3. How do servomechanical press controls differ from mechanical press controls?
One of the biggest differences between mechanical and servo press controls is the use of cam-based functions. These typically use linear distances during stroking instead of angle-based settings, as servo presses have many more special stroke profiles that traditional mechanicals can’t perform.
Servo press controls enable operators to request unique profiles, while customized motion curves allow as many as 20 various segments in a cycle curve, defined by segment position, speed and pause-duration parameters.
Integrated servo press controls on direct-drive and link-assisted servo presses allow an unlimited number of stroke lengths and slide-movement profiles, while supplying full working energy capacity, even at low speeds. With servo press controls, operators can perform a variety of jobs—drawing, restriking, warm forming—in one press.
Standard features for a servo press control should include:
- Automatic slide adjustment and die-height auto-correction (optical linear sensor)
- Pulse-generator wheel for die tryout
- Press-speed optimization during the working and nonworking portion of the stroke
- Synchronization with the servo press’s various speeds, with other presses and with automation
- Ethernet link
- Task-assignment software.
4. What are some essential features and capabilities? Which types of applications require optional features?
Essential features include tool storage availability, cam/PLS channels and some die-protection channels, along with having a good diagnostic menu for troubleshooting and spotting faults. Also, a stamper should ask for expansion availability for extra cams and die protection. A tonnage-monitor option would be next on the list, as this is a valuable tool to use for process control and tooling condition monitoring, and to know how hard the press is working, tonnage-wise.
5. How do press controls provide die protection?
Typically, die protection is standard for most press controls; however, the available number of circuits and channels varies. Generally, most large press controls come with eight circuits as standard, with options for additional circuits. Die protection allows for users to integrate and program their tooling and production monitoring sensors easily. Most press controls come equipped with designed and implemented die-protection modules for many common production-monitoring functions.
6. What is a configurable controller?
This is more of an option/availability on a press control than a type of press control. Most of the major press controllers have—or can offer—configurable inputs, both dual-safety (dual cross-checked pairs) and single, non-safety inputs to use for auxiliary equipment to stop and notify of some error. The term “configurable” also may be referred to as “programmable,” depending on the press control brand, but both do the same thing.
7. Is there a type of press control that allows access to press production remotely?
Most press controls, especially the major brands, offer optional access to remote servers. Some may require additional software or firmware updates to allow remote communication, but most come with communication ports as standard.
8. Can a press control also control the feed line?
No, not for dedicated press controls. Integration from the feeder control to the press control to let the feeder be the master is the common way to achieve that. This would be applicable for long feed lengths. Some press controls do offer a servo-feed interface, with some feedlines that allow for some information exchange such as feed speed and feed length. That can be stored in the press control’s tool-storage menus.
9. How would a high-volume, mild-steel stamping application control differ from one for a high-strength-steel automotive structural part?
This would come down to options needed for the process. Control options for stamping high-tensile-strength steel in a high-tonnage press may need the press controls to be housed in a separate cabinet on the floor rather than mounted on the press frame.
10. Have controls been adapted for use by operators coming onboard who are less experienced but with smartphone and gamer proficiency?
Just because new, young operators are good at touching buttons, that does not make them better operators. Most controls offer layers of password protection that limit what inexperienced operators and setup techs can do and require a supervisor with a higher-level passcode to access complicated functions and features. MF
Patrick Thomas is customer service manager, Stamtec Metal Stamping and Forming Equipment; pthomas@stamtec.com.
See also: Stamtec, Inc.
Technologies: Pressroom Automation, Sensing/Electronics/IOT