INSTRUCTION MANUAL R.S.ENTERPRISES BANGALORE

Transcription

1 R S ENTERPRISES #12/90,1 st MAIN ROAD, NEW KALAPPA BLOCK, RAMACHANDRA PURAM, BANGALORE , KARNATAKA, INDIA, - rsentblr@yahoo.co.in Phone: mobile:

2 INSTRUCTION MANUAL R.S.ENTERPRISES BANGALORE 2

3 PREFACE THANK YOU for purchasing fast WINDER. Our machine uses latest technology in coil winding which are aimed for better quality and fast production. The machine uses 8 bit microcontroller to accomplish the given task. With lot of processing power the machine has got actual control over program flow for better performance. These machines are dependable and user friendly. FAST WINDER MACHINE is designed for linear coil winding use and supports different type of coil windings such as regular winding, layer winding, sine speed winding etc, with maximum of 15 tapings. This machine is having 400 program banks. Please read the instruction manual first, for programming, operating and for any clarifications. 3

4 CONTENTS Chapters 1. Safety precautions 2. Overview 3. Password setting 4. Editing a program 5. Executing a program 6. On line operating keys and its use 7. Deleting all programs 8. Technical specifications 4

5 Please read manual carefully before any conclusion. The controller is programmed to make it more user friendly, so during on line if controller finds any parameter (such as speed) to be modified then the controller will make a temporary change automatically in that parameter, without affecting quality of coil being wound. This change is purely temporary will not be saved or updated for next coil. whenever controller needs user intervention it will display on LCD screen. All the necessary setting is done inside, the operator can feed his/her program and can run it. Any suggestions are welcome. 5

6 1. SAFETY PRECAUTIONS This machine uses 230V AC high Voltage power supply there is chance of electric shock if proper care is not taken. So never disassemble, open, and repair the machine. As doing such activity can give electric shock and may cause injury. We recommend three plug pin for input power supply so as to avoid electric shock. Make sure that the earth terminal to the machine is connected properly. For any servicing, repair please consults to us. 2. OVERVIEW The central processing unit (CPU) senses all the inputs and depending upon the events occurred it takes necessary actions on the output. The program validity is checked at their respective locations including parameters value while editing. User need not have to remember these ranges of each parameter. The controller itself will take are all these parameters value only when they go beyond their respective ranges by forcing user to program its default value. 6

7 3. PASSWORD SETTING On resetting the memory the password will become zero however the factory programmed password is zero. If the password is non-zero, unauthorized program modification can be avoided. If you want to change the present password, then follow these steps:- Power on the machine. When the display reads EDIT RUN then choose EDIT option. Press the ENTER key for its selection. PASSWORD? Message will appear. Only feed your current password correctly however avoid pressing enter key now. After all the digits inputted, press & hold down the stop key and then press ENTER KEY. CHANGE PSW: NO_ Message will appear. Using edit keys select YES to change the password else select NO to go directly to edit without changing current password. After choosing the option press ENTER key. If YES is selected machine will ask ENTER NEW PSWD. Feed new password Press ENTER Key. The new password is now effective. 7

8 4. EDITING A PROGRAM In its chapter you will learn how to edit or modify a program. Editing is done by using edit keys. The editing keys are as ENTER, INC, DEC, RIGHT AND LEFT Keys. Whenever power is applied for the first time and if the machine is not resuming from power (backup) failure then it goes directly to run, the last executed parent program by aligning and setting the machine. It will be ready to accept START KEY. In this status you can do manual adjustment of machine just before actual START. Instead of START KEY if you press following keys you will get corresponding functions:- Press ENTER KEY to select EDIT or RUN option. (see further details) Press STOP KEY to clear turns counter (unique stage to reset counter). Press RESET KEY to realign the traverse for the same program. Press INC, DEC, RIGHT and LEFT KEYS for manual adjustment of traverse. Press LAYER KEY to toggle layer option. Press BRAKE KEY to toggle brake option. Press PREV KEY to go previous program for execution. Press JOG KEY to run in jog speed. Do not press DIA KEY now as it will be ignored here. 8

9 4.1 PROGRAMMING THE MACHINE Once you pressed ENTER KEY in above steps you will get two options on LCD screen as shown below:- EDIT RUN Push the cursor below edit option then press ENTER KEY. Feed correct password. password valid, you will get following screen:- If PRG TO EDIT : 001 In this mode change program parameters. To do so you must input the valid password. By default the password will be zero. When you delete all programs then password will be forced to zero. Before any editing, the controller will always ask for a valid password. In this way unauthorized program modification is avoided. Once you entered the correct password then you are allowed to enter the actual editing process. While editing you will use EDIT keys, however you can use START, STOP KEYS also. The START KEY is used to terminate the editing process (in between anywhere) while the STOP KEY is used to go to previous menu. In other words press START KEY to finish editing and press STOP KEY to go back (one menu for each press). 9

