HBL-standard training

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HBL System Training
Punching system HBL general
Tutor:
Wang Aimin

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HBL System Training
Punch press hydraulics - general overview
HBL - functional principle and part search guide
Service guide & trouble shooting

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Voith - Standard systems
performance
ECOplus
HRL
HRE
HBL
HBL System Training

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HBL System Training

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HBL System Training
Punch operation - general reflection
sheet metal
punch movement

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HBL System Training
Punch operation - general reflection
pressure and oil flow
during ram movement
high oil flow required
ram movement control
position has to
be adjustable
ram force requirement
force not always necessary

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HBL System Training
Basis functions
pressure and flow conditioning
accumulator charging control
consumption optimized hydraulic
ram movement control
position control
short cycle times
ram force supply
load sensing control
high pressure on demand

Präsentation
HBL System Training
Basis functions
pressure and flow conditioning
accumulator charging control
consumption optimized hydraulic
ram movement control
position control
short cycle times
ram force supply
load sensing control
high pressure on demand

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HBL System Training
General reflection – oil requirement
oil required
no oil required
no oil required
no oil required
oil required

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HBL System Training
General reflection – oil requirement
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.

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HBL System Training
Oil requirement – accumulator charging

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HBL System Training
Oil requirement – accumulator charging sequence

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HBL System Training
Accumulator charging
Key Features:
- Reliable: pure mechanical steering
constant flow rate pump
- Low noise: soft switching valve
- Efficient: low bypass pressure saves energy
- Setup: no complex adjustments
- Dynamics: good response to load changes

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devices
accumulator
safety valve (pressure relief)
charging valve main stage
charging valve pilot stage
electr. discharging valve
check valve
pressure switch
HBL System Training
Accumulator charging

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accumulator
type of construction - diaphragm
precharge pressure (nitrogen)
according to hydraulic circuit
HBL System Training
Accumulator charging - device guide
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.

Präsentation
safety valve (pressure relief)
type of construction – poppet seat valve
HBL System Training
Accumulator charging - device guide
remark:
for security issues only
do not brake seals
do not make any adjustments
do not lose certificates

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

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HBL System Training
Accumulator charging - device guide
electrical discharging
main stage
pilot stage
pilot stage
main stage

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type of construction:
cartridge valve
mounted in manifold
HBL System Training
check valve:
Accumulator charging - device guide

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pressure switch
type of construction – piston valve
HBL System Training
Accumulator charging - device guide
remark:
for monitoring pressure only
no other functions
has to be controlled by machine control
adjustment pressure according to hydraulic circuit

Präsentation
HBL System Training
pressure and flow conditioning
accumulator charging control
consumption optimized hydraulic
Basis functions
ram movement control
position control
short cycle times
ram force supply
load sensing control
high pressure on demand

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HBL System Training
Ram force supply
sheet metal
punch movment
high force requiered

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HBL System Training
Ram force supply - low/high pressure operation
high pressure requiered
low pressure business
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

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device guide
slow move valve
(high pressure switch on)
high pressure relief valve
check valve
HBL System Training
Ram force supply

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slow move valve
high pressure switch on!
directly controlled
fast switching
solenoid valve
HBL System Training
Ram force supply - device guide
example 4/3 solenoid valve

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high pressure relief valve
directly controlled
pressure relief valve
HBL System Training
Ram force supply - device guide

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HBL System Training
Ram force supply - device guide
check valve
poppet seat valve

Präsentation
HBL System Training
Basis functions
pressure and flow conditioning
accumulator charging control
consumption optimized hydraulic
ram movement control
position control
short cycle times
ram force supply
load sensing control
high pressure on demand

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device guide
main valve
slow move valve
linear measuring device
HBL System Training
Ram movement control

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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%)
HBL System Training
Ram movement control

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main valve
type of construction
pilot operatet spool valve
HBL System Training
Ram movement control - device guide

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HBL System Training
Ram movement control - device guide
main valve
pilot operated
fast switching
rugged design
easy to handle

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HBL System Training
Ram movement control - device guide
slow move valve
directly controlled
fast switching
solenoid valve
high pressure switch on!

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HBL System Training
Ram movement control - device guide
Linear measuring system (LMS)
feedback sensor for ram position
incremental signals, magnetic system
gap adjustment 0.8 mm!

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HBL System Training
Other ram devices
Tank line shock absorber
piston accumulator
damping pressure peaks
in tank line

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HBL System Training
mechanical feedback parts
guiding bar
mechanics
Other ram devices

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HRE System Training
Hydraulic power unit

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HBL System Training
Hydraulic power unit
device guide
air cooler
return line filter
motor
temperature control (option)
gear pump combination
oil level control (option)

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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
HBL System Training
Hydraulic power unit - device guide

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heat exchanger
type of construction
oil air cooler
integrated thermo switch
switch on temperarure 40 °C
HBL System Training
Hydraulic power unit - device guide

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temperature control
monitoring oil temperature
HBL System Training
Hydraulic power unit - device guide

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oil level control
monitoring oil level
HBL System Training
Hydraulic power unit - device guide

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HBL System Training
Service guide - first meeting with the machine

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HBL System Training
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

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HBL System Training
Service guide- first meeting with the machine
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.

Präsentation
HBL System Training
Service guide- first meeting with the machine
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)

Präsentation
HBL System Training
Service guide- first meeting with the machine
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.

Präsentation
HBL System Training
Service guide- first meeting with the machine
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

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HBL System Training
Service guide- first meeting with the machine
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

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HBL System Training
Service guide – trouble shooting

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HBL System Training
Service guide - trouble shooting
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

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HBL System Training
Service guide - trouble shooting
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!)

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HBL System Training
Service guide - trouble shooting
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!

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HBL System Training
Service guide - trouble shooting
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!

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HBL System Training
Service guide - trouble shooting
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!

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HBL System Training
Service guide - trouble shooting
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!

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HBL System Training
Service guide - trouble shooting
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!

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HBL System Training
Service guide - trouble shooting
Ram moves down after hydraulic/electronic off
slow creeping movement is normal (mass higher than friction of cylinder seals)

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HBL System Training
Service guide –
software tool strokemaster
displays soft- and FW-revision
modify / display parameter
control RAM
analyse last RAM movement

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HBL System Training
Service guide - stroke master file
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
stepper
ram
(stroke extender moves up)
state messages
sample time

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HBL System Training
Service guide - stroke master file
PARAMETERS_START
POS1 80
POS2 8800
POS3 8900
POS4 9000
POS5 9550
POS6 9020
POS7 0
POS8 0
stroke parameter

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HBL System Training
Service guide - questions
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: