TOX®-Training ElectricDrive line-Q Training ElectricDrive ED Team 1 Training TOX® PRESSOTECHNIK ElectricDrive Training realisation: Norbert Buemann Dipl.Ing.(FH) TOX®-ElectricDrive Department Riedstraße 4 88250 Weingarten Tel.: +49 (0)751 / 5007-154 Fax: +49 (0)751 / 5007-9154 E-Mail: NBuemann@tox-de.com ElectricDrive - Hotline service: +49 (0)160 96372299 Training ElectricDrive ED Team 2 program • TOX® PRESSOTECHNIK - Company, Products • ElectricDrive overview, principle diagram • ElectricDrive Spindle (setup, function, maintenance) • ElectricDrive Controller (interfaces) • TOX®softWare, overview (setup, structure) • TOX®softWare, Modul Server • TOX®softWare, Modul Worx (data, setting up parameters, sequence) • TOX®softWare, Modul HMIconfig , HMI • TOX® PLC Communication • Questions and Comments • Practical exercises Training ElectricDrive ED Team 3 TOX® PRESSOTECHNIK - Company Training ElectricDrive ED Team 4 A medium-sized business in the international market Founded : 1978 by Eugen Rapp Owner : Eugen Rapp, Susanne Eberhardt, Stefanie Reich Employees : World-wide approx. 650 Headquarters Weingarten approx. 300 Sales : - Weingarten and more than 18 subsidiary companies in USA, China, France, Japan, Korea, Italy, Great Britain, Switzerland, Austria, Australia, Brazil, South Africa, India, Malaysia, Poland Offices in Belgium, Netherlands and Mexico - Represented in additional industrial countries by Joint Ventures Web address: www.tox-de.com as of Jan 2011 Training ElectricDrive ED Team 5 TOX®- Service world-wide, performed by 19 TOX®companies and 19 Joint-Ventures. Training ElectricDrive ED Team 6 The TOX®-Companies world wide: TOX® Germany TOX® USA (& Mexico & Canada) TOX® Switzerland TOX® China TOX® GB TOX® Brazil TOX® Korea TOX® Italy TOX® Austria TOX® France TOX® Japan TOX® South Africa TOX® Australia (& New Zealand) TOX® India TOX® Malaysia TOX® Poland (1978) 298 employees (1985) 45 (1990) 2 (1993) 238 (1993) 3 (1994) 18 (1996) 9 (1996) 3 (1996) 1 (2000) 4 (2000) 9 (2004) 1 (2004) 2 (2005) 30 (2006) 2 (2008) 6 671 employees Sales office in Belgium (1) and Netherlands (1) Training ElectricDrive ED Team 7 Business Partner in A Argentina P Portugal C Colombia Czech Republic R Romania D Denmark S Slovakia Russia E Estonia Slovenia F Finland Spain H Hungary Sweden L Latvia Lithuania T Taiwan Thailand Turkey Training ElectricDrive ED Team 8 TOX® PRESSOTECHNIK USA (since 1985) Sales for USA, Canada and Mexico With 45 employees Sales of the entire product range in USA, Canada and Mexico. Design and manufacturing of presses, tools and special equipment for the market in USA, Canada and Mexico. TOX® Test Centre for USA, Canada and Mexico Training ElectricDrive ED Team 9 TOX® PRESSOTECHNIK China (since 1993) With 238 employees Sales of the entire product range in China via 14 sales offices in all industrial areas. Series production of cylinders and parts for the TOX®-Powerpackage product range Design and manufacturing of presses, tools and special equipment for the local and Asian market TOX® Test Centre for China Training ElectricDrive ED Team 10 The TOX® sales structure Sales world-wide regional oriented nationwide oriented Field service, subsidiaries, representations Key Account Management Retail Standard machines Standard modules / components Product competence Technological qualification Service competence TOX®-Service Training TOX®-Drives TOX®-Presses, Tongs, etc. Equipment TOX®-Joining • Powerpackage • Presses • Multipoint tools • ElectricDrive • FinePress • Controls TOX®-Clinching TOX®-ClinchRivet • Hydraulic cylinder • Hand tongs • Monitoring • PowerKurver • Stationary tongs - Sensors • Robot tongs - Process monitoring Special machines Large projects Solid punch riveting / punching / coining / bending / inserting / mounting a.m.m. Positioned world-wide TOX® with guaranteed retention force Test reports with guarantee! TOX®softWare Training ElectricDrive ED Team 11 TOX®-ElectricDrive Electro-mechanical Servo-Spindle TOX®-ElectricDrive Training ElectricDrive ED Team 12 TOX®-ElectricDrive – A complete system 1. mechanic: spindle 2. Controller line-Q / line-X 3. Software EDC1/2 S&M 6105 / Lenze L9400 modulare spindle design EPM Electric Power Module Training ElectricDrive EDC-Compact / EDC-L9400Achs-Controller ElectricDriveController ED Team TOX®SoftWare 13 Why TOX® electrical spindles? Reasons: Ecological Economical (Total cost of ownership) complete unit (controller + spindle + cables + sensors) minimum construction times (system inclusive data for mech./el. construction CAD/EPLAN) no programming only inputting of parameters (ready functions and PLC interface) Controller Backup with Copy/Paste, documentation in pdf-file < 10sec Features during the process very flexible and very dynamic the best solution if you have different product types depending upon application saving of mechanics (e.g. 1 Clinch robot instead several) Integrated Sensors Reduced maintenance Shortened engineering times no air, no oil energy consumption only when needed drive to Force and hold (adjustable), bending up compensation no limitation of the force position (limitation only by holding time I²T) Surely in the future ...new requirements to be solved by the software! Training ElectricDrive ED Team 14 Easy Integration with the TOX®-Axis Controller Option Ethernet network Ethernet Server • Support for field bus systems • Ethernet TCP/IP for programming & data storage • Can function as a standalone Fieldbus or I/O interface Force sensor, Resolver, Motor connection Station Controller, PLC Ethernet • Easy integration into dial machines & assembly lines PC for programming TOX®-Press-Controller Spindle EPM Training ElectricDrive ED Team 15 The Driver: TOX®-Electric Power Module EPM A Design for every application EPMS Standard EPMK Compact EPMR Tongs - Actuators EPMK Version 060 with Holding Brake