OPERATOR SOFTWARE MANUAL WM3,4 & 5 / MINICOILER SPRINGCOIL MACHINE

Manual COILERS R1

LCN BV.

Content Prolog Technical data Safety information Remaining precautions Installation settings Mechanical settings Operating sequence General Information Menus Startup screen Customer menu Save data Delete data Spring Information Coil data (menu) Progressive (menu) Manual control (menu) Utilities (menu) Setup (menu) Alarm / error messages 3 4 5 7 8 9 10 12 13 14 15 18 20 22 23 25 27 29 30 32

1 Prolog: This machine is build by: MERWEDE INTERNATIONAL B.V. Molensteijn 17, 3454 PT De Meern Nederland. We thank you for your confidence and wish you a successful production for now and many years to come.

The WM / MINI COILER is a Semi-automatic Spring coil machine based on the latest technology by using a NC/C-IPC control system. This manual belongs to the WM / MINICOILER and contains important information for a correct and save operation of the WM / MINICOILER. This machine has a twelve-month warranty. This warranty becomes invalid if machine components are changed or replaced without written permission from MERWEDE INTERNATIONAL B.V. This machine is suitable for coiling cylindrical and conical springs and has been constructed around a robust steel frame. The springs are coiled around a spindle. This machine can also be used to coil torsion springs with straight ends. Either rings or rods can be used to feed wire into the machine. If rings are used, the wire can be fed automatically. Rods must be fed manually or with the help of a robot. The machine is quick and easy to use. It takes 2 minutes to set up the machine to coil a different spring. This makes the machine very economical for coiling small and medium-sized series of springs. We would be pleased to hear of any questions or comments you may have concerning the operation of the machine or the software, so that we can make any necessary alterations.

2 Technical data: This machine must be connected to an earthed 400 Volt, 3-phase electrical connection with a neutral conductor (PEN system). The connection must be made by a qualified electrician. General specifications WM / MINICOILER : Length: Width: Height: Weight: Wire diameter: 50CRV 4 Class C Cr/si Maximum spring diameter: Maximum spring length: Spindle speed: Type of control: Internal memory: Communication: Nominal current: 5000 / 2000 mm 800 / 500 mm 1300 / 800 mm 2500 / 500 kg 4-28 / 0,5-8 mm 4-20 / 0,5-6 mm 4-17 / 0,5-6 mm 300/ 120 mm 2150 / 950 mm 1-110 / 1-300 RPM Sigmatek C-IPC 733MHZ Compact flash 64 MB/Sdram:512 Ethernet 63 / 25 A

Safety information:

The machine may only be operated by authorized and suitably trained personnel. MERWEDE INTERNATIONAL B.V. provides such training and gives instructions for the use of the machine on delivery. Make sure the machine is switched off, to avoid unauthorized personnel operating the machine when the operator is absent.

Wear good fitting clothing when working with this machine. This machine has rotating components. Loose fitting clothing may get caught on these components and this may put you in danger. Always pay attention to your personal safety! In dangerous situations, press the emergency stop button. This will cut the power to the motors and allows them to be moved manually. If necessary, turn the machine off using the main switch. Use the emergency stop button if you leave the machine unattended for a short period of time. Make sure the power cables are not damaged. If they are damaged, have them replaced by a qualified electrician. Never place tools or springs on the machines work surface. Make sure the spring remains on the clamping chucks key, so that the key can never be left unattended in the clamping chuck. Make sure the protective cover around the clamping chuck remains intact. Replace the protective cover if it becomes damaged. 5

Wear safety goggles and, if necessary, gloves and safety shoes. This machine is intended for coiling springs. Therefore, do not use it to bend objects. Never allow other persons near the MINICOILER during production and never let other persons touch the Touch Screen. To clean the machine, do not use water, a damp cloth or aggressive cleaning products which may harm the plastic.

MAKE SURE TO UNDERSTAND AND OBEY ALL THE ABOVE MENTIONED! .

Remaining precautions: Whilst cutting the wire, hold the wire with one hand to prevent the wire from slipping out of the wire guide. To prevent slipping adjust the pressure on the wire by rotating the nut on top of the wire guide. Never put your hand in the wire guide during production.

4 Installation, settings The machine should preferably be positioned on a flat surface. The machine is fitted with fixing points, which can be used to secure the machine to a solid floor. The machine must be secured to the floor when using a top reel. The machine must be connected by a qualified electrician. Make sure the machine is connected to the correct voltage supply (400 Volt AC). The direction of rotation of the hydraulic units motor is indicated by an arrow. Depending on the power supply, the connection may need to be altered. An error message will appear on the screen Phase sequence incorrect. Make sure the cables from the console to the machine are sufficiently protected (in steel cable ducts). Make sure the hydraulic tubing are fitted correctly. N.B. Once the machine has been operational for two weeks, all the nuts, bolts and connections must be retightened to check that they have not been loosened.

