manual em ingles dobradeira - s 530 operator%27s guide

Esa/Gv s.r.l. 15 via Zamboni, CP 43 41011 Campogalliano Modena Italy tel. +39 059 851414 - fax +39 059 851313 http://www.esagv.it - E-mail: [email protected]

Numeric Control for Bending

Presses

Operator's Guide (GB)User Documentation

Valid for: Product: S530 - SW 198

Edition: Novembre 2010 Code: 91803.GB.0.GB

Esa/Gv ii

Restrictions Duplication, transmission and use of this document or its contents shall be considered

prohitibed unless prior authorization has been received from Esa/Gv. All rights are

reserved.

Even when authorized, modification of this document (either by computer or on paper)

voids the guarantees specified below.

Guarantees The product may offer performances that are not described in these manuals. Esa/Gv

shall neither be obliged to maintain these functions in new versions of the product nor

to guarantee the relative assistance.

Checks have been carried out in order to ensure that the contents of these manuals

correspond to the documented product. Despite this fact, there may be discrepancies.

Esa/Gv therefore offers no guarantees as to the full compliance and completeness of the

texts.

The information in this document is periodically revised and new editions are issued

when necessary.

This manual has been compiled in partial compliance with ANSI/IEEE std 1063-1987

“IEEE Standard for software User Documentation”.

Editions This document is liable to be modified without prior notice. These modifications may

involve further editions or revisions of the document.

Further editions imply complete substitution of the document.

Revision involves replacement/addition/elimination of pages of the document.

Each page is identified by the code of the document at the bottom.

Notes

MS-DOS® Trademark registered by Microsoft Corporation.

Esa/Gv iii

The chronological list of editions of this document is given in the following table:

Evolution of the document

Edition Document Code Release Type of edition

29/11/2010 91803.GB.0.GB 0 New documento

Modifications

Release Chapters - Pages Description

Esa/Gv iv

GB Brief Guide

Esa/Gv i

Operator's Guide

Notes for the reader......................................................................................................i

Explanation of the symbols ................................................................................................................ i

Printer’s conventions..........................................................................................................................ii

Glossary............................................................................................................................................ iii

1 Brief Guide part 1 ..................................................................................................1.1

1.1 Operations to carry out on powering ........................................................................................ 1.1

1.1.1 Ram sizing .................................................................................................................. 1.1

1.1.2 How to size the locator axes....................................................................................... 1.1

1.2 List of Punches and Dies ......................................................................................................... 1.2

1.3 How to draw a new punch........................................................................................................ 1.7

1.3.1 Punches to draw......................................................................................................... 1.9

1.3.2 Preset punches......................................................................................................... 1.14

1.4 How to draw a new die........................................................................................................... 1.15

1.4.1 Die to be drawn......................................................................................................... 1.17

1.4.2 Preset dies................................................................................................................ 1.23

2 Brief Guide part 2 ..................................................................................................2.1

2.1 List of programs ....................................................................................................................... 2.1

2.1.1 Program update.......................................................................................................... 2.4

2.2 Numeric program set-up .......................................................................................................... 2.6

2.3 Graphic program entry (Options feature) ............................................................................... 2.16

2.4 Automatic calculation of the bending sequence (Options feature) ........................................ 2.21

2.5 Manual calculation of the bending sequence (Options feature)............................................. 2.24

2.6 How to bend a box ................................................................................................................. 2.27

2.7 Program execution in the automatic mode ............................................................................ 2.28

2.8 Materials Table ...................................................................................................................... 2.34

2.8.1 How to access the Materials Table mask ................................................................. 2.34

2.8.2 How to use the Materials coefficient ......................................................................... 2.34

2.9 Clinching/Coining Coefficient ................................................................................................. 2.36

2.9.1 How to access the Correction Coefficients mask ..................................................... 2.36

2.9.2 How to use the Clinching/Coining coefficient............................................................ 2.37

2.10 Internal radius correction ..................................................................................................... 2.38

Brief Guide GB

Esa/Gv ii

2.11 DIN formula selection for the stretch calculation ................................................................. 2.38

2.11.1 Program checking................................................................................................... 2.38

3 Brief Guide part 3 ..................................................................................................3.1

3.1 “Sheet Metal-working Machine” function.................................................................................. 3.1

3.1.1 How to enable the “Sheet Metal-working Machine” function ...................................... 3.1

3.1.2 “New Bend” function ................................................................................................... 3.1

3.1.3 Flattening bend Forcing .............................................................................................. 3.2

3.2 New “Machine functions” mask................................................................................................ 3.3

3.3 “Manual Bend” Function........................................................................................................... 3.3

4 Integrated Cad .......................................................................................................4.1

4.1 Introduction .............................................................................................................................. 4.1

4.2 Drawing function ...................................................................................................................... 4.1

4.2.1 Polar entry of the drawing data................................................................................... 4.1

4.2.2 General data ............................................................................................................... 4.2

4.3 Drawing page........................................................................................................................... 4.3

4.4 Drawing data entry ................................................................................................................... 4.4

4.4.1 How to enter a drawing in the polar mode .................................................................. 4.4

5 Management of the data in the memory ..............................................................5.1

5.1 Introduction .............................................................................................................................. 5.1

5.2 Memory devices....................................................................................................................... 5.1

5.2.1 Internal memory (buffered RAM) ................................................................................ 5.1

5.2.2 SSD (Flash Hard Disk) ............................................................................................... 5.1

5.2.3 USB Key ..................................................................................................................... 5.1

5.3 Logic site of the data................................................................................................................ 5.2

5.4 Data exchanging between storage devices ............................................................................. 5.3

5.4.1 Saving / Loading the Configuration Parameters ......................................................... 5.4

5.4.2 Saving / Loading the Axes Parameters ...................................................................... 5.6

5.4.3 Saving / Loading the PILZ Configuration Parameters ................................................ 5.7

5.4.4 Saving/Loading the punches ...................................................................................... 5.8

5.4.5 Saving/Loading the dies ........................................................................................... 5.10

5.4.6 Saving/Loading all the tools ...................................................................................... 5.12

5.4.7 Saving/Loading programs......................................................................................... 5.13

5.4.8 Saving/Loading all the programs .............................................................................. 5.15

5.5 Recommended security savings ............................................................................................ 5.16

GB Brief Guide

Esa/Gv iii

5.5.1 Advice for the bending press manufacturer.............................................................. 5.16

5.5.2 Advice for the end user............................................................................................. 5.16

6 Description of the program data ..........................................................................6.1

6.1 Header section......................................................................................................................... 6.1

Name ................................................................................................................................... 6.1

Bend .................................................................................................................................... 6.1

Section................................................................................................................................. 6.1

6.2 Supplementary non-modifiable information ............................................................................. 6.2

6.3 Workpiece data section ........................................................................................................... 6.3

Pieces made........................................................................................................................ 6.3

Pieces to make .................................................................................................................... 6.3

Measurements..................................................................................................................... 6.3

Length.................................................................................................................................. 6.4

Comment ............................................................................................................................. 6.4

6.4 General data section................................................................................................................ 6.5

Width ................................................................................................................................... 6.5

Thickness ............................................................................................................................ 6.5

Strength ............................................................................................................................... 6.5

Material ................................................................................................................................ 6.6

Die ....................................................................................................................................... 6.6

Slot....................................................................................................................................... 6.7

Punch................................................................................................................................... 6.7

Die direction......................................................................................................................... 6.7

Punch direction .................................................................................................................... 6.7

6.5 Angles and axes data section .................................................................................................. 6.8

Y1 Angle .............................................................................................................................. 6.8

Y1 B.D.C.............................................................................................................................. 6.8

Y1 corrections...................................................................................................................... 6.8

T.D.C. (Top Dead Center) ................................................................................................... 6.8

Y2 Angle .............................................................................................................................. 6.9

Y2 B.D.C.............................................................................................................................. 6.9

Y2 corrections...................................................................................................................... 6.9

X1 ........................................................................................................................................ 6.9

X1 Recoil ........................................................................................................................... 6.10

X1 corrections.................................................................................................................... 6.10

X2 ...................................................................................................................................... 6.10

X2 Recoil ........................................................................................................................... 6.10

Brief Guide GB

Esa/Gv iv

X2 corrections.................................................................................................................... 6.11

R1 ...................................................................................................................................... 6.11

R2 ...................................................................................................................................... 6.11

A1 (Mechanical cambering)............................................................................................... 6.11

6.6 Machining data section .......................................................................................................... 6.12

Force.................................................................................................................................. 6.12

Camb. (Cambering) ........................................................................................................... 6.12

S.C.T. (Step Changing Time) ............................................................................................ 6.12

P.C.P. (Plate Contact Point) .............................................................................................. 6.12

S.C.P. (Speed Changing Point) ......................................................................................... 6.13

B. Time (Bending Time)..................................................................................................... 6.13

Accomp. (Accompanying).................................................................................................. 6.13

Speed ................................................................................................................................ 6.13

Functions 1 to 20 ............................................................................................................... 6.14

Rep. (Repeats) .................................................................................................................. 6.14

Direction............................................................................................................................. 6.14

Ri (Internal Radius)............................................................................................................ 6.15

END OF SUMMARY

GB Notes for the reader

Esa/Gv i

Notes for the reader

General information The information in this manual only applies to the software versions indicated on the

frontispiece.

Not all the available functions may be described in this manual. In these cases, Esa/Gv

shall be obliged to neither guarantee these functions nor include them in future versions.

Purpose The purpose of this manual is to help the operator during use of the product described

in the frontispiece and when installing / using the office software.

Users This manual contains information for:

• machine operators with no basic knowledge of computer work;

• operators/installer technicians familiar with the P.C. MS-DOS environment.

Use of the manual The manual is divided into chapters describing the more common functions of the

numeric control and the Office Software installation procedure.

Notification of

difficulties

Please contact Esa/Gv if any difficulties should arise when this manual is used.

Explanation of the symbols

Graphic symbols may appear beside the text. These are used to emphasize information

of particular importance.

Attention

This symbol is used when failure to take the appropriate precautions could cause slight

damage to persons and property.

Danger

This symbol appears when failure to take the appropriate precautions or

accomplishment of incorrect manoeuvres could cause serious damage to persons

and/or property.

Important

This symbol appears in the manual to indicate information of particular importance. It

is essential to read these sections in order to fully understand the manual.

Option

This symbol indicates sections of the manual that describe optional functions or parts.

Use of optional performances must be established with the machine manufacturer.

Notes for the reader GB

Esa/Gv ii

Manufacturer

This symbol indicates those sections of the manual reserved to the machine

manufacturer.

Password

This symbol indicates sections of the manual that describe functions access to which is

safeguarded by software passwords.

CN

This symbol indicates sections of the manual that describe functions only available in

CN and not in the PC.

PC

This symbol indicates sections of the manual that describe functions only available in

the PC and not in CN.

Printer’s conventions

Particular printer’s conventions are used to make it easier to identify the information in

this manual. These conventions are illustrated below.

Keyboard and video The following conventions are used.

• The names of the screen-printed keys are indicated in boldface and are enclosed

within square brackets. If the name of the key is preceded by “button”, reference is

being made to a key on the push button panel.

− [ENTER]. Identifies the key that bears the word ENTER.

− [+] indicates the + key of the keyboard, while button [+] indicates the + key of

the push button panel.

• The names of the function keys are indicated in boldface italics and are enclosed

within square brackets.

− [Plc Menu]. Identifies the function key that bears the words Plc Menu.

• References to fields and/or messages on the video are written in boldface italics.

• The specific text to be digitized by the user is underlined.

− If the manual indicates “digitize ok, the user must digitize exactly “ok”.

• DIRECTION or DIRECTIONAL keys is the collective name used to indicate the

UP, DOWN, LEFT and RIGHT keys.

• Pressure, in sequence, on a series of keys is written by separating the identifiers of

the required keys with the “>“ character.

− [Manual] > [START]. Describes pressure, in sequence, on the [Manual] and

[START] keys.


Esa/Gv iii

• Pressure on several keys at the same time is indicated by separating the identifiers

of the keys themselves with the “+” character.

