modular transfer system tlm 1000 -...

Modular transfer system

TLM 1000

User manual

&

Maintenance guide

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Table of contents

1 General information ........................................................................................................................ 3

1.1 Important remarks .................................................................................................................. 3

1.2 Applicable standards ............................................................................................................... 3

1.3 Applications ............................................................................................................................. 3

1.4 Conditions of use ..................................................................................................................... 3

1.5 Safety instructions ................................................................................................................... 4

1.6 Safety instructions regarding the motor ................................................................................. 4

1.7 Additional information ............................................................................................................ 4

2 Technical specifications ................................................................................................................... 5

3 Commissioning ................................................................................................................................ 6

3.1 Receipt ..................................................................................................................................... 6

3.2 Transfer elements ................................................................................................................... 6

3.3 Stopper .................................................................................................................................... 6

3.4 Positioning unit ........................................................................................................................ 6

3.5 Workpiece carrier .................................................................................................................... 7

4 Maintenance ................................................................................................................................... 7

4.1 Belts wear ................................................................................................................................ 7

4.2 Passageways of workpiece carriers ......................................................................................... 7

4.3 Pins .......................................................................................................................................... 7

4.4 Wear of the belt guide ............................................................................................................ 7

4.5 Transfer parts .......................................................................................................................... 8

4.6 Stopper .................................................................................................................................... 8

4.7 Positioning unit ........................................................................................................................ 9

4.8 Heavy positioning unit ........................................................................................................... 12

4.9 Other transfer parts .............................................................................................................. 13

5 Motor Replacement ...................................................................................................................... 14

5.1 Disassembly ........................................................................................................................... 14

5.2 Reassembly of the motor ...................................................................................................... 16

5.3 Changing the belt – Flat belt ................................................................................................. 16

5.4 Changing the belt – Timing belt ............................................................................................ 18

6 Responsability ............................................................................................................................... 19

7 Customer service ........................................................................................................................... 19

8 Appendix ........................................................................................................................................ 20

8.1 Maintenance schedule .......................................................................................................... 20

8.2 ISO 9001 certification ............................................................................................................ 21

8.3 Spare parts list ....................................................................................................................... 22

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1 GENERAL INFORMATION 1.1 Important remarks The following instructions will be used as technical documentation for the manufacturer of the

final machine. elcom is the supplier of this TLM 1000 transfer system sub-assembly .

The manufacturer of the final machine must make sure that:

- All safety equipment is provided and functional,

- Regular checks are carried out,

- All danger (pinching, squashing) due to moving parts is controlled,

- The documentation is complete.

1.2 Applicable standards

According to the 2006/42/CE European directive, elcom transfer systems are considered as partly

completed machines. They therefore are exempt of a CE conformity declaration.

However, the following standards are taken into account during the design and the manufacturing of

the elcom transfer systems:

– The European Machinery Directive 2006/42/CE

– The European Low Voltage Directive73/23/CE

elcom ensures an adequate follow-up and products quality formalized by the ISO 9001 certification.

For environmental reasons, elcom also meets the requirements of the ISO 14001 standards.

1.3 Applications

The elements of the linear TLM 1000 transfer systems are designed to carry and position workpiece

carriers according to the end customers’ configuration.

They are intended to be incorporated the customers' production line.

1.4 Conditions of use

The elements of the TLM 1000 transfer systems are suited for a use in normal industrial areas such as

a final assembly plant or equivalent, in a dry environment.

They are not suited for transporting materials such as sand, balls or grain.

The maximum load applicable on the transfer system is mentioned in the catalog and must never be

ignored.

To ensure a proper functioning of the transfer system on a maximum period of time, you must follow

this advice:

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- Use temperature between 0 and 40°C (30 and 140°F)

- Avoid dusty or smoky atmosphere

- Avoid accumulation of sharp objects on the transfer system

- Avoid setting the machine in direct exposition to UV rays

1.5 Safety instructions

Safety rules regarding transfer systems, especially the ones regarding the electrical devices, must be followed during all the use phases: mounting, transport, production. Disregarding these rules would be regarded as a wrong use of the machine.

Using the transfer system in an explosive atmosphere can have a negative impact on the transfer system and is strongly discouraged.

Never perform any maintenance on your own. Another worker must be present at all

time in order to shut the power down or perform first aid actions if needed.

Changing the motor position or removing security parts must only be done when the

transfer system is unplugged from any power supply.

When carrying maintenance or handling tasks while the transfer system is operating (belt

tension setting), take care not to slide your hand between the belt and the belt support

in order to avoid any accident.

All the different types of positioning units include several mobile parts driven by

pneumatic cylinders. Therefore, they must be well protected in the end-user machine in

order to avoid any risks of pinching or squashing. We recommand to mount a protective

housing around it.

