COILERS Hand Lei Ding ENG_R2

8/3/2019 COILERS Hand Lei Ding ENG_R2

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OPERATOR SOFTWARE MANUALWM3,4 & 5 / MINICOILER™ SPRINGCOIL MACHINE

Manual COILERS™ R1 LCN BV.



Content

Prolog 3Technical data 4Safety information 5

Remaining precautions 7Installation settings 8Mechanical settings 9Operating sequence 10General Information 12Menus 13Startup screen 14Customer menu 15Save data 18Delete data 20Spring Information 22

Coil data (menu) 23Progressive (menu) 25Manual control (menu) 27Utilities (menu) 29Setup (menu) 30Alarm / error messages 32

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1 Prolog:

This machine is build by:

MERWEDE INTERNATIONAL B.V.Molensteijn 17, 3454 PT De MeernNederland.

We thank you for your confidence and wish you a successful production for now and many years to come.

The WM / MINI COILER is a Semi-automatic Spring coil machine based on the latesttechnology by using a NC/C-IPC control system.

This manual belongs to the WM / MINICOILER and contains important informationfor a correct and save operation of the WM / MINICOILER.

This machine has a twelve-month warranty. This warranty becomes invalid if machine components are changed or replaced without written permission fromMERWEDE INTERNATIONAL B.V.

This machine is suitable for coiling cylindrical and conical springs and has beenconstructed around a robust steel frame. The springs are coiled around a spindle.This machine can also be used to coil torsion springs with straight ends. Either rings

or rods can be used to feed wire into the machine. If rings are used, the wire can befed automatically. Rods must be fed manually or with the help of a robot.

The machine is quick and easy to use. It takes 2 minutes to set up the machine tocoil a different spring. This makes the machine very economical for coiling small andmedium-sized series of springs.

We would be pleased to hear of any questions or comments you may haveconcerning the operation of the machine or the software, so that we canmake any necessary alterations.

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2 Technical data:

This machine must be connected to an earthed 400 Volt, 3-phase electrical

connection with a neutral conductor (PEN system).The connection must be made by a qualified electrician.

General specifications WM / MINICOILER :

Length: 5000 / 2000 mm

Width: 800 / 500 mm

Height: 1300 / 800 mm

Weight: 2500 / 500 kg

Wire diameter: 50CRV 4 4-28 / 0,5-8 mm

Class C 4-20 / 0,5-6 mm

Cr/si 4-17 / 0,5-6 mm

Maximum spring diameter: 300/ 120 mm

Maximum spring length: 2150 / 950 mm

Spindle speed: 1-110 / 1-300 RPM

Type of control: Sigmatek C-IPC 733MHZ

Internal memory: Compact flash 64 MB/Sdram:512Communication: Ethernet

Nominal current: 63 / 25 A

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Safety information:

The machine may only be operated by authorized and suitably trained personnel.MERWEDE INTERNATIONAL B.V. provides such training and gives instructions for

the use of the machine on delivery.

Make sure the machine is switched off, to avoid unauthorized personnel operatingthe machine when the operator is absent.

Wear good fitting clothing when working with this machine. This machine has rotatingcomponents. Loose fitting clothing may get caught on these components and thismay put you in danger.

Always pay attention to your personal safety! In dangerous situations, press theemergency stop button. This will cut the power to the motors and allows them to bemoved manually. If necessary, turn the machine off using the main switch.

Use the emergency stop button if you leave the machine unattended for a shortperiod of time.

Make sure the power cables are not damaged. If they are damaged, have themreplaced by a qualified electrician.

Never place tools or springs on the machine’s work surface. Make sure the springremains on the clamping chuck’s key, so that the key can never be left unattended inthe clamping chuck.

Make sure the protective cover around the clamping chuck remains intact. Replacethe protective cover if it becomes damaged.

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Wear safety goggles and, if necessary, gloves and safety shoes. This machine isintended for coiling springs. Therefore, do not use it to bend objects.

Never allow other persons near the MINICOILER during production and never letother persons touch the Touch Screen.

To clean the machine, do not use water, a damp cloth or aggressive cleaningproducts which may harm the plastic.

MAKE SURE TO UNDERSTAND AND OBEY ALL THE ABOVE MENTIONED !.

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Remaining precautions:

Whilst cutting the wire, hold the wire with one hand to prevent the wire from slippingout of the wire guide.

To prevent slipping adjust the pressure on the wire by rotating the nut on top of thewire guide.

Never put your hand in the wire guide during production.

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4 Installation, settings

The machine should preferably be positioned on a flat surface. The machine is fittedwith fixing points, which can be used to secure the machine to a solid floor. The

machine must be secured to the floor when using a top reel.

The machine must be connected by a qualified electrician. Make sure the machine isconnected to the correct voltage supply (400 Volt AC). The direction of rotation of thehydraulic unit’s motor is indicated by an arrow. Depending on the power supply, theconnection may need to be altered. An error message will appear on the screen“Phase sequence incorrect”. Make sure the cables from the console to the machineare sufficiently protected (in steel cable ducts).

