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Turntable Positioner

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1. aaa ubah 11 Positioner Sweep Sequence 12 LOGIC y uu aaa TM 14 Madex ReCover CONIO eG A 15 PPheumalles COMM y uyu Z db etiem a 16 EAA 17 1 Check Shocks Air Wiring Rotate Sweep 17 2 Tessie S WCD a 18 3 POSING s squa 19 AOUS IOC PP ea 19 AdU SCAN POSS UG tamana ss 19 20 UNO Sasa 21 Genesis Systems Group FO uu o 23 E RR TN E RERO 23 snag M 24 Tee 24 SMENA 24 24 WAINTE NANG 25 EVE m 25 miele m 25 Il uman 25 EIergency stop BUONG suero iesus apu ea 25 RETE E 26 26 Axis Bearings amp Locking Collars 3M3 26 Gearboxes SMS RCS ROSE
2. 23 Genesis Systems Group logic timers 14 lubrication 26 27 30 31 37 main enclosure 23 maintenance 25 1 34 10 35 PNEUMATICS 16 DOSITIONGE 25 erf 2 proximity sensors 34 watunman 19 25 12 recovery 15 regulator 16 roto ground clamps 27 shock absorbers 19 36 essen 17 side A s 9 slow down 13 20 17 SWeep 13 17 18 System Specifications 20 14 11 LOOMING 24 tooling balance 4 tooling mounting plate 7 5 troubleshoot 21 turntable uu uuu uu tees 30 valves 16 28 WID 17
3. RC3 RC3L Balancing Tool For proper tooling installation the tool must be balanced within specifications This involves Finding total weight of tool plus parts Locating center of gravity Calculating imbalance torque Possibly altering assembly or using counterweights pU Ic 1 Find Total Tool Part Weight Determine the total weight of the tool plus parts by weighing the tool part assembly 2 Locate Center of Gravity If the center of gravity for the backbone frame tooling and parts to be welded cannot be calculated easily use the Crane and Plumb Bob method 1 Lift the assembly using two hooks Place the first hook where an A is located then place the other hook at the A on the other end Lift the assembly and use a plumb bob to mark a vertical line directly below the lifting point 2 Setthe assembly down and lift it again but this time use the two points marked B Again mark a line straight down from the lifting points Where the two lines A and B intersect is the center of gravity for the assembly in two dimensions The third dimension does not present a problem when dealing with Torque Imbalance and can be ignored CENTER OF GRAVITY Crane and Plumb Bob Method Qlenesis Systems Group 3 Calculate Imbalance Torque After finding total weight of the tool part assembly and locating center of gravity the Imbalance Torque must be calculated The Imbal
4. 26 Ground Brush u 26 Roto Ground Clamps 3M3 RC3L 27 viai 28 kO uU 28 Brake Cover HOUSING uu l 28 28 BIKE oodd ep UI II UAE 28 LL DT 28 28 gigs E 29 29 DV SIC inl 29 BENG Eom 30 Gable Carers AGS AGS a tebe 30 31 boss 32 ANNUI cma A A A N 34 EU M ER rat 34 EIC OCO 35 Programmable Logic Controller PLO 35 DMOCK ADSOIDElS 36 around Eug NUDZ u uu Te 36 Every 20 000 Hours of 37 Gearboxes safe ata diea E 37 Gearbox Lubrication QUANTITIES 38 Maintenance 39 Genesis Systems Group Positioner Installation Installation of Positioner involves leveling and anchoring Positioner setting up the air supply balancing the tooling and mounting the tooling Leveling and Anchoring Parts supplied with Positioner one per anchor point a leveling pad b 114 inch leveling bolt
5. 750 001 gt 000 f qu BOLT HOLES DRILL 27 54 X THRU 1 2 13 UNC X THAU N 6 HOLES SPACED 8 375 24 999 002 s N x N 1 i e A T ait 4 Gearbox Faceplate for RV Gearbox 8 Genesis Systems Group Positioner Control The Positioner is a system of components that work together to rotate turntable between a load area and a robot area turntable has two sides A and B The components Include one or two pneumatic cylinders package proximity sensors shock absorbers and a brake Control Components 4 See Pneumatics Control Inputs Outputs 1 Position A 5 Cylinder Retract 2 Position B 6 Cylinder Extend 3 Position Center 7 Brake Release 4 Air Package Genesis Systems Group 9 10 Control Component Details INPUTS Position A Control point used to indicate the Positioner is position A Two 2 proximity sensors are located at this point for integration with a control reliable circuit Position B Control point used to indicate the Positioner is at position Two 2 proximity sensors are located at this point for integration with a control reliable c
6. 1 inch leveling nut 5 8 inch anchor bolt length varies 7 8 inch washer 5 8 inch anchor nut Q gt Tools supplied by user Level Drill 11 2 inch Socket wrench 15 16 inch Socket wrench 3 Ib Mallet hammer To ensure proper operation the Positioner must be level front to back and side to side To level the Positioner perform the following steps 1 Locate all anchor holes 2 Place leveling pad a on the floor under each anchor hole aligning the center of each pad with the center of each threaded anchor hole 3 Thread a nut c onto each leveling bolt b Thread the nut all the way up the bolt Thread a bolt nut assembly b c into each anchor hole until bolt touches leveling pad a 4 Place level on the Positioner at various locations and adjust the height of each bolt b as necessary until the Positioner is level front to back and side to side Genesis Systems Group 1 After leveling Positioner anchor it Into position by performing following steps 5 Going through the center of each leveling bolt b with 5 8 inch drill bit drill into the cement floor about 1 inch farther than the length of the anchor bolt d 6 Add a washer nut f to each anchor bolt Insert an anchor assembly d e f through the leveling b bolt down into the floor 7 Using a mallet hammer pound down on the anchor bolt until the washer
7. and the Hold sequence This action removes Positioner momentum created from the Retract and Push stages of the sweep sequence When slowdown is complete the Sweep Cylinder Retract Coil de energizes and the Positioner coasts until the Hold sequence 15 activated 5 Positioner Sweep Sequence Hold Position The Hold sequence is activated at the end of the coast time This should engage just prior to or at the end of rotation when the cylinder makes contact with the shock absorber or hard stop This sequence remains active until another sweep sequence starts assuming Control Power remains on The Hold Position energizes the Sweep Cylinder Extend Coil to push and hold the Positioner against the hard stop The Hold remains active unless one of the following variables changes its logical state At Position A or B normally logic one Control Power Emergency Stop normally logic one e Sweep Request is made Emergency Stop Conditions When the machine is E stopped all electrical power is removed from the solenoids This causes the table brake to engage stopping the table Genesis Systems Group 13 14 Logic Timers Logic Timers Genesis Timer Systems Group Standard PUSH SLOWDOWN POINT PUSH Sets the length of time the extend cylinder coil is energized after the Positioner reaches position center SLOWDOWN POINT Sets the location of where the slowdown sequ
8. VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL QUANTITY pints 40 51 53 66 1 24 1 54 41 5 81 97 91 1 1 Greased and sealed by manufacturer no change of grease req d MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE REOO HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL Genesis Systems Group 2 2 2 6 6 97 5 71 3 37 4 06 10 88 13 1 14 8 15 4 275 254 623 602 634 634 1 638 1 257 3 886 Maintenance Chart Use this chart as a reference for doing maintenance and to record the dates when maintenance is done Also refer to the component manufacturers documentation for additional maintenance instructions check Before Every L lubricate Every Shift Six Months clean Cables amp hoses Locking collars Ground brush L Roto ground L Turntable bearing EE Cylinders Camfolowers o NM Proximity sensors Shock absorbers Ground lug nuts
9. m Genesis Systems Group 39 40 NOTES Genesis Systems Group 9 17 19 24 air DA asss 28 air MIET au ass 16 29 air pressure 25 28 2 6 26 30 1 adea 9 28 brake override lever 16 OrUS 26 cable carrier 30 m 26 cam followers 32 27 CO AS 13 counterweight 6 cylinder extend 12 cylinder retract 12 eX d TR 9 2 9 31 electrical 23 Emergency Stop 24 5186102 incide dick sues 35 E stop buttons 25 faceplate 7 fence posts 2 TIL 16 29 TUNG aus 31 ej 24 gearboxes 7 26 37 ground brush 26 ground lug nuts 36 hold 13 NO SCS 26 ay P 10 INSTANATION aus 1 H 1 locking collars 26 lockout tagout
10. then back off 1 4 turn Genesis Systems Group 27 Semiannually Brake IMPORTANT Make sure the air supply to the brake is OFF WARNING Perform brake maintenance every six months Failure to perform maintenance could lead to brake malfunction and possibly cause serious injury or death Upper Brake Pad Brake Disk Upper Actuator 1 Cover Housing Lower Brake Pad Carefully remove the brake cover housing Itis attached to the air bag and to hoses Remove the cover raising it about an inch so that its two nodes clear the holes they rest in then sliding it away from the system Actuators With the air supply to the brake OFF make sure the upper and lower actuators are parallel to each other If they are not parallel adjust them using the brake s two pivot bolts Brake Pads Check brake pads for wear If pads are less than 1 8 inch thick replace them Air Bag Check the air bag and air valve for leaks by looking with safety glasses on and listening Control power must be on Muffler Use only a clean UCI MHC 3 or NUMATICS M3MN muffler on the brake s air bag UCI MHC 3 IMPORTANT The actuators must be parallel to each other Measure from the lower side of the upper actuator to the upper side of the lower actuator in two places making sure measurements are within 1 8 inch of each other am NUMATICS M3MN 28 Genesis System
11. Initiate the sweep If an error occurs refer to Start up Troubleshooting The axis should sweep in one smooth continuous motion If necessary make adjustments to the shocks and air pressure For a system with balanced tooling within the recommended ranges these external adjustments should be all that Is necessary to make the sweep function properly For a system with maximum tool weight or unbalanced weights it may be necessary to adjust parameter values but first attempt to compensate by adjusting the shocks and air pressure After making changes to parameters it may be necessary to adjust the shocks and air pressure again 18 Genesis Systems Group 3 Adjust the Sweep Adjust Shocks If motion 15 abruptly reduced or reversed when the sweep contacts the shock reduce stiffness of the shock by increasing the setting value Increase the setting half number Increments only Finer adjustments may be necessary for final adjustment If the sweep bounces when it contacts the hard stop increase the stiffness of the shock by decreasing the setting value Decrease the setting 1 half number increments only Finer adjustments may be necessary for final adjustment IMPORTANT Do NOT adjust shock setting to less than 2 If setting is less than 2 shock life decreases dramatically NOTE Adjustment settings apply to ACE shocks only If using different shocks check the manufacturer s instructions Adjust Air Pressu
