Fitting Zx5 Crank Upgrade : Différence entre versions

[version en cours de rédaction]

Version actuelle datée du 18 novembre 2024 à 11:12

Fitting the crank upgrade to Z065, Z066, Z067

Auteur Gareth Green | Dernière modification 18/11/2024 par Stuga Engineer en cours de rédaction ⧼frevu-button-review-label⧽

Difficulté

Difficile

Durée

2 jour(s)

Fitting the crank upgrade to Z065, Z066, Z067

Difficulté

Difficile

Durée

2 jour(s)

Sommaire

1 Introduction
2 Étape 1 -
- IF EATON DRIVES ONLY* Program Drives before they leave
3 Étape 2 - Remove Link arm connecting to rack and pinion
4 Étape 3 - Remove pivot shaft and arm
5 Étape 4 - Undo clutch and remove Cam
6 Étape 5 - Add sprocket to clutch
7 Étape 6 - Fix idler plate to upright
8 Étape 7 - Fix split sprocket onto drive shaft
9 Étape 8 - Drill and pin split sprocket to shaft
10 Étape 9 - Add chain minimum length sprocket to sprocket
11 Étape 10 - Fit Module C Crank Home sensor plate to Arm 5
12 Étape 11 - Fit Module C Crank Out sensor plate to Arm 5
13 Étape 12 - Fit Module D Crank Home sensor plate to Arm 5
14 Étape 13 - Fit Module D Crank Out sensor plate to Arm 5
15 Étape 14 - Fit Module E Crank Out sensor plate to Arm 5
16 Étape 15 - Fit Module E Crank Home sensor plate to Arm 5
17 Étape 16 - Remove 2 off motor breakers and contactors from Module C
18 Étape 17 - Add 2 off 10A single pole MCB's in Module C
19 Étape 18 - Add 2 off drives to Module C
20 Étape 19 - Remove breaker and contactor from Module E
21 Étape 20 - Add 10A single pole MCB in Module E
22 Étape 21 - Add 1 Off drive to Module E
23 Étape 22 - For each WEG drive
24 Étape 23 - Wire Sensor Cables to EtherCAT boxes
25 Étape 24 - Latest Front End software installed
26 Étape 25 - Map new Links
27 Étape 26 - Activate Configuration
28 Étape 27 - Add new IO Refs to IODef.mul
29 Étape 28 - Latest Front End software installed
30 Étape 29 - Programme WEG drives
31 Étape 30 - Test Function
32 Commentaires

ZX5, Crank Fitting_Zx5_Crank_Upgrade_DSC_0261.JPG

Introduction

This upgrade replaces the crank arm assemblies on Z065, Z066 and Z067 with a direct drive system to improve reliability

This procedure involves mechanical fitting, electrical wiring and help from a TwinCAT3 competent engineer at HQ for software changes

...The drives must be programmed before parts sent out

...Motors must be rewired for Delta and NOT Star

Étape 1 -
IF EATON DRIVES ONLY* Program Drives before they leave

Running frequency

Control mode

Accel time

Decel time

https://stuga.dokit.app/wiki/Programming_Eaton_DE_Drive

Étape 2 - Remove Link arm connecting to rack and pinion

Étape 3 - Remove pivot shaft and arm

Étape 4 - Undo clutch and remove Cam

Étape 5 - Add sprocket to clutch

B0001166

Étape 6 - Fix idler plate to upright

Étape 7 - Fix split sprocket onto drive shaft

...Line up with a straight edge

Étape 8 - Drill and pin split sprocket to shaft

Étape 9 - Add chain minimum length sprocket to sprocket

Use idler to create tension

Étape 10 - Fit Module C Crank Home sensor plate to Arm 5

Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes

Étape 11 - Fit Module C Crank Out sensor plate to Arm 5

This one has an extension that may or not be required. See Module D Crank Out Sensor for more info.

Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes

Étape 12 - Fit Module D Crank Home sensor plate to Arm 5

Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes

Étape 13 - Fit Module D Crank Out sensor plate to Arm 5

This one has an extension

Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes

Étape 14 - Fit Module E Crank Out sensor plate to Arm 5

Sensor cables run to rear Module E cabinet - EtherCAT fieldbus boxes

Étape 15 - Fit Module E Crank Home sensor plate to Arm 5

This one has an extension

Sensor cables run to rear Module E cabinet - EtherCAT fieldbus boxes

Étape 16 - Remove 2 off motor breakers and contactors from Module C

Étape 17 - Add 2 off 10A single pole MCB's in Module C

Tidy wires away for the spare 2 phases

Étape 18 - Add 2 off drives to Module C

May need to move trunking or mount directly to side of enclosure.

Drive can be WEG or EATON

Étape 19 - Remove breaker and contactor from Module E

Étape 20 - Add 10A single pole MCB in Module E

Étape 21 - Add 1 Off drive to Module E

May need to move trunking or mount directly to side of enclosure.

Drive can be WEG or EATON

Étape 22 - For each WEG drive

Live wire
Neutral wire
Earth wire
0v supply
FWD and REV Signals
Motor cables wire directly into bottom of the drive

Étape 23 - Wire Sensor Cables to EtherCAT boxes

Module C and D cranks to back of Module C cabinet

Module E crank to back of Module E cabinet

Étape 24 - Latest Front End software installed

Backup Old multi folder
Copy in new winMulti version to c:\multi overwriting what is there

Étape 25 - Map new Links

Overwrite existing links if any exist

See the wiring for MC2C and MC2E in Step 22 for the link IORefs and locations

Étape 26 - Activate Configuration

And restart in run mode when prompted

Étape 27 - Add new IO Refs to IODef.mul

Ask HQ to download a relevant IODef.mul file

Failing this, the following IO refs need to be added

OuC_CrankFWD,273,2,0,0,False,False,3,8,-,False,0
OuC_CrankREV,274,2,0,0,False,False,3,9,-,False,0
OuD_CrankFWD,275,2,0,0,False,False,3,10,-,False,0
OuD_CrankREV,276,2,0,0,False,False,3,11,-,False,0
OuE_CrankFWD,277,2,0,0,False,True,64,0,-,False,0
OuE_CrankREV,278,2,0,0,False,True,64,1,-,False,0

And these removed

Étape 28 - Latest Front End software installed

Backup Old multi folder
Copy in new winMulti version to c:\multi overwriting what is there

Étape 29 - Programme WEG drives

Follow link below for information on programming WEG drives:

WEG Inverter Setup

Étape 30 - Test Function

Ensure all Out and home sensors are working and correctly oriented. Home is towards rear of machine, Fwd or Out is towards front.
Ensure the clutches are set to slip if the crank bottoms out
Test direction of all cranks (Fwd is towards front). Switch phases on motors if direction needs to change. The PLC has hard code to switch the outputs off when the sensors are covered

Key Pointers

End stops should be set so the rack can never run off the pinion - always a full tooth engaged
Each crank motion stops when the input is seen, and then decelerates. Therefore, set the crank input position to allow for this deceleration before hitting end stop. Normally about 30mm
The crank clutches should be set to slip before damage is done to the crank end stops in the event that the sensors do not work

