vision line operation - kval inc

Innovation, Quality & Honesty

Operator’s Manual

Published: Nov 22 2017

Vision SystemVision-FS Infeeder/Outfeeder, Face-SS, and Edge-SS

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Operator’s Manual

Proprietary Notice

This Manual is confidential and contains proprietary information and intellectual property of KVAL Inc., and is to be used solely by Customer as an operating manual for KVAL Inc. machines. Neither this Manual nor any of the information contained herein may be reproduced or disclosed under any circumstances without the express written permission of KVAL Inc. For authorization to copy this information, please call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and Canada, call (707) 762-7367.

Manual Part Number: DOC-179_1-OpLine

Vision-FS, Face-SS, and Edge-SS are trademarks of Kval Incorporated.

Copyright 2017 Kval Incorporated. All rights reserved.

Beckhoff® , TwinCAT 2,TwinCat 3, and EtherCat® are registered trademarks and are licensed by Beckhoff Automation GmbH

Windows 7® is a registered trademark of Microsoft Corporation.

All other products are trademarks or registered trademarks of their respective holders, all rights reserved. Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated.

Contacting KVAL

Customer Service: For further information about this manual or other Kval Incorpo-rated products, contact the Customer Support Department

• Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

• Phone and Fax:

In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• Business hours:

Technical Support:

6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday

6:30 AM to 1:30 PM Pacific Standard Time, Friday

Parts & Service Sales:

6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday


(Other sales related inquiries: http://www.kvalinc.com)

• Email: [email protected]

KVAL Vision System Operator’s Manual


Your Feedback is Welcome: To help us design products that make your job easier and your business more successful, we'd like to gain your perspective about your user experience with our product - that is, the manual, the machinery, the software, etc. What was easy or difficult to use or to learn? If you could change something about the design, what would it be? Please email your comments and suggestions for improve-ment to [email protected]. (NOTE: This is not a customer support email link. For that, please refer to the Customer Service contact information above.) Thank you!

http://www.kvalinc.com


NOTICE OF OWNERSHIP OF KVALCAM SOFTWARE AND LIMITED LICENSE TO USE

READ THIS NOTICE CAREFULLY BEFORE USING THE KVALCAM SOFTWARE WHICH OPERATES KVAL MACHINERY. THIS DOCUMENT CONSTITUTES NOTICE TO YOU THAT YOU HAVE A LIMITED LICENSE TO USE THE KVALCAM SOFTWARE ON THE TERMS AND CONDITIONS APPEARING BELOW.

BY USING THE KVALCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE KVALCAM SOFTWARE.

KVAL, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You are the purchaser of KVAL Machinery operated by the KVALCAM Software are the “Licensee”.

The computer program(s) and related documentation and materials (herein collectively referred to as “the KvalCAM Software” and further defined herein) which are used in the operation of the KVAL Machinery are licensed, not sold, to you for use only upon the limited terms of this license, and Licensor reserves any rights not expressly granted to you. Licensor retains all ownership of the KvalCAM Software.

Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with KVAL, Inc. The KVALCAM Software is protected by copyright laws and treaties. Title and related rights in the content generated through the KVALCAM Software are also the property of the Licensor and are protected by applicable law.

1. Definitions.

a.“KVALCAM Software” means the KVALCAM computer application installed in the KVAL Machinery and written documentation and materials provided to you, as well as any revisions or updates of such computer application and documentation.

b.“Install” means storing of the KVALCAM Software in the computer component of the KVAL Machinery.

c.“Use” means executing the KVALCAM Software for purpose of operating the KVAL Machinery and use of the documentation for properly operating KVALCAM Software.

2. Grant of License.

a.Licensor hereby grants Licensee a non-exclusive, non-transferable license to Use the KVAL-CAM Software upon payment of all amounts due for the purchase of the related KVAL Machin-ery.

b.Licensee will make no copies of the KVALCAM Software or alter the KVALCAM Software in any way. Title to the KVALCAM Software will remain vested in Licensor, and nothing in this License will give or convey any right, title or interest therein to Licensee except as a licensee.

c.Licensee agrees that it will use the KVALCAM Software or related documentation directly or indirectly for the benefit of Licensee, and only pursuant to the scope of the grant of the License set forth herein.

d.Licensee will not decode, alter, decompile, reverse engineer, perform reverse analysis on or disassemble the KVALCAM Software.

e.This License will terminate automatically if Licensee fails to comply with the limitations described above.


Table of Contents

Chapter 1 Introduction to the Vision Door SystemOverview of the Vision System ................................................ 1-2

About this Manual .................................................................................1-3

Safety First!.............................................................................. 1-4Safety Sheet Sign-Off Sheet.................................................................1-4Safety Terminology of Labels................................................................1-4Safety Guidelines..................................................................................1-4

Lockout-Tagout Guidelines ...................................................... 1-8Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-8

Lockout Tagout Procedure....................................................... 1-9Pre-Steps Before Lockout Tagout .........................................................1-9Lockout Tagout Power ..........................................................................1-9Lockout Tagout Air Supply ..................................................................1-10Start Maintenance...............................................................................1-10Post Maintenance Steps .....................................................................1-10

Zero-Energy to Start-Up........................................................... 1-11

Getting Help from KVAL........................................................... 1-13On-Line Help.......................................................................................1-13Product Return Procedure ..................................................................1-13

How to Download the Service Application ............................... 1-15Download Application .........................................................................1-15

Safety Sign-Off Sheet .............................................................. 1-18A Note to the Operator........................................................................1-18

Chapter 2 Operation of the Vision LineAbout the Machine Line ........................................................... 2-2

About the Vision-FS..............................................................................2-3About the Face-SS ...............................................................................2-3About the Edge-SS ...............................................................................2-3

Initial Powering Operations for the Vision Line ........................ 2-4How to Power Up the Vision Line .........................................................2-4Description of the Six Light Panel ........................................................2-5Home the Machine Line........................................................................2-6How to Power Down the Machine.........................................................2-6About Emergency Shutdown and Recovery .........................................2-7

KVAL Vision Series Operator’s Manual

To Resume Normal Operation after an E-Stop .....................................2-7Other Safety Controls ...........................................................................2-7

Machine Line Start Summary................................................... 2-8

About the Vision-FS Process ................................................... 2-10

About the Face-SS Process .................................................... 2-11

About the Edge-SS Process .................................................... 2-12

Summary of the KvalCAM Interface ........................................ 2-13Libraries and Machine Line Screens ..................................................2-13Machine Control and Calibration Screens ..........................................2-13Status and Log Screens......................................................................2-14

About Machine Status Feedback ............................................. 2-15

About the Libraries Screen ...................................................... 2-16About The Door Job Library And Template Library Lists ....................2-16About the Door Job/Template Buttons ................................................2-17Job Creation Screen ...........................................................................2-17

About the Machine Line Screen............................................... 2-24Machine Line Screen ..........................................................................2-24

About the Vision-FS Interface Screens.................................... 2-28About the Vision-FS Main Control Screen ..........................................2-28About the Vision-FS Servo Control Tab ..............................................2-32

About the Face-SS interface Screens ..................................... 2-34About the Face-SS Main Screen ........................................................2-34About the Face-SS Manual Servo Control Tab...................................2-36

About the Edge-SS Interface Screens..................................... 2-38About the Edge-SS Main Screen........................................................2-38About Speed Control ..........................................................................2-39About the Edge SS Manual Servo Control Tab...................................2-41About the Tool Path Preview Test Tab ................................................2-43

About the Tool Config Tabs (Face-SS and Edge-SS) .............. 2-44General Operating Controls................................................................2-44Unlock the Tool Slot Configuration......................................................2-45About the Tool Pop-up Screens ..........................................................2-45About Tool Locations (Edge-SS and Face-SS)...................................2-46About Using Tool Configuration ..........................................................2-48Measuring Tool Length .......................................................................2-48About Entering Data into the Pop-up Menu ........................................2-48

About the Status and Log Screens .......................................... 2-50 About the Status Screen ....................................................................2-50About the Log Screen .........................................................................2-51


Definitions ................................................................................ 2-52

Chapter 3 Calibration of the Vision LineAbout Calibration ..................................................................... 3-2

About the Calibration Menus and the Calibration Reference Cut .........3-2Before you Calibrate .............................................................................3-2

About the Calibration Tabs....................................................... 3-3Access to the Calibration Adjustments .................................................3-3Unlock the Calibration (Option).............................................................3-4Enter a Positive or Negative Number? .................................................3-4

How to Enter Calibration Data ................................................. 3-5About Restore Points............................................................................3-5

About the Vision-FS Calibration Screen .................................. 3-6Vision-SS Calibration Screen ...............................................................3-6Summary of Available Calibrations .......................................................3-6Adjust Lift Head Location......................................................................3-7Adjust Feeder And Stacker Tables Parameters ....................................3-7

About the Face-SS Calibration Screen.................................... 3-8Face-SS Calibration Screen .................................................................3-8Summary of Available Calibrations .......................................................3-8Face-SS: Full Calibration......................................................................3-9Using the Door Stops Calibration..........................................................3-9Using the Face Carriage Axes Calibration..........................................3-10Using the Face Tools Calibration ........................................................3-11About Edge Carriage Calibration (Face-SS).......................................3-15About Lock Tools Calibration (Face-SS).............................................3-16

About the Edge-SS Calibration Screen ................................... 3-18Edge-SS Calibration Screen...............................................................3-18(First Calibration) Calibrating the Feelers ...........................................3-19Identify the Hinge and Lock Head Designations.................................3-20Using the Carriage Axes Calibrations.................................................3-20Samples of Carriage Axes Calibrations ..............................................3-21About Tools Calibration.......................................................................3-21Tool Slot Identification.........................................................................3-22Typical Edge-SS Adjustments ............................................................3-23

Chapter 4 Tour of the Vision-FSAbout the Vision-FS ................................................................. 4-2


Identification of Key Parts of the Vision-FS ............................. 4-3Vision-FS Top View...............................................................................4-3

About the Lift Assembly ........................................................... 4-4Boom Assembly....................................................................................4-4Carriage Assembly ...............................................................................4-5

About the Infeed and Outfeed Tables ...................................... 4-6Table Components................................................................................4-7

About Controls on Vision-FS ................................................... 4-8Vision-FS Main Control.........................................................................4-8Staging Area Controls...........................................................................4-9

About the Safety Curtain.......................................................... 4-10If the Field is Broken ...........................................................................4-10To Resume Normal Operation after an Field is Broken ......................4-10Location of Fields on the Vision-FS ....................................................4-11

About the Electrical Panels...................................................... 4-12

Chapter 5 Tour of the Face-SSAbout the Face-SS .................................................................. 5-2

Identification of Key Parts of the Face-SS ............................... 5-3Top View ...............................................................................................5-3

Front View of the Face-SS....................................................... 5-4Foot Pedal Control................................................................................5-5Operator’s Station .................................................................................5-5Indicator Light .......................................................................................5-5Face-SS Fence, Clamps, and Stops.....................................................5-6Laser Safety Scanners .........................................................................5-6

Back View of the Face-SS ....................................................... 5-7About the Cutter Head ..........................................................................5-7Chisels and Face Plate Router (Option) ...............................................5-8

Servo Motor and Valve Bank Locations ................................... 5-10Servo Motor Locations........................................................................5-10Valve Bank Locations .........................................................................5-10Typical Valve Bank Controls ...............................................................5-11About Sensors ....................................................................................5-12


About the Nodes ...................................................................... 5-15Typical Block Diagram of Network Connections .................................5-15Illustration of Node Connections.........................................................5-16


Chapter 6 Operation of the Edge-SS LineAbout the Edge-SS .................................................................. 6-2

Identification of Key Parts of the Edge-SS............................... 6-3Top View ...............................................................................................6-3

Front View of the Edge-SS ...................................................... 6-4Edge-SS Controls .................................................................................6-5Main Machine Controls .........................................................................6-5Foot Pedal Control................................................................................6-5Operator’s Station (Vision Line) ............................................................6-6Indicator Light .......................................................................................6-6Operator’s Station on the Edge-SS ......................................................6-6Operator’s Screen Layout.....................................................................6-7Edge-SS Fence, Clamps, Stops, and Feeler ........................................6-8About the Door Length Feeler ..............................................................6-8Laser Safety Scanners .........................................................................6-9

Assemblies on the Main Cutter Head ...................................... 6-10

Servo Motor and Valve Bank Locations ................................... 6-11Servo Motor Locations........................................................................6-11Valve Bank Locations .........................................................................6-12Typical Valve Bank Controls ...............................................................6-12


About the Nodes ...................................................................... 6-15Typical Block Diagram of Network Connections .................................6-15Illustration of Node Connections ........................................................6-16


CHAPTER 1 Introduction to the Vision Door System

Chapter 1 at a Glance

The following information is available in this chapter:

TABLE 1-1. Summary of Chapter

Section Name Summary Page

Overview of the Vision Door System

This section provides an overview of the machine. It includes a general description and a table of available options

page 1-2

Safety First! IMPORTANT safety information is described in this section

page 1-4

Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-8

Zero-Energy to Start-Up Procedure to power up your machine for the first time.

page 1-11

Getting Help from KVAL This section describes the method to contact the KVAL service center for help. The section includes how to get information from the specification plate tor provide to KVAL, service center hours, and return procedures

page 1-13

Safety Sign-Off Sheet A record to track operators that are trained on the machine.

page 1-18

1-1

KVAL Operation Manual

Overview of the Vision System


The Vision Series Line is a system of computer controlled machines designed to feed and process archi-tectural doors for almost any door hardware including locks, hinges, door light cutouts, as well as strike plates, flush bolts and concealed door closers.

Grooving for veneer inlay or mould-ing is also included.

The KvalCam software package pro-vides the capability to enter all of the machining requirements for each door at the first machining station, the Face-SS.

Alternatively the file for each door can be associated with a barcode label and scanned one time for auto-matic retrieval at each machine.

As the door is transferred to each succeeding station that machine will automatically select the correct instructions to process the door until all of the required machining for that door at each machine is completed. The software tracks doors in process, so specifications for every door can be different at each station.

Vision-FSS

Face-SS Edge-SS

Together, the Vision-FS, Face-SS and Edge-SS form a U shaped cell designed for single piece flow with a high degree of flexibility. Door size differences require no adjustment, and integrated Kval computer software makes it practical for every door to be different. It allows one operator to effi-ciently rout, drill and corner square both door faces and all four door edges with nearly instant changeover (door face squaring is limited to door lights).

The Stations have the following functions:

• Vision-FS: Transfer doors to Face-SS and accept doors from the Edge-SS. Also stack, rotate and invert doors.

• Face-SS: routs door faces for locks and viewers

• Edge-SS: routs door lock edge and ends for hardware


1-2


About this Manual

This manual is part of a package delivered with the machine line.

Integration Package includes the following:

Operation Manual includes the following:

Service Manual includes the following

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

2Operation Inter-face

Descriptions of how to power machine line, and operator inter-face user screens.

3Calibration Descriptions of Calibration Rou-

tines and how to use the interfaces

4Tour of Vision-FS Identification and descriptions of

the Vision-FS machine assemblies.

5Tour of Face-SS Identification and descriptions of

the Face -SS machine assemblies.

6Tour of Edge SS Identification and descriptions of

the Edge-SS machine assemblies.

Chapter Title Description

1 Introduction Safety Information.

2System IT Admin-istration

Descriptions of the PLC system, and computer system.

3Maintenance Maintenance steps for the

machine line

4Trouble Shooting Troubleshooting tips and theory of

operation.

1-3


Safety First!

Safety First!

This machine is a powerful electro-mechanical motion control system. You should test your motion system for safety under all potential conditions. Failure to do so can result in dam-age to equipment and/or serious injury to personnel.

Safety Sheet Sign-Off Sheet

At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-teria to understand before operating the machine. It is highly recommended that personnel operat-ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be signed and kept for records. See “Safety Sign-Off Sheet” on page 1-18.

Safety Terminology of Labels

In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-vide safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible.

There are three types of warning labels or decals:

• DANGER means if the danger is not avoided, it will cause death or serious injury.

• WARNING means if the warning is not heeded, it can cause death or serious injury.

• CAUTION means if the precaution is not taken, it may cause minor or moderate injury.

Safety Guidelines

In addition to the caution and warning labels affixed to this machine, follow the guidelines below to help ensure the safety of equipment and personnel.

Ensure that all employees who operate this machine are aware of and adhere to all safety precautions posted on the machine and are trained to operate this machine in a safe manner.

Training


1-4

Safety First!

Never operate the machine without proper eye and ear protection.

Protective Gear

• Never reach hands beyond safety cage. Servo motors can unexpectedly move quickly.

• Never clear screws or hinges out of the machine while it is running.

• Never reach into the router area to retrieve a hinge. The router may still be running down after shut down.

• Never perform any maintenance unless machine is at zero state.

• Never clean the machine while it is running.

• Never walk away from the machine while it is running.

When the Machine is ON

The compressed air system connected to this machine should have a three-way air valve for shut-off and pressure relief.

All cylinders on machine are under high pressure and can be very dangerous when activated. Before performing any mainte-nance or repairs on this machine turn off the main air disconnect. Lockout and tagout this connection.

See “Lockout Tagout Procedure” on page 1-9.

Compressed Air

1-5


Safety First!

Electrical circuitry on this machine is protected by an approved lockable disconnect circuit. In addition to this equip-ment, you must install an approved disconnect for the electrical power supplying this machine.

When opening the cabinet you must first turn off the disconnect switch. When the cabinet door is open there is still power on the top side of the disconnect switch. Some machines are powered by more than one supply located at different locations. Before performing any repairs or mainte-nance, lockout and tagout must be installed at all locations

All maintenance and repairs to electrical circuitry should only be per-formed by a qualified electrician.

Still has powerin OFF position

Electrical

Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, tag out, or lock out the electrical and air pressure systems. This should be done in accordance with applicable state and/or federal code requirements.

Before Conducting Maintenance

Laser Warnings

On some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions.


1-6

Safety First!

KVAL advises that you request an on-site state safety review of your installation of this machine. This is to ensure conformance to any additional specific safety and health regula-tions which apply in your geographic area.

Compliance with Codes and Regulations

Other Hazard Control Action

Report a Hazard Before You Report an Accident

If you believe any part or operation of this machine is in violation of any health or safety regulation, STOP pro-duction. It is your responsibility to immediately protect your employees against any such hazard.

Additional detailed safety guidelines are included in the operating instructions of this manual. KVAL will be pleased to review with you any questions you may have regarding the safe operation of this machine

Follow Your Company’s Safety Procedures

In addition to these safety guidelines. Your company should have on-site and machine specific safety proce-dures to follow.

