Ferris Wheel Positioner
Contents
1. 15 BIG C I 15 16 SLL S a 16 SNIEN arian 16 NO GING 16 AN apn DEE ODED as 17 BES EVO ONI 17 FOS NOUN a ee pars 17 ARETE SSU re OE O eee 17 SIOD LOIN tiaras stants csi daisies 17 18 danad FOSES 18 Axis Bearings amp Locking Collars 18 6122119 6 2 e nae 18 18 ROLO ocean 19 Genesis Systems Group 20 20 21 VNC LS 22 22 Cai E 22 ANNUA soz a SS Daa 23 Proximity Sensors ORZ FW2. Ferris Wheel Positioner Versa 4M CRZ FW ROBOTIC WORKCELL 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 for 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 A 52806 563 445 5600 Version 041307 Copyright 2007 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 563 386 9693 For all other TROUBLESHOOTING and TECHNICAL
3. 9 10 24 LOOMING 16 tooling 3 tooling mounting plate 6 TON GUC 4 13 20 8 9
4. On the CRZ FW two shock absorbers are located inside the headstock module with the cylinders encoder etc 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 Ibs of force with about one foot lever Check each shock absorber for leaks Replace if leaking NOTE Ifthe axis bounces off the hard rest stop at the end of its rotation noisier than normal the shock absorbers are too loose Adjust setting to a lower number If the axis 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 dial adjusting at the most to the next half number increment For example adjust from 3 to 3 or from to 20 DO NOT adjust shock absorbers to less than 1 NOTE Adjustment settings apply to ACE shocks only If using different shocks check the manufacturer s instructions Genesis Systems Group If the Positioner has an encoder encoder helps ensure accurate positioning of the major axis Look at the encoder Make sure it is making contact with the tube 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 major axis No maintenanc
5. 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 a level on the Positioner at various locations and adjust the height of each bolt 0 as necessary until the Positioner is level front to back and side to side Genesis Systems Group After leveling Positioner anchor it into position by performing following steps 5 Going through the center of each leveling bolt b with f a 5 8 inch drill bit drill into the cement floor about 1 inch farther than the length of the anchor bolt 6 Adda washer and nut f to each anchor bolt Insert an anchor assembly d e f through the leveling bolt down into the floor b 7 Using a mallet hammer pound down on the anchor bolt until the washer is flush with the leveling d 8 Use 15 16 inch wrench to hand tighten anchor nut f 9 Use a 1 Winch socket wrench to hand tighten each leveling nut d ii cae OND OE TL asi All Rl WAYA If the 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
6. 22 CableS 18 24 cam followers 22 19 counterweight 5 cylinders 8 22 elecitrical 15 Emergency 16 aaa 25 energy chain 22 E stop 17 faceplat e 6 fence 15 2 ne 8 MENOS carri 22 e AEE E NE 16 6 18 26 ground brush 18 ground lug 25 NOSOS 18 1 limit switches 24 locking collarsS 18 lockout taQOUt 15 lubrication 18 19 22 6 Genesis Systems Group main 15 maintenance 17 eae a 20 Sila a 23 25 e 25 pneumatics 8 positioner 17 DOSS 2 proximity 8 23 SI wens As 17 2 8 roto ground clamps 19 shock absorbers 11 24 SHOCKS a 9 SAE AB 8 UD SSeS 9 SWEED
7. 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 your documentation readily available when calling for assistance on your system Genesis Systems Group Genesis Systems Group Table of Contents E EER 1 EVENING ANG ANCOR 5 RSs 1 2 Toong INSTAAN 3 SAARC TOO E 3 Total TOOMPaAN WCQ t eea 3 2 Locate Genter Ol Gravity a as 3 SSR 6 OONO 8 Pneumatics Control 8 9 1 Check Shocks Air Wiring Sweep 9 2 WEST UNG 10 ING SWEEP 11 SHOCKS 11 Adjust Air oe abies 11 12 Starup 252 ssn edged Banyo 13 DOCK OUT Tagout stitches
8. 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 Recommended 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 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
9. ground 15 tight on the tailstock shaft torqued to 90 108 Make sure unit makes firm contact with shaft yet is able to rotate Hand tighten bolt with wrench snug then back off 1 4 turn Genesis Systems Group Funnel 19 Semiannually Brake IMPORTANT Make sure the air supply to the system 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 Brake Cover Housing Carefully remove the brake cover housing It 15 attached to the air bag and to hoses Remove the cover by removing the two mounting bolts Actuators With the air supply to the brake OFF make sure the left and right 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 k UCI MHC 3 NUMATICS M3MN 20 Left Brake Pad lt gt Left Actuator Brake Disk Right Brake Pad ch Pivot Bolt Right Actuator lt gt 1 8 IMPORTANT The actuators must be parallel to each other Measure from the inside of the
10. left actuator to the inside of the right actuator in two places making sure measurements are within 1 8 inch of each other Pivot Bolts Genesis Systems 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 malfunction and possibly cause serious injury or death 314 Ea System Every six months inspect the system air filter It is located either near the peripheral equipment or in the headstock enclosure Look through the sight glass If the unit is dirty disassemble and clean it or replace it Genesis Systems Group 21 Cylinders The two cylinders at the headstock end of the major axis have three grease fittings Give each fitting one pump of a high quality lithium based NLGI 2 or 3 bearing grease Cam Followers The system has three cam followers at the headstock end Give each cam follower one pump of a high quality lithium based NLGI 2 or 3 bearing grease Make sure the top cam follower is making contact with the tube Cable carriers An energy chain cable carrier may be mounted at the headstock end of each minor axis It carries the power cabling If the Positioner has an energy chain visually inspect it Look for cracked or separated links R
