HBL System Training

1.

JFY
Voith Turbo H + L Hydraulic
HBL System Training

2.

JFY
HBL System Training
Punching system HBL general
2 |HBL system training 10-2010| Wang Aimin
Tutor:
Wang Aimin

3.

JFY
HBL System Training
• Punch press hydraulics - general overview
3 |HBL system training 10-2010| Wang Aimin
• HBL - functional principle and part search guide
• Service guide & trouble shooting

4.

JFY
HBL System Training
Voith - Standard systems
HRE
HBL
4 |HBL system training 10-2010| Wang Aimin
ECOplus
performance
HRL

5.

5 |HBL system training 10-2010| Wang Aimin
JFY
HBL System Training

6.

JFY
HBL System Training
Punch operation - general reflection
6 |HBL system training 10-2010| Wang Aimin
punch movement
sheet metal

7.

JFY
HBL System Training
Punch operation - general reflection
pressure and oil flow
7 |HBL system training 10-2010| Wang Aimin
during ram movement
high oil flow required
ram movement control
ram force requirement
position has to
be adjustable
force not always necessary

8.

JFY
HBL System Training
Basis functions
pressure and flow conditioning
accumulator charging control
consumption optimized hydraulic
8 |HBL system training 10-2010| Wang Aimin
ram force supply
load sensing control
high pressure on demand
ram movement control
position control
short cycle times

9.

JFY
HBL System Training
Basis functions
pressure and flow conditioning
accumulator charging control
consumption optimized hydraulic
9 |HBL system training 10-2010| Wang Aimin
ram force supply
load sensing control
high pressure on demand
ram movement control
position control
short cycle times

10.

JFY
HBL System Training
General reflection – oil requirement
no oil required
no oil required
10 |HBL system training 10-2010| Wang Aimin
oil required
no oil required
oil required

11.

JFY
HBL System Training
General reflection – oil requirement
11 |HBL system training 10-2010| Wang Aimin
accumulator operation idea
during punch operation ram has
high oil consumption.
accumulator and pump provide
together the required very high oil
flow.
during X/Y axis movement no oil
consumption of the ram.
during that time pump refills the
accumulator for the next punch
cycle.

12.

JFY
HBL System Training
Oil requirement – accumulator charging
Accumulator
(diaphragm type)
Connection to oil
consuming circuit
P out
12 |HBL system training 10-2010| Wang Aimin
T return
Check valve
P
T
Accumulator
charging valve
Pump
with constant
flow rate
Pressure
adjustment

13.

JFY
HBL System Training
Oil requirement – accumulator charging sequence
13 |HBL system training 10-2010| Wang Aimin
P
P out
P out
P out
P out
T return
T return
T return
T return
T
P
T
P
T
P
T
Empty:
Filling:
Full:
Delivering:
Accu empty,
valve charging
Accu filling,
valve charging
Accu full,
valve = bypass
Accu dropping,
valve = bypass

14.

JFY
HBL System Training
Accumulator charging
Key Features:
- Efficient:
low bypass pressure saves energy
- Reliable:
pure mechanical steering
constant flow rate pump
- Setup:
no complex adjustments
P out
14 |HBL system training 10-2010| Wang Aimin
T return
P
T
- Dynamics: good response to load changes
- Low noise: soft switching valve

15.

JFY
HBL System Training
Accumulator charging
15 |HBL system training 10-2010| Wang Aimin
devices
accumulator
safety valve (pressure relief)
charging valve main stage
charging valve pilot stage
electr. discharging valve
check valve
pressure switch

16.

JFY
HBL System Training
Accumulator charging - device guide
16 |HBL system training 10-2010| Wang Aimin
accumulator
type of construction - diaphragm
precharge pressure (nitrogen)
according to hydraulic circuit
quick check for precharge pressure:
start up hydraulic, let it pressurize
stop pump, deenergize electr. discharge valve.
monitor pressure gauge
pressure must drop slowly until precharge level
is reached, then will drop abruptly to zero.

17.

JFY
HBL System Training
Accumulator charging - device guide
safety valve (pressure relief)
17 |HBL system training 10-2010| Wang Aimin
type of construction – poppet
seat valve
remark:
for security issues only
do not brake seals
do not make any adjustments
do not lose certificates

18.

