Operation manual for auto duct manufacture line

ACL MACHINE CO.,LTD

Please read carefully this manual before using this system! Precautions during use:
1. Check the system for any damage occurred during the transportation and the

conformity of the items inside the packing case with the packing list after unpacking.
2. The input voltage to the electrical cabinet is AC380V 10% 50HZ, and the

input voltage to the NC part of CNC control system is AC22010%50HZ. Check the mains voltage for correctness.
3. Each part of the CNC control system shall have correct wiring and good contact

with the ground wire so as to ensure safety.

4. Ensure the CNC control system operates under relatively clean conditions as

possible as practical.
5. The CNC control system shall be managed by specially designated person, and

adequate training provided for the operator.

6. In case of any problem, please contact ACL MACHINE CO.,LTD. Never attempt

to disassemble or assemble the system when you do not have sufficient relevant knowledge and prior permission. 7. The technical indicators of this system are subject to change without further notice.

Index

Operation manual for auto duct manufacture line

ACL MACHINE CO.,LTD

Chapter 1. Overview
1.1 System composition 3 1.2 Technical indicators.5

Chapter 2. Operation panel definitions

2.1 System panel 6 2.2 Auxiliary panel .7

Chapter 3. Operating instructions

3.1 Main menu.8 3.2 Manual adjustment ...9 3.3 Automatic forming ...10 3.4 Error correction .11 3.5 Dimension resetting .11 3.6 Automatic feeding 11 3.7 Parameter setting .12

Chapter 1. Overview
1.1 System composition

Operation manual for auto duct manufacture line

ACL MACHINE CO.,LTD

The host computer used in the GASNUC-001S CNC control system of air duct mechanical assembly automatic production line developed by ACL MACHINE CO.,LTD employs high performance 32-bit microprocessor, and a precision all digital AC servo controller manufactured by Anchion Corp. Japan as driver unit, in addition to a 14 color high resolution display, a fully enclosed industrial touch keyboard as well as heavy current control interfaces. It features high reliability, precise cutting operation and easiness to use. GASNUC-001S CNC control system mainly consists of the following parts: 1. System unit:
a) The host computer of the numerical control system employs industrial control

purposed PIA-628 CPU board manufactured by Taiwan Qingyi Corporation, a world famous American industrial control system board and card manufacturer (CPU: 80386DX-40MHz, RAM:4MB, VGA graphic display control chip, resolution: 640*480)16 color). b) System general line motherboard IBM-PC standard 4-slot AT general line motherboard c) CNC control special card (CNC-02 card) Servo motor control signal interface (+5V TTL)

Main shaft pulse coder signal interface (+5V TTL)

Parameter memory (EEPRAM 8KB nonvolatile)

d) Input/output interface card (CNC-03 card) 16-way photoelectric isolation +24 V input point 16-way photoelectric isolation +24 V output point 1-way 0 V10V simulated main signal output
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2. Display/keyboard unit (system operation panel)

a) 14 high resolution color display

b) 67-key touch filmed keyboard

c) Keyboard control interface board (CNC-01 card)

3. Machine tool operation panel (auxiliary operation panel) a) Processing program [Start]/[Stop]key

b) System power supply [switch on]/[switch off] key

c) Emergency stop key

4. Driver unit
1. 9KW all digital industrial AC servo driver and motor (20A2A/20DA0, 1/43

and astral cycloid step-down gear

5. transformer 2000W adapter transformer (system/driver unit/heavy current) 6. Coder 1024-2400-thread feed length detecting coder

1. 2 Technical indicators a) Minimum pulse equivalent b) Maximum dimension setting 0.002 mm (settable) 9999.999mm
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c) Quick feed speed limit d) Operation modes

8000 mm/min Manual adjustment, automatic control, error correction, dimension resetting, automatic laying off, parameter setting

e)English character prompt for operation

Chapter 2. Operation panel definitions

2.1

System operation panel:

