When it comes to efficient tooling in metal fabrication, mastering the ESA S860 Punches and Dies Setup is crucial. If you’re seeking guidance on setting up this specific equipment, you’re in the right place.

In this article, I’ll provide a clear and concise walkthrough of the ESA S860 Punches and Dies Setup process. Whether you’re new to using this machinery or looking to refine your skills, this guide will equip you with the essential steps and tips to ensure a seamless setup. Understanding this setup not only enhances your operational efficiency but also improves precision in your metalworking projects.

Шаг 1: Подготовка рабочей среды

Before diving into the ЕКА S860 Punches and Dies Setup, it is essential to ensure your workspace is clutter-free. A neat environment prevents accidental damage and enhances operational safety. Also, check that your surface is level, as this can impact the accuracy of your setup.

Step 2: Accessing the Punches and Dies List

To manage your tools, accessing the punches and dies list is the initial step. Use the provided keys to toggle between lists, ensuring you have the necessary tools visible.

В случае пробивки отверстий появится следующее окно:

The window on the left is the list window. The central boxes give the data of the punch to which the cursor has set (in the list). The window on the right gives a preview of the punch to which the cursor has set.

The following window will appear in the case of dies:

The window on the left is the list window. The central boxes give the data of the die to which the cursor has set (in the list). The window on the right gives a preview of the die to which the cursor has set.

When the available tools are many, for fast choice, is enough to flow the wheel visualized on the panel, with own touch.

Функциональные клавиши имеют следующие значения:

–[List] to shift the cursor to the list window

–[Selection] to move the cursor to the Select box and enter the name of the punch or die in manual mode

How to display the preview

Allows you to display the tool preview (to make it easier to identify). The preview function is normally enabled, but can be disabled if not required. Comply with the procedure below:

– select the [Предварительный просмотр] элемент.

When the preview item is disabled. Repeat the operation to re-enable the item again.

How to copy a punch or die

This allows you to create a copy of a tool with another name so that it can then be modified. Move to the tool you wish to copy and then comply with the procedure below:

– select the [Copy] элемент.

This accesses a window where the tool name must be entered. After the name has been entered, move to the [ХОРОШО] кнопку и нажмите [ВХОДИТЬ]

Step 3: Modifying Tool Entries

Modifying tool entries is a crucial aspect of mastering the ESA S860 Punches and Dies Setup. Whether it’s renaming, copying, or erasing a tool, each action has a straightforward procedure:

• Copying: Access the tool menu, select the [Copy] item and enter a new name.
• Renaming: Choose the [Rename] item, input the desired name, and hit[ВХОДИТЬ].
• Erasing: Press the required key, confirm by hitting[ВХОДИТЬ].

Step 4: Saving and Transferring Tools

Preserving your punches and dies on a USB device is crucial for backup and transfer purposes in the ESA S860 Punches and Dies Setup. Ensure your USB has sufficient space:

Insert USB, Access the tool menu, select the [Save Tools] and confirm the action.

Тools list on USB device

Used to display the list of tools USB device. The possible operations are the same as the tool list, then you can copy, rename, delete all tools present on the USB device. Select the list punches and dies and perform the following steps:

– insert into the USB port a device containing tools (created by kvara S860 Touch and S 660W).

– the list of punches or dies on USB will be displayed

– proceed with the required operation.

How to save all tools from USB to NC

Allows you to save the tools from floppy disk to NC, so that they can be downloaded from another numeric control. Comply with the following procedure:

– insert into the USB port a device containing tools (created by kvara S 860 Touch and S 660W)

– list is displayed punches and dies of the USB device.

– press the key to access the menu.

– select the [Save Tools] menu.

All the tools (dies and punches) will be saved from USB to NC. Tools can be transferred from USB to control units, making this step indispensable for continuity.

Step 5: Drawing New Punches

How to enter a new punch

Select the desired type of punch. The punch can either be completely drawn or three types of preset punches with fixed measurements can be used.

The following types of preset punch are available:

To add a new punch, select the type based on your requirements. There are preset options available, or you can custom draw:

-Use[New Drawing]for full customization.

-Opt for[New Type]when using preset options.

A window will be opened requesting entry of the punch dimensions:

Enter the total height and working height as indicated in the figure.

Access to the drawing mask

Access the drawing mask once the punch dimensions have been entered and the type of punch selected. The drawing mask changes, depending on the type of punch selected:

– move to the [Confirm] кнопку и нажмите [ВХОДИТЬ].

Ударные инструменты для рисования

The punches to draw mask is obtained by means of the drawing function (see relative chapter in the operator manual).

To utilize the punch drawing accurately in the ESA S860 Punches and Dies Setup, the tip must be clearly defined.