− [SHIFT] + [��] Describes contemporaneous pressure on the [SHIFT] and [��]

keys.

Text The following conventions are used.

• Italics are used to identify specialistic terms.

• Boldface is used to emphasize words of particular importance.

Glossary

CNC Initials that abbreviate Computerized Numerical Control and that indicate the instrument

that controls the machine, i.e. the electronic device through which the machining cycles

are programmed, the axes moved, etc....

Corresponds to one of the instruments whose operation is described in this manual.

SSD The Solid State Disk, also known as Flash Hard Disk, is a data-memorizing device

without moving parts, thus particularly suitable for an industrial environment.

Selection with the key On the front of some numeric controls is available a key switch to select the required

menu:

• Program and tool set-up menu (Key 0).

• Axes parameter menu (Key 1).

• Machine configuration menu (Key 2).

• Diagnostics menu (Key 3).

Menu selection

without the key

The previously described key switch is not available on the front of some numeric

controls (e.g. Kvara2000, Kvara2002, Kvara2003 and Kvara2004). To select the

required menu, press , then select the menu using the indicated number

(equivalent to the position of the key):

• Program and tool set-up menu (0).

• Axes parameter menu (1).

• Machine configuration menu (2).

• Diagnostics menu (3).


Esa/Gv iv

Menu.

Previous.

Next.

Save.

Cancel.

Arrows to move in the data entry fields.


Esa/Gv v

List of programs

Fixturing

Corrections

Save / Load from disk

Entries

Manual

Semiautomatic


Esa/Gv vi

Automatic

Stop

Start

Manual movement keys.

END OF PREFACE


Esa/Gv vii

GB Brief Guide part 1

Esa/Gv 1.1

1 Brief Guide part 1

1.1 Operations to carry out on powering

It is obligatory to size the ram in order to access the automatic phase and carry out a

machining program.

Sizing of the locator axes is a facultative operation. It is advisable when there are

doubts as to the correctness of the current locator axes targets. The current targets could

be incorrect if an axis was moved in the manual mode when the numeric control was off.

1.1.1 Ram sizing

Comply with the following procedure to size the ram:

• press ;

• if the ram is up, depress the down pedal to lower it below the zero marks;

• press the up pedal. If resetting has already been carried out, this operation will

achieve manual re-ascent.

The ram moves up until it finds both the zero marks of the optic lines of the two

cylinders where sizing takes place. It will now be possible to carry out a program in the

automatic mode.

To repeat the resetting procedure without switching off the NC:

• press [Repeat Sizing];

• press the re-ascent pedal.

1.1.2 How to size the locator axes

Comply with the following procedure to size the locator axes:

• press ;

• press .

The locator axes move towards the sizing limit switch. Once they have touched this

latter, their direction is reversed and, after having released the limit switch, they size on

the encoder’s first zero mark.

Brief Guide part 1 GB

Esa/Gv 1.2

1.2 List of Punches and Dies

Comply with the following procedure to access the tools list:

• press to display the list of punches or the list of dies;

• if the list of dies appears, press again to display the punches, and vice

versa;

• the following window will appear in the case of punches:

Figure 1.1 – List of punches

The window on the left is the list window.

The central boxes contain the data or preview of the punch on which the cursor is

positioned (in the list). The selection is made by means of the second function key.


Esa/Gv 1.3

the following window will appear in the case of the dies list:

Figura 1.2 – List of dies


The central boxes contain the data or preview of the die on which the cursor is

positioned (in the list). The selection is made by means of the second function key.

Just use the and keys to scroll through the tools available in the list.

− The function keys have the following meanings:

− [Insert] to insert the selected punch or die in the machining program or in the

selected bend.

− the meaning of the second function key changes depending on the type of

display activated: the meaning will be [Preview] if the tool preview must be

displayed or [Data] if the tool data must be displayed.

How to draw a punch

or die

Allows the user to completely draw a punch or die. Comply with the procedure

described below:

• press to access the menu;


Esa/Gv 1.4

− select the New Punch Drawing or New Die Drawing depending on the list in

question;

− the tool drawing mask will appear.

How to create a

punch or die of the

preset type

Used for creating tools of the preset type. Comply with the following procedure:


select the New Type 1 or New Type 2 or New Type 3 or New Type 4 item, depending on

the type of punch that must be created. Otherwise, press New Predefined if you wish to

create a die of the predefined type;

− use the mask that appears to enter the tool data.

How to display the

preview/data

Displays the preview/data of the tool (to make it easier to identify). It is normally

enabled but can also be disabled. Comply with the following procedure:


• select the Preview item;

• the tool preview or data window will be disabled (depending on the status of the

second function key);

• just repeat the operation to re-enable the function.

Copy of a punch or

die

Used to create a copy of a tool with another name, so that it can be modified. Go to the

tool to copy and comply with the following procedure:


• select the Copy item;

• enter the tool name in the window that appears.

• after having entered the name, go to the [Confirm] button and press [ENTER].

How to rename a

punch or die

Used for changing the name of a tool. Go to the tool to be renamed and comply with the

following procedure:



Esa/Gv 1.5

• select the Rename item;

• enter the new tool name in the window that appears;


How to save a punch

or die

Used for saving a tool on a USB key so that it can then be transferred to another numeric

control or to the kvara PC (also useful for creating backup copies). Go to the tool that

must be saved and comply with the following procedure:

• press ;

• the selected tool will be saved on the USB key.

How to cancel a

punch or die

Used for eliminating a tool. Go to the tool to be eliminated and comply with the


• press ;

• press [ENTER].

• the selected tool will be cancelled.

How to save all the

tools on USB key

Used for saving all the tools on a USB key so that they can then be transferred to

another numeric control or to the kvara PC (also useful for creating backup copies).

Comply with the following procedure:

• insert a USB key with sufficient space for the tools;


• select the Save Tools item;

• all the tools (punches and dies) will be saved on the USB key.

How to cancel all the

tools

Used for cancelling all the tools. Comply with the following procedure:


• select the Cancel Tools item;


Esa/Gv 1.6

• all the tools will be cancelled (confirmation is requested before each tool is

cancelled).

Tools list on USB key Displays the list of tools on theUSB key. The same operations as those of the tools list

can be carried out. Thus, all the tools on the USB key can be copies, renamed and

cancelled. Select the list of punches or dies and comply with the following procedure:

• insert a USB key containing the tools (created by kvara);

• press ;

• the list of punches or dies in the USB key will be displayed;

• carry out the operation required.

How to save all the

tools from USB key to

the NC

Used for saving the tools from the USB key to the NC so that they can be loaded from

another numeric control or from the kvara PC. Comply with the following procedure:

• insert a USB key containing the tools (created by kvara);

• press ;

• the list of punches or dies on the USB key will be displayed;


• select the Save Tools item;

• all the tools (dies and punches) will be saved from the USB key to the NC.


Esa/Gv 1.7

1.3 How to draw a new punch

Comply with the following instructions to draw a new punch:

• press to display the list of dies or punches;

• press again if the list of dies appears;

• select the required type of punch. The punch can either be drawn completely or the

four types of preset punch with fixed measurements can be used. By varying these

measurements, the punch is rescaled and re-drawn.

The following types of preset punch are available:

Type 1 Type 2 Type 3 Type 4

Figure 1.3 – Types of preset punch

It is advisable to use preset punches if the punch required is similar to one of the

proposed types (which have been taken from the catalogue) since it will be less difficult

to draw.

The punch must be drawn completely if it is not within the categories of preset punches.

Note Remember that punch drawing serves for anticollision controls in relation to graphically

drawn workpieces while the bending depth calculation is developed according to the

dimensional data of the punch. If it is too difficult to completely draw a punch, the

problem can be obviated by using a type of preset punch and attempting to adapt it to the

real shape as far as possible by means of the predefined data.


Esa/Gv 1.8


• select:

− New Punch Drawing to completely draw the punch;

− New Type 1 to use a preset punch type 1;

− New Type 2 to use a preset punch type 2;

− New Type 3 to use a preset punch type 3.

− New Type 4 to use a preset punch type 4 (round punch).

• A window with a request for entering the punch dimensions will appear;

Total

heightWorking

height

Figure 1.4 – Punch dimensions

• Enter the total height and useful height as shown in the drawing.

Access to the drawing

mask

Access the drawing mask once the punch dimensions have been entered and the type of

punch selected. The drawing mask changes, depending on the type of punch selected:

Go to the [Confirm] button and press [ENTER].


Esa/Gv 1.9

1.3.1 Punches to draw

The mask with the punches to draw is created by means of the drawing function (consult

the relative chapter in the operator manual).

Figure 1.5 – Punch drawing mask

The window on the left is the drawing window.

The two windows on the right are drawing data entry windows and change depending on

the line being drawn. They can represent:

• The polar drawing data;

• The vertex drawing data;

• The drawing data of an arc;

Drawing conventions The punch must be drawn in the anti-clockwise direction, remembering that the locator

is on the right-hand side of the punch.


Esa/Gv 1.10

Drawing

direction

Figure 1.6 – Drawing direction of the punch

Vertex entry The tip must be defined before the punch drawing can be used.

The line highlighted when the drawing begins represents one of the two sides of the tip.

Proceed as described to define the tip:

− enter length l (line l);

− press [ENTER];

− enter the tip angle (ang. angle);

− press [ENTER];

− enter the chamfer (S data item);

− press [ENTER];

− enter the tip radius (R data item);

− press [ENTER];

− enter the punch load (maximum tons per meter);

− press [ENTER].

The tip is drawn and the next line, with the same length as the one used for line 1, is

automatically entered.

How to do the

drawing

Supposing that the following punch must be drawn:


Esa/Gv 1.11

lp

ap

l1

l2

l3

p1

Figure 1.7 – Example of a punch to be drawn

The cursor will be in field 1 of the drawing tip data entry window:

• enter the tip data as described previously;

• enter the length of the second side of the tip (line 11);

• press [ENTER]: the cursor will move to the alpha field where the angle in relation

to the next line is entered;

• press ;

• press [ENTER]: the next line is drawn in the automatic mode. The line to which the

data refer is highlighted and the cursor moves to line length entry field 1;

• press [Arc];

• enter the length of line l2 in field 1;

• enter the depth corresponding to line p1 in field h;

• press [ENTER];

• enter the length corresponding to line l3 in field 1;

• press [ENTER]: the cursor will move to the alpha field where the angle in relation

to the next section is entered;

• enter value 90.0 in the alpha field;


Esa/Gv 1.12

• press [ENTER]: the next line is drawn in the automatic mode. the line to which the

data refer is highlighted and the cursor moves to line length entry field 1.

Continue to alternately enter lengths and angles to form the punch drawing. The more

the measurements and angles entered are similar to the real ones, the more the drawing

will be correct.

Graphic utilities When entering lines whose measurement may cause problems, the operator can use a

graphic utility that allows the value of the angle to be varied by symbol ±1° and the

length measurement by symbol ± 1mm at a time, so that the drawing corresponds to the

real punch.

The value of the angle is increased by 1° by pressing on the right-hand arrow and

decreased by one degree by pressing on the left-hand arrow, while the length value is

increased by pressing on the up arrow and decreased by pressing on the down arrow.

Drawing curved lines As seen in the example, the drawing function also allows curved lines to be drawn. Press

the [Arc] key to move the cursor to the arc data entry window.

The curved line corresponding to the data entered will be automatically plotted when

length 1 and depth h of the arc are entered.

How to correct the

entered data

Incorrect entries can be corrected when the drawing is being done.

It is possible to correct these entries and move amongst the various lines drawn by

means of the and keys, and by modifying the value of the

fields;

• use the key to switch to the previous entry field and thus switch

alternately between a line entry field (1) and an angle entry field (alpha);

• use the key to switch to the next line and thus always switch to the

line entry field (l);

• use [ENTER] to switch to the next entry field and to thus switch alternately

between a line entry field (1) and an angle entry field (alpha).

Error recovery A very frequent error (especially if the arrows are used to enter the angles) is to forget to

press [ENTER] after having entered an angle. This means that the length of the section

is entered in the angle entry field, thus creating an error in the drawing.


