Haas Automatic Pallet Changer Operation Manual Supplement v4
en
Haas Technical Publications Manual_Archive_Cover_Page Rev A
June 6, 2013
This content is for illustrative purposes.
Historic machine Service Manuals are posted here to provide information for Haas machine owners.
Publications are intended for use only with machines built at the time of original publication.
As machine designs change the content of these publications can become obsolete.
You should not do mechanical or electrical machine repairs or service procedures unless you are qualified and knowledgeable about the processes.
Only authorized personnel with the proper training and certification should do many repair procedures.
HAAS SERVICE AND OPERATOR MANUAL ARCHIVE
WARNING: Some mechanical and electrical service procedures can be extremely dangerous or life-threatening. Know your skill level and abilities.
All information herein is provided as a courtesy for Haas machine owners for reference and illustrative purposes only. Haas Automation cannot be held responsible for repairs you perform. Only those services and repairs that are provided by authorized Haas Factory Outlet distributors are guaranteed.
Only an authorized Haas Factory Outlet distributor should service or repair a Haas machine that is protected by the original factory warranty. Servicing by any other party automatically voids the factory warranty.
Automatic Pallet Changer Operators Manual 96-0012 RevC English June 2001
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Haas Technical Publications Manual_Archive_Safety_Pages Rev A
June 6, 2013
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READ BEFORE OPERATING THIS MACHINE: Onlyauthorizedpersonnelshouldworkonthismachine.Untrainedpersonnelpresentahazardtothemselvesandthe
machine,andimproperoperationwillvoidthewarranty.
Useappropriateeyeandearprotectionwhileoperatingthemachine.ANSIapprovedimpactsafetygogglesandOSHA approvedearprotectionarerecommendedtoreducetherisksofsightdamageandhearingloss.
Donotoperatethemachineunlessthedoorsareclosedandthedoorinterlocksarefunctioningproperly.Rotatingcut- tingtoolscancausesevereinjury.Whenaprogramisrunning,themilltableandspindleheadcanmoverapidlyatany timeinanydirection.
TheEmergencyStopbuttonisthelarge,circularredswitchlocatedontheControlPanel.PressingtheEmergencyStop buttonwillinstantlystopallmotionofthemachine,theservomotors,thetoolchanger,andthecoolantpump.Usethe EmergencyStopbuttononlyinemergenciestoavoidcrashingthemachine.
Theelectricalpanelshouldbeclosedandthekeyandlatchesonthecontrolcabinetshouldbesecuredatalltimes exceptduringinstallationandservice.Atthosetimes,onlyqualifiedelectriciansshouldhaveaccesstothepanel.When themaincircuitbreakerison,thereishighvoltagethroughouttheelectricalpanel(includingthecircuitboardsandlogic circuits)andsomecomponentsoperateathightemperatures.Therefore,extremecautionisrequired.Oncethema- chineisinstalled,thecontrolcabinetmustbelockedandthekeyavailableonlytoqualifiedservicepersonnel.
Consultyourlocalsafetycodesandregulationsbeforeoperatingthemachine.Contactyoudealeranytimesafetyis- suesneedtobeaddressed.
DONOTmodifyoralterthisequipmentinanyway.Ifmodificationsarenecessary,allsuchrequestsmustbehandledby HaasAutomation,Inc.AnymodificationoralterationofanyHaasMillingorTurningCentercouldleadtopersonalinjury and/ormechanicaldamageandwillvoidyourwarranty.
Itistheshopownersresponsibilitytomakesurethateveryonewhoisinvolvedininstallingandoperatingthemachine isthoroughlyacquaintedwiththeinstallation,operation,andsafetyinstructionsprovidedwiththemachineBEFORE theyperformanyactualwork.Theultimateresponsibilityforsafetyrestswiththeshopownerandtheindividualswho workwiththemachine.
Thismachinecancausebodilyinjury.
Donotoperatewiththedooropen.
Donotoperatewithoutpropertraining.
Alwayswearsafetygoggles.
Themachineisautomaticallycontrolledandmaystartatanytime.
Theelectricalpowermustmeetthespecificationsinthismanual.Attemptingtorunthemachinefromanyother sourcecancauseseveredamageandwillvoidthewarranty.
DonotpressPOWERUP/RESTARTonthecontrolpaneluntilaftertheinstallationiscomplete.
Donotattempttooperatethemachinebeforealloftheinstallationinstructionshavebeencompleted.
Neverservicethemachinewiththepowerconnected.
