Orbit Station - Novo Precision
Contents
1. F15 Eject spring in diatest F16 Resets alarms if present Saldovagen 9B Tel 46 0 8 795 27 30 10 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 Tekno Detaljer AB colom D 7 LOAD CALIBRATION Choose the menu LOAD CALIBRATION When calibrating the load cell the revolver shall be removed from ORBIT Removing the ORBIT revolver Unscrew the revolver s center screw lift up the lock washer that is under the center screw and pull the revolver out from the side 7 1 Check of Load Cell Installation Check that the load cell is correctly installed and that it does not touch the hole in which it is mounted Check using shims of about 0 1 mm that there is space between the detector and the hole in the plate Check that no debris or other foreign matter has fallen into the space between the load cell and the hole If necessary remove the detector and clean the hole Figure 1 Amplifier n PLi A 0 2 T at a ing a a aia a A Hea i SE FEN zE Ampifier board Load cell j LH E 4 chi in teal i avvivs Saldovagen 9B Tel 46 0 8 795 27 30 11 off 21 S 175 62 J rf lla Sweden Fax 46 0 8 761 08 03 35107201 HE colomb 7 2 LOAD CALIBRATION LOAD CALIBRATION LOAD CELL SIGNAL F4 ENTER LOW WEIGHT 0 N HHH LH o 50 F5 STORE LOW WEIGHT Sti F6 ENTER HIGH WEIGHT HH AHHH MN LOAD RESULOTION HHRHH N F7 STORE HIGH WEIGHT CURRENT LOAD FE N Fz F32. MM DD z f MM DD 2 f MM DD 2 SINE DIES f MM DD 2 f MM DD 2 TH ri EES TT o i Fal FR a Fal EIS TT io ag rT S ae rou a p 2 YY MM DD 2 TT E TT A Fal Er EIS TT fe Fal a ed rr YY MM DD 2H MM 353 Spring ja amtmed in YY MM DD 2 Spring jammed in t YY MM DD 2 Spring jammed in Y MM DD z spring Jarned in YY MM DD 2 Spring jammed in YY MM DD 2 Diameter too hig I Y MM DD 2 Diameter too small YY MM DD 2 Allowed reject 138 VY MM DD 2 Battery low in PLC Y HH DD 2 No spring into diatest Ti Hi DE Zz Wire is caught YY MM DD 2 Ipp2 not in position 1 YY MM DD 2 Ippe not in position z Tot ala INRE Guard is open Y MM DD 2 Feel guard door is open YY MM DD 2 Feject of the last 1007 Ola ss PF missing on last tube T MM DD 2 T MM DD 2 r MM DD 2 Y MM DD 2 T MM DD 2 F MM DD 2 Y MM DD 2 This message is displayed when five Check that the spring length is consecutive springs do not reach the lower correct of the two micrometers Check the electrode distance Check that the electrodes are clean Check the electrical system 9 1 2 Spring is too long This message is displayed when five Check that the spring length is consecutive springs reach the upper of the correct two micrometers Check the electrode distance Check that the electrodes are clean Check the electrical system Saldovagen 9B Tel 46 0 8 795 27 30 19 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 0
3. as for adjustment of length control and calibration of load cells Saldov gen 9B Tel 46 0 8 795 27 30 3 off 21 S 175 62 J rf lla Sweden Fax 46 0 8 761 08 03 35107201 Tekno Detaljer AB t 2 ORBIT ORBIT is an option for spring coiling machines or spring separators colomb ORBIT is a platform that can be complemented with options such as heat treatment length controlling load test and rejection of faulty springs and the distribution of springs to one or more delivery points 2 1 ORBIT consists of 1 Basic unit Double ORBIT featuring a round feed table with a revolver which has one input and two outputs for springs 2 Option UP and DOWN action head 2 1 1 Options for position 1 basic unit a Cool down blasting after heat treatment b Extra inputs c Extra outputs 2 1 2 Options for position 2 action head a Heat treatment station b Length controlling station faulty springs rejected c Length testing station with feedback d Load testing station faulty springs rejected Saldovagen 9B Tel 46 0 8 795 27 30 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 4 off 21 35107201 colomb Tekno Detaljer AB t 3 UNPACKING and INSTALLATION Connect air pressure min 5 5 bar max 7 bar Connect electrical power feed to system 3 1 Interface for Spring Coiling Machine ORBIT is started with an external signal from the line ORBIT signals the coiling machine to produce one spring and deliv