Esa/Gv 1.13

Use the key to go back to the angle entry field and enter the correct data

item.

How to save the

drawing

When the drawing has been terminated, press to memorize it. Enter the

name of the punch in the window that appears.

After the name has been entered, go to the [Confirm] button and press [ENTER].

Tolerated name

characters

The name entered can be formed by a combination of numbers and letters (e.g. the code

of the punch in the catalogue can be used).


Esa/Gv 1.14

1.3.2 Preset punches

The preset punches mask presents the shape of a pre-drawn punch and a series of data

that characterize the shape of that punch;

Figure 1.8 – Preset punch

Scroll through the data with the arrows or the [ENTER] key. An indication as to which

measurement corresponds to the selected data item will appear on the drawing.

Modify any of the values and press [ENTER] to re-plot the drawing and include the

modified data item.

How to save the

drawing

Once the drawing has been terminated, press to memorize it. Enter the

name of the punch in the window that appears.

After having entered the name, go to the [Confirm] button and press [ENTER].

Tolerated name

characters


of the punch in the catalogue can be used).


Esa/Gv 1.15

1.4 How to draw a new die

Comply with the following procedure to draw a new die:

• press . The list of punches or the list of dies will appear;

• press again if the list of punches appears;

• select the required type of die. The die can either be drawn completely or the preset

die with fixed measurements can be used. By varying these measurements, the die is

rescaled and re-drawn:

Figure 1.9 – Types of preset die available

It is advisable to use preset dies if the die required is similar to one of the proposed

types (both square and overturned T shaped dies can be drawn) as it will be less difficult

to draw.

The die must be completely drawn if it is not within one of the categories of preset dies,

if a die with several slots must be drawn, if square slots or pressing slots must be used.

Note Remember that die drawing serves for anticollision controls in relation to graphically

drawn workpieces while the bending depth calculation is developed according to the

dimensional data of the die. If it is too difficult to completely draw a die, the problem

can be obviated by using a type of preset die and attempting to adapt it to the real shape

as far as possible by means of the predefined data.


Esa/Gv 1.16


• select:

− New die drawing if the die is to be completely drawn;

− New Predefined die if the preset die data are to be used.

• A window appears asking for the die dimensions to be entered.

Die width

Die

height

Figure 1.10 – Die dimensions

Enter the die height and width as indicated in Figure 1.10.

Access to the drawing

mask

Access the drawing mask once the die dimensions have been entered and the type of die

selected. The drawing mask changes depending on the type of die selected:

Go to the [Confirm] button and press [ENTER].


Esa/Gv 1.17

1.4.1 Die to be drawn

The mask with the dies to be drawn is created by means of the drawing function (consult

the relative chapter in the operator manual).

Figure 1.11 – Die drawing mask


The two right-hand windows are used to enter the drawing data and change depending

on the line being drawn. They can represent:

1) The polar drawing data

2) The v slot drawing data

3) The square slot drawing data.

Drawing conventions The die is drawn in the clockwise direction, remembering that the locator is on the right-

hand side of the die.


Esa/Gv 1.18

Drawing direction

Figure 1.12 – Die drawing direction

The line highlighted represents the line proposed initially in the drawing mask.

How to do the

drawing

Supposing that the following die must be drawn:

aC1

aC2

a1

a2

l1 lC1 l2

l3

lC2

l4

Figure 1.13 – Example of a die to be drawn

The cursor is in field 1 of the polar entry window of the drawing data:

• enter the length corresponding to line 11 in field 1;

• press [ENTER]: the cursor will go to field α where the angle in relation to the next

line is entered. Now define the first die slot.


Esa/Gv 1.19

Slot entry Comply with the following procedure:

• press [Insert Slot]. The data entry window automatically switches to the slot data,

where the user must:

− enter the slot angle (angle aC1);

− press [ENTER];

− enter slot width 1 (line lC1);

− press [ENTER];

− enter slot radius R;

− press [ENTER];

− enter the slot load (maximum tons per meter);

− press [ENTER]. The slot is drawn and the next line automatically entered. The

cursor returns to the polar data entry window;

− enter the length corresponding to line l2 in field 1;

− press [ENTER];

− enter the value of angle a1;

− press [ENTER]. The next line will be automatically drawn. The line to which

the data refer is highlighted and the cursor moves to line length entry field 1;


− press [ENTER]. The cursor moves to field α where the angle in relation to the

next line is entered.

Now define the second die slot:

• press [Insert Slot]. The data entry window automatically switches to the slot data,

where the operator must:

− enter the slot angle (angle aC2);

− press [ENTER];

− enter slot width 1 (line lC2);

− press [ENTER];

− enter slot radius R;

− press [ENTER];

− enter the slot load (maximum tons per meter);

− press [ENTER]. The slot is drawn and the next line automatically entered. The

cursor returns to the polar data entry window;


− press [ENTER];

− enter the value of angle a2;

− press [ENTER].


Esa/Gv 1.20

Continue to alternately enter lengths and angles to form the die drawing. The more the

measurements and angles entered are similar to the real ones, the more the drawing will

be correct.

How to correct the

entered data

Incorrect entries can be corrected when the drawing is being done.

It is possible to correct these entries and move amongst the various lines drawn by

means of the and keys, and by modifying the values of the

fields.

• use the key to switch to the previous entry field and thus switch

alternately to a line entry field 1) and an angle entry field (alpha);

• use the key to switch to the next field and thus always switch to a line

entry field (l);

• use the [ENTER] key to switch to the next entry field and thus switch alternately to

a line entry field (l) and an angle entry field (alpha).

Error recovery A very frequent error (especially if the arrows are used to enter the angles) is to forget to

press [ENTER] after having entered an angle. This means that the length of the section

is entered in the angle entry field, thus creating an error in the drawing.

Use the key to go back to the angle entry field α and enter the correct data

item.

How to enter square

slots

Square slots can be entered with the die drawing mask. To enter one of these slots,

comply with the instructions described below when field where the angle of the line

prior to the slot is entered:

• press [Square slot].

• The square slot data must be entered in the window that appears;

• enter slot depth h;

• press [ENTER];

• enter slot width 1;


Esa/Gv 1.21

• press [ENTER];

• enter slot radius R;

• press [ENTER];

• enter the slot load (maximum tons per meter);

• press [ENTER]. A square slot with the newly entered data will be drawn. The

cursor returns to the polar data entry window in order to draw the next die line.

Conventions

concerning square

slots

If a square slot is drawn, the minimum bending angle that can be obtained is the angle

corresponding to a v slot with the set width and depth values.

Flattening slot

settings

Flattening slots can be entered in the die drawing mask. To define one, the user must

indicate which are the lines that determine die closing and must then draw a flattening

line on both side of the die:

• draw the open die profile with the recess of the flattening part;

• move the cursor to the line to be defined as the flattening one (vertical line);

• press [Flatten];

• the line defined as the flattening one will be dotted;

• the following figure gives an example of a bending-flattening die.

Figure 1.14 – Drawing of the flattening die


Esa/Gv 1.22

Pneumatic flattening

slot settings

Flattening slots can be entered using the die drawing mask. To define one, the user must

indicate two 0.001 mm flattening lines on both sides of the die.

• draw the open die profile, with the recess of the flattening part, but enter 0.001mm

for this section (just as though the die were closed);

• move the cursor to the line to be defined as the flattening one (small vertical line);

• press [Flatten];

• the line defined as the flattening one will be dotted (even though it will be difficult

to see);

• one the die drawing has been terminated, press [Die Dimensions] and digitize 1 in

the Pneumatic field;

• go to the [Confirm] button and press [ENTER];

• from this moment onwards, function 2 will be automatically enabled for the

flattened bends.

• During the flattening bend with the pneumatic die, this latter opens and then, by

moving down in the fast mode with the ram, the tools could touch each other in the

fast mode (something to be avoided). If the user wishes the ram to change its speed

(to the slow mode) beforehand (at a higher target) during the flattening bend phase,

he must enter the flattening opening target in the general parameters (refer to the

machine parameters manual)).

How to save the

drawing

Once the drawing has been terminated, press to memorize it. Enter the die

name in the window that appears.

After the name has been entered, go to the [Confirm] button and press [ENTER].

Tolerated name

characters


of the die in the catalogue can be used).


Esa/Gv 1.23

1.4.2 Preset dies

The preset dies mask presents the shape of a pre-drawn die and a series of data that

characterize the shape of that die.

Figure 1.15 – Preset die

Scroll through the data with the arrows or the [ENTER] key. An indication as to which

measurement corresponds to the selected data item will appear on the drawing.

Modify any of the values and press [ENTER] to re-plot the drawing and include the

modified data item.

How to save the

drawing

Once the drawing has been terminated, press to memorize it. Enter the

name of the die in the window that appears.


END OF CHAPTER


Esa/Gv 1.24


Esa/Gv 2.1


2.1 List of programs

Comply with the following procedure to access the programs list:

• press ;

• the following window will appear:

Figure 2.1 – Programs list


The central boxes contain the data or preview of the program on which the cursor has

positioned (in the list). The display is selected by means of the second function key.

Just use the and keys to scroll through the programs available in the list.

− The function keys have the following meanings:

− [New Numeric] to enter a new program in the numeric mode;


Esa/Gv 2.2

− use of the second function key changes depending on the display activated: the

meaning will be [Preview] if the user wishes to display the preview of the

program or [Data] if the data of the program are to be displayed.

How to display the

preview/data

Used to display the preview/data of the program (preview only if the program is

graphic). It is normally enabled but can be disabled if required. Comply with the


• press the key to access the menu;

• select the Preview item;

• the preview or program data window will be disabled (depending on the status of

the second function key);

• just repeat the operation to enable it again.

How to copy a

program

Creates a copy of a program with another name so that it can be modified. Go to the

program you wish to copy and comply with the following procedure:


• select the Copy item;

• the name of the program must be entered in the window that appears.

• After the name has been entered, go to the [Confirm] button and press [ENTER].

How to rename a

program

Changes the name of a program. Go to the program to be renamed and comply with the



• select the Rename item;

• enter the name of the program in the window that appears;

• after the name has been entered, go to the [Confirm] button and press [ENTER].

How to save a

program

Saves a program on a USB Key so that it can be transferred to another numeric control

or to the kvara PC (useful if backup copies need to be created). Go to the program to be

saved and comply with the following procedure:


Esa/Gv 2.3

• press the key;

• the selected program will be saved on the USB Key.

How to cancel a

program

Used to eliminate a program. Go to the tool to be eliminated and comply with the


• press the key;

• press [ENTER];

• the selected program will be cancelled.

How to save all the

programs on a USB

Key

Used to save the programs on a USB Key so that they can be transferred to another

numeric control or to the kvara PC (useful if backup copies need to be created). Comply

with the following procedure:

• insert a USB Key with sufficient space for the programs;


• select the Save Programs item;

• all the programs will be saved on the USB Key.

How to cancel all the

programs

Used to cancel all the programs. Comply with the following procedure:


• select the Cancel Programs item;

• all the programs will be cancelled (confirmation will be requested for each program

before it is cancelled).

List of programs on

USB Key

Used to display the list of programs on the USB Key. The same operations as those of

the tool list can be carried out, thus it is possible to copy, rename and cancel all the tools

on the USB Key. Select the programs list and comply with the following procedure:

• insert the USB Key with the programs (created by kvara);


Esa/Gv 2.4

• press the key;

• the list of programs in the USB Key will be displayed;

• carry out the required operation.

Saving a program

from USB Key to NC

Used to save a program from the USB Key into the NC so that it can be loaded from

another numeric control or from the kvara PC. Go to the program you wish to save and

comply with the following procedure:

• press the key;

• the selected program will be saved from the USB Key to the NC.

Saving all the

programs from USB

Key to NC

Used to save the programs from the USB Key to the NC so that they can be loaded from

another numeric control of from the kvara PC. Comply with the following procedure:

• insert the USB Key with the programs (created by kvara);

• press the key;

• the list of programs on the USB Key will be displayed;


• select the Save programs item;

• all the programs will be saved from the USB Key to the NC.

