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XM Controls Tandem-Wire Operation Manual

Tandem-wire saw system
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XM Controls
Tandem-Wire SAW System
Operation Manual
Advanced Manufacturing Engineering Technologies
Revision 0
May 2007

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Summary of Contents for XM Controls Tandem-Wire

  • Page 1 XM Controls Tandem-Wire SAW System Operation Manual Advanced Manufacturing Engineering Technologies Revision 0 May 2007...

  • Page 2: Foreword

    1 Foreword Throughout this manual, these icons will highlight specific information related to each category. Icon Function Note - Highlights or reviews important information and general points of interest. Caution - Highlights items, which can cause damage to the system and/or injury to operators.

  • Page 3: Table Of Contents

    Table of Contents FOREWORD ............................2 GENERAL SAFETY...........................4 XM TANDEM-WIRE SAW SYSTEM ....................10 XM TANDEM-WIRE SAW SYSTEM MODULE CABINET ............12 TANDEM WIRE SAW OPERATION QUICK START..............13 Power ............................13 5.1.1 Main Disconnect.......................13 5.1.2 Lincoln Power Supply ......................13 5.1.3 Meta Cabinet........................13 5.1.4 Weld Engineering ......................13 5.1.5...

  • Page 4: General Safety

    2 General Safety Arc Welding Safety Precautions WARNING HAZARDOUS. ELDING and others from possible serious injury or death! ROTECT YOURSELF at all times! EEP CHILDREN AWAY until such time as you have consulted your doctor. ACEMAKER WEARERS KEEP AWAY Welding exposes you to certain hazards. However, welding is safe when precautions are taken.
  • Page 5 LECTRIC HOCK Touching live electrical parts may cause fatal shocks or severe burns. The electrode and work circuit are electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire and torch are electrically live.
  • Page 6 1. Keep your head out of the fumes. Do not breathe fumes. 2. If indoors, ventilate the area and/or exhaust welding fumes and gases from the arc. 3. If ventilation is poor, use an approved air-supplied respirator. 4. Read the Material Safety Data Sheet (MSDS) and the manufacturer's instructions for metals, consumables, coatings, and cleaners.
  • Page 7 YLINDERS XPLODE AMAGED Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. 1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs. 2.
  • Page 8 ARTS AUSE EVERE URNS Avoid any contact with all HOT materials and substances. 1. Allow a cooling period before *handling* moving or servicing. 2. Use approved techniques, tools, and safety clothing (gloves, shields, shoes, eye protection, etc.). TEAM RESSURIZED OOLANT The coolant in the radiators and pressurized hoses is under pressure and can be very hot.
  • Page 9 3. Observe all Safety Lines and Limits at all times. 4. Wear appropriate safety gear when operating any function of this equipment. 5. If a malfunction occurs: A. Shut down the entire system. B. Contact the system manager immediately. 6. If the standard system motion becomes obstructed, DO NOT ATTEMPT to clear the obstruction yourself.

  • Page 10: Xm Tandem-Wire Saw System

    3 XM Tandem-wire SAW System The illustrations below shows the XM Tandem-wire SAW System: column & boom, pneumatic control box, travel car & track, control stand and pendant, XM Controller, SAW welding head, electronic cabinets, turning rolls. XM Tandem-wire SAW System 1...

  • Page 12: Xm Tandem-Wire Saw System Module Cabinet

    4 XM Tandem-wire SAW System Module Cabinet...

  • Page 13: Tandem Wire Saw Operation Quick Start

    5 Tandem Wire SAW Operation Quick Start 5.1 Power 5.1.1 Main Disconnect 1. Power the entire system with the main disconnect lever. 5.1.2 Lincoln Power Supply 1. Check to ensure both Lincoln Power Supply cabinets are on. 5.1.3 Meta Cabinet 1.

  • Page 14: Set-Up

    5.2 Set-Up 5.2.1 XM Controller 1. Enter Weld Mode on the XM Controller. 2. Make sure the E-stop is cleared on the XM Controller. 3. Load the appropriate longitudinal or circumferential weld program. 5.2.2 Tracking Laser Calibration (Longitudinal) 1. Feed the wire to a desired stick out length. 2.

