Table of contents Patriot Series 1. General Information Section Page 1.1 Contents of the Manual -------------------------------------------------------------------------------------- 1 1.2 Machine Data Plate ------------------------------------------------------------------------------------------- 2 1.3 Technical Support --------------------------------------------------------------------------------------------- 2 2. Technical Information 2.1 Description of the Machine --------------------------------------------------------------------------------- 3 2.2 Machine Footprint --------------------------------------------------------------------------------------------- 4 2.3 Capacities and Requirements ----------------------------------------------------------------------------- 4...
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Table of contents Patriot Series 4.4 Leveling -------------------------------------------------------------------------------------------------------- 12 4.5 Alignment ------------------------------------------------------------------------------------------------------ 13 4.5.1 Preparing the Bar Feeder ------------------------------------------------------------------------------- 13 4.5.2 Aligning the Center Lines ------------------------------------------------------------------------------- 14 4.5.3 Anchoring the Bar Feeder ------------------------------------------------------------------------------ 15 4.6 Installation of Accessories -- ----------------------------------------------------------------------------- 16 4.6.1 Moveable Anti-Vibration Device (MAVD) ----------------------------------------------------------- 16...
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Table of contents Patriot Series 6.8 Entering a New Program ---------------------------------------------------------------------------------- 30 6.9 Selecting and Editing an Existing Program ----------------------------------------------------------- 33 7. General Maintenance 7.1 Periodic Maintenance -------------------------------------------------------------------------------------- 34 7.2 Rotating Tip and Collet ------------------------------------------------------------------------------------ 34 7.3 Air Filter/Regulator/Lubrication Unit -------------------------------------------------------------------- 34 Parameters 8.
1. General Information Patriot Series General Information Please read and understand the Manual before operating the bar feeder Contents of the Manual The bar feeder manufacturer has provided this manual as an integral part of the machine. Adherence to the instructions of the manual will help prevent injury to the operator and damage to the machine as well as helping to realize the maximum potential of the bar feeder and machine tool.
(type) and serial number on hand. Refer to the machine data plate for this information. Technical Support For technical support please contact the Edge Technologies Service Department by phone at 314-692-8388 of by email edgeservice@edgetechnologies.com Important information When calling for technical support please have the machine model (type) and serial number on hand.
2. Technical Information Patriot Series Technical Information Description of the Machine The Patriot is a PLC controlled automatic bar feeder designed for both Swiss style and fixed headstock lathes. The bar feeder is constructed to handle a wide variety of material profiles from round to hex and square stocks and can be adapted to feed materials with a more unique shape.
2. Technical Information Patriot Series Compressed Air Supply Air supply to the bar feeder must be supplied through a line having a minimum inside diameter of 8mm. Pressure must be maintained at a minimum of 6 bar (85 PSI) for the bar feeder to operate properly.
2. Technical Information Patriot Series 2.5 Electrical Supply The Patriot draws electrical voltage from the lathe through the interface cable. Standard power input is 220VAC 3 Phase, 16 Amps. The transformer in the bar feeder cabinet has multiple input voltage taps to accommodate most lathe configurations without using an additional external transformer.
2. Technical Information Patriot Series Important Information The outer diameter of the bar collet must be at least 0.5mm smaller than the bar pusher outer diameter. Bar Stock Preparation and Straightness Requirements 2.7.1 Straightness Requirements Optimum performance of the bar feeder can only be achieved if the material to be run meets specifications for straightness.
2. Technical Information Patriot Series 2.7.3 Bar Stock Preparation The bar stock must be free of burrs, chips and excessive dirt. Clean bars will extend the life of the channel guides and bearing unit of the pusher as well as the oil pump impeller. The bar ends should be relatively square to the length of the bar.
3. Transportation and Handling Patriot Series Transportation and Handling Warning The weight of the bar feeder without packaging is approximately 2100 lbs. Verify the equipment to be used for moving the bar feeder is rated to safely lift the weight of the bar feeder plus the packaging material. Make special note that the bar feeder is top heavy and take proper precautions.