1.6 Safety instructions regarding the motor

In case of a power failure, turn off the transfer system: it could restart automatically when the power comes back which could cause damages and even injuries to the operator.

1.7 Additional information

These instructions aim at ensuring the safety of the people and the proper functioning of the transfer

system. If you wish to use the transfer system in any other conditions, please do not hesitate to

contact us.

Other information is available on our website, in the documentation section:

http://elcom-automation.com/transfers/documentation


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2 TECHNICAL SPECIFICATIONS

- Maximum load on a workpiece carrier: 2 kg

- Maximum accumulated load on the transfer system: 25 kg for a maximum 3-meters unit.

- Electrical power supply of the motors: 380V three-phase

- Motor power: V 9 m /min = 0.09 Kw

(V = belt speed) V 15m /min = 0.09 Kw

V 19m /min = 0.09 Kw

Air pressure supply = 5 to 6 bars

Every cylinder must be equipped with a flow limiter.

- Sound emission < 80 dB

- Weight of each part: See our catalogue Modular Transfer System & Flat belt conveyors.


Warning: All load exceedance can lead to a premature wear of the belt or any other

parts.


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3 COMMISSIONING

3.1 Receipt

When receiving the transfer system, check if the packaging has not suffered any damage and

that the machine is in perfect conditions.

The transfer system can be supplied in kit. It then needs to be assembled.

3.2 Transfer elements

When handling the equipment and parts, take special care to avoid shocks.

1. Assemble the parts according to the lay-out of the line with the delivered fastening parts,

2. Level perfectly the conveying units while checking that the belts are properly laid on the belt guide,

3. Ensure the perfect stability of the whole line. To achieve this and according to the lay-out of the line, it may be necessary to perform ground fastenings,

4. Check the settings of the motor magneto-thermic circuit breakers,

5. Check the running direction of the belt without any load,

6. Adjust the cams and the selectors using a workpiece carrier,

7. Start the transfer system with all the workpiece carriers on.

3.3 Stopper

1. Place the stopper right in the middle of the two profiles of the system, 2. Adjust the sensor for the detection of the workpiece carriers,

3. Adjust the flow control units.

3.4 Positioning unit

1. Put the positioning unit right in the middle of the two profiles of the system, 2. Adjust the sensor for the detection of the workpiece carriers, 3. Check on the high position that the pins of the workpiece carrier are free,

4. Lubricate the positioning units fingers with a fine layer of grease (see Maintenance),

5. Adjust the flow controllers.

Note: For the heavy positioning unit, check the lubrication of the drawer (see Maintenance).

All the different types of positioning units include several mobile parts driven by

pneumatic cylinders. Therefore, they must be well protected on the end-user machine

in order to avoid any risk of pinching or squashing. We recommend mounting a

protective housing.

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3.5 Workpiece carrier

1. Check that the springs of the pins located under the carrier are working properly.

2. Check that no part goes over the lower surface of the workpiece carrier.

4 MAINTENANCE

General visual check

Approximately every 500 hours, check the following points to ensure the proper functioning of the

transfer system:

4.1 Belts wear

Regularly verify visually the state of the belt and especially the welding area.

4.2 Passageways of workpiece carriers

The friction of the pins while operating can make some marks appear. Those marks may over the

long term require the part replacement.

4.3 Pins

Pins are sensitive to wear, especially if the load is heavy. Wear can be noticed as soon as a loss of

efficiency in the guiding of the workpiece carrier occurs.

4.4 Wear of the belt guide

Belt guide must be replaced as soon as wear marks or friction on the belt start to appear.

Wear area of the pins

Belt

Belt guide

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4.5 Transfer parts

Every 200 hours:

Remove the dust from the complete unit, using the product:

Ref 800 00 003 (polish plastics Air Industry 2101).

Every 3200 hours:

Check the lubrication of the conical torque.

Apply grease to obtain the initial lubrication state if necessary.

Use the grease reference 800 00 009.

4.6 Stopper

Every 5000 hours:

Eventual cleaning of the stopper depending on the working environment.

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Stopper can be disassembled by the two screws located underneath.

Once the screws are taken off, slide the stopper outside of the system for disassembly, cleaning and

greasing.

4.7 Positioning unit

Every 1000 hours:

All types except heavy positioning unit.

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Remove the positioning unit plate after unscrewing the fastening screw.

Check the lubrication of the guiding shafts.

Guiding shafts

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Changing the pins (locating and centering)

Extract the previous pins with the press.

Install the new pins in the press, using a bush ref. 120 03 006 from a workpiece carrier as a support

(insert the pin in the bush and then place the whole on the positioning unit plate).

Note: On the lift positioning unit, the cylinder can be lubricated without any prior disassembly.

Pins

Bush (ref. 110 03 005)

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4.8 Heavy positioning unit

Disassembly of the heavy positioning unit:

Unscrew the fixing screws that fasten the

positioning unit on the rails.

