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2. medicine
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IEF Werner GmbH
Handhabungstechnik
posyART
IEF Werner GmbH
Wendelhofstraße 6
Phone: 0049-(0)7723 / 925-0
Fax: 0049-(0)7723 / 925-100
www.IEF-Werner.de
[email protected]
D-78120 FURTWANGEN
December 2003
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IEF Werner GmbH
Handhabungstechnik
The use of trademarks and trade names does not affect their legal status. These texts and
examples were written with the utmost care. Nonetheless, errors cannot be ruled out. Special
applications cases were not considered for the examples given. The use of the examples
printed requires close checks on, for instance, the traverse distance or an acceleration value.
IEF WERNER GmbH is neither legally responsible nor liable in any way for missing or
erroneous information and its consequences.
IEF Werner reserves the right to change or improve software or hardware or parts thereof,
including the printed matter supplied or parts thereof, without prior notification. All rights to
copy (to photomechanical reproduction), even excerpts, are expressly reserved by IEF
WERNER GmbH.
We are always grateful for suggestions for improvements and notices of errors.
© November 2001 by IEF WERNER GmbH
posyArt Version 8.0
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Handhabungstechnik
Contents
1
2
Introduction
9
1.1 Generalities
9
1.2 Extension of the system
9
1.3 Function
10
1.4 Safety
11
1.5 Ranges of Application & Application examples
11
1.6 Example of application
12
1.6.1 Example of application 1
12
1.6.2 Example of application 2ppli
13
1.6.3 ca Example of application 3
14
1.7 Technical data
15
1.8 Loads
16
1.9 Construct with posyART
18
1.9.1 Replacing of belts
18
1.9.2 Connections with the transporting system
18
1.9.3 Clearances around posyART components
18
1.9.4 Clearance for dismounting of shafts
18
1.9.5 Clearance for dismounting of shunts and other components
18
Basic forms of the conveyor belts
21
2.1 Generalities
21
2.1.1 General maintenance instructions for
SIMPLEX and DUPLEX system
22
2.1.2 General errors of SIMPLEX and DUPLEX system
22
2.1.3 General repair instructions for SIMPLEX and DUPLEX system
23
2.2 DUPLEX -belt
24
2.2.1 Driving unit
24
2.2.2 Figures of posyART DUPLEX
25
2.3 SIMPLEX belt
29
2.3.1 Driving unit
3
29
Basic elements for change of direction in conveyor systems
33
3.1 Generalities
33
3.2 Rocker
34
3.2.1 Generalities
34
3.2.2 Description
34
3.2.3 Fitting instructions
34
3.2.4 Delivery volume
34
3.2.5 Maintenance instructions
35
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3.2.6 Cycle times
35
3.2.7 Figures of the rocker
36
3.3 Shunt
38
3.3.1 Generalities
38
3.3.2 Description
38
3.3.3 General sequence of operations:
38
3.3.4 Fitting instructions
38
3.3.5 Delivery volume
39
3.3.6 Maintenance instructions
39
3.3.7 Table of disturbances
39
3.3.8 Repair Instructions
40
3.3.9 Cycle times
40
3.3.10 Figures of the shunt
41
3.4 Curve 90° / 180°
4
49
3.4.1 Generalities
49
3.4.2 Description
49
3.4.3 Fitting instructions
49
3.4.4 Delivery volume
49
3.4.5 Maintenance instructions
49
3.4.6 Table of disturbances
50
3.4.7 Repair Instructions
50
3.4.8 Figures of the curve
51
Individual extensions of subassemblies
53
4.1 Generalities
53
4.2 Subassembly stopper
54
4.2.1 Generalities
54
4.2.2 Description
54
4.2.3 Fitting instructions
54
4.2.4 Delivery volume
54
4.2.5 Maintenance instructions
55
4.2.6 Table of disturbances
55
4.2.7 Repair Instructions
55
see fitting instructions
55
4.2.8 Figures of subassembly stopper
4.3 Subassembly centring unit
56
58
4.3.1 Generalities
58
4.3.2 Description
58
4.3.3 Fitting instructions
58
4.3.4 Delivery volume
58
4.3.5 Table of disturbances
59
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4.3.6 Repair Instructions
59
4.3.7 Cycle times
59
4.3.8 Figures of subassembly centring unit
60
4.4 Centring unit with active skip
64
4.4.1 Generalities
64
4.4.2 Description
64
4.4.3 Fitting instructions
64
4.4.4 Delivery volume
64
4.4.5 Table of disturbances
65
4.4.6 Repair Instructions
65
4.4.7 Figures of subassembly centring unit with active skip
66
4.4.8 Cycle times
70
4.5 Subassembly lift-and-revolve unit
71
4.5.1 Generalities
71
4.5.2 Description
71
4.5.3 Delivery volume
71
4.5.4 Table of disturbances
72
4.5.5 Repair Instructions
72
4.5.6 Figures of the subassembly lift-and-revolve unit
73
4.5.7 Cycle times
77
4.6 Subassembly lifting unit
78
4.6.1 Generalities
78
4.6.2 Description
78
4.6.3 Fitting instructions
78
4.6.4 Delivery volume
78
4.6.5 Table of disturbances
79
4.6.6 Repair Instructions
79
4.6.7 Figures of the subassembly lifting unit
80
4.6.8 Cycle times
83
4.7 Carrier
84
4.7.1 Generalities
84
4.7.2 Description
84
4.7.3 Delivery volume
84
4.7.4 Figure of subassembly carrier
85
4.8 Subassembly lift-and-tilt station
86
4.8.1 General
86
4.8.2 Description
86
4.8.3 Fitting instructions
86
4.8.4 Delivery volume
86
4.8.5 Maintenance instructions
86
4.8.6 Table of disturbances
87
4.8.7 Repair Instructions
87
Cover sheet
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4.8.8 Figures of subassembly lift-and-tilt station
4.9 Sensor
90
4.9.1 Generalities
90
4.9.2 Description
90
4.9.3 Delivery volume
90
4.9.4 Figure of complete subassembly sensor
91
4.10 Reading head
92
4.10.1 Generalities
92
4.10.2 Description
92
4.10.3 Delivery volume
92
4.10.4 Figure of subassembly reading head
(horizontal and vertical assembly)
93
4.11 Subassembly lateral positioning contrivance
94
4.11.1 Generalities
94
4.11.2 Description
94
4.11.3 Delivery volume
94
4.11.4 Figures of the subassembly lateral positioning contrivance
95
4.12 Subassembly passive lowerator
5
88
97
4.12.1 Generalities
97
4.12.2 Description
97
4.12.3 Fitting instructions
97
4.12.4 Delivery volume
97
4.12.5 Maintenance instructions
97
4.12.6 Table of disturbances
97
4.12.7 Repair Instructions
97
4.12.8 Figure of subassembly passive lowerator
98
Accessories
101
5.1 Generalities
101
5.2 Clamping element
101
5.2.1 Description
101
5.2.2 Delivery volume
101
5.2.3 Figure of accessories - clamping element
102
5.3 Supporting foot
103
5.3.1 Generalities
103
5.3.2 Description
103
5.3.3 Delivery volume
103
5.3.4 Figure of accessories - duplex belt support
104
5.4 Stand
105
5.4.1 Generalities
105
5.4.2 Examples of application: Case 1 and 2
105
5.4.3 Example of application: Case 3
105
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5.4.4 Description
105
5.4.5 Delivery volume
105
5.4.6 Figure of subassembly stand
106
5.4.7 Retrofitting of carriers
109
Assembly instructions
110
6.1 General assembly and repair instructions
110
6.2 Belt replacement
111
6.3 Tensioning the belt
112
6.4 Shifting the drive
113
Cover sheet
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1 Introduction
1.1
Generalities
The transporting and positioning system posyART is structured as follows.
The basic element of the workpiece transporting device consists of the transport line with the
revolving belt band or toothed belt band. It can be installed parallel as a single unit (posyART
SIMPLEX system), as well as a double unit (posyART DUPLEX system).
A number of spacers facilitate different widths of the double lines. Since every base
component functions independently, the different models can be varied as required.
1.2
Extension of the system
By means of numerous subassemblies, PosyART DUPLEX can be extended in accordance
with any requirements.
Using the different subassemblies as shunt, curve or rocker, square or rectangle circle forms
can be assembled. The curve guarantees retention of the orientation of the carrier.
Using the shunt subassembly, the outward or inward transfer of carriers can be accomplished,
provided that the secondary lines are coupled to the main line either parallel or right-angled.
Complete parallel lines in rectangular form can be coupled. The rocker device of the posyART
system provides an excellent solution to transfer carriers. The subassembly lift elevator allows
for the carrier to be transferred from one level to the a different one.
Due to the universality of the posyART system we are able to create everything from simple
feed-and-discharge lines to complex installations featuring automatic stations and manual
labour workplaces, in accordance with any requirements.
The modular structure of the whole system allows easy assembly, disassembly, maintenance
and repair of all posyART subassemblies.
NOTE
Warning: Clearances are required for assembling and disassembling
subassemblies and individual components. These clearances are given in the
subassembly illustrations. In case of customised components being used,
please contact us prior to assembly and read carefully chapter 2.7 "Construct
with posyART".
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Chapter 1
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1.3
Function
With the posyART transporting and positioning system, the material to be transported is
conveyed on motor-driven belt bands or toothed belt bands. The load transmission between
belt and the material to be conveyed is done within the system in connection with the carrier.
The following is intended to explain the posyART-DUPLEX system. They describe how the
system works and what the sequence of operations looks like.
The material to be conveyed is a workpiece being processed on a carrier. With the
transporting and positioning system, the workpieces are transported further along the line
without having to be lifted off.
The workstations are automatic stations and manual labour workplaces in accordance with
your requirements. There is friction between the carrier and the belts. Due to that, the carrier
may be stopped at any point of the constantly moving belts. Thus, the individual stations can
be coupled loosely. Via clocked de-coupling and storage facility, the circulating systems can
be used flexibly. The passage of the carrier needs to be controlled in accordance with the
manufacturing instructions and the corresponding state of processing.
The control system captures every operating sequence as well as the system conditions.
Every carrier can be equipped with an encoded item, which can be read at any point in
accordance with the given requirements. With this encoded item, data assignment to the
carrier in question can be controlled. With the posyART DUPLEX system, numerous
manufacturing and fitting tasks can be performed in various production environments.
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1.4
Safety
The installation is to be initialised by skilled staff only, who have been introduced to the job
and can anticipate possible hazards. The following topics have to be read through carefully
prior to operation of the corresponding installation. Please make sure that there are no
questions left unanswered.
•
•
•
Case 1:
The transport line is used as an independent subassembly, chapter 4 and 7 of the documentation
Case 2:
The transport line is used in conjunction with other posyART subassemblies, same as
case 1 and additional chapter 5 of the documentation as well as the description of Interbus, Profibus-DP, RS232 in the Interface Manual by IEF Werner GmbH and
Case 3:
the posyART system is completed with customer specific elements, as in case 2 plus the
operating and programming manual for the posyART control station.
Before undertaking any assembly, dismantling or repair work on the installation, turn off the
power and release the pressure.
Plugs may only be connected and/or removed when inactive.
The transport line subassembly features the appropriate safety contrivances, in accordance
with EN 292-1 and EN 294.
When joining posyART subassemblies (as in case 2 and 3), please result the descriptions in
question for information on the appropriate safety contrivances.
Do not operate the installation (in accordance with case 3) until you are certain that the device
to be integrated meets the standards laid out in the EU equipment 89/ 392/ EWG, 93/ 44/
EWG and 91/368/EWG, or the corresponding national standards. You should also ensure
conformance with the equipment guidelines supplied by the machine’s manufacturer or
supplier.
1.5
Ranges of Application & Application examples
The posyART transporting and positioning system is used in the industrial sector. There are
three different types of application:
•
•
•
The transport line is used as an independent subassembly.
The transport line is used in conjunction with other posyART subassemblies.
posyART is used in conjunction with customised components.
This shows how versatile posyART is. It can be used in simply material conveyance but also
in complex assembling and productions lines in the packaging, precision mechanics, tool
manufacture, timber or consumer goods industry.