See the following figure, with description given below:

Operation manual for auto duct manufacture line

ACL MACHINE CO.,LTD

(1) Full letter key area ([A]-[Z]+[SP]) (2) Number key area ([0]-[9]+[-]+[.]+[ENTER]+[SHIFT]) (3) CTRL/RESET key

Operation manual for auto duct manufacture line

ACL MACHINE CO.,LTD

(4) MODE/ESC key

(5) [][][][][] cursor shifting key (6) [+/Ins][-/DEL][

]insert/delete/clear key, for use in selecting feeding directions during manual operation.

(7) [K1][K2] (Defined as Ready to Cut/Start to Cut respectively) 2.2. Auxiliary panel See the following figure, with description given below:

Start

Stop

Emergency Stop

(1) Power On/Off: The green key and red key control the switching on and off

of the entire system power supply respectively. (2) Emergency stop key: The system stops working and the motor is halted in an emergency manner. For use in case of emergency when the special parameter is set to 1. (3) [Start] key ([ ]): The green square key enables Start of processing program in the automatic molding mode. Press this key after Stop during processing process to resume the program. (4) [Stop] key ([ ]): The red square key enables Stop of operating program in the automatic molding mode. Press the [Start] key to resume the program.

Chapter 3. Operating instructions

3.1 Main menu: When the system is switched on, the screen display is shown as follows:

Operation manual for auto duct manufacture line

ACL MACHINE CO.,LTD

AML-III

DUCT MACHINE AUTO-LINCE CNCSYSTEM

This system display employs functional menu window prompts, with which any functional menu can be accessed by pressing key [F1]-F6] as required under the main menu or returned to the main menu by pressing key [MODE]/[ESC]. Manual adjustment: Press key [F1] to enable manual adjustment, used to feed or reject materials. Auto-molding: Press key [F2] to enable auto-molding, used to automatically perform the preprogrammed processing program. Error correction: Press key [F3] to correct the errors occurred during plate cutting operation. Dimension resetting: Press key [F4] to set the system parameters (including system parameters, machine tool parameters, cutting tool parameters, graphic parameters and configuration parameters) Automatic laying off: Press key [5] to lay off the materials in batches. Parameter setting: Press key [6] to set the system parameters. Most parameters have been set in factory before delivery. Users are not allowed to change the parameters during use unless with prior permission, including the fluctuating frequency curve, system pulse equivalent and configuration parameter. The following mechanical actions can be carried out under the main menu:

Operation manual for auto duct manufacture line

ACL MACHINE CO.,LTD

Press key [A]: to punch a square notch, press [ENTER] to confirm and [ESC/MODE] to cancel. Press key [B]: to punch a pointed notch, press [ENTER] to confirm and [ESC/MODE] to cancel. Press key [C], CS down, press [ENTER] to confirm and [ESC/MODE] to cancel. Press key [D], CS up, press [ENTER] to confirm and [ESC/MODE] to cancel.

Press key [K1]: ready to cut the plate, press [k2] to confirm and [ESC/MODE] to cancel. Press key [k2]: start to cut the plate, be careful of your safety.

3.2 Manual adjustment Under the main menu, press key [F1] to enter into Manual Adjustment Mode. The screen then displays: [1]: Continuous feeding [2]:Size adjustment

[Ins]: Feeding forward [Del]: Feeding backward Operations: Press key [F1] to select Manual Adjustment. When the Continuous Feeding becomes active (Press [1]), the materials move forward when key [+/Ins] is pressed down, or move backward when key [-/Del] is pressed down. When the Feeding by Size becomes active (press key [2]), first enter the Length value in mm). The materials move forward when key [+/Ins] is pressed down, or move backward when key [-/Del] is pressed down.

