ARNOLD GXO User Manual

Auto-bagging system

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

GXO

Auto-Bagging System

Table of Contents

Troubleshooting

Need help?

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

Questions and answers

Summary of Contents for ARNOLD GXO

Page 1 Auto-Bagging System...
Page 2: Table Of Contents
Table of Contents Table of Figures ........................4 INTRODUCTION ........................5 Overview..........................5 Safety Circuits ........................5 BAG TRANSFER SYSTEM ....................8 Loading Autobag 850S ..................... 8 Operation of Autobag 850S ....................8 3-Axis Bag Transfer Machine ................... 9 Bagger Station Status Tower Lights ................
Page 3 MECHANICAL DRAWINGS ....................42 ELECTRICAL DRAWINGS ....................43 APPENDIX .......................... 44 Manuals and Documentation ..................44 Recommended Spare Parts List ..................46 Page 3 of 47...
Page 4: Table Of Figures
Table of Figures A handles left S and middle L stations; Operator B handles right S station..... 5 Figure 2. E-stop (red and yellow button) on main electrical enclosure......6 Figure 3. Outbound E-stop on main enclosure..............6 Figure 4.
Page 5: Introduction
INTRODUCTION Overview This system is a human-operated and machine-assisted garment bagging productivity solution. The system is designed to transfer incoming garments in totes from an inbound conveyor to an outbound conveyor, with each garment individually sealed in a labeled The system includes three independent bagging stations; the layout is such that two operators (labeled A and B in Figure 1) load garments individually into poly bags with an Autobag 850S machine.
Page 6: Figure 2. E-Stop (Red And Yellow Button) On Main Electrical Enclosure
at either end of the main enclosure tunnel. These e-stop buttons shut down the entire system (all bagger stations and all conveyors) when pressed. Figure 2. E-stop (red and yellow button) on main electrical enclosure. Figure 3. Outbound E-stop on main enclosure. Figure 4.
Page 7: Figure 5. Bagger Station Showing (1) Bagger E-Stop And (2) Bagger Reset
Each bagger station has a station-specific e-stop button on the bagger HMI, which stops the bagger, the bagger takeaway conveyor, and the three actuators for the bag transfer tray. Figure 5. Bagger station showing (1) Bagger E-stop and (2) Bagger RESET. The main enclosure tunnel has four doors on the side opposite to the Autobag machines, where each door has a locking safety switch.
Page 8: Bag Transfer System
BAG TRANSFER SYSTEM Loading Autobag 850S NOTE: If there is already a bag being held open by the Autobag 850S, then proceed to next sub- 850S for detailed instructions on threading bags into the Autobag machine. 2. In addition to following setup instructions from the Autobag manual, operator should check the following: a.
Page 9: 3-Axis Bag Transfer Machine
5. Before feeding the next bag, the machine waits on the printer to receive a signal from the next SKU scan. 6. Once the operator scans the next SKU, the machine feeds forward the next bag, he bag. 7. The machine holds the bag open, and operator repeats steps (3) (6).
Page 10: Bagger Station Reset Button
Figure 7. Tower lights lit GREEN during normal operation. Bagger Station Reset Button Reset Button Figure 8. Bagger Station Reset Button. its home position when pressed. Note that this button can be pressed regardless of Page 10 of 47...
Page 11: Understanding The Conveyor Traffic Control System
whether or not a bag is already on the tray. If a bag is on the tr button is pressed, then the tray will complete its transfer for the current bag before returning to the home position. In case an empty bag is dropped onto the tray, the bag will most likely remain on the tray during the tilt operation.
Page 13: Example Of Normal Sequence
Transfer operation is defined as the operation of the tray assembly, including: extending the tray (Linear Axis servo), rotating the table 90 degrees (Rotational Axis servo) and tilting the table (Tilt or Flip Axis servo). Example of Normal Sequence Following the product flow from right to left in the Schematic Representation diagram: 1) Bagger #3 dispenses a bag (Bag 1) onto the takeaway conveyor (Takeaway #3), 2) The transfer assembly (Linear, Rotation, and Tilt servos) move and discharge the bag onto Transition Conveyor 3 to 2,...