The transportation of animals or humans is strictly prohibited. The conveying belt needs to be
protected where operations producing many chaps or resulting in heavy soiling are carried out.
The turntable cannot be used in the chemical, foodstuffs or ex sector without supplementary
equipment. In case of doubts ask the producer.
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1.6
Example of application
The following representation is intended to give a brief overview of the feasible applications of
the posyART-DUPLEX system. We would be pleased to also furnish you with a CAD layout
for your application.
1.6.1
Example of application 1
Cross ways
Curve 180°
Driving unit
Centering unit
Pilot stopper and
stopper
Horizontal
stretch
Driving unit
Centring unit
Shunt (corner)
Pilot stopper
with sensor
Pilot stopper and
stopper
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1.6.2
Example of application 2ppli
Lift elevator 2
Centring station
Belt band 1
(top belt)
Driving unit
Support
Pilot stopper and stopper
Belt band 2
(bottom belt)
Lift elevator 1
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1.6.3
ca Example of application 3
Curve 180°
Rocker belt
Main line
Secondary line
Outward transfer
rectangle
rocker, extendable
as required
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Stations or manual
work places
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1.7
Technical data
transport height
900 mm
! other sizes on request!
max. length of line with 1 drive
4000 mm
! other sizes on request!
max. width of track
400 mm
! other sizes on request!
guide accuracy
+/- 0,5 mm
WT in the tracking channel of the
guide bead
Belt speed
6, 8, 13 or 16m/min
! other sizes on request!
max. carrier load
200N / carrier
transport load
barrage load drive of flat belt
400N(SIMPLEX) 750N(DUPLEX)
belt band TT5/1 (antistatic)
barrage load of the tooth belt drive
650N(SIMPLEX) 1200N(DUPLEX)
Toothed belt band 20AT5-PARPAZ
Type of belt band
belt band TT5/1 (antistatic)
toothed belt band 20AT5 PARPAZ
Connection conditions Pneumatic
4-6 bar oiled or not oiled, purified
air
Connection conditions Electric:
threephase current 5-connecting
strip (L1, L2, L3, N, PE)
Type of drive of the conveyor belt
threephase gear motor
worm gear pair
Type of drive of the curves
threephase gear motor
spur gear
Type of drive
threephase gear motor
worm gear pair
net performance
drive of belt band 0,18 KW;
drive of shunt 0,045 KW;
drive of curve 0,09 KW
! other sizes on request!
norminal voltage
230 / 400 V
! other sizes on request!
Frequency
50Hz
! other sizes on request!
drawing of current
drive of belt band 0,7 A
drive of shunt 0,25 A
drive of curve 0,4 A
norminal rotational speed
drive of belt band 1350 U/min;
drive of shunt 1350 U/min;
drive of curve 910 U/min
gear reduction
respectively desired tape speed
Drift moment
18 -42 Nm
according to the type of motor
used
fine graduation of the speed
20 % - 100 % optional regulation
with frequency converter
operating time
100 %
safety class
IP 55
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! other classes on request!
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1.8
Loads
During a series of test measuring the load-carrying capacity of a posyART DUPLEX belt, an
almost linear course of deflexion became apparent.
Measurement
200mm
500 – 3000 mm
kg
kg
Conditions:
Size of carrier:
200 mm
Weight of carrier:
5kg – 80 kg
posyART width:
200 mm
Measuring result of deflexion in mm:
l (mm) / m (kg)
5
10
15
20
30
40
3000
0,35
0,80
1,200
1,600
2,50
3,350
2500
0,34
0,50
0,730
0,980
1,48
1,950
2000
0,11
0,23
0,340
0,450
0,72
0,920
1,890
1500
0,05
0,09
0,140
0,195
0,31
0,410
0,810
1000
0,02
0,04
0,055
0,070
0,11
0,135
0,265
500
0,01
0,02
0,025
0,030
0,04
0,045
0,070
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Analysis
Db [mm]
3000 mm
3,5
3,0
2,5
2500 mm
2,0
2000 mm
1,5
1,0
1500 mm
0,5
1000 mm
500 mm
0
0
40,0
80,0
Deflexion in mm
Mass in kg
In case of the load being placed in the centre, the deflexion of the sustainer profiles is linear.
Should the load exceed 40 kg, we would advise you to ensure that the clamping’s interspace
is less than 3 m (for customised mounts).
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1.9
Construct with posyART
1.9.1
Replacing of belts
The endless belts can only be replaced when a minimum distance from the belt band profile to
the support of the spacer of 30 mm (tabletop, stand) is upheld (refer to Technical
documentation, chapter 7.2).
This distance is needed to push the tension roller of the drive to the end of the belt band
profile. A countersinking of the groove, where the tension roller is being guided is placed at the
end of the profile. The tension roller can be taken out downwards.
1.9.2
Connections with the transporting system
Fixed connections from the outside of the belt band profile to the stand must be avoided, when
a finished belt is installed. These connections must be removed, to be able to remove the old
belt from the system and install the new belt on the belt band.
If sensors or other assemblies should be needed to be fixed on the belt band, they must
always be fixed at the inner side of the belt band profile using a clamping element or a spacer.
1.9.3
Clearances around posyART components
Please ensure the size of openings in tabletops of manual workplaces for shunts or drives if
necessary. This is important, to enable access to these components in case of necessary
maintenance work.
1.9.4
Clearance for dismounting of shafts
Make sure that driven shafts can be taken out at one side. Furthermore, ensure space to be
able to loosen the shaft fixing screws.
1.9.5
Clearance for dismounting of shunts and other components
Most components of the posyART system can be taken out downwards from the belt band
profile. Please take into account the clearances below the belt band system to be able to
replace these components.
Distance between the belt bands
If a production line is assembled of several single belt bands, please ensure a space of 7 mm
between two belts, to be able to clip "covering cap up" to each belt (refer to figure “posyART
coupling / clearances” on the next page.
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posyART coupling / clearances
Covering cap up
7,5
Clearance for belt
replacement
65,0
170,0
Clearances for replacing the belts
5
The clearance has to be the same all along the transport line. If posyART subassemblies are
to be fixed to the sustainer profile, the clearance changes in accordance with the size in
question.
7
30
Spacer
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2 Basic forms of the conveyor belts
2.1
Generalities
The transport line is the base unit of the posyART system.
The number of lines running parallel is the explanation for the order names: SIMPLEX for one
single line and DUPLEX for a double line. The whole conveyor belt is available as strap belt or
as toothed belt band.
The DUPLEX system is designed for the following WS sizes: 160, 200, 240, 320 and 400 mm.
Other sizes of carrier on request.
PosyART is a conveying system which does not require a specific type of workpiece carrier!
Some subassemblies, however, require a posyART carrier to function perfectly.
The transport line is used as a continuous horizontal stretch. The maximum length of a driven
posyART stretch is 4000mm and is available in graduations of 500mm.
Longer stretches can be obtained by coupling several powered posyART lines. Coupling does
not constitute a problem. The end pieces of the sustainer profile are covered. For information
on the load carrying ability of the sustainer profile and on chucking, please refer to the
Technical Data in section 1.6. The pile-up loads refer to the drive and are documented in the
Technical Data.
The width of track of the transport line is fixed by spacers for the posyART DUPLEX system.
Coupling the posyART lines to the subassembly "curve" requires corresponding end pieces of
the lines. When ordering, please indicate the coupling in question. In general, the details given
relate to the moving direction.
Fundamentally, the transport line and the stand have to be anchored firmly to the ground.
Clamping brackets are available for anchoring posyART stands. If a customer intends to use
his/her own stands, the charge coefficients (chapter 1.7) are strictly to be adhered to. The
connection between stand and transport line has to be of such a kind that the bearing is being
steadied. The height can be adjusted via the adjustable pedestals of the posyART stands.
Every spacer features 2 headless pins with thrust pieces allowing precise adjustment and
levelling of the transport line. For information on how to shift the driving unit and how to
tension the belt, please refer to chapters 4.2 and 6.3.
When positioning the driving unit, please ensure a clearance of 250mm at both sides of the
centre of the actuation. It is needed when removing spanners or spanner pieces.
Free access is also crucial for changing the belt. There have to be clearances in case of
customer specific installations surrounding a transport line. These clearances are given in the
section 1.8.
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Kapitel 2
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2.1.1
General maintenance instructions for SIMPLEX and DUPLEX system
For trouble free operation, the degree of soiling of the transport line has to be as low as
possible. Dirt and shavings in the area of the revolving belts should be removed according to
the given conditions. The geared motors feature a lifetime lubrication. It is recommended to
check for excessive loss of lubricant after 100 hours of service (every 1000 hours later on).
All bearings have been installed with sealed anti-friction bearings. They feature a lifetime
lubrication (grease). The primary shaft plus bearing rests are to be re-greased every 300
operating hours (grease ISOFLEX super LDS 18). At the same time, the belt tension is to be
checked (refer to chapter 6.3).
Belt bands or toothed belt bands may be treated with a corresponding care spray to reduce
wear out of belts, belt guidance and sliding blocks on the carrier. Please notice the safety tips
and regulations of the manufacturer on the spray can.
2.1.2
General errors of SIMPLEX and DUPLEX system
Disturbance
Cause of disturbance
Remedying disturbance
nominal service life of anti-friction
bearings exceeded
replace driving unit and reversing unit
anti-friction bearings worn out due to
overload (the bearing rest of the
driving unit not in true alignment)
replace the complete driving unit (observe
alignment of the bearing rests)
reversing unit worn out
replace reversing unit
driving unit worn out
replace driving unit
geared motor defective
replace geared motor
inside of the toothed belt bands or
belt bands soiled heavily
replace belts and eliminate cause of soiling
belts damaged
replace belts
geared motor defective
replace geared motor
geared motor incorrectly connected
Check pin connection and change if needed
motor cable defective
check motor cable, replace if necessary
Belt band sliding on the driving roller
(when using belt band)
adjust relevant belt tension
slide rail worn out
replace slide rail
plastic inserts for WS worn out
replace plastic inserts completely
Increased running
noise
Transport line does
not move
WS is not being
transported
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2.1.3
General repair instructions for SIMPLEX and DUPLEX system
Replacing the driving unit
(1) dismount belts (see belt replacement chapter 7.2)
(2) squeeze off motor cable (must only be done by skilled staff/electrician), secure driving
unit vertically
(3) loosen the 2 headless pins M10 x 12 and remove them
(4) remove vertical safety device, shift the driving unit downwards
(5) install new driving unit in reverse order
NOTE
adjust belt tension! (refer to belt replacement chapter 6.2)
Replacing the reversing roller
(1) dismount belts (see belt replacement chapter 6.2)
(2) loosen and move the 2 cover strips (2 headless pins M3)
(3) press out cylinder pin 8h8 of the bore holes and take out reversing roller with the 2 spacer
rings
(4) mount the new reversing roller in reverse order
Replacing the geared motor
(1) squeeze off the motor cable
(2) remove 2 covering caps
(3) loosen tallow-drop screw M8 at one side of the driven shaft
(4) pull the driven shaft
(5) slacken torque converter bearing (cheese head screws M8x50) and remove the geared
motor
(6) install new geared motor in reverse order
NOTE
Secure the tallow-drop screw on the driven shaft with a screw locking.
Replacing the belt rest
(1) dismount belts (see belt replacement chapter 6.2)
(2) vertically remove the belt rest from the sustainer profile
(3) place bore hole with diameter 8,5 on the new slide rail and mount the new slide rail in
reverse order
Instructions on how to replace the belt can be found in chapter 6.2.
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2.2
DUPLEX -belt
The posyART conveying system is mostly used with the DUPLEX belt. The carriers (chapter
4.6) of the sizes from 160 to 400 mm are the most important accessories.
Delivery volume
The following parts are included in the delivery volume of the posyART DUPLEX system:
•
•
•
•
2.2.1
2 sustainer profiles assembled with conveying belts
spacer according to the width of the transport line
1 drive with driven shaft
4 covering caps each on top and front
Driving unit
The driving unit is an integral part of the transport line. It can be fixed at any spot of the whole
posyART line according to the customer’s requirements and can also be shifted later (see
chapter 6.4). The fitting position of the motor is as standard perpendicular. If desired, it can be
placed also horizontally (WS size 160 and 200 with limitations).
