NUOVA ELETTRONICA MCS User manual

DLAM01EN
Rev. 1.1 – Ed. 20/11/2012
MCS and DSP LASER AP
INSTRUCTION MANUAL
SAFETY DEVICE FOR PRESS BRAKES
WITH
VISIBLE LASER EMISSION
Revision 1.1 of 20.11.2012
NUOVA ELETTRONICA s.n.c. di Pasqui F. & C.
Via Parri ZI Moiano - 06062 Città Della Pieve - PG - ITALIA - UE
Tel. : [phone] Fax: [phone]
web: www.nuova-elettronica.com e-mail: [e-mail]

Status of manual
Manual code: DLAM01EN
Revision: 1.1
Issue: 20/11/2012
Chronology of document revisions
Date Revision Summary of changes
15/09/2012 1.0 Draft
20/11/2012 1.1 First issue
Copyright information
Possible information about copyright

DSP LASER AP with MCS
CONTENTS
1. Foreword.....................................................................................................................1
1.1. General information ......................................................................................................1
2. Symbols used in the manual......................................................................................2
3. Warranty......................................................................................................................3
4. Technical Service .......................................................................................................3
5. Safety precautions......................................................................................................4
5.1. Checks .........................................................................................................................4
5.2. Spare parts...................................................................................................................4
5.3. Decommissioning .........................................................................................................4
6. Legend.........................................................................................................................5
7. Planning safety measures..........................................................................................7
8. Overview......................................................................................................................8
8.1. System composition......................................................................................................8
8.1.1. MCS module.................................................................................................................8
8.1.2. DSP LASER AP..........................................................................................................13
8.2. Operating cycle of a press brake ................................................................................16
9. Signals and plate data..............................................................................................17
9.1. Leds and references: scheme and functions...............................................................17
9.1.1. MCS module...............................................................................................................17
9.1.2. DSP LASER AP..........................................................................................................24
9.2. Identification plates.....................................................................................................26
9.2.1. MCS module...............................................................................................................26
9.2.2. Receiver .....................................................................................................................26
9.2.3. Transmitter .................................................................................................................27
10. System Characteristics and Installation .................................................................28
10.1. Standard supply..........................................................................................................28
10.2. Transport and unpackaging ........................................................................................28
10.3. Mechanical installation................................................................................................28
10.3.1. MCS module...............................................................................................................28
10.3.1.1. Preparation...................................................................................................................................29
10.3.1.2. Installation....................................................................................................................................30
10.3.2. DSP LASER AP..........................................................................................................30
10.3.2.1. Preparation...................................................................................................................................30
10.3.2.2. Installation....................................................................................................................................33
10.4. Electric connection......................................................................................................34
10.4.1. List of signals managed by MCS.................................................................................34
10.4.2. MCS electric connection.............................................................................................40
10.4.2.1. Machine power supply connection...............................................................................................40
10.4.2.2. Foot Pedal Controls with “antipanic” and Emergency chain........................................................41
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DSP LASER AP with MCS
10.4.2.3. RH and LH side guards and other I/O..........................................................................................45
10.4.2.4. Emergency of auxiliary devices....................................................................................................47
10.4.2.5. Automatic tool clamping...............................................................................................................48
10.4.2.6. Connection to the Encoders monitoring Y1 and Y2.....................................................................49
10.4.2.7. Commmunications to/from CNC via I/O and serial port...............................................................50
10.4.2.8. Machine movement command (upstroke/downstroke/STOP) .....................................................52
10.4.2.9. Hemming......................................................................................................................................55
10.4.2.10. Rear guards..................................................................................................................................56
10.4.2.11. Robot function ..............................................................................................................................57
10.4.3. Electric connection of DSP LASER AP........................................................................58
10.4.4. Electric connection of other front protections...............................................................58
11. Commissioning .........................................................................................................59
11.1. Power supply and first functional verification ...............................................................59
11.2. List, description and programming of MCS parameters...............................................59
11.2.1. List of parameters and description...............................................................................60
11.3. System Test ................................................................................................................67
