Finn-Power E5 User manual

Brand: Finn-Power

Model: E5

Type: User manual

This manual is also suitable for

USER GUIDE

E5 TURRET PUNCH PRESS

Series 12.2

Control Siemens 840D

Revision/Date 2/2009-10-22

All copyrights, trademarks, patents, and all other intellectual property rights included in this documentation shall

be the exclusive property of the Finn-Power companies or the owners of the material. Except where otherwise

provided by law, the content of this documentation shall not be used, copied, edited, translated, distributed or

otherwise made use of without the express consent of the Finn-Power companies or the owner of the material.

The Finn-Power companies do not guarantee that the content of this documentation is accurate or updated. The

information may be amended, updated or deleted without prior notice.

Further information on the intellectual property rights of the Finn-Power companies is available on written request

from: Customer Documentation, Finn-Power Oy, P.O. Box 38, FI-62201 KAUHAVA, FINLAND.

FINN-POWER, THE FINN-POWER OF LIGHT, FINN-POWER LASER, SHEAR GENIUS, NIGHT TRAIN FMS,

FLEXIBLY YOURS, ENERGY IN EFFICIENT USE, ECOPUNCH, ECOCUT, ECOBEND, ECOMBI, COMBO

FMS, EXNER, TULUS, POWERFORM, NC EXPRESS, SHEAR BRILLIANCE, BENDTERM, BC-EXPERT, FOUR

–IN-ONE, NIGHT TRAIN, EXPRESS, FP, MULTI-TOOL

are registered trademarks of the Finn-Power companies.

Table of Contents

1. Introduction ...................................................................................................... 5

2. Safety instructions ........................................................................................... 6

2.1. Hazard levels .............................................................................................. 6

2.2. Safety symbols ........................................................................................... 6

2.3. Safety during operation and maintenance .................................................. 7

2.3.1. Operation stations and safety zones ................................................... 7

2.4. Safety devices and functions of the base machine ..................................... 8

2.5. Periodic inspection of safety devices .......................................................... 9

2.5.1. Safety light beams ............................................................................... 9

2.5.2. Emergency stop buttons and turret service door ............................... 10

2.5.3. Hydraulic and pneumatic system ....................................................... 11

2.5.4. Service door ...................................................................................... 11

2.5.5. Warning and instruction labels (E5/E5x/E6/E8) ................................. 11

3. Technical information, E5/E6/E8 ................................................................... 13

3.1. Notes on technical information ................................................................. 14

4. Operating description of turret punch press ............................................... 16

4.1. Misuse of the machine .............................................................................. 16

5. Main structure of the machine E5 ................................................................. 17

5.1. Machine axes ............................................................................................ 17

5.2. Coordinate table ....................................................................................... 17

5.3. Turret ........................................................................................................ 18

5.4. Clamps ...................................................................................................... 19

5.5. Brush tables .............................................................................................. 19

5.6. Punching mechanism, E machines ........................................................... 20

5.7. Control centre ........................................................................................... 20

5.8. Auto-index system .................................................................................... 20

5.9. Standard tool system Thick Turret ............................................................ 20

5.9.1. Clamp protection areas ..................................................................... 21

5.10. Control desk (Siemens) .......................................................................... 22

5.11. Control panel (Siemens) ......................................................................... 23

5.12. Remote control panel .............................................................................. 24

6. Using the machine ......................................................................................... 25

6.1. Starting the machine and emergency stop ............................................... 25

6.2. Production order run ................................................................................. 26

6.3. Production run control ............................................................................... 27

6.4. Production run after emergency stop ........................................................ 27

6.5. Shutting down the machine in a normal situation ..................................... 28

6.6. Turret rotation ........................................................................................... 28

6.7. Mounting a tool on the turret ..................................................................... 29

6.8. Operating modes ...................................................................................... 31

6.8.1. JOG mode ......................................................................................... 31

6.8.2. MDA and AUTOMATIC modes .......................................................... 33

6.8.3. Feed rate control ............................................................................... 33

6.8.4. Program control buttons and function keys ....................................... 34

7. Preventive maintenance ................................................................................ 36

7.1. E5 maintenance points ............................................................................. 37

7.2. E5/E6/E8 weekly maintenance ................................................................. 37

7.3. E5/E6/E8 monthly maintenance ............................................................... 39

7.4. Compact Express, monthly maintenance / LD, monthly maintenance ...

7.5. Recommended lubricants ......................................................................... 40

8. Multi-Tool tool station (option) ..................................................................... 42

9. Additional clamp (option) .............................................................................. 43

10. SU3/SU6C/SU9 sorting unit (option) .......................................................... 44

10.1. Technical data SU3/SU6C/SU9 .............................................................. 44

10.2. Control panel .......................................................................................... 45

10.2.1. Manual mode ................................................................................... 45

10.2.2. Automatic mode ............................................................................... 46

10.3. Sorting unit addresses ............................................................................ 46

1. Introduction

This instruction has been made for professional use. The instruction has to be stored the whole

