Impax 2000 Manual de usuario
2000
Supervisor’s
Guide
This manual is a comprehensive guide to the IMPAX 2000 Process Control System. It contains
all of the information from the IMPAX Operating Guide plus special instructions on
programming and troubleshooting, plus additional ideas and procedures for getting the best
performance from the system.
This User’s Guide should be read and kept for reference by managers and supervisors
responsible for the setup, operation, and repair of IMPAX monitoring systems. It is assumed
that the software in the IMPAX 2000 is versions 48 or 58.
If you are not sure not sure of the software version in your IMPAX 2000 unit please refer to
chapter 8 in the Supervisor’s Guide.
If you still have a question, problem, or an idea to make our system better, please let us know.
IMPAX Systems are manufactured and
distributed worldwide by:
Process Technologies Group, Inc.
30W106 Butterfield Road
Warrenville, IL 60555
Phone (630) 393-4777 Fax (630) 393-4680
“IMPAX” is designed and manufactured by Process Technologies Group, Inc. And is
produced under the United States and Foreign Patent number 4,481,589. Any additional
patents are pending or applied for. “IMPAX” is a trademark owned by Process
Technologies Group, Inc. Copyright 1996.
Table of Contents
Chapter Page
1. Introduction and Theory of Operation
2. Description of Controls
Control Console
3. Setup and Operation
Getting Started, Setting up new job
Clearing Counters
Clearing Tolerance/Errors
Starting a New Job
Tolerance Setup
Machine Operation
4. IMPAX Information Displays
Quantity Displays
Tolerance Displays
Error Displays
Force Displays
Backstroke/NoFeed Limilts
5. Tolerance Setting Guide
6. Troubleshooting and Service
Problems - cause/remedy
Simple Repairs
Initial Installation
Customer Service
7. Programming
System/Fault Procedures
Basic Information/Function #’s
Channel Definition
Machine/Relay Defintion
8. Diagnostics
9. Specifications and Drawings
1
3
4
5
5
6
7
8
9
13
14
14
15
17
18
21
22
24
24
25
27
30
31
32
33
33
39
45
49
Specifications
Back view of Control Console
Satellite Circuit
IMPAX Control Console
49
50
51
52
1
Chapter 1 - Introduction and Theory of Operation
INTRODUCTION
THEORY OF OPERATION
IMPAX can assist the operator of a forming, threadrolling or metal stamping machine by
counting parts produced, and monitoring stroke to stroke consistency. It is capable of stopping
the machine instantly when the job is completed or when it detects a problem.
IMPAX prevents smashups, scrap production, and overruns, thus making the forming operation
more productive and making the operator’s job easier. Because it is merely a tool, it cannot
replace skilled people, but it can help by reducing the drudgery of frequent inspections and
repairs.
Operation of the machine is not changed by the addition of IMPAX. IMPAX is ‘smart’ enough
to simply do its job, without interference or complication.
Although IMPAX operates mainly without attention, it does require the machine operator to
push a button once in a while. To get the best results from the system, you should become
familiar with its operation.
Operator attitude is very important when introducing and implementing IMPAX. Like any other
tool, its effectiveness depends on how well it is used. If machine operators perceive it as
unnecessary, complicated, an invasion of their routine, or a threat to their jobs, it will not work
even if it is technically perfect. It is vital that everyone understand that IMPAX can make
forming operations easier and more productive; that makes the whole company more
competitive, which in turn makes everyone’s job more secure.
The IMPAX monitoring system measures and remembers the forming force generated in each
forming station, for every machine stroke. The principle of operation is simply that when the
forming process changes (due to tool breakage, material variation, machine problems, etc.) The
forces required to form the part also change. IMPAX can be set up to detect a variety of changes
and stop the machine before further damage or waste occurs.
The heart of this system is the force measurement. Attached behind each forming station is a
piezoelectric force sensor. The piezoelectric element generates a voltage each time a part is
2
struck, twisted, deflected, etc. Another device, the machine position sensor, is turned on by a
timing cam when it is time for the part to be formed, at that time, the IMPAX monitor measures
the impulse from each force sensor. This measurement is converted to a number and stored in
memory. (The number is relative; it is not calibrated in any engineering units.) After a number
of new parts have been made, an average force level is determined and limits are set above and
below this average. Because some jobs run better than others, these limits are adjustable. When
the force of any stroke exceeds the limits, the process is stopped.
Stopping the machine is all the process monitor can do. It cannot fix the problem or restart the
machine. When a problem is detected a red light turns on to attract your attention and an error
message is displayed on the IMPAX unit’s display. The machine is stopped, and any accessories
are shut down in an orderly manner. A gate or diverter may also be used to trap the part which is
suspected to have caused the shutdown error.
Obviously, this system does not directly measure the quality of the parts; it indirectly measures
the consistency of the process. If a machine is running erratically or the raw material is
inconsistent, this monitor will not perform as well. Remember that IMPAX will not remedy any
problems with the manufacturing process, it can only detect them and shut the process down.
1. Ram Motion 6. Piezoelectric Sensor
2. Punch 7. Backplate
3. Finished Part 8. Machine Bed
4. Die 9. Kickout
5. Transmitted Force that will reach the sensor
Chapter 2 - Description of Controls
The IMPAX monitor is comprised of several components which are interconnected by wiring.
