Graphic Human Machine Interface (HMI) capability enables operators to see how the machine is functioning and speeds local/remote diagnostics and troubleshooting. Forging presses with advanced HMI capabilities, software that graphically presents information to operators about the state of various processes, can help them monitor what is happening, troubleshoot, and quickly get equipment back online when required.
While HMIs are becoming popular in the industry, there are distinct differences in capability between basic and advanced, next-level options.
Rudimentary HMIs are visual terminals where information can be entered and data viewed, but no new information is stored.
In contrast, advanced HMIs enable saving/retrieving data, custom searches, and the display of historical trends. Far from rudimentary, up-to-date PDF technical documents and the schematics of each component on the machine are searchable and can be quickly displayed as needed. However, the most distinguishing capability of HMIs is how the software applications ease operator understanding and control of the forge press, along with any necessary troubleshooting.
In fact, truly next level HMIs provide dynamically animated schematics that allow the operator to watch the forging equipment while it’s running. Operators can quickly “drill down” from a top-level animated schematic to review the performance of specific components, such as valves and pumps, as well as to locate information on part numbers and wiring schemes.
For example, in the case of an animated hydraulic schematic the hydraulic pressure source from multiple pumps is displayed in one location for instant verification. The operator can monitor the current press state displayed in a text box, as well as fields indicating the pressure in the main and pullback cylinders. The valve command and actual spool feedback are displayed for each proportional valve.
The press operator can also monitor main ram tonnage, main cylinder pressure, moving platen position, last cycle time, and current cycle time.
With this information, forge personnel can more effectively learn the press’s internal operation by observing all this data as it cycles through operation to enable quick diagnosis and action if there is a potential issue.
Whether for the forge operator or OEM, in terms of preventive or troubleshooting diagnostics, the integration of HMIs, sensors, and online technical support has also advanced.
For instance, one manufacturer has developed an online diagnostic system for remote monitoring and support through a remote Ethernet diagnostic connection provided on all new equipment. The Ethernet-based control system provides OEM engineers with a platform to remotely view the machine’s health as it is operating.
This capability – along with implementing some redundant components like electronic position transducers – can keep production online even if a component fails. If one fails, the manufacturer can dynamically switch to the good one. Traditionally, one failed transducer leads to downtime until a technician can acquire the correct part and change it out on site.
Such a system also enables the viewing of historical trends and up-to-date, searchable PDF technical documents and schematics, as well as dynamic animated schematics.
With historical data, if a component is starting to fail, maintenance can often identify and replace it before catastrophic failure.
Advanced HMIs also enable a historical review of how forging equipment functioned at specific dates and times. When the operator simply “pins” certain types of data or moves a graphic slider representing a slice in time that functions as an icon on a smartphone, the HMI displays the data on how the forging equipment was performed at the exact day and time.
Forge equipment with an HMI can include a library of datasheets for its electrical, mechanical and hydraulic devices. Electrical schematics, hydraulic schematics, and mechanical assembly drawings can be viewed and printed from an HMI. The data sheets are in PDF format, which enables keyword searching within the document.
Instead of spending days trying to locate the right technical documentation, and reading through data sheets or wiring schematics that can be 100 pages long, the data is searchable and immediately available to operators.
Next level HMIs, in fact, take search capability much farther by enabling the “drilling down” from a high- level, dynamic, graphic animation of the equipment to quickly “zero in” on the specific data, schematic, or drawing required.
As an example, at a dynamically animated schematic screen on the HMI, the operator can hover over the device to find the exact manufacturer’s part number or click on the device to access its specific datasheet.
Although forging presses are traditionally viewed as decades-old technology, advanced HMIs are becoming virtually as simple to monitor and use as an operator’s favorite smartphone, while making critical performance data readily available as well.
So, for manufacturers relying on the efficient use of forging equipment new capabilities can significantly increase production uptime and profitability, providing an important competitive edge.
For more information:
Info: Ajax/CECO/Erie Press
Call: (814) 455-3941
Email: sales@AjaxErie.com
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