untitled TRANSPORT RAILS MODULE OVERVIEW RAIL SYSTEM (RS) CHAPTER 19 TRANSPORT RAILS MODULE OVERVIEW RAIL SYSTEM (RS) Item Description Item Description 1 Transport Belt (2 positions) 6 Moving Rail Hom.
TRANSPORT RAILS MODULE OVERVIEW - RAIL SYSTEM (RS) CHAPTER 19 TRANSPORT RAILS MODULE OVERVIEW - RAIL SYSTEM (RS) Heavy Board Rails (optional) 10 Item Description Item Description Transport Belt (2 positions) Moving Rail Home Sensor Fixed Front Rail Board at Left Sensor Board at Right Sensor Moving Rear Rail Front Transport Belt Drive Motor Board Clamp (2 positions) Moving Rail Home Vane 10 Rear Transport Belt Drive Motor Chapter Issue Nov 11 Technical Reference Manual 19.1 TRANSPORT RAILS MODULE OVERVIEW - MODULAR TRANSPORT RAILS (MTR) OVERVIEW - MODULAR TRANSPORT RAILS (MTR) Item 19.2 Description Item Description Moving Rear Rail Board at Right Sensor Snugger/Clamping Module (Front and Rear Rails) Front Belt Drive Motor Rear Belt Drive Motor Fixed Front Rail Transport Belt and Pulleys (2) Board at Left Sensor Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE COMMON TRANSPORT RAIL COMPONENTS COMMON TRANSPORT RAIL COMPONENTS For the purpose of identification, the common components of the transport rail systems have been identified These components are shown below in the diagram, and they are listed in the table 13 12 11 Item 10 Description Item Description Rail Width Drive Pulley (2) [RS and MTR rail systems have different pulleys] Rail Lift Linear Bearing Rail Width Drive Belt Support Block and Bearing Rail Width Drive Motor 10 Rail Height Adjuster Rail Width Home Sensor and Vane 11 Clatter Bar (2) Rail Width Leadscrew (2) 12 Rail Lift Vane (2) Transport Leg [Items to 10] (4) [RS and MTR rail systems have different leg assemblies] 13 Rail Lift Sensor (2) Rail Guide and Damper Assembly Chapter Issue Nov 11 Technical Reference Manual 19.3 TRANSPORT RAILS MODULE SYSTEMS SYSTEMS Two transport rail systems are currently available: • The Rail System (RS) • The Modular Transport Rail (MTR) Both have two variants available: • High Throughput Conveyor (HTC) [see HTC chapter for details] • Dual Lane (DL) [see dual lane chapter for details] The variants are described in their respective chapters of this manual MTR offers system modularity; the centre section, which holds and locates the product, can be removed to accommodate any future upgrades, without having to replace the complete transport system Both systems have a programmable width conveyor system, set by the board width parameter, in the product file The rails transport the board, using belts, from the upline machine into the printer, where the board is positioned, clamped, and printed After printing, the board is transferred, using the same belts, to the downline machine On the RS, there is an option for heavy boards, the transport rails can transport boards weighing up to 6kg This is achieved using an extra drive pulley on each rail and flat profiled transport belts NOTE 1.To prevent damage to the camera board stop the remote board stop must be used for product boards over 1kg in weight 2.Information on the remote board stop is detailed in the Rising Table chapter of this manual The RS can be fitted with one of the following board clamping arrangements: • 250mm or 500mm Board Clamps (foiled) • 250mm or 500mm Foil-less Clamps • Board Snugger Assembly Board clamps are used to support boards using the foils fitted to the edge of the clamp This gives additional support to the top of the board but the printable image must not extend to the area occupied by the foils Foil-less clamps are utilized for thin pliable boards where there is a requirement to print close to the board edge The foil-less clamps are assisted with the use of a vacuum box beneath the product board Board snuggers are an alternative to the standard board clamps and are utilized when there is a requirement to print close to the board edge On the MTR the centre support section has an Over the Top Snugger (OTS) arrangement fitted (see the Centre Section detail later in this chapter.) 