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- Convert TC2 Project to TC3 + (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.)
- Guide to Fitting Eject Push Sensors on ZX Machines + (The Eject Push bar on the Saw Outfeed on t … The Eject Push bar on the Saw Outfeed on the ZX machines does not have sensors fitted to monitor the position of the cylinders. This causes an issue when the bar is obstructed and either does not fully extend or not fully extract. The cycle is not aware of the position of the cylinders and the machine will continue to run, often resulting in a collision. Not having sensors fitted also means that the Eject Push cycle is run via a timer. However, using a timer means that the system does not know the actual position of the cylinders. Having sensors fitted to the cylinders will allow us to have a cycle that monitors the position of the cylinders and we can determine the cycle has finished before allowing another operation to proceed. We can also use the sensors as feedback to stop the machine if the cycle fails. This will result in fewer collisions and damage to parts or products.
s and damage to parts or products. <br/>) - Beckhoff AX8000 Flowline Upgrade + (The Flowline range (Mk3, ZX3, ZX4) are Stu … 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.feedback on this document or its contents.)
- GE Control Components Changeover + (The GE control components are now obsolete … The GE control components are now obsolete and we have had to find a new manufacture to use. We have decided to go with Eaton control equipment for this. We are using the same supplier for these products and we have the added benefit if the supplier holding these parts in there stores. We had a choice to use either ABB, Eaton or Schneider components. Although all of the individual Eaton components are a direct replacement for the GE components, there are certain situation that we may be tripped up. This includes times when we need to change a motor breaker that has an auxiliary block connected to it. We can change the breaker but the GE auxiliary block will not fit on the new Eaton one. This means that the Eaton components need to have different part numbers to the GE components. This document will layout the new part numbers and what they relate to and instructions on how they are added and changed in the Sage system. are added and changed in the Sage system.)
- ZX5 MH Infeed Basic IO Test and Setup + (The MH infeed on a ZX5 is a module which c … The MH infeed on a ZX5 is a module which can be tested individually away from the fully installed machine. Once build stage is complete, to be able to test individually, the Infeed Module needs: - To be connected to mains power & be powered on - An air supply to the main blue line - Network connection (Network Cube) - HDMI & Keyboard dongle to be plugged into the Beckhoff PLC inside the cabinet. Input and output activation when testing the sole module is done through the Twincat project rather than through WinMulti The above is only required If the Machine is not fully installed and connected with power air and network already. The below guide is specifically for a fully installed and connected infeed.ically for a fully installed and connected infeed.)
- Autoflow Maintenance - Machining Centre + (The Machine has many moving parts, all which need regular maintenance. Below outlines what items need particular attention:)
- Autoflow Maintenance - Sawing Centre + (The Machine has many moving parts, all which need regular maintenance. Below outlines what items need particular attention)
- Autoflow Maintenance - Outfeed Table + (The Machine has many moving parts, all which need regular maintenance. Below outlines what items need particular attention)
- PC Recovery Process + (The PCs are now shipped with a memory stick that includes a full recovery image. If the system fails in future, this allows a full recovery of the initial setup of the entire drive. Mouse and Keyboard are required for recovery process.)
- Programming RS Automation Servo Drive Parameters + (The RS Automation drives are used on refurb Stuga machines to drive axes. They are set up electronically for each axis using a software tool called RSWare and programmed with a USB cable)
- Stuga Product Database - Edit Product Data + (The Stuga website has a parts database, much like a shop front for helping identify Stuga Machine parts. Keeping the data updated and logging nuggets of useful information is invaluable in helping identify parts on machines)
- Phantom Estops + (The TweinCat system is linked together by … The TweinCat system is linked together by remote modules throughout themachine. If any one of these modules loses coms or power it can show up in a n Estop/safety circuit/spindle fault. If not familiar with the system this can lead to lots of time wasted checking for the above faults when it could be a simple dropped voltage caused by a loose or damaged connection, or indeed a faulty network connection between modules. This guide will show how to use TwinCat to point you in the right direction, rather than crawling about on your hands and knees looking for blinking lights. Thanks Glenn and Joel for stepping me through this enough times to make it eventually stick @darrenCtimes to make it eventually stick @darrenC)
- Updating Beckhoff TwinCAT3 Backend Version + (The TwinCAT3 beckhoff systems have a speci … The TwinCAT3 beckhoff systems have a special version of TwinCAT installed - the "Runtime" version XAR (eXtended Automation Runtime). This differs from the full "Engineering version XAE that is installed in the front end and camera PCs in that it is the bare bones of TwinCAT for machine running purposes. '''It does not have the Visual Studio editor in it.''' The runtime version may need updating to 3.4024.xx to allow the latest front end and PLC code to work the latest front end and PLC code to work)
- Upgrade ZX Machine to Beckhoff Drives and Control + (The ZX3 and ZX4 machines that have control … 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.f. TwinCAT 3 PLC and AX8000 series drives.)