All components are mounted on the forming machine except for the IMPAX Control Console
which is isolated on its own pedestal.
The Control Console is the core of the system, housing the microcomputer and power supply.
Its front panel contains the Message Display Panel and the Keypad, through which you can
receive information and enter commands. It also contains the Locking Keyswitch which
accepts the Supervisor’s Key. This key allows the supervisor or operator to ‘program’ IMPAX.
The Satellite Box is the
junction for all the
controls and
components on the
machine. The Reset
Button is the only
operator control. The
red, yellow, and green
Status Lights indicate
the mode of operation
that the IMPAX unit is
in. The Bypass Key
Switch, operated by the
Supervisor’s Key,
disables the relay which
stops the machine and
its accessories, but has
no other effect on
operation. Note: There
is no machine
protection when the
IMPAX monitor is in Bypass mode.
Up to two Machine Position Sensors are used to sense the machine cycle and synchronize the
stop signal. Piezoelectric Sensors are installed in stressed locations near the forming stations;
on the back of the die-bolster or backing plate, on knockout rockers, in punch wedges, etc. A
recess is cut (about the size of a quarter), or a hole is drilled, and the sensor is installed using a
special epoxy adhesive. When the machine is reassembled, the sensors are out of sight, but
sensitive to the forming process.
Relays within the Satellite Box are also wired to the Machine Stop Circuit (if available), as
well as to the feed stop and other accessories, as required to stop the machine and the process.
The Control Console interfaces with the Satellite Box via a multi-conductor cable.
*Additional Keypad Reference on Page 52
CONTROL CONSOLE
The IMPAX Control Console contains a message display panel, a data entry keyboard, and a
locking keyswitch. The display panel shows information which is requested, or supplies
prompts or questions during operation. The Keypad* is used to enter commands or information,
and the keyswitch enables authorized users to program the unit. The function buttons may
operate differently depending on the position of the key switch. If the key is removed, IMPAX
will only display information. If the key is inserted, the Keypad can be used for programming
and diagnostics.
There are three kinds of buttons on the keypad. Functions buttons let you command IMPAX to
display or change things, Control buttons are used to enter commands and Data buttons let you
enter in numbers and codes.
5
Chapter 3 - Setup and Operation
Getting Started
To “Program” the IMPAX Controller, you must supply several basic types of information:
1. The total number of parts to be made on work order. (Up to 99,999,999)
2. The number of parts to be made prior to a predetermined inspection or tool change (this
feature may be omitted).
3. The force variation tolerance settings (scale of 1 to 9, automatic tolerance, or no tolerance)
for each forming process.
4. A “trend limit” which limits how much the force values can change as the machine heats
up or tools wear down (this feature may be omitted).
5. The desired number of exceptions, which let-by a small percentage of “bad” parts (this
feature may also be omitted).
Setting up the IMPAX unit for a new job may be done any time before beginning the job, by
anyone who has a Supervisor’s Key
Clearing the old job
Before setting up a new job you must Clear the existing functions which do not apply to the new
setup. When the old job is finished, insert the Supervisor’s Key and turn it to the right so it is in
a horizontal position.
Insert Key and turn to the right from the
Vertical position to the Horizontal position
Clearing Shift, Break, and Production Counters: 6
Clear SELECT TO CLEAR
Quantity CLEAR SHIFT?
Enter/Yes SHIFT CLEARED
CLEAR BREAK?
Next/No CLEAR BREAK?
Enter/Yes BREAK CLEARED
CLEAR PROD?
Next/No CLEAR PROD?
Enter/Yes PROD CLEARED
CLEAR EXPTS?
Next/No EXPTS CLEARED?
Press Clear . The display will show
“SELECT TO CLEAR”. This display
means that the IMPAX unit wants to
know what to erase.
Press Quantity. The display shows
“CLEAR SHIFT?” The IMPAX unit is
now asking whether or not you want to
erase the total number of parts made
during the shift. If not press Next/No.
(You may want to record this number
before erasing; to do so, see Chapter 4,
Information Displays.) If you wish to
erase this press Enter/Yes.
Now the shift total is erased and the
display shows “CLEAR BREAK?” The
IMPAX unit is now asking whether or
not you want to reset the counter which
makes the periodic stops for tooling
changes or inspection. If you do not
wish to do this, press Next/No. If you
desire to, press Enter/Yes.
Now the break counter is reset and the
display shows “CLEAR PROD?” The
IMPAX unit is now asking whether or
not you want to completely erase the
record of that preset production count.
This clears the total of parts made, as
well as the break counter. If you do not
wish to do this, press Next/No. If you
desire to, press Enter/Yes.
IF YOU HAVE AN IMPAX 2000, the
display will show “CLEAR
EXCEPTIONS”. If you wish to clear
this counter press Enter/Yes. If you do
not, press Next/No, and the display will
return to the default message display.
Press Display Will Show
IF YOUR ANSWER IS YES:
IF YOUR ANSWER IS NO:
IF YOUR ANSWER IS YES:
IF YOUR ANSWER IS NO:
IF YOUR ANSWER IS YES:
IF YOUR ANSWER IS NO:
Tabla de contenidos
