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Follow [https://stuga.dokit.app/wiki/TB0409_Setting_Up_Windows_10_PC_2018 technical bulletin 409] to setup PC with correct naming conventions and TeamViewer. +, Follow [https://stuga.dokit.app/wiki/TB0451_CX5120_Beckhoff_PC_Setup TB0451] to set up the Beckhoff PC
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<div class="icon-instructions-text">...All Netmatters CNC machines will have TwinCAT already installed, so you can normally skip this step</div>
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Install TwinCAT 3.16 from the mainserver (G:\Design\TwinCAT3\TC31-Full-Setup.3.1.4022.16). Go through the wizard and when prompted restart the PC. (2019 PCs will have this) +, …
Go to the PlayStore and download the e-Drawings app. This will cost (currently £1.25) therefore ask appropriate member for a company card. +,
# Go to the PlayStore and download the TeamViewer app and the TeamViewer QuickSupport app.
# Contact an employee with access to the TeamViewer Management Console (Administrator privileges). From there the engineer’s name and email need to be filled in. as well as this a password will need to be allocated. Use: Stuga(ii) (Where ii are the initials of the engineer).
# After the engineer has been invited they will receive an email for verification. They need to click the link in the email to verify the account.
# After they have done this you can alter the user’s shares. Go to the TeamViewer “User Management” console. Then go to the engineer’s name. When hovering over the engineers name a gear symbol will appear on the right hand side. Click on this. Click “edit user”. On the left click the “Shares” tab. Then go to add group and add all groups. Go to where it says read only and select “Full Control”. Now click Add. Now Save.
+,
# Go to the PlayStore and download the Forms app.
# Open the app and on the welcome screen select “Sign in to an Existing Team”, type your engineer’s full name and under “Organization key” put: STU855. Now press “Join My Team”.
# Contact an employee with access to the Device Magic management console. On this go to the devices tab and click the tick on the engineer’s row.
# Now on the table there will be a column called “Groups”. On the engineer’s row there will be many groups that they’re signed up to. To change this click on the groups. Then check/uncheck the relevant groups for the engineer.
+, …
Open box, unwrap printer, plug in power and plug Ethernet connected to network to the printer. As the printer boots up there will be a red light displayed on the front. After around 30 seconds this will turn green as the printer completes boot up. +, Using the latches on the sides, open the printer and place in a label reel as shown in photo. Now ok to close the printer and front roller. +, Hold down the button until the green light flashes once, then release. This should printout 8 labels with various parameters on them, look for the label with ‘IP Address’ as shown in figure 2. +, …
Using a stripped plug and making sure there is no power going through the plug during installation:
# '''Live wire''' (Brown) in the top port
# '''Neutral wire''' (Blue) in the second port
# '''Ground wire''' (Green + Yellow) in the bottom port
# The '''Joggers''' Serial port
# Plug in and '''turn on''' plug +,
#Once power is on press '''JOG ON'''
#Now keep pressing '''MODE''' until the screen outputs '''SEt-01'''
#Press '''ENTER''' to change the parameter.
#Change number in the setting and press '''MODE/SET''' to confirm.
#Press '''ENTER''' again to come out of the perimeter.
#Make your way through the list making sure you press '''MODE/SET''' each time to save the parameter.
+, After this go through the perimeters '''AGAIN.''' This is important as they can easily be set wrong. +, …
Press on the “Backup” button on WinMulti +, .zip file has been created +, Most Stuga machines have a backup folder, but it is more secure if you backup to another device, e.g.a memory stick
To locate to the standard Stuga backup folder:
# Navigate to “Local Disk (C:)”
# Open the “multi” folder.
# Select the “backup” folder and press ok. +
The control setup for AX8000 drives is no longer in the Drive Manager – A “Measurement Project” is automatically created at the end of the Visual Studio Solution
Select the drive in question and then the channel +, Select the Tune Drive Tab. The Velocity constant is Tn. This screen shows it in seconds (0.008s = 8ms) +, Change the value to 0.0008 to improve the accuracy. Press enter and the value changes to red. +, …
1. From Camera PC, use System Manager to activate original configuration
2. From Camera PC, use PLC Editor to login both original projects – PLC_Reset in Port 811, and the other main PLC control project in Port 801.
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<div class="icon-instructions-text">DO NOT FORGET TO ACTIVATE BOOT PROJECT</div>
</div><br/> +, Connect to camera PC +, Copy the latest tcMulti.pro file from g:\design\twinCAT to camera PC:\twinCAT\ +, …
The laser should be aligned to ensure the beam is level up / down and parallel to the backfence. The path should follow the Yellow edge of the lift rollers on the infeed table.
