Conveyor system X45 - Flex Line Automation, Inc.
Contents
1. XUUT DR Right Home Release Position Release E am XUUT DR 1 ae XUUT DR 2 Receive angle 1 Release angle 1 AL Home position Release angle 2 Receive angle 1 XUUT 90 DR Right iE DI 3 aed XUUT 90 DR 1 Home 22 position XUUT 90 DR 2 Release Receive angle 1 angle 2 5113196 3 Flex Link Mounting installation adjustment 5 3 4 Mounting instruction Merger Func Designation Assembly mechanical electrical tion XUUT MR Right XUUT 90 MR Right Angularity Item 1 2 DI 4 DI 2 ETT OI IN Par DI 3 DI 1 Home position Release E 1 Receive angle 2 Receive angle 1 1 A 2 8 Home DI4 elease Position Q 23 one XUUT MR 1 ola bat p ELEC XUUT MR 2 Receive angle 1 Receive angle 2 DI2 DI4 t Ca 145 Releas Receive pinasa N angle 2 angle 1 DI 3 poste DI 1 Receive angle 1 1 i t DI 4 DI 2 Release Receive 1 45 angle 1 angle 2 ka a XUUT 90 MR 1 SZ position XUUT 90 MR 2 DI 3 n es 2 Receive angle 1 DI 1 79 f 5113196 32. Service technicians A Service technicians must have Sufficient knowledge for reading technical information Ability to comprehend technical drawings Basic knowledge of mechanics Sufficient knowledge in the use of hand tools 5113196 3 Flex Link sa 1 2 3 Electricians N Electricians must have Experience from similar installations e Sufficient knowledge to work from drawings and wiring diagrams e Knowledge of local safety regulations for electrical power and au tomation To avoid risks only experienced personnel with technical knowledge and experience may perform repair work on the electronics components 1 2 4 Operators AN To correctly use the equipment operators must have appropriate training and or experience 5113196 3 5 Safety eG HexLink 1 3 Description of safety provisions Before putting the system into operation some safety provisions are to be taken care of The purpose of these safety provisions is to protect the user the product and the system against undesired situations damage Without these safety provisions FlexLink cannot give a guarantee on any damage caused in absence of these safety provisions The table below gives a general description of the safety provisions re quired Here it should be noted that only technically qualified employees are allowed to work on the settings of the safety provisions Control Remark Emergency stop switch It is recommended that th
3. 29 e Mounting installation adjustment D Flex ink 5 3 5 Mounting instructions Combined Diverter Merger Func Designation Assembly mechanical electrical Angularity Item 1 2 and 3 tion DI 2 A 1 Home b Receive angle 2 Release DI 4 DI 3 angle 1 bb H 57 i a B DI 1 1 1 i odes 2 Receive angle 1 2 XUUT 180 CR j DI 2 Right 8 a C elease Receive angle 2 DI 3 DI 4 angle 1 XUUT 180 CR 1 XUUT 180 CR 2 DI 1 5f i Release Receive angle 1 angle 2 i Rel DIS nee ange 1 DI 1 Home position 22 Release t angle 2 Receive angle 1 XUUT 90 CR DI 3 t _ ni 3 Release Receive angle 1 angle 3 XU UT 90 CR 1 DI 1 1 XUUT 90 CR 2 XUUT 90 CR 3 22 Cy 2 Release il L Receive angle 1 angle 2 30 5113196 3 FlexLink Mounting installation adjustment Function Designation XUUT PR Right XUUT 90 R Right 5 3 6 Mounting instructions Transfer Assembly mechanical electrical Angularity Item 1 2 XUUT PR 1 XUUT PR 2 Home Release position es angl
4. and or general drawing number shall always be spec ified when communicating with FlexLink with respect to the module Project number See module nameplate Supplier FlexLink Systems Polska Sp z 0 0 0 Module type See module nameplate Date of manufacture See module nameplate Identification no See module nameplate DESIGNATION MANUFACTURED DATE IDENTIFICATION NO MANUFACTURED BY Figure 1 Module nameplate The modules nameplate is located on the module near the electrical motor for the drive unit Safety 1 2 eG HexLink The most important safety conditions At the moment that the X45 system is going to be operated by a user the following safety conditions must be met 1 2 1 1 2 2 Only persons who have read and understood the operating in structions are allowed to operate maintain and clean the system Provide good ambient lighting to enable the operator to work well and orderly with the system General Incorrect use of the equipment can cause personal injury Do not wear clothing or other articles that can fasten Follow the instructions in this user manual when transporting the machine FlexLink Components AB must approve all modifica tions or changes to this system Only use recommended spare parts Only authorised personnel may open electrical units FlexLink is not responsible for damage if service on the equip ment is not performed in accordance with this user manual
