HGG PCL 600 Operator's Manual
  1. Manuals
  2. Brands
  3. HGG Manuals
  4. Robotics
  5. PCL 600
  6. Operator's manual

HGG PCL 600 Operator's Manual

Profile cutting line
Hide thumbs
Table of Contents

Advertisement

Quick Links

Profile Cutting Line
Operators Manual
Official manual of the Profile Cutting Line
Includes types: PCL 600

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PCL 600 and is the answer not in the manual?

Questions and answers

Summary of Contents for HGG PCL 600

  • Page 1 Profile Cutting Line Operators Manual Official manual of the Profile Cutting Line Includes types: PCL 600...
  • Page 2 PCL 600 Operators Manual v 2.0 Operators manual Profile Cutting Line This is the operator’s manual for the PCL 600 profile cutting line. For any questions or comments please contact: Manufacturer: HGG Profiling Equipment b.v. Address: Zuidrak 2 1771 SW Wieringerwerf...
  • Page 3 2.0 Preface This manual is part of a set of manuals for the PCL 600 robotic cutting machine. In this manual you will find the operating instructions. The complete set of manuals consist of the following manuals: Operator’s manual Contains information concerning the safe operation of the machine.

  • Page 4: Table Of Contents

      ............................13 AFETY LABELS     ..........................14 MERGENCY STOP     MACHINE DESCRIPTION .......................... 15     PCL 600 ..........................15 AY OUT     ......................... 16 ACHINE COMPONENTS     CONTROLS ..............................18     .......................... 18 ACHINE CONTROLLER  ...
  • Page 5 PCL 600 Operators Manual v 2.0     MENU BAR AND SETTINGS ........................33     ..............................33 ERVICE     ................................ 33     ..............................34 OOLS     ..............................34 UTTING     ......................34 ERVICE MENU ITEMS ETTINGS  ...
  • Page 6 PCL 600 Operators Manual v 2.0     10.2.9 ..........................56 LASMA UNIT     10.3 .......................... 56 MALLER COMPONENTS   APPENDIX A: TERMINOLOGY ........................57   APPENDIX B: NOTIFICATIONS, WARNINGS AND ERRORS..............58   APPENDIX C: CE CERTIFICATE ........................69...

  • Page 7: Introduction

    PCL 600 Operators Manual v 2.0 1 Introduction Intended use of the machine This machine is a stationary, computer controlled, programmable cutting machine. It should be used for the cutting of metal profiles such as angles, flat bars, bulbs, T-bars etc. using a plasma cutting process.

  • Page 8: Conditions For Use And Installation

    PCL 600 Operators Manual v 2.0 Conditions for use and installation The PCL 600 is suitable for installation and use in an environment with the following specifications:  Ventilated, wind- and rainproof environment.  Admissible ambient temperature of 0º C to +35º C.

  • Page 9: Non-Intended Use Of The Machine

    2.0 Non-intended use of the machine The PCL 600 should not be used for clamping or cutting pressurized cylinders, hermetically sealed containers or objects other than described in chapter 1.1. The machine should not be used for cutting flammable or explosive material. The machine should not be used for cutting coated materials that cause the formation of noxious gasses during cutting.

  • Page 10: Safety

    PCL 600 Operators Manual v 2.0 2 Safety The machine is designed to cut metal profiles using a plasma torch. The machine should only be used for industrial applications as outlined in chapter 1.1: Intended use of the machine. Care must be taken when loading material on to the machine.

  • Page 11: Personal Safety Instructions

    PCL 600 Operators Manual v 2.0 Personal safety instructions An operator has to keep the following safety instructions in mind:  Do not use the machine without following the instructions in the manuals.  Read and understand the Operators manual and all safety labels before operating or maintaining this machine.

  • Page 12: Residual Risks

    2.0 Residual risks The PCL 600 is designed to be safe. Despite all risk reduction measures, care must always be taken when operating the machine. Pay special attention to moving parts or machine components that are coloured orange, these parts/components may move suddenly or unexpectedly. Some risks cannot be entirely eliminated, the greatest potential residual risks of the are: ...

  • Page 13: Safety Labels

    PCL 600 Operators Manual v 2.0 Safety labels The residual risks of the PCL are expressed by safety labels. The following safety labels are placed: Label Description Location Fire, naked flame and smoking prohibited. Front side of the remote control.

