Kaltenbach KPS Series User manual

MANUAL
KPS 515
Serial No. 2008.01.14564

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0General Safety Instructions ........................................................... 7
0.1 Remaining dangers ............................................................................ 9
0.2 Safety regulations ............................................................................ 10
1Machine Information ................................................................. 12
1.1 Preface and working possibilities ....................................................... 12
1.2 Features & technical specifications ..................................................... 13
1.2.1 Vertical punch unit ........................................................................... 13
1.2.2 Features KPS501 ............................................................................. 14
1.2.3 Features KPS503 ............................................................................. 15
1.2.4 Features KPS 506 ............................................................................ 16
1.2.5 Features KPS 515 ............................................................................ 17
1.2.6 Flat shear unit.................................................................................. 18
1.2.7 Horizontal Punch Unit....................................................................... 19
1.2.8 Angle shear (DC Type 160*160*15)................................................ 20
1.2.9 Angle shear (SC Type 200*200*20) ................................................. 21
1.2.10 Angle shear (SC Type 200*200*25) ................................................. 21
1.2.11 Material pusher M100P.................................................................... 22
1.2.12 Transport T10.................................................................................. 23
1.2.13 Cross transport ................................................................................ 24
1.2.14 Product output table ......................................................................... 26
1.2.15 Product push-off device ..................................................................... 26
1.2.16 Marking unit ................................................................................... 27
1.2.17 General.......................................................................................... 28
1.3 Machine Layout ............................................................................... 29
1.4 Safety provisions.............................................................................. 30
2Setup Environment..................................................................... 31
2.1 Machine Layout and main dimensions ................................................ 31
2.1.1 Main Dimensions ............................................................................. 32
2.2 Fundament...................................................................................... 33
2.3 Enviroments..................................................................................... 34
2.4 Installation safetys ............................................................................ 35
3Installation ............................................................................... 36
3.1 Package and Stocking ...................................................................... 36
3.2 Transport ........................................................................................ 37
3.2.1 Lifting instructions............................................................................. 37
3.3 Preparation for setup ........................................................................ 38
3.3.1 Preperations.................................................................................... 38
3.4 Setup ............................................................................................. 39

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3.4.1 Setup the safety fences and safety light guards .................................... 39
3.4.2 Anchoring and levelling.................................................................... 40
3.4.3 Electrical connections ....................................................................... 41
3.4.4 Pneumatic connections...................................................................... 42
3.5 Initial Commissioning ....................................................................... 43
3.6 Safety............................................................................................. 44
4Operation................................................................................ 45
4.1 Switching on the machine ................................................................. 45
4.2 Switching Off The Machine ............................................................... 45
4.3 Lock out procedure........................................................................... 46
4.4 Stop procedure................................................................................ 47
4.5 Operation controls ........................................................................... 48
4.5.1 Operation controls Functions ............................................................. 48
4.5.2 Touchscreen Button Functions............................................................. 49
4.6 Fitting Tools and equipment............................................................... 53
4.6.1 Fixing Punch Tools ........................................................................... 53
4.6.2 Removing Punch Tools ...................................................................... 53
4.6.3 Fixing the knife in the shear unit......................................................... 53
4.6.4 Removing the knife of the shear unit ................................................... 53
4.6.5 Tensiontorque knife bolts................................................................... 54
4.6.6 Drill changing.................................................................................. 55
4.6.7 Fitting the Toolholder magazine ......................................................... 56
4.7 Adjustment...................................................................................... 57
4.7.1 Feed and drill speed ........................................................................ 57
4.8 Pusher mounting adapter .................................................................. 59
4.9 Start Operation............................................................................... 60
4.9.1 Initializing sequence......................................................................... 60
4.10 Software description......................................................................... 61
4.10.1 Introduction..................................................................................... 61
4.10.2 System requirements......................................................................... 62
4.10.3 Installing the software....................................................................... 63
4.10.4 Order manager ............................................................................... 65
4.10.5 Pattern manager .............................................................................. 72
4.10.6 Nesting manager............................................................................. 73
4.10.7 Optimize manager........................................................................... 75
4.10.8 Output manager .............................................................................. 80
4.10.9 Profile library .................................................................................. 83
4.10.10 Adding new profiles and changing data ............................................. 84
4.10.11 Tool manager.................................................................................. 85
4.10.12 Operator menu................................................................................ 87
4.10.13 Extern file import.............................................................................. 92