For the carrier sizes 200 and greater, the geared motor is generally fitted between the
sustainer profiles. In case of carrier size 160, the geared motor is generally fitted outside. It is
possible to fit in the motor on the left or right-hand side in accordance with the moving
direction. The length of the driven shaft depends on the width of the line. The design of the
driving roller and the spanners is determined by the belt type.
Description of the driving unit
The geared motor featuring the gear reduction device is located on top of the primary shaft.
The posyART DUPLEX system contains a torque converter bearing which is screwed with the
bearing bed of the driven shaft. Thus, the position of the geared motor is fixed.
As a standard, the motor is available a power of 180W. The standard transmissions enable
belt speeds of approx. 6, 8, 13 and 16m/min.
The sustainer profiles receive 2 tension rollers each, to ensure the belt tension using tension
jacks. Each belt is to be tensioned individually. By loosening and removing the tension rollers
and the tension jacks, the belt can be replaced at any time (see also chapter 6.2 and 6.3).
NOTE
To replace the belt, a clearances of approx. 230 mm each on both sides of the
motor flange.
In posyART DUPLEX system, the driving rollers are connected with the driven shaft.
NOTE
Please refer to chapter 2.1 for fitting and maintenance instructions, error
analysis and repair instructions.
Delivery includes the motor, bearing beds, driving rollers and spanners as well
as tension jacks and the necessary safety devices.
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2.2.2
2.2.2.1
Figures of posyART DUPLEX
Transport line
Reversing unit
30
Sustainer profile
keep this space always
free for belt replacement Geared motor 180W
Spacer
Driving unit
Protecting tube
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2.2.2.2
Driving unit
WS + 30 mm
WS + 1 mm
Bearing bed
Provide clearance for motor replacement 480 mm
Driving roller
400 mm
193 mm
Protecting tube
2.2.2.3
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Spacer
A
Guide strip WS 160
30
Cylinder screw M6x90
D
C
B
Pressure piece
Only one fixing bore hole for
WS 200 x 200 and smaller
Hollow DIN74-Km6
WS size
A
B
C
D
160
161
96,2
35
0
200
201
111,4
50
0
240
241
151,4
90
50
280
281
191,4
130
90
320
321
231,4
170
130
400
401
311,4
250
210
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14
IEF Werner GmbH
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Cross section of sustainer profile
21,0
80,0
2.2.2.4
Belt
Belt rest
Tension pin Ø 8x36
centered
Sustainer profile
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2.3
SIMPLEX belt
The posyART SIMPLEX system is used to transport smaller workpieces directly on the
conveying belt.
Delivery volume
The following parts are included in the delivery volume of the posyART SIMPLEX system:
•
•
•
2.3.1
1 sustainer profile assembled with conveying belt
1 drive with driven shaft
2 covering caps each on top and front
Driving unit
The driving unit is an integral part of the transport line. It can be fixed at any spot of the whole
posyART line according to the customer’s requirements and can also be shifted later. The
fitting position of the motor is as standard perpendicular. It is possible to fit in the motor on the
left or right-hand side in accordance with the moving direction. The design of the driving roller
and the spanners is determined by the belt type.
Description of the driving unit
The geared motor featuring the gear reduction device is located on top of the primary shaft. In
posyART SIMPLEX system, the motor is directly adapted to the bearing bed. As a standard,
the motor is available a power of 180W. The standard transmissions enable belt speeds of
approx. 6, 8, 13 and 16m/min.
The sustainer profiles receive 2 spanners each, to adjust the belt tension according to the
requirements using tension jacks.
By loosening and removing the spanners and the tension jack, the belt can be replaced at any
time (see also chapter 6.2 and 6.4).
NOTE
To replace the belt, a clearances of approx. 230 mm each on both sides of
the motor flange.
NOTE
Please refer to chapter 2.1 for fitting and maintenance instructions, error
analysis and repair instructions.
Delivery includes the motor, bearing beds, driving roller and spanners as well as one tension
jack and the necessary safety devices.
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IEF Werner GmbH
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Transport line posyART SIMPLEX
Lmax= 4000mm
Lmax x 0.5
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193 mm
Provide clearance for motor replacement 480 mm
400 mm
Transport line posyART SIMPLEX # driving unit
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posyART coupling
57,5 mm
7,5
65 mm
Clearance for belt replacement
Clearance for
belt replacement
167,5 mm
Clearances for replacing the belts
The clearance has to be the same all along the transport line. If posyART subassemblies are
to be fixed to the sustainer profile, the clearance changes in accordance with the size in
question.
230mm
clearance for belt
replacement
230mm
clearance for belt
replacement
30mm clearance for belt
replacement over the
complete line length
Driven shaft
Belt tensioner
Drive
torque converter bearing
Motor 180W
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3 Basic elements for change of direction in conveyor systems
3.1
Generalities
Basically there are two circulation systems for carriers: Systems where the orientation of the
carrier changes with a change of direction and systems where the orientation does not
change.
In a circulation system with shunts and rockers, the orientation of the WS changes of 90° after
each transfer.
The carriers' orientation is maintained in circulation system with curves.
September 2001
EN_posyArtK_R4a.doc
posyART Version 8.0
Grundelemente für Richtungsänderungen
Kapitel 3
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3.2
Rocker
3.2.1
Generalities
As a reasonable variant to the posyART shunt, the rocker technique has been developed.
The rocker technique realises an outward transfer of the carrier (WS) by a rock movement of
the crossway. All functions of a shunt can be realised using the rocker technique.
•
•
•
•
3.2.2
Stopping the carrier
Transfer of the carrier
Dropping the carrier on a secondary line and vice versa
Straight drive, without outward transfer of the carrier
Description
The outward transfer using the rock technique is a complete process. Outward transfers can
be connected with connection lines to a production line as required. An outward transfer
basically consists of:
•
•
•
•
1 main line
secondary line which contains usually a manual workplace or an automatic station
1 outward transfer rocker belt and
1 inward rocker belt.
Running on the main line, the WS enters the rocker (up to the buffer), is lifted off from the main
line and transported crosswise. For the transfer of the carrier to the secondary line, the rocker
belt is situated over the secondary line and the WS is stopped with a buffer. When the sensor
detects a WS at the stopper, the rocker belt is lowered at this side and thus, the WS is
deposited on the secondary line.
The inward transfer of a carrier is logically done in reverse order.
3.2.3
Fitting instructions
When installing an outward transfer rectangle and a rocker into a connection line or other
outward transfers, make sure that the belts are mounted exactly in the right height and
direction to assure a trouble free run of the carriers.
When an outward transfer rectangle is delivered without stand, the measures indicated in
chapter 2.2 must be adhered to.
3.2.4
Delivery volume
Delivery volume of the outward transfer assembly with rocker:
•
•
•
2 rocker belts with secondary mechanic system
1 main line
1 secondary line
The subassembly is delivered pre-assembled.
The outward transfer can be delivered with welded stand if required.
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3.2.5
Maintenance instructions
For trouble free operation, the degree of soiling of the transport line has to be as low as possible.
Dirt and shavings in the area of the revolving flat belts should be removed according to the given
conditions.
3.2.6
Cycle times
For cycle times see Shunt
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3.2.7
Figures of the rocker
3.2.7.1
Subassembly rocker
Stop edge
Roller conveyor
Sensor, stopper (accessories)
Rock mechanic
double stroke
Main line
Rock mechanic
single stroke
Secondary line
Double stroke:
Single stroke:
straight and transfer possible
only transfer possible
Figure without safety casing
Cylinder for
stop stroke
Single stroke
Double stroke
Cylinder for transfer stroke
Page 36 of 114
Cylinder for transfer stroke
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3.2.7.2
Subassembly rocker flow chart
See description of subassembly shunt
3.2.7.3
Subassembly shunt - pneumatic plan
See description of subassembly shunt
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IEF Werner GmbH
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3.3
Shunt
3.3.1
Generalities
The posyART separating filter is intended for the use of carriers (abbreviated WS in the
following). It is used for the following tasks:
•
•
•
rectangular inward and outward transfer of the WS into or out of a horizontal stretch
transfer of the WS from a horizontal stretch to a crossway and vice versa
transfer from one horizontal stretch to a second parallel horizontal stretch.
If a WS needs to pass through a shunt filter linearly, the latter must be equipped with 2 strokes
(2 cylinders). The buffers will be arranged in accordance with the intended type of application
(see figures to chapter 3.3 / page 42).
The shunt has its own drive. The speed of transport is 12m/min.
3.3.2
Description
The shunt may be assembled at any spot of the posyART DUPLEX belt. It is fixed by
clamping it between the dovetail grooves of the sustainer profile.
3.3.3
General sequence of operations:
Running on the horizontal stretch, the WS enters the shunt (up to the buffer), is lifted off from
the horizontal stretch and transported crosswise. In the opposite direction, the WS enters the
lifted shunt (up to the buffer) on the belts of the crossway. The belts lower the WS to the
horizontal stretch from where it gets transported further.
The passage position (shunt with buffers lowered below the line level) facilitates a linear
passage of the WS.
The shunt’s design keeps the WS from getting choked. During transportation, the pilot stopper
holds back a possibly following WS.
Impact load on the WS can be reduced by using a damped stopper for the shunt. Whether this
dampened version can be used depends on belt speed, WS weight and on the material to be
conveyed.
Our skilled staff will be glad to assist you in selecting the type best suited for your
requirements.
3.3.4
Fitting instructions
When mounting the shunt, please make sure that the pneumatic cylinders and the guide
(outside of the rectangle) are accessible from the outside.
Depending on the type of use, either one buffer (the one reached last in moving direction) is
fixed in top position or both of them are fixed in bottom position. There are two countersunk
screws to be loosened for each buffer, which then has to be revolved. To guarantee smooth
transfer of the WS from one shunt onto the next or onto a crossway, the components have to
be in true alignment.
The shunt with one cylinder may be retrofitted with a second one. One distance bolt (cheese
head screw M5) is to be replaced by the second cylinder. To do so, the pneumatic tubes need
to be loosened and the lifting plate including geared motor, fixing plate, guide pillar and
cylinder are to be removed in upward direction. In case of size 160 and 200, the geared motor
has to be removed from the fixing plate, for it is impossible to take it off completely.
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3.3.5
Delivery volume
The delivery volume comprises:
•
•
•
•
•
Drive
2 buffers
1 or 2 pneumatic cylinders with cylinder switches
2 spacers
1 detector
The subassembly is delivered pre-assembled.
3.3.6
Maintenance instructions
For trouble free operation, the degree of soiling of the shunt has to be as low as possible. Dirt and
shavings in the area of the revolving flat belts should be removed according to the given
conditions.
The geared motors feature a for-life lubrication. It is recommended to check for excessive loss of
lubricant after 100 hours of service (every 1000 hours later on). All bearings have been installed
with sealed anti-friction bearings. They feature a lifetime lubrication (grease). At the same time,
the belt tension is to be checked.
3.3.7
Table of disturbances
Disturbance
Cause
Remedying disturbance
nominal service life of antifriction bearings (driving roller)
exceeded
replace driving roller plus intermediate flange
nominal service life of antifriction bearings (reversing roller)
exceeded
replace reversing roller or tension
roller
geared motor defective
replace geared motor
inside of the flat belt soiled heavily
replace flat belt and eliminate cause
of soiling
flat belt defective
replace flat belt
geared motor defective
replace geared motor
geared motor incorrectly connected
Check pin connection and change if
needed
motor cable defective
check motor cable and exchange if
necessary
flat belt slides on the driving
roller
adjust relevant flat belt tension
nominal service life of friction
bearings exceeded
replace friction bearings
cylinder defective
replace cylinder
electrovalve defective
replace electrovalve
triggering sensor defective
replace sensor
Error in control system
check the control system
Increased running noise
WS does not move on shunt
lifting plate does not move
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3.3.8
Repair Instructions
If the flat belt needs to be re-tensioned, loosen the straining ring (cylinder screw M5) and
adjust the tension roller by turning the straining ring.