Operation manual for auto duct manufacture line

ACL MACHINE CO.,LTD

3.3. Automatic forming Under the main menu, press key [F2] to enter into Automatic Forming mode. The screen then displays: Front-end square opening allowance:.. Front square opening type 023:. end square opening allowance: Back-

Figure No.: Sheared opening A 0123 Sheared opening B 0123 Sheared opening C0123 backend opening 024 Quantity 1: pointed opening 2: Bend NO. [size] type [size] type [size] type [size] type NN3: CS down 4; CS up 1 2 3 4 5 [START]/[STOP] Press key [X] to enter data.

Operations: Press key [F2] to enter into Automatic Forming mode. Press key [X] to enter the process requirements and quantity to be process. Type description:
1.

Pointed opening Bend CS down CS up

2. 3. 4.

0: No action

5 6

1. Front-end square notch 2. Sheared notch A

3. Sheared notch B

4. Sheared
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notch C

5. Backend notch 6. Backend square notch

After entering the data, press [ESC/MODE] to quit. Then press key [START] to start processing. 3.4 Error correction Under the main menu window, press key [F3] to enter into Error Correction mode. The Error Correction mode is mainly used to correct the dimensional variation resulting from improper input value of pulse equivalent. The screen displays and operations: Set length:--------Actual length: --------Confirm (Y/N):--------After entering the data, press key [Y] to confirm, at this point, the pulse equivalent in the system parameters will be modified.

3.5 Dimension resetting Under the main menu, press key [F4] to display the Dimension Resetting.

3.6 Automatic laying off It is mainly used to lay off the materials in batches. The screen displays and operations: Length:--------Quantity: --------To start, press key [START]! After entering the values of length and quantity, press key [START] to start laying off materials. 3.7 Parameter setting
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Under the main menu, press key [F6] to enter into Parameter Setting mode. The screen displays: [1]: System parameter [2]: Configuration parameter Please enter the password: ***

Operations: To enter into the Parameter Setting menu, first enter a 3-digit password. The screen displays OK when the password is correctly entered, then proceed with the following operations. Press key [1] to enter into System Parameter Setting. Press key [2] to enter into Configuration Parameter Setting. Press key [MODE] to return to the main menu. Note: * After parameter setting, the set parameters will be saved permanently. * Change to some key parameters will affect the system performance. Nonprofessional person is not allowed to change any system internal parameter without prior permission and adequate familiarity. 3.7.1 System parameter setting In the Parameter Setting mode, press key [1] to enter into the System Parameter Setting.
The screen displays:

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System parameters
Rapid limit [mm/min]: 6000 Pulse unit[mm/p]:0.00696000 Accelerate Curve Frequency Interval [CTC]A6000 Frequency Interval [CTC]B5000 Frequency Interval [CTC]C4000 Frequency Interval [CTC]D3000 Frequency Interval [CTC]E2000 Frequency Interval [CTC]F1000 Frequency Interval [CTC]G800 Frequency Interval [CTC]H600 Frequency Interval [CTC]I400 Frequency Interval [CTC]J200 curvature correction+10 curvature correction+50 curvature correction+20 curvature correction+10 curvature correction+20 curvature correction- 2 curvature correction-5 curvature correction-10 curvature correction-50 curvature correction-100

Decelerate Curve Frequency interval[CTC]J200 Frequency interval [CTC]I400 Frequency interval [CTC]H600 Frequency interval [CTC]G800 Frequency interval [CTC]F1000 Frequency interval [CTC]E2000 Frequency interval [CTC]D3000 Frequency interval [CTC]C4000 Frequency interval [CTC]B5000 Frequency interval [CTC]A6000 curvature correction-100 curvature correction-50 curvature correction-10 curvature correction-5 curvature correction-2 curvature correction+2 curvature correction+10 curvature correction+20 curvature correction+50 curvature correction-10

Operations: Press key [] to move the cursor up. Press key [] to move the cursor down.

