Stamping Press Application

Press solutions for multiple sizes and types of metal forming equipment

Photo courtesy of Simpac

Helping You Differentiate Your Machines• Broad range of control, safety, and information disciplines with one single,

fully-integrated platform that provides actionable, real-time data - Integrated Architecture offers single-source buying to ease design, development,

and maintenance - Connected Component solutions for simple press solutions - Meet your customer demands for secure and information-enabled machines - Safety expertise and off-the-shelf integrated safety solutions - Low risk deployments with standard off-the-shelf solutions

• Global services and support and locally available spare parts

• Our end user relationships and dedicated OEM experts help extend your market reach

Machine Builder Challenges• Deliver safe, efficient, and reliable press automation solutions.

• Build equipment to accepted industry standards that easily integrate with other equipment.

• Reduce setup and changeover times with standardized solutions.

• Drive sustainable production to reduce downtime, line inefficiencies, and energy consumption.

• Balance machine performance, safety requirements, and machine costs.

End User Challenges• Reduce setup and changeover times.

• Develop solutions that reduce downtime and improve diagnostics to reduce repair times.

• Enhance repeatability and reduce material variations to minimize scrap.

• Provide connectivity for real-time data collection and analytics to drive continuous improvement.

• Provide secure remote access for remote troubleshooting.

• Implement off-the-shelf solutions with standardized products that can be supported globally.

Metal Forming and Stamping Line Layout

Coil Handling Area

StraightenerSizer

Flattener

Mechanical PressServo Press

Hydraulic Press

Typical ArchitectureUn-coiler to Press Feeder to Stamping Press

Feeder Area

Studio 5000 Logix Designer®Compact Guard Logix®

PanelView™ Plus 7Human Machine Interface

Press Angle Encoder

Two Hand Control

light curtain

EmergencyStop

Interlocking Switch

Safety I/O

Servo Drive - Kinetix® 5700 PowerFlex® AC Drive

EtherNet/IP

Stratix™ 5700

1734-AENTR Series-B

ModuleStatus

NetworkActivity

NetworkStatus

Point BusStatus

SystemPower

FieldPower

Link 1ActivityStatus

Link 2ActivityStatus

IP ADD

RESS

9 9 924VDC

Safety SinkInput

MS NS

LK

PWR

1734-IB8S

1734-AENTR Series-B

ModuleStatus

NetworkActivity

NetworkStatus

Point BusStatus

SystemPower

FieldPower

Link 1ActivityStatus

Link 2ActivityStatus

IP ADD

RESS

9 9 924VDC

Safety SinkInput

MS NS

LK

PWR

1734-IB8S

2

1

1

4

I/O

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

2

1

1

4

I/O

2

1

1

5

2

1

2

1

1 6

5 10 5 10

UFB-A UFB-b

I/O-A1 6

I/O-B

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

2

1

6

10

UFB

I/O

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

2

1

1

4

I/O

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

2

1

1

4

I/O

2

1

1

5

2

1

2

1

1 6

5 10 5 10

UFB-A UFB-b

I/O-A1 6

I/O-B

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

2

1

6

10

UFB

I/O

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

2

1

1

4

I/O

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

2

1

1

4

I/O

2

1

1

5

2

1

2

1

1 6

5 10 5 10

UFB-A UFB-b

I/O-A1 6

I/O-B

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

2

1

6

10

UFB

I/O

5700

ModNet

Risk of electric shock.Power off and wait 5 min.

SFTY RUN

SFTY TASK

SFTY LOCK

SFTY OK

SAFETY CPU

E4:90:69:A1:1A:EE

Compact Guard Logix

Un CoilerAC Motor

StraightenerAC Motor

Feeder Servo Motor

Type:Mechanical

Type:Servo

Control Option forMain Motor

Scalable Press Solutions with Integrated Safety Architecture

Mechanical PressServo Press

Hydraulic PressFinal Output

Faster Machine Start-upPower programming template in Studio 5000 Logix Designer™ offers modular program code to reduce engineering and commissioning time. Standard, reusable software modules and Add-on-Instructions (AOIs) also reduce development time.

Modular WiringEthernet solutions for drives, servos and I/O reduce wiring and start up times with modular building blocks.

Energy ManagementMotion Analyzer sizing tool helps identify the right drives products to optimize power usage.

Safety and ProductivityInnovative safety solutions improve press machine functional operation and help to increase personnel safety, efficiency, and productivity.

Real-time InformationInformation-enabled machines that use Rockwell Automation Integrated Architecture with EtherNet/IP easily integrate into production lines and provide actionable production information for improved decision making (e.g. OEE).

Pre-engineered SolutionsProven, off-the-shelf solutions include PressGuard™ and Compact PressMaster™ pre-engineered press control systems.

