Instruction manual
LNS America
4621 East Tech Drive
Cincinnati, Ohio 45245
ENG
9..021.MI.ANG
V1.0
TABLE OF CONTENTS
CHAPTER 1: BASIC NOTIONS .............................................................. 1-1
1.
2.
3.
4.
5.
STRUCTURE ......................................................................................................................... 1-2
RIGHTS ................................................................................................................................. 1-3
DECLARATION OF COMPLIANCE ..................................................................................... 1-4
SAFETY INSTRUCTIONS ..................................................................................................... 1-5
SAFETY DEVICES ................................................................................................................ 1-6
CHAPTER 2: TECHNICAL DATA........................................................... 2-1
1.
2.
3.
CHARACTERISTICS............................................................................................................. 2-2
FLOOR PLANS ..................................................................................................................... 2-2
LAYOUT OF THE ELEMENTS ............................................................................................. 2-5
CHAPTER 3: SETTING INTO OPERATION ........................................... 3-1
1.
2.
3.
4.
TRANSPORTATION ............................................................................................................. 3-2
MOUNTING ........................................................................................................................... 3-5
ELECTRICAL CONNECTIONS .......................................................................................... 3-15
PNEUMATICAL CONNECTIONS ....................................................................................... 3-15
CHAPTER 4: ELECTRICS ...................................................................... 4-1
1.
2.
3.
4.
ELECTRICAL EQUIPMENT .................................................................................................. 4-2
ELECTRICAL CABINET ....................................................................................................... 4-4
ELECTRICAL DIAGRAMS ................................................................................................. 4-10
INTERFACE ........................................................................................................................ 4-18
CHAPTER 5: PNEUMATICS .................................................................. 5-1
1.
2.
3.
4.
PNEUMATICAL EQUIPMENT .............................................................................................. 5-2
AIR FILTERING UNIT ........................................................................................................... 5-3
PNEUMATIC VALVE............................................................................................................. 5-5
PNEUMATIC DIAGRAMS ..................................................................................................... 5-6
CHAPTER 6: GENERAL DESCRIPTION ............................................... 6-1
1.
2.
3.
4.
5.
6.
7.
8.
BAR MAGAZINE ................................................................................................................... 6-2
LOADING TABLE ................................................................................................................. 6-7
PUSHER CARRIER............................................................................................................... 6-9
LOADING PUSHER ............................................................................................................ 6-10
FEEDING PUSHER ............................................................................................................. 6-11
BELT .................................................................................................................................... 6-13
RETRACTION ..................................................................................................................... 6-14
OPTIONS ............................................................................................................................. 6-16
CHAPTER 7: OPERATION ..................................................................... 7-1
1.
2.
POWERING UP ..................................................................................................................... 7-2
REMOTE CONTROL ............................................................................................................. 7-3
QUICK LOAD SERVO III MI
3.
4.
5.
6.
7.
8.
SET UP .................................................................................................................................. 7-7
SETTINGS ........................................................................................................................... 7-10
AUTOMATIC CYCLE .......................................................................................................... 7-31
END OF BAR POSITION ..................................................................................................... 7-33
TOP-CUT POSITION ........................................................................................................... 7-35
POWERING DOWN ............................................................................................................. 7-36
CHAPTER 8: MALFUNCTIONS / MAINTENANCE ................................ 8-1
1.
2.
3.
ALARMS ................................................................................................................................ 8-2
FACTORS AFFECTING PERFORMANCE ......................................................................... 8-11
MAINTENANCE ................................................................................................................... 8-13
CHAPTER 9: APPENDICES................................................................... 9-1
1.
2.
3.
ORDERING FORM ................................................................................................................ 9-2
LNS ADDRESSES & CONTACTS ........................................................................................ 9-3
PROGRAMMING EXAMPLE ................................................................................................. 9-4
QUICK LOAD SERVO III MI
CHAPTER 1: BASIC NOTIONS
1-1
CHAPTER 1:
BASIC NOTIONS
QUICK LOAD SERVO III MI
1-2
1.
CHAPTER 1: BASIC NOTIONS
STRUCTURE
This manual consists of various chapters, each containing several points, paragraphs, etc. Lists may be
contained in paragraphs.
•
•
•
The page number is indicated in the top outer corner of the page.
The chapter number and title are indicated in the top inner corner of the page.
The model of the bar feed system is indicated in the bottom right-hand corner of the page.
1.1. Cross-references
Each chapter generally contains all of the information related to the description and settings of the
devices and elements represented therein.
Therefore, if a setting must be made while you are handling the system, please refer to the chapter on the
device to be set, for example: (see chapter *) or (see point *).
1.2. Captions
Whenever possible, the reference numbers contained in the instruction manual are shown with the LNS
ordering number of the indicated element.
To make it easier to place an order of supplies, a form has been included in the annex at the end of this
manual.
1.3. Symbols and terminology
This sign recommends following the directions very closely avoiding causing an
incident that could result in injury, damage to the equipment, or data loss.
This sign indicates that safety measures must be taken to avoid possible electrical
shocks or mishaps.
The notes stress interesting points or comments, and provide useful advice for
optimal system operation.
This sign points out an advice about environmental protection.
QUICK LOAD SERVO III MI
CHAPTER 1: BASIC NOTIONS
2.
1-3
RIGHTS
All rights reserved. Reproduction, recording or transmission of all, or any portion, of this manual, in any
form or through any means whatsoever, whether mechanical, photographic, sound or other, without the
express written authorization of LNS SA, is prohibited. LNS SA disclaims all responsibility for errors which
may be contained in this manual and the problems which may result therefore.
LNS SA and its subsidiaries cannot be made responsible for the debts, losses, expenses, or damage
incurred, or suffered, by the buyer of this product, or a third party, following an accident, incorrect use, or
misuse, or stemming from modifications, repairs, or transformations not authorized by LNS SA.
LNS SA and its subsidiaries cannot be held responsible for damage and problems arising from the use of
options and products other than LNS products, or products approved by LNS SA.
The names of the products indicated in this manual are registered trademarks.
The instructions found in this manual are only for information ; they are subject to change without notice.
QUICK LOAD SERVO III MI
1-4
3.
CHAPTER 1: BASIC NOTIONS
DECLARATION OF COMPLIANCE
Sample representation; the original document is always shipped with the unit.
EC DECLARATION OF CONFORMITY
We declare that the following machinery complies with the next directives :
- Machinery Directive: 98/37/EC
- Low Voltage Directive: 2006/95/EC
- EMC Directive: 2004/108/EC
Manufacturer :
LNS SA
Route de Frinvillier
CH- 2534 Orvin
Suisse
Compiling relevant technical information :
Plaseco Kurt De Pauw
Chemin des Petits-Clos 12
CH- 1744 Chénens
Suisse
Description of the machine
: Automatic barfeed system
Type
: Quick Load Servo III MI
Serial number
: (see number on official document)
The
following
transposed
harmonised
standards
have
- Concerning the Machinery Directive :
•
•
•
•
•
•
•
•
•
•
EN 14121 - 1 & 2 : Safety of machinery – Risk assessment,
EN 12100 - 1 & 2 : Safety of machinery – Basic concepts & principles,
EN 294 : Safety of machinery – Safety distances,
EN 13850 : Safety of machinery – Emergency stop equipment,
EN 953 : Safety of machinery – Conception of movable guards,
EN 954-1 : Safety of machinery – Safety related parts of control systems,
EN 1037 : Safety of machinery – Prevention of unexpected start-up,
EN 1088 : Safety of machinery – Interlocking devices,
EN 60204-1 : Safety of machinery – Electrical equipment of machines,
CEI 60812 : Safety of machinery – FMECA Analysis,
- Concerning the Low Voltage Directive :
•
IEC 60439-1/3 : Low-voltage switchgear and control gear assemblies
- Concerning the EMC Directive :
•
•
EN 61000-6-4 : Generic emissions standard, Industrial environment
EN 61000-6-2 : Generic immunity standard, Industrial environment
Place and date :
QUICK LOAD SERVO III MI
Seal and signature :
been
used
:
CHAPTER 1: BASIC NOTIONS
4.
1-5
SAFETY INSTRUCTIONS
Only people who know the product and are sufficiently qualified, may install, put the spindle in
use, maintain and, where necessary, repair. The customer must ensure that the provisions
regarding internal monitoring, the indication prescribed events, organization of work, staff
training is available with instructions for assembly.
All persons who perform work on this machine, must have read and understood the notice
instructions. LNS disclaim all responsibility for possible accidents or property damage caused
when safety instructions are not followed :
• Do not handle the equipment without having
knowledge of the safety instructions and the
instructions for use. Safety instructions for
the bar feed system, as well as the CNC
lathe, must be strictly observed.
• Non-qualified personnel, children, and
persons under the influence of alcohol or
medication should not handle the equipment.
• Loose garments, long hair and jewellery can
be dangerous.
• Do not remove any covers while the bar
feeder or the machine is under electrical
power.
• Do not conduct any maintenance operations
during the automatic cycle.
• Do not grasp moving or rotating objects, or
nearby elements.
• If certain safety shields or safety covers are
removed to conduct maintenance, they must
be reinstalled as soon as the maintenance
work is completed.
• No servicing should be carried out on the
interface or inside the electrical cabinet while
the bar feeder or the lathe is under electrical
power.
• It is strictly prohibited to jump wire or remove
circuit breakers, main switches, and
especially safety switches.
• Don’t hit the barfeed when moving it, this
could result in damages.
• The work area surrounding the bar feed
system should always be clear of objects
and well lit. The presence of oil on the
ground could cause falls; it is important to
maintain the floor clean on a regular basis.
• Do not place the machine in a damp area
and make sure that water or oil does not
come into contact with the electrical
equipment.
• Do not open the clamping device (collet or
chuck) of the lathe manually when the bar
feeder is in automatic mode (Interface).
• Each time the diameter is changed, also
adapt spindle reduction tube. The use of
spindle
reduction
tubes
is
highly
recommended for machining bars with
diameters smaller than the maximum
capacity of the spindle.
• Do not attempt to recharge the batteries of
the PLC.
• For the use and maintenance of the bar
feeder, use only parts provided by or
recommended by LNS.
• If it is necessary to move the bar feeder once
it has been originally installed, do not
reinstall it before first contacting LNS or its
local representative.
• To avoid any harm to persons, or damage to
components, use only the indicated points
for lifting and moving the bar feeder system.
No one should be near the hanging load, or
within the operating range of the overhead
hoist/crane, forklift, or any other means used
for lifting and transportation. Do not knock
the bar feeder while moving it as this could
damage it.
• The rotating bar should never protrude the
rear of the lathe spindle.
• Do not move the bar feeder while it is
electrically powered on.
• LNS disclaim all responsibility for possible
accidents or property damage caused when
safety instructions are not followed.
• The maximum length (max. L) the bar feeder
system is allowed to load is given by the
length of the lathe spindle. The bar should
never extend more than 3 times its diameter
beyond the lathe clamping device without
support.
QUICK LOAD SERVO III MI
1-6
5.
CHAPTER 1: BASIC NOTIONS
SAFETY DEVICES
The Quick Load Servo III MI bar feed system has been designed with a focus on maximum safety during
its handling and complies with all EC requirements.
Safety covers and devices make access to the moving parts of the bar feed system impossible. Safety
switches keep the bar feed system from operating when these protections are open.
By pressing the emergency stop button located on the remote control, the functions of the bar feed
system and the lathe are immediately stopped.
The LNS company, or its local representative, may not be held responsible for possible
accidents or property damage, whether caused directly or not, by any means whatsoever,
if certain safety devices have not been included.
5.1. Layout
B
SQ10
SQ11
SQ12
A
Designation
Description
A
Main access cover
B
Protection grid for magazine table
C
Emergency Stop push button (not shown here)
SQ10
Safety switch for main access cover
SQ11
Safety switch for magazine protection grid
SQ12
Safety switch for retraction device (in position switch)
QUICK LOAD SERVO III MI
CHAPTER 2: TECHNICAL DATA
2-1
CHAPTER 2:
TECHNICAL DATA
QUICK LOAD SERVO III MI
2-2
1.
CHAPTER 2: TECHNICAL DATA
CHARACTERISTICS
Note : Depending on the country and the standards in effect, certain technical data, such as the
power supply, may vary. Please see the technical card delivered with the device.
Weight
Overall length
2048 mm
Overall width
1486 mm
Magazine depth
1000 mm
Height
Centerline range
X and Z axis retraction travel
900 - 1149mm / 1150 - 1400 mm
600 mm
6 mm
Maximum diameter (round)
102 mm
Minimum bar stock length
300 mm (*)
Maximum bar stock length
1300 mm (*)
Maximum bar stock weight
80 kg/barstock
Maximum air consumption
Main electrical power (volts)
Maximum current rate (amps)
Pushing force/torque
2.
1248 - 1748 mm
Minimum diameter (round)
Air pressure
(*)
570 Kg
5 bar
6 litres (per loading cycle)
220 - 480 volts / 50 Hz - 60 Hz
1A
167 Nm
Maximum feed rate
> 100 m/min
Loading cycle for bar stock
8 - 12 secs.
Loading cycle for shaft loading (one shot)
4 - 7 secs.
Depending on the barfeeder, these technical data may vary. Please refer to the Options for Quick
Load Servo III MI.
FLOOR PLANS
The following floor space plans indicate the most
frequently used dimensions for placing the bar feed
system. Details on the dimensions of other parts or
elements of the bar feed system will be furnished upon
request.
The plans 2.1. and 2.2. shows the Quick Load Servo II
MI bar feed system with left/rear loading (A).
The plans 2.3. and 2.4. shows the Quick Load Servo II
MI bar feed system with left/front loading (B).
All dimensions are in millimeters.
QUICK LOAD SERVO III MI
CHAPTER 2: TECHNICAL DATA
2-3
2.1. Loading from the left/rear with X-axis (lateral) retraction
QUICK LOAD SERVO III MI
2-4
CHAPTER 2: TECHNICAL DATA
2.2. Loading from the left/rear with Z-axis (longitudinal) retraction
QUICK LOAD SERVO III MI
CHAPTER 2: TECHNICAL DATA
3.
2-5
LAYOUT OF THE ELEMENTS
J
A
L
F
B
E
D
M
Designation
G
Description
A
Protection grate
B
Loading magazine
C
Magazine slope adjustment
D
Retraction system
E
Electrical control
F
Access door
G
Air filtering unit
H
Interface plug (acc. to OEM requirements) (not shown here)
I
Remote control (not shwn here)
J
Carrier
K
Feeding pusher (not shown here)
L
Loading table
M
Loading fingers
QUICK LOAD SERVO III MI
2-6
QUICK LOAD SERVO III MI
CHAPTER 2: TECHNICAL DATA
CHAPTER 3: SETTING INTO OPERATION
3-1
CHAPTER 3:
SETTING INTO OPERATION
QUICK LOAD SERVO III MI
3-2
1.