12. Make sure wheel is contacting actuator arm Plug N Play error actuator arm Encoder Manually move encoder wheel back and forth channels A and B reversed while monitoring inputs 0 and 1 on PLC If Inputs Faulty wiring Pull up do not flicker when wheel is moved check wiring resistors not functioning See electrical schematics for your system Retract Cylinder 1 Fuse Blown Fuse is bad or wiring is faulty Check fuse and wiring See electrical schematics Plug N Play error for your system Retract Cylinder 2 Fuse Blown Fuse is bad or wiring is faulty Check fuse and wiring See electrical schematics Plug N Play error for your system Genesis Systems Group 21 Start up Troubleshooting continued Sweep stops just after leaving hard stop Encoder signals reversed Check wiring of inputs 0 and 1 Recover sweep to Sweep Position value out of either Side A or B and cycle control power This range Plug N Play error will reinitialize the position count Safety circuit problem E STOP occurs as soon as sweep begins Light curtain blocked or Test functionality of light curtain and gates or malfunctioning Gate safety other safety device associated with sweep contact faulty Faulty wiring protection Check user wiring E String Safety circuit problem Sweep hesitates mid sweep Directional valves controlling Check valve wiring See electrical schematics for wrong cylinder Brake drag your system Check pneumatic plum
13. gt gt 7 m eA 7 gt 555 gt RAKE reta a ocu ata n tet ate 23 SLOWDOWN gt LEGEND Postion B 0 Retract OFF Extend OFF Retroct ON Extend OFF Retroct OFF Extend ON HOLD Sweep Complete 11 Positioner Sweep Sequence The Positioner sweep sequence be simplified into five stages 1 Retract 2 Push 3 Coast 4 Slow down 5 Hold Position Sweep Complete 1 Sweep Sequence Retract The Positioner sweep sequence begins with retracting the cylinder from Hold state The Hold needs to be released at the start of the Retract sequence When this sequence begins the Sweep Cylinder Retract Coil 15 energized thus beginning Positioner rotation The sequence remains energized unless one of the following variables changes its logical state Positioner Sweep Passes Center Position normally lo a zero e OKto Sweep Input normally logic one Control Power On Emergency Stop normally logic one During normal operation when position Center 15 reached the Push stage of the Sweep Sequence begins 2 Positioner Sweep Sequence Push When the Positioner sweep reaches position Center a Push is used to increase momentum of the Positioner The Sweep Cylinder Extend Coil 1s energized during this time When complete
14. 386 9693 For all other TROUBLESHOOTING and TECHNICAL SUPPORT call 563 445 5600 Regular business hours 7 30 a m 5 00 p m Central Time Please have your shop order number SO or J and your documentation readily available when calling for assistance on your system Genesis Systems Group Genesis Systems Group Table of Contents INSTANAWO Mi uuu u 1 L evelilngralig ATICHOIIIigQu u t 1 Air SUDDIVTZ ua aaa wine 2 3 Tooling Without Minor Axes RCT RCTL 3 Tooling With Minor Axes 3M3 RC3L 4 Pp lg ool u uuu ul 4 Total TOO ar WV CIO u uuu sss 4 2 Locate Center OM suu u 4 Calculate Imbalance 5 4 Alter Assembly or Use Counterweights 6 Pet 7 Gearbox Mounting 7 u Sua Aa GA Cubase upa paypa ush 8 OSINOMEh COM O PEE 9 79 11 118 GOImbOFIelilS uu des 9 Control Component 10 TM 10 10 CONTOLPTOO ANINO cl A 11 ide Ting
15. Turntable Positioner Versa 3M 3M3 RCT RC3 RCTL RC3L User s Manual PLS FORWVIATION ROBOTIC WOHKCELL PLATFORMS by Genesis Systems Group Important Safety Information Genesis Systems Group is concerned with the safety and welfare of its customers and their employees Careful consideration has been given to the design and integration of safety hardware and software into this system The safety equipment is intended as a supplement to the customer s complete safety program this installation These safety precautions are not meant to replace any related Federal State or Municipal laws regulations or guidelines pertaining to safety Genesis Systems Group believes that the appropriate levels of safety for an installation can best be determined by safety professionals who are most familiar with the intended application It is the responsibility of the customer to insure that this level of safety is accomplished We recommend that each customer consult with safety professionals in order to provide a workplace that allows for the safe application use and operation of this system For further information contact Genesis Systems Group 8900 North Harrison Street Davenport 52806 563 445 5600 Version 071409 Copyright 2009 Genesis Systems Group LLC Genesis Systems Group Gienesis Systems Group 24 HOUR HOTLINE For a PRODUCTION machine that is DOWN AFTER regular business hours call 563
