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FICEP 1001 DFB, Programming And Operating Manual

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FICEP 1001 DFB Programming And Operating Manual Download Page 8

Programming and operating manual 

Model 1001 DFB  

 

8 

FICEP S.p.A. 

Drilling-milling operations table ........................................................................................................... 40

 

Cutting operations table ...................................................................................................................... 42

 

Setup ...................................................................................................................................................... 43

 

Drilling-Milling operations setup window ............................................................................................. 43

 

Cutting operation setup window .......................................................................................................... 47

 

Codes describing the tool and the operations types ........................................................................... 48

 

Setup general page ............................................................................................................................ 50

 

CHAPTER 6: PROGRAMMING .................................................................................... 52

 

Preliminary remarks ............................................................................................................................. 52

 

Terminology ........................................................................................................................................ 52

 

The programming window .................................................................................................................. 53

 

To input a new program ...................................................................................................................... 54

 

Editing a program: preliminary remark .............................................................................................. 57

 

Programming: single hole ................................................................................................................... 58

 

Programming: linear pattern of holes with same diameter ................................................................. 59

 

Programming: matrix pattern of holes with same diameter ................................................................ 60

 

Programming: pattern of holes with same diameter arranged on an arc of circle or a whole circle ... 61

 

Programming: marking operations ..................................................................................................... 62

 

Programming: special functions ......................................................................................................... 63

 

Use of the absolute and incremental coordinates .............................................................................. 63

 

Temporary repositioning of the part origin .......................................................................................... 64

 

Permanent repositioning of the piece origin ....................................................................................... 65

 

Programming of special functions ...................................................................................................... 65

 

Milling operations ................................................................................................................................ 67

 

Automatic execution of particular drilling and pointing operations ...................................................... 69

 

Edit of program remarks ..................................................................................................................... 70

 

Bar nesting ............................................................................................................................................ 70

 

Basic procedure for nesting execution ............................................................................................... 72

 

Variants for basic nesting procedure: how to use the push-button “Rotation” .................................... 74

 

 Variants for basic nesting procedure: manual nesting ....................................................................... 75

 

 Variants for basic nesting procedure: automatic nesting ................................................................... 76

 

Bars list ............................................................................................................................................... 76

 

Execution parameters ......................................................................................................................... 77

 

CHAPTER 7 : PROGRAM EXECUTION ...................................................................... 80

 

Execution of working operations: introduction................................................................................. 80

 

Procedure to execute a program of a single piece ............................................................................. 82

 

Procedure to execute a program of a nesting .................................................................................... 86

 

The execution window ........................................................................................................................ 89

 

Operator controls during automatic execution .................................................................................... 90

 

Procedure to restart the line after emergency .................................................................................... 91

 

 Procedure to restart the line after unexpected power shut off ........................................................... 91

 

CHAPTER 8: SPECIAL AND ADDITIONAL OPERATIONS ........................................ 92

 

Alternatives using the pincher ............................................................................................................ 92

 

Working flat profiles ............................................................................................................................ 92

 

Working “U” profiles and square tubes ............................................................................................... 92

 

Working “D” profiles (different flanges)............................................................................................... 93

 

Change of pincher orientation ............................................................................................................. 93

 

Procedure for semi-automatic cut....................................................................................................... 94

 

Test working ....................................................................................................................................... 96

 

Operator parameters for basic operations ......................................................................................... 96

 

Verifying the correct axes displacement ............................................................................................ 97

 

CHAPTER 9: ARCHIVE OPERATIONS ....................................................................... 98

 

File management .................................................................................................................................. 98

 

Import operations ................................................................................................................................. 98

 

Import of DSTV files ........................................................................................................................... 98

 

Import of single piece or bar programs generated by third applications ............................................. 99

 

Final working data of the line ............................................................................................................ 101

 

Summary of Contents for 1001 DFB

Page 1: ...Line Model 1001 DFB Serial number 32292 Programming and operating manual...

Page 2: ...Programming and operating manual Model 1001 DFB 2 FICEP S p A Blank page...

Page 3: ...if partial of the graphic work the text or the images Some details described in the texts and or represented in the illustrations of this manual could be slightly different from the machine which ref...

Page 4: ...Programming and operating manual Model 1001 DFB 4 FICEP S p A Blank page...

Page 5: ...e paragraphs marked by this symbol are particularly im portant and related to programming Subjects dealt with in the paragraphs marked by this symbol are particularly important and related to machine...

Page 6: ...Programming and operating manual Model 1001 DFB 6 FICEP S p A Blank page...

Page 7: ...CNC WORKING ENVIRONMENT 21 CNC Software sections 21 Line start up 21 The main push button panel 22 Control and protections zone 23 Axes zero cycle 24 Preliminary remarks 24 Procedure to execute the ax...

Page 8: ...of program remarks 70 Bar nesting 70 Basic procedure for nesting execution 72 Variants for basic nesting procedure how to use the push button Rotation 74 Variants for basic nesting procedure manual ne...

Page 9: ...tput I O condition 103 Dynamic synoptic 105 Summary of all commands of menu View and Setup 106 Debug window 106 Graphic push button Installation Servicing 107 General rule 107 Contents of each tab 107...

Page 10: ...Programming and operating manual Model 1001 DFB 10 FICEP S p A Blank page...