  • Page 15: Tracking Laser Calibration (Circumferential)

    Left and right sides are determined by looking at the front of the weld head. 6. Select the corresponding top left or top right Soft Button on the XM Controller. 7. Move the wire to the other corner and check the Meta Tracking Laser Display to ensure the image displays a mirror image.

  • Page 16: Start The Weld

    3. Follow onscreen instructions. 5.3 Start the weld 1. Press the Start Sequence Button to begin the weld. 2. Observe the Meta Tracking Display. 5.4 Restart 1. If camera position changed, recalibrate the laser camera or scribe camera with the above steps;...

  • Page 17: Xm Controller

    6 XM Controller 6.1 XM Controller Features • Lightweight Ergonomic Controller: The X M Controller is easy to handle and comes with a pendant package for mounted use. • Powerful Graphical Programming Interface: The interface uses the latest electronic and manufacturing technologies for programming. Simply select and dial a value.

  • Page 18: Controller Components

    6.2 Controller Components Emergency Stop (4.1) Soft Buttons Mode Buttons (4.2) (4.8) Sequence Buttons (4.3) LCD Display (4.7) Soft Control Knobs Function Buttons Joystick Controls (4.4) (4.5) (4.6)

  • Page 19: Emergency Stop

    6.2.1 Emergency Stop The Emergency Stop button immediately stops current flow from the power supply and all servo-controlled motion. The system remains inactive until an operator pulls the Emergency Stop button and pushes the CLEAR E-STOP Soft Button. The Emergency Stop button should be used to avoid damaging the system or to avoid injuries.

  • Page 20: Function Buttons

    6.2.5 Function Buttons 6.2.5.1 Flux System Button Flux Recovery - Activates the flux recovery system. Flux Valve Open – Opens the valve for the flux system Scribe Line - Activates the plasma gas at the default flow rate. Plasma Gas will flow at this rate until the button is deactivated. 6.2.5.2 Track Laser On –...
  • Page 21 6.2.5.4 Motion Buttons Set Position - When this button is pressed, the POSITION 1 and POSITION 2 buttons are made ready for programming. To program position torch where desired, press SET POSITION, and then press the POSITION 1 or POSITION 2 button. The current position will be saved to the corresponding button.

  • Page 22: Joystick Controls

    6.2.6 Joystick Controls The Joystick Controls are programmable (see section 4.8.3.3). Each Joystick is divided into two axis of motion: a white axis and a yellow axis with corresponding labels. Each axis has programmable parameters (Command / High Speed / Low Speed).

  • Page 23: Mode Of Operation Select

    6.3 Mode Of Operation Select 6.3.1 Weld Mode To access WELD Mode, press the WELD Mode button represented by the icon above. The Weld screen is divided into three main sections. The top section contains the Soft Button labels. The center section contains weld schedule graphical information and a text message area.
  • Page 24 6.3.1.1 Soft Buttons Load - Selects a previously created weld program from the File Load Manager screen. In this illustration, the name of the current weld schedule is “documentation.” Clear E-Stop - Only displayed when the Emergency Stop button Clear E-Stop has been activated.
  • Page 25 6.3.1.2 Weld Schedule Information The Weld Schedule Information area consists of the following sections: 6.3.1.3 Weld Schedule File Name Weld Schedule File Name - Displays the loaded weld program ready to run. In this example, the name of the current weld schedule is “Part_26886- 1_VEE_Fill.”...
  • Page 26 6.3.1.7 System Messages System Messages - Displays each occurrence and the time they took place. 6.3.1.8 Meters Meters - Displays four (4) parameter meters at one time. Each meter can display the following: • Module name • Parameter Name • Real time value of the parameter and the unit of measure •...

  • Page 27: Tandem Wire Saw System

    7 Tandem Wire SAW System Trip Hazard Due to the number of cables inter connecting the turning rolls and power supply, a trip hazard can occur. Trip Hazard Due to the number of rails and supporting structures around the travel cart, a trip hazard can occur.
  • Page 28 7.1 Overview...