11. 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 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 15 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 10 Genesis Systems Group 3 Adjust the Sweep Adjust Shocks If motion is abruptly reduced or reversed when the sweep contacts the shock reduce the stiffness of the shock by increasing the setting value Increase the setting in 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 half number increments only Finer a
12. 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 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 13 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 Fau
13. 23 WIGS EI 24 24 EN COO gem tee eee 25 Programmable Logic Controller 25 co 8 aie eece O 25 Every 20 000 Hours of 26 26 Maimtenance Char 28 Genesis Systems Group Positioner Installation Installation of the Positioner involves leveling and anchoring the Positioner setting up the air supply balancing the tooling and mounting the tooling Leveling and Anchoring Parts supplied with system one per anchor point a leveling pad b 1 inch leveling bolt 1 inch leveling nut 5 8 inch anchor bolt length varies 7 8 inch washer 5 8 inch anchor nut Q x SN N Tools supplied by user Level Drill 1 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 a 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
14. MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL 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 N A 27 Maintenance Chart 28 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 W check Before Every L lubricate Every Shift Six Months clean Cables amp hoses Locking collars Ground brush Roto ground Brake Cylinders followers Cable carriers Proximity sensors Limit switches Shock absorbers Ground lug nuts Gearboxes L change Genesis Systems Group index 27041218 20 8 9 11 16 All 20 8 21 air 5 17 20 AN CMO 2 18 8 20 18 Cable carrier
15. RBOX TORQUE 7 6 Genesis 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 BOLT HOLES DRILL 27 64 X THRU TAP 1 2 13 UNC X THRU 6 HOLES EQ SPACED ON 8 375 Gearbox Faceplate for RV Gearbox Genesis Systems Group 7 Positioner Control The Positioner is a system of components that work together to rotate an axis between a load area and robot area The axis has two sides A and B The components include two pneumatic cylinders an air package proximity sensors or limit switches shock absorbers and a brake Refer to the Plug and Play Manual for control setup programming and operation Pneumatics Control The pneumatic valve assembly is mounted inside the cylinder enclosure at the headstock end of the workcell Refer to electrical schematics for wiring Brake Pressure Air Lines to Cylinders Cylinder 1 Valve ssem eti Cylinder 2 Valve Air Pressure Sensor Cylinder Pressure Regulator Brake Air Filter e Unrestricted 1 2 minimum inside diameter supply line e Filtered moisture free compressed air at 80 psi minimum e 130 rating 2 index
16. 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 the shielding 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 17 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 Axis Bearings amp Locking Collars Pillow Block Bearings 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 lub
17. djustments 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 Pressure 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 If 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 11 12 System Specifications e a SteckAbsonersanng _ a a o o wwe PP wwo sele fa aoa e wen mse mem esle eT oov Genesis
18. 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 Air Supply The air supply must conform to the following specifications e Unrestricted 1 2 minimum inside diameter supply line e Filtered moisture free compressed air at 80 psi minimum e 130 cfm rating 2 indexes per minute 2 Genesis Systems Group Tooling Installation Balancing Tool For proper tooling installation the tool must be balanced within specifications This involves 1 Finding total weight of tool plus parts 2 Locating center of gravity 3 Calculating imbalance torque 4 Possibly altering assembly or using counterweights 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 Set the assembly down lift it again but this time use the two points marked Again mark a line straight down from the lifting p
19. e is required The unit does not have a battery If problems occur with axis rotation encoder fault then connections may be loose Ground Lug Nuts Check that each ground lug nut connection is tight Tighten size 1 2 13 to 80 108 Tighten size 3 8 16 to 32 ft Ibs Check that each cable is firmly terminated Examine 4 0 ground cable insulation for abrasion and cracking 3 Repair or replace as required If unable to replace use electrical tape to cover bare cables until they can be replaced Genesis Systems Group 25 Every 20 000 Hours of Operation Gearboxes A 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 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 plug