1-7


Lockout-Tagout Guidelines

Lockout-Tagout Guidelines

• Place a tag on all padlocks. On the tag, each operator must put their own name and date. (These locks are only to be removed by the person who signs the tag)

• If more than one person is working on the machine, each additional person places a lock and tag on each disconnect.

• Only each operator may remove their own lock and tag.

Important: When many people are all working on the same machine you will need a multiple lockout device, such as the one shown here.

Follow the P-R-O-P-E-R lockout rule of thumb.

P...... Process shutdown

R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)

O...... OFF! Shut off all power sources and isolating devices

P...... Place lock and tag

E...... ENERGY: Release stored energy to a zero-energy state

R ...... Recheck controls and test to ensure they are in the “OFF” state


1-8

Lockout Tagout Procedure


This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991.

Use the following lockout procedure to secure this machine while it is powered down. During a lockout, you disconnect all power and shut off the air supply. Be sure to use the tagout guidelines noted below.

Pre-Steps Before Lockout Tagout

1. Evaluate the equipment to fully understand all energy sources (multiple electrical supplies, air supply and pressure, spring tension, weight shifts, etc.).

2. Inform all affected personnel of the eminent shutdown, and the duration of the shutdown.

3. Obtain locks, keys, and tags from your employer’s lockout center.

Lockout Tagout Power

4. Turn off machine. See Chapter 2 for power down and power up procedures.

5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF position. Then push the red tab to pop it out. Place a padlock through the hole. Place your tag on the padlock, as per the tagout guidelines below. (see illustration below).

Power

Note: When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided.

Insert Lock into hole.Turn Switch to the OFF position

Lock and Tag out

1-9



Lockout Tagout Air Supply

6. Turn all air valves to the OFF position and place a pad-lock through the hole (see illustration below).NOTE: Place your tag on the padlock, as per the tagout guidelines..

Start Maintenance

7. Once the locks and tags are in place and all personnel are clear, attempt to operate the machine to ensure equipment will not operate.

8. Maintenance or repairs may started.

Post Maintenance Steps

9. After maintenance is completed, the person performing the work must ensure all tools, spare parts, test equipment, etc., are completely removed and that all guards and safety devices are installed.

10. Before removing the locks and tags, the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re-energized.

11. The lock and tag can now be removed (only by the person(s) who placed them), and the machine can be re-energized.

12. The tags must be destroyed and the locks and keys returned to the lockout center.


1-10

Zero-Energy to Start-Up


Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of safety.

Start-up Guidelines

The following guidelines below should be followed to start the equipment.

Inspect

The equipment must be inspected for proper adjustment before starting equipment.

Clean Up

All materials and debris must be cleaned up. Any combustible materials or old parts used during repairs must be cleaned up and/or properly disposed of.

Replace Guards

Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, contact the KVAL Service team. See “Getting Help from KVAL” on page 1-13.

Check Controls

Confirm that all switches are in the “OFF” position. Please be advised that some com-ponents of the machine may start automatically when energy is restored.

Remove Locks

Each operator must remove his or her own lock and tag. This will ensure that all oper-ators are in a safe place when the equipment is started.

Perform Visual Checks

If the equipment is too large to see all around it, station personnel around the area and sound the personnel alarm before starting the equipment. If your operation is more complex, your company’s comprehensive safety procedure may involve additional steps. You will need to ask your supervisor about these procedures. The company’s lockout procedure should be posted at each machine. On larger or long-term mainte-nance or installation projects, the company’s procedures must be explained to all new operators and a copy of the company’s procedures should be posted on-site for the duration of the work.

The Company’s procedures should also include proVision-FSs for safely handling shift changes and changes in operators or new operators.Comprehensive lockout/tagout may use a gang box or other system to ensure that locks are secure and not removed without authorization.

1-11



Remember, lockout/tagout procedures work because you are the only one with the key to your lock. Proper lockout/tagout can save lives, limbs, and money. Help make your work environment safe for you and your fellow workers. Be sure to follow the P-R-O-P-E-R lockout/tagout procedures, and that those around you do also.

Close the Cage Gate

Verify all cage gates are securely closed. Ensure all safety protocols are in effect.


1-12

Getting Help from KVAL


Before you seek help, first try the troubleshooting procedures. Follow the procedures below.

If you are unable to resolve the problem:

1. Locate the machine’s Specification Plate and record the serial number, 3 phase volts, electrical print number, and air print number.

Serial Number

3 phase volts

Electrical Print

Air Print

2. Contact our customer support team:

• In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

• Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• Email address is [email protected]

• Hours:6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday


On-Line Help

On machines with a Beckhoff® PLC and an internet connection, our service team are able to con-nect, run, and troubleshoot your machine. Ask about this procedure when calling are service team

Product Return Procedure

If you’ve contacted KVAL for help and it is determined that a return is necessary, use the proce-dure below to return the machine or part.

Note: Non-Warranty returns are subject to a 15% restocking charge.

1. Obtain the packing slip and/or invoice numbers of the defective unit, and secure a purchase order number to cover repair costs in the event the unit is determined to be out of warranty.

2. Reason for return: Before you return the unit, have someone from your organization with a technical understanding of the machine and its application include answers to the following questions:

1-13



• What is the extent of the failure/reason for return? What are the relevant error mes-sages or error codes?

• How long did it operate?

• Did any other items fail at the same time?

• What was happening when the unit failed (e.g., installing the unit, cycling power, starting other equipment, etc.)?

• How was the product configured (in detail)?

• Which, if any, cables were modified and how?

• With what equipment is the unit interfaced?

• What was the application?

• What was the system environment (temperature, spacing, contaminants, etc.)?

3. Call KVAL customer support for a Return Material Authorization (RMA). When you call:

• Have the packing slip or invoice numbers available.

• Have the documented reason for return available.

4. Send the merchandise back to KVAL.

• Make sure the item(s) you are returning are securely packaged and well protected from shipping damage

• Include the packing slip or invoice numbers.

• Include the documented reason for return.

• Include the RMA number with the parts package.


1-14

How to Download the Service Application


On machines with Windows (8.1 / 8 / 7 / Vista / XP) and an internet connection, our service team are able to connect, run, and troubleshoot your machine by way of the operator station.

