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- 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))
- Upgrading Autoflow TwinCAT2 to Win10 and TwinCAT3 + (<div class="annotatedImageDiv" typeof=" … 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 This has now been superseded with TwinCAT3 which then has the benefit of compatibility with version 6 front end software.
The original PC cannot be used because
*It is not powerful enough to run v6 front end
*The operating system cannot be upgraded to Windows 10
*It cannot be upgraded to TwinCAT3
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
. It has an upgrade to 1.9Ghz 4 core processor.
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
era PC, hence the camera PC can be retired after the upgrade<br/>) - R0015114 Bench Assemble Valve Banks and Regulators + (<nowiki>'''<u>Tools Required&l …
'''Tools Required''' <br />P0001071 Valve base type41 8 position x 1<br /><br />P0001074 Fitting: 1/4" BSP Hex Head Silencer x 4<br /><br />P0001101 Male straight 1/4 bsp to 12mm x 2<br /><br />P0001102 Fitting male elbow 12mm 1/4 x 4<br /><br />P0001105 Bulkhead straight 12mm x 6<br /><br />P0001186 Valve. 24v dc smc x 8<br /><br /><br/></nowiki>)
Standard hex key set
Standard spanner set
Standard HSS drill set
Standard tap set
'''Parts Required'''
H0007998 Regulator internal mount 5 way x 1
P0000010 Elbow Adaptor 6mm - 1/8 BSPT (Taper thread) x 14
P0000020 Fitting: Plug 1/8" BSP (Grubscrew Type) x 9
P0000021 air gun assembly x 1
P0000024 hex nipple 1/4 x 3
P0000058 Regulator Mounting Kit x 1
P0000074 Elbow Adaptor 8mm - 1/8 BSP (Pneumax not acceptable) x 2
P0000096 Fitting: Brass Reducing Bush 1/2 - 1/4 x 2
P0000142 Elbow Adaptor 8mm - 1/8 BSP x 2
P0000145 tee equal 1/4 x 3
P0000159 Fitting: Stem Blanking Plug 6mm x 2
P0000277 Fitting: Bulkhead Female 8mm x 1/4 BSP x 1
P0000278 Regulator 0-2 bar x 1
P0000332 Regulator with Gauge G1/8'' 0-8 bar x 8
P0000361 1/4'' Male Probe to suit 1/4'' PCL Female coupling x 1
P0000419 Air Service Unit OH (P0283) x 1
P0001071 Valve base type41 8 position x 1
P0001074 Fitting: 1/4" BSP Hex Head Silencer x 4
P0001101 Male straight 1/4 bsp to 12mm x 2
P0001102 Fitting male elbow 12mm 1/4 x 4
P0001105 Bulkhead straight 12mm x 6
P0001186 Valve. 24v dc smc x 8 - R0015316 V notch Final Assembly Part 2 + (<nowiki>'''<u>Tools Required&l …
'''Tools Required''' BJ3-1 x 2<br /><br />P0001133 Cylinder: Ø50 x 500 x 2<br /><br />P0001134 Floating Joint M18x1.5 x 2<br /><br />P0001140 Pilot Check Valve: 8mm to 1/4" BSP x 2<br /><br />P0001141 Fitting: SMC Flow Controller Elbow Ø8-1/4BSP x 1<br /><br />P0001142 Adjustable Damper 150mm stroke (3000N) x 1<br /><br />P0001144 Reed Switch Mounting Band for Ø50 cyl x 2<br /><br />R0015084 Bench assemble and Drill Off Swarf chutes<br /><br />V0000028B-ZX5 Notching Blade: Ø300 x 96 teeth x 2.8mm pl x 3.3mm kf x24mm x 4</nowiki>)
Standard Hex key set
Standard Spanner set
ZX5 Blade tightening tool
Compressed air connection with regulation (for axis support)
'''Parts required'''
A0001069 Energy Chain Series B15.050 (48mm radius) Openable x 2
A0001070 Igus Mounting Br Set for A0001069 Non-Pivot x 2
B0000046 Slide Base Bearing Block (Straight Grease Nipple) x 4
B0000173 Blanking plug foc x 28
B0000426 Linear Rail MSB25 400mm Long (AMT) x 4
D0015156 Saw Bearing Plate x 2
D0015161 Saw Plate x 4
D0015162 Saw Mid Spacer Bar x 1
D0015163 Saw Bearing Spacer Bar x 1
D0015168B Balance Cylinder Bracket x 2
D0015169B Cylinder Rod Bracket x 2
D0015179 Energy Chain Bracket x 2
D0015180 Datum Switch Bracket (VZ) x 1
D0015183 VY Stop x 2
D0015235 VY Datum Switch Bracket x 1
D0015236 VY Energy Chain Bracket - Fixed x 1
D0015237 VY Energy Chain Bracket - Moving x 1
D0015250 Safe Sensor Block x 1
D0015251 Safe Sensor Finger x 1
D0015440 Spacer: Ø12.7 x 36, M6 tap thru x 2
D0015452 Scissor Cable Retainer x 1
D0015541 Energy Chain Deflector x 1
D0015704 Energy Chain Support Plate x 1
E0000336 Sensor: M8; 2mm, PNP N/O, M8 conn x 2
E0001185 Elte Saw motor x 4
M0001087 Rubber Bump Stop M6 Ø20x24 x2
P0000022 Fitting: Brass Reducing Bush 1/4 - 1/8 BSP x 1
P0000023 Fitting: Hex Nipple 1/8 BSP x 1
P0000026 Silencer 1/4 BSP x 1
P0000050 Fitting: Silencer 1/8'' BSP x 1
P0000077 Straight Adaptor 8mm - 1/8BSP x 1
P0000140 Fitting: Quick Exhaust Valve 1/8" x 1
P0001040 Fitting: 1/8BSP Hex Head Silencer x 2
P0001041 SMC Reed Switch Mounting Bracket BJ3-1 x 2
P0001133 Cylinder: Ø50 x 500 x 2
P0001134 Floating Joint M18x1.5 x 2
P0001140 Pilot Check Valve: 8mm to 1/4" BSP x 2
P0001141 Fitting: SMC Flow Controller Elbow Ø8-1/4BSP x 1
P0001142 Adjustable Damper 150mm stroke (3000N) x 1
P0001144 Reed Switch Mounting Band for Ø50 cyl x 2
R0015084 Bench assemble and Drill Off Swarf chutes
V0000028B-ZX5 Notching Blade: Ø300 x 96 teeth x 2.8mm pl x 3.3mm kf x24mm x 4 - R0015316 V notch Final Assembly + (<nowiki>'''<u>Tools Required&l …
