Functions in Auto Linked Mode

Switching to automatic loading

Workpieces are inserted directly into the fixture machine via the loading hatch (raw part) or removed from there (finished part). For the loading and unloading processes, the Z-axis of the machine travels to the loading position and the loading hatch is opened. The coordination for the loading and unloading processes is accomplished by the loader controller via the loader interface.

Deselecting the "Manual loading without automation" function switches the machine to automatic mode. Check, before starting fully-automatic production mode, whether the function in the "General" HMI screen is set as follows:

Opening the "General" HMI screen

Step 1:

Preconditions:

  • The machine is stationary.
  • Safety doors closed and locked.

Press the Setup key.

The machine is removed from the system linkage. Setup mode is activated. With Data menu key call up the basic menu on the main operator panel.

Press the "HMI" softkey.
The "Setup functions to HMI Standard" menu item appears.

Step 2:

Press lower horizontal softkey "Man.funct.".
The menu of the "Hand functions" area is opened.

Press upper horizontal softkey "Additional fu.".
The menu of the "Additional functions" area is opened (3rd menu level).

Step 3:

Press upper horizontal softkey "General".

The "General" HMI screen is opened. The "Manual loading without automation" function is available. Manual loading without automation is selected, the display field is highlighted.

Switching over to automatic mode

Step 1:

Press the right-hand softkey for the "..." line.
The "Deselected" display field is highlighted.Operation for automatic workpiece loading is set.

  • The loading hatch is controlled by the loader.
  • The safety doors are locked.

Checking the loader interface

The HMI "Interface" screen can be called in order to gain detailed insight into the automated loading and unloading of the machine via the loader. Individual interface signals are displayed, which can also be set manually if required.

Depending on the actual automation system, the HMI screen makes interface bits available on several pages. The incoming and outgoing signals are displayed in the left and right sides of the screen.

  • Incoming: Signals from loader
  • Outgoing: Signals from machine

Opening HMI "Interface" screen

Step 1:

Preconditions:

  • Drives and media switched on.
  • Safety doors closed and locked.
  • "OP AUTO" and "Auto" operating modes selected.

With Data menu key call up the basic menu on the main operator panel.

Press the "HMI" softkey.
The control switches to the "HMI" main menu.

Step 2:

Press lower horizontal softkey "Maintenance".
The "Maintenance" menu is opened.

Step 3:

Press upper horizontal softkey "Interface".
The HMI "Interface" screen is opened.

Loading Interface Pages

Page 1:

The HMI screen comprises several pages to accommodate the numerous interface signals. Selecting the orange title line opens a pull-down menu via which the other pages can be called up.

Each interface bit is mapped by a line which is preceded by a lamp symbol:

  • Green means: Interface bit set.
  • Black means: Interface bit not set.

The interface bits can be controlled as follows:

  • Select interface bit via vertical cursor keys. (Horizontal cursor keys for toggling between left and right sides of screen).
  • Set or reset the required bit via the corresponding softkey on the right edge of the screen.

Page 2:

The HMI screen comprises several pages to accommodate the numerous interface signals. Selecting the orange title line opens a pull-down menu via which the other pages can be called up.

Each interface bit is mapped by a line which is preceded by a lamp symbol:

  • Green means: Interface bit set.
  • Black means: Interface bit not set.

The interface bits can be controlled as follows:

  • Select interface bit via vertical cursor keys. (Horizontal cursor keys for toggling between left and right sides of screen).
  • Set or reset the required bit via the corresponding softkey on the right edge of the screen.

Page 3:

The HMI screen comprises several pages to accommodate the numerous interface signals. Selecting the orange title line opens a pull-down menu via which the other pages can be called up.

Each interface bit is mapped by a line which is preceded by a lamp symbol:

  • Green means: Interface bit set.
  • Black means: Interface bit not set.

The interface bits can be controlled as follows:

  • Select interface bit via vertical cursor keys. (Horizontal cursor keys for toggling between left and right sides of screen).
  • Set or reset the required bit via the corresponding softkey on the right edge of the screen.

Page 4:

The HMI screen comprises several pages to accommodate the numerous interface signals. Selecting the orange title line opens a pull-down menu via which the other pages can be called up.

Each interface bit is mapped by a line which is preceded by a lamp symbol:

  • Green means: Interface bit set.
  • Black means: Interface bit not set.

