I-MLA-500: MLA-5000 IOM Instructions

I-MLA-500: MLA-5000 IOM Instructions

Installation, Setup and Operation

INSTRUCTIONS

I-MLA-500B

for

SUNNEN

®

MLA-5000

AUTOMATION PACKAGE - GENERAL

READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING,

INSPECTING, OR INSTALLING THE SUNNEN ® AUTOMATION PACKAGE.

“SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”

SUNNEN ® PRODUCTS COMPANY • 7910 MANCHESTER AVENUE • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100

GENERAL INFORMATION

The Sunnen ® equipment has been designed and engineered for a wide variety of parts within capacity and limitation of equipment. With proper care and maintenance this equipment will give years of service.

READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THIS EQUIPMENT.

IMPORTANT: Read any supplemental instructions BEFORE installing this equipment. These supplemental instructions give you important information to assist you with planning and installation of your Sunnen equipment.

Sunnen Technical Service Department is available to provide telephone assistance for installation, programming, & troubleshooting of your Sunnen equipment. All support is available during normal business hours, 8:00 AM to 4:30 PM Central Time. Emergency breakdown support is available on a 24 hour / 7 day basis.

Review all literature provided with your Sunnen equipment. This literature provides valuable information for proper installation, operation, and maintenance of your equipment. Troubleshooting information can also be found within Instructions. If you cannot find what you need, call for technical support.

Where applicable, programming information for your Sunnen equipment is also included. Most answers can be found in literature packaged with your equipment.

Help us help you. When ordering parts, requesting information, or technical assistance about your equipment, please have following information available:

• Have ALL MANUALS on hand. The Customer Services Representative or Technician will refer to it.

• Have Model Number and Serial Number printed on your equipment Specification Nameplate.

• Where Applicable: Have Drive model and all nameplate data. Motor type, brand, and all nameplate data.

For Troubleshooting, additional information may be required:

• Power distribution information (type - delta, wye, power factor correction; other major switching devices used, voltage fluctuations)

• Installation Wiring (separation of power & control wire; wire type/class used, distance between drive and motor, grounding).

• Use of any optional devices/equipment between Drive & motor (output chokes, etc.).

For fast service on your orders call:

Sunnen Automotive Customer Service toll free at: 1-800-772-2878

Sunnen Industrial Customer Service toll free at: 1-800-325-3670

Customers outside USA, contact your local authorized Sunnen Distributor.

Additional information available at: http://www.sunnen.com or e-mail: [email protected]

NOTE: Sunnen reserves right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold.

Information contained herein is considered to be accurate based on available information at time of printing. Should any discrepancy of information arise,

Sunnen recommends that user verify discrepancy with Sunnen before proceeding.

ESD PREVENTION REVIEW

Let's review basics of a sound static control system and its effective implementation. First, in three step plan:

1.

Always ground yourself when handling sensitive components or assemblies.

2.

Always use a conductive or shielded container during storage or transportation. These materials create a Faraday cage which will isolate contents from static charges.

3.

Open ESD safe containers only at a static safe work station.

At static safe work station, follow these procedures before beginning any work:

A.

Put on your wrist strap or foot grounding devices.

B.

Check all grounding cords to make sure they are properly connected to ground, ensuring effective dissipation of static charges.

C.

Make sure that your work surface is clean and clear of unnecessary materials, particularly common plastics.

D.

Anti-static bubble wrap has been included for use at machine when an ESD safe workstation is not available.

You are now properly grounded and ready to begin work. Following these few simple rules and using a little common sense will go a long way toward helping you and your company in battle against hazards of static electricity. When you are working with ESD sensitive devices, make sure you:

GROUND

ISOLATE

NEUTRALIZE

ii

SUNNEN ® LIMITED PRODUCT WARRANTY

Sunnen ® Products Company and its subsidiaries (SPC) warrant that all new SPC honing machines, gaging equipment, tooling, and related equipment will be free of defects in material and/or workmanship for a period of one year from date of original shipment from SPC.

Upon prompt notification of a defect during one-year period, SPC will repair, replace, or refund purchase price, with respect to parts that prove to be defective

(as defined above). Any equipment or tooling which is found to be defective from improper use will be returned at customer's cost or repaired (if possible) at customer's request. Customer shall be charged current rates for all such repair.