Page 11: ...4 drilling unit 5 drilling head 6 cutting unit saw 7 marking unit optional 8 main switch 9 articulated arm 10 CNC and Operator s position 11 rollers unloading side Identification of the machine plate...

Page 12: ...ZZADA SCHIANNO VA ITALY Type XXXXX Serial Number XXXXX Drawing number DES XXXXX Year XXXX XXX V XX Hz 3 XX A Voltage Frequency Phases Max load XXX A Max load current GAZZADA SCHIANNO VARESE ITALIA SER...

Page 13: ...AXX Carriage axis for longitudinal positioning of material Material handling AXP Pincher positioning axis to suit profiles height optional APE Magnet positioning axis for transferring of cut pieces o...

Page 14: ...eb optional AXR Saw mitering axis Cutting operations AXS Saw band feedrate axis All axes tagged with a star are shown in the following pictures Origins and sign conventions of the axes NOTE The above...

Page 15: ...ning light To power the line it is necessary to rotate the main switch in ON position to start up the line it is neces sary to push the RESET push button to switch the blue warning light OFF Meaning o...

Page 16: ...mergency push button is on the portable push buttons panel for maintenance operations see Portable push buttons panel for service operations page 38 4 Controls and protections zone Key type selector s...

Page 17: ...ations Aided programming INSERT To move the curser on a blank table and input new working data it is named INS in the example To increase or decrease the axes speed or to program negative positive inc...

Page 18: ...Programming and operating manual Model 1001 DFB 18 FICEP S p A Blank page...

Page 19: ...FF To enter one of the four main pages or to shut down the system it is necessary to press the key corre sponding to the underlined character of the word of each graphic push button or press the scree...

Page 20: ...current time in the following format hh mm ss hours minutes seconds of the clock inside the PC 5 per cent value of the AXX axis movement speed from a min of 10 up to a max of 100 The value which has b...

Page 21: ...cles parameters display modification of axes parameters information about predefined working cycles information about CNC internal configuration diagnostic information Communication CAM graphic and te...

Page 22: ...uits ex the oil pump JOG manual movement of the selected axis to wards negative direction decreasing coordinates Stand by mode axes are not qualified Program ming and setup opera tions are enabled JOG...

Page 23: ...his push button if provided Locked position it is allowed only to pass from the current op erating mode to stand by mode and vice versa only the last se lected mode is kept active Unlocked position al...

Page 24: ...ram execution or a manual positioning of the axes it is necessary to perform the preset program called axes zero cycle The CNC when switched on is unacquainted on the true physical position of the axe...

Page 25: ...der pressure the LED of the push button remains illumi nated and the line is in stand by mode Select the automatic execution push button The continuous execution mode is selected The LED remains illum...

Page 26: ...id wrong commands the activation of each push button is to be performed at least for 0 5 1 second Attention Each axis has electronic barriers their purpose is to allow a controlled and soft stop of ea...

Page 27: ...Model 1001 DFB Programming and operating manual FICEP S p A 27 Blank page...

Page 28: ...in central position The operator can control the system Switch the auxiliary circuits on The oil pump starts and the oil pipes goes under pressure the LED of the push button remains illumi nated and t...

Page 29: ...resses JOG or JOG push button on the main push button panel or until the achievement of the electronic barrier 0 01 0 1 1000 mm each time the operator presses the JOG or JOG push button the axis execu...

Page 30: ...d roller way 09 Slow forward of the powered roller way 10 Slow backward of the powered roller way 11 Fast backward of the powered roller way 12 Reservation of the unloading table 13 Slow backward of I...

Page 31: ...the graphic push buttons is strictly complied to the 1001DFB configuration bought The followings generals pictures show all possible controls and can par tially correspond to the softkeys of the mach...

Page 32: ...width 12 It enables the vertical probing of profile height of the web and flanges 13 It stores the tool into the tool magazine in man ual mode 14 It stores the tool into the tool magazine in man ual m...

Page 33: ...Model 1001 DFB Programming and operating manual FICEP S p A 33 Soft keys window for sawing unit 02 01 03 04 07 05 08 06 09 10 11 12 13 15 16 14 17 18 19 20 21 22 23 24 25 26 28 27...

Page 34: ...in manual mode 13 It displays a window with two diagrams related to the band rotation speed and to the current drawn of its motor 14 It actuates the band rotation in manual mode 15 It enables the cutt...

Page 35: ...Model 1001 DFB Programming and operating manual FICEP S p A 35 Blank page...

Page 36: ...type 2 Both tool holders have two slots with same width but different depth the tool holder is to be inserted into the magazine so that the slot with less depth correspond with each reference pin if p...

Page 37: ...a tion Rotate the central selector in left position one of the wheel moves near to the other releasing the band by means of an hydraulic cylinder band tighten Rotate the central selector in right posi...

Page 38: ...condition activated key se lector in left position The system is in setup mode and the operator can operate in safety way through the portable push buttons panel after having extracted the key Select...

Page 39: ...t the alarm caused by protection barriers if provided CNC preparation Inside the CNC two databases are available TABLES it contains the technological information of all tools used on the line and it i...

Page 40: ...ist of tool types opens 02 All Minimum diameter of the tool 03 All Maximum diameter of the tool 04 All Nominal diameter of the tool this is the value used by the CNC to carry out its calculations 05 A...

Page 41: ...hickness 17 All Maximum distance covered by the drill inside the material before the replacement to allow its cooling 18 Milling tools Pocketing speed POCKET operation related to a front cutting tool...

