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Have you ever wondered why a CNC Tube Bending Machine has a permanently attached HMI?
Have you ever lost production simply because you had problems with a touch-screen, a disk drive, a monitor, a keyboard failure, etc.?
Or a corrupt software file or driver?
Have you ever had to call on your company's IT personnel
to help configure your PC-Based machine controllers
after having to reinstall software drivers or a disk-drive,
etc?
Do you have to be careful about powering the PC-based
control-system down and constantly worry that a
brownout or a blackout might occur or someone
absent-mindedly shuts-off the machine power
during a disk-write operation?
And how long do you have to wait for a machine re-boot?
And why is it that; Industrial PC systems based on so-called
"standard hardware and operating systems", are never up and running
without some long drawn-out setup and configuration?
Do you find it frustrating when trying to communicate the nature of a possible machine malfunction through a mobile phone from the shop floor to outside service personnel?
The fact is that an HMI is only required for inputting data, storing data, displaying data and providing diagnostic and production reports. So why should a valuable piece of production machinery become crippled and unable to produce parts because of a failure of any one of the relatively fragile elements that make up a tethered HMI system?
Another favorite is a corrupt system file or software driver due to the industrial PC not being shut down in the required manner, such as in the event of a power-failure, etc. This often results in needing a complete re-installation of the operating system, drivers, software licenses and then finding that machine parameters and part-data are lost or out-of-date.
For When Win-doesn't!
A failed touch-screen, monitor, keyboard, storage device, etc., renders the entire piece of equipment useless and tends to remain that way for longer than it should.
New part program creation.
Open an existing part program.
Save a part program (automatically backs-up to secondary local storage and cloud storage for access by other systems).
Link (Bluetooth) wirelessly to any compatible CNC Tube Bending Machine.
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File Menu
Data entry using standard Length, Rotation, Angle Values (Y, B, C in machine terminology).
Data entry using Cartesian (XYZ) coordinates.
Axis move-speed input.
Manual or automatic Springback compensation input.
Early Mandrel Extract parameter (degree).
TooliC axis / B axis clearance before coordinated motion allowed.
Pressure Die pulse timer for cycle-time optimization on non-servo actuator.
Mandrel extraction pulse timer for cycle-time optimization on non-servo actuator.
Mandrel Oscillation repeatedly extracts and advances the mandrel during the bending cycle.
Split Die feature, typically used to release non-round material after bending.
Mandrel lubrication on-time, during the bending cycle.
Y Overtravel to provide tube clearance beyond the programmed move before allowing the B axis rotation to commence.
C negative is used to reallign the tube with the Collet for recapture purposes. This is normally not required if Springback compensation is in effect.
C Extra causes the C axis to move in the positive direction after the clamp has opened. Typically used when the tube is binding-up in the die during bending and subsequently causing problems for the Y axis feed.
Programmable Hold will interrupt the sequence and is typically used to initiate the "Teach" mode in the event that the part geometry presents a problem that normal sequencing doesn't prevent part/machine interference.
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Table
Y Load Position provides a convenient tube-loading distance between the operator and the Collet.
Pressure Die length offset value to avoid interference with the Y axis Collet.
Clamp Length offset value used for Y axis minimum clearance calculation.
Center Line Radius required for clearance moves and also PDA and Y axis tracking.
Y Minimum offset to prevent interference between Y axis Collet and Wiper Die tooling.
Collet Depth and Tube Length required to calculate Y axis position for first bend.
Hitch Length, when used with a thru-collet, enables longer tubes to be loaded. As soon as enough Y axis travel becomes available, the Y axis will hitch-feed and capture the end of the tube.
Y Park Position is typically used when square or rectangular part-shapes are being produced. This feature prevents the workpiece from interfering with the Y axis carriage during the last bend.
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Offsets
This calculator compares the programmed bend-angle with the actual angle produced, then determines the constant and proportional factors to compensate each bend-value of the actual program.
The Springback compensation angle is added only during the bending cycle and does not modify the actual bend program.
The compensation value is also used to reallign the tube with the Y axis Collet in the event of a recapture.
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Automatic Springback Compensation
Each actuator/axis is selectable by touching the appropriate graphical representation.
The current state of the actuator is displayed and in the case of the directional actuators, it is possible to have them latch in the direction of jogging.
Each servo axis displays current position on the main screen and when selected for Jog, a separate screen appears showing the axis position, axis position-error and the axis torque command.
The "Zero B" function provides a consistent B axis position at the start of each bending sequence. This is useful when bending non-round material on machines not equipped with a B axis home sensor and also in the case where a Collet is not perfectly concentric and an automatic loading system relies on precise alignment.
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Manual Jog
The large speed dial makes for quick and easy axis speed adjustment during jogging.
The response of the axis motion is reflected in the on-screen oscilloscope which facilitates rapid and accurate axis calibration should this become necessary.
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Speed Dial & Oscilloscope
All machine inputs and outputs are displayed in real time on this screen.
The portability of Phenix means that it can be carried around the machine for troubleshooting purposes. A proximity sensor, for example, can be triggered manually by a technician and he can immediately see if that signal is being detected by the machine controller.
A history of diagnostic error messages is also stored here, providing many levels of detailed machine performance.
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Diagnostics
In order to keep menu selections to a minimum, all related functions are grouped together. Here, for example, along with the DOB (bend angle) input dialog, the user can also specify the preferred sequencing of the Clamp, Pressure Die and Mandrel along with the gearing ratio of the Pressure Die-Assist (PDA) for that particular bend.