  • Page 14: Emergency Stop

    PCL 600 Operators Manual v 2.0 Emergency stop Pressing the ‘Emergency stop’ button located on the remote control will stop all machine activity. It is possible that some machine components may decelerate to a stop without this movement being recorded by the CNC controller. Therefore it is important to check the alignment of the torch position if the emergency stop is pressed during profiling.

  • Page 15: Machine Description

    The PCL is capable of cutting a wide range of profiles including flat bars, bulbs, equal and unequal angle bars and T-bars. Lay out PCL 600 1 Gripper 7 Printer (inkjet) 13 Slatted outfeed belt + pusher...

  • Page 16: Machine Components

    PCL 600 Operators Manual v 2.0 Machine components Cutting cell The cutting cell is the heart of the PCL machine. A 6-axes, Staubli TX60 robot arm mounted inside the cutting cell holds a plasma torch and shock sensor. The rollers in the cutting cell measure and position the material.
  • Page 17 HGG. NOTE. Due to the flexibility of the PCL 600 machines many different configurations and combinations are possible. The images shown in this manual may differ from the specific configuration of your machine.

  • Page 18: Controls

    The control panel with touch screen, keyboard and trackball is the interface between operator and machine. The PCL 600 can be completely controlled from this control panel which is situated on a flexible arm attached to the cutting cell giving the operator a good view of the whole process.

  • Page 19: Using The Touch Screen Controls

    PCL 600 Operators Manual v 2.0 Using the touch screen controls This section describes the lay out of the touch screen and the functions of the buttons. The entire machine can be controlled from this screen. 4.3.1 General The buttons in the ‘General’ section are machine start up, shut down and safety controls.

  • Page 20: Controls

    PCL 600 Operators Manual v 2.0 4.3.2 Controls The buttons in the ‘Controls’ section are for activating, moving and homing the machine components. The profiling sequence and automatic functions are also located here. At the bottom of this section you will see two ‘mode selection’...
  • Page 21 PCL 600 Operators Manual v 2.0 Profiling mode: Infeed These buttons control the gripper, the infeed buffer chains and the sideways loading chains. These transport material to the (non-driven) cutting cell infeed conveyor. Move gripper to the left. Infeed buffer chains left.
  • Page 22 PCL 600 Operators Manual v 2.0 Profiling mode: Outfeed These buttons control the outfeed belt and pusher arm, the outfeed conveyor and the outfeed buffer chains. Move outfeed conveyor left. Move outfeed belt left. Move outfeed conveyor right.. Move outfeed belt right.
  • Page 23 PCL 600 Operators Manual v 2.0 The remaining sections of the ‘Calibration’ controls allow the operator to manually move all parts of the machine. This can be used to move material manually to the desired position or to safely prepare the machine for homing.

  • Page 24: Information

    PCL 600 Operators Manual v 2.0 4.3.3 Information The top half of the touch screen contains an information window where various information is available to the operator. The ‘Mode selection’ buttons at the bottom of the section change the information displayed.

  • Page 25: Operating The Machine

    PCL 600 Operators Manual v 2.0 5 Operating the machine Before starting the machine  Make sure the machine and the area around the machine is clean and free of tools and other obstacles.  Make sure you wear the correct personal protection equipment (PPE) as described in chapter 2.3.

  • Page 26: Profiling

    PCL 600 Operators Manual v 2.0 6 Profiling The PCL 600 can run in two cutting modes:  Manual selection of cutting data, single parts or nested parts.  Automatic cutting of data files that have been added to the auto cut list.

  • Page 27: Default Project Setting

    PCL 600 Operators Manual v 2.0 Default project setting The ‘Set project’ option in the ‘Cutting’ menu allows the operator to choose a Ship (project/nest project) and Lot (assembly/nest job) as the default project for loading GPD and TAF files. If a default project has been set, when selecting GPD or TAF the Ship and Lot fields will already be filled in for you.

  • Page 28: Status

    PCL 600 Operators Manual v 2.0 Status To assign a status to data files in the auto cut list, right click on the file to open the context menu with a list of all possible status assignments. Each status appears on the list in the same order as the material moves through the cutting process.