5. used for sensing the queue status of the infeed conveyor This sensor can be re placed by a RFID read write head When a puck arrives the rotation disc opens up to receive the puck The second sensor is used for detecting that the puck has reached the gap of the rotation disc This is the trigger signal for the main rotation of the rota tion disc with a puck in the gap The decision of which outfeed conveyor to release the puck on can be re ceived from the external bus via a local sensor or from a predetermined pattern Functions Flex Link 3 2 2 Mergers Mergers are used to combine the flow from two lines into one The lines can be parallel or in a 90 angle The merger is an active unit with two infeed and one outfeed conveyor There are four different variants of the merger e Merger Parallel Left e Merger Parallel Right e Merger 90 Left Merger 90 Right Figure 3 Merger parallel and 90 The unit has two sets of guide brackets each containing two photoelectric sensors The first sensor position on each side is used for sensing the queue status of the infeed conveyors These queue sensors are the trigger signal for the merger to moving the rotation disc to one of the two receive positions This is done either clockwise or counter clockwise depending on which conveyor to receive pucks from The last sensor is used for sensing pucks in the gap of the rotation disc This is the trigger signal for t
6. 1 18 Copyright FlexLink Sweden 2010 The machine was produced by Flexlink Components AB Tel 46 0 31 337 31 00 SE 415 50 G teborg Fax 46 0 31 337 31 95 Sweden E mail info flexlink se www flexlink com AN Note n case of failures please contact the system integrator 36 5113196 3 FlexLink Supplier s information EC Declaration of Incorporation Partly completed machinery FlexLink Components AB SE 41550 Goteborg Sweden We hereby declare that the following equipment is intended to be incorpo rated into a FlexLink conveyor system and thereby forming a machine Op eration is prohibited until it has been determined that the machine in which these products are incorporated has been declared in conformity with the Machinery Directive 2006 42 EC together with amendments which have entered into force as of the date of issue of this declaration with particular reference to the essential health and safety requirements in connection with the design construction and manufacture of the below specified equipment Conveyor modules X45 XUUC S XUUC SP XUUC V XUUC VP XUUC L XUUC LP XUUC U XUUC UP Corresponding EC directives Low Voltage Directive 2006 95 EC According to 2004 108 EC Electromagnetic Compatibility Directive EMC the listed device is not independently operable product but intended as part of a given fixed installation Compliance of the directive requires the correct installation of t
7. 20 eG HexLink 4 Unload the X45 system 4 1 Preparation This section describes the steps that are required for unloading the mod ules for the X45 system Note The operations concerned are to be carried out calmly in order to be able to carefully monitor any movement of the X45 module Before starting the unloading a good preparation is required The appropri ate devices must be available Apart from that the first transport check is an important part of the unloading as in case of damage this should be mentioned on the delivery note in relation to guarantee and the like The first transport check after arrival of the modules a transport check is to be carried out The check can be carried out at the moment the module has been unloaded from the container or the truck The technical specification gives the dimensions to be checked Is the module delivered undamaged and is it the correct module MANUFACTURED DATE Module serial number type plate with configurator string Note Any damage is to be mentioned on the delivery note and should immediately be reported to the supplier This with respect to the guarantee of the module 5113196 3 Flex Link Unload the X45 system 5113196 3 4 2 Unloading instructions Before starting unloading all fastening means securing belts screws etc that secure the module unto the means of transport must be removed Sub sequently check whethe