For any other kind of repair work to be carried out on the shunt, the lifting plate plus geared
motor and guide pillar have to be removed in upward direction. First, the pneumatic tubes are
released.
Size 160 and 200 constitute an exception (see Fitting instructions). The manufacturer will
replace both the geared motor and the driving roller plus intermediate flange.
3.3.8.1
Replacing the cylinder
•
•
•
•
Remove the pneumatic hoses with the one-way restrictors
Loosen and remove the cylinder from the fixing plate (4 cheese head screws M6)
Remove the thrust piece from the piston rod (countersunk screw M6) and remove it together with the distance bushing
Install new cylinder in reverse order.
Replacing the reversing roller
3.3.8.2
•
•
•
•
slacken the straining ring (cheese head screw M5) and revolve it together with the tension
roller
remove flat belt
pull out pin (cylinder pin)
mount the new reversing roller in reverse order.
Replacing the tension roller
3.3.8.3
•
•
3.3.9
remove cheese head screw M5 together with disk and distance ring
Pull tension roller from cylinder pin and install new tension roller in reverse order.
Cycle times
The indicated values refer to the transfer (corner) according to the flow diagram in chapter 3 /
page 36. The cycle time is indicated in seconds.
The given values apply to WS sizes from 200 to 400.
WS size in mm
Belt speed m/min
200
240
280
320
400
6
5,8
6,6
7,4
8,2
9,8
8
4,5
5,1
5,7
6,3
7,5
13
3,0
3,4
3,7
4,1
4,8
16
2,5
2,8
3,1
3,4
4,0
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3.3.10 Figures of the shunt
3.3.10.1
Subassembly shunt, lateral views
A
C – Clearance for replacing the WE
Reversing roller
Tension roller
Straining ring
Driving roller
Gear motor
Cylinder
Cylinder for
transfer stroke
Thrust piece
Guide tube
B
WS size
A
B
C
160
161
213
345
200
201
253
345
240
241
293
288
280
281
333
288
320
321
373
288
400
401
453
288
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Basic elements for change of direction
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IEF Werner GmbH
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3.3.10.2
Subassembly shunt, top view
Discharge sensor
50
45 105
Buffer (in top position), either
damped or undamped, as
ordered
Sensor before
pilot stopper
50
Buffer (in bottom position)
Pilot stopper
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3.3.10.3
Subassembly shunt, flow diagram, "single stroke"
Sensor S4
3.3.10.4
WT leaves S3
Sensor S2
WT switches S3
WT switches S1
flow chart
shunt
(cylinder Z3)
WT switches S2
Stopper
(cylinder Z1)
shunt is being brougth up
Sensor S1
Sensor S1
WT above Sensor
(WT feed)
WT at Sensor
Sensor S2
(WT in shunt)
WT above Sensor
Sensor S4
(pile-up)
lover
lift
valve Y1
(stopper)
working position
original position
valve Y3
(bring up shunt)
down
up
cylinder Z1
(stopper)
working position
original position
cylinder Z3
(bring up shunt)
transfer (corner)
original position:
after start
-Stopper
-shunt position
down
working position
in case of emergency off
*
up
original position
=Sensor occupled
=valve activated
=cylinder in extendet position
=cylinder working position
*= installation not deaerated
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Basic elements for change of direction
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IEF Werner GmbH
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Subassembly shunt, pneumatic plan, "single stroke"
Shunt
Clamp.modul
2.strok
ADVU-32-10-P-A
EV-32-5
Z1
Y1
Z3
Y2
2
Y3
2
14
14
1
3
4
2
5
1 3
14
1
3
84
R
ASI-CP valve terminal 2x3/2
R
3.3.10.5
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Subassembly shunt, flow diagram, "double stroke for outward transfer"
Sensor S4
reading head
shunt
Sensor S3
Sensor S2
WT leaves S3
WT switches S3
WT switches S2
WT leaves S4
WT switches S1
(cylinder Z2+ Z3)
WT switches S4
shund is being brougth up
Stopper
(cylinder Z1)
WT switches S2
flow chart
WT switches S1
3.3.10.6
outward transfer of signal
Sensor S1
WT above Sensor
Sensor S1
(WT feed)
WT at Sensor
Sensor S2
(WT in shunt)
WT above Sensor
Sensor S3
(pile-up)
WT above Sensor
Sensor S4
(pile-up)
valve Y1
lover
lift
t
(stopper)
lift
lover
valve Y2
(stop edge shunt)
lift
lover
valve Y3
(bring up shunt)
down
up
cylinder Z1
(stopper)
up
down
cylinder Z2
(stop edge shunt)
up
down
cylinder Z3
(bring up shunt)
signal input
(WT outward transfer)
outward transfer
accept
original position:
after start
-Stopper
-stop edge
-shunt position
down
down
down
December 2003
EN_posyArtK_Kap03_R3a.doc
in case of emergency off
up
down
down
*
=Sensor occupled
=valve activated
=cylinder in extendet position
*= installation not deaerated
posyART Version 8.0
Basic elements for change of direction
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IEF Werner GmbH
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Subassembly shunt, pneumatic plan, "double stroke for outward transfer"
Stopper
stop edge
tensioning module
EV-32-5
1.stroke
Y2
2
14
1 3
Z3
Y3
4
2
14
5
ADVU-32-10-P-A
Z3
Y1
84
2.stroke
ADVU-32-10-P-A
Z1
4
shunt
Y4
4
2
14
84
5
1 3
4
2
5
1 3
14
84
5
1 3
84
R
ASI-CP-valve isle 5/2
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Subassembly shunt, flow diagram, "inward transfer"
Sensor S4
Sensor S3
WT leaves S3
Sensor S2
WT switches S1
WT leaves S3
WT switches S3
shunt lovered
WT switches S2
WT switches S4
flow chart
shunt
(cylinder Z3)
Stopper 1
(cylinder Z1)
shunt is being brougth up
Sensor S1
WT switches S3
Stopper 2
(cylinder Z2)
WT switches S2
3.3.10.7
WT above Sensor
Sensor S1
(WT feed)
WT at Sensor
Sensor S2
(WT in shunt)
WT above Sensor
Sensor S3
(pile-up)
WT above Sensor
Sensor S4
(WTat the secondary line)
lover
lift
valve Y1
(stopper 1)
valve Y3
t
lift
lover
t
(bring up shunt)
valve Y2
lift
lover
t
(stopper 2)
down
up
cylinder Z1
(stopper 1)
cylinder Z3
up
down
(bring up shunt)
up
down
cylinder Z2
(stopper 2)
inward transfer
original position:
after start
-Stopper 1
-shunt position
-stopper 2
down
down
up
in case of emergency off
accept
*
up
down
up
=Sensor occupled
=valve activated
=cylinder in extendet position
*= installation not deaerated
December 2003
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Basic elements for change of direction
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3.3.10.8
Subassembly shunt, pneumatic plan, "inward transfer"
Stopper1
shunt
Stopper2
tensioning module
tensioning module
EV-32-5
2.stroke
ADVU-32-10-P-A
EV-32-5
Z1
Z3
Z1
Y1
Y3
Y2
2
2
14
14
1
3
4
2
5
1 3
14
1
3
84
R
ASI-CP-valve isle 2x3/2 1x5/2
Page 48 of 114
posyART Version 8.0
Cover sheet
R
December 2003
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Handhabungstechnik
3.4
Curve 90° / 180°
3.4.1
Generalities
The curve is intended for the use of carriers (WS). It serves for reversing the WS from a
DUPLEX stretch to one which runs parallel or at right angles. Its functional principles
guarantee retention of the direction of the carrier as well as the transport level of the
connected transport stretches. No jerks occur during transportation.
3.4.2
Description
The curve’s rotary table takes over the WS from one transport line and conveys it to the one
running parallel or at right angles, which again takes over the WS. In the process, the WS is
turned by 90° or 180° respectively. The curve’s guiding elements prevent the workpiece carrier
from getting choked.
The curve rests on the sustainer profiles of the two transport lines and is automotive. To give
an additional support to the curve, a pedestal can be mounted of required.
A WS pile-up on the curve must be avoided, because the curve is inadmissible for pile-up
operation. To avoid this, a discharge sensor releases the pilot stopper before the curve only in
case when the income WS has passed the curve completely.
The discharge sensor in not included in the delivery volume.
3.4.3
Fitting instructions
There has to be a clearance of 3,5 mm between the sustainer profiles of the curve and those
of the transport lines. This space is needed for the belt replacement and for mounting the
covering caps.
3.4.4
Delivery volume
The delivery volume comprises:
•
•
•
•
•
1 base plate
1 rotary table
connection and guide elements
covers
1 spur wheel back-geared motor (according to WS size and belt speed)
The subassembly is delivered pre-assembled.
3.4.5
Maintenance instructions
The geared motor features a for-life lubrication mixture. It is recommended to check for
excessive loss of lubricant after 100 hours of service (every 1000 hours later on).
December 2003
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posyART Version 8.0
Basic elements for change of direction
Page 49 of 114
IEF Werner GmbH
Handhabungstechnik
3.4.6
Table of disturbances
Disturbance
Cause
Remedying disturbance
helical gear unit defective
replace helical gear unit
geared motor defective
replace geared motor
tensioning set defective
replace tensioning set
geared motor defective
replace geared motor
geared motor incorrectly connected
Check pin connection
change if needed
motor cable defective
check motor cable and exchange
if necessary
Level of radial cam too low
adjust level
radial cam worn out
exchange radial cam
Increased running noise
Curve does not move
and
WS is not being transported
3.4.7
3.4.7.1
Repair Instructions
Exchange geared motor
The geared motor will be replaced by the manufacturer.
3.4.7.2
Replacing the rotary table
(1) Release the buffer plate from the two clamping elements
(2 cheese head screws M5 per clamping element)
(2) Release the locking ring from the flange (4 cheese head screws M8) and remove it
(3) Remove the rotary table vertically and
(4) mount the new rotary table in reverse order.
Page 50 of 114
posyART Version 8.0
Cover sheet
December 2003
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IEF Werner GmbH
Handhabungstechnik
3.4.8
Figures of the curve
3.4.8.1
Subassembly curve 90°
A
567
A
WS + 8mm
353
December 2003
EN_posyArtK_Kap03_R3a.doc
WS size
Size A
160 x 160
387
200 x 200
387
240 x 240
412
280 x 280
522
320 x 320
562
400 x 400
642
posyART Version 8.0
Basic elements for change of direction
Page 51 of 114
IEF Werner GmbH
Handhabungstechnik
3.4.8.2
Subassembly curve 180°
B
Buffer plate
Rotary table
Tensioning set
Clamping ring
567
A
353
Page 52 of 114
posyART Version 8.0
Cover sheet
WS size
Size A
Size B
160 x 160
562
165
200 x 200
566
150
240 x 240
646
150
280 x 280
776
200
320 x 320
856
200
400 x 400
1016
200
December 2003
EN_posyArtK_Kap03_R3a.doc
IEF Werner GmbH
Handhabungstechnik
4 Individual extensions of subassemblies
4.1
Generalities
A rectangular main line is the basic equipment for complex production lines. It is the basis for
efficient production for manual and fully automatic production processes. For complex
production systems, secondary line extensions to reach the different working places will be
needed. The availability of many individual extension subassemblies facilitate the design of
the transport system as well as the possibility to mount, process, check and repair items on
the ideal working places. The carriers can be assigned to the corresponding secondary lines
by the use of coding systems.
September 2001
EN_posyArtK_R4a.doc
posyART Version 8.0
Grundformen der Transportbänder
Kapitel 2
Seite 53 von 114
IEF Werner GmbH
Handhabungstechnik
4.2
Subassembly stopper
4.2.1
Generalities
The stopper can stop and separate carriers (WS) as well as customised material to be conveyed
at any point on a moving belt. The WS positions itself centric at the stopper. The possibility of
getting choked is therefore excluded. The design as tilt isolator avoids wear out of the WS contact
tread.
The WS passage in the system requires a stopper inside and in front of every workstation as well
as in front of the subassemblies shunt and curve.