  • Page 29: The Cutting Sequence For A Single Bar

    PCL 600 Operators Manual v 2.0 The cutting sequence for a single bar The flow chart below shows the cutting sequence for a single bar. Before loading the data file, start the machine up and calibrate the sideways infeed, gripper, clamps and printers as described earlier in this manual.
  • Page 30 PCL 600 Operators Manual v 2.0 1 Infeed When the material has reached the end of the infeed buffer chains (auto) or been loaded onto the machine and assigned a status (manual) it is transported by the chains and cams of the sideways loading chains to the non-driven infeed roller conveyor.

  • Page 31: Cutting Progress - Production Graphic

    PCL 600 Operators Manual v 2.0 Hold At any time during the cutting process the ‘Hold’ button can be pushed to halt the machine. When the machine is held it is possible to use the ‘Displace cut’ and ‘Reverse’ buttons. See below for more information.

  • Page 32: Automatic Cutting

    PCL 600 Operators Manual v 2.0 Automatic cutting The preparation procedure for automatic cutting is the same as for manual cutting. First start the machine up and calibrate the sideways infeed, gripper, clamps and printer as described earlier in this manual. Use the ‘Add’ button to add data files to the auto cut list. If you have added files you must also assign them a status to inform the PCL of their location.

  • Page 33: Menu Bar And Settings

    This item gives access to the ‘robot command’ window. The operator can move the robot arm to one of five positions. This item is usually only for use by HGG personnel, the remaining buttons in the dialog are for diagnostic purposes in the event of problems with the machine.

  • Page 34: Tools

    The operator can see at a glance which parts are in need of inspection or replacement. Maintenance This item is password protected. It is used by HGG software engineers for monitor diagnostics and troubleshooting. Data monitor This item is also intended for HGG engineers and software engineers for diagnostic purposes.
  • Page 35 LowerFlangeFirst Make the cuts (or markings) on the lower flange first. ShapeTrimDist These are settings that are predominantly used for other robot cutting machines in the HGG range. They are not applicable CornerTrimDist to the Profile Cutting Line machines. GrindReduction...

  • Page 36: Maintenance

    7.5.1 Maintenance Most of the options on the maintenance window are intended for HGG engineers and service engineers. The ‘Robot Command Window’ can be used to move the robot arm to five different positions. Two of these are useful for the operator.

  • Page 37: Tools Menu Items: Plasma Service Info

    7.6.1 Maintenance and Data Monitors These are diagnostic dialogs for the HGG service engineers. The maintenance monitor gives access to critical settings and is password protected for safety reasons. The data monitor contains the current information about the settings, positions and activities of various machine and software settings.

  • Page 38: Calibration

     Calibrate tool Tools and material The calibration column supplied by HGG is used for the first two of these procedures. For the plasma torch calibration you will need a flat bar that complies with the following conditions:  Web size = 200 to 300 mm ...

  • Page 39: Calibrate Clamps

    PCL 600 Operators Manual v 2.0 Calibrate clamps The calibration of the vertical and horizontal clamps in the cutting cell is carried out automatically using the wizard in the ‘Service’ menu. Before beginning any calibration procedures make sure that the machine is ready: ...

  • Page 40: Calibrate Active Frame

    Open the folder and create a new File folder and give it a name (e.g. GPD).  Now open the ‘Settings’ folder in the machine software (by default: C:\HGG\pcl\Settings).  Copy the file ‘CaliActiveFrame.gpd’ to the ‘GPD’ file folder you just created.
  • Page 41 PCL 600 Operators Manual v 2.0 WARNING! Never carry out the active frame calibration in automatic mode! The machine could start moving unexpectedly. The cutting process will be stopped if the cutting cell doors are opened. You may not have enough time to make a measurement before the torch moves to the next cut.
  • Page 42 2.0 Enter the measurements in the ‘Calibrate Active Frame’ dialog The dialog is the same for all configurations of the PCL 600. The top, bottom and front of the material vary depending on the cutting direction of the machine. The diagram below shows the surfaces for a column.