2.1.1 Program update

If a tool that has already be used in a program is modified, the program will have to be

updated as the targets calculated will no longer coincide.

How to update a

program

To update a program, first load it from the list and then comply with the following

procedure:


Esa/Gv 2.5

• access the set-ups mask and press the key to access the menu;

• select the Update Prog. item. All the program data will be re-calculated. Save if

necessary.


Esa/Gv 2.6

2.2 Numeric program set-up

Proceed as follows to set-up a new program:

press ;

press [New numeric] ;

General data set-up The first program data set-up window will appear:

Figure 2.2 – General data set-up mask


Esa/Gv 2.7

• Enter the width of the sheet of metal plate to bend;

• enter the thickness of the sheet of metal plate to bend;

• enter the strength of the material to bend, bearing the following convention in

mind:

− aluminium: 0 - 30;

− sheet metal: 31 - 50 (ideal value 42);

− stainless steel: over 50;

• the material is calculated automatically, depending on its strength;

• enter the die used to make the bend (the die must have already been designed);

• enter the slot in the die that will be used for bending (a die can have several slots.

Enter 1 if it only has one);

• enter the punch that will be used for the bend (the punch must have already been

designed);

• enter the die direction;

• enter the punch direction;

Bend set-up Now press PgDn to access the mask where the bending data are entered:

Figure 2.3 – Bending data set-up mask


Esa/Gv 2.8

Enter the following information for each bend:

− The required bending angle in the Y1 angle Y1 field;

− The required bend length in the X1 ends field.

All the other bend data are calculated automatically, but can be modified by the user.

Machining data entry Now press the PgDn key to access the mask where the machining data of the bend are

entered:

Figure 2.4 – Machining data entry mask


Esa/Gv 2.9

Workpiece data entry Comply with the following procedure to enter the workpiece data of the program:

• press the [Workpiece Data] key from the bending data set-up mask or machining

data set-up mask;

• a window with the workpiece data will appear.

Figure 2.5 – Workpiece data set-up mask

Machining data Used to display the data concerning the absolute T.D.C, S.C.P and P.C.P of that bend.

Go to the required bend and comply with the following procedure:


• select the Machining Data item;

• a window with the machining data will appear;

• to quit, just go to the [Confirm] button and press [ENTER].

How to copy a bend To copy a bend, go to the required one and comply with the following procedure:


Esa/Gv 2.10

• press the to access the menu;

• select the Copy Step item. The bend will be copied at the end of the section.

Bend insertion To insert a bend in a section, go to the bend after the one you wish to insert and comply

with the following procedure:


• select the Insert Step item. The bend will be inserted in front of the one on which

you were positioned.

Insertion of a copied

bend

To insert an identical bend to one of the ones already in the section, go to the bend after

the one you wish to insert and comply with the following procedure:


• select the Insert Step item. The bend will be inserted in front of the one on which

you were positioned;

• using the or keys, go to the bend you wish to copy;


• select the Copy Step item. The bend will be copied on to the one just inserted.

Rolling definition A utility for rolling can be activated in the numeric program’s data entry window:


• select the Rolling item. A window for entering the rolling data will appear;

• enter the required rolling angle in the Angle field;

• enter the rolling radius in the Radius field;

• enter the length of the rolling step in the Length field;


Esa/Gv 2.11

• enter the initial position of the locator in the X Target field;

• press [Confirm]. The calculated rolling steps will be automatically entered in thee

bending mask.

Rolling correction When rolling is carried out, it is unlikely to obtain a correct bend at the first attempt.

This inaccuracy depends on the fact that the angles to bend to achieve the rolling

operation are very open (e.g. 170°C) and it is difficult to obtain precise bends with these

angles.

To achieve a correct rolling operation, measure the difference between the obtained

rolling angle and the required one. The difference calculated must be homogeneously

divided amongst all the bends.

Example Supposing that a rolling operation with a 90° angle must be carried out and that 15

bends at 170° must be made. If the obtained result is 112.5°, it will be necessary to

proceed in the following way:

112.5 - 90 = 22.5° (difference between the real and theoretic angle)

22.5 / 15 = 1.5° (correction to make for each bend)

A 1.5° correction must be applied in the rolling step, which is repeated 15 times.

Bending and

flattening definition

A bending and flattening operation can be defined in the bend set-up window:

enter 0.0 in the Y1 Angle field. The ram’s arrival value will be calculated according to

the depth of the slot, the height of the slot for flattening and the thickness of the

workpiece. The position of X axis will be at the minimum target the axis can reach. R

axis is positioned by taking into account that the die is open.

Bending and

flattening correction

If a bending and flattening operation must be corrected, the value of the angle cannot be

modified. It will be necessary to change the numeric value in the B.D.C. field of Y1.

If the bend is pressed too much, this value must be increased.

The Y2 Target will be modified as a consequence.

Or it will be necessary to proceed in the following way:

• access the Corrections mask by pressing the key

• press the [Corrections Coeff.] key

• The target entered is added to or subtracted from the B.D.C. of both the Y values

and is a data item bound to the machine and not to the program. Press the [Lose

Correc.] key to annul the corrections.

How to carry out a

striking or coining

operation

Enter a normal bend with the same angle as the tools, but change the force and making

any corrections to the bend as may be required, straight in the set-up mask.

Coining correction Change the bottom dead center point of Y1 and Y2 to correct a coining operation.

If coining is too light, the bottom dead center point must be decreased.

If coining is too deep, the bottom dead center point must be increased.


Esa/Gv 2.12

Or proceed in the following way;

• access the Corrections mask by pressing the key

• press the [Correction Coeff.] key

• The target entered is added to or subtracted from the B.D.C. of both the Y values

and is a data item bound to the machine and not to the program. Press the [Lose

Correc.] key to annul the corrections.

Definition of a conical

bend

This function allows the “Conical” process to be carried out once special locators have

been assembled and X2 axis configured for conical operation. “Conical bending” is

carried out by an X2 axis installed on the bar of the X1 axis ( incremental type) or two

completely independent axes, X1 and X2 (absolute type) which, to allow the axes to be

staggered, moves after X1 has been positioned. Besides this special X2 axis, the locators

also have a special profile, which allows the metal plate to be blocked (see figure). The

data for making a conical bend can only be entered from the Setup masks and to enter

the conical bend, the X2 axis must be enabled for operation in the conical mode (either

incremental or absolute). In this case, once the typical data of a normal bend have been

entered, the final target of X2 axis will be calculated in the “incremental” or “absolute”

mode in relation to the final target of X1 axis. A utility can be activated in the data entry

window of the numeric program in order to make a conical bend:


Esa/Gv 2.13

Jig Locator

X1,Z1,R

Jig Locator

X2,Z2,R

Metal Plate

Figure 2.6 – Example of a conical bend


Esa/Gv 2.14

• enter the initial position of the locator in field X1;

• press to display the secondary menu;

• press [Conical] to access a window where the required conical angle can be

entered;

• enter the required conical angle in the Angle field (between -45 and 45);

• go to the [Confirm] button and press [ENTER]. Targets X1, X2 will be

automatically updated in the setups mask;

• in the case of positive phased angles, the final target calculated is X2, or X1 for

negative phased angles.

Once a conical bend has been created and the user wishes to change the phase angle or

metal plate width, before accessing the angle entry field with the [Conical] function key,

the bend must be cancelled and a new one set up. If this operation is not carried out, the

targets generated by the angle entered in the window will be without sense. If

modifications have been made to the data of a bend (e.g. metal plate width or thickness,

etc.), the targets are not calculated again: X2, X2 Corrections and X2 Recoil. In a

conical bend, the support function does not re-calculate the correction on the X2

Correction and X2 Recoil targets, thus the rest/support must be entered first and then the

conical bend data.

Definition of a conical

rolling operation

To enter a conical rolling operation, go to the first rolling bend and proceed with the

conical phase. The targets vary on the first bend as described previously. Nothing is

calculated if rolling is applied to a bend with a negative X1.

How to make off-slot

bends

In off-slot bends, the end of bend point is in the upper position in relation to the upper

die plane. The end of bend target is numerically higher than the theoretic plate crimping

target in the general data of the program.

The numeric control checks to make sure that the bending cycle targets are valid and

requires the following targets to be in decreasing numeric order:

• Top dead center.

• Speed change target (from version 13.2 onwards, the TDC cannot be lower than the

SCP).

• Target 180 (crimping target).

• End of bend target (bottom dead center).

The program cannot be executed in the automatic mode unless this order is complied

with.


Esa/Gv 2.15

For off-slot bends, the user must:

• Directly enter the end of bend value in the Y1 B.D.C. and Y2 B.D.C. fields of the

numeric program (the Y1 Angle and Y2 Angle fields will be set to zero).

• Enter a value in the P.C.P. field of the program’s machining data which, when

added to the Theoretic 180 target, gives a higher value than the set B.D.C. values.

• Enter a value in the S.C.P. field of the program’s machining data which, when

added to the Theoretic speed change target, gives a higher value than the theoretic

180 target + P.C.P.

• Make sure that the Top dead center (T.D.C) in the program steps is higher than the

Theoretic speed change target + S.C.P.

Example Supposing that a program has been setup in which:

Speed change target = 132.00;

180 target = 127.00;

Bending target (a = 135°) = 124.72;

After having checked to make sure that the required end of bend value is 142.35, this

value must be entered in the Y1 B.D.C. and Y2 B.D.C. fields.

To execute this program, the user must:

enter 20.00 in the P.C.P. field:

127.00 + 20.00 = 147.00 > 142.35;

enter 20.00 in the S.C.P. field:

132.00 + 20.00 = 152.00 > 147.00.

Make sure that the top dead center is higher than 152.00.

How to save the

program

Once the entries have all been made, press to access a window where the

program name must be entered.


Save as A program can be saved with a different name from the initial one. This may be useful if

the user does not wish to lose the modifications made to a program but does not wish to

change the program loaded (thus different programs can be obtained with different

corrections). Comply with the following procedure:


• select the Save as item;

• enter the name of the new program in the window that appears;



Esa/Gv 2.16

2.3 Graphic program entry (Options feature)

Proceed in the following way to enter a new graphic program:

press ;

press [New graphic];

General data entry A window is opened where the general data of the program can be entered:

Access to the drawing function will not be allowed unless these data are entered.

• Enter the width of the metal plate to bend;

• enter the thickness of the metal plate to bend;

• enter the strength of the material to bend, bearing the following convention in

mind:

− aluminium: 0 - 30;

− metal plate: 31 - 50 (ideal value 42);

− stainless steel: over 50;

• the material is automatically calculated depending on the strength;

• enter the work station if several stations are defined;

• enter the die to be used for the bend (the die must already have been drawn);

• enter the Die direction (0 = standard, 1 = turned through 180°);

• enter the die cavity to be used for the bend (a die can have several cavities. Enter 1

if it only has one);

• enter the punch to be used for the bend (the punch must have already been drawn);

• enter the Punch direction (0 = standard, 1 = turned through 180°);

• enter a Comment if required.

• move to the [Confirm] button and press [ENTER].

Drawing window The drawing window of the workpiece will be opened and the workpiece produced by

means of the drawing function.


Esa/Gv 2.17

Figure 2.7 - Workpiece drawing mask.


The four windows on the right and drawing data entry windows and respectively

represent:

1) The polar drawing data

2) The Cartesian drawing data

3) The roller-levelling drawing data

4) The pressed bend drawing data


Esa/Gv 2.18

How to draw a

workpiece

Supposing that the workpiece shown in the figure must be drawn:

20.0 30.070.0

40.0

45.0

120°

-120° -90°

90.0°

Figure 2.8 - Example of drawn workpiece

The cursor will be in field 1 of the polar drawing data entry window:

• enter the length corresponding to the first section of the workpiece (20.0) in field 1;

• press [ENTER];

• enter the value of the first angle (120.0°) in field α (value of the angle in relation to

the next section);

• press [ENTER]. The next section will be drawn in automatic mode. The section to

which the data refer will be marked;

• enter the length corresponding to the second section of the workpiece (45.0) in field

1 (length of the section);

• press [ENTER];

• enter the value of the second angle (-120.0°) in field α (value of the angle in

relation to the next section);



• enter the length corresponding to the third section of the workpiece (70.0) in field 1

(length of the section);

• press [ENTER];

• enter the value of the third angle (-90.0°) in field α (value of the angle in relation to

the next section);



• enter the length corresponding to the fourth section of the workpiece (20.0) in field

1 (length of the section);

• press [ENTER];


Esa/Gv 2.19

• enter the value of the fourth angle (90.0°) in field α (value of the angle in relation to

the next section);



• enter the length corresponding to the fifth section of the workpiece (30.0) in field 1

(section length);

• press [ENTER]. The drawing has been completed.

