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Norlok SL III Operation And Maintenance Manual

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OPERATION AND MAINTENANCE MANUAL SL III
ORIGINAL INSTRUCTION
SECTION 1.0 - Safety Guidelines .............................................................................................................................. 2
Safety Precautions Before Operating The Machine ............................................................................................. 2
Operator Safety Notice ...................................................................................................................................... 4
Risk Assessment................................................................................................................................................. 5
SECTION 2.0 - Surelok III Information ...................................................................................................................... 6
Surelok III Press Layout and General Description ................................................................................................ 6
Specifications - Surelok III .................................................................................................................................. 7
SECTION 3.0 - Installation and Operation ................................................................................................................ 9
Installation......................................................................................................................................................... 9
Initial Testing ................................................................................................................................................... 10
Measurement Of CLinch Quality - Non-Destructive Testing .............................................................................. 10
Tooling Adjustment Procedure ......................................................................................................................... 13
Safety Stroke Adjustment................................................................................................................................. 16
Pressure Switch Adjustment............................................................................................................................. 17
SECTION 4.0 - Clinchlok Basics .............................................................................................................................. 18
Clinchlok Principle ............................................................................................................................................ 18
Tooling Adjustment.......................................................................................................................................... 19
Materials To Be Joined ..................................................................................................................................... 19
Die Selection .................................................................................................................................................... 19
Joint strength................................................................................................................................................... 20
SECTION 5.0 - Clinching Terminology .................................................................................................................... 21
Views of the Clinchlok Joints ............................................................................................................................ 22
Joint Failure ..................................................................................................................................................... 23
Section 6.0 - Tooling Maintenance & Replacement ............................................................................................... 24
Standard Reversible Tooling - Punch Replacement........................................................................................... 24
Optional P-Tooling - Punch Replacement ......................................................................................................... 24
Replacing Die ................................................................................................................................................... 25
Die Insert Assembly ......................................................................................................................................... 26
SECTION 7.0 - Maintenance .................................................................................................................................. 27
Preventative Maintenance ............................................................................................................................... 27
Maintenance - Pressure Adjustments ............................................................................................................. 28
Maintenance - Regulator Draining & Filter Cleaning ........................................................................................ 28
Maintenance - Lubrication of Upper Tooling ................................................................................................... 28
SECTION 8.0 - Trouble Shooting Guide ................................................................................................................. 28
Operation Troubleshooting .............................................................................................................................. 28
Joining Issues ................................................................................................................................................... 29
Joint Quality .................................................................................................................................................... 29
SECTION 9.0 - DOCUMENT REVISION HISTORY ...................................................................................................... 31
SECTION 10.0 - Warranty Information ................................................................................................................... 32
Norlok Technology Inc. 519-759-5896
Document No: 110011
CONTENTS
fax 519-759-2948
26 Adams Blvd., Brantford, Ontario, Canada N3S 7V2
Fax 519.759.2948
E-mail info@norlok.com
www.norlok.com
519.759.5896
1
Page
|
Rev. No: 5.0

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  • Page 1: Table Of Contents

    26 Adams Blvd., Brantford, Ontario, Canada N3S 7V2 519.759.5896 OPERATION AND MAINTENANCE MANUAL SL III Fax 519.759.2948 ORIGINAL INSTRUCTION E-mail info@norlok.com CONTENTS SECTION 1.0 - Safety Guidelines ..........................2 Safety Precautions Before Operating The Machine ..................... 2 Operator Safety Notice ............................4 Risk Assessment..............................

  • Page 2: Section 1.0 - Safety Guidelines

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION SECTION 1.0 - SAFETY GUIDELINES Before operating the machine, study and follow all safety guidelines in this manual, these precautions are intended to prevent injury to you and your fellow workers. Please use EXTREME CAUTION before performing any procedure or operation.
  • Page 3 OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION Keep fingers and hands away from pinch point areas: Be sure all guards and covers are in place Between the punch stem and die, i.e., upper and lower tooling Keep this equipment properly maintained Check for worn or broken parts.

  • Page 4: Operator Safety Notice

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION OPERATOR SAFETY NOTICE The Surelok III is designed as a safe and reliable machine. However, as with any punching machine, the critical danger area is the pinch point between the punch and die.

  • Page 5: Risk Assessment

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION RISK ASSESSMENT Hazard Type Description Mitigation • Mechanical Top heavy machine tipping ¾” Threaded hole for lifting during transportation, lifting or at highest point • installation Wide stand and wide skids for transportation •...