Page 42: ...ns table Meaning of the fields L H side list of all thicknesses which can be cut depending on the band rotation speed R H side o Field Min Thickness the use of the selected band is restricted to mater...

Page 43: ...splayed with red back ground The operator has to set up the machine with the tools and the profile required and then confirms pressing the push button OK ATTENTION When the operator presses the OK pus...

Page 44: ...s not present the operator can press the push button Spindle and type in the number of the empty site Typing in 0 it signified that no tool is inserted into the spindle and each tool is in its own pla...

Page 45: ...by CNC according to the grinding angle 17 Milling coordinate where the spindle starts the contouring movement Pocketing real coordinate of working depth This value is negative 12 Drilling First stop c...

Page 46: ...by steps of 10 The graphic push buttons in the drilling setup window PUSH BUTTON FUNCTION Tool Life Pressing this push button a window is displayed where it is possible to define the maximum working l...

Page 47: ...length with a special drilling cycle which has a slow approach speed The val ue obtained is used for all the subsequent drilling operation of this tool The sensitive cycle could be performed only wit...

Page 48: ...then goes back until the start coordinate ATTENTION this operation can be performed only if a through hole is present The sensitive cycle for tool length pick up cannot be used FLARE Countersink The c...

Page 49: ...etric tapping See TAP TAP_43 Whitworth tapping See TAP TAP_44 Fine Whitworth tapping See TAP TAP_45 UNF tapping See TAP TAP_46 Gas tapping See TAP TAP_47 UNC tapping See TAP MILL Milling First it is n...

Page 50: ...page All fields shown in this page are only displayed the operator can read but not adjust them the only field that can be modified is the Measuring unit to change it follow this procedure 1 F2 Modify...

Page 51: ...Model 1001 DFB Programming and operating manual FICEP S p A 51 Blank page...

Page 52: ...e C horizontal upper side of the profile from here we shall call it upper web side D horizontal lower side of the profile from here we shall call it lower web L profiles side A vertical profile side t...

Page 53: ...e drawing also the posi tion of the feeding pincher is represented in blue colour Zone 4 selecting controls pressing the Filter push button a window is displayed where it is possible to choose the sel...

Page 54: ...mensions tools list operations for each side etc To input a new program Pressing the New push button in the programming section a window to compile the part program is dis played Description of the da...

Page 55: ...ame window it is possible to insert a new material or to modify an already existing one N B this window is the same of the one described on page 41 07 Type of profile to select a profile type press F4...

Page 56: ...layed in the selection window described at point n 08 13 The profile is represented open on the plane and not to scale 14 List of program instructions each instruction is so composed LINE progressive...

Page 57: ...ield of the instruction LINE TYPE SIDE DIAMETER X Y DETAILS 001 Pressing F4 when the cursor is in the diameter field a window with the list of all tools present in the tool table the CNC general datab...

Page 58: ...illing heads All profiles except L DCS only for machines with two drilling heads L profiles DBS only for machines with two drilling heads DETAILS DRILL Helicoidal tool sensitive cycle allowed DRILL 32...

Page 59: ...single hole DETAILS See single hole Selecting LIN in the TYPE field a window is displayed to insert the parameters of the holes pattern configuration and of the other field of the programming line Exa...

Page 60: ...window is displayed to insert the parameters of the holes pattern configuration and of the other field of the programming line Example matrix of twelve holes with diameter 20 mm executed on the web w...

Page 61: ...e DETAILS See single hole Selecting FLA in the TYPE field a window is displayed to insert the parameters of the holes pattern configuration and of the other field of the programming line Example seven...

Page 62: ...is displayed to insert the marking parameters and the other field of the programming line Example Marking of FICEP string by the marking unit on the flange see following picture n 1 mark ing of the c...

Page 63: ...ncremental coordinates It is possible to use the absolute coordinates as per all previous examples or the incremental coordinates as per the following one where the operation is programmed in the two...

Page 64: ...t according to the first hole position The position of both holes in both examples is the same Temporary repositioning of the part origin Pressing F4 with the cursor in the SIDE field the window for t...

Page 65: ...in point 4 013 DC 20 000 50 150 DRILL 4th Group of holes the holes coordinates are the same of the first one 014 DC 20 000 75 200 DRILL 015 DC 20 000 50 250 DRILL 016 ORG DC 200 100 New origin point 5...

Page 66: ...is forced by the programmer LINE TYPE SIDE DIEMETER X Y DETAILS EXECUTION ORDER 001 DC 22 000 400 110 DRILL 4 002 DC 22 000 600 130 DRILL 3 003 MISC M51 004 MARK DA 700 150 FICEP 1 005 MISC M50 006 DC...

Page 67: ...practical output of the previous program Milling operations OPERATION TYPE PROGRAMMING CODE EXAMPLE Pocketing POCKET Milling MILL The pocketing operation consists in slow approach to the material sur...

Page 68: ...int n 1 002 CUT DC 400 50 Removal up to point n 2 003 CUT DC 400 150 Removal up to point n 3 004 CUT DC 100 150 Removal up to point n 4 005 CUT DC 100 50 Removal up to point n 1 When the cursor is in...

Page 69: ...out in just one pass entry 06 entry 05 07 Increment between two subsequent passes this is the entry n 13 of the setup table see page n 45 This value is always positive because it is an increment and...