Prior to returning any SPC product, an authorization (RMA#) and shipping instructions must be obtained from Customer Service Department or items sent to SPC will be returned to customer.

Warranty Limitations and Exclusions

This Warranty does not apply to following:

• Normal maintenance items subject to wear and tear: (belts, fuses, filters, etc).

• Damages resulting from but not limited to:

› Shipment to customer (for items delivered to customer or customer's agent F.O.B., Shipping Point)

› Incorrect installation including improper lifting, dropping and/or placement

› Incorrect electric power (beyond +/- 10% of rated voltage) including intermittent or random voltage spikes or drops

› Incorrect air supply volume and/or pressure and/or contaminated air supply

› Electromagnetic or radio frequency interference from surrounding equipment (EMI, RFI)

› Storm, lightning, flood or fire damage

› Failure to perform regular maintenance as outlined in SPC manuals

› Improper machine setup or operation causing a crash to occur

› Misapplication of equipment

› Use of non-SPC machines, tooling, abrasive, fixturing, coolant, repair parts, or filtration

› Incorrect software installation and/or misuse

› Non-authorized customer installed electronics and/or software

› Customer modifications to SPC software

THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES. SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY

OTHER KIND, EXPRESS OR IMPLIED, WHETHER AS TO MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER. SPC IS NOT

RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS. SPC SHALL NOT BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL

DAMAGES INCLUDING BUT NOT LIMITED TO: LOSS OF USE, REVENUE, OR PROFIT. SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER

MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES. REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER, SPC's LIABILITY, IF ANY, FOR ANY AND

ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS, AND BUYER'S SOLE AND EXCLUSIVE REMEDY THEREFORE, SHALL IN ALL EVENTS BE

LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE.

Shipping Damages

Except in case of F.O.B., Buyer's destination shipments, SPC will not be liable for any settlement claims for obvious and/or concealed shipping damages.

The customer bears responsibility to unpack all shipments immediately and inspect for damage. When obvious and/or concealed damage is found, customer must immediately notify carrier's agent to make an inspection and file a claim. The customer should retain shipping container and packing material.

SUNNEN ® SOFTWARE LICENSE AGREEMENT

This document is a Legal Agreement between you, as user and licensee (Licensee), and Sunnen ® Products Company (SPC) with respect to preprogrammed software (Software) provided by SPC for use on SPC Equipment. By using Software, you, as Licensee, agree to become bound by terms of this Agreement.

In consideration of payment of license fee (License Fee) which is part of price evidenced by your receipt (Receipt), SPC grants to you as Licensee a nonexclusive right, without right to sub-license, to use particular copy of SPC Software licensed hereunder only on particular equipment sold with Software. SPC reserves all rights including rights not otherwise expressly granted, and retain title and ownership to Software including all subsequent copies or updates in any media. The Software and all accompanying written materials are covered by copyrights owned by SPC. If supplied on removable media (floppy disk), you, as Licensee, may copy Software only for back up purposes; or you may request that SPC copy Software for you for same purposes. All other copying of Software or of accompanying written materials is expressly forbidden and is in violation of Agreement.

The Software and accompanying written materials (including user's manual, if any) are provided in an "as is" condition without warranty of any kind including implied warranties of merchantability and fitness for a particular purpose, even if SPC has been advised of this purpose. SPC specifically does not warrant that it will be liable as a result of operation of Software for any direct, indirect, consequential or accidental damages arising out of use of or inability to use such product even if SPC has been advised of possibility of such use. It is recognized that some states do not allow exclusion or limitation of liability for consequential or accidental damages and to extent this is true, above limitations may not apply.

Any alteration or reverse engineering of software is expressly forbidden and is in violation of this agreement.

SPC reserves right to update software covered by this agreement at any time without prior notice and any such updates are covered by this agreement.

iii

SAFETY INSTRUCTIONS

READ FIRST

Before proceeding with these instructions, read all of the “Installation, Setup &

Operation Instructions for the ML-5000, taking care to note all safety instructions. This manual assumes the reader is already familiar with basic ML-5000 setup, operation, safety procedures.

