Artos MTX User manual

Machine Model MTX/STX Multi Task Wire
Processor Owners Manual Text
PN 6-119876-1 Rev.1Date 02 Dec. 2010
Artos Engineering Company
21605 Gateway CT
Brookfield WI 53042
Phone [phone] Fax [phone]
www.artosnet.com
[email protected]

MTX/STX OPERATORS MANUAL
Chapter Reference Guide
2.6 OR 2.7 2.9
2.5
2.10
2.3.4
2.6.4.2
2.3.1-2.2.3
2.3.6or 2.4 2.3.6 or 2.4 Refer to the Chapter
Numbers shown for
explanations of the
counter programming.
2.2.1
2.2.3 2.2.6.4.
2.2.2
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Table Of Content
1Machine Specifications And Installation.....................................................................................................5
1.1 Machine Specifications............................................................................................................................5
1.2 Machine Installation.................................................................................................................................6
1.2.1.1 INSTALLING THE COMPUTER ON THE INFEED END.................................................................................7
1.2.2 Installing The Computer On Outfeed End............................................................................................8
1.2.3 Process Station Installation................................................................................................................11
1.2.4 Collector Installation...........................................................................................................................11
1.2.5 Installing Terminal Reel Brackets.......................................................................................................12
1.2.6 Electrical Connection..........................................................................................................................12
1.2.7 Air Connection....................................................................................................................................13
1.3 Control Pushbuttons With Infeed Computer..........................................................................................14
1.3.1 Push Buttons......................................................................................................................................14
1.4 Control Pushbuttons With Out Feed Computer.....................................................................................15
1.4.1 Push Buttons......................................................................................................................................15
2Operating Software...................................................................................................................................16
2.1 Main Run Screen Definitions.................................................................................................................16
2.2 Cycle Mode Control...............................................................................................................................17
2.2.1 Cycle Mode.........................................................................................................................................17
2.2.2 Speed .................................................................................................................................................17
2.2.3 Single / Step Options..........................................................................................................................17
2.3 Manual Data Input (Mdi)........................................................................................................................17
2.3.1 Selecting An Existing Wire .................................................................................................................18
2.3.2 Creating A New Wire..........................................................................................................................18
2.3.3 Defining Wire Properties.....................................................................................................................18
2.3.4 Changing Wire Length, Strip Lengths, And Strip Pull Lengths...........................................................19
2.3.5 Short Wire Option...............................................................................................................................19
2.3.6 Loading Existing Lead Or Trail Processes.........................................................................................21
2.4 Creating New Lead Or Tail Processes..................................................................................................22
2.4.1 Determining A New Process Position.................................................................................................23
2.4.1.1 MANUALLY SETTING THE PROCESS POSITIONS ...................................................................................24
2.4.1.2 DETERMINING LEFT/RIGHT WIRE POSITION.........................................................................................25
2.4.1.3 DETERMINING IN/OUT WIRE POSITION ................................................................................................26
2.4.1.4 DETERMINING THE PROCESS HEIGHT (OPTION)..................................................................................26
2.4.1.5 DETERMINING ARRIVE AND DEPART EXTENSION .................................................................................27
2.4.1.6 SETTING THE PROCESS DEPARTURE VELOCITY AND ACCELERATION ...................................................28
2.4.1.7 DETERMINING PRE-TRIP AND POST TRIP TIME....................................................................................28
2.4.1.8 SELECTING STRIP INSPECTION,CFM,AND SPLIT CYCLE OPERATION....................................................28
2.4.1.9 HOME POSITIONS OF PIVOT,PROCESS EXTENSION,AND HEIGHT........................................................28
2.4.2 Setting Additional Process Properties................................................................................................29
2.4.2.1 SETTING THE WIRE OVERHANG VALUE...............................................................................................29
2.4.2.2 SETTING THE RETURN EXTENSION .....................................................................................................30
2.4.2.3 SETTING PROCESS STRIP PARAMETERS .............................................................................................30
2.4.2.4 NON-TERMINATING PROCESSES.........................................................................................................30
2.4.2.5 MULTIPLE SINGLE END PROCESSES ...................................................................................................30
2.5 Recalling Existing Part Programs..........................................................................................................32
2.6 Creating A New Part Program...............................................................................................................32