- ZX5 Datum and Grip Pin Setup + (The ZX5 has a different and much improved … The ZX5 has a different and much improved grip system where we use the 10mm cutter to put holes in the end of the profile. The profile is then gripped by the grip pins to give a more accurate and reliable grip. Along with better machining accuracy, this also allows the X axis to be run at higher speeds and virtually eliminates gripper slip. For it to work accurately and reliably the system first needs to be set up mechanically on both the X and SX axis. And crucially, if the datum is changed the loading position also has to be changed, and vice versa. This is extremely important for the operator, and any on-site maintenance staff to be aware of as changing either one without compensating the other can lead to accuracy issues and miss grips.an lead to accuracy issues and miss grips.)
- TB0447 ZX5 Setup - X Axis Beam Calibration + (The ZX5 has a moveable Beam on the Z axis. … The ZX5 has a moveable Beam on the Z axis. The design reason behind this is to keep the gripper arm short for reliability and stiffness, yet enable it to move out of the way for rear V notching During the calculations for the machining bar recipe, the software has to work out if and when the beam needs to be moved: · If there are no v notches on the bar, then machine all the operations without moving the beam. Beam moves at the very end when ejecting · If there is a V notch, move the bar during the first X axis position where position > beamStrokeLength Therefore, it is very important for the software to know how far the beam moves physically to offset all the positions to allow for it. The distance is measured and entered into parameter beamStrokeLength. It should be around 700mm. beamStrokeLength. It should be around 700mm.)
- ZX5 Adjusting V Notch Depth and Position + (The ZX5 has a twin blade system for the V … The ZX5 has a twin blade system for the V notches that is designed to be easier to set up. The overall process is: # Set the shape of the V notch (Mechanical adjustment) # Set the Depth of the V notch (Software adjustment in Notching Tab) # Set the Position of the V notch (Software adjustment in Notching Tab)otch (Software adjustment in Notching Tab))
- TB0445 ZX5 Setup - Infeed Measure Sensor Calibration + (The ZX5 has two bar measuring systems – th … The ZX5 has two bar measuring systems – the side laser and the sensor array. The side laser scans the bar as it moves into the final loading location, which gives the software a “heads-up” for the length of the bar. If the length is different to expected, the software will then use the sensor array to measure the bar length. There are 2 measurement methods because the side laser is not 100% reliable, especially on shorter lengths below 3000mm. However, it does mean the system does not have to grip and measure / reoptimize each bar length, so improves the cycle time. The sequence is as follows 1. During the conveyor loading, measure the length using the side laser 2. Once loaded to backfence, check the backfence sensor array. 3. If the sensor array rough measurement does not match the laser – a. If the laser measured length < infeedLaserRemeasure, continue and measure with rear sensors b. If the laser measured length < infeedLaserRemeasure, flag an error that laser has not measured correctly. c. If it does match, use the laser value to reoptimize the bar if it is different than expected 4. Load and Grip bar, if necessary, measure accurately with rear sensor arrayssary, measure accurately with rear sensor array)
- ZX5 Alignment Check + (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)
- Setting Arrow Heads on ZX5 or ZX5-E + (The Zx5 and Zx5e have an upgraded system o … The Zx5 and Zx5e have an upgraded system on the saw centralising which takes the best mechanical features of the standard saw centralising, yet adds an ability to move the central point for Y notches.
In general, this makes it easier to set up, because the overall centralise position can be changed in software , rather than adjusting a cylinder offset, and also to fine tune the centralise position for different profiles
the arrow head position permanently will also alter Y notch depths</div> </div><br/>) - Repairing R axis datum pin + (The datum pin on the old ZX4 at Sidey was … The datum pin on the old ZX4 at Sidey was recommended to be changed at my last service visit. Unfortunately there are quite a few different datum spindle plates and we were having problems tracking down the correct one so it was decided that I would be sent out the new replaceable datum pin carrier as Sidey have a small machine shop I could use to modify the existing plate to make it fit. Unfortunately the mounting holes of the new carrier interfered with the mounting holes of the pneumatic cylinder so it couldn't be used. After taking dimensions of the existing plate for identification I realised there was actually a very small and quick repair that could be carried out until the correct parts were identified. All you need is a cordless drill, a 2.5 and a 3.1mm drill, M3 tap and an M3 x 15mm cap head screw.l, M3 tap and an M3 x 15mm cap head screw.)