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5Maintenance ............................................................................ 93
5.1 Maintenance ................................................................................... 93
5.1.1 Tool lubrication system...................................................................... 94
5.1.2 Lubrication ...................................................................................... 95
5.1.3 Lubrication points............................................................................. 96
5.1.4 Hydraulic system............................................................................ 107
5.1.5 Lubrication table ............................................................................ 107
6Technical Documentation.......................................................... 108
6.1 General Instructions........................................................................ 108
6.2 Tools ............................................................................................ 109
6.2.1 Punch and Dies General Information................................................. 109
6.2.2 Punch-Die Clearance ...................................................................... 111
6.2.3 Correct tool order KPS503.............................................................. 112
6.2.4 Minimum punch position KPS 501 (Peddinghaus type)........................ 113
6.2.5 Minimum punch position KPS 503 (Peddinghaus type)........................ 113
6.2.6 Minimum punch position KPS 506 (Peddinghaus type)........................ 113
6.2.7 Minimum puns position KPS 515 (Peddinghaus type).......................... 113
6.2.8 Flat Shear Unit............................................................................... 114
6.2.9 Angle Shear Unit ........................................................................... 116
6.2.10 Grinding requirements knives .......................................................... 117
6.2.11 Knife Block Guiding System............................................................. 119
6.2.12 Drills General Information ............................................................... 120
6.2.13 Drill Types and qualities.................................................................. 120
6.2.14 Recommended drill Suppliers........................................................... 121
6.2.15 Grinding the drills .......................................................................... 122
6.2.16 Grinding instructions ...................................................................... 122
6.2.17 Drill Cooling.................................................................................. 124
6.2.18 Solving drill problems..................................................................... 125
6.3 Spare Parts ................................................................................... 126
6.3.1 Spare parts punch KPS503 ............................................................. 126
6.3.2 Spare parts punch KPS506 ............................................................. 127
6.3.3 Spare parts punch KPS515 ............................................................. 128
6.3.4 Flat shear knives ............................................................................ 129
6.3.5 Spare parts angle knives................................................................. 130
6.3.6 Spare parts ball bearing spindle ...................................................... 131
6.3.7 Spare parts drill unit....................................................................... 132
6.3.8 Spare parts Tool Changer ............................................................... 133
6.3.9 Suggested Spare part kit................................................................. 134
6.4 Pneumatic drawings ....................................................................... 135
6.5 Hydraulic drawings........................................................................ 136
6.6 Electric drawings ........................................................................... 137

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7Appendix .............................................................................. 138

KPS SERIES General Safety Instructions
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0General Safety Instructions
The punching-shearing machine is built according to the current safety regulations.
The necessary provisions are made for a safe way of working for the operator.
In spite of all taken precautions, dangers may occur however while working with the
machine.
A total safety does not exist !
Therefore it is requested that, while working with or at the machine, the necessary
attention should be taken in consideration.
-
WARNING
Read and understand manual before set up, operate or
servicing this machine.
Failure to follow instructions could result in personal injury or
damage to equipment.

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The following conventions are used to indicate and classify precautions in this manual.
Always follow the information provide with them. Failure to follow precautions could
result in personal injury or damage to equipment.
The conventions meets the ANSI Z535.5-1997 Designs and Definitions:
SIGN DESCRIPTION
indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal
word is to be limited to the most extreme situations.
indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
indicates a potentially hazardous situation which, if not
avoided, may result in minor or major injury."
signs used to indicate a statement of company policy
directly or indirectly related to the safety of personnel or
protection of property. This signal word shall not be
associated directly with a hazard or hazardous situation
and shall not be used in place of DANGER, WARNING or
CAUTION.
signs used to indicate general instructions relative to safe
work
The signs DANGER, WARNING and CAUTION are preceed by the
logo
DANGE
R
W
ARNING
CAUTION
NOTIC
E
SAFETY FIRST

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0.1 Remaining dangers
When persons are in danger zones when the machine is switched on (what is not
allowed), the following dangers can arise:
•Moving parts of the machine can inflict grievous bodily harm.
•Moving parts of the machine and tools can grab in clothes by which these
persons can be seriously injured.
•The carriage can inflict grievous bodily harm by moving.
•The products, waste or trim pieces can inflict grievous bodily harm to persons
which are in danger areas like on or in the input and output conveyors or at
the ends of the machine.

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0.2 Safety regulations
In order to minimize the chance on possible remaining dangers the following
instructions have to be followed:
•The machine may only be operated by fully instructed staff.
•The machine may only be operated by staff who has read and understood the
manual.
•The competence to operate the machine has to be put down in writing and
followed.
•The machine may only be operated by staff which are commissioned by there
authority.
•Outsiders are not allowed to operate the machine without commission and
instruction.
•It is not allowed to make alterations or to carry out repairs to the machine
without the written permission of KALTENBACH in advance.
•Irregularities of the machine during operation have to be reported immediately
to the supplier.
•The operator has to take the responsibility that there are no persons in the
reach of the moving parts of the machine when the machine is turned on.
•It is not allowed to reach, to sit, or to enter in the reach of the moving parts of
the machine.
•Maintenance or repair activities are only allowed when the machine is
switched off according the LOCKOUT procedure, so that thoughtless switch on
is not possible.
•Check or adjust activities are only allowed when the machine is switched off
(emergency stop activated).
•Be sure that the machine is without pressure while disconnecting the pneumatic
or hydraulic pipes.
•Electrical activities must only be done by certified electricians!

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•The use of the machine without the safety provisions or without taking in
consideration the safety regulations is not allowed.
•It is not allowed to enter inside the safety protection while the machine is
turned on.
•The machine may only be used for the purposes and materials for which it has
been designed.
•It is important to check the function of the operation mechanism and safety
provisions regularly (1.4). Replace damaged parts immediately.
•Use the personal protective means, safety shoes, Eye protection, ear
protection.
•In connection with the possibility to hurt hands to sharp sides of the material or
burn by heated chips it is required to ware gloves.

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1Machine Information
1.1 Preface and working possibilities
The KPS machine is designed for the special market requirements of steel fabricators
and steel service centres and is appropriate for punching, shearing, drilling and centre
marking of structural steel like, angle steel, U-profiles and flat-bar steel
For the possibilities in other working areas you can contact the sales department of
KALTENBACH.

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1.2 Features & technical specifications
1.2.1 Vertical punch unit
Features general
•The sideward positioning of the punch unit running on linear bearings by
means of ball screw spindle with servo motor.
•To prevent undesired process blockings the machine is standard equipped with
a automatic material lifter, which pulls the material out of the carriage at
burring.
•Program controlled pop-marking function via automatic punch force reduction.
•Automatic horizontal and vertical material clamping device within the
automatic cycle. Hardened clamping rollers running on linear bearings.
•Initial bar length control at the front edge of the bar via light scanner,
integrated in the infeed roller conveyor.
•Automatic program controlled tool lubrication system via spray oil mist system.

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1.2.2 Features KPS501
•Massive steel C-frame construction, designed to carry one vertical punch unit
with totally 1 tool.
•Hydraulic down holding device, arranged on the in- and outfeed side of the
material.
•Standard tool set of 3 Peddinghaus punch / dies for 16, 18 and 20 mm for a
plate thickness of 12 mm.
Specifications
Working range min Flat mm ......................... 50 x 5
max Flat mm ..................... 500 x 25
min Angle Steel mm ..................50 x 50 x 5
max Angle Steel mm ............160 x 160 x 15
min U-profiles mm ...............65 x 42 x 5.5
max U-profiles mm ............320 x 100 x 14
Automatic tool change Tool carriage piece...............................1
Punch diameter min. - max mm .......................... 5 - 40
Punch force kN ............................1250
Drive performance Positioning drive punch unit kW ..............................2.2

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1.2.3 Features KPS503
•Massive steel C-frame construction, designed to carry one vertical punch unit
with totally 3 tools.
•The punch tools are set up in line and can, due to the heavy punch guiding
construction with each of the three tools, the maximum punch power be
utilized.
•Hydraulic down holding device, arranged on the in- and outfeed side of the
material.
•Standard tool set of 3 Peddinghaus punch / dies for 16, 18 and 20 mm for a
plate thickness of 12 mm.
Specifications
Working range min Flat mm ......................... 50 x 5
max Flat mm ..................... 500 x 25
min Angle Steel mm ..................50 x 50 x 5
max Angle Steel mm ............160 x 160 x 15
min U-profiles mm ...............65 x 42 x 5.5
max U-profiles mm ............320 x 100 x 14
Automatic tool change Tool carriage piece...............................3
Punch diameter min. - max mm .......................... 5 - 40
Punch force kN ............................1250
Punch force distribution %.................. 70 - 100 - 70
Drive performance Positioning drive punch unit kW ..............................2.2

