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Norlok Sure-Lok 24, Operating Manual

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Norlok Sure-Lok 24 Operating Manual Download Page 35

SURELOK MANUAL 2002

34

SURE-LOK     Trouble Shooting  -    Problem with joints

A. Total failure of joint (also see section C - deformed or distorted joints)

Problem

Cause

Solution

A. No clinch formed

Broken punch or die.

Air pressure too low.

Auto return too fast.

Replace tool

Adjust to 100 psi.

Adjust to 1-second delay.

B. Clinch partially formed.

Metals not of specified
thickness.

Low air pressure or auto return
set too fast.

Die elastomer broken or weak.

Incorrect tooling for metal being
used

Incorrect die adjustment.

Use specified metals or
use proper die.

Adjust.

Replace.

Verify joint data.
Change tooling if
necessary.

Adjust die height.

C.  Piercing or cracking on
punch side of joint.

Metal not of specified thickness

Incorrect tooling for metals

Weak or broken elastomer.

Punch-die not concentric.

Correct material

Change tooling

Replace.

Realign tooling

B. Intermittent Failure

A. Same tooling  produces 

intermittently good &
bad parts

Insufficient stripper force to
compensate for part variation or
non-mating parts

Parts do not fit gauging or
nesting

Parts interfere with tooling
operation

Correct parts to conform-
increase stripper force

Correct parts or gauging to
fit

Correct parts gauging to
allow clearance

Summary of Contents for Sure-Lok 24

Page 1: ...s defective This warranty applies only if the product was a used in and applied correctly under normal operating conditions and good engineering practice b was installed operated and maintained in accordance with all instructions issued or published by Norlok c was used within the stated pressure and operating limitations published by Norlok d was not subject to abuse misuse or unauthorized modifi...

Page 2: ...OUR WORK AREA CLEAR OF ALL SCRAP OIL SPILLS RAGS TOOLS AND OTHER OBSTRUCTIONS WHICH COULD CAUSE YOU TO SLIP TRIP OR FALL Wear safety glasses at all times Be familiar with procedures of disconnecting and draining air from system Make sure hydraulic and pneumatic pressures are at specified levels before operating this equipment Be sure all guards and covers are in place KEEP FINGERS AND HANDS AWAY F...

Page 3: ... BASICS Clinchlok principle 13 Punch adjustment 14 Materials to be joined 14 Die selection 15 Joint strength 16 Joint failure 17 Views of joints 18 Testing joint strength 19 ADJUSTING PUNCH 20 SETTING LASER 23 OPEN HEIGHT ADJUSTMENT 24 MAINTENANCE Daily 25 Replacing die 26 Replacing die components 26 Replacing punch 28 Auto return adjustment 30 Pressure adjustments 31 Filter draining 31 Lubricatio...

Page 4: ...UARANTEE OF AN ACCIDENT FREE WORK PLACE 1 DISCONNECT AND DRAIN AIR BEFORE MAKING ANY ADJUSTMENTS OR SERVICING ANY SURE LOK COMPONENTS 2 ALWAYS BE ALERT WHENEVER OPERATING ANY MACHINERY 3 ONLY ONE PERSON SHOULD CONTROL THE MACHINE S NEVER ALLOW ANYONE TO OPERATE THE CONTROLS WHILE YOU ARE WORKING ON THIS EQUIPMENT IN ADDITION TO DISCONNECTING POWER ALWAYS USE LOCK OUTS AND WARNING SIGNS TO INDICATE...

Page 5: ...stroke to zero with an adjuster screw The machine features a fast change punch and die either of which can be changed in minutes The punch and stripper are located in the upper tooling and operate through the full stroke of the machine The height of the punch may be easily adjusted to suit different material thickness The die is located in the lower arm of the press and may be easily changed to su...

Page 6: ...UTY MAX Two ply 0 062 mild steel MIN Two ply 0 012 mild steel LIGHT DUTY MAX Two ply 0 032 mild steel MIN Two ply 0 010 mild steel Cycle speed Clinching stroke 1 1 second 100 duty cycle Air Requirements 80 psi minimum 125 psi maximum 125 psi recommended Air Consumption Approx 0 6 cu ft free air per cycle 5 HP 60 clinches per minute Dimensions Width 36 overall Length 59 overall Height 75 overall We...

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Page 10: ...dered 3 Check the condition of the press and record the serial number for reference SERIAL ________________ LEVELING AND BOLTING DOWN MACHINE 1 Locate the machine at its operating position 2 Level the machine by shimming the legs of the stand 3 Secure the stand to the floor with the four bolt down holes located on the ends of the legs 4 INSTALL ALL GUARDS AND SAFETY DEVICES IF THEY HAVE BEEN REMOV...