16. aligned vertically Remove the plugs siphon the grease from the lower hole into an acceptable container Use CAUTION grease may be HOT Pump grease into the lower hole so that the grease works its way up into the gears Refer to the Gearbox Lubrication Quantities chart to determine the type and quantity of lubrication Replace plugs Center shaft NOTE Horizontal vertical refers to the orientation of the center shaft Genesis Systems Group 37 38 Lubrication Quantities MAKE SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco Nabtesco MODEL F2C T35 F2C T35 F2C T45 F2C T45 F2C T65 F2C T65 RV 40E RV 40E RV 80E RV 80E RV 110E RV 110E RV 320C RV 320E RV 320E RV 320EL RV 320EL RV 450E RV 450E RV 700EL RV 700EL RV 900C RV 900C GH7 GH7 GH17 GH17 GH24 GH24 GH40 GH40 GH100 GH100 LUBRICANT OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE REOO APPLICATION HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL
17. ance Torque is the product of the weight in Ibs W and distance in inches from the axis of rotation to the center of gravity Equation T Imbalanced Torque The calculated value 7 must be less than 600 in Ibs If it 1s not the tooling and backbone need to be altered so the center of gravity moves closer to the axis of rotation Another solution 1 to balance the setup using counterweights to move the center of gravity Needs Balancing Genesis Systems Group 4 Alter Assembly Use Counterweights Alter Assembly If tooling backbone objects to welded are adjusted to change the center of gravity recheck the center of gravity using the Crane and Plumb Bob method Then recalculate If T is less than 600 in lbs further alteration is not needed If 771s too large continue to alter the assembly or consider using counterweights Use Counterweights Counterweights can be used to alter an assembly s center of gravity If the center of gravity lies at X Y from the axis of rotation then the assembly must be balanced so that lt 600 1 16 The easiest way to do this 15 to determine the weight acting at point X Y then place a counterbalance of the same weight at point X Y This will result in a balanced assembly Also if the weight needed at X Y 1s too great doubling the distance 2X 2Y will allow the counterbalance weight to be halved Balan
18. arameter may be too high Qlenesis Systems Group Lockout Tagout Only trained personnel should perform maintenance The following lockout tagout procedures should be followed before performing any maintenance In addition to these procedures other practices may be needed It is the responsibility of the customer to consult safety professionals to determine and apply the best safety practices WARNING Before performing any maintenance use lockout tagout procedures to prevent system operation Failure to prevent operation could result in serious injury or even death Electrical To prevent electrical power to the system from being turned on 1 Turn the main main disconnect to OFF 2 Secure knife switch with a lockout tagout device and padlock WARNING Lethal voltage is present in the enclosure whenever it is connected to a power source Be extremely careful to avoid electrical shock Turning the disconnect or knife switch to OFF removes power from the output side of the device only High voltage is always present at the input side whenever the enclosure is connected to a power source Genesis Systems Group 23 24 Air To prevent system air from being turned 1 Push the blocking valve down 2 Secure valve with a lockout tagout device and padlock System To prevent system operation press an E stop button Shielding Gas At the user supplied valve turn off shie
19. bing Check air pressure Sweep strikes hard stop harshly Shocks stiffness too low Check shock settings Replace shock if bounces in both directions of sweep Tool imbalance too great for adjustments do not change characteristics of current parameter settings shock Adjust parameter settings Check Air pressure not sufficient for regulator setting full slowing power Sweep strikes hard stop harshly Shock stiffness too low Check shock settings Replace shock if bounces in only one sweep direction Directional valve not able to adjustments do not change characteristics of apply retract pressure Tool shock Check functionality of directional valves to balance too great for current see if condition has been caused by a faulty coil parameter settings on retract side of valve This would also make the beginning of the sweep slower than normal but the sweep would still complete Adjust parameter settings oweep comes to complete stop before Shock stiffness too high Check shock Replace shock if adjustments do reaching hard stop and then completes Sweep MAX END parameter not change characteristics of shock Adjust Sweep too low Air pressure too parameter settings Check regulator setting high Sweep comes to complete stop or reverses Sweep MAX parameter Adjust parameter settings direction before reaching hard stop and then slowdown slope too slams into hard top with bouncing aggressive Sweep MIN END p
