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SCHMIDT® PressControlMachine control units

SCHMIDT® PressControl 3000 and 4000 are control units ofthe latest generation, which allow the design of modern pro-duction processes - from the single workstation to completeautomation. You benefit from our competence in:•• Safety technology – type-approved devices•• Process measurement technology – simultaneous measuring

during the process•• Process documentation

SCHMIDT® PressControl 3000

SCHMIDT® PressControl control units have the followingfeatures• Efficiency due to intuitive user interfaces•• Quick and secure process set-up e. g. thanks to the touch

screen with SCHMIDT® PressControl 3000 and hand wheelram control function with SCHMIDT® PressControl 4000.

•• The integrated PLC allows programming of additionalinputs/outputs or sensors/actuators and the application-specific design of the workstation or the line.

•• The integrated measurement technology is insensitive againstinterferences (EMC). This results in a high measurementsecurity of the entire system.

•• With integrated safety technology, the entire systembecomes a type-approved single workstation.

•• Service functions such as "Firmware Update" ensure the userhas the up-to-date version of the software

•• The software SCHMIDT® ControlTool of PressControl 3000and PressControl 4000 use the same user interface andhave an identical data structure.

•• Guaranteed complete process documentation with fulltraceability

•• The Statistical Process Control “SPC” is carried out onlineafter each pressing process.

SCHMIDT® PressControl 4000

Control unit SCHMIDT® PressControl 3000

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The press control unit SCHMIDT® PressControl 3000 is a com-pact control unit that combines the PLC functionality and theintegrated process monitoring technology.

Features:•• Integrated force/stroke monitoring1)

•• Built-in PLC for individual process design•• Quality evaluation based on window and stroke tolerances,

and thus provide detection of “failed” parts•• User-friendly, intuitive menu guidance•• Quick data transfer via USB•• Electromagnetic compatibility (EMC)

This results in economic production due to increased efficiencyand cost reduction by avoiding rejected parts.

Avoid verifying costs because of continuous and realtimeprocess monitoring.

SCHMIDT® PressControl 3000 consists of a robust industryhousing with touch screen display. Buttons for Emergency stopand ON/OFF switching are provided. The control unit is oper-ated via function and cursor keys and a number pad.

The following functions can be selected directly on the userinterface:

Data set managementManagement of up to 20 data sets (loading, storing, renam-ing).

System configurationStorage of control-specific or press-specific parameters andadministration of access rights.

Graphic mode1)

Allows the visualization of the process. QA monitors (8 window / 4 stroke tolerances) can be defined freely, eithergraphically via the touch screen or numerically for each dataset. Single curve areas can be displayed with high resolutionusing the zoom function. Switching between force/stroke [F/s],force/time [F/t] and stroke/time [s/t] is possible for processoptimization.

Data inputEntry of the working modes (force/stroke/set-up mode) and theprocess variables.

Data outputStatus information for the user as text output: e. g. Pass/Fail,max. stroke/force reached as well as number of pieces anderror acknowledgement.

Technical dataProcess monitoring 8 force/stroke windows, 4 stroke tolerancesScanning rate 2000 HzGraphical resolution 240 x 128 pixelDisplay Force/stroke, force/time, stroke/timeOperation Touch panel, On/Off, Emergency stopInterface USB, CANFlow chart Fully functional PLC with 8 inputs and 4 outputsData sets 20EMC Acc. to requirements of EMC law (EN50081, EN50082)Main supply 100 – 230 VSupply voltage 24 V DCSystem backup Buffer batteryAmbient temperature 0 – 40 °C / 32 – 104 °FWeight 7.5 kg / 17 lbs.Dimensions (W x H x D) 283 x 312 x 71 mm / 11.14 x 12.28 x 2.79“Protection class IP 54

USB connection10 [Mbit/s]

1) The graphic mode is deactivated for systems withoutforce/stroke monitoring

The SCHMIDT® PressControl 3000 is designed as a stand-alone solution. Extended functions are provided with the soft-ware programs SCHMIDT® ControlTool and SCHMIDT® SPC.

