Wednesday, 07 October 2015 20:13

Locate Unit: %Electrical Installation


Sensors have to be installed in the provided brackets. The wires have to be protected against chafing and secured against unintentional removal. Please pay attention to the correct switching distance and the right sensor size.
 
The controls, the sensors and the used logic can influence the function of the Pallet Locate Unit tremendously. This is the responsibility of the operating company if the controls haven’t been provided by LOGOMAT.
 
The stop unit used in the respective configuration has to be connected electrically according to the LOGO!MAT Stop Unit documentation.
 
In projects or situations where LOGO!MAT ITB Controls haven’t been purchased it must be noted that they are not part of the scope of delivery, which leaves the controls and related functions and safety control installations of the Locate Unit to be cpmpleted by the operating company. Since these controls have to meet the needs of our customers, LOGOMAT cannot give any detailed information or specifications to the controls concept.
 

Locate Electrical Installation


To operate the Locate Unit as safe as possible, please comply with the following information:

  1. If a cushioned stop unit gets utilized, it must only move in its home position if a pallet covers it.
  2. All service and maintenance work has to be done by authorized technical personnel only and must be performed with all energy devices (e.g. electrical or pneumatic power) shut down and secured against reconnection.
Freigegeben in L - Locate Unit
Wednesday, 07 October 2015 19:55

Locate Unit: %Mechanical Installation


To install the Locate Unit into a LOGO!MAT Roller Conveyor, please proceed as follows:
  1. Mark the intended installation area and adjust the roller locations to allow the required opening if necessary. Stub rollers should only be used if no other configuration of full rollers is possible. Please see the details about changing rollers in the documentation of the "Roller Conveyor".
    The additional rollers or stub rollers are not scope of supply. The required rollers have to be ordered separately if an additional Locate Unit has to be installed.
  2. Install the Stop Unit at the desired / required location within the roller conveyor. Please see the detailed information for the installation of the stop unit in the documentation of the Stop Unit.
  3. Make sure that you install the locate unit upstream of the stop unit, as shown below. The exact distance between the stop pin and the index pin depends on the nominal width of the conveyor and the utilized pallet (long or short pallet).

    Locate Mechanical Installation Step3

  4. Remove the two mounting clamps at one side of the index unit base plate and loosen the other two slightly.
  5. Hang the entire unit with the 2 loose mounting clamps into the lower slot of the bottom rail extrusion. Tighten the clamps slightly and install the remaining mounting clamps on the other side of the base plate. The unit should be hanging in the extrusion safely while still being possible to move it.
  6. Push an empty pallet into the stop unit so that the pallet sits in its final end position. If using a cushioned stop unit, the pallet has to be in its mechanical end position.
  7. Move and place the Locate Unit so that the index pin is locked in the rear index bushing of the pallet.

    Locate Mechanical Installation Step7

  8. Check the location of the pallet and adjust the stop and locate position if necessary.
    Please make sure that the index pin pushes the pallet slightly against the stop pin. Apply some pressure towards the stop unit while tightening the mounting clamps. That allows the given accuracy for pallet location that won’t be reached if there is no pre tension. The index pin needs to apply some pressure against the stop pin when engaging the index bushing.
  9. Brace the four mounting clamps with the conveyor extrusion. (Please pay attention to the exact correct locking of the clamps into the extrusion. Details shown in stop unit documentation.)
  10. Connect the pneumatic hoses and install the required sensors according to the provided schematics.
  11. Check the function of the entire Locate Unit.
 
Freigegeben in L - Locate Unit
Wednesday, 07 October 2015 15:46

Junction / Diverter: %Troubleshooting

Symptom:

The Diverter / Junction arm does not move.

Root Cause:
The cylinder doesn’t work
Remedial Action:
Check the valves and the controls
Root Cause:
The compressed air supply failed
Remedial Action:
Reset and restore the compressed air supply
Root Cause:
The sensors are not adjusted or not connected
Remedial Action:
Connect the sensors; re-adjust the sensors if required
Root Cause:
The drive motor is defective (only with electrical diverter)
Remedial Action:
Change the drive motor
Root Cause:
The drive motor is not controlled (only with electrical diverter)
Remedial Action:
Check the controls of the drive motor
Root Cause:
The friction clutch is set too low (only with electrical diverter)
Remedial Action:
Adjust the friction clutch
Root Cause:
Mechanical deadlock of the diverter arm
Remedial Action:
Align and level the roller conveyor (segments)

Symptom:

The Diverter arm does move to fast in its end position.

Root Cause:
No air flows for the controls of the cylinder used (only for pneumatic diverter)
Remedial Action:
Use exhaust air flows
Root Cause:
The air flows are not set correctly (only for pneumatically diverter)
Remedial Action:
Adjust the exhaust air flows (with a switching distance of at least 4 mm from one end position to the other)
Root Cause:
The electrical drive is not controlled by an frequency converter
Remedial Action:
Use a frequency converter for the drive and adjust the speed of rotation

Symptom:

The pallet gets stuck in the Diverter / Junction or does not move around the ‘corner’.

