Schmidt® Electricpress

Transcript

SCHMIDT ® ElectricPress A New Approach To Assembly Technology To use electric drives instead of pneumatic or hydropneumatic driven cylinders, is a modern advancement in assembly technology. SCHMIDT Technology combined its proven rugged mechanics with the latest electric drive technology to create assembly presses for industrial production applications. The high efficiency of electric drives may not be the only reason to choose them. The individual process, the infrastructure and the quality of the compressed air should also have a bearing on that decision. The key advantages of the SCHMIDT ® ElectricPress: Easy programming of parameters reduces set-up time Stored press ram motion profiles allow for quick changeover Enhanced flexibility Reduced tooling costs and wear due to precise positioning Elimination of the slip-stick-effect optimizes the assembly process Low noise level reduces operator fatigue and stress SCHMIDT® ElectricPress 43 Automation Simple, Efficient Solution For Complex Assembly Automation Base model without force  / stroke monitoring Standard PLC Features: Digital values for position, velocity, acceleration and deceleration Storage of complete NC-sets in the EP Assistant software Combination of up to 14 individual ram motion profiles into one complete profile by using a standard PLC Press to exact position (closed loop control stroke) Press to force (determined by motor current) to - press to final force - press to position but interrupt if force is exceeded - touch force to determine position of workpiece SCHMIDT ® EP Assistant Set-up Software for Automation Version SCHMIDT ® ElectricPress 43 With PressControl 75 And SafetyModule Manual Workstation With EC Type Approved Safety Technology SCHMIDT ® PressControl 75 for quick set-up or rapid change-over and easy programming of press parameters; stores up to 24 datasets. SCHMIDT ® ElectricPress manual workstation on PU 20 Simply the best! | 49 SCHMIDT ® ElectricPress 343 Automation With PressControl 600 Latest Assembly Technology An efficient and reliable assembly process is key to the success of your products in an increasingly competitive market. The all-new SCHMIDT ® ElectricPress 343 with SCHMIDT ® PressControl 600 is your most economical solution. Combining a cost effective fully programmable assembly press, using innovative electrical drive technology, provides closed loop position and force control with flexibility and precision to even the most complex assembly tasks. The system also uses integrated sensor technology to provide precise process monitoring, ensuring quality control on every part. SCHMIDT ®'s state-of-the-art assembly technology monitors and controls the entire manufacturing process rather than individual assembly steps. The proprietary SCHMIDT ® DataBase software maps the process data of all individual assembly steps into a data bank, including historic data. CAN-bus technology communication compatible with all established field CAN-bus systems is standard on all SCHMIDT ® monitored presses. And with the SCHMIDT ® PRC OPC software available on these models, data exchange will now become the automation standard. P R O F I PROCESS FIELD BUS B U S CANopen CANopen SCHMIDT® PRC DataBase Optional: Integrated remote hand-wheel for set-up of - stroke control - force control SCHMIDT ® ElectricPress 343 With PressControl 600 And SafetyModule Complete Workstation With EC Type Approved Safety Technology Rigorous Life-Cycle Test Of The SCHMIDT ® ElectricPress To meet the highest quality standards expected of a SCHMIDT ® Press, the EP 343 press system underwent a rigorous press-stroke test cycle over a 4 months period at a maximum force of 4 kN / 900 lbs. All mechanical, electrical and motor elements have passed that stress test with flying colors. Process visualization 50 | SCHMIDT ® Presses Press Type Force F max. Force F at 100 % duty cycle Ram stroke Ram speed max. Drive resolution Resolution PDA - Stroke - Force Throat depth Decibel level Power supply - Motor power - Logic unit Working hight frame 7 1) Working hight frame 7-600 1) S-H x S-B x S-T Weight PRC Gateway, number of I / O's A inch / inc lbs / inc inch dB A C F inch inch lbs Mounting surface with Frame - No. 7 - No. 7-600 WxL Frame Overview No. 7 No. 7-600 inch 43 343 900 560 3.93 5.90 <1 900 560 3.93 5.90 <1 5.07 60 0.0001 0.28 5.07 60 42 V DC / 13 A (22 A max.) 24 V DC / 0.5 A 2.44 – 10.78 3.93 – 24.01 13.11 x 8.14 x 14.25 75 42 V DC / 13 A (22 A max.) 24 V DC / 0.5 A 2.44 – 10.78 3.93 – 24.01 14.48 x 9.52 x 14.25 75 16 inputs / 16 outputs 11.49 x 14.40 11.49 x 18.42 11.49 x 14.40 11.49 x 18.42 Press Type Frame Height M (inch) Table Size B x T (inch) Table Height K (inch) 43, 343 43, 343 23.62 37.79 7.08 x 5.90 7.08 x 11.02 3.54 4.33 Press Type 343 Press Type 43 M8 Ø 10H7 1.18" 0.47" 0.70" M Ø 10H7 Ø 1.37" 0.35" ± 0.007" 0.27"± 0.003" A Ø 1.18" F C BxT K 0.66"± 0.039" Ø 20H7 5.43" L 0.39 ± 0.003 W S - B-Typ 343 60 ° 2.15" 0.052" S - B-Typ 34 M8 1.18" 0.47" 0.74" Ø 1.37" S - H-Typ 343 Typical values; can vary ± 0.118 inch due to cast and production tolerances S - H-Typ 43 1) lbs lbs inch inch /  s µm S-T Simply the best! | 51 SCHMIDT ® ServoPress / TorquePress The Reference For Precice Assembly An economic and high quality assembly is the key to the success of your product. The aim is to join together precise assemblies from low-cost individual components with different tolerances. Electrically driven spindle presses, servo presses, are ideal for such tasks. SCHMIDT ® ServoPress systems offer an integrated solution of SCHMIDT ® PressControl 600 or 5000 control unit and SCHMIDT ® ServoPress modules. They meet the most complex requirements, as stand- alone machines or in automatic production lines. Compared to high ratio electric motor driven presses the SCHMIDT ® TorquePress 200 has much lower inertia and therefore a much faster acceleration and deceleration. The noise level remains remarkably low under all load conditions. SCHMIDT ® TorquePress 200, like all SCHMIDT ® Servo Presses, is permanently load stable due to its active temperature-controlled cooling. A mechanical overload protection is automatically activated when the maximum force of 230 kN (51,700 lbs) has been exceeded. SCHMIDT ® TorquePress 200 features a highly precise, wearfree ram roller-guide, an integrated fail-safe force-stroke monitoring, and a true closed loop force control integrated in the drive control (continuous force control). The integrated two-channel category 4 safety technology allows the EC-type approval for complete systems, which is required for manual load work stations. Technical Data TorquePress 200 Force F max. Force F at 100 % ED Ram stroke Resolution (drive control) Process data acquisition - Stroke - Force Ram speed (max.) Overload protection 51,700 lbs 45,000 lbs 19.7 inch < 0.0004 inch Service life of the cycles acc. to standard operating profile Drive Power supply Weight / height resp. length - Modul (approx.) - H-frame (approx.) - Press base Control unit 52 | SCHMIDT ® Presses 8 µm / inc. / 0.0003 inch 100 N / inc. / 22.5 lbs / inc. 7.87 inch / s mechanical 1 x 10 7 Planetary roller screw drive 400 V 3~ / 32 A, 400 V power socket CEE 1,700 lbs / 90.5 inch (upright resp. horizontal) 2,160 lbs / 33.5 inch (upright resp. horizontal) approx. 275 lbs / height flexible SCHMIDT ® PressControl 5000 / 600 SCHMIDT ® ServoPress / TorquePress Superior Controlled Behavior The combination of a spindle with a servo drive is not sufficient to achieve optimum joining results. The key for intelligent assembly is quick and exact controlled behavior of the press. This requires an integrated system consisting of drive unit, processmeasurement SCHMIDT ® ServoPress Module technology and control unit. These requirements have been taken into account in the system architecture of a SCHMIDT ® ServoPress  / TorquePress. SCHMIDT ® PressControl 5000 Digitalized force / stroke signals Signal Amplifier (Digitalization preprocessing) Servo Amplifier Axis control force / stroke Spindle SCHMIDT ® PressControl 600 Target Force (F) Ram SCHMIDT ® ServoPress /TorquePress systems Other servo press axis Time (t) SCHMIDT ® ServoPress / TorquePress work with real-time force controllers, unlike the simple switching controllers used by other manufacturers *. That means: Quickly reaching the nominal values No overtravelling of the target values Precise positioning in the 1/100 mm range, even with dynami- cally changing force outputs High precision force control The control parameters can be adjusted. - Optimum adaptation to your application - No PLC programming necessary - The system works with predefined optimum acceleration values (no incorrect entries possible) Optimization of the processing times is possible due to an