Improperlyclampedpartsmachineathighfeeds/feedmaybeejectedandpuncturethesafetydoor.Machining oversizedormarginallyclampedpartsisnotsafe.
Windowsmustbereplacedifdamagedorseverelyscratched-Replacedamagedwindowsimmediately.
Thespindleheadcandropwithoutnotice.Personnelmustavoidtheareadirectlyunderthespindlehead.
Donotresetacircuitbreakeruntilthereasonforthefaultisinvestigated.OnlyHaas-trainedservicepersonnel shouldtroubleshootandrepairtheequipment.
Haas Technical Publications Manual_Archive_Safety_Pages Rev A
June 6, 2013
Followtheseguidelineswhileperformingjobsonthemachine:
Normaloperation-Keepthedoorclosedandguardsinplace,whilemachineisoperating. PartloadingandunloadingAnoperatoropensthedoororguard,completestask,closesdoororguardbeforepress- ingcyclestart(startingautomaticmotion). ToolloadingorunloadingAmachinistentersthemachiningareatoloadorunloadtools.Exittheareacompletely beforeautomaticmovementiscommanded(forexample,nexttool,ATC/TurretFWD/REV). Machiningjobset-upPressemergencystopbeforeaddingorremovingmachinefixtures. Maintenance/MachineCleanerPressemergencystoporpoweroffthemachinebeforeenteringenclosure. Donotenterthemachiningareaanytimethemachineisinmotion;severeinjuryordeathmayresult.
UnattendedOperation FullyenclosedHaasCNCmachinesaredesignedtooperateunattended;however,yourmachiningprocessmaynotbe safetooperateunmonitored.
Asitistheshopownersresponsibilitytosetupthemachinessafelyandusebestpracticemachiningtechniques,itis alsotheirresponsibilitytomanagetheprogressofthesemethods.Themachiningprocessmustbemonitoredtopre- ventdamageifahazardousconditionoccurs.
Forexample,ifthereistheriskoffireduetothematerialmachined,thenanappropriatefiresuppressionsystemmust beinstalledtoreducetheriskofharmtopersonnel,equipmentandthebuilding.Asuitablespecialistmustbecontacted toinstallmonitoringtoolsbeforemachinesareallowedtorununattended.
Itisespeciallyimportanttoselectmonitoringequipmentthatcanimmediatelyperformanappropriateactionwithout humaninterventiontopreventanaccident,shouldaproblembedetected.
DONOTmodifyoralterthisequipmentinanyway.Ifmodificationsarenecessary,allsuchrequestsmustbehandledby HaasAutomation,Inc.AnymodificationoralterationofanyHaasmachiningcentercouldleadtopersonalinjuryand/or mechanicaldamageandwillvoidyourwarranty.
MODIFICATIONSTOTHEMACHINE
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TohelpensurethatCNCtooldangersarequicklycommunicatedandunderstood,hazardsymboldecalsareplacedon HaasMachinesinlocationswherehazardsexist.Ifdecalsbecomedamagedorworn,orifadditionaldecalsareneeded toemphasizeaparticularsafetypoint,contactyourdealerortheHaasfactory.
Neveralterorremoveanysafetydecalorsymbol.
Eachhazardisdefinedandexplainedonthegeneralsafetydecal,locatedatthefrontofthemachine.Particularloca- tionsofhazardsaremarkedwithwarningsymbols.Reviewandunderstandthefourpartsofeachsafetywarning, explainedbelow,andfamiliarizeyourselfwiththesymbolsonthefollowingpages.
NEVEROPERATETHISMACHINEWITHTHEDOORSOPEN.
SAFETYDECALS Haas Technical Publications
Manual_Archive_Safety_Pages Rev A June 6, 2013
MILLWARNINGDECALS
Haas Technical Publications Manual_Archive_Safety_Pages Rev A
June 6, 2013
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LATHEWARNINGDECALS
Haas Technical Publications Manual_Archive_Safety_Pages Rev A
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Otherdecalsmaybefoundonyourmachine,dependingonthemodelandoptionsinstalled:
..
OTHERSAFETYDECALS
Haas Technical Publications Manual_Archive_Safety_Pages Rev A
June 6, 2013
96-0012 rev C 1
June 2001 O MPERATORS ANUAL
A u t o m a t i c P a l l e t C h a n g e r
1.0 AUTOMATIC PALLET CHANGER (APC)
SPINDLE LOAD
EMERGENCY STOP
CYCLE START FEED HOLD
POWER ON POWER OFF
HANDLE
1.1 OVERVIEW
IMPORTANT!