'''Tools Required''' BJ3-1 x 2<br /><br />P0001133 Cylinder: Ø50 x 500 x 2<br /><br />P0001134 Floating Joint M18x1.5 x 2<br /><br />P0001140 Pilot Check Valve: 8mm to 1/4" BSP x 2<br /><br />P0001141 Fitting: SMC Flow Controller Elbow Ø8-1/4BSP x 1<br /><br />P0001142 Adjustable Damper 150mm stroke (3000N) x 1<br /><br />P0001144 Reed Switch Mounting Band for Ø50 cyl x 2<br /><br />R0015084 Bench assemble and Drill Off Swarf chutes<br /><br />V0000028B-ZX5 Notching Blade: Ø300 x 96 teeth x 2.8mm pl x 3.3mm kf x24mm x 4<br /><br /><br/></nowiki>)
Standard Hex key set
Standard Spanner set
ZX5 Blade tightening tool
Compressed air connection with regulation (for axis support)
'''Parts required'''
A0001069 Energy Chain Series B15.050 (48mm radius) Openable x 2
A0001070 Igus Mounting Br Set for A0001069 Non-Pivot x 2
B0000046 Slide Base Bearing Block (Straight Grease Nipple) x 4
B0000173 Blanking plug foc x 28
B0000426 Linear Rail MSB25 400mm Long (AMT) x 4
D0015156 Saw Bearing Plate x 2
D0015161 Saw Plate x 4
D0015162 Saw Mid Spacer Bar x 1
D0015163 Saw Bearing Spacer Bar x 1
D0015168B Balance Cylinder Bracket x 2
D0015169B Cylinder Rod Bracket x 2
D0015179 Energy Chain Bracket x 2
D0015180 Datum Switch Bracket (VZ) x 1
D0015183 VY Stop x 2
D0015235 VY Datum Switch Bracket x 1
D0015236 VY Energy Chain Bracket - Fixed x 1
D0015237 VY Energy Chain Bracket - Moving x 1
D0015250 Safe Sensor Block x 1
D0015251 Safe Sensor Finger x 1
D0015440 Spacer: Ø12.7 x 36, M6 tap thru x 2
D0015452 Scissor Cable Retainer x 1
D0015541 Energy Chain Deflector x 1
D0015704 Energy Chain Support Plate x 1
E0000336 Sensor: M8; 2mm, PNP N/O, M8 conn x 2
E0001185 Elte Saw motor x 4
M0001087 Rubber Bump Stop M6 Ø20x24 x2
P0000010 1/8 6mm elbow x 1
P0000022 Fitting: Brass Reducing Bush 1/4 - 1/8 BSP x 1
P0000023 Fitting: Hex Nipple 1/8 BSP x 1
P0000026 Silencer 1/4 BSP x 1
P0000050 Fitting: Silencer 1/8'' BSP x 1
P0000077 Straight Adaptor 8mm - 1/8BSP x 1
P0000140 Fitting: Quick Exhaust Valve 1/8" x 1
P0001040 Fitting: 1/8BSP Hex Head Silencer x 2
P0001041 SMC Reed Switch Mounting Bracket BJ3-1 x 2
P0001133 Cylinder: Ø50 x 500 x 2
P0001134 Floating Joint M18x1.5 x 2
P0001140 Pilot Check Valve: 8mm to 1/4" BSP x 2
P0001141 Fitting: SMC Flow Controller Elbow Ø8-1/4BSP x 1
P0001142 Adjustable Damper 150mm stroke (3000N) x 1
P0001144 Reed Switch Mounting Band for Ø50 cyl x 2
R0015084 Bench assemble and Drill Off Swarf chutes
V0000028B-ZX5 Notching Blade: Ø300 x 96 teeth x 2.8mm pl x 3.3mm kf x24mm x 4 - R0015342 Bench Assemble Outfeed Parts + (<nowiki>'''<u>Tools Required&l …
'''Tools Required''' t;<br />P0001068 Valve Base: Type 41 2 Position Ø6 x 1<br /><br />P0001085 Fitting: SMC 1/4" to Ø8 Swivel Elbow x 1<br /><br />P0001163 1/4 bsp male silencer x 2<br /><br />P0001186 Valve/ 5/2 smc x 2 <br /><br />P0001198 1/8 bsp 6mm speed controller x 4<br /><br />P0000394 reed switch holder x 2<br /><br />P0000-444 Reed switch pneumax x 2</nowiki>)
Standard Hex Key set
Standard spanner set
Standard screwdriver set
Bearing press
Test box for cylinder switch function
'''Parts Required'''
B0000034 Linear Bearing: Ø16 x 30 Compact (Metal Case Only) x 8
B0000236 90 Deg Grease Nipple M6 ST/ST x 4
D0004311 Side Eject Block x 2
D0004591 Side Eject Housing x 2
D0004592 Eject Housing Plate x 2
D0005200 Safety Dead Stop Block x 1
D0005201 Safety Dead Stop Backer (5357) x 1
D0005202 Safety Dead stop Yoke (5358) x 1
D0005203 Safety Slider Cap x 2
H0004626 Shaft 16mm: 275 Eject Push x 4
M0000101 Compression Spring 11 D 15 D 25 Long x 1
P0000035 Cylinder 25x160 x 2
P0000174 Fitting: Plug 1/4'' BSP (Grubscrew Type x 2
P0000201 Flow Controller 6mm x M5 Elbow x 2
P0000367 16mm bore X 125 stroke with rod end clevis x 1
P0000369 Clamp to suit P0000367 x 2
P0000444 Reed Switch: Pneumax 1580U (5.0m Lead) x 2
P0001068 Valve Base: Type 41 2 Position Ø6 x 1
P0001085 Fitting: SMC 1/4" to Ø8 Swivel Elbow x 1
P0001163 1/4 bsp male silencer x 2
P0001186 Valve/ 5/2 smc x 2
P0001198 1/8 bsp 6mm speed controller x 4
P0000394 reed switch holder x 2
P0000-444 Reed switch pneumax x 2 - R0015341 Bench Assemble Electrical Cabinet with Pneumatics and controls + (<nowiki>'''<u>Tools required&l …
'''Tools required''' ;P0001070 Valve Base: Type 41 6 Position Ø6 x 2<br /><br />P0001074 Fitting: 1/4" BSP Hex Head Silencer x 8<br /><br />P0001101 Male straight 12mm to 1/4 bsp x 5 <br /><br />P0001102 Male elbow 12mm to 1/4 x 2<br /><br />P0001186 Valve 24v dc SMC x 12 <br /><br /><br /><br /><br/></nowiki>)
Tape rule
Steel rule
standard hex keys
Standard HSS drill set
Standard Tap set
Hack saw
Ball Pein hammer
Centre punch
'''Part Required'''
P0000010 Elbow Adaptor 6mm - 1/8 BSPT (Taper thread) x 3
P0000024 Fitting: Hex Nipple 1/4 BSP x 1
P0000096 Fitting: Brass Reducing Bush 1/2 - 1/4 x 2
P0000097 Fitting: Elbow Adaptor 8mm - 1/4 BSPT x 1
P0000159 Fitting: Stem Blanking Plug 6mm x 3
P0000160 Fitting: Flow Controller In Line 6mm x 2
P0000279 Female Cross 1/4'' NPT x 1
P0000297 HighLow Pressure Valve x 1
P0000419 Air Service Unit OH (P0283)x 1
