untitled TRANSPORT RAILS MODULE OVERVIEW RAIL SYSTEM (RS) CHAPTER 19 TRANSPORT RAILS MODULE OVERVIEW RAIL SYSTEM (RS) Item Description Item Description 1 Transport Belt (2 positions) 6 Moving Rail Hom.
Trang 1OVERVIEW - RAIL SYSTEM (RS)
CHAPTER 19 TRANSPORT RAILS MODULE
OVERVIEW - RAIL SYSTEM (RS)
4 Front Transport Belt Drive Motor 9 Board Clamp (2 positions)
Heavy Board Rails (optional)
1 10
2 3
9
8
4
5 7
6
Trang 2OVERVIEW - MODULAR TRANSPORT RAILS (MTR)
2 Snugger/Clamping Module (Front and Rear Rails) 6 Front Belt Drive Motor
5
78
4
32
1
6
Trang 3COMMON TRANSPORT RAIL COMPONENTS
COMMON TRANSPORT RAIL COMPONENTS
For the purpose of identification, the common components of the transport rail systems have been identified These components are shown below in the dia-gram, and they are listed in the table
1 Rail Width Drive Pulley (2) [RS and MTR rail
systems have different pulleys]
8 Rail Lift Linear Bearing
4 Rail Width Home Sensor and Vane 11 Clatter Bar (2)
6 Transport Leg [Items 7 to 10] (4) [RS and MTR
rail systems have different leg assemblies]
13 Rail Lift Sensor (2)
7 Rail Guide and Damper Assembly
76
89
13
12
Trang 4Two transport rail systems are currently available:
• The Rail System (RS)
• The Modular Transport Rail (MTR)Both have two variants available:
• High Throughput Conveyor (HTC) [see HTC chapter for details]
• Dual Lane (DL) [see dual lane chapter for details]
The variants are described in their respective chapters of this manual
MTR offers system modularity; the centre section, which holds and locates the product, can be removed to accommodate any future upgrades, without hav-ing to replace the complete transport system
Both systems have a programmable width conveyor system, set by the board width parameter, in the product file The rails transport the board, using belts, from the upline machine into the printer, where the board is positioned, clamped, and printed After printing, the board is transferred, using the same belts, to the downline machine
On the RS, there is an option for heavy boards, the transport rails can port boards weighing up to 6kg This is achieved using an extra drive pulley
trans-on each rail and flat profiled transport belts
NOTE 1.To prevent damage to the camera board stop the remote board stop must
be used for product boards over 1kg in weight
2.Information on the remote board stop is detailed in the Rising Table chapter of this manual.
The RS can be fitted with one of the following board clamping arrangements:
• 250mm or 500mm Board Clamps (foiled)
• 250mm or 500mm Foil-less Clamps
• Board Snugger AssemblyBoard clamps are used to support boards using the foils fitted to the edge of the clamp This gives additional support to the top of the board but the printa-ble image must not extend to the area occupied by the foils
Foil-less clamps are utilized for thin pliable boards where there is a ment to print close to the board edge The foil-less clamps are assisted with the use of a vacuum box beneath the product board
Trang 5require-BOARD CLAMPING ARRANGEMENTS
BOARD CLAMPING ARRANGEMENTS
Figure 19-1 Board Clamping Arrangements - RS
Figure 19-2 Board Clamping Arrangements - MTR
Board Transport Belts Rear Board Clamp
Trang 6ELECTRICAL SCHEMATIC (RS)
Front Belt Drive (8M03) Rear Belt Drive (8M04)
Sig 0V
Moving Rail Stepper
Motor 2B- Motor 2B+ Motor 2A- Motor 2A+
Trang 7THE MTR TRANSPORT SYSTEM
THE MTR TRANSPORT SYSTEM
End and Mid Rail
In both sections, there are two screws under the board guide which attach the rail body to the chassis The chassis is attached to the rail width bearing block
by the transport legs
During board transport the mid rail board guide lifts; for printing, the mid rail board guide lowers A pneumatically driven piston is used to lower the board guides; the mid rail screws have an outer guide sleeve fitted to allow this movement Two springs raise the guides to the transport (up) position