Length feedback from the measurement system is visible all the time on the service form.
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# Measure and mark the infeed table at fixed positions from the loading fence at MH end – (3m, 4m, 5m, 6m)
# Use a short offcut of profile with a label on the end to act a a fixed reflector at the marked positions – check against the feedback on the screen.
# Adjust the lengthMeasureOffset parameter to get the screen measurements to match reality (+/-10mm) +, Firstly, adjust the sensor dark / light and range correctly - see online video https://vimeo.com/294109652/c84d27e9f4
'''Note to experienced engineers''': the version 6 software makes this a lot easier to set up than older software versions
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# Using a tape rule from the MH end loading fence, note where the first sensor dot hits the tape
# Repeat for all 8 sensors
# Add these to the offcut sensor positions
# Run 3 different sizes of offcut through machine, noting the actual length, and the length measured by the machine. All the lengths should have a similar error
# Adjust the infeedToZeroX to get the machine measuring correctly (+5mm/-0mm). This parameter represents the distance from the loading fence to the zero datum +
The out and home sensors must be adjusted so that the "just" come on at the end of the stroke.
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<div class="icon-instructions-text">...This is important because the physical end stop position will directly affect the positional accuracy. If the end stop is not reached by as little as 0.5mm, the end stop sensor should be the fail-safe to ensure the machine stops with an alarm.</div>
</div><br/> +, Run a manual bar with a datum test at 500mm and 1200mm and a V notch at 750mm. This ensures the first datum test is done with the beam “out”, then the V notch forces the beam to move before the second hole. +, If the distance > 700, reduce beamStrokeLength by the difference and vice-versa +, …
Go to Control Panel then ‘Region and Language’ and select ’English (United Kingdom)’. +, Plug in the Ethernet, DVI, Keyboard and Mouse to the Beckhoff PLC. This can be done on a machine (as shown) or before installation (without etherCAT or slices).
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<div class="icon-instructions-text">Switch the Beckhoff PC off before plugging the screen in, because it probably will only detect the screen during power up</div>
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# Go to Internet Explorer and search "[http://www.teamviewer.com/en/download/windows/ www.teamviewer.com/en/download/windows/]".
# Scroll down to TeamViewer Host and click on 'Download Host',
# when prompted press 'Run' to start download.
# Make sure download is of the most recent version.
+, …
One difference between the GX420d and the ZD620d is the lack of a dedicated power switch. The newer ZD620d opts for a power button that must be pressed in order to turn on the printer after power is supplied. As our machines are fully un-powered after a machine is closed down it causes the operator to intervene and manually turn on the printer after power up.
Ideally the Zebra ZD620d has an '''Power Recovery Mode''' that acts as a permanent switch in case of power failure. We can use this on the machines to allow the printer to turn on upon power up.
1. Disconnect from power.
2. Remove module door and use Ethernet cable to remove (plug in and pull).
3. Move the switch that is annotated AUTO to the ON position.
4. Reinstall the module.
5. Reconnect power, this should now turn on. +, Plug in power and Ethernet cable connected to network to the printer. As the printer boots up there will be a red light displayed on the front. After around 30 seconds this will turn green as the printer completes boot up.
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<div class="icon-instructions-text">Also check the Network Light. If this is orange or red there is a connection issue between the printer and the network</div>
</div><br/> +, Underneath the printer will be two screws that hold the front label dispenser in place. Undo these using the tool provided in the peel off module box. When these are undone, slide the dispenser downwards to release. When this is off, slide the peel off module onto the printer. Reattach the screws and tighten +, …
<big>This means prepping the changing area so everything is in reach.</big>
*(6) Nappies
*(2) Baby wipes
*(3) Nappy Bag
*(4) Change of clothes
*(5) A toy (Distraction)
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* Lay the baby onto a safe soft surface
* Unfasten the tabs and raise the baby's bottom by holding onto their ankles to pull away nappy.
* Dispose of nappy into nappy bag
* Gently clean using wipes or use cotton wool for newborn.
* Slide a fresh new nappy under your baby and using the stepped process attached.....voila you have one happy clean baby.
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+
To check the centraliser closes fully, activate the ‘Clamp Positioner’ and ‘Centralise’ clamp from the IO screen with no profile in the saw cutting area. The side clamps should close down to around 40mm. '''A regular fault is a small offcut of profile trapped somewhere preventing the centralise clamp closing to the profile'''.
