Allen-Bradley Automation & Control Solution

Allen-Bradley Press Automation & Control

Allen-Bradley Press Automation & Control - Integrated W/ Our Press Pilot 150 Clutch/Brake Controller and PanelView HMI

Toledo Integrated Systems has been providing Allen Bradley solutions to the metal forming industry for over 13 years. In that time we have worked with all of the Allen Bradley hardware platforms including PLC5, SLC, MicroLogix, CompactLogix and ControlLogix. Our AB Maximizer TPC has many standard control and automation features but allows for easy customization and expandability.

The Max TPC is built to order with all the functionality and integration that the customer requires. This gives the customer complete control of the equipment using standard "off-the-shelf" hardware. The HMI is also selectable. Along with the standard Allen Bradley offerings for the HMI, we are capable of providing an industrial PC or a screen from a different vendor (if you have standardized on a certain screen).

Allen-Bradley Press Automation & Control

Allen-Bradley - Press Pilot 150 - HMI Communications

Below is a list of the standard features and options for the AB Max TPC. The options don't stop there. The true advantage with a PLC system is that it can be expanded and customized to the customer's exact needs.

All supplied controls comply with OSHA, ANSI and CSA Z142-02 regulations for mechanical stamping presses.

Press Control Features:

  • Dual processor w/watchdog circuit
  • Anti-tie down protection
  • Anti-repeat protection
  • Dual channel monitored E-stop circuit
  • Protected memory (each processor)
  • Off, inch, single & continuous modes
  • Clutch & counterbalance air pressure monitoring
  • Press position verified each cycle
  • Speed compensated top-stop
  • Top stop overrun protection
  • Uncommanded motion & drift detection
  • Clutch valve fault monitor input
  • 120 VAC or 24VDC E-stop circuit
  • Light curtain interlocks

Press Automation Features:

  • Sixteen (16) die protection inputs
  • Eight (8) programmable limit switches
  • Two (2) or four (4) channel tonnage monitor
  • Signature analysis & reverse tonnage
  • Individual window settings for all DP inputs and PLS outputs
  • Part, good part, stroke and two batch counters
  • Press position and SPM display
  • Two hundred (200) job storage/recipes
  • Ability to save/review comments with each recipe
  • Compact flash card memory
  • Individual alpha/numeric names for DP, PLS and job storage
  • PLS Speed compensation
  • Time based brake monitor
  • 90 degree stop test
  • Resolver based (360 degrees @ 1 res.)
  • Automatic alarm pages and messaging
  • Online help menus
  • 3 password levels
  • MaxNet connectivity capable (press room networking)

Typical Control Features Include:

  • Ethernet connectivity
  • Main motor control and monitoring
  • VFD or Eddy current control integration
  • SPM control
  • Flywheel brake control
  • Slide adjust control and monitoring
  • Lube pump control and monitoring
  • Hydraulic pump control and monitoring
  • Individual I/O diagnostics

Optional Control Features Include:

  • Additional DP & PLS (virtually unlimited)
  • Signature analysis & reverse tonnage
  • CCM (Critical Curve Monitoring)
  • Auto counterbalance
  • Auto shut height
  • Servo feed interface
  • Transfer system interlocks
  • Robot interlocks
  • Standard die sensor interface box
  • Universal die sensor interface box

Click Here To Download Press Control RFQ

Case Study #1

Case Study # 1

1000 Ton Bliss Press and Rowe Coil Feeder Controls Upgrade (during new HMS Transfer retrofit).

1000 Ton Bliss

Scope: Due to new and existing product demands the customer needed to add a transfer system to an old press line. The existing electrical controls on the press and feeder were obsolete, an electrician's nightmare and not up to the latest safety standards. Toledo Integrated Systems was contracted to provide a turn-key electrical controls upgrade on the existing 1000-Ton Bliss and Rowe Coil Feeder.

New Press and Feeder Controls Included:

  • Allen-Bradley Control GuardLogix (L72S) Safety PLC
  • 15" Industrial PC with Factory Talk View
  • Two hundred job recipe/storage
  • Die identification with Balluff I/O Link
  • Sixteen (16) die protection stations
  • Sixteen (16) transfer die protection stations with indexing
  • Eight (8) programmable limit switches
  • HMS linear transfer interlocks (Ethernet)
  • Auto counterbalance control
  • Light curtain interlocks
  • Ethernet communication
  • Hydraulic clutch
  • Main AC motor (Ethernet to Yaskawa drive)
  • Four (4) channel "through the stroke" signature tonnage monitor
  • Auto shut height control
  • Feeder servo motor

Maximizer Screen

Design Considerations: Toledo Integrated Systems (TIS) assigned the project to one of the control project engineers. The engineer's responsibility was to follow the project from initial design through on-site commissioning and training. As with all projects of this size, an investigative trip was scheduled with the customer to introduce the project engineer, gather additional information and to develop a solid installation plan. With the additional details and information, the project engineer used our standard electrical designs to develop the new press and feeder control. Hardware was purchased, built and assembled in the Toledo panel shop. The control panels were inspected, pre-tested and powered up. While the controls were still at Toledo's shop, initial programs were loaded. TIS was responsible for the installation of the new control system. The control panel was placed on a mezzanine over the feed line. The TIS installers used cable tray from the control panel, down into the pit and then up each column of the press to provide a clean yet functional installation.

