Flexologic FAMM User manual

1
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
User manual
FAMM
Full-automatic mounting machine
Summary
This document is the user manual for the Full-Automatic flexo plate mounting machine FAMM
of AV Flexologic BV and explains the procedures required for general operation of the FAMM.
Revision history
Date
Change
Revision
Name
20-jun-2016
Creation of document
V01-01
DaBe
NOTE: Document may only be used if the revision history states a “RELEASED” status

2
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
Contents
1. Introduction .............................................................................................................................................2
2. Safety information ...................................................................................................................................2
3. Liability.....................................................................................................................................................3
4. Contact information.................................................................................................................................3
5. Tools list ...................................................................................................................................................3
6. Starting the machine................................................................................................................................3
7. Emergency shutdown procedure.............................................................................................................5
8. Light pillar.................................................................................................................................................6
9. Adding a new job .....................................................................................................................................7
10. Adding plates to the cylinder...................................................................................................................8
11. Preparation before mounting ..................................................................................................................9
12. Mounting plates.......................................................................................................................................9
13. Printing mounting information (reports)...............................................................................................10
14. Microdot not recognized at pickup position..........................................................................................10
15. Microdots not recognized at mount position........................................................................................11
16. Adobe AcrobatTM Plug in........................................................................................................................14
17. ESKO graphics® PlatepatcherTM..............................................................................................................14
18. Importing a MOM file ............................................................................................................................14
19. External job creation..............................................................................................................................16
20. Non-disclosure .......................................................................................................................................17
1. Introduction
This is the user manual for the Fully Automatic Mounting Machine (FAMM), a mounting machine which
eliminates the human factor in the mounting process. This manual describes the operation of the FAMM.
The intended audience is the client, or client’s service/operational personnel. All steps in this manual are
required to be followed in detail. If there are any deviations, a remark can be placed in the comments
sections in this document and please contact the service department at AV Flexologic BV.
2. Safety information
Sound emission of this machine does not exceed 70 dB (A).
While using the FAMM the following personal protective equipment (PPE) is required:
#
Description
Qty
1
Steel toe boots
pair
2
NOTE: Please check the user manuals of the above PPE on responsible use of these PPE.

3
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
3. Liability
AV Flexologic BV is not accountable for injuries sustained from using the FAMM, if personnel is not
properly schooled, if steps in this manual were not followed in detail, if incorrect tooling was used, or if
proper personal protective equipment was not used.
4. Contact information
If there are any questions or obscurities during the use of this manual and there is no
means of continuing, please contact the service department of AV Flexologic at [e-mail]
5. Tools list
The following tools are required to operate the FAMM. Please make sure the tools are available before
starting. If these tools are not available, please do not use the FAMM.
#
Description
Qty
1
NONE
2
3
NOTE: Images are indicative, colours and/or shapes may vary.
6. Starting the machine
This section describes the power-up of the FAMM.
Step
Action
1
Make sure the machine has been powered down for at least 5 minutes.
2
Make sure the emergency stop button(s) are not activated (See section 7)
3
Turn the main power switch located on the front of the machine to the “ON” position:
4
Wait for the system to power up.
5
Enter username: Operator
Enter password: avmom
6
Wait for the software to completely boot up.
A
B
I: POWER ON POSITION (A)
O: POWER OFF POSITION (B)

4
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
7
Press the blue or white RESET button. (After reset the light of the button will go off)
8
The FAMM control software will automatically start-up and show the main screen.
Wait 30 seconds until the red bars disappear.
9
Click on Initialize (A) and wait for everything to turn green.
12
The machine is now fully powered up and ready to be used
13
DONE
Comments
A

5
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
7. Emergency shutdown procedure
This section describes the procedure for an emergency shut down.
Step
Action
The FAMM is equipped with 2 emergency stop buttons (A). These buttons are situated at the
front of the machine, one on the left and one on the right side of the machine. These buttons
are for situations in which the FAMM needs to immediately stop all actions.
1
In case of an emergency, press an emergency stop button firmly. The FAMM will immediately
stop all actions.
Use of the emergency stop buttons is only allowed in an emergency situation and may not
be used under normal operational conditions to switch off the machine. Use of the
emergency stop button can potentially lead to the need to (re) calibrate the machine.
2
After the emergency situation is resolved, rotate the red part of the activated pushbutton, as
indicated on the button, until it “pops” out to release it.
3
After resetting the emergency stop button, reset the machine as described in section 6 step 7.
4
DONE
Comments
A
A

6
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
8. Light pillar
This section describes the different signals on the light pillar on the FAMM.
Step
Action
When the light pillar is green, the machine is busy mounting.
No action is required.
When the light pillar flashes green, the machine has finished and the sleeve is ready to swing
out and be changed.
Operator assistance is required to continue.
When the light pillar is red, the machine has stopped, because an emergency stop has been
pressed.
The emergency needs to be resolved and the emergency stop button needs to be reset and
the reset button needs to be pressed.
When the light pillar flashes red, the machine has stopped because an error has occurred.
Operator assistance is required to solve the error and continue.