addi tional graphical display force / time [F / t], stroke / time [s / t] for an analysis of the process. The classic force / stroke [F / s] display of conventional electronic axis cannot be compared to the reliable recording and visualization possibilities of the SCHMIDT ® Servo Press / TorquePress These characteristics are achieved exclusively by combining the following features: Integrated measurement technology (scanning rate 2000 Hz) - Free-of-play distance measurement, force measurement without lateral forces Amplification of the process signals on the SCHMIDT ® Servo- Press / TorquePress module - Insensitive against electromagnetic interferences (EMC) The system is completed by using SCHMIDT ® PressControl 600 or 5000 (PC-based system), i. e. servo amplifier and motor receive nominal values from the control unit - Optimized PLC control algorithm - Force [F], stroke [s] or other external control inputs are simul- taneously processed - The control input can be freely selected Quick signal processing on software-based PLC with integrated CNC CNC with extended command set, in particular for controlling force-regulated positioning tasks * Regulated exclusively by position controller Simply the best! | 53 Dynamic Bending Compensation Patented Feature In order to achieve assembly requirements in the 1/100 mm range, compensation of the system yield is required. Workpiece, tooling and machine are elastically deformed by the varying forces induced during the pressing process. Once the operation is complete and the press force is removed, this deformation disappears. The result is that the assemblies are not joined to their programmed dimensions. This yielding effect makes it impossible to produce high precision joints regardless of a systems positioning accuracy. Force (F) First, a complete process representation of the force characteristic in loaded and unloaded state is necessary so that the system can carry out the required compensation. Conventional procedures end in the block position – but the process is not finished yet. The system is under force. Stroke (s) Patented Dynamic Bending Compensation by SCHMIDT  Technology Uncompensated Compensated Force (F) Force (F) Actual assembled position reached (unloaded) - force removed Target position Stroke (s) ∆ S1 ∆ S2 The system calculates the stroke position independently of the force Target position Stroke (s) Figure 1 Figure 2 In typical applications, the force required to complete an assembly varies up to 40% from part to part. When freely positioning, such as without a positive stop, the press ram extends to the same target position, regardless of load. But a closer inspection of the completed assembly and the force / distance curve generated, shows that the final pressed position will vary due to the forces in the operation. (figure 1) In order to overcome this effect, SCHMIDT ® ServoPress / TorquePress systems compensate dynamically to the changing forces. This compensation allows for the assembly to be pressed to the target position, regardless of force (figure 2). Example: Press in a Pin in a Bushing The elasticity of an assembly depends on the equipment, process and the component geometries. This effect becomes significant for assemblies with which the assembly forces of the individual components differ strongly from one another. This can particularly be seen in the example shown. Low Force (see force curve) 54 | SCHMIDT ® Presses ∆ S2 loaded s unloaded ∆ S1 loaded s unloaded The SCHMIDT ® ServoPress / TorquePress system determines easily and precisely the system elasticity and compensates it dynamically in real time Only with dynamic bending compensation, can the end position be reached to an accuracy of the 1/100 mm range Free positioning with compensation of the system elasticity is more accurate than pressing on hard tool stop Dynamic bending compensation does not reduce the process speed Dynamic bending compensation in connection with other intel ligent functions, such as offset of tolerance data, has been patented High Force (see force curve) „∆ S“ changes proportionally to the force output, that means, the components have different dimensions depending on the force requirement of each component. SCHMIDT ® ServoPress / TorquePress Operating Profiles And Applications SCHMIDT ® ServoPress  / TorquePress allows for a simple setup of the operating profiles. Different