CHAPTER 3: SETTING INTO OPERATION
TRANSPORTATION
Please read the safety precautions described at the beginning of this manual before
handling the following devices.
1.1. Description
Depending on its destination, the Quick Load Servo III MI bar feed system may be delivered either on a
pallet, or packed in a wooden crate. When sea or air transports it, the second solution is recommended.
Weight
Width
Length
Height
Crate
Pallet
820 Kg
1150 mm
2750mm
1800 mm
640 Kg
1150 mm
2250 mm
According to the centerline height
1.2. Unpacking
For practical and safety reasons, the bar feed system must be unpacked in a spacious, well-lit location.
Check to see that the lifting capacity of the hoisting crane, or lift truck, is adequate before
proceeding with the handling of the merchandise. No one should be near the hanging load,
or within the operating range of the overhead hoist/crane, forklift, or any other means used
for lifting and transportation.
1)
If the bar feed system is received in a crate, start
by unscrewing the front panel.
2)
Remove the top.
3)
Remove the side-walls.
From this point on, the bar feed system is unpacked in
the same way as when delivered on a pallet.
QUICK LOAD SERVO III MI
CHAPTER 3: SETTING INTO OPERATION
3-3
The Quick Load Servo bar feed system is always delivered as follows :
•
Magazine (A) is assembled on the bar feed system, but the two support axles (B) are bolted on
the pallet. The outer side of the magazine rests on the pallet.
•
The retraction mechanism (C) is supplied partly assembled, but is not mounted onto the bar feed
system.
•
A feeding pusher is supplied mounted on. The additional pushers, are affixed under the loading
table (D).
•
The notice instruction and the accessories are delivered in a separate package (E).
•
The bar feed system is held on the pallet by bolts and nuts (F).
Take out the parts, and place them in an easily accessible area for mounting
the bar feed system.
QUICK LOAD SERVO III MI
3-4
CHAPTER 3: SETTING INTO OPERATION
1.3. Preparation for mounting
For mounting and installing the bar feed system, it is advisable to contact LNS or one of its agents. The
latter cannot be held responsible for any malfunction resulting from an incorrect installation in which they
did not take part.
Note: If the eyed screws are not mounted, they should be among the parts in the separate package
•
Introduce two straps (A) into the lifting screws (B)
and hook them to a pulley (C). Lift the pulley to
stretch the straps
•
Remove the bolts (F) (see previous page), which
keep the bar feed system in place on the pallet for
transportation.
•
Lift the bar feed system (1) and remove the crate.
•
Now the bar feed system can also be moved with a
lift truck (E). In this case, place the arms of the lift
truck underneath the body of the bar feed system.
•
Move the bar feed system, taking care that it
remains horizontal, and that no one is nearby or
under the suspended load.
•
Do not knock the bar feed system as you move it;
this may damage it.
•
Place the bar feed system behind the lathe, as
close as possible, and in an approximate alignment
with the spindle. For the placement, the stationary
and mobile space requirements for the lathe and
bar feed system should be taken into account.
The distance between the lathe and the bar feed system should not exceed 20 mm.
Should an obstacle impose a greater distance, contact LNS or their local representative.
The area around the lathe and bar feed system must be cleared to allow for their maintenance and
handling. It should also remain clear after the installation is completed.
QUICK LOAD SERVO III MI
CHAPTER 3: SETTING INTO OPERATION
2.
3-5
MOUNTING
2.1. Mounting loading magazine
If, during the installation, it seems that the table collides with the lathe, it is possible to
move it back. The loading table is mounted towards the front of the unit at the factory, and,
except in special cases, it should not be moved.
Special protection plates (provided upon request) must be installed to the front of the
table. It is strictly prohibited to operate the device without the metal protection plates.
•
Bring the axle for setting the slope near the loading table. Unlock and remove the pins in the setting
forks, and then:
•
Lift the loading table.
•
Insert the fork located next to the setting lever on one of the eyed support piece of the loading table
(preferably centred on the loading table). Insert the pin and secure it with the latch.
•
Insert the fork located at the other end of the setting axle on the eyed support piece
A
B
E
Designation
Description
A
Magazine loading table
B
Slope adjusting axle
C
Adjusting handle
D
Eyed support piece on loading table
E
Eyed support piece
QUICK LOAD SERVO III MI
3-6
CHAPTER 3: SETTING INTO OPERATION
2.2. Mounting limiters
The magazine of the Quick Load Servo III MI bar feed system can simultaneously accept bars of various
lengths, from 130 mm to 1,600 mm.
The maximum length (max. L.) The
length
of
the
lathe
spindle
determines the length of bar stock
that may be loaded. It is strictly
prohibited to run a bar that extends
past the rear of the lathe spindle.
The bar may not extend more than
three times its diameter beyond the
front of the lathe clamping device
without support.
•
The bars are kept in place by two limiters. The first one
stationary (A), is located to the front, and is an integral
part of the loading table. The second one (B), movable,
is located on the table and fastened with screws.
•
Measure the length of the spindle from the rear to the
front face of the clamping device.
•
Lift the protection grid. Undo the lock screws holding the
rear limiter in place.
•
Place the limiter at the measured distance (L.max.) by
measuring from the front limiter. Tighten the lock screws.
•
Apply the self-adhesive marker on the loading table.
This marker will serve, in the future, to set the position of
the limiter without having to measure the length of the
spindle each time.
•
This allows the loading pusher to advance at great speed up to the rear limiter, and then to slow
down to avoid a collision at the time it comes into contact with the bar. Moreover, if the bar loaded is
too long, the bar feed system notices it when measuring it and stops the loading cycle.
L.max
Input the maximum length (L.max.) in the Service parameters. Only LNS or its
representative is allowed to change this value in the parameter.
QUICK LOAD SERVO III MI
CHAPTER 3: SETTING INTO OPERATION
3-7
2.3. Mounting retraction device
Please read the safety precautions described at the beginning of this manual before
handling the following devices.
Before handling the retraction mechanism, check to see that the interface cables between
the spindle and the bar feed system are long enough
The retraction mechanism may be assembled as necessary, to ensure longitudinal or lateral movement.
Longitudinal retraction for
Left/Rear Load
Lateral retraction for Left/Rear
Load
A
B
SQ12
C
D
B
A
Designation
Description
A
Guiding rails
B
Sliding bearings
C
Latches
D
Latch handle
E
Bracket (for lateral or longitudinal retraction)
F
Auto lock device (not shown here)
SQ12
E
Retraction system in position switch
On delivery, the elements of the retraction mechanism are not assembled on the bar feed system, as they
can be installed either laterally or in line with the lathe.
QUICK LOAD SERVO III MI
3-8
CHAPTER 3: SETTING INTO OPERATION
Installing the retraction mechanism laterally:
1.
Bring the rails on their correct side.
2.
Put the sliding bearings (D) in front of the opening (E).
3.
Push the rails (C) under the unit.
4.
Spread the sliding bearings to face the fixing holes.
5.
Put the fixing screws (F) in the bearings (D) without tightening.
6.
Install the cross girders (G) against the rails (C).
7.
Loose the fixing screws (H) and (I) (16 in all) on each anchoring square.
8.
Install the four levelling screws (J) to guarantee the parallel of the rails.
M
L
F
F
J
K
O
4
G
C
I
QUICK LOAD SERVO III MI
H
N
D
4
SQ12
CHAPTER 3: SETTING INTO OPERATION
3-9
9.
Tighten the screws (F) of the sliding bearings (D).
10.
Slide the plates (K) under the rails, then screw the screws (L) until they rest on the plates.
11.
Install the two loading table supports (M). Install the loading table.
12.
With screws (J), lift the bar feed system (5 mm between base plate and floor) and level it.
13.
Tighten the screws (H) and (I) and the locknuts (N)
14.
Install the auto-lock device (O).
15.
Introduce the key (Q) located at the front of the rail of the barfeeder in the safety switch, then fix the
safety switch on the retraction device with the screws (R). If the fixing holes of the switch are not
perfectly lined up, loosen the screws of the key (S), fix the switch and then the key.
16.
Proceed to the alignment as indicated on chapter 3/point 2.5.
When the barfeeder is fixed to the floor, check the alignment of the switch with the key by moving
the barfeeder backward and forward again to its working position.
QUICK LOAD SERVO III MI
3-10
CHAPTER 3: SETTING INTO OPERATION
Installing the retraction mechanism longitudinally:
1.
Bring the rails on their correct side.
2.
Put the sliding bearings (D) in front of the opening (E).
3.
Push the rails (C) under the unit.
4.
Spread the sliding bearings to face the fixing holes.
5.
Put the fixing screws (F) in the bearings (D) without tightening.
6.
Install the cross girders (G) against the rails (C).
7.
Loose the fixing screws (H) and (I) (16 in all) on each anchoring square.
8.
Install the four levelling screws (J) to guarantee the parallel of the rails.
QUICK LOAD SERVO III MI
CHAPTER 3: SETTING INTO OPERATION
3-11
9.
Tighten the screws (F) of the sliding bearings (D).
10.
Slide the plates (K) under the rails, then screw the screws (L) until they rest on the plates.
11.
Install the two loading table supports (M). Install the loading table.
12.
With screws (J), lift the bar feed system (5 mm between base plate and floor) and level it.
13.
Tighten the screws (H) and (I) and the locknuts (N)
14.
Install the auto-lock device (O).
15.
Introduce the key (Q) located at the front of the rail of the barfeeder in the safety switch, then fix the
safety switch on the retraction device with the screws (R). If the fixing holes of the switch are not
perfectly lined up, loosen the screws of the key (S), fix the switch and then the key.
16.
Proceed to the alignment as indicated on chapter 3/point 2.5.
When the barfeeder is fixed to the floor, check the alignment of the switch with the key by moving
the barfeeder backward and forward again to its working position.
QUICK LOAD SERVO III MI
3-12
CHAPTER 3: SETTING INTO OPERATION
2.4. Adjusting the table height
•
Remove front cover (A).
•
Check that the central screw (B) rests on the plate (D).
•
Carefully loosen the 16 screws (C).
•
Adjust the height of the bar feed system by tightening or loosening the central screw (B).
•
A hexagonal tube, delivered with the system, allows access to the adjusting screw from the top,
through the loading table.
•
When the correct height is reached, tighten the screws (C) and proceed with the alignment of the
bar feed system.
•
Remount the plate (A).
QUICK LOAD SERVO III MI
CHAPTER 3: SETTING INTO OPERATION
3-13
2.5. Alignment
Before aligning the bar feed system, check to see that the lathe is stable and, if possible,
levelled.
Reminders:
• The bar feed system should be placed as close as possible to the lathe spindle.
• To obtain a perfect alignment, it is advisable to install the largest feeding pusher.
• If a spindle liner is installed, make sure that its I.D. is larger than the O.D. of the feeding pusher.
• It is not mandatory that the lateral level of the bar feed system is perfect; just make sure that the
latter is as straight as possible.
• The longitudinal level of the bar feed system must be adjusted according to the level of the lathe,
even if the lathe lies only over three points and cannot be perfectly levelled.
Should the level of the bar feed system not correspond to that of the lathe, the feeding pusher
might touch the inside of the spindle.
Place the level on the loading channel. Adjust the level
with the screws (A).
Lock the feeding pusher manually, and move it behind
the lathe spindle.
If necessary, adjust the height, see preceding page, until
the feeding pusher is in the centre of the spindle.
Simultaneously, proceed with the lateral alignment, by
moving the device (with a plastic hammer, for example).
Move feeding pusher forward, checking its entrance into
the spindle. If the feeding pusher deviates, check again
whether the bar feed system is level.
The feeding pusher must be centred at the point of entry
(1), as well as behind the collet of the lathe (2), and
should never come into contact with the I.D. of the
spindle.
When the alignment is considered satisfactory, lock all
screw nuts.
Remove the eyed screws and install the plastic caps on the main access cover (the plastic caps should
be among the parts in the separate package).
QUICK LOAD SERVO III MI
3-14
CHAPTER 3: SETTING INTO OPERATION
2.6. Anchoring to the ground
Once the bar feed system is in place, and perfectly aligned, it should be anchored to the ground to make
it stable. To accomplish this, 4 x 2 anchorage points (A) have been provided.
8 anchorage bolts (B) must be furnished by the client (Minimum M 10 x 100 mm) (Minimum 1/2" x 4").
Once the anchoring bolts are tightened, check the alignment again, and correct it if necessary.
QUICK LOAD SERVO III MI
CHAPTER 3: SETTING INTO OPERATION
3-15
2.7. Security analysis for the correct incorporation
Before considering assembling the machine, it is necessary to consider the following points:
3.
•
Consider security strategies that reduce risks to an acceptable level;
•
Define the tasks required for applications to predict and assess the need of access and / or for
the approach;
•
Identify sources of risks, including failures and failure modes associated with each task. Risks
can come from:
o machine in which the device QLS III is integrated;
o its association with other equipment,
o People’s interaction with the machine.
•
Evaluate and assess the risks associated by using the machine QLS III MI:
o programming risks
o operation risks
o risks of use
o maintenance risks
•
Choose methods of protection :
o the use of protective devices
o the introduction of signals
o compliance with safe work procedures
ELECTRICAL CONNECTIONS
See CHAPTER 4: ELECTRICS, section 4. INTERFACE.
4.
PNEUMATICAL CONNECTIONS
See CHAPTER 5: PNEUMATICS, section 2. AIR FILTERING UNIT.
QUICK LOAD SERVO III MI
3-16
QUICK LOAD SERVO III MI
CHAPTER 3: SETTING INTO OPERATION
CHAPTER 4: ELECTRICS
4-1
CHAPTER 4:
ELECTRICS
QUICK LOAD SERVO III MI
4-2
1.
CHAPTER 4: ELECTRICS
ELECTRICAL EQUIPMENT
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
Particular attention should be given to the handling of electrical elements because of risks
of electrocution. In case of possible electrical malfunctions, it is advisable to contact LNS
or their local representative.
1.1. Description
This chapter contains all of the elements regarding the electrical circuit of the bar feed system. The
electrical parts, and groups, which may require a setting, at some time or other, are described herein in
detail.
Whenever possible, the article numbers of the elements are shown in tables below each drawing.
QUICK LOAD SERVO III MI
CHAPTER 4: ELECTRICS
4-3
1.2. Layout of the electrical elements on the bar feed system
M1
SQ10
SQ3
SQ5
SQ11
C
QS1
SQ12
M2
SQ2
SQ1
SQ4
Designation
Reference no.