20. ced Assembly IMPORTANT If counterweights are used they must remain inside the Swing Radius If a counterweight is used to alter the center of gravity recheck the center of gravity using Crane and Plumb Bob method Then recalculate If 1s less than 600 in Ibs further alteration is not needed Make sure W includes the counterbalance weight Also make sure the gearbox has a high enough value Qlenesis Systems Group Mounting a standard minor axis tooling installation with a bearing at tailstock end the headstock end remains fixed while the tailstock bearing is simply supported This allows the tooling shaft to move axially as the tooling deflects and pivots about the bearing To maintain structural integrity required of the Positioner certain tooling specifications must be met Gearbox Mounting Plate Tooling mounting plates must mate with gearbox faceplates provided by Genesis Systems Group MOUNTING PLATE SERVO MOTOR GEARBOX FACEPLATE TORQUE 7 _ Lu NL Th ctum aoc m Nd m x wiwa Lu enesis Systems Group Gearbox Faceplate Each RV gearbox faceplate conforms to the specifications shown in the following diagram NOTE Tooling should be mounted with 1 2 13 grade 8 bolts and torqued to SAE standards KEY DEPTH 28 0 25 PILOT DEPTH di 30 u 47 a j ja
21. cracks and burns Replace as needed using care when rerouting cables Hand tighten cable plugs to proxes being careful to not overtighten Genesis Systems Group If Positioner has encoder encoder helps ensure accurate positioning of the turntable Look at encoder Make sure it is making contact with the table Check the mounting bolt for tightness Check the connections to the PLC for tightness Programmable Logic Controller PLC If the Positioner has a MicroLogix 1000 PLC the PLC controls the rotation of the turntable No maintenance is required The unit does not have a battery If problems occur with table rotation encoder fault then connections may be loose Genesis Systems Group 35 Shock Absorbers A shock absorber 15 located on both sides of the turntable Each shock absorber has two spanner nuts Check that all spanner nuts are fastened securely To tighten use a spanner wrench and apply 75 to 100 165 of force with about one foot lever Check each shock absorber for leaks Replace if leaking NOTE If the turntable bounces off the hard rest stop at the end of its rotation noisier than normal the shock absorbers too loose Adjust setting to a lower number If the turntable bounces off the shock at the end of its rotation the shock absorbers are too stiff Adjust setting to a higher number To adjust shock absorbers use an Allen wrench to turn the d
22. d PSI Air supply shut off valve Check status of shut off valve Check user air closed User air supply supply Check functionality of regulator Check insufficient Improperly functionality of pressure switch adjusted or faulty regulator Improperly adjusted or faulty pressure switch Brake Release Fuse Blown Fuse is bad or wiring is faulty Check fuse and wiring See electrical schematics Plug N Play error for your system Brake Pressure Errors Brake pressure not present Verify both brake solenoids are acting at same Plug N Play error while output off time Check for main air pressure Brake pressure present while output on Control Power is Off System E stopped or faulty Check status of E string and wiring wiring Extend Cylinder 1 Fuse Blown Fuse is bad or wiring is faulty Check fuse and wiring See electrical schematics Plug N Play error for your system Extend Cylinder s Fuse Blown Fuse is bad or wiring is faulty Check fuse and wiring See electrical schematics Plug N Play error for your system Possible A at Robot Proximity Sensor Failure Faulty proximity sensor or Check functionality of proximity sensor Check wiring wiring See electrical schematics for your system Possible B at Robot Proximity Sensor Failure Faulty proximity sensor or Check functionality of proximity sensor Check wiring wiring See electrical schematics for your system Possible Encoder Malfunction Encoder wheel not contacting
23. ence begins This timer is enabled once the Positioner reaches position Center and completes at the point where the Positioner is beginning its slowdown sequence COAST This timer is enabled when the Push timer is completed and completes when the cylinder reaches the shock absorber ABNORMAL SWEEP This timer is enabled when an abnormal sweep condition is created It is used to apply the brake when an abnormal sweep condition occurs WATCHDOG This timer is enabled at the start of rotation when the initial request to sweep is present or if the table is not at Station A or Station B the timer reaches its preset value an abnormal sweep condition is created This value is set according to the application s normal sweep time The timer resets stops timing when the Positioner reaches Station A or B SWEEP TIME Measures the length of time from sweep start to sweep complete SLOWDOWN LENGTH Sets the length of time the retract cylinder coil is energized after the Slowdown Point timer is complete Genesis Systems Group Index Recovery Control Positioner rotation stops and recovery of the Positioner s position is needed if any of the following events occur lf neither Position A nor Position B signals are true and there is logical event to stop rotation of the Positioner e f neither Position A nor Position B signals are true and Control Power is false e Emergency stop When any of t