The control system must allow operator to be in work area during the Single Step mode for setup verification and fine adjustment. ALWAYS make sure hands are clear from the work area before starting the automation with “+” or “-” button.

Automation systems usually include special customized fixtures or other special devices. Because of the many possibilities they cannot be described in these instructions. Instructions for safe use and maintenance of these special devices will be supplied through training and/or special documentation provided by your Sunnen ®

Service Representative.

NEVER open or remove any machine cover or protective guard with power "ON."

Always disconnect power at main enclosure before servicing ML-5000 1 .

WARNING: Do not wear cotton or heavy gloves while operating this equipment! If gloves must be worn, wear only the tear-away type.

Always wear eye protection when operating MLA-5000.

Do not attempt to defeat any safety device of automated system. If a special automation component is added to this system, be sure that safety is not compromised. If necessary, obtain a special enlarged work area safety system from

Sunnen ® Products Co.

Indicates CE version ONLY.

1

DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished. WARNING: The capacitors are still charged and can be quite dangerous.

IMPORTANT NOTE

The temperature requirements of the Sunnen

®

MLA-5000 Power Stroked Honing Machine have been established as 35 degrees C (95 degrees F). Above this temperature, an optional cooler will be available to handle temperatures from 35º to 46º C (95º to 115º F). IT IS NOT recommended that the MLA Machine be operated at temperatures above 46º C (115º F). Sunnen Products Company warrants the MLA Machine for operating environments up to 35ºC (95º F). For operating environments of 35º to 46º C (95º to 115º F) the warranty only applies if the optional cooler is installed on the Machine. No warranty coverage is offered for operating environments above 46º C (115º F).

iv

TABLE OF CONTENTS

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

ESD Prevention Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

Sunnen

®

Limited Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Sunnen

®

Software License Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Important Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

General Information & Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

INSTALLATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

PREPARING FOR OPERATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SETUP & OPERATION

Operating Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ROUTINE MAINTENANCE

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 5 - TROUBLESHOOTING

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operational Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 v

GENERAL INFORMATION & SPECIFICATIONS

Sunnen ® MLA-5000 Automation Package for

Sunnen ® ML-5000 Power Stroked Honing Machines

Stroker Positioning Unit * -

Maximum Travel: 160mm from center of stroke adjustable damper stops.

Features - l

Single Step or Continuous Run modes.

l

Fault Indicator lights with legend card.

l

Adjustable cycle time limits.

l

Custom programming to accommodate a variety of optional actuators and sensors.

*Stroke and pick/place position are contingent on machine configuration, workpiece, and application.

INTRODUCTION

The MLA-5000 Automated Production Honing Machine consists of a Standard Automation Package assembled to a basic ML-5000 Production Machine. This manual provides information pertaining to MLA-5000 Standard

Automation only. Refer to manual for ML-5000 for information regarding the basic setup and operation of the machine itself.

The MLA-5000 consists only of components that are commonly required for majority of automated applications. This includes a stroker positioning unit and an integrated control system.

A complete automated honing system requires some special components such as workpiece holding fixtures and devices to accumulate, orient, and present workpieces to pick and place unit. This special equipment may be supplied by Sunnen Products but because it is not standard, it is not part of MLA-5000 and is not discussed in this manual. Make sure that you get all pertinent installation and maintenance instructions for this special equipment from a Sunnen Service Representative. With purchase of such turn-key systems, training will be provided by a Sunnen Service Representative.

Because each completed automation system is unique, this manual will present setup and operation in a very general manner dealing primarily with features common to all applications.

vi

FIGURE 1-1, MLA-5000

SECTION 1

-

INSTALLATION

GENERAL

The MLA-5000 is shipped with automation package already attached. However, it is possible that some larger special automation components may be shipped separately. These special applications will require a Sunnen Service Representative or special installation instructions for that particular application.

1

FIGURE 2-1, MLA-5000 Controls

2

GENERAL

Consult this section when preparing your machine for operation.

MAJOR COMPONENTS

For location of major components on this unit,

see

Figure 2-1

.

OPERATOR CONTROLS

For function and location of controls on Operator

Control Station.