Make sure the hydraulic tubing are fitted correctly.

N.B. Once the machine has been operational for two weeks, all the nuts, bolts andconnections must be retightened to check that they have not been loosened.

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Mechanical settings

The gearbox settings are automatically displayed on the monitor. These settingsmust then be manually changed to the correct settings. The handle gives a clear

indication.

The slanted position and the height of the wire guide can be set as required.

The wire can be fed into the machine using a top reel, using a horizontal reel or manually (rods).

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5 Operation

Operating sequence

The spring coiler is operated in the sequence stated below. The machine settings aremade using a software program developed by MERWEDE INTERNATIONAL B.V.The options are described in the following chapters.

A. Mechanical settingsSelect the correct spindle. Secure the spindle to the clamping chuck. Installthe correct carrier to the clamping chuck. Adjust the height of the wire guide.

B. Switching onThe main switch on the front side of the machine provides power to thecomputer and activates the controls. If any emergency stop buttons are

blocked, then they must first be unlocked by pulling the red knob towardsyourself. Next, press the <RESET> button on the touch screen. This will startthe hydraulic circuit.

C. Menu selectionAs desired (see the following paragraphs).

D. Activating the left foot pedalThe clamping chuck will move to the correct position. The wire guide will moveto the starting position and the center will cover the spindle.

E. Feeding the wireFeed the wire under the carrier once only.

F. Activating the left foot pedalThe clamping chuck will start to rotate and coil the spring. The wire guide willmove to the rest position and will make room for cutting. The center foldsback.

G. Cutting the springThe spring is cut free using the wire cutters (optional).

H. Remove the spring.

I. Repeat the process from point D.The operation and parameter settings are made using the menu-operatedsoftware.

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ATTENTION: Always be aware that this machine may only be operated by authorizedpersonnel! READ THIS MANUAL CARFULLY

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GENERAL INFORMATION:

The MINICOILER™ is fitted with a Touch Screen (TS).

All settings are changed by touching the appropriate field, this will activate a(numeric) keyboard to set your text or setting.

Each setting must be confirmed by pressing the or the key

Delete settings by pressing the or the key

Close the keyboards by pressing the key

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MENUS

Selecting different menus

- Information screen with general data of the selected customer / spring

- Spring settings

- Machine settings

- Progressive spring settings

- General settings

- Manual control

- Activation of the cutter after switch off timer

- Reset emergency stop

- Actual and historic alarms and error messages

- Customer / spring selection menu

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When the MINICOILER is operational the startup screen will be visible, by selectingthe appropriate flag, the language is set. 4 languages are standard selectable.

Press the key to continue.

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Customer menu:

The customer menu contains the next functions;

Current screen number next to the Merwede logo

The current status of the MINICOILER™, displayed in the red bar

The current date and time, top right side of the screen

The current, active, customer and spring are displayed in the grey bar

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Selection keys for saving and / or deleting dataSelection keys for loading customers and / or springs

One customer up

Load selected spring

Save selected spring (with altered parameters)

Save new spring

Add new customer

Delete spring

Delete customer

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Selecting a key will activate a choice menu

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SAVE DATA

Add new customer by pressing the key

By pressing the bar, the keyboard isactivated.

Enter the customer name and press the key to accept.

Pressing the key will create a new customer.

Press the key to select the customer from the database.

NEW SPRINGSelect from the database the appropriate customer, this will open thecustomer file

Press the key to save the new spring.

Press the bar to enter the new spring.

Press the key to save the new spring and the new spring will be addedto the database.

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The new spring will be displayed as shown below:

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DELETE DATA

Select the appropriate spring to delete from the database.

The selected field will turn blue

Press the key and accept with the key.

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SPRING PARAMETERS AND SETTINGS:

ATTENTION !

WHEN SAVING A NEW SPRING ALL DATA FROM THE LAST LOADED SPRING

WILL BE COPIED INTO THE NEW SPRING DATA

TO SAVE THE ALTERED SPRING DATA, YOU MUST PRESS THEKEY, AFTER YOU CHANGED THE SPRING DATA.

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SPRING INFORMATION

This info screen can be used for entering information.The first two fields are read only, to show you the current customer and spring.All entered data is for information only, it will have no effect on the operation of theCOILER.

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Adjust settings of the current loaded spring:Touch the appropriate parameter this will activate the numeric keypad.Enter a new value and accept.

Spring length in millimeter.ATTENTION: the exact spring length can differ from the set value ! the COILER willnot auto adjust to different coiling materials.

Number of coils is the number of revolutions of the clamping chuck.

Number of closed coils at the start, a low value will open the spring, a higher valuewill cause the coils to tighten.