4. 8 03 35107201 Tekno Detaljer AB t Cc ol om b 9 1 3 The ORBIT revolver does not stop at the correct position The ORBIT revolver does not stop at its Check the sensor distance at the sensor positions for the revolver s position indication 9 1 4 Spring coiling machine is not ready This message indicates that no springs The sensor does not detect the springs have passed through the ring sensor within The sensitivity of the sensor can be three seconds of sending the start signal adjusted with a small screwdriver No springs are delivered Check the ing coiler and spring feed tube Saldovagen 9B Tel 46 0 8 795 27 30 20 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 aT a Tekno Detaljer AB H colomb 10 MAINTENANCE 10 1 The pneumatic system The system requires no lubrication 10 2 Electro mechanical system Check and clean the electrodes every 400 hours Check that the electrodes and air cylinders are securely mounted every 400 hours Saldov gen 9B Tel 46 0 8 795 27 30 21 off 21 S 175 62 J rf lla Sweden Fax 46 0 8 761 08 03 35107201
5. F4 F5 F FF F ENTER STORE ENTER STORE SELECT LOW WEL LOW WEL HI WEL HI WEIL MEMU LOAD CALIBRATION To calibrate the load cell two known weights are required The heaviest should be 30 more than the spring load to be tested The lighter weight should weigh half as much as the heavier weight During calibration the load tester is adjusted for no load and two known loads If you choose a heavier load of about 250 grams the lighter load should be half as much meaning 100 150 grams 1 2 1 Calibration of Load Cell Calibration begins with the load cell unloaded Check that the signal from the load cell has the correct amplification at zero load The signal shall be about 10 and can be read on the scale in the menu window Any necessary adjustments to 10 are made with the potentiometer P2 Sensitivity is adjusted with the potentiometer P1 on the amplifier panel see Figure 1 Press F4 and enter the value 0 grams Store the zero load by pressing F5 Saldovagen 9B Tel 46 0 8 795 27 30 12 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 colomb Tekno Detaljer AB t Place the heavier load 250 grams on the load cell Press F6 and enter the known value of the heavier load Store the heavier load by pressing F7 When calibrating with the maximum load you should try to attain as large a load signal as possible although not over 80 at maximum load plus the tolerance To make a rough adjustment of t
6. Tekno Detaljer AB C O mM I gt e User Manual COLOMBI ORBIT Saldov gen 9B Tel 46 0 8 795 27 30 1 off 21 S 175 62 J rf lla Sweden Fax 46 0 8 761 08 03 35107201 CIN DE SCIPION e EE dass E E E 3 1 1 System Opera l T ss 15 sstnsssssssoissotdunsssortsnsdssttsvatesssbsidsed E EEE N SE Eai 3 2 ORDI aie cesses ces pars sateen a det nen iedsn oden E EE E E N E E I EENES 4 ME R BIT COn E ON ee NN is 4 2 1 1 Options for position 1 basic UlNIt ssssssssssssssrrrrerrssreerrrrrrrrrrrerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr rss 4 2 1 2 Options for position 2 action head m sssmsssssserresrsssseerrrrrrrrerrerrrrrrrrrsrrrrrrrrrrrrrrrrrrrrr rss 4 3 UNPACKING and INSTALLATION arssssosss ot osnsasaseennssstesnssssnsenssnstneneninesnsnsenersessdkerensnekers 5 3 1 Interface for Spring Coiling Machine ssmmmssssssssssrrrrrrrrrrrrrrerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr rr rna 5 AFE EI ee E E E sion asta aaa l ne st rst brrne dt 6 4 1 Emergency Stops and Safety ProteCtiOn sssssssrssorrorssrrerrrrrorrrrrerrrrrrrrrrr nn 6 ALL E o O e e E E E 6 4 1 2 Resetting After an Emergency Stop sessssssseseerssssssssseerrsssssssecerrssssssseeerrsssssssees 6 gt STARTING THES YSIEM cerrarse E E ES 7 5 1 Power up and prepare for prOodUCtiOnD sssssressersersrrrrrrrrrrrrrrrerrrrrrrrrrrrrrrrrrrrr rr nnn 7 O ADIUSIMENID ee E k rs tlns renen 8 6 1 Adjustments by Trained PerSsOnnel ssssssssssrrersrrrrrrrrrrrrrrrrrrrre