Read this entire section before attempting to install or run the APC. Serious injury or damage to the machine could result from not following these procedures.
The HAAS Automatic Pallet Changer (APC) is used to automatically load and unload pallets into a HAAS VF-3 or VF-4. The APC is controlled by the VMC control, and uses the same air and power supplies. A simple M code (M50) is all that is required to change pallets.
The APC assembly consists of the base, which serves as the home position for the two 19 x 40 pallets, and a receiver assembly, which is bolted to the VMC table and holds the pallets in place during machining opera- tions. The VMC unit contains air lines for clamping pallets, and a special automatic door in the side of the VMC enclosure allows for loading and unloading of pallets. The APC has its own operator's panel, which includes CYCLE START, FEED HOLD, PALLET READY, and EMERGENCY STOP buttons.
The APC can be programmed to load a pallet or change pallets by calling an M50. When a pallet change is programmed, the VMC table moves to the right and adjacent to the empty pallet position on the APC base. The receiver assembly then unclamps the pallet. The automatic door opens, the table moves to the unload position, and the pallet is pulled into its home position. The VMC table moves over to the other pallet position, the next pallet is pushed onto the receiver, and the pallet is clamped into position. The table then returns to its pro- grammed position and the door closes.
Pallet movement is accomplished through the use of a drive motor and chain. The drive motor has a nonadjust- able slip clutch that prevents damage to the motor if the pallet change is physically blocked.
NOTE: The machine will beep during a pallet change. This is an audible warning signal, and not an alarm.
INTRODUCTION
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INTRODUCTION
1.2 APC WORKING DIMENSIONS
B
A
D
C C
E
F
A.
B.
C.
D.
E.
F.
20 (50.8 cm) DOOR HEIGHT ABOVE PALLET.
40 (101.6 cm) DOOR OPENING WIDTH.
19 (48.26 cm) PALLET WIDTH.
3/8 (.95 cm) DISTANCE BETWEEN PALLETS.
1/2 (1.27) DISTANCE BETWEEN PALLET AND DOOR.
40 (101.6) PALLET LENGTH.
APC DIMENSIONS
APC WORK ENVELOPES
OF TOOL HOLDER V-GROOVE
LOWEST POINT ON CAROUSEL
9" (22.86 cm)
CL 0F TOOL HOLDER TOOL CHANGER COVER
CL
21.69" (55 cm)
TOOL CHANGE POSITION
26" (66 cm)
MAX Z-AXIS TRAVEL
MILL TABLE (AT HOME POSITION) SIZE: VF-3 48" x 18", (121.92 cm x 45.72 cm) TRAVEL: VF-3 40" x 20", (101.60 cm x 50.80 cm)
ENCLOSURE USEABLE WORK SPACE
19.38 (49.23 cm)
CHIP TRAY
PALLET
1.38 Chip Tray (3.51 cm)
5.8 (14.23 cm)
20 (50.8 cm)
APC DOOR OPENING
58 (147.32 cm)
46 (116.84 cm)
Top of Pallet
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June 2001 O MPERATORS ANUAL
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INTRODUCTION
APC PALLET CLEARANCES
A 1-1/4 D 3* B 1-3/8* E 1-1/2* C 6-1/4 F 4-1/2*
*The same for both VF-3 and VF-4
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2.0 MAINTENANCE SCHEDULE
The following is a list of required regular maintenance for the HAAS Automatic Pallet Changer. These specifica- tions must be followed in order to keep your machine in good working order and to protect your warranty.
PERIODIC MAINTENANCE
INTERVAL MAINTENANCE PERFORMED
DAILY Clean chips, coolant, and other debris from the APC and receiver areas. Pay special attention to the receiver clamping bars, and the pallet clamping rails and wipers. Clean chips and coolant from receiver pallet clamped switch. Apply a light coat of grease and work into plunger. Do not over grease.
WARNING:
Excessive chip buildup will require more frequent chip clean-up.
Clean the two locating pins in the receiver base and the corresponding bushings in the pallets. Apply a very light coat of general purpose grease to the pins and bushings, if needed.
Clean excessive chips and coolant from pallet drive chain.
WEEKLY Remove the two 1/4" screws from the control panel and rotate to open position. Clean chips and coolant from the drive sprocket and limit switch. Apply a light coat of general purpose grease and work into the switch plungers. Check air gauge/regulator at the VMC lube/air panel for 85 psi.
Check condition of wipers. There are two wipers on each pallet.