The left-hand window is the drawing window.

The four right-hand windows are drawing data entry windows and respectively represent:

• The polar drawing data
• The Cartesian drawing data
• The vertex drawing data
• The arc drawing date

Условные обозначения при рисовании

The punch must be drawn in an anticlockwise direction, remembering that the stop is on the right-hand side of the punch itself.

How to do the drawing

Follow these steps for accurate punch drawing using the ESA S860 machine’s touch environment:

• Field Entry:
  • Start with the cursor in Field 1 for tip data entry.
  • Input the second side length (l1) and press [ВХОДИТЬ] to move to the angle input field.
• Design Interaction:
  • Touch the display to engage with the design environment.
• Automatic Drawing:
  • Нажмите [ВХОДИТЬ] to draw the next section and highlight it.
  • Выбирать [Arc] and enter section length (l2) in Field 1 and depth (p1) in Field h. Press [ВХОДИТЬ].
• Further Input:
  • Input length for section l3 in Field 1 and press [ВХОДИТЬ].
  • Enter 90.0 in the alpha field and press [ВХОДИТЬ] for continued automatic drawing.

Example of a punch to be drawn:

To handle measurement challenges in the ESA S860 Punches and Dies Setup, operators can use graphic assistance for precise alignment. This feature allows angle adjustments by ±1° and length by ±1mm to match the drawing with the actual punch setup:

• Access the menu by pressing the designated key.
• Выберите 3&DYNAMIC option.

Use the right/left arrows to adjust the angle and the up/down arrows for length.

Drawing Curved Sections

To draw curved sections, press [Arc], and enter length and depth . The curve will be plotted automatically.

Correcting Entered Data

During the ESA S860 Punches and Dies Setup, you may encounter incorrect data entries. To correct these and navigate the drawing sections efficiently:

Нажмите [ВХОДИТЬ] to move forward, alternating between section (l) and angle (alpha) Fields.

Исправление ошибок

Avoid entering section lengths as angles by ensuring [ВХОДИТЬ] is pressed after setting angles. Return to correct fields as needed.

Сохранение рисунка

To save your setup, press the save key, enter the punch’s name, and confirm by pressing [ВХОДИТЬ]. Names can include letters and numbers, such as catalogue codes.

Tolerated name characters

The entered name can be formed by a combination of numbers and letters (e.g. the code of the punch in the catalogue can be used).

Preset punches

In the ESA S860 Punches and Dies Setup, a preset punch mask is shown with a drawing and data defining its shape. Using arrows or the [ВХОДИТЬ] key highlights the corresponding measurement on the drawing. Modifying any value and pressing [ВХОДИТЬ] updates the drawing to reflect the changes.

Step 6: Drawing New Dies

How to enter a new die

For new dies, the process parallels punch creation. Custom or preset options depend on the specific die type needed:

• Press the option key for new dies and select your drawing type.
• Program your die using the drawing mask, maintaining precision for functional accuracy.

These measurements can be varied in order to rescale and de-design the die:

It is advisable to use preset dies if the die to be entered is similar to one of the proposed types (both square and overturned T dies can be drawn), since the drawing will be less difficult. The die must be completely drawn if it is not within the preset die categories, if a die with several cavities must be drawn or if square or pressing cavities must be used.

In the ESA S860 Punches and Dies Setup, the die drawing is critical for anti-collision checks and accurate bending depth calculations. If fully drawing a die is challenging, use a preset die and adapt it with pre-defined data:

• Press:
  • [Новый рисунок] for a complete design.
  • [New Predefined] for preset die data.

A window will prompt you to enter the die dimensions:

Enter the height and width as shown.

Access the drawing mask after entering die dimensions and selecting the type. The mask adjusts based on the die type. Move to [Подтверждать] и нажмите [ВХОДИТЬ].

Штампы для рисования

The dies to draw mask is obtained by means of the drawing function (see relative chapter in the operator manual).

The left section serves as the drawing window for the ESA S860 Punches and Dies Setup. The four right-side data entry windows are:

• Polar drawing data;
• Cartesian drawing data;
• V cavity drawing data;
• Square cavity drawing data.

Условные обозначения при рисовании

The die must be drawn in a clockwise direction, remembering that the stop is on the right-hand side of the die itself.

The marked line represents the line initially proposed in the drawing mask.

Hкак сделать рисунок

Предположим, что необходимо вытянуть следующий кубик:

The cursor is in Field 1 of the polar drawing data entry window:

• Enter the length corresponding to section l1 in Field 1 for the ESA S860 Punches and Dies Setup.
• Нажмите [ВХОДИТЬ]: The cursor will move to the α Field. Here, enter the angle in relation to the next section to define the first cavity of the die for the ESA S860 Punches and Dies Setup.

