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Connection to Machine Electrical Cabinet:
In order to stop the machine, several wires must be run from the Satellite Box to the machine
electrical cabinet or control panel. These wires must be inside a conduit.
Sensor Connections:
Wires from the Position and Force sensors must be returned to the Satellite Box. Although it is
not strictly necessary that they be inside conduits, it is advisable to do so for the physical
protection of the delicate wires. Wiring should be spliced in such a way that troubleshooting or
replacement of sensors is not excessively difficult.
Installation of Force Sensors:
The sensor disk with attached wire is typically installed in a recess on a stressed location in the
forming machine, such as a die backing plate, punch wedge, ram, rocker, or other plate
depending on what force is to be measured. Consult Process Technologies Group if in doubt
about the best location. Once the location is chosen, cut the recess by milling, grinding or EDM,
as necessary. The dimensions of the milled pocket are available upon request from our
Technical Service Department. The groove for the wire should be cut so that the wire is safely
conducted away from the area into a conduit or under a cover; this is to protect it from damage.
Install the disk using the epoxy adhesive provided. The glue should be mixed thoroughly.
Apply a coating of adhesive to the recess, then press the sensor disk into place with the brass
side of the disk against the piece. The epoxy should set up in 1 to 2 hours. For best results allow
the epoxy to set overnight before running machine.
Installation of Position Sensors:
The Position Sensor, a proximity switch, is a non-contacting switch which is used to provide
timing information. Each time the machine makes a part, or strikes a blow, or reaches a certain
phase of its cycle, a position sensor can be adjusted to turn on or off to indicate it. Typically,
one sensor is used to count parts made (on and off once each time) and time the forming stroke
(on during the forming blow). Another sensor may be used on single and double die machines to
increase sensitivity. Observe the machine cycle to find a rotating or reciprocating member
which can be used to actuate the sensor. Attach a flag, cam, or sensor strip to the moving part
and position the sensor switch using appropriate brackets. The metal must move to within 1/4"
of the sensor for the 30mm prox. Switch to be “on”, and even closer for the 12mm prox. Switch.
When the flag or cam leaves that small space the switch will turn off until it passes close again.
Turn the machine through a full cycle to be sure that nothing touches or interferes. Verify that
the sensor is switched on and off at the intended times. It is important to note that on each
machine cycle of a single die, two blow header, two (2) blows occur. The proximity switch must
be timed off of the half speed shaft.
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