lifetime of the machine. If the machine is moved to another place or sold, the person in charge of the

handover must arrange for the instruction to follow the machine.

This instruction contains the following sections:

• Introduction

• Safety

• Technical data

• Main structure of the machine and operating description

• Operating instructions

• Maintenance instructions

Also the following documents are delivered together with the machine:

• Drawings

• Spare part book

• Other certificates and documents required by the delivery

These instructions of the machine are the original ones, drawn up in Finnish. Other language versions

are translations of the original instructions.

User Guide - E5 Turret Punch Press

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2. Safety instructions

The manufacturer's safety requirements are as follows:

• The operating and maintenance personnel must have all operating and maintenance instru-

ctions readily available, and they must be understood and followed. The owner of the machine

shall ensure that this is done.

• The operating and maintenance personnel must be appropriately trained, and they must have

read the instructions before performing their tasks.

• The operating and maintenance personnel must also have read the instructions for all other

equipment or components included in the delivery.

• The operating and maintenance personnel must be appropriately skilled and trained in their

tasks.

• The operating and maintenance personnel must be comprehensively trained in all operating

and maintaining procedures related to the delivered unit.

• The operating and maintenance personnel must observe local laws and regulations.

• The operating and maintenance personnel must use only approved and inspected lifting and

hoisting equipment.

2.1. Hazard levels

The term DANGER indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

The term WARNING indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

The term NOTICE indicates a hazard with a risk which, if not avoided, could

result in property damage.

2.2. Safety symbols

Warning

A yellow triangle with a black border and black symbol indicates danger.

Prohibition

A round sign with red border, cross-line and black symbol indicates that the

action in question is prohibited.

Compulsory action

A blue circle with a white symbol indicates that the action in question must

be carried out in order to avoid hazard.

User Guide - E5 Turret Punch Press

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2.3. Safety during operation and maintenance

WARNING

The machine must not be taken in production use before it has

been installed according to the layout and tested and handed

over to the customer according to the delivery contract.

2.3.1. Operation stations and safety zones

• During operation, the operator is normally stationed at the control panel / control desk.

• The machine's working area is surrounded by a safety zone.

• The safety zone is separated by fixed structures, safety fences and safety devices.

• The machine may be left running in automatic mode.

• During machine operation no one, including the operator, is allowed within the safety zone.

WARNING

• Do not store goods or products in the safety zone.

• Crushing hazard; the working movements of the machine and

the machined part present a serious risk of accident

• When starting the machine, always ensure that no people nor

foreign objects are within the safety zone.

User Guide - E5 Turret Punch Press

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Operation stations and safety zones (E5/C5)

Machine operating sides A and B

1. Control desk (operation station 1)

2. Remote control panel (operation station 2)

3. Safety zone

4. Safety fence

5. Safety light beam

6. Service door

2.4. Safety devices and functions of the base machine

The machine delivery includes the following safety devices and functions that trigger alarms and stop

the machine when necessary:

• Emergency stop buttons

• Safety limit switch for the turret service door

• Safety limit switch for the service door (option)

• Safety light beams

In addition, the machine is equipped with the following safety functions to protect it from damage:

1. Central locking and protection area control for clamps

2. Sheet detectors in clamps

User Guide - E5 Turret Punch Press

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3. Extreme limits of axis movements

4. Pressure switch for compressed air supply

5. Overload protection of the servo motor (in connection with upforming mechanism)

6. Supply voltage control

7. Operating temperature control for the NC control unit

8. Punch stripping control

9. Locking control of the auto-index system

10. Sheet distortion limit switch

2.5. Periodic inspection of safety devices

To ensure reliable and safe operation of the machine, periodic inspection of the machine's safety

devices must be performed. Carry out the inspections according to the following instructions.

WARNING

• TBy-passing a safety device is strictly forbidden.

