SCN 4635 allowed the Open Loop presses on an XL244CL to be configured for Feed to Stop operation.

This change had an unforeseen impact in that it was the first time the Shear on a Closed Loop controller was able to be configured as an Open Loop Feed to Stop.

There are many places in the code that test the type of shear press to determine if the controller is a Closed Loop Feeder or a Closed Loop Die Accelerator. This test is no a longer valid test in a lot of instances on a Closed Loop controller now.

Every place this test is used has had to be re-evaluated. There are so many places that require edits that all of edits are not practically able to be tested.

A combination of heavy code review and some spot testing is being used to verify these changes.

Eliminated the the possibility of a Divide by Zero error when calculating the die return velocity. The code was testing for a negative value but was failing to text for a zero value in the math doing the calculation.

When running a Feed to Stop press with a Closed Loop Die Accelerator, if the stopping operation is within the travel range of the die, the DA will delay its operation and do it with the die stationary.

This change optimizes production by calculating and positioning the die where it needs to be positioned so that it will be already be very close to the correct position to fire when the stopping press has stopped the material. After the material is stopped, for accuracy, the die is repositioned again based on the actual material stopped position vs the press target position.

On the XL202CL , XL206CL, XL212CL and XL270CL models there was no Switch Validation to ensure the second line encoder could only be enabled in Two-Encoder Feed-to-Stop mode. This has been resolved.

A customer needed MHA capability on the XL244CL model. One DIP switch has been defined for each Die.

Switch 22 enables MHA on Die 1.

Switch 23 enables MHA on Die 2.

A customer needed Multiple Presses defined on a Die Accelerator in the XL244XL. Each die may have additional presses configured for it using the following Switch settings.

Dip 25 Dip 24 Additional Presses on Die 1 Off Off 0 Off On 1 On Off 2 On On 3

Dip 27 Dip 26 Additional Presses on Die 2 Off Off 0 Off On 1 On Off 2 On On 3

These Switch settings require and utilize presses that are enabled using the existing Switch settings defined with Switches 4, 5 and 6.

Additional Presses for Die 1 start at Press 1. The first press and additional presses for Die 2 starts with the next remaining press after the presses defined on Die 1. Open Loop presses start with the next remaining press after the last press on Die 1, or Die 2, if enabled.

Two Speed operation shifts the material speed to the slow speed when the target reaches the Minimum Slow Distance from the Die's target.

Each Die on the XL244CL can now be individually configured for Two Speed operation.

Switch 28 Enables Two Speed operation for Die 1.

Switch 29 Enables Two Speed operation for Die 2.

The Two Speed Die operation was written prior to the ability for a Die Accelerator to be combined with Two Speed Open Loop Feed to Stop presses.

The Die Accelerator code used the Minimum Slow Distance with no consideration for current line speed. No attempt was made to advance the switch to slow speed early to achieve actual slow speed in the material by the time the target is within the Minimum Slow Distance. It was assumed the user would increase the Minimum Slow Distance to compensate.

If the Decel Factor parameter is active and visible the software was modified to periodically calculate an Advance Slow Distance based on current line speed. This distance is available for each Die to adjust (Advance) how early it switches to slow speed so that the behavior between an Open Loop press and a press on a CL Die Accelerator will appear identical.

In the future, when time is available, the Decel Factor and other relevant parameters will be enabled when Two Speed Die operation is enabled rather than relying on the existence of a Two Speed Open Loop Press being defined.

A phantom die stroke is a die stroke where the die cycles but does not fire the press. Die Accelerators configured with Multiple Presses on the Die could exhibit phantom die strokes coinciding with other open loop press targets.

Prior to recent changes to the XL244CL the only time this bug would be exhibited is if the controller had a also had a part printer installed.

There was a bug where the open loop press targets would also be added to the master press queue for Die1 due to a missing test in the code. The master press controls the die stroke for any slave presses on the die that have targets at the same time. If the master press does not have a target its queue target disables the master press from firing.

The bug has been fixed and the phantom die strokes no longer occur.