7. ad and length control and for setting the compression to OFF or ON This mode permits manual operation of up and down movements by the ORBIT head and indexing of the revolver ORBIT TEST LOAD INFO CURRENT VALUE BA HARAR N F3 HEATER SET VALUE LENGTH CONTROL OM HARE A Fl Be a F TEST DISC SELECT SPRING INDEX MENU Fiz Fiz Fi4 ETS Fi6 LENGTH OPR STOP ZERO DIATEST CONT OFF OUT LOAD EJECT Accessing this menu puts machine in cycle off mode Key must be in SERV position to enable use of some functions NOTE After having returned to the menu MAIN MENU from ORBIT TEST and pressing the button FI CYCLE ON ORBIT resets itself by emptying all of the revolver test sockets of springs through the outlet for faulty springs The revolver is then filled until two approved springs are in the delivery position 6 2 2 Heater info HEATER F3 Sets current for the heater Saldovagen 9B Tel 46 0 8 795 27 30 9 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 amp E colomb Tekno Detaljer AB t 6 2 3 Load info LOAD CURRENT VALUE Actual load on load 6 2 4 Status indicators 6 2 5 Function buttons in Orbit test menu F1 Makes one test spring F2 Moves Orbit nest one position F3 Sets current for the heater F8 Select menu F9 F10 Slides Orbit head up down F11 Heats spring in nest if Orbit head is down F13 Opens diatest for spring eject F14 Resets load value
8. ekno Detaljer AB 1 4 2 Function buttons in Load setup menu F8 Select menu F9 Load 1 nominal weight F10 Load I tolerance F11 Load 1 tolerance F12 Tare or zero load Saldovagen 9B Tel 46 0 8 795 27 30 16 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 colomb Tekno Detaljer AB t 8 LENGTH CONTROL 8 1 Automatic offset information ACTUAL SPRING Spring configuration selected in SPRING CONFIG menu PITCH ADJUSTED Offset position of pitch tool when coiling spring in adjusted by feedback from length control Saldov gen 9B Tel 46 0 8 795 27 30 17 off 21 S 175 62 J rf lla Sweden Fax 46 0 8 761 08 03 35107201 Tekno Detaljer AB i colom I gt 8 2 CALIBRATION Length Control and LOAD Test Figure 8 ORBIT with step gauge Remove the revolver see Chapter 7 Choose the menu ORBIT TEST Run the ORBIT slide down button F10 Using block gauges or a step gauge if supplied adjust the positions of the micrometer screws Saldovagen 9B Tel 46 0 8 795 27 30 18 off 21 S 175 62 J rf lla Sweden Fax 46 0 8 761 08 03 35107201 i colomb 9 TROUBLESHOOTING 9 1 Error Messages If problems arise the system stops the machine and an error message is shown on the control panel screen After the problem has been corrected the error message is acknowledged by pressing the F16 button Possible cause is displayed when alarm occurs ALARM LIST YY HAN ED 2 Y MM DD MH DD 2
9. er it to the ORBIT The coiling machine is then set to the ready mode and awaits new signals from ORBIT the line Saldovagen 9B Tel 46 0 8 795 27 30 5 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 Tekno Detaljer AB t colomb 4 SAFETY To fulfill the safety requirements of the European directive 89 392 EEC and OSHA these machines are equipped with protective safety hoods and emergency stop buttons 4 1 Emergency Stops and Safety Protection 4 1 1 Emergency Stop If the emergency stop button is pressed or 1f the covering safety hoods are opened the air pressure is expelled and the servomotors stop 4 1 2 Resetting After an Emergency Stop The emergency stop button is reset by pulling it straight out To reset the machine press the RESET button Correct the problem in accordance with any