AUTOMATION PARAMETERS

There are four pictograms in upper right hand corner above numeric display. These represent four adjustable parameters.

Parameter 1, Current Count

This parameter is value is current count of number of parts that have been honed. It can be toggled between 0 and current count. Range:

0 to 99999 parts

1 2 3

Parameter 2, Counter

This parameter sets maximum cycle count.

This function will stop automatic cycle when current count equals this value. At initial power up this value is set at zero which disables function. Range: 0 to 999 parts

Parameter 3, Cycle too Short

This parameter sets minimum allowable cycle time in seconds. An error will occur if actual cycle time is shorter than this value. At initial power up this value is set at zero which disables function. Range: 3 to 999 Seconds

Parameter 4, Cycle too Long

This parameter sets maximum allowable cycle time. An error will occur if actual cycle time is greater than this value. At initial power up this value is set at zero which disables function. Range: 3 to 999 Seconds

Parameter 5, Program Sequence Number

Displays what step automatic sequence machine is in.

Parameter 6, Current Cycle Time

Displays current cycle time in seconds.

Parameter 7, Step Table Number

Displays which step table is currently in use.

SECTION 2

-

PREPARING FOR OPERATION

AUTOMATION MODE SELECTOR

There are three modes of operation for automation package.

1. Setup

In this mode no air pressure is supplied to any of automation components. All of automation LED’s are turned off to illustrate state of automation portion. This is only mode that automation parameters can be adjusted.

To adjust a parameter press + or - until desired parameter is displayed. After correct parameter is displayed press both + & - at same time. This will cause value to start flashing. Press plus or minus to set new value. After new value is displayed press both + & - to enter value. New value is now displayed and is no longer flashing. After five seconds display will go blank again. There is a built in safe guard to protect parameter settings. If you change your mind after starting to adjust a parameter do not press both + & - to enter value.

Instead wait 5 seconds and it will automatically change back to original value. After another 5 seconds value will stop flashing.

Example:

Display 1-125

+ is pressed

Display 2-114

+ - are pressed

Display 2-114 (Original value Flashing)

+ is pressed

Display 2-115 (New value Flashing)

+ - are pressed

Display 2-115 (New Value not flashing)

+ is pressed

Display 3-250

+ - is pressed

Display 3-250 (Original value Flashing)

+ is pressed

Display 3-251 (New value Flashing)

After 5 seconds

Display 3-250 (Original value flashing)

After 5 seconds

Display 3-250 (Original value not flashing)

After 5 seconds

Display Blank

3

2. Single Step

In this mode air pressure is supplied to automation components. All of automation

LED’s are operational including error messages.

Pressing plus button will step forward through sequences. When it is allowed minus button will permit sequence to go back a step. The list of steps describes what happens at each step and when reverse stepping is allowed

(see page 7)

.

To run a part in setup or in automatic mode machine must be at home position. To get to home position press plus button until LED #0 is on. To hone a part once machine is at home press cycle start. In this mode machine will hone one part and stop. The operator will have to single step forward to load next part.

3. Automatic Operation

In this mode air pressure is supplied to automation components. All of automation

LED’s are operational including error messages. Pressing plus or minus button will change which parameter is displayed. The parameters can not be adjusted.

To run a part machine must be at home position.

Press cycle start to hone a part once machine is at home. In this mode machine will continue honing parts until loader is out of parts, maximum cycle count is reached, or an error occurs.

AUTOMATION INDICATOR LIGHTS

A bank of 16 lights communicates messages to operator. Because these messages may be different for special programs, messages are written on a card inserted under clear window in overlay. If a program is changed or modified, this card can be easily replaced with another card.

When Light #0 is on, automation is in “Home /

Ready to Hone” position. This is only position where a honing cycle can be started.

Lights #1 through 15 are fault indicators. During normal running they will be off. If operation halts in

Continuous mode or if pressing “+” will not step automation forward in Single Step mode, then look at these indicators to determine problem.

NOTE:

If continuous operation has halted and none of indicators are lit, then it usually means that safety system was breached causing operation to stop.

SETUP – GENERAL

Each automated application requires unique fixtures and other automation devices. Therefore this section can only give general setup instructions that will apply to most applications.