Electrical Panel

After the physical installation was finalized, power was turned on and a complete I/O check was conducted. Safety circuits and interlocks were tested and verified. Next, the remaining parts of the press were configured (hydraulic overloads, counterbalance, ram adjustment, main motor, etc.). Once the press control was completed, the engineers worked on commissioning the feeder. At this time, HMS was installing a new transfer system. The operator console was designed so that HMS could install their HMI in the same console as the press control. The customer would have complete control of the press, all from one place. Since Toledo provided controls for both the press and feeder, all associated screens were combined into one HMI. This ensured a seamless transition between the press and feeder screens as well as combining job data for both into one integrated HMI. Finally, the press was calibrated for tonnage and all the modes were tested and confirmed for proper functionality with the transfer system.

Results: The finished project was a success. The customer's control engineer had extensive input regarding the hardware to be used along with specific installation requirements. TIS worked closely with him throughout the installation and startup to make sure all his concerns were met. TIS and HMS were able to collaborate to ensure the integration of the press and transfer controls exceeded the customer's expectations. The upgrade not only cleaned up the entire electrical system but brought the press controls up to the latest OSHA & ANSI safety standards. The upgrade also made the electrical integration with a new HMS transfer system possible and very seamless. In the end, the controls were able to run all the new as well as the existing product demands for the upgraded press.

Case Study #2

Case Study #2

Relocating 4 Straight Side Presses - (2) 600 Ton PTC, (1) 800 Ton PTC,
(1) 600 Ton Bliss.

Relocating (4) Straight Side Presses

Scope: These four presses were completely disassembled, moved from the United States to Mexico and then reassembled. Toledo Integrated Systems (TIS) was contracted to provide updated press controls that not only eliminated obsolete hardware, but also were OSHA & ANSI compliant. TIS was tasked with designing new control systems that included coil feed line interlocking. To reduce cost, the customer decided on reusing the existing main motor drives as well as all the sensors currently on the presses. TIS engineers had to rely on only original electrical drawings and pictures to design the new press control systems.

Each Press Control System Included:

  • Allen-Bradley CompactLogix Processor
  • 15" AB VersaView PC with Factory Talk
  • Press Pilot 150 Clutch/Brake controller
  • Ethernet communication
  • Universal die protection interface box
  • One hundred job recipe/storage
  • Sixteen (16) die protection stations
  • Sixteen (16) programmable limit switches
  • Time based brake monitor
  • Main motor speed control
  • eWon remote ethernet access switch
  • Light curtain interlocks
  • Four (4) channel "through the stroke" signature tonnage monitor
  • Automatic shut height
  • Automatic counterbalance
  • Hydraulic overload control
  • Individual lube sensor monitoring
  • Bearing temperature monitoring
  • Interlocks with existing main drives
  • -Siemens main motor DC drive
    -Eddy current main motor AC drive
    -Two (2) ABB main motor AC drives
Design Considerations: The TIS engineer assigned to the job used the original electrical drawings as well as pictures gathered to design a new control for each press. The TIS engineer was responsible for developing the new electrical schematics as well as the PLC and HMI programs for each control. One of the requests from the customer was to separate low and high power so that the low power panel could be opened without going through the standard lockout procedure. The engineer came up with a custom panel design to essentially bolt two different enclosures together to accomplish the customer's request. The design included a new free standing two-door enclosure and a new slant face operator console to be used together.

Electrical cabinet and Slant face console

High power side of enclosure

The hardware was specified, purchased and then assembled at TIS. All the control panels were inspected to ensure proper wiring then pre-tested. Next, they were powered up and the engineer loaded the PLC and HMI programs into the control and set up communications. After the presses had been shipped to their new location, TIS's representative (Presmec International) physically installed the controls. After the installations were complete, TIS engineers traveled to the customer site to start up the new controls.

Upon arrival to start commissioning the presses, the power was turned on to the panels followed by verification of communications and a complete I/O check of all the sensors on the presses. The safety circuits and interlocks for the presses were tested. Then the remaining parts of the presses were configured (hydraulic overloads, counterbalance, ram adjustment, main motor, etc.). Finally, the press was calibrated for tonnage and all the modes were tested and confirmed for proper functionality. This whole process was then repeated for the remaining three press controls.

Press and custom control enclosure

Results: The project in total was a success. Toledo was able to design a new, reliable control for each of the relocated presses. Working closely with Presmec and the end customer, TIS made sure that the press controls were installed seamlessly even after having to put every piece back together on each machine. The customer was more than satisfied with TIS and Presmec at how we worked together and worked with their operators to tailor the HMI to their needs. Due to the ease of the touchscreen HMIs, job setup and overall operator efficiency were improved tremendously.

Inside Panel


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