8. 5113196 3 Conveyor system X45 User Documentation FlexLink 5113196 3 Conveyor system X45 Flex Link 5113196 3 Conveyor system X45 User Documentation Flexlink AB 2010 All Rights Reserved No part of this program and manual may be used reproduced stored or transmitted in any form or by any means without the written permission of FlexLink Components AB The contents of this manual are for informational use only All information and specifications contained in this document have been carefully checked to the best efforts of FlexLink Components AB and are believed to be true and accurate as of time of publishing However due to continued efforts in product development FlexLink Components AB reserves the right to modify products and its manuals without notice FlexLink Components AB assumes no responsibility or liability on any errors or inaccuracies in this program or documentation Any kind of material damages or other indirect consequences resulting from any FlexLink Components AB s product part documentation discrepancies and errors or non anticipated program behavior are limited to the value of appropriate products purchased from FlexLink Components AB The products are delivered to the customer at the as is state and revision level they are on the moment of purchasing and are declared in detail in the license agreements between FlexLink Components AB and user User accepts and is obliged to foll
9. de on the basic unit use a 3 mm Allen key 2 Remove the sideplates use a screwdriver 5113196 3 23 Mounting installation adjustment 3 Feed the chain into the conveyor until it reach the drive wheel at the driving end CAUTION Check the feed direction of the chain Continue to feed the chain around the drive wheel into the return part of the beam To avoid noise the number of links in the chain shall be adjusted so that a slight pretension is obtained CAUTION Make sure that the chain enters the drive wheel correctly Use a pair of slip joint pliers to insert the pin half way into the chain link 7 Join the chain ends 24 Press the pin through the chain Make sure that the pin snaps in to the correct position centered FlexLink 5113196 3 Flex Link Mounting installation adjustment 5 3 Assembly of modules The modules are to be assembled according to the system layout Find the correct position for connecting modules using the measurements in section 5 3 3 on page 28 to section 5 3 8 on page 32 When assemble the parallel conveyors use the beam spacer XUCD 15x20 see picture below The distance between the spacers is to be approxi mately no more than 600 mm Note that it is very important that the modules lines up horizontal according to picture A below To avoid incorrect readings from the sensors that are used for detecting the puck gu
10. e 2 Receive angle 1 Home position Release DI 1 iie XUUT 90 R 1 XUUT 90 R 2 1 Receive angle 1 Home position C DI 1 Release 5 angle 2 Receive angle 1 Home position Ge XUUT 180 R AC XUUT 180R 1 Right DI 1 D XUUT 180 R 2 1 1 I 2 Release Receive angle 1 angle 2 5113196 3 31 Mounting installation adjustment FlexLink XUUL 11 R Right 5 3 7 Mounting instructions Stop Function Designation Assembly mechanical electrical Angularity Item Home position G Fa o Release DI 1 angle 1 i Receive angle 1 Home 3 position C XUUS 11 R DI 1 il Release XUUS 11 R Right i angle 1 Receive angle 1 5 3 8 Mounting instructions Locating station Function Designation Assembly mechanical electrical Angularity Item A I us Home ition position Release angle 1 Receive angle 1 DI 1 Home Release position e i angle 1 Receive angle 1 XUUL 11 R 32 5113196 3 Flex Link Mounting installation adjustment 5 4 Adjustment 5 4 1 Parameter setting tool All software in the X45e motors are preloaded and the behaviour of the motors can be adjusted
11. e X45 conveyor system should be provided with one or more emergency stop switches that can be operated within reach of the user The switch must have the standard red colour Motor protection Should the motor be overloaded for certain reasons this should be detected Without this protection there is a chance that the Motor or other components of the X45 system will be damaged 5113196 3 Flex Link AN AN A 5113196 3 Safety 1 3 1 Noise level The noise level produced by the X45 conveyor system is under 65 dB A 1 3 2 Electrical cabinet Ensure that the electrical cabinet is closed and locked after working in the electrical cabinet Never bypass the safety system Before working in the electrical cabinet the main switch to the motor must be turned off and locked The key is retained by the service technician until work is finished Examples of service work include Disconnection of wiring e Replacement of motors etc e Service work in the electrical cabinet terminal boxes etc e Service work performed on the machine that cannot be seen from the electrical cabinet For adjustment of photo electric cells inductive sensors etc power is re quired Stop the system and wait until the moving parts have come to a complete stop sao FlexLink 1 4 Safety measures to be taken For a safe operation of the conveyor system a number of safety measures are to be taken These
