Wednesday, 21 October 2015 17:13

Lift Gate: %Adjustments of the Lift Gate


The Lift Gate is adjusted in the delivered configuration to be optimized for low operating forces. Adjustments of the forces and the operating behavior are just possible in the physical limits. The Figure in combination with Table below is showing the different adjustment possibilities with their results.
 

Lift Gate Adjustments 1

Lift Gate Adjustments 2

If you should have further questions about the adjustments of the Lift Gate, please contact the LOGOMAT customer service.

 

 

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Wednesday, 21 October 2015 16:45

Lift Gate: %Mechanical Installation


The Lift Gate can only be installed in the designated location within the conveyor layout (see the project layout). 
 
To install the Lift Gate, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Set up the adjoining conveyor tracks to the Lift Gate according to the project conveyor layout.
    The set up and installation has to be done according to the "Set up and Installation" section of the conveyor documentation. This document, included in the entire project documentation, describes the different steps in detail of how to set up, arrange and install the conveyor.
  3. Set up the Lift Gate in the assigned location. Pay attention to the necessary gaps between the gate and the adjoining conveyors. The distances should be 28.5 mm between the aluminum extrusion of the adjoining tracks and the pivoting conveyor.

    Lift Gate Mechanical Installation

  4. Level and adjust the height of the top of roller of the Lift Gate to the same level as the rest of the conveyor system.
  5. Level and mount the feeding conveyor segment to the base frame of the Lift Gate. Put the slot nuts in the lower slot of the bottom rail extrusion to bolt the conveyor to the frame.
  6. The position of the Lift Gate locking mechanism might need to be adjusted to guarantee safe closing of the Lift Gate. To move the locking mechanism, loosen the mounting bolts of the angle bracket and move the entire locking mechanism base angle. The correct setting is when the locking pins get pushed back and jump spring loaded into the locking bracket when the gate gets closed. Bolt the Lift Gate to the floor. (Please see more information in the Documentation „Set up and Installation“.)
  7. Check the mechanical function of the Lift Gate.
  8. Re-connect the electrical and pneumatic supply of the system.
Even if the conveyor system is set up and installed temporarily, the entire set up and all alignments have to be done correctly to ensure proper function.
 
The Lift Gate shouldn’t be opened if a pallet is in transition from the feeding conveyor section to the pivoting conveyor track or further to the next adjoining conveyor section!
 
It is forbidden to have a pallet on the Lift Gate conveyor when attempting to open it!
 
 
 
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Tuesday, 20 October 2015 21:12

Track Rotate: %Replacing the shot pin


The shot pin can be replaced without taking the Track Rotate apart and the entire unit is available as a spare part.
 
Please follow the steps to replace the shot pin unit:
  1. Disconnect the power supply and the pneumatic air supply and prevent them from being switched on by any other person.
  2. Take the M8 sensors out of the sensor bracket and mark their positions for the reinstallation. Mixing them will influence the controls.
  3. Remove the pneumatic air hose from the fitting.
  4. Loosen and take off the four mounting bolts of the shot pin unit. (Make sure that you keep all fastening material.)
  5. Replace the shot pin unit and install the new unit in reverse order.
  6. Make sure that the sensors are adjusted right and they see their target as needed.
  7. Test the function of the shot pin unit by operating its valve manually before releasing it to production.
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The rotating plate runs on rollers, which take the load and act like a bearing. Three guide wheels are rolling on the inside of the frame to center the rotate unit. They are attached to the rotation plate. Two of the guide wheels are fixed in their location and one is adjustable to match the diameter. The adjustment is important for the operation and the function of the Track Rotate.
 
Please follow the instructions to adjust or replace the guide wheels:
  1. Disconnect the power supply and prevent it from being switched on by any other person.
  2. Disengage the tension of the tooth belt pulley from the inner ring segment by pushing the drive motor back against the compression spring, and lock it in that position with an adequate device.
    The tooth belt pulley won’t have any further contact to the tooth belt anymore.
  3. Loosen the mounting bolts of the adjustable guide wheel and the eccentric plate and turn it away from the inner ring surface. Make sure that you secure the rotation plate because it can slide off the support wheels.
  4. Replace a guide wheel assembly if necessary. Replace only one guide wheel after the other. Do not take off all guide wheels at the same time.
  5. Push the entire unit with the two fixed guide wheels to the inner ring of the fixed lower structure.
  6. Move the adjustable guide roller towards the contact surface and apply some force by rotating the eccentric plate. Tighten the bolts of the adjustable guide wheel and the eccentric plate.
  7. Spin the rotate by hand and check if it spins freely. If it requires too much force, you can release the adjustable guide wheel slightly. Make sure that the shot pin is in the upper position while spinning.
  8. Remove the hold back device and bring the tooth belt pulley back in its normal tensioned position.
    Make sure that the tooth wheel will engage into the tooth belt correctly.
  9. Re-connect the power and test the rotate in all functions.
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The safety clutch is a safety element, which has to be adjusted properly for the operator safety. LOGOMAT automation systems, Inc. pre-adjusts it before delivery. If further adjustments are necessary, please first check the operating requirements. Overloading should be avoided in any case.
 
