FlexLink X45 Operator's manual

Created by EBCCW 96:05Created by EBCCW 00:06Created by EBCCW 96:05Created by EBCCW 00:06
Conveyor system X45
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User Documentation

Created by EBCCW 96:05Created by EBCCW 00:06

Created by EBCCW 96:05Created by EBCCW 00:06Created by EBCCW 96:05Created by EBCCW 00:06
Conveyor system X45
C
r
eated by EBCCW 00:06
5113196-3

Created by EBCCW 96:05Created by EBCCW 00:06

Created by EBCCW 00:06
Conveyor system X45
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© Flexlink AB 2010
All Rights Reserved
No part of this program and manual may be used, reproduced, stored or
transmitted in any form or by any means without the written permission of
FlexLinkComponentsAB.Thecontentsofthismanualareforinformational
use only. All information and specifications contained in this document
have been carefully checked to the best efforts of FlexLink Components
AB, and are believed to be true and accurate as of time of publishing.
However, due to continued efforts in product development FlexLink
Components AB reserves the right to modify products and its manuals
without notice.
FlexLink Components AB assumes no responsibility or liability on any
errors or inaccuracies in this program or documentation. Any kind of
material damages or other indirect consequences resulting from any
FlexLink Components AB´s product part, documentation discrepancies
and errors or non-anticipated program behavior are limited to the value of
appropriate products purchased from FlexLink Components AB. The
products are delivered to thecustomer at the ’as is’ state and revisionlevel
they are on the moment of purchasing, and are declared in detail in the
license agreements between FlexLink Components AB and user. User
accepts and is obliged to follow the guidelines stated in the separate
license agreement needed in using any parts of this product package.
User Documentation

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Preface
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Preface
Purpose of this manual
The purpose of this manual is to describe a number of operations that are
intended for the user concerned. Here it becomes clear how the user can
work as well and as safely as possible. By making use of clear illustrations
and texts FlexLink wants to achieve a simple and safe way of working with
the X45 system. This document contains remarks that point out a risky or
specific situation to the user. In many cases this situation is provided with
one of the symbols given below.
Compliance with the operations described in this document is important in
ordertopreventdangeroussituationsandunnecessarydamagetothe X45
system.Carefullykeepthisdocument!It isrecommendedtokeeponecopy
near the conveyor system and one copy with your technical documenta-
tion.
Structure of the manual
The user’s manual has been composed in such a way, that a number of op-
erations can quickly and easily be found. This manual will not describe op-
erations that are notmeant for the user. It does, however, indicate what the
user must do when carrying out a certain operation, for example calling in
technical staff. FlexLink would like to point out to the user that section 1
Safety is to be read carefully.
.
General warning for danger!
.
Warning for electrical voltage!
.
Attention, this is an important notice!

Preface
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Requirements of the user
The X45 Conveyor system must be operated by any adult person who has
become acquaintedwith section 1 Safety. If the user is not technically qual-
ified, he or she may not carry out any maintenance or repair activities on
the system.
. Note! Maintenance activities on the system may only be carried
out by a technically qualified person.
. NB: Technically qualified employees means: employees that
have followed an adequate training for carrying out the activities
involved and have a good ability to read and understand the
English language.

Safety
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1 Safety
The X45 conveyor system has been designed in such a way, that it can be
used and maintained in a safe way. This holds for the application, the cir-
cumstances and the instructions described in the manual. Any person
working with or on this system should study the manual and follow the in-
structions. It is the responsibility of the employer to make sure that the em-
ployee is familiar with and follows these instructions.
The company or the country in which the system is used may require extra
safety measures. This particularly applies to the working conditions. This
manual does not describe how these are to be complied with. In case of
doubt, consult your government or safety officer!
1.1 System information
The project number and/or general drawing number shall always be spec-
ified when communicating with FlexLink with respect to the module.
Figure 1 Module nameplate
The modules nameplate is located on the module nearthe electrical motor
for the drive unit.
Project number See module nameplate
Supplier FlexLink Systems Polska Sp z o.o.o
Module type: See module nameplate
Date of manufacture See module nameplate
Identification. no. See module nameplate