- TM017 Setting Cut Length on Saw + (The engineer will need a reasonable mechan … The engineer will need a reasonable mechanical knowledge, and a working knowledge of the operation of the machine. The following steps are taken to set the saw lengths correctly: · Scaling / calibration · Ensure cut length consistency · Set saw blade kerf · Set blade offsets / and \ · Check mitre / mitre cuts/ and \ · Check mitre / mitre cuts)
- TM018B Microline and ZX3 V Notch Blade Setup + (The engineer will need a reasonable mechan … The engineer will need a reasonable mechanical knowledge, and a working knowledge of the operation of the machine. You will need callipers (+/-0.05mm) and an accurate rule The setting of the V notch blades on a ZX3 Ring revolves around the setting of two groups of parameters: *V and W axis positions *Blade offsets for each blade The rough position of V and W axes is set first, then the individual blade offsets are set, and finally a test is run to tweak the accuracy to gain perfection. There are two “tweaking” parameters for each blade. The two parameters are: *Depth offset – how deep into the bar *X axis offset – position of point of blade relative to the spindle centrelinef blade relative to the spindle centreline)
- TB0422 Commissioning ZX5 Software 2018 + (The first step in commissioning a new mach … The first step in commissioning a new machine is to get the basic software setup correctly installed. Because the software is designed to be very flexible across many machine types, the simplest way to do this is to copy from a recently built similar machine.opy from a recently built similar machine.)
- Autoflow Mk1-Mk3 Daily Maintenance + (The following areas should be attended to daily This routine should take no more than 15 minutes)
- R0000299 Stroke assembly rebuild Part 2 + (The following instructions should be follo … The following instructions should be followed to ensure that correct assembly and setting are performed '''Tools / consumables Required''' Standard hex key set Standard spanner set Large adjustable spanner Drifts and punches Ballpein hammer Soft hammer FE10 Solvent Hylomar Gasket '''Parts Required''' Kit R0000299 containing B0000043 Double Angular bearing 15 I?D 35 O?D 15.9 long rubber seal 3 x 2 B0000105 Double Angular Bearing 15 I/D 35 O/D 15.9 Long x 1 B0000335 3ph Brake motor 2 pole 3000rpm x 1 B0000380 Double Angular Bearing 25 I/D 52 O/D 20.6 Long + rubber seal x 2 D0000059 Damper Bridge x 1 D0000062 Damper Bridge Boss x 2 D0007730 ZX4 V Notch Mk1 Spindle Shaft x1 D0007867 Bevel Gear (Left) x 1 D0007868 Bevel Gear (Right ) x 1 D0007873 Motor Gear x 1 D0007874 Pinion Gear x 1 D0007875 Pinion Shaft x 1 P0000165 damper x 174 Pinion Gear x 1 D0007875 Pinion Shaft x 1 P0000165 damper x 1)
- TB0383 Mint and RS Automation Drive Setup + (The following will show how to setup a mint controller i.e. NextMove ESB-2 with an RS Automation Drive and servo motor but to act as a stepper motor and being controlled from the ESB-2 as a stepper.)
- Training Laser on Ecoline + (The laser needs to be focused on the work area and not the receiver The smaller the dot for the profile to break/make the more accurate the laser)
- Dokit - Renaming a Page + (The name of a document cannot actually be changed once it is saved. However a similar result is gained by using the "Move" command, which creates a copy of the page and adds a forwarding link from the old to the new)
- Upgrade - R0000173 Conveyor Motor + (The original style of conveyor is used on many machines, but the motor that powers it is no longer available. This guide will allow a different motor/gearbox to be used.)
- X252 Forward Clamp Out Sensor Setup Stuertz Infeed + (The out sensor used for the vorlaufwagen c … 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 bodyso that the laser point is on the gripper body)
- Stuertz Infeed - Align and dowel GX rack + (The rack on a Stuertz infeed is a helical … The rack on a Stuertz infeed is a helical type and is supplied unpinned, as the motor is not connected before delivery to Stuga The alignment must be checked then dowelled with 5mm roll pins The racks are already located in the "Y" direction with location pins, this procedure is purely to align the racks to each other in the GX directionhe racks to each other in the GX direction)
- VM Upgrade Hardware + (The upgrade is to prep the machine ready for adding a Virtual Mahine (VM) to the setup.)
- WinMulti - Changing The Colour Identification Box + (The version 6 software has a feature to id … 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
# Via the Machine Settings->Colours Tab # From Bar Queue whenever a new colour is encountered.
Queue whenever a new colour is encountered. <br/>) - Viewing Camera Footage from Hikvision Cameras + (The video footage from a Hikvision camera … 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.
sion. For reasons unknown, Hikvision have not kept this up to date for the latest drivers (Edge and Chrome)</div> </div> <br/>) - Accessing Raw Production Data from Diagnostic SQLite Database + (The winMulti software stores the production data in a SQLite database. This tutorial describes how this data can be accessed for further analysis with tools such as Excel and Access)
- Archiving a TwinCAT Project + (There a many terminal and irretrievable pr … There a many terminal and irretrievable problems that can occur when modifying a TwinCAT project on Visual Studio.