How to carry out a

roller levelling

operation

When carrying out a roller levelling operation, remember that by convention, there must

be a section of metal plate before and after the roller-levelling step itself.


r = 60

20

30

Figure 2.9 - Example of a drawn roller levelling step

The cursor will be in polar drawing data entry field 1:

• enter the length corresponding to the first section of the workpiece (20.0) in field 1;

• press [ENTER];

• press [Roller levelling]. The roller levelling data window will appear;

• enter the desired roller levelling angle (90.0° ) in field αc;

• press [ENTER];

• enter the roller levelling radius (60.0) in field R;

• press [ENTER];

• enter the length of the required roller levelling step in field P;



• enter the length corresponding to the last section to draw (30.0) in field 1 (section

length);

• press [ENTER]. The drawing has been completed.


Esa/Gv 2.20

How to carry out a

bend-and-press step


L1=30

22

100

100

Figure 2.10 - Example of a drawn bend-and-press step

The cursor will be in field 1 of the polar drawing data entry window;

• enter the length of press-and-bend side L1 (30.0) in field 1;

• press [ENTER];

• press [Press-and-bend];

• enter the intermediate press-and-bend angle (e.g. 45.0°) in the alpha field;



• enter the length of the current section (100.0) in field 1;

• press [ENTER]. The cursor will move to the α field where the angle is entered in

relation to the next section;

• enter the angle value (-90.0° );

• press [ENTER]. The cursor will move to field 1 where the section length is entered;

• enter the length of the side (100.0) in field l;

• press [ENTER];

• press [Press-and-bend];

• enter the intermediate press-and-bend angle (e.g.: 45.0° ) in the alpha field;



• enter the length of the last section (22.0) in field 1. The drawing has been

completed.


Esa/Gv 2.21

Saving the drawing

At the end of the entry phase, press to access a window where the name of

the program must be entered.

After having entered the name, move to the [Confirm] button and press [ENTER].

2.4 Automatic calculation of the bending sequence (Options feature)

The automatic calculation procedure can be accessed from the workpiece drawing mask

by means of the following procedure:

• press [Calculate];

Calculation window The accessed window will present a simulation of the workpiece to bend including the

lower and upper parts of the bending press, the punch, the die, the stop and the

workpiece prior to bending.

There are three windows on the right-hand side of the mask. These respectively indicate

the number of rotations and overturnings to which the workpiece is subjected in the

found bending sequence plus search enabling of the bending sequence with all the

solutions.

The numeric control searches for the solution by attempting to always maintain the

larger part of the metal plate in the operator’s hand. By modifying the calculation

criteria, the sequence can be searched amongst all the possible solutions.


Esa/Gv 2.22

Figure 2.11 - Bending sequence calculation mask

The bending sequence can be calculated in two modes: automatic or manual.

Automatic search of

the bending sequence

The optimum bending sequence is established by the numeric control in automatic

search mode. Press [Optimize] to allow the numeric control to search for the solution on

its own.

Manual search of the

bending sequence

The bending sequence is established by forcing the bends in manual search mode.

The bending sequence can be completely or partially forced by the operator. If the

sequence is only partially entered, the remaining bends will be automatically calculated

by the numeric control.

The operator can move amongst the various bends by means of the and

keys.

To force the bends, press the [Bend] key on a level with the selected bend. If this key is

pressed on a level with an already forced bend, the bend will be straightened.


Esa/Gv 2.23

The operator can turn the workpiece by means of the [Turn] key.

ù press [Optimize] when the desired bends have been forced.

The numeric control searches for the solution by taking the sequence forced by the

operator into account.

Optimizing result If the workpiece is not feasible, the numeric control warns the operator by means of a

NO SOLUTION message.

In this case, the operator can attempt to calculate by means of the criterion that searches

for all the solutions.

If there is no possible solution, the operator can attempt to identify the bend that makes

it impossible to bend the workpiece. This is done by means of the manual bending

sequence search function. Any collisions of the workpiece with the various parts of the

machine are indicated by changing the colour at the side of the workpiece that actually

collides.

The operator must completely force the bending sequence to bend a workpiece even

when it is going to collide (when the collision will not damage the metal plate for

example).

If the workpiece is feasible, the numeric control informs the operator by a Solution

FOUND message. The operator can choose amongst the following functions in this

window:

• [Stop]: optimizing is interrupted so that modifications can be made;

• [Continue]: the numeric control searches for a different solution from the one just

found. If the operator continues to refuse the proposed solutions, the numeric

control will search until there are no other different ones. Once the solutions have

terminated, the search will end with a NO SOLUTION message;

• [Simulate]: the workpiece bend simulation will be displayed. The user can proceed

with the bending sequence by using the [Continue] key or can interrupt the

simulation with the [Stop] key;

• [Accept]: the values calculated in the found solution will be entered in the program.

Simulation The obtained bending sequence can be simulated in the optimizing window of the

graphic program, once the solution has been accepted:

• Press the [Simulate] function key to display the workpiece without bends, preset for

making the first bend.

• Press the [Bearing/Support] function key as many times as necessary to select the

first support or the second support (if available), or the bearing of the workpiece.

Clearly, the locator will only move to the support position if there are no collisions

and if permitted by the limit targets of the axes.

• Press the [Continue] function key to display the workpiece with the first bend

made.

• Press the [Continue] function key to display the workpiece with the first bend made

and in position for the second bend.

• Press the [Stop] function key to stop the simulation. Press the [Previous] function

key to return to the previous step in the simulation process.

• Press the [Continue] function key through to the end of the simulation (the

[Simulate] function key will appear again).


Esa/Gv 2.24

Bearing/Support The operator can choose whether to make a supported bend in the data entry window of

the graphic program:


making the first bend.






made.


and in position for the second bend.






key to return to the previous step in the simulation process.


[Simulate] function key will appear again).

• The function is displayed in the numeric program at the top, to the right of the bend

type (see meaning of the icons). The numeric control automatically calculates the

corrections required on the X and R axes. In the numeric mode, the

[Bearing/Support] function key does not work if the program is graphic. Access

the simulation mask to modify the bearing support.

2.5 Manual calculation of the bending sequence (Options feature)

The manual calculation procedure can be accessed from the workpiece drawing mask by

means of the following procedure:

press [Calculate].

Calculation window A window will appear with a simulation of the workpiece to be obtained from the

bending process, including the lower and upper parts of the bending press, the punch,

the die, the locator and the workpiece prior to the bend.

The three windows on the right-hand side of the mask respectively indicate the number

of times the workpiece is turned and overturned during the bending sequence found

(refer to the figure in the section describing Automatic Calculation of the bending

sequence).

Manual search for the

bending sequence

In the manual search mode, the bending sequence is established by the operator by

forcing the bends.


Esa/Gv 2.25

The operator can move amongst the various bends with the and

keys.

To force the bends, press [Bend] on a level with the selected bend. If this key is pressed

on a level with an already forced bend, this bend will be straightened.

The operator can turn the workpiece with the [Turn] key;

press [Optimize] when all the required bends have been forced.

The numeric control will search for the solution, taking into account the sequence forced

by the operator.

Result of the

optimizing process

If the workpiece is not feasible, the numeric control will warn the operator with the

Forced solution message.

If there is no forced solution, the operator can try to identify which bend prevents the

workpiece from being bent by means of the manual bending sequence search mode.

Collisions of the workpiece with the various parts of the machine are signalled by colour

changes at the side of the workpiece that would be liable to collide.

The operator must completely force the bending sequence to bend a workpiece even if it

would collide (e.g. when the collision would not damage the metal plate).

The numeric control informs the operator with the Solution Found message if the

workpiece is feasible. The operator can select the following functions in this window:

• [Stop]: the optimizing process is interrupted so as to allow modifications to be

made;

• [Accept]: the values calculated in the solution are added to the program.

Simulation The obtained bending sequence can be simulated in the optimizing window of the

graphic program, once the solution has been accepted:


making the first bend;




and if permitted by the limit targets of the axes;


made;


and in position for the second bend;


key to return to the previous step in the simulation process;


[Simulate] function key will appear again);


Esa/Gv 2.26

Bearing/Support The operator can choose whether to make a supported bend in the data entry window of

the graphic program:


making the first bend;






made;


and in position for the second bend;






key to return to the previous step in the simulation process;


[Simulate] function key will appear again);

• The function is displayed in the numeric program at the top, to the right of the bend

type (see meaning of the icons). The numeric control automatically calculates the

corrections required on the X and R axes. In the numeric mode, the

[Bearing/Support] function key does not work if the program is graphic. Access

the simulation mask to modify the bearing support.

Modification of the

bending sequence

Once the bending sequence has been optimized, the operator can still change it:

The operator can move amongst the various bends with keys and

.To remove the bends, press the [Bend] ion a level with the selected bend,

remove the other bend that needs to be switched, then press [Bend] to choose the new

sequence required for each bend removed.


Esa/Gv 2.27

2.6 How to bend a box

The numeric control does not allow a bent box to be directly developed on the flat.

To bend a box, the user must create a program with two bending sections in which the

bends of the horizontal section and the bends of the vertical section will be entered,

respectively.

The two programs will be executed one after the other, thus allowing the box to be

made.

Execution of a program with several sections always begins with the one where the

metal plate width is less.

How to add a section Comply with the following procedure to add a section:


• select the Change Section item.

How to cancel a

section

To cancel a section, go to the section required and comply with the following procedure:


• select the Cancel section item. The section will be cancelled and the program will

go back to bend 1 of section 1.


Esa/Gv 2.28

2.7 Program execution in the automatic mode

Once a numeric program has been entered, it can then be executed in the automatic

mode.

Press to access the automatic status.

Graphic automatic

mask

If the currently selected program is a calculated graphic program, the automatic graphic

mask can be displayed pushing the key than the key [Graphic]. This mask

consists of three windows:

the main window includes the drawing of the upper and lower parts of the machine, the

drawing of the punch and die entered in the program, the drawing of the workpiece

before and after bending and the drawing of the stop;

the second window contains an indication on how to position the workpiece for each

bend (overturning or rotation of the metal plate in relation to the previous bend);

the third window contains the data of the bend in progress and the workpiece counter.

Figure 2.12 - Graphic automatic mask


Esa/Gv 2.29

Numeric automatic

mask

The current targets of the axes are added to the numeric entry data. The data of the

program cannot be modified in the automatic status.

Figure 2.13 – Numeric automatic mask


Esa/Gv 2.30

A mask with larger characters can be displayed so that the axes targets can be seen more

clearly. This mask is activated by pressing . Press to go back to the

mask with the smaller characters.

Figure 2.14 – Enlarged numeric automatic mask

Automatic cycle

execution Press the button to begin automatic cycle execution. This operation allows the

locator axes to position.

Once the locators have positioned, press the down pedal to lower the ram and make the

bend.

Once the bend has been made, the ram returns automatically and the locator axes

position for the next bend.

When the last bend in the program has been made, the automatic cycle starts again from

the first bend.

Execution of the

sample workpiece

The calculations made by the numeric control are purely theoretic and, owing to

imperfections in the metal plate, may need to be corrected.

To simplify the way the bending data of a workpiece are corrected, there is a procedure

for making a sample workpiece which is carried out in the SEMIAUTOMATIC mask.

If this procedure is activated, step change does not occur at the end of a bend as the

cycle remains on the current bend to allow the operator to correct the bending data and

repeat the bend that has been corrected.