error messages and then acknowledge the error messages Close the protective hoods and restart the machine It is possible to run the machine without the protective hoods 1f the key is turned to the SERVICE position The machine will then be able to be run in the manual mode only external signals are blocked A machine that is delivered without safety equipment many not be put into service until it has been built in to system that fulfils the applicable regulations Saldovagen 9B Tel 46 0 8 795 27 30 6 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 HE colomb 5 STARTING THE SYSTEM 5 1 Powe
10. est 0 0 cents 18 2 TROUBLESHOOTING aer A E rere rT ey erer etree eres 19 OU Error INECSSA CCS r sterna eeese set asses ese T A T eee 19 Mel RSMO AS LOOS MOU a a E E TE tides na aneshiese ese one 19 DEZ SPIRE 1S 10 NOT aeaa R venga autennench ees aac EEE ceauatonetontgeecond 19 9 1 3 The ORBIT revolver does not stop at the correct position ssssssessssssssrrroa 20 9 1 4 Spring coiling machine is not ready snsmsesssssrrrrrrrrrssrererrrrrrrrsrrrrrrrrrrrsrrrrrrrrrr rr rr rr rr na 20 1O MAINTENANCE ne neo einn dua RE E E E E E EE 21 10 1 The pneumatic system nmosmmmmssssssssrrrererrssreererrreersrrrerrrrrrrrrrrrrrrrrrrrrrrrrrrr rss rss rr rr rr nns r rr ren 21 10 2 Electro mechanical SYSt D ssssssserererrrrerrrrrrrerrsrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr rss rr rer rr sr rr rr rn ren 21 Saldov gen 9B Tel 46 0 8 795 27 30 2 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 colomb Tekno Detaljer AB t 1 MACHINE DESCRIPTION This manual describes the COLOMBI ORBIT with length test feedback heater and load testing The PLC controller is an Allen Bradley SLC500 with a 1000 color panel display as an operator interface 1 1 System Operator The ORBIT test system is easy to use and requires no special user training to make minor adjustments such as modifying ejection times or changing probes For making basic adjustments some commands are available directly from the control panel display such
11. he signal use the switches see Figure 1 on the amplifier panel The lower the number of the switch the higher load signal attained for a given load NOTE If a switch position is changed zero load calibration must be repeated See Section 7 2 Check the function by removing the load the scale should show 0 or very close to 0 Place the weight on the load cell again The indicated value should be close to the actual load value Remove the heavier load place the lighter load 100 150 grams on the load cell and check that the display shows the correct value If an incorrect value is shown check that the load cell is not touching the plate on which the load cell is mounted Calibration of load cell is now complete The load cell values are shown in the info box diagram both as percentages of the maximum value and in grams F1 resets load cell Saldov gen 9B Tel 46 0 8 795 27 30 13 off 21 S 175 62 J rf lla Sweden Fax 46 0 8 761 08 03 35107201 D a a a j E ba 2 Load cell calibration into Calibration means the load tester shall be presented to 2 known loads normally the lower is O and the Higher if perhaps 950 grams The load tester will then calculate the ratio between deflection on the load cell and the load Calibration of the load cell 1s made by 1 Remove the disc from the Orbit 2 Check that the load cell is correctly mounted and that the plate does not touch the bore in which it is mounted If needed ta