Commentaires

en none 0 Draft

@@ Ligne 10 : / Ligne 10 : @@
 }}
 {{Introduction
-|Introduction=<translate>This upgrade replaces the crank arm assemblies on Z065, Z066 and Z067 with a direct drive system to improve reliability</translate>
+|Introduction=<translate>This upgrade replaces the crank arm assemblies on Z065, Z066 and Z067 with a direct drive system to improve reliability
+This procedure involves mechanical fitting, electrical wiring and help from a TwinCAT3 competent engineer at HQ for software changes
+{{Warning|...The drives must be programmed before parts sent out}}{{Warning|...Motors must be rewired for Delta and NOT Star}}
+<br /></translate>
 }}
 {{Materials}}
 {{EPI}}
 {{Tuto Step
-|Step_Title=<translate>Program Eaton Drives before they leave</translate>
+|Step_Title=<translate>*IF EATON DRIVES ONLY* Program Drives before they leave</translate>
 |Step_Content=<translate>Running frequency
@@ Ligne 24 : / Ligne 29 : @@
 Decel time
-<br /></translate>
+[[Programming Eaton DE Drive|https://stuga.dokit.app/wiki/Programming_Eaton_DE_Drive]]<br /></translate>
+|Step_Picture_00=Fitting_Zx5_Crank_Upgrade_eaton_de1.JPG
 }}
 {{Tuto Step
@@ Ligne 134 : / Ligne 141 : @@
 }}
 {{Tuto Step
-|Step_Title=<translate>Remove 2 off breaker and contactor Module C</translate>
+|Step_Title=<translate>Remove 2 off motor breakers and contactors from Module C</translate>
 |Step_Content=<translate></translate>
 |Step_Picture_00=Fitting_Zx5_Crank_Upgrade_DSC_0314.JPG
@@ Ligne 140 : / Ligne 147 : @@
 }}
 {{Tuto Step
-|Step_Title=<translate>Add 2 off single pole breaker Module C</translate>
+|Step_Title=<translate>Add 2 off 10A single pole MCB's in Module C</translate>
 |Step_Content=<translate>Tidy wires away for the spare 2 phases</translate>
+|Step_Picture_00=Fitting_Zx5_Crank_Upgrade_DSC_0317.JPG
 }}
 {{Tuto Step
-|Step_Title=<translate>Add 2 off Eaton Drive to Module C</translate>
+|Step_Title=<translate>Add 2 off drives to Module C</translate>
-|Step_Content=<translate>May need to move trunking or mount directly to side of enclosure.</translate>
+|Step_Content=<translate>May need to move trunking or mount directly to side of enclosure.
+Drive can be WEG or EATON</translate>
+|Step_Picture_00=Fitting_Zx5_Crank_Upgrade_DSC_0321.JPG
 }}
 {{Tuto Step
-|Step_Title=<translate>Add single pole breaker Module E</translate>
+|Step_Title=<translate>Remove breaker and contactor from Module E</translate>
 |Step_Content=<translate></translate>
 }}
 {{Tuto Step
-|Step_Title=<translate>Remove breaker and contactor Module E</translate>
+|Step_Title=<translate>Add 10A single pole MCB in Module E</translate>
 |Step_Content=<translate></translate>
+|Step_Picture_00=Fitting_Zx5_Crank_Upgrade_DSC_0322.JPG
 }}
 {{Tuto Step
-|Step_Title=<translate>Add 1 Off Eaton drive to Module E</translate>
+|Step_Title=<translate>Add 1 Off  drive to Module E</translate>
-|Step_Content=<translate></translate>
+|Step_Content=<translate>May need to move trunking or mount directly to side of enclosure.
+Drive can be WEG or EATON</translate>
+|Step_Picture_00=Fitting_Zx5_Crank_Upgrade_DSC_0326.JPG
 }}
 {{Tuto Step
-|Step_Title=<translate>For each Eaton Drive</translate>
+|Step_Title=<translate>For each WEG drive</translate>
-|Step_Content=<translate><br />
+|Step_Content=<translate>* Live wire
+* Neutral wire
-*1 phase
+* Earth wire
-*Neutral
+* 0v supply
-*Earth
+* FWD and REV Signals
-*Fwd and Reverse signals
+* Motor cables wire directly into bottom of the drive
-*Wire motor cables directly to bottom of drives
 <br /></translate>
-|Step_Picture_00=Fitting_Zx5_Crank_Upgrade_Module_C_Eaton_drives.JPG
+|Step_Picture_00=Fitting_Zx5_Crank_Upgrade_Module_C_control_wiring_for_Eaton_drives.JPG
-|Step_Picture_00_annotation={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":28,"top":70,"width":1148,"height":609,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":0.48,"scaleY":0.48,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/c/c3/Fitting_Zx5_Crank_Upgrade_Module_C_Eaton_drives.JPG","filters":[]}],"height":450.11286681715575,"width":600}
+|Step_Picture_00_annotation={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":84,"top":-3,"width":332,"height":363,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1.24,"scaleY":1.24,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/e/e1/Fitting_Zx5_Crank_Upgrade_Module_C_control_wiring_for_Eaton_drives.JPG","filters":[]}],"height":450,"width":600}
-|Step_Picture_01=Fitting_Zx5_Crank_Upgrade_Module_E_Eaton_drive.JPG
+|Step_Picture_01=Fitting_Zx5_Crank_Upgrade_Module_E_control_wiring_for_Eaton_drive.JPG
-|Step_Picture_01_annotation={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":146,"top":-1,"width":385,"height":637,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":0.71,"scaleY":0.71,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/a/ae/Fitting_Zx5_Crank_Upgrade_Module_E_Eaton_drive.JPG","filters":[]}],"height":450,"width":600}