10 Now input the required program to be edited and press ENTER KEY. Now you will get following window:- 4.2 MENUS 1. TURNS MENU :01 PROG :001 TURNS : In above window the menu number, program under editing and corresponding winding parameters are displayed. These are the winding turns and considered as a target turns. You can feed any value you want. The turns must be a non-zero values then this will flag INVALLID DATA error. As soon as these specified turns are the motor stops and goes for next winding cycle. Note: - The stored values will be recalled prior to editing so that can see these values and modify if required. To accept a change made, you must press ENTER KEY. When ENTER KEY is pressed controller will jump to next menu. Once all editing is over then only these values will be stored in non-volatile memory. The unchanged value remains as it was. Each program is identified by its unique number. The controller is programmed to check invalid entries whenever the corresponding value exceeds its range. 10

11 2. DECCELERATION TURNS MENU : 02 PROG :001 DEAC TURNS :100 Once balance winding turns matches to deceleration turns then the speed starts decreasing and approaches to default minimum speed. The default minimum speed is also programmable in next subsequent menu. During deceleration some keys are disabled. The deceleration turns should be less than the turns specified in menu BOBBIN WIDTH MENU : 03 PROG : 001 BOB WIDTH : 100.0mm This is the winding width. The wire will be spread across this width. This is physical length where turns to be put. 11

12 4. DECELERATION WIDTH MENU :04 PROG :001 DAC WIDTH : 10.0mm This is the balance bobbin width in a layer when matches to deceleration width the speed starts decreasing and approaches to default minimum speed is also programmable in next subsequent menu. During deceleration some keys are disabled. The minimum deceleration width should be 03.0mm. 5. SINE SPEED MENU : 05 PROG : 001 SINE SPEED: NO This is one of option and can be used for perfect layer winding. If YES is programmed the machine will not stop per layer, however the speed will go on increasing at the beginning of each layer and will go on reducing as it approaches end of layer. Here you must consider the bobbin deceleration width if production rate is important. Sine speed is useful where you want perfect layering at high speed. If you want to put insulation on each layer then select NO in this menu. This option has higher priority than the 12

13 status than status indicated by keyboard LAYER LED. If you want to do winding with full speed without any stop then you must select NO in above menu and disable the LAYER LED on keyboard. To stop the machine per layer, select SINE SPEED as NO and make LAYER LED glowing on keyboard by pressing the same LAYER key. 6. WIRE DIAMETER MENU :06 PROG :001 WIRE DIA : 0.200mm This is winding pitch and alternatively can be termed as wire diameter. This wire diameter is used in spreading the wire across the bobbin width. 7. TRAVERSE START MENU : 07 PROG : 001 TRAV START : 050.0mm This is the point where the actual winding starts and the distance specified is referred from the original home. The original home is that location where the traverse home sensor is fixed. A value in mm programmed in above menu will push the traverse out. This is used to align the wire guide to one of the bobbin flange. The value here can be zero. 13

14 You can manually adjust the traverse position by using UP or DOWN arrow keys, just before pressing START key and this is the unique stage where traverse can be adjusted. 8. MINIMUM SPEED MENU : 08 PROG : 001 MIN SPEED :14% This is default minimum speed. After deceleration the motor tries to reach this minimum speed and stabilizes there, however if the turns are over earlier, the motor may not reach minimum speed. In such situations there is a possibility of exceeding the turns than the set turns. This gives rise a term called stopping accuracy. The counting accuracy and stopping accuracy are totally different terms. Stopping accuracy depends upon the load, current speed, pulley ratio etc. The controller will maintain 0.1 turn accuracy on all speeds. You have to adjust the stopping accuracy by trail and error method. To stop exactly at set turns you must feed correct values in following menus:- MIN SPEED, WIND SPEED, DEAC TURNS, DAC WIDTH etc. 14

15 9. WINDING SPEED MENU : 09 PROG : 001 WIND SPEED : 00% This is the spindle s top speed. The spindle is coupled to the motor with different pulley ratio. The ratio determines the top speed. Speed is programmed in percentage of maximum speed that a motor can attain. Maximum speed can be 99% and it corresponding to 9500RPM. Any speed is totally dependent upon the voltage available at input and load applied. You can change this speed during winding by using UP ARROW and DOWN keys. The changed speed will be saved in memory when you stop the winding. 10. WINDING DIRECTION MENU :10 PROG : 001 WINDING DIR : CCW This is motor direction (direction of winding). Generally CCW direction is will suit you best; however you can specify any direction as per your need. Winding direction cannot be changed during on line. Each program has its own winding direction. 15

16 11. START FROM MENU : 11 PROG : 001 START FROM : LEFT From which bobbin flange you want to start the winding that option you have to specify here. The options are LEFT or RIGHT. Select any option you want. Press ENTER to go next. 12. SELF START MENU : 12 PROG : 001 SELF START : NO When you cascade a number of programs then after finishing current program you have to press START key to run the next cascaded program. Tf\his is time consuming and can be avoided with above option. So make SELF START to YES and all programs will be run as per their sequence given in NEXT PROG menu. If next program is not a valid then it shows corresponding message. So make sure to input a valid program number in next menu. This is useful in SMPS type transformers. Depending upon the option specified in SELF START the controller will decide whether to wait for start or continue immediately. 16