1. Setup Honing Machine.

Turn mode selector to Setup. Setup ML-5000

Machine as described in section titled “Setup -

Power Stroked Honing” in Installation, Operation, and Maintenance Instructions for ML-5000.

NOTE: Some of remaining steps may require that air pressure is applied to actuators, and that actuators be in certain positions. To do this, turn mode selector to

Single-Step and step forward until actuators are in desired position.

WARNING

Putting machine into Single-Step mode will open air flow to all automation actuators. Before putting machine into Single-Step mode, make sure that loader arm, loader carriage, and all other actuators will not strike anything when they move. Have hands clear from area before selecting

Single-Step mode.

2. Install and Adjust Work holding Fixture.

After installing your automated work holding fixture, adjust and center it so that it is aligned with mandrel. To test alignment manually, place a workpiece in fixture, and with stroker unlatched, push stroker carriage back until workpiece goes on to tool. Watch carefully to see if workpiece loads on to tool smoothly without catching on or deflecting tool.

3. Set load position of Stroker Carriage.

Loosen hand lever on Stroker Stop Block Assembly and slide it to set load position of Stroker Carriage.

To keep cycle time to a minimum, do not have carriage come out any farther than is necessary. If finished workpieces are to be pushed out back of fixture by next workpiece, then make sure there is enough room for finished workpiece to fall. If workpiece is to be ejected out front, then carriage may not have to move out too far if at all.

4. Adjust load position of Loading Arm.

With a workpiece clamped in fixture and Stroker

Carriage in load position, try pushing loader forward to see if loading pin will enter workpiece.

(If using a gripper with top loading, move loading arm to load position and observe its alignment with fixture.) It may be necessary to reposition complete loader assembly to put it in range of workpiece in fixture.

5. Set stroke and position of loader carriage.

NOTE:

Try to keep loader slide stroke as short as possible to keep cycle time to a minimum. (If a gripper is used to top-load into a fixture, then adjust loader slide stops so that stroke is zero, i.e. linear motion is not required.)

4

6. Adjust workpiece track and pick position of loader.

Be careful about adjusting loader here. Only one loader adjustment can be moved for this: top loader arm stop screw. All other loader adjustments have been set for load position and must not be moved.

7. Adjust workpiece presence sensor.

It is necessary to sense presence of workpiece that is next to be picked. Be sure that absence of a workpiece in that location will prevent machine from stepping forward when it is at that position.

8. Set Automation Parameters.

It is recommended that you set a minimum cycle time and a maximum cycle time. Minimum cycle time will detect workpieces that are already oversize before reaching honing operation. A cycle time that exceeds maximum will indicate an improper setup or a stone that is worn out.

NOTE:

Refer to “Automation Parameters” in this section, for description of LED display and how automation parameters are set.

9. Single-Step through a cycle.

Step through an entire cycle to be sure that everything is working properly. To hone this first workpiece, press Cycle Start when “Home / Ready to Hone” indicator light is “ON.”

10. Continuous Operation.

Once everything is working properly, step through sequence until “Home / Ready to Hone” indicator light is on. Turn mode selector to Continuous and press Cycle Start. Machine will now run unattended until a fault is detected.

WORKPIECE

PRESENCE

SENSOR

STROKER STOP

BLOCK ASSEMBLY

LOADER

SLIDE

FIGURE 2-2, Loading Arm

5

LOADING

ARM

NOTES

6

SECTION 3

-

SETUP & OPERATION

OPERATION NOTES

The MLA-5000 will run continuously until there is an interruption. There are two types of interruptions to continuous honing:

1. Cycle Stop Interruptions.

Pressing Cycle Stop will cause an immediate interruption. The spindle and stroker will stop and, if pick and place loader is in motion, it will halt after it completes step it just started.

Several faults will cause cycle stop type interruptions.

For example, if a workpiece presence sensor in a work holding fixture detects a workpiece that has slipped out of fixture. In general, cycle stop type interruptions occur only when a condition is detected that requires immediate halting of honing process to avoid damage to workpiece or tooling.