3. Transportation and Handling Patriot Series Machines in configuration “A” may be lifted only by the two 25mm eyebolts found under the hood on the bar plane. These eyebolts must also be used to remove the bar feeder from the skid.
4. Installation Patriot Series Installation Caution The following instructions should be carried out only by skilled, trained personnel. Proper alignment and installation is crucial to achieve optimal performance of the bar feeder. Improper alignment can cause poor finish quality and out of tolerance conditions on machined parts, damage to the bar feeder channels, pusher and collet and damage to the actuator and spindle bearings on the lathe.
4. Installation Patriot Series Height Adjustment Determine the distance from the floor to the center of the spindle of the lathe. Compare this dimension to the distance from the bottom of the bar feeder stand to the center of the opening of ±...
4. Installation Patriot Series maintaining the side to side level while performing this step. Once the center height is roughly the same as that of the lathe you are ready to align the bar feeder. Alignment The bar feeder is aligned to the lathe spindle by use of a nylon string which is stretched between the lathe collet/chuck and the alignment fitting at the rear plate of the bar feeder.
4. Installation Patriot Series 4.5.2 Aligning the center lines The bar feeder is aligned by moving the front and rear stands so that the distance from the string to the centerline of the lathe spindle and the centerline of the opening of the anti-vibration device is equal on all sides to within 0.15mm (approx.
4. Installation Patriot Series feeder check the position of the string relative to the bore of the anti-vibration device. It may be necessary to alternate between the front and rear adjustments until both are centered. When centered, tighten the jam nuts on the leveling screws.
4. Installation Patriot Series hold down nut against the bottom of the bar feeder stand on all four hold down rods. 6. Place a plastic pad under each of the four inside leveling screws. Tighten the leveling screws firmly by hand making sure the ball of the leveling screw is fully in the socket of the pad.
4. Installation Patriot Series 4.6.2 Fixed front nose For installations with fixed headstock lathes a fixed nose is supplied to fill the distance between the bushing device and the back of the lathe spindle or coolant collector. The flange of the fixed nose bolts to the face of the bushing device.
4. Installation Patriot Series 4.6.4 Synchronization device For installations on sliding headstock lathes a synchronization device may be used. A rod is linked to the moveable anti-vibration device mounted to the lathe spindle. This rod passes through the front plate of the bar feeder. Inside the bar feeder a piston assembly is attached to the rod.
4. Installation Patriot Series Oil for guide channel lubrication and dampening The bar feeder pumps oil into the guide channel for dampening vibration and lubrication of the revolving tip of the pusher. The oil tank should be filled with 60 liters (approx.16 gallons) of ISO 100 oil of the type listed in the cross reference below.
Frame Gripper Loading/Unloading Control Bases and Beam Feed Motor Drive Cutting Device Guide Channel Bar Pusher Support First Anti-Vibration Device Synchronization Device Telescoping / Fixed Nose Oil Collector Electrical Cabinet Oil Pump Oil Tank Tool Box...
5. Adjustments and Setting Patriot Series Adjustment of the loading device 5.2.1 Loosen the locking lever for the support plate (1) and lift the plate to the highest position. Tighten the lever (1). 5.2.2 Place one of the bars to be machined on the magazine.
5. Adjustments and Setting Patriot Series Chain adjustment and lubrication 5.3.1 Remove the sheet metal side cover of the bar feeder. Loosen the two screws (1). Adjust the chain by tightening equally the two flathead screws (2) that extend from the block through the rear plate of the machine. Tighten the two screws (1).
5. Adjustments and Setting Patriot Series Moveable Anti-Vibration Device (MAVD) adjustment Load a bar into the lathe headstock and close the collet. Press the Pre-Auto button the MAVD will close. Back the screw “A” off counterclockwise until no tension is felt on the screw.