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1.2.4 Features KPS 506
•Massive steel C-frame construction, designed to carry one vertical punch unit
with totally 6 tools.
•The twisting of the 6-station tool changer and the die carousel via servomotor
and rotary encoder.
•The punch revolver and the die carousel are aligned with each other
mechanically. Both devices are additionally locked at every position to prevent
them from turning.
•Hydraulic double down holding device arranged on the in- and outfeed side to
fix the material on the die carousel.
•Standard tool set of punch / dies for 16, 18, 20, 22, 26 and 32 mm for a
plate thickness of 12 mm.
Specifications
Working range min Flat mm ......................... 50 x 5
max Flat mm ..................... 500 x 25
min Angle Steel mm ..................50 x 50 x 5
max Angle Steel mm ............160 x 160 x 15
min U-profiles mm ...............65 x 42 x 5.5
max U-profiles mm ............320 x 100 x 14
Automatic tool change Tool carriage piece...............................6
Punch diameter min. - max mm .......................... 5 - 70
Punch force kN ..............................900
Drive performance
Positioning drive punch unit kW ..............................2.2
Positioning drive rotary automatic tool changer
and matrix plate kW ..............................2.2

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1.2.5 Features KPS 515
•Massive steel Portal-frame, with totally 15 punch- and 24 die tools.
•The punch- and die tools are set up independent on a under- and upper
carousel. Servo motor and a mechanical blocking system bring and hold the
carousel on the exact and guaranteed position.
•Hydraulic down holding and material correction device (4 t), arranged on the
in- and outfeed side of the material.
•Standard tool set of 3 Peddinghaus punch / dies for 16, 18 and 20 mm for a
plate thickness of 12 mm.
Specifications
Working range min Flat ................................... mm 50 x 5
max Flat ................................... mm 500 x 25
min Angle Steel ........................ mm 50 x 50 x 5
max Angle Steel ........................ mm 160 x 160 x 15
min U-profiles ........................... mm 65 x 42 x 5.5
max U-profiles ........................... mm 320 x 100 x 14
Automatic tool change Tool carriage .................. piece 15
tool die carousel .......................... piece 24
Punch diameter min. - max........................................mm 5 - 40
Punch force .........................................kN 1250
positioning drive punch- and die carousel ......................... kW 2 x 2.2
Drive performance Positioning drive punch unit ................kW 2.2

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1.2.6 Flat shear unit
Features
•Massive steel portal frame construction
•The sideward positioning of the complete shear unit running on linear bearings
by means of ball screw spindle with servo motor. To uniformly take up the
shear forces the flat shear unit always positions centric to the material width.
•The blades are, before grinding, multiple turnable.
•In the shear unit integrated hydraulic down holder to clamp the workpiece.
•Extreme short rest piece length: 2 x the material thickness to be processed
(min. 20 mm).
•A process without remnant is also possible by optimizing the bar configuration
(no remnant cut).
Specifications
Working range min ......................................mm 50 x 5
max ......................................mm 500 x 25
Shear force ......................................................... kN 2200
Drive performance .........................................................kW 2.2
Blade inclination 2 positions degrees 1,25/ 2,5
NC controlled flat shear indexing:
Swivelling range ................................degrees ±60
Drive performance ......................................kW 2.2
Working range 90° ......................................mm 500 x 25
±60° ......................................mm 400 x 25
±45° ......................................mm 350 x 25
±30° ......................................mm 245 x 25

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1.2.7 Horizontal Punch Unit
Features
•For angle steel profiles.
•The rigid construction is designed to carry two punch tools.
•The punch unit is located between the vertical punch unit and the flat shear
unit.
•Height positioning via ball screw spindle with servo-motor.
•Floating mounted punch carriage running on linear bearings.
•Punch wastes are being conveyed into a container via a stripping device and
an ejection channel.
•Automatic program controlled tool lubrication via spray oil mist system.
Specifications
Working range min Angle steel ..................... mm 50x50x5
max Angle steel...................... mm 160x160x15
min U-steel ............................ mm 65x42x5,5
max U-steel ............................ mm 320x100x14
Punch diameter min - max ..................................... mm 5 - 26
Punch force kN 2x550
Punch force in combination with angle steel shear unit,
200*200*25 single cut kN 2x750

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1.2.8 Angle shear (DC Type 160*160*15)
Feautures
•With the two-edges cutting method the material is being supported on two
sides of the cutting line.
This cutting action requires less force and prevents deforming of the material.
•Multiple utilization of the tool by simply turning the lower blade.
•Shortest product: 2 x the material thickness to be processed (min. 20 mm).
•Rest piece: not smaller than the flange width.
•A process without remnant is also possible by optimising the bar configuration
(no remnant cut).
•A blade for angle steel for 50x50x5 to 160x160x15 mm is included in the
standard scope of supply.
•Automatic program controlled tool lubrication via spray oil mist system.
Specifications
Working range min Angle steel ..................... mm 50x50x5
max Angle steel...................... mm 160x160x15
Shear force ..................................... kN 750
Drive performance positioning drive shear unit ................. kW 2.2