4.2.2
Description
The stopper consists of a spacer and a rocker which is lowered pneumatically. In normal position
the stopper is moved out. The carriers will therefor be automatically stopped during an
emergency-off. The stopper is fitted centric on a spacer. Thread holes to fix the stopper are
available.
The standard design of the stopper is damped. It may also be delivered without damping. Criteria
for the stopper damping are the buffer behaviour and the maximum pile-up load. A damped
stopper is always used for the pilot stopper and the pile-up separator. Depending on the belt
speed and the WS weight a damped or an undamped stopper will be used in the workstation.
The pile-up load can be suited to the requirements with the aid of additional stoppers used as a
pile-up separators. The maximum pile-up load on a stopper is defined by the belt speed and the
mass (WS weight with the workpiece to be transported) to be stopped. The pilot stopper damping
is available in 3 different degrees.
4.2.3
Fitting instructions
The stopper will be delivered completely fitted according to order and will be fitted vertically (from
the bottom) into the transport line. The fitting position of the stopper in connection with the
posyART subassemblies is explained in the corresponding subassembly.
If a damping set should be retrofit, the following fitting instructions must be adhered to:
(1) Loosen the headless pin M4x10
(2) Loosen and remove the countersunk screw M5x12.
(3) Remove the buffer
(4) Insert the damping set into the bore holes of the rocker
(5) Fit the buffer (countersunk screw M4)
Secure the buffer (headless pin M4x10).
4.2.4
Delivery volume
The delivery volume comprises:
•
•
•
1 stopper
1 spacer for the stopper
1 clamping module with pressure plate and
•
the damping set, when ordered
The subassembly is delivered pre-assembled.
Page 54 of 114
posyART Version 8.0
Individual extensions of subassemblies
December 2003
EN_posyArtK_Kap04_R3a.doc
IEF Werner GmbH
Handhabungstechnik
4.2.5
Maintenance instructions
The bearings of the rocker (friction bearings) as well as the buffer guide (2 membrane
bushings) should be greased according to the conditions of use.
4.2.6
Table of disturbances
Disturbance
Cause
Remedying disturbance
rocker bearing defective
Replace friction bearings GFM101216
Tensioning module defective
Replace tensioning module
electrovalve defective
replace electrovalve
triggering sensor defective
replace sensor
Error in control system
check the control system
bearing of the stopper guide defective
replace membrane bushings
Pressure spring defective
Replace pressure spring
nominal service life of stopper damping exceeded
Replace stopper damping
Stopper damping defective
Replace stopper damping
stopper does not tilt
Buffer firm
Intensive WS buffer noise
4.2.7
4.2.7.1
Repair Instructions
Replacing the stopper damping
see fitting instructions
4.2.7.2
Replacing the tensioning module
(1) Remove pneumatic tube
(2) Loosen and remove the complete stopper from the spacer (2 cheese head screws
M6x35)
CAUTION
Pressure spring inside the spacer is not fixed
(3) Loosen (4 cheese head crews M5x16) and remove tensioning module from the spacer
(4) Install new tensioning module in reverse order
December 2003
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posyART Version 8.0
Individual extensions of subassemblies
Page 55 of 114
IEF Werner GmbH
Handhabungstechnik
4.2.8
Figures of subassembly stopper
Presentation without rocker
Pressure
spring
Top view
78,2
46
Buffer
Clamping
module
Cylinder screw
M6x35
Page 56 of 114
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Individual extensions of subassemblies
December 2003
EN_posyArtK_Kap04_R3a.doc
IEF Werner GmbH
Handhabungstechnik
Stopper activated
Stopper not activated
Stroke 11,0
Fitting dimensions
87,0
57,5
WS
December 2003
EN_posyArtK_Kap04_R3a.doc
posyART Version 8.0
Individual extensions of subassemblies
Page 57 of 114
IEF Werner GmbH
Handhabungstechnik
4.3
Subassembly centring unit
4.3.1
Generalities
The centring unit is used for fixing components at a defined spot. In one single move, both
tensioning and centring are carried out by positive and non-positive locking. In the process,
the carrier (WS) is lifted 0.5 mm from the belt. Positioning precision is ± 0.05.
NOTE
These subassemblies will only be able to carry out centring tasks with the
given precision on the condition that posyART carriers are being used.
4.3.2
Description
The centring unit may be assembled at any spot of the posyART DUPLEX system. It is fixed
by clamping it between the dovetail grooves of the sustainer profile. The centring unit consists
of a spacer which supports the centring tappet, flange sleeve and the pneumatic cylinder and
is to be fixed on the inside of the posyART DUPLEX belt. A retaining strip is mounted on each
outside. The spacer features bore holes enabling external fastening of the subassembly.
A WS entering the station will be stopped by a stopper, centred via two centring tappets and
finally pushed against the retaining strips. The centring tappets grip into the centring bushings
in question. After processing, the centring tappets will be returned to the starting position. The
stopper then releases the WS for further transportation. During positioning, a pilot stopper
holds back the next WS. At 6 bar, the centring unit can cope with vertical forces of up to 500
N. For greater forces, the subassembly centring unit with active lowerator has been designed.
4.3.3
Fitting instructions
During assembly, please make sure that the stopper stops the carrier approx. 1mm behind the
centring position, thus allowing sufficient space for centring. This can be achieved by centring
the WS inside the CU and by allowing an interspace of 1mm when fixing the stopper to the
WS.
4.3.4
Delivery volume
The delivery volume comprises:
•
•
•
•
1 centring unit
2 retaining strip
2 pneumatic cylinder and
2 cylinder switches
The subassembly is delivered pre-assembled.
Page 58 of 114
posyART Version 8.0
Individual extensions of subassemblies
December 2003
EN_posyArtK_Kap04_R3a.doc
IEF Werner GmbH
Handhabungstechnik
4.3.5
Table of disturbances
Disturbance
Cause
Remedying disturbance
short-stroke cylinder defective
replace short-stroke cylinder
electrovalve defective
replace electrovalve
triggering sensor defective
replace sensor
Error in control system
Check control system
stopper position is wrong
rectify stopper position
Centring pins don’t move
Increased centring noise
4.3.6
4.3.6.1
Repair Instructions
Replacing the cylinder
(1) Remove the pneumatic tubes plus one-way restrictor
(2) Release cylinder switch
(3) Release the cylinder from the spacer (4 cheese head screws M5) and remove it
(4) Install the new cylinder in reverse order
CAUTION
The centring pins are not secured
4.3.6.2
Replacing the pressure spring
(1) See disassembling the cylinder(s)
(2) Remove the pressure spring from the centring pin
(3) Mount the new pressure spring in reverse order
4.3.7
Cycle times
With the ascertained cycle times, processing time is set to 0. Cycle time is stated in seconds.
WS size in mm
Belt speed m/s
160
200
240
280
320
400
6
X,x
3,1
3,5
3,9
4,3
5,1
8
X,x
2,5
2,8
3,1
3,4
4,0
13
X,x
1,7
1,9
2,1
2,3
2,7
16
X,x
1,5
1,7
1,9
2,0
2,3
The cycle times include the feed of the WS and the centring.
December 2003
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posyART Version 8.0
Individual extensions of subassemblies
Page 59 of 114
IEF Werner GmbH
Handhabungstechnik
4.3.8
Figures of subassembly centring unit
4.3.8.1
Centring unit
Entry sensor
Detector
Discharge sensor
Sectional view A - A
Centring tappet
Pressure spring
Spacer
Cylinder
Page 60 of 114
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December 2003
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IEF Werner GmbH
Handhabungstechnik
Subassembly centring unit - important measures
42 mm
27
126 mm
45 mm
4.3.8.2
December 2003
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posyART Version 8.0
Individual extensions of subassemblies
Page 61 of 114
IEF Werner GmbH
Handhabungstechnik
4.3.8.3
Subassembly centring unit - flow chart
centering tappet
(with cylinder Z3.1 + Sensor S4.1)
Stopper
(with cylinder Z2)
moving direction
pilot stopper
9 10 11
9 10 11
6 7 8
1 2
1 2
6 7 8
12
12
(with cylinder Z1)
3 4 5
3 4 5
Sensor S3
Sensor S1
WT2 switches S2
WT1 leaves S3
WT2 is being centered
WT2 switches S1
WT1 leaves S2
WT1 switches S3
Signal from the inside
edit
signal to the outside
centered
WT1 switches S1
flow chart
WT1 switches S2
centering tappet
(with cylinder Z3.2 + Sensor S4.2)
Sensor S2
WT above Sensor
Sensor S1
WT above Sensor
(WT feed)
Sensor S2
(WT on the Stopper)
centered
Sensor S4.1/4.2
(centring page 1/2)
WT above Sensor
Sensor S3
(pile-up)
lover
lift
valve Y1
(pilot stopper)
lover
lift
valve Y2
(Stopper)
lift
impulse valve Y3.1
(centering tappet)
lover
Y3.2
up
down
cylinder Z1
(pilot stopper)
up
down
cylinder Z2
(Stopper)
up
down
cylinder Z3.1
(centering tappet)
Z3.2
edit start
signal output
(WT centered)
signal input
ready
(undo centring)
edit end
original position:
after start
-pilot stopper
-Stopper
-centering tappet
down
up
down
in case of emergency off
up
up
depending on operation
*
=Sensor occupled
=valve activated
=cylinder in extendet position
t = waiting periot (until WT reaches Stopper)
= installation not deaerated
Page 62 of 114
posyART Version 8.0
Individual extensions of subassemblies
December 2003
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IEF Werner GmbH
Handhabungstechnik
Subassembly centring unit - pneumatic plan
4.3.8.4
pilot stopper
stopper
EV-32-5
EV-32-5
C1
C2
Y1
Y2
2
1 3
AEVU-32-10-P-A
C3.1
S4.1
Y3.1
S4.2
2
14
1 3
C3.2
Y3.2
4
2
14
14
cylinder ZE
12
51 3
R
PRS-M5-4
December 2003
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posyART Version 8.0
Individual extensions of subassemblies
R
Page 63 of 114
IEF Werner GmbH
Handhabungstechnik
4.4
Centring unit with active skip
4.4.1
Generalities
The centring unit with active skip is used to fix components at a defined spot. In one single
move, both tensioning and centring are carried out by means of positive and non-positive
locking. Positioning precision is ± 0.05.
NOTE
These subassemblies will only be able to carry out centring tasks with the
given precision on the condition that posyART carriers are being used.
4.4.2
Description
Structure and function of the centring unit with active skip correspond to those of the centring
unit. In addition, 2 tensioning modules and 3 buffer blocks each are fitted to the retaining
strips.
Once the WS has been centred and lifted off, it is pushed onto the corresponding WS support
(anvil). The belt rest is divided in the working sector and runs on spring bearings to avoid
clamping of the belt (see subassembly passive lowerator). This type of subassembly is used
where vertical process forces exceeding 500N occur.
NOTE
The WS support is to be positioned within the area of the WS base plate and 1
mm below the belt’s level.
4.4.3
Fitting instructions
During assembly, please make sure that the stopper stops the carrier approx. 1mm behind the
centring position, thus allowing sufficient space for centring.
This can be achieved by centring the WS inside the CU and by allowing an interspace of 1mm
when fixing the stopper to the WS.
CAUTION
To be used in connection with the passive belt lowerator only.
4.4.4
Delivery volume
The delivery volume comprises:
•
•
•
•
•
1 centring unit
2 retaining strip
2 pneumatic cylinders
2 cylinder switches
4 tensioning modules
The subassembly is delivered pre-assembled.
