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U
With the development of full colour ranges for profiles, the older flowline opto sensors often have trouble "seeing" the darker profiles. An upgrade kit is available (R0019014) to replace the optical sensors with an ultrasonic version
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The ZX3 and ZX4 machines that have control systems that pre-date the Beckhoff hardware now have an upgrade available. The upgrade will bring up-to-date hardware to the machines control system and drives. The control system and drives will be changed to Beckhoff. TwinCAT 3 PLC and AX8000 series drives. +
<div class="annotatedImageDiv" typeof="Image" data-resource="Fichier:Beckhoff C6015.jpg" data-sourceimage="https://stuga.dokit.app/images/0/00/Beckhoff_C6015.jpg"><span ><div class="floatright"><a href="/wiki/Fichier:Beckhoff_C6015.jpg" class="image"><img alt="Beckhoff C6015.jpg" src="/images/0/00/Beckhoff_C6015.jpg" width="445" height="445" data-file-width="445" data-file-height="445" /></a></div></span></div>Autoflows from A2001 to A2015 were initially produced with TwinCAT2 software. This has now been superseded with TwinCAT3 which then has the benefit of compatibility with version 6 front end software.<br /><br />The original PC cannot be used because<br /><br />*It is not powerful enough to run v6 front end<br />*The operating system cannot be upgraded to Windows 10<br />*It cannot be upgraded to TwinCAT3<br /><br /><br />The Beckhoff C6015 PC has been chosen to be the replacement PC. It is compact, yet powerful enough to run the v6 front end and TwinCAT in the same <br />. It has an upgrade to 1.9Ghz 4 core processor.<br /><br />Because it has a limited 40Gb SSD memory, a compact 64Gb memory stick is inserted into the USB 3.0 port. This acts as a separate drive for the DDRIVE dynamic storage for all machine setup. The internat drive is for the Operating System only. This mimics the current Autoflow setup of a remote Camera PC, hence the camera PC can be retired after the upgrade<br/> +
How to upgrade the .pro file (project) on a Beckhoff TwinCAT2 system
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<div class="icon-instructions-text">...TwinCAT2 was used on Early Autoflows and ZX3/4 machines before the adoption of TwinCAT3. Instead of a Visual Studio interface, it uses a program called "TwinCAT PLC Control" to download the PLC project</div>
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Because this upgrade is normally done to include source control directly in the project, you will have to also upgrade the Git Credential manager, as the one installed as party of the TcXAEShell has a bug in it +
=== Requirements: ===
* The PC must have '''Wi-Fi hardware''' that supports Hosted Network (most do).
* You must have an active internet connection to share. +
V
The upgrade is to prep the machine ready for adding a Virtual Mahine (VM) to the setup. +
As an alternative to having a separate camera PC. Adding a VM (Virtual Machine) to the Front end allows access to the BE and cameras without interrupting the operator. +
The video footage from a Hikvision camera can only be viewed via Windows "Internet Explorer". The camera web page also has the facility to playback and download the recorded images stored on the memory card in the camera.
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<div class="icon-instructions-icon"><i class="fa fa-hand-paper-o"></i></div>
<div class="icon-instructions-text">...You cam only view and download video if your PC is on the same local network as the cameras you wish to view</div>
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<div class="icon-instructions-text">...Only the old "Internet Explorer" can be used for all the features of Hikvision. For reasons unknown, Hikvision have not kept this up to date for the latest drivers (Edge and Chrome)</div>
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W
21/08/25 Moved to Confluence
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The version 6 software has a feature to identify the colour of the profile and also to help operators load foiled profile in the correct orientation.
Updating the colours is a very simple job that can be done in 2 ways
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# Via the Machine Settings->Colours Tab
# From Bar Queue whenever a new colour is encountered.
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X
The out sensor used for the vorlaufwagen cannot be a standard reed switch because the cylinder that drives this output is a telescoping version. It is impossible to detect the out position.
Therefore, a sensor is fitted that must be programmed to set a high output when it detects the full range has been reached
The sensor is a [https://www.pepperl-fuchs.com/global/en/classid_53.htm?view=productdetails&prodid=42559#overview Pepperl+Fuchs VDM28-8-L]
Datasheet can be downloaded [https://files.pepperl-fuchs.com/webcat/navi/productInfo/45/452859n.pdf?v=20220926110229 here]
'''Function'''
The distance measurement device contains one transmitter and one receiver incorporated into a single housing. The transmitter light is reflected back to the receiver from a target. The sensor determines the distance to the target and triggers a switching function or supplies the relevant measured value for processing.
'''Assembly instructions'''
The sensor can be mounted by means of through holes or by using a mounting bracket or mounting clamp
Ensure that the surface is level in order to prevent the housing from becoming distorted when the fittings are tightened. It is advisable to secure the nuts and screws using spring washers in order to prevent the sensor from being incorrectly adjusted.
'''Connection'''
Connect the device in accordance with the connection diagram in the datasheet.
'''Adjustment'''
The green LED lights up when the operating voltage is switched on.
Adjust the sensor so that the laser point is on the gripper body +
Z
Difficulty can be had when trying to accurately measure the width of a Z transom profile section. This guide will show you how to accurately measure the width of the Z section to within 0.1mm which is required when setting up Y notching accurately +
This guide explains how to install the counterweight assembly on the current ZX3 ring +
A plate has been designed to strengthen the installation of the first roller. +
Alignment and check procedure for mounting of hepco rail To main frame
Parts required
B0001102 hepco rail
D0015492 5 off vertical adjustment plate
D0015493 5 off Lateral adjustment plate
D0015072 1 off Carriage Plate
B0000184 journal wiper 4 off
B0000185 journal 2 off
B0000186 journal 2off
Hepco Levelling Jig
Hepco rail v block jigs
Hepco rail Drive rack pitching jig +
19/11/2025 Moved to Confluence
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The ZX5 machine can be tricky to align as there are many adjustments designed into the table to offset manufacturing tolerances. This step by step guide follows the correct protocol to ensure the starting point and sequence of alignment is correct +
18/11/2025 Moved to Confluence
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27/08/25 Moved to confluence
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