The centre section is used for holding the product securely during printing This section is modular, and it is designed to allow for a variety of clamping arrangements Currently, the centre section houses the OTS arrangement
(for clarity only one side is shown annotated)
Width Adjustment
Side View (Centre Section Removed)
Trang 8ELECTRICAL SCHEMATIC (MTR)
Front Belt Drive (8M03) Rear Belt Drive (8M04)
Sig 0V
Moving Rail Stepper
Motor 2B- Motor 2B+ Motor 2A- Motor 2A+
Main Machine I/O Node 5
CAN In CAN Out
Trang 94 Pneumatic Regulators
1
3 4
7
5
6
2
Trang 10The OTS Clamps
Figure 19-3 Rear OTS Rail
Brake Cylinders (16) Snugger Guide (2)
Snugger Actuator (2)
Forward/Back Cylinder
(Top clamp movement)
Top Clamp Plate
Top Clamp Plate and Mid Plate Assembly
Brake Surface (inner wall)
Snug Plate
Board Support
Trang 11MECHANICAL DETAIL (OTS)
MECHANICAL DETAIL (OTS)
The System The OTS system comprises:
• Board Support and Snug Plate (fixed on the front rail)
• Mid Plate housed in the Machined Body (it has a pneumatic manifold located at the rear of the assembly)
• Over the Top Clamp, comprising; the Swivel Plate, the Bearing Support Plate, and the Top Clamp Plate
• A Pneumatic Manifold
• Magnetic Tooling PinsBoard Support and
Snug Plates The board support, supports the product while it is in the tooling area of the machine The snug plate moves in and out to snug the product This
move-ment is provided by the snugger actuators and guides in the mid plate bly If a product is a shape that does not have parallel sides the snug plate pivots to accommodate it On the front rail this plate is fixed and does not move in the Y axis
assem-Mid Plate Sixteen brakes hold the mid plate in place during printing; they brake against
the flanges and the side wall of the machined body Print pressure up to 20Kg can take place To release the brakes, a vacuum ejector valve switches on; this pulls the brakes away
Over the Top Clamp This assembly comprises three plates: Swivel, Bearing Support and Top
Clamp The swivel plate is mounted on the bearing support plate which has a central bearing and linear guides at both sides If a product is a shape which does not have parallel sides, the clamps can pivot to accommodate the shape and align with the snugger The top clamp plate slides over the top of the product to give top clamping
Modes of operation can be programmed via the software The parameter, OTS Retain Mode, if enabled, allows the board to be held during the unclamping phase of the cycle (see Sequences later in this manual.) If disabled, the clamp
is retracted preventing the possibility of smudging the print
A forward/back cylinder mounted in the centre front of the block is used to move the over top clamp forward or backward The combination of up or down and forward and backward movements allows the over the top clamp to be moved This either clamps the product, or it comes to rest at the same height
as the product, where it is positioned behind the snug plate at the rear of the assembly
Manifold The manifold delivers pneumatic air pressure through ‘O’ ring sealed ports to
the various actuators which drive the OTS movements
NOTE Any attempt to disassemble parts invalidates all warranty agreements Modules must be serviced by a suitably qualified DEK trained engineer.
Trang 12Magnetic Tooling Pins
Tooling pins used on MTR machines have a lower shoulder than standard ing pins Magnetic tooling pins supplied with RS rails (p/n 112069) must not be used on machines fitted with MTR rail systems The tooling pins used for MTR systems (p/n 202582) may be used on all transport rail systems; they are backwardly compatIble A warning label is displayed on machines fitted with MTR
tool-CAUTION MAGNETIC TOOLING PINS CLASH DAMAGE MAY OCCUR IF THE INCORRECT TOOLING PINS ARE USED ON MODULAR TRANSPORT RAIL (MTR) PRINTERS.