Description
A
4.972
B
4.068/4.074
C
-
QS1
4.242
Main disconnect switch
M1
4.569
Servo motor
M2
4.307
Motor for diameter adjustment
SQ1
4.484
Loading table in lower position
SQ2
4.484
Loading table in upper position
SQ3
44.0072
SQ4
4.391
Proximity switch for diameter adjustment
SQ5
4.391
Proximity switch for pusher in home position
SQ10
4.284
Main access cover safety switch
SQ11
4.277
Magazine grid cover safety switch
SQ12
4.291/4.292
Remote control (not shown here)
24 pin connector with cover (not shown here)
Control cabinet
Measuring cell
Retraction system in position switch (incl. key)
QUICK LOAD SERVO III MI
4-4
CHAPTER 4: ELECTRICS
ELECTRICAL CABINET
1.3. Layout of the elements in the electrical cabinet
!
*
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ecurity
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8
Designation
Reference no.
-
-
-
44.0081
-
-
-
4.907
Programmable controller PCD3 (PLC)
AJ1
4.705
Servo amplifier 400W
FU1
4.419
Diameter adaption motor fuse 2A
K3
4.932
Safety contactor
KS
4.985
Start relay
K8-K9
4.931
Safety control module
K10
4.932
Safety contactor
KA1
4.606
Relay : Motor M2 “Up”
KA2
4.606
Relay : Motor M2 “Down”
QF1
4.815
Circuit breaker 4A
QS1
4.242
Main disconnect switch
R1-R5
4.925
Interface relay (not shown here)
T1
4.769
Transformer 1ph
T2
4.779
24 VDC Power supply 150W
QUICK LOAD SERVO III MI
Description
Input – output terminal blocks X1 (YV1 – YV8)
Ethernet switch
Safety terminal blocks X3 (T1 – T6)
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CHAPTER 4: ELECTRICS
4-5
1.4. Description of the elements in the cabinet
1.4.1. Main disconnect switch QS1
In accordance with the requirements of the international IEC standards, when the main disconnect switch
is at 0off, it interrupts the input of the three phases in the control cabinet of the bar feed system.
1.4.2. Main circuit breaker QM1
Circuit breaker QM1 interrupts the 3 phases, which power the hydraulic motor.
If the motor requires excessive power, the circuit breaker
activates and push-button (C) STOP is released. For safety
reason, the power supply to the motor is immediately
interrupted. After having located and repaired the problem
causing this interruption, reset the circuit breaker by pressing
the push-button (F) START.
A
1L1
3L2
3.5
4
O I
B
At the factory, the breaking current is set to 2.5 amperes.
3
C
Designation
5L3
F
2.5
Description
A
Power in connecting terminal
B
Setting the breaking current
C
Release button
D
Power out connecting terminal
E
Test push-button
F
Reset button
Test
2T1
E
4T2
6T3
1.4.3. Circuit breaker QF1 (4 Amps)
Circuit breaker QF1 protects the two phases, which power the
transformer.
Should the latter require excessive power (>4 Amps), the breaker
activates and lever (B) flips down.
A
MULTI 9
C60H
The power supply to the transformer is immediately interrupted to
avoid material damages.
After having located and repaired the problem causing this
interruption, reset the lever (B) of the circuit breaker.
Designation
Description
A
Power in connecting terminal
B
Lever on/off
C
Power out connecting terminal
B
C
QUICK LOAD SERVO III MI
4-6
CHAPTER 4: ELECTRICS
1.4.4. Transformers 230 V (T1) and 24 VDC (T2)
The transformers T1 and T2 power the entire low voltage network of the bar feed system, as well as a
portion of the interface signals, (see section 3. INTERFACE in this chapter).
The transformer T1 has an output of 230 Volts which powers the amplifier of the SERVO motor
A fuse installed in a support protects the transformer T1 output.
To replace the fuse:
1.
2.
Unscrew the cap a quarter of a turn to the left.
Remove and replace the fuse with an identical one, and put the cap back.
On the primary side, the transformer accepts a voltage of 220 to 480 volts, 50 or 60 Hz. Measure the
power provided by the lathe, and, if necessary, adapt the cable on the power terminal block (A).
N -5% 200 230 400 480
A
B
C
230
Designation
230
Description
A
Primary terminal block, 220V-480V / 50hz or 60 Hz ± 15%
B
Secondary terminal block, 230 V
C
Fuse (3.15 A)
The transformer T2 has an output of 24 VDC and powers the rest of the barfeed.
The transformer T2 output is protected by the fuse FU1 installed in a support in the electrical control
cabinet.
Although fuses seldom need replacing, is it advisable to keep some spare ones on hand.
QUICK LOAD SERVO III MI
CHAPTER 4: ELECTRICS
4-7
1.4.5. Servo amplifier
By means of the SERVO amplifier, the programmable controller controls the movements of the motor.
The input values, as well as the position of the pusher carrier, are continuously registered. The values are
saved by means of a battery, and, therefore, the axles do not need to be placed at zero when the bar
feed system after powered up.
Although the batteries last for a relatively long time (4-7 years), it is advisable to keep spare ones on hand.
When a battery becomes low, the amplifier signals this through a control light. The battery is not
rechargeable, and must be replaced right away. The replacement must be done while the bar feed
system is still powered up.
Procedure :
1.
Raise cover (I), Pull out plug (D).
2.
Ease clip to the right and remove the battery. The wires on the extremities of the battery connecting
it to the switch are part of the battery.
3.
Install the new battery inside the support, connect the plug and close the cover.
Used batteries must be disposed off in an ecologically safe manner.
D
C
I
MITSUBISHI
H
E
OPEN
F
C
N
1
A
C
N
1
B
C
N
2
C
N
3
G
A
CHARGE
L1
L2
L3
U
V
W
A
U
V
W
B
Designation
Description
A
230 V + ground power supply
B
Power output to SERVO motor
C
Battery (ordering number 4.714)
D
Battery plug
E
Emergency stop contact
F
Encoder connecting plug
G
Programmable controller / SERVO amplifier connecting plug
H
Alarm and codes display of amplifier
I
Cover
QUICK LOAD SERVO III MI
4-8
CHAPTER 4: ELECTRICS
1.4.6. Programmable controller (PLC)
The programmable controller (PLC) continuously scrutinizes all data from the remote control, probes,
switches, cells, interface, etc.
The program loaded into the PLC manages this information. The PLC then distributes the interface
signals, controls the SERVO drives as well as the pneumatic valves, and displays the appropriate
messages on the remote control station.
A
Designation
A
Description
Information module
M1
Slot for software updates
M2
Slot for memory expansion (in use as standard)
Information module:
Batt: The PLC does not need a backup battery on the information module.
Run: The PLC is in RUN mode. This is the standard mode.
Halt: The PLC is in HALT mode. Contact your LNS SA dealer.
Error: The PLC is in a failure mode. Contact your LNS SA dealer.
M1 slot:
Usually this slot is left unused, and is used for software updates through flash (red) cards. Do not insert
any flash card unless instructed by LNS SA.
M2 slot:
This slot is used by a flash (blue) card as memory expansion. Do not remove the flash card unless
instructed by LNS SA.
QUICK LOAD SERVO III MI
CHAPTER 4: ELECTRICS
4-9
1.4.7. PLC inputs / outputs
Inputs
Input
Des.
I0
K8
Description
Outputs
Output
Des.
Description
Safety relay
O32
YV1A
Lower loading table
Raise loading table
I1
SP1
Air pressure switch
O33
YV1B
I2
SQ10
Main cover safety
O34
KA1
Motor M2 up
I3
SQ11
Loading magazine grid safety
O35
KA2
Motor M2 down
I4
SQ12
Retraction safety switch
O36
SON
Servo motor ON
I5
-
Not in use
O37
-
I6
-
Not in use
O38
YV3
Not in use
Guiding profiled bar (option)
I7
-
Not in use
O39
-
I8
SQ1
Loading table in lower position
O40
YV2
I9
SQ2
Loading table in upper position
O41
-
Not in use
I10
SQ3
Measuring cell
O42
-
Not in use
I11
SQ4
Diameter adjustment
O43
-
Not in use
I12
SQ5
Pusher in home position
O44
-
Not in use
I13
SQ30
Loading magazine empty (option)
O45
-
Not in use
I14
SQ31
Telescopic pusher (option)
O46
-
Not in use
I15
-
Not in use
O47
KS
Start relay
I16
-
Not in use
O48
-
Not in use
I17
-
Not in use
O49
-
Not in use
I18
-
Not in use
O50
-
Not in use
I19
-
Not in use
O51
-
Not in use
I20
-
Not in use
O52
-
Not in use
I21
-
Not in use
O53
-
Not in use
I22
-
Not in use
O54
-
Not in use
I23
-
Not in use
O55
-
Not in use
Interface
Not in use
Telescopic pusher (option)
Interface
I24
A1
Clamping device signal
-
-
Not in use
I25
A2
Lathe in auto cycle
-
-
Not in use
I26
A3
Feed order
-
-
Not in use
I27
A4
Push order
-
-
Not in use
I28
A..
Programmable interface input
-
-
Not in use
I29
A..
Programmable interface input
-
-
Not in use
I30
A..
Programmable interface input
-
-
Not in use
I31
A..
Programmable interface input
-
-
Not in use
QUICK LOAD SERVO III MI
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QUICK LOAD SERVO III MI
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QUICK LOAD SERVO III MI
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QUICK LOAD SERVO III MI
=3# 9
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-
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$
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4-18
3.
CHAPTER 4: ELECTRICS
INTERFACE
Before connecting, check to make sure that the voltage of the bar feed system
corresponds to the one provided by the lathe. The voltage of the bar feed system is
indicated on the identification plate. Only LNS (or certified) technician is authorized to
modify the interface or parameter system.
3.1. Description
The interface cable(s), between the bar feed system and the lathe is (are) provided by LNS.
Although an example of an interface diagram is provided, the diagram for the interface corresponding to
your device, essential when making the electrical connection, is located inside the electrical cabinet.
When making connections, ensure that the cables are long enough to allow the entire travel of the
retraction system (500 mm).
Should the interface instructions not be observed during the setting into operation, the
damaged elements as well as the resulting damages are not covered by warranty.
3.2. Connections
3.2.1. Power supply
Voltage:
Maximum current:
3 x 220-480 V, 50 / 60 Hz + Ground (± 10%)
1A
In the case where the voltage supplied by the lathe does not match that provided for the barfeed, the
transformer T1 must be adapted.
The LNS bar feed systems are equipped with their own thermal protection systems (breakers, thermal
relays and fuses, etc.). The power supply for the bar feed system should be connected to the output of a
breaker mounted in the electrical control box of the lathe (10 A max.).
2
For the wiring inside the lathe, the section of the cables should be at least 1.5 mm (AWG 16).
3.2.2. Signals from the lathe to the barfeed system
Always refer to the electrical diagrams shipped with the bar feed system and placed in the electrical
cabinet. Although an example of an interface diagram is provided, the diagram for the interface
corresponding to your device, essential when making the electrical connection, is located inside the
electrical cabinet.
a)
24 V dc power supply
Corresponds to the +24 V of the bar feed system. This power shall be used to connect the signals from
the lathe to the PLC.
•
•
All signals from the lathe to the PLC shall be powered by the +24 V dc of the bar feed system.
All signals from the bar feed system to the lathe shall be powered by the +24 V dc of the lathe.
For the other types of connections, please contact LNS S.A. or their local representative.
b)
"EMERGENCY STOP" signal of lathe XT8-XT9
This signal is part of a safety link (Emergency Stop circuit) of the bar feed system. XT8-XT9 corresponds
to the Emergency Stop signal of the lathe. If the circuit is open, the bar feed system will go into an
Emergency Stop mode.
When the lathe is in an Emergency Stop mode, or if the safety line of the bar feed system is interrupted,
an alarm will go off and the R1 relay of the bar feed system will be triggered (see description of the R1
relay, below).
QUICK LOAD SERVO III MI
CHAPTER 4: ELECTRICS
4-19
c)
Lathe clamp signal (PLC input A1)
This signal is for checking the mode of the lathe clamping device (open), and is mainly used for the
feeding of a part, which takes place each time the clamp opens.
For safety reasons, wire a normally open contact, coming from the signal of the lathe
clamp. A clamp open signal must be selected.
d)
Lathe in automatic cycle (PLC input A2)
This signal indicates that the lathe is in automatic cycle.
e)
Load command (PLC input A3)
Should the lathe be equipped with a sub-spindle or the lathe is of twin spindle type, should the part
require multiple feeds, this signal will be used as a load command from the lathe.
For safety reasons, and to prevent collisions between the part being transferred to the second spindle
and the newly loaded bar stock when there is a simultaneous loading, the lathe must control the loading
of a new bar.
f)
Feeding pusher control (PLC input A4)
This signal orders the forward movement of the feeding pusher and the bar, independently of the mode of
the lathe clamp.
As long as this signal is present, the signal of the foot switch to open and close the
clamping device of the lathe must be locked. The lathe should not start up in automatic
cycle as long as the clamping device does not grip the bar.
3.2.3. Signals from the bar feeder to the lathe
a)
R1 alarm relay
When the bar feed system is in normal operation, the R1 relay signal is energized. In the event of an
alarm or break in the emergency stop circuit, this relay is de-energized.
For safety reasons, this signal should bring to a stop all of the axis movements of the lathe as well as the
rotation of the spindle.
When the bar feed system is in alarm mode, the feeding pusher control signal should also deenergize.
b)
R2 start and stop of the lathe
Either:
- Confirmation of the feeding pusher forward command
And/or
- Confirmation of the loading of a new bar
After the loading and positioning of the new bar on the lathe spindle, relay R2 confirms the end of the
loading cycle or the part feed out.
The operational cycle of relay R2 (pulsed, latched, etc.) is controlled by Services parameters.
QUICK LOAD SERVO III MI
4-20
CHAPTER 4: ELECTRICS
c)
R3 end of bar signal relay
When the feeding pusher reaches the End of Bar position, relay R3 energizes. This signal is used to
indicate to the lathe that there is not enough material left to make another part. The CNC must jump into a
sub-program to allow the remnant to be dejected.
The operational cycle of relay R3 (pulsed, latched, etc.) is controlled by Services parameters.
d)
R4 automatic mode relay
This signal is present as soon as the bar feed system is in automatic cycle (Aut + Start).
e)
Emergency stop button of the bar feed system (EM1-EM2)
When the Emergency Stop button is pressed, the contact opens. The lathe must be in Emergency Stop
mode, and the feeding pusher signal from the lathe must turn off. Two normally closed contacts of the
Emergency Stop button are available for connection in the Emergency Stop circuit of the lathe.
3.2.4. Options
The options described below are an integral part of the standard equipment of the LNS bar feed systems.