Take off the positioning unit from the

transfer system.

Unscrew the fixing screw fastening the

plate.

Remove the plate to allow access to the

drawer.

Every 1000 hours:

Lubrication of the drawer (inside and outside)

Use the recommended grease (grease Gulf Crown EP2).

Plate fixing screw

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Lubricate the positioning unit finger with a film of grease.

Use the grease ref. 800 00 002 (Crown, ref. 7041 spray).

Changing pins (locating/centering)

Extract the previous pins with a press.

Put the new pins in place with the press while using the bush of a workpiece carrier as a support

(Insert the locating pin in the bush, and then place the whole back on the positioning unit plate.).

For re assembly, follow the previous steps in reverse order.

4.9 Other transfer parts The others parts of the transfer system do not need any maintenance. A visual check, looking for

wear or breaking parts is recommended from time to time.

Drawer (réf 110 11 007)

Areas to be lubricated

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5 MOTOR REPLACEMENT

5.1 Disassembly

Unscrew the four screws from the plastic cover.

Take the circlip and the washer off.

Washer

Screws from the

plastic cover

Circlip

Washer

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Remove the motor from the shaft.

Unscrew the anti-rotation screw of the reducer, on the transfer side.

Anti-rotation screw

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5.2 Reassembly of the motor

Put the screw back on the new reducer.

Lubricate the shaft with copper grease.

For reassembly, follow the previous steps in

reverse order.

5.3 Changing the belt – Flat belt

Calculate the belt required length for a single unit:

[(L-100) x 2 + 173] x 0.98

L = total length of the transfer system, including the return.

Calculate the belt required length for a U-shape unit:

[(L-160) x 2 + 678] x 0.97

L = total length of the transfer system,

including the return.

Cut the first bevel.

Trace the point zero.

Cut the right length.

Cut the second bevel with the same

bevelling device.

Do not forget to take the length of the bevel into account when calculating the

length of the belt. The superposition of this length must be subtracted from the

total length.

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Place the belt on the transfer system.

a) Pull

b)Push

Tension the belt until the bevels are juxtaposed.

Clean both sides of the bevels with alcohol.

Spray glue on both sides of the bevels (Glue expiration date: 1 month after opening. We advise you

to write the opening date on the glue bottle. Do not keep it later than one month after this date).

Place the thermic press correctly aligned with the belt.

Fasten the belt on the press.

Use 2 belt pieces to align perfectly the 2 bevels.

Belt position

Driving direction

Driving direction

Belt position

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Close the press and let warm up for 35 minutes at 120°C (250°F).

Let the thermic press cool down for 30 minutes. Remove excess glue with some abrasive paper.

5.4 Changing the belt – Timing belt

The new timing belt is delivered already welded.

Unscrew the caps on each side of the transfer system and slide the new belt in place of the worn

one. (Respect the passage way between the pulleys and belt guide).

Covers to be removed

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Stretch the belt using the tensioning screw and put the covers back into place.

6 RESPONSABILITY elcom cannot be held responsible for any damages or harms due to non-authorized modification of

any parts, especially the safety parts.

Only original components can be used for maintenance or fixing.

elcom cannot be held responsible for any malfunction if some spare parts have been used without

the validation of elcom.

elcom reserves the right to make improvements and technical modifications without any further

notice.

7 CUSTOMER SERVICE Do not hesitate to contact us for any question or advice. We will be glad to assist you.

Tel: + 33 (0)4 74 43 99 61

E-mail: [email protected]

Adress : 1 rue Isaac Asimov ZAC de la Maladière 38300 Bourgoin-Jallieu

France

Belt passage way Access to the tensioning screw

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Prior to any contact, please note down the serial number of the transfer system. This number can be

found on the transfer system sticker.