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SCHMIDT® PressControl 3000System architecture

Up to 6 systems can be operated simulta-neously with one PC

USB hub

SCHMIDT® ManualPress

Manual workstations

I/O processing I/O processing

I/O processing I/O processing

I/O processing

Safety technology,category 4

Safety technology,category 4

Two-hand release Light curtain

SCHMIDT® Pneumatic andHydroPneumaticPress

Automation

CANCAN

USB

Using the software SCHMIDT® ControlTool, up to 32 SCHMIDT® PressControl 3000 controlunits can be linked with a PC. Six systems can be operated simultaneously. Features:•• Data interfacing via USB (10 Mbit/s) allows for the quick transfer of high-resolution curves,

also with short cycle times.•• Different press types, manual workstations and automated machines can be connected in a

network.•• All production data, such as curves and data sets, are centrally stored on a PC (Statistical

Process control [SPC] is optionally available).•• Short changeover times because data sets can be prepared offline.•• Parameter change is possible during the running process (hot keys).

USB hubSCHMIDT® Pneumatic andHydroPneumaticPress

Manual workstations withSafetyModule- redundend electronic safety

circuit (cat. 4)- wear-free, no mechanical

relays- long life- suited for two

hand safetyswitches orlight curtainoperation.

Control unit SCHMIDT® PressControl 4000

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SCHMIDT® PressControl 4000 is a control unit for the opera-tion of compact, standardized single workstations as well ascomplex, highly flexible assembly automation systems. The real-ization and the extension of assembly lines is considerably sim-plified using SCHMIDT® PressControl 4000 in connection withSCHMIDT® ServoPress modules. All configuration and opera-tion parameters are managed and documented via control unitSCHMIDT® PressControl 4000.

Features:•• Control is based on an industry PC•• Operation of up to 6 ServoPress modules or NC axis via CAN

bus•• Multi-functional process control PLC for an individual design

of process and user interface. The scan rate is 5 ms and isindependent of the length of the program code. The PLC isin constant communication with the process data acquisitionand the CNC.

•• Integration of more than 2000 I/O•• Integrated process monitoring•• Quality evaluation based on window and stroke tolerances,

and thus a safe detection of “failed” parts.•• Statistical documentation optionally with SCHMIDT® SPC•• User-friendly, intuitive menu guidance•• Operating modes:

- Set-up mode via hand wheel- Cycle mode via function key- Automatic mode (e. g. via light curtain [1-cycle, 2-cycle],

external keys or external signal)

TFT display 10.4”High-resolution process visualization

Integrated hand wheel (for set-up mode)Can switch to any CNC axis with selectable resolution to sim-plify set-up of an operation. The press ram can approach adesired target based on distance or force increments via handwheel.

Number padIntegrated membrane keypad for the input of numerical valuesand choice of functions.

Function keys/softkeys Presets a freely programmable membrane keys to simplify han-dling.

Control elementsEssential machine functions are clearly arranged as buttons onthe operating panel, e. g. Control ON/OFF (if components aredelivered without control button).

Emergency stop buttonSeparates the motor electrically from the drive, and a mechani-cal brake is activated. This guarantees safe stopping of the ram.

Track ballSubstitutes an integrated mouse, robust element adapted toany work environment.

Top view

~15”

Bracket system connection

~12

”

~18

”~

9”~

5”

~5”

Technical dataIndustry PC with - integrated PLC

- integrated CNC with fully digital drive control(integrated force, speed andposition control circuit) for up to 6 axis

- process monitoring- diagnosis and service functions- Microsoft Windows™ operating system.

Drives - integrated hard disk- 3.5” floppy drive

Screen integrated TFT display 10.4”Field bus CAN with possibilities for connection:

- up to 6 SCHMIDT® ServoPress modules or other CNC axis

- more than 2000 I/OsInterfaces - Ethernet (10/100 Mbit)

- 2 x serial (COM1/COM2), 1 x parallel (LPT)EMC acc. to requirements of EMC law

(EN50081, EN50082)Main supply 230 V~, 110 V~Current consumption < 2 AAmbient temperature 0 – 40 °C / 32 – 104 °FWeight approx. 16 kg / 35 lbs.

