Changes made for Pathfinder 5226 controllers.

Some folding machines have an automatic radius adjust that controls the air gap between the nose of the clamp and the bending beam. This allows users the ability to adjust the gap depending on the thickness of the material. In most cases to achieve this adjustment the radius adjust usually moves the position of the clamp nose. Double folder machines do this adjustment for both the lower and upper bending beams. Since this adjustment can be made for both that means that the clamp nose can be moved past the zero point to have the air gap for the upper beam. A rule was then made to make sure the machine does not damage itself. This was that the beam could not be past its zero point in reference to which bending beam it is being moved for. As in the clamp cannot be at a negative position for the lower bending beam and cannot be positive for the upper beam.

It turns out though that some double folders are actually fine with going past the zero point to get a tighter air gap to get more bend out of the material to make up for the mechanical gap that is always there for both beams. To adjust for this the generic parameter Mechanical Air Gap was created. This parameter can be set to move the clamp past its zero points. So if this parameter is non zero the controller will subtract this parameter from the target radius adjust position for the lower beam and add on when using the upper beam. This allows the user to get more bend out of the material.

As a disclaimer if this parameter is used then the user will have to adjust backgauge offsets to make up for the extra space that is now between the nose of the clamp and the backgauge. If this gets set up in the material table then the backgauge position will be adjusted for every step to account for this parameter.

Change made for Pathfinder 5226 controllers.

The big advantage in having grippers on a machine is that the user can grip on to the material and then just let the machine run through multiple steps without additional pedal or button presses. One problem does come from this though in that if something happens like not a successful hem smash or the material is no longer fully against the backstop the machine will keep going and potentially cause more harm to the part.

To counteract this the Pause on Step Mode was added to bend and hem steps to help with steps that are known to have problems. When selected this will make the machine pause once the clamp is fully closed. At this time the user can open the clamp and manipulate the grippers. If the user thinks the step ended up successfully they can just press the Full Automatic button or the Next Step pedal and it will move on to the next step if the clamp is closed. This allows the user to potentially re-smash a hem or adjust the material to the correct position.

Changes made for Pathfinder 5226 controllers.

This is now the expected movement for double folders with and without FoldGuard for all modes.

Full Automatic Mode

Required Features:

Grippers, Hazard Zone/Area Light Fence

Description:

To enter this mode the Grippers must be closed and the Light Fence must not be Blocked. The machine will move in Fast Speed once the Full Automatic/Hazard Area Clear input has been turned on.

Expected Movement When:

Light Fence is Clear:

Light Fence has to be Clear to Start Movement. Clamp will not stop at Safety Stop. Once each Operation is finished it will transition to the next one without any stoppage. The only time the machine will stop when the Light Fence is Clear is if there is a Manipulation Operation, the Step is set up for a Pause Mode or the Part has been finished.

Light Fence Becomes Blocked:

If the machine is in Full Auto Mode and the Light Fence becomes broken the machine will stop the machine, but not drop out of Run. The machine cannot go back into Full Automatic Mode until the Light Fence has been Cleared. Once Cleared pressing the Full Automatic/Hazard Area Clear button will put the machine back in Full Automatic Mode.

Semi-Automatic Mode w/ Grippers Closed and w/ FoldGuard

Required Features:

Grippers, Hazard Zone/Area Light Fence, FoldGuard Laser

Description:

To enter this mode the Grippers had to be Closed and the user has decided to initiate movement with the Next Step Pedal. The machine will move in Safe Speed and anytime the Next Step Pedal is released the machine stop all movement, but not drop out of Run.

Expected Clamp Movement:

Hazard Zone/Area Blocked:

For FoldGuard to be Active the Light Fence has to be Broken. Pressing the Next Step Pedal will start the Clamp moving. When the FoldGuard Laser is not Broken the Clamp target will be fully clamped and not stop at the safety stop height. If the Laser is Broken then FoldGuard will require the Pedal to be Released and a Second press to get in an override state. The Clamp will then move in Slow Speed down to FoldGuard's Safety Stop Height. Pressing the Pedal again will move the Clamp into a Clamped position. If the Clamp starts moving with the Laser clear, but then becomes broken FoldGuard will stop the Clamp. A Second press will get Foldguard into the override state and movement will begin again in slow to FoldGuard's Safety Stop Height.

Hazard Zone/Area Clear:

For the machine to be in Hazard Zone/Area Clear Mode the Light Fence has to be Clear. FoldGuard will no longer be Active in this situation. Pressing the Next Step Pedal will start the Clamp moving. The Clamp target will be the Safety Stop Height in Pathfinder. Once the Safety Stop move has finished Second Press will move the Clamp into a Clamped State.