24. has two cam followers on each side of the table four total Look at each cam follower and see if they all touch the table If a cam follower does not touch the table perform the following steps 1 Use an adjustable wrench to loosen the cam follower s jam nut Use a 7 16 inch allen wrench to adjust the cam follower up or down so that it touches the table Retighten jam nut Turn off the brake Rotate the table by hand 180 making sure the table rotates freely does not bind If table rotation binds or is impeded by any cam follower lower that cam follower only One or more cam followers may not touch the table at some points during rotation If necessary repeat step 3 for all cam followers Turn on brake Cam Followers 32 Genesis Systems Group Adjusted to Maximum UP Position Genesis Systems Group 33 Annually Proximity Sensors Proximity sensors proxes help ensure accurate positioning of the turntable Proximity sensors are located under the turntable on each side of it and at the center point of its rotation Check each proximity sensor for tightness and proper distance from its target The distance should be such that the LED lights up but the prox does not touch its target Jam nuts and prox brackets should be firmly tightened Prox brackets should be fastened with lock nuts washers and a removable thread locker if necessary Examine prox cables for abrasion
25. hese events occur the Positioner brake output 15 de energized and any active step of the sweep sequence 15 deactivated To recover from this situation the Positioner brake output needs to be energized To recover the Positioner into position the extend cylinder coil is pulsed until the Positioner reaches position or At that time the Hold sequence is re enabled O O CO gt lt 5 lt lt p gt 9 a QD 2 gt gt 02 O O ne c e 5 QD x 5 c 9 E c LLI LLI Position A HM Position Position Center Cylinder Retract F1 Cylinder Extend Brake Release Genesis Systems Group 15 Control The pneumatic valve assembly 1 mounted on the side of the workcell Refer to electrical schematics for wiring Air Pressure Sensor System Pressure Regulator Cylinder 1 Valve Brake verd Lever Cylinder 2 Valve Main Air af AC a 17 Valve NUMATICS Assembly Brake Air System Air 1 Filter org HNN b c Air Lines to Cylinders e Unrestricted 3 8 minimum inside diameter supply line e Filtered moisture free compressed ai
26. ial adjusting at the most to the next half number increment For example adjust from 3 to 3 or from 3 to 2 DO NOT adjust shock absorbers to less than 1 IMPORTANT The shock is not used as a hard stop If a shock absorber is replaced make sure there is a 3 16 stroke left in the shock when hard stops are against each other NOTE Adjustment settings apply to ACE shocks only If using different shocks check the manufacturer s instructions Ground Lug Nuts Check that each ground lug nut connection is tight Tighten size 1 2 13 to 80 ft Ibs Tighten size 3 8 16 to 32 ft Ibs Check that the cable is firmly terminated Examine the 4 0 ground cable insulation for abrasion and cracking Repair or replace as required If unable to replace use electrical tape to cover bare cables until they can be replaced Genesis Systems Group Every 20 000 Hours of Operation Gearboxes 3M3 RC3L servo driven gearbox 15 located at the head of each minor axis Every 20 000 hours of run time change the grease In each gearbox To change the grease 1 2 Remove the tool Rotate the axis for about 15 minutes to warm up the grease and make it flow more easily Each gearbox has two plugs Locations vary depending on the gearbox It may be that both plugs are on the front side or one plug is on the front and one on the back Locate the plugs Make sure the axis is positioned so that the two plugs are
27. ircuit Position Center Proximity sensor mounted at the center of the Positioner s rotation and is actuated by a tab attached to brake disc This signal is used to reverse the cylinder s direction from retract to extend Air Package Air regulator used to maintain proper air flow psi pressure switch used to detect proper air flow psi brake override lever used to release brake allowing table to be rotated by hand OUTPUTS J Cylinder Retract Signal sent to cylinder air valve energizing the coil that retracts the cylinder This is energized when Positioner rotation is started It can also be used to slow down the Positioner at the end of sweep The output is pulsed to briefly slow the speed Cylinder Extend Signal sent to cylinder air valve energizing the coil that extends the cylinder This is energized to hold the Positioner against the hard stops along with pushing the Positioner past center during rotation Brake Release Signal sent to brake release air valve energizing the coil to release the brake This is energized during normal operation 15 not used to control sweep speed nor is it used for absolute positioning The coil is de energized to stop the Positioner in an Emergency Stop condition The manual override lever releases the brake making the Positioner moveable by hand The manual override also blocks air flow to the extend portion of the cylinder making the environment safe to rota