Trang 13MECHANICAL DETAIL (OTS)
OTS Control Rail
A DIN rail at the rear of the machine houses the electrical, pneumatic and tro-pneumatic control assemblies The complete assembly consists of a man-ifold, three pressure regulators, two programmable ITV valves, a vacuum ejector and electrical input/output Node 5 The individual components are itemised in the graphic above
elec-Pneumatic
Manifold
There are six solenoid valves in the manifold they are designated as follows:
• Valve 1 Mid Plate Up
• Valve 2 Mid Plate Down
• Valve 3 Over Top Plate Extend/Retract
• Valve 4 Top Plate Up/Down
• Valve 5 Vacuum
• Valve 6 Snug and BrakeThe solenoid valves (1 and 2) control two pairs of double acting cylinders in the mid plate of the OTS rails With Valve 2 ON a programmable ITV valve is used to proportionally control mid plate down Valve 1 when on, pushes the mid plate up, when off, the balance regulator supplies low pressure to support the weight of the unit A pair of speed controllers are used to control the speed
of the mid plate up; this prevents board bounce during unclamping Air lines to
IO Node 5
Programmable ITV (Snugger Pressure)
Programmable ITV (Clamp Pressure)
Venturi Vacuum Valve (Vacuum ejector) Mid Plate Up Valve
Mid Plate Down Valve Over Top Plate Extend/Retract Valve Top Plate Up/DownValve
Vacuum Valve Snug and Brake Valve Balance Valve Regulator
Over Top Cylinder
Regulator (extend)
Air In ‘Tee’
Air Isolating Switch
Trang 14and from the mid plate cylinders are coloured blue.
ITV Clamp Pressure
Mid Plate Cylinder
Speed Controllers
Mid Plate Cylinder
In
Valve 2 Mid Plate Down
Valve 1 Mid Plate Up
2A 1A
Balance Valve
Trang 15MECHANICAL DETAIL (OTS)
The over top plate valve (3) controls a pair of double acting cylinders which cause the plate to extend or retract A pressure regulator controls each action; the regulators are factory set and must not be adjusted Two speed controllers are employed to control the speed of the over top clamp retract movement; this prevents board movement at the end of the clamp sequence If a clamp-ing problem persists escalate it to DEK Customer Support Group Air lines to and from the over top clamp cylinders are coloured red
Top plate up/down valve (4) controls the top plate movement Speed lers, in the top plate up line, are used to prevent board bounce during the unclamping Air lines to and from the over top clamp cylinders are coloured yellow
control-Over Top Cylinder
Over Top Cylinder
Out
Out
In 3A
Top Plate Cylinder
Top Plate Cylinder
Speed Controllers 4A
4B
Valve 4 Top Plate Up/Down
Trang 16Vacuum valve (5) controls the vacuum generated by the venturi valve The vacuum is used to release the brakes in the mid plate.
Snug and brake valve (6) combines both actions, when on, the snug and brake are activated, when off the vacuum is used to pull the brakes back (provided valve 5 is on.)