6. Control Operation and Descriptions Patriot Series 6. Control Operations and Descriptions Manual ALARM START Pre-Auto Automatic OPEN BACK TORQUE START STOP Bar Separators Grippers Reverse Jog Forward Jog Channel Shuttle Open / Close Sequence to manually change bars Retract the bar stock from the lathe guide bushing and open the lathe collet. Make sure the lathe tools are clear of the guide bushing for the new bar to come in.
6. Control Operation and Descriptions Patriot Series To Power Up and Place the Bar Feeder In Automatic Turn on the main switch on the bar feeder electrical cabinet. Check to make sure the emergency stop buttons on the pendant and the main control panel are released.
6. Control Operation and Descriptions Patriot Series Resetting the Bar Feeder Home Position All positions to control bar feeder function are referenced from the zero position. Should the zero position shift the bar feeder will not function properly. To reset the zero position follow these steps: Move the bar pusher forward of the home proximity switch (PS2).
6. Control Operation and Descriptions Patriot Series Description of the MANUAL Screen The Manual screen has several information items and function buttons. In the upper left corner is the mode status showing if the bar feeder is in Manual or Automatic mode.
6. Control Operation and Descriptions Patriot Series Description of the AUTOMATIC Screen The AUTOMATIC screen has one function button to change to Manual mode and several information screens. The top line shows the bar feeder mode status and the current program number.
6. Control Operation and Descriptions Patriot Series Loading With the Bar On and Bar Off Buttons A new bar can be loaded by using the BAR ON button. Make sure the guide channel is closed. If there is material in the guide channel it must be short enough to fall through the remnant slot.
6. Control Operation and Descriptions Patriot Series Entering a New Program The Patriot can store up to 36 individual program setups. Each setup will have a user chosen 4 digit number. This allows the user to repeat jobs on the bar feeder with only a few steps.
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6. Control Operation and Descriptions Patriot Series Press the value button for Feedout 1-1. Page 1.1 will be displayed. Feedout 1 If using only one feedout per part, enter the same value as Part Length 1. If using more than one feedout per part, enter only the distance of the first feedout on this page and the other feedout distances on the appropriate parameter pages.
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6. Control Operation and Descriptions Patriot Series Page 3 continued Open Collet Speed This parameter allows adjustment to the feeding speed of the bar stock in Automatic mode. Open Collet Torque This parameter allows adjustment of the pushing force of the bar pusher in the Automatic mode.
6. Control Operation and Descriptions Patriot Series Selecting and Editing an Existing Program Press the SETUP button on the Manual screen. Press the button for a previously entered program. A screen with the program number selected will be displayed. Press the LOAD button to initialize the program.
7. Maintenance Patriot Series 7. General Maintenance Hazard Warning Before doing bar feeder maintenance, turn off 3 phase power and disconnect the air supply. For consistent operation of the bar feeder maintenance checks should be performed regularly. The area around the barfeed should be kept clean to avoid safety issues.
8. User Parameters Patriot Series Parameter Page 1 PART LENGTH 1 Used with Max Feed Position to generate an end of bar signal. Calculate the proper setting by adding the Length of part + Width of cut-off tool + facing stock. End of bar is generated when the encoder reads the position (Max Feed Position –...
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8. User Parameters Patriot Series Parameter Page 1.1 Feedout 1 Used when making multiple feedouts per part. Feedout 1-1 is the first of 3 possible feedouts per part. Parameter is disabled if set to zero. Press the dimension button to set the length of the first feedout for fixed headstock lathes, or for the distance of headstock travel before the first re-grip on sliding headstock lathes.
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8. User Parameters Patriot Series Parameter Page 1.2 Feedout 2 Used when making multiple feedouts per part. Feedout 2 is the 2nd of 3 possible feedouts per part. Parameter is disabled if set to zero. Press the dimension button to set the length of the second feedout for fixed headstock lathes, or for the distance of headstock travel before the first re-grip on sliding headstock lathes.
