AMS Controls Die Accelerator Calculations Utility

This program is Freeware to the employees and customers of AMS Controls.

This utility was created to make setup and modification of Closed Loop servo app
lications simpler. The application has four sections, which are described below
.
***Advanced users may want to select the Edit/Eliminate Most Pop Ups menu option
to avoid seeing a lot of pop up error messages. When checked, this option stil
l informs the user of incomplete information by coloring required fields in red.
Project Information
This section is handy for maintaining documentation on specific die accelerator
applications. Each axis of a machine can be named, maintained and saved. Enter
the project information and click the Lock button. The information in this sec
tion can be updated at any time by clicking the Edit button.

Automatic Calculations
This section is useful for calculating critical parameters such as minimum die d
istance, total die travel distance, and the shortest part length possible for a
given set of conditions. A list of required data follows:
Line Velocity
- Users may enter this figure in Feet Per Minute or Inches Per Second. The sof
tware will calculate and display line speed in whichever format the user does no
t enter.
-Typically, the line speed entered will be the maximum speed of the line. Lower
speeds may be entered in order to calculate the best set of parameters to maxim
ize through-put.
-If no maximum return velocity is entered, the program will use Line Velocity as
a default.
Acceleration
-If no return acceleration is entered, the program will use forward acceleration
as a default.
Press Dwell Down
-This is the amount of time required to cut through the thickest material to be
run. The die will be tracking targets at line speed during this time.
Press Dwell Up
-This is the amount of time require for the punch/shear tool to clear the materi
al. Even if no up signal is required by the press, some amount of time must be
entered or the die will decelerate while the tooling is still in the material, p
ossibly resulting in equipment damage.
Press Reaction
-For slow presses, especially mechanical presses, press reaction time can shorte
n the overall die travel. Press Reaction time causes the press to fire before t
he die is up to speed and in position on a target. The idea is to fire the pres
s early so that the die has matched speed just before the tooling contacts the m
aterial.
Available Die Travel
-The program will check the available die travel against the calculated die trav
el distance. If the calculated travel distance is greater than the available tr
avel distance, a warning will result.
Settling Time
-Minimum die distance is the amount of linear distance the die must travel at th
e programmed acceleration rate in order to reach the indicated line speed. Due
to the nature of the application, some overshoot and settling time is typically
required once reaching the calculated minimum die distance for the die to acurat
ely match position and speed with the target. Unless the lag time of the servo
is known, the program will assume a settling distance of 10% of the calculated m
inimum die distance.

Line Resolution
This section is handy for calculating Line Resolution for encoders and measuring
wheels. If an AMS Controls encoder is used, check the box labeled "I am using
an AMS Encoder" and enter the encoder model number. The prequadrature and postq
uadrature encoder pulses will be displayed automatically.
Prequadrature Encoder Pulses
-If a brand of encoder other than AMS Controls is used, enter the prequadrature
encoder pulses per revolution expected in this text box.
-If no value is entered for postquadrature encoder pulses, the program will calc
ulate and display the number. Alternately, the postquadrature encoder pulses ma
y be entered. In this event, the software will calculate and display the prequa
drature encoder counts.
Wheel Diameter/Circumference
-Measuring wheel diameter or circumference can be entered. The software will ca
lculate and display the number that isn't entered.
-When entering wheel diameter, precision is important for an accurate result.

Die Resolution
Choose the actuator type to be used. Once an actuator type is chosen, the user
is prompted for the prequadrature and postquadrature motor encoder pulses per re
volution. These text boxes work just like the text boxes in the Line Resolution
section.
If a gear box is present, click the check box and the software will prompt the u
ser for the gear ratio.
The Resolution Correction button in this section will provide an easy to use for
m for working out mechanical error in the die resolution calculations. Any time
a belt driven or rack & pinion actuator is used, or if a gear box is used, the
procedure for physically checking the die resolution should be followed. Precis
ion ball screw actuators are typically very accurate and do not usually require
this method.