or Safety Brake (required for highest Safety Category) Training ElectricDrive ED Team 16 TOX®-EPM: The flexible and high precision Actuator Technical Data: Force Range: 0,5 – 400 kN Standard Stroke length: 250/300 mm Speed: from approx 0 to 300 mm/s Accuracy: Force: Distance-RepeatabilityAccuracy: Intl. Protection Level: ≤ +/- 0,5% from maximum force +/- 0,01 mm IP 54 Customer specific solutions are possible: Stroke length, speed, force . . . Training ElectricDrive ED Team 17 TOX®-EPM: Performance Data Main Features: Modular, compact Servo Motor with resolver Force sensors built on to the housing High performance - Planetary roller screw EPMX Model (Standard) EPMX10 EPMX25 EPMX55 EPMX100 EPMX200 EPMK400** from 0,5 1,25 2,75 5 10 20 to 10 25 55 100 200 400 Speed [ mm/s ] 300 220 200 200 85 40 Stroke [ mm ] 250 250 300 300 300 300 Overall Length EPMS [ mm ] 939 1200 1270 1380 1610 - Overall Length EPMK [ mm ] 657 657 761 854 973 1260 Flange Ratio, A/A1 [ mm ] 70/92 70/92 95/120 115/142 145/170 250/276 Weight EPMS [ kg ] 21 25 43 72 140 - Weight EPMK [ kg ] 22 26 46 78 154 543 Force Range* [ kN ] *In pressing direction, in tension direction 30% of that, except for EPMK 400 - 100 % in both directions Training ElectricDrive ED Team ** Only in connection with the line-X Axis -Controller 18 TOX®-EPMR: The compact and light Tong-Actuator Main Features: Small design Special flanges for TOX®-Robot-Tongs mountings EPMR Model (Standard) Force Range [ kN ] EPMR55 EPMR100 from 2,75 5 to 55 100 100 200 120 Speed [ mm/s ] 120 200 100 Overall Length [ mm ] 567 667 668,5 Flange Ratio, A/A1 [ mm ] Weight [ kg ] Training ElectricDrive 95/120 38 pr. 45 115/144 68 ED Team 19 TOX®-EPM: The Design Hold Brakes / Safety Breaks Durable, Robust, Compact Safety Brake: 1 Brake feedback: Hall–Sensor 1 separate cable incl. contactorcombination Enclosed High Performance Planetary roller screw Working Piston Planetary gear Synchronous Servomotor Resolver Precision and accessibility Force Sensor Training ElectricDrive max. Energy efficiency max. Controllability ED Team 20 Cross Section View of an EPM highly efficient planetary roller screw , coupler Training ElectricDrive holding/ safety brake (option) belt working rod force sensor (hollow axle) lubricating nipple resolver bearings servo motor ED Team planetary gearbox 21 View of the TOX®-Drive EPM servo motor with resolver 2x force sensors coupler Planetary gearbox bearings belt & pulleys working rod highly efficient planetary roller screw Training ElectricDrive ED Team 22 Principle of Planetary Roller Screw Advantages of the planetary roller screw vs. ball, acme screw - higher power density - longer lifetime - higher dynamic - higher static capacity - higher rigidity - higher transmission speed - high revolutions up to 6000 min-1. Our planetary roller screw is designed to the highest standards in the industry, ensuring the highest life expectancy under full load cycles. Training ElectricDrive ED Team 23 Anti-Rotation built on working rod Training ElectricDrive ED Team 24 The Order Number For Types: EPMS / K / R EPMK 200.060.300.001 Stroke [mm] Type (060= Single Brake, 030= no Brake) Max. Force [kN] Type (Standard, K(Compact), Robot Tong) Electric Power Module Training ElectricDrive ED Team 25 Transporting the Spindle All EPMK-Types, all EPMR-Types Transporting with a crane or a lifting jack There are threaded holes on the flange lid for a ring screw to hoist the EPM Types K and R. The smaller EPMS devices do not have holes for screws, on all EPM Types of size 100 and 200 there are threaded holes on the bearing housing and on the front flange. These threaded holes are closed with a machine screw, which must be removed before the ring screw can be installed. Replace this machine screw again after transporting the spindle. only EPMS / K / R 100 / 200 Training ElectricDrive ED Team 26 Transporting Tongs Transporting with a crane or lifting jack There are threaded holes for ring screws to hoist the tong. These can be found on the C-Bow of the tongs. Screw two ring screws in the diagonally positioned threaded holes and fasten the transport harness the lifting jack and the ring screws. Training ElectricDrive ED Team 27 Cleaning Clean the EPM on a weekly basis in order to minimize dust deposit to ensure that the motor is dust free. • Caution: Burn hazard Let the drive (in particular the motor and the brake(s)) cool down before starting to work on it!) • Cleaning agent Do not use high-pressure cleaners or any cleaning agents to clean the machine. Training ElectricDrive ED Team 28 Inspection Yearly inspection (approx. every 2500 hours of operation) 1 Pos. Component Work description Safety, Note 1 Guide block / guide roller Check the play of the block by turning the working rod, exchange by TOX® PRESSOTECHNIK if necessary Skilled technician! Make sure machine cannot be enabled, Attention: During repair prevent tool from dropping! – All mechanical components Pay attention to unusual noise Skilled technician ! Caution during while machine is in process! If unusual noise can be heard, please contact TOX® PRESSOTECHNIK. Training ElectricDrive ED Team 29 Before Maintenance and Repair Seals (sealed threads) During all maintenance and repair work, do not open any seals (sealed threads) unless otherwise noted. Safeguarding the machine The following text describes how the machine must be secured against accidental start up. The following steps can be performed only if the machine is locked out and protected against accidental restarting, dangerous movements must come to a standstill, all steps must be followed to prevent an accidental or unexpected start up, and the initiation of potentially dangerous movements due to stored energy must be prevented. During maintenance and repair secure the machine Working rod, tool, and tool mount must be secured against movement during any maintenance and repair work. This is especially important if brakes and the anti-rotation of the working rod must be disassembled during maintenance or repair work: Without additional safety, the working rod can uncontrollably move downwards! Training ElectricDrive ED Team 30 Maintenance TOX® press spindle No special support is needed. The spindle must be lubricated periodically. We strongly recommend the TOX® special lubricant or a TOX® approved lubricant. Greasing 1. 