INTERVAL MAINTENANCE PERFORMED
MONTHLY Check door for proper operation, both up and down. Clean and grease door side guide rails as required.
MAINTENANCE
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June 2001 O MPERATORS ANUAL
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3.0 INSTALLATION
TOOLS REQUIRED:
Machinists' level (2) Forklift capable of lifting 5,000 lbs, with forks at least 6' long 6' straightedge Included - APC chain rotation tool (P/N 20-0102) Allen wrenches Included - APC jumper
Prior to installing your VMC, make certain that there is enough floor space on the right-hand side of the VMC to place the APC. The APC will add approximately 52 1/
2 " (58 1/
2 " for the VF-4) to the width of the VMC. Ensure
that all the air and power requirements for the VMC have been met.
GENERAL REQUIREMENTS
Operating Temperature Range 41F to 104F (5 to 40C) Storage Temperature Range -4F to 158F (-20 to 70C) Ambient Humidity: less than 90% relative humidity, non-condensing Altitude: 0-7000 ft.
VF/APC FOOTPRINT
VF 3/4 WITH APC FOOTPRINT
INSTALLATION
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A u t o m a t i c P a l l e t C h a n g e r
3.1 M CODES FOR APC SETUP
The following M codes are used during the APC Installation procedure. These M codes are not intended to be used to program the APC at any other time.
M14 Go to pallet #1 load position M15 Go to pallet #2 load position M17 Unclamp pallet and open automatic door M18 Clamp pallet and close automatic door
CAUTION! When commanding M Codes, always command M17 to open the door before commanding M14 or M15 to position the table to a pallet load/ unload position. With a pallet present on the receiver the pallet drive leg will interfere with door movement.
3.2 ROUGH LEVELING / ALIGNMENT
In this section, the APC will be set in place and roughly aligned to the VMC. When the alignment procedure is complete, the rollers on the VMC receiver and on the APC base will be at the same height and aligned with each other. In the "Fine Tuning" section, the APC will be aligned more precisely by adjusting variables in the VMC control.
1. Remove the APC from its shipping crate. Remove all tie-downs and strapping materials. Remove the pallet shipping bolts and install the socket set screw plugs with Loctite (see Figure 2.1). Lift off the pallets and set them aside. Remove the door air cylinder and the cable bundle from their storage positions in the APC pan.
1 2
Remove pallet shipping bolts and install 1/2-13 plugs. Use Loctite. Visually check to verify that plugs do not extend into roller channels.
Figure 2.1 Removal of Shipping Bolts
INSTALLATION
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CAUTION! The pallets have wipers on the bottom of the clamp rails at the VMC end. These wipers should overhang any temporary storage position.
2. Important! Before installing the APC, ensure the VMC has been installed and leveled. Also make sure the APC jumper is installed in the"5th Axis" port on the side of the VMC control cabinet (see Figure 2.2).
5th Axis Port
Figure 2.2 Fifth Axis port on the side of the Figure 2.3 Air cylinder installation. VMC control cabinet
3. Remove the lock nut and washer from the end of the air cylinder rod, but leave the jam nut in place. Connect the automatic door air cylinder and bracket to the machine with four 1/4"-20 BHCS, as shown in Figure 2.3.
4. Insert the air cylinder rod into the door bracket, then attach the lock nut and washer to the bottom of the cylinder rod.
5. Install the door switch and bracket onto the VMC with two SHCS. Ensure the switch is pointing towards the door. Insert the door air line into the fitting at the base of the air cylinder.
6. POWER ON the VMC and ZERO RETURN all axes. Verify that the VMC operates normally.
7. In MDI mode, command an M17. The table will unclamp (raise) and the automatic door will open. The door and table will stay up. Clean all shipping protectant from the rollers, alignment pins and clamp bars.
8. In MDI mode, command an M14. The table will move to the pallet #1 load position. (The front right corner of the VMC).
NOTE: M14 will move the table slowly in case a pallet is present.
INSTALLATION
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June 2001 O MPERATORS ANUAL
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9. Raise the APC with the forklift and install the leveling screws into the legs. As a preliminary height setting, turn the screws until the length of screw extending above the APC leg is the same as the length of VMC leveling screw extending above the VMC base. Set the leveling pads (3) in place.
10. Set the APC in place on the leveling pads, so that it is centered in the VMC door opening (see Figure 2.4). Ensure that the lip of the APC enclosure is centered in the VMC drip trough (see Figure 2.5).
Figure 2.4 Gaps A and B should be equal. Figure 2.5 The APC lip should be centered in the VMC drip trough.
