zipldr_setup&operations
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Zip Loader Setup & Operations
Omni
Turn
Page 29 of 44
InPlace
Setup:
Part in Dead-Length Collet
Rodless Cylinder
Home Stop
Shuttle
Push-rod
Shuttle Stop
InPlace sensor
Spindle Liner
2
9
4
6
10
(for D-L Collet)
NOTE:
Dead-Length Collet not
necessary if diameter of
stock is held very close.
1
Spring-Loaded Stop
Put part in collet at correct length.
With pusher against part, locate Shuttle Stop .
Set InPlace sensor to light.
Spring-Loaded Stop depressed 1/4"
Spring-Loaded Stop lamp lit
Sensor
ZipLoader
STOP MODE
5
Home
Home sensor
Locate Home Stop to just clear part in vee.
Set Home sensor to light when shuttle
is at Home stop.
Collet Bushing
Pusher
(Slightly larger than part)
(Same size as bar)
(Qualify Rear)
3
Slow
7
Slow sensor
Eject
Eject sensor
8
QUALIFY REAR
Part Located
STOP MODE
( Qualify Rear)
QUALIFY REAR
Stop Mode (M52)
Component Parts and Setup
Refer to the illustration above.
1.
Spring-Loaded Stop & Part Located Sensor (1):
The spring-loaded stop holds the part against the
push-rod while the collet is closed. The stop (and Shuttle Stop) automatically extends with M47, and
retracts when load is complete.
For
setup
, use M45 to extend this stop and the Shuttle Stop (10); use
M46 to retract. Move stop into place before M47. Set the tool so that the spring is compressed about .050
- .200”. Loosen band holding sensor, and adjust so the lamp lights when the spring is compressed this
amount, but doesn’t light if not compressed. This provides “no part in collet” fault.
2.
Spindle Liner (2):
The liner should be .020 - .040 larger than the bar to insure vibration-free operation
and reliable feeding.
3.
Pusher (3):
The pusher should be about the same size as the bar. The Pusher rides on the ‘vee’ of the
Loader and guides the bar into the liner. It is pressed onto 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 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 Sensor must light when the shuttle is at the Home Stop with the shock
absorber compressed. The sensor is held in place with a tiny screw. Do not over-tighten the screw as this
may damage the sensor.
6. InPlace Sensor (6):
The In Place Sensor signals the PLC to close the collet and stop pushing. If the shut-
tle doesn’t reach the In Place sensor within 5 seconds after passing Slow sensor, the loader will fault; part
could be too long. If the shuttle passes the In Place sensor the loader will fault; no part or part too short.
7. Slow Sensor (7):
When the shuttle crosses the Slow sensor, the pusher speed is controlled by the set-
ting of the ‘slow’ needle valve (see page 8). For shortest cycle times locate this sensor close to InPlace
(about two inches) and set the ‘slow’ needle valve to act as a brake.
8.
Eject Sensor (8):
The Eject Sensor is mounted near the far right of the Rodless Cylinder. It must light
when the shuttle is at the far right end of the cylinder. If not, loader will fault after M48 (eject remnant).
9. Collet Bushing (9):
If Dead-Length collet is required, the liner must be shortened because the i.d. of D-L
collet is smaller than standard. Make a delrin bushing from 3/4 stock and put it in collet to guide part.
10. Adjustable Shuttle Stop on Rodless Cylinder (10):
The Shuttle Stop is set so that when the pusher
is against extended shot pin with a part in the collet, the part is correctly located for mahining. Z-axis tool
offsets will be used to achieve precise overall length. The shot-pin automatically extends with M47, then
retracts when load is complete.
The illustration on the next page shows the operation of the ZipLoader in “Stop” mode. The M-functions
are described with programming tips.
NOTE:
Early Zip Loaders have combine “End of Bar” and “In Place” sensors, for a total of four.