2. 3. 4. 5. Move the spindle into its home position. Should the rear lubricating nipple not be accessible in home position, move the spindle nipple to the other position and use the second hole. Remove the screw plugs on the cylinder tube of the spindle. Make sure that the spindle cannot be powered up unintentionally. Grease the spindle with the amount of grease according to the table (grease nipple at side panel; use TOX®-grease gun). Training ElectricDrive ED Team 31 Spindle Lubrication Use only high pressure grease For greasing purposes, only high pressure grease should be used, e.g. Use the TOX® special grease for TOX®ElectricDrive Systems Example: EPMK55 max. position programmed =100mm acc. table: all 245.000 cycles approx. 5,5 cm² grease Training ElectricDrive RE GREASING EPMx 05/010 EPMx 025 EPMx 055 EPMx 100 EPMx 200 EPMx 400 Quantity grease for nut [cm3] 1.7 2.0 5.5 11 21 14 (total) stroke per cycle [mm] Regrease after ... cycles Regrease after ... cycles Regrease after ... cycles Regrease after ... cycles Regrease after ... cycles Regrease after ... cycles 50 100 150 200 250 300 350 400 450 500 550 300 1.150.000 575.000 380.000 285.000 230.000 190.000 165.000 140.000 - 525.000 305.000 230.000 195.000 175.000 145.000 125.000 105.000 - 420.000 245.000 185.000 155.000 140.000 115.000 100.000 85.000 75.000 70.000 - 900.000 525.000 400.000 335.000 300.000 250.000 210.000 185.000 165.000 150.000 135.000 125.000 825.000 480.000 365.000 305.000 275.000 225.000 195.000 170.000 150.000 135.000 125.000 115.000 585.000 340.000 260.000 215.000 195.000 160.000 135.000 120.000 105.000 95.000 85.000 80.000 ED Team 32 Force Sensor, Wear out brake Force Sensors The force sensors should be re-calibrated 1 x year or depending of company internal quality standards. Wear out brake The brake wear out will be check with the brake test. (80% of the nominal brake moment) A defect or worn out brake brake must be changed immediately from qualified personal. How to change a brake is described in the Hardware manual. Training ElectricDrive ED Team 33 Control Overview, System Layout, -> line-Q Controller Ethernet Server Option Ethernet TOX®-Press-Controller “EDC Compact” line-Q Field bus or I/O interface Spindle EPM Station Controller, PLC Force sensor, Resolver, Motor connection Ethernet or RS232 TOX®-AxisController and spindle are pre commissioned together. Please control the numbers PC for programming Training ElectricDrive ED Team 34 TOX®-Axis-Controller line-Q For each TOX®-ElectricDrive the suitable controller size EPMx 10 061.05.20.KF EPMx 25 061.05.20.KF Powerarea : 22A / 40 A Devicesize: W x H x D: 123,5 x 310,8 x 273,5 Training ElectricDrive EPMx 55 061.05.20.KF EPMx 100 EPMx 200 061.05.20.IF 061.05.20.IF EPMx 400 Rackcontroller Powerarea : 22A / 80 A Devicesize: W x H x D: 123,5 x 310,8 x 273,5 Powerarea : 30A / 120 A Devicesize: W x H x D: 249 x 266 x 312 ED Team 35 Start processes in the TOX®-Axis Controller Station PLC 3 Possibilities to select and start the 3. I/O 24Vdc interface X50/X51 processes in the controller: 1. Field bus: Profibus-DP with TOX®-Siemens-FB / Interbus (8 Bytes), Gateways TOX®Press-Controller 1. Fieldbus Profibus, Interbus or Gateways • 2. Ethernet TCP/IP : 2. Ethernet with HMI with TOX®-HMI • 3. Digital I/O: with z.B. 4 Inputs X50 Bezeic Pin hnung Funktion Standard X51 Bezeic Pin hnung Funktion Standard 1 24 V 11 OUT7 free/Br2Test 2 0V 12 OUT6 Free/Br1Test 3 IN7 Prbit 3/Brake 2FB 13 OUT5 free 4 IN6 Prbit 2/Brake1FB 14 OUT4 Press ready 5 IN5 Processelectbit 1 15 OUT3 NOK 6 IN4 Processelectbit 0 16 OUT2 OK 0001 => Process 2 home pos 7 IN3 (Sensor Ref.) 17 OUT1 Ready 0011 => Process 4 jog forward 8 IN2 frei 18 OUT0 Amplifier On 1111 => Process 16 customer pr. 9 IN1 Start signal 19 RIO - n.c. 10 IN0 E-Stop 20 RIO + n.c • -> 16 processes 0000 => Process 1 Referenz Training ElectricDrive ED Team Force sensor, Resolver, Motor Spindle EPM 36 TOX®-Axis-Controller EDC Compact • Integrated digital controller / amplifier • Compact design (High: 273,5 mm Wide: 125 mm Deep: 285 mm) • Main voltage: 3 x 360- 504 VAC • Transient filtering of AC main voltage • Integrated motor overload protection • Digital closed loop system with 500µs scan time • Drive Status Display LEDs • Electric isolation between controller and amplifier • Category 3/4 safety on board, no external relay necessary Training ElectricDrive ED Team 37 TOX®-Axis-Controller EDC Compact • Standard: Ethernet, Profibus-DP and RS232 (Interbus is optional) • Interface for transducers (force sensors) • 2x RS 232 Ports for data extraction (ASCII) • Real Time Clock • 8 digital inputs and 8 digital outputs on board • On board diagnosis and process supervision • Efficient firmware specially made for press and joint operations Training ElectricDrive ED Team 38 Hardware Controller, Front Panel • LED status indications • X2 COM, terminal interface / programming interface • LED for status indications of the inputs and outputs • Not used: X6 SIO, connector for serial input and output modules X4, X5 angle pulse inputs X3 angle pulse output • X1 Feedback, connection of the motor feedback • Option module (1mV or 2mV) ? Training ElectricDrive ED Team 39 Hardware Controller, Front Panel, LED • LED status indications, Operating manual Training ElectricDrive ED Team 40 Hardware Controller, Bottom View X7 Ethernet Option: Option: X8 MODLINK, CAN X9 