2. Stop After Step Interruptions.

If mode selector is switched from Continuous to

Single-Step while machine is operating, honing cycle will not stop immediately but will finish honing part and then halt. Likewise, if pick and place loader is in motion it will complete step it just started. Some detected faults will initiate just such an interruption if such a fault poses no danger to tooling or workpiece being honed if step is allowed to finish.

If continuous operation is halted by fault detection, make note of fault indicated. Be aware that any workpiece that may be in fixture at that time may not have been honed to size if interruption was a

Cycle Stop type interruption. To be safe, always check size of that workpiece if you are not sure whether honing process was allowed to finish before operation was halted.

Any time that continuous operation is halted, for whatever reason, it will be necessary to single-step until “Home / Ready to Hone” indicator is lit. Then and only then can continuous mode be selected and then initiated by Cycle Start.

NOTE:

When continuous operation is halted, control system remembers step where it was halted. Then, if

Single-Step mode is selected and “+” button pressed, next step in program sequence will be executed.

There is one exception to this. If E-Stop button is pressed, then when power is turned on again program sequence will go to “Home / Ready to Hone” position. If machine is in Single-Step or Continuous mode then automation actuators will also move to that “Home” position. By this means, pressing

E-Stop will accomplish a “program reset” function.

WARNING

The automation components are in an energized state when machine is in Single-Step or

Continuous mode with power ON. Any time that automation is switched off (by selecting Setup mode or turning power OFF), caution must be exercised before returning automation to an energized state. If program was reset (by E-Stop) or if an actuator was moved manually when it was de-energized then automation components may move when automation is energized again.

Although this movement follows program logic by moving actuators to position that correspond to step it should be in (as described above), this movement may appear unexpected to operator.

The soft-start valve will keep this motion slow, but that cannot fully eliminate risk of tooling damage or personal injury.

For personal safety ALWAYS keep clear of work area when turning power ON or switching from

Setup mode to another mode.

To prevent tooling damage: If you are not absolutely certain what step automation will be in when you switch it to an energized state, then do following:

• Press E-Stop

• Manually move actuators to “Home” position or some other position that you are sure will not result in an undesirable motion when power is returned.

WARNING

DO NOT WEAR COTTON OR HEAVY GLOVES

WHILE OPERATING THIS EQUIPMENT! IF

GLOVES MUST BE WORN, WEAR ONLY THE

TEAR-AWAY TYPE.

7

NOTES

8

SECTION 4

-

ROUTINE MAINTENANCE

GENERAL

Most of standard automation components included in

MLA-5000 require little or no maintenance. All moving parts are either lubricated for life or need no lubrication.

INSPECTION

With high cycle rate that can be expected with this machine, wear will eventually cause some components to fail. The following inspection procedures are recommended:

Daily:

• Closely observe operation of automation components, preferably by single-stepping through at least one complete cycle. Does any thing hesitate, bind, catch, or load roughly? By vibration or wear, some of actuator stops may require adjustment for smoother loading and unloading. Do actuators move quickly but without undesirable impact on stopping?

It may be necessary to adjust flow control valve for smoother operation.

Weekly:

• Inspect all moving parts for signs of wear. Note especially bundles of cables and air lines. Are they wearing or flexing excessively? If necessary move them and/or secure them to minimize wear and flexing.

9

NOTES

10

SECTION 5

-

TROUBLESHOOTING

GENERAL

This section contains Troubleshooting information which should be used when problems occur with machine. Included is a list of problems and solutions.

OPERATIONAL TROUBLESHOOTING

Because many applications include special automation devices, following list cannot be considered complete or accurate for all circumstances.

PROBLEM: Cycle too short.

SOLUTIONS:

• Workpiece was oversize before honing.

• Minimum Cycle Time parameter is set too high for given application.

PROBLEM: Cycle too long.

SOLUTIONS:

• Stone is worn out. Replace Stone

• Stone is glazed. Increase Feed Force or Spindle

Speed, Stroker Speed, or Cycle Time Control.

(See

ML-5000 Instructions for details.)

• Maximum Cycle Time parameter is set too low.

• There may be an unusually large amount of material to be removed from that particular workpiece. Place it back in queue to be honed again.

PROBLEM: No workpiece to load.

SOLUTIONS:

• The workpiece magazine / accumulator is out of workpieces.