12. ed the unit opens up to receive a puck Directly after the unit has opened up it closes and releases the received puck This unit can be controlled either via the external bus or in local mode by a signal in the local digital input Figure 6 Stop unit Functions Flex Link 3 2 6 Locating station The locating Station is an active unit acting on a single conveyor The station has only one photoelectric sensor This is detecting that the puck has reached the gap of the rotation disc The locating station can also be equipped with a RFID read write head on the locating position The sta tion can be controlled either via the external bus or using only local control The rotating disc guides the puck sideways out of the conveyor into the lo cating position A spring function included in the rotating disc presses the puck towards a v shaped block In this position the puck is locked vertical and can take limited vertical forces e g unload or load a test tube No loads are aloud in the X Y plane Locating accuracy is 0 5 mm 5113196 3 Flex Link 5113196 3 Functions 3 3 Maximum permissible weight Load 15 20 Speed m min Figure 8 The diagram shows the maximum permissible weight of a group of pucks product weight puck weight that the functions Divert Merger Combined Diverter Merger Stop and Locating station are capable stopping as a function of the conveyor speed Unload the X45 system
13. er that section 1 Safety is to be read carefully Preface gt gt Flex Link Requirements of the user The X45 Conveyor system must be operated by any adult person who has become acquainted with section 1 Safety If the user is not technically qual ified he or she may not carry out any maintenance or repair activities on the system Note Maintenance activities on the system may only be carried out by a technically qualified person NB Technically qualified employees means employees that have followed an adequate training for carrying out the activities involved and have a good ability to read and understand the English language 5113196 3 Flex Link 5113196 3 Safety 1 Safety The X45 conveyor system has been designed in such a way that it can be used and maintained in a safe way This holds for the application the cir cumstances and the instructions described in the manual Any person working with or on this system should study the manual and follow the in structions It is the responsibility of the employer to make sure that the em ployee is familiar with and follows these instructions The company or the country in which the system is used may require extra safety measures This particularly applies to the working conditions This manual does not describe how these are to be complied with In case of doubt consult your government or safety officer 1 1 System information The project number
14. er which the X45 conveyor system can be applied partly depend on the materials selected FlexLink has defined a number of parameters within which the system would be allowed to function Should the system still be applied beyond these limiting values FlexLink cannot guarantee the good functioning of it Ambient temperature in operation 20 to 60 C During transport storage 5 to 40 C Relative air humidity RH 10 to 95 not condensing Lighting Normal ambient lighting 10 5113196 3 Flex Link 5113196 3 Functions 3 Functions The control system of the platform X45e is structured in an object oriented way All motors in the platform have embedded control units and local sen sors are connected directly to each motor unit This layout gives a big ad vantage regarding software developing electrical design and electrical in stallation 3 1 1 Function control The motor unit consists of a motor circuit boards and eight connectors in an encapsulated housing There are two types of motor units the drive unit and the function unit All that differs on these variants are the motor and the mechanical housing The drive unit has a permanent magnetic PM motor and the function unit has a stepper motor with an analogue position feedback sensor An em bedded microprocessor is dedicated for the application control Local sen sors are connected directly to this unit The motors can be autonomous