Mechanical settings The gearbox settings are automatically displayed on the monitor. These settings must then be manually changed to the correct settings. The handle gives a clear indication. The slanted position and the height of the wire guide can be set as required. The wire can be fed into the machine using a top reel, using a horizontal reel or manually (rods).

5 Operation Operating sequence The spring coiler is operated in the sequence stated below. The machine settings are made using a software program developed by MERWEDE INTERNATIONAL B.V. The options are described in the following chapters. A. Mechanical settings Select the correct spindle. Secure the spindle to the clamping chuck. Install the correct carrier to the clamping chuck. Adjust the height of the wire guide. B. Switching on The main switch on the front side of the machine provides power to the computer and activates the controls. If any emergency stop buttons are blocked, then they must first be unlocked by pulling the red knob towards yourself. Next, press the <RESET> button on the touch screen. This will start the hydraulic circuit. C. Menu selection As desired (see the following paragraphs). D. Activating the left foot pedal The clamping chuck will move to the correct position. The wire guide will move to the starting position and the center will cover the spindle. E. Feeding the wire Feed the wire under the carrier once only. F. Activating the left foot pedal The clamping chuck will start to rotate and coil the spring. The wire guide will move to the rest position and will make room for cutting. The center folds back. G. Cutting the spring The spring is cut free using the wire cutters (optional). H. Remove the spring. I. Repeat the process from point D. The operation and parameter settings are made using the menu-operated software.

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ATTENTION: Always be aware that this machine may only be operated by authorized personnel! READ THIS MANUAL CARFULLY

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GENERAL INFORMATION:
The MINICOILER is fitted with a Touch Screen (TS). All settings are changed by touching the appropriate field, this will activate a (numeric) keyboard to set your text or setting.

Each setting must be confirmed by pressing the Delete settings by pressing the Close the keyboards by pressing the or the key key

or the

key

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MENUS
Selecting different menus

Information screen with general data of the selected customer / spring

Spring settings

Machine settings

Progressive spring settings

General settings

Manual control

Activation of the cutter after switch off timer

Reset emergency stop

Actual and historic alarms and error messages

Customer / spring selection menu

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When the MINICOILER is operational the startup screen will be visible, by selecting the appropriate flag, the language is set. 4 languages are standard selectable. Press the key to continue.

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Customer menu:

The customer menu contains the next functions; Current screen number next to the Merwede logo

The current status of the MINICOILER, displayed in the red bar The current date and time, top right side of the screen

The current, active, customer and spring are displayed in the grey bar

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Selection keys for saving and / or deleting data Selection keys for loading customers and / or springs One customer up

Load selected spring Save selected spring (with altered parameters) Save new spring Add new customer Delete spring Delete customer

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Selecting a key will activate a choice menu

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SAVE DATA

Add new customer by pressing the

key

By pressing the activated. Enter the customer name and press the Pressing the Press the key to accept.

bar, the keyboard is

key will create a new customer. key to select the customer from the database. this will open the

NEW SPRING Select from the database the appropriate customer, customer file Press the key to save the new spring.

Press the Press the to the database.

bar to enter the new spring. key to save the new spring and the new spring will be added 18

The new spring will be displayed as shown below:

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DELETE DATA

Select the appropriate spring to delete from the database. The selected field will turn blue Press the key and accept with the key.

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SPRING PARAMETERS AND SETTINGS: ATTENTION! WHEN SAVING A NEW SPRING ALL DATA FROM THE LAST LOADED SPRING WILL BE COPIED INTO THE NEW SPRING DATA TO SAVE THE ALTERED SPRING DATA, YOU MUST PRESS THE KEY, AFTER YOU CHANGED THE SPRING DATA.

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SPRING INFORMATION

This info screen can be used for entering information. The first two fields are read only, to show you the current customer and spring. All entered data is for information only, it will have no effect on the operation of the COILER.

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Adjust settings of the current loaded spring: Touch the appropriate parameter this will activate the numeric keypad. Enter a new value and accept.

Spring length in millimeter. ATTENTION: the exact spring length can differ from the set value ! the COILER will not auto adjust to different coiling materials.

Number of coils is the number of revolutions of the clamping chuck.

Number of closed coils at the start, a low value will open the spring, a higher value will cause the coils to tighten.

Pitch of closed coils at the start, the wire guide will move the number of mm per revolution of the clamping chuck.

Is used to accelerate quickly to the desired pitch. The entered value is normally 0.3 rev. more than the pitch closed coils start.

