Tube Bender Control Mach4

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 Note: This is a user’s manual, not a teacher’s manual! This manual assumes you know the basics of tube benders and their functions.

Emergency Stop
In case of an emergency, press the large red E-Stop button located on the operator’s panel. All motion will stop immediately

1.0 Getting Started

To operate your machine, begin by turning on the computer. Rotate and release the key on the back right hand side of the control. When the computer has completed its startup procedure, double click on the Tube Bender icon on your desktop (Figure 1). 
Figure-1-Tube-Bender-Icon.JPG

Figure 1 Tube Bender Icon
The MachMotion Tube Bender Control will open.

Warning
Severe damage may be caused to the control by turning off the power of the tube bender without first shutting down the control properly. See “Shutting Down the Control” for proper instruction.

 

Figure-2-Tube-Bender-Control-Screen.JPG 

Figure 2 Mach Motion Tube Bender Control

This control has three modes: Run Mode, Manual Mode, and Program Mode. Before you should proceed to any of the modes, the tube bender should be homed. To home, pull out the E- Stop button on the operator’s panel.  Then push the Pump On button to start the hydraulic pump.

Then click the Enable button as shown below: 

 Figure-3-Reset-Button.JPG

Figure 3 Reset Button

Now while holding in the System Enable button click on the Home All button (Figure 2). The tooling will be commanded to its open position, the bend arm will move and the carriage will travel toward the rear of the machine. When the tube bender has stopped moving, the homing routine has completed. Now you can proceed to the other modes. During normal operation you can use the three buttons at the right of the screen to switch modes.
Figure-4-Different-Modes.JPG

Figure 4 Different Modes

2.0 Manual Mode

In Manual Mode you have control of each moving part of your tube bender. Each function, such as the pipe clamp and pressure die, can be operated in this mode. You can also do manual bends. This is a good place to start when learning the control.

 Figure-5-Manual-Mode.JPG

Figure 5 Manual Mode

DANGER:
Stand clear of the C arm or serious injury may be incurred. During each C bend the pipe clamp, pressure die, mandrel and mandrel lubricator can all function. Keep your hands and all other objects clear.

You can be killed or seriously injured if you get behind the bend arm when it is closing. Stay far away from the machine when the C axis is returning.

2.1 Axes
The carriage (Y Axis), rotational (B Axis), and bend arm (C Axis) can be moved in two ways: Jog and latch.

 Jog-or-Latch.JPG

2.2 Jog
To manually jog an axis, click the button next to the axis you would like to move. Then, while holding the enable button (green pushbutton switch to the left side of the control console), press + or – push buttons (black pushbuttons on the operator’s panel). The selected axis will move as long as you hold the buttons.  Adjust the Feed Rate knob to control the speed of motion.

2.3 Latch
The first input field on the left of the screen is the + or - distance for the axis to move. All moves are incremental, meaning that the axis will move the distance from the current position
Figure-6-Input-Fields.JPG

Figure 6 Input Fields
To move any axis, click the Select.JPG  button next to the axis you would like to move, enter your distance into the input field for that axes, click outside of the axis field. Then, while holding the enable button (green pushbutton to the left side of the control console), press + or – push buttons (black pushbuttons on the operator’s panel) to move the selected axes in the positive or negative direction.

DANGER:
You can be killed or seriously injured if you get behind the bend arm when it is closing. Stay far away from the machine when the C axis is returning.

The  Bend.JPG  button can be used to make semi-automatic bends. It will operate the bend arm to the degrees entered in the input field for the C axis, as well as sequencing the pressure die and clamp to allow for making a single bend. Select the latch function, the bend button, and then press the + button on the operator panel to sequence the clamps and make a single bend. Press the – button to open the clamps and return the bend arm to 0 degrees.

