Created by EBCCW 00:06 96:05 Created by EBCCW 00:06 5113196-2 Conveyor system X45 User Documentation
Created by EBCCW 00:06 96:05
Created by EBCCW 00:06 96:05 Created by EBCCW 00:06 5113196-2 Conveyor system X45
Created by EBCCW 00:06 96:05
Conveyor system X45 User Documentation © 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 FlexLink Components AB. The contents of this manual are for informational 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.
5113196-2
1 Preface 1 Safety 3 1.1 System information 3 1.2 The most important safety conditions 4 1.3 Description of safety provisions 6 1.4 Safety measures to be taken 8 2 9 Technical specification 2.1 Technical characteristics X45 9 2.2 Operating conditions 10 3 11 Functions 3.1 Motors 11 3.2 Diverters, Mergers, Combined Diverter/Mergers, Transfers, Stop and Locating station for Puck handling 12 Created by EBCCW 00:06 3.
4 Unload the X45 system 4.1 Preparation 20 4.2 Unloading instructions 21 5 Mounting, installation, adjustment 22 5.1 Provisions to be provided 22 5.2 Mounting chain to X45 conveyor modules – Idler end 23 5.3 Assembly of modules 25 5.4 Adjustment 33 6 Technical maintenance 6.
Preface 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.
Preface Requirements of the user The X45 Conveyor system must be operated by any adult person who has become acquainted with section 1 Safety. If the user is not technically qualified, he or she may not carry out any maintenance or repair activities on the system. . . 2 Note! Maintenance activities on the system may only be carried out by a technically qualified person.
Safety 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 circumstances and the instructions described in the manual. Any person working with or on this system should study the manual and follow the instructions. It is the responsibility of the employer to make sure that the employee is familiar with and follows these instructions.
Safety 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 instructions 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 . • Incorrect use of the equipment can cause personal injury.
Safety 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 automation To avoid risks, only experienced personnel with technical knowledge and experience may perform repair work on the electronics components. 1.2.4 Created by EBCCW 00:06 .
Safety 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 is to protect the user, the product and the system against undesired situations (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 required.
Safety ... . 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.
Safety 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: • 8 Clean floor surface - With a clean floor surface the operator will not be hindered while operating the system. This can prevent tripping or slipping, so that the operator does not unexpectedly come into contact with the system.
Technical specification 2 Technical specification 2.
Technical specification 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.
Functions 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 sensors are connected directly to each motor unit. This layout gives a big advantage regarding software developing, electrical design and electrical installation. 3.1.1 Function control The motor unit consists of a motor, circuit boards and eight connectors in an encapsulated housing.
Functions 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. DL DR DL DR 90° 90° The diverter is an active unit with one infeed and two outfeed conveyors. There are four different variants of the diverter.
Functions 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 replaced 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 rotation disc, with a puck in the gap.
Functions 3.2.2 Mergers Mergers are used to combine the flow from two lines into one. The lines can be parallel or in a 90° angle. ML MR ML MR 90° 90° 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.
Functions 3.2.3 Combined Diverter/mergers A combined diverter/merger are used to create a sub line for example to guide pucks out and in on a satellite conveyor from the main conveyor. They can also be used as "shortcuts". Figure 4 CL CR CL 90° 90° 180° CR L 180° R Combined Diverter/Merger 90° and 180° Created by EBCCW 00:06 This function has the behaviour from both the diverter and the merger. The prioritized order can be predetermined or decided dynamically from a line controller.
Functions 3.2.4 Transfers Transfers are used to transfer the puck between the conveyors in a system. The parallel transfers are passive but the 90° and 180° angled transfers are driven by a motor. PL PR L R L R 90° 90° 180° 180° There are six different variants of the transfers.
Functions 3.2.5 Stop The stop unit is an active unit acting on a single conveyor. The unit has only one photoelectric sensor. This detects a puck in the queue. The default position of the stop unit is closed, i.e. it is able to resist a queue of puck. If the stop is deactivated the unit opens up to receive a puck. Directly after the unit has opened up it closes and releases the received puck. This unit can be controlled either via the external bus or in local mode by a signal in the local digital input.
Functions 3.2.6 Locating station The locating Station is an active unit acting on a single conveyor. The station has only one photoelectric sensor. This is detecting that the puck has reached the gap of the rotation disc. The locating station can also be equipped with a RFID read/write head on the locating position. The station can be controlled either via the external bus or using only local control.
Functions 3.3 Maximum permissible weight Load gr 3000 2500 2000 1500 1000 500 5 10 20 15 Speed m/min Created by EBCCW 00:06 Figure 8 The diagram shows the maximum permissible weight of a group of pucks (product weight + puck weight) that the functions Divert, Merger, Combined Diverter/Merger, Stop and Locating station are capable stopping, as a function of the conveyor speed.