standard operating profiles are provided for a quick set-up. According to experience, these standard operating profiles and the combinations of them cover most applications. TDC = top dead center of the process 1) PS = Pressing start, start of the process data recording 1) PP = Probing position (depending on the component geometry) IP = Intermediate position 1) (is required for monitoring purposes) EP = End position 1) 1) adjustable Target is “Stroke” Normal operating profile, is typically combined with bending compensation. Target is “Delta Stroke” with probing Force For processes in which component tolerances must be detected. The press detects the surface and presses to a programmed distance from. Target is “Force” For processes in which the force reached is a measure for the process quality e. g. material compression. Target is “Force Increase” The return stroke is triggered by detecting a customer defined force slope. TDC TDC TDC TDC PS PS PS PS IP IP IP PP IP EP Pressing until reaching a specified position leads to precise results in connection with bending compensation. EP Plugging blind bores – a sphere is pressed in and crimped. Force output correlates to material displacement to determine density and retain force independent of stroke. EP Pressing to a predetermined force which identifies a target feature with which the final pressing distance is measured and pressed. EP Pressing of “Beta” plugs or „König“ expanders. Sealing and retaining function depend on a force increase that is the return stroke criterion for the press. Simply the best! | 55 Uncompromising Mechanical Quality The solid, unique mechanics of the SCHMIDT ® ServoPress  / TorquePress are essential for precise joining results, even in the toughest industry environments. Test Bench Before a new model is released, modules are endurance tested under the most severe operating conditions. The rigorous testing helps identify limitations. Improvements are implemented, which ultimately benefit you. Continious Full Load Capable Modules Over the entire ram stroke With rapid process times Via exact roller guiding of the ram with little play Square ram benefits - Insensitive to lateral forces - Locked against rotation (without additional friction such as with slot guidance) Built-in Auto-Protection And Maintenance Fully automated spindle lubrication Mechanical clutch as overload protection for motor & load cell Cooling and thermal monitoring of mechanical and electronic system Current limitation if exceeding admissible load Machine safeguarded against operator error Service-Friendly Low maintenance Easy module change possible. The control unit recognizes the new module. No modifications of the data sets are necessary. This is achieved due to a high-precision ram position in the reference point with relation to the supporting surface Built-in Safety in LV system EC type-approved Two-channel safety circuit, PLe As a Result, this means the following for your Application: Excellent efficiency Maximum capacity High production safety Test duration is 3 months 20 million loading cycles over the entire working stroke with nominal force and lateral forces components at full travel speed Cycle time approx. 2 seconds 56 | SCHMIDT ® Presses ServoPress / TorquePr SCHMIDT ® ServoPress / TorquePress SCHMIDT ® ServoPress Modules With Large Application Range Press Type 405 Press Type 415 / 416 Press Type 417 Press Type 420 ServoPress 405 Press Type 450 / 460 ServoPress 415 to 460 H H BB AA BB D AA D J B J B E F E Module separation L for fastening from below K for fastening from above T S Q P U K for fastening from above C A C M N in reference point R 28 for fastening from below A in reference point M N L F O V R S T top ram position top working position Q G P Y U W X Z G W X V top ram position top working position for pin bore for thread Simply the best! | 57 Modules With Force Outputs of 15 N to 150 kN / Ounces up to 33,720 lbs. Servopress Type Force F Force F at 100% duty cycle Ram stroke Resolution (drive control) Resolution data acquisition - Stroke - Force Ram speed Overload protection F F 405 415 416 417 420 450 460 max. lbs lbs mm / inch inch 180 110 150 / 5.90 < 0.0004 1,010 340 200 / 7.87 < 0.0004 1,125 675 200 / 7.87 < 0.0004 3,150 1,690 300 / 11.81 < 0.0004 7,870 4,500 400 / 15.74 < 0.0004 16,860 11,240 500 / 19.68 < 0.0004 33,720 22,480 500 / 19.68 < 0.0004 inch / inc < 0.0001 0.0001 0.0001 0.0001 0.0002 0.0003 0.0003 lbs / inc inch / s 0.06 0 - 11.81 - 0.22 0 - 7.87 Mech. clutch 0.22 0 - 7.87 Mech. clutch 0.90 0 - 7.87 Mech. clutch 2.25 0 - 7.87 Mech. clutch 5.39 0 - 7.87 Mech. clutch 10.79 0 - 3.93 Mech. clutch 2 x 10 7 2 x 10 7 2 x 10 7 2 x 10 7 2 x 10 7 2 x 10 7 1 x 10 7 ball screw ball screw ball screw ball screw roller screw roller screw roller screw 400 V 3~/16 A 400 V 3~/35 A 400 V 3~/35 A 265 530 530 Service life of the cycles acc. to standard operating profile Drive 230 V 1~/6.3 A 230 V 1~/6.3 A 230 V 1~/6.3 A 230 V 1~/16 A (208 V 3~/6.3 A) (208 V 3~/6.3 A) (208 V 3~/6.3 A) Power supply Weight (standard) approx. lbs 44 60 60 154 Module Dimensions Servopress Type 405 415 / 416 417 420 450 / 460 Housing A B C D inch inch inch inch 23.22 12.16 17.32 4.29 22.04 12.99 17.08 4.29 29.99 16.22 23.62 5.27 38.50 21.06 30.03 7.08 45.90 26.65 39.05 9.29 E F inch inch ~ 2.95 ~ 2.36 ~ 2.95 ~ 2.36 ~ 3.54 ~ 2.36 ~ 3.93 ~ 2.36 ~ 3.54 ~ 2.36 G H J K L M N O AA BB inch inch ± 0.004" ± 0.004" ± 0.004" Ø mm inch inch Ø inch Ø mm 1.85 2.95 2.36 2.36 1.57 45h7 0.43 0.01 5.3 M5 3.03 2.95 3.46 2.48 59.4 x 59.4 45h7 0.43 0.01 6.3 M6 3.62 5.11 4.72 4.52 2.95 65h7 0.74 0.01 8.4 M8 4.80 5.51 6.29 4.72 4.72 5.90 8.26 5.11 90h7 1.25 0.19 10.1 M12 100h7 1.29 0.19 12.0 M14 P Q R S T U V W X Y Z inch Ø mm inch Ø 0.55 6H7 0.70 M5 0.31 1.57 1.18 1.25 x 1.25 10H7 1.18 M8 0.39 1.96 1.53 0.86 0.86 M5 5H7 1.65 x 1.65 20H7 1.96 M10 0.78 2.36 1.29 1.25 1.25 M6 5H7 2.16 x 2.16 20H7 1.57 M10 0.78 2.36 1.77 1.57 1.57 M8 8H7 2.55 x 2.55 20H7 1.96 M10 0.78 2.36 1.77 1.57 1.57 M8 8H7 Cable connection Flange Ram External ram dimensions Ram bore Top working position Top ram position for pin bore for thread inch inch inch ± 0.0008" inch Ø mm Standard Operating Profile V max Advancing movement with max. ram speed (load-free) Press movement with nominal force Travel speed ¼ Vmax ¾ Smax Smax -Vmax Return stroke with max. ram speed (load-free) 58 | SCHMIDT ® Presses SCHMIDT ® ServoPress / TorquePress Manual Workstation With Light Curtain exa mina ti All systems are EC type-approved n EC pe Included in the scope of delivery are: SCHMIDT ® ServoPress / TorquePress module mounted on a frame SCHMIDT ® PressControl 600 or PressControl 5000 with pendant arm system Press base PU 20 / PU40 Transparent protective guarding with light curtain Distance light curtain adjustable in order to ensure a safe distance to the tool Auxiliary control cabinet o ty SCHMIDT ® ServoPress / TorquePress manual workstations are delivered ready for operation with press base, transparent protective guarding and light curtain. These systems are single workstations, which can be delivered with all SCHMIDT ® ServoPress / TorquePress modules. Simply the best! | 59 Workstations SCHMIDT ® ServoPress Designed To Support Presses From 15 N to 150 kN / Ounces up to 33,720 lbs. ServoPress Type 405 Dimensions - single workstation Width B Depth T Height H Working area Ram center - light curtain Weight C D F K BxT 420 450 / 460 inch Ø mm inch inch inch inch Ø inch inch inch inch inch inch inch inch inch inch inch 405 415 / 416 417 420 450 / 460 5.11 20H7 9.84 3.66 6.29 x 5.51 6.29 x 13.58 0.35 1.96 8.66 5.11 20H7 11.81 4.44 8.66 x 6.88 8.66 x 15.94 0.43 3.14 9.84 5.90 40H7 15.23 5.03 9.84 x 7.87 9.84 x 18.11 0.43 3.14 9.84 12.79 13.58 20.07 40.00 5.51 6.29 15.35 15.74 24.80 43.30 7.87 8.66 16.92 18.11 30.70 56.29 8.66 9.84 6.29 40H7 20.27 6.10 11.81 x 8.66 11.81 x 22.16 0.51 3.34 11.81 1.96 13.77 20.78 22.16 42.51 72.24 11.02 11.81 6.29 40H7 20.15 / 19.76 7.48 / 8.66 14.56 x 9.05 14.56 x 25.00 / 14.56 x 29.92 0.51 3.74 13.77 1.96 15.74 / 19.68 23.62 / 28.54 25.00 / 29.92 41.33 / 42.99 80.70 / 81.49 13.77 14.56 T SH 2 O SL 1 SL 2 SL 3 SL 4 SL 5 SL 6 SH 1 SH 2 SB 1 SB 2 417 inch ~ 44.09 ~ 44.09 ~ 44.09 ~ 44.09 ~ 44.09 inch ~ 35.03 ~ 35.03 ~ 44.88 ~ 44.88 ~ 44.88 min. inch 74.01 74.01 87.79 103.54 110.62 inch ~ 33.46 x 27.55 x 25.59 ~ 33.46 x 27.55 x 25.59 ~ 33.46 x 27.55 x 25.59 ~ 33.46 x 27.55 x 25.59 ~ 875 x 38.58 x 25.59 inch 12.60 12.99 10.95 - 14.57 12.99 - 16.92 14.56 - 18.50 approx. lbs 670 685 860 1,260 1,740 ServoPress Type Frame Throat depth Table bore Working height Table height Table size Mounting surface 415 / 416 SH 1 H C F 0.39 T 0.62 +0.01 O K D SL 1 0.27 0.64 SL 3 SL 2 SL 4 SL 5 SL 6 60 | SCHMIDT ® Presses SB 1 SB 2 B B See workstation options on page 71.