ALFAMATIC Press-Right User manual

U S E R M A N U A L
PRESS-RIGHT
FOR ELECTRIC PRESS
 User manual

1 General information .............................................................................................................5
1.1 Introduction to the monitoring theory....................................................................................... 5
1.2 Characteristics of the device..................................................................................................... 5
1.3 Device operating principle........................................................................................................ 5
2 Installation of Press-Right....................................................................................................8
3 Getting started ......................................................................................................................9
3.1 The keyboard of Press-Right..................................................................................................... 9
3.2 First approach ........................................................................................................................ 10
3.3 Set visualization ...................................................................................................................... 11
3.4 Using the menus...................................................................................................................... 11
3.5 The main menu........................................................................................................................ 11
4 The JOB..............................................................................................................................13
4.1 Create a new job ..................................................................................................................... 13
4.2 Select a job.............................................................................................................................. 13
4.3 Edit the job name .................................................................................................................... 14
4.4 Copy a job............................................................................................................................... 14
4.5 Delete a job............................................................................................................................. 14
4.6 Edit a job................................................................................................................................. 14
4.7 Job counters............................................................................................................................ 14
4.8 Managing the automatic selection of jobs as an external user............................................... 14
4.9 The graph................................................................................................................................ 15
4.10 Scraps options and management............................................................................................. 16
4.11 Managing the phases .............................................................................................................. 16
4.12 Channel management.............................................................................................................. 17
4.13 Self-verification....................................................................................................................... 17
4.14 Managing further monitoring ................................................................................................. 17
5 Parameters ..........................................................................................................................19
5.1 Motion management................................................................................................................ 19
5.2 Limits and thresholds.............................................................................................................. 19
5.3 Check points............................................................................................................................ 20
5.4 Job options.............................................................................................................................. 20
6 The tolerance range ............................................................................................................22
6.1 Create the range...................................................................................................................... 22
6.2 Change the range.................................................................................................................... 22
6.3 Delete the range...................................................................................................................... 24
7 Scrap piece .........................................................................................................................25
7.1 The discard causes.................................................................................................................. 25
7.2 Scrap management.................................................................................................................. 26
8 Measured values .................................................................................................................27
8.1 The window of measured values ............................................................................................. 27
8.2 Analysis cursor........................................................................................................................ 28
9 The Tools menu..................................................................................................................29
9.1 Display management............................................................................................................... 29
9.2 Counters and self-verification................................................................................................. 30
9.3 Manual cylinder movement..................................................................................................... 30
9.4 Advanced options.................................................................................................................... 30
10 Device configuration ..........................................................................................................31
10.1 General options....................................................................................................................... 31
10.2 Job, phase and channel configuration .................................................................................... 32
10.3 Diagnosis ................................................................................................................................ 33

10.4 Firmware version.................................................................................................................... 33
11 Password.............................................................................................................................34
12 Computer connection .........................................................................................................35
12.1 Connection via USB port ........................................................................................................ 35
12.3 Connection via LAN port (Ethernet)....................................................................................... 37
13 Specifications and troubleshooting ....................................................................................39
13.1 Troubleshooting ...................................................................................................................... 39
13.2 The tool does not communicate via the USB port................................................................... 39
13.4 The tool does not communicate via the LAN port (Ethernet).................................................. 39
13.5 Messages................................................................................................................................. 39
13.6 Error codes ............................................................................................................................. 39
13.7 Technical data......................................................................................................................... 41

1 General information
Press-Right is a monitor and measuring device that is connected to a press and monitors the quality
of productive processes.
Being interfaced with a displacement transducer and a load cell, it continuously monitors its
positions and instantaneous force.
1.1 Introduction to the monitoring theory
During sample production, the data regarding cylinder position and the force exerted by it are
entered; the following graph may be created: position-force representing production.
If several runs are performed on similar pieces, their position-force curves will also be similar. On
the other hand, if one of the manufactured pieces is different from the sample, its curve will be
different from the sample. It is clear that monitoring the curve may affect the quality of
manufacturing.
This product must not be disposed of as an unsorted urban waste; secure proper
recycling.
1.2 Characteristics of the device
Press-Right manages and monitors the profile of the cylinder speed.
It works on a continuous tolerance range monitoring the whole position-force curve.
It monitors the peak position and the peak force values.
It stops the press once a position target or force target is reached.
It monitors the initial height measured upon contact with the piece.
It monitors critical points through position-force curve check points.
It manages up to four consecutive phases with independent parameters.
All parameters are saved in 200 independent and selectable jobs.
Advanced management of users by means of passwords and personal authorizations.
Press-Right may be connected to the computer and, by means of the WinScope software, it may
save curves, edit settings, run statistical analyses, print data.
Saving curves on the SD memory card.
It allows the connection of up to three enabling signals.
It allows the connection of up to three additional OK/NOK check signals.
Programmable periodic self-verification function.
Programmable periodic request for the replacement of worn-out tool.
Programmable periodic request for maintenance.
1.3 Device operating principle
The Press-Right PE is sold together with an electric press: it measures the position of the cylinder
instant by instant, and the force exerted by the cylinder by using a force transducer instant by
instant.
In order to increase the precision of its height, it may be associated with an external micrometric
probe.
The work phases (pressing) are performed as follows:
 Fast approach up to a END APPROACH POSITION at the APPROACH SPEED
 Pressing job at the WORK SPEED up to the FINAL POSITION or up to the STOP FORCE
 Stationing on the piece for a time set as WAITING BEFORE RETURN
 Return to the RETURN POSITION at the RETURN SPEED