15. he main rotation of the rotation disc with a puck in the gap When the rotation disc has reached the release position the cycle is complete and the unit waits for a new puck to arrive 5113196 3 Flex Link Edi 3 2 3 Combined Diverter mergers A combined diverter merger are used to create a sub line for example to guide pucks out and in on a satellite conveyor from the main conveyor They can also be used as shortcuts Figure 4 Combined Diverter Merger 90 and 180 This function has the behaviour from both the diverter and the merger The prioritized order can be predetermined or decided dynamically from a line controller 5113196 3 15 Flex Link 3 2 4 Transfers Transfers are used to transfer the puck between the conveyors in a system The parallel transfers are passive but the 90 and 180 angled transfers are driven by a motor There are six different variants of the transfers Transfer Parallel Left Transfer Parallel Right e Transfer 90 Left Transfer 90 Right e Transfer 180 Left Transfer 180 Right Figure 5 Transfer parallel 90 and 180 16 5113196 3 Flex Link 5113196 3 Functions 3 2 5 Stop The stop unit is an active unit acting on a single conveyor The unit has only one photoelectric sensor This detects a puck in the queue The default position of the stop unit is closed i e it is able to resist a queue of puck If the stop is deactivat
16. he product the observance of specific installation notes and product documentation FlexLink Components AB Flexlink Components AB SA JA NA MEEN Svante Anderholm Chief Operating Officer Responsible Technical file FlexLink Components AB Telephone 46 31 337 31 00 SE 415 50 G teborg Fax 46 31 337 22 33 Sweden www flexlink com 5113196 3 37 Supplier s information FlexLink 38 5113196 3
17. ide rails must be mounted transversely to the beam according to picture B below B Si X 5113196 3 25 FlexLink e Flex ink Mounting installation adjustment 5 3 2 Wiring The functions motors are to be connected according to picture below and mounting instructions section 5 3 3 on page 28 to section 5 3 8 on page 32 Markings on plate Explanation BUS B Internal bus Used for parameter settings DI2 Digital input 2 Sensor connect if used see section 5 3 3 on page 28 to section 5 3 8 on page 32 DI4 Digital input 4 Sensor connect if used see section 5 3 3 on page 28 to section 5 3 8 on page 32 BUS A2 External bus out Connect this if external CANOpen network is used 5113196 3 27 Mounting installation adjustment Flex Link The following schematic presentation shows how the various modules are combined to form a complete X45 conveyor system mechanical installa tion as well as the electrical interface are showed 5 3 3 Mounting instruction Diverter Designation Assembly mechanical electrical Angularity Home position Release angle 1 Release angle 2 Receive angle 1 Item 1 2
18. include the following measures e Clean floor surface With a clean floor surface the operator will not be hindered while operating the system This can prevent trip ping or slipping so that the operator does not unexpectedly come into contact with the system 5113196 3 Flex Link 2 1 Technical specification Technical characteristics X45 Technical specification Beam width Chain width Chain pitch Drive unit capacity Chain tension limit Item width Maximum conveyor length Maximum weight on conveyor Maximum load per 100 mm conveyor length see picture below Maximum single item weight horizontal transport See picture below Conveyor speed Horizontal bends Radius 150 mm Note Maximum 2 bends conveyor Vertical bends Radius 400 mm Note 2 bends conveyor Electrostatic discharge feature ESD 45 mm 43 mm 12 7 mm 100 200 N 100 200 N 10 100 mm 6m 30 kg 800 g 100 g link 800g 5 20 m min 30 45 90 180 5 15 Standard conductive Max permissible single item weight 800 g Example Max permissible puck weight Max permissible base fixture product product weight 200 g Max 250 g puck Max 100 g link x Puck 43 7 gt 100 mm 8 links 5113196 3 Technical specification eG Flex Link 2 2 Operating conditions The circumstances und
19. ly controlled only by the input of the local sensors or controlled from a line controller over a CANopen network The motor unit has also a LED on each side indicating its status If the mo tors are in autonomous mode they only need power 24VDC to work prop erly 3 1 2 Line control If a line controller is used up to 127 motors can be interlinked via an exter nal CANopen network RFID reader writers can be connected to the line controller via a separate network Profibus DeviceNet or Ethernet All dy namic route handling has to be implemented in the line controller The main electrical cabinet supplies the motor units with power 24 VDC The power is divided in safe and continuous power in order to have the pos sibilities to implement emergency or safety stops Functions Flex Link 3 2 Diverters Mergers Combined Diverter Mergers Transfers Stop and Locating station for Puck handling 3 2 1 Diverters Diverters are used to split a flow of pucks from one line into two The lines can be parallel or in a 90 angle The diverter is an active unit with one infeed and two outfeed conveyors There are four different variants of the diverter Diverter Parallel Left Diverter Parallel Right e Diverter 90 Left Diverter 90 Right 5113196 3 Flex Link 5113196 3 Functions Figure 2 Diverter parallel and 90 The unit has two positions for photoelectric sensors The first one is