These signals, however, are not required for the proper operation of the devices, or the safety locking for
protecting persons and materials. The options are available only to optimize production conditions.
a)
R5 auxiliary end of bar relay
This signal may be used to reduce the length of the remnant in case the remnants exceed the maximum
admissible length for the parts catcher of the lathe or its chip conveyor. Relay R5 energizes as soon as
the feeding pusher reaches the programmed position
b)
R6 bar stock magazine empty relay
Contact of relay R6 (optional). Relay R6 engages after verification of the presence of a bar during the
loading cycle of a new bar.
3.2.5. Recapitulation of safety instructions related to the interface
•
The lathe foot switch for opening the lathe clamping device should not be operational during the
automatic cycle of the lathe.
•
The lathe pedal should not be operational as long as the feeding pusher feed command signal is
present.
•
Whenever possible, it is advisable to interlock lock the manual command for opening the lathe
clamping device while the feeding pusher command signal is on.
•
If the lathe is in the Emergency Stop mode, the bar feed system must also be under the
Emergency Stop mode, and vice-versa.
•
If the bar feed system generates an alarm, the lathe must go into alarm mode. The feeding
pusher feed command signal must go off, the spindle axis and rotation must stop.
QUICK LOAD SERVO III MI
CHAPTER 5: PNEUMATICS
5-1
CHAPTER 5:
PNEUMATICS
QUICK LOAD SERVO III MI
5-2
CHAPTER 5: PNEUMATICS
1.
PNEUMATICAL EQUIPMENT
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
1.1. Description
The following automatic movements of the bar feed system are done via pneumatic elements, namely:
• Bar stock loading into the loading table
• Pusher locking system
• Loading table moving / down
To guarantee an optimal operation of the bar feed system, a minimum pressure of 5 bars (75 PSI), and a
maximum pressure of 6 bars (90 PSI) is mandatory.
1.2. Layout of the pneumatic elements
C
C
D
C
A
Designation
Reference no.
A
3.636/3.638
B
3.407
C
3.95020.A.30
D
3.656
QUICK LOAD SERVO III MI
Description
Air filtering unit
Cylinder for feeding pusher locking mechanism
Cylinder for loading channel up/down motion
Pneumatic valve battery
CHAPTER 5: PNEUMATICS
2.
5-3
AIR FILTERING UNIT
2.1. Description
The air filtering device serves to filter air and to set its pressure before it is distributed into the pneumatic
circuit of the bar feed system.
The air must be furnished at a maximum pressure of 6 bar, and whenever possible, clean and dry.
2.2. Layout of the elements
Designation
Description
A
Pressure regulator
B
Pressure gauge with pressure switch
C
Inlet
D
Regulated pressure outlet
E
Decanter
F
Automatic purging
D
A
C
B
E
F
2.3. Connection
The pneumatic connection (C) is located behind the control cabinet.
For the pneumatic connections of the bar feed system, the customer must provide a hose (B) with an
inside diameter of 1/2" (12.7 mm). For USA, 3/8" (9.5mm).
Provide an air hose long enough to allow the complete travel (600 mm) of the retraction system.
When the hose is connected, it should not lie on the
ground because it could become damaged.
1.
Place clamp (A) around hose (B).
2.
Insert fitting (C) into hose.
3.
Tighten the flange (A) to make it airtight.
B
A
C
QUICK LOAD SERVO III MI
5-4
CHAPTER 5: PNEUMATICS
2.4. Settings
1.
Unlock the adjusting knob by pulling it upward.
To increase the pressure, turn it clockwise. To decrease it, turn
it in the opposite direction. The operational pressure should be
set at 5 bar.
2.
When the settings are done, lock the adjuster by pushing it
downward.
QUICK LOAD SERVO III MI
1
-
+
2
CHAPTER 5: PNEUMATICS
3.
5-5
PNEUMATIC VALVE
3.1. Description
The pneumatic battery includes the control and monitoring elements of the barfeed system pneumatic
circuit.
3.2. Layout of the elements
B
Designation
C
A
Description
A
Inlets
B
Outlets
C
Silencer
3.3. Manual operation
Directly controlled by the PLC, the electro-valves activate the pneumatic cylinders.
By pressing a key (B), the pneumatic cylinders can be activated manually. This manoeuvre may prove to
be useful during tests or maintenance.
When the (B) key is released, the pneumatic cylinder returns to its resting position (except for pneumatic
cylinders activated by 2 electro-valves).
Designation
Description
A
Air outlet
B
Manual activation key
B
A
A B
VQC........-5
SMC
4
5
2
1
3
3.4. Air pressure switch
To guarantee an optimal work of the bar feed system, the service
pressure must be at least 5 bars (75 Psi). The pressure switch serves to
confirm that this pressure is present and adequate.
The air pressure switch is directly integrated into the pressure gauge.
Set up procedure for the pressure switch:
• Remove the glass of the pressure gauge
• With a screwdriver, turn the setting screw
• Place back the glass
QUICK LOAD SERVO III MI
5-6
4.
CHAPTER 5: PNEUMATICS
PNEUMATIC DIAGRAMS
4.1. Symbols
Symbol
Description
Pressure switch
QUICK LOAD SERVO III MI
SP1
Pneumatic cylinder
3.301
Air filtering unit
3.305
Electro-valve
4.2. Pneumatic diagram
Designation
YV1A / YV1B
CHAPTER 6: GENERAL DESCRIPTION
6-1
CHAPTER 6:
GENERAL DESCRIPTION
QUICK LOAD SERVO III MI
6-2
1.
CHAPTER 6: GENERAL DESCRIPTION
BAR MAGAZINE
Please read the safety precautions described at the beginning of this manual before
handling the following devices.
1.1. Description
Placed to the side of the Quick Load Servo III MI bar feed system, the loading magazine, 1,000 mm deep,
can receive bars of various lengths, between 300 mm and 1,300 mm.
To facilitate the moving of the bars on the magazine table, the latter is equipped with a grate on which the
bars are placed. If, however, certain bars (i.e.
profiled bars) cannot slide, the slope can be
increased via an axle located under the table.
If, on the other hand, bars with small
diameters overlap, then the slope can or must
be reduced.
A protection grid impedes access to the
loading table during the automatic cycle. In
manual mode, the grid, mounted onto hinges,
can be lifted, and thus allows the operator to
conduct
the
necessary
maintenance
operations.
In no case should a rotating bar extend past the rear of the lathe spindle. The lathe spindle gives the
maximum length the bar feed system can load. The bar may not extend more than three times its
diameter beyond the front of the lathe clamping device without support. A limiter makes it possible to set
the maximum bar length on the table.
When they are on the loading table, stopping fingers laid out on an axle holds the bars.
The position of the fingers is set automatically when the loading diameter is entered into the
bar feed system parameters.
QUICK LOAD SERVO III MI
CHAPTER 6: GENERAL DESCRIPTION
6-3
1.2. Layout of the elements
B
A
SQ11
G
F
C
E
D
Designation
Description
A
Magazine table
B
Protection grid
C
Rear limiter
D
Slope inclination adjusting axle
E
Fingers for bar selection
F
Holding rod
G
Bar safety stopper
SQ11
Grid closed safety switch
QUICK LOAD SERVO III MI
6-4
CHAPTER 6: GENERAL DESCRIPTION
1.3. Position setup
If, during the installation, it appears that the magazine table collides with the lathe, or hinders the
maintenance of the lathe, the table can be moved backwards.
A Service parameter, indicating the position of the loading table, must be changed. In this
case, only a LNS or certified technician is allowed to move the magazine loading table.
Procedure:
The axle for setting the slope must be installed after the table has been moved.
1.
Lift loading table (A) and measure the distance (X) at which it should be positioned.
2.
If need be, remove the metal protection plates (B) and (C).
Remove screws (D) of the hinge connecting the loading table to the bar feed system.
3.
Move the table the (X) distance previously measured. Mount the hinge with screws (D).
Special protection plates (provided upon request) must be installed to the front of the table
as well as in replacement of protection plates (B) and (C). It is strictly prohibited to operate
the device without the metal protection plates.
Proceed with the installation of the axle for setting the slope, as explained in the previous section.
QUICK LOAD SERVO III MI
CHAPTER 6: GENERAL DESCRIPTION
6-5
1.4. Limiters
1.4.1. Rear Limiter
The magazine of the Quick Load Servo III MI bar feed system can simultaneously accept bars of various
lengths, from 300 mm to 1,300 mm.
The maximum length (max. L.) of the lathe
spindle determines the length of bar stock
that may be loaded. It is strictly prohibited to
run a bar that extends past the rear of the
lathe spindle. The bar may not extend more
than three times its diameter beyond the
front of the lathe clamping device without
support.
The bars are kept in place by two limiters. The first one stationary (A), is located to the front, and is an
integral part of the loading table. The second one (B), movable, is located on the table and fastened with
screws.
Procedure :
•
Measure the length of the spindle
from the rear to the front face of the
•
Clamping device. Lift the protection
grid. Undo the lock screws holding the
rear limiter in place.
•
Place the limiter at the measured
distance (L.max.) by measuring from
the front limiter. Tighten the lock
screws.
•
Apply the self-adhesive marker on the
loading table. This marker will serve,
in the future, to set the position of the
limiter without having to measure the
length of the spindle each time.
•
Input the maximum length (L.max.) in
the Service parameters (only LNS or
its representative is allowed to change
this value in the parameter).
This allows the loading pusher to advance at
great speed up to the rear limiter, and then
to slow down to avoid a collision at the time
it comes into contact with the bar. Moreover,
if the bar loaded is too long, the bar feed
system notices it when measuring it and
stops the loading cycle.
QUICK LOAD SERVO III MI
6-6
CHAPTER 6: GENERAL DESCRIPTION
1.4.2. Loading variable bars
Although the Quick Load Servo bar feed system can load bars of various lengths it is advisable to place
them on the loading table in order of decreasing length, and to center them (A) between the limiters so
that they do not go side-ways (B).
1.4.3. Loading constant bars
Quick Load Servo III MI may also be used as a loading magazine for piston rods, axles, or forged parts.
A corresponding interface, however, is required if one wishes to attain minimum loading
times. These possibilities should be studied beforehand and discussed with the
manufacturer of the lathe or the Distribution Company.
When the parts are of the same length, it is possible to move the rear limiter to decrease the loading time.
•
•
•
•
•
•
Lift the protection grid.
Place a bar on the loading table, leaning against the front limiter.
Move the rear limiter to 1 mm behind the bar. Check that the limiter is parallel by rolling the bar on
the table.
Tighten the lock screws.
Lever la grille de protection.
A parameter must be changed, see chapter 7 / point 4.2.1
To facilitate the moving of the bars on the magazine table, the latter is equipped with a grate on which the
bars are placed. If, however, certain bars (i.e. profiled bars) cannot slide, the slope can be increased via
an axle located under the table. If, on the other hand, bars with small diameters overlap, then the slope
can or must be reduced.
1.4.4. Loading of profiled bars
According to the profile of the bars to be loaded, some settings and some optional accessories are
necessary. Please contact your LNS agent.
QUICK LOAD SERVO III MI
CHAPTER 6: GENERAL DESCRIPTION
2.
6-7
LOADING TABLE
Please read the safety precautions described at the beginning of this manual before
handling the following devices.
2.1. Description
When positioned on the magazine, the bars rest against the loading fingers (B). The fingers are located
on an axle (C) connected to the loading table (D). The setting of the fingers is done automatically by the
M2 electrical motor at the same time as the setting of the loading table (centerline height).
The loading table of the Quick Load Servo III MI bar feed system has two functions:
1. Selection of material:
When slide (A) is in a low position, feeding pusher (B) faces spindle (C). The pneumatic
cylinders are activated, the channel rises and selects a bar (D) leaning against the stops (E) of
the loading table.
2. Guiding the material:
When in a high position, the loading channel faces the spindle. The bar can then be introduced
into the spindle.
In order for the bar always to be perfectly aligned with the center of the spindle, regardless of its diameter,
the height of the loading table is automatically set by a motor (M2) when the diameter of the bar is
entered into the parameters (See Chapter 7 / point 4.2.1).
QUICK LOAD SERVO III MI
6-8
CHAPTER 6: GENERAL DESCRIPTION
2.2. Loading table calibration
In order to ensure optimal loading, it is essential that the bar be perfectly aligned with the spindle,
regardless of its diameter. Whenever the diameter or the profile is changed, the position of the table is
automatically adjusted according to the diameter and the profile entered in the Quick Load Servo III MI by
the operator.
If, for any reason whatsoever, the position of the table should be incorrect (either too high or too low), it
can be corrected.
The pneumatic cylinders, controlling the vertical movement of the table, release the
pressure to allow motor M2 to proceed with the setting. After the setting is complete, they
are reactivated.
Conditions:
•
•
Bars are on the magazine
The loading table is in lower position
1.
Select manual mode by pressing the [F2] key.
2.
Bring the loading table in upper position [F2].
3.
The bar now faces the spindle of the lathe.
4.
The remote command offers icon [F4] Forward.
To obtain the icon [F1] Adjust the height of the
loading table, press and hold the [F3] key until
the icon shows up.
5.
Press the [F1] key.
6.
Three icons are displayed :
[F1] lower the table
[F3] ENTER (save)
[F4] raise the table
Each time the [F1] or [F4] key is pressed, the
vertical position of the table is modified by 0.25
mm. For substantial adjustments, keep pressing
the key to keep the table moving in a continuous
motion.
7.
When the desired position is reached, press the
[F3] ENTER key to validate the choice and
recalibrate the device at this new position.
8.
Since the calibration must be changed, the
command automatically accesses "Parameters
related to set-up, diameter, length, etc.
The command asks the operator to confirm the setting of the diameter.
9.
Using the keypad, enter the diameter of the bar used to center the table. Press the [F3] ENTER
key twice to validate.
QUICK LOAD SERVO III MI
CHAPTER 6: GENERAL DESCRIPTION
6-9
2.3. Positioning the roller supports
Quick Load Servo III MI is delivered initially with 6
roller supports, laid-out to cover the entire length
of the bar magazine.
When limiter (B) is positioned during the
installation (See point 1.4.1 / Lmax.), move the
supports (A) installed behind the limiter and install
them in the front, to assure better support of the
bar.
3.
PUSHER CARRIER
Please read the safety precautions described at the beginning of this manual before
handling the following devices.
3.1. Description
By means of a timing belt, the SERVO motor starts drives the carrier. While the loading pusher is
advancing towards the spindle, the feeding pusher remains stationary. When the carrier returns to its
home position, the feeding pusher is locked, which, at that point, is attached to the carrier.
The locking/unlocking mechanism of the feeding pusher is pneumatically connected to the valves of the
loading channel :
1.