To configure cavities during the ESA S860 Punches and Dies Setup, follow these steps:

1. First Cavity Configuration:
   • Нажмите [Insert Cavity] to switch to cavity data input.
   • Enter cavity angle (aC1) and press [ВХОДИТЬ].
   • Enter cavity width (lC1) and press [ВХОДИТЬ].
   • Enter cavity radius (R) and press [ВХОДИТЬ].
   • Enter cavity load (maximum tons per meter) and press [ВХОДИТЬ].
   • The cavity is drawn, and the cursor returns to the entry window for the next section.
2. Define Additional Sections:
   • Enter the length for section l2 and press [ВХОДИТЬ].
   • Enter angle a1 and press [ВХОДИТЬ].
   • Repeat the process for the next sections (l3, l4, etc.), alternating lengths and angles.
3. Second Cavity Configuration:
   • Нажмите [Insert Cavity] to switch to the next cavity data input.
   • Enter cavity angle (aC2), length (lC2), radius (R), and load, pressing [ВХОДИТЬ] after each.
   • The next cavity is drawn, continuing with the length and angle input process.

Entered data correction

During the ESA S860 Punches and Dies Setup, errors may occur in drawing entry. Correct these and navigate through different sections using the following methods:

• Use the key to revert to the previous entry field, then switch alternately between a section entry field (l) and an angle entry field (alpha).
• The key advances directly to the next section, specifically to the section entry field (l).
• Нажмите [ВХОДИТЬ] to move to the next entry field and alternate between a section entry field (l) and an angle entry field (alpha).

Square cavity entry

To enter square cavities in the ESA S860 Punches and Dies Setup, follow these steps in the angle entry Field α:

• Нажмите [Square cavity] to access the data entry window.
• Enter and confirm the cavity’s depth, width , radius , and load (maximum tons per meter) by pressing [ВХОДИТЬ] after each value.

Pressing cavity entry

For pressing cavities, define sections affecting die closure and draw as squashed sections:

• Sketch the open die profile with the part nook.
• Draw the open die with the flattening part recess.
• Position the cursor on the vertical section.
• Нажмите [Нажмите] to hatch the flattening part, marking completion in the ESA S860 Punches and Dies Setup.

The following figure shows an example of the bending flattening die.

How to enter cavities for squashing pneumatics

To define cavities for squashing pneumatics in the ESA S860 Punches and Dies Setup:

1. Section Definition:
   • Indicate two 0.001 mm squash sections on both sides of the die.
   • Draw the die profile with the flattening recess, entering 0.001 mm for the relevant section (as if closed).
2. Setup Steps:
   • Move the cursor to the section for squashing and press [Squash].
   • The flattening part will be subtly hatched.
   • Нажмите [Die Dimensions], enter 1 in the Pneumatic field, move to [ХОРОШО], and press [ВХОДИТЬ].
   • Function 2 is now enabled on clinched bends.

Pneumatic Flattening Die Support Entry

From version 13.2 onwards:

• Enter data in the General Parameters Configuration mask.
• Setup allows flattened bends in graphic mode with standard dies, without special bending-flattening die drawings.

Сохранение рисунка

• Complete the drawing and press the key to save.
• Enter the die’s name, move to [ХОРОШО], and press [ВХОДИТЬ].

Naming Conventions

Names can include numbers and letters, using catalog codes for easy reference in the ESA S860 Punches and Dies Setup.

Preset dies

The preset die mask, essential for the ESA S860 Punches and Dies Setup, appears as a pre-drawn die with data defining its shape. Scrolling through these data with the arrows or [ВХОДИТЬ] key highlights the corresponding measurement on the drawing. Modifying a value and pressing [ВХОДИТЬ] updates the drawing to reflect the changes.

Часто задаваемые вопросы (FAQ)

Заключение

In conclusion, mastering the ESA S860 Machine Setup is crucial for ensuring optimal functionality and precision in your metal fabrication tasks. The key steps involved include preparing the work area, powering and configuring the NC system, and managing essential operations such as ram sizing and stop axes calibration. A clean and level workspace, combined with a well-maintained machine, minimizes errors and maximizes productivity.

To extend the lifespan and performance of your machine, regular maintenance and adherence to setup guidelines are essential. This approach will help you reduce downtime and increase production efficiency.

For further assistance, more detailed support, or specific inquiries regarding the ESA S860 Machine Setup, please don’t hesitate to contact our team. Additionally, we invite you to explore our other documentation for more insights and tips on optimizing your machinery.