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<div class="icon-instructions-text">...the “centralise” clamp output is NOT the same as the “side” clamp output, which will not highlight this problem.</div>
</div><br/> +, An easy check will demonstrate if there is a profile symmetry issue:
* Cut two lengths of profile [ ] and mark the front face
* Turn one piece around and butt it up to the other piece
This picture shows a poor quality profile where the narrow face is not centralised to the rest of the profile. The outer edges are lined up, but it is clear that the narrow edges on the top face are not. +, To check the 45 degree cuts, run off a few 300mm \ / cuts and check the angles +, …
If this process is to be carried out on a flowline, it is very important for the full scaling procedure to be followed, to ensure accuracy across both machines +, It is important to ensure that the cut lengths are consistent before any changes are made. An inconsistent result could throw all accuracy adjustments out, and will not find the root cause of the problem.
1. Cut 19 off 300mm pieces [ ] from a 6m length.
2. Mark each piece as it is cut
3. Check lengths of each one, measure across the '''BOTTOM '''of the profile
4. Check each cut for squareness
5. To pass, all cut lengths must be within '''0.5mm'''
Factors affecting cut length consistency:
<table class="wikitable" border="1" cellspacing="0" cellpadding="0">
<tr>
<td width="236" valign="top">'''''Possible Cause'''''
</td><td width="271" valign="top">'''''Solution'''''
</td></tr><tr>
<td width="236" valign="top">Backlash in saw pusher
</td><td width="271" valign="top">Mesh the pinion into the rack tighter
</td></tr><tr>
<td width="236" valign="top">Profile “jumping” because a pneumatic function is jogging the profile
</td><td width="271" valign="top">Smooth the motions with flow control valves and lock off with pliers.
</td></tr><tr>
<td width="236" valign="top">Profile jumping on Eject Clamp
</td><td width="271" valign="top">Fit flow control to eject clamp down stroke
</td></tr><tr>
<td width="236" valign="top">Alignment / level of saw infeed
</td><td width="271" valign="top">Check alignment with laser level
Saw infeed is forward of saw backfence
</td></tr><tr>
<td width="236" valign="top">High / Low Clamp pressure sticking on high
</td><td width="271" valign="top">Faulty valve or pressure regulator; electrical fault
</td></tr><tr>
<td width="236" valign="top">On standalone saw: Slack Chain
</td><td width="271" valign="top">Tension chain
</td></tr><tr>
<td width="236" valign="top">Pusher disappearing inside profile
</td><td width="271" valign="top">Infeed tables raised
</td></tr></table> +,
# Ensure batch is complete
# If running on a flowline, make sure the machining centre program is exited to desktop
# Measure the saw blade kerf with callipers
# Input into “Machine Parameters” menu.
# Cut [ ] 300mm, 1000mm, 2000mm and check lengths. An incorrect kerf will change the cut length by the same amount on each different length.
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<div class="icon-instructions-text">...If the calibration is incorrect, the length will grow or shrink, depending on the length of each piece cut. This will mean re-calibration before you can go any further</div>
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+, …
A calibration mnd file has been written to help line up the x offsets called VTEST. This program creates the following pattern on the bottom of the profile using a 10mm spindle and the notching blades themselves:
Run the VTest operation on a length of large outer frame of at least 1m long. Put the operation at a position of 500mm.
The pattern allows you to measure the offsets required with calipers.
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<div class="icon-instructions-text">...Profile is viewed from the bottom face, Basically turn it over when it comes of the transfer table.</div>
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# Measure between the VI blade and the edge of the 10mm slot – This value is the xoffsetVI (and also the xoffsetWI). (We need to add 5mm to the measured Value). ''' 50.33mm'''
# Measure between the VO blade and the edge of the 10mm slot – This value is the xoffsetVO (and also the xoffsetWO). (We need to add 5mm to the measured Value) '''87.59mm'''
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<div class="icon-instructions-text">...The 5mm is added becasue this is half the 10mm slot width - thus measuring to the centreline of the slot</div>
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+,
#Make sure the Datum is correct first.
#V notch blades are not buckled.
#Check that the profile width is correct for the profile you are testing.
Find out which V Notch files the machine is using by checking the operation setup. A simple way of doing this is shown in the pictures by starting a "Manual Input".
Picture 1 - shows this machine uses VF / VR codes
Picture 2 - shows a different machine using VAF3 codes
Note this "mnd type" for later
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<div class="icon-instructions-text">...The VF... codes are the original method of setting up the machines, the VAF3 codes are seen as an improvement because it makes the naming of the variables for the offsets a little clearer and groups them together. It also improves the machine cycle time by allowing the use of startOffset - the x axis needs to move only once to the start of the V notch</div>
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+, …
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# one
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