Loading channel in loading position (upper position)
The loading pusher faces the spindle, the feeding pusher is not locked.
2.
Loading channel in working position (lower position)
The feeding pusher faces the spindle, the feeding pusher is locked onto the carrier.
The length of the feeding pushers is unvarying and does not depend on the length of the spindle. For
safety reasons, the feeding pushers are equipped with a mechanical stop.
To load tubes, profiled bars or short bars, optional accessories may be installed. Please contact your
local LNS representative.
QUICK LOAD SERVO III MI
6-10
CHAPTER 6: GENERAL DESCRIPTION
3.2. Layout of the elements
Designation
A
Carrier
B
Loading pusher
C
Feeding pusher
D
Mechanical stop
E
Linear rail
F
Notched belt
G
Linear unit belt
3.95020.A.30
M1
4.
Description
Locking cylinder
Servo motor
LOADING PUSHER
Contrary to the feeding pusher, the loading pusher (A) does not need to be replaced when the bar
diameter changes.
Same-length bars may be loaded directly with a loading pusher without using the feeding pusher. To do
this, a special extended loading pusher, available as an option, is required. Selected parameters must
then be chosen; see Chapter 7 / point 4.2.7.
QUICK LOAD SERVO III MI
CHAPTER 6: GENERAL DESCRIPTION
5.
6-11
FEEDING PUSHER
5.1. Description
Three feeding pushers are necessary to cover the entire range of the Quick Load Servo III MI barfeed
system. Each pusher has a defined range of operation :
Pusher diameter
Ordering Nr
Diameter Range
**6,35 mm (1/4")
*021.011.022 / 6
6 mm - 15 mm (1/4" - 1/2")
12 mm (1/2")
*021.011.062
16 mm - 32 mm (>2/3" - 1 1/4")
25 mm (1")
*021.011.022 / 25
33 mm - 120 mm (>1 1/4" - 4,7")
*
This ordering number corresponds to the complete pusher, with all of the elements indicated below.
When a feeding pusher is ordered for the first time, use this number.
**
2 extra roller supports, intended to bolster the support of bars of small diameter, are furnished with
the 6.35 mm diameter pushers. Their placement on the loading table will be determined by the length of
the bars to be loaded.
5.2. Layout of the elements
6,35 (1/4")
12
25
Ordering Nr
Ordering Nr
Ordering Nr
A
-*
-*
-
Pusher rod
B
-*
-*
914.06.06
Set screw
C
-*
-*
011.07.444
Head
D
011.07.234
011.007.184
011.07.014
Mechanical stop
E
021.05.244
021.05.164
011.007.194
Guide bushing
A+B+C
**021.011.074
**021.011.294
**021.011.304
Pusher Assembly
Des.
Desc.
*
On 6.35 mm and 12 mm pushers, parts (A), (B), and (C) are welded.
**
This number is used when the bar feed system is already fitted out with elements (D) and (E).
QUICK LOAD SERVO III MI
6-12
CHAPTER 6: GENERAL DESCRIPTION
5.3. Pusher Replacement
1.
Bring the loading channel into working mode
position (down position), then place the bar feed
system into the STOP mode (remote station).
2.
Loosen the fastening screws (A) sufficiently to free
the groove (C) that holds the pusher (B) in the
connecting piece (D).
3.
Slide the pusher forward by making into the guide
bushing (E).
4.
When the rear of the pusher is sufficiently loosened
to be able to remove it, pull the guide bushing (E)
toward the back to dislodge it.
5.
The pusher is now free and can be removed.
•
Place the new pusher into the opening, and
insert the guide bushing.
•
Introduce the rear of the pusher into the
connection piece and push to a stop.
•
Tighten the fastening screws so that they
lodge into the groove of the pusher.
•
Check to see that the mechanical stop sleeve
is properly positioned (see next section)
QUICK LOAD SERVO III MI
CHAPTER 6: GENERAL DESCRIPTION
6.
6-13
BELT
After it has been in use for some time, the bar feed system may indicate, by means of a message on the
display, that the tension of the belt (A) should be adjusted.
Should the tension be adjusted, make sure that while adjusting the belt remains under
tension in order not to lose the reference point. Should the reference point be lost, enter
the new reference point (Chapter 7 / point 5.2). Same procedure when the belt needs
replacement.
Procedure :
•
Switch the bar feed system to STOP mode (remote station).
•
Open the main access cover.
•
Use a lever (C) in the opening between the pulleys to take the weight of the motor.
•
Holding the weight of the motor, loosen the fixing screws (B).
•
With the lever (C) push the motor up to tighten the dented belt (A).
•
Holding the belt taut, tighten the fixing screws (B).
•
Remove the lever and close the main access cover.
QUICK LOAD SERVO III MI
6-14
7.
CHAPTER 6: GENERAL DESCRIPTION
RETRACTION
Please read the safety precautions described at the beginning of this manual before
handling the following devices.
Before handling the retraction mechanism, check to see that the interface cables between
the spindle and the bar feed system are long enough
7.1. Description
When a lathe is equipped with a bar feed system, certain elements (motors, spindle reduction tubes, etc.)
become inaccessible, and sometimes it is difficult, or even impossible, to proceed with their maintenance.
To facilitate these tasks, the Quick Load Servo III MI is equipped with a retraction system, which allows
the operator to move the bar feeder.
The retraction mechanism may be assembled as necessary, to ensure longitudinal or lateral movement.
The retraction mechanism may be assembled as necessary, to ensure longitudinal or lateral movement.
A
Z-axis (longitudinal) retraction for Left/Rear Load
B
X-axis (lateral) retraction for Left/Rear Load
QUICK LOAD SERVO III MI
CHAPTER 6: GENERAL DESCRIPTION
6-15
7.2. Layout of the elements
SQ12
C
D
B
A
E
Designation
Description
A
Guiding rails
B
Sliding bearings
C
Latches
D
Latch handle
E
Bracket (for lateral or longitudinal retraction)
F
Auto lock device (not shown here)
SQ12
Retraction system in position switch
7.3. Use of the retraction
Mounted onto four extremely rigid bearings (B), the bar feed system slides on two cylindrical rails (A) that
keep it aligned when it is in operational position. In this position, the bar feed system is fastened by two
solid hooks (C).
A safety switch (SQ12) impedes any handling as long as the bar feed system is not in operational
position.
•
To move the bar feed system, unlock the hooks by lifting the latching handles (D). An autolock
device (F) will prevent the bar feed system to move back.
•
To bring the bar feed in operational position, lift the auto lock device.
QUICK LOAD SERVO III MI
6-16
8.
CHAPTER 6: GENERAL DESCRIPTION
OPTIONS
Please read the safety precautions described at the beginning of this manual before
handling the following devices.
8.1. Kit for square stock
The use of an adaptor for square stocks is required in order
to orientate the square stock from the 120° V-channel into
the spindle centre.
This kit includes:
- Steel angle support 120° to 90°
- additional limiter
Depending on the unit configuration, different references are
available :
Unit version
Left / Rear loading rack
Reference no.
021.002.163
8.2. Kit for One Shot Shaft loading
Parts of the same length can be loaded with a specially designed pusher (A).
The loading procedure is simplified, and the loading cycle
time can be reduced with specific interface and adaptations.
This kit includes a loading pusher ø12 mm for shaft loading,
adjustable to the part length.
Description
One shot shaft loading
QUICK LOAD SERVO III MI
Reference no.
021.018.012
CHAPTER 6: GENERAL DESCRIPTION
6-17
8.3. Loading of tubes
When bar stocks to be loaded are tubes, an adapter is necessary to create a flat contact surface between
the tube and the pusher.
The adapter must be adapted to the outside diameter of the tube (by turning the outside diameter of the
adapter), and then be mounted on the tip of the 25 mm pusher.
QUICK LOAD SERVO III MI
6-18
QUICK LOAD SERVO III MI
CHAPTER 6: GENERAL DESCRIPTION
CHAPTER 7: OPERATION
7-1
CHAPTER 7:
OPERATION
QUICK LOAD SERVO III MI
7-2
1.
CHAPTER 7: OPERATION
POWERING UP
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
The motor of the QUICK LOAD SERVO III MI bar feed system is equipped with a built-in absolute
encoder that continuously controls the position of the pusher.
When the bar feed system is powered down or there is a power failure, this position is kept in the memory
by the PLC.
When powering up, the value saved is immediately taken into account, thus avoiding any input from the
beginning. The status parameters saved in the PLC prior to powering down are then checked by the PLC
which analyses them. The latter then gives the operator access only to those handling operations, which
should be undertaken.
To power up the bar feed system, turn (1) the switch handle to
the right, to the Ion position.
1
IO
n
To power down, turn the switch to the left, to the 0off position.
The main switch can be locked with a padlock. This way, it is
impossible to turn the bar feed system on.
Push (2) the locking mechanism and insert (3) the padlock into
the opening. Lock the padlock.
3
2
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
2.
7-3
REMOTE CONTROL
The ergonomic and user-friendly remote control with a clear built-in display facilitates the handling of the
bar feed system. Depending on the sequence under way, the bar feed system gives access only to those
functions which are available, thus avoiding any incorrect handling, and reducing the access time to the
necessary functions.
The display reads, continuously and clearly, the status of the bar feed system and the production,
allowing one to verify at all times the functions, diagnostics, error signals, or their analysis. The most
recent error signals are saved in a register and can be recalled to establish the diagnostics.
The remote control has five distinct segments, namely: display (A), function keys (B), directional keys and
numeric pad (C), modes buttons with STOP, MENU and HELP buttons (D), and the emergency button (E).
E
A
B
C
D
QUICK LOAD SERVO III MI
7-4
CHAPTER 7: OPERATION
2.1. Display
The liquid crystal display with touchscreen function provides the operator with all the necessary data, both
for handling the bar feed system and for maintenance.
General aspect
Current
barfeed
sequence
Current status
or
working
mode
Information
screen on
current
action or
mode
Unit
system
(mm or inch)
Bar
diameter
and
feedout
length
Current
torque
applied
Clamping
device status
Current
feeding axis
position
Information line
on
current
action
Available functions, depending on
the current situation
The icons available are the following:
Icon
Signification
Icon
Signification
Referencing position
Set a new value
Switch to automatic mode
Escape
Stop after machining one bar stock
Return to previous menu
Switch to manual mode
Jump to next menu
Pusher forward
reversed)
(picture
may
be
Move the loading table up + load a new bar
into the loading table
Pusher reverse
reversed)
(picture
may
be
Move the loading table down
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
7-5
Switch between normal feed rate and
slow feed rate (only in manual mode) for
added positioning accuracy
Automatic Top-Cut positioning in manual
mode (picture may be reversed)
Validate
Teach data
Cancel
Offset correction
Confirm. In setup mode, the button
must be hold for 3 seconds to
validate the change.
Increment data in offset correction mode
Start sequence
Decrement data in offset correction mode
Enter the loading table calibration mode
Lower the loading table (in calibration mode)
Rise the loading table (in calibration
mode)
QUICK LOAD SERVO III MI
7-6
CHAPTER 7: OPERATION
2.2. Function keys F1 - F4
These keys are located right below the display. The functions attributed to them are indicated on the
display by icons.
As the operator advances in the handling, the functions of the keys are automatically reattributed to
correspond to the circumstance and availability of the bar feed system.
2.3. Left / right / up / down keys
These keys allow entering values (bar stock diameter, part length, etc.) or parameters.
2.4. Emergency stop button
When a dangerous situation arises, pressing the emergency stop switch interrupts immediately all bar
feed system and lathe functions (if interface is wired accordingly).
To cancel the alarm, release the switch by rotating its red knob counter-clockwise, then press [STOP].
2.5. MODE buttons
2.5.1. MENU key
The MENU key allows access to the main menu, where the parameters concerning the production, the
interface and the general settings of the barfeed can be reviewed and changed.
2.5.2. STOP key
The STOP key allows interrupting the sequence under way.
Important: the automatic cycle of the lathe must first be interrupted.
By pressing the STOP key, allows to exit the setting mode, regardless of the level reached, and to return
to the work screen.
The STOP key is not an emergency button, and cannot be interpreted as such. For
emergency cases, always use the emergency button located on the top of the
remote control.
2.5.3. HELP key
The HELP key displays useful information about the software version, the firmware of the critical
components, the current status of the inputs and outputs of the system.
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
3.
7-7
SET UP
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
All handling, optional accessories and settings required by the bar feed system to carry out a specific job
are part of the set-up.
A few simple operations are necessary to prepare the device to handle another range of diameters.
The set-up must be modified when following parameters change:
•
•
•
Bar stock diameter
Bar stock shape
Part length
3.1. Barfeed mechanical setup
3.1.1. Pusher adaptation
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
Depending on the bar stocks to feed, a changeover of the pusher may be necessary. In this case, please
refer to CHAPTER 6, section 5.2. Pusher replacement of this user manual.
QUICK LOAD SERVO III MI
7-8
CHAPTER 7: OPERATION
3.2. Lathe mechanical setup
3.2.1. Clamping method
Collets
There are different kinds of collets that are more or less effective:
a) Simple cone collet
The bar is held over about 350 degrees, over a
length from 0.5 to 7 times the diameter.
Efficiency : good to very good
b) Bi-conical collet
Clamping over 1 or 2 x 350 degrees, over an
approximate length of 1.2 times the diameter.
Efficiency : very good to excellent
c) Double cone collet
The double cone clamp has the great advantage
of holding the bar at two points separated by
about 1.5 the diameter, with a clamping 2 times
350 degrees over about 0.5 times the diameter.
Efficiency : excellent
3-jaws chuck
With this type of clamping, one should be very careful given that in many cases the bar is held only at
three points, thereby greatly increasing the risk of vibration.
Frequent errors and possibilities for improving the effectiveness of the clamping grip.
12
Wrong :
The radius of the grip is greater than the radius of
the bar.
The jaws press against only 3 points at 120
degrees.
0°
a) Hard grips
60°
Correct :
Modify the centres of the jaws to obtain 2 times 6
support clamping points at 60 degrees.
1/3
QUICK LOAD SERVO III MI
1/3
1/3
CHAPTER 7: OPERATION
7-9
12
Wrong :
The radius of the jaws is greater than the radius of
the bar.
The jaws press against only three points at 120
degrees.
0°
b) Soft grips
60°
Correct :
Modify the centres of the jaws to obtain 2 times 6
support clamping points at 60 degrees.
1/3
1/3
1/3
3.3. Lathe – barfeed adaptation
3.3.1. Spindle reduction tubes
The efficiency of the bar guiding while in rotation in the lathe is determined by the clearance between the
spindle bore and the rotating bar. The greater the clearance is, the more frequent the vibrations are.
Using reduction tubes helps to decrease this clearance. Guiding is thus improved, but, in addition, the
insertion of the bar into the clamping device of the lathe is made much easier.