Download Application

.1. To download the application, go

the KVAL website (http://

www.kvalinc.com)

2. At the KVAL website, select the Support tab. Follow the instruc-tions on the Support web page.

3. Click the Download button to download the application that allows the KVAL technician to have access to the operator sta-tion.

4. After the download is com-pleted, double-click the program icon.

Note: Web browsers have different methods of downloading programs. Below are samples of i.e Explorer and Google web browsers.

Sample of Google Browser: Located at the bot-tom left of the screen.

Sample of i.e Explorer: Located at the bottom of the screen. select the arrow and choose Save and Run

1-15



5. A pop-up window is displayed. Accept the request to run the program.

Note: Security settings may differ from plant to plant. If issues occur, con-tact your IT department.

6. The interface of the KVAL Support App will be dis-played. Enter your name in the Your Name field. The fields are described below:

Session code: An internal number to track this machine. It is auto filled.

Allow Remote Control: Program is ready to allow technicians to access machine computer

Your Name Field: Enter your name. The KVAL techni-cian will use this field to identify this machine.

Description: Enter machine Serial number and issue.

Indicator: Green indicates there is a good connection to the service center. If red, there could be an issue with a LAN connection. Check the connections in the plant.

7. After the KVAL Support App is loaded and completed, call the KVAL service center(1-800-553-5825) and have the technician con-nect to the machine computer.

8. Click the Allow button to give the KVAL service technician permis-sion to access the operator station.

We are now ready to troubleshoot.


1-16


Page Intentionally Left Blank

1-17


Safety Sign-Off Sheet


Machine Model Number:_____________________________

A Note to the Operator

This machine can help you be highly productive only if you understand how to use it properly and follow the safe operating practices described in this document and the machine’s manual. If you do not understand the machine’s proper operation or ignore the safe operating practices, this machine can hurt or kill you. It’s in your best interest to safely and properly operate this machine.

Personnel Safety Concerns:

• I have been properly trained in the operation of this machine.

• I will always wear ear protection when operating this machine.

• I will always wear eye protection when operating this machine.

• I will never wear loose clothing or gloves when operating this machine.

• I will watch out for other people. Make sure everyone is clear of this machinebefore operation.

• I will always follow my company’s safety procedures. I have read and understandthese guidelines.

Machine Safety Concerns:

• I have been given a tour of the machine and understand all the safety labels, E-Stops and the actions to take in case of an emergency.

• I will make sure all guards are in place before operation

• I will turn off the compressed air, before loading hardware (staples, screws, etc)

• I will turn off the electrical power, for setup

• If the machine should operate in an unexpected manner stop production I willimmediately and notify a manager, a supervisor, or a qualified service technician.

I have read and understand this document and agree to operate this machine in a safe man-ner as described above.

Employee

Name (print):___________________ Signature: __________________ Date:____/____/____

Supervisor/Safety Officer/Trainer

Name (print):__________________Signature: __________________ Date:____/____/___

Note: It is recommended you make a copy of this sheet for new operators. If a copy is needed, you may download a PDF at the KVAL website (http://www.kvalinc.com). You may also contact our Service Department at (800) 553-5825 or email at [email protected].


1-18


1-19


CHAPTER 2 Operation of the Vision Line

This chapter describes components, assemblies, and the user interface of the KVAL Vision System. The content is geared to help operators understand the basic operation of the machine. Included are instructions to calibrate the machine and process a door.



About the Machine Line A Summary of the entire machine line. page 2-2

Initial Power Operations Description of powering up the line from the off state. Includes: Power down description, Six Light Panel, and homing the machine line.

page 2-4

Machine Start Summary A quick summary of running a door through the machine.

page 2-8

About Machine Process Describes the process of the Vision-FS, Face-SS and Edge-SS

page 2-10

Summary of the KvalCam Interface

A one page description of the KvalCam interface.

page 2-13

About the Libraries Screen

Description of Libraries Screen. Includes: job creation, job editing, loading templates, and verifying job creation.

page 2-16

About the Machine Line Screen

Description of the Machine Line Screen.: Includes Line Control Buttons, Queued Jobs and Machine Activity.

page 2-24

About the Vision-FS Screens

Descriptions of the Screens that interface with the Feeder and Stacker.

page 2-28

About the Face-SS Screen Descriptions of the Screens that interface with the Face-SS

page 2-34

About the Edge-SS Screen Descriptions of the Screens that interface with the Vision-FS

page 2-38

2-1


About the Machine Line


The Vision Line is genius due to it’s simplicity. One operator can process many doors during the shift. The added KvalCam operator interface adds the power of creating templates remotely and have automatic G-Code operating in the background. Office to shop floor. If needed, templates can be adjusted or created at the machine line. The machines in the line are connected by Kval-Cam. One change affects all machine operations.

The “U” layout of the line saves valuable square footage in the plant.

Vision-FS

FIGURE 2-1. Vision System


2-2


About the Vision-FS

For detailed descriptions of Vision-FS, see Chapter 3 of this manual.

The Vision-FS feeds doors from a stack and also re-stacks after processing. The vacuum lifting head also rotates 180° for proper handing. This capability eliminates the requirement to manually orient doors correctly in the stack before processing. Stacks can be front loaded against the con-veyor table or rolled in end-wise on floor conveyor sections

Note: A servo drive is located on the Stacker Table for consistent positioning without door end reference stops. This ensures accurately aligned door stacks in both width and length.

About the Face-SS

For detailed descriptions of Face-SS, see Chapter 4 of this manual.

The KVAL FACE-SS is a computer-controlled router and drill for cylinder or mortise lock func-tion holes, viewers or routed pockets in a door's face to fit hardware such as exit devices or card locks. Motors are mounted above and below the door in matched pairs, with the same diameter router bit or drill bit in each pair. Holes or slots can be processed simultaneously from top and bot-tom with the cutting tools almost touching in the middle of the door.

About the Edge-SS

For detailed descriptions of Edge-SS, see Chapter 5 of this manual.

The Edge-SS is a computer-controlled router designed to machine architectural doors for hinge pockets, T-strikes, concealed closures, flush bolts, leaf and European hinges, end pivots, as well as edge work for either cylindrical or deep pocket locks. Many customers also use the Edge for re-railing & re-stiling operations.

2-3


Initial Powering Operations for the Vision Line


This section describes how to power up and to power down the Vision Line.