• Check for workpiece jams that may be preventing workpiece from moving to pick position.

PROBLEM: Loader slide not in / Part too small.

SOLUTIONS:

• Is anything in work area obstructing slide motion?

If so, turn mode selector to Setup to remove air pressure from all actuators and then remove obstruction.

• Check that workpiece in load position will fit on to loading pin. If too small, then workpiece cannot be loaded.

NOTE:

The loading pin should be sized so that it cannot accept a workpiece with a bore size smaller than minimum for mandrel being used.

• Is pick position on workpiece track out of alignment with loading pin? Adjust as necessary.

PROBLEM: Loader Arm not down.

SOLUTIONS:

• Is anything in work area obstructing loading arm motion? If so, turn mode selector to Setup to remove air pressure from all actuators and then remove obstruction.

PROBLEM: Loader Slide not out / Gripper not open.

SOLUTIONS:

• If a front loader slide proximity switch is used

(optional), then check for obstructions that would prevent loader slide from moving forward.

• If a gripper with a sensor is used, determine why gripper did not fully open.

PROBLEM: Stroker does not reach load position.

SOLUTIONS:

• Is anything in work area obstructing stroker motion? If so, turn mode selector to Setup to remove air pressure from all actuators and then remove obstruction.

PROBLEM: Workpiece not Clamped.

SOLUTION:

• Sensor on fixture (optional) has determined that torque fixture has not clamped workpiece.

PROBLEM: Fingers not Actuating.

SOLUTION:

• Check stroking fingers (optional) for free operation.

PROBLEM: Loader Arm not up.

SOLUTIONS:

• Is anything in work area obstructing loading arm motion? If so, turn mode selector to Setup to remove air pressure from all actuators and then remove obstruction.

PROBLEM: Stroker not in stroke position.

SOLUTIONS:

• Is anything in work area obstructing stroker motion? If so, turn mode selector to Setup to remove air pressure from all actuators and then remove obstruction.

• Check alignment of fixture to tool.

Continued on next page

11

• If you cannot push Stroker Carriage back, and it appears that it is almost in stroke position, then stroker may be stopped at back of honing stroke and

Stroker Positioning Unit cannot return Carriage to that position. Try following:

1. Turn mode selector to Setup.

2. Turn Stroker selector to Unlatch.

3. Push Stroker Carriage back until it stops.

4. Turn Stroker selector to Auto.

5. Press and hold in Stroker Jog button to move

Stroker to front of its honing stroke.

6. Turn mode selector to Single-Step and step through sequence until “Home / Ready to Hone” indicator light is on.

7. Turn mode selector to Continuous and press

Cycle Start to resume continuous operation.

PROBLEM: Part Not in Fixture.

SOLUTION:

• The workpiece Presence in Fixture Sensor

(optional) has failed to detect workpiece properly seated in fixture. Check action of fixture during loading and honing. If workpiece comes out of fixture during honing cycle it may be necessary to reduce feed pressure used during honing operation.

PROBLEM: Cross Pin Not in Hole.

SOLUTION:

• The Cross Pin Sensor (optional, for cross pin type fixtures) has detected that pin did not engage cross hole in workpiece to resist honing torque. Try to reload workpiece and start again. If this is a frequent problem, check fixture and pin for problems.

PROBLEM: Maximum Cycle Count Reached.

SOLUTION:

• Continuous operation has halted after completing number of workpieces set by Automation Parameter

“Maximum Count”. If you do not wish to use this feature, set maximum count to zero.

(See

Automation Parameters.)

PROBLEM: Continuous operation has stopped but no indicator lights are lit.

SOLUTION:

• The safety system may have detected something entering work area and as a result stopped cycle.

Try to resume continuous operation after singlestepping to “Home”. Note that any workpiece in fixture may not have been honed to size before operation was halted.

Like any machinery, this equipment may be dangerous if used improperly. Be sure to read and follow the instructions for the operation of the equipment.

12

APPENDIX A

DECLARATION OF CONFORMITY (CE)

SAM

PLE

CE D

OCU

MEN

T

13

FRACTION / DECIMAL / MILLIMETER EQUIVALENTS CHART

FRACTION

INCH

DECIMAL

. . . .