The angle or length of the bend can be corrected step by step or in a uniform way for all

the bends.


Esa/Gv 2.31

The corrections entered are automatically made to the program.

The procedure can be activated from the AUTOMATIC mask in the following way:

• press ;

• press to position the locator axes;

• press the down pedal to make the bend;

• measure the bend made in terms of bending length and angle;

If the bend is not correct:

• press to access the correction data. To make a correction in all the

steps (e.g.: if all the bends must have the same angle, it is advisable to correct the

program in the general mode), enter the data under the workpiece column. To

correct the data of a section, enter the data under the section column. To correct the

data of a bend, enter the data under the bend column;

• enter the correction data.

Figure 2.15 – Correction mask


Esa/Gv 2.32

Correction data entry The correction data to enter are in mm when it comes to the position of the locator axes

and in degrees for the bending angle;

the data entered are added to the value in the program.

Example: if the bend is closed by 2°, a positive correction value must be entered

(+2.0°). If the bend is open by 2°, a negative correction value must be entered (-2.0°).

If the length of the bend is less than the required length, enter a positive value

corresponding to the difference ascertained in the X1 Corr. field. If the length of the

bend is greater than the required length, enter a negative value corresponding to the

difference ascertained in the X1 Corr. field;

if several corrections are made to the data of the same bend, the last value entered is

added to the previous ones.

Example: if a bend is initially closed by 3° and, after the correction (+3.0°), is open 1°,

enter 1.0° in the angle correction field.

In the step correction, the angle correction data are separate per cylinder. The Y1 angle

can therefore be corrected differently from the Y2 angle;

in the general correction, the bending angle is the same for both cylinders.

The entered values overlap if a step correction and a workpiece correction are made in

the same step.

Example: if a -2.0° step correction and a -1.0° workpiece correction are made, the

angular correction for that step will be -3.0°.

Once the correction data have been entered:

• Press ;

• press to re-position the locator axes (their position may have been

corrected);

• repeat the bend;

• check whether the bend is correct:

− if it is correct:

repeat the procedure for all the bends in the program. Use the or

keys to move amongst the various bends;

− if it is not correct:

make new variations to the current bend data.

When the data have been corrected for all the bends:


Esa/Gv 2.33

• press . The automatic cycle will start again from the currently selected

bend.

• There are new methods for making the corrections, as described below.

How to annul the

correction data

Press [Lose Correc.] to annul the modifications made to the corrections.

The values present when the mask was accessed will be restored.


Esa/Gv 2.34

2.8 Materials Table

The Materials Table contains the correction coefficients of the stretch calculation,

divided amongst the 9 available materials.

2.8.1 How to access the Materials Table mask

Comply with the following procedure to access the Materials Table mask:

• access the Corrections mask by pressing

• press the [Materials Table] key.

The mask illustrated in the figure appears:

Figure 2.16 – Materials Table

2.8.2 How to use the Materials coefficient

Access the Materials Table and enter the materials correction coefficients.


Esa/Gv 2.35

This parameter will be used for calculating the stretch for all the bends entered after the

coefficients are modified and for all the new programs. The angle must be re-entered in

each bend order to apply the corrections to the existing programs.

The default value of the coefficients is 1. The standard stretch is calculated with this

value, re-processing the DIN6935 standard. The value entered in the coefficients is

multiplied by the stretch calculated. Thus, entry of value 2 calculates double stretch

while halved stretch is calculated if value 0.5 is entered.

The tolerated values are between 0 and 9. Up to 2 decimals are allowed.

How to disable the

stretch calculation

Just set the coefficients to 0 to disable the stretch calculation.

The X calculations will no longer be calculated when the calculation is disabled.

How to save the

coefficients

Just press the save key to save the coefficients entered.

How to load the

coefficients

Just press the [Load from disk] to load the coefficients entered from a USB Key.

The coefficients are also saved and loaded in the automatic mode from the Configure

mask by means of the [Save ALL] and [Load ALL] function keys.


Esa/Gv 2.36

2.9 Clinching/Coining Coefficient

The Correction Coefficients mask contains the Clinching/Coining coefficient alone.

2.9.1 How to access the Correction Coefficients mask

Comply with the following procedure to access the Correction Coefficients mask:

• access the Corrections mask by pressing

• press the [Corrections Coeff.] key.

The mask illustrated in the figure appears:

Figure 2.17 – Correction coefficients


Esa/Gv 2.37

2.9.2 How to use the Clinching/Coining coefficients

Access the Correction Coefficients mask and enter the parameters.

These parameters are used in the B.D.C. calculation for all bends of the

Clinching/Coining type.

How to save the

coefficients

The coefficients are saved automatically whenever the Correction Coefficients mask is

quitted.

The current machining program is not saved, but remains bound to the machine.

How to annul the

modifications made to

the coefficients

Press the [Lose Correc.] key to annul the modifications made to the coefficients.

The values present when the mask is opened will be restored.


Esa/Gv 2.38

2.10 Internal radius correction

The internal radius of the bend is displayed in the machining data setup mask. The

internal radius is calculated and the calculation method can be selected in the generic

parameters. This field can also be modified by the operator, if the internal radius must

be used to re-calculate the length of the workpiece. Modification of the internal radius

influences the stretch calculations.

Refer to the machine parameters manual for the various internal radius application

modes.

2.11 DIN formula selection for the stretch calculation

The operator can choose whether to use the standard DIN formula (for stretch

calculations). To select the standard formula, enter 1 for the generic stretch Formula

parameter.

Refer to the machine parameters for the various internal radius application modes.

2.11.1 Program checking

Once the modifications have been made, press to set the axes in position. The

program is checked automatically and if an error is found, a message will appear and the

program will remain in the STOP status of the semiautomatic mode.

Autolearning cycle There are particular conditions in which the bending target calculated by the numeric

control cannot be used for making a bend (rounded punches, stamped bends, off-slot

bends, etc....).

In these situations, it is convenient to use the bending target autolearning cycle which

can be carried out in the SEMIAUTOMATIC mask.

If this procedure is activated, step change does not occur at the end of a bend but the

cycle remains on the current bend to allow the operator to autolearn the required end of

bend target.

The operator can use several different methods to find the correct end of bend target:

• if the target to reach is higher than the calculated end of bend target, the target can

be found by using the pedal alone;

• if the target to reach is lower than the calculated bend target, the operator must

enable the Re-ascent to TDC with ascent enabling input, release the pedal at the

end of bend target and use the and buttons, which allow the ram

to move up or down by a tenth of a millimeter at a time.


Esa/Gv 2.39

The procedure can be activated from the SEMIAUTOMATIC mask in the following

way:

• press ;

• press to position the locator axes;

• press the down pedal to make the bend;

• find the required end of bend point by means of the previously described procedure;

• press [AutoLear. Y];

• press the up pedal;

• repeat the procedure for all the bends in the program. Use the or

keys to move amongst the various bends.

When autolearning has been accomplished for all the bends:

• press and run through the program from the first bend.

END OF CHAPTER


Esa/Gv 3.1


3.1 “Sheet Metal-working Machine” function

The following “Sheet Metal-working Machine” functions can be enabled:

• “New Bend” function

• Flattening bend forcing

3.1.1 How to enable the “Sheet Metal-working Machine” function

•

• Press the key two times ;

• Select item 2) Configuration

• Select item 7) Generic Parameters

• Press the [Nexte] key

• Digitize the password and press [OK]

• Digitize value 1 in the Sheet Metal-working Machine field and press

The two functions, “New Bend” and “Flattening Bend Forcing” functions will be

enabled from this moment onwards.

3.1.2 “New Bend” function

This function, which is activated in the Setups mask, is used to create new bends

containing the same data as the previous bend. However, the new bends normally have

only the same general data as the previous bend.

This function is activated in the following cases:

• Next function: Press the key when positioned on the last bend of the

section to insert a new bend at the end of the section itself. This new bend will

contain the same data as the preceding one.

• Insert Step function: select the Insert Step item from the menu to add

a new bend in the current position.

• This new bend contains the same data as the preceding one.


Esa/Gv 3.2

Note When the function is enabled, pay attention to the Next function. If you are positioned

on the last bend in the section, you will actually add new ones if you continue to press

the key in order to scroll through the bends.

It is advisable to use the key to scroll through the bends.

To allow new steps to be added in the normal way, a [New Step] function key is

activated in the bend data entry mask when the “New Bend” function is activated.

Pressure on this key corresponds to pressure on when the function is not

enabled thus, in this case, each new bend will only contain the general data of the bend

that precedes it.

3.1.3 Flattening bend Forcing

This function, which is activated in the Setups mask, allows the user to enter a bend as a

Flattening one (Coining) by simply entering value 0 in the Y1 Angle field.


Esa/Gv 3.3

3.2 New “Machine functions” mask

20 machine functions are available. Functions 1 to 4 are accessible in both the new

machine functions mask and the machining data entry mask, while the new functions can

only be accessed in the following way:

• access the Setups mask and press to access the menu;

• select the Machine Functions item to access a window that allows the functions to

be enabled for that bend;

Figure 3.1 – Machine functions

3.3 “Manual Bend” Function

Need to make a single bend that does not belong to the program, and then resume the

program from the bend where it where it left off.

To enable the Manual Bend mode, presst the key [Manual Bend] from the Automatic

page.


Esa/Gv 3.4

Figura 3.2 - The Manual Bend page

The last bend used in Manuale Bend mode is loaded.

To execute the bend press [Execute] function key and then the button.

To modify the bend press the function key [New] .

To restore the program previously interrupted by Manual Mode press the key [Exit

Manual Bend]

END OF CHAPTER

GB Integrated Cad

Esa/Gv 4.1

4 Integrated Cad

4.1 Introduction

The S530 numeric control has a function that allows the following graphic elements to

be drawn:

• punch;

• die;

• workpiece to bend.

Access to the drawing function for the elements listed above is described in the brief

guide.

4.2 Drawing function

The drawing function works by plotting straight line segments depending on the data

entered by the operator.

The data may only be entered in polar form.

4.2.1 Polar entry of the drawing data

This function is used to define the lines that form the drawing via entry of a pair of data

items:

• length of the line;

• angle in relation to the next line.

The angles entered must be between ±180.0°.

The convention according to which these angles must be entered is as follows:

Direction of the drawing

Integrated Cad GB

Esa/Gv 4.2

+90°

-90°

180°

+135°

-135°

+90°

+135°180°-135°

-90°

Drawing

direction

+90°

+90° -90°

-90°

180°

180°

+135°

+135°-135°-135°

Drawing

direction

Drawingdirection

Drawing

direction

Figure 4.1 – Angle entry conventions

4.2.2 General data

Before beginning to draw a graphic element, the operator must enter certain general data

items which vary depending on the object being drawn.

The data items that must be entered in this phase are described in the chapters dedicated

to each individual object.

Activation To access the drawing, go to the [Confirm] button and press [ENTER].

GB Integrated Cad

Esa/Gv 4.3

4.3 Drawing page

The drawing page comprises several windows:

• Area 1 window for graphic plotting of the drawing which displays:

the drawing corresponding to the data entered.

• Area 2 window for polar drawing entry in which:

the data for the length of the line to draw “l” and for the angle in relation to the next

line “alfa“ can be entered.

Area 3 window that displays the image of the element being drawn.

Area 1

Area 2

Area 3

Figure 4.2 – Drawing window

Use of the dedicated data entry windows is described in the section of the brief guide

dedicated to each graphic object.

Integrated Cad GB

Esa/Gv 4.4

4.4 Drawing data entry

The first line of standard length is plotted on access to the drawing in Area 1.

The line is highlighted by a circle.

The initial direction of the drawing can be modified by pressing one of the arrows.

The cursor is on field “l” in Area 2. There is a standard value in the field.

Note Each data item entered must be confirmed with the [ENTER] key.

4.4.1 How to enter a drawing in the polar mode

As described in the “Polar entry of the drawing data” chapter, the values to enter are:

1) the length of the line. The line is rescaled depending on the length entered and the

cursor moves to the “alfa” angle entry field;

2) the angle in relation to the next line.