However, there is no issue that cannot be resolved, if the Visual Studio solution is '''archived'''.
This archive contains all data relevant to a project so you can start from scratch
vant to a project so you can start from scratch <br/>) - Diagnosing EtherCAT Issues - Advanced + (There are many tools available to help tra … There are many tools available to help trace EtherCAT faults. This document describes some more advanced features that can help pinpoint an intermittent or hard to find issue. You will need a good working knowledge of the machine and the basis of EtherCAT networking See Also [[TwinCat Connection Faults]][[TwinCat Connection Faults]])
- Recovery of Bar Queue following winMulti Crash + (There have been cases of software crashing … There have been cases of software crashing on the Stuga front end software, but the machine will continue to cut the holes and slots on the bar and eject it to the transfer table. This creates the situation that the bar is physically finished, but the software has not registered it as finished. This can lead to confusion for the operator and put the bar queue out of sync, which can lead to wasted profile of sync, which can lead to wasted profile)
- Gripper Push Speed on Flowline and ZX + (There is a cylinder called Grip push, when … There is a cylinder called Grip push, when bar is moved to its unload position the Gripper Comes OFF then Grip push is activated to push the profile of the gripper to clear ready for the Eject push onto transfer Table. The video shows what happens if the grip push is set too fast. The speed of the cylinder is Far too Fast and is Throwing/punching back down machine. -- This needs to be slowed Down. machine. -- This needs to be slowed Down.)
- Hikvision Camera Setup + (These are the Hikvision DS-2CD2343G0-I Cameras (C0001152) that will replace the obsolete UCAMs that have been used on previous machines. Connected via a multi way PoE injector (C0001238). And with SD card (C0001239).)
- PLC Source Control - Adding a Repository + (These instructions give details of how to … These instructions give details of how to set up a repository so that any changes made to the core project will be tracked. For the git source control to work it is important that GIT has been chosen as the source control program. see Prerequisits. The instructions start from : The project has been created and PLC code has been loaded in to the TwinCAT Xae Shell program.oaded in to the TwinCAT Xae Shell program.)
- PLC Source Control - Working with GIT and TcXaeShell + (These steps outline typical actions that make up a development cycle for changing code on a machine, saving changes locally and saving to the cloud repository using Git as the Source control tool.)
- Fitting R0019199 Upgrade: Autoflow Slewing Ring Guard Kit + (This area is prone to collect sharp - cornered offcuts which can pull the seal from the SR axis bearing. The kit will help prevent damage. Use Kit R0019199 Upgrade: Autoflow Slewing Ring Guard Kit <br/>)
- Autocut Regular Maintenance + (This checklist needs to be carried out at … This checklist needs to be carried out at regular intervals, in conjunction with the daily maintenance.
gt; <td>Single Shift Full Time </td><td>Bi-Weekly </td></tr><tr> <td>Up to 50% utilisation </td><td>Monthly </td></tr></table>)Use Profile Regularity 2-3 Shifts per day Weekly Single Shift Full Time Bi-Weekly Up to 50% utilisation Monthly
- Autocut Daily Maintenance + (This checklist should be carried out at the end of every day)
- Alignment guide using wire line + (This dokit is to help with the use of a wi … This dokit is to help with the use of a wire line to set alignment correctly on mechanical build up. Using a wire line correctly will ensure a very accurate straight line is achieved . Accuracy of + - 1 mm over any distance can be achieved using the following method. Using one incorrectly can also easily be done.! The steps shown can be applied to all types of alignment , when you have a vertical face on components that require aligning. face on components that require aligning.)
