- 1 - SCS AUTOMATION & CONTROL PROJECT XXXX Issue A Winder Customer: XXXXXXX Ltd.. Automation Center 156 Stanley Green Road Poole Dorset England BH15 3AH
- 2 - Contents 1. Introduction 2. Safety 3. Specification 4. System Functionality 4.1. Operator Station 4.2. Fault Conditions 5. Interconnections 6. Recommended Spares 7. Electrical Drawings 8. Mechanical Drawings
1 Introduction - 3 - ATTENTION The machine is a ServoMotor based system and as such can generate high speeds, forces and torques. Only those who are familiar with the NextMove BXII digital motion controller and associated machinery should plan or implement the installation, startup and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage. The object of this document is to define how the system functions together with the controls available to configure and run the system. There are two operator control stations 1.1 The Operator Panel This is a Can Bus Keypad node consisting of a four line text display with six function keys and a numeric input pad. It is a dumb terminal controlled via Can Bus by a NextMove BxII position controller. All system configuration can be done from this station as well as homing, jogging and running the system. 1.2 The LabView terminal. This is a PC based piece of software written to edit, load and save coil parameter recipes to the position controller and to disc. Both stations are described in more detail later in this manual.
- 4-1 Safety You must receive specific safety training before you can begin to train on or perform any operational or maintenance tasks associated with this process or equipment. This safety training must guarantee that you understand: The identity and associated hazards of all moving parts involved with the process or equipment. How to avoid contact with and protect yourself from those hazards. 2.1 Safety Training All personnel must receive safety training prior to performing any operation or maintenance procedures on this machine. This training must guarantee that you understand: The identity and associated hazards involved with the process or equipment. How to avoid contact with and protect yourself from those hazards. Additionally, there must be a trained operator/technician in the area when an untrained employee is training on the equipment. Only trained operators/technicians may execute the procedures listed in this manual and only when an additional employee is within sight or hearing distance. 2.1.1 Additional Safety Precautions Listed below are some of the basic safety precautions that you should observe when operating the Coil winder Machine. Only trained personnel specifically designated are allowed to operate and maintain this machine DO NOT perform any maintenance activities if you are trained only as an operator. Only trained maintenance personnel specifically designated should perform maintenance functions. DO NOT locate this machine in damp areas or near anywhere that the machine could possibly become wet. Be sure that all electrical requirements are met and compliant prior to starting this machine. Make sure that you know and understand all safety precautions and warning signs posted on the equipment before attempting to operate the machine. Never try to reach over or under any equipment to remove or adjust anything while the machine is in operation. Never remove, dismantle or circumvent installed safety equipment.
- 5-2.2 Electrical Hazards The following information is general about electrical hazards associated with the Coil winder. Note: The main electrical enclosure is locked and the key is not accessible to operators. No access to the interior of the cabinet is required during normal operation of the machine. High Voltage! Instructed Operators must never open any electrical enclosure for any reason. If electrical problems arise, turn off the machine and contact a qualified service technician. High Voltage! Can cause bodily injury. Use extreme caution when working in electrical cabinets with the main power disconnect switch turned on. High Voltage! Can cause bodily injury. Yellow cables carry lethal voltages that are not de-energised by the machine's main power disconnect switch. Do not touch anything connected to the yellow cables. High Voltage! Can cause bodily injury. Turning off the main power disconnect switch also turns off the power to the ac utility outlets on the machine. High Voltage! Can cause bodily injury. Lockout the module and install a lockout ID tag before performing maintenance activities. Note that there may still be live voltages inside the main electrical cabinet even when the main disconnect is off. Disconnect facilities power to the machine prior to service. Always refer to the electrical schematics when measuring, adjusting, calibrating, repairing or troubleshooting electrical devices and circuits.
- 6-2.3 Mechanical Hazards The following information is general about mechanical hazards associated with the Coil winder. MOVING PARTS! Can cause bodily injury. Never reach around the machine for any reason while operating the machine. MOVING PARTS! Can Cause bodily injury. Lockout the machine and install a lockout ID tag before servicing machine.