CAN, analog Input RJ 45-plug with 8- female connector Bottom view 8 1 Pinbelegung der Buchse X20 motor plug Training ElectricDrive ED Team 41 Hardware Controller, Side View X 52 - 24V Supply/Thermal Contact X30,X31 Power 3 × 480 VAC X 40 new – Category 4 Safety circuit X 40 X 30 X 31 Designation 21 Thermal contact 22 24 V internal 23 24 V external 24 0V X 50 / X 51 - Inputs and Outputs of the Logic Signals X 52 X 50 X 51 X50 Design Pin ation Training ElectricDrive X52 Pin Function Standard X51 Design Pin ation Function Standard 1 24 V 11 OUT7 free 2 0V 12 OUT6 free 3 IN7 Program bit 3 13 OUT5 free 4 IN6 Program bit 2 14 OUT4 Press Ready 5 IN5 Program bit 1 15 OUT3 NOK 6 IN4 Program bit 0 16 OUT2 OK 7 IN3 free 17 OUT1 Ready OUT0 Amplifier ON 8 IN2 free 18 9 IN1 Start signal 19 No connection 10 IN0 E - STOP 20 No connection ED Team 42 Hardware Controller, Option module 2 LEDs (Fieldbus Communication OK) X13 Connection for passive/active transducer 1 DMS strain gauge for measuring forces (350/700 Ohm, 1 mV/V up to 4 mV/V sensitivity) COM3 COM2 (Serial interface to export data) (Serial interface to export data) X11,X12 Interbus-Connection Interbus- Input (X12) , Interbus-Output (X11) X10 Profibus-Connection Training ElectricDrive ED Team 43 TOX®softWare Suite: The Software for Paramatization – Operation - Visualization The software allows the operator a quickly and easily establish or change of the pressing sequences. • Multiple languages • Operating system independent • Various user levels • Start-up / Launching function • Operator friendly • Integrated documentation TOX®softWare Suite Composed of: • WORX • HMI • Server - Work Level - Operation Level - Connection of PC to Axis-Controller Training ElectricDrive ED Team 44 Software, Functional Diagram PLC Program Software on the PC HMI Worx / Toxware Training ElectricDrive TOXServer Software on the EDC Ethernet or RS232 Process Application Firmware ED Team 45 Software for the PC HMI Human Machine Interface shows status, diagnostics, process values, and evaluation curves to the user. Fit for touch screen on industrial PC. Worx Engineering platform for parametric processes on the EDC. Shows force over distance diagrams, controls the process. TOXServer Background process for communication between the PC and EDC. Training ElectricDrive ED Team 46 Software Inside the Controller Process Made by the customer, configures the process and determines positions, velocities and forces in the process. Application Program to realize all the possible process functions. Made by TOX® PRESSOTECHNIK. Changes by TOX® PRESSOTECHNIK only. Firmware Software made by the controller manufacturer to reach the special requirements and properties of TOX® PRESSOTECHNIK Training ElectricDrive ED Team 47 TOX®softWare: Installation Java Runtime Machine =>Version 1.5 must be installed (uninstall version 1.4 !) Insert the CD into the CD drive and run the SETUP.EXE program. Needed free hard disk space: about 45 MB Training ElectricDrive ED Team 48 TOXServer Get Connected Between PC and EDC To supervise adjust and change processes, a connection between the PC and the EDC is necessary. Two different ways are possible: Connection fault 1. Connection via serial interface (RS232) disadvantage: communication is slow, only point to point connection. 2. Connection via Ethernet (recommended) advantage: fast communication between more than two units possible. Connection OK Training ElectricDrive ED Team 49 TOXServer Setup Ethernet Communication Ethernet Communication: Connect the EDC with PC and start the TOX Server. Go on Authentication, Log on.. And log on with at least level 2 (default password tox2). In device, add, EPx… and then a new screen will open Select the Ethernet connection and fill in the module number. Confirm with OK. Default module number is 0, default IPAddress is 192.168.50.99 (old 192.168.1.99) (make sure that the IP-address is reachable, windows ping command ) Training ElectricDrive ED Team 50 TOXServer Setup communication RS 232 Serial communication: Connect the EDC with the PC and start the TOXServer. Go on Authentication, Log on. Log on with at least level 2 (default password tox2). In device, add, EPx… and then a new screen will open. In this screen select Serial and select the right port and address. Confirm with Ok. Training ElectricDrive ED Team 51 Worx TOX®softWare: Worx Menu bar Symbol bar symbol bar Tab sheet Status bar z Scroll-bar File system window Training ElectricDrive Window on the Workspace evaluation windows ED Team 52 Worx Password Level Password protection TOX®softWare LEVEL 4 LEVEL 3 LEVEL 2 LEVEL 1 TOX OEM Maintanance Operator Training ElectricDrive ED Team After every start, the program is in access level 1. Level 1 Operator Level: Observation only no editing of any Values or changing of programs. • Level 2 Level for Maintenance and advanced Operators: Editing and Programming of press cycle and parameters possible. • Level 3 Level for Machine Builder: all functions are enabled except 'Generate spindle data'. Level 4 Highest level. Reserved for TOX® PRESSOTECHNIK 53 Worx TOX®softWare: Mount File system File \ Mount File system When this menu option is selected, a window is opened in which you can select from a list the file system you want to mount: The mounted directory is displayed in the 'File systems' window. In doing so, you can save data on the PC hard drive. Training ElectricDrive ED Team 54 Worx System Data In the system data you can see the software version and the name of the software. Firmware This information can help us find problems or to find a decision to download new firmware and application. Application Training ElectricDrive ED Team 55 Worx Device Data Editor The device data editor is used to adjust IPaddress and other features of the EDC. IP-Address: assess the address on the Ethernet bus. Default is 