- ZX3 Counterweight Installation + (This guide explains how to install the counterweight assembly on the current ZX3 ring)
- Units of Measure modification CIM50 + (This guide is to show how to amend units o … This guide is to show how to amend units of measure of existing stock items. If a new product is created please ensure the Units of measure is always set up correctly from the beginning . The CIM50 guide for Units of Measure setup is [https://cimservices.sharepoint.com/:w:/s/Cim50PartnerMarketing/EZhA_HF6SFJLmkVO5WANYXIBZdMx4hbVnuY3cdIF78p7lg?rtime=FcNQz7GE2Ug here]4hbVnuY3cdIF78p7lg?rtime=FcNQz7GE2Ug here])
- R0015146 Pneumatic pipe Installation Part 2 + (This instruction is to incorporate assembl … This instruction is to incorporate assembly R0015033B Module F Wiring loom alongside this See Electrical department for prepared components from above assembly '''Tools Required''' Pipe cutters Pipe identification markers Flush cutters '''Parts Required''' P0000010 6mm 1/8 elbow fitting x 6 P0000046 Fitting: 'Y' Adaptor 6mm x 6 P0000047 Bulkhead Elbow 6mm x 1 P0000159 Fitting: Stem Blanking Plug 6mm x 2 P0000160 Fitting: Flow Controller In Line 6mm x 2 P0000551 6mm inline Quick Exhaust Fitting x 3 P0001030 Fitting: SMC 6mm Equal Tee x 1 P0001008 regulator x 3 P0001009 Regulator nut x 3 P0001106 Plug in reducer 12-8mm x 1 P0001107 Fitting 12mm equal tee x 1 P0001166 12mm tube to tube elbow x 17 Fitting 12mm equal tee x 1 P0001166 12mm tube to tube elbow x 1)
- R0015146 Pneumatic pipe Installation Part 3 + (This instruction is to incorporate assembl … This instruction is to incorporate assembly R0015033B Module F Wiring loom alongside this See Electrical department for prepared components from above assembly '''Tools Required''' Pipe cutters Pipe identification markers Flush cutters '''Parts Required''' P0000010 6mm 1/8 elbow fitting x 6 P0000046 Fitting: 'Y' Adaptor 6mm x 6 P0000047 Bulkhead Elbow 6mm x 1 P0000159 Fitting: Stem Blanking Plug 6mm x 2 P0000160 Fitting: Flow Controller In Line 6mm x 2 P0000551 6mm inline Quick Exhaust Fitting x 3 P0001030 Fitting: SMC 6mm Equal Tee x 1 P0001008 regulator x 3 P0001009 Regulator nut x 3 P0001106 Plug in reducer 12-8mm x 1 P0001107 Fitting 12mm equal tee x 1 P0001166 12mm tube to tube elbow x 17 Fitting 12mm equal tee x 1 P0001166 12mm tube to tube elbow x 1)
- R0015146 Pneumatic pipe Installation + (This instruction is to incorporate assembl … This instruction is to incorporate assembly R0015033B Module F Wiring loom alongside this
See Electrical department for prepared components from above assembly
'''Tools Required'''
Pipe cutters
Pipe identification markers
Flush cutters
'''Parts Required'''
P0000010 6mm 1/8 elbow fitting x 6 P0000046 Fitting: 'Y' Adaptor 6mm x 6
P0000047 Bulkhead Elbow 6mm x 1
P0000159 Fitting: Stem Blanking Plug 6mm x 2
P0000160 Fitting: Flow Controller In Line 6mm x 2
P0000551 6mm inline Quick Exhaust Fitting x 3
P0001030 Fitting: SMC 6mm Equal Tee x 1
P0001008 regulator x 3
P0001009 Regulator nut x 3
P0001106 Plug in reducer 12-8mm x 1
P0001107 Fitting 12mm equal tee x 1
P0001166 12mm tube to tube elbow x 1
12mm equal tee x 1 P0001166 12mm tube to tube elbow x 1 <br/>) - Setting Ultrasonic Sensor - Horizontal + (This involves setting a "window" for a minimum and maximum range when mounted horizontally)
- Allocations + issuing received parts + (This involves splitting down received orde … This involves splitting down received orders into the JC/Pick bins the parts have been allocated to by Sage. If there are parts to be allocated, after filling in the 'this delivery' column and pressing save, if there are parts to be allocated a list will appear. this list is in order of part number and in the sub-screen after highlighting each part number the specific Job card numbers will show quantities required for each bin and also the quantity to be allocated from the order received.y to be allocated from the order received.)
- Ecoline - Setting V Notches on winMulti Software + (This is the full setup procedure for V not … This is the full setup procedure for V notches on an Ecoline. This should only be needed on initial commissioning or if the shape of the notch has changed due to some physical intervention, for example -
- Blade Change
- Blade buckled
here is no sense carrying on because you cannot complete this setup unless the machine is consistent and reliable</div> </div> <br/>) - PC Bios Power settings + (This power setting enables the PC to Boot … This power setting enables the PC to Boot up automatically when power is first detected, in other words when the power is “lost” and then “returns”, without the necessity to manually press the power button on the PC. The following description shows how to set the auto power-up on but beware this Technical Bulletin only applies to the “ASUS UEFI Utility BIOS Version 2.x.x”. This document is for the ASUS Pcs For the Dell PCs use [[PC Bios Power Settings - Dell]]ttings - Dell]])
- Importing Picking List from Sage To Monday + (This procedure demonstrates how to use the … This procedure demonstrates how to use the "Sage Hooks" MS Access database to grab the data created in Sage and exort to a spreadsheet. The spreadsheet is then imported into a new Monday board, then copied across to the correct Picking List for the machine build.