Safety
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1.2 The most important safety conditions
At the moment that the X45 system is going to be operated by a user, the
following safety conditions must be met:
• Only persons who have read and understood the operating in-
structions are allowed to operate, maintain and clean the system.
• Provide good ambient lighting to enable the operator to work well
and orderly with the system.
1.2.1 General
. • Incorrect use of the equipment can cause personal injury.
• Do not wear clothing or other articles that can fasten.
• Follow the instructions in this user manual when transporting the
machine. FlexLink Components AB must approve all modifica-
tions or changes to this system.
• Only use recommended spare parts.
• Only authorised personnel may open electrical units.
• FlexLink is not responsible for damage if service on the equip-
ment is not performed in accordance with this user manual.
1.2.2 Service technicians
. Service technicians must have:
• Sufficient knowledge for reading technical information
• Ability to comprehend technical drawings
• Basic knowledge of mechanics
• Sufficient knowledge in the use of hand tools

Safety
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1.2.3 Electricians
. Electricians must have:
• Experience from similar installations
• Sufficient knowledge to work from drawings and wiring diagrams
• Knowledge of local safety regulations for electrical power and au-
tomation
To avoid risks, only experienced personnel with technical knowledge and
experience may perform repair work on the electronics components.
1.2.4 Operators
. To correctly use the equipment, operators must have appropriate training
and/or experience.

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1.3 Description of safety provisions
Before putting the system into operation some safety provisions are to be
taken care of. The purpose of these safety provisions isto protect the user,
theproductandthesystemagainstundesiredsituations(damage).Without
these safety provisions FlexLink cannot give a guarantee on any damage
caused in absence of these safety provisions.
The table below gives a general description of the safety provisions re-
quired. Here it should be noted that only technically qualified employees
are allowed to work on the settings of the safety provisions!
Control Remark
Emergency stop switch It is recommended that the X45 conveyor system should be provided with
one or more emergency stop switches that can be operated within reach
of the user.
The switch must have the standard red colour.
Motor protection Should the motor be overloaded for certain reasons, this should be
detected. Without this protection there is a chance that the Motor or other
components of the X45 system will be damaged.

Safety
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. . . 1.3.1 Noise level
. The noise level produced by the X45 conveyor system is under 65 dB(A).
1.3.2 Electrical cabinet
. Ensure that the electrical cabinet is closed and locked after working in the
electrical cabinet.
Never bypass the safety system.
Before working in the electrical cabinet, the main switch to the motor must
be turned off and locked. The key is retained by the service technician until
work is finished.
Examples of service work include:
• Disconnection of wiring
• Replacement of motors, etc.
• Service work in the electrical cabinet, terminal boxes, etc.
• Service work performed on the machine that cannot be seen from
the electrical cabinet.
For adjustment of photo-electric cells, inductive sensors, etc., power is re-
quired:
- Stop the system andwait until the moving parts have come to
a complete stop.

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1.4 Safety measures to be taken
For a safe operation of the conveyor system a number of safety measures
are to be taken. These include the following measures:
•Clean floor surface - With a clean floor surface the operator will
not be hindered while operating the system. This can prevent trip-
ping or slipping, so that the operator doesnot unexpectedly come
into contact with the system.

Technical specification
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2 Technical specification
2.1 Technical characteristics X45
Beam width 45 mm
Chain width 43 mm
Chain pitch 12,7 mm
Drive unit capacity 100- 200 N
Chain tension limit 100-200 N
Item width 10-100 mm
Maximum conveyor length 6 m
Maximum weight on conveyor 30 kg
Maximum load per 100 mm conveyor length (see picture below) 800 g (100 g/ link)
Maximum single item weight, horizontal transport (see picture
below)
800 g
Conveyor speed 5-20 m/min
Horizontal bends: 30°/45°/90°/180°
Radius 150 mm
Note! Maximum 2 bends/conveyor
Vertical bends: 5°/15°
Radius 400 mm
Note! 2 bends/conveyor
Electrostatic discharge feature (ESD) Standard/conductive
Max permissible puck weight
Example:
Max
100 g/ link
>= 100 mm (8 links)
Max permissible single item weight 800 g
Puck Ø 43,7
Max 250 g/ puck
Max permissible
(base, fixture, product)
product weight 200 g