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2.6.1 Setting The Release Delay.................................................................................................................33
2.6.2 Setting Conveyor Speed (Option) ......................................................................................................33
2.6.3 Pre And Post Processes.....................................................................................................................33
2.6.3.1 CREATING OR EDITING APRE-PROCESS ............................................................................................34
2.6.4 Completing The New Part Program ...................................................................................................34
2.6.4.1 CREATING AN OPERATOR MESSAGE...................................................................................................34
2.6.4.2 ENTERING TOTAL AND BATCH QUANTITIES .........................................................................................35
2.6.4.3 SAVING ANEW OR EXISTING PROGRAM .............................................................................................35
2.7 Editing Existing Part Programs..............................................................................................................35
2.8 Creating A Double Program (Options Required)...................................................................................36
2.8.1 Creating A Double Program...............................................................................................................37
2.8.2 Configuring Vertical Or Horizontal Double .........................................................................................38
2.8.2.1 SEQUENCE........................................................................................................................................38
2.8.2.2 CONFIGURATION................................................................................................................................38
2.8.3 Double Termination............................................................................................................................39
2.9 Creating And Editing Job Programs......................................................................................................39
2.9.1 Creating A New Job Program.............................................................................................................40
2.9.1.1 BATCH MODE ....................................................................................................................................40
2.9.1.2 HARNESS MODE ................................................................................................................................41
2.10 File Management ..................................................................................................................................42
2.10.1 Data Organizer...................................................................................................................................42
2.10.2 Data Back Up.....................................................................................................................................42
2.11 Password Authorization ........................................................................................................................43
3Language Editor.......................................................................................................................................44
4Maintenance.............................................................................................................................................46
4.1 Lockout Procedure For Mechanical Maintenance.................................................................................46
4.1.1 Suggested Shutdown And Lock Out And Tag Out Procedure...........................................................46
4.2 Mechanical Adjustments........................................................................................................................47
4.2.1 Wire Straightener................................................................................................................................47
4.2.2 Tonking...............................................................................................................................................48
4.3 Pneumatic Tonker Option......................................................................................................................49
4.4 Blade Change........................................................................................................................................50
4.5 Feed Belt Replacement.........................................................................................................................51
4.6 Maintenance Software...........................................................................................................................52
4.7 Device Configuration.............................................................................................................................52
4.7.1 Establishing Process Station Home (Reference) Position.................................................................53
4.7.2 Establishing The Device Type............................................................................................................53
4.7.3 Setting Device Trip.............................................................................................................................53
4.7.4 Setting Station “T”...............................................................................................................................54
4.7.5 Selecting Strip Inspection, Cfm, And Air Feed Die.............................................................................54
4.7.6 Selecting Another Station...................................................................................................................54
4.8 Setting Machine Configuration Properties.............................................................................................54
4.9 Using I/O And Servo Maintenance Screens..........................................................................................57
4.9.1 Using Machine States Screen............................................................................................................57
4.9.2 Using Discrete I/O Screen..................................................................................................................58
4.9.3 Using Servo Maintenance Screen......................................................................................................59
4.9.3.1 SERVO MOTOR POSITION...................................................................................................................59
4.10 On-Line Preventative Maintenance Screens ........................................................................................60