P0001070 Valve Base: Type 41 6 Position Ø6 x 2
P0001074 Fitting: 1/4" BSP Hex Head Silencer x 8
P0001101 Male straight 12mm to 1/4 bsp x 5
P0001102 Male elbow 12mm to 1/4 x 2
P0001186 Valve 24v dc SMC x 12 - R0015028D ZX5 Hepco Beam Alignment Module C part 2 + ('''<u>Tools Required</u>''' … '''Tools Required''' Engineers level Hepco flat spanner T0000491 Hepco Box spanner T0000492 Standard hex key set Incremental shim pack '''Parts Required''' B0000046 Slide Base Bearing Block (Straight Grease Nipple) x 6 B0000184 Journal Cap Seal 34 x 4 B0000185 Double Row Long Stud Journal Eccentric x 2 B0000186 Double Row Long Stud Journal Concentric x 2 B0000234 Straight Grease Nipple M6 ST/ST x 6 B0001006 Linear rail 25mm x 820mm x 6 B0001102 Double edge spacer slide and beam 7600mm x 1 D0015072 Carriage Plate x 1 D0015492 Vertical Beam Adjustment Plate x 5 D0015493 Lateral Beam Adjustment Plate x 5 P0000200 Elbow Adaptor 6mm - M5 x 2 B0000173 blanking cap x 90 F0000331 M6 threaded plate x 120 x 2 B0000173 blanking cap x 90 F0000331 M6 threaded plate x 120)
- R0015028D ZX5 Hepco Beam Alignment Module C + ('''<u>Tools Required</u>''' … '''Tools Required''' Engineers level Hepco flat spanner T0000491 Hepco Box spanner T0000492 Standard hex key set Incremental shim pack '''Parts Required''' B0000046 Slide Base Bearing Block (Straight Grease Nipple) x 6 B0000184 Journal Cap Seal 34 x 4 B0000185 Double Row Long Stud Journal Eccentric x 2 B0000186 Double Row Long Stud Journal Concentric x 2 B0000234 Straight Grease Nipple M6 ST/ST x 6 B0001006 Linear rail 25mm x 820mm x 6 B0001102 Double edge spacer slide and beam 7600mm x 1 D0015072 Carriage Plate x 1 D0015492 Vertical Beam Adjustment Plate x 5 D0015493 Lateral Beam Adjustment Plate x 5 P0000200 Elbow Adaptor 6mm - M5 x 2 B0000173 blanking cap x 90 F0000331 M6 threaded plate x 120 x 2 B0000173 blanking cap x 90 F0000331 M6 threaded plate x 120)
- R0015329 Fit Head Spindle Posts + ('''<u>Tools Required</u>'''
… '''Tools Required'''
Standard hex key set
Standard flat hand file
Emery tape 120
standard hand tap set
Stubby hex key set
Ratchet/hex bit set
Blade flange spanner
'''Parts Required'''
D0004002 Webb x 1
D0004003 Top Shaft Block x 2
D0004004 Brace Support Bar (D7451) x 1
D0004157 Motor plate spacer x 3
D0004342 Damper Bracket (5312) x 1
D0007451 Brace Support Bar OH (D4004) x 1
D0015490 Saw Turntable Sensor Flag x 1
D0015491 Saw Turntable Flag Bracket x 1
H0004024 Infeed Clamp Post x 1
H0004025 Outfeed Clamp Post (5302) x 1
H0004510 Shaft 30mm: 540 Saw Stroke x 2
P0000055 Adjustable Damper 200mm (Saw Stroke) x 1
R0000560 Bench Assemble Spindle x 1
R0000569E Bench Assemble Head Spindle Posts Mk5 x 1
V0000043B Saw Blade: Ø500 x 160 teeth x 3.2mm pl x 4mm kf x 30mm bore x 1
Blade: Ø500 x 160 teeth x 3.2mm pl x 4mm kf x 30mm bore x 1 <br/>) - R0015100 Fit Guarding + ('''<u>Tools Required</u>'''
… '''Tools Required'''
Standard hex key set
Standard spanner set
'''Parts Required'''
D0001878 Rear Door Saw Mk4 (1879) x 1
D0004584 Outfeed Side Rest x 3
D0015703 Air Gun Bracket x 1
D0016203 Compliance Guard - Saw Lower Front x 1
D0016204 Compliance Guard - Saw Lower Side x 1
D0016265 Saw Front Door: Bernstein Mount Plate x 1
D0016266 Saw Front Door: Bernstein Guard x 1
E0001569 Guard Lock Switch: Bernstein Radius Actuator (Key) x 1
M0000055 Saw Blade Spanner (24mm Combination) x 1
M0001051 Bullet Catch 70 x 12 x 1
P0000010 Elbow Adaptor 6mm - 1/8 BSPT (Taper thread) x 6
P0001008 Regulator: ARG20 0 - 8.5 Bar c/w Gauge x 3
P0001009 Panel Mount Nut (To suit P0001008) x 3
R0015041 Bench Assemble Top Hood Assembly x 1
R0015337 Bench assemble guarding components x 1
R0015338 Bench assemble serial plate x 1
g components x 1 R0015338 Bench assemble serial plate x 1 <br/>) - R0000574 Fit Motor and Swarf Chute + ('''<u>Tools Required</u>''' … '''Tools Required''' standard hex keys Standard spanner set 1 meter steel rule Copper slip Chute flap template jig Standard Hss drills Standard taps Ratchet 3/8 drive and 13mm socket Copper/hide hammer '''Parts Required''' B0000048 Taperlock Set SPZ 80-2 1210-24 x 1 B0001175 Saw V-belt (special size 987mm) for 500mm blade x 2 D0005628 Saw chute infill panel x 1 H0004637 Offcut Chute (H0005333) x 1 H0004660 Chute Bracket x 1 P0000609 Reed Switch Mount (Tie Bar) x 3004660 Chute Bracket x 1 P0000609 Reed Switch Mount (Tie Bar) x 3)
- R0000571 Fit and Level Cut Tables , Finalise Eject + ('''<u>Tools Required</u>''' … '''Tools Required''' 1 meter straight edge 500mm rule Standard hex key Standard spanner set Feeler gauges Engineers level Adjustment shim '''Parts Required''' A0001069 Energy Chain Series B15.050 (48mm radius) Openable x 0.5 A0001070 Igus Mounting Br Set for A0001069 Non-Pivot x 1 A0001074 igus mounting bracket set x 1 D0004551 Cylinder Spacer x 1 D0004553 Cover Fixing Bar x 1 D0004554 Bar Spacer Short x 1 D0004555 Bar Spacer Long x 1 D0004769 Ejector Clamp Pad to be made in conjuction with D5121 (5305) x 1 D0004770 Infeed Clamp Pad to be made in conjunction with D5122 (5299) x 1 D0005121 Ejector Clamp Stainless Pads (5306) x 1 D0005122 Infeed Clamp Pad (5300)x 1 D0005199 Ejector Cover x 1 D0005412 Energy Chain Adapter Plate x 1 H0004556 Fixing Bar Gap Cover (5297) x 1 H0004656 Material Trip Stripx 1 P0000368 Extension 1/8 bsp x 22 long x 1 P0000443 Cleanline Cylinder 32 x 450 PN11246 x 1 P0000444 Reed Switch: Pneumax 1580U (5.0m Lead) x 2 P0001198 flow controller 6mm elbow 1/8 x 2580U (5.0m Lead) x 2 P0001198 flow controller 6mm elbow 1/8 x 2)