The inside diameter of the reduction tubes should be chosen in terms of the diameter of the bar (Ø of the
bar + 1 mm), but should always be larger than that of the diameter of the feeding pusher.
For inserting and removing the spindle reductions, move the bar feed system using the retraction device
(see CHAPTER 6, section 7. RETRACTION for further information).
Spindle reduction tubes are available from LNS, upon request.
QUICK LOAD SERVO III MI
7-10
4.
CHAPTER 7: OPERATION
SETTINGS
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
4.1. Description
The QUICK LOAD SERVO III MI has several parameters and functions allowing the operator to configure
it so that it adapts as closely as possible to the lathe on which it is installed, as well as to the production
mode under way.
The position of the flag, or the quantity of material left to be machine, can be known at any time by
checking the remote control.
The pushing torque of the motor is automatically selected according to the bar stock diameter.
When hexagonal or squares bars must be loaded, the servo motor intelligently manages the loading into
the lathe.
This section indicates the activating and setting procedures for these functions.
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
7-11
4.2. Access to the functions
By pressing the MENU key, it is possible to access the setup functions.
To modify these parameters, the bar feed must be in STOP mode. To validate some
values or parameters, hold the [ENTER] key until the icon disappears.
Depending on your lathe or your production needs, some of the parameters may not be
visible at first. The missing parameters can be unmasked under SERVICE > DISPLAY.
Part setup
Allows to define the parameters and values
of the part, like:
• Bar stock shape (round, hex, square,
other)
• Bar stock diameter
• Overall part length to feed
• Number of clamping device openings
• Overall part length for the auxiliary part
(remnant machining)
Application setup
Allows setting quickly the working mode by
selecting the desired application. Following
working modes are always available:
•
•
•
Feed with turret
Feed without turret
Dry Run
Positions setup
Quick access to the following position
values:
• End of bar
• Top cut
• Auxiliary end of bar
Torques setup
Quick access to the following position
values:
• Torque for the bar stock loading
• Torque for the part feeding
Language setup
Allows the access to the other languages
Miscellaneous functions
•
•
Reference point request
Timings on lathe’s clamping device
Service setup
Reserved for maintenance to LNS
technicians and for unlocking features /
displays.
QUICK LOAD SERVO III MI
7-12
CHAPTER 7: OPERATION
4.2.1. Part setup
Material shape, diameter and length, variable face-off distance
C
Lp
Lt
Material shape
Round material:
• outer bar diameter
Hex / square material:
• diameter across flats
• diameter across corners
• Front rest guiding element
• When the material is profiled, the bar feed system will try several times (for 2 minutes), to position
the bar inside the clamping device of the lathe. The accuracy of the positioning is also assured by
a positioning procedure designed specifically for profiled bars.
Total part feed out length
The feed-out length (Lt) includes the part length (Lp), the cut-off tool width (C) and the face-off length (not
represented on the picture, depending on the program).
Variable face-off distance
Distance from the face of the lathe’s chuck to the cutting position.
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
7-13
Number of clamping device openings for overall part length
1
2
1
When the machining of a part requires several openings of the clamping device (for ex.: a long part, or
transfer of the part to the sub-spindle), some interface conflicts may occur during the feeding process.
It is important for the bar feed system to be “informed” of the number of times the clamping device must
open for the machining of a part.
The bar feed system only carries out the first positioning for a single part. The following positioning (if
any) must be done by the turret.
Top-cut position (may be not visible)
z
During the loading cycle, the bar is automatically loaded into the spindle and automatically positioned in
the clamping device of the lathe (chuck or actuator).
This positioning corresponds to a value (Z) programmed by the operator, which is equal to the distance
between the measuring cell and the position of the material in the lathe clamping device.
With this system, the setting is the same for any bar length.
More information the section 7. TOP-CUT POSITION of this chapter.
QUICK LOAD SERVO III MI
7-14
CHAPTER 7: OPERATION
Optional auxiliary end of bar (may be not visible)
Lt2
Lt2
When machining remnants (A) that are rather long, a second mode of production for machining the rest of
the stock can be selected (depending on the capabilities of the lathe).
Top-cut position (may be not visible)
z
During the loading cycle, the bar is automatically loaded and positioned into the spindle, outside the
clamping device of the lathe (chuck or actuator).
This positioning corresponds to a value (Z) programmed by the operator, which is equal to the distance
between the measuring cell and the position of the material in the lathe clamping device.
With this system, the setting is the same for any bar length.
More information the section 7. TOP-CUT POSITION of this chapter.
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
7-15
End Of Bar (may be not visible)
5mm
The end of bar position determines the moment when the bar feed enters the loading cycle.
Usually, the end of bar position is adjusted as closely as possible behind the clamping system of the lathe
(approximately 5 mm or a 1/4" behind the chuck jaws or collet pads).This will provide minimum bar stock
remnant.
Regardless of the length of the bars, or parts, the end of bar position is always the same. In very special
cases, a different end of bar setting needs to be selected.
More information the section 6. END OF BAR of this chapter.
Pusher reversing distance
This parameter allows to define the clearance between the bar stock and the pusher after the part feed
out, when the clamping device closes and the bar is rotating again. This value should be set so that the
pusher never touches any rotating part (bar or spindle, or spindle liner).
QUICK LOAD SERVO III MI
7-16
CHAPTER 7: OPERATION
Loading flag position (may be not visible)
This parameter allows to define the length of a specific loading pusher, and is used in shaft loading
applications.
Bar length variable or constant (may be not visible)
This parameter allows to specify the accuracy of the bar lengths. If accurate enough, when the bar length
is set on “constant”, the bar feeder will only measure the first bar length, and use the same value for all
the next bar stocks, to speed up the loading process. This parameter should only be used with a physical
limiter on the loading magazine to avoid the loading of longer bars, which could lead to damages on the
lathe.
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
7-17
Loading with fixed spindle liner (may be not visible)
This parameter allows to work in a specific mode, where a non-rotating spindle liner allows premature
shaft loading, to speed up the loading process. This parameter should only be used with a physical limiter
on the loading magazine to avoid the loading of longer bars, which could lead to damages on the lathe.
Please contact your LNS agent for further information on this application.
Feed rate for part feed out (may be not visible)
This parameter allows to adapt the feed rate to the actual weight of the bar, for example when feeding
aluminium bar stocks.
QUICK LOAD SERVO III MI
7-18
CHAPTER 7: OPERATION
4.2.2. Application setup
Part feed out with or without turret
1
2
Lt
Part feed out with turret
This parameter determines whether the lathe or the bar feed will control the positioning of the part.
Additional parameter (may be not visible):
a) The turret is parked in position:
the turret travels to the point the bar stock will be pushed to and waits that the bar feed has pushed
the material to this point.
b) The turret is moving to position:
The turret comes to the bar stock end; the bar feed starts pushing against the turret. Then, the turret
moves to the desired feeding length, the bar feed still maintaining the bar stock pressure against the
turret.
Part feed out without turret
The bar feed drives the feeding cycle. When the clamping device opens, the bar feed pushes the bar
stock according to the parameter "overall part length" value. The bar feed is not able to drive the feeding
cycle if the machining process requires several clamping device openings.
Part feed out with M-function
This parameter is used to deactivate the M function receipt of the turret if this function is not used in the
lathe interface. In this case, a timer can be used to give the receipt.
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
7-19
Part feed out by the sub-spindle
In the case the part feed out is executed by the sub-spindle, this parameter allows to count the clamping
device openings, so that the bar feeder is still able to give an End Of Bar signal even if it does not follow
the bar stock physically.
One Shot shaft loading
This parameter enables the One Shot shaft loading, where the shaft is directly brought into top-cut
position by the loading pusher. Please contact your LNS agent for further information on this application.
QUICK LOAD SERVO III MI
7-20
CHAPTER 7: OPERATION
Miscellaneous applications
Dry Run (may be not visible)
This function allows the lathe to run without the bar feeder, ex.: hand loading pieces, etc.
Mechanical stop
In this application, the feeding pusher is used as a depth end stop, to safely load shafts manually.
This application might not work on lathes with “door open” signal connected to the safety
line, where no pusher movement is allowed when the door of the lathe is open.
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
7-21
4.2.3. Positions
Position end of bar signal (may be not visible)
5mm
The end of bar position determines the moment when the bar feed enters the loading cycle.
Usually, the end of bar position is adjusted as closely as possible behind the clamping system of the lathe
(approximately 5 mm or a 1/4" behind the chuck jaws or collet pads).This will provide minimum bar stock
remnant.
Regardless of the length of the bars, or parts, the end of bar position is always the same. In very special
cases, a different end of bar setting needs to be selected.
More information the section 6. END OF BAR of this chapter.
Top-cut position
z
During the loading cycle, the bar is automatically loaded and positioned into the spindle, outside the
clamping device of the lathe (chuck or actuator).
This positioning corresponds to a value (Z) programmed by the operator, which is equal to the distance
between the measuring cell and the position of the material in the lathe clamping device.
With this system, the setting is the same for any bar length.
More information the section 7. TOP-CUT POSITION of this chapter.
QUICK LOAD SERVO III MI
7-22
CHAPTER 7: OPERATION
Auxiliary end of bar position (may be not visible)
Depending on the lathe and its options, the auxiliary end of bar may be used in several ways, for example
for the opening of an external rest. The procedure is the same as this for the end of bar setting.
4.2.4. Torques
Pusher torque rate during part feed out and according to bar stock diameter (%)
Depending on the diameter of the bar, the bar feed system will automatically select an appropriate
pushing torque and speed. The operator may modify this selection if necessary. When the material to be
loaded has a high specific weight, the torque must be significant. The contrary applies if the specific
weight of the bars is low.
Torque rate during loading according to bar diameter (%)
Same principle as for the couple fast forward, applied this time to loading.
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
7-23
4.2.5. Miscellaneous functions
Language
This parameter allows to adapt the language in which the messages will appear, depending on the
country of destination of the bar feed system (for practical reason, it is not necessary to stop the bar
feeder to select a language).
Miscellaneous functions
Referencing
This operation allows the bar feed system to find the original position of the servo motor and the
parameters when and if these have been lost.
Clamping device signal inversion (may be not visible)
The interface signal is reversed depending on whether the clamping device functions by pushing or by
pulling. It is therefore essential to know the operation of the clamping device, without this, the feeding
process cannot be done correctly.
Time for clamping device to close (may be not visible)
This is the time it takes for the clamping device to be physically closed. The majority of CNC lathes are
equipped with confirmation switches to provide this signal. The time is set at a default value of zero
seconds.
Time for clamping device to open (may be not visible)
In the case of a clamping device with jaws, sometime may be provided to prevent any movement before
the clamping device is completely open.
QUICK LOAD SERVO III MI
7-24
CHAPTER 7: OPERATION
4.2.6. Parts Library
PART LIBRARY
The main « Parts Library » shows the current state of the library.
• Active part: shows the part ID currently in use.
• Total parts: shows the total number of parts stored in the library.
• Memory present: A memory expansion is necessary for the parts library.
o Green: the memory expansion is installed on the PLC and in operation
o Red: there is no memory expansion card on the PLC. No part can be loaded, added or
deleted from the Parts Library.
• Memory used: shows the total currently used memory for parts, in kilobytes.
• Memory free: shows the total unallocated memory, in kilobytes.
LOAD PART
This screen allows recalling and loading the parameters of an existing part from the parts library into the
parts parameters, by calling its part ID.
• Active part: shows the part ID currently in use.
• Total parts: shows the total number of parts stored in the library.
• Enter part ID: type the ID of the part to recall and load.
QUICK LOAD SERVO III MI
CHAPTER 7: OPERATION
7-25
ADD PART
This screen allows adding a new part to the Parts Library by storing all the current parameters under a
new part ID.
Caution: Entering and confirming an existing ID overwrites the stored parameters with the new ones.
Once confirmed, the parameters of the old ID are permanently overwritten in the Parts Library and cannot
be recovered.
• Active part: shows the part ID currently in use.
• Total parts: shows the total number of parts stored in the library.
• Enter part ID: type a new ID to store the parameters.
DELETE PART
This screen allows deleting a part from the Parts Library by calling its part ID.
Caution: Once confirmed, the parameters of this ID are permanently erased from the Parts Library and
cannot be recovered.
• Active part: shows the part ID currently in use.
• Total parts: shows the total number of parts stored in the library.
• Enter part ID: type the ID of the part to delete.
QUICK LOAD SERVO III MI
7-26
CHAPTER 7: OPERATION
4.2.7. Service
The service parameters allow to configure the bar feed system in its environment and to
adapt the interface connected to the lathe. Changing these values can damage the
devices and create safety issues. Therefore, these parameters are protected with a
password, and only LNS (or certified) technician is authorized to modify them.
1. Barfeed
These parameters set the values of speed, position and torque for a functioning barfeed system
1.
2.
3.
4.
Bar feeder location (left hand / right hand)
Unit (mm/inch)
Time for clamping device to close (factory value 0.0 sec)
Time for clamping device to open (factory value 0.0 sec)
2. Position
1.
2.
3.
4.
5.
6.
7.
Position behind the clamping device (mm)
Feed out safety tolerance when feeding with lathe’s turret (factory value 10 mm)
Forward limit position of loading flag (mm)
Maximum bar length (mm)
Position of front limiter (mm)
Position of measuring cell (mm)
Length of feeding pusher (mm)
3.
Speed/Torque
1.
2.
3.
4.
5.
6.
7.
8.
9.
Feed rate before bar measuring (factory values min-max 80 - 400 min )
-1
Feed rate during loading cycle (factory values min-max 100 -3000 min )
-1
Feed rate without bar stock (factory values min-max 1000 - 4000 min )
-1
Feed rate for part feed out (factory values min-max 100 - 3000 min )
-1
Forward feed rate in manual mode (factory values min-max 100 - 1000 min )
-1
Reverse feed rate in manual mode (factory values min-max 100 - 2000 min )
Torque without bar stock (factory values min-max 0 - 100%)
Torque during part loading (factory values min-max 2 - 80%)
Torque during bar loading (factory values min-max 2 - 80%)
QUICK LOAD SERVO III MI
-1
CHAPTER 7: OPERATION
4. Options
5. Interface
(standard
parameters)
1.
2.
7-27
Barfeed with profiled bar guide (no/yes)
Barfeed with telescopic pusher (no/yes)
These parameters set the communication and working mode between the lathe and the barfeed.
PI00
PI02
PI03
PI04
PI05
PI06
PI09
PI10
PI11
PI13
PI14
PI15
PI16
PI17
PI18
PI19
PI20
PI21
PI22
PI23
PI24
PI26
PI27
PI30
PI31
PI32
PI33
PI34
PI35
PI36
PI37
PI39
PI40
PI41
PI42
6. Working
mode setup
1.