7
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
9. Adding a new job
This section describes how to create a new job on the FAMM operator terminal.
Step
Action
1
Click on Add a job (A) and add a job name (B), job number (C), number of cylinders (D),
operator name (E) and optional comments (F).
Click on the Save button.
2
Select the plate type for both cameras. (A)
Click on the Save button
3
You have now created a new job
4
DONE
Comments
A
B
C
D
E
F
A

8
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
10. Adding plates to the cylinder
This section describes how to add a plate to a cylinder in the FAMM software.
Step
Action
1
Find the cylinder you want to add a plate to in the job tree on the left and click on the “+” next to
the job name / item number to open the job (A).
Click on the “+” next to ‘cylinder 1’ to open the cylinder (B).
Click on “add a plate…” (C).
2
Fill out the details of the plate:
A–X coordinate
B–Width between microdots
C–Top height
D–Bottom height
Click on Save (E)
3
Copy the current cylinder for multiple colours by clicking “copy” (A):
4
DONE
Comments
A
B
C
A
B
C
D
E
A
A

9
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
11. Preparation before mounting
This section describes the preparations to be made prior to mounting.
Step
Action
1
Select a job from the drop down menu.
2
Check if the correct cylinder size is set in the job description.
3
Open the safety fence
4
Place a cylinder
5
Close the safety fence
6
Click on X
7
DONE
12. Mounting plates
This section describes how to start mounting plates onto the cylinder.
Step
Action
1
Check if the correct sleeve size is inside the machine.
Check if the plate(s) is/are on the conveyor belt.
2
Click on “Mount” in the home screen (A).
3
Click on “Start” in the mounting screen (A).
4
The machine will start mounting the plates.
5
DONE
Comments
A
A

10
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
13. Printing mounting information (reports)
The following section describes how to print reports from the mounted plates.
Step
Action
1
Go to the quality or graphs screen and click on the “print” button
2
A dialogue will appear with options on how to print the report.
3
The print options are:
Option
Result
Job information
General job information
Set information
Table with set information.
Mounting marks information
Coordinate table with mounting marks sorted
by sets
Repeat marks information
Coordinate table including report mars
information (only possible when job was
mounted with this option) sorted by sets
Graphs
The graphs of selected sets
4
Press OK to generate the report.
5
The report will standard be saved as report.rpt, or the custom name is given in the dialog box.
6
DONE
Comments
14. Microdot not recognized at pickup position
This section describes how to solve the microdot not being recognized on the FAMM when the plate has
gone too far beyond pickup position.
Step
Action
1
Click on “Manual” (A) at the pickup position when the microdots are not found.
A

11
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
2
Use the arrows on the bottom right to move the plate backwards and get the microdots within
the field of view of the camera.
3
Click on “Close” and “Ok” to continue automatic mode.
4
DONE
Comments
15. Microdots not recognized at mount position
This section describes the microdots not being recognized by the FAMM at mount position.
Step
Action
1
When the button continue not found (A) is blinking, check if the microdots are within the field of
view of the camera;
2
When the microdots are not in the field of view, go to section13. If they are within the field of
view of the cameras continue to the next step.
3
Click on “manual” to enter the Semi-auto mounting screen:
4
Reset the zoom by clicking on “zoom” in the reset box:
A

12
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
5
Use the control buttons to roughly position the red cross over the micro dot.
6
Use the slider to zoom in on the microdot by setting the slider to 3.0
7
Use the controls to fine tune the positioning of the red cross over the micro dot:

13
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
8
Click on “train target” to teach the target to the FAMM
9
Click on “continue”
10
DONE
Comments