20. eck 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 parameter may be too high Genesis 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 15 To prevent system
21. eplace if necessary Make sure all fasteners are tight 22 Genesis Systems Group Annually Proximity Sensors CRZ FW Proximity sensors proxes help ensure accurate positioning of the CRZ FW s major axis Proxes are located near the shock absorbers 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 bracket 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 cracks and burns Replace as needed using care when rerouting cables Hand tighten cable plugs to proxes being careful to not overtighten If necessary wipe proxes with a clean dry cloth IMPORTANT Proper alignment of proximity sensors is essential for operations Use care not to bump or move them NEVER step on or set anything on a sensor or its bracket Genesis Systems Group 23 Limit switches 4M Limit switches monitor positioning of the 4 major axis They are located on either side of the major axis Sweep Check that the limit switches are fastened securely to the mounting brackets Check that each cable connector 15 firmly connected to its switch Make sure the switches are operating properly Shock Absorbers On the 4M a shock absorber is located on each side of the major axis two total
22. es per minute 8 Genesis Systems Group Start up The Positioner s components must be checked tested and possibly adjusted before operations are started Perform the following steps 1 Check Shocks Air Wiring Sweep Rotation 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 WARNING Step 4 could result in unexpected motion of the sweep Do step 4 only if both tools A and B are mounted or both tools A and B are removed Gradual motion is expected but if dramatic movement results the tooling should be checked for balance Failure to keep the area clear of people and objects could result in serious injury or even death 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 Genesis Systems Group 9 2 Test the Sweep After checking the shocks air wiring and sweep clearances perform the 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
23. ity If the center of gravity lies at X Y from the axis of rotation then the assembly must be balanced so that 77 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 Balanced 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 15 less than 600 in lbs further alteration is not needed Make sure W includes the counterbalance weight Also make sure the gearbox has a high enough value Genesis Systems Group Mounting Tool In a standard minor axis tooling installation with a bearing at the 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 4 SERVO MOTOR GEA
24. lty 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 plumbing Check air pressure Sweep strikes 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 Sweep 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 Ch
25. oints 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 Genesis Systems Group 3 3 Calculate Imbalance Torque After finding the total weight of the tool part assembly and locating the center of gravity the Imbalance Torque must be calculated The Imbalance Torque is the product of the weight in Ibs W and distance in inches from the axis of rotation to the center of gravity 4 Equation T W d Imbalanced Torque The calculated value must be less than 600 1 If it is not the tooling and backbone need to be altered so the center of gravity moves closer to the axis of rotation Another solution 15 to balance the setup using counterweights to move the center of gravity Needs Balancing Genesis Systems Group 4 Alter Assembly or Use Counterweights Alter Assembly If the tooling backbone and objects to be welded are adjusted to change the center of gravity recheck the center of gravity using the Crane and Plumb Bob method Then recalculate If 1s 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 grav
26. rication 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 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 Ground Brush 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 Roto Ground clamps may be located at the end of each minor axis The units are lubricated before being shipped Once a week turn the cap one full turn 360 Turning the cap forces lubricant into the unit When the cap 15 fully screwed down can no longer be turned then add lubricant To add lubricant perform the following steps 1 Remove the cap 2 Fill the funnel cap with Tweco Electrical Joint Compound and Lubricant 3 Screw the cap back on turning only until resistance is felt Make sure roto
27. s Center shaft NOTE Horizontal vertical refers to the orientation of the center shaft 26 Genesis Systems Group Gearbox 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 135 F2C 135 2 45 2 45 2 65 2 65 40 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 GH17 GH17 GH24 GH24 GH40 GH40 GH100 GH100 Genesis Systems Group LUBRICANT OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO OPTIMUM LONGTIME PDO MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE REOO MOLYWHITE 00 MOLYWHITE REOO MOLYWHITE REOO APPLICATION HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL HORIZONTAL VERTICAL QUANTITY pints 40 51 53 66 1 24 1 54 41 2 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
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