Technical specification
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2.2 Operating conditions
The circumstances under which the X45 conveyor system can be applied
partly depend on the materials selected. FlexLink has defined a number of
parameters within which the system would be allowed to function. Should
the system still be applied beyond these limiting values, FlexLink cannot
guarantee the good functioning of it.
Ambient temperature (in operation) -20° to +60°C
During transport / storage 5 to +40°C
Relative air humidity (RH) 10% to 95%, not condensing
Lighting Normal ambient lighting

Functions
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3 Functions
3.1 Motors
The control system of the platform X45e is structured in an object oriented
way. All motors in the platform have embedded control units and local sen-
sors are connected directly to each motor unit. This layout gives a big ad-
vantage regarding software developing, electrical design and electrical in-
stallation.
3.1.1 Function control
The motor unit consists of a motor, circuit boards and eight connectors in
an encapsulated housing. There are two types of motor units, the drive unit
and the functionunit. All that differs on these variants are the motor andthe
mechanical housing.
The drive unit has a permanent magnetic (PM) motor and the function unit
has a stepper motor with an analogue position feedback sensor. An em-
bedded microprocessor is dedicated for the application control. Local sen-
sors are connected directly to this unit.
The motors can be autonomously controlled only by the input of the local
sensors or controlled from a line controller over a CANopen network.
The motor unit has also a LED on each side indicating its status. If the mo-
tors are in autonomous mode they only need power (24VDC) to work prop-
erly.
3.1.2 Line control
If a line controller is used up to 127 motors can be interlinked via an exter-
nal CANopen network. RFID reader/writers can be connected to the line
controller via a separate network (Profibus, DeviceNet or Ethernet). All dy-
namic route handling has to be implemented in the line controller.
The main electrical cabinet supplies the motor units with power, 24 VDC.
Thepower is divided insafe andcontinuouspower inorderto have the pos-
sibilities to implement emergency or safety stops

Functions
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3.2 Diverters, Mergers, Combined Diverter/
Mergers, Transfers, Stop and Locating
station for Puck handling
3.2.1 Diverters
Diverters are used to split a flow of pucks from one line into two. The lines
can be parallel or in a 90° angle.
The diverter is an active unit with one infeed and two outfeed conveyors.
There are four different variants of the diverter.
• Diverter, Parallel, Left
• Diverter, Parallel, Right
• Diverter, 90°, Left
• Diverter, 90°, Right
DL DLDR DR
90° 90°

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Figure 2 Diverter, parallel and 90°
The unit has two positions for photoelectric sensors. The first one is used
for sensing the queue status of the infeed conveyor. This sensor can be re-
placed by a RFID read/write head.
When a puck arrives the rotation disc opens up to receive the puck. The
second sensor is used for detecting that the puck has reached the gap of
the rotation disc. This is the trigger signal for the main rotation of the rota-
tion disc, with a puck in the gap.
The decision of which outfeed conveyor to release the puck on can be re-
ceived from the external bus, via a local sensor or from a predetermined
pattern.

Functions
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3.2.2 Mergers
Mergersare usedto combinethe flow fromtwolinesintoone.The lines can
be parallel or in a 90° angle.
The merger is an active unit with two infeed and one outfeed conveyor.
There are four different variants of the merger.
• Merger, Parallel, Left
• Merger, Parallel, Right
• Merger, 90°, Left
• Merger, 90°, Right
Figure 3 Merger parallel and 90°
The unit has two sets of guide brackets each containing two photoelectric
sensors. The first sensor position on each side is used for sensing the
queue status of the infeed conveyors. These queue sensors are the trigger
signal for the merger to moving the rotation disc to one of the two receive
positions. This is done either clockwise or counter clockwise depending on
which conveyor to receive pucks from.
The last sensor is used for sensing pucks in the gap of the rotation disc.
This is the trigger signal for the main rotation of the rotation disc, with a
puck in the gap. When the rotation disc has reached the release position
the cycle is complete and the unit waits for a new puck to arrive.
ML MLMR MR
90° 90°