4.11 Suggested Preventative Maintenance Schedule..................................................................................61
4.12 Drive Belt Replacement ........................................................................................................................62
4.13 Machine Reference Process.................................................................................................................62
4.13.1 Overview............................................................................................................................................62
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4.13.2 Master Reference (Mtx/Stx)...............................................................................................................62
4.13.3 Machine Reference............................................................................................................................63
4.13.4 Reference Failure Troubleshooting: ..................................................................................................64
4.13.5 Reference Pulse ................................................................................................................................65
4.13.6 Upper Cutterhead Belt.......................................................................................................................67
4.13.7 Lower Cutterhead Belts .....................................................................................................................67
4.13.8 Feed Assembly Belts.........................................................................................................................68
4.13.9 Pivot And Strip Belts..........................................................................................................................69
4.14 Master Reference Procedure................................................................................................................70
4.14.1 Centering The Cutterhead.................................................................................................................72
5Troubleshooting........................................................................................................................................73
5.1 Mtx/Stx Troubleshooting Guide.............................................................................................................73
5.2 Machine Function Error Codes..............................................................................................................76
6Appendix...................................................................................................................................................77
6.1 S-1 Option .............................................................................................................................................77
Window And Long Lead Strips...........................................................................................................79
Twister...................................................................................................................................................80
Twister Operation...............................................................................................................................80
Tinning...................................................................................................................................................81
Sonic Welding........................................................................................................................................81
Seal / Seal Crimp Application
Notes (Customer Entry) ................................................................................................................81 ......................................................................................................................81
6.1.1
6.2
6.2.1
6.3
6.4
6.5
6.5.1
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MTX/STX OPERATORS MANUAL
1 MACHINE SPECIFICATIONS AND INSTALLATION
Thank you for your purchase of an Artos MTX/STX Series Modular Wire Processing machine. Please read the
following instructions prior to unloading and operating you machine.
1.1 MACHINE SPECIFICATIONS
The machine specifications have been provided as a general guideline to the capabilities of your new MTX/STX
machines. Your machines actual capabilities will depend on your material and application.
Wire Size: 0,15 to 6 mm2( 26 to 10 AWG)
Wire Cut Lengths: 51mm to 100M (2” to 3938”)
Wire Stripping Lengths: 0 to 12.7mm (0 to 0.5”)
Wire Feed Rate (Max.): 5M/Sec (197 inches/Sec.,)
Weight: 1818 Kg (4000lb)
Dimensions: 3.17 X 1.73 X 1.84M (125X70X73 IN.)
Electrical
1. Power Supply:
220, 380, 415, 440 VAC ±10%, 50 or 60 Hz. ±5% Three Phase
2.2 Kva (Nominal)
Included: 2 x TU10
2 x Paper Take Up
PoweredCollector
2. Connection to Supply: Fused, Lockable Disconnect
3. Protection Against Electrical Shock: Grounded Metal Enclosure
Environmental
1. Temperature:
Operating 0°C to +45°C
Storage -25°C to +55°C
2. Relative Humidity:
30% to 90% (Non Condensing)
3. Sound Level:
63 dbA Quiescent
80 dbA Automatic Cycle
Included: 2 x Gamma Presses
Passive Collector
79 dbA Automatic Cycle
Included: 2 x TU10 Presses
2 x Pawomat Seal Applicators
Powered Collector
4. Other:
This equipment is designed for normal operation in a dry location where it is not
likely to be subjected to drip, splash, or spray of water or other liquid.
.
Air Requirements: 6 Bar (80 PSI)
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1.2 MACHINE INSTALLATION
Before removing your machine, check the content of your shipment with the packing memo provided. Contact your
local Artos representative if items appear to be missing.
Your machine will be bolted to the packing skids using six bolts. Remove these bolts. Be sure support the machine
for lifting by placing the forks in the areas shown. It is important to avoid contact with the upper guard assembly and
the lift truck boom. When lifting the MTX/STX machine, be certain to use a truck capable of lifting the machine
weight.
FORK
Once lifted, remove the shipping plates. This will require a 15/16’” (24 mm) socket wrench. Insert the 6 padded feet.
Set the 4 feet on the machine frame to an equal length about half way in to the hole. Make the 2 feet on the electrical
cabinet shorter so they do not tough the floor when the machine is set in place. Lower the machine into place. Using a
machine level, adjust the 4 padded feet so the machine is level. Now turn the feet on the electrical cabinet down until
they are firmly on the floor.
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1.2.1.1 INSTALLING THE COMPUTER ON THE INFEED END
Unpack the computer, monitor, keyboard and mouse from their shipping boxes.
Control components are mounted as shown. Set down the keyboard and mouse and run cables thru the hole
provided before installing the computer.