The programmable ITV valve is used to proportionally control the snug sure
pres-Air lines in this part of the system are coloured black
Programmable
ITV
The programmable ITV valves take electrical inputs and convert them to a portional pressure output The output is dependant upon the upper level set at the machine input supply solenoid
pro-The valves comprise: a control circuit which performs the voltage/pressure conversion, an exhaust valve which discharges excess air pressure, an air supply valve which controls the output pressure for the specific function and a pressure sensor which provides feedback to the control circuit
Brakes
VAC Generator
Snugger Pressure ITV
Valve 6 Snug & Brake
Valve 5 Vacuum Snugger Cylinder
Trang 17MECHANICAL DETAIL (OTS)
In the OTS system, two functions are programmable: clamp pressure and snugging pressure
Vacuum Ejector The vacuum ejector valve provides vacuum to release the brakes Sixteen
brake cylinders are used giving a maximum holding power of 20Kg print sure
pres-The brakes are applied during the clamp sequence, they are released during the unclamping sequence The valve works on the venturi principle where air
is evacuated through a tapered tube creating a vacuum
Pneumatic
Regulators
Three pneumatic regulators are employed to regulate the pressure for the lowing functionality:
fol-• Over top cylinder extend
• Over top cylinder retract
• Mid plate balanceOTC horizontal movements are controlled by the two over top regulators The mid plate balance valve provides sufficient upward lift to hold the mid plate weight All three regulators are factory set to achieve the optimum response for the operation
- Control Circuit
Air Supply Valve
Out
Out
Exhaust Supply Valve
Discharge
Pressure Sensor+
Air In
Vacuum
Venturi Exhaust Silencer
Circuit Symbol
Trang 19ELECTRICAL SCHEMATIC (OTS)
ELECTRICAL SCHEMATIC (OTS)
Mid Plate Up (8SOL10)
Trang 20PNEUMATIC SCHEMATIC (OTS)
Overtop Clamp Extend/Retract
V Mid Plate Down
Trang 21ADJUSTMENTS AND SETTINGS
ADJUSTMENTS AND SETTINGS
3 Use Next or Previous to highlight Rising Table.
4 Select Select Module.
5 Ensure that Home Rising Table is highlighted.
6 Select Run Diagnost.
7 Select Exit.
8 Use Next or Previous to highlight Rail System.
9 Select Select Module.
10 Ensure that Home Rail Width is highlighted.
11 Select Run Diagnost.
12 Remove the left and right hand safety covers to gain access to the rear rail
13 Place a 0.5mm feeler gauge between the rail shock absorber on the rear
right rail transport leg and the rail stop bar (clatter bar)
Right Transport Leg
Rear Rail
Front View of Rail System
Left Transport Leg
Linear Bearing
Feeler Gauge
Rail Stop Bar
Opto Vane Opto
Shock Absorber
Sensor LED
Enlarged View of Right Rail Opto
Trang 2214 Adjust the vane bracket using a 2.5mm Allen key, so that the sensor LED is Off with a 0.5mm feeler gauge fitted and On with a 0.7mm feeler gauge
fitted
15 Repeat Steps 13 and 14 for left hand end of the rear rail
16 Select Adjust, the following window is displayed:
17 Use Incr or Decr to set the Board Width to 50mm.
18 Select Exit.
19 Use Next or Previous to highlight Drive Rail To Board Width.
20 Select Run Diagnost.
21 Repeat Steps 13 to 15 for setting the vane at the 50mm width
22 Use Next or Previous to highlight Home Rail Width.
23 Select Run Diagnost.
24 Repeat Steps 13 to 15 at the home position
25 Use Next or Previous to highlight Cycle Rails.
26 Select Run Diagnost.
27 Ensure the left and right sensor LED’s remain Off over the full travel of the
mm Cycles
Trang 23ADJUSTMENTS AND SETTINGS
Board at Left/
Right Optos (RS
and MTR)
The board at left/right optos switching threshold can be adjusted by means of
a sensitivity control This ensures that when a board is fed into the machine (via the transport belts) the sensor output switches to ON
To achieve an optimum setting carry out the following procedure:
1 Place a board on the rails covering the sensor
2 Turn the sensitivity control fully anti-clockwise, ensure that the amber LED
Trang 245 Turn the board 90° and position back onto the rail system, (so that the board lies on top of the rail system as shown in the figure below).
6 Confirm that the amber LED is extinguished If the amber LED illuminates, turn the sensitivity control anti-clockwise until the amber LED extinguishes
7 Remove the board
8 Position the board back on the rail system, as in Step 1, and confirm that the amber LED illuminates
9 If the board has holes or cut-outs, go to Step 11
13 Repeat Steps 11 and 12 until the correct setting is achieved
14 Remove the board from the rails and confirm that the amber LED guishes
extin-Front Rail Parallelism (RS)
WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP.