28. is flush with the leveling bolt d 8 Use a 15 16 inch wrench to hand tighten anchor nut f 9 Use a 112 inch socket wrench to hand tighten each leveling nut np mtem m seis If Positioner has fence posts anchor each post with 3 8 inch anchor bolts and nuts usually four holes per post 10 Going through each hole with a 3 8 inch drill bit drill into the cement floor about one inch farther than the length of the anchor bolt 11 Add a 3 8 inch washer and nut to each anchor bolt Insert a washer nut bolt assembly through each hole down into the floor 12 Using a mallet hammer pound down on the anchor bolt until it is about an inch above the floor bracket 13 Use a 9 16 inch wrench to hand tighten each leveling nut LI nS UA P Air Supply The air supply must conform to the following specifications Unrestricted 3 8 minimum inside diameter supply line e Filtered moisture free compressed air at 80 psi minimum 75 cfm rating 2 indexes per minute 2 Genesis Systems Group Tooling Installation Tooling Without Minor Axes 3M RCT RCTL For Positioners that do not have minor axes tooling and components must be securely mounted Inside the maximum table diameter and be within the maximum weight capacity of the Positioner See System Specifications Genesis Systems Group Tooling With Minor
29. lding gas before performing any maintenance Tooling Make sure all parts are removed Genesis Systems Group Maintenance Proper maintenance of the Positioner is essential for maintaining its optimum operating condition Perform maintenance according to the schedules recommended in this manual Also refer to component manufacturers documentation for additional maintenance instructions Before Every Shift Positioner Clean the positioner and remove any objects that are not needed for safe operation of the system Remove excessive spatter and dust build up on the work surfaces Air Pressure Check air pressure Make sure it is 80 100 psi Emergency stop Buttons Check that every E stop button stops table rotation Genesis Systems Group 25 Weekly Cable and Hoses Check all external cables and flexible hoses for damage Check hoses for abrasion cracking kinks and burns Repair or replace as required being careful to reroute hoses properly Pillow Block Bearings Axis Bearings amp Locking Collars 3M3 RC3 RC3L Pillow block bearings are located at the tailstock ends of the axes These bearings are greased before being shipped They do not require any further lubrication or maintenance Make sure the locking collars are tight Locking Collars A servo driven gearbox is located at the head of each minor axis These gearboxes are greased before being shipped They do not require further
30. lubrication except for changing the grease every 20 000 hours of operation They should be inspected for leaks Check for fluid on the underside of the gearbox and faceplate and on the floor If a unit is leaking call Genesis Systems Group Gearboxes 3M3 RC3 RC3L Ground Brush 3M3 RC3 RC3L A ground brush may be located at the end of each minor axis Once a week lubricate each brush To lubricate pull back on the copper unit Cover the entire surface of the copper unit wherever it comes In contact with the axis with a thin coat of Tweco Electrical Joint Compound and Lubricant Replace ground brush when this distance Is less than 24 mm 93 inches Genesis Systems Group Roto Ground Clamps 3 3 RC3L Roto Ground clamps may be located at the end of each minor axis The untts are lubricated before being shipped Once a week turn the cap one full turn 360 Turning the cap forces lubricant into unit When the cap 1 fully screwed down no longer be turned then add lubricant To add lubricant perform the following steps 1 Remove the cap 2 Fill the funnel and cap with Tweco Electrical Joint Compound and Lubricant 3 Screw the cap back on turning only until resistance is felt Make sure roto ground 15 tight on the tailstock shaft torqued to 90 ft Ibs Make sure unit makes firm contact with shaft yet is able to rotate Hand tighten bolt with wrench snug
31. r at 80 psi minimum 75 cfm rating 2 indexes per minute Genesis Systems Group Start up The 5 components must be checked tested and possibly adjusted before operations are started Perform the following steps 1 Check Shocks Air Wiring Rotate Sweep Before applying power to the system complete the following tasks 1 Make sure shock stiffness is at the setting indicated in the System Specifications table 2 Make sure air pressure is at the setting indicated in the System Specifications table 3 Make sure all air lines are tightened and are not in the motion area 4 Make sure the sweep area is clear then manually override the brake directional valve With the brake released rotate the sweep by hand to check clearances enesis Systems Group 17 2 Test the Sweep After checking the shocks air wiring and sweep clearances perform following steps to test the sweep WARNING Before performing the following steps make sure the sweep area and actuating area are clear of people and objects Failure to keep these areas clear of people and objects could result in serious injury or even death 1 Make sure the sweep and actuating areas are safe and secure This should include but not be limited to robots clear of sweep all gates closed light curtains are functional and headstock doors are closed or marked as dangerous 2 Make sure the Emergency stop buttons are functional 3