Page 64 of 114
posyART Version 8.0
Individual extensions of subassemblies
December 2003
EN_posyArtK_Kap04_R3a.doc
IEF Werner GmbH
Handhabungstechnik
4.4.5
Table of disturbances
Disturbance
Cause
Remedying disturbance
short-stroke cylinder defective
replace short-stroke cylinder
electrovalve defective
replace electrovalve
triggering sensor defective
replace sensor
Error in control system
Check control system
stopper position is wrong
rectify stopper position
tensioning modules (retaining strip)
defective
Replace tensioning module
electrovalve defective
replace electrovalve
triggering cylinder switch defective
Replace cylinder switch
Error in control system
Check control system
lowerable belt rest defective
replace belt rest completely
Centring pin doesn’t move
Increased centring noise
No vertical move of belt
4.4.6
Repair Instructions
4.4.6.1
Replacing the cylinder
•
4.4.6.2
see subassembly centring unit
Replacing the tensioning modules in the retaining strip
(1) Release the retaining strip from the clamping element (3 cheese head screws M5) and
remove it
(2) Remove pneumatic tube
(3) Release the tensioning module from the retaining strip (4 cheese head screws M4) and
remove it
(4) Install new tensioning module in reverse order
December 2003
EN_posyArtK_Kap04_R3a.doc
posyART Version 8.0
Individual extensions of subassemblies
Page 65 of 114
IEF Werner GmbH
Handhabungstechnik
4.4.7
Figures of subassembly centring unit with active skip
4.4.7.1
General view
Centring tappet
Spacer
Pressure spring
WT-Laufrichtung
Cylinder
Entry sensor
Detector
Discharge sensor
Discharge sensor
Page 66 of 114
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Individual extensions of subassemblies
December 2003
EN_posyArtK_Kap04_R3a.doc
IEF Werner GmbH
Handhabungstechnik
Subassembly centring unit with active skip- important measures
126 mm
42 mm
27 mm
45 mm
4.4.7.2
December 2003
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posyART Version 8.0
Individual extensions of subassemblies
Page 67 of 114
IEF Werner GmbH
Handhabungstechnik
4.4.7.3
Page 68 of 114
posyART Version 8.0
Individual extensions of subassemblies
December 2003
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IEF Werner GmbH
Handhabungstechnik
ubassembly centring unit with active skip- flow chart
tensioning module
WT tension
Z4.1,Z4.2
centering tappet
(with cylinder Z3.1 + Sensor S4.1)
Stopper
(with cylinder Z2)
pilot stopper
(with cylinder Z1)
moving direction
Sensor S1
Sensor S3
WT2 switches S2
WT1 leaves S3
WT2 is being centered
WT2 switches S1
WT1 leaves S2
Signal from the inside
edit
signal to the outside
WT1 switches S3
centering tappet
(with cylinder Z3.2 + Sensor S4.2)
Z4.3,Z4.4
centered
flow chart
WT1 switches S2
WT1 switches S1
tensioning module
WT tension
WT above Sensor
Sensor S1
WT above Sensor
(WT feed)
Sensor S2
(WT on the Stopper)
centered
Sensor S4.1/4.2
(centring page 1/2)
WT above Sensor
Sensor S3
(pile-up)
lover
lift
valve Y1
(pilot stopper)
lover
lift
valve Y2
(Stopper)
lift
impulse valve Y3.1
t
lover
(centering tappet)
Y3.2
tension
relax
valve Y4
(tensioning module)
up
down
cylinder Z1
(pilot stopper)
up
down
cylinder Z2
(Stopper)
up
down
cylinder Z3.1
Z3.2
cylinder Z4.1-Z4.4
(centering tappet)
tense
relaxed
(tensioning module WT tension)
t
t
signal output
edit start
(WT centered)
ready
signal input
edit end
(undo centring)
original position:
after start
-pilot stopper
-Stopper
-centering tappet
-tensioning module WT tension
down
up
down
relaxed
December 2003
EN_posyArtK_Kap04_R3a.doc
in case of emergency off
up
up
depending on operation
depending on operation
*
=Sensor occupled
=valve activated
=cylinder in extendet position
t = waiting periot (until WT reaches Stopper)
= installation not deaerated
posyART Version 8.0
Individual extensions of subassemblies
Page 69 of 114
IEF Werner GmbH
Handhabungstechnik
Subassembly centring unit with active skip- pneumatic plan
pilot stopper
Stopper
EV-32-5
EV-32-5
Z1
Z3.1
Z3.2
S4.2 Z4/1
Z4/2
Z4/3
Y3.2
4
2
14
1 3
S4.1
Y3.1
Y2
2
ev-15/63-4
AEVU-32-10-P-A
Z2
Y1
14
tensioning module WT tension
cylinder ZE
Z4/4
Y4
2
2
14
5
1 3
1
3
1 3
R
PRS-M5-4
4.4.8
R
Cycle times
With the ascertained cycle times, processing time is set to 0. Cycle time is stated in seconds.
WS size in mm
Belt speed m/s
160
200
240
280
320
400
6
Y,y
3,3
3,7
4,1
4,5
5,3
8
Y,y
2,7
3,0
3,3
3,6
4,2
13
Y,y
1,9
2,1
2,3
2,5
2,9
16
Y,y
1,7
1,9
2,1
2,2
2,5
The indicated cycle times include the feed of the WS and the centring.
Page 70 of 114
posyART Version 8.0
Individual extensions of subassemblies
December 2003
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IEF Werner GmbH
Handhabungstechnik
4.5
Subassembly lift-and-revolve unit
4.5.1
Generalities
The lift-and-revolve unit is used to change the orientation of the carrier according to the
requirements. To achieve this, the WS will be lifted off the belt, revolved by 90° or 180° and
then placed back onto the belt.
WARNING
This subassembly is cased in accordance with EN 294 regulation (prevention
of accidents).
4.5.2
Description
The lift-and-revolve unit is fixed by jamming it between the dovetail grooves of the sustainer
profile. It can thus be fitted at any point of the posyART DUPLEX belt. The subassembly
consists of an index plate with centring pins, two guides, one pneumatic cylinder and a
swivelling driving gear.
A WS entering the station will be stopped by a stopper. Then the swivelling driving gear with
index plate and centring pins is lifted off. Having been centred and lifted (10 mm above belt
level), the WS is turned by ±90° or 180° and then lowered onto the belt again. The stopper
then releases the WS for further transportation.
A pilot stopper holds back the next carrier during the lift-and-revolve procedure. The speed of
the lift-and-revolve unit can be adjusted by means of the one-way restrictor.
The torque moment is adjusted in accordance to the geometric sizes of the carriers. That
means for the WS sizes 160-240 mm = 5 Nm and for the WS sizes 280 - 400 mm = 10 Nm. It
is designed for vertical forces (centred action) of 50N (WS sizes 160 - 240mm) and 80N (WS
sizes 280-400).
CAUTION
Working operations are only permissible without force impact.
4.5.3
Delivery volume
The delivery volume comprises:
•
•
•
•
•
•
1 lift-and-revolve unit with integrated stopper
2 pneumatic cylinders
2 cylinder switches
1 swivelling driving gear with
2 sensors and
2 final position dampers
The subassembly is delivered pre-assembled.
December 2003
EN_posyArtK_Kap04_R3a.doc
posyART Version 8.0
Individual extensions of subassemblies
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4.5.4
Table of disturbances
Disturbance
Cause
Remedying disturbance
cylinder defective
replace cylinder
electrovalve defective
replace electrovalve
triggering sensor defective
replace sensor
Error in control system
Check control system
stopper position is wrong
rectify stopper position
swivelling driving gear defective
replace swivelling driving
gear
electrovalve defective
replace electrovalve
triggering sensor defective
replace sensor
Error in control system
Check control system
swivelling driving gear defective
replace swivelling driving
gear
index plate not lifted
Increased centring noise
index plate does not rotate
Increased revolving noise
4.5.5
4.5.5.1
Repair Instructions
Replacing the cylinder
(1) Remove the pneumatic hose with the one-way restrictors
(2) Loosen and remove the cylinder from the base plate (4 cheese head screws M6)
(3) Remove the flex bushing from the piston rod and
(4) install new cylinder in reverse order.
Because of the adjustment of dampers, internal buffers and sensors, replacement of the
swivelling driving gear is always carried out by the manufacturer.
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4.5.6
Figures of the subassembly lift-and-revolve unit
4.5.6.1
General view
45 mm
Detector at
pilot stopper
Pilot stopper
27 mm
Index plate
Detector
Stopper
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4.5.6.2
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Page view
Moving direction
Vorstopper
Stopper
Revolution cylinder
Stroke cylinder
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4.5.6.3
Subassembly lift-and-revolve unit - flow chart
Sensor S2
1 2
9
Sensor S1
moving direction
10 11
4 5
1 2
6 7 8
12
3
9 10 11
12
swivelling driving gear HDE
(with swivelling driving gear Z4 + Sensor S5.1,S5.2)
3
Sensor S3
6 7 8
4 5
Stopper
(with cylinder Z2)
pilot stopper
(with cylinder Z1)
cylinder HDE
(with cylinder Z3.1 + Sensor S4.1,S4.2)
WT2 is being revolved
WT2 is being lifted
WT2 switches S2
WT1 leaves S3
WT1 switches S3
WT2 switches S1
WT1 leaves S2
revolve
lifted
WT1 switches S2
WT1 switches S1
flow chart
WT above Sensor
Sensor S1
WT above Sensor
(WT feed)
Sensor S2
(WT on the Stopper)
lifted
Sensor S4.2
(lifting movement)
lowered
Sensor S4.1
(lifting movement)
revolved 90° or 180revolved 90°
respectively
Sensor S5.1
(Drehung)
revolved 0°
Sensor S5.2
(Drehung)
pile-up
Sensor S3
WT above Sensor
(pile-up)
lover
lift
valve Y1
(pilot stopper)
lover
lift
valve Y2
(Stopper)
lift
lover
impulse valve Y3.1
(cylinder HDE)
revolved 90° or 180revolved 90°
respectively
impulse valve Y4.1
(swivelling driving
gear HDE)
Y4.2
revolved 0°
up
down
cylinder Z1
(pilot stopper)
up
down
cylinder Z2
(Stopper)
up
down
cylinder Z3.1
(cylinder HDE)
revolved 90° or 180revolved 90°
respectively
revolved 0°
swivelling driving
gear Z4
(swivelling driving gear HDE)
original position:
after start
-pilot stopper
-Stopper
-cylinder HDE
-swivelling driving gear HDE
down
up
down
revolved 0°
in case of emergency off
up
up
depending on operation
depending on operation
*
=Sensor occupled
=valve activated
=cylinder in extendet position
t = waiting periot (until WT reaches Stopper)
= installation not deaerated
4.5.6.4
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Subassembly lift-and-revolve unit- pneumatic plan
pilot stopper
Stopper
cylinder HDE
swivelling driving gear HDE
in acccordance with size and swing angle
Z1
Z2
Y1
Z3.1 S4.1 S4.2
Y3.1
Y2
2
2
14
14
1
3
Y3.2
4
2
5
3
14
1
3
Z4
S5.1 S5.2
Y4.1
12
Y4.2
4
2
5
3
14
12
R
PRS-M5-4
4.5.7
R
Cycle times
With the ascertained cycle times, processing time is set to 0. Cycle time is stated in seconds.
WS size in mm
Belt speed m/s
160
200
240
280
320
400
6
Z,z
5,4
5,8
5,8
6,2
7,0
8
Z,z
5,7
5,0
5,0
5,3
5,9
13
Z,z
3,8
4,0
4,0
4,2
4,6
16
Z,z
3,5
3,7
3,8
3,9
4,2
The cycle times include the feed of the WS and the time for a rotation of 180°.
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4.6
Subassembly lifting unit
4.6.1
Generalities
The lifting unit is used to move the carrier from the belt height to a varied working height. This
can be achieved by means of a pneumatic cylinder having the relevant stroke.
WARNING
This subassembly is to be equipped with a housing in accordance with the
regulations for prevention of accidents, for, according to EN 294, there is a
high risk of injury. If an automatic station is to be operated from the lifting
unit the housing should include both.
The operation of the posyART lifting unit without housing is not allowed! It
does not form part of the delivery volume.
4.6.2
Description
The lifting unit may be assembled at any spot of the posyART DUPLEX system. It is fixed by
clamping it between the dovetail grooves of the sustainer profile. It consists of a stroke plate
with centring bolts, two guides, and a pneumatic cylinder.
A WS entering the station will be stopped by a stopper and then be centred and lifted by two
centring pins. The centring pins grip into the corresponding cylinder bushings of the WS. After
processing, the centring pins will be returned to the starting position. The stopper then
releases the WS for further transportation.
