NUOVA ELETTRONICA DSP LASER AP, Instruction Manual

Page 1: ...DEVICE FOR PRESS BRAKES WITH VISIBLE LASER EMISSION Revision 1 1 of 20 11 2012 NUOVA ELETTRONICA s n c di Pasqui F C Via Parri ZI Moiano 06062 Citt Della Pieve PG ITALIA UE Tel 39 0 578 298066 Fax 39...

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Page 3: ...ual code DLAM01EN Revision 1 1 Issue 20 11 2012 Chronology of document revisions Date Revision Summary of changes 15 09 2012 1 0 Draft 20 11 2012 1 1 First issue Copyright information Possible informa...

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Page 5: ...ons 17 9 1 1 MCS module 17 9 1 2 DSP LASER AP 24 9 2 Identification plates 26 9 2 1 MCS module 26 9 2 2 Receiver 26 9 2 3 Transmitter 27 10 System Characteristics and Installation 28 10 1 Standard sup...

Page 6: ...11 3 System Test 67 11 4 First installation of TX and RX 71 11 5 Verification of the stop distance 75 11 6 Sheet Edge Acquisition 75 11 7 Verification of Low Speed and High Speed 76 11 8 Speed change...

Page 7: ...relevant to the safety in the work environment and to the accident prevention The manual must be kept with care both by the machine manufacturer and by the user in such a place to be immediately avail...

Page 8: ...on can cause serious dangers for the operator Residual risk The information signals a risk which had been impossible to eliminate Caution Indicates a situation of possible danger which if not avoided...

Page 9: ...and phenomena not depending on the normal operation e g wrong voltage or frequency values of the mains d repair interventions carried out by persons or Technical Service Centres not authorized by Man...

Page 10: ...self Disconnect the device and take care that qualified personnel checks it To disconnect the device refer to the procedure described in the chapter relevant to the device removal 5 2 Spare parts Spar...

Page 11: ...of the press brake MONITORING Safety function ensuring the intervention of a safety measure if the capability of a component or an element in executing its function is reduced MUTING Temporary inhibit...

Page 12: ...olid state outputs FEEDBACK TIME Maximum time between the moment when the test piece is introduced inside the detection area of DSP LASER AP device and the moment when MCS outputs switch to OFF state...

Page 13: ...andard EN 12622 2009 The laser contained in DSP LASER is classified as CLASS 1M according to standard CEI EN 60825 1 2009 DSP LASER AP device if properly installed and used as described in this Manual...

Page 14: ...adaptation and the use of the press brake in different planning methods Types of front protections controlled by MCS As you can see in Figure 1 MCS controls the photoelectric device DSP LASER AP as ma...

Page 15: ...this system the machine speed is measured and controlled Other controls and automatisms are moreover implemented necessary to the management of the safety and of the operativity of the bending machin...

Page 16: ...press brake operation and not devoted to safety functions Figure 3 Figure 3 represents the components which can be connected to MCS inputs to be controlled and monitored MAIN FOOT PEDAL CONTROL SECON...

Page 17: ...y but effective assignment function allows controlling different configurations of the actuators preposed to the machine closing Information Usually we refer to hydraulic components because the great...

Page 18: ...an interface is necessary with the personnel devoted to its installation during the construction of the machine and with the personnel which then will use it The module has two types of interface towa...

Page 19: ...rrupt the laser beams hitting at least one of the enabled sensors Detecting the object causes the intervention of the device which must stop the movement of the machine or activate an action foreseen...

Page 20: ...or if the rear backgauges are intercepted As regards the Automuting function the detection areas are 3 Area A Area B and Area C Area Task Area A Area A is composed by the 3 lowest sensors one front se...

Page 21: ...enerated by the laser Anyway the device does not replace the necessary training of the personnel and the information relevant to the residual risks described in chap 12 Residual risks MCS module has b...

Page 22: ...ues the High Speed more than 10 mm s closing movement up to PCV where the speed automatically decreases to a value lower than or equal to 10 mm s defined Low Speed For special machining or maintenance...

Page 23: ...bering of the inputs and the outputs connected to the corresponding connectors the type and the value of the power supply for the module the numbering of some connectors GREEN NUMBERS 1 2 3 7 8 9 They...

