Hydraulic Press Automation & Control

Case Study #1

Scope: Two smaller hydraulic presses (50 ton capacity) needed an updated control and safety system. We were contracted to update the existing system with new PLC's, HMI's, safety products and integrate the following into the press line.

Products (Each Press):

Method: We were also contracted to remove all of the old and unnecessary components to the upgrade. After removal, the team installed and wired all control and automation components and performed an I/O check.

Our control package included two (2) PLC processors providing a safe and redundant control of the solenoids controlling the ram speed and position. A pendant arm with the attached HMI also made the operator interface easy to access and view the entire press. Along with the individual press controls and safety, the team interfaced with an air feeder system. These parameters were stored with each job and sent automatically on a job change.

As with every press, the stamping process is unique in its own way. The team talked with operators and process engineers on how the press ran in the past and programmed the new controls accordingly. For this specific application, the press had three (3) stages for both the downstroke and upstroke. Each zone had the same tonnage, but the speed through each zone was different.

Results: The finished project was a success. We were able to correctly tie all existing and new components together and bring both of the presses up-to-date control and safety wise.

Case Study #2

Scope: A 350-Ton hydraulic press needed updated press controls. Our assignment was to bring these controls up-to-date with the latest hardware and safety features, along with making the press run as it had before the update. All controls were to be ANSI, OSHA and CSA compliant.

Products:

Method: After removal of all unneeded wire and components, we installed and mounted all of the new field and control hardware, along with the new enclosure. Once in place and wired, we were able to apply power and verify all new and existing connections.

After our I/O check was successful, the analog vales were tested and calibrated. For this specific press, four (4) analog valves controlled the ram position and speed.

This particular application required two (2) zones to form the part. Each required a different ramp speed, however the same tonnage was applied throughout each zone. Also required for this project was robot interlocking. For this specific press, a single robot was used to transfer the blank through each of the stations (3 total). The press was programmed to run at a slow speed during the stroke until the signal was sent from the robot confirming it was in the return position. Once at the home position, the ram would increase in velocity and form the part.

Results: The finished project was a success. We were able to correctly tie all existing and new components together and interface successfully with the robotic transfer.

Case Study #3

Scope: This hydraulic press was being moved from Ohio to Monterrey, Mexico and Toledo Integrated Systems was contracted to provide a turn-key OSHA & ANSI compliant press control system. Our services required a removal of all unneeded electrical components and wires, re-wire the entire press and automation system, update the controls, automation system, safety circuit and HMI, re-commission the press and provide training for the new operators and maintenance personnel.



Products:

Method: : After removal of all unneeded wire and components, we installed and mounted all of the new field and control hardware, along with the new enclosures. Once in place and wired, we were able to apply power and verify all new and existing connections.

After our I/O check was successful, the main pump variable volume controller was calibrated and checked for any problems. Once the main pump was calibrated, the team was able calibrate tonnage and then incorporate the customer's specific control process.

This particular application required five (5) zones to form the part. Each zone required a different rate to tonnage, tonnage and duration. Once the five (5) stages were completed, the ram would automatically open to a settable opening and the part would be sprayed with a coating substance, IMC (Injection Molding Compound). After spraying, the part would run through five (5) more zones at which point the finished part would be ejected.

Results: The finished project was a success. We were able to correctly tie all existing and new components together after the transplant. We were also able to beat our deadline during the run-off.