  • Page 43: Calibrate Tool

    PCL 600 Operators Manual v 2.0 Calibrate tool The tool calibration is carried out by cutting a small square within a square and measuring the distances indicated in the ‘Calibrate tool’ dialog. The top right hand corner is cut from the outside square to identify which side is which.
  • Page 44 PCL 600 Operators Manual v 2.0 7 In the ‘MDI’ module, select the part. In the first column (Start), click on the green plus to open the ‘Select start macro’ dialog. From the list of macros, select ‘TestPiece’ (you will skip this cut later but it must be programmed to create a valid part).
  • Page 45 PCL 600 Operators Manual v 2.0 13 These properties can be changed. If you wish the square to be cut nearer to the end of the raw material for example, change the ‘distance’ property. If you want to cut two squares next to each other, change the ‘offset’...

  • Page 46: Cut The 'Toolcalmid' Calibration Piece

    PCL 600 Operators Manual v 2.0 8.4.2 Cut the ‘ToolCalMid’ calibration piece Place the piece of material on the infeed conveyor so that it can be grabbed by the gripper. On the remote control touch screen activate the ‘Robot high power’. Select the ‘Calibration’ screen.

  • Page 47: Enter The 'Calibrate Tool

    PCL 600 Operators Manual v 2.0 8.4.3 Enter the ‘Calibrate tool’ measurements Be careful! The calibration piece will be hot after cutting. Wait until it has cooled down before making any measurements. The operator must wear flame proof gloves when handling pieces.

  • Page 48: Cutting Compensation

    SAME direction(s) and can be used as a quick fix for calibration deviations or material deviations. This should not be used as a calibration procedure. If in doubt, please contact HGG for more information. 8.5.1...

  • Page 49: Cutting Tables

    PCL 600 Operators Manual v 2.0 9 Cutting tables Many factors influence the quality of the cut, the most important are the plasma current (Amperes), the cutting speed (mm/min.) and the kerf width (mm). These factors vary according to the cutting thickness. The distance between the torch and material during cutting, ignition and piercing also vary with the cutting thickness.

  • Page 50: Columns In The Cutting Table

    PCL 600 Operators Manual v 2.0 Columns in the cutting table Cutting thickness The thickness of the cut (not the material). The material thickness and cutting thickness are only the same if the cut is perpendicular to the material (90°). When cutting at an angle the cutting distance will be greater.
  • Page 51 PCL 600 Operators Manual v 2.0 Melt – inside bevel During the cutting of bevels the heat generated can cause a rounding of the edges. This can result in the part being shorter than specified. This correction offsets the cut by the value entered in millimetres (positive = longer, negative = shorter).

  • Page 52: Transport And Storage

    If for any reason the machine needs to be moved to a new location or decommissioned and placed in storage please contact HGG for detailed advice. The instructions below outline where preparation and precautions must be taken with some parts of the machine.

  • Page 53: Storage

    PCL 600 Operators Manual v 2.0 10.2 Storage In the event that the machine is to be decommissioned the preparations described earlier should be carried out. To dismantle the machine follow the steps described in the Installation Manual in reverse order. The weights and packing instructions for the individual machine components are described here below.

  • Page 54: Conveyors And Passive Support Legs

    PCL 600 Operators Manual v 2.0 10.2.3 Conveyors and passive support legs Disassemble the conveyor into sections. The sections can be stacked onto pallets. Conveyor sections with cylinders must be separated by wooden supports to prevent damage to the cylinders (below left). Sections without cylinders should be separated by wooden planks (below centre).

  • Page 55: Cutting Cell

    PCL 600 Operators Manual v 2.0 10.2.6 Cutting cell Disconnect the cutting cell from the other components. Cover the control panel with protective padding and secure it to the cutting cell. Support the arm at the top of the cell and use an extra piece of wood to prevent it from swinging during transport.

  • Page 56: Dust Collector

    PCL 600 Operators Manual v 2.0 10.2.8 Dust collector Make sure all power supplies and hoses are disconnected. Remove all piping from the dust collector. The filter unit has holes in the bottom for transportation with a fork lift or hooks at the top for movement with an overhead lifting device, place on a pallet and secure firmly.