JFY
HBL System Training
Accumulator charging - device guide
18 |HBL system training 10-2010| Wang Aimin
accumulator charging valve consisting of:
main stage –> chartridge valve (in manifold)
pilot stage –> for pressure adjustment
electrical discharging -> 4/2 solenoid valve
remark:
restrictor in cartridge valve has to be clean!
if restrictor is blocked -> no pressure

19.

JFY
HBL System Training
pilot stage
Accumulator charging - device guide
19 |HBL system training 10-2010| Wang Aimin
main stage
main stage
pilot stage
electrical discharging

20.

JFY
HBL System Training
Accumulator charging - device guide
20 |HBL system training 10-2010| Wang Aimin
check valve:
type of construction:
cartridge valve
mounted in manifold

21.

JFY
HBL System Training
Accumulator charging - device guide
pressure switch
21 |HBL system training 10-2010| Wang Aimin
type of construction – piston
valve
remark:
for monitoring pressure only
no other functions
has to be controlled by machine control
adjustment pressure according to
hydraulic circuit

22.

JFY
HBL System Training
Basis functions
pressure and flow conditioning
accumulator charging control
consumption optimized hydraulic
22 |HBL system training 10-2010| Wang Aimin
ram force supply
load sensing control
high pressure on demand
ram movement control
position control
short cycle times

23.

JFY
HBL System Training
Ram force supply
high force requiered
23 |HBL system training 10-2010| Wang Aimin
punch movment
sheet metal

24.

JFY
HBL System Training
Ram force supply - low/high pressure operation
low pressure business
24 |HBL system training 10-2010| Wang Aimin
consumption optimised punching
two pressure solution
with high and low pressure
nibbling and punch processes with
low force demand under low
pressure
only on high force demand
high pressure generation
high pressure requiered

25.

JFY
HBL System Training
Ram force supply
25 |HBL system training 10-2010| Wang Aimin
device guide
slow move valve
(high pressure switch on)
high pressure relief valve
check valve

26.

JFY
HBL System Training
Ram force supply - device guide
26 |HBL system training 10-2010| Wang Aimin
slow move valve
high pressure switch on!
directly controlled
fast switching
solenoid valve
example 4/3 solenoid valve

27.

JFY
HBL System Training
Ram force supply - device guide
high pressure relief valve
27 |HBL system training 10-2010| Wang Aimin
directly controlled
pressure relief valve

28.

JFY
HBL System Training
Ram force supply - device guide
check valve
28 |HBL system training 10-2010| Wang Aimin
poppet seat valve

29.

JFY
HBL System Training
Basis functions
pressure and flow conditioning
accumulator charging control
consumption optimized hydraulic
29 |HBL system training 10-2010| Wang Aimin
ram force supply
load sensing control
high pressure on demand
ram movement control
position control
short cycle times

30.

JFY
HBL System Training
Ram movement control
30 |HBL system training 10-2010| Wang Aimin
device guide
main valve
slow move valve
linear measuring device

31.

JFY
HBL System Training
Ram movement control
31 |HBL system training 10-2010| Wang Aimin
description of function
main & slow move valve
-> working in parallel
both valves together
-> fast movement
-> full force
only slow move valve
-> slow movement
-> high presicion
only main valve
-> reduced punch force
(only about 15%)

32.

JFY
HBL System Training
Ram movement control - device guide
main valve
32 |HBL system training 10-2010| Wang Aimin
type of construction
pilot operatet spool valve

33.

JFY
HBL System Training
Ram movement control - device guide
33 |HBL system training 10-2010| Wang Aimin
main valve
pilot operated
fast switching
rugged design
easy to handle

34.

JFY
HBL System Training
Ram movement control - device guide
34 |HBL system training 10-2010| Wang Aimin
slow move valve
directly controlled
fast switching
solenoid valve
high pressure switch on!

35.

JFY
HBL System Training
Ram movement control - device guide
35 |HBL system training 10-2010| Wang Aimin
Linear measuring system (LMS)
feedback sensor for ram position
incremental signals, magnetic system
gap adjustment 0.8 mm!

36.

JFY
HBL System Training
Other ram devices
36 |HBL system training 10-2010| Wang Aimin
Tank line shock absorber
piston accumulator
damping pressure peaks
in tank line

37.

JFY
HBL System Training
Other ram devices
37 |HBL system training 10-2010| Wang Aimin
mechanical feedback parts
guiding bar
mechanics

38.

38 |HBL system training 10-2010| Wang Aimin
JFY
HRE System Training
Hydraulic power unit

39.

