This is a property of type Text.
A
The following areas should be attended to daily
This routine should take no more than 15 minutes +
The Autoflow R axis uses a slewing ring which has a seal that is subject to ingress of swarf. Over time, this seal can become dislodged, resulting in a major failure of the machine. +
B
To rectify the obsoletion of B0000082 drive motor, the following replacement kit has been designed to enable continued support of older assemblies within stuga machines .
The kit consists of a new motor and appropriate gearbox, adapter plate and new fasteners . Also details are included here for a small modification to enable the upgrade to function correctly
Following parts are required for this upgrade
B0000082b load motor and gearbox 1 off
D0008225b adapter plate
F0000189 M6 x 25 set bolts 4 off
F0000058 A form washer 4 off
F0000190 M8 x 40 set bolts 2 off
F0000007 M5 x 16 cap head bolt 4 off +
The Flowline range (Mk3, ZX3, ZX4) are Stuga built and designed machines for prepping and cutting uPVC windows and doors. The Flowline is the first machine of the Stuga 'U' shaped machines which has prepping and cutting working in the same machine package. The Flowline is still a fantastic machine for the industry, however, due to the age of the machines and older control systems becoming obsolescent, we have had to find an upgrade route that does not only keep the machine going, but also provides improvements from the original model and up-to-date technology to future proof the machine.
The upgrade that we have developed for the Flowline is supplied from an automation supplier named Beckhoff. We also use Beckhoff on our new build machines. This gives us better lead times, more understanding of the products and better diagnostics/ support for our customers. The drive system that we use is called the AX8000 series. These drives are a compact multi axis servo system that use an EtherCAT interface and STO safety functions. These servo drives, coupled with Beckhoff AM8*** series OCT servo motors provide quicker installations and all round performance increases from any system we have previously used. To drive all of the new system, we are using a Beckhoff IPC controller that runs TwinCAT 3. This links into the system via EtherCAT. All of the machine can now link together via EtherCAT to provide quick and stable communications.
This tutorial will give you step by step guides on the physical upgrade requirements needed when upgrading a Flowline Mk3 to a Flowline Mk3 with Beckhoff AX8000 Control. Each step will provide you with written information and pictures to guide you through the upgrade. Each step will contain necessary information which will also provide you with rationale for the design and an idea of the benefits over using different methods.
Please always feel free to provide Stuga with any feedback on this document or its contents. +
C
Users have concurrent licenses - ie we can have many users, but only the number of users can be logged in concurrently
Users do need to be set up in a specific way. +
When to use.
If when you need room on a disk TreeSize shows large usage in "System Volume Information"
Then use this procedure to remove the files. +
Replacement of Beckhoff CX5120
Skill Level: Experience with Twincat & Visual Studio
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<div class="icon-instructions-text">...Don’t Switch CF cards around. Keep them in the CX5120’s they came with.</div>
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Stuga recommends this blade be changed after 1-2 weeks of cutting - symptoms to determine if the blade needs changing:
* Awful cutting sound / smell
* Profile dragging (sizes too short)
* Brown burnt swarf
* Smoke coming out of profile end while cutting
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<div class="icon-instructions-text">...The 500mm blade is sharp and can be awkward to manouver out of the saw, please be careful</div>
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In March 2022 the password policy of the system behind SourceTree / Bitbucket and Atlassian changed - [https://community.atlassian.com/t5/Bitbucket-articles/Announcement-Bitbucket-Cloud-account-password-usage-for-Git-over/ba-p/1948231 link]. This meant all machine would need a complex password login change for the SourceTree program used for version control of the PLC code.
This was not straight-forward to resolve, so the decision was made to change the version control system to the one that is packaged with the Visual Studio system by default. This is a better method anyway, but it needs the "TcXaeShell" installed.
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<div class="icon-instructions-text">...The TcXaeShell is simply a newer version of Visual Studio that includes Source control, rebadged for TwinCAT3</div>
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A password can be set up within FlowlineOps that limits access to the Edit Machining and Edit Profiles buttons, This tutorial will explain how to setup or change this password. +
Infeed Off-Cut Laser sensors are used to check the length of profile with the proposed length from the software. This is to avoid incorrect lengths and profiles being cut. The sensors will be put at specific lengths along the infeed which will be input in the software files. When profile hits the back fence all covered sensors will trigger, hence, the profile must be larger that the final triggered sensor. +
Commonly used during sawing on Z transoms, the Z block operation is used to fasten the profile, making sure it does not move during sawing. There are 6 possible states the z block can be in. Each of these can have a different length of protrusion for different profiles.
12 x M8 Screws
12 x M8 Nuts
12 x wire numbers 1 - 6 +
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<div class="icon-instructions-text">...Any stepper motor drives will need the EP7041 drive to be programmed first</div>
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The Beckhoff system provides a system for upgrading to TC3 from a TC2 project. This tutorial goes through the steps required to ensure the links and setup of the original TC2 project are copied through to TC3. +
How to correctly Adjust the Saw conduit to prevent it hitting the guard locking device +
Accuracy problem on A2001 was traced to a non-linear rack. This tutorial demonstrates how to test the linearity of a rack and the systems in place to correct the linearity.
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<div class="icon-instructions-text">Modifying the linearity of a rack is a very complex and sensitive issue. You must be absolutely certain that there is a case for linearity with REPEATED tests that produce the same result. It is far more likely that accuracy problems are cause by other mechanical issues. This is the only machine in the 20 year history that has needed these alterations</div>
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If you are confident and proficient in using the Visual Studio editor to create TwinCAT projects, you can shortcut a lot of the data inputting by copying and modifying an existing project. This will keep the naming conventions and links exactly the same
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<div class="icon-instructions-text">...This should only be attempted if the machine has exactly the same EtherCAT box, drive and module setup</div>
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<div class="icon-instructions-text">...Beckhoff Technical help is available on 01491 410539 option 3</div>
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When modifying a TwinCAT project, particularly when modifying to change version numbers, etc, the mapping information can be lost. This can be a time consuming and error-prone process to re-do.
However, the mapping information can be exported before any changes are made and then re-imported
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<div class="icon-instructions-text">...The reason that the mappings disappear when a project is replaced is because the Instance data is not created - the mappings need an instance to get the textual information of the IO links from</div>
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D
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<div class="icon-instructions-text">...This procedure is now obsolete - it is kept for historical purposes only</div>
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All information provided to the service engineers on Device Magic can all be linked to a single Excel document. This document provides all customer names, machine numbers, emails and employee information. Linking this document with Device Magic provides fields that make it easier for engineers to fill out the form.
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<div class="icon-instructions-text">This document must only be used internally at Stuga and not be sent to engineers or customers in coordination with Data Protection standards.</div>
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