Computer components are mounted as shown. The monitor and computer plugs into the UPS (un-interruptible
power supply) backup receptacles. The UPS connects to the appropriate cord, 110 VAC or 220 VAC (export).
The monitor, keyboard, and mouse connect to the computer as described in the computer manual (follow the color
code).
The optional UPS sets on the shelf inside
the console. Insert from the left with
control facing out. It is helpful pass the
computer and monitor power cords over
the shelf and out the hole so they can be
p
lu
gg
ed into the batter
y
bac
k
-u
p
outlets
The serial cables are marked for their respective “COM PORTS” on the computer.
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1.2.2 INSTALLING THE COMPUTER ON OUTFEED END
Unpack the computer, monitor, keyboard and mouse from their shipping boxes.
Control components are mounted as shown. Set down the keyboard and mouse and monitor. The cables are
routed through the hole in the back of the support tube.
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Feed the mouse and keyboard cable trough the tube first then the monitor cables. Bundle and tie the cables neatly
allowing enough of the bundle out of the tube to allow for rotation.
Remove the rear guard. This requires the special key that was ship with the loose parts of the machine. Inside
you will find the mating cable connections.
1. Route the cables up over the rear guard track and down along the leg on the inside.
2. Connect the cables to there respective mates.
3. The AC power connection for the monitor will be found along the sealtite bundle near the cutter head
motor.
Rear Guard
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MTX/STX OPERATORS MANUAL 10
STEP 1
STEP 3
STEP 2
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MTX/STX OPERATORS MANUAL 11
Computer components are mounted as shown. The monitor and computer plugs into the UPS (un-interruptible
power supply) backup receptacles.
The UPS connects to the appropriate power cord, 110 VAC or 220 VAC (export). The monitor, keyboard, and
mouse connect to the computer as described in the computer manual (The cables will be labeled Mouse and
Keyboard, and monitor).
The serial cables are marked for their respective “COM PORTS” on the computer.
1.2.3 PROCESS STATION INSTALLATION
The process stations will need to be installed onto the working table of the MTX/STX. The mounting bases
should have been installed at the Artos factory, with mounting hardware provided. All electrical and pneumatic
requirements will also be provided through the worktable. The device and base will have matching numeric or
alphabetic markings.
1.2.4 COLLECTOR INSTALLATION
The passive collector comes installed on the MTX/STX worktable. If your machine has one of the optional
motorized collectors it would be necessary to mount the stationary collector to the table, the mobile unit is slid
into place making certain that the centering pin located at the front of the collector is firmly located into the
locating receptacle on the machine. Loosen the levers on each end and adjust the height so the collector just
clears the swing of the tail side stripping clamp assembly. Finally, connect the electrical and air plugs to the
machine.
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MTX/STX OPERATORS MANUAL 12
1.2.5 INSTALLING TERMINAL REEL BRACKETS
Terminal reel brackets are installed from the bottom side of the worktable. Prior to attaching the bracket to the
worktable, slide the rotating assembly onto the shaft. Each shaft should next be assembled into the table.
Finally, the terminal reel holders can be assembled onto the rotating assembly. Please note that the threads on
reel holding arms may be left hand thread. Note marking on the hub. This is so the weight of the reel will tighten
the bolt.
Terminal brackets 5-141149 and 5-141104 are shipped installed. Consult the drawings for detail.
Terminal reel brackets
Paper take-up
on bracket
1.2.6 ELECTRICAL CONNECTION
Caution: Prior to attempting electrical connection, ensure the main power source has been switched off. Also
check the voltage to ensure it is the same as specified on the MTX/STX nameplate.
The electrical drop should be located to the left and rear of the machine. Run your cable through the provided
fitting, and into the rear electrical cabinet. Remove the three main fuses and insert the cables into the top of the
main connecting block, tightening the screws to ensure a firm contact. Do not allow the drop to interfere with the
wire supply area to the straightener
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MTX/STX OPERATORS MANUAL 13
Connect power to terminals behind fuses. The fuse holders pull out to expose the terminals
Most motors on the machine are not phase sensitive. However, some presses are phase sensitive. If you have
added options that are phase sensitive, be certain to check the rotation of these motors prior to operation.
