XM Controls Tandem-Wire Operation Manual Download

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Revision 0

May 2007

Tandem-Wire SAW System

Operation Manual

Advanced Manufacturing Engineering Technologies

XM Controls

Summary of Contents for Tandem-Wire

Page 1: ...Revision 0 May 2007 Tandem Wire SAW System Operation Manual Advanced Manufacturing Engineering Technologies XM Controls ...

Page 2: ...eral points of interest Caution Highlights items which can cause damage to the system and or injury to operators Tip Identifies programming suggestions and operational information for the XM Safety Identifies specific safety concerns These items may vary depending on how the system is equipped however general safety practices remain constant in all situations and environments ...

Page 3: ...ER 17 6 1 XM Controller Features 17 6 2 Controller Components 18 6 2 1 Emergency Stop 19 6 2 2 Soft Buttons 19 6 2 3 Sequence Buttons 19 6 2 4 Programming Knobs 19 6 2 5 Function Buttons 20 6 2 6 Joystick Controls 22 6 2 7 LCD Display 22 6 3 Mode Of Operation Select 23 6 3 1 Weld Mode 23 7 TANDEM WIRE SAW SYSTEM 27 8 SAW SYSTEM OPERATIONS OVERVIEW 29 8 1 Boom Mast Manipulator with Travel Car 29 8 ...

Page 4: ... this section p 6 Read and follow all Safety Standards DANGEROUS LASER BEAM It is dangerous to look directly into the laser beam Ensure that suitable precautions are taken so that direct viewing of the beam or viewing of direct reflections from shiny surfaces is not possible 1 A key switch is provided to allow the laser to be disabled 2 The laser should be disabled before any maintenance is perfor...

Page 5: ...good electrical earth ground 8 Do not touch electrodes while you are in contact with the work ground circuit 9 Use only well maintained equipment Repair or replace damaged parts at once 10 Keep all panels and covers securely in place ARC RAYS CAN BURN EYES AND SKIN NOISE MAY DAMAGE HEARING Arc rays from the welding process produce intense heat and strong ultraviolet rays that will burn eyes and sk...

Page 6: ...ed 2 Wear proper body protection to protect skin WELDING CAN CAUSE FIRE OR EXPLOSION Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot work piece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire 1 Protect yourself and others from flying sparks and hot meta...

Page 7: ... cylinders are in use or connected for use 8 Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 9 Near the top of the tank each cylinder has a label which identifies its contents by name and a brief symbol which identifies safety concerns It is very important you read and understand all the Material Safety Data Sheets MS...

Page 8: ...ly opening system 3 Treat all hoses hot or cold with caution Pressure can cause injury ELECTRICAL SHOCK CAN KILL This identification label is used to call attention to immediate or imminent conditions which if not avoided will result in serious injury or death Have only QUALIFIED personnel install operate repair or perform any maintenance on this equipment AUTOMATED AND ROBOTIC EQUIPMENT MAY MOVE ...

Page 9: ...commended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamph...

Page 10: ...The illustrations below shows the XM Tandem wire SAW System column boom pneumatic control box travel car track control stand and pendant XM Controller SAW welding head electronic cabinets turning rolls XM Tandem wire SAW System 1 ...

Page 11: ......

Page 12: ...4 XM Tandem wire SAW System Module Cabinet ...

Page 13: ...on the outside of the cabinet 2 Turn on the Sola Power Supply on the inside of the Meta Cabinet 5 1 4 Weld Engineering 1 Turn on the Weld Engineering Mighty Mac X 2 Turn on the Weld Engineering AV 3000 3 Turn on the Weld Engineering Main Control 5 1 5 Meta Software 1 Turn the Meta Software Laser Key Switch to the On Position 2 If the Meta Software does not automatically boot open the Meta Software...

Page 14: ...he wire to a desired stick out length 2 Turn the Laser on with the XM Controller Laser On Function Button 3 Move the wire tip to the starting point in the weld groove until the Meta Display shows an acceptable image 4 Adjust the Meta Tracking Laser manual adjusting screws until the Meta Tracking Laser Display shows the lowest point of the weld centered on the crosshairs 5 Position the 1st Weld Wir...