8 APPENDIX

8.1 Maintenance schedule

Maintenance of the modular transfer system TLM 1000

Frequency Action Component Chapter

200 hours To dust Transfer parts 4.5

500 hours To check Belt - Belt guide – Workpiece carrier 4.1

1000 hours To

lubricate Positioning units (shaft and cylinder) 4.7

1000 hours To

lubricate Heavy positioning units (shaft, drawer and cylinder) 4.8

3200 hours To

lubricate Conical torque 4.5

5000 hours To clean Stoppers 4.6

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8.2 ISO 9001 certification

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8.3 Spare parts list

11001001 Belt guide

11001201 Belt 12.5 x 1

11002001 Piston

11002006 Plate

11002008 Body

11002009 Guide

11002010 Tray

11002011 Sensor bracket L

11002012 Sensor bracket R

11002201 Spring

11002202 Joint

11003003 Pin

11003005 Bush diam. 6

11003201 Spring

11003202 Cover dia 6

11004001 Cap

11004002 Cam SD 100

11004003 Cam SG 100

11004004 Support

11004005 Support

11004006 Plate

11004007 Cam support

11004008 Rail

11004009 Rail

11004010 Selector

11004011 Selector L

11004012 Cap

11004013 Cap

11004014 Selector G

11005001 Driving unit block 100

11005002 Pulley dia 26

11005003 Washer

11005004 Spacer

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11005005 Driving pulley

11005008 Shaft

11005009 Cap

11005010 Ring

11005201 Bearing dia 8

11005202 Bearing dia 35

11005203A Motor 10m

11005203B Motor 15m

11005203C Motor 20m

11005205 Driving shaft

11006001 Idling unit block 100

11006005 Cap

11007001 Plate

11007003 Nozzle

11007005 Guide

11007006 Selector D

11007007 Selector G

11007008 Rail

11007009 RAIL

11007201 Cylinder

11007201F Cylinder 16-5

11008001 Plate

11008002 Body

11008003 Selector

11008201 Spring

11009001 Plate

11009001F Plate FESTO

11009002 Body

11009003 Positioning unit plate

11009005 Finger

11009005F Finger FESTO

11009006 Shaft

11009007 Locating pin

11009008 Centering pin

11009010 Hook L

11009011 Hook R

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11009012 Anti-bouncing back L

11009013 Anti-bouncing back R

11009205 Bush

11010001 Plate


11010003 Stand

11011001 Lever

11011002 Nozzle

11011003 Shaft

11011004 Cylinder plate

11011005 Plate

11011006 Plate

11011008 Block

11011009 Shaft

11011010 Tray L

11011011 Tray R

11011201 Ring

11011202 Cylinder

11011202F Cylinder 25-25

11011203 Shoulder screw

11012001 Plate

11012003 Shaft

11012005 2 shaft 14 for lift positioning unit

11012005A Machining tapping

11012006 Guide

11012007 Centering pin

11012008 Locating pin

11012011 Cylinder plate

11012012 Position unit plate

11012201 Cylinder 32 - XXX

11012201F Cylinder 32 - XXX

11012202 Ball bearing 14

11014004 Rail

11014005 Rail

11014101 Festo cylinder fastening plate

11014101A Festo cylinder fastening plate

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11014102 Spacer

11014201 Cylinder 12

11015001 Spacer

11016001 Stand support

11017001 Sensor bracket

11018002 Squarre

11018003 Cap L

11018004 Cap R

11019001 Positioning unit plate modification

11019001F FESTO Positioning unit plate modification

11019001U Positioning unit plate modification

11019001UF Positioning unit plate modification

11019002 Plate

11019003 Spacer


11020002F FESTO Positioning unit plate modification

11020002UF Positioning unit plate modification

11022001 Piston

11022003 Guide

11022201 Seal 2.5 x 1.5

11023003 Tray

11034001 External guide

11034002 Central guide

11034003 Main plate

11034004 Idling unit block

11034006 Gearing with shaft 11034005

11034007 Lower housing

11034008 Upper housing

11034009 Cap

11034010 Idling cap

11034011 Conical torque

11034012 Shaft

11034013 Spacer

11034014 Shaft

11034015 Clavette

11034016 Gear+shafts+spacer

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11034201 Belt

11050001 Driving block 1000 notched

11050002 Idling pulley

11050003 Anti-winding pulley

11050004 Spacer

11050005 Poulie motrice

11050006 Wedge-1 mm thickness

11050007 Retaining bar

11050008 Idling pulley axis

11050009 Poulie dentée

11050010 Driving pulley flange

11050011 Motor-off flange

11050012 Upper cover

11050013 Left driving flange

11050014 Right driving flange

11050015 Wedge-2 mm thickness

11050016 Idling pulley timing belt

11050020 Belt guide 1000 notched

11050021 Profile 40x20 1000 notched

11050201 Bande antistatique

11050201A Belt joining part

11050203A Motor 10m/mi

11051001 Idling unit block 100 timing belt

11051002 Idling cap timing belt

11051003 Sym idling cap timing belt

11052001 Joining part cap 100

11052002 Sym joining part cap 100

11052003 Joining part square

11053001 Driving flange left cam support

11053002 Driving flange right cam support

11053003 Idling flange left cam support

11053004 Idling flange right cam support

11053005 Cam SG 100 notched

11053006 Cam SD 100 notched

11053007 Training support timing belt

11054003 Main plate timing belt

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11054004 Spacer plate

11054005 Conical torque flange

11054006 Low housing

11054007 Obturateur

11054008 Upper housing

11054009 External square

11054010 Central square

11054011 Split washer

11061003 Detection bar

11062001 Plastic base unidirectional 100*100

11062001T Plastic base U 100x 100 with shock absorber

11062002 Plate

11063001 Plastic base 100*100 multidirectional

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