.003937

MILLIMETER

0,1000

FRACTION

INCH

DECIMAL

9/32 .281250

MILLIMETER

7,1438

FRACTION

INCH

DECIMAL

21/32 .656250

MILLIMETER

.062500

.078125

.078740

.093750

.109375

.118110

.125000

.140625

.156250

.157480

.171875

.187500

.196850

.203125

.218750

.234375

.236220

.007874

.011811

.015625

.015748

.019685

.023622

.027559

.031250

.031496

.035433

.039370

.046875

. . . .

1/8

9/64

5/32

. . . .

1/16

5/64

. . . .

3/32

7/64

11/64

3/16

. . . .

13/64

7/32

15/64

. . . .

. . . .

. . . .

1/32

. . . .

. . . .

. . . .

3/64

. . . .

. . . .

1/64

. . . .

. . . .

51/64

13/16

. . . .

53/64

27/32

55/64

. . . .

7/8

57/64

. . . .

29/32

59/64

15/16

. . . .

61/64

31/32

. . . .

. . . .

43/64

11/16

45/64

. . . .

23/32

47/64

. . . .

3/4

49/64

25/32

. . . .

11,0000

11,1125

11,5094

11,9063

12,0000

12,3031

12,7000

13,0000

13,0969

13,4938

13,8906

14,0000

14,2875

14,6844

15,0000

15,0813

15,4781

7,5406

7,9375

8,0000

8,3344

8,7313

9,0000

9,1281

9,5250

9,9219

10,0000

10,3188

10,7156

.433071

.437500

.453125

.468750

.472441

.484375

.500000

.511811

.515625

.531250

.546875

.551181

.562500

.578125

.590551

.593750

.609375

.296875

.312500

.314961

.328125

.343750

.354331

.359375

.375000

.390625

.393701

.406250

.421875

. . . .

7/16

29/64

15/32

. . . .

31/64

1/2

. . . .

33/64

17/32

35/64

. . . .

9/16

37/64

. . . .

19/32

39/64

19/64

5/16

. . . .

21/64

11/32

. . . .

23/64

3/8

25/64

. . . .

13/32

27/64

1,5875

1,9844

2,0000

2,3813

2,7781

3,0000

3,1750

3,5719

3,9688

4,0000

4,3656

4,7625

5,0000

5,1594

5,5563

5,9531

6,0000

0,2000

0,3000

0,3969

0,4000

0,5000

0,6000

0,7000

0,7938

0,8000

0,9000

1,0000

1,1906

1/4

17/64

. . . .

FORMULAS:

MULTIPLY

INCHES (in)

FEET (ft)

.250000

.265625

.275591

x x

BY

25.4

0.3048

6,3500

6,7469

7,0000

=

=

5/8

. . . .

41/64

.625000

.629921

.640625

TO GET

MILLIMETERS (mm)

METERS (m)

15,8750

16,0000

16,2719

MULTIPLY

MILLIMETERS (mm)

METERS (m)

63/64

1

1-1/16

.984375

1.000000

1.062500

BY x 0.03937

x 3.281

25,0031

25,4000

26,9880

TO GET

= INCHES (in)

= FEET (ft)

“SUNNEN ® AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”

Sunnen ® reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify discrepancy with Sunnen before proceeding.

PRINTED IN U.S.A. 1202

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U.S.A. Toll-Free Sales and Service:

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©COPYRIGHT SUNNEN ® PRODUCTS COMPANY 2012, ALL RIGHTS RESERVED

.796875

.812500

.826772

.828125

.843750

.859375

.866142

.875000

.890625

.905512

.906250

.921875

.937500

.944882

.953125

.968750

.984252

.669291

.671875

.687500

.703125

.708661

.718750

.734375

.748031

.750000

.765625

.781250

.787402

20,2406

20,6375

21,0000

21,0344

21,4313

21,8281

22,0000

22,2250

22,6219

23,0000

23,0188

23,4156

23,8125

24,0000

24,2094

24,6063

25,0000

16,6688

17,0000

17,0656

17,4625

17,8594

18,0000

18,2563

18,6531

19,0000

19,0500

19,4469

19,8438

20,0000

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