11. Attach the APC brace to the VMC and the APC with six screws (four 3/8" screws in the APC legs and two 1" screws in the VMC base), but DO NOT TIGHTEN (see Figure 2.6). The VF-3 uses the two holes in the brace that are closest to the VMC, while the VF-4 uses the two holes farthest from the VMC.
Figure 2.6 Installing the APC brace (VF-3 shown).
INSTALLATION
96-0012 rev C 9
June 2001 O MPERATORS ANUAL
A u t o m a t i c P a l l e t C h a n g e r
12. Place the straightedge on top of the rollers of both the VMC receiver (unclamped) and the APC, to check the APC height (see Figure 2.7). Make sure that the straightedge is on top of at least two rollers on both the unclamped receiver and the apc in order to get an accurate reading. Adjust the leveling screws in the APC legs until the straightedge lays completely flat on all rollers.
Figure 2.7 APC roller alignment setup.
13. Place the straightedge against the side of the rollers on the VMC receiver and the APC, to ensure that the rollers are aligned in the Y-axis. The straightedge must extend past at least two rollers on both the APC and VMC to get an accurate reading.
If the rollers are not parallel, the APC must be moved. The APC can be moved slightly by tapping on the leveling pads with a hammer.
NOTE: If the rollers are parallel, but are not aligned, the adjustments will be made later in the "Fine Tuning" section.
14. In MDI mode, command an M15. The table will move to the pallet #2 load position (right rear corner of the VMC). Repeat Steps 12 and 13 with the table in this position.
15. Tighten down the four 3/8 SHCS and two hex-head bolts (see Figure 2.6) on the APC brace evenly, so the APC is not pulled out of alignment. Recheck the level and all alignments.
INSTALLATION
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June 2001 O MPERATORS ANUAL
A u t o m a t i c P a l l e t C h a n g e r
16. Open the hinged APC operator's panel cover by removing the two BHCS (see Figure 2.8).
Figure 2.8 APC operator's panel cover.
17. Ensure that the drive roller on the APC chain is centered under the control box, as shown in Figure 2.9. If not, use the chain position adjustment tool to rotate it into this position.
To use this tool, place it into the center of the drive sprocket with the key in the sprocket's keyway (see Figure 2.10). Note that the tool only goes about 1/4" into the sprocket. Push down and turn the tool with a wrench in order to position the chain.
Important! Remember to remove the adjustment tool when finished.
Figure 2.9 Chain drive roller positioning. Figure 2.10 Chain position adjustment tool placement.
INSTALLATION
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June 2001 O MPERATORS ANUAL
A u t o m a t i c P a l l e t C h a n g e r
18. Insert two 1/2"-13 eyebolts into each pallet (see Figure 2.11). Attach straps or chains to the eyebolts, and use a forklift or hoist to lift each of the pallets onto the APC. Ensure that each pallet is placed with it's drive leg pawl under the APC operator's panel, and that the APC rollers fit into the grooves on the bottom of the pallets (see Figure 2.12).
NOTE: Be careful not to set the pallets on top of the chain drive roller. If necessary, rotate the chain slightly using the chain position adjustment tool.
CAUTION! Use extreme caution when moving the pallets; each pallet weighs 300 lbs., and can cause serious injury. Be careful not to damage the pallets or the APC rollers.
1/2 - 13 EyeboltsPallet
Pallet Drive Leg Drive Leg Pawl
Drip Pan
Clamp Rail
Wiper (2)
(2)
Figure 2.11 Lifting eyebolt locations. Figure 2.12 Pallet placement.
19. Pull the pallets onto the friction blocks and against the hard stop (see Figure 2.13). Rotate the chain slightly, using the chain position adjustment tool, to allow each drive leg pawl to clear the chain drive roller.
Figure 2.13 View of APC base showing friction block and hard stop.
INSTALLATION
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June 2001 O MPERATORS ANUAL
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20. Power OFF the VMC.
WARNING!
This will cause the automatic door to fall. Keep hands clear.
21. Remove the jumper from the Fifth Axis (B) port on the side of the VMC control cabinet (see Figure 2.2), and insert the APC amphenol connector into this port. Tie-wrap the cable to the door switch cable and the air hoses at the rear of the VMC.
22. Screw the air blast hose into the APC. Remove the piece of tubing from the top fitting of the VMC lube/air panel cross fitting, and replace it with the APC air hose (see Figure 2.14).
Figure 2.14 APC air hose connection to VMC air/lube cross fitting.
