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OmniTurn GT-75, Installation, Operations, And Technical Documentation

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OmniTurn GT-75 Installation, Operations, And Technical Documentation Download Page 18

DIVIDER

FRONT

 GA

TE

FLOOR

Gate Clearance

Adjustment

Floor Front-stop

Adjust jam-nut

Loosen to slide 
hopper toward knee 
(both sides)

Floor Speed

Adjust

Lip

Tray

zipldr_setup&operations

www.OmniTurn.com  

 [email protected]  

  (541) 332-7004  

  (541)-332-1018 fax

Fast... Precise... A

ff

 ordable...

Zip Loader Setup & Operations

Omni

Turn

Page 18 of 44

Hopper Operational Description

The parts hopper is designed to be used with the Omniturn Zip Loader to increase the 

number of parts that can be loaded with the ZipLoader. The hopper allows small diameter 

parts (1/2” - 1/8”) to be loaded in quantity in a 3-1/2”h x 11-3/4” x 24-1/8” wide box, the 

quantity depending on the diameter of the part. The length of the part can be from ap-

proximately 2 inches, to 24 inches. The parts are then presented to the top of the knife in 

the ZipLoader, and loaded into the rear of the spindle for machining. The hopper can be 

mounted to any ZipLoader.

NOTE:

Refer to separate document “ZipLoader Hopper Kit Installation” for more detailed informa-

tion regarding the hopper

.

Summary of Contents for GT-75

Page 1: ...fed through the spindle liner into the collet Parts can be qualified from the face or from the rear for overall length When the part is located the collet is closed and the part is machined After mac...

Page 2: ...s 10 Push rods for small diameter parts 10 Vee 1 8 pushrod adjustment 11 1 8 Push rod and Pushrod Adapter 11 Section 2 Setup and Alignment Loader Setup and Alignment Mechanical 12 Loader Setup and Ali...

Page 3: ...er Major Components Before using your Zip Loader become familiar with the component parts PLC Cabinet Air Panel Home Stop Shuttle Stack Lamp Tray Adjustable Tray Guide Manual Control Box Foundation Br...

Page 4: ...rts for overall length Shuttle Plate carries the Pushrod on the rodless cylinder Bearings give additional support to the Shuttle Plate rodless cylinder has internal bearings Home Stop is set so end of...

Page 5: ...stop too hard but can be set faster for special applications Experiment with location of Slow sensor to best suit your particular application InPlace When using the loader in Part Mode M51 or Rear Sto...

Page 6: ...el pressure relief valve can be set to overcome stiction by allowing initial airflow to bypass flow control increasing accelleration Turn ing grey knob CCW tends to bypass the flow control turning kno...

Page 7: ...56 from MDI mode to force a loader fault then re set initialize before continuing Manual Auto Switch Knife Up Push Shuttle right Retract Shuttle left Reset Initialize Component Parts Tray guide Should...

Page 8: ...tube The center of the tray pivot is such that different diameters down to about 1 4 stay on center without lateral adjustment Component Parts Micrometer Adjustment Adjust knob Lock knob Right side Tr...

Page 9: ...less simply rotating the tray assembly may not be satisfactory because the accuracy required to align the part with the liner is much higher for small parts Spindle Liner Vee Front Shuttle Plate Push...

Page 10: ...06 standard pushrod w barb For 1 4 parts a plain 1 4 pushrod is used It is as drawing above except 30 25 long no barb p n 790 02 017 plain 1 4 pushrod For parts 1 4 to 3 16 the same 1 4 plain pushrod...

Page 11: ...uttle is at the far right side of the loader eject sensor lit Vee 1 8 pushrod adjustment Pushrod Adapter Vee Front Pushrod Spindle Liner Shuttle Plate When aligning the ZipLoader for parts with diamet...

Page 12: ...aller parts used with the 1 16 knife require more attention to alignment details If the loader was aligned at the factory the settings will be pretty close but may have changed during shipment Pushrod...

Page 13: ...loaded table stop required for parts that must be qualified from the rear for overall length see 6 below Route the yellow tagged cable from the PLC cabi net to the spindle drive cabinet door at conne...

Page 14: ...e LED on sensor should light 6 Move the shuttle to EoB sensor End of Bar the LED on sensor should light 7 Push the shuttle right until Eject sensor LED lights 8 Set Auto Manual keyswitch on Loader Man...

Page 15: ...ers on center if this ini tial alignment is properly done Parts with diameter less than 1 4 will probably require some additional adjustment to insure consistent feeding To accommodate different bar d...

Page 16: ...y shown below The four middle ones are M4 screws which hold the plate to the shuttle The two rows of two on either side of the four are 10 32 which attach the slide bearings The three 6 32 on the far...

Page 17: ...a small chamfer inside the collet to insure reliable feeding A die grinder with a cone shaped tool is adequate Speed of the pusher is also important and the in feed chamfer on the liner can be a fact...

Page 18: ...iturn Zip Loader to increase the number of parts that can be loaded with the ZipLoader The hopper allows small diameter parts 1 2 1 8 to be loaded in quantity in a 3 1 2 h x 11 3 4 x 24 1 8 wide box t...

Page 19: ...led on standard 1 8 knife ZipLoader setup for loading 5 8 parts Hopper installed on optional 1 16 knife ZipLoader setup for loading 0 085 parts NOTE Special modifications are necessary to reliably loa...

Page 20: ...32 SHCS then loosen the tray lock knob and remove mi crometer lock knob Swing entire tray assembly up and out of the way to clear flange on liner Liner is held in place with o rings it can take some...

Page 21: ...dd re fill tray Stop Mode M52 In Stop Mode the ZipLoader operates as a shaft loader and part is qualified at rear The shuttle stops against shot pin on adjustable rear stop on ZipLoader Spring loaded...

