Sacmi BTA 900 User manual

TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇAO TÉCNICA
DOCUMENTAZIONE
TECNICA
ENGLISH
INSTRUCTIONS MANUAL
166.07.A02
KNURLING MACHINE FOR ALUMINUM CAPS
CUTTING MACHINE FOR PLASTIC CAPS
BTA 900
Revision 00 Date 18.10.1998

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TABLE OF CONTENTS
166.07.A02 Revision 00 Date 18.10.1998

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166.07.A02
TABLE OF CONTENTS
Revision 00 Date 18.10.1998
MANUFACTURER
SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
PUBLISHED ON
18.10.1998
REVISED
00
VERSIONS
BTA 900.00.002/003 - BTA900A
SERIAL NUMBER
YEAR OF MANUFACTURE
INSTRUCTIONS MANUAL
KNURLING MACHINE FOR ALUMINUM CAPS
CUTTING MACHINE FOR PLASTIC CAPS
BTA 900

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TABLE OF CONTENTS
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166.07.A02
TABLE OF CONTENTS
Revision 00 Date 18.10.1998
1GENERAL INFORMATION........................................................................................................................1 - 1
1.1 INTRODUCTION........................................................................................................................ 1 - 1
1.2 WHERE TO KEEP THE MANUAL ............................................................................................. 1 - 1
1.3 HOW TO USE THE MANUAL.................................................................................................... 1 - 1
1.4 USERS OF THE MANUAL......................................................................................................... 1 - 1
1.5 WARRANTY............................................................................................................................... 1 - 2
1.6 ENCLOSURES........................................................................................................................... 1 - 2
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL ...1 - 2
1.8 MACHINE IDENTIFICATION PLATE..........................................................................................1 - 3
2MAIN FEATURES ......................................................................................................................................2 - 1
2.1 MACHINE DESCRIPTION ......................................................................................................... 2 - 1
2.1.1 MAIN DEVICES...........................................................................................................................2 - 2
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ............................................... 2 - 16
2.2 OVERALL DIMENSIONS......................................................................................................... 2 - 17
2.3 TECHNICAL CHARACTERISTICS.......................................................................................... 2 - 18
2.3.1 SPECIFICATIONS ................................................................................................................... 2 - 18
2.3.2 ALLOWABLE FLUCTUATIONS............................................................................................... 2 - 19
2.3.3 RATING PLATE ....................................................................................................................... 2 - 19
2.3.4 MATERIALS THAT CAN BE HANDLED.................................................................................. 2 - 20
2.3.5 NOISE EMISSION LEVELS..................................................................................................... 2 - 21
2.3.6 LUBRICANT SPECIFICATIONS.............................................................................................. 2 - 22
2.4 DIAGRAMS .............................................................................................................................. 2 - 23
2.4.1 PNEUMATIC SYSTEM DIAGRAM .......................................................................................... 2 - 23
2.4.2 COOLING SYSTEM DIAGRAM ............................................................................................... 2 - 24
2.4.3 VACUUM SYSTEM DIAGRAM ................................................................................................ 2 - 24
3SAFETY EQUIPMENT AND PRECAUTIONS.......................................................................................... 3 - 1
3.1 SAFETY DEVICES INSTALLED.................................................................................................3 - 1
3.2 GENERAL .................................................................................................................................. 3 - 3
3.3 SAFETY RULES FOR HANDLING .............................................................................................3 - 4
3.4 OPERATOR TRAINING ............................................................................................................. 3 - 5
3.5 SAFETY RULES FOR OPERATION AND MAINTENANCE ..................................................... 3 - 6
3.5.1 HAZARDS THAT MAY BE ENCOUNTERED IN THE MECHANICAL SYSTEM ...................... 3 - 7
3.5.2 HAZARDS THAT MAY BE ENCOUNTERED IN THE ELECTRIC SYSTEM ............................3 - 8
3.5.3 HAZARDS PRESENT IN THE HEAT SYSTEM..........................................................................3 - 9
3.5.4 SAFETY RULES FOR MAINTENANCE OPERATIONS............................................................ 3 - 9
3.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED .................................................3 - 9
4INSTALLATION ........................................................................................................................................ 4 - 1
4.1 SHIPPING AND HANDLING...................................................................................................... 4 - 1
4.2 POSITIONING THE MACHINE.................................................................................................. 4 - 3
4.3 CONNECTING AND HOOKING UP THE MACHINE .................................................................4 - 5
4.3.1 CONNECTING THE MACHINE TO THE COMPRESSED AIR LINE ........................................ 4 - 5
4.3.2 CONNECTING THE MACHINE TO THE COOLING SYSTEM ................................................. 4 - 5
4.3.3 ELECTRICAL HOOK UP.............................................................................................................4 - 6
5START UP..................................................................................................................................................5 - 1
5.1 GENERAL .................................................................................................................................. 5 - 1