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8. User Parameters Patriot Series Parameter Page 1.3 Feedout 3 Used when making multiple feedouts per part. Feedout 3 is the 3rd of 3 possible feedouts per part. Parameter is disabled if set to zero. Press the dimension button to set the length of the third feedout for fixed headstock lathes, or for the distance of headstock travel after the third re-grip on sliding headstock lathes.
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8. User Parameters Patriot Series Parameter Page 2 (Option) PART LENGTH 2 Used with Max Feed Position to generate second end of bar signal. This makes possible using the remnant to make shorter length parts after the end of bar signal is made.
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8. User Parameters Patriot Series Parameter Page 2.1 Feedout 1 Used when making multiple feedouts per part. Feedout 1-1 is the first of 3 possible feedouts per part. The parameter is disabled if set to zero. Press the dimension button to set the length of the first feedout for fixed headstock lathes, or for the distance of headstock travel before the first re-grip on sliding headstock lathes.
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8. User Parameters Patriot Series Parameter Page 2.2 Feedout 2 Used when making multiple feedouts per part. Feedout 2 is the 2nd of 3 possible feedouts per part. The parameter is disabled if set to zero. Press the dimension button to set the length of the second feedout for fixed headstock lathes, or for the distance of headstock travel before the first re-grip on sliding headstock lathes.
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8. User Parameters Patriot Series Parameter Page 2.3 Feedout 3 Used when making multiple feedouts per part. Feedout 3 is the 3rd of 3 possible feedouts per part. The parameter is disabled if set to zero. Press the dimension button to set the length of the third feedout for fixed headstock lathes, or for the distance of headstock travel after the third re-grip on sliding headstock lathes.
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8. User Parameters Patriot Series Parameter Page 3 Bar Diameter Diameter of the material to be used. The control uses this information to set default values for the program. Facing Length Stopping point of the material at the end of a bar change and bar on sequence.
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8. User Parameters Patriot Series Parameter Page 4 Open Collet Timeout Allows for the lathe collet to be open when the bar feeder is in automatic for up to the number of seconds set in this parameter. If the length of time is exceeded an alarm is generated.
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8. User Parameters Patriot Series Parameter Page 5 Feeding Type Selects the mode of feeding material in automatic. In feeding to a turret stop the bar feeder begins to push when the lathe collet opens and stops pushing when the lathe collet closes.
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8. User Parameters Patriot Series Parameter Page 6 MAVD Close After Opening Position Enables or disables the moveable anti-vibration device from closing on the bar pusher after it has opened to allow the bar pusher collet to pass through. MAVD Opening Position Sets the position for the moveable anti-vibration device open.
9. Factory Parameters Patriot Series Parameter Page 11 Max. End Of Bar - Collet Fixed headstock lathes: Distance of bar pusher with the collet at the back of the gripping surface of the collet pads to the home position. Sliding headstock lathes: Distance of the bar pusher from the gripping surface of the collet pads when the lathe headstock forward to the quide bushing.
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9. Factory Parameters Patriot Series Parameter Page 12 First Feeding Distance Sets the stopping point for the pre-feed pusher. Oil Pump Shutoff Distance Sets the position from zero for the oil pump to turn off. MAVD Opening Position Sets the position from zero that the movable anti-vibration device opens to allow the bar pusher to pass through.
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(also called the fixed steady roller). Position should be set 1-2 inches before the pusher collet reaches the steady roller unit. 2nd Anti-Vibration Opening Position Not used on the Patriot Series. 3rd Anti-Vibration Opening Position Not used on the Patriot Series.
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9. Factory Parameters Patriot Series Parameter Page 14 End of Bar Type Selects between different modes of generating the end of bar signal. Choices are: Off at Bar Change: Signal resets when the command “Bar Change” is received from the lathe.
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9. Factory Parameters Patriot Series Parameter Page 15 Bar Change Return Delay Sets a delay in seconds for the pusher to begin the return to home position after the bar change command is received. Cycle Start Delay Sets a delay in seconds for the signal to the lathe that the bar change is complete to be sent.