Page 70: ...erator presses the push button NESTING the CNC software chooses all pieces to be real ized with same material and same profile If the operator would like to nest only some particular pieces he must fi...

Page 71: ...indow Pincher scrap is selected this field contains the total scrap zone n 3 zone n 1 of nested bar If in the Parameters window Leading edge scrap is selected this field contains the total length of t...

Page 72: ...hold limit see the section Execution parameters on page 77 Basic procedure for nesting execution Control Meaning Remark Start condition Window for nesting operations in the zone n 19 the list of piece...

Page 73: ...the total quantity is not available in the factory storehouse If needed the operator can de fine a new length for the bars to use press OK to re execute the nesting procedure for remaining pieces till...

Page 74: ...to save material and tool life If the operator presses the push button Automatic in the rotation window the CNC software performs it self the rotation of the pieces but without the possibility of diff...

Page 75: ...keypad The operator types in the number of pieces to nest in the bar shown in the zone n 2 and confirms pressing Enter The content of cell n 17 quantity in the zone n 14 pieces arranged in the bar is...

Page 76: ...the bars list is automatic and the operator doesn t need to press Save When an automatic nesting is performed neither quantities in the zones n 14 and n 19 nor drawing in the zone n 2 are updated Bars...

Page 77: ...all ended nestings from the list 12 Open the nesting window for the selected nest maybe to display the pieces nested Execution parameters By pressing push button n 21 in the nesting window see page 7...

Page 78: ...e single pass but divided for each working side 05 Checking this box the CNC automatically start the next job when the current is com pleted 06 The job is to be executed in two different phases drilli...

Page 79: ...6 in tool tables normally used to differentiate tools with same diameter but with some other different characteristic for instance the suppli er 19 Checking this box the operator defines the priority...

Page 80: ...NC software can execute programs in two modes single piece execution bar execution Many push buttons Execute are available to start different execution modes Single piece execution Programming window...

Page 81: ...the window If not adjust the right value in the field n 1 in the Execution parame ters window as described in the previous section Nesting execution option 2 Bars list window the push button Execute...

Page 82: ...sh button Programming Activation of main pro gramming window In the lower area of the window there is the list of pro grammed pieces Arrow keys Selection of the piece to be executed Select the piece t...

Page 83: ...eters Adjust if needed the execution parameters opening the related windows by pressing the push button Parame ters Note that in the parameters window for single piece you can find two extra parameter...

Page 84: ...or must remove the problem and af ter he must re execute the program ESC of the PC keyboard and then graphic push button Execution To supervise the execu tion of the program The Execution window is di...

Page 85: ...The operator executes all fitting operations carefully checking type and position of all fitted tools the new physical setup must be exactly like requested from the CNC At the end of operations the o...

Page 86: ...tart condition Line powered axes zero cycle executed auxiliary circuits ON oil pump etc no active alarm main page of CNC software displayed program for nesting already edited and ready to execute Push...

Page 87: ...e opera tor must confirm pressing OK or abort pressing Can cel ESC Coming back to the piece list The canonic program has been perfectly generated with out errors If an error occurs for instance the pr...

Page 88: ...atically shows the setup window In this page correct tools have green back ground colour while incorrect tools have red background colour Setup mode to fit the line The operator must switch the line i...

Page 89: ...rdinates change dynami cally the line is working The execution window Reference Meaning 01 Controls bar 02 Display of coordinates of main axes 03 Graphic information of worked profile 04 Program in ex...

Page 90: ...o execute among a new piece program a new nesting program or a cycle Cycles are special test programs stored in the CNC memory in FICEP factory 12 Soft keys for machine tuning and direct control of so...

Page 91: ...for interruption of optical barrier if provided 5 restart auxiliary circuits oil pump etc 6 select manual mode 7 if the blade of the saw and or the drilling tool are inside the material but free to mo...

Page 92: ...it is necessary to fit the line with open rollers to allow the passing of the pincher Working other type of profiles it should be better close the rollers to avoid wrong positioning of material Workin...

Page 93: ...nal devices to support the shorter flange Normally the longer flange is to be on the datum line side To fit the add on equipment refer to related documentation Change of pincher orientation The pinche...

Page 94: ...le instead is the same of which to be cut all preliminary steps can be skipped and the procedure can start directly from manual mode selection Control Meaning Remark Start condition Powered line axes...

Page 95: ...th the pincher 3 by e of main push button panel move the material to place it in the exact position to cut 4 if necessary select R axis saw rotation 5 by e of main push button panel adjust the cutting...

Page 96: ...he blade when in up down mode see saw softkeys on page n 34 GEN498 mm Correction factor the CNC add this value to the web height to get the height where it must start the up down movement of the blade...

Page 97: ...Write the coordinate on a sheet of paper 3 Visibly scratch on a fixed part of the machine a reference mark corresponding to a chosen point of the axis 4 Move the axis in manual mode till any other pos...

Page 98: ...e four fields Delete allows to delete selected programs eventually sorted by operator filter from the list Delete all allows to delete all programs or all profiles or all materials Recovery allows to...

Page 99: ...d as a pair of holes N B All other fields without reference are not used on 1001 DFB line The Drilling tab represents all post processor values for drilling operations the correct values can quickly b...

Page 100: ...tion on machine work as described below in the next section To achieve import operations the operator needs only to Select the program s to import checking them double touching on the screen or pressi...

