Calibrating Force Monitoring Press and Setting Limits
Force Calibration:
DESCRIPTION:
AIM Joraco FM-FS Presses incorporates a programmable force set value, (as well as a ramping function). Which is set with the TECO PLC Controller. The TECO PLC Controller converts the desired engineering units to a voltage signal which sets the air pressure of the electronic SMC unit located in the back of the press. This unit has a RED digital displace showing the pressure (psi) the unit is set to. When the press reaches end of stroke, the RDP Force Monitoring Unit reads force (lbs) and compares to the setpoint limits for Good Part/Bad Part.
L1 is the lower limit threshold value. L2 is the upper limit threshold.
If lower limit is NOT reached – unit reports BAD Part
If lower limit AND upper limit are reached – unit reports BAD Part
If lower limit is reached, but NOT the upper limit – unit reports GOOD Part.
Accessing MENUS:
MENU OVERVIEW:
TO ACCESS A MENU FROM THE UNIT’S NORMAL OPERATING MODE, PRESS THE SETUP KEY FOR
AT LEAST ONE SECOND. THE DISPLAY WILL SHOW THE PROMPT [UL 1]. PRESS THE ▲OR ▼
KEY TO STEP THROUGH THE VARIOUS OPTIONS, WHICH ARE:-
DISPLAY ACCESS
[UL 1] USER SETUP MENU
[UL 2] CALIBRATION AND USER SETUP MENU
[UL 3] CONFIGURATION, CALIBRATION AND USER SETUP MENU
WHEN THE REQUIRED USER LEVEL IS DISPLAYED, PRESS THE LIMITS KEY TO SELECT THE
DISPLAYED OPTION. THE DISPLAY WILL NOW SHOW A NUMBER ENTRY PROMPT [00000] WITH THE
LAST DIGIT FLASHING. AT THIS POINT THE RELEVANT PASSWORD SHOULD BE ENTERED
SETUP INSTRUCTIONS: LIMITS
SETTING LIMITS:
Enter UL1, (Password 00001) as you scroll through the menu:
[Filter] DO NOT CHANGE – FACTORY SET
[Count] DO NOT CHANGE – FACTORY SET
[L1-2] Press Enter
LIMIT L 1-2
LOWER LIMIT SETTING:
L1 ON
[HI] HIGH. The limit activates when the input signal is higher than the set point.
Function : n-IP
SETPOINT – Value the limit needs to reach to trigger.
[Lat.N] Latching NO
UPPER LIMIT SETTING:
L2 ON
[HI] HIGH. The limit activates when the input signal is higher than the set point.
Function : n-IP
SETPOINT – Value the limit needs to reach to trigger.
[Lat.N] Latching NO
When screen cycles back to L1 – press RESET to exit, [run] press ENTER.
SETUP INSTRUCTIONS: FORCE / LOAD CELL
CALIBRATION OF LOAD CELL:
Enter UL 2(Password 00002) as you scroll through the menu:
[dP] DO NOT CHANGE – FACTORY SET
[CAL.IP] press ENTER.
00000 press ENTER to move along Digit. PRESS THE ▲OR ▼ to change value
Once last digit is assigned value: example 26000
Press ENTER & RESET at the same time to accept the cal value.
Screen value will change
Press MODE & ZERO at the same time to clear previous Cal.
Screen value will change
REMOVE LOAD from PRESS (Apply Zero Load)
Press ZERO
On the TECO PLC Screen Press the Down Arrow to enter Ram setup Screen.
Press Two Hand Controller to Apply Force.
With the RAM Down.
Press SETUP (Sets New Calibration value to the applied force)
Press MODE & SETUP at the same time
[E.OFF] Exit Calibration – Press RESET.
Exit RAM only mode on TECO PLC to retract Ram .
Operate press normally. Confirm calibration. Repeat if necessary.
TROUBLESHOOTING:
HP-30 Example (30 Ton Press)
30T * 2000lbs = 60,000 lbsF at 100psi(100%)
60,000 / 100psi = 600lbs/psi reading
If Force set to 26,000 lbs the SMC unit should read 43.
26,000/60,000 *100 = 43.
SMC: Force
100 60,000
75 45,000
50 30,000
25 15,000
Calibration Accuracy +/- 2% (+/- 1200lbs)
If variation in readings are occurring – it is important to note that the positioning of the tooling, the attachment point of the load cell, and any variability in the fixturing will affect the readouts.
It is recommended to perform a calibration verification using the ram setup feature on the Teco PLC unit to compare the input/output readings. If different by more than Calibration Accuracy, before performing a calibration, inspect the fixturing, tooling and load cell mounting plate are secure. Any variation in their locations will change the output reading.
It is recommended to calibrate the system to the force range you are working within for best results.
LoadCell:
The loadcell is very sensitive and delicate. The loadcell ram assembly should be secured to top of tooling fixture or die set. This will ensure the load cell and wiring do not twist or result in damage. Securing the tooling offers the best results in data readout, capture and consistency.