Doosan DVF Series Operation User's Manual
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Doosan DVF Series Operation User's Manual

Doosan DVF Series Operation User's Manual

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AWC
(Automatic Workpiece Changer System)
Operation / User Manual
DVF Series
VMCTOPEAWC18B

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Summary of Contents for Doosan DVF Series

  • Page 1 (Automatic Workpiece Changer System) Operation / User Manual DVF Series VMCTOPEAWC18B...
  • Page 3 INTRODUCTION Thank you for choosing our machine tools. We are proud to have you among our machine tools family of users. Manuals contain concise information on the setup and operation of your machine tool. To make the most of its outstanding performance over a long period, the machine must be properly installed, and operating and maintenance procedures must be clearly understood and carefully followed.

  • Page 4: Table Of Contents

    CONTENTS Part 1 SAFETY PRECAUTIONS ....2 General ................... 3 Machine Installation ............... 4 Power Supply ................. 4 Setup ....................5 Automatic operation ..............7 Operation stop ................8 Completion of Machining & Power shutoff ........8 Inspection/Adjustment/Maintenance ..........9 Part 2 GENERAL ........
  • Page 5 How to operate in the {MAIN} screen of AWC ........20 How to operate in the {MANUAL} screen of AWC ....... 25 TRANSFER TEACHING Sequence ............. 27 INDEX ORIGIN Sequence ..............28 Part 4 AUTOMATIC OPERATION ..29 Schedule Operation of Automatic Workpiece Changer (AWC) . 29 Summary of the Schedule operation ............

  • Page 6: Part 1 Safety Precautions

    Part 1 SAFETY PRECAUTIONS This machine is equipped with several safety devices to protect the operator and the machine from unexpected accidents. The operator shall not be overconfident with these safety devices and shall be fully aware of the safety guidelines given below for safe operation. This safety guideline and the warning plates attached on the outer surface of the machine represent only the common dangers expected to occur, not the hazardous factors having potential dangers to occur.

  • Page 7: General

    General (1) Always carry out any of work by the specified procedures after fully acknowledging the machine specification and its functions. (2) Plan for the scope and the sequence of each work. (3) Carry out a work with only the specified number of person by specifying a required number of persons for the work.

  • Page 8: Machine Installation

    Machine Installation (1) Get yourself familiarized with the contents of the machine’s manual. (2) Establish a plan of and carry out preventive checks. (3) When collaborating, establish a signal method to be able to communicate each other. (4) Check whether all the required equipment and tool are prepared. (5) Use an authorized equipment and tools.

  • Page 9: Setup

    Setup (1) Get yourself familiarized with the contents of the machine’s manual. (2) Check the settings of all gauges and the conditions of moving parts. (3) Use hoist or crane when handling a heavy workpiece. (4) Be careful not to touch the lamp as it is very hot if it has remained ON for a long period of time.
  • Page 10 (12) Check if the setup has been completed. (13) If set-up condition has changed, check whether it is possible to execute machining without a problem by operating the machine step by step. (14) When working with a new settings, check the setting before operation once again. (15) Do not press the operation panel’s touch screen with hard pointed objects (awl, driver, pen, etc.,) or with an excessive force.

  • Page 11: Automatic Operation

    Automatic operation (1) Get yourself familiarized with the contents of the machine’s manual. (2) Do not lean against the machine during auto operation. (3) Be careful not to touch other switches. When using switches on the operation panel, always look at them. (4) Always close all doors before starting an operation.

  • Page 12: Operation Stop

    Operation stop (1) Stop operation of the machine immediately by pressing the emergency stop switch when a problem occurs. (2) The operator must exactly know the state of the machine according to each stopping method. (3) Check if the machine fully stopped. Completion of Machining &...

  • Page 13: Inspection/Adjustment/Maintenance

    Inspection/Adjustment/Maintenance (1) Get yourself familiarized with the contents of the machine’s manual. (2) Plan for the scope and the sequence of each work. (3) Carry out a work with only the specified number of person by specifying a required number of person for the work. (4) During maintenance work, please put up "Under Maintenance Work"...

  • Page 14: Part 2 General

    Part 2 GENERAL Introduction Overview This manual provides information on operation and manipulation of Automatic Workpiece Changer (hereinafter “AWC”). AWC consists of basically 8 work stations. Compared with the standard equipment of APC(2 pallets), AWC allows longer period of operation in the auto mode and machines various workpieces using scheduled operation function.

  • Page 15: Awc Power Switch

    AWC Power Switch Layout of power switches Location of the control panel at the side of AWC - AWC Control panel - MCCB handle for AWC Power switch control This is a switch to supply power to the Automatic Workpiece Changer (AWC).

  • Page 16: Part 3 Operation

    Part 3 OPERATION Basic Operation of Automatic Workpiece Changer (AWC) The symbols used in this manual are described below. [Main] ; Operation Screen {Layout} Operation Screen in layout format {List} Operation Screen in a list format [Manual] ; Manual Mode Screen {Manual Mode} Manual Mode Screen {Pallet Transfer} Manual Workpiece Transfer Screen {Teaching} Teaching Mode Screen...

