Hydraulics Case Study

Project Scope:

Toledo Integrated Systems was contracted to provide a turn-key OSHA & ANSI compliant press control system for this case study. Our services required the removal of all unneeded electrical components and wires, re-wiring the entire press and automation system, updating the controls, automation system, safety circuit, and HMI, re-commissioning the press, and providing training for the new operators and maintenance personnel.

Toledo Integrated Systems Toledo Transducers

Press: 3000-Ton Lake Erie Hydraulic Press

3000 Ton Erie Hydraulic Press

New Press Control System Included:

- (2) Allen-Bradley Compact Logix Processors

- (1) 15" Automation Direct Industrial HMI

- Hydraulic Pressure Transducer

- Oil Temperature Thermocouple

- (1) Servo Amplifier Modules

- 102" Linear Transducer

- Light Curtain Interlocks

- Ethernet Distributed 1/0

Method:

After the removal of all unneeded wire and components, we installed and mounted new field and control hardware, and enclosures. Once in place and wired, we applied power and verified all new and existing connections.

After our 1/0 check was successful, the main pump variable volume controller was calibrated and checked for any problems. Once the main pump was calibrated, the team could calibrate tonnage and then incorporate the customer's specific control process.

This particular application required five zones to form the part. Each zone required a different rate of tonnage and duration. Once the five stages were completed, the ram would automatically open to a settable opening and the part would be sprayed with a coating substance- IMC (Injection Molding Compound). After spraying, the part would run through five more zones at which point the finished part would eject.

Results:

The finished project was a success. We were able to correctly tie all new and existing components together after the transplant. We also beat our deadline during the run-off.