Page 24: ...he state of the output ON 24Vcc LED ON or OFF 0Vcc LED OFF CONNECTOR 3 0Vcc 24Vcc They indicate one of the two MCS connection to power supply by means of the clamps 0Vcc and 24Vcc the connection to gr...

Page 25: ...ou access to the second screen Figure 12 Figure 12 Screen 2 Line 1 The label ING indicates that the state of the generic inputs is displayed Line 2 State of the generic inputs ING1 ING6 The input numb...

Page 26: ...ng ARROW UP key you access to the fifth screen Figure 15 Figure 15 Screen 5 Line 1 List of errors or alarms E1 E3 of channel A sorted in chronological order Line 2 List of errors or alarms E1 E3 of ch...

Page 27: ...der 1 connected to the axis or hydraulic cylinder Y1 and connections to the inputs of channels A and B of encoder 2 connected to the axis or hydraulic cylinder Y2 0V ENC indicates the 0V reference of...

Page 28: ...bering of the inputs and the outputs connected to the relevant connector and the numbering assigned to the connector Figure 18 GREEN NUMBER 6 Number of the male connector present on the module which t...

Page 29: ...ixed ON Foot Pedal control nr 1 active and system ready to work OFF Foot Pedal control nr 1 not selected the alarm of the Emergency chain has been activated or the alarm of open rear guards has been a...

Page 30: ...2 the LED ON will be BLUE LED in CENTRAL AREA With Mode 3 the LEDs ON will be BLUE LED in FRONT AREA BLUE LED in CENTRAL AREA The YELLOW LED OFF indicates the device is in Mode 1 or in Mode 2 but with...

Page 31: ...lighted The WHITE LED OFF indicates MCS in active operation The LED ON indicates MCS in lock state TRANSMITTER TX front panel Figure 20 displays the transparent area for the passage of the laser beam...

Page 32: ...voltage and consumption ALIMENTAZIONE 24 Vcc 10W Serial number N S and manufacturing date DATA Figure 21 9 2 2 Receiver DSP LASER AP RX rear identification plate Figure 22 reports the following data...

Page 33: ...of the Patent BREVETTO which protects the device 0001342651 Device safety level ESPE type 4 Logo Costruito in Italia CE marking Logo of the Notified Body which has executed the certification Indicatio...

Page 34: ...ticular problems nor risks both for the transport and the unpackaging operations Caution The elements constituting the package must not be dispersed in the environment Contact the specialized collecti...

Page 35: ...ons Figure 26 Figure 27 indicates the positions for the drilling of the panel on the four points marked with the letter F where MCS will be fastened Then drill the four holes for the fastening and the...

Page 36: ...ction area must be placed under the upper tool The manufacturer of the press has to install the device properly on the machine while the users has to adjust the device properly according to the indica...

Page 37: ...The front installation is discouraged because the plates could create areas of mechanical danger due to the movement of the table and to the possible contact of the sheet against the table during the...

Page 38: ...he supports is such to allow the correct use of the tools with minimum and maximum height indicated by the press manufacturer Information Install the minimum height tool move the TX and RX supports as...

Page 39: ...n the supplied 5MA thread nuts Caution Make sure the nuts are tighten in such a way the machine vibrations do not loose them The torque of the screws must not be less than 1 96 N m 20 kgf cm The devic...

Page 40: ...the controlled devices OUTS8 is lacking can be assigned to different operating states by means of a programming procedure under password and using only the display and the MCS keys Information The sh...

Page 41: ...INS3 Selector Foot Pedal1 Control input 4 INS4 Selector Foot Pedal2 Control input 4 INS5 Pedal Downstroke1 Main NO INS6 Pedal Downstroke1 Main NC INS7 Input for Monitor of EV1 OUT1 NC with EV OFF 5 6...

Page 42: ...t in emergency 9 OUTRL2 Output for Relay components to set in emergency 9 OUTV Push pull output for sheet interception for CNC 21 INPUTS from LINEAR ENCODERS 5V 8 10mA CHAE1 Input of channel A of the...

