1 Overview[edit | edit source]
The new PMM design for small winders does not contain any hydraulic components any more.
All movements of chucks, cutting arm, turning fixing and core ejector are done now by spindle positioning drives with sinamics.
2 Definition of calibration positions[edit | edit source]
All positioning drives of course need to be calibrated. The calibration positions have been defined as follows:
2.1 Cutting Arm General[edit | edit source]
At the small winders, the cutting arm is mounted below the winder.
Movement: Positive direction from down to up. Down = park; Up = work;
Calibration: Measure the distance of the cutting arm between the fixing points (point A and point B in the picture).
The park position is defined by a distance between A and B of 697mm. Calibrate the drives on a position of 1.5mm. (Measured 697mm == 1.5mm).
The work position differs with the diameter of the empty core (cutting arm must go up further with smaller cores). This value for work position can be found in the document "schedule for adjustment of cutting impl" ("Einstellschema f. Schneidvorrichtung"). This document must be available on site - ask your site-manager.
For example: On a small PMM winder with 450mm cores the document defines a work position of 559.5mm (or measured between A and B 1255mm).
Additional drawing from mechanics:
Adjust the values like this:
Position Setpoint Minimum: 0mm
Position Setpoint Maximum: 600mm
Position 1 Setpoint: 1.5mm
Position 1 Hysteresis: 0.5mm
Position 2 Setpoint: 559.5mm (depending on enmpty core diameter)
Position 2 Hysteresis: 0.5mm
2.2 Cutting Arm OLD Version[edit | edit source]
Limitswitches:
These spindle positioning elements have internal limitswitches to protect the spindle from being damaged.
Those limitswitches should never be reached while moving but of course the correct function needs to be checked.
Limitswitches should be already pre-adjusted correctly by GROB (supplier of the spindle elements).
Therefore make sure that the connection is correct - all limitswitches are normally closed and give "true"-signal if they are not reached.
PVSS / Input check:
Position Maximum alarm should appear, if the spindle is in work position and you turn the top - screw CCW to reduce the spindle stroke to test the signal. After the test, turn two revolutions back (CW).
Position Minimum alarm should appear, if the spindle is in park position (697mm) and you turn the bottom - screw CW to reduce the spindle stroke to test the signal. After the test, turn two revolutions back (CCW).
Do not change the position too much to increase the spindle stroke (reduce is no problem)! They still must protect the device from getting damaged.
| Limit Switches Screw | Limit Switches graphic function |
|---|---|
| Template:Image | Template:Image |
Mechanical Data: spindle pitch = 4mm; gear ratio = 3.75 : 1 (-->375:100 in LinDrvCfg); Line Speed: 1513.0; LUperRev: 4000
Torque Difference and Lubrication
Please pay attention during commissioning if there is a significant torque difference between the two spindles while moving the cutting arm.
Has the arm been properly aligned in parallel to the core?
Consult your mechanical engineer on site to re-adjust the mounting fixture of the spindle element. Also have a look if the spindle "eye" is not touching and no forces from the sides are applied (if the spindle is jamming sideways somewhere).
Insufficient lubrication has caused spindle damages on several projects already.
GROB spindles can only be lubricated properly when the spindle is fully extracted (in work position) - otherwise the grease goes somewhere without effect.
To answer our customer's question on how to lubricate:
- bring the cutting arm up to work position
- press an E-Stop so that the safety gate is released
- lubricate according to maintenance manual (mechanic)
2.3 Cutting Arm NEW Version[edit | edit source]
Because of some gearbox problems with the old version (plastic gears) and lubrication issues, the mechanic implemented a new version.
ATTENTION The new spindle Hub has different gearbox ratio!!!
Mechanical Data:
- Spindle pitch = 5mm --> LUperRev: 5000
- Gear ratio = 6.4 : 1 (-->64:10 in LinDrvCfg)
- Line Speed: 1560.0
Calibration of New Spindle Hub motor:
The park position is easy and must be like this: You will find on the back side of the motor an big screw where below is an lubrication point for mechanics. So they need to be able to access this! Take care, that this point is in the middle of the screw and you also have the input of the limit switch. Normaly this is perfect matching from the default setting from spindle supplier! If not you can move up 1-2mm and the lubrication is still accessable. Don't move the limit switch lower then the original End-stoppers!