32. re Air pressure adjustment is not normally necessary but may be required in certain applications If adjusting air pressure refer to the System Specifications table for maximum and minimum allowable pressure settings and note the following guidelines Increasing air pressure increases the sweep speed but it also increases the effect of the slowdown Adjust air pressure in 5 psi increments Decreasing air pressure decreases the sweep speed but it also decreases the effect of the slowdown Adjust air pressure in 5 psi decrements Air pressure adjustment also affects brake operation air pressure is too low below 80 psi the brake will drag on the brake disk slow the speed of the table and increase wear on the brake pads Genesis Systems Group 19 20 System Specifications em O Available Tool Lengths 96 table 60 72 84 9 96 Maximum Tool Weight Per Side 1500 _ 150015 1500 108 1500 _ 15005 1500 2000 1500 2000 bs Maximum Tool Imbalance 600in lbs Rotational Minor Axis Maximum Imbalance Between Tool A and B External Adjustment L m m m m moov s s _ moe e f e ow s Qlenesis Systems Group Start up Troubleshooting Abnormal Sweep Stop Sweep was not in position Recover sweep to Side A or B Plug N Play error when control power was turned on Undefined condition stopped sweep Air Pressure Below Recommende
33. s Group Air Filters Brake Every six months inspect the brake air filter If the filter is discolored not white replace it with the same type and brand WARNING Inspect the brake air filter every six months Failure to perform maintenance could lead to brake mallunction and possibly cause serious injury or death System Every six months inspect the system air filter Look through sight glass If the unit is dirty disassemble and clean it or replace it Genesis Systems Group 29 Turntable Bearing Grease turntable Rotek bearing after the first ten days of operation Then grease it every six months To grease the bearing perform the following steps 1 Pump grease into the fittings several times while rotating the bearing Use a high quality lithium based NLGI 2 or 3 bearing grease 2 Check the seals Repeat greasing and rotating until grease starts to seep out at the seals Cable Carriers RC3 RC3L A cable carrier may be mounted at the headstock end of each minor axis It protects the power cabling Visually inspect it Look for cracked or separated links Replace if necessary Make sure all fasteners are tight 30 Genesis Systems Group Cylinders A grease fitting is located at each end of each cylinder Give each grease fitting one pump of a high quality lithium based NLGI 2 or 3 bearing grease Genesis Systems Group 31 Followers Each turntable
34. te the Positioner without electronic control Genesis Systems Group Control Programming turntable 15 Intended to be controlled by a Genesis Systems Group Plug N Play controller or by a machine s master controls Index Timing Chart represents proper operation of the turntable Confirm operation by monitoring the pneumatic valve s LED output lights It is important to the turntable s components that the table be in a coast state after mid sweep prior to making contact with the shock absorber The Positioner s brake 1 used for Emergency Stop conditions only It is not used to control speed of the Positioner nor for positioning Confirm this operation once upon start up and debug of the integration of this Positioner Index Timing Chart lt 9 co 000 G z pan 42 5 85 5 5 5 O 9 S gt 5 5 D 2 2 5 5 S 2 Coast 1 Coast 2 Position Cylinder Retract Coil Cylinder Extend Coil Brake Release Increment time sec 1 00 0 25 1 75 0 25 0 50 Accumulated time sec Position Center S d PL PE PE lE b jj 1 00 1 25 3 00 3 25 3 75 All times estimated Position Center Sweep Start Genesis Systems uroup PUSH COAST ut 3 5555 2 eed 1 gt ed 05 x ON 55 lt e c
35. the Sweep Cylinder Extend Coil de energizes This begins the initial Coast stage of the Sweep Sequence With heavy load capacity and large design configurations it may not be necessary to have a Push In this case momentum from the initial sequence is sufficient to complete Positioner rotation The remains energized unless one of the following variables changes its logical state OK to Sweep Input normally logic one Control Power On Emergency Stop normally logic one Push timer done Qlenesis Systems Group 3 Positioner Sweep Sequence Coast During the Coast sequence the Positioner uses momentum from the retract and push stages to continue the sweep Neither the Push nor Retract cylinder coils are energized during this stage of the sweep When the Coast timer is done the Hold stage of the Sweep Sequence begins 4 Positioner Sweep Sequence Slow Down This sequence of the sweep is not used on every application Smaller Positioner designs and lighter Positioner loads do not require this sequence The logic may be included with the timer length set to To start the Slow Down the Sweep Cylinder Retract Coil is energized for a very short duration of time a pulse The Slow Down is activated at a set time after the Positioner passes Positioner Center Normally this is activated halfway between position Center

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