CAN bus connections

Ethernet

Hand wheel

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SCHMIDT® PressControl 4000System architecture

The SCHMIDT® PressControl 4000 control unit functionssimultaneously as a control for the line as well as monitoringthe process. The hardware and software components usedform a system concept with real-time behavior. This is guaran-teed by a system architecture that contains two CAN bus sys-tems. CAN 1 transfers data for the NC axis, e. g. ServoPressmodules or other NC axis, are controlled. Recorded measuringdata and I/O data are transferred via CAN 2. This prevents busconflicts in the event of high data densities.

The communication with other systems is realized via Ethernet(OPC).

Ethernet

CAN 1 DrivesCAN 2 Process data

acquisition

X/Y compound table NC rotary table

CAN 2I/O coupler

CAN profibusgateway

I/O digital/analog

Axis safety, 2-channel

Auxiliary Box

OPCSPC

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User interface for professional assemblyfor PressControl 3000 and 4000

SCHMIDT® ControlTool is the platform of the SCHMIDT® PressControl 4000 and is available optionally withSCHMIDT® PressControl 3000 in combination with a PC. Thefunctionality of ControlTool has been developed especially forassembly operations with direct intervention in the process.

SCHMIDT® ControlTool is a program with “Look and Feel” ofMicrosoft WindowsTM.

The following functions are available in ControlTool:•• Process visualization•• Process data management•• Development tool (PLC editor)•• Statistical Process Control (SPC), optional

Features:•• Easy and quick setup of the processes•• Definition of the data sets and operating profiles by parame-

ters•• Process optimization due to switchover of the process display

(F/s, F/t, s/t)•• Easy and quick definition and evaluation of the processes

using the quality monitor•• Guaranteed detection of “failed” parts•• Unambiguous documentation and component assignment•• Software PLC for freely programming processes•• Service functions for diagnosis and system updates

SCHMIDT® ControlTool functions

Software functions are enabled or disabled depending on theaccess rights.

The language of the software user interface can be set toGerman, English or French.

SCHMIDT® SPCoptional

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Visualization and analysis for PressControl 3000 and 4000

Visualized displayForce output and press stroke are important parameters forevaluating the quality of pressed assemblies. The data of thesemeasurements are recorded during the process and displayedby the software as force/stroke behavior curve F/s, F/t ors/t. Freely definable tolerances in the form of force/strokewindows and stroke tolerances are provided for qualityassurance of the assembly process. Using the softwareSCHMIDT® ControlTool, up to 8 force/stroke windows and 4stroke tolerances can be defined. With the help of these crite-ria, quality-critical areas can be monitored selectively. If the tol-erances in the monitored curve areas are not met, application-

specific interventions can be carried out (e. g. selection mea-sures).Using the software SCHMIDT® ControlTool, it is easy to createtolerance criteria and to display curve behaviors exactly. For anevaluation of the behavior, the working stroke and thereturn stroke are important. The high resolution of our mea-surement systems allows a large number of measuring pointsthat are required for a process-safe evaluation. Zoom and mea-suring functions are integrated into the software allowingdetailed documentation about the assembly processes.

Process analysis – graphic display force over time Process analysis – graphic display stroke over time

Zooming area

Measuring cursor

Process analysis – graphic display force over stroke

The curve must passthe window from leftto right.

Stroke tolerance inreturn stroke

Stroke tolerance inworking stroke

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Process data management for PressControl 3000 and 4000

Press, quality and SPC parameters as well as system settings are menu-guided, extended and modified. This does notrequire programming knowledge. The parameters are definedwithin the data sets under customer defined identifications.Setting up additional data sets are simple via a menu drivenwizard. Loading of a different data set can occur manually orvia external, automated input.

SCHMIDT® PressControl 3000 SCHMIDT® PressControl 4000

Entry of the parameters via dialog fields

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Software architecturefor PressControl 3000 and 4000

Input and output mask PLC CNC Module

Output window

Process

Measuring dataProcess data acquisition

The function of the SCHMIDT presses is based to a largeextent on the control architecture. The combination of processentries, PLC, CNC and process data acquisition is the key tosolving highly complex joining tasks precisely and efficiently.The force and stroke measuring systems with integrated signalamplification used in all monitoring based press systems bySCHMIDT Technology are evaluated in high resolution by theprocess data acquisition and transferred as ACTUAL values tothe PLC for graphic or numeric output.