• Repair any faults or defects detected during inspection imme-

diately, or contact Finn-Power service.

• The machine must not be used until all detected faults have

been repaired.

2.5.1. Safety light beams

Check the safety light beams once a day

Check the safety light beams (option) on the A and B sides as follows:

• Check that the safety light beam is mounted securely.

• Check that the safety light beam is undamaged.

• Check that the surfaces of the safety light beams are clean.

With the machine running, interrupt the light beam. When the light beam is interrupted, check that

1. the axis movements of the machine stop

2. blue indicator light lights up on the reset button of the A-side remote control panel

3. blue indicator light lights up on the B-side reset button

If the light beam is interrupted, the machine cannot be operated

in automatic mode.

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2.5.2. Emergency stop buttons and turret service door

Figure: Emergency stop buttons and turret service door

1. Emergency stop buttons (control desk, remote control panel, turret cover)

2. Turret service door

The delivery may also include other emergency stop buttons.

Check the emergency stop buttons once a month

Check that

• the button is easily accessible

• the button is clean and easy to see

• the body of the button is properly attached to its mounting tray

• the button part is not loosened or detached from its shank

• the button is not damaged by dents (e.g., cracked)

• there is no dirt between the moving parts of the button

• the button release is not over-sensitive

• the button locks reliably in the open position.

With the machine running, press down the emergency stop button.

Check that

User Guide - E5 Turret Punch Press

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1. the axis movements of the machine stop

2. the green indicator light on the control desk goes out

3. the value on the pressure gauge of the machine's service unit (PN1) changes to 0 bar.

Use the emergency stop button only in hazardous situations.

Check the turret service door once a month

Check that

• the safety limit switch is mounted securely

• the sensing surfaces of the safety limit switch are clean

• the safety limit switch is not damaged by dents

• the service door locking mechanism functions properly.

Open the turret service door, exit the safety zone, and reset the safety devices. Check that X and Y

movement of the machine is not possible.

2.5.3. Hydraulic and pneumatic system

Check the hydraulic system once a month

Check the hydraulic system in connection with turret service door checking. Check the control panel

of the machine to ensure that there is no pressure in the hydraulic system when the service door is

open.

Check the pneumatic system once a month

Check the pneumatic system in connection with an emergency stop. Check that the value on the

pressure gauge of the machine's service unit (PN1) changes to 0 bar.

2.5.4. Service door

Check the service door (option) safety limit once a month

Check the safety limits of the service doors:

• Check that the service doors are mechanically in good condition.

• Check that the limit switch is mounted securely.

• Check that the sensing surfaces of the limit switch are clean.

• Check that the limit switch is not damaged by dents.

Open the service door. Check that

1. the axis movements of the machine stop

2. blue indicator light lights up on the control box button next to the service door.

2.5.5. Warning and instruction labels (E5/E5x/E6/E8)

• 003319

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• 003147

• 003027

• 003002

• Indicates an electrical hazard

• 003378

• Indicates the weekly maintenance points of the

index tool holders and Multi-Tools

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3. Technical information, E5/E6/E8

Performance

Ram force 200 kN / optional 300 kN (later upgrading is possible)

Punching stroke electrical servo motor

Tool stations in the turret 20

Tools Thick Turret

Max. punch diameter 89 mm

Clamps, pneumatic 2 pcs / optional 3 pcs (E5) 3 pcs / optional 4 pcs (E6/

E8)

Turret rotation 23.8 r/min (E5) 30 r/min (E6/E8)

Tool change time

(1)

1–3 s

Auto-index system:

• Index tool stations standard 2 pcs / max. 10 pcs

• Max. punch diameter 89 mm

• Max. tool rotation 166 r/min

Indexable upforming system (option):

• Upforming force 200 kN

• Die stroke height in forming programmable by increments of 0.001 mm (max. 12

mm; NC axis)

• Upforming speed with 25 mm form-to-

form distance

(2)

80–150 1/min

E5 E6/E8

X-traverse 2584 mm 3144 mm

Max. X-traverse, axis speed 90 m/min 120 m/min

Y-traverse 1317 mm 1615 mm

Max. Y-traverse, axis speed 60 m/min 90 m/min

Max. positioning speed 108 m/min 150 m/min

Max. hit speed

(3)

E5 E6/E8

• 1 mm between holes

• 25 mm between holes

• 250 mm between holes

800 1/min

430 1/min

160 1/min

900 1/min

Punching accuracy according to LKP-7100

(4)

