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TPC ERN 22, Руководство пользователя

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Winding procedures

68 / ERN 

Ñ

Winding procedures creation programmes for the winding machine ERN-C:

Winding procedures are able to provide winding machine operators with additional important
information on winding. If a winding programme is accompanied with a corresponding winding
procedure a current winding step technological operation description is displayed on the winding
machine monitor automatically. This information comes from the winding procedure and it can be 
represented in form of texts or images.

Application of the winding procedures can:
- support a technological discipline and reduce a frequency of operator failures according to ISO 
standards requirements
- help to change produced assortment operatively even in the case of complicated winding procedures
- quicken and simplify new personnel training

WD_TEXT.EXE - text winding procedures creation (text dociument ".rtf").
The programme makes possible to enter text descriptions of individual programme steps in the order
they will be displayed during the winding process. The whole procedure description is stored in a single 
file with a filename "WindingProgrammeName.rtf" (e.g. the winding procedure description for the
winding programme "trafo.475" is to be saved under the filename "trafo.475.rtf") in the same
directory as the winding programme is.
The programme is provided with the animated help for the quick programme mastering.

Winding procedures in the form of the text

WD_JPG.EXE - imagine winding procedures creation (images ".jpg").
Firstly, some proper photographs of individual steps of the winding programme steps are to be prepared.
Photographs are not to be of the high quality, 16:9 ratio has proved to be advantegeous.
Place the photographs in a new directory in the PC. Start the WD_JPG.EXE programme and open
the winding programme and prepared photographs. The programme makes possible to link individual
photographs to the corresponding steps of winding. After linking the photographs are reduced in size,
renamed and saved under new filenames in the directory where the winding programme is stored.
The original photographs remain without changes.
The programme can start a photo-editor provided that it is necessary to add some text to the image
or to highlight some important information. The winding procedure images are named 
"WindingProgramme.StepXY.jpg", where XY stands for a number of the step and it is necessary
to keep them in the same directory the winding programme is.
The programme is provided with the animated help for the quick programme mastering.

Содержание ERN 22

Страница 1: ...COIL WINDING MACHINE ERN C VERSION USER SGUIDE ERN 22 32 32S 42 52 TPC s r o P lenica 53 79 03301 Liptovsk Hr dok SLOVAKIA Tel 421 44 5221366 Fax 421 44 5222088 E mail tpc tpc sk www tpc sk...

Страница 2: ...of turns correction 5 9 4 Total counter 5 9 5 Wire guide correction 5 9 6 Wire guide direction change 5 9 7 Step abort 5 9 8 Back winding 5 9 9 Deceleration ramp for the STOP button 6 Programming 6 1...

Страница 3: ...ice 8 10 Counter clearing mode 9 ERROR report 10 Application programme closing Color_Disp 11 Firmware upgrades 11 1 Upgrade of the application programme Color_Disp 11 2 Upgrade of the control board ke...

Страница 4: ...positioning wire guide on ball bearings with a separate stepping motor accurate reversible turn counting microprocessor controlled winding cycle without time waste wide programming options memory 2 G...

Страница 5: ...linear deceleration and stop is running automaticly after pressing the START button Deceleration is controlled by microprocessor to ensure accurate stopping and spindle positioning rpm MAX SPEED NUMB...

Страница 6: ...R button enters data to the memory 9 PLUS and MINUS buttons parameters correction and step choice 10 RESET sets the initial state 11 Numeric buttons enter the coil name as well 12 Multifunction button...

Страница 7: ...T I IR D G W E E U T D N IR C I E O E A P L D OI P NT O P INT F E E L R T V H R R T V IG E R C R O T g h c o s C e n y P o n d t r y c o o mp u l a te 2 S p 0 y r La e io 0 5 s P 6 o it n 1 t p D e I...

Страница 8: ...with a PC we can use the supplied mouse which we plug into the USB port No 2 Some advanced computer operations can be performed only with the mouse Into USB connectors it is possible to connect also...

Страница 9: ...eted by this and prepared to work 4 1 Connection to the power The machine must be powered ERN 22 32 by 230V 50 Hz AC with tolerance 5 and max power consumption 1 2 k VA ERN 32S 42 52 by 3 x 400V 50 Hz...

Страница 10: ...5 8 3 6 9 Model ERN 22 Gear 6000 ENTER ENTER PRESS GEAR CHANGE GEAR CHANGE MEM POS OFF MEM POS OFF 5 WINDING OPERATION 5 1 MACHINE SWITCHING ON AND GEAR SETTING After switching on 1 the start window s...