INSTALLATION
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June 2001 O MPERATORS ANUAL
A u t o m a t i c P a l l e t C h a n g e r
3.3 FINE TUNING
The APC was set up, run, and adjusted at the factory. Due to slight variations when disassembling and reassembling, it will be necessary to fine tune the APC to ensure that the pallets load and unload as smoothly as possible.
NOTE: It is normal to hear a 'clunking' sound during pallet loading and unloading. Unless it is excessive, do not mistake this noise for misalignment.
MACRO VARIABLES
The following macro variables control the location of the VMC table during pallet changes. Fine tuning consists of adjusting variables #500-507 and the height of the APC. For instance, #500 controls the X position that the VMC table will move to in order to load pallet 1. If the receiver does not clamp the pallet due to misalignment of the locating pins and the pallet bushings, this value can be changed to move the receiver closer to or farther from the APC. The drive pin on the chain should drop the pallet directly over the locating pins. Similarly, if the pallet is misaligned in the Y-axis, causing the pallet to shift to one side during loading and unloading, variable #501 can be modified.
The following macro variables can be modified to adjust the table location for loading and unloading of pallets:
# 500 = X pallet 1 load position # 501 = Y pallet 1 load position # 502 = X pallet 1 unload position # 503 = Y pallet 1 unload position # 504 = X pallet 2 load position # 505 = Y pallet 2 load position # 506 = X pallet 2 unload position # 507 = Y pallet 2 unload position
Macro Variable #510 can be set to zero in order to leave both pallets on the APC. This can be done in order to clean or maintain the receiver.
Macros must be enabled in order to use these statements. The macro variables can be viewed on the CURNT COMDS (Current Commands) page of the VMC display. The PAGE UP and PAGE DOWN keys may then be used to locate the correct list of macro variables. To scroll through this list, use the Cursor Right and Left buttons. Refer to the VMC Operators Manual for instructions on how to modify these variables.
1. POWER ON the VMC. Release the E-STOP button and press RESET.
2. In MDI mode, command an M17, then an M14, to position the VMC table.
3. Manually push the pallet adjacent to the receiver from the APC to the receiver. If necessary, use the chain position adjustment tool to rotate the chain until the chain drive roller clears the drive leg pawl.
NOTE: M14 will align the receiver with Pallet #1 (the pallet nearest the front of the VMC). M15 will align the receiver with Pallet #2 (the pallet nearest the rear of the VMC).
INSTALLATION
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A u t o m a t i c P a l l e t C h a n g e r
4. Push the pallet between the receiver and the APC a number of times. As the pallet goes over the receiver rollers, note if the Y or Z axis is out of alignment.
If the alignment is slightly off in the Y-axis, handle jog the table in the Y-axis (in increments of .001) until pallet loading and unloading is smooth. Record the final Y-axis position in macro variables #501 and #503. These two variables should be set to the same value initially, and may be adjusted separately later if either loading or unloading is not smooth.
If alignment appears to be incorrect in the Z-axis, adjust the APC height by turning the leveling screws until pallet loading and unloading is smooth.
5. Push the pallet back onto the APC. In MDI mode, command an M15 to move the pallet to load position #2. Repeat Steps 3 and 4 above for pallet #2.
The APC height and the Y-axis alignment (macro variables #501, 503, 505, and 507) are now set.
6. In MDI mode, command an M18 to clamp the pallet and close the automatic door.
NOTE: The message "PEND MOVE - CY/ST" will appear and motion will stop during an M18. The CYCLE START button must be pressed to continue motion.
7. The X-axis alignment must now be checked. To do this, perform the following steps :
To stop a pallet change in order to adjust the macro variables, press FEED HOLD at any time. This will cause the pallet change to stop after the present step is completed. Pressing CYCLE START will restart the program. If E-STOP is pressed during a pallet change, the motors will stop instantly, and the machine will have to be reset. If one of the chain location switches is not tripped at this time, the chain position will also have to be reset using the chain position adjustment tool.
WARNING
If a pallet change sequence is stopped for any reason (e.g. E- Stop, power outage, or low air supply), both the pallet and chain locations must be checked before operating the VMC. See the Power Outage / E-Stop Recovery section of this manual.
Under no circumstances attempt to operate the VMC until the pallet drive arm is disengaged from the pallet drive pin on the chain.
Place a program in MDI that consists of an M36 (flash "Pallet Ready" light), an M50 (pallet change), and an M99 (repeat).
Press CYCLE START and the PALLET READY light will flash.
