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-Remove the gripper pin block by taking out the centre bolt between the pins,
-Pull the block piece from the gripper body. to remove
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<div class="icon-instructions-text">...These Changes are Required on both MH and Saw side Grippers</div>
</div><br/> +, -Ensure the small black pins on the back of the block and the bushes in the gripper body are still inserted correctly.
-Push the gripper pin block into the desired bushes. The top position is for the profiles above 90mm in height
-Tighten the Centre bolt back in to fully secure the grip pin block. +, - Loosen the Kip clamp handle (Anti-Clockwise) (1)
-Slide the Clamp body up on the pillars to the max position stop for the tall profiles above 90mm or down to the minimum stop position for regular height profiles.
- Tighten up the Kip Clamp Handle (Clockwise) +
In SETTINGS > PARAMETERS > MEASUREMENT > loadingPos=11
If set at a different figure, update to 11 and SAVE +, First we need a piece of standard outer frame around 1.5 – 2mtrs in length. The end of the profile that will be gripped MUST be square both horizontally and vertically. There is a jig sent out with all ZX5’s which is used for this purpose, but they can go missing or be thrown out as operators will not be aware of their use.
To create our test piece, we need to go into MANUAL INPUT, select a standard outer frame , select DATUM TEST and position at 250, ADD OP, then ENTER.
Run the test and allow the gripper to pull the profile onto the outfeed table and stop the machine.
<br/> +, Once mechanical setup has been carried out we need to check the datum and carry out any adjustment. Using another fresh piece of profile carry out another datum test at 250mm. Once complete remove the profile and measure from the bottom side of the profile to the edge of the hole (it is important to use a good quality tape measure that has no slop or play in the tang, or a good 1mtr steel rule). This measurement should be 245mm (250mm minus half the diameter of the 10mm tool)
If this measurement is correct then no adjustment is required and you can carry on to a POS test to check the back to back accuracy of the saw side for handle hole positions etc.
If the measurement is wrong, we need to carry out the test again with datum at 270mm and then 290mm, it is important that the machine is reinitialised between each test. This is to ensure the result is repeatable and not being caused by a mechanical fault, i.e. worn pinion gear.
If the result is repeatable and is always out by the same amount, i.e. 0.5mm, go to SETTINGS > DATUM TEST. Enter the results of the test in the boxes highlighted.
If the MEASURED DISTANCE is LOWER than the EXPECTED DISTANCE, then the datum will be moved further AWAY from the gripper. If it is HIGHER then the datum will be moved CLOSER to the gripper. By changing the DATUM position, the machining centre will move ALL operations along the X axis by the corresponding amount, i.e. 0.5mm. This includes the holes for the grip pins as it is just another operation, therefore if the datum hole is moved away from the gripper, then the grip pin holes will also be moved away from the gripper and vice versa. This can result in accuracy issues, missgrips, and gripper slip. Therefore, the LOADING POS will also need changed by the same amount, but in the OPPOSITE direction. +, …
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]]
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#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
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<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]]
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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
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* 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. +, …
# X axis of module is levelled from the two indicated points . Use a 2 meter straight edge between these points and an engineers level on top
# y axis is levelled from these two indicated points . an engineers level rested on this face is sufficient for levelling
+, 1 Adjust height of saw outfeed table to align faces shown
2 Check that eject table cylinder can freely move beneath frame on full range of travel
3 Align front faces of saw and outfeed frame to be inline
Check that Blue push bar is behind Saw rear fence rollers by at least 5mm( Adjustment is possible if not via slots on push bar assemblies )
<br/> +, Fit waste conveyor to out feed frame using 2 off M8 socket caps
Adjust waste conveyor feet to minimise gap shown between saw module rear panel and waste guide on conveyor +, …
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.
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<div class="icon-instructions-text">...Always check previous adjusted loading arm isn't affected by changes to the next arm</div>
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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 +, Position module B into approximate position and use reference points as listed
1 Set Y axis position using Module C gripper and Module B backfences as reference. Visually set approximately gripper just in front of datum rollers
2 Set X axis position by using back of module B and transfer buffer bar as reference. Set bars shown visually parallel and approximately 150mm apart
3 Ensure all 4 adjustment feet and set in levelling pads and touching +, 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/> +, …
Follow the instructions in [[Programming Eaton DE Drive|this]] tutorial.
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<div class="icon-instructions-text">...It is vital that the Eaton drives are programmed correctly as the distance the cranks travel and the time they take to stop depend on the acceleration and deceleration of the drive.</div>
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<div class="icon-instructions-text">...Programming the drives after the mechanical set up may lead to crashes. Ensure this is done first.</div>
</div><br/> +,
# Loosen the two bolts holding the idler
# Adjust until the idler sprocket is applying some pressure to the chain
# Use a C spanner or a hammer and drift to tighten the clutch.
<div class="icon-instructions idea-icon">
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<div class="icon-instructions-text">...Don't lock the clutch in place with the tabs until you're sure the correct tension has been achieved</div>
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+, Using a pair of 13mm spanners, nip the proximity sensors in place so that they are roughly in the middle of the slot.
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<div class="icon-instructions-text">...Ensure that the black part of the sensor is close enough to the rack that it makes the sensor but not so close that it is likely to get damaged by contact</div>
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Do this for all 6 sensors (2 on each assembly - 1 'home' and 1 'out')
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<div class="icon-instructions-text">...The 'Home' position for all cranks is when the pop ups are in the closest position to the machining centre - ready to receive the profile</div>
</div><br/> +, …
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. +, …
Using a straight edge placed BETWEEN the teeth of the blade (W/I) you can see we have a gap around 2-3mm. On the opposite blade (W/O) we need to turn the setting bolt anti clockwise until the tips of the teeth just touch the straight edge, as seen in the second picture. If the tips of the teeth were overlapping we would need to increase separation by turning the adjusting bolt clockwise.
Transfer the straight edge to the opposite blade (W/O) and adjust W/I as above.
<br/> +, This step can be skipped but was left in to show how close you get after following the above.
Lock off the four retaining bolts followed by the locking nut.
We should now be pretty close with only a small pip left in the centre of the notch.
<br/> +, We can now repeat the process on the front V notches. +, …
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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