5.2 PRELIMINARY CHECKS...........................................................................................................5-1
5.3 DAILY START UP ...................................................................................................................... 5 - 2
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6USE OF THE MACHINE ........................................................................................................................... 6 - 1
6.1 CONTROL DEVICES ................................................................................................................. 6 - 1
6.1.1 SWITCHBOARD ........................................................................................................................ 6 - 2
6.2 MANUAL OPERATION ...............................................................................................................6 - 4
6.3 AUTOMATIC OPERATION ........................................................................................................ 6 - 4
7ADJUSTMENTS........................................................................................................................................ 7 - 1
7.1 CAP INFEED CHANNEL.............................................................................................................7 - 1
7.2 INFEED TURN-TABLE............................................................................................................... 7 - 4
7.3 WORK DRUM .............................................................................................................................7 - 6
7.4 TOOL ADJUSTMENTS ...............................................................................................................7 - 8
7.4.1 ADJUSTMENTS......................................................................................................................... 7 - 8
7.4.2 DISASSEMBLING AND REPLACING THE TOOLS...................................................................7 - 9
7.5 SPINDLE ADJUSTMENT......................................................................................................... 7 - 13
7.5.1 ADJUSTING THE RADIAL POSITION OF THE SPINDLES ................................................... 7 - 14
7.5.2 ADJUSTING THE KNURLING STAGE FOR ALUMINUM CAPS............................................ 7 - 16
7.5.3 REPLACING THE SPINDLE PINION FOR SIZE CHANGE-OVER......................................... 7 - 17
7.5.4 REPLACING THE MOVABLE TOOLS FOR SIZE CHANGE-OVER....................................... 7 - 17
7.6 EXIT CHANNEL ....................................................................................................................... 7 - 17
7.7 CONVEYING CHANNEL.......................................................................................................... 7 - 19
7.8 LOWER FRAME....................................................................................................................... 7 - 19
7.9 DRIVE UNIT ............................................................................................................................. 7 - 19
7.10 PNEUMATIC SYSTEM ............................................................................................................ 7 - 21
7.11 COOLING SYSTEM ................................................................................................................. 7 - 21
7.12 VACUUM SYSTEM .................................................................................................................. 7 - 21
7.13 ELECTRICAL CABINET........................................................................................................... 7 - 21
7.14 SAFETY DEVICES AND GUARDS ......................................................................................... 7 - 21
8MAINTENANCE OPERATIONS ............................................................................................................... 8 - 1
8.1 SCHEDULED MAINTENANCE.................................................................................................. 8 - 2
8.2 SPECIAL MAINTENANCE ......................................................................................................... 8 - 4
8.3 TROUBLESHOOTING ............................................................................................................... 8 - 4
8.3.1 TROUBLESHOOTING THE MACHINE ......................................................................................8 - 5
8.3.2 TROUBLESHOOTING THE PRODUCT .................................................................................... 8 - 6
9DISMANTLING...........................................................................................................................................9 - 1
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GENERAL INFORMATION 1
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1 GENERAL INFORMATION
1.1 INTRODUCTION
E0004P
WARNING!
Carefully read the entire Maintenance and Operations Manual before working on the machine and/or the packaging
of the various parts.
This manual contains important information for safeguarding the operators, the maintenance staff as well as the
machine itself.
Sacmi reserves the right to make changes to the machine and in the manual without giving prior notice.
Copyright. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI.
The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,
reproduced, disclosed or transferred.
Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.
1.2 WHERE TO KEEP THE MANUAL
E0004P
WARNING!
This manual is to be considered an essential part of the machine and must be kept along with it even if the machine
is sold. Always keep the manual near the machine where it can be easily consulted. The manual must always be at
hand so that the operator and maintenance staff are able to consult it rapidly at any time.
1.3 HOW TO USE THE MANUAL
The lay out of this manual allows it to be easily consulted as all the information and instructions provided are grouped
together and divided into chapters and paragraphs. The user has to simply refer to the table of contents.
The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to the
operator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and
are written in italics, as shown below.
E0004P
WARNING!
The SAFETY EQUIPMENT AND PRECAUTIONS chapter (chapter 3) must be carefully read in its entirety as it
contains important information and warnings regarding safety.
1.4 USERS OF THE MANUAL
In this manual the machine operators are categorized as follows:
- Operator: this is the person responsible for supervising and operating the machine.
- Routine maintenance men.
For a more detailed description, see paragraph 3.4 which deals with OPERATOR TRAINING found in the SAFETY
EQUIPMENT AND PRECAUTIONS chapter (chapter 3).