See aforementioned.

Value of the last closed coil, a small value will result in a more open spring, the higher the value will result in the coils to tighten.

The pitch value to result in a nice and flat last coil.

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The number of revolutions the clamping chuck in the opposite direction to ensure the coiling material is retentioned. ALWAYS check if the spring is not under tension before you cut of the spring.

The pitch is used for longer tension springs, it will make the wire guide move in negative direction. To save the altered data press the key.

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Adjust settings of the current loaded spring: Touch the appropriate parameter this will activate the numeric keypad. Enter a new value and accept.

Use the stages for adjusting the progressive stages in a spring.

Stage 1 to set the acquired pitch relative to the revolution.

Pitch stage 1 to set the acquired pitch.

Stage 2 to set the acquired number of progressive coils.

The settings for a progressive spring must be entered as follows: In order to reduce the speed after the acceleration, there must be a difference of approximately 0.3 coils between the Acc. coils field and End stage 1. Enter the correct value for Pitch stage 1. Enter the number of coils for End stage 2 and enter the same pitch for Pitch stage 2 as for stage 1. For a spring coiled without steps, enter a value for Pitch stage 2 higher than for Pitch stage 1. Stepless progressive coiling: Settings as in stage 1, set pitch stage 2 for example 10 mm higher. This will result in a, step less, increase of the pitch of stage 1 to the pitch of stage 2 To save the altered data press the key.

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DELETING ALL PROGRESSIVE DATA Press the deleted. key and press the YES key and all data will be

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Standard NO functions preselected.

Rotating the clamp chunk with the foot pedal.

Moving the wire guide from left to right with the foot pedal. EXTRA FUNCTIONS FOR THE WM3, 4 & 5

Moving the center in start position

Moving the center in rest position

Moving the center to front / back

Moving the center in / out

Moving the wire guide to the front / back

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Raise / lower the top pay-off

SELECTED KEYS A selected key is indicated by a highlighted bar. The acquired action is activated with the foot pedal. Pressing the left / right pedal will activate an opposite action.

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Settings with Changed data will be written directly into the controls.

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General Machine Setting

Setting the zero position of the clamp chunk in degrees, null degrees is vertical.

Setting the zero position of the support to allow the wire to position exactly under the carrier.

Support position: left = start coiling from the clamping chuck right = coil from the rear of the machine This feature is especially useful to coil left coiled springs with bended wire, in case the wire contains not enough resistance to coil solid around the Dorn.

Setting the number, or a fraction of coils, to allow the pitch to slowly decrease at the end of the spring.

Setting the number of mm, after coiling and slackening, the spring can be moved from the spindle.

Setting the speed of the clamping chuck.

Setting the direction of the rotation of the clamping chuck. L = anticlockwise R = clockwise

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Activate this option to, automatically start the MINICOILER after the referencing. For safety reasons there is no option on the MINICOILER for a fully automated operation.

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The historic and current alarms are displayed

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ERROR REPORTS: 01 EMERGENCY STOP ! CHECK MACHINE AND PRESS RESET 02 Reset 03 Phase sequence incorrect 04 05 Position Control X-Ax 06 Position Control Y-Ax 07 08 09 10 11 alarm11 12 alarm12 13 alarm13 14 alarm14 15 alarm15 16 17 18 19 Not enough rest wounds 20 Not enough rest length 21 ERROR !! NO REST PITCH 22 INPUT ERROR !! 23 INCORRECT SPEED SETTING

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RESET ERRORS: 01 EMERGENCY STOP ! Check the machine Emergency stop circuit is active, in case of a manual emergency stop check the reason, solve the problem and press the RESET key on the screen. 02 Reset Press the RESET key on the screen. 03 Phase sequence incorrect Occurs when installing the MINICOILER for the first time, or relocating the MINICOILER . Swap two phases from the main power supply (trained electrician!) 05 Position Control X-Ax (Spindle) Drag error, press emergency stop button, reset button and press the reset key on the screen, if the error I still active, switch of the machine and restart. 06 Position Control Y-Ax (Support) Drag error, press emergency stop button, reset button and press the reset key on the screen, if the error I still active, switch of the machine and restart. 11alarm11 12 alarm12 13 alarm13 14 alarm14 15 alarm15 16 alarm16 17 alarm17 18 alarm18 19 Not enough rest coils Check the input fields and adjust to a correct value 20 Not enough rest length Check the input fields and adjust to a correct value 21 ERROR !! NO REST PITCH Check the input fields and adjust to a correct value 22 INPUT ERROR !! Check the alarm screen and correct the current alarm 23 SPEED NOT CORRECT Check the input fields and adjust to a correct value

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