The safety clutch is not infinitely variable. It should be adjusted loosely enough so that the operator is able to stop the Track Rotate during rotation without excessive force, but not so that it will stall when the shot pin is pushed in at the ramps.
 
You can find more information in the documentation of the manufacturer of the friction clutch.
 
The operating company can replace the friction clutch of the Track Rotate and the work should be performed in the same way as a motor gets replaced (see previous chapter).

Track Rotate Adjustments friction clutch

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Tuesday, 20 October 2015 20:52

Track Rotate: %Changing the drive motor


Electrical voltage warning: The entire conveyor system must be de-energized before performing the following work!
 
The drive motor of the Track Rotate can be replaced by the operating company. Please follow the instructions:
  1. Disconnect the power supply and prevent it from being switched on by any other person.
  2. Remove the four bolts of the motor mounting plate and take the whole unit off.

    Track Rotate Changing drive unit 1

    Track Rotate Changing drive unit 2

  3. Loosen the bolts of the mounting plates and take them off the motor shaft with an adequate device.

    Track Rotate Changing drive unit 3

  4. For reinstallation of the drive motor, follow the steps in reverse order and adjust the friction clutch according to the clutch maintenance manual to a proper force.
The Track Rotate should be operated with as little force as possible for safety reasons, but it shouldn’t stall when going into the hard stops. Make sure that the drive station gets enough force to the tooth belt and the hold back device is taken out before operating the rotate. 
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Tuesday, 20 October 2015 20:45

Track Rotate: %Pneumatic Installation


The shot pin is activated by an integrated pneumatic cylinder which is manufactured by LOGOMAT automation systems Inc. The pin is spring loaded to return in the extended position for safety. In case of a pressure loss, the shot pin will go down and the Track Rotate will stop in the next index bushing.
 
A 3/2 pneumatic valve is needed for operating the shot pin. The installation is done with one 6 mm air pressure line which gets connected to the pre-installed fitting. The air hose has to be routed in the cable track to ensure no damage while rotating the unit.
 
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Damages on the Track Rotate or on surrounding machines which were caused by incorrect operation or control errors are not in the responsibility of LOGOMAT automation systems, Inc.
 
Switching Status of the Track Rotate at the beginning of the rotation:

Rotate Unit Switching status 1 home position

 
Switching Status of the Track Rotate during rotation:

Rotate Unit Switching status 2 during rotation

 
Switching Status of the Track Rotate short before the end position:

Rotate Unit Switching status 3 before end position

 
Switching Status of the Track Rotate at the end position:

Rotate Unit Switching status 4 at end position

 

 

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The rotation motor of the Track Rotate has to be controlled by a frequency converter, because it has to be decelerated before the rotation position is reached.
 
Every stop position of the Track Rotate needs two proximity switches. (Two adjoining tracks would need four, three tracks would need six and a rotate with all four exits would need eight rotation switches.)
 
The sensor target is installed at the rotation plate. If the Track Rotate reaches a locked position, both sensors at that position are activated and see the target. (Status “ON”)
 
Shortly before reaching the final position, the first sensor recognizes the target and that signal will decelerate the drive speed. As soon as both sensors recognize the target and the shot pin is extended and the drive motor will switch off.
 
The shot pin locates into the index bushing in each stop position and locks the Track Rotate in position.
 
Each stop position of the Track Rotate gets one index bushing since the shot pin is rotating with the module. (NOTE: The index bushing for a certain stop position is located perpendicular to the conveyor track direction.) A four exit Track Rotate would have one shot pin and four index bushings.
 
The shot pin is pressed in against its spring by a ramp at the index bushing. The position of the shot pin piston gets sensed with two sensors (up / down). That signal is an additional feature to identify the locked position to start travelling pallets.
 
The fully defined stop position is reached if both turning sensors recognize the target and the shot pin is extended.
 
Before starting the turn motion, the shot pin is retracted. After that, the turn motor can start with the nominal speed. As soon as the position sensors lose their signal, the shot pin gets extended to be ready to catch the next index bushing.
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Tuesday, 20 October 2015 20:25

Track Rotate: %Electrical Installation


The LOGO!MAT Track Rotate has to be equipped with sensors and the rotation drive has to be controlled through a frequency converter to soften the stop of rotation. These electronic components have to be supplied and installed by the operating company.
 
The controls logic for a proper function and safe operation has to be done by the customer if the unit isn't ordered with the LOGO!MAT ITB Control Integration.
 
Two sensors have to be installed per stop position. With these two sensors, it is possible to define the turning direction by checking which of the two sensors will recognize the target first. In addition, the drive should decelerate when the first sensor recognizes the target. It has to turn the drive off when both sensors recognize the target and the shot pin is in the down position.
 
The shot pin up / down sensing can be either done with one sensor, or with two M8 sensors for both positions.
 
All sensors have to be adjusted for the right switch distance to allow a proper function. The controls have to include a certain signal time for the sensors to eliminate malfunctions because of short fault sensor signals.
 
Damages on the Track Rotate which were caused by incorrect operation or control errors are not in the responsibility of LOGOMAT automation systems, Inc.
 

Track Rotate Electrical Installation 2 adjoining tracks

Track Rotate Electrical Installation 3 adjoining tracks

Track Rotate Electrical Installation 4 adjoining tracks

Track Rotate Electrical Installation shot pin sensor

 

 

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