2.
3.
4.
Barfeeder in : Working mode (normal operation)
Simulation
Demo mode
Interface simulation with lathe, without bar
7. Applications
display
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Parameter access: Sub-spindle (no/yes)
Parameter access: One shot shaft loading (no/yes)
Parameter access: Loading with fixed spindle liner (no/yes)
Parameter access: Use the pusher as mechanical stop (no/yes)
Parameter access: Dry run function (no/yes)
Parameter access: Turret waits in position or follows bar (no/yes)
Parameter access: Feed out to part length with or without M-code (no/yes)
Parameter access: Sub-spindle: fixed or sliding headstock (no/yes)
Parameter access: End of bar (yes/no)
Parameter access: Top-cut position (no/yes)
Parameter access: Clamping device signal inversion (no/yes)
Parameter access: Position of loading flag (no/yes)
Parameter access: Bar length: variable or constant (no/yes)
Parameter access: Production selection (no/yes)
Parameter access: Feed rate for part feed out (no/yes)
8. Network
settings
1.
2.
3.
4.
5.
6.
Ethernet Interface (disabled/enabled)
Ethernet interface type (1: MTCONNECT / 2: OKUMA / 3: MORI SEIKI / 4: MAZAK)
CPU – IP Address
CPU – Subnet mask
CPU – Default gateway
ANYBUS – IP Address
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7-28
CHAPTER 7: OPERATION
4.2.8. Help screens
From any screen in manual or automatic mode, pressing the HELP button, or on the “?” button on the
screen, displays the help screens to troubleshoot or gather information about the software and
components.
1. Software
This screen displays the current software running the barfeeder and its version.
2. Interface
This screen shows the current signals being sent / received through the interface between the
barfeed and the lathe.
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CHAPTER 7: OPERATION
7-29
3. Inputs
This screen shows the current input signals being used in the barfeed.
4. Outputs
This screen shows the current output signals being used in the barfeed.
5. Alarms list
This screen shows the history of the last 10 alarms.
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7-30
CHAPTER 7: OPERATION
6. Memory list
This screen helps entering and monitoring specific bits (status in green/red), and
register values (value in left box).
7. Force
Ethernet
signals
This screen helps force interface signals through the ethernet cable to troubleshoot the
communication between the barfeed and the lathe.
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CHAPTER 7: OPERATION
5.
7-31
AUTOMATIC CYCLE
The barfeed autonomy is depending on the bar stocks placed by the operator on the loading ramp. This
task can be performed at anytime in the production cycle.
Every time the automatic cycle is to be started, it is recommended to check following points:
•
•
•
The pusher must be adapted to the bar stock diameter and to the spindle inner diameter (including
spindle liner).
The pushing force must be adapted to the bar stock material.
On the lathe, the clamping device must be adapted to the bar stock diameter.
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7-32
CHAPTER 7: OPERATION
5.1. Sequence flowchart
BAR FEED
IN AUTOMATIC
MODE
NO
START BAR
FEED IN
AUTOMATIC
MODE
LOAD NEW
BAR STOCK
(SUBPROGRAM)
LOADING
TABLE
MOVES
DOWN
YES
PUSHER MOVES
BAR TO
TOP-CUT
POSITION
OPEN COLLET
NO
PUSH
FORWARD
COMMAND FROM
LATHE ?
NO
LOAD NEW BAR
/ DWELL
COMMAND
(M CODE)
END OF BAR ?
TOP-CUT REACHED?
YES
YES
PUSHER
RETRACTS
NO
COLLET CLOSE
MAIN PART
PROGRAM
LOADING
TABLE
MOVES UP
OPEN COLLET
NO
FIXED
HEADSTOCK
HEADSTOCK
HOME
YES
LOADING
FINGER
MOVES BEHIND
THE BARSTOCK
TOP-CUT NEW
BAR STOCK
SUB-PROGRAM
COMPLETE
PART FEED
CLOSE COLLET
MACHINE PART
LOADING
FINGER
MEASURES
THE BARSTOCK
LOADING
FINGER
MOVES TO
THE END OF
STOKE
CUT-OFF
PART
LOADING
FINGER
MOVES BACK
TO REFERENCE
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RETURN TO
MAIN PART
PROGRAMM
CHAPTER 7: OPERATION
6.
7-33
END OF BAR POSITION
6.1. Description
The end of bar position determines the moment when the bar
feed enters the loading cycle.
Usually, the end of bar position is adjusted as closely as
possible behind the clamping system of the lathe (approximately
5 mm or a 1/4" behind the chuck jaws or collet pads).
This will provide minimum bar stock remnant.
5mm
Regardless of the length of the bars, or parts, the end of bar
position is always the same.
In very special cases, a different end of bar setting needs to be
selected.
The length of the remnant may vary :
•
The minimum remnant length (Min) is obtained when the
feeding pusher is just behind the clamping device while the
last part is being machined.
•
The maximum remnant length (Max) is obtained when
there is not enough material for machining an additional
part (Lp - 1 mm).
Maximum remnant length = Lp - 1 mm + Min
Lp -1mm
Min.
Lp
Max.
6.2. Setting
Before handling the bar feeder, stop the lathe at the end of part cycle !
To edit these parameters, the bar feed system must be in STOP mode.
To validate a new parameter or a new value, keep [ENTER] pressed until the icon
disappears.
1
2
3
[STOP]
Press the key [STOP].
[MENU]
Press the key [MENU].
[PAGE DOWN]
The remote command displays the following text : "PARMETERS RELATED TO".
Press twice the key attributed to the icon [PAGE DOWN].
4
[ENTER]
The remote command displays the following text : "SETTINGS FOR
POSITIONING".
Press the key attributed to the icon [ENTER].
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7-34
5
CHAPTER 7: OPERATION
[SET]
The remote command displays the following text : "END OF BAR POSITION".
Press the key attributed to the icon [SET].
Depending on which sequence the bar feed is in when the parameter is selected,
the available functions and icons can change :
Conditions
-
Loading channel down
No bar stock in the loading channel
Icon [+/-]
Icon [TEACH IN]
Loading with extended loading
pusher
Icon [+/-]
---
Setting by offset correction:
Setting by teach in:
6
[+/-]
Functions
By offset correction
By teaching
jump to point 6
jump to point 7
[+/-] by offset correction:
• press the key corresponding to the icon [+/-].
• the current end of bar position (z) is displayed.
• enter with the direction keys the correction to insert, and press the [+]
icon to add the value, or the icon [-] to subtract it. the new value is
stored.
• to exit the end of bar set mode, press the key attributed to the icon
[ESC].
jump to point 8.
7
[TEACH IN]
[FWD]
[ENTER]
8
[ESC]
[TEACH IN] By teaching:
• Press the key attributed to the icon [TEACH IN]. The display shows the
current end of bar position.
• Press the key [FWD] and advance the pusher to the desired position
(see previous page).
• To validate the new end of bar position, keep [ENTER] pressed until the
icon disappears.
To exit the set mode, press the keys [ESC] or [STOP].
or
[STOP]
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CHAPTER 7: OPERATION
7.
7-35
TOP-CUT POSITION
7.1. Description
During the loading cycle, the bar is automatically loaded and
positioned into the spindle, outside the clamping device of the
lathe (chuck or actuator).
z
This positioning corresponds to a value (Z) programmed by the
operator, which is equal to the distance between the measuring
cell and the position of the material in the lathe clamping device.
With this system, the setting is the same for any bar length.
7.2. Setting
Before handling the bar feeder, stop the lathe at the end of part cycle !
To edit these parameters, the bar feed system must be in STOP mode.
To validate a new parameter or a new value, keep [ENTER] pressed until the icon
disappears.
1
2
3
[STOP]
Press the key [STOP].
[MENU]
Press the key [MENU].
[PAGE DOWN
The remote command displays the following text : "PARMETERS RELATED
TO".
Press twice the key attributed to the icon [PAGE DOWN].
4
[ENTER]
[PAGE DOWN]
The remote command displays the following text : "PARAMETERS RELATED
TO POSITIONING".
Press the key attributed to the icon [ENTER].
The remote command displays the following text : "END OF BAR POSITION".
Press once the key attributed to the icon [PAGE DOWN].
5
[SET]
The remote command displays the following text : "TOP CUT POSTION".
Press the key attributed to the icon [SET].
Depending on which sequence the bar feed is in when the parameter is
selected, the available functions and icons can change :
Functions
Conditions
-
Loading channel down
No bar stock in the loading
channel
Loading with extended loading
pusher
Setting by offset correction:
Setting by teach in:
6
[+/-]
By offset
correction
By teaching
Icon [+/-]
Icon [TEACH IN]
Icon [+/-]
---
jump to point 6
jump to point 7
[+/-] By offset correction:
QUICK LOAD SERVO III MI
7-36
CHAPTER 7: OPERATION
• Press the key corresponding to the icon [+/-].
• The current end of bar position (Z) is displayed.
• Enter with the direction keys the correction to insert, and press the
[+] icon to add the value, or the icon [-] to subtract it. The new value
is stored.
• To exit the end of bar set mode, press the key attributed to the icon
[ESC].
Jump to point 8.
7
[TEACH IN]
[START]
[FWD]
[ENTER]
8
[ESC]
[TEACH IN] By teaching:
• Press the key attributed to the icon [TEACH IN].
• Press the key attributed to the icon [START].
• The loading channel raises and grasps a bar as it passes by. The
feeding pusher inserts the bar into the lathe spindle. The feeding
pusher returns to its reference position. The loading channel goes
down. The feeding pusher is now facing the spindle.
• Press the key [FWD] and advance the bar stock to the desired
position (see previous page).
• To validate the new top cut position, keep [ENTER] pressed until
the icon disappears.
To exit the set mode, press the keys [ESC] or [STOP].
or
[STOP]
8.
POWERING DOWN
Before handling the bar feeder, stop the lathe at the end of part cycle !
When powering off the barfeed, make sure the pusher is in reference position, table in
lower position, and no bar stock is present in the guiding element.
To power down, turn the switch to the left, to the 0off position.
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CHAPTER 8: MALFUNCTIONS / MAINTENANCE
8-1
CHAPTER 8:
MALFUNCTIONS / MAINTENANCE
QUICK LOAD SERVO III MI
8-2
1.
CHAPTER 8: MALFUNCTIONS / MAINTENANCE
ALARMS
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
Particular attention should be given to the handling of electrical elements because of risks
of electrocution. In case of possible electrical malfunctions, it is advisable to contact LNS
or their local representative.
1.1. PLC alarms
AL01 - SAFETY LINE OPEN !
Description
The lathe or the bar feeder goes into an emergency stop condition. The problem is generated anytime the
safety line opened.
Solutions
Check the states of the emergency stop buttons of barfeed and lathe.
Check the wiring according to the
Electrical drawings.
Check the PLC connection.
AL02 - MAIN ACCESS COVER OPEN !
Description
The PLC does not detect the input (I2 – SQ10) of the safety switch on the main access cover. The
problem is generated when the main access cover on the bar feeder is open, exposing automated
mechanical parts.
Solutions
Close the main access cover.
Check the switch SQ10.
AL03 - PROTECTION GRID OPEN !
Description
The PLC does not detect the input (I3 – SQ11) of the safety switch on the protection grid. The problem is
generated when the protection grid on the bar feeder is open, exposing automated mechanical parts.
Solutions
Close the protection grid cover.
Check the switch SQ11.
AL04 - BARFEEDER NOT IN WORKING POSITION !
Description
The PLC does not detect the input (I4 – SQ12) of the safety switch on the retraction system. The problem
is generated when the barfeeder has not been brought into working position.
Solutions
Check the barfeeder position.
Check the switch SQ12.
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CHAPTER 8: MALFUNCTIONS / MAINTENANCE
8-3
AL05 Not in use.
AL06 - AIR PRESSURE TOO LOW !
Description
The PLC does not detect input (I1 – SP1). The problem is generated anytime air pressure is not sufficient,
below 3 bar or 45 psi, to make the air pressure switch.
Solutions
Check the air pressure (min. 3 bar, max. 6 bar).
Set up the air pressure switch SP1.
Replace the air pressure switch SP1.
AL07 Not in use.
AL08 Not in use.
AL09 Not in use.
AL10 - FAILURE ON SWITCH SQ1 !
Description
The PLC does not detect input (I8 – SQ1).
Solutions
Check the switch SQ1.
AL11 - FAILURE ON SWITCH SQ2 !
Description
The PLC does not detect input (I9 – SQ2).
Solutions
Check the switch SQ2.
AL12 - FAILURE WHILE LOADING TABLE MOVING UP !
Description
A mechanical obstruction prevented the table from moving up.
Solutions
Check that there is no mechanical obstruction
Check switches SQ1 and SQ2.
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8-4
CHAPTER 8: MALFUNCTIONS / MAINTENANCE
AL13 - FAILURE ON SWITCH SQ1 !
Description
The PLC does not detect input (I8 – SQ1).
Solutions
Check the switch SQ1.
AL14 - FAILURE ON SWITCH SQ2 !
Description
The PLC does not detect input (I9 – SQ2).
Solutions
Check the switch SQ2.
AL15 - FAILURE WHILE LOADING TABLE MOVING DOWN !
Description
A mechanical obstruction prevented the table from moving down.
Solutions
Check that there is no mechanical obstruction
Check switches SQ1 and SQ2.
AL16 - FAILURE ON SWITCH SQ3 !
Description
The PLC does not detect input (I10 – SQ3).
Solutions
Check the switch SQ3.
AL17 - FAILURE ON SWITCH SQ4 OR MOTOR M2 !
Description
The PLC does not detect input (I11 – SQ4).
Solutions
Check the switch SQ4.
Check the motor M2.
AL18 - FAILURE ON SWITCH SQ5 !
Description
The PLC does not detect input (I12 – SQ5).
Solutions
Check the switch SQ5.
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CHAPTER 8: MALFUNCTIONS / MAINTENANCE
8-5
AL19 Not in use.
AL20 - OPTICAL SWITCH SQ3 ACTIVATED TOO SOON !
Description
The "Optical switch activated too soon" alarm occurs when the PLC detects input (I10 – SQ3)
before the safety maximum length has been reached during the bar stock length measuring.
Solutions:
Press the STOP key on the remote control to clear the message and reset the alarm.
Press the MENU key.
Choose the SERVICE item.
From the new menu, choose the POSITION item.
Press the key corresponding to PAGE DOWN as many times as necessary to display the text
"MAXIMUM BAR LENGTH".
This value cannot exceed the spindle length. If necessary, correct this value.
Measure the bar stock. This bar length cannot exceed the value entered in the remote control.