19.4 Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE BOARD CLAMPING ARRANGEMENTS BOARD CLAMPING ARRANGEMENTS Rear Board Clamp Board Transport Belts Board Transport Belts Board Transport Belts Board Clamps Rear Foil-less Clamp Foil-less Clamps Rear Snugger Plate Counterweight Block Board Snuggers Figure 19-1 Board Clamping Arrangements - RS End Rail Mid Rail Centre Section - Over theTop Snuggers (OTS) Board Transport Belts MODULAR TRANSPORT RIALS Figure 19-2 Board Clamping Arrangements - MTR Chapter Issue Nov 11 Technical Reference Manual 19.5 19.6 USB NOTE The breaks in the CAN Bus chain reflect that additional I/O Nodes may be fitted, refer to Machine Control chapter for the complete CAN Bus chain Motherboard Machine PC Technical Reference Manual Dual Stepper X3 NextMove Interface Card X4 NextMove ES (I/O Node 1) X5 Machine Control Enclosure M36PL22 M36PL19 M36PL17 M36PL18 CAN Bus Motor 2A+ Motor 2B+ Motor 2A- Motor 2B- DIG IN DIG IN 11 DIG IN 10 DIG IN DIG IN DIG OUT !DIG OUT DIG OUT DIG OUT N2SK2 8PL10 8PL12 8PL15 8PL22 Main Machine I/O Node N2PL4 8PL20 8PL26 8PL03 8PL04 8SK21 8SK23 GND N/C N/C DIG OUT +12V Sig 0V (L) +12V Sig 0V +12V Sig 0V +12V Sig 0V (L) +12V Sig 0V (L) M M 8M2 Enable Direction 24V SW 0V Enable Direction 24V SW 0V Moving Rail Stepper Moving Rail Home (8SE6) Board at Right Sensor (8SE7) Board at Left Sensor (8SE8) Rail Lift Left (8SE5) Rail Lift Right (8SE4) Front Belt Drive (8M03) Rear Belt Drive (8M04) Board Clamp/ Snugger Solenoid (16SOL10) TRANSPORT RAILS MODULE ELECTRICAL SCHEMATIC (RS) ELECTRICAL SCHEMATIC (RS) Chapter Issue Nov 11 TRANSPORT RAILS MODULE THE MTR TRANSPORT SYSTEM THE MTR TRANSPORT SYSTEM End and Mid Rail The MTR system comprises four end rails, four mid rails and two centre sections (MTR) End Rail Centre Section Mid Rail Width Adjustment (Screws in Slots) Mid Rail End Rail Mid Rail Screws End Rail Screws (behind board guide) (behind board guide) Top View Board Guides Rail Body Mid Rail Chassis End Rail Transport Leg Side View (Centre Section Removed) Guide Sleeve Pull Down Piston Guide Sleeve Transport Leg MODULAR TRANSPORT RAILS (for clarity only one side is shown annotated) The end and mid rail sections have width adjustment screws in slots; these allow the board guides to be adjusted to allow the product to run through the system without binding In both sections, there are two screws under the board guide which attach the rail body to the chassis The chassis is attached to the rail width bearing block by the transport legs During board transport the mid rail board guide lifts; for printing, the mid rail board guide lowers A pneumatically driven piston is used to lower the board guides; the mid rail screws have an outer guide sleeve fitted to allow this movement Two springs raise the guides to the transport (up) position The centre section is used for holding the product securely during printing This section is modular, and it is designed to allow for a variety of clamping arrangements Currently, the centre section houses the OTS arrangement Chapter Issue Nov 11 Technical Reference Manual 19.7 19.8 USB NOTE The breaks in the CAN Bus chain reflect that additional I/O Nodes may be fitted, refer to Machine Control chapter for the complete CAN Bus chain Motherboard Machine PC Technical Reference Manual Dual Stepper X3 NextMove Interface Card X4 NextMove ES (I/O Node 1) X5 Machine Control Enclosure M36PL22 M36PL19 M36PL17 M36PL18 CAN Out CAN In Motor 2A+ Motor 2B+ Motor 2A- Motor 2B- DIG IN DIG IN 11 DIG IN 10 DIG IN DIG IN DIG OUT !DIG OUT DIG OUT DIG OUT N5SK1 N5SK2 8PL10 8PL12 8PL15 8PL22 Main Machine I/O Node N5PL10 N5PL6 8PL20 8PL26 8PL03 8PL04 8SK21 8SK23 N/C N/C 8SK22 (part of) +12V Sig 0V (L) +12V Sig 0V +12V Sig 0V +12V Sig 0V (L) +12V Sig 0V (L) M M 8M2 Enable Direction 24V SW 0V Enable Direction 24V SW 0V Moving Rail Stepper Moving Rail Home (8SE6) Board at Right Sensor (8SE7) Board at Left Sensor (8SE8) Rail Lift Left (8SE5) Rail Lift Right (8SE4) Front Belt Drive (8M03) Rear Belt Drive (8M04) Clamp Pressure Regulator Snugger Pressure Regulator OTS Solenoid Bank (8SOL10 thru 15) TRANSPORT RAILS MODULE ELECTRICAL SCHEMATIC (MTR) ELECTRICAL SCHEMATIC (MTR) Chapter Issue Nov 11 TRANSPORT RAILS MODULE CENTRE SECTION (MTR) CENTRE SECTION (MTR) Over the Top Snuggers (OTS) OTS clamps are fitted to the centre section of the rail system They provide a means of holding the product flat prior to snugging Item Description Item Description Rear Rail OTS Assembly Isolator Switch Valve Front Rail OTS Assembly Vacuum Ejector Pneumatic Valve Manifold ITV Valves Pneumatic Regulators Chapter Issue Nov 11 Technical Reference Manual 19.9 TRANSPORT RAILS MODULE CENTRE SECTION (MTR) The OTS Clamps Top Clamp Plate Top Clamp Plate and Mid Plate Assembly Mid Plate Lift Guides (4) Lift Cylinder (2) Manifold Swivel