Rollformer Controller (iCON AP0107-03C)

AP0AP0AP0AP0111100007777----03030303CCCC Rollformer CutRollformer CutRollformer CutRollformer Cut----totototo----lengthlengthlengthlength with Punchingwith Punchingwith Punchingwith Punching:::: OpOpOpOperator’s Manualerator’s Manualerator’s Manualerator’s Manual

© System Electronics Pty. Ltd. 20System Electronics Pty. Ltd. 20System Electronics Pty. Ltd. 20System Electronics Pty. Ltd. 2011113333 See www.icontrol.net.au for more information about iCONiCONiCONiCON Page 1111

Operator’s ManualOperator’s ManualOperator’s ManualOperator’s Manual

iCONiCONiCONiCON AP0AP0AP0AP0111100007777----03030303CCCC

Rollformer CutRollformer CutRollformer CutRollformer Cut----totototo----LengthLengthLengthLength & Quad & Quad & Quad & Quad PunchingPunchingPunchingPunching

DOC- OP0107FK PC-1.2



Disclaimer:Disclaimer:Disclaimer:Disclaimer:

We have made a sincere effort to ensure the accuracy of the material described herein; however the author

and System Electronics Pty Ltd make no warranty expressed or implied with respect to the quality, correctness,

reliability, currentness, accuracy or freedom of error of this documentation of the product it describes. We make

no representation or warranty with respect to the contents hereof and specifically disclaim any implied

warranties of fitness for any purpose. The author and System Electronics Pty Ltd disclaim all liability for any

direct, indirect, incidental or consequential, special or exemplary damages resulting from the use of this product

or from the use of any other products described within this document.

Please refer to our website http://www.icontrol.net.au for any corrections or improvements to this manual.

© 2013: System Electronics Pty. Ltd.



Contents Contents Contents Contents

Page No.

IntroductionIntroductionIntroductionIntroduction 1111

Axes BasicsAxes BasicsAxes BasicsAxes Basics 2222

Using outboard equipmentUsing outboard equipmentUsing outboard equipmentUsing outboard equipment 3333

Explanation of iCON Screens:Explanation of iCON Screens:Explanation of iCON Screens:Explanation of iCON Screens:

START Screen and Colour Codes 6

MAIN MENU

MAINTENANCE

CALIBRATION & JOGGING Screen

7

8

9

Programming a JOB

Running a JOB

10

11

BACK-UP/RESTORE Screen 12

HISTORY Screen 13

Naming a JOB 13

System Screen 13

Operations Notes

Using a “JOB WIZARD” Special option

14

15

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• Circuit drawings and technical files to assist installation and system set-up

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Introduction Introduction Introduction Introduction

This iCONiCONiCONiCON - identified as Application No. AP0107FK-PC has been specifically designed to control a servo or VSD or hydraulic roll forming and cut-to-length system with an integrated 4 punching stations.

Your iCONiCONiCONiCON controller has been customized to suit your physical machine tool configuration by the commissioning technician. (Refer Commissioning Manual)

To custom prepare the iCONiCONiCONiCON to operate your Cut-to-length system the commissioning engineer has set detailed parameters into the controller memory.

When a Job is selected and in automatic operation, iCONiCONiCONiCON will cause cuts and punches in the job to be executed in sequence. At the end of the sequence (nominated “CUT”), X axis material feed will stop. The job cut lists can be restarted again by pressing the “GO” key. iCONiCONiCONiCON will continue the operation until the required quantity has been completed for each cut sequence until the “QTY COUNT=0”. Each punching station is labeled P1, P2, P3 and P4. These punches can be named as required during the commissioning process The punch will be actuated from 0mm at this programmed dimension.

Definitions Definitions Definitions Definitions



Axes BasicsAxes BasicsAxes BasicsAxes Basics

X AxisX AxisX AxisX Axis

1. The horizontal axis on the feeder is nominated as “X”. The position readout on the iCONiCONiCONiCON shows the dimension from the cutting blade to the end of the material being feed out. The calibrated position is 0.00mm at the cutting line of the blade. The iCON iCON iCON iCON readout will increase as the material is fed out past the cutting tool.

2. Each cut/punch in a job is allocated as a dimension in XXXX.X mm relative to the position of the cutting blade (0.0mm). Each dimension is allocated a quantity of parts cut and punched at the positions programmed. During automatic operation, the feeder moves the material forward until the programmed length is reached and the punch and the cut is executed. Each punch is allocated a dimension form the cutting blade. iCON calculates and tracks up to 10 independent work pieces on the punching table at any time. It correctly initiates punching and cutting in a complex function which results in all pieces correctly punched at the dimensions programmed. This action is repeated until the quantity as programmed is reached. The next batch in the cut list is then executed.