  • Page 17: Awc Screen Components

    AWC Screen Components AWC Screen consists of the following 4 categories. - Main Screen, Manual Operation Screen, Information Screen and Setup Screen (1) AWC Main Screen - Main Screen consists of VIEW and the LIST. You can view information on Pallet No., Program No. and Order sequence by pressing the [Main] button and then {VIEW} or {LIST} button.
  • Page 18 2) LIST : A screen to enter a workpiece schedule information is provided in a list format. (2) AWC Manual Operation Screen Manual Operation Screen consists of jog operation, the workpiece transfer, and teaching screen. After pressing the [Manual] button, the sub-screen of jog operation, the workpiece transfer, and teaching features.
  • Page 19 2) Workpiece Transfer : This screen is for an easy manual transfer of workpiece. 3) Teaching : The location of each station of AWC can be set in this screen. Used when adjusting for the first time. OPERATION | 015...
  • Page 20 (3) AWC Signal Information Screen (I/O state screen) 1) Input: Screen to check input signal of AWC. 2) Output: Screen to check output signal of AWC. 016 | Part 3...
  • Page 21 (4) AWC Setup Screen (Version information, Alarm History, Language Converting, User Setting) 1) Version Information : S/W version information. 2) Alarm History : A screen to check Alarm history. 3) Language Setup : Supports 2 languages. OPERATION | 017...
  • Page 22 4) User Setting : ▶ TEACHING MODE : Defines the position of TRANSFER or INDEX ▶ AWC TEST MODE : Used when the setup is always ON (In-house continuous operation) ▶ TRIAL RUN (Without M/C): Used for commissioning without a machine (at the customer site) ▶...

  • Page 23: Awc Op Panel Functions

    AWC OP Panel Functions ▶ AWC is designed for standalone operation without the equipment and it uses the OP Panel for AWC shown below, not the standard APC OP Panel. (1) EMERGENCY stop button Pressing this switch stops all the actions of the Machine and AWC. (same as the Emergency button on the Main OP panel) Please refer to the Instruction Manual.

  • Page 24: Detailed Description Of Automatic Workpiece Changer(Awc) Operation

    Detailed Description of Automatic Workpiece Changer(AWC) Operation How to operate in the {MAIN} screen of AWC (1) AWC VIEW screen elements Status Pallet color Description Information Machining in Light Green Cutting in progress progress Setup completed (Standby for operation after mounting Green Schedule workpiece)
  • Page 25 (2) AWC LIST screen elements This is an AWC ORDER table screen for AWC Schedule operation and consists of below items. Schedule can be made in this screen. ▶ STATION Displays the name and workpiece No. of each AWC station. ▶...
  • Page 26 ▶ ORDER : Displays the sequence to load into the setup station or the machining sequence. - Order No. > 0: Schedule Setup Completed (‘1’ is the top priority) - Order No. < 0: Sequence to load into the setup station (‘-1’ is the top priority) - If M60 is enabled, the work completes at the machine area while the order value becomes automatically re-ordered.
  • Page 27 ▶ Complete setup for workpiece, turn the toggle switch to AUTO and press [AUTO START] to start the Schedule operation. Pressing the {AUTO STOP} key stops AWC after the completion of the work in cycle, and data value can be modified. (Pressing Edit button enables edit function) ▶...
  • Page 28 2) How to creating a machining program AWC operates normally only when M60;, M30 are entered in the last block of the machining program. (M60 : Pallet Change Command) EX) O1000 G91G28X0.Y0.Z0. M3S3000 G90G01X500.F100 …. … 024 | Part 3...

  • Page 29: How To Operate In The {Manual} Screen Of Awc

    How to operate in the {MANUAL} screen of AWC (1) JOG operation Manual operation is possible after switching to MANUAL using the toggle switch on the AWC operation panel. ▶ MACHINE WORK : The transfer moves to 4Position while the button is pressed and hold.
  • Page 30 (2) Workpiece Transfer In the above screen, pressing a desired {ACTION} button for the Work station No. on the left feeds the workpiece. ▶ SET UP : Move the workpiece to the setup position. ▶ IN : Load the workpiece inside the machine. ▶...

  • Page 31: Transfer Teaching Sequence

    TRANSFER TEACHING Sequence ▶ Press the “TEACHING MODE” SELECTION button. ▶ Press [FWD] or [REV] to feed to the teaching position (1Position~4Position). ▶ Using the UP/DOWN buttons, select a target position for teaching. (1) INDEX WAIT - >1 (2) INDEX WORK, - > 2 (3) MACHINE WAIT,- >...

  • Page 32: Index Origin Sequence

    ▶ Press [CW] or [CCW] to move the INDEX Workpiece to the number “1”. By moving the transfer in the forward/backwards directions, find an index where there’s no interference. ▶ Set reference position at Doosan Servo Amp. 028 | Part 3...

  • Page 33: Part 4 Automatic Operation

    Part 4 AUTOMATIC OPERATION Schedule Operation of Automatic Workpiece Changer (AWC) Summary of the Schedule operation ▶ The SCHEDULE operation is an operation done by the schedules registered in the [AWC ORDER] table. The first workpiece (whose Order No. is closest to 1) is brought to Transfer Station, the cutting for the workpiece in cutting room is completed, an automatic APC is done by M60 command, and an cutting job is performed according to a program saved in the [AWC ORDER] table.

