SUGIYAMA ELECTRIC SYSTEM INC.

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Common question

General product

Every product
  • What is not covered by the product warranty?
    • If the product is disassembled or modified without our permission, it will not be covered by the product warranty even during the warranty period.
  • What should I do first before installation?
    • Before installing the product, read the instruction manual and familiarize yourself with the product and how to install it.
  • What are the precautions for wiring work?
    • ・Be sure to cut off the power supply before wiring.
      ・When connecting or disconnecting connectors, be careful not to contaminate the connector contacts.
      ・Do not expose connectors to liquids such as water and oil.
      ・Use M3 terminals with a width of 6 mm or less for the terminal block.
      ・The terminal block will be damaged if a terminal with a width bigger than 6 mm is used.
  • What should I do before using the product?
    • Please read the instruction manual and understand how to use the product before using it.
  • Should I need a start-up inspection?
    • Be sure to perform the start-up inspection to prevent trouble.
  • Is it necessary to record the setting value in function setting mode?
    • ・If change the settings from the factory-configured, record and save the settings.
      ・Please note that the substitute device for repair will be shipped in the factory-configured setting.
  • Do you have any materials that simply explain malfunction detect?
    • There is an introductory version of manga to use our detectors well.
      There are Japanese, English, and Chinese versions. If you are registered as a member, you can download it from our website.

Slug detector

PS-464
  • What is die height detector?
    • The change of the gap between the upper stripper and our proximity sensor installed on the lower die is calculated as the bottom dead center displacement for each stroke.
      The device outputs a stop signal to the press when a displacement exceeds the set value.
  • Why does the display of PS-462/4 show an E-01 or E-02 error?
    • It is standard value level error.
      Check for material thickness variations and edge burrs.
      If this error occurs frequently, set the detection range to 200 µm (1 µm step sensitivity).
  • What is a spare wire?
    • This is the name of the wiring that is connected inside PS-462/4 from the terminal block on the back of the device to 12P connector.
      Make wiring with the press machine easier by connecting between the terminal blocks as required.
  • What is the shape of the sensor head?
    • A number of sensor heads with different shapes are available.
      Please refer to sensor head in product information for details.
  • What should I pay attention to when installing the sensor head?
    • The sensor head is installed to the lower die and the upper movable stripper is used as the object to be detected.
      Install it to make the gap from the object at the bottom dead center is 0.7 to 1.5 mm.
      Cover the sensor sensitive center with a diameter of 30 mm or more When using a mounting bracket, use a rigid one that does not bend due to vibration during stamping.

      If not meet the above requirement, the original performance cannot be exerted.
  • What is the PS-4643 analog monitor unit?
    • This is a circuit unit for observing analog signals of PS-462/4.
      Installed on the back of PS-462/4. Observe the waveform around the bottom dead center by using an oscilloscope.
      This will enable to determine the internal angle timing or external timing of PS-462/4 by inferring the stripper plates behavior.

Malfunction detector

PS-661/2
  • What is malfunction detector?
    • This device outputs a stop signal to the press machine when detect defects such as miss feeding and product ejection failure, mainly in progressive dies, in combination with various sensors.
  • What kind of plug is used for the sensor?
    • When supplying DC power (+12V) from a plug,
      Maximum 600mA in total can be used from the PS-661/2.
      Use a φ6.3 stereo phone plug.
      A 3-prong plug of a 6.3 mm (1/4 inch) diameter used for headphones. It is used in our light sensors, etc.
      When no need power,
      Uses RCA pin plugs.
      A 2-prong plug of a 3.2 mm diameter used for video etc. It is used in our spring sensor.
  • What is a spare wire?
    • This is the name of the wiring that is connected inside PS-661/2 from the terminal block on the back of the device to 12P connector.
      Make wiring with the press machine easier by connecting between the terminal blocks as required.

Digital cam

Common thing in digital cam
  • What is digital cam?
    • The device outputs a signal between the set angle (crank angle of the press machine).
      A rotary encoder is used for angle detection.