Press key [] to move the cursor left. Press key [] to move the cursor right. Press key [ENTER] to move the cursor to head of the next line. Press key [-] to delete the character where the cursor points to.
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Press key [+] to insert a space where the cursor points to. Press key [ ] to clear all the characters behind the cursor. Press key [MODE] to return to the main menu. Instructions: * The high back speed means the maximum speed limit for feeding. The maximum speed limit is dependent on the connection methods used in transmission part of the machine tool and the motor loading capacity, usually with a 20% allowance. Range: 1000-8000mm/min. * The value of fluctuating frequency curve is used to control the acceleration and deceleration process of the motor and has significant impact on the maximum efficiency and guaranteed precision of the motor itself. Its numeric area has direct relations with the conditions of loading of the machine tool itself and motors characteristics. The up/down frequency curve has 10 intervals in total:

The value input in the left column is CTC internal fractional frequency, with the minimum unit of 1/8 Mhz. The higher the value is, the lower the frequency will be. The value input represents the span between the 10 continuous intervals.

The value input in the right column is the CTC internal correction. <+> represents the value of change to CTC in every step, the higher the value is, the faster the acceleration will be. <-> represents the number of tempo for stop of CTC in every step, the higher the value is, the slower the acceleration will be. 3.7.2 Configuration parameter setting In the Parameter Setting mode, press key [2] to enter into the Configuration Parameter Setting. The screen displays:
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System Parameters Motor pulse output mode: X+L0 X+H1 X+L0 X+H2

Pulse coder line number: 1200 Pulse coder test shaft diameter: 100 EEPROM write-in delay constant: 40000 Motor pulse delay constant: 2 Square opening lower punch control period: 1 Square opening uplift control period: 1 Pointed opening lower punch control period: 1 Pointed opening uplift control period: 1 CS machine push up control period: 1 CS machine uplift control period: 1 Materials compressing control period: 1 Materials loosing control period: 1 Sheared plate closing control period: 1 Sheared plate opening control period: 1 Bend upturn control period: 2.5 Bend dropdown control period: 3.0 Reference point to square notch distance:165 Reference point to pointed notch distance: 000 Reference point to CS machine reversal point distance: 000 Reference point to shear distance: 922.5 Reference point to bender distance:1039.5 Square notch width: 30 Special parameter: 0 Operations: Press key [] to move the cursor up. Press key [] to move the cursor down. Press key [] to move the cursor left. Press key [] to move the cursor right. Press key [ENTER] to move the cursor to head of the next line. Press key [-] to delete the character where the cursor points to. Press key [+] to insert a space where the cursor points to. Press key [ ] to clear all the characters behind the cursor. Press key [MODE] to return to the main menu.

Instructions:
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Operation manual for auto duct manufacture line

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* The motor pulse output format definitions:

7 6 5 4 3 2 1 0
-pulse + pulse

Motor conversion: Motor running forward <> Motor running backward 1<>2. * EEPROM Write-in delay constant: (30000-60000), used to modify the delay time for writing data into EEPROM. The higher the value is, the longer the waiting period will be. * Motor pulse delay constant: (1-10), used to modify the width of feeding pulse signal sent from CNC-02 card to the driver unit. The higher the value is, the wider the pulse width will be. If all the relay action control periods are set to zero, the system will wait for answer signal of corresponding action. If the special parameter is set to 1, the emergency stop key and [START]/[STOP] functions of auxiliary panel become active.