  • Page 6: Section 2.0 - Surelok Iii Information

    The Surelok series is developed for sheet metal joining process and available in different sizes. Intended Use: The Surelok III (SL III) is Floor Mounted Pneumatic Mechanical Press designed for sheet metal operations such as clinching, punching, and riveting depending on the tooling applied. The tooling applies a high force to perform these sheet metal forming operations.

  • Page 7: Specifications - Surelok Iii

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION SPECIFICATIONS – SURELOK III Designation: Pneumatic mechanical press Press Design: Solid 3” steel "C" frame. Features: Advanced power unit Regulator and Shut-off Valve Foot pedal operated Stroke: 2 1/2” max (adjustable) Throat: 25”...
  • Page 8 OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION NORLOK’S EC DECLARATION SL III NOTE: NORLOK’S SURELOK III IS CE CERTIFIED NOW FROM SERIAL NUMBER 22007 AND LATER. ONLY APPLICABLE IF MACHINE NAME PLATE STATES AND CONFIRMS CE. Page Norlok Technology Inc. 519-759-5896 fax 519-759-2948 www.norlok.com...

  • Page 9: Section 3.0 - Installation And Operation

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION SECTION 3.0 - INSTALLATION AND OPERATION INSTALLATION UNCRATING: 1. The press can be lifted using the forklift cutouts in the stand, using a ¾”NC eye bolt inserted into the top of the frame or using a chain hoist near the centre of mass which is in line with the ¾”...

  • Page 10: Initial Testing

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION INITIAL TESTING A. The machine is shipped already set up for your material. This can be confirmed easily and it is recommended. B. Ensure that all guards are in place. C. Slowly open the main air supply valve and check the pressure at the regulator on the machine.
  • Page 11 They may not identify the ideal clinch in different material but they provide a starting guideline for clinch inspection. Further testing and more accurate gauges can be developed. Figure 3 Measuring a Button Diameter (BD) using a Norlok GoNoGo Gauge Go/NoGo Gauge Part# Suitable material 07763.238.246 30ga 07763.250.260...
  • Page 12 OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION Figure 4 Measuring a Clinch Thickness (CT) Figure 5 Trouble Shooting Quick View Page Norlok Technology Inc. 519-759-5896 fax 519-759-2948 www.norlok.com Document No: 110011 Rev. No: 5.0...

  • Page 13: Tooling Adjustment Procedure

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION TOOLING ADJUSTMENT PROCEDURE SQUEEZE ADJUSTMENT 1. The tooling must be adjusted to produce the correct amount of "squeeze" between the punch and die when the joint is made. 2. As described earlier, the correct tooling adjustment is very important for producing a good joint and to maximize punch and die life.
  • Page 14 OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION • Loosen set screw • Using an Allen key, rotate the adjuster block • Rotating right increases squeeze • Rotating left decreases squeeze • SEE DECAL FOR REFERENCE Figure 7 E Tooling Adjustment Page Norlok Technology Inc.
  • Page 15 OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION RESET SQUEEZE SETTING AFTER EVERY TOOLING SWITCH OVER OBSERVE ALL SAFETY PRECAUTIONS, AND MAKE SURE ALL GUARDS AND COVER PLATES ARE IN PLACE. 8. Make a sample clinch joint using the correct material.

  • Page 16: Safety Stroke Adjustment

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION STROKE ADJUSTMENT FOR SLIII The stroke is the maximum distance between the punch and die at the beginning of a clinch cycle, or when the tooling is at rest. It can be adjusted using adjustment screw at the top of the SLIII.

  • Page 17: Pressure Switch Adjustment

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION PRESSURE SWITCH ADJUSTMENT Figure 10 Pressure Switch • The standard pressure switch is located at the back of the frame. • Turning the knob clockwise increases the pressure at which the clinch cycle resets – but may increase the cycle time and if set too high the clinch cycle will not restart.

  • Page 18: Section 4.0 - Clinchlok Basics

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION SECTION 4.0 - CLINCHLOK BASICS CLINCHLOK PRINCIPLE WHAT IS “CLINCHING”? Clinching is a method of fastening sheet metal together without the use of heat, rivets, fasteners or adhesives. It is fast, clean, and reliable and does little or no damage to painted surfaces.