  • Page 34: Setup Data Input & Change

    Setup Data Input & Change - The schedule data can be edited by pressing the {AUTO STOP} key to stop AWC and pressing the {EDIT} button. 1) Program ① The same and actual cutting program must exist in the machine. ▶...
  • Page 35 ③ State ▶ Empty. No order : Select this when the workpiece is not used. (Manual) ▶ Schedule : Select this when the workpiece is used for an auto operation. (Manual) ▶ Cutting : Select this when the workpiece is being cut inside the machine. (Automatic) ▶...

  • Page 36: Part 5 Awc Alarm

    AWC ALARM Part 5 Automatic Workpiece Changer Alarm & Countermeasures When AWC Alarm occurs, Automatic Workpiece Changer ALARM is displayed on the LCD screen of the equipment. The details of the alarm can be viewed on the RPS graphic panel. (1) SERVO ALARM (4000) ▶...
  • Page 37 (7) NO DATA INPUT (4006) ▶ 4006 : PROGRAM NUMBER AND ORDER ENTERED WITH OUT PALLET. CHECK LIST. - It occurs when entering a program No. and an order for non-existent pallet. ▶ Check and correct the schedule list. (8) SERVO TEACHING ALARM (4009) ▶...
  • Page 38 (13) OVER HEAT ALARM (4018) ▶ 4018 : ENSURE THAT THE HEAT SINK TEMPERATURE IS ABOVE 100. CHECK THAT THE OPERATION FREQUENCY IS ABOVE THE SPECIFIED VALUE. - Occurs when the internal IPM device is faulty. ▶ Check if the heat sink temperature is over 100 degrees. Check if the operation frequency is higher than the standard.
  • Page 39 (19) EXCESSIVE POSITION DEVIATION ALARM (4025) ▶ 4025 : MAKE SURE THAT PARAMETER 18 IS SET TOO LOW. CHECK ENCODER CABLE AND MOTOR STATUS. - Occurs when the residual pulse exceeds the specified limit set in the Parameter 18 during position controlling. ▶...

  • Page 40: Part 6 Appendix

    Part 6 APPENDIX How to load Graphic Panel drawing file (1) Plug USB to front mini USB port by using an OTG gender. When USB device is not connected, always close the USB port with the protective cap. When the port is exposed to dusts or foreign substances, it may lead to damage or malfunction.
  • Page 41 (3) Select the touch screen drawing file (XXX.HBZ) and press OK. (4) Current project will be replaced. Transmit the drawing file by pressing OK if the message “Proceed?” appears. APPENDIX | 037...

  • Page 42: How To Load Plc S/W File Using Sd Card

    How to load PLC S/W File using SD Card (1) Save the prepared project files to SD card. (2) Switch to PLC stop state. (3) Inserting SD card into an empty slot of the controller, the controller updates automatically. (4) The run lamp blinks and remains illuminating if update is completed. (5) Remove SD card.

  • Page 43: Machine Ethernet I/P Setting

    Machine Ethernet I/P Setting (1) Press the operation on [SYSTEM], then press “EtherNet/IP”. (2) You can set IP of the machine in [COMMON] section. APPENDIX | 039...
  • Page 44 (3) On [PING], communication state with AWC can be checked. -> PING EXEC (4) In [COM STATE], communication state with AWC can be checked. (5) On [TASK STATE], communication state with AWC can be checked. 040 | Part 6...
  • Page 45 (6) If [NEXT PAGE] is pressed, EIP S SET/ EIP S MAINTE item appears. (7) Press [OFF LINE] to put the network to “OFFLINE”. * On offline, “SIMPLE SET” is allowed. APPENDIX | 041...
  • Page 46 (8) Enter “R3900” in [STATUS ADDRESS]. (9) Set up the communication properties by pressing [SIMPLE SET]. (10) Set up AWC IP, Address, and the communication properties under [SIMPLE SET]. 042 | Part 6...
  • Page 47 (11) When placing cursor on channel “0” indication after exiting to [EIP S SET], State should display “ENABLE”. (12) Check if “MS: DEVICE OPERATIONAL / NS: CONNECTED” is displayed by pressing [EIP S MAINTE]. (Check if the connection is fine) APPENDIX | 043...
  • Page 48 (13) If Data Server and RPS are being used at the same time, additional parameter setup is required. FAST ETHERNET BOARD 1 PORT : DATA SERVER FAST ETHERNET BOARD 2 PORT : RPS INTERFACE (14) [Set up additional parameters related with DATA SERVER / ETHERNET IP.] PARAMETER NO.

  • Page 49: How To Connect Machine And Equipments

    How to connect machine and equipments (1) Inside the electric cabinet, connect M/C OP and LAN cable to the NC Master port no. 2 in the OP Box. (2) Connect PLC module of AWC electric cabinet to the Lan port. (3) Connect AWC emergency stop switch and the machine’s APC emergency stop (PCB board) terminal.

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