Pitch of closed coils at the start, the wire guide will move the number of mm per revolution of the clamping chuck.

Is used to accelerate quickly to the desired pitch.The entered value is normally 0.3 rev. more than the pitch closed coils start.

See aforementioned.

Value of the last closed coil, a small value will result in a more “open” spring, thehigher the value will result in the coils to tighten.

The pitch value to result in a nice and flat last coil.

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The number of revolutions the clamping chuck in the opposite direction to ensure thecoiling material is retentioned.

ALWAYS check if the spring is not under tension before you cut of the spring.

The pitch is used for longer tension springs, it will make the wire guide move innegative direction.

To save the altered data press the key.

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Adjust settings of the current loaded spring:Touch the appropriate parameter this will activate the numeric keypad.

Enter a new value and accept.

Use the stages for adjusting the progressive stages in a spring.

Stage 1 to set the acquired pitch relative to the revolution.

Pitch stage 1 to set the acquired pitch.

Stage 2 to set the acquired number of progressive coils.

The settings for a progressive spring must be entered as follows:

In order to reduce the speed after the acceleration, there must be a difference of approximately 0.3 coils between the “Acc. coils” field and “End stage 1”.Enter the correct value for “Pitch stage 1”.

Enter the number of coils for “End stage 2” and enter the same pitch for “Pitch stage2” as for “stage 1”.

For a spring coiled without steps, enter a value for “Pitch stage 2” higher than for “Pitch stage 1”.

Stepless progressive coiling:Settings as in stage 1, set pitch stage 2 for example 10 mm higher.This will result in a, step less, increase of the pitch of stage 1 to the pitch of stage 2

To save the altered data press the key.

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DELETING ALL PROGRESSIVE DATA

Press the key and press the “YES” key and all data will be

deleted.

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Standard NO functions preselected.

Rotating the clamp chunk with the foot pedal.

Moving the wire guide from left to right with the foot pedal.

EXTRA FUNCTIONS FOR THE WM3, 4 & 5

Moving the center in start position

Moving the center in rest position

Moving the center to front / back

Moving the center in / out

Moving the wire guide to the front / back

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Raise / lower the top pay-off

SELECTED KEYS

A selected key is indicated by a highlighted bar.The acquired action is activated with the foot pedal.Pressing the left / right pedal will activate an opposite action.

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General Machine Setting

Setting the zero position of the clamp chunk in degrees, null degrees is vertical.

Setting the zero position of the support to allow the wire to position exactly under thecarrier.

Support position: left = start coiling from the clamping chuck

right = coil from the rear of the machineThis feature is especially useful to coil left coiled springs with bended wire, in casethe wire contains not enough resistance to coil solid around the Dorn.

Setting the number, or a fraction of coils, to allow the pitch to slowly decrease at theend of the spring.

Setting the number of mm, after coiling and slackening, the spring can be movedfrom the spindle.

Setting the speed of the clamping chuck.

Setting the direction of the rotation of the clamping chuck.L = anticlockwiseR = clockwise

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Activate this option to, automatically start the MINICOILER after the referencing.

For safety reasons there is no option on the MINICOILER for a fully automatedoperation.

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The historic and current alarms are displayed

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ERROR REPORTS:01 EMERGENCY STOP ! CHECK MACHINE AND PRESS RESET02 Reset03 Phase sequence incorrect

0405 Position Control X-Ax06 Position Control Y-Ax0708091011 alarm1112 alarm1213 alarm1314 alarm14

15 alarm1516171819 Not enough rest wounds20 Not enough rest length21 ERROR !! NO REST PITCH22 INPUT ERROR !!23 INCORRECT SPEED SETTING

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RESET ERRORS:01 EMERGENCY STOP ! Check the machine

Emergency stop circuit is active, in case of a manual emergency stop checkthe reason, solve the problem and press the RESET key on the screen.

02 Reset

Press the RESET key on the screen.03 Phase sequence incorrect

Occurs when installing the MINICOILER for the first time, or relocating theMINICOILER . Swap two phases from the main power supply (trainedelectrician!)

05 Position Control X-Ax (Spindle)Drag error, press emergency stop button, reset button and press the reset keyon the screen, if the error I still active, switch of the machine and restart.

06 Position Control Y-Ax (Support)Drag error, press emergency stop button, reset button and press the reset key

on the screen, if the error I still active, switch of the machine and restart.

11alarm1112 alarm1213 alarm1314 alarm1415 alarm1516 alarm1617 alarm1718 alarm18

19 Not enough rest coilsCheck the input fields and adjust to a correct value

20 Not enough rest lengthCheck the input fields and adjust to a correct value

21 ERROR !! NO REST PITCHCheck the input fields and adjust to a correct value

22 INPUT ERROR !!

Check the alarm screen and correct the current alarm

23 SPEED NOT CORRECTCheck the input fields and adjust to a correct value

COILERS Hand Lei Ding ENG_R2

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