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Sensor Enable Modes



When a die protection program is well established, and the tools are fully protected with sensors, die crashes are most likely to occur when presses are run with the die protection system disabled. This may be due to an operator forgetting to re-enable the sensors after an event that requires them to be temporarily disabled, or because someone decided that it would be 'easier' to run the die without protection. Regardless of the reason, a die protection system cannot prevent die crashes when it is turned off. The SmartPAC has a number of built-in safeguards that make it much more difficult to run the dies with the sensors inadvertently (or surreptitiously) disabled.

Sensor Enable Modes
The SmartPAC has three sensor enable/disable modes - two of which are designed to 'bail out' the press operator if he or she forgets to enable the sensors:

Manual Enable/Disable - When this mode is selected, the sensors are enabled and disabled 'manually' via a toggling menu selection. Once disabled, the sensors will stay that way until they are manually re-enabled. Sensors are also automatically enabled whenever a new tool is loaded. (This is true whether the enable mode is set to manual or automatic). The manual enable mode provides the least protection against running the press unprotected.


The Auto Enable By Tool Mode limits the number of cycles during which the sensors are disabled

SmartPAC PRO's "Auto Enable By Tool" mode limits the number of cycles during which the sensors are disabled

Auto Enable By Tool - When this mode is selected, the sensors are manually disabled, but will be automatically re-enabled after a preset number of machine cycles, as specified by the Auto Enable Counter. The Auto Enable Counter value is stored with the each die's tool number settings. When this mode is used, all of the sensors are enabled together when the counter preset is reached.

Auto Enable By Sensor - When this mode is selected, the sensors are manually disabled, but will automatically be re-enabled individually after a preset number of machine cycles. Unlike the Auto Enable By Tool selection - where a single Auto Enable Counter value applies to all of the sensors, the Auto Enable By Sensor Mode allows you to set an auto enable counter value for each sensor installed in the die. This allows the SmartPAC 2 to enable each sensor individually as the strip progresses through the die.

On the SmartPAC PRO, the sensor enable mode is set by tool, from the bottom of the main die protection programming screen (in the program mode). In the SmartPAC 2, the enable mode is a global setting accessed by going to the SmartPAC 2's initialization menu and selecting SENSOR ENABLE MODE.

Setup Mode
Sensors are often disabled during coil changes to eliminate the need for the operator to reset the sensor errors that occur on every stroke as the new strip is loaded into the die. This is particularly true for progressive and transfer dies with many stations. The SmartPAC 2 has a feature called the "Setup Mode" that can make it unnecessary to manually disable the sensors during a coil change. The Setup Mode feature can be set to automatically disable the cyclic (Green) sensors when the press is switched to the "inch" mode, and to re-enable the sensors automatically when the operating mode is changed to "continuous" or "single stroke".


When enabled, the Setup Mode disables the cyclic sensor while the press is in the inch mode

When enabled, the SmartPAC PRO's Setup Mode disables the cyclic sensor while the press is in the "inch" mode

Static (Red and Yellow) sensors are unaffected by the Setup Mode, and will stay enabled while the setup mode is active. This allows the die protection system to detect events like material buckle while the strip is being fed into the die. The Setup Mode is accessed by going to the SmartPAC's initialization menu and selecting SENSOR ENABLE MODE.

Security Settings
The sensor enable status can also be protected using the SmartPAC's keyswitch, or with a password. There is a line item for DISABLE SENSORS in the security settings in SmartPAC's Initialization mode. This setting allows you to assign one of three security levels to the the 'disable sensors" function:

  • RUN AND PROGRAM MODES - This is the 'wide open' setting that will allow operators to disable the sensors in either the run or program mode without having to enter a password.

  • PROGRAM MODE ONLY - The sensor may only be disabled when the SmartPAC is in the program mode. Since the program mode is accessed using SmartPAC's Run/Program keyswitch, the key is required to disable the sensors.

  • PASSWORD REQUIRED - A password must be entered in order to disable the sensors.

The security setting enable you to control <u>who</u> has the ability to disable the sensors

The security setting enable you to control who has the ability to disable the sensors

Sensors Disabled Output
The SmartPAC's DiProPAC board has an output that actuates whenever the sensors are disabled. This output can be connected to a strobe light, siren, or some other indicator to alert the operator (or anyone else in the area) when the sensors are disabled.

Most users employ a combination of the safeguards described in this article provide the right level of security for their operation. Fortunately, the SmartPAC has the flexibility and features necessary to allow you to customize the solution that works best for you.





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