Picking List for the machine build. <br/>) - Flowline 6 to 6o5m Extension + (This procedure describes how to upgrade a … This procedure describes how to upgrade a flowline to increase the standard capacity from 6.0m to 6.5m. The procedure involves extending the machining centre outfeed travel and saw infeed travel base to 6.0m to cope with a longer rail on each side. These are generally supplied as a new part. Other ancillary parts that will need extending * Cables * Energy Chainsl need extending * Cables * Energy Chains)
- ACEpc Installing netedit with NetSetGo disk + (This procedure will completely overwrite a … This procedure will completely overwrite any data on the hard drive of the ACEpc.
This is not a problem on a flowline where the data resides on the main MH hard drive in a shared directory c:\saw.
If this process is to be carried out on a standalone saw or router, make sure the data is backed up first.
e sure the data is backed up first. <br/>) - Setting Up C0000422-KIT - Full Hardware 2023 + (This process takes the components to creat … This process takes the components to create a standard "C000422-KIT". This kit can then be stored and pulled off the shelf when required. It will then need to be set up for the particular customer machine using [[Setting Up Windows PC C0000422-KIT 2023]] =Notes= *There are two PCs running on the same hardware, The Host PC and the Virtual machine. **'''Host PC''' (For support) ***The base Windows install running directly on the hardware installed to Dell NVME drive. ***Has its own OEM Windows license supplied by Dell linked directly to the hardware (no product code – stored in the Dell hardware) ***Imaged by Macrium reflect. **'''Virtual PC – Stuga VM''' ***Used for Stuga software - the VM can run on any PC without changing drivers, etc. Host OS version / hardware unimportant as long as it runs Hyper-V. ***A second install of Windows running on a virtual machine, hosted by the Host PC above. It has a dedicated SSD (the Kingston Drive) stored on [:Fichier:///D:/VMPC.vhdx D:\VMPC.vhdx], with 8GB RAM. ***Has its own dedicated Windows 11 PRO license present in the kit, product code stored on Monday and on the license. ***Copied to host and setup manually during install. There is a setup program for the specific client after this process has completed: '''P_Stuga_P… '''on the desktop of the host.'P_Stuga_P… '''on the desktop of the host.)
- A2001 - Light Curtain Timer + (This step by step guide will explain how to wire a timer relay into the light curtain and estop circuit on the A2001 Autoflow.)
- Dokit - Creating A Work Instruction + (This tutorial guides you in how to create … This tutorial guides you in how to create Work Instructions in Dokit and to avoid the pitfalls.
If the Work Instruction is already created, follow the process [[Dokit - Editing Work Instructions]]
= Warnings =
a fa-exclamation-triangle"></i></div> <div class="icon-instructions-text">...Do not publish anything inflammatory, offensive or illegal</div> </div><br/>) - Setting Up New Printer - GX420d + (This tutorial requires a basic knowledge o … This tutorial requires a basic knowledge of IP addresses - what are they and what are they forork. This is contained in the Saw Parameters - printerIPAddress. </div> </div>)
- Dokit - Editing Work Instructions + (This tutorial shows you how to edit the co … This tutorial shows you how to edit the content of a work instruction, allowing you to
*Add New Steps
*Add numbering and bullets to the text
*Add and crop Photos
*Annotate photos with arrows, numbers and text
*Change step sequence and insert steps
*Add Call-outs and warnings
*Add Links to other websites or other Dokit pages
=Warnings=
a fa-exclamation-triangle"></i></div> <div class="icon-instructions-text">...Do not publish anything inflammatory, offensive or illegal</div> </div><br/>) - ZX5 Transfer Table Crank set up + (This tutorial will show you how to mechani … This tutorial will show you how to mechanically set up the cranks and sensors so that the correct overlaps between the different cranks are achieved. Crank C is the crank on the Machining Centre Outfeed that controls the single pop up. Crank D is also mounted on the Machining Centre Outfeed and controls the pop ups on the Transfer Table. Crank E is the crank on the Saw Infeed and controls the single pop up that moves the profile in to the channel. that moves the profile in to the channel.)
