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INSTALLATION MANUAL
-Second Version-
1 Installation process
1.1 Shipping conditions.
1.2 Machine positioning.
2
Section 1
Installation process
Installation process
Accessory box
Main Machine
Weight : 13 TONS
[Fig.1-2:lifting
1.2 Machine positioning
1)Please make a positioning line on the floor before machine delivery
(You can measure each height of AY plates position before delivery if you have auto scope
leveler, that is more easy way for adjust machine lever job.)
Machine size(mm)
AE2510NT 5120 X 4155 X 215
[Fig.1-3:ベースプレート配置図]
AY plate
M30 bolt
2) Roll and tow the machine with hook the rope there.
Lower the machine onto the AY plates and installing M30 bolts in the AY plates.
MEMO
Section 2
Removing Shipping Brackets
[Fig.2-1:X-axis shipping]
[Fig.2-2:Y-axis shipping]
The AE model has the carriage base raised by M30 size 3pcs bolts at the center and held
with front and rear side brackets.
1) Remove the bolts between carriage base and hold table brackets (front and rear side).
6) Make 5mm gap for both side between carriage base bottom and support table brackets.
* The carriage base shipping bracket can be turned angle between shipping
angle and around right angle.
8) Turn the lower rear Y-axis ball screw until the bolt holes of carriage base align
with those of the support brackets.
9) Slowly loosen the carriage base suspending screws to lower the carriage base
onto the support bracket.
Notice
Please don’t pinch the rear side adjustment block.
10) To prevent the carriage base front backward reamer screw from being galled, adjust
the position of the carriage base so that the reamer screw be pushed in by hand,
and slowly finger-tighten the reamer screw.
11) Remove the 3pcs screws from on the carriage base shipping.
12) Rear side has the right angle adjustment block That block has adjustment screw
with flexible flat surface ball. That surface mast be parallel with the carriage
base. Please make flat by your hand.
NG OK
13) Pull in the carriage base to the block slowly till just before touching.
Notice:
Old serial number machines has female screw at the separate block.
(AE2510NT serial number 46 and older machines)
That female screw block is already adjusted with shims by Factory side.
Please don’t touch and loose those screws.
Don’t touch
16) Fix the carriage base and the support bracket with M20 screws and washers by hand
temporally. (11 set of screws and washers.)
Notice: Will be tight after done the leveling, so don’t tight now.
17) Remove the carriage base shipping from the carriage base.
18) Remove the carriage base support table brackets (front and rear both side).
19) Fix the carriage base support bracket by M12 size screws.
Front side
Hold it by hand. Install screws vertical side Install screws top side
Rear side
1)Take out the center table cover for put the leveling gauge.
3)Tilt and avoid the relay terminal box and plate, then put the leveling gauge there.
4)Tap all 4 base plates with hammer or the like to verify that they are all firmly
supporting the machine. Insert shims under any floating base plate to make them all press
firmly on the ground.
5)Set a jack on the turret and carriage ends inside of the machine frame.
Turret side Carriage side
Hole Thickness
Qty (mm)
Add new thickness size of shims Non 3.2
since AE series. (0.5mm and 0.6mm) 1 2
That can be made 1.1mm thickness 2 1.6
with combination. 3 1.2
4 1
5 0.8
6 0.6
7 0.5
7) Bring back the level to the turret end and check the levelness again. Verify that the
level limit has not runs out to the edge.
Level location
* If the level runs out of the instrument in either the X or Y direction, the frame is possibly
twisted between the turret and carriage ends. Readjust until the level stops running out
on the turret end. Take the level back to under the center table point on the carriage end,
and verify or readjust the levelness to 0.05mm/M or better. Repeat these steps until the
levelness becomes within the tolerance.
8) When the required levelness has been obtained at both turret and carriage ends, rotate
each of the M30 base plate securing screw(4 locations) until it hits the bottom of the
base plate. Now, Loosen it back approx 2 turns.
M30 screw
M30 Nut
M30
Base plate
9) While holding the M30 hex head screw with 46mm spanner wrench, tighten the M30
Nut with another 46mm spanner wrench completely.
10)Verify that the machine is at the position delineated at the end. If not, use a jack or
the like to move the machine.
11)Drill a hole using a 17mm anchor drill. Insert an “Allanchor” gently.