- R0015035 Bench Assemble V Notch Components + ('''<u>Tools Required</u>'''
… '''Tools Required'''
Standard hex key set
Standard spanner set
Standard HSS drill set
Vernier 150mm
2 meter straight edge
40mm shaft pin jigs
Feeler gauge set
Internal circlip pliers
External circlip pliers
8mm hand reamer
'''Parts Required'''
B0000041 5 x 5 x 19 key x 1
B0000109 Linear Bearing (IKO) 40 D x 62 D x 80 L x 8
B0000427 Leadscrew Ø25x10 435 Long x 1
B0001047 Fixed Bearing Support Block Ø17 x 1
B0001120 Circlip 62mm External x 16
B0001127 ROTEX GS Coupling Ø14/Ø15 Bore & Key (98 Shore Spider) x 1
B0001134 Ball Bearing 15ID 35OD 11 Long x 10
C0001122K Servo Motor: Beckhoff AM8032-1E10 (Keyed) x 1
D0010132 SZ Drive Mount Plate x 1
D0010563 Y Axis Servo Mount x 1
D0015147 V Notch Upper Support Bar x 1
D0015148 V Notch Lower Support Bar x 1
D0015149 VZ Shaft End Plate x 4
D0015152 V-Notch Upper Moving Bar x 1
D0015153 V-Notch Rear Moving Bar x 1
D0015154 V-Notch Front Moving Barx1
D0015157 Saw Motor Bar x 4
D0015158 Shaft 40mm: 190mm ZX V Notch Saw Motor Slide x 8
D0015159B Saw Motor Adjustment Screwx 4
D0015160 Saw Motor Block x 4
D0015164 VY Leadscrew Block x 1
D0015166 VY Motor Mounting Plate x1
D0015258 Upper Link Mount 1 x 1
D0015259 Upper Link Mount 2 x 1
D0015260 Upper Link x 2
D0015261 Lower Link x 2
D0015262 Lower Link Mount x 2
D0015263 Mid Link Shaft x 2
D0015264 Lower Link Shaft x 2
M0001093 Shaft Clamping Element (Ø15-20 shafts) x 16
haft x 2 M0001093 Shaft Clamping Element (Ø15-20 shafts) x 16 <br/>) - R0015337 Bench Assemble Guarding Components + ('''<u>Tools Required</u>'''
… '''Tools Required'''
Standard hex key set
Standard spanner set
Standard HSS drill set
Acoustic mat cutting board and straight edge
Utility blade
'''Parts Required'''
D0000770 Door Hinge (M0016) x 2
D0001886 Front Door Saw Mk 4 x 1
M0000002 12mm Grey Acoustic Foam with Black PVC Facing x 1
M0000539 Handle Black Nylon 200mm M8 Fixings x 1
M0000031 panel edging ( consumable stock )
M0000150 Stuga sticker clear x 1
M0000154 Stuga service sticker x 1
uga sticker clear x 1 M0000154 Stuga service sticker x 1 <br/>) - R0015041 Bench Assemble Top Hood Assembly + ('''<u>Tools Required</u>'''
… '''Tools Required'''
Standard hex key set
Standard spanner set
Standard Hss drill set
Standard tap set
Acoustic foam cutting board and straight edge
Utility Blade
'''Parts Required'''
Pre wired light, beacon and network cable from electrical department
C0001152 Camera: HikVision DS-2CD2343G0-I-2.8mm x 1
C0001239 Micro SD Card 32Gb Class 10 x 1
D0000770 Door Hinge (M0016) x 2
D0001877 Saw Top Door Mk4 x 1
D0004641 Hinge Pin Block (D7445) x 1
D0004642 Flap Counterbalance Bar x 1
D0004645 Safety Flap Hinge Pin x 1
D0004679 Flap Stiffening Bar x 1
D0004705 Flap Hinge Bar x 1
D0004747B top door screen x 1
D0004807 Flap x 1
D0007445 Hinge Pin Block OH (D4641) x 1
D0016251 Saw Hood Switch Mount Plate (Bernstein) x 1
E0000275 Button: Base Fixing 1 N/C x 1
E0001072 Emergency Stop Module Bevelled 1NO 1NC x 1
E0001569 Guard Lock Switch: Bernstein Radius Actuator (Key) x 1
H0004643 4mm Axxis Clear 145mm x 690mm x 1
M0000002 12mm Grey Acoustic Foam with Black PVC Facing x 1 (consumable stock )
M0000036 Sign - Ear Protection x 1
M0000048 Gas Spring 15mm x 100mm x 1
M0000539 Handle Black Nylon 200mm M8 Fixings x 1
100mm x 1 M0000539 Handle Black Nylon 200mm M8 Fixings x 1 <br/>) - R0015311 Install and Align Datum rollers + ('''<u>Tools required</u>''' Standard hex key set 2 meter straight edge 1 meter straight edge 12" engineers level 12" inch engineers square Feeler gauge set '''<u>Parts Required</u>''' R0015297 Mount V Notch Datum rollers)
- Stuertz Infeed - Freeing Roller under Gripper Arm + ('''Applies to: A2026-A2030 Autoflow Mk4 wi … '''Applies to: A2026-A2030 Autoflow Mk4 with Jetta Locking motors'''
In certain circumstances, the forward clamp roller arm has stuck itself under the gripper arm. Freeing from this situation requires a set process because the GZ axis motor is braked and probably in an overload condition
