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Overview
OverviewRockwell Automation offers various systems, bundled packages, and kits for meeting the safety-related control standards for the clutch/brake of mechanical stamping presses. These solutions are designed to meet the safety requirements of ANSI B11.1, OSHA 1910.217, CAN/CSA Z142-M90, IEC-61508, EN-954 and EN-692.
The 6556 Clutch/Brake kits are bundled packages consisting of redundant PLC components with application software, wiring diagrams, relays and documentation. Each solution is designed with independent redundant programmable controllers with additional electromechanical components and the application software to provide the necessary monitoring, self testing, security, and verification that make up a control-reliable design.
The PLC-5/x6 based kits come with the clutch/brake software secured in program file #16, and the user can add other logic to other files. The PLC-5-based kits are designed for large presses with extensive automation.
The MicroLogix™ kits are pre-programmed with the ladder program locked in flash memory. Certain features in the fixed kits are configurable. The MicroLogix-based Compact PressMaster™ kit, for example, has a variety of standard features to control ancillary functions such as lube and programmable limit switch that can be configured through pre-programmed PanelView screens. The fixed kits are easy to use, require no programming, and are designed for small to medium-size presses retrofitted by the user.
The StamPro™ system is a complete, ready-to-install, Logix-based press control system that comes with controllers and hardware for controlling a stamping press. Ancillary control functions, which can be purchased from Rockwell Automation or supplied by the user, are integrated into the system hardware and software designs. The StamPro system is designed for end users, OEMs and integrators. The system can be purchased either with pre-programmed optional functions or can be programmed by the user.
Some press functions which can be integrated with our solutions include:
- Clutch/Brake. The Allen-Bradley controller designed system that controls the dual-valve clutch/brake mechanism as found on all mechanical stamping presses. This system includes dual redundant controllers with application software for monitoring and self-testing to achieve safety regulation compliance.
- Programmable Limit Switch (PLS). Ladder Logic for switching outputs according to crankshaft position. The PLS is often used to integrate and synchronize other press auxiliary functions such as feeders, grippers, blow-off and ejector valves. This feature requires a resolver position input for accuracy. The PLS is usually pre-programmed and configured by the user for each job or die.
- Die Monitoring. Logic that monitors a variety of in-die sensors to determine misalignment, double blanks, misfeeds, part positioning, plus other critical conditions. The die monitor function requires a resolver input and is generally pre-programmed and configured for each job or tool.
Modes of Operation
The following table lists the modes of operation for each Rockwell Automation press control solution.
| Press Modes of Operation | MicroLogix™ Clutch Brake | Clutch Pro™ | Compact Press Master™ | StamPro™ System |
| Off | X | X | X | X |
| Inch | X | X | X | X |
| Micro Inch | X | X | ||
| Single | X | X | X | X |
| Continuous | X | X | X | X |
| Remote & Auto Single | X | |||
| Contact your local Rockwell Automation sales office or Allen-Bradley distributor for pricing and order information. | ||||
Press Features/Functions
The table below summarizes the various press control functions available for each press control solution.
(S = Standard, O = Optional, P = User Programmable, Blank table cell = Function not available).
| Press Control Features | MicroLogix™ Clutch Brake | Clutch Pro™ | Compact Press Master™ | StamPro™ System |
| Clutch/Brake Control | S | S | S | S |
| Operator Interface | O | O | S/P | S/P |
| E-Stop & MCR Relays | S | S | S | S |
| Run Sta. Monitored | 4 | 4 | 4 | 4+ |
| Main Motor Control | S | S/P | ||
| RCLS Position Capable | S | S | S | S/P |
| Resolver Capable | O | O | O | O/P |
| Brake Time Monitor | S | S | S | S |
| Var. Speed Top Stop | S | S | S | S/P |
| Production Counters | S | S/P | ||
| Prog. Limit Switch | O | O/P | ||
| Die Protection Mon. | O | O/P | ||
| Recipe Storage | S/30 | S/99 | ||
| Var. Speed Comp. | S | S | S | |
| Lubrication Control | S | S/P | ||
| Tonnage Monitoring | O | O/P | ||
| Auto Counterbalance | O | O/P | ||
| Shut Height Adjust | S | S/P | ||
| Var. Speed Drive Interf. | O | O/P | ||
| Servo Feed Interface | O | O/P | ||
| Robot Interface | O | O/P | ||
| Coil Feed Interface | O | O/P | ||
| Die Cushion Control | O | O/P | ||
| Die Clamp Control | O | O/P | ||
| Bolster/Die Cart Cntl. | O | O/P | ||
| Aux. Automation Intrf. | O | O/P | ||
| Prod. Monitoring/OEE | S | S/P | ||
| Hydric. Overload Cntl. | O | O/P | ||
| Light Curtain Interface | S | S | ||
| Disconnect/Starters | O | O | ||
| Open Net. Interface Capable‡ | S | S | S | S |
| User Prog. Capable | S | S | ||
| Enclosure Assembled | O | O | O | O |
| Complete System | O | O | O | O |
| ‡ Ethernet, DeviceNet, Controlnet, RS-232 | ||||