11.4. First installation of TX and RX.....................................................................................71
11.5. Verification of the stop distance...................................................................................75
11.6. Sheet Edge Acquisition ...............................................................................................75
11.7.Verification of Low Speed and High Speed..................................................................76
11.8. Speed change point and Automuting...........................................................................76
11.9. Blanking Modality of DSP LASER AP..........................................................................80
11.10. Operation in Robot mode.............................................................................................86
12. Residual risks............................................................................................................87
12.1.Risks typical of the laser source ..................................................................................87
12.2. Blanking ......................................................................................................................87
12.3. Risks deriving from dangers of mechanical type..........................................................88
12.3.1. Manual support of the sheet........................................................................................88
12.3.2. Installation and uninstallation of tools ..........................................................................89
12.3.3. Work organization .......................................................................................................89
13. Use .............................................................................................................................90
13.1. Light Indicators............................................................................................................90
13.2. PCV setting .................................................................................................................90
13.3. Verification of stop distance.........................................................................................90
13.4. Sheet Edge Acquisition ...............................................................................................91
13.5. Adjustment after the tool change.................................................................................91
14. Maintenance...............................................................................................................95
14.1. Alarms/errors and possible solution of the problems....................................................95
15. Removal and reinstallation after the repair .............................................................99
16. Technical characteristics........................................................................................100
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DSP LASER AP with MCS
1. Foreword
Purpose of this manual is to inform both the technical personnel responsible of the
installation, manufacturer or overhauling the press brakes (from now on indicated with
“manufacturer” for ease of writing) and the user of the machine where the device will be
installed about the operations of assembly, installation, use and maintenance of the
equipment. The information relevant to the use of the machine have to be integrated with
the information present in this document. The instructions are addressed to the
manufacturer’s personnel, in charge of integrating the equipment on the press, and to the
personnel of the press brake user, devoted to the normal working activities once the
equipment has been installed (use, setup, maintenance, ecc.). The installation of this device
requires a minimum of technical know-how and the use foresees the respect of the current
laws in force relevant to the safety in the work environment and to the accident prevention.
The manual must be kept with care, both by the machine manufacturer and by the user, in
such a place to be immediately available every time it is necessary.
Contact Nuova Elettronica for explanations and to require possible additional copies or
updates of the manual itself.
Nuova Elettronica reserves the discretion to change the production and the manual without
the obligation to update the previous production and manuals.
1.1. General information
This manual has been written by the equipment manufacturer and constitutes integral part
of the equipment itself.
It defines the purpose which the equipment has been created for and contains all the
information necessary to ensure a correct and safe use.
Nuova Elettronica, in pursuing a policy of continue development and update of the product
together with the evolution of the state-of-art of the laser safety devices for press brakes,
can carry out changes without any notice.
Nuova Elettronica declines any responsibility for changes made by the user to the device.
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DSP LASER AP with MCS
2. Symbols used in the manual
The important information has been highlighted and accompanied by the word:
Warning:
Lack of reading this information can cause serious dangers for the
operator
Residual risk:
The information signals a risk which had been impossible to eliminate
Caution:
Indica
tes a situation of possible danger which, if not avoided, can cause
minor damages
Information:
Additional information not relevant to safety
Technical information of major importance is highlighted with bold font.
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DSP LASER AP with MCS
3. Warranty
The manufacturer ensures his own products for a period of 12 months from the sale date.
The warranty covers the parts of the device, if it is demonstrated that they are faulty in
materials or assembly, respecting the following conditions:
1) With warranty we mean the replacement of all those parts which have been found
faulty for manufacturing in conditions of normal use.
Warranty is not valid if not accompanied by the copy of the invoice attesting the
purchase.
Moreover, the warranty is not valid in the following cases:
a) any kind of tampering of the device;
b) use of the device in modes not in compliance with the warnings reported in this
manual;
c) damages caused by the not suitability of the environment where the device
works and phenomena not depending on the normal operation (e.g.: wrong
voltage or frequency values of the mains);
d) repair interventions carried out by persons or Technical Service Centres not
authorized by Manufacturer.
2) The costs and the risks of the transport, of the packaging and of the possible labor
necessary for this purpose are at Purchaser’s charge.
3) The replacement of the device, as even the extension of the warranty after the
intervention for fault, is excluded.
4) No refund is foreseen for the possible inactivity period of the device during the period
necessary for the repair.
4. Technical Service
Technical and Repair Service, as the replies to the request of specific information or
explanations, are provided directly by the equipment manufacturer:
NUOVA ELETTRONICA s.n.c. of Pasqui F. & C.
Via Parri ZI Moiano - 06062 Città Della Pieve - PG - ITALIA - UE
Tel. : [phone] Fax: [phone]
web: www.nuova-elettronica.com
e-mail: [e-mail]
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DSP LASER AP with MCS
5. Safety precautions
5.1. Checks
•Check the operating voltage of the device before use.
The operating voltage (24Vcc ± 10%) is indicated on the plate located on MCS module.
The device is not disconnected from mains until MCS module is physically connected to
the electric panel, even if the device seems “off”.
•Stop immediately using the device in case of penetration of liquids or objects
inside the device itself.