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9. Factory Parameters Patriot Series Parameter Page 16 End Of Bar Pulse Sets the length of time in seconds for the signal to remain on when the end of bar signal is set to pulse. Feed Confirm Pulse Sets the length of time in seconds for the signal to remain on when the feed confirmation signal is set to pulse.
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9. Factory Parameters Patriot Series Parameter Page 17 Manual/Auto Allows the bar feeder to accept the Manual / Automatic signal from the lathe as either a normally open or normally closed signal. Lathe Door Safety Allows the bar feeder to accept the Lathe Door Open signal from the lathe as either a normally open or normally closed signal.
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Patriot Series 9. Factory Parameters Collet Open Changes how the bar feeders PLC puts out the Signal. Bar Change Changes how the bar feeders PLC puts out the Signal. Feed Stop Changes how the bar feeders PLC puts out the Signal.
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9. Factory Parameters Patriot Series Parameter Page 18 Barfeed Alarm Test button to check the operation of the output for Barfeed Alarm. Pressing the button will turn on output Y24 and relay R1. Barfeed Auto Test button to check the operation of the output for Barfeed in Automatic.
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9. Factory Parameters Patriot Series Parameter Page 19 Manual Feed Provides visual aid to check the signal Manual Feed from the lathe. Button highlights when the signal is active. Input X16 will also be on. Manual Return Provides visual aid to check the signal Manual Return from the lathe. Button highlights when the signal is active.
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9. Factory Parameters Patriot Series Parameter Page 20 User New Program Password Sets a password to be required before access to write a new barfeeder program is allowed. Default password is 0. User Load Program Password Sets a password to be required before access to load a new barfeeder program is allowed.
9. Factory Parameters Patriot Series Parameter Page 21 User Page 2 Allows User Page 2 to be seen and accessed in User parameters when set to ON. User Page 4 Allows User Page 4 to be seen and accessed in User parameters when set to ON.
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10. Service Technician Parameters Patriot Series Parameter Page 22 Bar Change Return Speed Speed of the bar pusher as it retracts to the home position at the beginning of a bar change. Feed Speed 1 Speed of the pre-feed pusher as it advances until it reaches the slow down position.
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10. Service Technician Parameters Patriot Series Parameter Page 23 Facing Speed 1 Forward speed of the bar pusher during the facing operation until it reaches the Facing Speed Slowdown Distance. Facing Speed 2 Forward speed of the bar pusher during the distance specified in the Facing Speed Slowdown Distance Parameter.
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10. Service Technician Parameters Patriot Series Parameter Page 24 Manual Forward Speed Forward speed of the pusher and pre-feed pusher when commanded to move via the jog buttons or through the input for Manual Forward. Manual Forward Torque Sets the amount of force developed by the clutch when moving the bar pusher forward in manual mode via the jog buttons or through the input for Manual Forward.
10. Service Technician Parameters Patriot Series Parameter Page 25 Collet Close Speed Speed of the bar pusher motor in automatic mode when the lathe collet is closed. Collet Close Torque Sets the pushing force for the bar pusher when the bar feeder is in automatic mode and the lathe collet is closed.
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10. Service Technician Parameters Patriot Series Parameter Page 26 Pusher Back Off Tolerance Sets an allowable distance for the bar pusher to move backward when the bar feeder is in automatic and the lathe collet is open. If the pusher moves backward in excess of the setting an alarm is generated.
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11. Alarms Patriot Series -HMI Cable not attached to PLC - Check the cable from the PLC in the electrical cabinet (round black cable located on the front of the PLC next to the Run/Stop switch) to the back of the control panel (rectangular 9-pin plug connected to the COM 2 port).
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11. Alarms Patriot Series -K41 not energized -Torque setting exceeded - Reduce the Open Collet Torque on User Parameter page 3. -Max torque on time exceeded - Reduce the length of time the lathe collet is open when the bar feeder is in automatic.
