied controls comply with OSHA, ANSI and CSA Z142-02 regulations for mechanical stamping presses.
Press Control Features:
- Dual processor w/watchdog circuit
- Anti-tie down protection
- Anti-repeat protection
- Dual channel monitored E-stop circuit
- Protected memory (each processor)
- Off, inch, single & continuous modes
- Clutch & counterbalance air pressure monitoring
- Press position verified each cycle
- Speed compensated top-stop
- Top stop overrun protection
- Uncommanded motion & drift detection
- Clutch valve fault monitor input
- 120 VAC or 24VDC E-stop circuit
- Light curtain interlocks
Press Automation Features:
- Sixteen (16) die protection inputs
- Eight (8) programmable limit switches
- Two (2) or four (4) channel tonnage monitor
- Signature analysis & reverse tonnage
- Individual window settings for all DP inputs and PLS outputs
- Part, good part, stroke and two batch counters
- Press position and SPM display
- Two hundred (200) job storage/recipes
- Ability to save/review comments with each recipe
- Compact flash card memory
- Individual alpha/numeric names for DP, PLS and job storage
- PLS Speed compensation
- Time based brake monitor
- 90 degree stop test
- Resolver based (360 degrees @ 1° res.)
- Automatic alarm pages and messaging
- Online help menus
- 3 password levels
- MaxNet connectivity capable (press room networking)
Typical Control Features Include:
- Ethernet connectivity
- Main motor control and monitoring
- VFD or Eddy current control integration
- SPM control
- Flywheel brake control
- Slide adjust control and monitoring
- Lube pump control and monitoring
- Hydraulic pump control and monitoring
- Individual I/O diagnostics
Optional Control Features Include:
- Additional DP & PLS (virtually unlimited)
- Signature analysis & reverse tonnage
- CCM (Critical Curve Monitoring)
- Auto counterbalance
- Auto shut height
- Servo feed interface
- Transfer system interlocks
- Robot interlocks
- Standard die sensor interface box
- Universal die sensor interface box
Click Here To Download Press Control RFQ
Case Study #1
Case Study # 1
Project: 1000 Ton Bliss Press and Rowe Coil Feeder Controls Upgrade (during new HMS Transfer retrofit).
Scope: Due to new and existing product demands the customer needed to add a transfer system to an old press line. The existing electrical controls on the press and feeder were obsolete, an electrician's nightmare and not up to the latest safety standards. Toledo Integrated Systems was contracted to provide a turn-key electrical controls upgrade on the existing 1000-Ton Bliss and Rowe Coil Feeder.
New Press and Feeder Controls Included:
- Allen-Bradley Control GuardLogix (L72S) Safety PLC
- 15" Industrial PC with Factory Talk View
- Two hundred job recipe/storage
- Die identification with Balluff I/O Link
- Sixteen (16) die protection stations
- Sixteen (16) transfer die protection stations with indexing
- Eight (8) programmable limit switches
- HMS linear transfer interlocks (Ethernet)
- Auto counterbalance control
- Light curtain interlocks
- Ethernet communication
- Hydraulic clutch
- Main AC motor (Ethernet to Yaskawa drive)
- Four (4) channel "through the stroke" signature tonnage monitor
- Auto shut height control
- Feeder servo motor
Design Considerations: Toledo Integrated Systems (TIS) assigned the project to one of the control project engineers. The engineer's responsibility was to follow the project from initial design through on-site commissioning and training. As with all projects of this size, an investigative trip was scheduled with the customer to introduce the project engineer, gather additional information and to develop a solid installation plan. With the additional details and information, the project engineer used our standard electrical designs to develop the new press and feeder control. Hardware was purchased, built and assembled in the Toledo panel shop. The control panels were inspected, pre-tested and powered up. While the controls were still at Toledo's shop, initial programs were loaded. TIS was responsible for the installation of the new control system. The control panel was placed on a mezzanine over the feed line. The TIS installers used cable tray from the control panel, down into the pit and then up each column of the press to provide a clean yet functional installation.
After the physical installation was finalized, power was turned on and a complete I/O check was conducted. Safety circuits and interlocks were tested and verified. Next, the remaining parts of the press were configured (hydraulic overloads, counterbalance, ram adjustment, main motor, etc.). Once the press control was completed, the engineers worked on commissioning the feeder. At this time, HMS was installing a new transfer system. The operator console was designed so that HMS could install their HMI in the same console as the press control. The customer would have complete control of the press, all from one place. Since Toledo provided controls for both the press and feeder, all associated screens were combined into one HMI. This ensured a seamless transition between the press and feeder screens as well as combining job data for both into one integrated HMI. Finally, the press was calibrated for tonnage and all the modes were tested and confirmed for proper functionality with the transfer system.
Results: The finished project was a success. The customer's control engineer had extensive input regarding the hardware to be used along with specific installation requirements. TIS worked closely with him throughout the installation and startup to make sure all his concerns were met. TIS and HMS were able to collaborate to ensure the integration of the press and transfer controls exceeded the customer's expectations. The upgrade not only cleaned up the entire electrical system but brought the press controls up to the latest OSHA & ANSI safety standards. The upgrade also made the electrical integration with a new HMS transfer system possible and very seamless. In the end, the controls were able to run all the new as well as the existing product demands for the upgraded press.
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