Press PALLET READY, and the pallet will start to load. Important! When the chain starts to move, immedi- ately press FEED HOLD. This will cause the pallet to load, but not be clamped.
When the pallet has stopped, check that the bushing in the bottom of the pallet is directly over the locating pin in the receiver (within+/- .09). If the pin and bushing are not aligned, the load position of the receiver will have to be changed.
Nudge the pallet to align the pin and bushing then press CYCLE START. The pallet should clamp fully down.
Before starting another pallet change, change the macro variable for the load position of the next pallet. Use 500 for pallet 1, or 504 for pallet 2. Typically the load and unload positions will be the same for both pallets.
INSTALLATION
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A u t o m a t i c P a l l e t C h a n g e r
Repeat the X-axis alignment process until the pin and bushing are aligned.
A perfectly aligned pallet will move straight up and down when clamping and unclamping. Pallets using some of the .09 tolerance on location will appear to settle left or right when moving up and down with the clamping action. This settling does not affect the final alignment of the pallets. The pallet position tolerance is .0005.
NOTE: The machine will beep during a pallet change. This is an audible warning signal, and not an alarm.
8. To confirm the correct X-axis pallet load positions, run the program that consists of an M36, M50, and M99 again. Note any places that the process does not run smoothly, press FEED HOLD, and change one of the macro variables to adjust this misalignment.
NOTE: Make sure to confirm the alignment at both pallet load positions. After confirmation the variables should be written down or saved to disk.
INSTALLATION
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4.0 PROGRAMMING
4.1 PROGRAM COMMANDS
These instructions are for hardcoded macro-programmed Automatic Pallet Changers.
The APC is controlled by a program in CNC memory. M codes are used in the parts program to control the APC. The pallet change routine is run by using an M50 code in the parts program. In order for M50 to work the APC load and unload coordinate must be set (settings 121 through 128) and the X coordinate safe distance must be set (setting 129).
The APC can be programmed to run one program on both pallets, or a different program on each pallet. The "Sample Programs" section consists of two basic programs: the first sample program runs the same part on both pallets, and the second program runs a different part on each pallet.
The APC has its own operator's panel, which includes CYCLE START, FEED HOLD, and EMERGENCY STOP buttons that perform the same functions as those on the VMC control panel. This panel also includes a PALLET READY button, which is used for APC functions. Refer to figure 3.1.
Figure 3.1 APC operator's control panel (top view).
If the pallet ready key has not been pressed, the APC will flash the "PALLET READY" light at the completion of the user's part program, and wait until the PALLET READY button has been pressed before performing the pallet change. This feature prevents a pallet change from occurring before the operator is ready. The PALLET READY button can be pressed at any time and will be recognized when the next program is finished and a pallet change is required.
Important! If alignment adjustments are necessary during operation, refer to the "Installation" section and modify the appropriate settings.
PROGRAMMING
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4.2 M CODES
Only one M code may be programmed per block of a program. All M codes are effective or cause an action to occur at the end of the block. The following M codes are used to program the APC:
M14 Move APC table to pallet 1 load position M15 Move APC table to pallet 2 load position M17 Unclamp APC pallet and Open APC door M18 Clamp APC pallet and close APC door M50 Perform pallet change M90 Perform Pallet Unload Only
4.3 SAMPLE PROGRAMS
Example #1:
Basic program using the "Pallet Ready" light on the APC.
Oxxxxx M36 (Flash "Pallet Ready" light - wait until PALLET READY button pressed to
continue) M50 P1 (Perform pallet change after "Pallet Ready" button is pressed)
(P1 will load pallet 1, P2 will load pallet 2, P0 unload - both pallets returned to the APC)
- (USERs PART PROGRAM) - M99 (Repeat program)
Example #2:
Basic pallet change program that tracks which part is to be machined on each pallet.
Oxxxxx M36 (Flash "Pallet Ready" light - wait until PALLET READY button pressed to
continue) M50 (Perform pallet change after "Pallet Ready" button is pressed) M96 Q27 Pxx (USERs PART PROGRAM FOR PALLET #1) M96 Q26 Pxx (USERs PART PROGRAM FOR PALLET #2) M99
NOTE: M99 at the end of the program will cause continuous operation. M30 at the end of a program will cause the control to wait for the operator to press Cycle Start.