Page 43: ...ot active and the output OUTS7 together with the input INS20 relevant to Monitor7 can be used as the other safety outputs Instead if the value ON is assigned to this parameter the output OUTS7 is moni...

Page 44: ...state they must assume in the different machine states Upstroke Stop Slow Downstroke Fast Downstroke The programming parameter C15 allows selecting which outputs among OUTS1 OUTS2 OUTS3 and OUTS4 you...

Page 45: ...not controlled by MCS commands can be controlled by CNC via RS232 interface see item 13 Safety Outputs 18 It is suggested to use the generic output OUG12 to transmit the MCS Lock state to CNC when you...

Page 46: ...ply line present in the machine electric panel The power consumed by MCS is 10W and includes even the power supply of DSP LASER AP Almost all the consumed power is used to supply solenoid valves and s...

Page 47: ...e foot pedal control led When Pedal 2 is pressed for example the led pedal 1 in the foot pedal control 1 will blink Parameter B2 INS 3 INS 4 INS21 Selected Foot Pedal Control 1P X X X Foot Pedal Contr...

Page 48: ...ter B4 If B4 has value RST AUTO Reset Auto it is sufficient to release completely the downstroke pedal in such a way it returns to the first position rest position If B4 has value RST UP P Reset with...

Page 49: ...ou wish to repeat the Stop Distance Verification function after the request of the Sheet Edge Acquisition function it is necessary to press again the Sheet Edge request button and keep it pressed for...

Page 50: ...DSP LASER AP with MCS Figure 34 44 DLAM01EN...

Page 51: ...the machine downstroke in Low Speed even if the conditions allow the downstroke in High Speed This signal is connected in parallel through the diode indicated in Figure 35 to the Low Speed request si...

Page 52: ...of which connected to inputs IN1 and INS2 one NO contact not connected to any input and the common connected to 24V Position1 of the selector must close the contact1 not connected to common 24V leavi...

Page 53: ...ncy and to the rear guards are not active and the feedback signals are correct This configuration can be used to set other devices in emergency or to communicate to other safety devices as the safety...

Page 54: ...roke movement is allowed When the control signals connected to ING1 and ING6 return to state OFF 0V and as consequence the control signals of the relevant pressure switches connected to INS23 and INS2...

Page 55: ...poles shield The shield must be connected to 0V ENC of only one device to CNC or to MCS The reference 0V ENC of each encoder is connected to one of the three poles of each cable on CNC side and toget...

Page 56: ...s the value OFF 0V otherwise it normally is in state ON 24V OUT PD LS REQ MCS STATE Machine Movements Allowed x x OFF No movement allowed OFF x ON Only Upstroke allowed ON ON ON Upstroke and Downstrok...

Page 57: ...DSP LASER AP with MCS RS232 port RS232 port present on MCS is of type DB9 female 3 wires pin2 TXD pin3 RXD pin5 GND Figure 39 DLAM01EN 51...

Page 58: ...safety outputs are set to 0V by MCS For every output except OUTS8 we can activate the use of the relevant monitor The monitors of the first four outputs OUTS1 OUTS2 OUTS3 and OUTS4 are managed by MCS...

Page 59: ...er and Lower Grippers X X Low Speed Value Control X X High Speed Value Control X X Direction Control X X X Encoder Control X X X Stop Distance Verification X Misalignment Control X X The symbol X in t...

Page 60: ...DSP LASER AP with MCS Figure 40 54 DLAM01EN...

Page 61: ...ON to the programming parameter B8 With function active when the control signal connected to INS20 switches from state OFF 0V to state ON 24V MCS will set the output OUTS7 from state OFF 0V to state...

Page 62: ...ear guard reset button Once the reset button is pressed if the procedure has been executed correctly the led relevant to the rear guard alarm turns OFF If you wish to use a single signal for the rear...

Page 63: ...ty PLC which controls the Robot By a NO key selector always connected to INS22 in combination to the activation messages sent by CNC via communication port RS232 Figure 43 Warning This work mode is re...

Page 64: ...4 Electric connection of other front protections To connect instead of DSP LASER AP a DSP LASER device or a photoelectric barrier to MCS it is sufficient to connect the safety outputs OSSD1 and OSSD2...