  • Page 19: Tooling Adjustment

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION TOOLING ADJUSTMENT 1. The amount of joint squeeze is controlled by adjusting the upper tooling (punch) either towards the die or away from the die with the tooling adjusting screw. 2. For thin material the punch will have to be lowered (moved towards the die) and for thick material it will have to be raised (moved away from the die).

  • Page 20: Joint Strength

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION JOINT STRENGTH Figure 11 Pull - Peel Layout 1. There are two ways to measure the strength of a Clinchlok joint, pull and peel (see Figure 11 Pull - Peel Layout). 2. Pull is almost always stronger than peel and is less sensitive to die adjustment.

  • Page 21: Section 5.0 - Clinching Terminology

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION SECTION 5.0 - CLINCHING TERMINOLOGY Figure 14 Clinching Terminology 1 Figure 14 Clinching Terminology 2 Figure 14 Clinching Terminology 3 Page Norlok Technology Inc. 519-759-5896 fax 519-759-2948 www.norlok.com Document No: 110011 Rev. No: 5.0...

  • Page 22: Views Of The Clinchlok Joints

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION VIEWS OF THE CLINCHLOK JOINTS Figure 15 – Cross Section of Joint Figure 16 Clinch Button Page Norlok Technology Inc. 519-759-5896 fax 519-759-2948 www.norlok.com Document No: 110011 Rev. No: 5.0...

  • Page 23: Joint Failure

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION JOINT FAILURE 1. If pulled hard enough any clinchlok joint will pull apart. 2. There are normally two ways for a clinchlok to pull apart: NON-TEARING FAILURE The two halves of the joint will pull apart leaving a male joint half (punch side) and a female joint half (die side).

  • Page 24: Section 6.0 - Tooling Maintenance & Replacement

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION SECTION 6.0 - TOOLING MAINTENANCE & REPLACEMENT DISCONNECT AND DRAIN AIR BEFORE ANY TOOLING CHANGES OR MAINTENANCE STANDARD REVERSIBLE TOOLING – PUNCH REPLACEMENT • Remove the setscrew from the reversible tooling shaft.

  • Page 25: Replacing Die

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION 1. Secure the tooling using the flats on the tooling base. 5. Re-insert the spring. 6. Grease the threads on the tooling base and screw the stripper cup back on. 7. Punch should be approximately 0.020”...

  • Page 26: Die Insert Assembly

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION DIE INSERT ASSEMBLY 1. Remove the Die Insert as described above. 2. Remove and discard the old elastomer. 3. Set new blades around the die anvil and hold in place. 4. Press new elastomer over the die blades pushing it down until it slips into the groove on the outside of the die blades.

  • Page 27: Section 7.0 - Maintenance

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION SECTION 7.0 - MAINTENANCE PREVENTATIVE MAINTENANCE DESCRIPTION DAILY WEEKLY MONTHLY Ensure all guards and safety equipment are in place. Drain moisture from air tank (if supplied). Maintain correct inlet air pressure. Check and maintain correct air regulator pressure.

  • Page 28: Maintenance - Pressure Adjustments

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION MAINTENANCE - PRESSURE ADJUSTMENTS • Supply the machine with 125 PSI (max) 80 PSI (min) clean dry air. We recommend a 1/2” (min) air line at 120 psi. MAINTENANCE - REGULATOR DRAINING & FILTER CLEANING •...

  • Page 29: Joining Issues

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION JOINING ISSUES PROBLEM CAUSE SOLUTION Replace – see punch replacement Punch broken section in manual Replace – see die replacement Die broken section in manual A. No Button Formed See tooling adjustment section in...
  • Page 30 OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION Weak or broken stripper spring Replace C. Lump or Irregularity on Chipped punch or die Replace button Stripper failure Replace or repair D. Concentric double button Double hit Check controls re-train operator E.

  • Page 31: Section 9.0 - Document Revision History

    OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION SECTION 9.0 - DOCUMENT REVISION HISTORY REV No: Issue Description Date Revised By Initial check in 2021-11-15 Sameh Helmy Removed ISO 2022-01-10 Nishit dave Table 11 Page Norlok Technology Inc. 519-759-5896 fax 519-759-2948 www.norlok.com...

  • Page 32: Section 10.0 - Warranty Information

    1. The buyer notifies Norlok in writing of the claimed defect within one year of the shipment from the Norlok factory (thirty days in the case of punches and dies).

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