Page 101: ...e Pressing RegCam push button the operator can get some numerical and graphic information on jobs and general working time of the machine Just as an example in the picture below you can see the window...

Page 102: ...e leaving connected only the CNC The action is the same of the emergency push button A red message normally occurs when something dangerous happens like a collision a damaged driver the emergency push...

Page 103: ...2 03 e 04 are available on the lower part of all win dows too Sometimes it could happen that the signalling window is not foreground but under some other open window in this case the operator can pres...

Page 104: ...and technicians First row of the matrix is called INP01 1 40 and display the condition of all digital inputs addressed from 1 to 40 the second one for inputs from 41 to 80 and so on The meaning of col...

Page 105: ...draulic drawings of your line Dynamic synoptic Clicking on View Synoptic command in the Execution window the operator gets a dynamic representation of current movement and tool the synoptic takes plac...

Page 106: ...wo different windows in the first one open by Configuration command the oper ator can configure what type of channels he wants to display in the second one open by Set Reset command the oper ator can...

Page 107: ...ask for a password because many functions are protected The operator can insert the right password pressing the push button Password if present Agreement If there are some tables of values and the col...

Page 108: ...is a CAN device for each device following information are availa ble ID logic address of the device on CAN bus LINE number of CAN line on which the device is connected TYPE clearly type of device STAT...

Page 109: ...Model 1001 DFB Programming and operating manual FICEP S p A 109 Blank page...

Page 110: ...nking all tools are moved in safety position far from material OPERATOR Access to drilling unit soft keys Release the tool in its place in the magazine soft key n 13 page 31 if the machine has the sec...

Page 111: ...h is rotated counter clockwise to switch off the power ATTENTION the installation of operative system and all software applications is carried out in protect mode directly in FICEP thus normally unexp...

Page 112: ...r zero cycle not present probably an axis is out of barrier 020 n Max barrier axis n a movement further the coordinate is required 023 n Timeout for service movement n cause F I vices not closed in ti...

Page 113: ...or manually clear all life counters 200 100 The same of message 200 099 but for second optional drilling head 200 105 Wait for part unloading displayed if a bar is waiting to be worked while the cutt...

Page 114: ...vice probe DOWN not activated within the preset time displayed for not correct positioning of the probe on the datum line side 203 009 Same of message 203 008 but for mobile line side 208 034 Carriag...

Page 115: ...Model 1001 DFB Programming and operating manual FICEP S p A 115 REMARKS...

Page 116: ...Programming and operating manual Model 1001 DFB 116 FICEP S p A REMARKS...

Page 117: ...1045 Gazzada Schianno Va Italy Tel 39 0332 876 111 Fax 39 0332 462 459 e mail ficep ficep it http www ficep it Document Instruction and Operator Manual Product Drilling and Sawing Line Model 1001 DFB...

Page 118: ......

Page 119: ...CTIONS THAT CAN BE PROCESSED 2 3 2 1 2 WORKING UNITS 2 4 2 1 3 DRILLING UINT 2 4 2 1 4 SAWING UNIT 2 5 2 1 5 UNLOADING DEVICE WITH MAGNET 2 6 2 1 6 CNC CONTROLLED AXES 2 7 2 1 7 AXIS STROKE 2 7 2 1 8...

Page 120: ...4 3 14 FLANGES PROBE SENSING DEVICE SETUP 4 17 4 3 15 WEB PROBE SENSING DEVICE SETUP OPTIONAL 4 17 4 3 16 SAW JAWS SETUP 4 18 4 3 17 SAW SETUP 4 18 4 4 HYDRAULIC SYSTEM SETUP 4 20 4 4 1 CHART LISTING...

Page 121: ...TULATION TABLE OF ROUTINE MAINTENANCE INTERVENTIONS 4 32 4 8 TECHNICAL INFORMATION 4 34 4 8 1 MATERIAL IN FEED HANDLING SYSTEM 4 34 4 8 2 WORKING UNIT 4 35 4 8 3 THE DRILLING MACHINE IS SUPPLIED WITH...

Page 122: ......

Page 123: ...1 SAFETY EQUIPMENT AND REGULATIONS...

Page 124: ......

Page 125: ...iled description of the machine We have enclosed within the following pages a set of drawings prints charts description information etc which can neither be partly nor entirely reproduced reprinted di...

Page 126: ......

Page 127: ...INSTRUCTION AND OPERATOR MANUAL FICEP S p A General Safety EQUIPMENTS HANDLING CHARTS...

Page 128: ......

Page 129: ...P 1001 DFB Drilling Sawing Line Page 1 1 EQUIPMENT HANDLING CHART Lifting of MODEL 1001 DFB DRILLING UNIT Mass weight KG 8 500 Lifting mean Bridge crane Type of sling Steel wire ropes Min safety facto...

Page 130: ...ATIONS Page 1 2 1001 DFB Drilling Sawing Line FICEP EQUIPMENT HANDLING CHART Lifting of SCS 100 Mass weight KG 4 600 Lifting mean Bridge crane Type of sling Steel wire ropes Min safety factor 6 1 Pers...

Page 131: ...NS FICEP 1001 DFB Drilling Sawing Line Page 1 3 EQUIPMENT HANDLING CHART Lifting of ROLLERWAY ELEMENT Mass weight 350 KG Lifting mean Bridge crane Type of sling Steel wire ropes Min safety factor 6 1...

