ALFAMATIC Press-Right User manual

Issue 2 - August 8, 2023
USER MANUAL
PRESS -RIGHT
•User manual

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1General informations........................................................................................................................ 5
1.1 Introduction to control theory..................................................................................................... 5
1.2 Control of the position-force curve............................................................................................ 5
1.3 Absolute and relative odds........................................................................................................ 5
2Installation Press-Right .................................................................................................................... 7
3How to start ...................................................................................................................................... 8
3.1 Press-Right user interface......................................................................................................... 8
3.2 First approach ........................................................................................................................... 8
3.3 Set the view............................................................................................................................... 9
3.4 The main menu ......................................................................................................................... 9
4Jobs10
4.1 Create a new job..................................................................................................................... 10
4.2 Change the job name.............................................................................................................. 10
4.3 Selecting a job......................................................................................................................... 10
4.4 Selection of a job by barcode.................................................................................................. 10
4.5 Selecting a job via tool recognition.......................................................................................... 10
4.6 Selection of a job via fieldbus.................................................................................................. 11
4.7 Modify job identification codes ................................................................................................ 11
4.8 Copy a job ............................................................................................................................... 11
4.9 Delete a job ............................................................................................................................. 11
4.10 Edit a job ................................................................................................................................. 11
4.11 Job counters............................................................................................................................ 12
4.12 The graph................................................................................................................................ 12
4.13 Phase management................................................................................................................ 12
5Parameters..................................................................................................................................... 14
5.1 Stop values.............................................................................................................................. 14
5.2 Control limits............................................................................................................................ 16
5.3 Checkpoints............................................................................................................................. 17
6Job options ..................................................................................................................................... 18
6.1 Counters.................................................................................................................................. 18
7The tolerance range ....................................................................................................................... 20
7.1 Create the tolerance range ..................................................................................................... 20
7.2 Modify the tolerance range...................................................................................................... 20
7.3 Remove the tolerance range................................................................................................... 21
8Rejected pieces.............................................................................................................................. 22
8.1 The causes of rejected............................................................................................................ 22
8.2 Rejected management............................................................................................................ 23
8.3 Additional sensors................................................................................................................... 23
8.4 Force transducers ................................................................................................................... 23
8.5 Accessories............................................................................................................................. 23
8.6 Repetition................................................................................................................................ 23
8.7 Verification............................................................................................................................... 23
8.8 Codes of the job...................................................................................................................... 24
9Measured values............................................................................................................................ 25
9.1 The measured value page ...................................................................................................... 25
9.2 Analysis cursor........................................................................................................................ 25
10 The tools menu............................................................................................................................... 26
10.1 Display options........................................................................................................................ 26
11 Instrument configuration................................................................................................................. 27
11.1 General options....................................................................................................................... 27
11.2 Job selection ........................................................................................................................... 28
12 Diagnosis........................................................................................................................................ 29
12.1 Firmware version..................................................................................................................... 29
13 Special configurations .................................................................................................................... 30
13.1 Additional force transducer ..................................................................................................... 30
13.2 Self-test................................................................................................................................... 30
13.3 Management of supplementary controls................................................................................. 31

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13.4 Tools recognition..................................................................................................................... 31
14 Data storage................................................................................................................................... 33
15 Password........................................................................................................................................ 34
16 Calibration ...................................................................................................................................... 35
16.1 Force transducer calibration.................................................................................................... 35
16.2 Position transducer calibration................................................................................................ 35
16.3 Encoder alignment .................................................................................................................. 36
17 Connection to computer ................................................................................................................. 38
17.1 Connection via USB port......................................................................................................... 38
17.2 Connection via LAN port (ethernet)......................................................................................... 38
18 Field bus......................................................................................................................................... 40
18.1 Organization............................................................................................................................ 40
18.2 Status and Control................................................................................................................... 40
18.3 Modbus/TCP ........................................................................................................................... 40
18.4 PROFINET and EtherNet/IP ................................................................................................... 40
18.5 Strings ..................................................................................................................................... 42
19 Registry organization...................................................................................................................... 43
19.1 Execution of commands.......................................................................................................... 43
19.2 Register table.......................................................................................................................... 45
19.3 Description of Check Point logs .............................................................................................. 49
19.4 Description unit of measure .................................................................................................... 50
20 Technical data ................................................................................................................................ 51
20.1 Instrument features ................................................................................................................. 51