Page 15: ...the torch at a starting point 5 2 3 Tracking Laser Calibration Circumferential 5 2 3 1 Adjust the Scribe Camera In addition to the above steps in order to do a circumferential weld you must do the following 1 Place the calibration tool in view of the camera and parallel to the groove 2 Press the LTS Calibration button on the Meta Display Left and right sides are determined by looking at the front ...

Page 16: ...ss the Restart Soft Button 2 If cameras are the same continue the weld by pressing the Restart Soft Button Restart This continues a weld from an operator s previous stop point This will restart the weld at the point in the program when the stop button was pressed Pressing the Start Sequence Button will begin the weld from the beginning of the segment The Restart Soft Button begins the weld from th...

Page 17: ...eadability Dedicated Buttons Designed for the most commonly used welding functions 3 Programmable Joysticks The joysticks control up to 6 axis of motion 4 Programming Knobs Easily program parameters and offer override control in welding programs Integrated Power Supply Control For virtually any arc welding supply Build or expand your own system with the industry s first Plug and Weld modules The X...

Page 18: ...LCD Display 4 7 6 2 Controller Components Soft Buttons 4 2 Emergency Stop 4 1 Mode Buttons 4 8 Sequence Buttons 4 3 Soft Control Knobs 4 4 Joystick Controls 4 6 Function Buttons 4 5 ...

Page 19: ...am The Start button begins the current weld program The Stop button terminates any running process or operation If used during a weld program the Stop button will either end the current weld segment and go to the post weld segment or terminate the program if already in the final segment The Next button s function depends on the weld program and requires an operator to advance to the next programme...

Page 20: ...ns the Meta Tracking laser on 6 2 5 3 Jog Buttons Sub Arc Lead Wire Jogs the Sub Arc Lead Wire Sub Arc Trail Wire Jogs the Sub Arc Trail Wire Scribe Line Activates the plasma gas at the default flow rate Plasma Gas will flow at this rate until the button is deactivated Set Reference Opens the screen to calibrate the tip of the wire on the Top Left or Top Right edge of the weld ...

Page 21: ...eadout XVC Home Moves the XVC Slide to its hardware home position and zeros the position Home All Moves all slides or rotation devices with Home capabilities to their hardware home positions and zeros the position readout High Speed Changes the jog speed of all motion axes that are controlled by joysticks Changes JOG buttons to the HIGH SPEED setting Continuous Jog Illuminates when active and is u...

Page 22: ...rogrammable parameters Command High Speed Low Speed Joystick Yellow Axis White Axis Top Joystick XVC X Slide Middle Joystick Travel 1 Travel 2 Bottom Joystick Up Down Left Right 6 2 7 LCD Display The LCD Display presents the graphical interface screens required for the different Modes The WELD EDIT and SETUP Modes and their program screens are described in detail in section 4 8 Mode of Operation S...

Page 23: ...The top section contains the Soft Button labels The center section contains weld schedule graphical information and a text message area The bottom section displays the program Meters Each Meter will display weld program parameter information and parameter override data Soft Button Labels 4 8 1 1 Meters with Parameter Values 4 8 1 8 Weld Schedule Information 4 8 1 2 4 8 1 7 ...

Page 24: ... Section 4 8 3 2 for meter assignments Weld No Weld Weld No Weld In the WELD state the weld schedule performs as programmed In the NO WELD state the weld schedule proceeds without weld current and disables the WIRE FEED and AVC All other remaining weld parameters are still active Data Data Displays previous data files Restart Restart This continues a weld from an operator s previous stop point Thi...

Page 25: ...h segment completes 6 3 1 5 Segment Status Segment Status Alphanumerically displays the segment status It displays both the segment condition and the segment s current progress The Segment Status subdivision also illustrates progress with a progressive task bar which changes color as it advances 6 3 1 6 Segment Sequence Segment Sequence Indicates the segment being performed The current segment has...

Page 26: ...grammed Parameter value Override value operator input To override a parameter value turn the associated Knob to reach the desired value To view the next available parameter for that module press the Knob once Press the Knob again to toggle through the parameter list for each module The Meters Soft Button toggles the meters between the 4 primary and 4 auxiliary meters See Section 4 8 3 2 for Meter ...