Page 14: Human Machine Interface (Hmi)
The above description follows forth for Bagger # 1 zone of control. Note that whenever a bagger zone receives an incoming bag signal, regardless of which zone the bag originated, the above sequences will occur. Since it has no upstream bags, Bagger #3 will have no incoming bag signal to contend with;...
Page 15: Typical Icon Conventions
Typical Icon Conventions Screen navigation Icons are used to move to different screens are as shown in the example below: These are the screen navigation icons. They appear on the left hand side of each screen. By touching one of the icons, the operator is able to access the needed screen (see the screen map following for details on avalable screens Touch one of these...
Page 16 Display icons Display icons require no operator action. They are meant to provided pertinent information on the machine process, and guidance to operator activity. Shown below is the Home Screen Display Icon. Notice the nine different states that will be indicated automatically by machine logic through this same icon.
Page 17: Screen Map
Toggle icons Toggle icons appear similar to pushbutton icons. However, once operated, the icon will remain in the new state until the operator again presses the icon. This shows the Bagger #1 system as being Enabled. If the operator wishes to disable Bagger #1 system, simply touch on;...
Page 19: Initial Power Up Screen Navigation
Initial Power Up Screen Navigation Upon initial power up, after both the PLC and the HMI have finished their self-test routines, the following screen will be displayed: Home Screen Display Icon (See above discussion) Figure 11. HOME Screen 1. This screen will provide the operator with all of the functions necessary to run the machine.
Page 20: Home Screen Display Icon
Home Screen Display Icon The Home Screen Display Icon (shown above on the HOME Screen) will provide a number of messages to guide the operator. If any system faults are active, they should be cleared by pressing the FAULT RESET button. Additionally, all of the access doors into transition conveyor area (if they are indicating an UNLOCKED state) should locked by pressing the DOOR INTERLOCKS icon.
Page 21 If a problem has occurred, the operator is guided to what steps are necessary to restart the system If the outbound conveyor stops, this message will be displayed when a bag reaches the discharge part of the transition conveyors. This message will orange button will display to switch the system back to Auto Mode and process bags.
Page 22 Bagger Station Controls Enable Button Reset Station Button Station Status Display Enable Button: If the operator wishes to enable or disable the Bagger Station, simply toggle between the two states. Reset Station Button: if , press this button to restore the tray back to its pushbutton, and the system needs to enabled.
Page 23: Screen Security
Door Interlocks Control the door interlock, you will gain access to the conveyor transition system. Make sure to close all doors firmly after opening any door. The interlocks status lights will also indicate its status as follows. Solid Green: door is closed and locked. Blinking Green: door is either closed and unlocked or open with the lock signal enabled.
Page 24: Maintenance Screens
Screen Security The operator should use the numeric portion to enter the proper 4-digit security code for the appropriate level of clearance. The code for the MAINT group is 2222. Please note that the only difference between MAINT group and ADMIN group is that the ADMIN group can read and edit fault history, while MAINT group can read (but not edit) fault history.
Page 25: Figure 13. Manual Screen
The MAINT Screen, shown above, is the access point for the secured screens. The screen navigation buttons for these screens are located on the right-hand side of the screen. By touching the Conveyors Manual pushbutton icon, the following screen will be displayed: Start/Stop Conveyor Speed pushbutton...