12)With the M30 nut completely tightened, parts of the base plate may be off the floor
due to the unevenness of the customer’s floor. In this case, be sure to fill the gap as
much as possible with something like cut steel plates.
Allanchor
13)Drive in the 16mm “Allanchor” with a hammer, and secure it with 19mm spanner
wrench.
14)Check both carriage and turret end again for the levelness within the tolerance. If not,
loosen all M30 nuts at 4 locations and readjust the levelness. Tighten the M30 nuts
at 4 locations again and verify the levelness.
The leveling method has been changed to check the levelness at both carriage and
turret ends. The idea is to use a severe leveling method to recreate the factory accuracy
in the turret center to prevent the occurrence of off centered stations on the customer’s
site as much as possible.
It required extra work but leveling is normally done only once at the trial operation as a
rule.
4.2 Fixing carriage base
1)Tighten the carriage base mounting screws reference pin in the following sequence.
TURRET
11 10 12 8 3 9
4 1 5 6 2 7
1)Extend and downward by big size jack screws approx height 100mm by 46mm spanner
wrench.
Then extend and down the small size jack screws till reach to the blocks by 19mm spanner
wrench, then lift up the cabinet with half turn the each big size screws, then
tighten the nuts.
2)Remove the 3pcs of M16 cap screws that connect the electrical control cabinet to
the machine frame, then remove the spacer plate between there.
Insert here
Stand
2)Install a flange socket screw (M8) and attach the feed table to the LM guide block., like
below.
Brush table
Brush table
Brush table
5)Hold up little bit the feed table when tight the screws (M8).
Brush table
6) Install Hex head screws (M12) under the carriage.
Complete
8) Tighten screws for fix the carriage base brackets (front & rear side).
2)Remove 2pcs of narrow side H-shape stands, that’s already assembled with H-shape.
Remove 4pcs of M8 size screws from bottoms side
shipping of H-shape stands.
70mm
Fix 2pcs of longitudinal brace bars with 8pcs of M8 size flange socket screws
Flip the
frame
Connection plates
Notice:
Only one leg has a connection plate, that plate must face to the machine flame side.
Other 3pcs of legs does not have that plate.
Lift the brush table from shipping with hook lope to the
eye screws on the top. If no crane there, the fork lift also
can be used.
Remove 2pcs of M8 size screws from the tops side yellow color bracket.
Notice
Be careful, Don’t pinch your fingers!
Down the table by the crane, then put wooden blocks under the table when make flat,
and take out the rope.
Wooden blocks
Lift the table with horizontal by the crane or fork lift. Then putting down the table to the
top connection plate of legs, and fix with 16pcs of M12 size screws.
Notice: Don’t make scratch when use the fork lift.
6)Refer to above procedure for both side support tables (front and rear side).
6.2 Put the support tables
1)Fixed tightly the joint brackets to the side of machine frame, front side and rear side.
Bind 4pcs air tubes and 1pc signal cable with the cable ties.
2)Move the table to the actual position, and fix the table with joint bracket hand tight
for level adjustment, then connect tubes and a cable.
Connector Tubes
3)Adjust the pass line height by the jack bolts check with eyes.
4)Refer to above procedure for both side support tables (front and rear side).
6.3 Installing Safety fence door (rear side)
1) Fixing the safety fence door to the rear side support table by 4pcs M8 screws.
2) Connect the cable (Inter-lock signal) that come from the machine side.
2) Connect 2pcs signal cable connector to the X-axis relay terminal box inside.
3) Connect one each red color and blue color air tubes to the one-touch fitting that
located around Y-axis runner flex.
4) Open the cover of the machine circuit breaker, and connect the shop power to the
machine circuit breaker.
5)Plug the foot switch connector in to the socket in the machine frame.
7)Fix the carriage cover front end one, then connect cable connector.
7)Connect the SUB control stand connector to the behind of electrical cabinet.
8)Connect the rear side fence cable connector to the behind of electrical cabinet.
Section 8
Adjusting X-axis
Positioning support tables
1) Move X-axis any direction over the 100mm for initialized ABS setting.
*FANUC motor can be initialized by rotating more than one turn.
2) Turn OFF the NC with NC OFF button is pressed.
3) Turn OFF the main breaker.
4) Turn ON again the NC with main breaker and NC ON button are pressed..