Powering up the system includes:

• Applying power to the entire system

• Starting the Control CircuitPowering down the system includes:

• Shutting down the control power

• Removing power from the entire system

How to Power Up the Vision Line

1. Ensure factory air is applied to each machine and main air supply is turned on.

2. Check that all E-Stop buttons are out and safety gates are closed.

Note: A pop-up is displayed on the user screen if an E-Stop is pressed. The pop-upwill indicate which E-Stop has been activated

3. Make sure the electrical disconnect each electricalcabinet is turned to the ON position.

4. Switch the green CONTROL TRANSFORMER switches to the ONpositions. They should light up.

5. Push the green START MACHINE buttons to “boot up” themachines.

Note: Boot up may take 2 to 3 minutes.

6. All lights on the status light panels on the electricalbox should be illuminated. See “Description of theSix Light Panel” on page 2-5

Note: If a status light does not turn on during the power up process, see the trouble shooting chapter in the Service Manual.

.


2-4


Description of the Six Light Panel

The six lights on this panel in8

dictate the status of the power-up of the system. Each machine has this panel.

The Sequence the lights activate is as follows:

Sequence Order

Light Designation

Description

1 Control Power This light illuminates when the Control Transformer turned on and the power is working on secondary side-of transformer

2 Overload Relay Checks the Overload Relay in the E-Box. In some cases, this circuit is jumped. In these cases it should always light when the Control Power turns on.

3 E-Stop All gates are closed and the E-stops are not activated when this light is on.

4 Stop This light will be on if Machine Stop button is deactivated.

5 Start This light will be on once the Machine Start button is pressed and the ACR Relay is latched.

6 24VDC This light comes on once the ACR is latch and the 24VDC power Supply is working

Control Power

First

Overload Relay

Second

E-Stop

Third 24VDC –

Sixth

Stop –

Fourth

Start –

Fifth

2-5



Home the Machine Line

The Machine Line must go through a homing routine before any operations are performed. The homing routine sets a zero reference from which each machine measures its movement and cut-ting process.

If power is lost or any machine is reset, the homing routine must be performed again. Each machine has a Home button on it’s associated Main Control Screen or the entire machine line can be Homed using the Home Machine Line button located on the Machine Line Screen.

How to Power Down the Machine

1.

1

2

3

Push the Stop button for each machine, located on the Operator’s Station

2. Shut down the operating system, by selecting Shutdown from the Desktop.

Note: Make sure Windows is shutdown completely before turning off the machine. Hard drive or data may be damaged if not turned off in this order.

3. Switch the green CONTROL TRANSFORMER switches for each machine to the OFF position.

4. KVAL also recommends that you turn the disconnect switches on the electrical cabinets to OFF; this helps reduce possible damage resulting from power surges from electrical storms.


2-6


About Emergency Shutdown and Recovery

Important: Learn all safety precautionary controls on the machine.

Depending on the model of machine, there are emergency shutdown (E-Stop) switches located at key points around the machine.

The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.

When an E-Stop switch is activated, high voltage power is cut to the machine. The motors will stop, but power to the PLC and the Operator Station Screen will remain on.

To Resume Normal Operation after an E-Stop

If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved:

1. De-activate the E-Stop switch by pulling it out.

2. Push the START MACHINE button on the operator's station

3. Home the Machine.

Other Safety Controls

Other safety controls can include:

• Gate Latches: Sensors are located on the gates surrounding the machine. If a gate is opened the machine will shut down.

• Laser Safety Scanners: These are located on the front of the Edge-SS and Face-SS. These assemblies create an invisible safety field protecting the Operator from entering the cutting area of the machine.

• Safety Curtain: This is similar to the Laser Safety Scanners. This creates an invisi-ble curtain on all entrances to the Vision-SS.

See the Vision-SS, Face-SS, and Edge-SS Chapters for more information about restarting the machine after activation.

2-7


Machine Line Start Summary


This is a summary of the start sequence for the Vision Line. These instructions assume that a Door Job has been created to be used in the machining process. To learn more about Door Jobs and Templates, see “About the Libraries Screen” on page 2-16.

Ensure factory air and power is present at the machine. For more information: See “Initial Powering Operations for the Vision Line” on page 2-4

1. Ensure the machine main Air Supply Valve is on.

2. Turn on the Red Power Lever at each Electrical Panel.

3. Turn on each Green Control Transformer Lever on the Operators Station.

4. Press each Green Start Button on the Operators Station to boot-up into Desk-top environment.

After the computer is completed booting up, the KvalCAM User Interface will start automatically.

However, for instruction purposes, below are manual steps to start the programs

Double Click the KvalCAM.exe desktop icon.

KvalCAM will boot-up to the Machine Line Screen

Select the Home Machine Line Button. Every machine in the line will Home. On comple-tion, each machine status will display Idle in the Machine Feedback Status box.

Note: Each machine can also be homed indi-vidually from each machine’s Main Screen.


2-8


After the door has completed the Home sequence:

Select the Libraries Tab

Select a door job from the Door

Job Library list.

Select the Edit button

From the Door Job Creation Screen, make sure the door job is correct.

Note: (If needed create or add a feature to the door job. For example select the Add From Library button to add a pre-determined template.)

Add the Quantity of Doors in the Door Qty: box

Select the Add to Queue button.

Select a Door Job

Select (Libraries Tab)

Select (Edit)

Verify or Modify Job

Enter Qty. Select (Add to Queue)

If completed for the day, power down the machine. For more information: See “How to Power Down the Machine” on page 2-6

1. Press the Red Stop button, located on the Operators Station.

2. Shut down the operating system, by selecting Shutdown from the Desktop.

3. After computer has fully shutdown, turn off the Green Control

Transformer lever on the Operators Station.

4. Turn OFF the Red Power lever the Electrical Panels.

2-9


About the Vision-FS Process

About the Vision-FS Process

Ensure the Start-up process has been completed (See page 2-4), that the machine has been Homed, doors are loaded to be processed, and the area is clear and safe to start production.

Note: If cutting a beveled door, ensure the wide side is up.

3º 3ºUp

Door

1. Set the job parameters from the Vision-FS

Main Screen.See “About the Vision-FS Interface Screens” on page 2-28 , for instructions.