17 13. NEXT PROGRAME MENU :13 PROG : 001 NEXT PROG : 002 In order to run a multiple programs in a correct sequence on the same bobbin then in such condition make use of feeding a valid program number in above field. Each program may have a different set of parameters to be executed. As soon as the current program is over, the controller will check the value specified in NEXT PROG. If next program s value is zero or same as currently executed program the machine simply returns to starting of the current program for a fresh start of next bobbin. If this value is different and has valid parameters then this program will be taken for next execution. 14. TAPPING MENU :14 PROG :001 TAP[01] : In some transformers you may need to put external connections such as taps, here tapping option is provided, a maximum of 15 taps can be provided. Each tap specified must have larger turns 17

18 than its preceding one. Tap turns are always less than set turns. 15. SPINDLE POSITION MENU : 15 PROG : 001 SPINDLE POSI : 1 By default where to rest the idle spindle is specified in this option. The value will indicate its position. There are 10 positions in a turn. To make it effective the spindle option must be enabled. How to enable the spindle is give on a separate chapter. 16. TRAVERSE LOCK MENU : 16 PROG : 001 TRAV LOCK : NO This is one of the useful feature. Once the winding is over, the traverse aligns immediately to the next cycle. Due to this the wire goes on dragging across the bobbin. To avoid this dragging you can lock the traverse as soon as the winding finishes. Select YES in above menu to lock it. This is also useful if you want to put a final insulation layer on bobbin. 18

19 5. EXECUTING A PROGRAM When ENTER key is pressed in section 4 (please refer section 4) you will get following display to select one of the option given on LCD. The same display window appears as you finished the editing process. EDIT RUN Now push the cursor below RUN option and press ENTER key. The controller will ask which program to run. For example: PROG TO RUN :001 Feed a valid and pre-edited program number for execution and press ENTER key. If the program is not edited earlier the corresponding message will appear on display. Pressing START key actually starts the winding cycle with following display:- 19

20 PG : 01 RPM : 0700 TURNS : Prior to start you can do following functions as per you need. The some functions can be toggled such as BRAKE, LAYER, and JOG. I) press BRAKE key to activate brake function. Brake key is used to release and lock the spindle firmly. During running the brake always remain free even if it is applied prior to start of winding will be recorded and will be kept the same as soon as motor stops. II) Press UP/DOWN, LEFT/RIGHT arrow keys (prior to start of windings) to do manual adjustment of traverse home position. Once you press START key the modified traverse position will be saved in memory. If you don t want to save this changed traverse positions simply press ENTER key. III) Press PREV key to go to starting of current program once again. IV) press LAYER key toggle layer option, LED gives its status. V) Press JOG key to remain always in default minimum speed. VI) Press DIA key (during pause condition only) to change the diameter of wire. 20

21 6. ON LINE OPERATING KEYS AND ITS USES UP/DOWN arrow keys are used to change the speed. If you want to change diameter of the wire after start, you can do so. First stop the machine and press DIA key on key on key panel, respectively menu will appear, feed the new value and press ENTER key to come back to the same status. This is semi online function. LAYER can be toggled online with LAYER key. JOG SPEED can be toggled online with JOG key. 7. DELETING ALL PROGRAMS To delete all programs follow these steps:- 1. Switch off the machine. 2. Press and hold down ENTER key (keep on Pressing). 3. Now switch on the machine. 4. Once the RESET MEMORY: NO_ message appears release ENTER key quickly. 5. Select YES to delete, NO for undelete. 6. Press ENTER to proceed further 7. If YES, controller will start deleting all programs. 8. Finished. 21

22 8. TECHNICAL SPECIFICATIONS: RANGE Wire diameter Traverse movement Bobbin size Wire cut sensor : 0.002mm to 9.99mm : 99.9mm : 99.9mm : Self detecting AC INPUT Power : 230 volts 50 Hz 180w Winding speed (maximum) : 9500RPM GENERAL Display Memory Acceleration Deceleration : 16X2 line LCD : 399 programs : Fixed : Fixed 22

23 MODEL : RSW FOUR COIL WINDING MACHINE CONTROLLER 2. TENSIONER STAND 3. ADJUSTABLE KNOB 4. PULLEYS 5. TENSIONER BOX 6. MIDDLE SUPPORT PULLEY 7. WIRE GUIDE UNIT 8. TRAVERSE 9. FELT 10. MANDRIL HOUSING 11. TAILSTOCK 23

24 MODEL: RSW 150 FOUR COIL WINDING MACHINE TURNS ACCURACY : TURNS WINDING SPEED : 4000 RPM WINNDING LENGTH : 99 mm SWING DIAMETER : 100 mm WIRE DIAMETER : 0.07 mm TO 0.40 mm PROGRAMS : 399 in built memory DISPLAY : 16 X 2 Line LCD BREAK : Electro Magnetic Disc TRAVERSE : Hybrid step motor WATT : 300 VOLT : 220 Single Phase MAIN MOTOR : 180 Volt DC, ¼ HP MOTOR SPEED : 3000 RPM 24