Page 132: ...ONS Page 1 4 1001 DFB Drilling Sawing Line FICEP EQUIPMENT HANDLING CHART Lifting of CARRIAGE GUIDE Mass weight 800 KG Lifting mean Bridge crane Type of sling Steel wire ropes Min safety factor 6 1 Pe...

Page 133: ...1001 DFB Drilling Sawing Line Page 1 5 EQUIPMENT HANDLING CHART Lifting of CARRIAGE GUIDE CARRIAGE PINCHER Mass weight 2000 KG Lifting mean Bridge crane Type of sling Steel wire ropes Min safety fact...

Page 134: ...6 1001 DFB Drilling Sawing Line FICEP EQUIPMENT HANDLING CHART Lifting of TRANSFER TABLE OF THE CATCHES TYPE Mass weight 700 KG Lifting mean Bridge crane Type of sling Steel wire ropes Min safety fac...

Page 135: ...ONS FICEP 1001 DFB Drilling Sawing Line Page 1 7 EQUIPMENT HANDLING CHART Lifting of CHIPS CONVEYOR Mass weight 720 KG Lifting mean Bridge crane Type of sling Steel wire ropes Min safety factor 6 1 Pe...

Page 136: ...the machine as indicated in the machine plate as well as in this Manual If you intend to replace some of the machine components shown in the Tables enclosed in this Manual please remember to specify a...

Page 137: ...ne must conform strictly to the information and details given in the foundation and installation prints supplied by us prior to shipment of the machine Machine foundations should be adequately modifie...

Page 138: ...not condensating Have an ambient temperature during the operation with forced ventilation from 5 C to 40 C Max permitted temperature variations 1 1 K min Max altitude 1000 m a s l no restrictions 200...

Page 139: ...oint The disregard of this rule may cause troubles and or permanent damages to the electronic control equipment of the machine 1 6 HYDRAULIC SYSTEM Make sure to use the type and grade of oil or equiva...

Page 140: ...oelectric barrier is made by means of the barriers reset push button it is necessary to verify that no person is present within the area protected by the safety barriers When the Operators enters into...

Page 141: ...days it is necessary to check for each axis driven by a braked motor the wearing state of the transmission belt between the pulleys the one of the balls screw and the one of the motor In the event it...

Page 142: ...vers or doors of barriers 1 9 SAFETY EQUIPMENT AND REGULATIONS See enclosed diagram DES 23123 FICEP s Automatic Lines are usually furnished with the following anti hazard equipment and devices which i...

Page 143: ...SAFETY EQUIPMENT AND REGULATIONS FICEP 1001 DFB Drilling Sawing Line Page 1 15...

Page 144: ...E OPERATION According to these Standards and Regulations one operator only is allowed into the machine area and he must always stand by the control console Should he move away from this area he must s...

Page 145: ...limit switches or photocells to be connected to the emergency signals thus obviating any possibility for the machine to operate when the operator is within the loading unloading zone must be provided...

Page 146: ...Y EQUIPMENT AND REGULATIONS Page 1 18 1001 DFB Drilling Sawing Line FICEP IMPORTANT Make sure to hand over to the machine operating and maintenance Engineers copy of these Safety Equipment and Regulat...

Page 147: ...2 FEATURES...

Page 148: ......

Page 149: ...ping of the structural steel sections pincher powered lifting system loading system complete with catches type transfer table optional WORKING UNITS complete with One Monospindle mitering DRILL HEAD O...

Page 150: ...ystem stationary reference units unloading system complete with catches type transfer table optional short pieces unloading device optional HYDRAULIC POWER PACK to suit the Drilling and Sawing Unit EL...

Page 151: ...m Angles min max 80x80x8 250x250x40 mm mm Flats min max 100 1000 mm mm Square tubes min max 80x80 450x450 mm mm Rectangular tubes min max 80x40 1000x450 mm mm Range of section lengths that can be proc...

Page 152: ...b 20 to 995 mm TOOL CHANGE number of tools change devices n 1 number of tools to be changed each n 6 adaptor size ISO 45 Electronic device for zero reference setting top side Device for the automatic...

Page 153: ...for sections cold sawing sawing capacity at 90 min 80 x 10 mm sawing capacity at 90 1015 x 450 mm sawing capacity at 45 620 x 450 mm sawing capacity at 60 350 x 350 mm sawing band motor 5 5 kW sawing...

Page 154: ...red onto the unloading device for short pieces see relevant option and then laterally unloaded by manual action of the operator on a pushbutton Finished pieces having a minimum length of 1200 mm Thank...

Page 155: ...scent S axis 2 1 7 Axis stroke Carriage X axis 0 to 20000 Horizontal axis web gaugeline Spindle in C position Y axis 20 to 995 Vertical axis stationary side flange gaugeline Spindle in A position Z ax...

Page 156: ...s 0 1 mm Y axis 0 1 mm Z axis 0 1 mm Positioning accuracy within holes of the same group pattern 0 5 mm within groups of holes positioned at L distance L measured in metres 0 5 Lx0 06 The above accura...

Page 157: ...ydraulic system Hydraulic Power Unit System hydraulic power unit system DES 28694 power unit motor 4 kW variable delivery pump 35 litres min working pressure 75 bar power unit reservoir capacity 78 li...

Page 158: ...r Connection specifications shop supply line min cable dia 3 4 gas FRL connection min cable dia 1 2 gas NOTE For more detailed information see Pneumatic System Diagram DES 29977 Useful data Type of no...