4. The Vacuum Carriage moves over the infeed door Stack and lifts door (Note: Door may be rotated 180 at this point.)

5. The table pops up and door is centered.

6. Door is placed on the conveyor table. When all conditions are met, the door is fed into the Face-SS.

7. The Door is processed by the Face-SS and.or the Edge-SS

8. After processing and all conditions are met, the Edge-SS feeds the door out to the Stacker portion.

9. The stacker conveyor drive will pop up to accept the door.

10. The Vacuum Carriage moves the door onto the selected Outfeed stack.

2. Ensure the correct quantity of doors is entered in the Quan-

tity Box.

3. Press the Start Feeder

Button.

1 2 3

1 2 3

Actions

Door is Stacked at Position 1,2,or3.

Actions

Door is fed into the Face-SS.

Actions

After Processing is completed, Door is fed into the Stacker por-tion of the Vision-FS

Actions

Enter Qty of Doors

Press Start Feeder Button.

Door is picked from Position 1,2,or 3


2-10

About the Face-SS Process

About the Face-SS Process


1. If necessary, set the job parameters from the Face-SS

Main Screen. See “About the Face-SS interface Screens” on page 2-34 .

7. If the machine is set on Auto Clamp, the clamps will automatically unclamp. If not set to Auto Clamp, press the Door Clamp Foot Pedal to unclamp

8. Next, move the door to the Edge-SS

2. At the machine press the Call Door Button. The door will feed into the machine.

3. Press the Door Stop Foot

Pedal to Pop-Up the stops.

4. Manually position the door against the stop and fence

5. Press the Door Clamp Foot

Pedal to secure the door

6. Press the Start Sequence

Button to process Door

Actions

Press Call Door

Move door into machine

Actions

Door Stops

Position Door

Clamp Door

Start Sequence

Process Door

Actions

Unclamp

Move door to the Edge-SS

LH Top of door

RH Top of door

2-11


About the Edge-SS Process

About the Edge-SS Process


1. If needed, set the job parameters from the Edge-SS

Main Screen.See “About the Edge-SS Interface Screens” on page 2-38 for instructions.

2. Move the door from the Face-SS into the Edge-SS.

7. If the machine is set on Auto Clamp, the clamps will automatically unclamp. If not set to Auto Clamp, press the Door Clamp Foot Pedal to unclamp.

8. Follow any other process instructions on the screen and position door accordingly.

9. After all cuts are completed, press the Blue Door

Finished Button to Feed the completed door into the Vision-FS Stacker

3. Push the Door Stop Foot Pedal to pop-up the stops.

4. Position the door against the stop and fence accord-ing to the Opera-tor’s Screen

5. After the door is set, press the Door

Clamp Foot Pedal to secure the door.(Note: If not clamped correctly, press the clamp pedal again, re-set and press the pedal again.)

6. Press the Start Sequence Button to begin the cutting process.

Note: The indicator lights will follow the per-programmed cut. If needed use the Edge Toggle Button to manually process.

Actions

Pull door in from the Face-SS. Roll the door into the machine

Actions

Door Stops

Position Door

Clamp Door

Start Sequence

Process Door

Check Screen

Complete Cuts

Actions

Press Feed Out

Feeder will move door out into the Stacker


2-12

Summary of the KvalCAM Interface


The KvalCAM software includes a single User Interface to control the entire machine line. Each machine can also be controlled separately or as a collective. Door Jobs and Features from a library can be downloaded remotely and created at the station.The KvalCAM interface uses tabbed navigation to jump to desired screens.

Libraries and Machine Line Screens

Below are screen shots that show the programming and machine line program operations

Create, edit, clone, delete, and download door jobs and door templates. Power-ful and flexible database of door cuts.

See “About the Libraries Screen” on page 2-16.

Libraries

Create, edit, clone, delete. View the entire process of the machine line.queued jobs, quantity and remaining doors, and status of each machine. Some line con-trol is available.

See “About the Machine Line Screen” on page 2-24.

Machine Line

Machine Control and Calibration Screens

Below are screen shots of the operator screens that control the machine.

Includes auto controls, speed control, and sequence controls

See “About the Vision-FS Interface Screens” on page 2-28.

See “About the Face-SS interface Screens” on page 2-34.

See “About the Edge-SS Interface Screens” on page 2-38.

Main Control

Manual Servo Control

From this screen, move the Cutting Head and Table.

See “About the Vision-FS Servo Control Tab” on page 2-32.

See “About the Face-SS Manual Servo Control Tab” on page 2-36.

See “About the Edge SS Manual Servo Control Tab” on page 2-41.

2-13



Tool Config

From this screen, set parameters for each tool in the Cutting Head.

See “About the Tool Config Tabs (Face-SS and Edge-SS)” on page 2-44.

Calibration

From this screen, Calibrate the machine.

See Chapter 3

Status and Log Screens

Status

From this screen, check the status of the assemblies on the machine. See what state the assemblies are in.

See “About the Status and Log Screens” on page 2-50.

Log Screen

From this screen, the feedback codes from the machine.

See “About the Status and Log Screens” on page 2-50.


2-14

About Machine Status Feedback

About Machine Status Feedback

At the left-hand side of the screen, feedback from all machines is displayed. The machines are constantly polled, feeding back their state of operation. This feedback is a great tool to instantly view the status of each machine.This information can be used to troubleshoot any issues that may occur.

Select the tabs to jump to associated Operator’s Screen. The active screen will highlight.

2-15




Libraries are the heart of the versatility of KvalCAM. The library is a working data base of stored cuts (templates) and door parameters or door jobs. A list of doors/door jobs is displayed under the Door Job Library Tab while templates are listed under the Template Tab. Door specifics can be cre-ated, edited, cloned (copied), or deleted directly at the Operator’s Station. Select the Libraries Tab to jump to these screens.

About The Door Job Library And Template Library Lists

Select the corresponding tab to jump to each list. Each screen has a table listing the name of the (Door Job/Template), a description, date created, and date modified. At the bottom of the screen is a count of the door jobs/templates in the table and buttons to edit, create, clone or delete door jobs /templates.

Door Job List

Door Job Buttons

Door Job Count

Template ListTemplate Count

Template Buttons

FIGURE 2-2. Screen Shots of Door Job and Templates


2-16


About the Door Job/Template Buttons

Create Button:

Select this button to jump to the Job Cre-ation Screen.