Page 26: Figure 14. Numeric Entry Keypad
MAINT Screen, Once in the MANUAL MODE, when the CONVEYOR SPEED icon is touched, the operator will be presented with a numeric keypad which will be used to make the desired speed setting. Speed settings are based on a 0-60 hertz basis (representing the frequency at which the associated motor will run).
Page 27: Figure 15. Servo Control Screen
By touching the Servo Control pushbutton icon, the following screen will be displayed. SERVO homing controls SERVO Warning Figure 15. SERVO Control Screen. and Fault # The SERVO control screen provides the operator with information regarding the 9 servo drives incorporated in this assembly. Each of the baggers utilizes three (3) servo motors and drives to perform the transfer function that moves the bagged item from the takeaway conveyor to the transition conveyor.
Page 28: I/O Status Screen
For each transfer system, the above screen provides push-button icons that will allow maintenance personnel set the home or reference position of each axis. Rehoming is not required unless the reference point is lost or a new motor is installed. Axis motors keep track of their position even if they are powered down and moved manually.
Page 29 The I/O Status screen is provided primarily as a maintenance tool. Since the controlled flow of product through the assembly is, by a large part, determined by photo-electric sensors, this screen provides and easy means to verify the operation of 16 sensors. On this screen, when the photo-sensor is not sensing a product, it will appear as shown to the left.
Page 30: Troubleshooting Warnings And Faults
TROUBLESHOOTING WARNINGS and FAULTS During the normal operation of this equipment, there will be occasional occurrences that will require operator intervention, to re-start, or continue machine operation. Pre- programmed logic will provide WARNING and FAULT activations in response to abnormal machine conditions. Each of the three subsystems (Bagger, Transfer mechanisms, and Transition Conveyors) have their own fault monitoring algorithms.
Page 31: Troubleshooting
TROUBLESHOOTING WARNINGS and FAULTS The banner will remain until the WARNING condition has cleared. The WARNING condition will be recorded in the table on the FAULT Screen for reference (refer to FAULT Screen information, following). FAULTS are conditions that will result in the end of processing, and will require operator intervention in order to restore the assembly to running condition.
Page 32 TROUBLESHOOTING WARNINGS and FAULTS WARNINGS and FAULTS to which this equipment responds are shown in the table below: ITEM# WARNINGS BAGGER#1 LINEAR SERVO 553 WARNING BAGGER #1 TILT AXIS SERVO WARNING BAGGER #2 ROTATIONSERVO504 WARNING BAGGER #2 LINEAR SERVO 704 WARNING BAGGER#2 TILT SERVO 753 WARNING BAGGER #3 ROTATION SERVO 804 AXIS WARNING BAGGER#3 LINEAR ERVO 553 WARNING...
Page 33: Figure 17. Warnings And Fault Table
TROUBLESHOOTING WARNINGS and FAULTS BAGGER # 1 - TILT ACTUATOR DID NOT REACH POSITION FAULT BAGGER #1 TILT ACUATOR DID NOT REACH INITIAL POSITION FAULT BAGGER # 1 ROTATION ACTUATOR DID NOT REACH INTIAL POSITION FAULT BAGGER #1 LINEAR ACTUATOR DID NOT RETURN TO INITIAL POSITON FUAL BAGGER #2 LINEAR ACTUATOR DID NOT REACH POSITION FAULT BAGGER #2 LINEAR ACTUATOR DID NOT REACH SHORT POSITION FAULT BAGGER #2 ROTATION ACTUATOR DID NOT REACH POSITION FAULT...
Page 34: Fault Screen
TROUBLESHOOTING WARNINGS and FAULTS Fault Screen Whenever a WARNING or FAULT occurs, as mentioned previously, an entry will automatically be made in the FAULT table which is contained on the FAULT SCREEN. FAULT Table FAULT Banner FAULT HISTORY Figure 18. Fault Screen. Screen navigation Active WARNINGS and FAULT entries appear with a color banner;...
Page 35: Figure 19. Fault History Screen
Fault Screen Active Fault With colored banner Figure 19. FAULT HISTORY Screen. The FAULT HISTORY Screen contains the same data as contained on the FAULT Screen. However, the lower portion of the screen provides several more pushbutton icons that will be useful. The CLEAR ALL pushbutton icon may be used to clear all inactive items from the list.