192.168.50.99 Start signal source: define the source for start. You can choose between input or fieldbus as start signal. Interface: final values and status can send via RS232 interface to a Host PC. Process clearance: process clearance can be made dependent on different variables. Training ElectricDrive ED Team 56 Worx Spindle Data The content of SPINDLE DATA describes all the electrical and mechanical data of the spindle. The data has been created by TOX® PRESSOTECHNIK and cannot be changed. Exceptions are the values for calibration factor, input for program selection and a few other variables. These values can be changed in authorization level 3. The spindle data of the actual spindle is stored in the controller and on the CD. Training ElectricDrive ED Team 57 Worx Adjust Press Force The EPM does not measure the force directly. The unit measures the tension in the housing. So it is necessary to adjust (calibrate) the force to the tension. The data can be written in a chart, and the average is calculated by Worx. Download the value to the controller and reference the spindle. Training ElectricDrive ED Team 58 Worx Final Values Memory for approx. 1000 processes like date, status, force position and limits for force and position. This memory can be read out and the data can be stored on a PC. Via field bus it is possible to read out the last data set. Training ElectricDrive ED Team 59 Worx State of Variables Shows all the variables and markers of the application program. This data is often helpful to adjust a process or find a problem. Training ElectricDrive ED Team 60 Worx Process Creating a Process To create a process (press program) the functions are selected and set up into a sequence. This sequence will then be configured by the programmer by changing the parameter. In the functions, it is not possible to enter data that exceeds the max. and min. values of the spindle data. In that case a warning appears and a download of the data on the EDC is not possible. Training ElectricDrive ED Team 61 Worx Process Creating a Process Procedure to create a Process: At first a new process must be generated with a click of the right mouse button on the Line processes. Then appears a selection and a new process can be added. Select these and finish the process with double-clicking. You can give the process a name with the right mouse button. Change the mouse pointer to the programming process and double-click on the process. The process window opens. The function selection occurs by double-clicking on the desired function. The function will appear behind the last function and marked grey. The order of the functions may be freely chosen and can be changed. Copying and deleting functions is also possible. Training ElectricDrive ED Team 62 Process Worx Move Functions Function Acts like Feed forward Motion to one position or force. Limits could be either force or position. Limits for both are required to generate an evaluation window in the graphical chart. Will use fast motion to arrive at work position. Feed forward to a relative position Motion onto a position relative X mm from the previous position. Use this function only to compensate for position deviations of components. Feed forward to PLC values Motion to one position or force. Limits could be either force or position. The parameters are delivered by the fieldbus interface from a PLC. Training ElectricDrive ED Team 63 Process Worx Move Functions Function Acts like Feed forward to compensated PLC values Motion to a position over Fieldbus. At the same time the deflection of the mechanic and the tool will be compensated. Use with accurate positioning related to the component, and with floating process forces. Pressing Motion to a position or force. Potential limits are either position or force. Both limits have to be entered if you want to see an evaluation window in the chart. Function will be used with high pressing forces. Pressing deflection compensated Function is similar to pressing, but the deflection of the mechanics and the tool will be compensated. It will be used on pressing on a position with strong floating process forces, to achieve a stable result of the component. Training ElectricDrive ED Team 64 Process Worx Move Functions Function Acts like Feed back Move to one position. Used to get back to the starting point. Jog forward Jog manual in positive direction with adjustable speed. With the start input or start command over fieldbus the axis is moving. Jog reverse Jog manual in negative direction with adjustable speed. With the start input or start command over fieldbus the axis is moving. Training ElectricDrive ED Team 65 Process Worx Switch and Additional Functions Function Acts like Position monitoring A window with minimum and maximum position may be entered. The final position must be located in this window. Time supervision Reaching a position can be combined with time-control. When the time is reached and the position is not, then the axis is stopped with a fault. Transition velocity Speed between this and the following function will be aligned so that the axis at the end of the section is the speed of the following section. The next section will begin without stopping. Stop contact When this is active, the section with the entered contact will end. The functions of the switch and additional functions applies to all branches of an association that are active. Training ElectricDrive ED Team 66 Process Worx Process Control Function Acts like Referencing Function used after switching on the axis or after altering the Spindle data. The default is a reference on the inner wall position of the spindle. After reaching the inner cylinder wall, the axis moves X mm forward. This location is the zero point of the module. All parameter limits are fully programmable. Time delay Time delay or latency in the