1.2.7 AIR CONNECTION
The airdrop should be located to the left rear of the machine. Connect the air supply to the regulator using at
least a 3/8” (10mm) hose. Do not allow the drop to interfere with the wire supply area to the straightener
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MTX/STX OPERATORS MANUAL 14
1.3 CONTROL PUSHBUTTONS WITH INFEED COMPUTER
The controls for the MTX are positioned for operator convenience.
1.3.1 PUSH BUTTONS
The guard will go back up if it meets any resistance in it’s
decent. Do not hold the button in the down position.
The control buttons function as follows:
•E-Stop will stop all motion and shut down all
power to the motors and dump all the air.
•Master Start Applies power to the motors and
auxiliary equipment and turns on the air.
•Feed Roller will open and close the feed belts.
•Feed Jog will slowly advance the wire. Use this
for wire loading.
Main Guard Open / Close
•Cycle Start will initiate the cycle mode as chosen
in the run screen.
•Cycle/Master Stop will stop the action of the
machine at the end of the current cycle. Holding it
down will lead to a complete shut down of power
and air.
Emergency Stop
Main Guard
Open Only
Master Start
(Orange)
Belt Open/Close
(White w/belt)
Feed Jog
(White w/ arrow)
Cycle Start
(Green)
Cycle Stop/
Master stop
(Red)
Outfeed Controls
Infeed Controls
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MTX/STX OPERATORS MANUAL 15
1.4 CONTROL PUSHBUTTONS WITH OUT FEED COMPUTER
1.4.1 PUSH BUTTONS
The guard will go back up if it meets any resistance in
it’s decent. Do not hold the button in the down
position.
The control buttons function as follows:
•E-Stop will stop all motion and shut down all
power to the motors and dump all the air.
•Master Start Applies power to the motors
and auxiliary equipment and turns on the air.
Infeed Controls
•Feed Roller will open and close the feed
belts.
•Feel Jog will slowly advance the wire. Use
this for wire loading.
•Cycle Start will initiate the cycle as chosen
in the run screen.
•Cycle/Master Stop will stop the action of the
machine at the end of the current cycle.
Holding it down will lead to a complete shut
down of power and air.
E-sto
p
Master Start
C
y
cle Start
C
y
cle sto
p
Guard
Open/close
(On end)
Feed Belt
Open/Close Feed Jog
Outfeed Controls
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MTX/STX OPERATORS MANUAL 16
2 OPERATING SOFTWARE
2.1 MAIN RUN SCREEN DEFINITIONS
Job: Name of Job (group of parts) to be run sequentially in a batch or Harness mode.
Part: Name of a specific wire assembly to be produced. Includes information on wire identity, wire length, strip
lengths, lead and trail end process, quantity produced, and pre or post process.
Wire: Name of active wire chosen from existing database of all wires entered.
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MTX/STX OPERATORS MANUAL 17
Lead / Tail Process: This is the name of the wire end treatment process associated with the Part program or
selected in MDI mode. They are selected from a library of pre-established processes.
Cycle Mode: Selects the machine operating sequence – Automatic mode (AUTO), Single Cycle mode (SINGLE), or
Step-by-Step Mode (STEP).
2.2 CYCLE MODE CONTROL
The Cycle Mode can be modified to aid in the set-up procedure.
2.2.1 CYCLE MODE
This selection allows you to select between Auto for production, Single for single piece production for inspection or
Step to step the processes thru its operation for set-up or troubleshooting.
2.2.2 SPEED
This selection allows you to control the global speed of the machine In Auto Mode Or Single/Step Modes.