The interface bits can be controlled as follows:

  • Select interface bit via vertical cursor keys. (Horizontal cursor keys for toggling between left and right sides of screen).
  • Set or reset the required bit via the corresponding softkey on the right edge of the screen.

Page 5:

The HMI screen comprises several pages to accommodate the numerous interface signals. Selecting the orange title line opens a pull-down menu via which the other pages can be called up.

Each interface bit is mapped by a line which is preceded by a lamp symbol:

  • Green means: Interface bit set.
  • Black means: Interface bit not set.

The interface bits can be controlled as follows:

  • Select interface bit via vertical cursor keys. (Horizontal cursor keys for toggling between left and right sides of screen).
  • Set or reset the required bit via the corresponding softkey on the right edge of the screen.

home position

The home position is the defined starting point for many NC programs. In the home position, the axes move to their start position. Machining of the workpiece can be started from here.

Step 1:

Preconditions:

  • Drives and media switched on.
  • Safety doors closed and locked.

Press the Auto and OP Auto Keys.
The machine is switched to automatic mode.

Step 2:

Press the Master Return key.
The machining aces move to their home position.

  • The machine axes move to their home position.

The lamp comes on when the home position is reached.

Move machine to home position

Step 1:

The home position is the defined starting point for many NC programs. In the home position, the Z-slide is retracted and in the "Start position". Machining of the workpiece can be started from here.
Preconditions:

  • Drives and media switched on.
  • Channel 1 and 2 active.
  • Safety doors closed and locked.

Press OP Auto and Auto keys.
The machine is switched to automatic mode.

Step 2:

Press the Master Return key.
The machine moves to the home position.

  • The machine axes move to their home position.

    • The lamp comes on when the home position is reached.

Starting production

Step 1:

Preconditions:

  • Fixtures of the machine have been changed over to the workpiece type that is to be machined.
  • Axes in home position.
  • Drives and media switched on.
  • Safety doors closed and locked.
  • There is a raw workpiece on the load conveyor.
  • "Manual loading without automation" function is deselected.

Press the Interlinked Operation Mode (OP Auto) key.
The machine is included in the system linkage.

  • The lamp "OP AUTO" illuminates.
  • The "AUTO" NC mode is automatically selected. The "AUTO" lamp comes on.

Step 2:

Press the Start/Step key.
The loader control opens and closes the workpiece hatch door safety door and controls the workpiece flow within the system in accordance with the transport program.
For the machine, this means:

  • If the fixture is empty, it is loaded with a raw part at the next opportunity (load request).
  • If the fixture is occupied by a finished part, the latter is unloaded at the first opportunity (unload request).

The system operates cyclically in continuous operation.

Runout Machine

The basic sequence for loading and unloading workpieces in automatic production mode can be defined via the "Runout" HMI function.

Standard sequence: "Runout" deactivated

  • The machine is loaded with a new raw part.
  • When the workpiece has been machined, the machine is unloaded.
  • The machine is loaded with the next raw part.
  • etc.

Special sequence: "Runout" activated:

  • The current workpiece will be finish-machined and then unloaded.
  • No new workpiece will be loaded.

Activating runout

Step 1:

A new workpiece type is to be produced. An old workpiece type is still located in the machine and is to be unloaded.

Preconditions:

  • Drives and media switched on.
  • Safety doors closed and locked.
  • "Cycle types" HMI screen is opened.

Press the left-hand softkey.
The respective display field "..." is highlighted.

Starting the unloading operation

Step 1:

Press the Interlinked Operation Mode (OP Auto) key.
The machine is switched to linked mode.

Step 2:

Press the Start/Step key.
The loader performs the unloading operation.

  • As soon as the workpiece has left the machine, the program is interrupted and the machine stops.
  • No new workpiece will be loaded.

Deactivating runout again

Step 1:

Preconditions:

  • "Cycle types" HMI screen is opened.

Press the left-hand softkey.
The respective display field "..." is highlighted.

The machine is set for regular production mode.

If an irregularity was discovered or a tool fracture occurred during machining, the operator can systematically unload the workpiece. To do this, the workpiece status must be set manually to "NOK workpiece for unloading". This unqualified part (NOK part) is picked up by the loader and set down at a special location (e.g. SPC location).