JFY
HBL System Training
Hydraulic power unit
39 |HBL system training 10-2010| Wang Aimin
device guide
air cooler
return line filter
motor
temperature control (option)
gear pump combination
oil level control (option)

40.

JFY
HBL System Training
Hydraulic power unit - device guide
40 |HBL system training 10-2010| Wang Aimin
return line filter
contamination indicator has to be
checked regularly
filter elements are not reusable
do not try to clean used elements
contaminated filterelements have to
be replaced by orgninal HYDAC
spare sparts
do never run the hydraulics without
filter elements

41.

JFY
HBL System Training
Hydraulic power unit - device guide
41 |HBL system training 10-2010| Wang Aimin
heat exchanger
type of construction
oil air cooler
integrated thermo switch
switch on temperarure 40 °C

42.

JFY
HBL System Training
Hydraulic power unit - device guide
temperature control
42 |HBL system training 10-2010| Wang Aimin
monitoring oil temperature

43.

JFY
HBL System Training
Hydraulic power unit - device guide
oil level control
43 |HBL system training 10-2010| Wang Aimin
monitoring oil level

44.

JFY
HBL System Training
44 |HBL system training 10-2010| Wang Aimin
Service guide - first meeting with the machine

45.

JFY
HBL System Training
45 |HBL system training 10-2010| Wang Aimin
Service guide - first meeting with the machine
pressure adjustments (low pressure)
accumulator charging frequency
accumulator precharge pressure
high pressure switch on
pressure adjustments (high pressure, pressure switch)
other controls:
- general punching behavior
- noise (machine, pump, pipes and hoses)
- LMS adjustment
- external leakage

46.

JFY
HBL System Training
Service guide- first meeting with the machine
46 |HBL system training 10-2010| Wang Aimin
Pressure adjustments (low pressure)
hydraulic pressurized, machine not running – look at gauges
low pressure 70bar (see hydraulic circuit), hysteresis 10% (7 bar).
pressure drops down very slowly to about 63 bar. Fast reloading back to 70 bar.
pressure adjustment only at accumulator charging valve (pilot stage).
upper switching point is defined as working pressure. For correct working pressure
see hydraulic circuit.
monitor pressure during punching. low pressure should be in a range between 70 to
50 bar and not drop below 40 bar.

47.

JFY
HBL System Training
Service guide- first meeting with the machine
47 |HBL system training 10-2010| Wang Aimin
Accumulator charging frequency – low pressure
hydraulic pressureized, machine not running, ram has to stay somewhere in
mid-oil position - look at gauges
low pressure charging frequency in a brandnew machine about 1-3 times a
minute.
high low pressure charging frequency can be caused by
- to low accumulator precharge pressure
- internal leakage caused by wear or cavitation in main valve
- internal leakage through check valve (1.4.7)

48.

JFY
HBL System Training
Service guide- first meeting with the machine
48 |HBL system training 10-2010| Wang Aimin
Accumulator precharge pressure - fast check
stop pump, deenergize electrical discharge valve, monitor pressure gauges
pressure must drop slowly until precharge level is reached, then will drop
abruptly to zero.
required precharge pressure see hydraulic circuit (about 35 bar)
precharge pressure has to be measured under working temperature (45°C)
Remark:
this procedure only useable for fast check, for detailed measureing appropriate
measuring equipment required.

49.

JFY
HBL System Training
Service guide- first meeting with the machine
49 |HBL system training 10-2010| Wang Aimin
Pressure adjustment (high pressure)
put a pressure gauge in measuring port „MA“
hydraulic pressurized, machine not running – look at gauges
(you see about half the low pressure value at „MA“)
move the ram down to the cylinder lower hard stop by
switching “on“ the “slow move valve“ (Pos. 1.3.1) „manually“
with external 24 volt.
look at gauges, you see high pressure value (285 bar) at
„MA“
high pressure adjustment only at high pressure relief valve

50.

JFY
HBL System Training
Service guide- first meeting with the machine
50 |HBL system training 10-2010| Wang Aimin
Pressure adjustment (pressure switch)
measure electrical resistance
at pressure switch pin1 -> pin 3
at working pressure pin1 -> pin3
connected
deenergize electrical discharge
valve, pressure drops slowly
monitor pressure gauge, connection 1-3
opens at adjusted pressure value
required switching point see
hydraulic circuit

51.

JFY
HBL System Training
51 |HBL system training 10-2010| Wang Aimin
Service guide – trouble shooting

52.