2.2.3 SINGLE / STEP OPTIONS
This selection allows you to modify the programmed cycle while in the Single or Step modes as follows:
•Cut Only = Cut, no strip
•Cut / strip only = Cut and strip but no presentation to the end processes
•No lead trips = Cut and strip with presentation to the lead end processes but no activation
•No tail trips = Cut and strip with presentation to the tail end processes but no activation
•Use short wire = wire length will only be 4” (100mm) to conserve wire when working with end processes
Speed: Percent of maximum cycle speed for operation. Auto is the speed used when in production cycle mode, while
Single/Step is the speed used under single cycle and step mode. Used for set-up and trouble-shooting
2.3 MANUAL DATA INPUT (MDI)
The MTX/STX can be programmed in manual data input (MDI) mode. To select this mode, Click on Part and select
MDI.
This mode is used to create parts without utilizing stored programs.
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MTX/STX OPERATORS MANUAL 18
2.3.1 SELECTING AN EXISTING WIRE
To select a wire from the existing wire database, Click on the tab next to the Wire box and select the wire name
required. Or,
2.3.2 CREATING A NEW WIRE
To create a new wire, Click on Wire, to open the wire database. Click on New and enter the wires properties as
described below.
2.3.3 DEFINING WIRE PROPERTIES
Each wire entered into the database contains unique properties, which should be programmed to optimize the
operation of the machine:
Name: The part number or name given to the wire.
Description: Available space for further definition of the wire.
Feed Rate: Rate at which the wire is feed through the machine from the end of acceleration to the beginning of
deceleration. Rates are in inches per second from 20 to 197.
Acceleration: Rate at which the wire reaches its maximum feed rate. Rates are in percentage of maximum from 3 to
120%. Rates of over 100% may cause wire jams. The Deceleration will mirror the acceleration profile.
Strip Diameter: The closing position of the blades while stripping.
Strip Delay: Time delay in milliseconds to allow the stripping blades to cut into elastic insulation materials.
Cutter Home Position: The furthest opening position of the cutter-head which allows the leading end terminal to pass
through the blades with out hitting the blades.
Cutter Ready Position: The the cutter-head closes to this position after the leading end of the wire has cleared the
stripping blades. This allows for shorter cycle times by reducing the cutter-head travel time at the end of the feed.
Cutter Wayback Position: This is the distance the stripping blades retract from the strip diameter prior to the wires
being stripped. This feature is used to avoid scrapping of the wire conductor by the stripping blades.
Feed roller Pressure: (Option) This setting determines the pneumatic pressure setting for the feed belts. Settings are
in percentages of line pressure from 1 to 100%. This is a manual adjustment on machines without this option.
Strip Jaw Pressure: (Option) This setting determines the pneumatic pressure setting for the stripping jaws. Settings
are in percentages of line pressure from 1 to 100%. This is a manual adjustment on machines without this option.
Wire Length Calibration: This value is utilized to calibrate the overall wire length. It is determined by running a
sample of 5 wires at 50 inches (1250mm), and measuring these wires to obtain the average length. This average
length should then be entered into this field to ensure proper length values for all wire lengths.
Strip Acceleration: This is the rate, in percentages from 1 to 100%, at which the stripping process reaches the “Strip
Velocity”
Strip Velocity: This is the maximum speed, in percentages from 1 to 100%, at which the stripping process will occur.
Depart Acceleration: This is the rate, in percentages from 1 to 100%, at which the departing wire reaches the
“Depart Velocity”
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MTX/STX OPERATORS MANUAL 19
Depart Velocity: This is the maximum speed, in percentages from 1 to 100%, at which the wire departs after
stripping is completed.
Color: Identifies the color or colors to be displayed on the main run screen. Top is the base color and the bottom is the
strip color. (Check Dual Color to display strip color)
.
2.3.4 CHANGING WIRE LENGTH, STRIP LENGTHS, AND STRIP PULL LENGTHS
The main run screen graphically indicates the values of the total wire length, strip lengths, and strip pull lengths. To
change any of these values, simply click on top of the value to be changed, and enter the new required value and press
<Enter>.
PULL-OFF
LENGTH Click on desired value
and the field will open
for data entry.
STRIP
LENGTH
2.3.5 SHORT WIRE OPTION
By using a Short Wire Blade Pack the MTX/STX can process short wires of approximately
30mm. This requires a change of blades and knockout in the cutterhead.
The following considerations should be understood when using the Short Blade Pack:
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