  • Page 29: Saw System Operations Overview

    8 SAW SYSTEM OPERATIONS OVERVIEW Boom & Mast Manipulator with Travel Car 8.1.1 Boom The XM system (X-Linear Module- Boom) controls the Boom speed and direction in the program and by XM Control Pendant JOG controls in WELD Mode. Moving Parts Hazard During operation of the Mast &...

  • Page 30: Mast & Travel Car

    Moving Parts Hazard During operation of the Mast & Travel Car, a horn will sound and a light will flash to help awareness in the work area. Care should be taken and the Manipulator or car moved only by trained and diligent personnel. Do Not Step In normal operation, personnel should not need to get up on the travel cart.

  • Page 31: Turning Rolls

    8.1.4 Turning Rolls The XM system (X-Rotary Module) controls the Turning Rolls speed and direction in the program and by XM Control Pendant jogging controls. The Turning Rolls can be added or subtracted from the system configuration to enable Circular seam or Linear seam Welding. Activate the turning rolls with the following steps: 1.

  • Page 32: Meta Seam Tracking & Joint Scanner Operation

    9 META Seam Tracking & Joint Scanner Operation 9.1 Application Software The Tracking application runs on the Windows XP Professional operating system and is located in the directory C:\MAF\MAF.exe. If the program is closed it can be restarted at any time by selecting this executable file or by double clicking the icon on the Windows desktop.

  • Page 33: Components Of The Main Display

    9.2 Components of the main display Sensor Image: This is the profile of the surface seen by the scanning spot sensor. The sensor can only see light of the same wavelength as the projected laser and cannot see any background illumination. In this way only the surface profile of the laser scan is seen by the sensor which represents the profile of the weld surface.
  • Page 34 Each of these Joint Profiles has the following tracking position selections: • TL – Top Left • BL – Bottom Left • TLC – Top Left Centre • BLC – Bottom Left Centre • TLI - Top Left Inside • BLI - Bottom Left Inside •...
  • Page 35 LASER OFF/ON: This turns laser on and starts analysis of the received profile using the current settings. In this state the laser is on and the system is analyzing the image. However, the system is not issuing any tracking corrections. Therefore it is safe to turn the laser on at any time to check the image from the sensor.
  • Page 36 Profile Measurement Display: During analysis, various parameters of the current joint profile are measured. These are displayed as shown opposite: − Correction: The current Tracking corrections in both horizontal and vertical axes are shown. − Profile: Hilo represents the mismatch. −...
  • Page 37 Current Pass Indicator: During multi-pass welding the current pass is indicated as shown opposite. The four types of pass are ROOT, HOT, FILL and CAP and the current pass type is highlighted. Once the number of passes for a particular layer has been calculated this will be shown in the numbered indicator as shown opposite for a selected Fill Pass of three layers.
  • Page 38 Line Tracking Display: The Line Tracking System is designed to maintain the horizontal position of the weld torch during welding when the joint has been filled to a level where standard laser tracking is not possible. This is achieved by visually tracking a narrow line viewed by the Line Tracker sensor.
  • Page 39 9.3 Index to Supporting Manuals Equipment description Applicable Manual Manual Location Process Control AMET XM Controls Main Fixture AMET International Welding Power Supplies Lincoln PowerWave 1000 Joint Tracking & Scanning META Inc Flux Handling Weld Engineering...

  • Page 40: Addendum A: Quick Reference Charts

    10 Addendum A: Quick Reference Charts System Power Up Turn power ON Check power ON Check power ON Check power ON at main at Lincoln power at META System at the SOLA power disconnect supplies cabinet door supply switch Check power ON Check META Boot META software META...
  • Page 41 Tracking Laser Calibration Press the WELD Mode button on the Press the Left or XM Controller Right Soft button on the XM Controller Clear and check clear the E-Stop Jog the wire to the opposite groove edge Load the desired weld program Verify the META Laser display is...

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