2 Specification 3.1 Electrical System Supply: - 7 - Single Phase and Bonded Earth, 230 Volts, 50 Hz, protected by fuses or circuit breaker at 25A. Temperature: The system is designed to work in an ambient temperature of between 0 50 degrees C. (140F). Storage: Store within an ambient temperature range of 0 to 65C and a relative humidity range of 5 to 95% non-condensing. EU directives: The system is designed to meet the following European Union directives - EN 60204-1: Safety of Machinery - Electrical Equipment of machines. EN 50081-2: EMC Generic Emission Standard, Part 2 Industrial Environment EN 50082-2: EMC Generic Immunity Standard, Part 2 Industrial Environment. 3.2 Computer Minimum Specification Platform - Windows 2000/NT 4.0/XP/Me/98 (Windows 95 is not supported) CPU - LabView requires a minimum of a Pentium III or Celeron 600MHz or equivalent processor, but National Instruments recommends Pentium 4 or equivalent. Memory Minimum of 128MB, but National Instruments recommends 256MB. The computer must have one 9 pin D Type RS232 Communication ports defined as COM1
3 System Functionality 4.1 Operator Station - 8 - After the system initialises, the Operator Panel displays a number of options allowing the operator to configure, home, jog and run the system 4.1.1 Opening Menu If the system has not been homed the message F1 HOME F2 MANUAL F3 EDIT Performs the home function on the Linear Drive and then returns to the Opening Menu (See Section 4.1.2) Enters Manual Mode allowing the operator to jog the Axes (See Section 4.1.3) Enters the Edit Variables Menu allowing the operator to edit system and process Variables (See Section 4.1.9) If the system has been homed the message F1 RUN Enters Run Mode (See section 4.1.14) F2 MANUAL F3 EDIT Enters Manual Mode allowing the operator to jog the Axes (See Section 4.1.3) Enters the Edit Variables menu system, allowing the operator to edit System and Process Variables (See Section 4.1.9)
- 9-4.1.2 Homing While homing the message is displayed and the following option given to the operator F3 ABORT Stops the homing sequence and returns to the previous screen. If abort is not pressed the system returns to the previous screen when the homing is complete. 4.1.3 Manual Mode The message F1 JOG Enters Jog Mode (See section 4.1.4) F2 HOME F3 EXIT Performs the home function on the Linear Drive and then returns to the Manual Mode Screen (See Section 4.1.2) Returns to the Opening Menu
- 10-4.1.4 Jog Mode The message is displayed and the following options given to the operator F1 SYSTEM Jog the entire system in reverse. This is used to unwind wire from a spindle. (See Section 4.1.5) F2 TORQUE Jog the Tensioning Drive. (See Section 4.1.6) F3 EXIT Returns to the Opening Menu F4 SPINDLE Jog the Spindle Drive (See Section 4.1.7) F5 LINEAR Jog the Linear Drive (See Section 4.1.8) 4.1.5 Jog System The message F1 FOR F2 REV F3 EXIT This unwinds wire from the spindle with the Linear drive moving to the right. Used to unwind even numbered layers from the spindle. The system speed is controlled by the Spindle, which runs at Spindle Jog Speed. This unwinds wire from the spindle with the Linear drive moving to the left. Used to unwind odd numbered layers from the spindle. The system speed is controlled by the Spindle, which runs at Spindle Jog Speed. Returns to the Jog Mode Menu
- 11-4.1.6 Jog Tension Motor The message F1 FOR This sets an anti-clockwise torque on the Tensioning Motor. F2 REV This sets a clockwise torque on the Tensioning Motor. F3 EXIT Returns to the Jog Mode Menu 4.1.7 Jog Spindle The message F1 FOR The Spindle rotates forward at Spindle Jog Speed. F2 REV The Spindle rotates in reverse at Spindle Jog Speed. F3 EXIT Returns to the Jog Mode Menu
- 12-4.1.8 Jog Linear The message F1 LEFT The Linear Drives moves to the left at Linear Jog Speed. F2 RIGHT The Linear Drives moves to the left at Linear Jog Speed. F3 EXIT Returns to the Jog Mode Menu 4.1.9 Edit Variables The message F1 PROCESS F2 SYSTEM F3 EXIT F4 RECIPES Edit Process Variables; Operator Password required. (See Section 4.1.10) Edit System Variables and Passwords; Engineering Password required. (See Section 4.1.11) Returns to the Opening Menu Edit Process Recipes; Operator Password required. This allows the operator to upload and save process recipes stored in memory. (See Section 4.1.18)