Page 159: ...EN14121 1 in the version in force at the date of shipment of the machine The electric cabinet includes the Minosse CNC drives for the brushless motors safety devices for the emergency stop and the pho...

Page 160: ...al PC containing the CNC and having the following specifications 600 Mhz CPU with L2 512 KB cache 512 MB RAM memory Touch screen colour video TFT 12 1 Keyboard panel and auxiliary pushbutton panel 10...

Page 161: ...ead to operate in multitasking mode in its working area even with automatic tool changer Automatic control to prevent any possible collision of the drill Drilling parameters table All the indications...

Page 162: ...n and wearing We suggest to use lithium soap grease for rolling bearings Alternatively it is possible the use of mineral oils Lubrication takes place through a nipple which is of standard supply and i...

Page 163: ...S REFERENCE NUMBERS Foundation and ducts drawing DIS 754005 Wiring diagram DES 31407 Hydraulic system diagram for the hydraulic power unit DES 28694 Pneumatic system diagram DES 29977 Hydraulic system...

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Page 165: ...3 CONTROLS...

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Page 167: ...of data input when the machine is not working Mode 4 it is used for parts loading unloading for tools change and to orient the drill external lubrication jet From the point of view of operator s safe...

Page 168: ...e mode 4 is present if the photoelectric barrier has been installed States and modes standard sequence at the machine switch off is the following 5 3 6 cabinet switch off 3 1 1 Video and CNC Push Butt...

Page 169: ...present cycle is under way it is interrupted if in a position to be interrupted otherwise it is completed the machine goes into the standby 3 mode To restart it is necessary to select the single or c...

Page 170: ...feedrate c9 Hold push button Active in automatic execution 1 mode when pressed axes stop and if a drilling marking if present cycle is under way it is interrupted if in a position to be interrupted o...

Page 171: ...h button for slow backward of transfer table c20 Push button for fast backward of transfer table c21 Push button for automatic unloading c22 Push button for manual activation disactivation of the magn...

Page 172: ...ntinued drilling operation by depressing the drill emergency push button c26 Push button to operate the VICE opening Repetition of this control causes the continuous opening of the vice Disactivated w...

Page 173: ...d to position the drill head to the preset coordinate for the tools change If the marking unit optional is present it used to include the marking body and enable the manual adjustment of the gaugeline...

Page 174: ...ength pickup with photo cell in MANUAL mode 20 Push button for selection of drill head in A position Active only in manual mode 21 Push button for selection of drill head in C position Active only in...

Page 175: ...ice which stands in the sector of the negative mitering 5 Not used optional 6 Selecting switch RISE of vertical hold down 1 Active in MANUAL mode It enables the rise of the hold down switch stands in...

Page 176: ...elector for manual DESACTIVATION of the blade guide To move the stationary reference band guide it is necessary to execute the zero cycle 13 Selector to control band rotation Start Stop Start it quali...

Page 177: ...tion of operative mode locked In this position the machine stays in the operatiion mode previously selected It is possible to go into safer modes or states for example from the automatic execution mod...

Page 178: ...y press it before entering in the machine protected area the system goes in setup mode in order to adjust the external lubrication jet 3 2 Push button of RESET optional Fig 2 1200 Emergency stop reset...

Page 179: ...emergency STOP Same function as the main emergency stop on CNC IMPORTANT NOTE All the push buttons used for the sawing machine operation are described in the Programming Manual 3 2 2 Unloading chips...

Page 180: ...indle rotation unlocking Note one only motor operates the head or spindle rotation depending if it is pin locked the spindle or the head rotation respectively f Tool release in the spindle g Push butt...

Page 181: ...CONTROLS FICEP 1001 DFB Drilling Sawing Line Page 3 15...

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Page 183: ...4 MACHINE SET UP...

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Page 185: ...l the set up sequences as described in this Part of the Manual thus making it possible to identify the program data necessary to process a part The machine set up has been divided into the following p...

Page 186: ...ent accidental activation of any control and to insure operator s max safeguard apply power to the system and perform the zeroing cycles rotate the key type selector switch of the machine operative mo...

Page 187: ...your servicing Engineer be in attendance at the machine start up thus carrying out the following checks all the parts that have been serviced and maintained are fitted back home connectors wires to te...

Page 188: ...erations the control device inside the electric panel does not go into alarm lighting of illuminated blue push button for barrier reset makes this easier to note must stop the machine operation till w...

Page 189: ...nstalled on the door of the main board is in enabling position pulling it out all the way in fact since the cabinet doors is opened it would be impossible to connect the circuits close the main automa...

Page 190: ...ternal handle the light in the respective push buttons provided on the control panel will go ON check that the white cabinet live lamp is on reset the safety device pressing the illuminated blue reset...

Page 191: ...the above set up operations must comply with the information coming from the Production and Programming Departments The information passed over to the workshop by the Production and Programming Depar...

Page 192: ...ction having variable length which involves the processing of a part For every CANONIC PROGRAM the operator will normally have a display listing all the necessary parameters for the SETUP operations S...

Page 193: ...drilled on the section head e For the sawing machine please refer to the attached instruction manual At this stage the operator may proceed with the machine setup cycle as follows adjust the pincher...

Page 194: ...see TAB 43 4 3 6 Pincher arm positioning Once the machine operator knows the dimensions of the section to be handled he will proceed acting on the selector switch to position the pincher arm at the co...