Example #3:
Oxxxxx M36 (Flash "Pallet Ready" light - wait until PALLET READY button pressed to
continue) M50 P1 (Load Pallet #1) M98 Pxx (USERs PART PROGRAM FOR PALLET #1) M36 M50 P2 (Load Pallet #2) M98 Pxx (USERs PART PROGRAM FOR PALLET #1) M99
PROGRAMMING
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5.0 TROUBLESHOOTING
5.1 MACHINE SEQUENCE
The machine performs the following sequences when these M codes are commanded.
M14 - GO TO PALLET #1 LOAD POSITION (Used for machine installation only)
Move table into pallet #1 load position.
M15 - GO TO PALLET #2 LOAD POSITION (Used for machine installation only)
Move table into pallet #2 load position.
M17 - UNCLAMP PALLET AND OPEN AUTOMATIC DOOR (Used for machine installation only)
If table is near door, move table away from door. Unclamp pallet. Open automatic door. Check Door Open switch - If door not open, generate alarm #638. Check Receiver Unclamp switch - If receiver not unclamped, generate alarm #632.
M18 - CLAMP PALLET AND CLOSE AUTOMATIC DOOR (Used for machine installation only)
Clamp pallet. Check Receiver Clamp switch - If receiver not clamped within the amount of time set in parameter #316, generate alarm #633. Close automatic door. Check Door Open switch - If door not closed, generate alarm #639.
M36 - HOLD UNTIL PALLET READY BUTTON IS PRESSED
When PALLET READY button is pressed, enable an M50 pallet change (see below).
M50 - PERFORM PALLET CHANGE
Prepare for Pallet Change: Turn coolant OFF. Turn Through the Spindle Coolant OFF (if applicable). Stop the spindle. Enable APC motor. Turn beeper ON. (The 'beeper' refers to the audible APC warning signal, and not to an alarm condition.) Read all 3 pallet position switches (one switch for Receiver Clamp/Unclamp and two switches for Pallet Home / Location) to determine empty position.
Read Switches: If both pallets are home on APC, move to load pallet position. If a pallet is on the receiver, determine the unload position. Move the table to the correct unload position. Open the automatic door.
TROUBLESHOOTING
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Execute Pallet Change (with a pallet on the receiver): Unclamp receiver. Start chain drive (unload pallet). Stop chain drive when pallet hits stop switch.(If M50 P0 or M90, this finishes the sequence) Move table to appropriate load position. Start chain drive (load pallet). Stop chain drive when Chain Switch Block trips the Chain Stop switch. Clamp receiver. Move table away from automatic door.
Return to Normal Operation: Turn beeper off. Disable chain drive. Close automatic door.
NOTE: The M50 pallet change must be successfully completed before normal VMC operation can continue.
If the M50 pallet change is interrupted, software switches will not allow normal VMC operation. Another M50 must be run to reset the switches. If this puts the wrong pallet into the VMC then an additional M50 must be run.
The operator must exercise caution when running multiple M50 com- mands to position pallets. The operatoer must be aware of incomplete fixturing, tool, and personnel locations.
5.2 LIMIT SWITCHES
The APC contains limit switches and a proximity sensor that monitor machine operation:
Door Open Switch - Senses when the door is in the fully up position.
Receiver Clamp/Unclamp Proximity Sensor- Senses whether or not the receiver is in the down (clamped) position.
Pallet Stop / Location Switches (2) (Home) - Sense whether each pallet is home (on the APC). When a pallet is being unloaded, the chain drive will stop when this switch is tripped.
Chain Stop / Location Switches (2) (pin clear) - Sense the chain location, and whether it is in the correct position to perform an operation. After a pallet has been loaded, the chain drive will stop when this switch is tripped.
WARNING!
Do not move the limit switches for any reason.
TROUBLESHOOTING
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5.3 RECOVERY FROM POWER OUTAGE OR E-STOP
Recovery from a power outage or an E-Stop initiated during a pallet change:
TROUBLESHOOTING
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Figure 1 Pallet known locations. Pallet 1 is on the receiver and engaging the Pallet Clamped switch. Pallet 2 is on the APC and engaging
the Pallet Home Swtich under the control panel.
Figure 2 Alignment Pin and Bushing alignment must be verified
when manually positioning a pallet on the receiver.
TROUBLESHOOTING
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Pin Clear Switch
Pallet Drive Leg
Pin Clear Switch
Pallet Home Switches
Trip Block
Chain/Sprocket Rotation Tool
Figure 3 With pallet 2 clamped on the receiver, the trip block must be engaging the switch as shown.
Figure 4 Press and hold the solenoid actuation buttons (small
white buttons) to keep air pressure flowing to unclamp<