Страница 11: ...s shifted left home zero position zero number of turns zero step and the last set block is set Model ERN 22 Gear 12000 ENTER ENTER PRESS GEAR CHANGE GEAR CHANGE MEM POS OFF MEM POS OFF 12000 12000 300...

Страница 12: ...city drop FOR USING THIS FUNCTION THE MACHINE MUST BE EQUIPPED WITH THE UNINTERRUPTIBLE POWER SUPPLY UNIT UPS AND THE REPORT OF ELECTRICITY DROP relay for POWER MUST BE INSTALLED IF THE MACHINE IS NOT...

Страница 13: ...activates interrupted run and there is no step shifting 10 ERN C 0 00 0 00 BACK WINDING BACK WINDING TOTAL COUNTER TOTAL COUNTER CORRECTION N of turns CORRECTION N of turns Step Step 2 2 0 0 0 0 Posit...

Страница 14: ...loaded to the working part of memory either from internal memory of the Winder USB flash drive or a PC equiped by software GRAPHIC USB PC with software GRAPHIC Proceeding by program selection interna...

Страница 15: ...RELEASE left pedal releases the spindle brake right pedal works as parallel START button Double foot pedal controls SPEED BRAKE RELEASE left pedal releases the spindle brake right foot pedal controls...

Страница 16: ...ened but the spindle speed will be limited for safety value automatically When the shield is closed during the winding the cycle continues with the speed values programmed previously Acceleration and...

Страница 17: ...itch 6 turn the spindle manually to the required position and return the switch 6 to the former position press RESET then ENTER Note When you switch the machine ON by switch POWER or EMERGENCY STOP RE...

Страница 18: ...L L NA 2 L L NA 2 L L NA 3 L L NA 3 L L NA 4 L L NA 4 L L NA PEDAL Pedal speed taken from program PEDAL Pedal speed taken from program TM TM WINDING STOP WINDING STOP 780 00 780 00 RESET RESET Range...

Страница 19: ...NDING STOP WINDING STOP 780 00 780 00 68 30T 68 30T BACK WINDING BACK WINDING COUNTER COUNTER CORRECTION N of Turns CORRECTION N of Turns Step Step 2 2 24 4 24 4 Position Next step 3 SHIFT Name prikla...

Страница 20: ...re guide while winding 68 30 68 30 BACK WINDING BACK WINDING TOTAL COUNTER TOTAL COUNTER CORRECTION N of Turns CORRECTION N of Turns Step Step 2 2 24 4 24 4 Position Next step 3 SHIFT Name priklad2 Po...

Страница 21: ...am TM TM WINDING WINDING 780 00 780 00 5 9 8 Back winding Correction allows you to wind back the required number of turns 68 30 68 30 BACK WINDING BACK WINDING TOTAL COUNTER TOTAL COUNTER CORRECTION N...

Страница 22: ...r the STOP button Deceleration ramp for the STOP button can be set This ramp is whenever a bit faster control by software than programmed deceleration ramp PEDAL PEDAL STOP RAMP 1 STOP RAMP 1 PEDAL se...

Страница 23: ...E OF STEP TYPE OF STEP 2 2 3 3 5 5 6 6 8 8 9 9 C C 2 2 3 3 5 5 6 6 8 8 9 9 C C 4 4 0 0 4 4 0 0 1 1 4 4 0 0 7 7 PROGRAM 20 ERN C NEW PROGRAM NEW PROGRAM LOAD PROGRAM LOAD PROGRAM SAVE PROGRAM SAVE PROG...

Страница 24: ...am is logical sequence of a few 1 350 joined steps STOP STOP STOP STOP ContSLOW ContSLOW END END type of cycle type of cycle type of cycle type of cycle shift shift winding winding step 1 step 4 step...

Страница 25: ...ch left and right reversal point Shift spindle is not turning and the wire guide is shifting to the programmed coordinate Jump spindle is not turning and the wire guide is shifting from its position t...

Страница 26: ...R CANCEL CANCEL Step Step 1 1 Turns 780 00 L Rev 0 0 R Rev 0 0 Speed 0 Acc Dec 11 Pitch 0 000 Cycle Shield CLOSE Turns 780 00 L Rev 0 0 R Rev 0 0 Speed 0 Acc Dec 11 Pitch 0 000 Cycle Shield CLOSE 1 L...