nfident in using TwinCAT on the VM machine to navigate to settings</div> </div><br/>) - TB0314 Updating Mint File in Workbench + ( * Updating software can be very complicat … * Updating software can be very complicated, so care must be taken and always ensure there is a route to retrace your steps in the event of a failure – with Baldor .mnt files this is easy because each version is a separate file and therefore easy to load the old one back in again * In general, the Baldor (.mnt) software has been designed to be backwards compatible, but there are a few steps that needed to be taken that made this impossible. In these cases, the front end software (winMulti or winSaw) also needs to be updated – you will get an error to tell you that this is the case * Version numbers have always followed a numerical order, so the higher the number, the later the version * Mnt files should always be stored in ** c:\multi on MH side – called Multi X.xxx.mnt ** c:\saw on Saws or Saw side of flowline – called IgSaw X.xx.mnt aw side of flowline – called IgSaw X.xx.mnt )
- DM - Updating Resources + (<div class="icon-instructions caution-i …
All information provided to the service engineers on Device Magic can all be linked to a single Excel document. This document provides all customer names, machine numbers, emails and employee information. Linking this document with Device Magic provides fields that make it easier for engineers to fill out the form.
used internally at Stuga and not be sent to engineers or customers in coordination with Data Protection standards.</div> </div><br/>) - OBSOLETE Installing SourceTree Version Control Software + (<div class="icon-instructions caution-i … Use this [https://stuga.dokit.app/wiki/Changing_Version_Control_to_Visual_Studio link] From Jan 2020, Sourcetree will be increasingly used to properly maintain changes to the Stuga source code. Each machine with TwinCAT3 will need the Sourcetree program installed, and a change to where and how the source code is stored This tutorial deals with installing the Sourcetree program from Atlassian code is stored This tutorial deals with installing the Sourcetree program from Atlassian)
- Setting Up Windows PC C0000422-KIT 2023 + (<div class="icon-instructions idea-icon … stuga.dokit.app/wiki/Setting_Up_C0000422-KIT_-_Full_Hardware_2023</div> </div>)
- R0015312 Finalise V Notch Subframe + (<u>'''Tools Required'''</u> … '''Tools Required''' 2 off 2 meter straight edge 1 meter straight edge Engineers level Engineers 12" square Feeler gauges Standard hex key set Standard HSS drill set Standard tap set Clamp blocks 600m steel rule Vernier 300mm parallels 1" parallels '''Parts required''' R0015310 install v notch subframe''Parts required'''</u> R0015310 install v notch subframe)
- R0015029D Hepco Beam Alignment + (<u>'''Tools Required'''</u> … '''Tools Required''' Engineers level Hepco flat spanner Hepco Box spanner Standard hex key set Incremental shim pack Torque wrench '''Parts Required''' B0000184 Journal Cap Seal 34 x 4 B0000185 Double Row Long Stud Journal Eccentric x 2 B0000186 Double Row Long Stud Journal Concentric x2 B0001102 Double Edge Spacer Slide and Beam 7600mm x 1 D0015072 Carriage Plate x 1 D0015492 Vertical Beam Adjustment Plate x5 D0015493 Lateral Beam Adjustment Plate x 5 P0000200 Elbow Adaptor 6mm - M5 x 1 F0000529 T-Nut M6 (slot 10) x 3 F0000530 T-nut M8 (slot 10) x11 F0000529 T-Nut M6 (slot 10) x 3 F0000530 T-nut M8 (slot 10) x1)
- R0015029D Hepco Beam Alignment Part 2 + (<u>'''Tools Required'''</u> … '''Tools Required''' Engineers level Hepco flat spanner Hepco Box spanner Standard hex key set Incremental shim pack Torque wrench '''Parts Required''' B0000184 Journal Cap Seal 34 x 4 B0000185 Double Row Long Stud Journal Eccentric x 2 B0000186 Double Row Long Stud Journal Concentric x2 B0001102 Double Edge Spacer Slide and Beam 7600mm x 1 D0015072 Carriage Plate x 1 D0015492 Vertical Beam Adjustment Plate x5 D0015493 Lateral Beam Adjustment Plate x 5 P0000200 Elbow Adaptor 6mm - M5 x 2 F0000529 T-Nut M6 (slot 10) x 3 F0000530 T-nut M8 (slot 10) x12 F0000529 T-Nut M6 (slot 10) x 3 F0000530 T-nut M8 (slot 10) x1)
- R0015290 Bench Assemble Top guard + (<u>'''Tools Required'''</u>
… '''Tools Required'''
Standard hex key set
Acoustic foam cutting edge and Back board
Stanley blade
Standard HSS drill set
Standard tap set
Step drill
'''Parts Required'''
D0001352 Printer Shelf TLP2844-Z x 1
D0004719E Cut Bar Guard Mk5 (5476E) x 1
E0000249 Sounder Beacon x 1
M0000002 12mm Grey Acoustic Foam with Black PVC Facing x 1
M0001127 Cable Tie Base (m6) x 1
with Black PVC Facing x 1 M0001127 Cable Tie Base (m6) x 1 <br/>) - R0015310 Install V Notch Subframe + (<u>'''Tools Required'''</u> … '''Tools Required''' Standard hex key set Standard Spanner set Parallel setting blocks 600mm rule 1 meter straight edge 2 meter straight edge 12 " engineers level 12" engineers square '''Parts Required''' D0015151 Shaft End Washer x 8 D0015155 Vertical Spacer Bar x 4 D0015150 shaft 40mm zx v notch x 4 D0015169B cylinder rod bracket x 2 R0015035 Bench Assemble V Notch Componentsinder rod bracket x 2 R0015035 Bench Assemble V Notch Components)
- R0015321 Bench Assemble Guards and Doors + (<u>'''Tools Required'''</u>
… '''Tools Required'''
Standard hex key set
Standard spanner set
Dymo label printer
'''Parts Required'''
C0001152 Camera: HikVision DS-2CD2343G0-I-2.8mm x 3
C0001239 Micro SD Card 32Gb Class 10 x 3
D0007643B Perspex Glazing - Door x 4
D0007644B Machining Centre Door 1 x 2
D0007645B Machining Centre Door 2 x 2
D0007654B Perspex Glazing - Front Guard MkB x 1
H0015747 8mm diameter rod x 1 ( in process of changing to D0015747 x 4 )
M0000036 Sign - Ear Protection x 1
M0000201 T Handle Cabinet Lock x 2
gn - Ear Protection x 1 M0000201 T Handle Cabinet Lock x 2 <br/>) - R0015297 Mount V Notch Datum Rollers + (<u>'''Tools Required'''</u> Standard hex key set <u>'''Parts Required'''</u> R0015038 Bench Assemble V notch Datum Rollers)
- TB0444 Renewing CF Card on TwinCAT2 Systems + (<u>Problem</u> These machines … Problem These machines use a CX5020 PC with a 2Gb CF card running TwinCAT2 PLC system. The CF card can fail, which is effectively the windows operating system. The CF card has a very small capacity, so needs to be created from an image. This TB outlines the steps in the process to ensure a successful conclusion. 1. Create a new CF card at stuga using the beckhoff imaging tool on a CX5020 2. Boot up with the CX5020 3. Ensure PLC is set to Enable on start-up (default is config mode) 4. Rename the PC 5. Install TeamViewer host v10 or less from a USB stick 6. If you have a copy of the version of winMulti it was running, copy this in to the c:\ multi folder. If not, a “'''''new version install'''''” will be needed so copy in data from the g:\builds\PC Installs\Autoflow\Multi folder 7. Set up and customer specific network parameters to ensure TeamViewer will work when it is plugged in on site 8. Send to customer Once on site, follow procedure A if the winMulti version is preserved, or B if it is a '''''new version install'''''eserved, or B if it is a '''''new version install''''')
- TB0449 Ecoline Clearing out Old Archived Data + (= Problem = Software takes a long period of time to find bar after scanning barcode.)
- TB0428 Connecting To Yaskawa with Silex USB + (== What is the Silex DS-510? == The Silex … == What is the Silex DS-510? == The Silex unit is a USB server, allowing a PC to have a USB port anywhere over an ethernet network. This is useful to connect the PC to a Yaskawa inverter when they are located in different cabinets. The software sets up a virtual USB port which can then be used to run the Yaskawa DriveWorks software.ed to run the Yaskawa DriveWorks software.)
- TB0415 Method to Prevent Loosening of Saw Blade + (==Problem==
On Z063 the bolt holding the s … ==Problem==
On Z063 the bolt holding the saw blade onto the spindle has regularly been loosening during use.
==Solution==
The M16 bolt will be replaced with a stud and castle nut that can be locked with a cotter pin.
==Tool List==
Drill with Ø5.0 bit
24mm Spanner
C Spanner
= Parts List =
0000549 </td><td width="319">Split Pin 4mm x 32 </td><td width="302">1 </td></tr><tr valign="TOP"> <td width="76">F0000550 </td><td width="319">Castle Nut M16x1.5 </td><td width="302">1 </td></tr></table>)D0004031B Saw Washer 3mm 1 D0015560 Spindle Stud 1 F0000273 Spirol Pin Ø6 x 30 1 F0000549 Split Pin 4mm x 32 1 F0000550 Castle Nut M16x1.5 1 - Monday - Getting Started For Engineers + (==Why Change?==
*mHelpdesk limitations
** … ==Why Change?==
*mHelpdesk limitations
**Cludgy to use
**Slow response
**Cannot connect to other apps or emails
*Monday advantages
**Easier and more elegant to use
**More configurable
**easy to email into
**Better searching
**Expandable to whole business
**Cheaper
==Similarities to mHELPDESK==
*Monday consists of a set of user definable “Boards” that contain a list of “Pulses”.
*The “pulses” can be configured however we like.
*I have created a “Board” called “Service Jobs”
*On the Service Jobs Board, I have designed the “Pulses” to mimic the service jobs, so this will include the machine, the status, the type classification, etc
*Any pulse has associated “Updates”. These are just like the “items” on an mHelpDesk job, but is much more flexible than the plain text of mHelpdesk
*The service team will assign jobs as before
*The job should be updated by yourself during your visit
*The database of jobs is searchable so you can find the machine history
so you can find the machine history <br/>) - ZX4 Infeed Roller Reinforcement + (A plate has been designed to strengthen the installation of the first roller.)
- Correcting Linearity with Rack Offset File + (Accuracy problem on A2001 was traced to a … Accuracy problem on A2001 was traced to a non-linear rack. This tutorial demonstrates how to test the linearity of a rack and the systems in place to correct the linearity. machine in the 20 year history that has needed these alterations</div> </div>)
- ZX5 - ZX3 Hepco alignment Module E Saw Infeed + (Alignment and check procedure for mounting … 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 jigk jigs Hepco rail Drive rack pitching jig)
- R0000728 R0000729 Stroke Assembly Dismantling + (Assemblies fitted to MK1 ZX4 will require … Assemblies fitted to MK1 ZX4 will require refurbishment at some point of life cycle.