Plate Cover Linear Bearing (2) Bearing Support Plate Snugger Actuator (2) Snugger Guide (2) Brake Cylinders (16) Forward/Back Cylinder (Top clamp movement) Brake Surface (inner wall) Brake Flanges (2) Machined Body Figure 19-3 Rear OTS Rail Snug Plate Board Support Figure 19-4 Snugger Assembly 19.10 Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES Centre Section Where like-for-like replacement is required; this procedure can be used to remove and replace the centre section of the MTR system Currently, the over the top snugger OTS system is available Replace OTS Module Locate the rail centre sections Slip the transport belt off of the associated end rail pulley Isolate the air supply by switching off the isolator switch valve Isolator Switch Valve System Pneumatic Manifold Locate the pneumatic manifolds and the pneumatic connections at the rear of each assembly Disconnect the pneumatic connectors (eight on the front rail), (ten on the rear rail); to remove, push the collar in while simultaneously pulling the tube out NOTE The front rail does not have an active snugger; the pneumatic tubes 7A and 7B are not fitted to the front manifold 3B 3B 3A 3A 1A 1A 7A 2A 2A 6A 6A 4A RTN 4B 7B RTN 4B REAR RAIL FRONT RAIL 19.44 4A Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES Disconnect the large black tube (6A); to remove it, pull it out of the barbed fitting, the tube is held by friction and should release without over-stretching Locate the two M5 x 20 screws under the assembly that hold it to the rail Pneumatic Connectors M5 x 20 Screws (4 Positions) Remove the screws and lift the unit free of the rail NOTE If the OTS assembly is to be replaced by another module, all pneumatic connections must be end terminated or completely removed as necessary Board Clamp Replacement (RS only) WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP Select Open Cover Commands Select Carriage To Rear Select Unload Screen Open the front printhead cover Remove the screen from the machine Chapter Issue Nov 11 Technical Reference Manual 19.45 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES Remove the board clamp securing screws and remove the board clamp Board Clamp Securing Screws 250mm Board Clamp Mechanism Board Clamp Securing Screws 500mm Board Clamp Mechanism Place the new board clamp in position on the location plates Secure the board clamp in position with the screws removed in Step NOTE The Board Clamp Setting procedure is not required after board clamp replacement Refit the screen 10 Close the front printhead cover 11 Press the System button 12 Select Load Screen 13 Select Back Board Clamp Foil Replacement (RS only) WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP If the board clamp is fitted to the machine, use the Board Clamp Replacement procedure to remove and refit the board clamps Remove the M2.5 x 6mm pan headed slotted screws securing the foil to the 19.46 Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES board clamp Discard the foil and retain the screws Fit the new foil with the screws removed in Step Clamps to Snuggers (RS only) WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP NOTE This procedure is valid when converting from either board clamps or foil-less clamps Select Open Cover Commands Select Carriage To Rear Select Unload Screen Open the front printhead cover Remove the screen from the machine Remove the securing screws from the rear board clamp and remove the board clamp Board Clamp Securing Screws 250mm Board Clamp Mechanism Board Clamp Securing Screws 500mm Board Clamp Mechanism Repeat Step for the front board clamp Fit the appropriate snugger base plate to the rear rail and secure using the Chapter Issue Nov 11 Technical Reference Manual 19.47 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES M4 pan head screws Snugger Base Plate Fixed Width Chase Snugger Base Plate Adjustable Screen Mount (ASM) 19.48 Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES Fit the appropriate front snugger plate to the front rail and secure using the M4 pan head screws Front Snugger Plate Adjustable Screen Mount (ASM) Front Snugger Plate Fixed Width Chase 10 Fit the rear snugger plate, don’t tighten the M4 pan head securing screws Rear Snugger Plate Snugger Base Plate Downstops Front Snugger Plate Plan View of Rail System 11 Close the front printhead cover 12 Press the System button Chapter Issue Nov 11 Technical Reference Manual 19.49 