PS-701
  • How to check the program version
    • The current product displays the program version when the set button is held down for 2 seconds or longer when press machine stop.
      The old type displays the angle.
  • Error contents (old type)
    • If any of the displayed number from 1 to 6 are blinking, the angle setting of the blinking channel exceeds the range from 0 to 359.
      If the MD lamp lights up, it is possible that the data backup is defective or the motion detector is detected.
  • Error contents (current type)
    • When it alternately displays F and the program version.
      Data backup error when the first digit displays F.
      Encoder Z-phase error when the second digit displays F.
      Encoder AB phase error when the third digit displays F.
      If E and a number are blinking, there is an error in the setting value of the indicated number channel, or the angle setting value exceeds the range of 0 to 360.
      If the MD lamp lights up, it is possible that the motion detector is detected.
  • The angle of the press machine and the angle display of PS-701 do not match.
    • When the angle of the press does not match the angle displayed on the PS-701,
      The teeth of the pulley and belt may be misaligned.
      A standard 19XL pulley has a difference of about 20 degrees per tooth.
      When PS-701 does not display the number of rotations whlie the press machine is running,
      Breakdown of rotary encoder, encoder connection cable or connector may be defective.
  • Why is it outputs differ angle from the setting angle?
    • Digital switch for setting angle may be broken.
      Replace the assembly of the front panel.
      The press machine was stopped or inched during automatic advance angle output.
      A precondition for using automatic advance angle is that the press is running continuously.
  • What is automatic advance angle?
    • This function compensates for the operation delay time of equipment controlled by digital cam output. This keeps the angle at which the equipment operates constant.
      It does not work unless setting to use advance angle time for each channel in the function settings.

PS-731
  • What is a spare wire?
    • This is the name of the wiring that is connected inside PS-731 from the terminal block on the back of the device to 20P connector.
      Make wiring with the press machine easier by connecting between the terminal blocks as required.

  • What are the defects shown on the numeric display?
    • Display shows E05
      Encoder AB phase error
      Display shows E06
      Encoder Z phase error
  • The angle of the press machine and the angle display of PS-731 do not match.
      In case of the teeth of the pulley and belt are misaligned.
    • A standard 19XL pulley has a difference of about 20 degrees per tooth.
      Is SPM of the press machine displayed?
      If the press machine is running more than 8 SPM, it will display SPM.
      No SPM displayed even though the press is running above 8 SPM.
      Breakdown of rotary encoder, encoder connection cable or connector may be defective.
  • Why is it outputs differ angle from the setting angle?
    • The press machine was stopped or inched during automatic advance angle output.
      A precondition for using automatic advance angle is that the press is running continuously.
  • What is automatic advance angle?
    • Compensates for operation delay time of equipment controlled by digital cam output. The channel (cam) to use must be angle controlled. It does not work unless the advance angle time is set.

Mist spray system

Common thing in mist spray system
  • What is mist spray system?
    • The device sprays the oil onto materials.
      It is designed to reduce splash of oil.
  • What is a spare wire?
    • This is the name of the wiring that is connected inside PS-216 or P-S218 from the terminal block on the back of the device to the connector.
      Make wiring with the press machine easier by connecting between the terminal blocks as required.

PS-216
  • Does increasing the tank pressure of the PS-216 increase the amount of oil feed?
    • The amount of oil will increase, but air bubbles are more likely to occur in the pipe.

PS-218
  • Does increasing the tank pressure of the PS-218 increase the amount of oil feed?
    • The amount of oil will reduce due to the structure that opens the solenoid valve to adjust oil against the pressure inside the tank, In addition, air bubbles are likely to occur in the pipe.

PS-219
  • Does increasing the tank pressure of the PS-219 increase the amount of oil feed?
    • Yes, it does. It controls the amount of oil by pressurizing the oil.
      Air bubbles are less likely to occur because there is no valve-based flow regulator in the pipe.

Box changer

CS-860
  • What is CS-860(Box changer)?
    • It counts and replaces boxes when boxing workpieces without stopping the press machine.
  • What are the advantages of introducing CS-860?
    • Production efficiency is improved because the operator does not need to stop the press machine every time the box is replaced.
      Reduced the burden of workers and saving-labor.
  • Number count may not match actual count.
    • Counting errors occur when multiple products pass through the counting sensor at once.
      A similar symptom occurs due to a problem with the count timing signal from the press machine.
  • It is no longer possible to exchange boxes that could be exchanged until now.
    • In case of a problem with the lift operation.
      Checking slide rails and cables for damage.
      In case of a problem with the clamping action.
      Check that the slide guide opens and closes without hindrance.
      In case of a problem with the box feeding operation.
      Check for metallic wear and lack of oil because it is conveied by chain. If there is foreign mateial on the sprocket, it pose a problem for behavior.
      A 10% drop in supply voltage will reduce the driving motor torque by approximately 20%.
      Also, in areas where the power frequency is 50Hz, the torque drops by about 17%. In such cases, reduce the set packing value to reduce the load.