The following instructions should be followed to ensure that correct assembly and setting are performed
'''Tools Required'''
Standard hex key set
Standard spanner set
Double pin saw flange spanner
Drifts and punches
Ballpein hammer
Soft hammer
Degreasing bath
pein hammer Soft hammer Degreasing bath <br/>) - R0000711 Rotary Base Assembly REV2 + (Detailed steps to correctly install rotary … Detailed steps to correctly install rotary gear and journals Checks for correct installation of oil feed system Tolerance limits and requirements '''Tools Required''' Standard hex key set 0-25mm micrometer Ring support blocks for assembly Work Table Mag Base and D.T.I Hepco flat spanner 17mm socket Torque Wrench '''Parts required''' D0006423-2mod Drive ring x 1 D0007651 Face plate x 1 B0000185 journal x 6 B0000186journal x 2 D0006503 Journal washer x 8 D00007692 wiper x 4 D0006521 x2 D0007693 x 2 D0007713 rotary ring cap x 1iper x 4 D0006521 x2 D0007693 x 2 D0007713 rotary ring cap x 1)
- Z Transom Width Measurement + (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)
- Placing a TwinCAT3 Machine Under Source Control + (<div class="icon-instructions caution-i … Click [https://stuga.dokit.app/wiki/Changing_Version_Control_to_Visual_Studio here] for the latest procedure For many years, the source code for the PLCs has resided on the G:\drive and then a copy on each and every one of the PCs used to edit the code, so at least one on each machine. This is a recipe for disaster because maintaining all the copies and version numbers is incredibly difficult and adds a lot of time overhead to fixes and changes. This has worked because there has been only one developer, but this is set to change in future as more programmers will be trained and tracking versions becomes more difficult From 2020, the PLC code version control has been improved by using an industry standard source control system called "Git" along with "BitBucket" to store the PLC code in the cloud. The program "SourceTree" is used to commit, push and pull the changes [https://www.atlassian.com/git/tutorials/what-is-version-control Click here] for an introduction to version control using Git This tutorial is a step by step guide to setting up an existing machine or diagnostic PC to a standard uses on all Stuga machines to enable quick, easy and stress free version control.standard uses on all Stuga machines to enable quick, easy and stress free version control.)
- Installation Procedure - Autoflow Mk4 + (General Procedure is * Prepare Area * Unload from Transport * Locate and level infeed table * Locate, level and align machining module * Locate, level and align outfeed table * Fix to floor * Locate waste conveyor system * Guard fencing assembly)
- Upgrading Project File on TwinCAT2 System + (How to upgrade the .pro file (project) on … How to upgrade the .pro file (project) on a Beckhoff TwinCAT2 system
ram called "TwinCAT PLC Control" to download the PLC project</div> </div><br/>) - Full Version Upgrade TwinCAT3 WinMulti + (If a PC fails on a machine in the field an … If a PC fails on a machine in the field and the hard drive data cannot be recovered, it is necessary to replace the PC. This may create a version conflict, as the new PC will have later versions of twinCAT installed than the original
This tutorial outlines the steps required to bring all the machine systems up to the latest level to ensure compatibility
ions-text">...This is a one-way process that cannot be reversed</div> </div><br/>) - Ecoline - Disabling V axis To Swap Faulty Drive + (If a drive fails on an Ecoline, the V axis … If a drive fails on an Ecoline, the V axis can be utilised to enable the Ecoline to still run as a machining centre, albeit with V notching now disabled. This is a better situation than no machining at all, as all factories have V notching capability in addition to an Ecolineching capability in addition to an Ecoline)
- Disabling a Tool Home or Tool Out Sensor + (If there is a failure of a tool out or too … If there is a failure of a tool out or tool home sensor on the Stuga spindle ring, it is important to be able to quickly disable the input so the machine can continue production until the problem can be properly resolved. The software has an inbuilt functionality to do this - this tutorial takes you through the necessary stepsrial takes you through the necessary steps)
- Changing Version Control to Visual Studio + (In March 2022 the password policy of the s … In March 2022 the password policy of the system behind SourceTree / Bitbucket and Atlassian changed - [https://community.atlassian.com/t5/Bitbucket-articles/Announcement-Bitbucket-Cloud-account-password-usage-for-Git-over/ba-p/1948231 link]. This meant all machine would need a complex password login change for the SourceTree program used for version control of the PLC code. This was not straight-forward to resolve, so the decision was made to change the version control system to the one that is packaged with the Visual Studio system by default. This is a better method anyway, but it needs the "TcXaeShell" installed. Visual Studio that includes Source control, rebadged for TwinCAT3</div> </div>)
- Commissioning - Off-Cut Laser Sensor + (Infeed Off-Cut Laser sensors are used to c … Infeed Off-Cut Laser sensors are used to check the length of profile with the proposed length from the software. This is to avoid incorrect lengths and profiles being cut. The sensors will be put at specific lengths along the infeed which will be input in the software files. When profile hits the back fence all covered sensors will trigger, hence, the profile must be larger that the final triggered sensor.be larger that the final triggered sensor.)