process. The delay function can be used to add latency in the process. The function will wait for input. Training ElectricDrive ED Team 67 Process Worx Process Control Function Acts like Repair strategy If a function ends with an error, this function will generate a recovery (i.e. Feed back to home) If the program selection is done by Fieldbus, it is recommended to do the fault reaction in the PLC. Define stop contact Here an input can be defined, whose programmed limit value completes the current process. In this process the stop contact must be present. acceleration Put a defined acceleration in mm/s². This acceleration remains active as long as another acceleration is set. deceleration Put a defined delay in mm/s². This delay remains active as long as another deceleration is set. Training ElectricDrive ED Team 68 Process Worx Process Control Function Acts like Synchronization Function to syncronize processes with each other. Mainly used to syncronize the PLC and a press. Synchronizing is made via flags or Inputs/Outputs. Wait for start contact This function is used in the hidden process 0. It shouldn't be used in any other processes. Training ElectricDrive ED Team 69 Process Worx Diagram Function Acts like Start curve record Set the trigger for chart. In the diagram, the Trigger program must be selected. In the HMI the Trigger Sequence must be selected. If this function is not used Uservariable0. Training ElectricDrive ED Team 70 Process Worx I/O Function Acts like Wait for input This function makes the process wait for the programmed input to reach the selected state. Inputs must physically be present. The state can be 0 or 1 (low or high). Set output Sets an output to a defined state. The output cannot be physically present. The state can be 0 or 1 (low or high). Training ElectricDrive ED Team 71 Process Worx Transducer (Force Sensor) Function Acts like Initialize transducer Initializes the transducer, detects the offset value of the sensor, sets the current value to 0, and checks the function of the sensor. This function should always follow the reference run. The function gives an error when the limits of this function are not reached. Check transducer Takes over the value of the function, and initializes and checks the transducer. The function should only be used when the working rod is not under force. Keep in mind that this function delays the start around 0.2 s. Training ElectricDrive ED Team 72 Process Worx Process Data Function Acts like Save intermediate value Saves the data and borders for force and position from the previous function. Save intermediate value can be used 2 times per process. Save end value Saves the data and borders for force and position from the previous function. Set the Controller Outputs OK/NOK and the Siemens FB Outputs. In the EDC saved process data, it has a time/date stamp that can be read out. Across the field bus, only the last data record can be read out. Training ElectricDrive ED Team 73 Process Worx Special functions Function Acts like after running test This function is special for presses with the highest safety level. This is only necessary to measure the after running time of the press. Only to use by TOX® PRESSOTECHNIK. Only visible for presses with the highest safety level. Training ElectricDrive ED Team 74 Process Worx Utility Function Function Acts like Comment This allows the user to insert comments about the processes to make them comprehendable. Training ElectricDrive ED Team 75 HMI Connect HMI Config 1. Global 2. Application packages Training ElectricDrive ED Team 76 HMI Connect HMI Config 4. Connections to the controller 3. Languages Training ElectricDrive ED Team 77 HMI HMI Start screen QSM Quick_Start_Menue Zum TTM TOX_Touch_Menue Training ElectricDrive ED Team 78 HMI HMI Config TTM, QSM Display screen: Config TTM TOX® Configuration Menu Arrangement, create the visual screens Display screen: Config QSM Arrangement, create the short key menu Training ElectricDrive ED Team 79 HMI HMI Diagnostic Display screen: Diagnostic View Errors, warnings, information Training ElectricDrive ED Team 80 HMI HMI Manual Screen Display screen: Manual screen Display. Command masks Input , output Training ElectricDrive ED Team 81 HMI HMI Counter All Counter counts ascending Can be reset at any time e.g. 0 if shift ends OK Counter counts ascending Can be reset at any time e.g. 0 if shift ends Maintenance Counter counts descending. Message shown if 0. Can be reset at any time e.g. 0 after maintenance Training ElectricDrive ED Team 82 HMI HMI Press Screen Display screen: Chart View-screen Configuration Force-distance diagram Training ElectricDrive ED Team 83 Replace Controller 1. 2. 3. 4. 5. 6. Disconnect all connections to the controller. Replace the controller. Make sure that the replaced controller is of the same type. (e.g. Controller Typ: 0610520KF1242 43B Motor: HLR 48180 8pol. 7200U/min, 60Grad, X13 Transducer Input: 1 or 2 mV/V see plate) Set Dipp switches for Motor EPROM ! Reconnect all connectors to the controller, and check the connectors. Set the address wheel to the position of the old controller. Switch on the machine. Connect the laptop (PC) to the EDC Controller and go online. Ethernet (192.168.50.99 oder RS232 seriell) Following menu appears on the screen: You need the rights for 'User level 3' or 'User level 4' (see the entry in the status line). Training ElectricDrive ED Team 84 Tausch / Replace Controller (Note Firmware and Applikation) Training ElectricDrive ED Team 85 Replace Controller (Note Firmware and Application) 7. Go to “system data” and check the firmware and the application Firmware Firmware TPPEN35 = ToxPressotechnik Profibus Application Application name Date TK41M100 = Kat 4 1 Brake 100 KN 8. The firmware and the application must be the same as in the replaced controller. If it is not, please contact