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES 13 Locate the magnetic plate on the right hand side of the machine containing the pneumatics for the snuggers 14 Turn the pneumatic switch On 15 Load the product file to be printed, the rear rail moves to set the board width NOTE With Auto Rail Width set to Disabled the rear rail does not set the board width, but it can still be moved in diagnostics 16 Select Maintenance 17 Select Machine Setup 18 Select Basics 19 Select Clamp Type 20 Select Snuggers 21 Select Accept 22 Select Back 23 Select Back 24 Select Back 25 Carry out Snugger Base Plate Height Adjustment in the Adjustments and Settings section of this chapter NOTE The Board Clamp Setting procedure is not required after board clamp/foilless clamp to snugger replacement 19.50 Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES Snuggers to Clamps (RS only) WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP NOTE This procedure is valid when converting to either board clamps or foil-less clamps Select Open Cover Commands Select Carriage To Rear Select Unload Screen Open the front printhead cover Remove the screen from the machine On the rear rail, remove the two rear snugger plate securing screws and remove the rear snugger plate Rear Snugger Plate Snugger Base Plate Downstops Front Snugger Plate Plan View of Rail System On the rear rail, remove the snugger base plate securing screws and remove the snugger base plate On the front rail, remove the front snugger plate securing screws and remove the front snugger plate Fit the board clamp to the rear rail and secure using the M4 pan head screws 10 Fit the board clamp to the front rail and secure using the M4 pan head screws 11 If foil-less clamps have been fitted continue with Step 12 If board clamps have been fitted go to Step 14 12 Fit the appropriate foil-less clamp to the rear rail and secure using the M4 Chapter Issue Nov 11 Technical Reference Manual 19.51 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES pan head screws Foil-less Clamp Adjustable Screen Mount (ASM) Downstops Foil-less Clamp Fixed Width Chase 13 Repeat Step 12 for the front rail 14 Locate the magnetic plate on the right hand side of the machine containing the pneumatics for the snuggers 15 Turn the pneumatic switch On 16 Select Maintenance 17 Select Machine Setup 18 Select Basics 19 Select Clamp Type 20 Select Board Clamps 21 Select Accept 22 Select Back 23 Select Back 24 Select Back 19.52 Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES 25 This completes the procedure if board clamps have been fitted If foil-less clamps have been fitted continue with Step 26 26 Carry out Foil-less Clamp Height Adjustment in the Adjustments and Settings section of this chapter NOTE The Board Clamp Setting procedure is not required after snugger to board clamp/foil-less clamp replacement Rear Rail Drive Belt At the rear of the rising table, slacken the adjustable idler pulley by means of the nut at the front face of the rail drive plate Adjustable Idler Pulley Rail Drive Plate Drive Belt Left Hand Drive Shaft Moving Rail Stepper Motor Pulley View on Rear of Rising Table Slide the adjustable idler pulley to slacken the drive belt Remove the drive belt and discard Fit the replacement drive belt Using a suitable cable tie, engage a forcemeter with the adjustable idler pulley Apply a horizontal force of 6kg Maintaining this force, tighten the adjustable idler pulley securing nut Using a tension meter on the top of the drive belt, check the tension is 38Hz to 45Hz Adjust the drive belt tension as necessary to achieve the reading in Step Select Maintenance 10 Select Diagnostics 11 Use Next or Previous to highlight Rail System 12 Select Select Module 13 Use Next or Previous to highlight Drive Rail Width Using Two Button Control 14 Select Run Diagnost 15 Using the left jog button drive the rear rail to the rear for a few seconds to even out the tension in the belt Chapter Issue Nov 11 Technical Reference Manual 19.53 TRANSPORT RAILS MODULE REPLACEMENT PROCEDURES 16 Repeat Steps and 17 Select Exit 18 Select Exit 19 Select Back Heavy Board Rails Drive Belt Slacken the adjustable idler pulley securing screw, at the rear of the motor bracket Adjustable Idler Pulley Motor Bracket View on Inside of Front Rail Slide the adjustable idler pulley to slacken the drive belt Remove the drive belt and discard Fit the replacement drive belt Using a suitable cable tie, engage