The work position for the cutting arm is also very easy defined according the picture below. The first column is the value for WinCC. So how much the stroke is moving. The second column is to measure direct the stroke with a meter to recheck it on the machine! This is the only way to be sure to don't damage the spindle hub element and don't touch any limits! You can also see the maximum movement for an WIH Dm 240 with 599mm. Let's keep 4mm backup, so MAXIMUM Value for the spindle hub element is 595mm!
To recheck the calibration you can measure the stroke like here. Measure from the end of the zylinder to the end of the spindle.
Summary:
- Position Setpoint Maximum: Depend on the charging bar and touching the core, BUT spindle hub element is 595mm. So if you will not reach the maximum according process, then you need to move the machnical support points!
- Position 1 Setpoint: 1mm
- Position 2 Setpoint: Depend on the picture above: 599, 594, 588, 569, 540mm! --> These are just values for orientation. These can be slightly adjusted with process
Limitswitches:
The new limit switches are absolutely perfect! Same as the limit switches at the festo zylinders, just that these limit switches are NC, because wire break safe.
Maybe the drawings are still not correct: Now this is an magnetic switch and so we need there GND, +24V and the feedback signal. You can change the wiring with the existing cable!
Adjust the limit switches as follow: Be sure, that you reach the work + park position. Then move the switch to the point where the light of the switch goes off. Move the switch out of the range where the light goes on again (around 1cm).
2.4 Core Ejector[edit | edit source]
Movement: Positive direction = push towards core. park = pusher retracted; work = pusher extended.
Calibration: 0mm = When the spindle touches the pusher, i.e. the pusher piston starts to move. Do this calibration with winder 1 (red winder).
Adjust the values like this:
Position Setpoint Minimum: -5mm
Position Setpoint Maximum: 105mm
Position 1 Setpoint: -5mm
Position 2 Setpoint: 100mm (core must be free)
Position 1 + 2 Hysteresis: 0.5mm
When in park position (-5mm) there must be a 5mm gap between spindle and pusher (you can see it when you look behind the turning wheel).
2.5 Turning Fixing[edit | edit source]
Movement: Negative direction from closed to open position. park = open position; work = closed position.
Calibration: Fully closed position is 0mm. Exact 0mm-position is found by closing the fixing with a limited load of 20%. Check visually together with the mechanics that the teeth are correctly in.
Adjust the values like this:
Position Setpoint Minimum: -30mm
Position Setpoint Maximum: 0mm
Position 1 Setpoint: -30mm (turning wheel must be free).
Position 1 Hysteresis: 0.5mm
Position 2 Setpoint: 0mm
Position 2 Hysteresis: 2.5mm
First time raw calibration:
Measure as indicated in the picture below. Calibrate roughly accordingly (146mm = 0mm Calibration Set).
The minimum mechanical end position is 111mm, but we move only from 146mm-30mm=116mm.
Do not move the spindle below 115mm, otherwise the locking nut would touch the housing.
ATTENTION don´t set the clamping torque too high, this can lift out the whole winder. 25% is enough.
So the park position is electrical -30mm and mechanical you can measure 116mm!
2.6 Chucks[edit | edit source]
Movement: Negative direction from closed position to open position. park = open position; work = closed position;
Calibration: Omm-Position is reached when the Chucks are fully closed. The fixing happens with a spring package which is squeezed after the chuck is on block with the core.
The clamping torque should be around 20-30%. When closing the chuck, the spring package should be pushed in and there should be a gap (yellow part) of 2-3mm - hysteresis is 5mm (reduce or increase the clamping torque if you can't reach this position).
First time raw calibration
Position 1 Setpoint: -200mm
Position 1 Hysteresis: 2mm
Position 2 Setpoint: 0mm
Position 2 Hysteresis: 5mm
ATTENTION Beware not to move the spindle Chucks too much backwards! The spindle can stuck when reaches the end!!!
Conical clamping
Radial clamping
Normally WIH 600mm.