Transfer detector

Common thing in transfer detector
  • What is transfer working?
    • This is a processing in which necessary die is added in series while transferring an independent material.
  • What is transfer detector?
    • It detects each grip failure by the grip sensor installed on the feed bar of the transfer press machine while material is transferring.
      It also detects malfunction of the grip sensor during the return process of the feed bar.
  • Even if the workpiece is gripped, it is in a mis-gripped state.
    • Check the performance of the grip sensor.
      The grip sensor must output a signal when gripping the workpiece.
      Check the connection cable from the sensor to the transfer detector for breaks or other damage.
  • It becomes detection of sensor failure.
    • Check the performance of the grip sensor.
      The grip sensor must not output a signal when releasing the workpiece.
  • Disconnection of the wiring of the moving part.
    • We recommend using flex resistance cable.
      Since the feed bar reciprocates for each process, install a distribution box and connection cable to maintain wiring easy.

Counter

Common thing in counter.
  • Number count may not match the press-worked actual count.
    • Check the rotary cam, etc. used for counting timing.
      If contact outputs such as limit switches and relays are used for counting timing for a long time, they may need to be replaced.
  • The memory retention (backup) of number count is not possible, or the storage period is short.
    • If the period of time of power ON is short , the battery charge will be in short supply.
      If the performance of the memory retention battery has deteriorated, it must be replaced.

Light sensor

Common thing in light sensor.
  • What is light sensor?
    • It is an infrared light sensor that outputs a signal when an object passes through the detection range of the sensor and shades the light.
      A magnetic loop sensor is recommended if there is a splash of oil.
  • What is the detection behavior?
    • When an object is detected, the output transistor turns off and voltage is output via an internal pull-up resistor.
  • What are the output specifications?
    • DC+12V pull-up resistor type
      NPN transistor output (B operation)
      Output current is 50mA (maximum sink current)
      *LS series only
  • No output signal
    • Check the output cable for damage.
      If there is no problem with the output cable, the output transistor of the sensor may be broken.
  • Decreased detection sensitivity
    • Clean the smear on the reflector or replace the reflector.
  • Do not detect stationary objects in the detection area.
    • It is designed not to detect moveless objects.
      The detection sensitivity for the case of slow verocity passing speed also affects the size of the object. Please contact us in the case.

Loop sensor

Common thing in loop sensor.
  • What is loop sensor?
    • It is a magnetic sensor that outputs a detection signal when an object passes through the detection range of the sensor.
      Detection is not affected by oil.
  • What are the output specifications?
    • DC+12V pull-up resistor type
      NPN transistor output (B operation)
      Output current is 50mA (maximum sink current)
  • No output signal
    • Check the output cable for damage.
      Check the output cable for damage.
      If there is no problem with the output cable, the output transistor of the sensor may be broken.
  • Need to prevent the detection coil form damage.
    • It is recommended to replace the resin inner guide before the detection coil is damaged.
  • Decreased detection sensitivity
    • Since it is a magnetic type, the detection sensitivity for non-magnetic objects (objects that do not react to magnets) is greatly reduced.
  • Do not detect stationary objects in the detection area.
    • It is designed not to detect moveless objects.

Vibration sensor

AS-11
  • What is vibration sensor?
    • Vibration (shock) is detected using a sensor that uses a piezoelectric element.
      It is used to detect the product ejected by the knock-out mechanism of the upper die.
      Fix the sensor to the pan which receives the product.
  • A signal is output even though the product has not been ejected.
    • Adjust the sensitivity to output the signal only when the product is ejected.
  • No output signal
    • Check for disconnection in the sensor and the conection cable.

Spring sensor

Common thing in Spring sensor.
  • What is spring sensor?
    • It is used as an antenna for contact detection.
      A metal spring is attached to a Φ8mm resin holder.
      Nose shape is Φ0.8mm, and the assembly part to the holder is a coil spring shape.
  • Is there only one type of spring sensor shape?
    • Several types are available according to usage conditions. Please refer to the spring sensor in the product information for details,
  • Can the nose section be bent for use?
    • It can be bent and used according to the usage situation.
  • Is it possible to detect objects (workpieces) that are not in contact with the die or press machine?
    • Not detectable. It is necessary for the detection target to be in electrical contact with the spring sensor through the die or press machine.

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