- Fitting Zx5 Crank Upgrade + (This upgrade replaces the crank arm assemb … This upgrade replaces the crank arm assemblies on Z065, Z066 and Z067 with a direct drive system to improve reliability
This procedure involves mechanical fitting, electrical wiring and help from a TwinCAT3 competent engineer at HQ for software changes
></div> <div class="icon-instructions-text">...Motors must be rewired for Delta and NOT Star</div> </div> <br/>) - R0019207 Upgrade SR Axis Spigot + (This upgrade utilises upgraded parts to en … This upgrade utilises upgraded parts to ensure a mechanical fix is maintained between the SR axis gearbox and main drive pin , whilst also giving the ability once upgraded for the gearbox to be removed with minimal mechanical time. three main parts will be replaced in this upgrade, obsoleting the removed parts Main components of upgrade D00004019E Turntable Mk5 D0004033E Alignment disc Mk5 D0004147E Turntable shaft Mk5nt disc Mk5 D0004147E Turntable shaft Mk5)
- B0000082b Motor replacement For Obsolete part B0000082 + (To rectify the obsoletion of B0000082 driv … 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 off F0000007 M5 x 16 cap head bolt 4 off)
- Replacing Beckhoff PC + (To replace a broken PLC requires the installation of the original project. This project needs to be made aware of the new hardware, along with the Stuga software)
- PLC Source Control - Selecting GIT as the source control Plug-in + (TwinCAT3 can use different source control programs for source control. These instructions show how to select Git as the source control Plug-in.)
- Upgrade Autoflow to Windows 10 + (Update 2024 - Upgrades now consist of a ne … Update 2024 - Upgrades now consist of a new Windows 11 PC with VM for the front end and a C6017 PC for the back end.
Upgrading an Autoflow to Windows 10 involves upgrading two PCS
#The Beckhoff control PC - replaced with a C0001225-KIT
#The Camera PC - replaced with a C0000422-KIT with a VM setup. this now becomes the front end PC
=== For Historical reference, these are the pre-2024 notes: === ''Upgrading an Autoflow to Windows 10 on site involves upgrading two PCS'' #''The Beckhoff control PC'' #''The Camera PC'' ''
The Beckhoff PC is not upgradable so needs to be completely replaced. We use the miniature [https://www.beckhoff.com/english.asp?industrial_pc/c6017.htm Beckhoff C6017] for this'' ''It is not cost effective to upgrade and old camera PC, so a new one is supplied'' ===''Notes''=== *''The Beckhoff PC is now powerful enough to run the front end and back end.'' *''The camera PC is there to replace the camera PC on site and contains the storage for the machine cameras'' *''Because the Beckhoff PC has limited hard drive space, the DDRIVE will be on the cameraPC''hard drive space, the DDRIVE will be on the cameraPC'') - R0010309 Ecoline Ultrasonic Material Loaded Upgrade + (Upgrade of load sensor For infeed table on … Upgrade of load sensor For infeed table on Ecoline machines
'''Component list'''
A0001046 P Clip 6mm Steel / Rubber Liner x 2
D0010973 Material Loaded Sensor Plate x 1
E0001104 PreMade Cable: M8 Socket 4 Way Cable 5m x 1
E0001120 Sensor: Ultrasonic M8 20-150mm x 1
M0001053 Copper Tube 6mm x 4.4mm 10m Coil x 0.3
P0000046 Fitting: 'Y' Adaptor 6mm x 1
P0000069 Tube to tube fitting 6mm x 1
P0000160 Fitting: Flow Controller In Line 6mm x 1
000160 Fitting: Flow Controller In Line 6mm x 1 <br/>) - CIM50 - Creating New Shop Floor Data Capture User + (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.)
- Stores - Updating Location + (Using CIM50 to update a stock location)
- Upgrade - Outfeed Cord Stop Pusher 2021 + (Version A of this assembly has been supers … Version A of this assembly has been superseded by this version, due to lack of material availability in version A. The new version is provides exactly the same functionality, is fully backwards compatible and is designed to be replaced as a complete sub-assembly. The driver behind this upgrade is that the 2 main tubes are no longer available in the tolerances that they were. This has resulted in some not fitting inside the other, making assembly impossible. Therefore we have changed the sizes of the smaller tube (new part is D0015949 - Telescopic Pusher (2021)), and as a result updated the "top hat" (new part is D0015950 - Spring Retainer Top Hat (2021)) that fits in the end of it. If any version of this pusher fails in the field, for any reason, it needs to be replaced with the latest version of R0000677Blaced with the latest version of R0000677B)
- TwinCat Connection Faults + (We are quite often faced with multiple Axi … We are quite often faced with multiple Axis/Door Open/ Estop faults all being reported at the same time. More often than not this is caused by a bad connection on the TwinCat system somewhere. If there is any dropout of connection at any point in the system it will result in this error. You could spend some time crawling about on your hands and knees, opening electrical cabinets and trying to find the fault manualy, but by using TwinCat we can save some time and effort, and pinpoint the cause almost immediately.and pinpoint the cause almost immediately.)
