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Align the infeed roller block so that it is square (check the roller with a straight edge against the other rollers). Fit the bracket using the 2 off M8 x 25 Bolts. Mark through the clearance holes on the bracket onto the roller block. +, Reinstall strengthening bracket with 2x M8 x 16 Bolts (F0000023) into the infeed roller block, and the 2x M8 x 25 Bolts (F0000025) into the infeed arm. +
Locations of jigs required
mounting method +, Levelling jigs
1st level jigs individually
2nd level jigs to each other
<div class="icon-instructions caution-icon">
<div class="icon-instructions-icon"><i class="fa fa-exclamation-triangle"></i></div>
<div class="icon-instructions-text">...Lowest datum point must be held when levelling jigs
explain</div>
</div><br/> +, Use wire to align jigs to each other
Double checks ensure levels are correct after wire alignment
Q/C +, …
Mount gearbox to servo motor
Correct orientation of gearbox for access
Correct torque setting of friction coupling
Marking of gearbox for torque setting
Blanking plug fitting +, Fitment of gearbox assembly to mounting adapter plate
Fitting of drive pinion to gearbox shaft
Fitting of assembly to carriage plate
Correct setting of drive pinion Height to hepco rail
<br/> +, Correct setting of drive pinion backlash at various points on x axis +, …
Make sure the cables and piped are fixed with cable ties to the fingers of the bracket to avoid movement or twisting inside the energy chain. +, The Bracket to which the finger energy chain bracket fixes to should not rub or catch on the trays during movement
Also the fold of the energy chain shouldn't ride along the side of the trays when moving towards the multi or saw end +, To avoid any contact with the button heads which fix the trays to the 'L' brackets adjust the brackets on the slots.
Tray heights are also important, make sure there is a consistent gap (consistent as possible) between the top of the bend and the top tray all the way along.
The end corners of the trays may require bending out slightly, there have been occasions where one chain tray has been slightly more bent in than the other meaning when the chain moves from one tray to the next it clips the corner of the next tray. +, …
No hard pipe under the Saw. +,
* Add air temporarily to the lift rollers to create datum in their up position.
* Use laser to level and set height so that the M/C Outfeed rollers are parallel to M/C Rollers, but 0.5-1.0mm lower than the M/C Rollers.
+,
* Measure up diagonals to get the two transfer frames fully parallel.
* Measure the gap between the frames, ensuring the male posts on the stub arms (on frames) are same distance as the hole centres on the transfer beams.
* Level the frame.
* Position Transfer Arms 1 and 9 to fine tune the frame positions.
* Place a level on these two transfer arms.
* Level the frame again using the two transfer arms to indicate if the Saw Infeed frame needs to be raised or lowered.
* Recheck level and squareness of Saw Infeed.
+, …
Identify if either saw infeed or multi head outfeed is the logical frame to place first .
Consider access to machine when installing 1st frame
Consider handing of machine +,
# Saw infeed or Multi head outfeed
# multihead outfeed or saw infeed
# transfer table
# Machining centre
# Machining centre infeed
# Saw module
# Saw outfeed table
# Conveyor
# Extraction
# Guarding
+, In each step if applicable, Manufacturing links have been included to aid the installation progress for correct understanding of assembly process to achieve desired results
Please use the links if any adjustments have to be made on site, as critical measurements and setting details will be provided within the build data
Please ensure any quality/ discrepancies are correctly reported if encountered +, …
Check X axis alignment of horiczontal and vertical rollers using 2 meter straight edge and feeler gauges
Any discrepancy must be reported and rectified if present
Tolerance 0.002" / 0.05mm
[https://stugaltd.monday.com/boards/3628350043/pulses/4665028475][[R0015311 Install and Align Datum rollers]]
<br/> +,
#x axis machine levelling. use a 2 meter straight edge between the indicated points and an engineers level on top to level this axis
#Y axis levelling. Use an engineers level to straddle the 2 indicated points to level the y axis of the machine
[[R0015311 Install and Align Datum rollers]]
[[R0002913E Install and Align Rotary head Subframe]]
[[R0002913E Install and Align Rotary head Subframe PART 2]]
[[R0015046 Bench Assemble Infeed Clamps]]
+, Machining center is aligned to the outfeed using the following
Grip pin setting jig
Laser level
2 meter straight edge
X axis position is determined by hepco rail travel at full extent and center clamp bar within machining center. The gap here should be approximately 75mm.
Y axis position is determined by the grip pin jig and the machining center backfence rollers. The grip pin jig must be used at 2 points for correct alignment . Infeed datum rollers and v notch datum rollers.
Ensure gripper pins fall freely and centrally into alignment jig when setting.