  • Page 57: Appendix A: Terminology

    PCL 600 Operators Manual v 2.0 Appendix A: Terminology Term Definition Plasma cutting Plasma cutting is a process that is used to cut metals and other materials using a plasma torch. In this process, an inert gas (in some units, compressed air) is blown at high speed from a nozzle, simultaneously an electric arc is formed through the gas from the nozzle to the surface being cut, turning some of that gas to plasma.

  • Page 58: Appendix B: Notifications, Warnings And Errors

    Error initializing Pmac with values from <named> These errors are problems with the Pmac brick motion controller, if you 003:000:017 Error downloading Pmac: <named> see these errors contact HGG. 003:000:018 Error initializing Pmac PLC0 program 003:000:019 Error approaching Pmac 003:000:020 Invalid Pmac motor status count received <named>...
  • Page 59 Error opening Pmac download file <named file> These errors are problems with the Pmac brick motion controller, if you 003:000:023 Invalid Pmac global status count received see these errors contact HGG. <named> 003:000:024 Pmac cannot start data gathering while already gathering.
  • Page 60 <number> configuration, contact HGG. Calculator 003:008:003 Calculation did not respond. There is a problem with the calculation module, contact HGG. 003:008:004 Calculation failure: <named error> 003:008:009 Starting calculation failed. Calculation still running. Wait for the current calculation to be completed, try again. Disable the macro calculator in the settings.
  • Page 61 PCL 600 Operators Manual v 2.0 Error number Error text Problem/Reference chapter Staubli robot 003:010:029 Error sending Staubli Arc control Move robot to safe, this will re-send the Arc control data Plasma tool ignition 003:012:301 Plasma pilot/main arc timeout Check the nozzle, clean if necessary and try again.
  • Page 62 PCL 600 Operators Manual v 2.0 Error number Error text Problem/Reference chapter Settings 009:001:005 Unable to change name! Name already exists The name of this setting already exists, choose a different name. 009:001:006 Removal not allowed These are essential files, which may not be removed.
  • Page 63 Turn on the plasma unit. Wait until it is ready before continuing. 014:008:026 Robot spline not running while cutting. Make a note of the error and events leading up to it and call HGG. 014:008:101 Error calculating macros. File: <named file>. 014:008:105 Calculator returned no profiles.
  • Page 64 PCL 600 Operators Manual v 2.0 Error number Error text Problem/Reference chapter Material handling 014:016:050 Error. Gripper has lost material. Re-grip the material. Check that the material detection mechanism is not 014:016:055 Error. No material in gripper. fully retracted. 014:016:058 Function only allowed in program mode.
  • Page 65 PCL 600 Operators Manual v 2.0 Error number Error text Problem/Reference chapter Infeed 014:019:002 Infeed home timeout. It has taken too long to home the sideways infeed, turn off ‘Slow’ material handling if it is activated. Check that the home switch is working.
  • Page 66 PCL 600 Operators Manual v 2.0 Error number Error text Problem/Reference chapter Printer 014:025:101 Timeout moving printer axis to home. It has taken too long to home the printer axis. Check that the switch is not dirty or damaged. Check that the motion runs smoothly.
  • Page 67 PCL 600 Operators Manual v 2.0 Error number Error text Problem/Reference chapter Clamp calibration 014:028:105 Unable to start clamp calibration procedure when Press the ‘Robot to safe’ button robot not in safe. before beginning the calibration procedure. 014:028:106 Unable to continue clamp calibration procedure when robot not in safe.
  • Page 68 PCL 600 Operators Manual v 2.0 Error number Error text Problem/Reference chapter Infeed buffer chains 014:041:001 Infeed storage wago fuse blown. Replace the fuse. 014:041:002 Infeed storage frequency controller error. Trigger the emergency stop. Wait 20 seconds, reset the emergency stop.

  • Page 69: Appendix C: Ce Certificate

    NPR-ISO/TR 14121-2:2008 NEN-EN-ISO 13850:2008 NEN-EN-IEC 60204-1:2006   NEN-EN-IEC 61000-6-4:2007 NEN-EN-ISO 9013:2005 The party authorised to compile the technical file is: HGG Profiling Equipment B.V., Zuidrak 2, 1771 SW Wieringerwerf. The Netherlands. The Netherlands, Wieringerwerf 09-08-2013 ……………………………………………………………… Mr. Mark Helder Managing Director ...

Table of Contents

Save PDF