Страница 27: ...SPEED 4000 SPEED 4000 SHIELD CLOSE SHIELD CLOSE Step Step 1 1 PROGRAMMING Accel Dec PROGRAMMING Accel Dec Range 11 88 Enter acceleration deceleration Range 11 88 Enter acceleration deceleration 22 22...

Страница 28: ...000 Range 0 0 210 0 mm Enter left reversation point Range 0 0 210 0 mm Enter left reversation point 0 0 0 0 Step Step 1 1 PROGRAMMING LEFT REV POINT PROGRAMMING LEFT REV POINT SHIFTING ON SHIFTING ON...

Страница 29: ...3 L L NA 4 L L NA 4 L L NA PEDAL Pedal speed value taken from program PEDAL Pedal speed value taken from program TM TM WINDING WINDING LAYER LAYER CANCEL CANCEL Step Step 1 1 Turns 780 00 L Rev 10 0 R...

Страница 30: ...on Spindle deceleration is canceled Only winding steps can be joined by this cycle Type of cycle Set the type of cycle and choose how to continue to the next step CYCLE TYPE OF CYCLE TYPE OF ENTER 27...

Страница 31: ...ht rev point the same but left moving 6 3 4 Wire guide shift Coordinate of shift LAYER LAYER CANCEL CANCEL Step Step 1 1 Turns 780 00 L Rev 10 0 R Rev 60 0 Speed 4000 Acc Dec 22 Pitch 0 300 Cycle Shie...

Страница 32: ...PEDAL 0 TM TM SHIFT SHIFT WINDING WINDING JUMP JUMP DELAY DELAY Step Step 2 2 PROGRAMMING SHIFT PROGRAMMING SHIFT Range 0 1 210 0 mm Enter wire guide position Range 0 1 210 0 mm Enter wire guide posi...

Страница 33: ...NA 3 L L NA 4 L L NA 4 L L NA PEDAL 0 PEDAL 0 TM TM SHIFT SHIFT SHIFT SHIFT JUMP JUMP DELAY DELAY Step Step 3 3 PROGRAMMING WINDING PROGRAMMING WINDING Range 0 1 99990 00 turn Enter number of turns R...

Страница 34: ...ER LAYER Step Step 3 3 Lenght 10 0 Cycle Lenght 10 0 Cycle 1 L L NA 1 L L NA 2 L L NA 2 L L NA 3 L L NA 3 L L NA 4 L L NA 4 L L NA PEDAL 0 PEDAL 0 TM TM JUMP JUMP SHIFT SHIFT JUMP JUMP DELAY DELAY Ste...

Страница 35: ...ge 1 99990 msec Enter time of delay 1 LAYER LAYER Step Step 4 4 Delay 1200 Cycle Delay 1200 Cycle 1 L L NA 1 L L NA 2 L L NA 2 L L NA 3 L L NA 3 L L NA 4 L L NA 4 L L NA PEDAL 0 PEDAL 0 TM TM DELAY DE...

Страница 36: ...5 5 8 8 1 1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 31 ERN G V 3 0 Step Step 1 1 PROGRAMMING LAYER PROGRAMMING LAYER Range 0 250 layer Assign layer number Range 0 250 layer Assign...

Страница 37: ...L NA 4 L L NA PEDAL Pedal speed value taken from program PEDAL Pedal speed value taken from program TM TM WINDING WINDING Layer Layer 1 1 CORR CORR COPY STEP COPY STEP Range 1 0 210 0 mm Setup relati...

Страница 38: ...WINDING WINDING Delete this step press YES Delete this step press YES 2 2 3 3 SHIFT SHIFT COPY STEP COPY STEP Range 1 0 210 0 mm Setup relative position Range 1 0 210 0 mm Setup relative position 5 0...

Страница 39: ...2 PROG corr COPY STEP PROG corr COPY STEP YES YES COPY COPY WINDING WINDING Copy this step press YES Copy this step press YES 2 2 2 2 WINDING WINDING ENTER 36 ERN C COPY STEP COPY STEP Range 1 0 210 0...

Страница 40: ...H PROG corr GLOBAL CH Range 0 000 40 000 mm Enter pitch Range 0 000 40 000 mm Enter pitch 0 300 0 300 Step Step 2 2 GLOBAL CH PITCH GLOBAL CH PITCH 6 5 4 Global change Function allows you to change on...

Страница 41: ...OG corr COORD OFFSET RIGHT OFFSET RIGHT OFFSET All programmed coordinates left right reversal points and shifts are incremented about value 20 0 mm COPY STEP COPY STEP Range 1 0 210 0 mm Setup relativ...