TOX® PRESSOTECHNIK or load the firmware and application into the new controller. (Firmware+Application must be from the same folder! e.g Tox_345) Training ElectricDrive ED Team 86 Replace Controller (Load Firmware) Select the File and load firmware file ******.XPR Training ElectricDrive ED Team 87 Replace Controller (Load Firmware) Training ElectricDrive ED Team 88 Replace Controller (Load Application) Select the File and load application file ******.61 Training ElectricDrive ED Team 89 Replace Controller (IP-Address) 9. Select ‘Device Data'. Check the IP-Address, and change it if necessary. Training ElectricDrive ED Team 90 Replace Controller (Spindle Data) 10. Copy the spindle data from an offline project to the spindle data of the online adapter. Training ElectricDrive 11. Control the spindle data: type, spindle length of the online data. 12. Download the data to the controller Load the Data into the Controller. (RAM und EPROM !) ED Team 91 Replace Controller (Process Data) 13. Load the last saved copy of the process data and save the data on the controller. 14. Control the spindle, start reference program (no. 1) and start the process program. Training ElectricDrive ED Team 92 Replace Spindle (Change Spindle) 1. Switch off and lock the machine. Disconnect all connectors at the spindle motor to the cabinet. Motor cable, Resolver cable, 2. Replace the spindle, make sure you replace the spindle of the same type. (Information Machine Builder how to replace the spindle ?) (For another new spindle on the same controller you must have a set of spindle data, Backup) Write /Save the new calibration factor from the new spindle to the spindle data. Reconnect all connectors to the replaced spindle. Switch on the machine. Ready to Start. 3. 4. 5. Training ElectricDrive ED Team 93 Replace Spindle (Different Type of Spindle -> Change Spindle Data) 5. If you have a different Spindle: Connect the Laptop ( PC) to the EDC Compact Press Controller and go online. You need the rights for 'User level 3' or 'User level 4' Copy the correct spindle data to the spindle. (If you do not have, ask Tox Pressotechnik to send them) load the data into the controller. RAM and EPROM ! Training ElectricDrive ED Team 94 Robot/PLC Program TOX® Communication Protocol (Fieldbus) Training ElectricDrive ED Team 95 PLC Program Summary of TOX®-Siemens PLC FB (Function Block) The function block communicates to the controller. In S7: The HW configuration uses the TOX®-GSD-element for the TOX®-Controller: Profibus address = controller switch + 3 Configure the communication to 8 bytes Profibus DP Max. 12 Mbaud. Bus Status LED Green = OK Training ElectricDrive ED Team 96 Robot/PLC Program TOX® Communication Protocol line-Q (Telegram Structure 8 bytes) Inquiry Telegram, (Command Bytes) 8 bytes of data transmitted / sent by the PLC to the CNC module Reply Telegram, 8 bytes of data transmitted from the CNC module received by the PLC or Robot Training ElectricDrive ED Team 97 Roboter/PLC Programm TOX® Communication Protocol (Inquiry Telegram) Inquiry Telegram, (Command Bytes) 8 bytes data transmitted / sent by the PLC Byte# Name Meaning 0 CMD_SBYTE control byte for the command transmission Bit # Name Meaning 0 CMD_VALID start command 1 CMD_DISABLE disable command 2 res reserved 3 res reserved 4 res reserved 5 CMD_USER user bit 6 CMD_HBEAT heartbeat bit 7 CMD_SYNC synchronization of modules 1 CMD_BYTE command byte, contains the command number 2 CMD_HI handle index 3 CMD_HSI handle sub index 4 ... 7 CMD_PAR double word (4 bytes) for the parameter transmission to the CNC module Training ElectricDrive ED Team 98 Roboter/PLC Programm TOX® Communication Protocol (Reply Telegram) Reply Telegram, 8 bytes, data transmitted from the CNC module (received from the PLC) Byte# Name Meaning 0 CNC_SB0 status byte 0 Bit # Name 0 CNC_DONE 1 CNC_ACKN 2 CNC_ERR 3 --4 CNC_INPOS 5 CNC_USER 6 CNC_HBEAT 7 CNC_SYNC status byte 1 Bit # Name 0 CNC_INIT 1 CNC_RUN 2 CNC_ON 3 CNC_CAL 4 CNC_VZERO 5 CNC_HANDLEFAU LT 6 CNC_VARC 1 2 3 4 ... 7 Training ElectricDrive CNC_SB1 CNC_SB2 CNC_SB3 CNC_PAR Meaning command finished, toggle command received, toggle error message --in position window user bit heartbeat bit synchronization modules Meaning initialization necessary application program runs regulator ON calibrating actual speed = ZERO transmission error ref. speed 7 CNC_PILIMIT peak current status byte 2, error and message codes status byte 3, user byte command return value ED Team 99 PLC Programm TOX®-Siemens PLC FB (Function Block) Inputs: - Start (Start the Program) Outputs: - Cancel (Stop running Prog.) - FaultReset - Jog Mode - ResetPosForceOKNOK - EDC Brakecontrol - HW Input-PB-Adress - HW Output-PB-Adress - DB-Tox Values (e.g.DB121) - ControlBrake 1 - Brake1Braked - ControlBrake 2 (if 2 brakes) - Brake2Braked (if 2 brakes) - Supervision Timer (e.g T1) - BrakeTimer (e.g. T2) - HBeatTimer (e.g T3) - Write values in EDC - Number of Sets (1-3, 4=all) - Sequence_nr (only for sequence control) - Set Output x on EDC - Value from output (0/1) -ReadyFor Operation -FaultBit_EDC (1=fault) -Faultcode_EDC -Faultbit_FB (1=fault) -Faultcode_FB -CommandRuning -Referencing_Done -PositionOK -PositionNOK -ForceOK -ForceNOK Training ElectricDrive -ReleaseBrake1 -ReleaseBrake2 -Position (actual Pos. ) -Force act. (actual Sen1) -Sequenz feedback from HMI -End sent values to EDC ED Team 100 PLC Program TOX® Siemens PLC DB (DB_Tox_Values) The program and the parameter must first be written into the DB. After that, the controller process can be started via the FB start input. Enter Worx Program Number in Controller 11 values for “Press to external PLC values“ Training ElectricDrive ED Team 101 PLC Program TOX® Siemens PLC DB (DB_Tox_Values) After the process is finished the final values can be read from the DB. Finalvalue Intermediate value 1 Intermediate value 2 Training ElectricDrive ED Team 102 PLC Program TOX® Siemens PLC DB (DB_Tox_Values) Timer to control the program-sequence and FB time State of the Inputs / Outputs controller Training ElectricDrive ED Team 103 PLC Program TOX® Siemens PLC DB (DB_Tox_Values) Allowed spindle min/max values when pressing to external PLC values In program 1 – 30 it is possible to press to external PLC values. Number of functions in one process with the function “pressing to external PLC values“. Release the process when it is present in the controller. Program number (1-30) Activate the reading of the final values and intermediate values Training ElectricDrive ED Team 104 PLC Program TOX® Siemens PLC FB (Error_Code from Controller) List of the error codes from the Controller EDC No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 ... 