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Equipment limit linear diameter of 2.5 mm2 recommended 2.5mm2 Marking occurence number Revised Document No. Signature Date
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Design Verification Inspect Standardization Approval Design mark Weight Ratio ACL MACHINE CO., Ltd Production lines I and III

1. System composition (see the system location map). The system consists of following parts. 1.1 Host computer system Including industrial control board, special board, input/output board and switching power supply. 1.2 System operation panel Including the display, operation keyboard, keyboard control interface board
1.3 Auxiliary operation panel

1.4 Heavy current board (input/output) 1.5 Heavy current panel

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1.6 Ancheon servo shaft and Ancheon motor 1.7 Adapter transformer Schematic circuit diagram

Servo () CRT KEY panel Main board () System power supply Operation panel () Fan () 03 card (03 ) 02 card (02 ) Industrial control () Heavy current panel () Transformer () complex wiring description Relay board () Gating () Input signal () Servo feedback () Coder () hydraulic motor () Output signal Servo motor () Stepping motor dynamic electricity ( ) patch panel

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2. Host computer system jack definition and connections

2.1 Industrial control board jack definition and external connections. 2.1.1 Industrial control board has two plugs: VGA jack and keyboard jack (See the Industrial Control Board User Manual).

Keyboard jack 1 Clock 2 data

VGA jack

keyboard adapter definitions 5 +5V

3 null 4 GND

VGA (15-pin jack)

VGA interface definitions PIN 1 3 DESCRIPTIONPIN PIN visual output(red) 2 visual output(blue) 4 DESCRIPTION visual output(green) NC
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5 7 9 11 13 15

GROUND GROUND NC NC horizontal synchronization NC

6 8 10 12 14

GROUND GROUND GROUND NC vertical synchronization

2.1.2 Industrial control board cabling

Keyboard jack

Display power supply Industrial control board

System operation panel

a. Keyboard cable
KEY

5-core cylindrical plug (pinhead)

9-core pinhead

KEY connection point 1 2 4 5

XI connection point 1 2 4 5

Description Clock Data GND +5V

b. VGA cable See the Industrial Control Board User Manual. 2.2 Special board plug definition and external connections

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Detecting coder jack Motor given jack Special board Coder Servo shaft Motor given Motor coder Servo power supply Motor drive 2.2.1 The special board has two plugs: J1 motor given interface and J2 detecting coder interface. J1 1 7 9 15-core jack definition XCW XCOM XCCW

J2 1 2 3 4 5 6 7 8 9 2.2.2 Special board cabling a. Motor given cable

9-core pinhead definition VCC A* B* Z* GND A B Z GND

50-core (50 ) ;15-core pinhead 15 ) ;Rid of heavy current board Servo shaft ICN Special board JI Connection point Connection Heavy current XT0 point Connection point number Remarks

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number 8 12 711 29 40 30 47

number 1 9 7 B8 A17 B3 B2 XCW XCCW XCOM 180 S-RDY S-ON 24VGND +24V

b. Detecting coder cable

9-core pinhead 9 ; adapter Detecting coder

Special board J2 Patch panel Connection point Connection number number 1 1 2 2 3 3 9 4 5 5 6 6 7 7

2.3

Detecting coder point Connection point number 68 13 15 10 12 1 3

Remarks

VCC A* B* GND GND A B

Input/output board jack definition and external connections

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Input/output board /

Heavy current board

2.3.1 The input/output board has two plugs: J1 output interface and J2 input interface.

a. J2 input cable Input/output J2

heavy current board J2

25-core port head

25-core port head

Signal connections are made in one-to-one correspondence manner. b. J1 output cable Input/output J1

Heavy current board J1

25-core pinhead 25-core pinhead Signal connections are made in one-to-one correspondence manner.

2.4

Motherboard plug and connections.

Motherboard supply socket Pin number 1 2 3 4 5 Definition POWER GOOD +5V +12V -12V GND Color Orange Red Yellow Blue Black
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6 7 8 9 10 11 12

GND GND GND -5V +5V +5V +5V

Black Black Black White Red Red Red

2.4.1 Motherboard power supply connection

Motherboard, 6-core Power supply

3. Servo shaft plug definition and connections

Servo shaft manual controller jack 1CN(50-core) given jack connection to special board J1 2CN(20-core) feedback plug connection to servo motor coder plug Patch panel Servo motor 3.1 Feedback cable Servo shaft 2CN