Страница 42: ...ic wire guide correction after start winding or layer Stop after each layer or programmed number of turns Automatic wire guide correction after start winding or layer LAYER STOP OFF LAYER STOP OFF Ste...

Страница 43: ...ch layer or programmed number of turns Automatic wire guide correction after start winding or layer LAYER STOP OFF LAYER STOP OFF Step Step 2 2 PROGRAMMING SPECIAL FUNCTIONS PROGRAMMING SPECIAL FUNCTI...

Страница 44: ...E AS R CORR WIRE GUIDE POSITION WIRE GUIDE POSITION ENTER Range 0 210 0 mm Setup wire guide position Range 0 210 0 mm Setup wire guide position 61 40 61 40 Step Step 2 2 WIRE GUIDE POSITION WIRE GUIDE...

Страница 45: ...utomatic switch to manual regime after finish winding or layer AUT to MAN OFF AUT to MAN OFF Step Step 2 2 PROGRAMMING SPECIAL FUNCTIONS PROGRAMMING SPECIAL FUNCTIONS NEXT 2 NEXT 2 AUT CORR OFF AUT CO...

Страница 46: ...AMMING SPECIAL FUNCTIONS NEXT 3 NEXT 3 Range 0 0 99 0 mm Enter left trapezoidal value Range 0 0 99 0 mm Enter left trapezoidal value Step Step 2 2 PROGRAMMING LEFT TRAPEZOID PROGRAMMING LEFT TRAPEZOID...

Страница 47: ...dings 44 ERN C RIGHT TRAPEZOID OFF RIGHT TRAPEZOID OFF Shifting left reversal point after each layer Shifting right reversal point after each layer Shifting left reversal point after each layer Shifti...

Страница 48: ...ed in standard equipment 6 7 1 View window for inputs and outputs Controller ERN Auxiliary equipment 12V 0 OUTPUT INPUT 5 24V I max 0 5A IN OUT IN OUT Digital outputs 1 4 Digital inputs 1 4 45 ERN C S...

Страница 49: ...NTER 2x 46 ERN C Step Step 2 2 PROGRAMMING INPUT 1 PROGRAMMING INPUT 1 NA input not activated I cycle interruption S cycle start SB cycle start blocked NA input not activated I cycle interruption S cy...

Страница 50: ...1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 ENTER 47 ERN C Step Step 2 2 PROGRAMMING OUTPUT PROGRAMMING OUTPUT Range 1 4 Enter desired output Range 1 4 Enter desired output Step Step 2 2 PROGRAMMING OUTPUT 1 PROGRA...

Страница 51: ...H L START H L DELAY DELAY 2 2 H H H H ENTER 2 2 3 3 5 5 6 6 8 8 9 9 C C 3 3 6 6 9 9 C C 2 2 5 5 8 8 1 1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 48 ERN C Step Step 2 2 PROGRAMMING O...

Страница 52: ...TART H L START H L DELAY DELAY 2 2 L L H H IN OUT IN OUT 49 ERN C Step Step 0 mV turn 0 mV turn 2 2 PROGRAMMING ANALOG PROGRAMMING ANALOG Start 0 mV Decr curve press Start 0 mV Decr curve press CURVE...

Страница 53: ...GRAMMING START 0 Range 0 10200 mV Enter start value Range 0 10200 mV Enter start value 320 320 INCREMENT 0 INCREMENT 0 Step Step 0 mV turn 0 mV turn 2 2 PROGRAMMING ANALOG PROGRAMMING ANALOG Start 320...

Страница 54: ...the storage medium is used CF card On the C drive is installed operating system entry on disc C is not allowed So PC is protected against viruses and unauthorized intervention For manufacturer applic...

Страница 55: ...ESS GEAR CHANGE GEAR CHANGE MEM POS OFF MEM POS OFF 0 00 0 00 COUNTER COUNTER CORRECTION N of Turns CORRECTION N of Turns Step Step 0 0 0 0 0 0 Posit Next step 1 EMPTY Name example156 Posit Next step...

Страница 56: ...C 4 4 R R F F V V 5 5 T T G G B B 6 6 Y Y H H N N 7 7 U U J J M M 8 8 I I K K 9 9 O O L L 0 0 P P pr klad2 pr klad2 d d REFRESH REFRESH EDIT NAME EDIT NAME example 1 example 1 example 1 example 1 ENT...

Страница 57: ...INDING PROGRAMS TPC ERN TPC ERN D D Delete Rename New Directory How to copy from directory into directory choose the file for copy from directory press COPY choose the directory where do you want to c...