20. ow the guidelines stated in the separate license agreement needed in using any parts of this product package 5113196 3 FlexLink 5113196 3 Preface Preface Purpose of this manual The purpose of this manual is to describe a number of operations that are intended for the user concerned Here it becomes clear how the user can work as well and as safely as possible By making use of clear illustrations and texts FlexLink wants to achieve a simple and safe way of working with the X45 system This document contains remarks that point out a risky or specific situation to the user In many cases this situation is provided with one of the symbols given below A General warning for danger Warning for electrical voltage 1 Attention this is an important notice Compliance with the operations described in this document is important in order to prevent dangerous situations and unnecessary damage to the X45 system Carefully keep this document It is recommended to keep one copy near the conveyor system and one copy with your technical documenta tion Structure of the manual The user s manual has been composed in such a way that a number of op erations can quickly and easily be found This manual will not describe op erations that are not meant for the user It does however indicate what the user must do when carrying out a certain operation for example calling in technical staff FlexLink would like to point out to the us
21. r the transport supports are still connected well to the module After this the unloading procedure may be started 4 2 1 Shipment Modules are normally delivered in flat boxes with a maximum length of ap proximately 3 m See photo below Conveyor modules will be delivered in sections of maximum 3 m which are easy to reassemble 21 Mounting installation adjustment 22 Flex Link 5 Mounting installation adjustment This section deals with the operations to have the modules function well within a transport system Longer conveyor modules approx 53m are delivered in sections The sec tions are marked up and can easily be joined together Also the corre sponding conveyor chain is marked up and has to be assembled according to section 5 2 5 1 Provisions to be provided Make sure before assembly that the surroundings are clean and free from obstacles and the mounting surface is clean and level Besides it should be repeated that the operations are to be carried out in a calm and control led way After having placed the modules in the correct position the modules is to be fastened to the mounting surface by using the holes in the adjusting feet 5113196 3 e Flex ink Mounting installation adjustment 5 2 Mounting chain to X45 conveyor modules Idler end 5 2 1 Tools 5 2 2 Procedure 1 Usethe screwdriver to remove the plastic cap on the idler end Loosen the screws on both si
22. to different performance such as function type speed and angle settings by a parameter setting tool kit 5113070 For more information see User documentation Parameter setting tool on flexlink com and Technical library 5113196 3 33 Technical maintenance eG Flex Link 6 Technical maintenance 6 1 Maintenance intervals Within the application where X45 equipment is normally used environ mental conditions are clean compared to many other FlexLink system in stallation sites During these conditions X45 modules normally require a minimum of maintenance The following maintenance interval is recommended for X45 equipment An inspection for all equipment is recommended regularly every 1500 operating hours or every 3rd month depending on which case that occurs first Table 1 Interval Interval 1 shift Every 3 rd month 2 shift Every 3 rd month 3 shift Every 1500 hours In case of less clean environmental conditions certain wear can occur and more frequently planned maintenance intervals are recommended If this is the case consult your FlexLink supplier 34 5113196 3 Flex Link Pe 7 Recommended spare parts See separate Spare parts list on flexlink com and Technical library 8 Supplier s information This manual goes together with the module of the type mentioned on the order and on the title page of this manual This document was drawn up by FlexLink Components AB Date 2010 0
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