- 13-4.1.10 Edit Process Variables Allows the editing of the following variables Part Number Core Diameter Wire Diameter Core Length Start Position Winding Speed Spacing Number of Layers Wire Tension Unwind Diameter Pre-Wind Part Number Diameter of spindle core in mm Diameter of the winding wire in mm Length of spindle core in mm Position offset of the linear drive at the start of each layer in mm Base speed of the spindle when running in rpm Space between each coil on the spindle in mm Number of Wind Layers Tension of the wire being wound in gms Diameter of the unwind reel in mm Number of winds of wire made on the spindle to secure the wire before running 4.1.11 Edit System Variables The message F1 SPINDLE Edit Spindle Drive Variables (See Section 4.1.12) F2 LINEAR Edit Linear Drive Variables (See Section 4.1.13) F3 EXIT Returns to the Opening Menu F4 PASSWORDS Edit Passwords (See Section 4.1.14)
- 14-4.1.12 Edit Spindle Drive Variables Allows the editing of the following variables Run Acceleration Run acceleration of the spindle in RPM/s Run Deceleration Run deceleration of the spindle in RPM/s Jog Speed Spindle jog speed in RPM Jog Acceleration Spindle jog acceleration in RPM/s 4.1.13 Edit Linear Drive Variables Allows the editing of the following variables Run Acceleration Run acceleration of the linear drive in mm/s ² Run Deceleration Run deceleration of the linear drive in mm/s ² Jog Speed Linear drive jog speed in mm/s Jog Acceleration Linear drive jog acceleration in mm/s ² Home Speed Linear drive home speed in mm/s Home Acceleration Linear drive jog acceleration in mm/s ² Home Offset - Distance ( in mm) from the initial home position used as the starting point for all subsequent linear drive moves. 4.1.14 Edit Passwords Allows the editing of the following passwords Op. Password Eng. Password LV Password The Operator password allows access to the process variable edit menu. The Engineering Password allows access to the System variable and the password edit menus. The LabView Password allows the variables on the LabView screen to be edited (See Section 4.3)
- 15-4.1.15 Run Mode The message F1 RUN Starts the Run Cycle (See Section 4.1.16) F2 CORE F3 EXIT F4 RESTART F5 RETURN F6 TAPE 4.1.16 Run System The message Allows the operator to edit the length of the spindle core Returns to the Opening Menu If the system had been stopped part way through the run sequence by pressing the ABORT button, this will restart the run where it left off. Returns the Linear Drive to the home position. Allows the operator to rotate the Spindle at slow speed with the guard open in order to apply the spiral tape wrap to the winding. (See Section 4.1.17) F3 ABORT Stops the run. When the run is complete the screen returns to the Ready To Run Screen.
- 16 - When the guards are opened to set up the next run, the message is displayed. When the guards are re-closed, the system returns to the Ready to Run screen. 4.1.17 Tape Mode The message F1 JOG F2 - EXIT 4.1.18 Edit Recipes The message Allow the operator to rotate the Spindle in reverse to apply the spiral tape. Returns to the Run Mode menu. F1 SAVE Save the current process recipe to memory. (See Section 4.1.19) F2 - LOAD Load a process recipe from memory. (See Section 4.1.21) F3 EXIT Returns to the Run Mode menu. F4 - DELETE Delete a process recipe from memory. (See Section 4.2.22)
4.1.19 Save Recipes - 17 - If a part with the given part number is not found in the memory then the message F1 YES F2 NO Recipe will be saved to memory Returns to the Edit Recipes Menu. If a part with the given part number is found in the memory then the message F1 YES F2 NO Recipe will be saved to memory Returns to the Edit Recipes Menu. If the memory is full so there is no room for another recipe to be saved then the message F1 YES Overwrite an existing recipe with the current process recipe. F2 NO Returns to the Edit Recipes Menu.