• Max. hole location deviation (X/Y axis) 0.1 mm

• Max. hole-to-hole distance deviation (X/Y

axis)

+/- 0.05 mm

• Max. angular deviation (CNC Index Tool) +/- 0.1°

Positioning accuracy according to VDI/DGQ 3441

(5)

• Positional deviation, Pa (X/Y axis) 0.08 mm (+/- 0.04 mm)

• Positional scatter, Ps (X/Y axis) 0.04 mm (+/- 0.02 mm)

Sheet dimensions

Max. sheet size X x Y 2530 mm x 1270 mm (E5) 3074 mm x 1565 mm (E6)

4300 mm x 1565 mm (E8)

Max. sheet weight

(6)

200 kg

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Max. sheet thickness 8 mm

Connections

Electrical connection (E1):

•

Average power consumption

(7) 5 kVA / 4 kW

•

Power requirements

(8) 11 kVA

• Min. fuse size 16 A

Compressed air connection (P1):

• Min. compressed air pressure 6 bar

• Max. compressed air consumption 5 Nl/s

•

Average compressed air consumption

(9) 2.5 Nl/s

Ethernet connection 100 Mbps yes

Additional data

Work chute (option), max. part size 500 mm x 500 mm

NC control Siemens Sinumerik 840D

Program memory 1.5 MB

Machine weight 12 500 kg (E5) 13 500 kg (E6/E8)

Painting two-component acrylic polyurethane paint and epoxy/

polyester powder paint

Colours: blue RAL 5015

grey Tikkurila TVT 854H (AKZO 160 A1)

yellow RAL 095 90 59

black RAL 9011

Gloss grade: 85% epoxy/polyester powder paint

90% two-component polyurethane paint

Noise sound pressure level may exceed 85 dB (A)

3.1. Notes on technical information

(1) When special tools are used, the tool change time may differ from the value given.

(2) Upforming speed depends on the form height, ram speed, acceleration/deceleration rate of

the X and Y axes, and axis speed.

(3) Hit speed depends on the programmed stroke length, ram speed, and acceleration/

deceleration rate and speed of the axes.

(4) Punching accuracy is tested according to the Finn-Power standard LKP-7100 by punching

holes in a 1 m x 1 m sheet at 100% speed and measuring the location (X/Y) and angle (CNC

Index Tool) of the holes punched in the sheet.

(5) Positioning accuracy is measured by a laser-interferometer from the X and Y slides of the

machine's coordinate table according to the VDI/DGQ 3441 standard.

(6) The allowable acceleration/deceleration rate of the X and Y axes depends on sheet weight.

Part accuracy depends on the acceleration/deceleration rate and on the sheet size and weight.

(7) Average power consumption is based on the production run of a typical nesting program with

nominal sheet size and 1.5 mm sheet thickness. The effective value can be used in calculation

of energy costs.

(8) This value must be used when the power supply is dimensioned for the machine (size of

possible transformer and cable).

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(9) Average compressed air consumption is based on the production run of a typical nesting

program with nominal sheet size and 1.5 mm sheet thickness. The value can be used in

calculation of energy costs.

We reserve the right to change technical specifications without prior notice.

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4. Operating description of turret punch press

The turret punch press is constructed for processing of sheet material. Tools for punching are located

on the turret. Sheets are processed by punching them with a punch and die. In the process the sheet

is moved according to NC control commands. Punching can be executed as a single stroke or a stroke

sequence (nibbling or cutting out).

The machine is constructed to be suited to its purpose of use and to be operated, adjusted and

serviced without exposing people to danger as far as the operations in question are performed in the

way the manufacturer has intended and in accordance with the manufacturer's instructions.

4.1. Misuse of the machine

The machine must not be used for any other purpose than for processing of sheet material. The

operating values specified in the technical data must not be exceeded. Neither the application, the

construction or any part thereof must be changed nor any auxiliary equipment added without a written

consent from the manufacturer.

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5. Main structure of the machine E5

2 9

511

1. Frame

2. Turret

3. Coordinate table

4. Clamps

5. Brush tables

6. Punching mechanism

7. Control centre

8. Turret cover

9. Manual turret rotation push-buttons

10. Control desk

11. Remote control panel

12. Turret service door

5.1. Machine axes

• Three linear axes for X, Y, and RAM movements

• Two rotating axes (0 to 360°)

• C for index

• TUR for tool change

Options

• TU axis for TU6 tapping unit

• FORM axis for upforming

5.2. Coordinate table

• The coordinate table moves the sheet in the X and Y axis directions, being controlled by the

NC control. Axis speed is freely programmable.