Disconnect the device and take care that qualified personnel checks it.
To disconnect the device, refer to the procedure described in the chapter relevant to the
device removal.
5.2. Spare parts
Spare parts can be supplied only by Nuova Elettronica.
5.3. Decommissioning
If You decide to stop using DSP LASER AP and MCS device because obsolete or
irremediable faulty, decommission it making the device itself not operating and deprived of
risks. Seal the device within a robust package and dismantle it acting in compliance with the
current laws in force, contacting the local bodies charged for these operations.
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DSP LASER AP with MCS
6. Legend
TERM MEANING
HIGH SPEED
Speed of the mobile part of the machine when closing or approaching the
sheet
ANTIPANIC
Alarm generated by the pressure of the third position of the downstroke
pedal
BEND AXIS
Axis of the section perpendicular to the punch length
AUTOMUTING
Automatic inhibition of a detection area
LOW SPEED
Speed of the mobile part of the machine, when closing or approaching the
sheet, equal to or lower than 10 mm/s
BLANKING
Function inhibiting part of the detection area
DETECTION
CAPACITY
Minimum size of the test piece capable to be detected
COLLIMATION
Procedure allowing the alignment of the laser beam generated by TX to
the RX receiving area
SAFETY DISTANCE
Distance between the punch tip and the lower edge of the detection area,
equal to the sum of the maximum stop distance and 5 mm
DSP LASER AP
Name of the device charged to monitor the front part of the press
ESPE
Electro-Sensitive Protective Equipment
INHIBITION
Automatic and temporary interruption of the safety functions executed by
the safety parts of the control system
BENDING LINE
Line defined by the pungh tip along all the press
MCS
Name of the module for the monitoring and control of the functions to use
in safety state of the press brake
MONITORING
Safety function ensuring the intervention of a safety measure if the
capability of a component or an element in executing its function is
reduced
MUTING
Temporary inhibition of the device charged to safety monitoring
OSSD
Output Signal Switching Devices
MUTE POINT
Mute Point: point of the closing stroke where the speed changes from fast
approaching speed (Fast Speed)
to safety or work speed, lower than or
equal to 10 mm/sec (Low Speed)
PROGRAMMING
PARAMETERS
MCS parameters which can be changed, through proper procedure, to
configure functions and outputs of MCS
BENDING LAYER
Sliding layer of the bend line during the punch movement
PMI
Bottom Dead Center: lowest point of the moveable table stroke, generally
set by the numeric control to achieve the wished bend
PMS
Top Dead Center: highest point of the moveable table stroke, generally
set by the numeric control to achieve the wished bend
MPMS
Maximum Top Dead Center: highest point of the stroke, achievable by the
moveable table
REDUNDANCY
Use of more than one device or system or parts of them with the aim of
ensuring that, in case of fault of a single component during its function,
another compont is capable to execute that function
RX
Name of the receiver, part of DSP LASER AP, which includes the
sensitive function and the leds
STOP DISTANCE
Distance covered by the moveable table after the interception of the
detection area of DSP LASER AP
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DSP LASER AP with MCS
STATE OFF
State where the output circuit is open and interrupts the flow of current or
is at potential 0V, if we deal with solid state outputs
STATE ON
State where the output circuit is closed and allows the flow of current or is
at potential 24V, if we deal with solid state outputs
FEEDBACK TIME
Maximum time between the moment when the test piece is introduced
inside the detection area of DSP LASER AP device and the moment when
MCS outputs switch to OFF state
TX
Name of the transmitter part of DSP LASER AP. It generates and emits
the laser beam and the system synchronism
RECEIVING AREA
Area within which the beam emitted by the transmitter is detected by the
receiver
DETECTION AREA
Area within which the specified test is detected
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DSP LASER AP with MCS
7. Planning safety measures
The whole system has been developed and designed to achieve the necessary level SIL3
or PL=e, respecting the indications of the standards:
CEI EN 62061 : 2005 and EN ISO 13849-1 : 2008
DSP LASER AP device has been, moreover, designed respecting even the indications
specified by the standards CEI EN 61496-1:2005 and CEI CLC/TS 61496-2:2007. It can be
classified as ESPE of type 4
MCS device has been, moreover, designed respecting even the indications specified by the
standard EN 12622:2009
The laser contained in DSP LASER is classified as CLASS 1M, according to standard CEI
EN 60825-1:2009.