16 17 18 ... 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 … 71 72 73 74 Training ElectricDrive Name ERR_NONE ERR_VALUE ERR_STATE ERR_BUSY ERR_FLASH_ERASE ERR_FLASH_CHECK ERR_FLASH_ID ERR_FLASH_WR ERR_CHECK_SUM ERR_EEPROM ERR_ZPULS_CRITIC ERR_WRONG_PARA ERR_BUS ERR_CONFIG ERR_PAR ERR_TASK_CNT ERR_DC ERR_USER_0 ERR_USER_1 ERR_USER_2 ERR_USER_3 ERR_USER_4 ERR_USER_5 ERR_USER_6 ERR_USER_7 ERR_USER_8 ERR_USER_9 ERR_USER_10 ERR_USER_11 ERR_USER_12 ERR_USER_13 ERR_USER_14 ERR_USER_15 ERR_ANGLE_MAX ERR_ANGLE_MIN ERR_START_LOST ERR_TIME_OUT ERR_TORQUE_MAX ERR_TORQUE_MIN ERR_TRANSDUCER ERR_PAR_GROUP ERR_TIMEOUT_SYNC Description No error Wrong Parameter or local Function not allowed in Module working Error erasing Checksum Error ID-Error FLASH_EPROM Write Error FLASH_EPROM Checksum Error EEPROM-Error Problematic Null impulse Wrong Parameter Bus Error Configuration Error Reserve Parameter Error Too many parallel programs Voltage Error Reserve User Defined Error Display User Defined Error Display User Defined Error Display User Defined Error Display User Defined Error Display User Defined Error Display User Defined Error Display User Defined Error Display User Defined Error Display User Defined Error Display User Defined Error Display User Defined Error Display Empty Barcode Fault between 1. and 2. Zero Position Fallen Below Parameter area exceeded Maximal position exceeded Minimal position not reached Start interrupted Time out Over Torque Torque not reached Reserve Transducer-Error false Parameter Group Sync Error Time fallen below ED Team No. 75 76 77 ... 79 80 81 82 83 84 85 86 87 88 89 90 ... 96 97 98 ... 128 129 130 131 Name ERR_CANCEL ERR_NOBARCODE ERR_WRONG_CMD ERR_WRONG_SIZE ERR_CMD_FAULT ERR_WRONG_ELEM ENT ERR_DNC ERR_NO_DATA ERR_NOT_CAL ERR_STAGE_OFF ERR_NOT_AUTO ERR_CANCEL ERR_START ERR_NO_SPINDEL_S EL ERR_FREQ_HIGH ERR_DIR_CHANGED ERR_LIMIT ERR_P14V ERR_N14V 132 ... ERR_OVERLOAD 134 135 136 ERR_OVERVOLTAGE ERR_FEEDBACK ERR_PTC 137 138 ... 140 141 142 143 ERR_TEMP ERR_IIT 144 ... 150 152 153 ERR_E_STOP ERR_LIMIT_P ERR_LIMIT_N ERR_POWERFAIL ERR_TRACKING_ER ROR ERR_RON ERR_MOD ERR_IBS Description Section aborted No Barcode Reserve Wrong Command Wrong Size Command Error Wrong Element DNC-Error No Data No Calibration Amplifier is off Auto mode is off Command was aborted No Start Reserve No spindle selected Frequency too high Direction has changed Reserve Reserve Software-Limit Switch No positive Voltage No negative Voltage Short Circuit / Emergency Stop Reserve Overvoltage Feedback is defective Motor-PTC Heat Sink Temperature Too High I2t-Overload Reserve Emergency Stop Positive Limit Switch Negative Limit Switch Input Voltage not OK Slip Error Reserve Controller not On Modlink-Error IBS Error 105 PLC Program TOX® Siemens PLC FB (Error_Code from FB) List of the error codes from the TOX®-function block Number 1xy Error 1 Process not released Comment Process must be released in DB_TOX_Werte 2 Drive is not referenced Process Nr. 1 (referencing) must be executed 3 Drive not Ready Drive was not ready when Start-command was set 64 Positioning window left Given position limits where left 68 Force window left Given Force limits where left wrong parameter x: Parameter-Nr. y: set-Nr. 5xy 8xy 9xy 41xy 42xy 43xy 89xy Training ElectricDrive Brake Error e.g.: 134 wrong parameter 3 (position limit high) in parameter set Nr. 4 parameter 1: position limit low smaller than min spindle position parameter 2: position smaller or equal position limit low Parameter 3: position limit high smaller or equal position Parameter 4: position limit high bigger than max. spindle position Parameter 5: Force smaller or equal than force limit low Parameter 6: Force limit high smaller or equal than force Parameter 7: Force limit high bigger than max. spindle force Parameter 8: Speed smaller or equal than 0 Parameter 9: Speed larger than max. spindle speed xy: exact Fault binary coded 01: Brake 1 is not releasing 02: Brake 1 is not braking 04: Brake 2 is not releasing 08: Brake 2 is not braking 600 Timeout EDC-Livebit xy: Step-Nr. in fb-program Handle-Fault** xy: Step-Nr. in fb-program Step Timeout Fault State CNCDone** xy: Step-Nr. in fb-program xy: Step-Nr. in fb-program Fault State CNCPDone** Error in conversation of xy: Step-Nr. in fb-program two INT-Values into one REAL-Value** Process aborted by user xy: Step-Nr. in fb-program ED Team 106 TOX®-Complete Press Systems: The Drives... Powerpackage ElectricDrive EPMK ElectricDrive EPMS ...and the TOX®-Press frames MCC CEB/CMB Training ElectricDrive MC MB/MBG ED Team MA/MAG PC/PG 107 TOX® Duty Cycle (example EPM100; 100 KN, 300 mm) Example of TOX® duty cycle: 1. Fast stroke with max. speed from pos. 0 mm to pos. 290 mm 2. Press 10 mm with max. power 100 KN 3. Back with max. speed from pos. 300 mm to pos. 0 mm 4. Duration of life typically 5 million cycles! Pressing Forward 100KN, 300mm, 150mm/s Reverse 0mm Training ElectricDrive 300mm ED Team 108 Last But Not Least Thank you for listening! Thank you ! Training ElectricDrive ED Team 109