JFY
HBL System Training
Service guide - trouble shooting
52 |HBL system training 10-2010| Wang Aimin
No system pressure on pressure gauge
electrical discharging valve not switched on
-> lose connector plug
-> jammed solenoid valve
accumulator charging valve (main stage) does not close
-> blocked restrictor in main stage piston
extrem external leakage
-> broken hose inside the powerpack

53.

JFY
HBL System Training
Service guide - trouble shooting
53 |HBL system training 10-2010| Wang Aimin
System pressure problems (machine stand by)
system pressure does not reach required level
-> wrong pressure adjustment (accumulator charging valve)
-> external leakage in powerpack - hose or flange connection
-> broken pump (internal leakage)
-> very high internal leakage in ram (search for source of heating!)
to high accumulator charging frequency
-> to low accumulator precharge pressure
-> internal leakage ram (search for source of heating!)

54.

JFY
HBL System Training
Service guide - trouble shooting
54 |HBL system training 10-2010| Wang Aimin
System pressure problems (machine punching)
system pressure not high enough, machine stops very often during punching
-> external leakage in powerpack - hose or flange connection
-> wear in pump, does not deliver enough oil (internal leakage)
-> internal leakage ram (losing oil)
system pressure drops down too far during each punch stroke
-> to low accumulator precharge pressure
-> to long punch strokes
system pressure seems to be fine, machine stops very often during punching
-> check pressure switch adjustment
Make punch master files!

55.

JFY
HBL System Training
Service guide - trouble shooting
55 |HBL system training 10-2010| Wang Aimin
No home cycle possible
low pressure not available -> see „no system pressure“
“slow move valve“ (Pos. 1.3.1) does not switch correctly
-> check electrical connectors, valve piston blocked due to dirt?
Make Punch master files!

56.

JFY
HBL System Training
Service guide - trouble shooting
56 |HBL system training 10-2010| Wang Aimin
Tool change position (Pos1) not reached in time
“slow move valve“ (Pos. 1.3.1) does not switch correctly
-> check electrical connectors, valve piston blocked due to dirt?
Make Punch master files!

57.

JFY
HBL System Training
Service guide - trouble shooting
57 |HBL system training 10-2010| Wang Aimin
Punching under high force not possible (more than 15% max. punchforce)
high pressure valve (Pos 1.3.1) not switching
-> check electrical connectors, valve piston blocked due to dirt?
check valve (1.6) does not close
-> does piston of check valve move smooth?
punching force to high
-> punching force and striker force together higher than possible punching force
wrong punching parameters
- pos 5 to high or to deep
Make punch master files!

58.

JFY
HBL System Training
Service guide - trouble shooting
58 |HBL system training 10-2010| Wang Aimin
Forming mode – machine stops because of overtime
“slow move valve“ (Pos. 1.3.1) does not switch correctly
-> check electrical connectors, valve piston blocked due to dirt?
Make punch master files!

59.

JFY
HBL System Training
Service guide - trouble shooting
Ram moves down after hydraulic/electronic off
59 |HBL system training 10-2010| Wang Aimin
slow creeping movement is normal (mass higher than friction of cylinder seals)

60.

JFY
HBL System Training
Service guide –
60 |HBL system training 10-2010| Wang Aimin
software tool strokemaster
displays soft- and FW-revision
modify / display parameter
control RAM
analyse last RAM movement

61.

JFY
HBL System Training
Service guide - stroke master file
stepper
61 |HBL system training 10-2010| Wang Aimin
Tool to see what happens
ram movement real
short punch cycles
-> sample time 2 ms
long form cycles
-> sample time 3-5 ms
make „master-files“ to
be able to compare
ram
(stroke extender moves up)
state messages
sample time

62.

JFY
HBL System Training
62 |HBL system training 10-2010| Wang Aimin
Service guide - stroke master file
PARAMETERS_START
stroke parameter
POS1
80
POS2
8800
POS3
8900
POS4
9000
POS5
9550
POS6
9020
POS7
0
POS8
0

63.

JFY
HBL System Training
Service guide - questions
63 |HBL system training 10-2010| Wang Aimin
If you contact H+L for any questions please provide the following information:
end user company
ram type (example:HBL20to)
firmware version
date of machine installation
description of failure / machine behavior
stroke master files
any remarks:

64.

64 |HBL system training 10-2010| Wang Aimin
JFY