AL21 - EMPTY BAR MAGAZINE !
Description
No bar has been detected in the bar feeder.
Solutions
Check for bar stocks on the barfeeder rack.
Load new bar stocks to continue production.
AL22 - LOADING CYCLE INTERRUPTED !
Description
The signal A2 has been lost.
Solutions
Check the connection lathe <-> barfeeder.
Check the wire of the signal A2 'lathe in auto mode'.
Check the part program in the lathe.
AL23 - LOADING TIME ELAPSED !
Description
The time allowed to reach the position has been exceeded.
Solutions
Remove the bar stock from the spindle.
Restart the top cut cycle.
Check the part settings.
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8-6
CHAPTER 8: MALFUNCTIONS / MAINTENANCE
AL24 - LATHE DID NOT START IN PRODUCTION CYCLE !
Description
The "Lathe did not start in production cycle " alarm occurs if the bar feed does not recognize the chuck
signal input (I24 – A1) within 1 minute after reaching top-cut position.
Solutions
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message
and reset the alarm. Restart the bar feeder and the lathe automatic cycle.
AL25 - LATHE CHUCK OPENED DURING PRODUCTION CYCLE !
Description
The signal A1 (lathe’s chuck signal) has been detected at a wrong moment.
Solutions
Check the lathe program.
AL26 - LATHE CHUCK CLOSED BEFORE END OF FEED OUT !
Description
The signal A1 (lathe’s chuck signal) has been lost before the end of the positioning.
Solutions
Check the lathe program.
Check the interfacing wiring.
AL27 - PART FEED OUT TIME ELAPSED !
Description
The time allowed to reach the position has been exceeded.
Solutions
The signal A1 is missing.
Check the presence of the closed clamping device signal, when it is closed.
Check the wiring of the clamping device signal A1.
AL28 - M-CODE PART BEGIN NOT IN SYNC !
Description
The parts counter and the chuck openings do not match.
Solutions
Check the lathe program.
Check the quantity of chuck openings per part.
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CHAPTER 8: MALFUNCTIONS / MAINTENANCE
8-7
AL29 Not in use.
AL30 Not in use.
AL31 Not in use.
AL32 Not in use.
AL33 Not in use.
AL34 Not in use.
AL35 Not in use.
AL36 Not in use.
AL37 Not in use.
AL38 - CC-LINK COMMUNICATION FAULT !
Description
There is a communication fault between the lathe and the barfeeder.
Solutions
Contact your LNS agent.
AL39 - CUT OFF FEED FAULT !
Description
The values do not match.
Solutions
Check length more than 0mm.
Check length not more than 50mm.
Check length not more than remnant length.
Part ID must in 9990-9999 range.
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8-8
CHAPTER 8: MALFUNCTIONS / MAINTENANCE
AL40 - BAR DETECTED IN SIMULATION MODE !
Description
A bar has been detected in the bar feeder in simulation mode, which presents a hazard.
Solutions
Check that no bar stock is in the barfeeder.
AL41 - PART ID DOES NOT EXIST !
Description
Wrong part ID requested.
Solutions
Check the correct part ID was requested. Create part ID.
AL42 - FILE READ ERROR !
Description
File not readable.
Solutions
Check the file, if not able to load, delete and recreate.
AL43 - INCORRECT PART CONFIGURATION !
Description
Part requested does not match with current settings.
Solutions
Check the bar stock diameter and shape.
AL44 - PART LOADING FAULT !
Description
M-Code request parameter disabled.
Solutions
Check that the M Code request is active.
AL45 - POSITIONING COULD NOT BE ACHIEVED !
Description
An obstacle prevented the progress of the pusher.
Solutions
Remove any mechanical obstruction.
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CHAPTER 8: MALFUNCTIONS / MAINTENANCE
8-9
AL46 - SERVO DRIVE NOT READY !
Description
Communication between PLC and servo drive broken.
Solutions
Check that the cable CN1B is properly connected to the servo amplifier.
Check that the output for SON on the PLC is activated when the manual or auto cycle is started.
AL47 - ALARM ON AMPLIFIER !
Description
An alarm has been generated on the amplifier, in the electrical cabinet.
Solutions
Please refer to the CHAPTER 8: MALFUNCTIONS / MAINTENANCE, section 1.2. Servo amplifier
alarms.
AL48 - COMMUNICATION ERROR !
Description
Communication between PLC and servo drive broken.
Solutions
Check the connection between the PLC and the amplifier.
Check the 24VDC power supply for fluctuations of the voltage.
AL49 - AMPLIFIER BATTERY LOW !
Description
The battery level of the amplifier is low.
Solutions
Replace the battery as soon as possible. Do not shut down the barfeeder until the battery has been
replaced.
AL50 - AMPLIFIER FIRMWARE NOT COMPATIBLE !
Description
The firmware of the servo drive is not compatible with the LNS software.
Solutions
The amplifier must be replaced. Please contact your LNS agent.
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8-10
CHAPTER 8: MALFUNCTIONS / MAINTENANCE
1.2. Servo amplifier alarms
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
Particular attention should be given to the handling of electrical elements because of risks
of electrocution. In case of possible electrical malfunctions, it is advisable to contact LNS
or their local representative.
Alarm code (note 2)
Alarm deactivation
Pin
CN1A18
Power
ON->
OFF
AL.10
0
1
0
Undervoltage
AL.12
0
0
0
AL.13
0
0
AL.15
0
0
AL.16
1
AL.17
AL.19
Warnings
Alarms
Display
Pin
CN1B19
Note 1:
Note 2:
Press
"SET" on
the AMP
Needs
ALM reset
signal
Memory error 1
-
-
0
Clock error
-
-
0
Memory error 2
-
-
1
0
Encoder error 1
-
-
0
0
0
Board error
-
-
0
0
0
Memory error 3
-
-
AL.1A
1
1
0
Motor combination error
-
-
AL.20
1
1
0
Encoder error 2
-
-
AL.24
1
0
0
Main circuit error
-
-
AL.25
1
1
0
Absolute position erase
-
-
AL.30
0
0
1
Regenerative error
AL.31
1
0
1
Overspeed
AL.32
1
0
0
Overcurrent
AL.33
0
0
1
Overvoltage
-
-
AL.35
1
0
1
Command pulse frequency error
AL.37
0
0
0
Parameter error
-
-
AL.45
0
1
1
Main circuit device overheat
AL.46
0
1
1
Servo motor overheat
AL.50
0
1
1
Overload 1
(note 1)
(note 1)
(note 1)
AL.51
0
1
1
Overload 2
(note 1)
(note 1)
(note 1)
AL.52
1
0
1
Error excessive
AL.8A
0
0
0
Serial comm. time-out error
AL.8E
0
0
0
Serial communication error
88888
0
0
0
Watchdog
Error name
AL.90
Home position return incomplete
AL.92
Open battery cable warning
AL.96
Home position setting warning
AL.98
Software limit warning
AL.9F
Battery warning
AL.E0
Excessive regenerative warning
AL.E1
Overload warning
AL.E3
Absolute position counter warning
AL.E6
Servo emergency stop warning
AL.E9
Main circuit off warning
Power ON> OFF
-
Removing the cause of occurrence
deactivates the alarm automatically.
To deactivate the alarm, allow 30 minutes of cooling time after removing the cause of occurrence.
0 = off / 1 = on
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-
CHAPTER 8: MALFUNCTIONS / MAINTENANCE
2.
8-11
FACTORS AFFECTING PERFORMANCE
2.1. Installation
The installation is a very important phase that, if neglected, could seriously impede the operation of the
bar feed system.
Distance
It is essential that the mounting of the bar feed system is done in accordance
with the instructions indicated in Chapter 3. Setting into operation.
Alignment
The bar feed system serve, by definition, to guide the bar outside the lathe.
The alignment of the bar feed with the axis of the spindle must be perfect.
It is essential that the alignment of the bar feed system is done in accordance
with the instructions indicated in Chapter 3. Setting into operation.
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8-12
CHAPTER 8: MALFUNCTIONS / MAINTENANCE
2.2. Material
Bars
To obtain a perfect insertion inside the collet of the bar feed system,
the bars must be chamfered concentrically (at the rear) at 30o. At the
feeding process, it is recommended to deburr the bar at the front, to
avoid possible catching during the introduction of the bar inside the
spindle.
In some cases, when the diameter of the bar is close to the external
diameter of the collet (see Assembly of pushers), the rear of the bars
must be machined to the inside diameter (D) of the collet. The length
of the machining (L) must be at least 30mm.
Tubes
To prevent mixing the oil from the feeding process and the cutting oil
from the lathe, it is recommended to put a plug in the rear of the tubes
to be machined.
Profiled material
It is recommended to install a bushing, inside the clamping device, with the same inside profile (+ 0.2
mm) as the bar.
The rear of this collet and the front of the bars should be flat. During the loading cycle, a slight rotation of
the spindle (about 30 RPM) is desirable.
Bars straightness
Performances may vary, depending on the material machined, the length of the bar, etc.
To obtain optimum output, the bars must be straight. If the torsion of the bars exceeds 0.5 mm/m,
performance will automatically be reduced in regards to speeds of rotation while vibrations will increase
accordingly.
In this instance, the quality of the guidance is not the cause.
Material composition
In general, the difficulty increases with the specific weight of the bar. Steel bars are relatively easy to
guide.
Because of their great flexibility and specific weight, brass bars are relatively difficult to guide at high
speeds. Aluminium bars are very easy to guide.
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CHAPTER 8: MALFUNCTIONS / MAINTENANCE
3.
8-13
MAINTENANCE
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
3.1. Pneumatics
The air-filtering device is equipped with an automatic drainage valve, making it unnecessary to empty it.
The water recuperated comes from the pneumatic circuit of the building. It is advisable to make certain
that the air received by the bar feed system is as dry as possible (see CHAPTER 5: PNEUMATICS).
3.2. Batteries
In the event of a power failure, a backup battery saves the data contained in the SERVO amplifier. It is
possible that with time this battery will slowly drain; in this case a message will be displayed on the
remote control. The battery must be replaced as soon as possible with a battery of the same type.
Switching power off when the message “Battery low” could lead to loss of parameters.
Don’t switch the power until the battery has been replaced.
3.3. Belt
It is possible that after a certain period of use the transmission belt will need to be tightened. Please refer
to CHAPTER 6: GENERAL DESCRIPTION, section 6. Belt.
3.4. Cleaning
As with any vehicle, machinery, or device, regular cleaning of your bar feed system can only serve to
improve its operation and prolong its useful life.
For cleaning on the outside, use a soft cloth and a regular detergent, for the inside, use a cloth or a brush.
However, make sure that the rollers and parts made of synthetic materials do not come into contact with
these products.
The use of compressed air for cleaning is not advisable, because particles could become lodged in
sensitive areas and impede the proper operation of the bar feed system.
At no time should solvents, such as acetone, or diluents be used for cleaning the bar feed
system. At no time should cleaning products come into contact with electrical components.
3.5. Spare parts
Without the written consent of LNS SA, no addition or modification of the machine or spare parts
can be undertaken.
LNS SA assumes no responsibility when using spare parts which were not provided by LNS SA.
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8-14
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CHAPTER 8: MALFUNCTIONS / MAINTENANCE
CHAPTER 9: APPENDICES
9-1
CHAPTER 9:
APPENDICES
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9-2
1.
CHAPTER 9: APPENDICES
ORDERING FORM
This form should be photocopied, duly filled out, and returned to your retailer or nearest LNS agent
Company name:
Person in charge:
Address:
ZIP:
City:
Country:
Phone:
Fax:
Type of device:
Serial number:
Qty.
Ordering no.
Expected delivery:
Location and date:
Signature and stamp of the company:
QUICK LOAD SERVO III MI
Description
CHAPTER 9: APPENDICES
2.
9-3
LNS ADDRESSES & CONTACTS
LNS AGENCIES
SCHWEIZ / SUISSE
LNS S.A.
Headquarter
Case postale 33
CH – 2534 ORVIN
sales@Lns-world.com
service@Lns-world.com
www.Lns-group.com
TEL. +41 / 32 358 02 00
FAX +41 / 32 358 02 01
FRANCE
LNS France
Pae les Jourdies
BP 355
St-Pierre en Faucigny
Lnsfrance@Lns.fr
www.Lns-europe.com
TEL. +33 4 50 03 93 32
FAX +33 4 50 03 93 34
GREAT BRITAIN
LNS TURBO UK Limited
Waterside Park, Valley Way
Wombwell
GB – Barnsley S73 0BB
sales@Lnsturbouk.com
www.Lns-europe.com
TEL. +44 1226 27 00 33
FAX +44 1226 27 00 44
ITALIA
LNS AUTOMAZIONE S.R.L.
Via Mons. Colombo 34
IT – 21053 CASTELLANZA – VA
Lns@Lnsautomazione.it
www.Lns-europe.com
TEL. +39 0 331 501 901
FAX +39 0 331 482 101
USA / CANADA / MEXICO
LNS AMERICA INC
4621 East Tech Drive
CINCINNATI, OHIO 45245
USA
sales@Lnsamerica.com
customerservice@Lnsamerica.com
www.Lns-america.com
TEL. +1 513 528 56 74
FAX +1 513 528 57 33
AGENTS LNS
LNS Europe :
LNS America :
LNS Asia :
www.lns-europe.com
www.lns-america.com
www.lns-asia.com
QUICK LOAD SERVO III MI
9-4
3.
CHAPTER 9: APPENDICES
PROGRAMMING EXAMPLE
MAIN PROGRAM
N...
”M” CODE “LATHE IN AUTOMATIC
CYCLE”
N...
SPINDLE STOP
N...
COOLANT OFF
N...
TURRET TO FEED IN POSITION
N...
COLLET OPEN
N...
TURRET TO FEED OUT POSITION
N...
END OF BAR CHECK
(PROGRAM JUMP) >
>
SUB-PROGRAM
N...
CLOSE COLLET
N...
TURRET HOME
N...
CLEAR TURRET
...
“M”CODE (DWELL/LOAD)
N...
CLOSE COLLET
N...
START SPINDLE
PART PROGRAM
N...
COLLANT ON
N...
X, Z, G, F, T, S, M, ...
N...
TOP CUT MATERIAL
N...
MACHINE PART
N...
N...
PARTS CATCHER IN (IF AVAILABLE)
N...
N...
CUT OFF
N...
END OF SUB-PROGRAM
N...
PARTS CATCHER OFF (IF
AVAILABLE)
<
(RETURN TO MAIN PROGRAM)
N...
N...
N...
N...
X, Z, G, F, T, S, M, ...
N...
N...
END OF PROGRAM (LOOP)
Important: The above is an example only. Programming may change according to the interface
between the lathe and the bar feed.
QUICK LOAD SERVO III MI