+|Step_Picture_01_annotation={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":103,"top":0,"width":260,"height":357,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1.26,"scaleY":1.26,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/e/eb/Fitting_Zx5_Crank_Upgrade_Module_E_control_wiring_for_Eaton_drive.JPG","filters":[]}],"height":450,"width":600}
-|Step_Picture_02=Fitting_Zx5_Crank_Upgrade_Module_C_control_wiring_for_Eaton_drives.JPG
+|Step_Picture_02=Fitting_Zx5_Crank_Upgrade_CRANK_D_AND_E.JPG
-|Step_Picture_02_annotation={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":84,"top":-3,"width":332,"height":363,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1.24,"scaleY":1.24,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/e/e1/Fitting_Zx5_Crank_Upgrade_Module_C_control_wiring_for_Eaton_drives.JPG","filters":[]}],"height":450,"width":600}
+|Step_Picture_03=Fitting_Zx5_Crank_Upgrade_CRANK_E.JPG
-|Step_Picture_03=Fitting_Zx5_Crank_Upgrade_Module_E_control_wiring_for_Eaton_drive.JPG
-|Step_Picture_03_annotation={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":103,"top":0,"width":260,"height":357,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1.26,"scaleY":1.26,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/e/eb/Fitting_Zx5_Crank_Upgrade_Module_E_control_wiring_for_Eaton_drive.JPG","filters":[]}],"height":450,"width":600}
 }}
 {{Tuto Step
@@ Ligne 188 : / Ligne 202 : @@
 }}
 {{Tuto Step
-|Step_Title=<translate>Latest Back End Software installed</translate>
+|Step_Title=<translate>Latest Front End software installed</translate>
-|Step_Content=<translate>* Open Visual Studio
+|Step_Content=<translate>* Backup Old multi folder
-* Update from Target
+* Copy in new winMulti version to c:\multi overwriting what is there</translate>
-* Save Solution as Archive with Bnn.yyyy.mm.dd
-* Close VS
-* Open File Transfer
-* Local folder G:\Design\TwinCAT3\tc3Multi_6_24
-* Remote Folder C:\TwinCAT\Stuga\Bnnn\tc3Multi_6_24
-* In remote folder, delete all files and folders except _CompileInfo and _Libraries
-* Send new folders (Data Types, Global Variables, POUs) and files below to remote
-* Open VS and check if version number correct in Version_Info.txt
-* Ensure the correct machine build is un-Remmed</translate>
 |Step_Picture_00=Fitting_Zx5_Crank_Upgrade_Annotation_2019-10-16_140117.jpg
 |Step_Picture_01=Fitting_Zx5_Crank_Upgrade_Annotation_2019-10-16_140536.jpg
@@ Ligne 207 : / Ligne 212 : @@
 {{Tuto Step
 |Step_Title=<translate>Map new Links</translate>
-|Step_Content=<translate><br />
+|Step_Content=<translate>Overwrite existing links if any exist
-{| class="wikitable"
-|+
+<br />See the wiring for MC2C and MC2E in Step 22 for the link IORefs and locations</translate>
-!Output Ref
+|Step_Picture_00=Fitting_Zx5_Crank_Upgrade_Annotation_2019-10-16_141758.jpg
-!Name
+}}
-!EtherCAT Slice
+{{Tuto Step
-!Channel
+|Step_Title=<translate>Activate Configuration</translate>
-|-
+|Step_Content=<translate>And restart in run mode when prompted</translate>
-|273
+}}
-|Crank C Fwd
+{{Tuto Step
-|MC2C
+|Step_Title=<translate>Add new IO Refs to IODef.mul</translate>
-|9
+|Step_Content=<translate>Ask HQ to download a relevant IODef.mul file
-|-
-|275
-|Crank D Fwd
+Failing this, the following IO refs need to be added<syntaxhighlight>
-|MC2C
+OuC_CrankFWD,273,2,0,0,False,False,3,8,-,False,0
-|10
+OuC_CrankREV,274,2,0,0,False,False,3,9,-,False,0
-|-
+OuD_CrankFWD,275,2,0,0,False,False,3,10,-,False,0
-|274
+OuD_CrankREV,276,2,0,0,False,False,3,11,-,False,0
-|Crank C Rev
+OuE_CrankFWD,277,2,0,0,False,True,64,0,-,False,0
-|MC2C
+OuE_CrankREV,278,2,0,0,False,True,64,1,-,False,0
-|11
-|-
+</syntaxhighlight>
-|276
-|Crank D Rev
-|MC2C
+And these removed</translate>
-|12
-|-
-|277
-|Crank E Fwd
-|MC2E
-|10
-|-
-|278
-|Crank E Rev
-|MC2E
-|11
-|}</translate>
 }}
 {{Tuto Step
@@ Ligne 252 : / Ligne 245 : @@
 }}
 {{Tuto Step
-|Step_Title=<translate>Test</translate>
+|Step_Title=<translate>Programme WEG drives</translate>
-|Step_Content=<translate></translate>
+|Step_Content=<translate>Follow link below for information on programming WEG drives:
+[[WEG Inverter Setup]]</translate>
+}}
+{{Tuto Step
+|Step_Title=<translate>Test Function</translate>
+|Step_Content=<translate># Ensure all Out and home sensors are working and correctly oriented. Home is towards rear of machine, Fwd or Out is towards front.
+# Ensure the clutches are set to slip if the crank bottoms out
+# Test direction of all cranks (Fwd is towards front). Switch phases on motors if direction needs to change. The PLC has hard code to switch the outputs off when the sensors are covered
+Key Pointers
+*End stops should be set so the rack can never run off the pinion - always a full tooth engaged
+*Each crank motion stops when the input is seen, and then decelerates. Therefore, set the crank input position to allow for this deceleration before hitting end stop. Normally about 30mm
+*The crank clutches should be set to slip before damage is done to the crank end stops in the event that the sensors do not work</translate>
 }}
 {{Notes}}