A pilot stopper holds back the next carrier during the lifting procedure.
The stroke speed can be adjusted via the one-way restrictors.
The lifting unit will be offered in the stroke range 0 - 100 mm (stroke of the WS from the belt).
It has been designed for vertical forces of 300N (centred action) and is available for the WS
sizes ranging from 160-400mm.
4.6.3
Fitting instructions
During assembly, please make sure that the stopper stops the carrier approx. 1mm behind the
centring position, thus allowing sufficient space for centring.
This can be achieved by centring the WS inside the CU and by allowing an interspace of 1mm
when fixing the stopper to the WS.
The fitting dimension of 11mm between the top edge of the sustainer profile and the top edge
of the lifting plate (see chapter 5.6) must be maintained. Readjust at the Flexo clutch if
necessary.
4.6.4
Delivery volume
The delivery volume comprises:
•
•
•
1 lifting unit
2 pneumatic cylinders and
2 cylinder switches
The subassembly is delivered pre-assembled.
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4.6.5
Table of disturbances
Disturbance
Cause
Remedying disturbance
cylinder defective
replace cylinder
electrovalve defective
replace electrovalve
triggering sensor defective
replace sensor
Error in control system
Check control system
stopper position is wrong
rectify stopper position
vertical fitting is wrong
check fitting dimension
lifting plate does not move
Increased centring noise
WS comes upon the centring
pins
4.6.6
4.6.6.1
Repair Instructions
Replacing the cylinder
(1) Remove the pneumatic hoses with the one-way restrictors
(2) Loosen the flexo clutch from the cylinder
(3) Loosen and remove the cylinder from the base plate (4 cheese head screws M6)
(4) Install new cylinder in reverse order.
4.6.6.2
Replacing the guides
(1) Loosen the fastening screws (2 x M8) of the guide shafts
(2) Take out the guide shafts in downwards direction
(3) Install new guide shafts in reverse order
CAUTION
When tightening the cylinder screws (2 x M8) ensure smooth moving of the
guide shafts.
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4.6.7
Figures of the subassembly lifting unit
4.6.7.1
View (stroke 20mm) top view
45
Entry
sensor
126
Pilot stopper
42
27
Detector
Discharge
sensor
4.6.7.2
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View (stroke 20mm) lateral view
234 + stroke
305 + stroke
Centring pins
Lifiting plate
Flexo
clutch
Guide shaft
Cylinder
WS - 83
4.6.7.3
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Subassembly lifting unit - flow chart
Cylinder HE
(with cylinder Z3.1 + Sensor S4.1; S4.2)
sensor S1
sensor S2
9 10 11
7 8
6
1 2
3 4 5
6 7 8
12
1 2
12
3 4 5
sensor S3
moving direction
9 10 11
pilot stopper
(with cylinder Z1)
stopper
WT2 switches S2
WT1 leaves S3
WT2 is being lifted
WT1 switches S3
WT2 switches S1
WT1 leaves S2
Signal from the inside
edit
signal to the outside
lifted
WT1 switches S1
flow chart
WT1 switches S2
(with cylinder Z2)
WT above Sensor
Sensor S1
WT above Sensor
(WT feed)
Sensor S2
(WT on the Stopper)
lifted
Sensor S4.2
(lifting movement)
lowered
Sensor S4.1
(lifting movement)
WT above Sensor
Sensor S3
(pile-up)
valve Y1
lover
lift
(pilot stopper)
valve Y2
lover
lift
(Stopper)
t
impulse valve Y3.1
lift
(cylinder HE)
lover
Y3.2
up
down
cylinder Z1
(pilot stopper)
up
down
cylinder Z2
(Stopper)
cylinder Z3.1
(cylinder HE)
Z3.2
up
down
signal output
edit start
(WT centered)
ready
edit end
signal input
(undo centring)
original position:
after start
-pilot stopper
-Stopper
-cylinder HE
down
up
down
in case of emergency off
up
up
depending on operation
*
=Sensor occupled
=valve activated
=cylinder in extendet position
t = waiting periot (until WT reaches Stopper)
= installation not deaerated
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4.6.7.4
Subassembly lifting unit - pneumatic plan
Stopper
pilot stopper
EV-32-5
cylinder HE
EV-32-5
in accordance stroke
PRS-M5-3
4.6.8
Cycle times
With the ascertained cycle times, processing time is set to 0. Cycle time is stated in seconds.
The given values apply to a stroke of 20 and 100 mm. Other stroke sizes on request.
Belt
Carrier
200
in
240
mm
speed
160
280
320
400
in m/s
stroke
20
stro
ke
100
strok
e 20
strok
e
100
stroke
20
strok
e 100
strok
e 20
stroke
100
strok
e 20
stroke
100
stro
ke
20
strok
e 100
6
X,x
Y,y
3,4
4,4
3,8
4,8
4,1
5,2
4,6
5,6
5,4
6,4
8
X,x
Y,y
2,8
3,8
3.1
4,1
3,4
4,4
3,7
4,7
4,3
5,3
13
X,x
Y,y
2,1
3,0
2,3
3,2
2,4
3,4
2,6
3,6
3,0
4,0
16
X,x
Y,y
1,8
2,8
2,0
3,1
2,2
3,2
2,3
3,3
2,6
3,6
The cycle times include the feed of the WS and the lifting off.
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4.7
Carrier
4.7.1
Generalities
The carrier (WS) is intended for the transportation of all kinds of components. It guarantees
troublefree transportation and function-related positioning of the components by the
posyART-DUPLEX system, including all subassemblies.
Depending on the kind of components to be transported, the WS size and thus the structural
shape and the width of the posyART system are determined. Generally, 6 different WS sizes
are available.
4.7.2
Description
The carrier consists of:
•
•
•
•
1 aluminium base plate with special countersinkings
4 plastic inserts and
4 hardened centring tappets
2 encoded items optional
The base plate receives the components to be transported and, as an option, the encoded
item to identify the WS. This encoded item contains data to be assigned to the WS in question.
A reinforced base plate can receive process forces accordingly (see figures to chapter 4.4).
Each of the 4 sides (bottom) features an opening for separation. The whole surface may be
used for fastening components or workpieces.
The four plastic inserts at the bottom side of the WS ensure a wear-and-tear-free power
transmission between belt and WS.
Four centring tappets guarantee a positioning precision between ± 0.02 and ± 0.04mm in the
X and Y direction depending on the WS size. The WS guiding precision along the transport
line is ± 0.5mm. This can be increased to ± 0.07mm, when mounting the lateral positioning
contrivance. When openings or drilled fastening holes are required in the base plate, the
restricted areas (see figure to this point) are to be observed.
4.7.3
Delivery volume
The delivery volume comprises:
•
•
1 carrier assembled with rail shoe and centring tappets
2 encoded items optional
The subassembly is delivered pre-assembled.
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4.7.4
Figure of subassembly carrier
WT - size
58,5*
70
½ WT - size
A
72,5
72,5
58,5*
A
Area intended for
customised openings
Not available at WT 160
WS size
A ± 0,01
160
67,8
200
83
240
123
280
163
320
203
400
283
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4.8
Subassembly lift-and-tilt station
4.8.1
General
The lift-and-tilt station is intended for the use of carriers (WS). With the use of this station
components are placed to the ideal position to execute the task in question at the manual
workplace. This subassembly is equipped with a case in accordance with the regulations for
prevention of accidents.
The necessary two-hand operating device forms part of the delivery volume.
4.8.2
Description
The lift-and-tilt station may be fitted at any point of the posyART DUPLEX system. It is fixed
by clamping it between the dovetail grooves of the sustainer profile. The type of construction is
basically the same as the one of the lifting unit. In addition, a lifting plate with 2 roller levers
and 2 roll slopes has been installed.
A WS entering the station will be stopped by the stopper, centred by the centring pin and
finally lifted off. By means of the roller lever, the lifting movement takes place in concert with a
tilting movement of 30°. After processing, the centring pins will be returned to starting position.
The stopper then releases the WS for further transportation. A pilot stopper keeps subsequent
WS from entering the workplace zone. The worker activates both the lift-and-tilt station and
stopper by means of switches and independently determines the cycle.
4.8.3
Fitting instructions
During assembly, always make sure that the carrier is stopped approx. 1mm behind the
centring position, thus allowing sufficient space for centring.
This can be achieved by centring the WS inside the lift-and-tilt station and by allowing an
interspace of 1mm when fixing the stopper to the WS.
4.8.4
Delivery volume
The delivery volume comprises:
•
•
•
•
•
1 lift-and-tilt station
1 pneumatic cylinder
2 dampers with support
2 control switches and
1 detector
The subassembly is delivered pre-assembled.
4.8.5
Maintenance instructions
The guide shafts plus bearing rest and the cylinder pins of the index plate are to be re-greased
every 300 operating hours (grease ISOFLEX super LDS 18).
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4.8.6
Table of disturbances
Disturbance
Cause
Remedying disturbance
cylinder defective
replace cylinder
electrovalve defective
replace electrovalve
triggering sensor defective
replace sensor
Error in control system
Check control system
stopper position is wrong
rectify stopper position
nominal service life of bearings
exceeded
replace bearings
Index plate does not move
Increased centring noise
Increased stroke noise
4.8.7
Repair Instructions
Repair work will be carried out by the manufacturer.
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4.8.8
4.8.8.1
Figures of subassembly lift-and-tilt station
General view
Moving direction
151,4
200
Cylinder
80
Guide pillar
Roll slope
Detector
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Page view
4.8.8.2
151,0
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EN_posyArtK_Kap04_R3a.doc
275,0 (Clearance for HKS replacement
108,0
195,0
32,5
27,5
Roller lever
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4.9
Sensor
4.9.1
Generalities
The sensor subassembly is used for identifying the WS position on the posyART DUPLEX
belt.
It is listed as an extension subassembly and thus needs to be ordered separately. Proximity
switches (size M18x1) are applied when needed. Other initiators are available on request.
4.9.2
Description
The sensor subassembly may be fitted in horizontal direction at any point of the posyART
DUPLEX system. It is fixed by clamping it between the dovetail grooves of the sustainer
profile. During installation, please make sure that the sensor does not project over the upper
edge of the profile. There has to be an interspace of 2mm between aluminium parts and the
sensor.
When a WS passes the sensor, the latter transmits an electric signal to the control system.
Based on the current state of the sensor, it can be easily seen whether a WS is present at this
position of the transport system or not.
4.9.3
Delivery volume
The delivery volume comprises:
•
•
•
1 clamping element assembled for the sensor
1 sensor with connection cable and
fixing screws
The subassembly is delivered pre-assembled.
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4.9.4
Figure of complete subassembly sensor
30
97
81,5
16
Cylinder screw M4
14
36
Sensor M18x1
33
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4.10
Reading head
4.10.1 Generalities
The reading head is part of a non-contact identification system for the identification of carriers.
4.10.2 Description
The reading head subassembly may be fitted in horizontal direction at any point of the
posyART DUPLEX belt. It is fixed by clamping it between the dovetail grooves of the
sustainer profile. The clamping element allows either a horizontal or a vertical position of the
reading head.
When a WS pass the reading head, the encoded item is read and the information is sent to the
analysis unit. The WS is recognised from the specific data.
4.10.3 Delivery volume
The delivery volume comprises:
•
•
1 complete clamping element for reading head and
1 reading head
The subassembly is delivered pre-assembled.
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4.10.4 Figure of subassembly reading head (horizontal and vertical assembly)
43,0
58,0
112,0
45,0
115,0
50,0
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4.11
Subassembly lateral positioning contrivance
4.11.1 Generalities
The lateral guiding of the carrier on the transport line is carried out via two guide beads. If a
higher guiding precision is required at certain positions, the subassembly lateral positioning
contrivance will be assembled at the point in question. The guide beads are not removed
therefore. The subassembly lateral positioning contrivance guarantees a lateral guiding precision
of +/- 0,07 mm and can be fitted at any place.