Page 11: ... the gauge does not read the correct pressure adjust and lock the regulator NOTE The tank pressure must be higher than the required regulator pressure in order to set the regulator pressure 2 Making sure all guards are in place operate the foot pedal WARNING THIS ACTION ACTIVATES THE HIGH PRESSURE CLINCHING STROKE Keep your foot on the foot pedal and the machine will activate the high speed clinch...

Page 12: ... The machine operates through a single clinching stroke each time the foot pedal is activated 5 The automatic return is set to about 1 second on standard machines If set too fast a good joint may not be formed If set too slow production will be reduced Machines fitted with high speed valving or Production Controls will operate faster 6 The clinching stroke will be terminated before the automatic r...

Page 13: ...pecial design and should not be sharpened 4 Under normal operation both punch and die should last for approximately 200 000 to 300 000 cycles AIR TANK 1 The air reservoir tank is located on the back of the machine 2 The air surge tank features a 3 4 filter regulator which is set to 100 psi for the Medium Duty tooling and 80 psi for the Light Duty tooling The filter should be drained regularly and ...

Page 14: ...f squeeze is very important to the strength of the clinchlok joint and to the life expectancy of the punch and die 3 It will be noted that the die is of a very special design that allows the clinchlok to mushroom 4 The punch is also a special design and unlike a normal punch the edge of the punch is not sharp but is rounded This is known as the punch tip radius 5 Neither the punch nor die can be s...

Page 15: ...e found with the thicker material on the upper punch side of the two ply although this is not always possible 3 The thicker material should not be more than twice the thickness of the thinner material and the combined thickness of the two ply should not exceed 0 125 for MD machines and 0 062 for LD machines 4 Other materials can be joined with the SURE LOK as long as they are not harder than comme...

Page 16: ...elow One is for Medium Duty machines 3 16 punch diameter 5 8 die diameter One is for Light Duty Machines 1 8 punch diameter 7 16 die diameter 4 MD Material thickness LD Material thickness Die size punch die side Die size punch die side MD 50 0 062 0 062 LD 30 0 032 0 032 0 062 0 052 0 032 0 028 0 062 0 040 0 028 0 028 0 052 0 052 0 028 0 022 0 052 0 040 0 022 0 022 MD 40 0 040 0 040 LD 25 0 022 0 ...

Page 17: ...material will affect the joint strength If the material is softer than mild steel these strengths will be reduced according to the strength of the material MEDIUM DUTY Material thickness Joint strength Recommended Each two ply PULL PEEL Die 0 06 475 lb 175 lb MD 50 0 05 430 lb 150 lb MD 50 0 04 400 lb 120 lb MD 40 0 03 375 lb 100 lb MD 40 0 02 285 lb 70 lb MD 30 LIGHT DUTY Material thickness Joint...

Page 18: ... The correct adjustment is when the joint fails in peel sometimes as non tearing and sometimes as tearing This will give the greatest peel strength 6 If the peel strength of a correctly adjusted joint is less that shown in the joint strength chart and the joint tends to fail by tearing apart the incorrect die too deep may have been selected MD Change 50 die to 40 die Change 40 die to 30 die LD Cha...

Page 19: ... 18 VIEWS OF THE CLINCHLOK JOINTS 1 2 3 4 TOOLING TOOLING TOOLING TOOLING UNDER ADJUSTED OVER ADJUSTED CHIPPED ADJUSTED CORRECTLY OR BROKEN CROSS SECTION OF JOINT TOP VIEW OF JOINT PUNCH SIDE BOTTOM VIEW OF JOINT DIE SIDE ...

Page 20: ...eel with a pull tester and the upper and lower limits of joint strength are found the cap diameters for these two limits can be measured Calipers or a GO NOGO gauge can then be used in production to see if the cap diameter is within the measured limits NOTE a If the material changes or the die is changed the cap diameters will change b When using the button cap diameter shear and peel tests should...

Page 21: ...tened 2 Make sure the automatic return is set correctly The punch cannot be set correctly if the automatic return is set too fast If in doubt slow the return to a 3 second delay when setting the die adjustment See maintenance section for adjustment 3 Make sure that the pressure on the inlet filter is set correctly 4 Loosen do not remove access plate securing screw and slide the cover plate to the ...

Page 22: ...made the punch should be raised by 1 16th of a turn and the joint strength checked If the joint produced at this new setting is weaker that the original reset the punch downward by 1 16th turn If the joint produced at this new setting is as strong as the original raise the punch by another 1 16th turn and repeat the process 13 If it is found that the punch tip extends below the stripper when adjus...

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Page 24: ...he way 5 If necessary the laser can be focused with a small tool provided with the laser the focus ring is in the front of the laser Let the laser beam shine through the focus tool 6 To set the position of the laser spot on the material a Using a small sample say 2 square of the materials to be joined scribe a cross in the center of the sample b Place the sample on the lower tooling with the cross...