12. ke the plate out and clean the bore 3 Check that you have got a calibrated weight with a known load 4 Calibration starts with empty load cell Press F4 and enter the value oa 5 atore the low load by pressing FS 6 Place the higher load on the load cell 7 Fress FA and enter the value of the High load o Store the high load by pressing F7 9 Calibration is now ready Check the function by removing the load the scale shall display O or very close to Place the weight on the load cell again the displayed value shall be the real load FS SELECT If this calibration does not result in a good function MENU the amplifier must be adjusted To do this check the Orbit manual Fi Saldovagen 9B Tel 46 0 8 795 27 30 14 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 7 4 LOAD SETUP LOAD SETUP LOAD INFO CURRENT LOAD HH HHHK N FO NOMINAL WEIGHT HR RRHH N NOMINAL WEIGHT 7 4 1 Load info CURRENT LOAD Actual load on load cell F9 NOMINAL WEIGHT Desired spring force for spring F10 TOLERANCE Maximum force tolerance for spring force outside this value rejects measured spring F11 TOLERANCE Minimum force tolerance for spring force outside this value rejects measured spring F12 ZERO LOAD Tares load cell if pressed with a spring in position over load cell Saldovagen 9B Tel 46 0 8 795 27 30 15 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 colomb T
13. r up and prepare for production Refer to section 1 1 in system manual for startup procedure Tekno Detaljer AB ot i MAIN MENU PITCH ADJUSTED HH HHH DIAMETER ADJUSTED HH HHH DIAMETER ACTUAL HHRHRH DIAMETER LAST HHRHH ACTUAL SPRING NE HEF CURRENT LOAD HR HHHH N LAST LOAD HR HHHH N AUTO OM Saldov gen 9B Tel 46 0 8 795 27 30 S 175 62 J rf lla Sweden Fax 46 0 8 761 08 03 AUTO MODE KEY IN Pos 1 MACHINE NOT READY ORBIT DISABLED F F PARE SELECT LOILILER MEMU Fie 7 off 21 35107201 F colomb 6 ADJUSTMENTS 6 1 Adjustments by Trained Personnel Because the adjustments below require a certain amount of skill and experience we recommend that they be performed by personnel who know the machine 6 1 1 Password To gain access to the menu ORBIT TEST the correct password must be entered After entering the 4 digit password press ENTER to open the ORBIT TEST menu ENTER PASSWORD C om F RETURN TO PREVIOUS MBNU The menu for entering the four digit password Adjustments on ORBIT are made when the system is not in production Turn the key to the SERVICE position 6 2 ORBIT Related menus LOAD CALIBRATION CALIBRATION TEST describes procedures for calibration LOAD SETUP DIAMETER TEST Saldovagen 9B Tel 46 0 8 795 27 30 8 off 21 S 175 62 Jarfalla Sweden Fax 46 0 8 761 08 03 35107201 HE colomb 6 2 1 ORBIT TEST The ORBIT TEST menu is used to adjust the lo
14. rrrrrrrrrrrrrrrrrrrrr rr rr rr rr rr rr ra 8 Oiled PASS VOU E ete va ssa E E E sessectasue gutta E tise Ne 8 6 2 ORBIT Related menus sissoooororereeeeererrrrererersrressssrererrrrrrrrrrrrrrrrrsss rss rrrrrrrrrrrrrrr rss rss rr rr rr 8 L ORBIT TE Toere a E E A ere dr 9 OZ e O E A E E tand E E E sauces 9 2o Lond TNO ereverdn bstn vener snarkade EE EEE 10 OZ Saus INCHICALOTS sisese NEN NS NON NON ENA SNS NANSEN ANOR SNR 10 6 2 5 Function buttons in Orbit test MCNU ssseesserssssrsrrrrrrrrssrrrrrrrrrrrsrrrrrrrrrrrrrrnrrr rna 10 TOR DICK TATE RNE Ol Paeeennenremerresnnnn wernrrer rere merrier mein rental entre E 11 7 1 Check of Load Cell Installation sssssssssssssssseeeeerrrrrrrrrrrrrrrsssrrrrrrrrrrrrrrrrrrrr rss rr r rr rr 11 Ta LOAD CALIBRA TON d sssvovskosirsvsseisrsunsssotsusigesvsnssnsnvsnnosderssn sn dsssen ber r sNet ENEN 12 dhel Ca on OT PO AGC en S 12 7 3 LOAD CELL CALIBRATION INFORMATION 5 sbosorrrsssssssssseseeessssssssssssssssssrrrrr 14 Ta COSDSETUP ee A erry errr Terr 15 Pa EOE a besten tera bes den Ulereek sketen ende best rt Utred 15 7 4 2 Function buttons in Load setup menu sseeereesssssrrrrrrrrrrrsrrrrrrrrrrrrrrrrrrrrrrrsrrrrrrrrr rss 16 5 th Cal ie A OO ad Deeeereeeerrrone rere rer ie entree reece oe rrr mer er mo nere reer ee reer Tere 17 8 1 Automatic offset infOrma atiOn ssssssssssssssssesesssssrerererrrrrrrrrrrrrrrrsssrrrrrrrrrrrrrrrnrrrr rr rna 17 8 2 CALIBRATION Length Control and LOAD T
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