Page 195: ...MACHINE SET UP FICEP 1001 DFB Drilling Sawing Line Page 4 11...

Page 196: ...er to meet specific requirements can be supplied on request after their application has been thoroughly discussed with our Technical Division Engineers Top mobile jaw Drwg N 7 0 6 6 1 2 thickness from...

Page 197: ...moves whereas the other one remains stationary We suggest to position the mobile jaw at approx 20 mm from the section flange to considerably reduce the time required by the clamp closing cycle during...

Page 198: ...of any particular adjustment Adjustments referred to the drilling head stroke and feed rate are CNC controlled The different spindle rotation speeds are given by an A C motor connected to an Inverter...

Page 199: ...ive device The above device enables to automatically change from rapid advance to drilling speed feed rate as the drill contacts the material and then change to rapid return as the drill has completed...

Page 200: ...on The Drilling Machine is also capable to perform pointing cycles so as to have a reference point for the next operations and a direct control of the program to be processed The pointing cycle can be...

Page 201: ...rking conditions and that the cams will operate to the best of their efficiency 4 3 14 Flanges probe sensing device SETUP On the clamp mobile jaw of the vice it is fitted the device for the automatic...

Page 202: ...suggest to position the mobile jaw at approx 20 mm from the section flange to considerably reduce the time required by the jaw closing cycle during the machine operation 4 3 17 Saw setup Band mountin...

Page 203: ...is obtained by correctly performing all the operations and the setup sequences The operator must be well trained and thoroughly familiar with the machine and its operations I t i s a l s o a M U S T...

Page 204: ...luid recommended by us is the H Y D R U S 3 2 produced by I P or equivalent oils as per table in the next page 4 4 1 CHART LISTING TYPES AND QUALITIES OF OIL EQUIVALENT TO HYDRUS 32 PRODUCED BY I P D...

Page 205: ...with our recommendations and that possible water infiltration did not deteriorated it clean all the oil inlets and nozzles accurately Pour the oil into the reservoir through the proper filter use the...

Page 206: ...ecially in the event of previously opened cans 4 4 6 How to bleed the air from the circuit Before starting up the machine bleed all the air that might have entered the circuit and make sure that there...

Page 207: ...ve conditions fail to exist the oil will be prevented from circulating especially during the initial start up as the lubrication is taken care of by the hydraulic fluid 4 4 9 Adjustment of the safety...

Page 208: ...Short break of the system No special attention is required when the system is left inoperative for a short period of time normally shorter than two months 4 4 13 Long break of the system When the sys...

Page 209: ...or based on the user s direct experience depending upon the operational conditions 4 4 16 Flanges piping and fittings connection As previously recommended make sure to use well known products only suc...

Page 210: ...functions Look for signs of leakage Check the oil level in the reservoir Should the oil look milky it means that it is water or air saturated 4 5 2 Sound inspection It is extremely important to listen...

Page 211: ...w fundamentals The supply line must be large enough to insure the system max efficiency especially when the air compressor is located far away from the machine The following conditions are responsible...

Page 212: ...pressure gauge The purpose of the filter is to eliminate the water and the impurities existing in the pneumatic system you are therefore required to check and clean the filter accurately at regular i...

Page 213: ...to check the energizing and locking units at regular intervals for wear 4 6 3 Periodical cleaning operations It is therefore recommended to clean the valves thoroughly at regular intervals The sludge...

Page 214: ...high make sure to use appropriate solenoid valves 4 6 5 Maintenance of the FRL lubrication filtering and adjusting unit inlet unit Filter with manual drain Remove the filtering element at regular int...

Page 215: ...ening the main breaker of the electric board Every three weeks It is recommended to remove the covers from the machine to perform the cleaning of filters placed on the air intake of the electric board...

Page 216: ...g tables reduction gears and topping up if necessary 120 L3 manual lubrication on appropriate points of loading unloading rollerways 60 L4 check of oil level in the carriage reduction gear and topping...

Page 217: ...g Line Page 4 33 code intervention description frequency system working days notes replacements R1 oil replacement in the hydraulic power unit 120 R2 oil filter replacement in the hydraulic power unit...

Page 218: ...the carriage to clamp and position the section along the in feed conveyor The pincher assembly is powered and the pincher lifting or lowering stroke is adjustable by a selector switch to suit the sec...

Page 219: ...les 90 0 90 The drilling unit is fitted with one 15 kW motor single pole for spindles rotation one driving belt system for spindle rotation one electronic adaptive device to automatically change from...

Page 220: ...he driving belt system for the spindle rotation motor The spindle shaft which comes out from the box lower portion carries the spindle tools holder The drilling unit is complete with a pivoting device...

Page 221: ...tioned on the datum line of the machine The tool change system consists of no 1 support suitable to accept no 6 tools The insertion and removal of the tool as well as the tool choice are made automati...

Page 222: ...quired 4 8 10 Sensing Unit probe for the for the Drilling Unit in Horizontal position optional Electronic device for zero reference setting top side Device for the automatic zero reference setting of...

Page 223: ...led by an hydraulic cylinder the band guiding system and the rotating brush to ensure chips removal from the band are all mounted on the saw head clamping system to ensure horizontal of the section cl...

Page 224: ...h ball bearings Suitable zero reference units are also mounted on the outfeed conveyor The entry side idle roll and the exit side powered roll of the saw can be lifted simultaneously through solenoid...

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