Unload the X45 system 4 Unload the X45 system 4.1 Preparation This section describes the steps that are required for unloading the modules for the X45 system. Note! The operations concerned are to be carried out calmly in order to be able to carefully monitor any movement of the X45 module. Before starting the unloading a good preparation is required. The appropriate devices must be available.
Unload the X45 system 4.2 Unloading instructions Before starting unloading, all fastening means (securing belts, screws, etc.) that secure the module unto the means of transport must be removed. Subsequently check whether the transport supports are still connected well to the module. After this the unloading procedure may be started. 4.2.1 Shipment Modules are normally delivered in flat boxes with a maximum length of approximately 3 m. See photo below.
Mounting, installation, adjustment 5 Mounting, installation, adjustment This section deals with the operations to have the modules function well within a (transport) system. Longer conveyor modules (approx >3m) are delivered in sections. The sections are marked up and can easily be joined together. Also the corresponding conveyor chain is marked up and has to be assembled according to section 5.2. 5.
Mounting, installation, adjustment 5.2 Mounting chain to X45 conveyor modules – Idler end 5.2.1 Tools Allen key 3 mm Pin insertion tool Screwdriver 5.2.2 Procedure 1 Use the screwdriver to remove the plastic cap on the idler end. Loosen the screws on both side on the basic unit, use a 3 mm Allen key. Created by EBCCW 00:06 2 Remove the sideplates, use a screwdriver.
Mounting, installation, adjustment 3 Feed the chain into the conveyor until it reach the drive wheel at the driving end. CAUTION! Check the feed direction of the chain 4 Continue to feed the chain around the drive wheel into the return part of the beam. 5 To avoid noise the number of links in the chain shall be adjusted so that a slight pretension is obtained. CAUTION! Make sure that the chain enters the drive wheel correctly.
Mounting, installation, adjustment 5.3 Assembly of modules The modules are to be assembled according to the system layout. Find the correct position for connecting modules using the measurements in section 5.3.3 on page 28 to section 5.3.8 on page 32 When assemble the parallel conveyors use the beam spacer XUCD 15x20 (see picture below).
Mounting, installation, adjustment 5.3.1 Slide rail cutting, RFID Slide rail cutting to clear RFID when placed between two parallel conveyors at C-C 60 mm. See picture below. 1. 511 269 5 A A 64 A-A Cut to here 2.
Mounting, installation, adjustment 5.3.2 Wiring BUS A1 BUS A1 BUS A2 BUS A2 DI 4 DI 4 DI 3 DI 3 DI 2 DI 2 DI 1 DI 1 PWR PWR BUS B The functions motors are to be connected according to picture below and mounting instructions section 5.3.3 on page 28 to section 5.3.8 on page 32. BUS B Created by EBCCW 00:06 1 Markings on plate Explanation PWR Power in Connect power cable BUS B Internal bus Used for parameter settings DI 1 Digital input 1 Sensor, connect if used, see section 5.
Mounting, installation, adjustment The following schematic presentation shows how the various modules are combined to form a complete X45 conveyor system, mechanical installation as well as the electrical interface are showed. 5.3.
Mounting, installation, adjustment 5.3.
Mounting, installation, adjustment 5.3.
Mounting, installation, adjustment 5.3.
Mounting, installation, adjustment 5.3.7 Function Designation Mounting instructions, Stop Assembly mechanical/electrical Angularity Item Home position Stop + Release angle 1 DI 1 XUUS 11 L XUUS 11 L (Left) Receive angle 1 Home position XUUS 11 R DI 1 + Release angle 1 (Right) XUUS 11 R Receive angle 1 5.3.
Mounting, installation, adjustment 5.4 Adjustment 5.4.1 Parameter setting tool All software in the X45e motors are preloaded and the behaviour of the motors can be adjusted to different performance (such as function type, speed and angle settings) by a parameter setting tool kit, 5113070 For more information see "User documentation, Parameter setting tool" on flexlink.com and "Technical library". Created by EBCCW 00:06 .
Technical maintenance 6 Technical maintenance 6.1 Maintenance intervals Within the application, where X45 equipment is normally used, environmental conditions are clean compared to many other FlexLink system installation sites. During these conditions X45 modules normally require a minimum of maintenance.
Recommended spare parts 7 Recommended spare parts Created by EBCCW 00:06 See separate Spare parts list on flexlink.
Supplier’s information 8 Supplier’s information This manual goes together with the module of the type mentioned on the order and on the title page of this manual. This document was drawn up by: FlexLink Components AB Date: 2010/01/18 Copyright: FlexLink Sweden, 2010 The machine was produced by: Flexlink Components AB Tel: +46 (0)31-337 31 00 SE-415 50 Göteborg Fax: +46 (0)31-337 31 95 Sweden E-mail: info@flexlink.se www.flexlink.com .
Supplier’s information EC Declaration of Incorporation Partly completed machinery FlexLink Components AB SE-41550 Göteborg Sweden We hereby declare that the following equipment is intended to be incorporated into a FlexLink conveyor system and thereby forming a machine.
Supplier’s information 38 5113196-2