Patch panel

Motor coder

Remarks

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Connection point Connection number number 16 1 17 2 18 3 19 7 14 5 15 6 8 456 9 123 20 10

point Connection point number A B C D E F H G J

A A* B B* C C* +5V 0V Shielding layer

3.2 Servo driven cable

Servo shaft

Motor

Motor 1 2 3 4

Terminal U V W PE

Color Red White Blue Green

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System location map Front view back view

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wiring slot ; Servo ; host computer ; Power supply ; Front side of the cabinet ;04 board 04 Patch panel ; Ground wires ;Transformation 24V relay board description 1. Functionality 16-way input switchover, each way has a red light indicator. 16-way relay output, each way has a red light indicator. 24V AC input is outputted as 2V DC through voltage stabilizer, with the lit red light indicating the power supply is normal. 2. Plug and terminal block definition J1output plug: Switched over from the system J2input plug: Switched over from the system J3input terminal: Connected to machine tool
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J4output terminal: Connected to the machine tool or heavy current control 2.1 J1 output point definition Point number 1 2 3 4 Designation O0 O2 O4 O6 Point number Designation 14 O1 15 O3 16 O5 17 O7

5 O8 18 O9

6 O10 19 O11

7 O12 20 O13

8 O14 21 O15

12 24V power supply 24 24V power supply

13 24V grounded 25 24V grounded

2.2 J2 input point definition Point number 1 2 3 Designation I0 I2 I4 Point number Designation 14 I1 15 I3 16 I5

4 I6 17 I7

5 I8 18 I9

6 I10 19 I11

7 I12 20 I13

8 I14 21 I15

12 24V power supply 24 24Vpower supply

13 24V grounded 25 24V grounded

Point number Designati on

2.3 J3 input terminal definition Printed board, from left to right > 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8

1 0 1 9

11 11 0

12 11 1

13 11 2

14 11 3

15 11 4

16 11 5

17 24VGr ounde d

18 24Vpo wer supply

2.4 J4 output terminal definition

Point number Designation Point number Designation A1 -24A B1 -24 B A2 24A B2 +24 V A3 O0 A B3 O0 B A4 O1 A B4 O1 B A5 O2 A B5 O2 B A6 O3 A B6 O3 B A7 O4 A B7 O4 B A8 O5 A B8 O5 B A9 O6 A B9 O6 B A10 O7 A B10 O7 B A11 O8A B11 O8B A12 O9A B12 O9B A13 O10 A B13 O10 B A14 O11 A B14 O11 B A15 O12 A B15 O12 B A16 O13 A B16 O13 B A17 O14 A B17 O14 B A18 O15 A B18 O15B

*Note: A and B are a pair of open contacts.

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3. Light up definition 3.1 Input terminal light up (red light) definition Printed board from right to left
silk-screen printing Designation D33 10 D34 11 D35 12 D36 13 D37 14 D38 15 D39 16 D40 17 D41 18 D42 19 D43 110 D44 111 D45 112 D46 113 D47 114 D48 115

3.2 Output terminal light up (red light) definition

Silk-screen printing Designation D17 O0 D18 O1 D19 O2 D20 O3 D21 O4 D22 O5 D23 O6 D24 O7 D25 O8 D26 O9 D27 O10 D28 O11 D29 O12 D30 O13 D31 O14 D32 O15

3.3 Power light indicator (green light)D49

4Size and location map of printed board.

5. Input point definition descriptions 16servo ready 17emergency stop 18sheared plate closed 19sheared plate open 110.bend upturn
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111bend dropdown 112compressing tightened 113compressing loosened 114Start 115Stop

6. Output point definition description 0 Square notch down 1Square notch up 2Pointed notch down 3Pointed notch up 6Servo ready 7Heavy current ready 8Sheared plate closed 9Sheared plate open 10Bend upturn 11Bend dropdown 12Compressing tightened 13Compressing loosened 14Hydraulic backflow 15Hydraulic motor

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