A circle indicating which line is being drawn makes the drawing easier to do.

Once the entry has been made, the cursor moves to field “l”, where the length of the new

line is entered.

Entry of this pair of data items must be repeated until the drawing is completed.

How to update the

information in the

drawing

The drawing is automatically rescaled if the measurements exceed the size of the

window.

How to terminate the

drawing

Enter zero for the angle of the last line to indicate that the drawing has terminated.

How to select the

drawing data

To select the drawing data, scroll through them with the and

keys.

Key scrolls backwards through the data that form the drawing in the

sequential mode, passing between the “alfa” field and the “l” field each time. Key

GB Integrated Cad

Esa/Gv 4.5

scrolls forwards through the data in the sequential mode, passing through

the “l” field each time.

The line relative to the displayed data is highlighted when the data of a drawing are

scrolled.

How to modify the

data of a drawing

Proceed in the following way to modify the data of a drawing:

• select the data item;

• enter the new value;

• press [ENTER] to confirm the new data item;

the drawing will be plotted again to suit the new data item entered.

Use of the arrows and

direction keys

The arrows and direction keys can be used to automatically enter the angle of a line in

relation to the next one.

Press one of these keys to plot a new segment pointing in the direction that corresponds

to the key pressed.

The direction keys are: [Home], [PgUp], [PgDn], [End] and they are near the arrows.

Home

TAB

End

PgUp

PgDn

Figure 4.3 – Positions of the direction keys

The arrows position the segment horizontally or vertically.

Integrated Cad GB

Esa/Gv 4.6

Initial

DrawingDrawing after arrow towards

the right has been pressedDrawing after arrow towards

the left has been pressed

Initial

Drawing

Example 1

Example 2

Drawing after upward arrow

has been pressed

Drawing after downward

arrow has been pressed

Figure 4.4 – Use of the arrows

The direction keys position the segment diagonally.

Use of the directional arrows

PGUP Key HOME Key

PGDN Key END Key

Figure 4.5 – Use of the direction keys

The angle between the current line and the segment plotted in accordance with the

direction key pressed, is automatically entered in the “alfa“ field.

GB Integrated Cad

Esa/Gv 4.7

This angle must be confirmed with the [ENTER] key if the length of the new line must

be entered.

How to cancel a

drawing line

To cancel a drawing line, first select the line to be cancelled and then press the

key.

The current line will be cancelled. The successive lines will be positioned in accordance

with the angle entered in the line preceding the one that is cancelled.

120

20 20

50 50

Section to cancel

Drawing before cancellation

20

50

50 20

Drawing after cancellation

a

The angle value remains unchanged

after cancellation

a

Figure 4.6 – Line cancellation

If the last line entered is cancelled, it will be substituted by a line of standard length. To

eliminate this line as well, go to the data of the preceding line and terminate the drawing.

END OF CHAPTER

GB Management of the data in the memory

Esa/Gv 5.1

5 Management of the data in the memory

5.1 Introduction

Types of data There are certain categories of data of fundamental importance for operation in Esa/Gv’s

S530 numeric control for bending presses:

• Configuration parameters of the machine (Menu 2)

• Axes parameters (Menu 1)

• Work programs (graphic or numeric)

• Fixturing (punches and dies).

5.2 Memory devices

These data can be stored in the following memory devices:

ù

• Buffered RAM

• SSD (Solid State Disk) Flash Hard Disk

• USB Key.

5.2.1 Internal memory (buffered RAM)

This is the memory device of the numeric control (that resides on the

MULTIFUNCTION board) into which all the machine data are downloaded before

being used. Thanks to the battery, these data are also maintained when the numeric

control is off.

5.2.2 SSD (Flash Hard Disk)

This is the storage device that contains a copy of the operating system, the Kvara

application program and its Backup copy, plus the data saved by the Kvara application

program (machine data, fixturing programs).

5.2.3 USB Key

This is a normal USB Key.

It is used for saving the machine’s configuration parameters and for the axes parameters.

It is also used for saving the security copy of the programs, punches and dies.

The contents of the USB Key can be viewed on any IBM-compatible Personal

Computer.

Management of the data in the memory GB

Esa/Gv 5.2

5.3 Logic site of the data

Foreword Logic site of the data means the storage device in which they reside on powering.

At the time of use, the data reside in the internal memory.

Summary table

Type of data item Storage device

Configuration parameters Internal memory + SSD

Axes parameters Internal memory + SSD

Work programs SSD

Punches SSD

Dies SSD

Files associated with

the data

All the machine data (Configuration and Axes) are memorized on files so that they can

be recovered following a memory loss or incorrect entry.


Esa/Gv 5.3

5.4 Data exchanging between storage devices

Data exchanging means moving data from the internal devices to the diskette (SAVING)

or from the diskette to the internal storage devices (LOADING).

All the data handles by the KVARA program and listed in the previous sections can be

Loaded and/or Saved as illustrated below:

CONFIGURATION PARAMETERS AND AXES PARAMETERS

SSD (Flash

Hard

Disk)USK Key

INTERNAL

MEMORY

Saving

Loading

Figure 5.1 – Saving/Loading CONFIGURATION and AXES parameters

PROGRAMS AND FIXTURES

SSD (Flash

Hard

Disk)USB Key

Saving

Loading

Figure 5.2 – Saving/Loading PROGRAMS and FIXTURES parameters


Esa/Gv 5.4

As can be seen in the figure, the files are first memorized in SSD and then transferred to

the destination device when the Axes Parameters or Configuration Data and

loaded/saved. This ensures that there is always a copy (SSD) of the last operation

carried out on the data if one of the storage devices (either the USB Key or internal

memory) becomes faulty.

The machine parameters and configuration parameters can be saved and/or Loaded

contemporaneously and in the automatic mode. This particular function is described in

the “Saving/Loading all the parameters” section.

The loading and saving operations for each category of data are described below.

5.4.1 Saving / Loading the Configuration Parameters

The configuration parameters comprise the following data:

Description Type (name on

screen)

File name

Axes configuration parameters Axes Conf. COFASSI.CNF

General configuration parameters General Conf. GENERALI.GEN

Valve configuration parameters Valve Conf. VALVOLE.VAL

Special parameters Special Conf. SPEC.PAR

Generic parameters Generic Conf. GENER.PAR

Generic parameters 2 Generic 2 Conf. GENER2.PAR

I/O configuration parameters I/O 1 Config. CONFIGIO.PAR

I/O configuration parameters I/O 2 Config. CONFIGIO2.PAR

Table of Materials Materials MATERIAL.TMT

Angle correction Angle Corr. CORRANG.DAP

Drawing of top part of press RAM SUPERIOR.SUP

Drawing of lower part of press BASE INFERIOR.INF

Loading and/or saving can be carried out in one of the following ways:

• SINGLE saving/loading: the type of parameter selected is subjected to the

operation;

• GLOBAL saving/loading: the operation is carried out for all types of configuration

parameters.


Esa/Gv 5.5

Single saving Proceed in the following way to save a single type of configuration parameters:

1) Select the Configure 2 Menu;

2) select the type of parameter to be saved (keys 1 to 8) and access the corresponding

mask;

3) press to save the file containing the selected data on the USB Key.

Example An example of the way that VALVE configuration parameters are saved is illustrated

below. To save the other types of parameters, repeat the procedure after selecting the

type to be saved.

a) Select the Configure 2 menu;

b) press ;

c) press .

Single loading Proceed as described below to load a single type of configuration parameters:


2) select the type of parameters to be saved (keys 1 to 8) and access the corresponding

mask;

3) press [Load from Disk] to load the files containing the selected data from the USB

Key.

Global saving Proceed as described below to save all the configuration parameters on the USB Key:


2) press [Save All].

Global loading Proceed as described below to load all the configuration parameters from the USB Key:


2) press [Load All].


Esa/Gv 5.6

5.4.2 Saving / Loading the Axes Parameters

The machine parameters comprise the following data:

Description Name displayed File name

Machine parameters of the axes Axes Parameters ASSI.AXE

Machine parameters of the AC

Ram axis

Axes Parameters PESTAC.PAR


• single saving/loading: the operation is carried out by accessing the parameters mask

in Select Axes Parameters 1 Menu;

• global saving/loading: the operation is carried out along with the Configuration

Parameters in the global saving/loading procedure described in the previous

paragraph.

Single saving Proceed as follows to save the Axes Parameters alone:

1) Select the Axes Parameters 1 Menu;

2) press or to save the file containing the data on the USB

Key.

Single loading Proceed as follows to load the Axes Parameters alone:

1) Select the Axes Parameters 1 Menu;

2) press [Load from Disk] to load the files containing the data from the USB Key.

Save/Load ALL the

parameters

ALL the configuration parameters and axes parameters can therefore be saved or loaded

in USB Key by selecting the Configure 2 Menu and pressing the relative function key,

i.e. [Save All] or [Load All].


Esa/Gv 5.7

5.4.3 Saving / Loading the PILZ Configuration Parameters

The CNC can be connected to a PILZ safety PLC via serial link. The configuration

parameters comprise the following data:


PILZ configuration parameters Pilz Test PAR.DAT


• single saving/loading: the operation is carried out by accessing the parameters mask

in the Diagnostic 3 Menu;

• global saving/loading: the operation is carried out along with the Configuration

Parameters in the global saving/loading procedure described in the previous section.

Single saving Proceed as described below to save the PILZ Configuration parameters alone:

1) Select the Diagnostic 3 Menu;

2) select the test mask (key 5). A request to enter the password will appear;

3) enter the password: 851414;

4) press the [Pilz Test] function key;

5) press to save the file containing the data on the USB Key.

Single loading Proceed as described below to load the PILZ Configuration parameters alone:

1) Select the Diagnostic 3 Menu;

2) select the test mask (key 5). A request to enter the password will appear;

3) enter the password: 851414;

4) press the [Pilz Test] function key;

5) press [Load from Disk] to load the file containing the data from the USB Key.

Save/Load ALL the

parameters

ALL the configuration parameters, axes parameters and PILZ configuration parameters

can therefore be saved or loaded in the USB Key by selecting the Configure 2 Menu and

pressing the relative function key, i.e. [Save All] or [Load All].


Esa/Gv 5.8

5.4.4 Saving/Loading the punches

The punches comprise the following data:


Data that form the punch drawing filename nomefile.PNZ

The punch data that reside in SSD do not require specific loading or saving procedures

in order to be modified. After having selected the punch from the punches list and

pressed to access the drawing:

• press to memorize the modified data;

• go to another mask to lose the changes made.

Saving on USB Key Proceed as described below to save a punch on the USB Key:

1) access the punches list by pressing the key;

2) move with the cursor to the punch to be saved;

3) press .

Loading from USB

Key

Proceed as described below to load a punch from the USB Key:

1) access the list of punches by pressing key twice;

2) press to display the list of punches on the USB Key;


Esa/Gv 5.9

3) move with the cursor to the punch to be loaded;

4) press .


Esa/Gv 5.10

Saving/Loading the dies

The dies comprise the following data:


Data forming the die drawing filename nomefile.MTX

• The die data reside in the SSD and do not require specific loading or saving

procedures in order to be modified. After having selected the die from the dies list

and pressed to access the drawing:

• press to memorize the modified data;

• go to another mask to lose the modifications made.

Saving on USB Key Proceed as described below to save a die on the USB Key:

1) access the list of dies by pressing the key;

2) move with the cursor to the die to be saved;

3) press .

Loading from USB

Key

Proceed as described below to load a die from the USB Key:

1) access the list of dies by pressing the key;

2) press to display the list of dies on the USB Key;

3) move with the cursor to the die to be loaded;


Esa/Gv 5.11

4) press .


Esa/Gv 5.12

5.4.5 Saving/Loading all the tools

Saving on USB Key Proceed in the following way to save all the punches and dies on the USB Key:

1) access the list of punches or dies by pressing the key;

2) press the key to access the menu and select [Save tools]. All the tools

will be saved on the USB Key.

