EITEL PRESS AUTOMATION
To automate the EITEL Press machine for its different sections i.e gauging, straightening, aligning, Mill-cutting, chamfering, ultrasonic.
We provided the solution with the help of Control Logix PLC, LVDT’s, HMI’s, studio 5000 and HMI , FT View ME, all the PB are provided for ON/OFF, Emergency Switch and Indication Light on the desk panel. PLC program of EITEL press with 4 operating mode: Manual, semi-auto, Run-out, Full Auto.
Through HMI the gateway is given to the user to control the desired parameters of the machine like pressure, temp. etc.
This project is for a axle manufacturer through cold forging,the finishing process is carried out in EITEL Press.
The steps are explained in brief as follow:
First the axle is passed through washing/ airing section, where it is being washed and dried with air nozzles to remove the dirt or any unwanted material stick to it.
The axle is being transferred through feeder on transfer 1, transfer 2 and further.
Here the variation is being checked on the component, 5 LVDT’s are used for testing the axle TIR Run out ( Total Indicator Reading).
All the proximity sensors, position encoders of Pneumatic Cylinder are commissioned with PLC to take the input and thus all the parameters are shown on HMI.
On this station TIR Run out of axle is being calculated and then the component is transferred to next station i.e. straighten.
As per the TIR Run out the axle is being straightened in this section as per the requirement or as per specification.
The axle is aligned here to an accurate position. It works on all operation modes such as full auto, semi-auto , manual etc.
On this station the component is aligned for further process of cutting the extra length of the axle.
Programming is done of motion axis as per the requirement of operation. All the cutting position of component is being set and calculated and can be adjusted by operator through HMI. The component is being cut for the extra length and the machine is so programmed for the specification so that it is cut as per the desired specification.
After going through MILL- CUTTING Section the component gets sharp edges, to remove the same chamfer is done.
All the chamfering is done as per the calculation based on the requirement of process.
Since the component has passed so many stages and undergone through different pressure and temperature . The cracks can be formed inside the component which can further affect its strength and stability.
Here in ultrasonic section the cracks are being detected and it so programmed that if crack is found then it is rejected and if component found ok then it is further fed to the accepted lot.
All the valves and sensors are programmed and commissioned as per the specific requirement of the process.
The axle gets manufactured through cold forging and goes through various operations , on all the modes like semi-auto, full-auto, manually etc.
This makes the product more accurate as per specification.