Page 65: ...guration of the press brakes and activating some additional safety functions These parameters are characterized by a letter indicating the parameter type and a progressive number Parameters of Type A...

Page 66: ...r the calculation of the Stop Distance The value is expressed in mm A6 100 2000 Maximum time necessary to the press to move from the moment when MCS commands the safety outputs to operate a movement T...

Page 67: ...tipanic is automatically executed releasing the pedal RST AUTO or pressing the Upstroke pedal RST UP P B5 A B A CNC B CNC Type of Blanking used in Mode2 A Operator Enabling B Stop Go A CNC and B CNC t...

Page 68: ...w Speed C6 0000 1111 State ON OFF 0 OFF 1 ON of the Generic outputs OUTG3 OUTG5 OUTG8 OUTG12 in condition of Low Speed C7 0000xxxx 1111xxxx State ON OFF 0 OFF 1 ON of the Safety outputs OUTS1 OUTS2 OU...

Page 69: ...xx0000 xxxx1111 Output management by MCS 0 OFF 1 ON OFF Output not controlled by MCS and downgraded to generic output ON Safety outputs OUTS5 OUTS6 OUTS7 and OUTS8 controlled by MCS C17 0000 1111 Outp...

Page 70: ...ws Disconnect MCS from power supply for ease extract the female of CON nr 3 see Figure 9 Press the keys Arrow Down and Enter at the same time and reconnect MCS to power supply put CON nr 3 in position...

Page 71: ...achine parameters The parameters are displayed in sequence as in the table of par 11 2 1 and can be read or updated by making they scroll on the display using the key Enter Once the wished parameter h...

Page 72: ...t to the left Then starting from the combination 0000 pressing Arrow Down the successive combinations are in sequence 0001 0010 0011 0100 and so on Pressing Arrow Up the sequence of combinations is in...

Page 73: ...those configured Parameter Pre assigned values A1 10 A2 13 A3 Encoder resolution A4 3 A5 50 A6 1000 A7 20 A8 500 A9 500 B1 OFF B2 1P B3 AUTO B4 RST AUTO B5 A B6 SINGLE B7 OFF B8 OFF B9 OFF C1 0000xxx...

Page 74: ...inputs are ON Open the contact relevant to OUTP1 output Verify that the orange Led relevant to the input INP1 is OFF Repeat this operation for all the 8 pulsed inputs outputs Safety Inputs There is on...

Page 75: ...ed of INS11 is ON and the Led INS12 and INS13 are OFF When CNC commands a Downstroke in Low Speed verify that the Leds INS11 and INS12 are ON and the Led INS13 is OFF When CNC commands an Upstroke ver...

Page 76: ...execute a test on the wiring respecting the above modalities Once the additional functions have been added and the wiring has been tested configure the safety outputs depending on the configurations...

Page 77: ...area changes Figure 52 The first adjustment to execute is to position the laser beam in parallel to the tip of the upper tool for all its length To do this act as follows 1 Set a reduced closing speed...

Page 78: ...DSP LASER AP with MCS Figure 53 Figure 54 7 The lower edge of the laser emission must be parallel to the checking line for the vertical positioning of TX as in Figure 55 72 DLAM01EN...

Page 79: ...e beam is in a different position very likely situation adjust TX in accurate way in direction of arrows 3 and 4 without intervening on the calibration executed previously movements indicated by arrow...

Page 80: ...the circular light is within one of the RX VERTICAL POSITIONING REFERENCES The reference must be the one with the same number of the line where has been positioned the LOWER EDGE OF THE LASER EMISSION...

Page 81: ...Edge will change to fixed ON test of stop distance successful otherwise it will continue blinking and the test shall be repeated Before executing the test of the stop distance it is however possible t...

Page 82: ...e the distance it records even the speed reached by the machine This speed is the maximum speed plus tolerance the machine can reach in operating mode in High Speed If this speed is exceeded MCS enter...

Page 83: ...n Muting state and the machine can continue the stroke as in Figure 60 Figure 60 The point where the exclusion of the Area takes place depends on the tolerance set in parameter A4 If the sheet toleran...