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1.5 WARRANTY
SACMI shall be held responsible only for the machine as it was configured at the time of delivery.
Anyoperations that alterthe configuration ofthe machine oroperating cycle mustbe carried outby SACMI personnel
or duly authorized by SACMI’S Engineering Dept.
SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.
E0004P
ATTENTION!
The machine operator or maintenance staff are not responsible for carrying out operations under warranty, special
maintenance and repairs. These operations are to be performed only by the manufacturers specially trained
technicians. For this reason, these types of operations are not dealt with in this manual.
1.6 ENCLOSURES
Information regarding the electric and electronic components of the machine are given in three handbooks provided
under separate cover and are entitled:
- USE OF THE MICROPROCESSOR CONTROL SYSTEM (Instructions B manual)
- LIST OF DEVICES, SETTING DATA AND NOTES ON USE
These handbooks are supplied with this manual.
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE
MANUAL
WARNING SYMBOLS
E0004P
General hazard
E0002P
Danger of being burnt on hot surfaces (when plastic caps are handled)
E0003P
Danger of hands being crushed
E0007P
High tension, danger of being electrocuted

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T1133
TIPO
TYPE
MATRICOLA No.
SERIAL NUMBER
ANNO
YEAR
VIA SELICE PROVINCIALE 17/A IMOLA - ITALIA
E0020
ALERT SYMBOLS
E0005O
Heavy duty work gloves must be worn (when plastic caps are handled)
E0006O
Machine must be connected to an effectively grounded power point
ADDITIONAL SYMBOLS
E0009C
A list of the tools required to carry out maintenance is provided
1.8 MACHINE IDENTIFICATION PLATE

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2 MAIN FEATURES
2.1 MACHINE DESCRIPTION
The BTA900 is a rotary machine that operates on a horizontal axis .
Theparticularfeatureofthismachine is its ability toknurl,profileandcutthecylindricalpartofformedaluminum caps.
Whenplasticcapsarehandled,themachineisalsocapableofcuttingtheplastictoform the safety seal. The machine
consists of two coaxial drum assemblies placed opposite each other. The infeed turn-table supplies the caps to the
spindles located on the work drum. Thanks to the microprocessor-based switchboard, all the required information for
operation is provided in real time. The machine can be basically subdivided as illustrated in the figure below.
Fig. 2.1 - OVERALL VIEW
1 Cap feed channel
2 Infeed turn-table
3 Work drum
4 Tools
5 Spindle
6 Exit channel
7 Conveying channel
8 Lower frame
9 Drive unit
10 Pneumatic system
11 Cooling system
12 Switchboard
13 Safety guard
14 Vacuum system
3
5
1
T1135
7
6
9
14
8
3
13 42
T1134
2
11
10
12

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2.1.1 MAIN DEVICES
2.1.1.1 Cap infeed channel
(see figures 2.1.1.1/A and 2.1.1.1/B)
The caps are directed into the machine by the infeed channel (1) secured to the base. A section of the channel can
be inspected by opening the door (2) with the knob (3). Two adjustable air blowers (18 and 19) are mounted on the
door to feed the caps and prevent jamming. A fiber optic photocell (6) is mounted on the infeed channel. The purpose
ofthis device is todetect when the levelof caps in thechannel reaches minimum. Thepneumatic cylinder (4) controls
the cap flow and stops the caps, when required, by applying pressure. This happens when the fiber optic photocell
(6) located at the entrance of the cap infeed channel is free (no caps present) or when
the photocell located in the exit channel is activated (channel full of caps). The pressure applied by the caps is strictly
related to the pressure of the air that supplies the cylinder.