• Axis acceleration can be reduced by programming.

• The working area in the X-direction can be expanded automatically by means of the reposi-

tioning function.

User Guide - E5 Turret Punch Press

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5.3. Turret

Figure: Turret

• The machine comes with a 20-station turret.

• The turret is completely protected by cover plates.

• The turret comes with separate tool holders, which allows making the turret layout to customer

specification.

• The tool holders are easy to change.

• There is a service door in the brush table to give access to the turret.

• The turret can be rotated manually by pressing the buttons in the turret cover when the turret

service door is open.

• The buttons are operational only in JOG mode.

• When the turret service door is open, other axes cannot be moved.

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Figure: Turret tools

1. Upper turret plate

2. Lower turret plate

3. Tool holder, upper (B)

4. Tool holder, lower (B)

5. Tool holder, upper (C)

6. Tool holder, lower (C)

7. Index tool holder, upper (Di)

8. Index tool holder, lower (Di)

9. MT6-A/135

Interchangeable tools

10. Tool assembly

11. Die

5.4. Clamps

• The clamps are equipped with a pneumatic central locking system.

• All punch presses have connectors for the installation of an additional clamp (option).

• The programmable clamp setting system (PCS) positions and locks the clamps in the positions

defined in the NC program.

• NC control measures the clamp positions and controls automatically that the clamps do not

collide with anything.

5.5. Brush tables

• The brush table damps sheet vibration and noise, and it does not damage the underside of the

sheet.

• The table on the loading side is equipped with sheet support rollers which rise when a sheet is

being loaded. Thanks to the rollers, it is easy to load sheets and insert them between the clamps.

When the clamps are closed, the sheet support rollers retract automatically.

• The brush table can be equipped with a work chute (option) in front of the turret through which

the parts are dropped from the table to be sorted.

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5.6. Punching mechanism, E machines

• The punching stroke is generated by a servomotor-driven mechanism.

• The upper and lower limits of the punching stroke can be set numerically (NC axis).

• In forming, the upper and lower limits of the ram are freely adjustable from the bottom position

up.

• With forming tools, you can program a lower ram speed and use a lower forming speed and a

positioning tolerance based on the G code, which allows making exact and intricate shapes.

5.7. Control centre

• The control centre accommodates the central processing unit of the NC control, the servo am-

plifiers, the cell control computer, and other electrical equipment.

• The computer in the control centre is equipped with a LAN connection.

• The NC control display, the main operation panel of the machine, and the touch screen are

located in a separate control desk.

5.8. Auto-index system

• The auto-index system enables automatic rotating of the tool in the working position according

to the numerical control.

• It is possible to perform punching strokes and nibbling with the tool at a freely programmable

angle.

• The system turns the tool automatically to the programmed angle while the X and Y axes of the

machine move the sheet.

• The index mechanism is mounted on the machine frame, due to which the index tool stations

in the turret are uncomplicated and interchangeable.

• A desired number of index tool stations can be mounted on the turret; the number of stations

can flexibly be changed afterwards.

5.9. Standard tool system Thick Turret

The standard tool system of a turret punch press is Thick Turret (AM). The turret punch press can

also be equipped with other tools to special order.

AM = Thick Turret (Wilson Tool Int. Inc. USA / MATE Precision Tooling, USA)

Tool holders for 110 mm holes

Fixed Thick Turret tool Max. punch diameter

A A (0.5 in) 12.7 mm (0.50 in)

B B (1.25 in) 31.75 mm (1.25 in)

C C (2 in) 50.8 mm (2.00 in)

Tool holders for 135 mm holes

Fixed Index station Forming station Thick Turret

tool

Max. punch diameter

B/135 Bi Bif B (1.25 in) 31.75 mm (1.25 in)

C/135 Ci Cif C (2 in) 50.8 mm (2.00 in)

D Di Dif D (3.5 in) 88.9 mm (3.50 in)

E E (3.5 in) 88.9 mm (3.50 in), CLUSTER

punching area D118 mm

User Guide - E5 Turret Punch Press

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Finn-Power E5 User manual

Brand: Finn-Power

Model: E5

Type: User manual

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