Loading from USB

Key

Proceed as described below to load all the punches and dies from the USB Key:

1) access the list of punches or dies by pressing the key;

2) press to display the list of punches or dies on the USB Key;

3) press the key to access the menu and select [Save tools]. All the tools

will be loaded on USB Key.


Esa/Gv 5.13

5.4.6 Saving/Loading programs

Foreword The programs can consist of several files:

• nomefile.PRG containing the workpiece drawing data;

• nomefile.PRN containing the axes targets and bending data.

The files saved (by pressing the key) depend on the mode in which the

program is set-up.


Numeric program Filename nomefile. PRN

Non-calculated graphic program Filename nomefile. PRG

Calculated graphic program Filename nomefile. PRN

nomefile. PRG

The data of the program reside in SSD and do not require specific loading and saving

procedures in order to be modified. Just press after having selected the

program.

Type of program Data modification

Graphic programs • cannot be modified.

Numeric programs

Calculated graphic

programs • press to access the

numeric data of the workpiece;

• press to memorize

the modified data;

• re-select the name of the

program from the programs list in order to lose the

modifications made.

Saving the current

program on USB Key

Press from the SET-UPS mask to save the currently selected program on

the USB Key.


Esa/Gv 5.14

Saving a program on

USB Key

Proceed as described below to save any program in SSD on the USB Key:

1) press to select the programs list;

2) move with the cursor to the program to be saved;

3) press .

Loading a program

from USB Key

To load a program from the USB Key:


2) press to select the list on the USB Key;

3) select the program to be loaded;

4) press : the program will be copied from the USB Key to SSD;

5) Now press again (list in SSD). The newly copied program should be

in the list. To access the data in the program, select them and press

to load them.


Esa/Gv 5.15

5.4.7 Saving/Loading all the programs

Saving on USB Key Proceed as follows to save all the programs on the USB Key:


2) press to access the menu and select [Save programs]. All the

programs will be saved on the USB Key.

Loading from USB

Key

Proceed as follows to load all the programs from the USB Key:


2) press to display the list of programs on the USB Key;

3) press to access the menu and select [Save programs]. All the

programs will be loaded from the USB Key.


Esa/Gv 5.16

5.5 Recommended security savings

Foreword Security saving means memorizing the data that allow the bending press to operate on a

USB Key.

Parameters Security saving of the parameters must be carried out at the time of shipment. Any

successive modifications must be saved immediately.

Programs Security saving of the programs must be carried out periodically by the customer

depending on the number or importance of the programs he sets up.

Fixturing Security saving of the fixturing must be carried out after all the tools of a customer have

been entered. The customer must save again whenever he enters a new punch or a new

die.

5.5.1 Advice for the bending press manufacturer

It is advisable to keep:

• a USB Key containing the machine parameters of each bending press sold (in

duplicate or a copy on the hard disk of a Personal Computer);

• a USB Key containing the fixturing supplied with the bending press.

5.5.2 Advice for the end user

It is advisable to keep:

• a USB Key containing a copy of all the machine parameters, fixturing and programs

commonly used in the numeric control;

• a security USB Key identical to the one described above;

• a copy of the machine parameters in the hard disk of a Personal Computer;

• a USB Key containing the programs of each individual customer so as to free the

greatest amount of memory possible and achieve faster search phases (this USB

Key is only required if there is a large number of programs).

END OF CHAPTER

GB Description of the program data

Esa/Gv 6.1

6 Description of the program data

6.1 Header section

This section describes all the header information in the top part of all three SET-UP

masks:

Name

Minimum value: Maximum value:

Default value: Meas. unit: alphanumerical characters

Type of data: Protection level:

Available from SW version 1.0 Change activated

Description: This is the name of the program currently in progress. If nothing is written in this field,

the program is the temporary type and has not yet need saved.

Bend

Minimum value: 1 Maximum value: 80

Default value: Meas. unit: pure number

Type of data: unsigned word Protection level:


Description: This is the bend currently in progress.

Section



Type of data: unsigned word Protection level:


Description: This is the section currently in the bending phase. Section means the direction of the

metal plate on which the bends are being made.

Description of the program data GB

Esa/Gv 6.2

6.2 Supplementary non-modifiable information

The header section also includes certain non-modifiable information:

The type of bend. Can take on the following values:

N normal bend in air

C rolled bend

A conical roller bend

R flattened (clinching) or stamped (coining) bend

I conical bend


Esa/Gv 6.3

6.3 Workpiece data section

This section contains data that concern the entire workpiece.

Pieces made


Default value: 0 Meas. unit: pure number

Type of data: dword Protection level:

Available from SW version 1.0 Change activated data entry

Description: Indicates how many workpieces have been made by the program in progress. The data

item is updated automatically during the operations, but the user can modify it as

required.

Pieces to make



Type of data: dword Protection level:


Description: Indicates how many workpieces the user wishes to make. The number is automatically

decreased at the end of each workpiece. At the end of the last workpiece, automatic

execution stops and the user is asked to press the START button to continue.

Measurements



Type of data: unsigned char Protection level:


Description: Indicates whether the user describes the workpiece by means of external or internal

measurements. Can have the following values:

0 = external measurements (default)

1 = internal measurements


Esa/Gv 6.4

Length


Default value: Meas. unit: mm

Type of data: double Protection level:


Description: Indicates the total length of the metal plate.

Comment



Type of data: Protection level:


Description: Adds a comment to the program if required.


Esa/Gv 6.5

6.4 General data section

This section describes the general data concerning the workpiece. The user can modify

them bend by bend if necessary.

Width

Minimum value: 0 Maximum value: 99999.9




Description: Indicates the width of the metal plate in the bending point.

Thickness

Minimum value: 0.01 Maximum value: 99.99




Description: Indicates the thickness of the metal plate in the bending point.

Strength


Default value: Aluminium = 25

Iron = 45

Stainless steel = 70

Meas. unit: Kg/mm²



Description: Indicates the strength of the material. It is advisable to use the default values given if

you do not know the real strength value, but if there are errors in the final angle or in

the length calculation, you will have to check whether an incorrect entry for this data

item conditions the results.


Esa/Gv 6.6

Material





Description: Indicates the type of material and can have the following values:

1 = aluminium type 1

2 = iron type 1

3 = stainless steel type 1


5 = iron type 2



8 = iron type 3


this data item is initialized automatically, depending on the strength value entered. For

instance, aluminium type 1 is used if the strength value is between 0 and 30; iron type 1

is used if the value is between 31 and 50, while stainless steel type 1 is used if the value

is over 50. The user is responsible for checking whether the material proposed must be

changed to suit the results obtained.

Once the program has been set up, the Material must be selected in the Manual mode,

even if the strength is reset. A new program must be made to generate the Material

according to the strength in the automatic mode.

The material data item refers to the materials table in the Corrections mask.

Die



Type of data: char[9] Protection level:


Description: This is the name of the die used to make the bend.


Esa/Gv 6.7

Slot





Description: This is the number of the slot used for making the bend. Remember that multiple-slot

dies identical to the real ones can be drawn. The slots are numbered automatically in

the progressive mode whilst the drawing is being done.

Punch



Type of data: char[9] Protection level:


Description: This is the name of the punch used for making the bend.

Die direction


Default value: 0 Meas. unit: alphanumerical characters



Description: Indicates the direction of the die when the bend is made.

Punch direction


Default value: 0 Meas. unit: alphanumerical characters



Description: Indicates the direction of the punch when the bend is made.


Esa/Gv 6.8

6.5 Angles and axes data section

This section describes the data in the second entry mask, where the bending angles, the

positions of the axes and the corrections can be entered.

Y1 Angle

Minimum value: -179.9 Maximum value: 180.0

Default value: Meas. unit: degrees



Description: This is the bending angle required on the cylinder piloted by Y1 axis.

Y1 B.D.C.





Description: This is the position that the Y1 axis must reach to obtain the required angle.

Y1 corrections





Description: This is the correction to make to the bending angle resulting after the bend so as to

obtain the correct angle. It can also be entered in the CORRECTIONS mask.

T.D.C. (Top Dead Center)





Description: Indicates by how many millimeters the bending press must open at the end of the bend

(space between the die edge and the punch).


Esa/Gv 6.9

Y2 Angle





Description: This is the bending angle required on the cylinder piloted by Y2 axis.

Y2 B.D.C.





Description: This is the position that Y2 axis must reach in order to obtain the required angle.

Y2 corrections





Description: This is the correction to make to the bending angle resulting after the bend so as to

obtain the correct angle. It can also be entered in the CORRECTIONS mask.

X1





Description: This is the position that X1 axis must reach to obtain the required bending length.


Esa/Gv 6.10

X1 Recoil





Description: This is the distance at which X1 axis must move back when the ram reaches its contact

point with the metal plate (PCP) to prevent this latter from colliding against the locator.

X1 corrections





Description: This is the correction to make to the position of X1 axis to obtain the required bend

length.

X2





Description: This is the position that X2 axis must reach to obtain the required bend length.

X2 Recoil





Description: This is the distance at which X2 axis must move back when the ram reaches its contact

point with the metal plate (PCP) to prevent this latter from colliding against the locator.


Esa/Gv 6.11

X2 corrections





Description: This is the correction to make to the position of X2 axis in order to obtain the required

bend length.

R1





Description: This is the position the locator must reach in height to allow the metal plate to rest.

R2





Description: This is the position the locator must reach in height to allow the metal plate to rest.

A1 (Mechanical cambering)


Default value: Meas. unit: %



Description: This is the position of the mechanical cambering table (WILA type) expressed in % of

the maximum bed deflection take-up.

This function is only present if the press is pre-engineered for handling this type of

cambering.


Esa/Gv 6.12

6.6 Machining data section

This section described the machining data used, bend by bend.

Force


Default value: Meas. unit: tons



Description: This is the force required to bend the metal plate.

Camb. (Cambering)


Default value: Meas. unit: %



Description: This is the compensation required for straightening the bending press. It concerns the

force used for bending and is a percentage of the machine’s maximum force.

S.C.T. (Step Changing Time)


Default value: 0 Meas. unit: seconds



Description: This is the time with which locator start-up is delayed when step changing occurs, to

allow the user to remove the metal plate from the bending press.

P.C.P. (Plate Contact Point)





Description: Indicates by how many millimeters the theoretic plate contact point must be modified to

achieve correct crimping.


Esa/Gv 6.13

S.C.P. (Speed Changing Point)





Description: Indicates by how many millimeters the theoretic speed changing point must be

modified to achieve a correct speed change.

B. Time (Bending Time)


Default value: 0 Meas. unit: seconds



Description: This is the time the ram remains at a standstill at bottom dead center to allow the metal

plate to be rolled.

Accomp. (Accompanying)


Default value: 0 Meas. unit: m/min



Description: This is the speed (slow) used for accompanying the metal plate when this is very heavy,

so as to prevent an excessively fast re-ascent from overturning the plate on to the

operator. Speed used by the ram for lifting from BDC to PCP.

Accompanying does not take plate if this data item is left at zero.

Speed


Default value: 0 Meas. unit: m/min



Description: This is the bending speed. If the user must make delicate bends (e.g. thin thicknesses) it

is advisable to use a lower speed than the maximum speed tolerated.


Esa/Gv 6.14

Functions 1 to 20





Description: These data are used for handling special functions such as pneumatic R axes pr

pneumatic bending and flattening dies. They can have the following values:

0 = function not enabled

1 = function enabled

Comply with the instructions in the relative chapter of the brief guide to access the

functions that are not directly displayed in this mask.

Rep. (Repeats)





Description: Indicates the number of times the bend must be repeated before passing on to the next

one.

Direction

Minimum value: -1 Maximum value: 1




Description: Indicates whether the metal plate must be inserted in one direction or the other. This

information is displayed enlarged in the automatic mask to allow the operator to know

how to insert the workpiece even when the program has been written in the numeric

mode.


Esa/Gv 6.15

Ri (Internal Radius)





Description: Indicates the internal radius of the bend, calculated by the NC. If the program is

numeric, any changes made to this data item will directly influence the length

calculation.

END OF CHAPTER

manual em ingles dobradeira - s 530 operator%27s guide

Documents

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documented product

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prior authorization

prior notice

list of punches

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