5) Adjust and fix same front end surfaces between first clamp front side and the clamp
rail front side.
6) Clamp a sheet metal, then move and make X-axis position gap 30mm between X-gauge
block and first clamp base end.
30mm
Center table
Turret
Feed table
Support table
Feed table
Support table
Beam
Notice:
Side beam fitting screws should be loosen when adjust the pass-line height, due to
keep stabilization of the table when adjust height.
5)Adjust pass-line of both side feed tables by adjustment screws under the tables.
6)Tighten screws between the joint brackets and support tables after complete pass-line
height adjustment.
Frame
Joint bracket
7)Adjust clearance gap approx 12mm between feed tables and support tables.
Confirm the equal clearance gap of 12mm along the length and the feed table.
Support table
Feed table
Must be same clearance
between A and B.
Turret Center table A B
Feed table
Feed table
Support table
Support table
8)Fix the front side support table to the floor strangeness. Put 8pcs M12 size all ancor
bolts on the special flange brackets. Due to the Front side support table has the
X-gauge block. That mast be not move.
Notice
Face the each ready-made flange brackets to the out side, due to the clearance gap must be
fix always between the feed table and support table.
MEMO
Section 9
Centering Turret
Checking Square-ness
9.1 Centering Turret
1)Check the square-ness by punch with test program after re-assemble the carriage.
G06A2.3B0
G92X2500.Y1270.
G93X0.Y0.
F4
G70G91Y-40.T349
G70G90X100.Y840.
G70G90X150.Y790.
G04X0.5
G91X0
G04X0.5
G70G90X100.Y275.
G70G90X150.Y225.
G04X0.5
G91X0
G70G90X700.Y275.
G70G90X750.Y225.
G04X0.5
G91X0
G04X0.5
G70G90X700.Y840.
G70G90X750.Y790.
G04X0.5
G91X0
M692
G50
2
1 1 2
3 4 3 4
Flip and place on the
second work sheet.
<Example>
When square-ness is checked, the upper punched holes are shifted right, and the lower punched holes are shifted left.
the diameter of largest pin gauge that can be inserted into these holes is 9.94mm.
1) Put the dial indicators against to the front and rear side edges of the carriage base.
2) Loosen all 12pcs screws on the carriage base.
Turret
11 10
10 12
12 8 9
3
4 1 5 6 2 7
HEX head screws under the feed
table (2pcs each at front and
rear total 4pcs)
1200
4)Turn the carriage base toward the rear by the calculated amount.
- In this example, turn it as shown right 0.06mm.
Turning carriage base
5)Secure again the carriage base and the front and rear tables.
(Tighten all the fasteners loosened before to turn the carriage base.)
- Check the dial indicators again to see that they read the same value.
6)Restart the machine, punch holes in another two work sheets, and check the square-ness.
2)Put the front side covet that is close to the machine flame, then put small cover under the
machine flame, then put the rear side cover that is close to the machine flame, then fix
those covers between covers and brackets.
The X-and Y-axes use absolute encoders and cannot be adjusted by shifting the grid. Adjust
them as described below.
1) Test punch with below program, then check accuracy X and Y.
G92X2500.Y1270.
G06A1.6B0 300
G90X100.Y100.T333
G91X300. 300
G91X300.
G 100
100
2) Adjust edge accuracy for X and Y-axes if out of target.
<X-axis> Adjust X-gauge block position.
<Y-axis> Move to actual origin point at MDI.
3) Set the X-axis origin and Y-axis origin.
1: Change the parameter setting No.1815 bit5 from 1 to 0, then setting of bit4
automatically changes to 0.
No.1815 Original setting New setting
X-axis 00110000 00000000
Y-axis 00110000 00000000
1) Reconfirm X-axis position, actually done this adjustment at section8,but have fixed front
side support table after that, so need to check again.
2) Retract origin.
3) Adjust and fix same front end surfaces between first clamp front side and the clamp rail
front side.
4) Clamp a sheet , then move and make X-axis position gap 30mm between X-gauge block
and first clamp base end.
30mm
12.1 Shift the duct hose location from left hand side to right hand side.
12 Installing Slug suction
12.1 Shift the duct hose location from left hand side to right hand side.
1) Remove the hose fitting from right hand side, then fix to the right hand side.
2) Put the blower unit under the front table, then fix the hose.
Hose band