Declaring workpiece as NOK part

Step 1:

Preconditions:

  • "Setup" machine mode is active.
  • "Workpiece" HMI screen is opened.
  • Access rights granted (EKS key).

Press the right-hand vertical softkey which is assigned to the "..." line.
The workpiece is declared as a NOK part (reject part).
The right-hand display field "ack. unload. " is highlighted.

Unloading NOK part

Step 1:

Preconditions:

  • Drives and media switched on.
  • Safety doors closed and locked.
  • "Setup" machine mode is active.

Press the Interlinked Operation Mode (OP Auto) key.
The machine is switched to linked mode.

Step 2:

Press the Start/Step key.
The workpiece is unloaded from the loader at the next opportunity. Production mode is then continued.

If malfunctions occur, the machine stops in its current position for safety reasons. An error message is displayed on the screen.
Once the cause of the malfunction has been remedied, you must confirm this in the "Acknowledge" HMI screen. No machine will not execute any further movements until you have done so.

Calling up the "Acknowledgment" HMI screen

Step 1:

Preconditions:

  • Safety doors closed and locked.
  • Drives and media switched on.
  • "HMI" main menu open.

Press the Setup key.
The machine is removed from the system linkage. Setup mode is activated.

Step 2:

Press lower horizontal softkey "Man.funct.".
The menu of the "Manual functions" area is opened.

Press upper horizontal softkey "Additional fu.".

The menu of the "Additional functions" area is opened (3rd menu level).

Operation at the main operator panel or HT8

If operation is toggled between the stationary operator panel (main operator panel) and the mobile handheld operating unit (HT8), the mobile handheld operating unit can remain inserted on the main operator panel.

To transfer the command from the "mobile" to the "stationary" operator panel and vice versa, only the "Mobile handheld operating unit focus change" HMI function needs to be actuated.

Preconditions:

  • "Setup" machine mode is active.
  • "Acknowledge" HMI screen is opened.
  • The "HT8 Focus change" function is available.

Operation at the HT8

Step 1:

Press the right softkey "..." for the "HT8 Focus change" line. Operation is transferred from the stationary operator panel to the mobile handheld operating unit.

Operation at the main control panel

Step 1:

Press the left softkey "..." of the "HT8 Focus change" line. Operation is transferred from the handheld operating unit to the stationary operating unit.

Reset machining depth

The control has a depth marker for re-entry into the last machining step.

Please refer to programming instructions (PA) in Chapter 1.

The depth marker is cleared when the machining depth is reset.

Step 1:

Preconditions:

  • "Setup" machine mode is active.
  • "Acknowledge" HMI screen is opened.

Press the right softkey "Requested" for assigning to the "Reset machining depth" line.

Step 2:

Press the NC Reset key.

Acknowledging workpiece location check

The control has reported a workpiece location error.

The location malfunction message can be cleared by location repeat, e.g. by

  • Blowing-off the workpiece support.
  • Raise the lifting device and then lower again.

Preconditions:

  • Safety doors closed and locked.
  • Drives and media switched on.
  • "Setup" machine mode is active.
  • "Acknowledge" HMI screen is opened.

Confirming location check as OK

Step 1:

Preconditions:

  • Location malfunction message no longer occurs.

Press the right softkey "Set WST OK" for assigning to the "..." line.
The right-hand field "set" is highlighted.

Confirming location check as NOK

Step 1:

The location fault cannot be corrected. The error message is still displayed.

The workpiece must be removed for a closer inspection of the locating faces.

Press the left softkey "Reject NOK Workpiece" for assigning to the "..." line.
The left-hand field "set" is highlighted.
The workpiece is unloaded at the next opportunity.

If the location fault is not caused by the workpiece, the clamping fixture must be inspected.

Acknowledge test grip of loader

Whenever the workpiece data register of the machine is faulty, the control sends a request to the loader to execute a test grip.

While the Z slide of the machine is at its loading/unloading position, the loader enters the work area with an empty gripper and carries out its "test grip" (workpiece presence check). Subsequently, the loader moves back to its home position.

Finally, the operator must acknowledge the process in the machine control.

Step 1:

Preconditions:

  • Message from loader control "Test grip performed".
  • Machine in linked operation.
  • "Acknowledge" HMI screen is opened.

Press the left softkey "Set" for assigning to the "..." line.
The result of the test grip is written to the data register. The "Set" field is highlighted.