Only move Machining centre to adjust this position
Height is determined by the datum horizontal rollers in the machining center and the blue rollers on the outfeed table. Out feed rollers and platform should be less than 1mm below the Machining centre rollers
<br/>
#position machining center roughly in place on the end of the outfeed table
#level using previous step
#once the module has been levelled, final levelling of the outfeed x axis can be done , as it uses the machining center as a datum to hold the laser level
<div class="icon-instructions caution-icon">
<div class="icon-instructions-icon"><i class="fa fa-exclamation-triangle"></i></div>
<div class="icon-instructions-text">...Levels must be extremely accurate in the machining center +- 1 division for this step to be accurate</div>
</div>Place laser level in the rear datum roller section of the machining center
Position gripper carriage as close to the laser level as possible
Mark a horizontal line of the carriage plate as a height datum
Move the carriage to above the next section of frame feet and adjust the pair of jacking bolts to adjust line to be on laser level mark
Repeat this step above every pair of frame legs where jacking bolts are<div class="icon-instructions caution-icon">
<div class="icon-instructions-icon"><i class="fa fa-exclamation-triangle"></i></div>
<div class="icon-instructions-text">...Make sure frame bolts are accurately rotated when adjusting as pairs. If this isn't done, y axis level will be lost and unnecessary strain will be added to frame sections</div>
</div>These steps will ensure the outfeed is now set on a dead flat plain
4. Use the pin jig to adjust the position of the machining center to allow the gripper pins to align with the jig at all points along the back fence rollers. hepco beam should also be moved from in to the out position also to double check this jig setting
5. Use laser against machining center rollers to cast a laser line along the outfeed. Pull the gripper as close as possible to the laser, and mark a vertical line on the gripper where the laser dot falls.
Move the gripper to the end of the hepco rail and check if the laser stop still aligns on the vertical line previously marked . If it doesn't , grip pin alignment will need re checking as it is crucial that both of these areas are correct
6 final height adjustment is set by using a 2 meter straight edge through the machining center rollers to the first set of rollers on the outfeed table. Machining center can be adjusted up or down to bring these rollers all onto the same height plain (-1mm maximum)
[[R0015028D ZX5 Hepco Beam Alignment Module C]]
[[R0015028D ZX5 Hepco Beam Alignment Module C part 2]]
<br/> , …
All control pneumatic connections will be identified with identification numbers
All permanently fed supply lines will be identified by the use of Red pneumatic pipe
All Emergency stop switched air feeds will be identified by the use of Blue pneumatic pipe +, Machining centre to Machining centre Infeed connections
12mm diameter blue pneumatic pipe from Infeed table to connect to Machining centre main Air service unit . Runs along cable basket on infeed table and drops out of end to connect to air service unit
Mains air connection to machine via PCL connector . Do not connect until all subsequent pneumatic connections are complete +, Connections from rear of Module B
<br/>
* 2 off 12mm diameter Red pneumatic pipes trailing from transfer table wire basket to connect to 12mm bulkhead connections on rear of machining centre. These will be identified as 12mm Red on machining centre
* 1 off 12mm diameter blue pneumatic pipe trailing from module C wire basket to be connected to bulkhead fitting on machining centre. This connection is next to the 2 off red connections and will be identified as 12mm Blue +, …
Make sure the reset of the Estop circuit works. Be aware when resetting this will reset the air to home all pneumatics.
Test each emergency stop button individually (Button box, infeed rear middle and end) making sure this breaks the circuit when pressed and the air is dumped. The Infeed beam sensor should be tested, when broken should also break the circuit and dump the air.
Check on Service menu - IO tab that each input works correctly for each Estop unit. +, The home position of the roller beds should be up when the Estop circuit is ok and air is on.
Open the Service menu - IO infeed tab and use the output Y157 OUA_Roller to activate, moving the roller beds to the down position under the infeed plastics.
If they are moving the correct orientation, ensure all beds move up and down together, and arrive to position at the same speed or as close to as possible. Speeds should be roughly set when roller bed units are assembled. A rough setting is to wind each flow reg fitting completely in and then wind out 2 full turns.
Some may need tweaking to even out the speeds across all tables. +, Home position for the loader is up on the rubber stop.
home sensor Input X304 InA_WheelHm should be on (red) when the loader wheel is up in the home position. if it isn't the sensor on the cylinder needs to be adjusted.
Activate the loader wheel down using Output Y154 OuA_WheelDo. When activated set the pressure gauge on the back of the infeed cabinet to around 1Bar.