Page 36: Responding To Faults
Fault Screen Figure 20. ALARM COUNT Screen. The operator may use the UP/DOWN pushbutton icons to move around the list as needed. Touch the ALARM SUMMARY pushbutton icon to return to the ALARM HISTORY Screen. As required, the RESET COUNT pushbutton icon will return the count for SELECTED items to ZERO (0).
Page 37: Figure 21. Fault Correction Table
Should a more intensive procedure be required, see the following table. ITEM # (from WARNINGS and FAULTS Table -see above) DESCRIPTION CORRECTIVE ACTION 1,2,3,4,5,6,7,8 Various Warnings for SERVOS Items are informative only. Operator should touch the OK pushbutton on the WARNNG pop-up window to close the window 9,10,11,12,13,14,15...
Page 38: System Sensors & Switches
SYSTEM SENSORS & SWITCHES Keyence Digital Fiberoptic Sensor FS-N40 Figure 22. Keyence fiberoptic thru-beam sensor detects bags along conveyors, providing signals to properly control the flow of bags in the system. The Keyence digital fiberoptic sensor and the Thrubeam Active Receiver Fibers are used to detect the presence and absence of a package on the conveyors.
Page 39: Keyence Locking Door Switch
edge of the transfer tray. As the tray tilts and a bag slides down the tray, it breaks the beam, signaling that it is falling off the tray. When the bag clears the tray and lands on the transition conveyor, the thru-beam makes, signaling that the bag is off the tray, Keyence Locking Door Switch Figure 24.
Page 40: System Maintenance
SYSTEM MAINTENANCE Shaft and Bearing Maintenance Both the vertical shaft, responsible for 90-degree rotation, and the horizontal shaft, responsible for 45-degree tilt, are raw steel shafts. Consequently, both shafts require application of linseed oil to mitigate onset of oxidation. In addition, both the vertical and horizontal shafts are supported by two needle-roller bearings.
Page 41: Robotunits Conveyor Belt Tracking
Figure 26. Location of horizontal bearing block grease fitting (right-angled): 1/8 NPT threads. Robotunits Conveyor Belt Tracking On an as-needed basis, it may be necessary to track the Robotunits C5N conveyor belts by adjusting tension of the belts. If the belts seem or the other, then follow the instructions on Page 26 of the included Robotunits conveyor belt tension.
Page 42: Mechanical Drawings
MECHANICAL DRAWINGS Page 42 of 47...
Page 50: Electrical Drawings
ELECTRICAL DRAWINGS Page 43 of 47...
Page 62: Appendix
APPENDIX Manuals and Documentation Vendor Part No. Description Document Name Allen- Variable Bradley 520 Series Frequency Drive 520-um001_-en-e (Rockwell (VFD) Manual Automation) 2D Drawing 850S-Footprint-Drawing-FP2161E-PDF Automated Packaging Autobag Systems 850S (Sealed Air) User Manual AB8-UM AB- Actuator EGC-TB_EGC-HD-TB_instruction_2019- Instructions 06d_8110940g1 Mounting Assembly EAMM-A-L_N_-_GH-8_-_Variante_H_2018-...
Page 63 Swivel Mounting EAHS Instructions - for EAHS-P2_assembly-instr_2021-01a_8135704g1 EPCC Servomotor EMMT EMMT-AS_operating-instr_2020-11b_8146164g1 Instructions Servo Drive CMMT-AS-C2_C4-3A-_-S1_instruction_2019- Instructions 07b_8113965g1 Servo Drive CMMT-AS-C2_C4-3A-_-S1_instruction_2019- CMMT Installation 07b_8113965g1 Servo Drive CMMT-AS-SW_manual_2020-11f_8146068g1 Manual Operator Unit CDSB CDSB-A1_instruction_2018-06_8088695g1 Instructions Fiberoptic Sensor FS Series AS_93132_FS-N40_UM_731GB_WW_GB_1098_3 Manual Photoelectric PZ Series AS_124346_PZ-G_IM_96M17098_WW_GB_2111_1 Sensor Manual Keyence...
Page 64: Recommended Spare Parts List
Recommended Spare Parts List Vendor Part No. Description Qty. Allen-Bradley (Rockwell Variable Frequency Drive (VFD) for Automation) Series conveyors Linear Axis Gearbox for EGC EPCC-150 Linear Cylinder for Rotation EPCC-100 Linear Cylinder for Tilt EMMT Servomotor linear axis FESTO EMMT Servomotor rotation axis EMMT Servomotor tilt axis...
Page 65 NEKM Plug Kit for Servo Drive * NEBM Servomotor cable, 5m PZ Series Retro-Reflective Photoelectric Sensor * R Series Reflector * FU Series Fiber unit, Thru-beam * Keyence FS Series Amplifier * OP Series Amplifier Cable, M8 Quick Disc. 5m * OP Series Amplifier Cable, M8 Quick Disc.