Fitting Zx5 Crank Upgrade : Différence entre versions

Version actuelle datée du 18 novembre 2024 à 11:12

Sommaire

Introduction

Étape 1 - IF EATON DRIVES ONLY* Program Drives before they leave

Étape 2 - Remove Link arm connecting to rack and pinion

Étape 3 - Remove pivot shaft and arm

Étape 4 - Undo clutch and remove Cam

Étape 5 - Add sprocket to clutch

Étape 6 - Fix idler plate to upright

Étape 7 - Fix split sprocket onto drive shaft

Étape 8 - Drill and pin split sprocket to shaft

Étape 9 - Add chain minimum length sprocket to sprocket

Étape 10 - Fit Module C Crank Home sensor plate to Arm 5

Étape 11 - Fit Module C Crank Out sensor plate to Arm 5

Étape 12 - Fit Module D Crank Home sensor plate to Arm 5

Étape 13 - Fit Module D Crank Out sensor plate to Arm 5

Étape 14 - Fit Module E Crank Out sensor plate to Arm 5

Étape 15 - Fit Module E Crank Home sensor plate to Arm 5

Étape 16 - Remove 2 off motor breakers and contactors from Module C

Étape 17 - Add 2 off 10A single pole MCB's in Module C

Étape 18 - Add 2 off drives to Module C

Étape 19 - Remove breaker and contactor from Module E

Étape 20 - Add 10A single pole MCB in Module E

Étape 21 - Add 1 Off drive to Module E

Étape 22 - For each WEG drive

Étape 23 - Wire Sensor Cables to EtherCAT boxes

Étape 24 - Latest Front End software installed

Étape 25 - Map new Links

Étape 26 - Activate Configuration

Étape 27 - Add new IO Refs to IODef.mul

Étape 28 - Latest Front End software installed

Étape 29 - Programme WEG drives

Étape 30 - Test Function

Commentaires

Étape 1 -
IF EATON DRIVES ONLY* Program Drives before they leave