3. The X axis moves the material forwards to the desired position. When running to a position the controller will gradually ramp up to its full speed output, run at the full speed, ramp down to its positioning output and finally attempt to stop in the correct place. The ramp up and ramp down values can be set independently, and for systems such as a large roll former machine being run by a VSD the ramp down distance could be as much as 750mm to obtain acceptable stopping tolerances.

CCCCutting utting utting utting

The cutting or blade will be activated after the clamp has succeeded. The blade will come down to make a cut, and then return until hitting the HOME switch on the upstroke. Determining when a cut is completed can come from two sources. This decisions are made at commissioning time.

1. CUT switch. CUT switch. CUT switch. CUT switch. The cut will be completed once the CUT switch closes, beginning sending the blade back to the TOS position. This is the lower trigger switch on the actuator.

2. BBBBlade Cut Timerlade Cut Timerlade Cut Timerlade Cut Timer. If the parameter G7 is not disabled then the blade will come down until the timer expires. This allows use of systems missing a CUT switch, or can be used in combination with the cut switch to provide a faster stroke

If both the cut timer and cut switch are used then the cut will run until either the timer expires or the switch fires, whichever comes first.

The blade down motion can be set to be either latching or non-latching. If it is non-latching then the operator must hold the GO input on for the duration of the cut stroke, releasing the input early will cause the blade to return to the top of stroke. If set to be latching then once the input is brought on the motion will continue until the motion is completed.

The above aspects can also apply to the punches.

ClampClampClampClamp

The clamp is required to be active prior to a cut being initiated to ensure that the material cannot move. The clamp action is controlled via two mechanisms: a clamp good input, and a clamp timer. There are 4 main configurations for the clamp action:

1. No Clamp control optionNo Clamp control optionNo Clamp control optionNo Clamp control option: If G5 Clamp Delay is set to DISABLED, input hard wired to SHORT CIRCUIT. Controller will not delay for clamp and continue immediately to cut action. Clamp output will remain high during the cut cycle regardless

2. Monitored clamp.Monitored clamp.Monitored clamp.Monitored clamp. If G5 is set to DISABLED, input wired to switch/sensor. Controller will activate the clamp output, and await the input closing prior to continuing with the cut

3. Timed clampTimed clampTimed clampTimed clamp. If G5 is set to ##.#s, input left O/C. Controller will activate the clamp output, wait for the specified time, and then continue with the cut

4. Monitored and timed clampMonitored and timed clampMonitored and timed clampMonitored and timed clamp. If G5 is set to ##.#s, input wired to switch/sensor. Controller will activate the clamp output, and await EITHER the timer to expire OR the input to close, at which point time the cut will continue.



Explanation of KeyExplanation of KeyExplanation of KeyExplanation of Key iCON ScreensiCON ScreensiCON ScreensiCON Screens

START Screen: START Screen: START Screen: START Screen:

This screen appears when iCONiCONiCONiCON is powered.

1. “ABOUT”“ABOUT”“ABOUT”“ABOUT” calls SYSTEM screen see “SYSTEM SCREEN”

2. “GO”“GO”“GO”“GO” cals MAIN MENU for job selection and editing.

3. “Y CAL”“Y CAL”“Y CAL”“Y CAL” calls Y axis jog screen to show calibrate and set up functions.

4. Selects Language.

Screen Colour “Screen Colour “Screen Colour “Screen Colour “CodingCodingCodingCoding”””” Screen fields and items used in the iCON system are colour coded. This is very helpful for an operator to understand the finer points of the controller operation. Data Fields text .

• YELLOW: General iCON data. Showing present positions and conditions of the control. • BLUE : A data variable which is set by iCON and has not yet been edited. • GREEN: A data value input by the operator. • RED: A value in error. Machine tool action will be limited.

Note boundaries and the text on the action button show the colour normal (not edited). Button Colours:

• GREEN: Action • BLUE: Navigation / data entry

Thus if a value is a different colour than its boundary then a manual edit has occurred.Thus if a value is a different colour than its boundary then a manual edit has occurred.Thus if a value is a different colour than its boundary then a manual edit has occurred.Thus if a value is a different colour than its boundary then a manual edit has occurred.