4.1.20 Overwrite a Recipe - 18 - The operator will be prompted to enter the Part Number of the recipe they wish to overwrite. If this Part Number is not found then the message F3 OK Return to the Edit Recipes Menu If this Part Number is found then the message F1 YES F3 OK Deletes the chosen recipe from memory and saves the current process recipe in its place. Return to the Edit Recipes Menu
4.1.21 Load Recipe - 19 - The operator will be prompted to enter the Part Number of the recipe they wish to upload from memory. If this Part Number is not found then the message F3 OK Return to the Edit Recipes Menu If this Part Number is found then the message F1 YES F3 OK 4.1.21 Delete Recipe Loads the chosen recipe from memory. Return to the Edit Recipes Menu The operator will be prompted to enter the Part Number of the recipe they wish to delete from memory. If this Part Number is not found then the message F3 OK Return to the Edit Recipes Menu
- 20 - If this Part Number is found then the message F1 YES Deletes the chosen recipe from memory. F3 OK Return to the Edit Recipes Menu
- 21-4.2 Fault Conditions 4.2.1 Emergency Stop or Guards Open If the Emergency Stop button is pressed or the guards are opened the message is displayed. When cleared the system will return to the Opening Menu. 4.2.2 Linear Limits If either of the Linear Drive Limit Switches are pressed the message F1 - Jog Allows the operator to jog the Linear Drive away from the Limit Switch. (See Section 4.2.3) F3 - EXIT If the operator manually moves the Linear Drive away from the Limit Switch then pressing F3 will cause the program to reset and restart.
- 22-4.2.3 Jog Linear The Message F1 LEFT (OR RIGHT) F3 - EXIT 4.2.4 Drive Fault If the forward limit is covered then the system will only allow you to jog left. If the reverse limit is covered then the system will only allow you to jog right. If the drive has been jogged away from the limit then pressing F3 will cause the program to reset and restart. A fault has occurred on one of the motor controllers. A message will be displayed defining which drive is in error. 4.2.5 Following Error A following error fault can occur on the Spindle or the Linear Drive and a message is displayed showing which one is at fault.
5 Interconnections 5.1 PC to Position Controller - 23 - Connect RS232 Communications cable WX20 between COM1 on the PC and fixed connector XP03 on the right side of the control desk.
- 24-6 Recommended Spares Below is list of first line electrical spares. These are considered to be long lead-time items, which would effect the machines down time if any were to fail. This critical list however, could change from time to time due to changes made by manufacturers, which is outside the control of. REF Qty Part Number Description U01 1 NextMove BXII 2 Axis servo controller U04 1 Sprint 200XLC DC Motor Amplifier U05, 1 Copley - Accelus Servo amplifier U06 ASP-090-09 M04 1 Escap Unwind Motor 28D11 M05 1 Allen Bradley Spindle motor N3406 M06 1 Allen Bradley Linear Motor / Encoder N2304 GS02 1 Allen Bradley 24 Volt, 3Amp PSU 1794-PS3 QF01 1 Allen Bradley Main Circuit Breaker 1792-SP2D320 QF01 1 Allen Bradley 10A 2 Pole Circuit breaker 1492-SP2D100 QF02 1 Allen Bradley 4A 2 Pole Circuit Breaker 1492-SP2D040 QF05,6 1 Allen Bradley 4A 2 Pole Circuit Breaker 1492-SP1D104 KA05 1 Piltz Safety relay KA01, KA02, KA03, KA04, KA06 KM05, KM06 PNOZ X1 1 Omron MY4 4 Pole Signal Relay 1 Allen Bradley 100C12D 4 Pole Contactor
- 25-7 Electrical Drawings The electrical system utilises a number of pre-made multi-core cable assemblies. To make them easily identifiable the following numbering scheme is used. Each cable has a cable marker in the format - Wxnn where x has one of the following meanings - S = Digital signals (Switched inputs) B = Encoder M =Motor X = Communication cables and nn is a two-figure number. Example WS030 WS refers to a Digital signal cable. The 03 refers to the input number of the unit that processes that signal. In this case the signal is wired to input 3 of the Position Controller. Example WM02 WM indicates that it is a motor cable. The 02 indicates that the motor is being controlled by servo drive U02. Below is the complete table of cables used, with a brief description. Cable Number Description Part Number WM04 Unwind Motor power cable WM05 Linear Motor power cable WS05 Linear Motor feedback cable WM06 Spindle Motor power cable WS06 Spindle Motor feedback cable WS05 Linear Drive Forward (Right) limit Switch SQ05 WS06 Linear Drive Reverse (Left) limit switch SQ06 WS07 Linear Drive Home switch SQ07 WX20 Coil winder control serial cable P0023-3000/2000
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- 34-8 Mechanical Drawings
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