Expected Movement Once Clamped:

Hazard Zone/Area Blocked:

If this step is a Load or Re-Load of the material then the Next Step Pedal must be pressed again for all other Axes to start moving. Holding down the Pedal will complete the Operation. Once the Operation is complete the controller will move on to the next Operation. If the Pedal is being continuously pressed the controller will Run through all of the steps without stopping. FoldGuard is Active during this time and is Allowing Clamp Movement if the Laser is not Blocked. The only time the machine will stop is if the Next Step Pedal was Released, the Operation is a Manipulation Step, the Step has been set up to be a Pause Mode Step or if the Part is finished being made.

So this is running the machine using the NS pedal but outside haz area?

Hazard Zone/Area Clear:

If the Light Fence is not broken then the controller will continue with the rest of the operation once clamped. Holding down the Pedal will complete the Operation. Once the Operation is complete the controller will move on to the next Operation. If the Pedal is being continuously pressed the controller will Run through all of the steps without stopping. There will be no stops at the Safety Stop Height once the initial Load has been completed. The only time the machine will stop is if the Next Step Pedal was Released, the Operation is a Manipulation Step, the Step has been set up to be a Pause Mode Step or if the Part is finished being made.

Semi-Automatic Mode w/ Finger/Nose Gauge and w/ FoldGuard

Required Features:

Finger/Closed Grippers for Gauging, Hazard Zone/Area Light Fence, FoldGuard Laser

Description:

To enter this mode the Step has to be set up to use a Finger or Closed Grippers for Gauging. The machine will move in Safe Speed and anytime the Next Step Pedal is released the machine stop all movement, but not drop out of Run.

Expected Clamp Movement:

Hazard Zone/Area Blocked:

For FoldGuard to be Active the Light Fence has to be Broken. Pressing the Next Step Pedal will start the Clamp moving. When the FoldGuard Laser is not Broken the Clamp target will be fully clamped and not stop at the safety stop height. If the Laser is Broken then FoldGuard will require the Pedal to be Released and a Second press to get in an override state. The Clamp will then move in Slow Speed down to FoldGuard's Safety Stop Height. Pressing the Pedal again will move the Clamp into a Clamped position. If the Clamp starts moving with the Laser clear, but then becomes broken FoldGuard will stop the Clamp. A Second press will get Foldguard into the override state and movement will begin again in slow to FoldGuard's Safety Stop Height.

Hazard Zone/Area Clear:

For the machine to be in Hazard Zone/Area Clear Mode the Light Fence has to be Clear. FoldGuard will no longer be Active in this situation. Pressing the Next Step Pedal will start the Clamp moving. The Clamp target will be the Safety Stop Height in Pathfinder. Once the Safety Stop move has finished Second Press will move the Clamp into a Clamped State.

Expected Movement Once Clamped:

FoldGuard Active:

The user must release the Next Step Pedal and press again. This will start the rest of the operation and holding down the Pedal will complete the Operation. Once the Operation is complete the controller will raise the Clamp. The controller will now require another Pedal press and will go through the same rules that apply for Clamp Movement explained above for when the Light Fence is Broken.

Hazard Zone/Area Clear:

The user must release the Next Step Pedal and press again. This will start the rest of the operation and holding down the Pedal will complete the Operation. Once the Operation is complete the controller will raise the Clamp. The controller will now require another Pedal press and will go through the same rules that apply for Clamp Movement explained above for when the Light Fence is Clear.

Changes made for Pathfinder 5226 controllers.

The Request Clamp Move Down output and Enable Clamp Move Down input were created to work with the FoldGuard laser system. The Request Clamp Move Down will send a signal to FoldGuard saying it wants to move the clamp down. FoldGuard will then process if the move will be safe and sends a signal to the Enable Clamp Move Down input of the controller. The controller will then turn on everything needed to move the clamp down. If the Enable Clamp Move Down input turns off during the move the controller will attempt to stop. For more information refer to:

SCN 3621 - 5223, 5225, 5226; Added Request Clamp Down Move Output SCN 3622 - 5223, 5225 5226; Added Enable Clamp Move Down Input

The way this was implemented though it seemed like the controller could possibly try to move the clamp down without doing the request. Because of this a last line of defense was added to make sure we are requesting and FoldGuard is giving permission. This fix ensures a proper handshake logic happens between the 5226 controller and the FoldGuard system.