Trang 25ADJUSTMENTS AND SETTINGS
4 Open the front printhead cover
5 Remove the screen from the machine
6 Close the front printhead cover
7 Press the System button.
8 Select Back.
9 Select Maintenance.
10 Select Diagnostics.
11 Use Next or Previous to highlight Rail System.
12 Select Select Module.
13 Ensure that Home Rail Width is highlighted.
14 Select Run Diagnost.
15 Select Exit.
16 Use Next or Previous to highlight Rising Table.
17 Select Select Module.
18 Use Next or Previous to highlight Raise Table to Vision Height.
19 Select Run Diagnost.
20 Select Exit.
21 Use Next or Previous to highlight Rail System.
22 Select Select Module The board clamps are released.
23 Open the front printhead cover
24 Remove any tooling from the manual tooling plate
25 Remove the board clamp from the front transport rail, Board Clamp Replacement - Replacement Procedures section of this chapter refers
26 There are two versions of the rail setting jig and they are labelled:
• Standard Rails (DEK Part No 199140 - round belts)
• Heavy Board Rails (DEK Part No 199142 - flat belts)
27 Confirm which type of rails are fitted to the machine and select the ate rail setting jig
appropri-28 Place the jig on the manual tooling plate ensuring that the location pins on the underside of the jig abut the front face of the manual tooling plate Check
Trang 26there is no gap using a 0.05mm feeler gauge.
29 Secure the jig to the front rail using the two jig to rail thumbscrews
30 Secure the jig to the rising table using the two jig to table thumbscrews
31 Check that the location pins are up against the front edge of the manual
tooling plate using a 0.05mm feeler gauge, as in Step 28.
32 Using feeler gauges check that the gap between both alignment pads and
View on Left Hand Side
Rail Setting Jig
View on Rear of Transport Rails
Jig to Table Thumbscrews
Jig to Rail Thumbscrew Jig to Rail Thumbscrew
Trang 27ADJUSTMENTS AND SETTINGS
the belt support plate of the front rail is 0.25mm ±0.05mm.
33 If adjustment is not necessary continue with Step 46
Feeler Gauge Alignment
Pad
Belt Support Plate
View on Rear of Transport Rails
Trang 2834 Using a 3mm Allen key slacken the four securing bolts attaching the right
hand transport leg to the carriage nut
35 Repeat Step 34 on the left hand transport leg
36 Using a 4mm Allen key, through the access holes in the board edge guide,
slacken the four rail securing bolts (two each side)
Rail Setting Jig
Securing Bolts Securing Bolts
Transport Leg
View on Right Hand Side of Front Transport Rail
Carriage Nut
Access Holes Access Holes
Board Edge Guides
Trang 29ADJUSTMENTS AND SETTINGS
40 Recheck the parallelism as detailed in Step 32
41 Tighten the bolts slackened in Steps 34 to 36
42 Recheck the parallelism as detailed in Step 32
43 When the adjustment is complete, remove the board edge guides from each end of the rail
44 Remove each bolt disturbed (one at a time), apply a suitable locking compound and fully tighten
45 Refit the board edge guide to each end of the rail
46 Remove the rail setting jig from the rising table
47 Fit the board clamp to the front rail
48 Close the front printhead cover
49 Press the System button.
50 Select Exit.
51 Select Exit.
52 Select Back.
Front Rail Parallelism (MTR)
1 Select Open Cover Commands.
2 Select Carriage To Rear.
3 Select Unload Screen.
4 Open the front printhead cover
5 Remove the screen from the machine
6 Close the front printhead cover
7 Press the System button.
8 Select Back.
9 Select Maintenance.
10 Select Diagnostics.
11 Use Next or Previous to highlight Rail System.
12 Select Select Module.
13 Ensure that Home Rail Width is highlighted.
14 Select Run Diagnost.
15 Select Exit.
16 Use Next or Previous to highlight Rising Table.
17 Select Select Module.
18 Use Next or Previous to highlight Raise Table to Transport Height.
19 Select Run Diagnost.
20 Open the front printhead cover
21 Remove any tooling from the manual tooling plate
22 Place the rail setting jigs on the manual tooling plate, spaced approximately