a forcemeter with the adjustable idler pulley Apply a horizontal force of 5.1kg to 6.1kg Maintaining this force, tighten the adjustable idler pulley securing screw Select Maintenance Select Diagnostics Use Next or Previous to highlight Rail System 10 Select Select Module 11 Use Next or Previous to highlight Drive Belts Using Two Button Control 12 Select Run Diagnost 13 Using either the left or right jog button, drive the belt motors for a few seconds to even out the tension in the belt 14 Recheck the belt tension 15 Select Exit 16 Select Exit 17 Select Back 19.54 Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE CALIBRATIONS CALIBRATIONS NOTE Where the printer is connected to inline equipment make sure that the FMI functionality is turned OFF before proceding Board Transport Belt Speed (RS and MTR) The front and rear board transport belts are driven independently by two variable speed motors Inevitably one motor drives faster than the other motor It is necessary to calibrate these motors so that they drive at the same speed Feeder motor speed is measured using a tachometer on the input or output pulley and adjusted by a potentiometer control on each motor Calibration Procedure Remove the right hand side safety cover to gain access to the transport belt motors Select Maintenance Select Diagnostics Use Next or Previous to highlight Rail System Select Select Module Use Next or Previous to highlight Belt Speed Calibration Select Run Diagnost The following window is displayed: Belt Speed Calibration FRONT L R SPEED FRONT R L SPEED REAR R L SPEED REAR R L SPEED FRONT L R ALT SPEED FRONT R L ALT SPEED REAR L R ALT SPEED REAR R L ALT SPEED 64 64 64 64 64 64 64 64 NOTE Belt Speed Calibration figures displayed on this page have no relevance to the belt speeds on the machine Select Front L R Speed Select Incr or Decr to start the belts Chapter Issue Nov 11 Technical Reference Manual 19.55 TRANSPORT RAILS MODULE CALIBRATIONS 10 Using a tachometer fitted with the surface speed test wheel, positioned on the input or output pulley of the front belt motor, measure the speed of the motor right to left NOTE For heavy board option the ‘Front’ settings refer to the rear rail and the ‘Rear’ settings refer to the front rail 11 Ensure that one of the following speeds is achieved: a 29 to 31 m/min for standard transport rails b 37 to 39 m/min for heavy board transport rails c Repeat steps 10 and 11 a for Front R L, Rear L R, and Rear R L 12 In the table highlight Front L R ALT Speed 19.56 Technical Reference Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE CALIBRATIONS 13 Using a tachometer fitted with the surface speed test wheel, positioned on the input or output pulley of the front belt motor, measure the speed of the motor right to left NOTE For heavy board option the ‘Front’ settings refer to the rear rail and the ‘Rear’ settings refer to the front rail 14 Select Incr or Decr to adjust the motor speed to achieve 14 to 16 m/min 15 Repeat steps 13 and 14 for Front R L Alt Speed, Rear L R Alt Speed, and Rear R L Alt Speed 16 If adjustment is required, remove the belt speed adjuster cap on the appropriate motor ([MTR] adjuster cap located on top of the motor assembly) and adjust using a suitable trimming tool 17 Select Next Chapter Issue Nov 11 Technical Reference Manual 19.57 TRANSPORT RAILS MODULE CALIBRATIONS 18 Select Incr or Decr to start the belts running left to right 19 Ensure that one of the following speeds is achieved for both the front and rear belts: a 29 to 31 metres/min for standard transport rails b 37 to 39 metres/min for heavy board transport rails NOTE There is no separate adjustment between left to right and right to left If the above speed is not achievable in both directions, the motor may be faulty 20 Select Exit 21 Select Exit 22 Select Back 23 Refit the safety cover 19.58 Technical Reference Manual Chapter Issue Nov 11 ... Solenoid (16SOL10) TRANSPORT RAILS MODULE ELECTRICAL SCHEMATIC (RS) ELECTRICAL SCHEMATIC (RS) Chapter Issue Nov 11 TRANSPORT RAILS MODULE THE MTR TRANSPORT SYSTEM THE MTR TRANSPORT SYSTEM End.. .TRANSPORT RAILS MODULE OVERVIEW - MODULAR TRANSPORT RAILS (MTR) OVERVIEW - MODULAR TRANSPORT RAILS (MTR) Item 19.2 Description Item Description... Manual Chapter Issue Nov 11 TRANSPORT RAILS MODULE BOARD CLAMPING ARRANGEMENTS BOARD CLAMPING ARRANGEMENTS Rear Board Clamp Board Transport Belts Board Transport Belts Board Transport Belts Board Clamps