DSP LASER AP device, if properly installed and used as described in this Manual, is in
compliance with the provisions of:
•Machinery Directive 2006/42/CE and relevant reference laws and specifications:
oCEI EN 61496-1:2005 and CEI CLC/TS 61496-2:2007
oEN ISO 12100 : 2010
EN 12622:2009, CEI EN 60204-1:2006, CEI EN 60825-1:2009
•Low Voltage Directive 2006/95/CE and relevant reference laws
oCEI EN 61496-1:2005
oCEI EN 60204-1:2006
•Electromagnetic Compatibility Directive 2004/108/CE and relevant reference laws
oCEI EN 61496-1:2005
oCEI EN 61000-6-3 : 2007 and CEI EN 61000-6-2 : 2006
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DSP LASER AP with MCS
8. Overview
8.1. System composition
8.1.1. MCS module
MCS is an electronic module whose logic has been planned to monitor and operate the
systems and the components, present on a press brake, which ensure a safe use of the
press itself according to what foreseen by standard EN12622.
The concepts used for its design and manufacturing allows achieving, for some safety
functions, the category 4, PL=e according to standard EN ISO 13849-1 and SILCL3
according to standard EN 62061, the highest possible as regards the realization of
equipment preposed to the costruction of safe machines. The structure is characterized by
two processors and, then, two channels, usually named “Channel A” and “Channel B”.
The system nature and its partial capability to be programmed allow the adaptation and the
use of the press brake in different planning methods.
Types of front protections controlled by MCS
As you can see in Figure 1, MCS controls the photoelectric device DSP LASER AP as main
component for the protection against the access to the front part of the bending machine.
This generates a protection photoelectric area with advanced characteristics, allowing the
achievement of high machine performances, ensuring however a very high protection
degree for the operator.
MCS can manage even the protection photoelectric area generated by DSP LASER or by a
generic protection barrier. In this case, refer to the manual of the device you wish to use.
Information:
The standard version of MCS software is the PS version suitable to the
use of DSP LASER AP. If you use MCS with a device different from DSP
LASER AP, make sure to have purchased the version
with the special
PG software version installed.
Figure 1
DSP LASER AP
DSP LASER
PHOTOELECTRIC BARRIER
M
C
S
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DSP LASER AP with MCS
Section for the monitoring of speed/position/direction
Figure 2
Figure 2 shows a scheme of the section which allows connecting in parallel to channels A
and B of the two, usually linear, encoders present on the synchronized press. They
measure the stroke of the hydraulic jacks responsible of the movement and the operation of
the moveable table. With this system, the machine speed is measured and controlled. Other
controls and automatisms are moreover implemented, necessary to the management of the
safety and of the operativity of the bending machine, as the monitoring of the direction of
the moveable part movement and its position with respect to the fixed part.
If the machine is not provided with encoders for the adjustment of the position of the jacks,
proper encoders can be installed in order to carry out the measures and the monitoring
mentioned above.
M
C
S
C
N
C
E
N
C
O
D
E
R
Y
1
E
N
C
O
D
E
R
Y
2
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DSP LASER AP with MCS
Components and systems managed by MCS
MCS module monitors and manages even other machine systems and components, some
of them with safety functions and others complementary to these or, generally, as
completion of the press brake operation and not devoted to safety functions.
Figure 3
Figure 3 represents the components which can be connected to MCS inputs to be
controlled and monitored.
MAIN FOOT PEDAL
CONTROL
SECOND FOOT PEDAL
CONTROL
EMERGENCY
CHAIN
RIGHT SIDE
GUARD
LEFT SIDE
GUARD
REAR
GUARD
M
C
S
SELECTOR 1 or 2
FOOT PEDAL CONTROLS
TOLL AUTOMATIC
CLAMPING
CUTTING SYSTEM
for ROBOT
DSP LASER AP
OPERATING MODES
HEMMING OPENING
CONTROL
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DSP LASER AP with MCS
Safety outputs and monitor inputs
Figure 4 represents the MCS safety outputs which are realized at solid state, have high
current in output and are synchronized with the MCS inputs available for the possible
monitors of the devices they control.
The already set MCS functional states can be assigned to these outputs. This easy, but
effective, assignment function allows controlling different configurations of the actuators
preposed to the machine closing.
Information:
Usually we refer to hydraulic component
s because the great part of the
bending machines use them, but the safety outputs can control any type
of actuator, as the command is electric.
Figure 4
Interface MCS – CNC / PRESS BRAKE
Figure 5
SOLENOID VALVE 2
SOLENOID VALVE 4
SOLENOID VALVE 5
SOLENOID VALVE 6
SOLENOID VALVE 7
M
C
S
SOLENOID VALVE 3
SOLENOID VALVE 8
SOLENOID VALVE 1
M
C
S
CNC
PRESS BRAKE
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DSP LASER AP with MCS
For the operation, it is necessary that MCS transmits and receives some simple ON/OFF
information to/from CNC and to/from the press brake (Figure 5).