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Data Input Dialog
Thanks to Phenix’s integrated cameras, it is possible to make notes regarding a particular tooling setup and to store those notes with the related program data. Each file provides three separate image and text-input fields.
Selecting an image field causes the camera controls to appear on the screen to facilitate image capture. Selecting a text-input box causes the on-screen keyboard to appear.
Images may be deleted and re-captured at any time.
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Notes
The production screen displays the currently running part name, the current part count, the batch-limit for the current production-run, the piece-part cycle time and the machine’s real-time status.
The part-count and batch-limit values can be edited at any time simply by selecting the appropriate display area on the touch-screen.
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Production
Bend data can be input as Cartesian coordinates and bend-radii then automatically converted to Lengths, Rotations, Angles (YBC’s in machine axis terminology).
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XYZ - YBC
On a bending machine that is equipped with a remotely controlled hydraulic pressure valve, the actual force of the Follower Slide can be programmed to vary relative to the angle of the bending axis during the bending cycle. For example, in some applications, it is helpful to provide an extra push at the start of the bend and then gradually taper-off the force.
In cases where a very fine line exists between obtaining a good quality result or a failure due to wrinkling or tube-breakage, this profiling capability can provide the optimum control required to minimize or eliminate scrap material.
Click image to enlarge
Pressure-Die Assist (Follower Slide)
On a bending machine that is equipped with a remotely controlled hydraulic pressure valve, the actual force of the Pressure-Die can be programmed to vary relative to the angle of the bending axis during the bending cycle.
In cases where a very fine line exists between obtaining a good quality result or a failure due to wrinkling or tube-breakage, this profiling capability can provide the optimum control required to minimize or eliminate scrap material.
Click image to enlarge
Profiled Pressure-Die Force
On a bending machine that is equipped with a Carriage-Boost system, the actual force of the Carriage can be either limited or programmed to vary relative to the angle of the bending axis during the bending cycle.
This feature is not just limited to assisting the bending process but also helps to eliminate clamp slippage that can occur with non-serrated clamping dies or in cases where the die serrations become clogged by material coating deposits, etc.
Click image to enlarge
Profiled Carriage (Y-Axis) Boost
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Industrially ruggedised interfaces
Adaptive Motion produced the Industry’s first PC-based CNC Bender control in 1987. This was for a 5-axis, double-head bender that was used to produce mini-van seat frames.
As Phenix is based on commercially available components, you have the option of sourcing these components directly from the manufacturer or as a ready-made kit from Adaptive Motion.
Most maintenance personnel with an electrical background and an understanding of servo-drives will have little trouble undertaking the actual installation. At start-up, we recommend that you involve our services via net-based remote control. We will perform the debug and calibration of the servos, along with making any required sequence changes to suit your particular machine. For this, we would require a PC near the machine, equipped with a web-cam and audio input/output.
Yes, please contact the factory with/for the specifics.
We wanted to simplify the entire package to improve reliability and functionality while at the same time reducing overall cost. The touch-screen’s resilience surpasses that of many so-called industrial terminals, the portability is a great help to the troubleshooter and the integrated cameras, WiFi and audio systems facilitate true remote diagnostic capability. Furthermore, a fresh install is a matter of loading just a single file, no drivers, no licenses, no .ini files, no IP address-setup, etc...
Yes, it is absolutely safe. Unlike many PC-based systems, Phenix plays absolutely no part in the real-time aspect of machine control. It is purely a human-machine-interface (HMI) running on the Android OS. The actual machine controller uses a proprietary real-time OS, has no direct online connection and runs totally independently of the HMI and is, therefore, totally immune to such viruses as Stuxnet and Beckhoff.App.dll that can play havoc with PC-based controllers.
Click here to read the Control Systems Security Wiki.
Phenix is compatible with the industry-standard +/-10v motor command format and also has direct PWM output if a digital command is preferred.
Adaptive control techniques are employed to compensate for the inherent dead-band due to spool overlap. Our algorithm literally guides the axis to within a single encoder count if such precision is required.
Of course! All-electric, all-hydraulic or hybrid machines, it really doesn’t matter to the Phenix controller.
Many machine manufacturers today rely on the servo-motor’s integrated encoder or resolver for axis position information. The problem with this approach is that any backlash between the servo-motor and the driven load will not be accounted for and therefore the accuracy and repeatability of the axis cannot be guaranteed.
The dual-loop method features an auxiliary feedback device that is coupled directly to the load. In this case, the main encoder loop becomes responsible for maintaining a fast, stable servo response while the auxiliary encoder loop facilitates accurate load positioning, regardless of any mechanical backlash.
Occasionally it is necessary to bring a machine or work-cell to a complete and immediate halt via the Emergency Stop system. If this occurs while the CNC bender is in mid-sequence, the sequence is typically aborted and the workpiece is lost. In the case of a work-cell, this means that the entire cell sequence typically has to be reset resulting in lost time and material.
Phenix was designed from the ground-up to be able to recover completely from such conditions without losing a single workpiece.
Pretty much anything you can imagine including:
- Side-loaders
- Front-loaders
- Integrated Shears
- Hole Punches
- Weld Seam finder/positioners
- RFID-based automatic tool-set identification
- Tube inspection systems
- Complete cell integration
Our standard package includes support for up to eight dual-loop-capable servo axes.
Mutiple eight-axis controllers can be linked together up to a maximum of 256 axes.
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Quick release articulated screen-mount facilitates convenient positioning of the user-interface and rapid detachment for remote usage.
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