Страница 58: ...0 mm Programming UNLOCK Model ERN 22 Number 0 Version 055 929 552 Licence 1140 Gear 12000 rpm Max width 210 0 mm Programming UNLOCK MODEL MODEL Step Step 1 1 MACHINE setup MENU MACHINE setup MENU NEXT...

Страница 59: ...nce 1140 Gear 12000 rpm Max width 210 0 mm Programming UNLOCK SHOW LAYER SHOW LAYER Step Step 1 1 MACHINE setup MENU MACHINE setup MENU NEXT 5 NEXT 5 OTACKY 250 OTACKY 250 Roz Dob 16 Roz Dob 16 STOP R...

Страница 60: ...22 Number 0 Version 055 929 552 Licence 1140 Gear 12000 rpm Max width 210 0 mm Programming UNLOCK PROGRAM LOCK PROGRAM LOCK Step Step 1 1 MACHINE setup MENU MACHINE setup MENU NEXT 1 NEXT 1 Digital co...

Страница 61: ...C C 1 1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 1 1 4 4 0 0 7 7 2 2 5 5 8 8 C C 3 3 6 6 9 9 ENTER 58 ERN OTACKY 250 OTACKY 250 Roz Dob 16 Roz Dob 16 STOP RAMPA O1 STOP RAMPA O1 PEDAL nast PROGRAM...

Страница 62: ...52 Licence 1140 Gear 12000 rpm Max width 210 0 mm Programming UNLOCK Model ERN 22 Number 0 Version 055 929 552 Licence 1140 Gear 12000 rpm Max width 210 0 mm Programming UNLOCK MODEL MODEL Step Step 1...

Страница 63: ...40 Gear 12000 rpm Max width 210 0 mm Programming UNLOCK Model ERN 22 Number 1 Version 055 929 552 Licence 1140 Gear 12000 rpm Max width 210 0 mm Programming UNLOCK MACHINE NUMBER MACHINE NUMBER Step S...

Страница 64: ...r 0 Version 055 929 552 Licence 1140 Gear 12000 rpm Max width 210 0 mm Programming UNLOCK Model ERN 22 Number 0 Version 055 929 552 Licence 1140 Gear 12000 rpm Max width 210 0 mm Programming UNLOCK SH...

Страница 65: ...ateral power on the wire guide overcomes the torque of the step motor Next procedure press RESET ERROR Protection shield is open Next procedure press ENTER and close the shield ERROR Spindle speed ver...

Страница 66: ...TM WINDING WINDING 780 00 780 00 Close Settings Version Program copy Men obsluhy update For the application programme closing click the mouse right button over the status panel and in the displayed m...

Страница 67: ...s of the winding machine right click over the status panel and by choosing Close close the application entering Master code is necessary at the desktop window click on the Upgrade_C_D shortcut and sta...

Страница 68: ...nges never change header it has to remain on the first row in the form MenaObsluhy all the following rows have to be in form numerical code of the operator name and surname of the operator e g 127 Joh...

Страница 69: ...xml file regularly transfer it for further processing on the PC and delete them in the winding machine computer serial port used for the communication with the winding machine control board 0 00 0 00...

Страница 70: ...cedures Modification of the winding procedures if this option is selected winding programmes can be created and edited directly in the winding machine The keyboard usage is necessary The winding machi...

Страница 71: ......

Страница 72: ...iption for the winding programme trafo 475 is to be saved under the filename trafo 475 rtf in the same directory as the winding programme is The programme is provided with the animated help for the qu...

Страница 73: ...onnection the device would be recognized like a new one once again Next hibernation for the new device drivers saving can be performed as follows connect the mouse and close the Color_disp programme c...

Страница 74: ...dehibernate it make and test your settings and to hibernate the system again Dehibernation of the operating system To dehibernate the system do as follows select START select RUN in the Open box ente...

Страница 75: ...me parameters type command xpepm restart and press ENTER the computer restarts and the system is loading in an usual way open the comand prompt window again type command ewfmgr c activatehorm and pres...

Страница 76: ...ear high remove both timing gears Put the gear with the arm flange on the spindle shaft and gear high on the motor shaft Put on the shorter narrower timing belt tension and attach it with the screws 1...

Страница 77: ...s simple To ensure trouble free work following operations are recommended clean regulary the winding space of dust dirt and wire ends check tension of the timing belt the ball bearings have permanent...

Страница 78: ......

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