Page 27: ...d Due to the number of rails and supporting structures around the travel cart a trip hazard can occur Do Not Step In normal operation the operator should not need to get up on the travel cart Due to the number of hazardous conditions the travel cart should not be climbed upon unless authorized and only by trained personnel with specific need to do so ...

Page 28: ...7 1 Overview ...

Page 29: ... 1 2 SAW Welding Head The Welding Head consists of the torches wire feed assemblies flux delivery recovery nozzles the line marking scribe and travel encoder reference assembly non contacting pyrometer and the two META sensor assemblies that provide scanning and tracking sensing capability for the process Each of these assemblies has various programmed and or control functions For instance the XM ...

Page 30: ...ould not need to get up on the travel cart Due to the number of hazardous conditions the travel car should not be climbed upon unless authorized and only by trained personnel with a specific need to do so 8 1 3 Mast Travel Car The Mast Travel Car place the weld head in the general position with respect to height and boom centerline location Move the Mast Travel Car with the Manipulator hand pendan...

Page 31: ... being welded This assembly is used to verify travel speed on the surface to help adjustment for can wall thickness 8 1 5 Flux delivery recovery System The Weld Engineering Flux delivery recovery System is enabled by the XM Control Pendant Function Button controls The flux recovery system is not in the weld program 8 1 6 Lincoln Power Wave Power Supplies The XM system X PS Power Supply Control Mod...

Page 32: ...in the directory C MAF MAF exe If the program is closed it can be restarted at any time by selecting this executable file or by double clicking the icon on the Windows desktop This will restart the tracking program Only one instance of the MAF application can be run at any one time The following image shows the main display of the MAF application during operation ...

Page 33: ...s off then the display will be blank This surface profile image is analyzed to determine the position of the joint features and these are shown as green or yellow lines indicating a feature on the profile The current tracking position is represented by the green cross The large crosshairs indicate the current tracking reference position Status Indicators These show the currently selected parameter...

Page 34: ...ion READY Operate Signal is Off waiting to start tracking SEARCH Operate Signal is ON Laser is On and searching for joint bead Once the position is within the threshold range then the status will change to TRACKING TRACKING Sensor is following weld joint and position correction moves are being sent ERROR A serious error has occurred The system will not track in this state BL Bottom Left BLC Bottom...

Page 35: ...sor It will analyze this image and find the tracking position of the weld profile corresponding with the current settings This position will be stored as the new Tracking Reference Position This procedure can only be used in the READY state ZOOM IN The Sensor Image shows the complete profile that is seen by the sensor however it is compressed to fit the smaller area of the Sensor Image display Sel...

Page 36: ...ill procedures Depth Three measurements of current joint depth are taken at the left right and centre joint positions All of these parameters are averaged to remove the effect of noise from the measured values The amount of averaging used is set in the Parameters menu User Offset buttons These buttons allow the operator to adjust the horizontal and vertical tracking position by a defined amount Th...

Page 37: ...tialization and operation of the system various messages may be generated and displayed in the message log This is a scrolling list and will generally indicate that the system is functioning normally however they can also warn of problems during initialization and of any problems that may occur during operation Normal message are shown in black and error messages are shown in red The latest messag...

Page 38: ... the necessary position corrections are calculated and sent to the motion control system The video image that is received by the sensor is always displayed in this area of the display In the READY state the normal image is shown which allows the operator to setup the sensor and lights to achieve the best possible image of the line to be tracked During SEARCH and TRACKING the analyzed line signal w...

Page 39: ...s Equipment description Applicable Manual Manual Location Process Control AMET XM Controls Main Fixture AMET International Welding Power Supplies Lincoln PowerWave 1000 Joint Tracking Scanning META Inc Flux Handling Weld Engineering ...

Page 40: ...TA System cabinet door Check power ON at Lincoln power supplies Check power ON at the three Weld Engineering panels Check META Laser Key switch is ON Check power ON at the SOLA power supply System Power Up Check the XM Controller is ON Boot META software from touch screen META software booted END YES ...

Page 41: ...ng point Turn ON the LASER Run out weld wire 1 to prescribed distance Press the Left or Right Soft button on the XM Controller Move wire to a top edge of groove Press the START button on the XM Controller Verify the META Laser display is mirror image of reference point Jog the wire to the opposite groove edge Jog the torch to the starting point in the groove Press the Set Reference Function button...

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