Page 25: ... no effect on the joint strength or any other adjustments on the machine TOP OF WAMP UNIT PROCEDURE 1 Disconnect the air supply and drain the air tank 2 Loosen the open height locking nut 3 Adjust the open height screw with the hex key supplied with the tool kit until the required daylight gap is obtained the maximum gap is the same as the stroke of the machine 1 4 Re tighten the locking nut Do no...

Page 26: ... correct inlet air pressure 5 Check and maintain correct air regulator pressure 6 Check automatic return and adjust if necessary 7 Clean and oil die 8 Clean and oil punch 9 Make sure that the machine is set for the correct material thickness a Correct die b Correct punch adjustment 10 Check tightness of all bolts especially those on the lower arm 11 Check for air leaks ...

Page 27: ...EPLACE THE LEXAN GUARD if it has been removed 10 Connect air supply 10 Test the joint and set punch adjustment as described previously in the manual MAINTENANCE REPLACING DIE COMPONENTS DIE INSERT ASSEMBLY 1 Remove the Die Insert as described above 2 Remove and discard the old elastomer 3 Set new blades around the die anvil and hold in place 4 Press new elastomer over the die blades pushing it dow...

Page 28: ...SURELOK MANUAL 2002 27 ...

Page 29: ...rewing it will be necessary to prevent the upper tooling from rotating as follows a Using the open height adjustment screw lower the upper tooling b A wrench flat will be visible on the exposed portion of the upper tooling c Using a 1 wrench hold the upper tooling by the flats and loosen the punch stripper as described d Wind the open height adjustment screw to achieve maximum open height 5 Pull t...

Page 30: ...URELOK MANUAL 2002 29 SURE LOK UPPER TOOLING DETAIL BARREL MAIN PUNCH GUIDE WRENCH FLATS TO ACCESS THE WRENCH FLATS WIND THE UPPER TOOLING DOWN AS SHOWN IN THE OPEN HIEGHT ADJUSTMENT PUNCH STRIPPER PUNCH ...

Page 31: ...e the return delay slow the press down 4 Adjust the valve so that the upper tooling returns after approximately one second if the foot pedal is kept pressed 5 If the return valve is set too fast the WAMP air power unit may not reach full operating pressure and the joint quality will be reduced especially if the air pressure is low 6 Turning the adjuster screw all the way in will turn off the autom...

Page 32: ...ire draining 2 The inlet filter will collect any air contaminates that have collected in the air tank If filter requires draining other than daily then the inlet air is contaminated It may be necessary to install an extra inlet filter before the air tank 3 There is a small filter on the exhaust of the foot pedal If the filter becomes blocked the press may not return when the foot pedal is released...

Page 33: ... Remove a 1 4 NF set screw that is located in the upper of the two 1 4 NF screw holes with a 1 8 hex key wrench This set screw is not visible from the outside of the barrel and is used to seal in the grease 6 Make sure that the upper tooling is between 1 4 and 1 from the lower die adjust the open height if required 7 Force grease into the grease hole a grease fitting can be used if required Do not...

Page 34: ...oes not return when foot pedal is released Auto return valve failed Foot pedal exhaust filter blocked Operator valve jammed WAMP mufflers blocked Replace Replace Clean or replace Remove and clean 3 Press does not return unless the foot pedal is released Auto return valve set too slow Auto return valve failed Adjust to 1 second return delay Replace 4 Weak joint or no joint formed Low air pressure A...

Page 35: ...ustment Use specified metals or use proper die Adjust Replace Verify joint data Change tooling if necessary Adjust die height C Piercing or cracking on punch side of joint Metal not of specified thickness Incorrect tooling for metals Weak or broken elastomer Punch die not concentric Correct material Change tooling Replace Realign tooling B Intermittent Failure A Same tooling produces intermittentl...

Page 36: ...t for metals Punch die not concentric Weak or broken stripper spring Use specified metals or change to proper tooling Change tooling Realign tooling Replace spring C Concentric Irregularity on clinch Chipped punch or die Replace D Concentric double clinch Missing non functional stripper Double hit Replace or repair stripper Check controls or operator E No back flow of clinch round top squeezed Bro...

Page 37: ...pper Add leaf shielding I Clinch not round Leaf not open Deflection is binding leaves Flexing of force frame Punch and die are not concentric Check for interference Check leaf guarding Check for damage Realign tooling J Parts are distorted during joining Insufficient stripper force Stripper tip too small Die not protected Die leaf below shield Mis gauging nesting Replace stripper spring to suit Re...

Page 38: ...000204 000204 Punch stripper cap 000331 000332 Laser c w holder and bracket 900001 900001 Operator Valve standard 200013 200013 Inlet Filter Reg standard 200026 200026 Operator valve high speed 200096 200096 Inlet filter high speed 200094 200094 Inlet regulator high speed 200093 200093 Auto return Valve 200015 200015 Foot Pedal 200032 200032 Lexan Punch Guard 000253 000253 WAMP exhaust mufflers 3 ...

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