If the carriage is in the pressure die interference zone (i.e. the pressure die will collide with the carriage if the die closes). The clamp will close, the collet will open and the carriage will back out of the interference zone. The pressure die will then close and the C axis will move to the commanded position. If the carriage is in the pressure die interference zone (i.e. the pressure die will collide with the carriage if the die closes). The clamp will close, the collet will open and the carriage will back out of the interference zone.  The pressure die will then close and the C axis will move to the commanded position.

2.4 Bender Functions
This section explains how to operate each individual function that can be controlled in Manual Mode.
Bender-Functions.JPG

Jog: In jog mode when a function is selected you may move it incrementally by holding the Enable (green) button on the left side of the console and selecting the direction with the + or – (black push- buttons on the console).  The function will be commanded to move as long as you hold both buttons.

Latch: In latch mode you can command the full motion of a function. Select the function you would like to command then while holding the Enable (green) button on the left side of the console press the the + or – (black push-buttons on the console) to select the direction for the function to latch.

Note: For any function pressing the + push button will move the function towards the pipe or towards the bend die. I.E. for mandrel + will extend the mandrel toward the bend die. For clamp + will clamp towards the pipe. For follower + will extend towards the bend die.

2.5 Mandrel Lube
To manually activate the mandrel lubrication pump, click the Mandrel Lube button. Each click of the button toggles the mandrel lube pump.

2.6 Settings
Clicking on the Settings button will open the following screen which allows setting the parameters for several machine constants as well as selecting options for various functions included on your particular machine.

Figure-7-Settings.JPG
 
 

Figure 7 Settings

Table length: This is the distance from the tangent point on the bend die to the front of the collet when the carriage is at its rear limit of travel (at the Y home limit switch). To set up: Home the machine, Jog the collet as far back as it can go, measure between the points shown below, input that value into the Table Length table.

C Homing Speed: is the command sent to the bend arm to move it slowly to its home position when the home all command is issued.

Hydraulics Timeout: After this time the high and low pressure will turn off. Position After Homing: This is the position that the Y axis will go to after homing Y Min Default:

Pressure Die Interference Zone Default: This is the value that will be used if there isn’t a program opened

Wiper Die Interference Zone Default: This is the value that will be used if there isn’t a program opened

Retractable Die Interference Zone Default: This is the value that will be used if there isn’t a program opened

Machine Lube Rate: This is a time delay that will command the machine lube pump.

Tube Support Interference: This is the distance from the tangent point of the bend die to the farthest interference point of the tube support. If the Y axis ever gets in this range the tube support will be commanded down.

Reverse Torque: Changes the direction of the Y axis command during the bending action.

Reverse C Home: Changes the direction C axis will home. If active the C axis will home in the + or bending direction.

2.7 Functions Settings:
On the right tab there is selection of the functions present on your particular machine. This must be setup to match your machine.

3.0 Program Mode

The Program Mode is where you will create or edit your programs.

3.1 Create a new part file
To create a new part file:

  1. Click the Program Mode button (Figure 4).
  2. Click New File.
  3. This will load a default file that you can now
  4. Click Save.
  5. This will open a dialog allowing you to give your new file a name.

Save-File.JPG

  1. Figure 8 Enter New Program Name
  2. Enter your new program name.
    As shown above, the program name is “NewProgram.”

  3. Press If another program with the same name exists, it will ask you if you want to overwrite the existing file.

Figure-9-Erase-Existing-File.JPG

Figure 9 Erase Existing File

3.2 Part Configuration
The part configuration screen is where all the settings for the part program are entered. This will be saved in the code so that when you load your file months later all the settings will be loaded with it.  

Figure-10-Program-Mode.JPG

 Figure 10 Program Mode

3.3 Operator Safety Distance
This is the distance that the operator should stand away from the machine to be safe. This is configured manually and is only for your reference.

3.4 Enable Options
Clicking the buttons will enable that function. If a button is green, that corresponding function will be enabled for that program.

 Enable-Options.JPG

3.5 Pipe Characteris