The excellent control behavior of SCHMIDT® PressControl4000 is a direct result of the quick, bidirectionalcommunication between PLC, CNC and drive of the servo axis.

SCHMIDT® PressControl 4000

Data set

ACKCNT-0-PCT-0-PCT offPCTon1

3.0 sec1.0 sec20

15.000 mm

2.0 sec24.000 mm

1500 N 1

9 8 Alarmtime press error7 Alarmtime quan. reached6 Target count5 Counter access4 Start/Stop PDA3 Unlock at target time2 Unlock at target stroke1 Unlock at target force0 Mode : F=0, s=1, m=2

Input Dataset 1

SCHMIDT® PressControl 3000

Software development toolsfor PressControl 3000 and 4000

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PLC process controlThe PLC processes signals or values. Apart from this basic func-tion provided with standard PLC systems, our control also car-ries out a large number of tasks and decisions that influencethe process.

Features of the PLC editor:• Easy troubleshooting due to cyclical and static debugger•• Easy overview due to separate debug window•• Commonly used operands (inputs/outputs, words, flags, etc.)

are listed •• Useful search function •• Function-oriented programming

Resources editorA resources editor is providedas programming interface,which supports the easy andstructured creation of instruc-tion sets. The description ofthe operands by user-definedsymbols facilitates an easyoverview. In addition, manypre-defined functions simplifyprogramming.

Unlimited design of the userinterface•• Process output window,

clear and unambiguousinterface for the user withdynamical and static text andgraphic display

•• Clear instructions for theuser to intervene in theprocess, e. g. by pressing afunction key

•• Unrestricted definition andlabeling of function keys

•• Individually designable textoutput (e. g. as supplementto the process output for theadministrator) and parameterentry

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SCHMIDT® SPCStatistical Process Control for PressControl 3000 and 4000

In the overview display, you see all necessary information fromthe process, such as characteristics (monitors), informationpass/fail, current measuring value, SPC status, average value,Cp and Cpk value, at a glance.

The software package SCHMIDT® SPC is used for determiningthe process capability. The program calculates the statisticalparameters from the process and tolerance data. The charac-teristics of all quality criteria are calculated online after eachassembly process, and the calculation is available for documen-tation. Contrary to conventional systems, the user is constantlyinformed about the course of the assembly and the processquality. User-defined upper and lower warning and intervention limitsinform the process control when exceeding or falling belowthese limits about which application-specific measures can betaken.

Each single process can be reconstructed using the productionbacktrack.

Apart from the system-related monitors, other process-relevantinformation can be prepared statistically, such as the work inte-gral (area under the F/s curve) or external measuring data (e.g.temperature).

Considering the individual characteristics, additional importantvalues are displayed graphically and numerically.

Standard deviation

Histogram

Numerical values

SCHMIDT® MoveTolPatented offset of tolerance data software for PressControl 3000 and 4000

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Assembled parts are subject to certain manufacturingtolerances. Measured deviations of the parts result in an offsetof the curves in the curve window. The curves of the parts withthe largest tolerance deviations may then be situated outside ofthe defined tolerance limits and are classified as “failed” part.

Using the function “Offset of tolerance data”, the tolerancesof parts can be taken into account. The tolerance windows andstroke tolerances are offset in the graphic display by the offsetvalue.

Offset of tolerance data in relation to freely selectable reference

SCHMIDT® Interface software

The communication with coordinated control system is realizedvia a standardized interface program with SCHMIDT®

PressControl 3000 and 4000

All relevant system states as well as “failed” productions aretransferred from one control to another via a simple signaltransfer.

All standard physical interfaces, such as

•• I/O interface•• CAN-CAN bus connection•• CAN-profibus connection

can be used for signal transfer with the automation environ-ment.

Reference curve Current curve

Force/strokewindow offset

Intersection point 1

OffsetStroke tolerances

Stroke [mm]

Forc

e [k

N]

Intersection point 2

Win. 1 Win. 2

Tol. 1 Tol. 1’