- Filling Out An Online Daily Timesheet Form + (We are using Monday.com to handle daily ti … We are using Monday.com to handle daily timesheet entries. The layout of the form has been designed to make data input as minimal as possible. We are looking to improve accuracy of time capture, cut down administration time and to make historical data available without the need to store paperwork or take pictures. You will only be able to view and edit your timesheet when logged into your Monday.com account. Other employees are unable to see your data.her employees are unable to see your data.)
- Removing TwinCAT3 Interpolation Licence + (Wen creating a new project on conversion f … Wen creating a new project on conversion from a TwinCAT2 to TwinCAT3 system, there may be a reference to a an unrequired NCi licence (interpolation)
variable speeds to create a shape, like a diagonal line or circle</div> </div><br/>) - Autocut Cutting Tall Profiles + (What to do when cutting tall profiles; such as VS outerframe and patio outerframe)
- WinDelay for Twincat Startup + (When Windows Boots up and WinMulti is star … When Windows Boots up and WinMulti is started the TwinCat PLC is not in Run mode ready for the application. The Run mode of Twin cat normally takes between 70 to 90 seconds.
WinStartDelay is a piece of software which delays Winmulti Starting up until the Amount of Time Delay needed has been run.
of Time Delay needed has been run. <br/>) - Ecoline - Datum and MitreOffset Tests + (When an Ecoline is commissioned, the posit … When an Ecoline is commissioned, the positional accuracy needs to be set up.
These are also useful tests to check if the machine is maintaining positional accuracy
tent, repeatable results before making any parameter changes</div> </div><br/>) - PLC Source Control - Git Credential Manager for Windows Install + (When connecting to the tc3Multi repository … When connecting to the tc3Multi repository on BitBucket.org, some times the validation credentials are not accepted. Check that the password you have is correct, if the problem persists , install or update Git Credential manager for windows to the latest version.manager for windows to the latest version.)
- TM016 Arrow Head Adjustment on Saw + (When in arrow head or centralising mode, t … When in arrow head or centralising mode, the pivot point of the saw blade is moved from the bladetofence position to the central position of the current section. The mechanism that achieves this allows for any width of profile from 45 mm to 130 mm. If the arrow head position is not central to the profile, the centraliser position may need to be adjusted
to close fully, or an issue with the symmetry of the profile</div> </div><br/>) - Creating Backup of TwinCAT Mapping + (When modifying a TwinCAT project, particul … 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
ed an instance to get the textual information of the IO links from</div> </div><br/>) - CNC Disk Drive FULL - Shadow Copies + (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.)
- Upgrade Flowline Opto Sensors to Ultrasonic + (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 <br/>)
- Easily resizable forms for any screen resolution in Visual Studio + (if you have issues with certain screen resolutions cropping off buttons and need to design a form which works at all resolutions, and also allows the user to resize parts of the form, then this tutorial will help.)
- R0015079 Infeed extension assembly + (instructions and parts required for fittin … instructions and parts required for fitting of frame extension Parts required Levelled infeed frame D0015475 Infeed frame Extension leg 1 off D0015476 Infeed frame Beam upper 1 off D0015477 Infeed Extension Beam Lower 2 off F0000266 M16 set bolt x 2 F0000234 M16 nut x 2266 M16 set bolt x 2 F0000234 M16 nut x 2)
- Dannys test + (quad welder interface)
- R0000299 Stroke assembly rebuild + ( The following instructions should be fol … The following instructions should be followed to ensure that correct assembly and setting are performed '''Tools / consumables Required''' Standard hex key set Standard spanner set Large adjustable spanner Drifts and punches Ballpein hammer Soft hammer FE10 Solvent Hylomar Gasket '''Parts Required''' Kit R0000299 containing B0000043 Double Angular bearing 15 I?D 35 O?D 15.9 long rubber seal 3 x 2 B0000105 Double Angular Bearing 15 I/D 35 O/D 15.9 Long x 1 B0000335 3ph Brake motor 2 pole 3000rpm x 1 B0000380 Double Angular Bearing 25 I/D 52 O/D 20.6 Long + rubber seal x 2 D0000059 Damper Bridge x 1 D0000062 Damper Bridge Boss x 2 D0007730 ZX4 V Notch Mk1 Spindle Shaft x1 D0007867 Bevel Gear (Left) x 1 D0007868 Bevel Gear (Right ) x 1 D0007873 Motor Gear x 1 D0007874 Pinion Gear x 1 D0007875 Pinion Shaft x 1 P0000165 damper x 174 Pinion Gear x 1 D0007875 Pinion Shaft x 1 P0000165 damper x 1)
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