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1 General informations
Press-Right is a control and measurement instrument which, when connected to a press, guarantees the
quality control of the production processes.
Interfaced to a position transducer and a load cell, it continuously detects the position and the instantaneous
force.
1.1 Introduction to control theory
During machining on sample pieces, the data relating to the position of the cylinder and the force exerted by it
are recorded; the graph can be drawn: position-force which is characteristic of the work carried out.
If several machining operations are carried out on similar pieces, the respective position-force curves will also
be similar. If, on the other hand, one of the workpieces differs from the sample, the relative curve will deviate
from the sample curve. It is intuitive how curve control can ensure consistent machining quality.
1.2 Control of the position-force curve
From a theoretical point of view there is an ideal curve which is obtained by machining perfect pieces (in
practice there may be a sample curve obtained by machining carefully selected pieces). Any geometric
tolerances or material differences lead to a deviation from this ideal curve.
In practice, the Press-Right controls the curve through a tolerance range, check points and limits.
The tolerance range positioned around the sample curve is such that if the curve obtained from the current
machining does not pass within this range, the piece is rejected.
The limits control the position and the force values reached. The limits are as follows: minimum peak force,
maximum peak force, minimum peak position and maximum peak position. If the position reached does not
exceed the minimum peak position and/or exceeds the maximum peak position, the piece is rejected. In the
same way, if the force reached does not exceed the minimum peak force and/or exceeds the maximum peak
force, the piece is rejected.
The check points are used to control the curve in discrete points, for example it is possible to check that in a
pre-established position the measured force is between a minimum and a maximum, or that at a pre-
established force the measured position is between a minimum and a maximum. If the values measured in a
check point are not correct, the piece is rejected.
1.3 Absolute and relative odds
The positions referred to the zero of the cylinder are called absolute positions. The positions referred to the
contact position on the piece are called relative positions. The Press-Right can use both absolute and relative
positions. The load cell is used to detect the contact position: when the force measured by the load cell exceeds
a programmed value, the position values is set to zero. This force value is called CONTACT DETECTION
THRESHOLD. The position in which the contact is detected (contact position) is recorded and can be
controlled with two limits, minimum and maximum, to continue or not.

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1) Top dead centre
2) Zero absolute position
3) Zero relative position
Figure 1
The accuracy of the contact position detected with the load cell depends on the speed of the cylinder and
above all on the type of piece to be machined. In inserting operations, the two pieces have rounded corners,
consequently the contact position also varies with the variation of the bevel and the force used to position one
part into the other.

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2 Installation Press-Right
To install the instrument on the machine, consult the specific manual.

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3 How to start
This chapter will walk you through the basics of programming and using the Press-Right instrument.
To better illustrate the operations, it is advisable to carry out the tests in practice; to do this it is very useful to
have an elastic support of adequate compliance to simulate repeated machining.
Figure2
To turn on the instrument there is a button on the back. When it is pressed, after a few seconds, the display
lights up and the graph appears.
3.1 Press-Right user interface
If you touch the menu button, the items that make up the main menu are displayed. To select an item in the
menu it is possible to move with the arrow keys and press the OK button or it is possible to directly touch the
item itself.
The RESET button cancels the operations and allows you to return to the main screen.
3.2 First approach
A few seconds after being switched on, the display lights up and shows the main screen. The main screen
displays the graph area and below it the values measured by the connected transducers.
First let's create a simple job:
•Touch the menu button
•Touch the JOBS LIST item
•Touch the CREATE A NEW JOB item
•Enter the name that identifies the job (example TEST 1) and press the enter key.
Note: in the rest of this manual, when it is indicated, for example, “JOBS LIST > CREATE A NEW
JOB” command, we mean to press the menu button, then press the JOB LIST item and finally press the
CREATE A NEW JOB item.