MAIN MENU ScrMAIN MENU ScrMAIN MENU ScrMAIN MENU Screen:een:een:een:

1. Selects the last JOB run to be the current JOB..

2. Requests the name of the job number of the desired job to become the current JOB.

3. Selects the Y AXIS CALIBRATE screen.

4. Selects the X AXIS CALIBRATE screen.

5. Returns to last screen.

6. Selects the MAINTENCE MENU.

7. Selects the TOOLING MENU.

8. Shows the graphic for the current part.

9. Name the current job.

10. Select the next blank job to become the current job.

11. Real time clock. When GREEN indicates valid password is current.



MAINTENANCE MENU SMAINTENANCE MENU SMAINTENANCE MENU SMAINTENANCE MENU Screen:creen:creen:creen:

1. Selects HISTORY information..

2. Requests PASSWORD ………to see the settings and parameters for this iCON.

3. Finds a JOB by number or by name.

4. Special application programs as they become available.

5. Returns to last screen.

6. Set the current time and date.

7. Selects the LANGUAGE.

8. Set the password to allow access to maintenance areas and clear the password when finished. The password will automatically clear after 1 hour.

9. Selects more testing functions for technician.

10. Selects the BAKCUP and RESTORE MENU.



X AX AX AX AXIS JOG ScreenXIS JOG ScreenXIS JOG ScreenXIS JOG Screen

This screen is accessed from the MAIN MENU or from the quick key at the RHS of the screen.

The X axis (see page 1) can be moved manually to a position or the GOTO function can be used to move to a dimension.

1. Displays the current position of the X axis with respect to the tip of the top tool.

2. Jogs the gauge forward at the set federate.

3. Sets the federate of the X axis 0-100%

4. Absolute Calibration. Enter the current dimension of the X axis. GOTO. Will cause the X axis to be positioned at the entered dimension. This is the usual method of calibrating the X axis.

5. GOTO. Will cause the X axis to be positioned at the entered dimension.

6. Jogs the gage back at the set federate.

Jogging controls for the Jogging controls for the Jogging controls for the Jogging controls for the CutCutCutCut----totototo----Length lineLength lineLength lineLength line

12. Display current length dimension. The distance from the cutting blade to the end of the material.

13. Jog Forward. The Blade must be at Top of Stroke (TOS).

14. Jog Reverse. The Blade must be at Top of Stroke (TOS).

15. Set servo velocity as a % of full speed. Usually set at 100%.

16. AUTO CALAUTO CALAUTO CALAUTO CAL. Is used when the length of the material is not as accurate as it should be. There are many and variable reasons for an inaccuracy. This Auto Cal function corrects such errors. When pressed the keyboard will present and the measured dimension of the last cut piece will be entered. iCON will then recalculate its internal parameters to fine tune the error out of the system.\

17. CALCALCALCAL Enter the actual dimension of the material from the blade to the material end.

18. GO TO GO TO GO TO GO TO . Enter a dimension for the iCON to feed material out to.

19. EDIT DATAEDIT DATAEDIT DATAEDIT DATA. Password protected. For service personnel only.

20. Error messageError messageError messageError message. In this case the X axis has failed to move as requested.



JOB JOB JOB JOB Programming Programming Programming Programming ScreenScreenScreenScreen

A typical Punch/Cut List is shown above. It includes up to 20 individual Punch and cut dimensions. At the end of each sub group of punches (P1 etc.) “CUT” wil cause the material to be cut off

Batch number (1-5) number for the cut list

1. Cut dimension for the batches 1-5.

2. Dimension to the first punch P1 in this case.

3. Nominated the Punch to be energised at this dimension.

4. Cut dimension for the batches 6-10.

5. Programe the dimension for the punch or the final cut.

6. See 3.above

7. Go to next screen for batches numbered 11-20.

8. OK to execute the cut list.

9. Select/ Name a job. (250 jobs are available).



Running a Programmed Job.Running a Programmed Job.Running a Programmed Job.Running a Programmed Job.

This screen is used to Run a job. The Punch/cut list has been entered and the material loaded and ready. At this time it may be reuired to activate a cut to remove unwanted material from the guillotine area. Before pressing AUTO use the “GO” key on the pendant to cause the manual cut. On completion of the cut X=0.00mm. The system is ready for AUTO run.

1. X position. Displays the distance run since the CUT.

2. Symbol of each punch. . . . Shows as red when actuve down. Touch the symbol to activate the punch in manual mode.

3. Symbol of rollers. Show when in motion.

4. Sets the feedrate of the X axis. Only for proportional X axis control if applicable

5. The count counts down from a pre set quanatity nominated. System stops at “0”.

6. Set the system to run in AUTOMATIC as per the program for the job.



BACKING UP / RESTORE Screen BACKING UP / RESTORE Screen BACKING UP / RESTORE Screen BACKING UP / RESTORE Screen

1. “BACKUP PARA”“BACKUP PARA”“BACKUP PARA”“BACKUP PARA” causes all axis parameters to be set into permanent memory.

2. “RESTORE PARA”“RESTORE PARA”“RESTORE PARA”“RESTORE PARA” Reads axis parameters from permanent memory into the iCON operating memory.

