Multiple Applications
The Profiler can be programmed to control most types of between-press or in-press transfer automation, including tri-axis and crossbar STFs, orientation stations, loaders, unloaders, shuttles, and turnovers. It can also control swing shears and oscillating dies.
Programmable Cam Profiles
Profile control emulates the motion curves provided by the cams of most mechanical feed systems, including modified sine, modified cosine, trapezoidal, parabolic, and asynchronous cycloidal. Custom profiles can also be created upon request.
Maximum SPM Calculation
The software calculates the maximum speed at which the automation can run based upon the specified part profile and the motor, drive, and machine data. It reports the segment of the motion profile that sets the limitation and identifies the limiting factor. Using this information, the die setter can make adjustments that optimize production and minimize machine wear, while the operator can be prevented from running the equipment too fast.
Press Simulator
A built-in press simulator assists in die setup and troubleshooting by allowing the automation to simulate automatic operation without moving the press. The simulator can be jogged forward or reverse at one of two preset speeds and can be configured either to automatically stop at the home position or to run continuously.
Smooth Start
Smooth Start technology starts the machine in automatic mode with the press on top and the automation in a home position. The automation will not start moving until the press reaches an angle that matches the automation home position.
Smooth Stop
With Smooth Stop technology, the automation continues moving smoothly to its home position while the press stops on top during a cycle stop.
Smooth Return
Smooth Return technology smoothes operation by insulating the automation from the vibration and mechanical backlash of the press. The control dynamically switches between following the press and following an internal simulator for a portion of every stroke. The simulator is synchronized to the speed and position of the press during the transition, and press position is continually monitored to ensure that the simulator does not fall behind.
Smooth Transfer
Using Smooth Transfer technology, the drive switches from following one press to another on the fly using an optimal trajectory to compensate for differences in the velocity and position of the two presses. The automation leaves the first press at a designated safe point then follows a simulated press angle that is generated to match the velocity and position of the second press within the specified press angle window. The automation then starts following the second press.
Programmable Limit Switches
An advanced Programmable Limit Switch (PLS) controller provides contact outputs that turn on and off based on the position of the press, automation, or both. These outputs can be used to control grippers, vacuum cups, die lifters, oil sprays, and part tracking windows. Each PLS output has independent speed compensation to ensure, for example, that grippers will open and close in the same place regardless of press speed.
Off-Path Jog
Each axis controlled by the Profiler may be jogged individually without moving the other axes or the press. The control can be configured to limit off-path motion to the limits of the programmed motion path or to the mechanical travel limits.
Go-To Positions and Angles
As many as four go-to positions and four go-to angles can be configured for each drive. For each go-to position, the user specifies where the axis will move to, how fast it will move, and how much torque may be used during the move. These go-to positions can then be selected with digital I/O to send the automation to the preprogrammed positions. This is particularly useful for sequencing an automatic die-change routine. Go-to angles similarly send the simulator to preprogrammed positions that all synchronized drives will follow.
Multiple Referencing Schemes
The Profiler supports snug-up (positive stop) referencing, limit-switch referencing, and learn/teach referencing. The drive does not need to be re-referenced every time the machine is powered down if at least one of its feedback devices is an absolute encoder. Referencing is only required if the encoder is replaced or its coupling is loosened.
Multiple Motor Types
The controller supports any combination of motors, including AC induction, brushless or permanent-magnet AC synchronous, and wound-field or permanent magnet DC motors.
Common Bus Architecture
Profiler drive systems use a common-bus architecture that allows multiple drives to be tied together and share a single line-regenerative or non-regenerative front end. The result is a more streamlined design that greatly reduces peak energy demands.
Event-Driven Data Logging
A built-in data logger can record any drive parameter or any analog, digital, or serial I/O data within the drive. Multiple channels of data can be grouped into a channel set, and multiple channel sets can be configured. Each channel and channel set can be sampled at different sample rates. Sampling can be continuous or triggered by complex user-defined trigger conditions. Captured data can be read and displayed by an HMI in real time, subject to limits of the serial connection, or buffered in the drive for subsequent retrieval and analysis. An optional memory expansion module is also available that allows multiple sample sets to be stored on a removable SD memory card.
Program Extensibility
The control can be customized to a specific installation using UEdit™, a powerful Windows-based programming tool that lets users add their own ladder logic and function-block programming.