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Once the job has been created, indicate to the instrument when it has to stop the press by entering a stop
value. The stop value can be a position value or a force value. The difference in usage is explained in chapter
5. Press EDIT JOB > STOP VALUES > STOP FORCE, enter a value lower than the maximum force that the
press can exert and confirm.
By giving the machine start command, the press will advance and will exert a force that will increase up to the
stop value that we entered previously.
If a too high stopping force value has been entered, the press will continue to push; to stop the press manually,
press the RESET button. In this case the piece is rejected because the work has been interrupted.
3.3 Set the view
The central part of the display is occupied by the position-force graph. It is possible to modify the full-scale
values using the commands in the EDIT JOB > GRAPH SETUP.
3.4 The main menu
Note: Some menu items are not visible if not needed.
The main menu is the first displayed by pressing the menu key.
JOBS LIST allows the choice of the job to be used, the creation of a new job or the elimination of the job in
use.
The PHASE EDIT is visible when the job is divided into several phases. It allows the modification of all the
parameters of the displayed phase.
The EDIT JOB allows you to modify all the parameters of the job in use. See chapter Errore. L'origine
riferimento non è stata trovata.. When the job is divided into several phases, the modification of the
parameters of the single phase will be possible from the PHASE EDIT menu while the options common to all
phases will be present in the JOB PROPERTIES menu.
The SHOW MEASURED VALUES displays the values measured during the last cycle.
The TOOLS allows the modification of the instrument configuration and the possibility of moving the cylinder
manually.
The item RESET COUNTERS is used to reset the counters of processed pieces. When the batch number is
managed, this menu will be replaced by the NEW PRODUCTION BATCH menu which allows the batch
number to be entered. This number will be stored together with the curve.
The PART NUMBER item allows the insertion of the identification number of the piece being processed. This
identifier will be stored together with the curve.
The USER item allows the operator's identification to be entered. This identifier will be stored together with the
curve.
The PHASE TO EXECUTE item allows you to select the next phase to be executed by modifying the normal
execution sequence. When a phase runs out of sequence, immediate stops on reject are disabled. This
command is available only if the phase sequence is adjusted by the instrument.

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4 Jobs
The Press-Right memorizes all the settings (parameters, tolerance range, limits and counters) relating to the
various jobs in an internal memory. Each group of settings is called Job. Each job has its own name.
JOBS LIST item is present in the main menu. Through this menu it is possible to choose a job among those
present, create a new one, or delete the job in use.
4.1 Create a new job
To create a new job, use the JOBS LIST > CREATE A NEW JOB and give it a name. As a name you can use
the drawing number, the customer's name or whatever you prefer to be able to easily identify it.
When creating a new job, you are asked if you want to make a copy of the job currently in use. If you choose
to copy the current job, the parameters of the current job will be duplicated and will remain unchanged. In the
other case the new one will be empty.
After having created the job, you can set the parameters, options and tolerance range.
4.2 Change the job name
To change the name of a job, you must first select it. Once you have selected the job to which you want to
change the name, you can use the command EDIT JOB > PROPERTIES AND OPTIONS > NAME OF THE
JOB.
4.3 Selecting a job
SELECT JOB command is present in the JOBS LIST menu. When this command is selected, the list of jobs
present is displayed. The date and time the job was last modified is shown next to the name.
If the list is very long, look for the name by touching the magnifying glass icon.
To prevent manual selection of a job, the selection of jobs can be locked with a password. To activate the
password, activate the Job selection option in the TOOLS > PASSWORD > FUNCTIONS WITH PASSWORD.
4.4 Selection of a job by barcode
If a barcode scanner is connected, it is possible to select the job automatically by simply reading the barcode.
To activate this function, activate the Jobs with identification codes option in the TOOLS > SETUP > JOB
SELECTION.
After activating the Jobs with identification codes option, the relative identification codes must be assigned to
the jobs. To assign the codes to the job see chapter 4.7.
4.5 Selecting a job via tool recognition
It is possible to connect sensors and RFID antenna to the instrument to automatically recognize the tool used.
It is possible to recognize up to three parts, for example the punch, the placement, and a simple mechanical
selector. These signals can be used to automatically select the job to be used or to enable machine operation.
To activate the recognition of the tools, the relative options must be configured in the TOOLS > SETUP >
ELECTRICAL CONNECTIONS > TOOLS.
After having configured the recognition of the tools, it is necessary to activate the automatic selection in TOOLS
> SETUP > JOB SELECTION. Finally, the relative tool code must be assigned to the jobs in EDIT JOB >
PROPERTIES AND OPTIONS > ACCESSORIES.