4.11.2 Description
The subassembly lateral positioning contrivance consists of 4 positioning elements. The
positioning element is composed of clamping element 50, clamping lath 50, positioning lath
and roller. The positioning lath featuring a roller will be fixed at the outside of the sustainer
profile, using the clamping element and the clamping lath. The screwed connection between
the positioning lath and the clamping lath allows for the positioning elements to be adjusted.
4.11.3 Delivery volume
The delivery volume comprises:
•
4 positioning elements including all fixing elements
The subassembly is delivered pre-assembled.
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4.11.4 Figures of the subassembly lateral positioning contrivance
4.11.4.1
Assembling details
WT
9,5
3
One set contains 4 of the
clamping elements shown,
plus small rail and small rollers
4.11.4.2
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Top view
Fixed side
Adjustment side
Cylinder pin
(adjustment
point)
without
cylinder pin
Cylinder pin
Cylinder pin
(adjustment
point)
without
cylinder pin
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4.12
Subassembly passive lowerator
4.12.1 Generalities
At working stations where vertical forces effect the carrier (at centring stations from 500N), the
flat belt may be clamped between the belt rest of the belt band and the rail shoe of the carrier.
The subassembly passive belt lowerator has been developed to avoid this.
4.12.2 Description
The passive belt lowerator is a component which enables the belt to escape downwards, when
vertical forces are effecting, thus to avoid a clamping of the belt.
Depending on the size of the WS, the support profile of the belt rest in the working station is
replaced by a spring element. This element is specially available for each size and weight of
carriers.
4.12.3 Fitting instructions
During installation, please make sure that the spring part is mounted with the spring inserts
downwards.
4.12.4 Delivery volume
spring part with integrated spring inserts for each side of the profile mounted on the belt line
4.12.5 Maintenance instructions
Check the smooth of the spring inserts annually.
4.12.6 Table of disturbances
Disturbance
Cause
Remedying disturbance
Flat belt stops shortly during pressing procedure
Flat belt cannot escape downwards
check smooth of spring inserts and
replace if necessary
Carrier does not exit the station
Belt rest profile is clamped in
bottom position
check smooth of spring inserts and
replace if necessary
4.12.7 Repair Instructions
•
•
Dismantling of the belt rest (see description in chapter 3, section 3.1 Replacing the belt
rest)
Take out the spring part in upward direction
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4.12.8 Figure of subassembly passive lowerator
4.12.8.1
Page view
Plastic insert
Spring thrust pieces
4.12.8.2
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Top view
WS weight
total (N)
Thrust
pieces
125-168
32
82-125
24
60-82
16
38-60
12
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Arrangement of thrust pieces
posyART Version 8.0
Individual extensions of subassemblies
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posyART Version 8.0
Individual extensions of subassemblies
December 2003
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IEF Werner GmbH
Handhabungstechnik
5 Accessories
5.1
Generalities
The accessories of the posyART system allow you an efficient and save application of the
base subassemblies and extension subassemblies described in the chapters 2 - 4, as well as
your own installations. We will be pleased to develop further possibilities of any accessories
for you on request.
5.2
Clamping element
Clamping elements are used for fixing both posyART and customised subassemblies to the
sustainer profile.
They are available in the standard widths 20, 50 and 100 mm. Tapped bore holes for the
clamping lath are already available. The clamping element may be altered according to the
customer’s requirements as far as length, width and the position of further bore holes are
concerned.
Clamping element and clamping lath are also available by the metre, separately and without
bore holes. The clamping element (20 mm) is used for fixing the guide bead while the
clamping element (100 mm) is used when posyART transport lines are being joined. Using
the 50 mm clamping element, subassemblies of any kind are adaptable to the sustainer
profile.
5.2.1
Description
The clamping elements are inserted into the dovetail groove of the sustainer profile and fixed
at any point, using the clamping lathes. This type of clamping facilitates precise shifting to any
point without the profile getting indented or damaged in any other way.
For the measurements, please refer to the figure below.
5.2.2
Delivery volume
The delivery volume comprises:
•
•
1 clamping element
1 clamping lath and fixing screws
The subassembly is delivered pre-assembled.
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5.2.3
5.2.3.1
Figure of accessories - clamping element
Standard element size A
15
4,5
66,7
35,0
5.2.3.2
50,0
Standard element size B
44,8
15
12,5
13
7
35,0
6,5
43,0
69,0
80,0
2
50,0
The sizes of the clamping element are to be selected according to the requirements.
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Accessories
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5.3
Supporting foot
5.3.1
Generalities
The supporting foot is intended to hold duplex belts of long production lines at the prescribed
height. The horizontal sturdiness of the duplex belts is assured through the connection of the
single stretches with the clamping elements (see Accessories, section 5.2).
The supporting feet allow a space-saving and cost-effective installation of long posyART
production lines.
5.3.2
Description
The supporting foot consists of welded tube profiles 50x50x3. To fix the foot on the belt band
profile, the spacer seats are made of steel and are fixed using standard clamping elements.
5.3.3
Delivery volume
•
•
•
•
1 supporting foot welded of tube profiles 50x50x3
4 clamping elements for fixing
2 pedestals M8x80
3 squared stoppers
The subassembly is delivered pre-assembled.
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Accessories
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5.3.4
Figure of accessories - duplex belt support
Spacer
Vertical sleeper
Welded profile
Pedestal
welded
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5.4
Stand
5.4.1
Generalities
The stand is designed for the posyART components. It is an independent subassembly.
Advantages compared with single supports:
•
•
•
5.4.2
simple and time saving assembling and dismantling
the stand may be aligned, levelled and anchored to the ground an uneven surface will not
affect the posyART components the posyART system will be fixed when disconnected
onto the stand and fixed in position
additional components can be fixed onto the stand
Examples of application: Case 1 and 2
The stand serves as support for either a posyART DUPLEX belt line (EZ1) or 2 posyART
DUPLEX belt lines (EZ2) arranged parallel.
For 6 WS sizes and for transport lines from 1500mm and 4000mm (in steps of 500mm each),
standard stands are available.
5.4.3
Example of application: Case 3
The stand serves as support for a posyART DUPLEX system of rectangle type. The WS size
and the dimensions of the rectangle are to be stated when ordering. For rectangles with
lengths up to 4000mm and widths up to 2200mm, a complete stand is available. In case those
dimensions are exceeded, the stands will be joined together accordingly.
Transport height is min. 900mm. It guarantees the fitting of the electric components underneath
the transport lines in accordance with the VDE regulations.
5.4.4
Description
The stand is designed as weld subassembly. Basis is a structural tubing shape of
60x60x3mm. The profile ends are equipped with crowns, the surface is varnished (RAL7032).
Base plates with threaded holes have been welded in to support the adjustable pedestals. The
adjustable pedestals guarantee a stable standing and the height can be adjusted by ± 50mm.
The threaded holes required for fixing the spacers are available.
Pneumatic components as well as cable channels can be fitted easily. A perforated plate is
available therefore. The max. loading capacity of the stand is 6000N. Clamping brackets are
used for anchoring the device to the ground.
5.4.5
Delivery volume
The delivery volume comprises:
•
1 stand with pedestals and squared stoppers
The subassembly is delivered pre-assembled.
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Accessories
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5.4.6
5.4.6.1
Figure of subassembly stand
C stand (case 1)
900
Main board
790
Cable channel
Vertical sleeper
Pedestal
Sleeper rest
DUPLEX stretch
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Accessories
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5.4.6.2
I stand (case 2)
900
Switch cabinet
790
Switch cabinet
Vertical sleeper
Pedestal
Sleeper rest
DUPLEX stretch
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Accessories
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Switch cabinet
900
Rectangle stand (case 3)
790
5.4.6.3
Vertical sleeper
Pedestal
DUPLEX stretch
Sleeper rest
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Accessories
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5.4.7
Retrofitting of carriers
The customer can retrofit the 6 WS of the posyART system with holders, workpiece
receptacles, etc. according to his requirements.
The threaded holes and fixing elements required therefore are not available in the basic
equipment of the WS. We can adapt the basic equipment of the WS according to your
specifications.
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Accessories
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6 Assembly instructions
6.1
General assembly and repair instructions
Replacing the driving unit
(1) dismount belts (see belt replacement chapter 6.2)
(2) squeeze off motor cable, secure driving unit vertically
(3) loosen the 2 headless pins M10 x 12 and remove them
(4) remove vertical safety device, shift the driving unit downwards
(5) install new driving unit in reverse order
NOTE
adjust belt tension! (refer to belt replacement chapter 6.2)
Replacing the reversing roller
(1) dismount belts (see belt replacement chapter 6.2)
(2) loosen and move the 2 cover strips (2 headless pins M3)
(3) press out cylinder pin 8h8 of the bore holes and take out reversing roller with the 2
spacer rings
(4) mount the new reversing roller in reverse order
Replacing the geared motor
(1) squeeze off the motor cable
(2) remove 2 covering caps
(3) loosen tallow-drop screw M8 at one side of the driven shaft
(4) pull the driven shaft
(5) slacken torque converter bearing (cheese head screws M8x50) and remove the geared
motor
(6) install new geared motor in reverse order
CAUTION
Secure the tallow-drop screw on the driven shaft with a screw locking.
Replacing the belt rest
(1) dismount belts (see belt replacement chapter 6.2)
(2) vertically remove the belt rest from the sustainer profile
(3) place bore hole with diameter 8,5 on the new slide rail and mount the new slide rail in
reverse order
Instructions on how to replace the belt can be found in chapter 6.2.
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Grundformen der Transportbänder
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6.2
Belt replacement
Clearance
250 for belt replacement
250
250
7
8
1
5
6
4
2
3
NOTE
Please make sure that all exterior add-on pieces, such as sensors and cylinders,
are of plug-in type. Please take into account the clearances for belt replacement
stated in the documentation!
Work is to be executed in following order:
(1) Switch off motor!
(2) Loosen the tension jack 1 (2 cheese head screws M6x30)!
(3) Turn the tension jack 1 within the profile and remove it in downward direction!
(4) Remove caps 2 and 3 !
(5) Dismantle distance piece 4 from the alignment unit (screw M8x110 and M8x75)!
(6) Loosen the spanners 5 and 6 (Umbraco screw M8x16)!
(7) Push the spanners 5 and 6 right to the end of the sustainer profile and remove them in
downward direction!
(8) Remove caps 7 and 8 !
(9) Replace the belt 9!
(10) Assemble the subassemblies and the component parts in reverse order.
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Assembly instructions
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6.3
Tensioning the belt
3
1
2
CAUTION
When tensioning the tension roller completely, the flat belt is adjusted with the necessary belt tension.
When tensioning the toothed belt bands, please make sure that the toothed wheel
work of belt and driving roller catch merely without slipping!
Do not tension to the maximum!
Work is to be executed in following order:
(1) Switch off motor!
(2) Push spanner 1 within the sustainer profile towards the tension roller and jam it (screw
M8x16)
(3) Push spanner 2 manually towards the tension roller and jam it
(4) Push tension jack 3 within the sustainer profile towards spanner 2 and jam it (2 screws
M6x30)
(5) Only for flat belts!
Loosen the spanner 2 and shift (tension) it towards the driving roller using the headless
pin M10x80 of the tension jack 3. The buffer must be reached.
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Assembly instructions
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6.4
Shifting the drive
4
5
3
2
6
1
7
Work is to be executed in following order:
(1) witch off motor!
(2) rrange the safety rests 1 underneath the driving unit!
(3) emove caps 2 and 3 !
(4) oosen the tension jack 4 and shift it within the sustainer profile!
(5) oosen the tension jacks 5 and 6 and shift them within the sustainer profile!
(6) lacken the clamping between the driving unit and the sustainer profile
(loosen 2 headless pins M10x12 7 by one turn)!
CAUTION
If the headless pins are slackened by more than one turn, the driving unit and the
sustainer profile can get de-coupled (safety rest have to be in position)!
(7) hift the driving unit assembly within the sustainer profile!
(8) estore clamping between the driving unit and the sustainer profile
(2 headless pins M10x12 7)!
(9) e-adjust the belt tension as described in chapter 6.3!
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Assembly instructions
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posyART Version 8.0
Assembly instructions
December 2003
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