How to Integrate Hydraulic Press Automation Systems

Hydraulic presses are widely employed in a range of industries. Automotive designers rely on them to fabricate parts for cars and trucks.

Controlling the force of a hydraulic press's ram is essential for automation. To accomplish this, store the accurate pressure and ram travel information in the controller's memory.

Inductive Sensors

Inductive sensors detect metal targets without physical contact by creating an electromagnetic field. This emitted magnetic alternating field interacts with the metal object, causing eddy currents to be generated. These extract energy from the sensor's LC oscillator, altering signal level within the detector and switching its output stage.

These sensors offer excellent performance under extreme temperatures, are resistant to the chemical corrosives used in food and beverage production, and are ECOLAB(r) certified. Constructed with one-piece stainless-steel (V4A/AISI 316L) housings and highly rated to IP68 and IP69K standards, these inductive sensors deliver ultimate accuracy and dependability at an economical price point - offering high-performance presence- and position sensing solutions at a great value.

KCC's automation system now prevents presses from progressing to tool change with incorrectly closed tools, reducing downtime and avoiding production faults that could damage either the tools or press itself. Furthermore, this PLC-based system automates direction reversal based on pressure measurements, guaranteeing parts are consistently pressed at an even depth and extending machine life.

PLC Controllers

A PLC (programmable logic controller) is an integrated computer capable of controlling various devices and components. Its input can include sensors that provide data about a process, while its output directs actuators such as electric motors or hydraulic cylinders.

A typical PLC has multiple input and output ports to communicate with various devices and components. Its internal memory stores programs and data that are programmed by the user.

For easier interaction between the operator and PLC, it can be equipped with a Human Machine Interface (HMI). This interactive panel displays visual representations of system health in real time.

Integrating a hydraulic press automation system requires using a PLC controller with an integrated HMI. This eliminates time-consuming and costly tasks such as PLC-Panel wiring and communication configuration.

I/O Modules

I/O modules are used for connecting input and output signals to sensors or actuators. They come in various styles, offering features like isolation, termination and signal indication of the signal's status.

These I/O modules can be configured to accept discrete signals or analog data that changes over time, such as temperature, pressure or level. Some even offer burnout detection capabilities.

Leuze I/O masters support a range of protocols, such as PROFINET and Ethernet/IP. These enable process data, diagnostic information, and device details to be securely transmitted to higher systems or cloud applications. This system boosts machine adaptability and transparency while cutting maintenance/stocking costs by centrally commissioning sensors and actuators through web browsers.

Safety Circuits

There are various methods to protect an industrial hydraulic press operator or other plant personnel. Some are straightforward, like making sure they stay out of the way of moving machinery; however, other measures require design engineers to use more complex circuits and components.

One solution to this is using dual control circuits for cylinders. These allow for two-handed operation and are less taxing on operators than single controls.

These circuits often include a lock valve that prevents the cylinder from drifting or sagging, even when only one of the valves is shifted.

Another approach is to incorporate monitored safety valves into both the upstream and downstream process. The monitored valve is retrofitted into the system between the pump supply point and downstream process.

De-energising the valve isolates it from the pump and any residual energy in the downstream process is taken out. This information is then sent to your PLC via M12 connection.