Page 22: ...o the push rod and held by a barb 4 Home Stop 4 The Home Stop is clamped to the Rodless Cylinder with cap screws It mounts a shock absorber that the shuttle contacts when at home For most bar work the...

Page 23: ...stration above 1 Mode Set M50 The Bar mode is ZipLoader default but for consistency with the other modes you should put M50 in a block by itself just below the program header and comment it Bar Mode 2...

Page 24: ...goes here m30 End of main program 1 sub 1 new bar This subroutine is called by first m97 block load new bar x0z0 move out of way This moves tools away to allow remnant to eject m48 eject remnant This...

Page 25: ...It mounts a shock absorber that the shuttle contacts when at home For shortest cycle times set the Home Stop so that the Pusher just clears the end of the part when at Home 5 Home Sensor 5 The Home S...

Page 26: ...ration above 1 Mode Set M51 Put M51 in a block by itself at top of program and comment it Part Mode 2 Load Part Qualify at face M47 M47 loads next part as illustrated in M47 1 M47 2 above Locate the p...

Page 27: ...part m47 load new part Load new part and close collet m43 retract pusher Move the pusher away from the back of the part t2 Your first cutting tool x0z0 All your machining goes here m59 slow eject If...

Page 28: ...w Down sensor signals the PLC to change speed so part does not hit hard stop too hard IN PLACE This sensor signals the PLC that part is against hard stop Collet is closed and rodless cylinder stops pu...

Page 29: ...d by a barb 4 Home Stop 4 The Home Stop is clamped to the Rodless Cylinder with cap screws It mounts a shock absorber that the shuttle contacts when at home For shortest cycle times set the Home Stop...

Page 30: ...or Lit Part Located Sensor Stop Mode M52 Operation and M functions Refer to illustration above 1 Mode Set M52 Put M52 in a block by itself at top of program and comment it Stop Mode 2 Load Part Qualif...

Page 31: ...on tooling plate x0z0 Locate part stop at face of part m47 load new part Load new part and close collet InPlace Part Located lit m43 retract pusher Move the pusher away from the back of the part m03s4...

Page 32: ...in Verify that In Place LED lights If not loosen tiny screw and slide sensor to left until lamp lights If you go past move sensor to right until light goes out then do it again 6 Issue M49 to press sh...

Page 33: ...d held by a barb 4 Home Stop The Home Stop is clamped to the Rodless Cylinder with cap screws It mounts a shock absorber that the shuttle contacts when at home For shortest cycle times set the Home St...

Page 34: ...will fault as follows M47 If Home X3 is not found within 3 seconds after M47 If knife is not raised in 2 seconds If Slow X4 is not reached within 10 seconds after leaving home In Part Mode M51 if load...

Page 35: ...are delicate put just before m48 m48 eject bar or part and go home m50 set bar mode m51 set part mode m52 set stop mode m53 set 2part mode M functions used for setup m40 knife up m41 knife down m44 st...

Page 36: ...hen End of Bar condition occurs code for program m97i10c1p2 Execute Subroutine 2 when Input 10 turns on m30 Or m02 end of program 1 code for subroutine 1 m99 End of sub routine 2 code for subroutine 2...

Page 37: ...0 1 10 3 2 2 GO ACCEL PRESSURE RELIEF PUSHER SPEED IN PU TS X PLC O UTPUTS Y ZL1219 Mini Regulator 0 100 psi 697 11 102 Pressure Relief Valve 797 11 001 Regulator Filter 697 11 015 Flow Control 797 11...

Page 38: ...or small diameter parts 1 4 and less rod will rest in vee SHUTTLE BEARINGS 4 per McMaster 94701A308 Adjust to barely touch sides of cylinder BEARING ASSEMBLY 2 per 790 24 004 RODLESS CYLINDER 797 27 0...

Page 39: ...00psi RESET INITIALIZE FT301 SOLENOIDS FT302 LIMIT SWITCHES INLET EXHAUST 10 10 SL305 EXTEND STOPS 797 15 001 SHUTTLE STOP ACTUATOR STOP EXTENDED SWITCH X12 AC303 TABLE STOP ACTUATOR AC304 PART LOCATE...

Page 40: ...C AUX PS COM 13 2VDC 4 110VAC 12 CHASSIS GND AUX PS N P 14 13 14 AUX PS COM 13 2VDC PLC TB302 14 PLC TB302 2 110VAC AUX PS COM 13 2VDC 110VAC PLC PANEL CHASSIS GND 13 14 8 4 12 13 PLC terms on Conn Ca...

Page 41: ...R PS 110VAC 12V COM 12VDC 4 110VAC 12 CHASSIS GND COMPUTER PS FAN WIRES FAN WIRES LINE FILTER 14 13 14 12V COM 12VDC PLC TB302 14 PLC TB302 2 110VAC 12V COM 12VDC 110VAC PLC PANEL CHASSIS GND 13 14 8...

Page 42: ...rations www OmniTurn com support OmniTurn com 541 332 7004 541 332 1018 fax Fast Precise A ordable Zip Loader Setup Operations OmniTurn Page 42 of 44 M G4 CNC SPINDLE DRIVE PWB CURRENT ZIP CVR INTERLO...

Page 43: ...i f e U p X 2 K n i f e D n X 3 P u s h e r H o m e X 4 S l o w X 5 I n P l a c e X 6 P a r t E j e c t e d X 7 C l r F a u l t X 1 0 E o B t o C N C X 1 1 A u t o M o d e X 1 2 S h t l S t p U p X 1...

Page 44: ...zipldr_setup operations www OmniTurn com support OmniTurn com 541 332 7004 541 332 1018 fax Fast Precise A ordable Zip Loader Setup Operations OmniTurn Page 44 of 44 This page intentionally blank...

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