Allen-Bradley Press Automation & Control - Integrated W/ Our Press Pilot 150 Clutch/Brake Controller and PanelView HMI
Toledo Integrated Systems has been providing Allen Bradley solutions to the metal forming industry for over 13
years. In that time we have worked with all of the Allen Bradley hardware platforms including PLC5, SLC, MicroLogix,
CompactLogix and ControlLogix. Our AB Maximizer TPC has many standard control and automation features but allows
for easy customization and expandability.
The Max TPC is built to order with all the functionality and integration
that the customer requires. This gives the customer complete control of the equipment using standard "off-the-shelf"
hardware. The HMI is also selectable. Along with the standard Allen Bradley offerings for the HMI, we are capable of
providing an industrial PC or a screen from a different vendor (if you have standardized on a certain screen).
Allen-Bradley - Press Pilot 150 - HMI Communications
Below is a list of the standard features and options for the AB Max TPC. The options don't stop there. The true
advantage with a PLC system is that it can be expanded and customized to the customer's exact needs.
All supplied controls comply with OSHA, ANSI and CSA Z142-02 regulations for mechanical stamping presses.
Press Control Features:
- Dual processor w/ watchdog circuit
- Anti-tie down protection
- Anti-repeat protection
- Dual channel monitored E-stop circuit
- Protected memory (each processor)
- Off, inch, single &continuous modes
- Clutch & counterbalance air pressure monitoring
- Press position verified each cycle
- Speed compensated top-stop
- Top stop overrun protection
- Uncommanded motion & drift detection
- Clutch valve fault monitor input
- 120 VAC or 24VDC E-stop circuit
- Light curtain interlocks
Press Automation Features:
- Sixteen (16) die protection inputs
- Eight (8) programmable limit switches
- Two (2) or four (4) channel tonnage monitor
- Signature analysis & reverse tonnage
- Individual window settings for all DP inputs and PLS outputs
- Part, good part, stroke and two batch counters
- Press position and SPM display
- Two hundred (200) job storage / recipes
- Ability to save/review comments with each recipe
- Compact flash card memory
- Individual alpha/numeric names for DP, PLS and job storage
- PLS Speed compensation
- Time based brake monitor
- 90 degree stop test
- Resolver based (360 degrees @ 1° res.)
- Automatic alarm pages and messaging
- Online help menus
- 3 password levels
- MaxNet connectivity capable (press room networking)
Typical Control Features Include:
- Ethernet connectivity
- Main motor control and monitoring
- VFD or Eddy current control integration
- SPM control
- Flywheel brake control
- Slide adjust control and monitoring
- Lube pump control and monitoring
- Hydraulic pump control and monitoring
- Individual I/O diagnostics
Optional Control Features Include:
- Additional DP & PLS (virtually unlimited)
- Signature analysis & reverse tonnage
- CCM (Critical Curve Monitoring)
- Auto counterbalance
- Auto shut height
- Servo feed interface
- Transfer system interlocks
- Robot interlocks
- Standard die sensor interface box
- Universal die sensor interface box
Click Here To Download Press Control RFQ
Case Study #1
Case Study #1
Project: Provide AB Maximizer TPC packages for four
(4) 30-Ton Oak Presses.
Scope: Design, panel build, program and commission press controls using
Allen-Bradley CompactLogix PLC, Press Pilot 150 and PanelView Plus 1000 HMI's.
Design Considerations: All devices to communicate over Ethernet including the
main motor drive (AB PowerFlex). Provide servo feed interface with a Vamco feeder. Press to run
at a maximum of 1000 SPM. High speed linearization for Top-stop speed compensation.
Features Included in AB Maximizer TPC:
- Resolver based control
- Fifty (50) job storage
- Eight (8) die protection
- Eight (8) programmable limit switches
- Four (4) channel tonnage monitoring
- Time based brake monitor
- Automatic shut height control and display
- Servo feed interface
- All motor control and monitoring
- Oak standard "slide lift system"
- Scrap conveyor interlocks
- Production counters
- Material lace mode
- SPM control including separate INCH SPM
Case Study #2
Case Study #2
Project: Provide AB Maximizer TPC package for a
1200-Ton Verson Press.
Scope: Design, panel build, program, turn-key installation and commission
press control using Allen Bradley SLC 5/04, Press Pilot 100 and 15" Industrial PC HMI. Add
interlocks for a new HMS transfer system.
Design Considerations: Use DeviceNet for remote junction boxes to reduce
installation wiring. Reuse main motor eddy current controller and all starters. Provide
serial interface with the dynamatic eddy current controller for SPM control.
Features Included in AB Maximizer TPC:
- Resolver based control
- Fifty (50) job storage
- Die identification
- Share job/recipe with HMS transfer system
- Sixteen (16) die protection
- Eight (8) programmable limit switches
- Four (4) channel tonnage monitoring
- Time based brake monitor
- Automatic shut height control and display (resolver based)
- Automatic counterbalance control
- Servo feed interface
- All motor control and monitoring
- Flywheel brake control and monitoring
- Hydraulic overload control and monitoring
- Rolling bolster control and monitoring
- Die clamp control and monitoring
- Die cushion control and monitoring
- HMS transfer system interlocks
- Littel feeder interlocks
- Conveyor control and monitoring
- Production counters
- Semi-automatic die change sequence