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11. Alarms Patriot Series -Check Air Pressure 6-8 Bar - If the pressure is low, adjust the regulator to increase setting. -Check the incoming pressure to the bar feeder - Observe the pressure gauge while the bar feeder operates. A rapid decrease in pressure as an air cylinder operates may indicate low volume.
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11. Alarms Patriot Series -Check air cylinder for operation - Operate the pusher shuttle without material in the collet to check for proper operation. -Check air valve for operation - Operate the pusher shuttle without material in the collet to check for proper operation.
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11. Alarms Patriot Series -Not enough air pressure to lift channel – Check the air pressure gauge. Increase pressure with the regulator if necessary. -Bind in channel opening mechanism – Check for loose channel sections, alignment of pusher flag in opening, attachment of the air cylinder to the upper channel mechanism.
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11. Alarms Patriot Series -Flag stuck in down position – Manually operate the measuring flag. Check for debris impeding the operation of the flag. Check the flag for damage. -Material impeding flag movement – Remove the material from the flag area.
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11. Alarms Patriot Series -Check pusher position – The zero proximity switch must be on, the pusher position should read near 0. -Check zero proximity switch – Move the pusher back and forward under the zero proximity switch and check that the LED lights, check input X2 - it should light when the proximity switch lights.
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11. Alarms Patriot Series -Lathe collet was open longer than set time allowed in collet open timeout parameter -Lathe collet was closed longer than set time allowed in collet close timeout parameter -Pusher could not return to home sensor within the time allotted – Check pusher flag for damage, check bar pusher for protruding roll pins.
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11. Alarms Patriot Series -Verify the Max Feed Position – If the max feed position is set to a value higher than the actual position the lathe headstock may push the bar pusher off the material when retracting to re-grip for the last part.
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11. Alarms Patriot Series -Check spindle for steps that catch bar -Check prefeed distance parameter - Setting should place the rear of the bar to rest slightly on the edge of the channel so the pusher collet will clear the bar when the channel closes.
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11. Alarms Patriot Series -Leave lathe in auto during bar change – Some lathes must be left in cycle to maintain the automatic signal. Turn of the single block mode and leave the lathe door closed during bar change. -Material feedout shorter than setting in parameter – Check open collet torque setting.
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11. Alarms Patriot Series -Material feedout longer that setting in parameter – Tighten the pusher drive chain. Verify the pusher collet is fully seated on the material. -Set long feed value longer than feedout for part – The value should be set at least 1mm longer than the part feedout.
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11. Alarms Patriot Series -Material feedout shorter than setting in parameter – Check open collet torque setting. Check lathe collet/spindle for debris. Check for impedance to the bar pusher. -Set short feed value shorter than feedout needed for part – The value should be set at least 1mm shorter than the part feedout.
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11. Alarms Patriot Series -Material feedout longer that setting in parameter – Tighten the pusher drive chain. Verify the pusher collet is fully seated on the material. -Set long feed value longer than feedout for part – The value should be set at least 1mm longer than the part feedout.
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11. Alarms Patriot Series -When the bar feeder is in Auto and the lathe collet open, reverse movement in excess of 4mm was detected. -Check lathe is not pushing or pulling material back into barfeed – Check the bar feeder synchronization device.
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11. Alarms Patriot Series -Open lathe collet – Verify that the lathe collet is open. -Check input X33 – The input should turn on and off with the collet opening and closing. -Close the lathe door – Verify that the lathe door is closed and the safety switches are enabled.
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11. Alarms Patriot Series -Adjust facing position – Alarm occurs when facing mode is set to Turret Stop and the bar travels 5 – 25mm short of the turret stop or in excess of 250mm past the facing length. -Check S2 switch is on – Verify that the LED of the PS2 switch is on when the pusher reaches the home position and that input X2 is on when the LED of PS2 is on.
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