Root Cause:
The roller conveyor tracks are not aligned correctly to each other
Remedial Action:
Align and level the roller conveyor (segments)
Root Cause:
The drive motor of one conveyor segment is not switched on
Remedial Action:
Switch on the drive motor
Root Cause:
Check the roller configuration in the Diverter / Junction area
Remedial Action:
Use fixed driven rollers in the Diverter / Junction area; replace rollers if necessary

 

Freigegeben in L - Junction / Diverter

To change the drive motor, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Remove the safety cover of the rotation unit to get free access to the drive unit.
  3. Dismount the entire motor retaining plate, where the drive motor is installed on, and remove it downwards carefully.
  4. Remove the four mounting bolts of the drive motor.
  5. Remove the set screw, which secures the sprocket on the motor shaft.
  6. Pull down and remove the sprocket from the motor shaft with suitable tools.
  7. Install the new drive motor in reverse order.
    It is essential to make sure that the main gear sprocket and the one on the motor shaft are aligned to each other and are secured by the set screw.
  8. Connect the electrical connections and check the function of the entire unit. Check the setting of the friction clutch and adjust it according to the chapter "Adjustment of the friction clutch" if necessary.
 
Diverter Junction Changing drive motor 1
 
Diverter Junction Changing drive motor 2
 
Freigegeben in L - Junction / Diverter

To change the diverter / junction arm, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Open the Diverter arm half (45°) manually.
  3. Remove the mounting bolts of the upper gusset plate to the top rail extrusion. Remove the entire rotation unit and place it on a secure surface / base.
  4. Remove the remaining three bolts of the upper gusset plate to get free access to the Diverter / Junction arm.
  5. Remove the three mounting bolts of the Diverter / Junction arm and remove the arm upwards.
  6. Install the new Diverter or Junction arm in reverse order. Please pay attention to the correct position of the arm and the correct installation of the sensor plate.
  7. Please move and check the unit first manually to visualize possible mechanical blockages.
  8. Check the entire unit driven for its function.
It must be ensured that the Diverter / Junction arm can be moved in its end positions (opened and closed) without any problems. Due to the mounting of the arm, there is a slight vertical movement given so that safe function is guaranteed!
 
Diverter Junction Changing arm 1
 
Diverter Junction Changing arm 2
 
Freigegeben in L - Junction / Diverter

To change the rotation brake, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Remove the mounting bolts of the rotation brake.
  3. Pull off and remove the rotation brake from the axle. Ensure that the connection adapter is not lost.
  4. Install the new rotation brake in reverse order. Ensure the correct installation position: First insert the connection adapter into the rotation brake, secondly slide it on the main shaft.
  5. Please move and check the unit first manually to see possible mechanical blockages.
  6. Check the entire unit driven for its function.
 
Diverter Junction Changing rotation brake
Freigegeben in L - Junction / Diverter

To change the cylinder, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Remove the safety covers of the rotation unit to get access to the pneumatic cylinder.
  3. Tag and remove both pneumatic tubes, which are in order to the compressed air supply connections of the cylinder.
  4. Dismount and remove the two positioning sensors.
  5. Release and remove the two mounting bolts of the cylinder. The cylinder is now hanging at the piston rod. The rod must be detached with an open-end wrench.
  6. Remove the pneumatic cylinder laterally.
  7. Install the new cylinder in reverse order. Please pay attention that the air supply connections are pointing outwards and the sensors have the required switching distance.
  8. Install all safety covers.
  9. Please check the entire unit first manually to visualize possible mechanical blockages. Check the unit driven normally through the entire function.
The exhaust air throttles should be set so that the Diverter arm needs at least two seconds for one complete movement!
 
Diverter Junction Changing pneumatic cylinder 1
 
Diverter Junction Changing pneumatic cylinder 2
 
Freigegeben in L - Junction / Diverter
Wednesday, 07 October 2015 14:46

Junction / Diverter: %General Maintenance


All LOGO!MAT Components are developed to make very little preservative maintenance necessary, but all components will last much longer if the following tasks are performed in the shown intervals. The maintenance and inspection work listed below is to be carried out at the listed intervals to keep the warranty and to follow up constantly if the LOGO!MAT Component is working well. Any defects found must be documented and fixed before operating again. All time specifications are based on single-shift operations.

With an interval of one (1) month the following preservative maintenance should be carried out:
  1. Check all parts for wear and damage.
  2. Visual check of the unit for proper function, damages and detection of leaks.
  3. Replace covers if missing or damaged.
  4. Make sure that all safety covers are installed.

With an interval of six (6) month the following preservative maintenance should be carried out:

  1. Check the friction of the friction clutch and adjust it, if necessary (only with the driven Diverter Unit).
  2. Check if all rollers in the Diverter area are installed and tightened in the frame.
  3. Check all removable connections and connection elements. Retighten loose bolt connections.
  4. Check the motor / cylinder, rotation unit, Diverter / Junction arm and the mechanics for proper function.
Freigegeben in L - Junction / Diverter

The pneumatic installation of the LOGO!MAT Diverter has to be done according to the pneumatic schematics to guarantee proper function of the unit. The connections for the pneumatic tubes are designed for a tube diameter of 6 mm. Please ensure that pressurized air is dried and filtered and the pressure is in the stated range. LOGOMAT automation systems, Inc. recommends two 3/2- or one 5/2- or one 5/3-way valve for the control of the cylinder.
 
Exhaust flow controls have to be used for both air lines in any case! The air flow should be set so that the diverter arm needs at least two seconds from one end position to the other.
 
Freigegeben in L - Junction / Diverter