For this purpose, some digital I/O are available, not regarding the safety, whose state will be
then ON /OFF. It is even possible, but not necessary, that some of these data are
transmitted via serial port RS232.
Interface MCS - Operator
MCS manages a great number of signals and executes different machine functions. Then,
an interface is necessary with the personnel devoted to its installation during the
construction of the machine and with the personnel which then will use it.
The module has two types of interface towards the external world (Figure 6). The first
interface is realized with:
•LEDs showing the I/O states.
•Alpha-numeric display showing messages and data regarding the operation of the
system and of the machine.
•Keys for the selection of the operation options.
Figure 6
The second interface is realized by the CNC display. The data and the messages to display
are processed by CNC depending on the signals coming from MCS through the serial port.
DISPLAY
RS
232
M
C
S
KEYS
LED
CNC
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DSP LASER AP with MCS
8.1.2. DSP LASER AP
The safety device DSP LASER AP is a visible laser emission barrier which, realized and
placed as described in Standard EN12622, protects the operator of the press brake against
the danger to be squashed between the upper tool and the lower tool during the closing of
the press in high speed. The device is constituted by a transmitter TX, which generates the
laser emission, and by a receiver RX, which receives it and transmits the processing of the
received signals to MCS module.
Main task of DSP LASER AP is detecting, within the limits defined by its detection
capability, the intrusion of any opaque physical element into the “detection area”.
Figure 7 represents the position of DSP LASER AP on the machine and the section of the
detection area with the sensors present in the receiver lighted by the laser beam.
Figure 7
Not during all the phases of the machine cycle or in the different operating modalities, all the
receivers are necessarily enabled to detect an object entering the detection area. To be
detected, the object has to interrupt the laser beams hitting at least, one of the enabled
sensors. Detecting the object causes the intervention of the device, which must stop the
movement of the machine or activate an action foreseen by the operating cycle, as the
inhibition of a set of sensors in case of blanking. Figure 8 represents the section of the
protection area and its logic of positioning with respect to the upper tool.
The horizontal protection layer is located from the tip of the tool at a safety distance equal to
the maximum stop distance allowed for the safe use of the press brake with the DSP
LASER AP device + 5mm. The maximum allowed values are, as described later, three:
14mm, 18mm and 24mm.
The safety area preempts the movement of the upper tool for such a distance which allows
stopping the tool without this can squash any opaque object possibly between itself and the
lower tool.
The object possibly under the protection area, once penetrated it, should generate the
command to stop the machine, which will stop within a distance called “machine stop
distance”.
As the stop command has been generated at a distance equal to “maximum allowed stop
distance”+ 5mm, the tool has ended its movement at a distance = maximum allowed SA –
machine SA + 5mm, clearly without even brushing on the object.
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DSP LASER AP with MCS
Figure 8
As regards the Blanking function used for bending boxes, the detection area is subdivided
in 3 different areas: a front area (towards the operator), a central area (under the tip of the
upper tool and sligthly shifted towards the rear part of the press) and a rear area (towards
the rear part of the press brake).
Area
Task
Front
Protects the operator’s fingers too close to the working area. Moreover, it
protects against the risk of squashing between the die edge and the tip of the
upper tool.
This area can be inhibited for special machining.
Central
Protects the operator against the squashing between the tip of the upper tool
and the sheet/die.
Rear
Avoid the squashing between the tip of the upper tool and the rear
backgauges.
This area can be inhibited for special machining or if
the rear
backgauges are intercepted.
As regards the Automuting function, the detection areas are 3: Area A, Area B and Area C.
Area
Task
Area A
Area A is composed by the 3 lowest sensors: one front sensor, one central
sensor and one rear sensor. The set of sensors of the Area A
is that
intercepting first an obstacle during the downstroke.
The detection of the sheet
thickness is executed by the central sensor of the Area A.
Note. If the machine Stop Distance, measured by MCS dur
ing the test, is less
than 6mm, the Area A is automatically disabled by DSP LASER AP dur
ing the
normal operation.
It remains, however, active during the verification of the Stop
Distance and the Sheet Edge Acquisition.
Area B
Area B is composed by the 3 sensors located above the Area A: one front
sensor, one central sensor and one rear sensor.
Area C
Area C is composed by the 3 sensors located above the Area B: one front
sensor, one central sensor and one rear sensor.
This set of sensors is the
closest to the tool tip.
14 DLAM01EN