- J0001000H Autoflow Mk4 Mechanical installation-Alignment + (Information to clarify correct process for installation of J0001000H Autoflow Mk4 Levelling tolerance of 0.004" /0.1mm over 300mm (1 division on engineers level) must be adhered to)
- Assembly - R0000377B Mk11 Gripper + (Mk11 Gripper was designed to give a variab … Mk11 Gripper was designed to give a variable stop height position for the Mk10 gripper assembly. This is needed on systems with multiple chambers, where there is no "sweet spot" for the open grip position to suit all chambers. A Somatec turret stop is used to provide different stop heights
The design details are here [https://stugaltd.monday.com/boards/315478853/pulses/640717084 Design Notes]
853/pulses/640717084 Design Notes] <br/>) - Updating Teamviewer Host + (Older versions of Teamviewer are being pha … Older versions of Teamviewer are being phased out by the Teamviewer company from September 15th 2021. The advice on the website suggests you need to upgrade to version 15. However, v15 is not compatible with the older Windows XP machines in the field. The latest XP compatible downloadable version of the Host program is 13.2 and is available [https://download.teamviewer.com/download/version_13x/TeamViewer_Host_Setup.exe here] Regrettably, the update process on older versions is not simple, and frustratingly cannot be done remotely. It needs intervention from an operator at the machine with a small amount of technical know-how with a small amount of technical know-how)
- TB0301 Autoflow Saw Head Reinforcement - Additional Enhancements + (On Autoflow 2 Sawing Centres following 5 y … On Autoflow 2 Sawing Centres following 5 years of use., it has been found that the internal saw centre framework can lose its rigidity. this is probably due to "bruising" or denting of the aluminium joints introducing a slight amount of play. This is exacerbated by the design where it is attached and driven on from the base up A retrofit kit of parts has previously been created to allow additional reinforcement to be introduced within the structural framework. This kit builds upon the first kit to provide further accuracy enhancements by #Adding left right stability with additional slide rails at the top of the subframe #Adding front / back stability by moving the SY axis leadscrew to the same height as the saw table ====Parts required: ==== R0010272 Kit: Saw Frame Rigidity Pt 2 This kit consists of 2 carriage assemblies, specifically designed to provide further rigidity to the top of the Saw Head Assembly. In addition, 2 mounting blocks required to relocate the Saw Y Axis Assembly are also included. This allows the Saw Y Axis Assembly to continue to operate accurately, but improves the life of associated components. See also [[TB0259 Autoflow Saw Head Reinforcement]][[TB0259 Autoflow Saw Head Reinforcement]])
- Move SR Datum Sensor to Higher Level R0019217 + (On a Mk4 Autoflow, The SR axis daum sensor … On a Mk4 Autoflow, The SR axis daum sensor is originally located at the rear and to the base of the SR axis. This area is prone to offcuts, so a new location has been designed at the top, with the following design parameters
*Easy to retrofit
*Sensor is protected in a case
*Short distance to connection box
*Uses existing mounting holes
*Easy to adjust and maintain
*Sensing end location should be vertical onto a plate, not horizontal on to a radiused surface
*Can use E0000336 2mm range sensor reliably
*Incorporate a front fence to help deflect offcuts down the chute and to protect the sensor
The parts are supplied in Kit R0019217B
illustrated here are from a Right to Left feed machine. Parts are unhanded so can be fitted to either hand machine</div> </div><br/>) - ZX5 V Notch Blade Mechanical Setup + (On previous models the V notch separation … On previous models the V notch separation was set via the software. This could be quite time consuming and required multiple tests and measurements to get it right. Four variables were used for each V notch and it is not straight-forward to get the shape, depth and position correct. On the new ZX5 the '''shape''' of the V notch is set mechanically and once set it should never need changed again, but remember that some customers sharpen their V notch blades instead of replacing them. The following was carried out on the rear V notches using some standard outerframe but the process is exactly the same for the front. Once set you can use the usual software settings to increase/decrease depth and to align back to back. 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) you will be in close proximity to the V notch blades and tooling.</div> </div>)
- Setting Infeed Loading Wheel + (Setting the pressure and clutch tension on … Setting the pressure and clutch tension on the loading wheel is critical for the reliable and accurate running of the machine If set incorrectly, the profile will slip and not load correctly or will not give an accurate start position for the datum holes The goal is to set the system to a "goldilocks" zone where there is enough pressure and clutch tension to reliably load a bar, but not too much so the clutch limits any correctional movement from the gripper arm on loading e video demonstrates how easy it is for the wheel to become loose</div> </div>)
- ZX5 Transfer Table Setup + (Sometimes the mesh between all the parts i … Sometimes the mesh between all the parts is too tight and left with no adjustment. This causes too much pressure on the moving parts, especially the delrin rollers which are not designed to take heavy loads. Any excess force on them leads to excessive wear and premature failure.s to excessive wear and premature failure.)
- 500mm Saw Blade Upgrade + (Step by step guide of how to carry out the … Step by step guide of how to carry out the 400mm to 500mm saw blade upgrade including long reach clamps. Time to complete is very dependant on condition of the machine, ie rusted or rounded off bolts which may need to be drilled out and holes re-tapped. Replace all screws with Loctite except grub screws on taper lock pulleys, grub screws for shafts on clamp pads and slit strip retaining screws or where a locking nut is used on cylinder rods.re a locking nut is used on cylinder rods.)
- Changing Main Saw Blade + (Stuga recommends this blade be changed aft … Stuga recommends this blade be changed after 1-2 weeks of cutting - symptoms to determine if the blade needs changing:
* Awful cutting sound / smell
* Profile dragging (sizes too short)
* Brown burnt swarf
* Smoke coming out of profile end while cutting
p and can be awkward to manouver out of the saw, please be careful</div> </div><br/>) - ACEpc Changing IP address using netedit + (The ACEpcs use two different systems for c … The ACEpcs use two different systems for connecting a network #NETBeui - this was used on earlier machines but reliability depends on the customer network setup. Reconfiguration after initial setup is difficult #IP addressing - A setup system was written using IP addresses to connect. This is a little harder to set up, but is easier to change later. A special program called netedit was written which updates all the correct files in the backgroundes all the correct files in the background)
- Replacing Baldor Microflex Drive with RS Automation + (The Baldor Microflex drive with Beckhoff m … The Baldor Microflex drive with Beckhoff motor was a drive system combination that has now been superseded with a better performance system using an RS Automation Drive and motor combination The Part number for the upgrade is R0019052X Kit: X Axis Replacement using RS Automationit: X Axis Replacement using RS Automation)
- 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.)
- 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.)
- 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 +
- 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/>) - 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.)
- 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)
- ZX5 Gripper Energy Chain & Tray Setup + (<div class="icon-instructions caution-i … The main problems we’ve had during commissioning with these energy chains is that if they are not positioned well enough , the chain will clip the button heads that hold the trays to the L brackets To get over this the brackets sometimes need adjusting on the slots along with possibly bending into a better shape or by adjusting the chain bracket position on the slots in the ‘finger’ bracket Things to look out for: *There should be three links which are reversed at the bracket end of the energy chain. *Servo cable and the pipes and cables from the energy chain are fixed with cable ties to the fingers on the bracket to minimise possible movement and twisting which changes where the energy chain sits in the trays, meaning it could start clipping the button heads. *Tray heights and energy chain length, there should be a consistent gap all the way along between the energy chain and the top tray (viewed from inside the tray) and when at the full travel either end the chain shouldn’t be tight hitting the fence too much at the end. *It is also worth checking if all of the links fitted are the same radius type, as we have had occasions where some have been a smaller radius meaning at certain points down the rack the radius of the bend becomes smaller and falls out from the support of the top tray, especially when the gripper is at either end of the rack. There is a code on the side of each link in the energy chain. *A last thing to be weary of is is the end corners of the trays may require bending out, 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 We normally get the gripper on a reversing cycle movement to test this through the twincat project at different speeds, starting slow and working up to higher speeds.gh the twincat project at different speeds, starting slow and working up to higher speeds.)
- 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)
- 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/>) - 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.)
- 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.)
- 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/>) - 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.)
- 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/>) - 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)
- 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/>) - 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/>) - 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/>) - 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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