14
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
16. Adobe AcrobatTM Plug in
The PDF plug-in was developed to increase the efficiency and accuracy in the pre-press process.
The pre-press process starts at the DTP-department and ends in the mounting department.
The plug-in stores the coordinates of the register marks made by the DTP department and saves them into
a separate files with the extension ‘mom’, short for Mount ‘O’ Matic, and from now on called MOM files.
This generated mom file can be read (imported) by the FAMM. The MOM file contains all the information
to automatically generate a new job that contains all the necessary information. All data does not need to
be added manually anymore which saves time and prevents errors.
To be able to use the PDF plug-in, the Adobe Acrobat™ standard or professional needs to be installed.
For further information on how to operate the PDF plug-in please refer to the PDF plug-in manual.
17. ESKO graphics® PlatepatcherTM
The DTP software developed by ESKO graphics® called Plate patcher™ has the possibility to generate MOM
files which can be imported by the FAMM. This software has 2 additional features being:
1) The possibility to generate clichés with multiple register mark pairs (as the FAMM supports)
2) The possibility to include the plot file which can be read in and drawn by the mounting machine
(Not supported by the FAMM)
This makes it possible to automatically generate the clichés which have three register mark pairs.
For further information on how to operate the plate patcher™ software, please consult the
plate patcher™ manual.
18. Importing a MOM file
To import the required MOM file, open the import screen by clicking the “Import’ button on the main
screen. Select the MOM file in the import screen. It is also possible to manipulate the coordinates
in the MOM file during import:
Mirror horizontally, Mirror vertically, Rotate or None.
The selected option will not change the contents of the MOM file itself.
The image is read from the MOM file, manipulated (mirroring) and stored in the database as a new job.
The DTP department has to define an area in which all the clichés are located. This area will be used as the
reference for the optional manipulation during import.

15
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
Below are some examples to clarify the functionality:
The mom file consists of three clichés positioned as shown below.
When ‘No mirror’ is selected the job is created with the clichés positioned as shown below.
With ‘Hor. Mirror’ they are mirrored horizontally over a vertical axis.
With ‘Vert. Mirror’ they are mirrored vertically over a horizontal axis.
Using horizontal and vertical mirroring at the same time, is equal to an 180orotation.
1
2
3
Area from DTP
1
2
3
1
2
3
As in MOM file
After ‘No mirror’
1
2
3
1
2
3
As in MOM file
After ‘Hor. mirror’
1
2
3
1
As in MOM file
After ‘Vert mirror’
3
2

16
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
Every time a MOM file is imported a new job is created. Not all fields in the imported job may be filled in
correctly. The fields which are not present in the MOM file will be filled in with the default values.
These default values are the same as when a new job is created manually.
If these default values are not the correct values for this job, they need to be changed before you can start
mounting. The values which might need changing after import are:
Field name
Description
Cylinder width
With of the to be used cylinder/sleeve
Cylinder repeat
The repeat of cylinder /sleeve including buildup
Tolerance
The accepted mounting tolerance
Check tolerance
The accepted check tolerance for OK or NOK
Press overshoot
Additional press distance to press down the entire cliché
Plate data
Name of plate type selected
Tape data
Name of tape type selected
Remarks
Will indicate this was an imported job
19. External job creation
Besides the usage of plug-in software, it is possible to have an additional PC dedicated for entering jobs.
This PC is also known as the Offline Filling Database (OFD).
While entering jobs manually into the FAMM with the OFD, the FAMM can still mount simultaneously.
Both computers are connected via a network cable and share the database containing the jobs.
The OFD computer is dedicated for creating jobs and cannot control the FAMM.
There are 2 different ways to implement this system:
Option 1
The image below shows the so-called ‘stand-alone’ solution.
The FAMM is connected to the OFD using a cross-link Ethernet cable.
Jobs are stored on 1 of the computers, preferably the FAMM computer, and the other computer has access
through the Ethernet connection. The computer which holds the jobs must be switched on for the other
computer to reach them. This is why it is preferred to locate the jobs on the FAMM computer.
1
2
3
1
As in MOM file
After ‘hor. and vert. mirror’
3
2

17
H. Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands
CONFIDENTIAL - THIS DOCUMENT MAY NOT BE DISCLOSED TO ANY THIRD PARTY OR USED FOR ANY
OTHER PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF AV FLEXOLOGIC BV
CONFIDENTIAL
Option 2
The ‘stand-alone’ network of the FAMM is connected to the existing internal company network using a
switch or hub. This way, the FAMM is integrated in to the total company network. Jobs can be located on
the company server. Which in most cases is never switched off. Multiple SAMMs can access the same
database of jobs.
Disadvantage of option 1 compared to option 2 is that if the jobs are stored locally there are
no automatic backups of the jobs.
20. Non-disclosure
This document, and all parts of this document including images, drawings and schematics, remain property
of AV Flexologic BV and may not be distributed, copied digitally, photocopied, photographed or copied in
any other way. All information described in this document is classified and may not be discussed or
negotiated with third parties without express written permission of AV Flexologic BV.
The recipient(s) of this document is (are) aware of this confidentiality and agree to the above.
Violating this non-disclosure may result in penalties decided by Dutch law and/or international corporate
law.
FAMM with control computer
OFD computer
Ethernet (TCP/IP) connection
Stand-alone configuration
FAMM with control computer
Server or workstation
Ethernet (TCP/IP) connection
Server or workstation
Customer network
Network configuration
HUB