Más contenido relacionado La actualidad más candente (20) Similar a Tonnage Monitors-101 - A Basic Guide for Stamping Press Load Monitoring (20) Tonnage Monitors-101 - A Basic Guide for Stamping Press Load Monitoring1. © 2018 - Wintriss Controls Group - All rights reserved
Tonnage Monitors 101
Jim Finnerty
Product Manager – Wintriss Controls
2. Tonnage Monitoring
What is it?
A system that monitors the force being
exerted by a press during the working
portion of the cycle
Compares the actual working force to
preset limits, and stops the machine when
the limits are exceeded
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3. Tonnage Monitoring
How do Tonnage Monitors work?
Sensors called strain links are mounted on the frame of
the press in known locations where strain is proportional
to load
The strain links measure the deflection of the press frame
under load
A calibrated controller converts the strain link signal to a
tonnage value
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4. Deflection
When the press is under load, the frame deforms
It will either stretch or compress depending on the shape
of the frame and the location on it
The columns of straight side presses get longer under
load
The inside front portion of a gap frame press stretches
under load
The back of a gap frame press compresses under load
Deflection is measured in “microstrain” (parts-per-million)
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5. Straight Side Presses
A straight side press is constructed like a sandwich
The base and crown are the “bread”, and the columns are the “meat”
There are big threaded rods called tie rods inside the columns that
hold the whole thing together
The tie rods have nuts at each end that are tightened to pre-stress
the whole machine
The columns are permanently compressed when the press is
assembled
Tonnage monitors measure the columns “relaxing” slightly under load
© 2018 Wintriss Controls Group LLC- All rights reserved
6. Calibration
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Calibration is the process that enables the tonnage
monitor to read the actual force being exerted by the
press
Load cells are used to measure the actual force under
the ram, then the tonnage monitor’s output is dialed in to
match
Once the tonnage monitor is calibrated, the press itself
becomes a force-measuring instrument
Calibration isn’t 100% necessary, but it provides some
benefits
7. Zero Cam
The press frame expands and contracts with changes in temperature
The strain links measure this change, but we really wish they wouldn’t
The load monitor cancels out the temperature change by reading the
strain link output during a non-load generating portion of the stroke
(i.e. TDC), and subtracting this reading from the overall load
The “Zero Cam” is a latching magnetic limit switch (LMCS) that
provides a timing signal to the tonnage monitor through the top of the
stroke
The LMCS tells the load monitor where in the stroke to zero out the
tonnage
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8. Setpoint Limits
Setpoint limits are thresholds that are set for each tool
When a setpoint limit is exceeded, the tonnage monitor
stops the machine
High Tonnage Limit – If the peak tonnage exceeds this limit, the
press will stop
Low Tonnage Limit – The peak tonnage must exceed this level
or the press will stop
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11. Nuisance Stops
It’s normal to see gradual changes in the peak
tonnage value thought the day
Your high and low setpoints must allow for this
variation or nuisance stops will result
This makes it impossible to monitor small tonnage
variations with only high and low setpoints
Fortunately, there is a 3rd setpoint type
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12. Repeatability Limit
Gradual changes in tonnage are normal, but abrupt changes
usually mean trouble
The Repeatability Limit is the maximum allowable variation in
tonnage from one stroke to the next
High and low limits can be relaxed to prevent nuisance stops,
but still protect the machine and die
The Repeatability Limit can be set to a very precise value
(often in the tenths of tons) without causing nuisance stops
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14. Reverse Load
As regular (forward) load increases, the press frame loads up
like a giant spring
When the punches break through, the spring suddenly
releases, and the load direction reverses
Presses are designed to withstand forward load, but not
reverse load (20% of capacity max).
Excessive reverse load damages bearing cap bolts, and the
ram adjust mechanism
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15. Tonnage Monitor Benefits
More repeatable setups
Reduce off-center loading
Detect loss of lubrication
Detect material variations
Detect tool wear
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16. Your Insurance Policy
Even if you utilize other forms of monitoring such as die
protection sensors or in-die measurement systems, tonnage
monitors are still an important part of the overall monitoring
package
Unlike those other devices, a tonnage monitor requires no tool-
specific sensors or programming
The tonnage monitor becomes your “insurance policy” against
machine or tool problems that are unusual or unforeseen – the
things you would never install a specific sensor to detect
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17. AutoSet Load Monitors
Wintriss Controls offers a series of accurate and
reliable stand-alone press tonnage monitors suitable
for any application
The basic model 1500 provides economical
protection for any machine
The 1500 Plus and 1504 Plus models provide
advanced features that are extremely easy to use
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18. AutoSet Load Monitors
AutoSet 1500
2 inputs, high tonnage limit only
AutoSet 1500+
2 inputs, high and repeatability limits, reverse load display
AutoSet 1504+
Same as the 1500+ but with 4 inputs
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19. AutoSet 1500
This is the simplest and cheapest tonnage
monitor we make
Available with either an enclosure or
panel mount
The AutoSet 1500 uses auto-setpoints
It reads the tonnage during a sample
period, and sets the high limit “X” percent
above the highest reading
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20. AutoSet 1500
Setpoint limit percentage is set by the user with a rotary switch
on the board
The sample period is either 1 or 15 strokes.
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21. AutoSet 1500/1504 Plus
The “Plus” models have both high and
repeatability setpoint limits
There’s a momentary pushbutton on the
front panel that allows the user to display
reverse load
The AutoSet 1500+ has two inputs
The AutoSet 1504+ (shown) has 4 inputs
© 2018 Wintriss Controls Group LLC- All rights reserved
22. Contact Us
Backed by 60+ years of manufacturing
experience, Wintriss has the expertise to help
you protect your presses and keep your
stamping operation performing smoothly and
efficiently.
Contact us by:
Calling (800) 586-8324
Submitting this simple form
© 2018 Wintriss Controls Group LLC- All rights reserved