Page 84: ...ing state the machine can continue the stroke Figure 62 Figure 62 When the sensors of Area C are in the position of the previous ones an no object has penetrated the detection area they are set in Mut...

Page 85: ...ge Point position programmed on CNC shall have such a value that when DSP LASER AP is in the condition of set the area C in Automuting the machine is already in Low Speed in such a way to allow the co...

Page 86: ...e it is equipped with a single pair of tools one upper and the other lower for all the machine length or when the rear backgauges are next to the bending line and intercepting the detection area do no...

Page 87: ...position or the shape of the rear backgauges could shade the rear part of the detection area Small size pieces The shape of the detection area has been properly shaped in the front part to limit the i...

Page 88: ...nsors of the front area in blanking status and those of the rear area in exclusion state Both at switch on of DSP LASER AP device or at the selection of the operating mode 2 and after a machine upstro...

Page 89: ...e punch has stopped Figure 64 All the receiving areas are active and the shading of any receiving element causes the OFF state of the RX outputs The MCS control device immediately stops the closing mo...

Page 90: ...er to avoid these situations and at the same time to protect the operator mode 2 can be set Figure 65 The main difference with the operating mode 1 consists in the blanking of the front area and the e...

Page 91: ...the function and forbid its abuse In some cases the backgauges could intercept the rear protection area causing the stop of the press even if the operator is out of the dangerous area In order to avoi...

Page 92: ...rol Encoder Control DSP LASER AP Control and Side Guard Control To access to this operating mode the relevant selector must be activated and MCS must receive the proper signals from CNC via RS232 In a...

Page 93: ...e objects present in the movement area e g bottom of the box while the rear area avoid the squashing between punch and backgauge The system is equipped with operating modes which allow the inhibition...

Page 94: ...speed coupled with a handheld command Then is the operator who aware of the residual risks commands the closing of the press If the sheet is hold by hand during the approaching and the bending risks...

Page 95: ...the work starting from the initial study of the piece up to the real bending operations In order to optimize the choice of the work instruments and to ensure the safety of the operators the main preve...

Page 96: ...nces scheme and functions Warning If you detect a fault to one of the LEDs it is necessary to stop immediately the machine and call NUOVA ELETTRONICA to repair the device 13 2 PCV setting PCV setting...

Page 97: ...is important that during this operation the laser is not obstructed by anything if not by the sheet Therefore remove everything you think can interfere with the execution of this function 13 5 Adjust...

Page 98: ...TX back in position according to the direction of arrow A Figure 72 5 Put the TEST instrument on point B Figure 72 6 Set a reduced closing speed less than or equal to 10 mm sec and lower the tool unt...

Page 99: ...tion area must be contained within the two surfaces delimited by the two vertical lines and marked with the letters R and F Should the conditions above were not verified and a mechanical adjusting int...

Page 100: ...ver the lower tool and command the press in fast closing keeping outside of the die area To make the test meaningful the speed change point must be set as nearest as possible to the die For the same r...

Page 101: ...le faults or malfunctions both of MCS DSP LASER AP and of the press brake The first and essential verifications to do are LCD of MCS stays OFF Verify that the 24 Vcc voltage is present on connector nr...

Page 102: ...rm D Alarm Low Speed the press has exceeded the allowed low speed Verify that the sheet edge acquisition has been correctly executed and that the speed change point has been correctly set Note Press t...

Page 103: ...arm Upper Clamps Open the upper clamps are open The press cannot close Close the clamps to restore the proper operation T Error Upper Clamps the signals relevant to the upper clamps are not correct Ve...

Page 104: ...ion of the monitor and the connection of the monitor to MCS INS17 h Error Monitor7 The monitor relevant to solenoid valve driven by OUTS7 has given a wrong output Verify the correct operation of the m...

Page 105: ...screwing the four screws Figure 75 Extract the 4 pole female connector from the male one on TX Extract the 8 pole connector on RX Extract even the Faston female connector from the male connector ancho...

Page 106: ...bsolute absence of fine dust 15 m Suggested operation distance 0 5 8 metri in normal industrial environment GENERAL DATA MCS response time 2 5ms DSP LASER AP response time 5 ms PFH 7 75 10 9 Detection...