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Fig. 2.1.1.1/A - FIXED ALUMINIUM CAP INFEED CHANNEL
1 Cap infeed channel
2 Door
3 Knob
4 Pneumatic cylinder
6 Fiber optic photocell
7 Screw
8 Fiber optic mount
9 Fiber optic
14 Bracket
15 Nut
16 Insert
17 Grub screw
18 Air blower
19 Air blower
14
16
15
17
4
T1167
7
1
419 3
2
18
9
6
4
8

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Fig. 2.1.1.1/B - FIXED INFEED CHANNEL FOR PLASTIC CAPS
1 - Infeed channel
2- Door
3 - Knob
4 - Air cylinder
6 - Fiber optic photocell
7 - Screw
8 - Fiber optic mount
9 - Fiber optic
14 - Bracket
15 - Nut
16 - Insert
18 - Air blower
19 - Air blower
4
7
6
9
8
18
2
3
19
1
T1745
14
15
4
T2028
4
16

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2.1.1.2 Infeed turn-table
(see figure 2.1.1.2)
The infeed turn-table picks up the caps from the channel and deposits them on the spindles of the work drum.
The feed rods (2) are mounted on the drum body (1).
The incoming caps are held in place against the wheel (3) until they are finally placed in the cavity (4) mounted on the
rod (2).
The caps are placed on the spindles thanks to the rod (2) which follows the movement of the cam (5) by means of the
rollers (8).
The vacuum distributor (15) is found inside the cam (5) and is held against the body of the turn-table (3) by the spring
(16). Vacuum reaches the feed rods (2) through the ducting in the body (1).
The caps are held inside the cavities (4) by the vacuum created until they are let onto the spindles of the work drum.
Once the work-cycle has been completed, the rods (2) pick up the caps from the spindles and then place them inside
the exit channel. This is accomplished as the rods follow the cam’s (5) movement through the rollers (8) provided.

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27
8
5
6
16
21
20
19
21
4
11
12
3
1
15
Figure 2.1.1.2 - INFEED TURN-TABLE
1 Turn-table body
2 Feed rod
3 Wheel
4 Cavity
5 Cam
6 Guard
7 Guide tab
8 Rollers
11 Screw
12 Screw
15 Vacuum distributor
16 Spring assembly
19 Shaft
20 Mount
21 Extension

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2.1.1.3 Work drum
(see figure 2.1.1.3)
The spindles are mounted on the work drum which turns them and ejects the caps into the feed units.
Theshaft(1),keyedto the mount (2),seesthatthebodyoftheworkdrum(3)rotates. The gear(4)securedtoasleeve
actsasafixedgearwheelwhichdrivesthespindles.Thedistributor(6)isheldagainstthering(7)bythedisk(8)through
the spring units (9). Nozzles (10) are mounted on the ring (7). The latter blow air through the spindle (10) to eject the
caps. The first flange bearing (11) can be warmed up. In addition, wedges (15) (two for each spindle) ensure that the
spindles (19) are locked in place.

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T1142
Figure 2.1.1.3 - WORK DRUM
1 Shaft
2 Mount
3 Drum body
4 Gear
6 Distributor
7 Ring
8 Disk
9 Spring unit
10 Nozzle
11 First flange bearing
15 Wedge
16 Screw
17 Section
18 Dowel
19 Spindle
10
4
7689
2
A
15
3
11
19
1
T1140
A
4
4
17 16
18
8

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2.1.1.4 Tools
Fixed and movable tools need to be used to produce caps that meet the customer’s own individual requirements.
A data sheet is provided for all the tools, whether they be fixed or movable, which states the dimensions and
specifications of each individual part. This is done to ensure correct exchange with the spare parts.
2.1.1.5 Spindle
(see figure 2.1.1.5)
The movable tools which are needed to produce the caps are mounted on the spindles. The unit consists of a bush
(1) that houses the ball bearings that support the shaft (3). The pinion (4) is mounted on the rear of the shaft (3) and
is secured in place by the nuts (5). A seat which houses the movable tools is found at the front. The spindles are
mounted in the seats of the work drum (9) and are held in place by the wedges (7).

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T1143
Figure 2.1.1.5 - SPINDLE
1 Bush
3 Shaft
4 Pinion
5 Nut
7 Wedge
8 Flange
9 Drum
11 Movable tools
7
9
T1140
3
1
4
5
8
11