Reprogramming of an automatic industrial press

Describing the operating principle in effect, as well as the changes that need to be made
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Operating principle of the equipment

The equipment consists of three main units that operate synchronously:

• stepper motor feeder (feeder);
• die for punching holes;
• guillotine for cutting blanks.

The stepper motor feeds the strip to the die. During the movement of the material, the die performs hole punching with a step of 36 mm. After each punching cycle, the strip is fed further. When the length of the blank reaches the set value, the guillotine performs the cut.

Since the step between the holes is 36 mm, the length of any blank must always be a multiple of 36 mm.

For example, for a blank length of 900 mm:

900 / 36 = 25

Thus, the die will perform 25 strikes, after which the guillotine will cut the blank.

Length control is carried out based on signals from the stepper motor feeder. Currently, the software calculates the moments of operation of the die and guillotine based on the distance traveled, which is tracked by the stepper motor.

Task set

Instead of the existing die, a new die is installed, which performs five cycles of the previous die in one strike. That is, in one strike, 5 holes are formed with a total step length of 180 mm (5 × 36 mm).

It is necessary to make changes to the software so that after replacing the die, the ability to produce blanks of any length, a multiple of 36 mm, remains.

Example of the old die's operation:

• die step — 36 mm;
• blank length — 828 mm;

828 / 36 = 23 strikes.

After the 23rd strike, the blank is cut.

For the new die:

• die step — 180 mm;
• blank length — 828 mm.

828 / 180 = 4.6

That is, the length of the blank is not a multiple of the new step of 180 mm.

In this case, the system should:

1. Perform 4 full strikes of the die of 180 mm.
2. After that, determine the remaining length:

828 − (4 × 180) = 108 mm.

3. To complete the blank, perform feeding and positioning not by the step of 180 mm, but taking into account the base step of 36 mm.
4. After reaching the total length of 828 mm, perform a cut with the guillotine.

Thus, the program should automatically switch from working with a step of 180 mm to precisely finishing the length of the blank according to the base step of 36 mm in all cases where the length of the blank is not a multiple of 180 mm, but is a multiple of 36 mm.