3. “BACKUP JOBS”“BACKUP JOBS”“BACKUP JOBS”“BACKUP JOBS” causes all JOB data to read into permanent memory.

4. “RESTORE JOBS“RESTORE JOBS“RESTORE JOBS“RESTORE JOBS” Reads all JOB data from permanent memory into iCON operating memory.

HISTORY Screen HISTORY Screen HISTORY Screen HISTORY Screen

1. Indicates the time running hours since last cleared.

2. Indicates the “BENDS ““BENDS ““BENDS ““BENDS “ since last cleared..

3. Indicates the ”PARTS “ ”PARTS “ ”PARTS “ ”PARTS “ manufactured since last cleared.



NAMING A JOBNAMING A JOBNAMING A JOBNAMING A JOB

1. Use the keyboard to edit or name a job.

2. Veiw the part selected.

3. Use the keyboard to edit or name a job.

iCON SYSTEM Screen iCON SYSTEM Screen iCON SYSTEM Screen iCON SYSTEM Screen

About this iCON :About this iCON :About this iCON :About this iCON :

“ABOUT” Screen

1. Input DC voltage to iCON nominal 24V 2. Present DC Amps to iCON and DC USER 3. iCON on board temperature 4. Software revision level 5. iCON Identification code 6. Go back 7. Touch Screen Calibrate 8. Go to axis paremeter data (password protected) 9. Go to Main Menu 10. Go to Mini Card 2 condition 11. Go to Mini Card 1 condition 12. Go to the Amps set for each output 13. Go to OUTPUTS maintenance screen 14. Go to INPUTS maintenance screen 15. Go to last JOB 16. Go to calibrate the main Axis (short cut)



Operation points to note Operation points to note Operation points to note Operation points to note on AP0107on AP0107on AP0107on AP0107 ApplicationApplicationApplicationApplication::::

• The only way to make the controller forget about what is currently queued inside the rollers is to go to the X AXIS screen and press on the LOAD button. This will set the X position to the nominated load position in the parameters, and clear the work in progress

• The CLEAN button on the WIZARD screen does the following o It will enumerate from JOB 1 to JOB 1000

� If the job QTY <= 0 the job is cleared � If the job QTY > 0 the job is moved forward to the first empty job slot

o This will move all jobs to complete to the front of the job list • The following describes how the system queues jobs:

o Every time the controllers goes to move the X axis, it will populate the work in progress list until it is full of work pieces

o If insufficient pieces can be found, the controller will not allow further movement. So when no more work is queues the system will stop and await further programming

o New pieces are taken from the current job number onwards, so if we’re currently on job number 5 the controller will try to add a new job from 5, then 6, then 7, etc, then 999, then 1000, then 1, then 2, then 3, then 4

o The current job number will be changed if the piece leaving the machine is the last run of that job (i.e. when the QTY reaches 0) and the piece leaving the machine is the current job number. Then the current job number will be changed to the next piece to leave the machine

EXAMPLE:

We show up at work on Monday morning, and have a job list from the office of what to make up on a brand new coil. We load up the coil by using the pendant to manually job the material. Once it is in the correct place, we press the LOAD button on the X AXIS screen. This tells the controller we have a brand new coil loaded and ready to go.

Then we go to the WIZARD screen and type in a length, a quantity, then press on the GO button to program the job. Pressing back returns us to the WIZARD screen where we press NEW JOB and repeat to program the new job. This back and forth gives an opportunity to confirm that the job was programmed correctly. We program up the following job list:

JOB NUMBER LENGTH QTY

1 250 2

2 500 5

3 550 3

4 230 5

5 750 2

6 0 0



After a while of operation the boss comes over and says he needs 3 pieces that are 350mm long ASAP. The job list is currently in the current state:

JOB NUMBER LENGTH QTY

1 250 0 (2 have been done)

2 500 3 (2 have been done, 3 in machine)

3 550 3 (1 is in the machine)

4 230 5

5 750 2

6 0 0

We go to the WIZARD screen, press NEW JOB, then program the length and QTY, press GO to program the job, then GO again to start AUTOMATIC mode

Now we’re currently running in job number 6, with two of job numbers 2 and 3 already queued in the machine. Now when the machine runs the very next piece to be queues will be the new 350mm’s the boss has requested. Next to come out of the machine will be the job number 2 from before, this will happen 3 times, then 1 of job number 3 will come out. After this catch up the 3 350mm pieces will come out, after which (assuming jobs 7 and above are empty) the controller will then loop back around to running job number 3 as it was before the boss interrupted the normal work flow.

Devices & Hardware

Rollformer Controller (iCON AP0107-03C)