Adjust the flow reg fittings to set the speed of the wheel down and wheel home. See video for rough speed required. +, …
Position module F at end of Module E infeed frame
Approximately Align Saw roller back fences to Saw infeed back fences
Approximately align X axis position by setting the to frames spaced at the distance shown of 20mm +, Saw module should be raised or lowered to align with blue load rollers on saw infeed table
Saw module should sit above blue rollers by no more than 1mm
Ensure levels previously set are not compromised when adjusting height
Double check levels are still correct once height has been adjusted +, With the laser still casting along the infeed table, slowly return the gripper along the axis and inspect the laser dot in relation to lines added to gripper. Discrepancy should be less than 4mm on both axis +, …
Position module A in front of module B
Use Infeed back fence to Multi head datum rollers as initial alignment guide for Y axis
Set gap of 23mm -+ 2mm between module A roller frame and module B roller block +, 1 Use green strip on indicated loader arms and yellow 1 meter level to read level of arms indicated
2 Adjust level of arms using jacking points below.
<br/><div class="icon-instructions idea-icon">
<div class="icon-instructions-icon"><i class="fa fa-lightbulb-o"></i></div>
<div class="icon-instructions-text">...Always check previous adjusted loading arm isn't affected by changes to the next arm</div>
</div>
Recheck all levels on arms are correct once final arm has been adjusted +, Module A height must now be adjusted to match the height of Module B datum rollers
Ensure the adjustment points are always turned the <u>EXACT</u> same rotation when adjusting. This will ensure that Y axis level is not compromised
Adjust height to match height of Module B datum rollers. Tolerance -+1mm +, …
Before installing module B, module C roller tables should be double checked for correct positioning
1 To do this inspect tables 1, 2,3 and 4 for level as shown.
2 Also inspect alignment with 2 meter straight edge. All rollers should be on the same height and no bump up should be present when moving the straight edge over the table.
3 Ensure fixed table is at same height as rollers
Report any discrepancies to supervisor for correct remedial action +, Before installation a quality check should be performed on Module ?b datum rollers
Check horizontal and vertical rollers
Use 2 meter straight edge to check alignment of rollers as shown . Tolerance 0.002" /0.05mm . Any discrepancy should be reported to supervisor for suggested remedial action
<br/> +, 1 Level Y axis using indicated point
2 Level X axis as shown using 2 meter straight edge on horizontal rollers +, …
The rollers on top are mounted on eccentric bushes. We only need these just tight enough to not allow any slop or vertical play. Slacken the cams off completelely, you will need an 8mm spanner with the faces ground down to fit in the space.
Slide the plate onto the rail and tighten the eccentric bushes until any vertical play is removed. Lightly try to move the assembly on the X axis, if there is any slop then it needs to be a little tighter but probably no more than an 1/8th of a turn. Once set you should still be able to spin the rollers by hand, but still feel a fair bit of resistance. Once set slide the assembly over the full length of the V rails to check fo any tight spots. If there are then you need to check that the two halves of the fail are fully mated!!! +, Remove pinion gear by slackening off grubscrews and sliding away. Good idea to mark up original position.
Disconnect airpipe feeding popup cylinder and slide off rack mounting plate.
Slacken all 20 caphead screws, they only need a half to full turn. Move the rails up as far as they will go and then tighten just the screws on each end, finger tight is enough. These rails come in two parts, ensure they are fully mated together or they will cause tight spots later on. Using the joiners square in the picture set to 47mm, use it to set height of the V rails when the bubble shows it is level. Check at each end and in the middle. Once level, tighten all screws and recheck level. +, If there is no adjustment between the mounting plate and the rack as shown in the first picture, then we need to introduce some. This is the most important step as it ensures all the parts are running parallel to eachother and not causing excessive force!!!
Get your sharpies oot and mark where the rack and pinion mate!!! Slacken off the larger screws, one at either end of the rack until you have a 3mm gap at each end. This is easy when removed, but once refitted you will need a cut down allen key to fit in the gap to adjust. Back off the set screws if not already. Slide the assembly back on and mesh the pinion to the rack at one of the ends, it does not matter which, lightly tighten a grubscrew on pinion to ensure there is no backlash felt between the key and keyway. Using a combination of the set screws and adjustment screw, adjust until there is no play between rack and pinion. Then turn each of the small set screws back an 1/8th to 1/4 turn and fully tighten the adjustment screw. This introduces a very small amount of play that should hardly be felt, but is just enough to stop premature wear between the two. Remove the pinion, slide the rack to the other end and repeat the process. Recheck the first end in case it has moved slightly while doing the second. Set distance from beam to popup cylinder using measurements from another assembly, or if you were clever enough you took these before taking everything apart? I wasn't! If it needs adjusted then slacken off the two setting bolts, they give around 10mm on the mounting slots. 1mm either way is good enough and will not cause problems. Reconnect air pipes, make sure everything is locked off and tight, job done. +, …
1 Open front door via control screen
2 Ensure emergency stop system is also activated for safe working
3 Remove swarf from saw +, 1 Flange C spanner D0005207
2 Align pins into main saw front flange and insert
3 24mm Spanner
4 Release bolt in direction shown +, 1 Remove M16 bolt and washer
2 Remove front flange +, …
1 Open front door via control screen
2 Ensure emergency stop system is also activated for safe working
3 Remove swarf from saw +, 1 Flange C spanner D0005207
2 Align pins into main saw front flange and insert
3 24mm Spanner
4 Release bolt in direction shown +, 1 Remove M16 bolt and washer
2 Remove front flange +, …
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