 If necessary, it is possible to run the last stretch of the work range at low speed by setting the
PRE-STOP POSITION and the PRE-STOP SPEED.
1.3.1 Absolute and relative positions
The positions referred to the cylinder zero point are referred to as absolute positions. The positions
referred to the contact point on the manufactured piece are referred to as relative positions. Press-
Right may set both the absolute and the relative positions. In order to measure the contact point on
the manufactured piece, Press-Right use the force transducer: when the force measured exceeds the
START FORCE planned value, the relative zero point is set. This zero point is called conctact
position. The conctact position may be monitored by using two limits, a minimum and a maximum
value (Chapter 5.2).
 Cylinder zero point
 Retorn position (rest)
 Relative zero point (start position)
Figure 1
The precision of the conctact position measured with the load cell may not be increased. It depends
on the cylinder speed and, in particular, on the type of piece to be manufactured. During the shrink-
fitting operations, the two pieces show chamfered edges; as a result the conctact position varies also
based on the chamfer and the force used to position a piece into the other.
1.3.2 Position-force value monitor
Press-Right enjoys different functions. The curve monitoring is performed by a tolerance range
(chapter 6) and its limits (chapter 5.2). The limits are the following: minimum and maximum force,
minimum and maximum position; they can be set or excluded and they monitor the maximum value
obtained during the production. If the position reached does not exceed the minimum position
and/or exceeds the maximum position, the piece is rejected. At the same time, if the maximum force

reached does not exceed the minimum force and/or does exceed the maximum force, the piece is
rejected.
From a theoretical point of view there is an ideal curve that may be obtained by manufacturing
perfect pieces (in practice a sample curve may be obtained by carefully manufacturing selected
pieces). Any geometric tolerance or difference in materials result in a curve that is different from
the ideal curve. In practice, there is a tolerance range around the sample curve such that, if the curve
obtained from the current process does not stay inside such range, the piece is classified as scrap.
The piece is good only if the analysis of the minimum/maximum limits and the tolerance range have
a positive result. Press-Right also monitors the cylinder return at the end of the production process.
Such return may result from the exertion of a specific force (stop force) or at a specific position
(final position). It is possible to set both force and position stop values at the same time; in this case
the first value to be entered will govern the cylinder return. By changing the value of the
configuration, it is also possible to command the cylinder return when the curve is off the tolerance
range. It is always possible to have the unit return by pressing the key on the keypad
(stopping the operation).

2 Installation of Press-Right
For the installation of the device on the machine, please refer to the specific manual.

3 Getting started
This chapter provides information on how to set up basic operations and using the Press-Right
device.
To better describe the operations, run practical tests.
Figure 2
To turn the device on use the key on the rear side. When it is pressed, after a few seconds, the
display turns on and the graph appears:
Figure 3
3.1 The keyboard of Press-Right
If the key is pressed, at the bottom of the display, a box appears divided into four parts
showing the items of the main menu; above this box, the menu title is highlighted. To select an item
of the menu, touch it.
The key cancels the operations and takes you back to the upper menu.
The key is used to confirm the values entered from time to time.
The key allows to cancel typing errors. When a menu is displayed, pressure allows to go back
to the initial screen. If no menu is displayed, it allows to activate the cursor.

3.2 First approach
First of all, get acquainted with the press by performing a number of manual motions.
To do so, proceed as follows:
- press the
- press the TOOLS item
- press the MANUAL MOVING item
- press the ENABLE JOG item
By using the keys, the cylinder may be moved.
Note: manual movements are possible outside the nominal range of the cylinder or with a load
applied to it, only at the minimum speed.
The lot of all parameters applied to the production process are referred to as Job.
First of all, let's create a simple Job:
press the
press the JOBS MANAGEMENT item
press the CREATE A NEW JOB item.
Note: in the following pages, when, for example, the phrase "select the JOBS MANAGEMENT >
CREATE A NEW JOB command" is reported, it means that key must be pressed,
followed by the JOBS MANAGEMENT item and then press the CREATE A NEW JOB item.
Enter the name to identify the job (e.g., TEST 1) and press the key.
Note: it is possible to create a sequence of jobs to be performed as individual phases on the same
piece.
Once the job is created, enter the motion parameters: JOBS MANAGEMENT > EDIT JOB > EDIT
PHASE > PHASE PARAMETERS > MOTION SETTINGS .
Then, before moving to the automatic operation, enter the parameters in the motion profile:
FINAL POSITION
The position to be reached.
STOP FORCE
Force commanding the stop of cylinder before the final position.
END APPROACH POSITION
Position to be reached during the rapid approach to bring the piece closer. Such position must
be lower than the piece height at contact. If the force is measured during the approach stroke,
the system runs a collision alert.
RETURN POSITION
Return position at the end of the pressing cycle. The cylinder is not required to go back to the
zero cylinder position.
WAITING BEFORE RETURN
In some cases it may be useful to stop the cylinder at the press end position for some seconds.
WORK SPEED
Press stroke speed.
APPROACH SPEED
Stroke approach speed while bringing the piece closer.
RETURN SPEED
Return speed at the end of the production process at rest height.
PRE-STOP POSITION
Pre-stop stroke initial position.