SFTY RUN

SFTY TASK

SFTY LOCK

SFTY OK

SAFETY CPU

E4:90:69:A1:1A:EE

Compact Guard Logix

PanelView™ Human Machine Interface

PowerFlex® DriveFlywheel Motor Drive

Compact GuardLogix™ PAC

Left Front Upright

Left Rear Upright

Magnetics Enclosure

Right Front Upright

Right Rear Upright

Basement

Slide Angle Single Turn

Slide Angle Single Turn

Non Safety PB/SS/LT

ROSS Valve InterfaceClutch Valve ResetReset OK

Mod Switch, Inch P/BClutch Control ResetControl ResetClutch Valve Reset

Die Block, E-Stop, Run Bar

Die Block, E-Stop, Run Bar

CES Interface (optional)

Motor Starter OutputsAux Contact Inputs

Die Block, E-Stop, Run Bar

Die Block, E-Stop, Run Bar

Press and safety control on a single platform to reduce system complexity

• BGIA certified instruction suite for metal forming industry – EN692, ANSI B 11.1 & CSA Z142.02 – Two hand Control station – Crank Shaft Position monitor – Main valve control – Position mode selector

§  BGIA certified instruction suite for metal forming industry

§  EN692, ANSI B 11.1 & CSA Z142.02 §  Two hand Control station §  Crank Shaft Position monitor §  Main valve control §  Position mode selector

§  Pre Configured Engineered solution for Press Control system – Press Guard

§  BGIA certified instruction suite for metal forming industry

§  EN692, ANSI B 11.1 & CSA Z142.02 §  Two hand Control station §  Crank Shaft Position monitor §  Main valve control §  Position mode selector

§  Pre Configured Engineered solution for Press Control system – Press Guard

Laser Scanner

Gate Switches

Light Curtains Safety Drives

Safety Contactors

Safety RelaysGuardmaster®

440C-CR30

Safety Mats

(For presses with physical guards)

E-Stops and Signaling

2080-10401 2 3 4 5 6

B VO CO CO1 V1 01 CO1

A COM COM COM COM V-5 C1-1

2080-10401 2 3 4 5 6

B VO CO CO1 V1 01 CO1

A COM COM COM COM V-5 C1-1

0 1 2 3 45 6 7 8 9

0 1 23 4 5

440C-CR30

SFTY RUN

SFTY TASK

SFTY LOCK

SFTY OK

SAFETY CPU

E4:90:69:A1:1A:EE

Compact Guard Logix

Compact Guard Logix

Component Safety Solution

Network EtherNet/IP, Modbus RTU

Controller Dual Micro850 controllers

Variable Frequency Drive PowerFlex 753 for fly wheel

Safety Devices Guardmaster®440C-CR30 and Guardmaster® GuardShield

Motion Dual encoder feedback from flywheeel

Stand-Alone Machine

• Scaled solutions to match press functionality needs.

• Leverage Connected Component solutions for simple press solutions using one common configuration software with broad portfolio of safety components in the industry.

• Software configurable safety relay with SIL 3/PLE certification.

• Controller plug-in modules offer cost-effective expansion of machine features and functions.

Common Programming SoftwareConnected Components Workbench™ software for Micro800® controller, PowerFlex AC drives, PanelView 800 HMI, and Guardmaster® 440C-CR30 safety relay.

Safety Functions and I/O provided by Guardmaster® 440C-CR30.

Heavy duty performance and high torque at low frequencies for fly wheel with PowerFlex 753 drive.

Versatility of controller interfaces up to six high speed counter inputs and up to three ‘Pulse Train Output’ over embedded digital I/O. Up to five plug-ins and up to four expansion I/O modules also allowed.

Controller expansion I/O and plug-in for Die Protector, Tonnage Monitor and CAM output.

Connected Components Workbench™ software

2080-10401 2 3 4 5 6

B VO CO CO1 V1 01 CO1

A COM COM COM COM V-5 C1-1

2080-10401 2 3 4 5 6

B VO CO CO1 V1 01 CO1

A COM COM COM COM V-5 C1-1

0 1 2 3 45 6 7 8 9

0 1 23 4 5

440C-CR30

EtherNet/IP

Encoder Encoder4 Position ModeSelect Switch

E-stop Interlocking Switch

Reset2 Hand Control

Stratix2000

Light Curtain

PowerFlex DriveFlywheel Motor Drive

Guardmaster® 440C-CR30

Relays& SSRs

Relays

Clutch Brake Valve

Neutral

Line

Micro850 A Micro850 B

PanelView 800Human Machine Interface

Typical Architecture for Micro-Solutions

Supporting Your Business Every Step of the WayAt every stage in the life cycle of your machines, Rockwell Automation is your collaboration partner. From design to build to operation and maintenance, you can count on the continuum of Rockwell Automation resources to deliver safe automation solutions for press applications.

By taking advantage of our products and services, you can lower your Total Cost To Design, Develop and Deliver®, while improving your time to market. You will be better equipped to react quickly to

change, increasing profits and attracting new customers with high performance and innovative machines. Whether providing you with single components, entire systems or specialized consultation or trying to achieve sustainable production initiatives, our goal is to offer solutions on a personalized level.

For More Information:Call a Rockwell Automation sales office or an authorized distributor today or visit us online at www.rockwellautomation.com

Publication OEM-BR060C-EN-P – July 2016 Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Allen-Bradley, Connected Components Workbench, CompactLogix, Integrated Architecture, Guardmaster, Kinetix, LISTEN. THINK. SOLVE., Micro800, Micro850, PanelView, PowerFlex, Rockwell Automation, Rockwell Software, Stratix, Studio5000 Logix Designer, and Total Cost to Design, Develop and Deliver are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA. All other trademarks and registered trademarks are property of their respective companies.

For more information about our OEM Solutions, please visit: http://www.rockwellautomation.com/go/lit/oem