Create Door jobs using the Features or by down loading G-Code

Edit/View Button:

Select a Template or Door Job.Either Edit a known Job /Template or use existing to run doors. Jumps to the Job Creation Screen

(Most Common Pathway to start the door Machining Pro-cess)

Clone Button:

Select a Template or Door Job from the list to copy and rename.

Delete Button:

Select a Template or Door Job from the list to Delete.

Job Creation Screen

FIGURE 2-3. Screen Shot of Job Creation

2-17



About the Job Name MenuJob Name: Job Name is displayed when the job is loaded into a queue for processing.

Note: If creating a Job, enter an appropriate title

Job Description: Additional text field to describe the job is displayed

Note: If creating a Job, enter an appropriate description

About the Door Data Menu

View, edit, or create the door parameters to be processed.

Door Parameters: Displays the basic parameters of the door being processed. If creating a door enter the parameters.

Door Hand: Select the Hand Ori-entation of the Door. From the drip down menu, select:

• Left Hand’

• Right Hand

• Left Hand’ Reversed

• Right Hand Reversed

Door Material: Select type of material of the Face, Hinge side, and Lock side of the door. (Wood, Fiber -Glass, or Steel)


2-18


About the Feature Tree Menu

View, edit, or create features of the door. Also known as “Group” or “Template”, a Fea-ture Group is a container in which individual or multiple features can be loaded to process a door. Feature Groups operate at the top level of the feature tree, from which child fea-tures branch out.

Child Features: Cuts that are part of the Feature Group. In this exam-ple: a Plate is being processed on the Lock Edge of the door. The Plunge is the Child of the Plate Cut.

Feature Group: Top level of the door cut. Contains the Child Fea-tures.

Add Group: Select to create a new Group Features can be created in the Features Details Menu

Add Child: Select to create a new child to a group or child.

Add from Library: Select to add a tem-plate from the Tem-plate Library

Delete: Select to delete a Group or Child

Notes:

Indicators next to the Child Features are color coded to reflect the location on the door. (Hinge Edge, Lock Edge, Hinge Pivot Face, Opposite Hinge Pivot Face, Top End, Bottom End)

If a cut is not correct, the cut will be highlighted in the Feature Tree Menu

2-19



About the Selected Feature Details Menu

All Feature Groups have their own L (Length), T (Thickness), and W (Width) location that is separate from the features contained inside. This allows the user to quickly move templates to new locations or to duplicate templates in multiple locations (by adding new

locations to the group). Feature Group Name: This field is required when saving a new tem-plate.

Description: Description of the Feature Group

Location: Add, Remove, Edit the Select the location of the Group Cut

Feature Name: Name of The Fea-ture Under the Group.

Feature Type: Select type of cut:

• Circle

• Hinge

• Rectangle

• TeeShape

• GCode

Door Side: Select Door Side:

• Lock Edge

• Hinge Edge

• Top End

• Bottom End

Features are created by adding children to a feature group. All features are specific cuts that can be made on a door. Feature Types for this line include Rectangle, Circle, Hinge, TeeShape, and GCode, each with their own parameters and validation requirements.

Data Table: Parameters of the cut


2-20


About the Control Buttons

Cancel: Select to quit this screen and jump back to the Library screen.

Validation Report: Select to ensure that the Door Job and Templates are valid.

Save: Select to Save all a new Door Job or save Edits to a Job

(Password Pro-tected)

Add to Queue and Door Qty:

The first step of door processing. Enter the quantity of doors to be processed and then select the Add to Queue button to start the process. See “Machine Line Start Summary” on page 2-8.

2-21



About the Job Preview Screen

The Job Preview screen is a interactive graphical representation of the Feature Group parameters. The door can be viewed from different perspectives and can be zoomed in and out.Viewing the process before cutting offers opportunities to edit or verify the pro-cess.

Display Area

Door Axis

Door Orientation

Preview Surface

Bottom EndTop EndHinge EdgeLock EdgeHinge Pivot FaceOpposite Pivot Face

Color Coded

Grid Lines (in): Change the size of the grid line

Scale Percent: Dis-plays the magnifi-cation value of the screen preview. Note: May use the mouse wheel to zoom in and out.

Grid Lines ON: Select to toggle Line or and OFF


2-22


About the Door Axises

The figure below represents the color coding of door orientation in the Job Preview Screen.

T= Thickness

L= Length

W= Width

Key (Lock) EdgeBottom End

Hinge Edge

Hinge Pivot Face

Opposite Pivot Face

Top End

Opposite Key “Face”

Opposite Hinge Pivot Edge

Hinge Pivot “Face” Edge

Key “Face”

2-23




The Machine Line Screen offers a snapshot of the operation of the entire machine line. Select the Machine Line Tab on the left side of the screen to jump to this screen. This includes:

Menu DescriptionMachine Activity For each machine, a table shows job name, quantity of remaining doors,

doors being processed, and status of the machine.

Queued Jobs: shows a list of the upcoming jobs.

Line Controls: Common operations to control the machine line

Machine Line Screen


2-24


About the Machine Activity Section

The Machine Activity Section shows the processing information of each machine. The rows are ccoded.

• Green: Actively working on a door job

• White: Machine is idle

• Orange: Machine is paused.

Machine: Lists the machines in the line.

Status: Lists the status of each machine.

Quantity: Lists the quantity of doors at the start of the Door Job

Job: Lists the name of the Job being processed. The Job name reflects the name assigned in the Door Job Library.

Remaining Lists remaining quantity of doors left in the Door Job

2-25



About the Queued Jobs Section

The Queued Jobs Section shows the door jobs in order of processing.

Queue Order: Lists the jobs that are going to be processed

Commands: Select the Remove button to clear the Job from the list

Creation Time: List the time when the job is put in queue.

Job: List the name of the Job.

Quantity: Lists the quantity of doors at the start of the Door Job.


2-26


About the Line Control Buttons

The Machine Activity Section contains a table that shows the processing information of each machine. of each machine. The rows are color coded.

Auto Feed: Select to toggle the machine between Auto Feed ON or Auto Feed OFF.

Auto Feed ON: The door will automat-ically feed through each machine.

Auto Feed OFF: The feed status must be set the machine Operator’s Screen

Clear Queued Jobs: Press to clear the entire list of door jobs in the Queued Job table.

Home the Machine Line: Press to Home every machine in the line

Reset the Machine Line: Press to reset the every machine in the line. You Must Home the line after this reset is performed.

2-27


About the Vision-FS Interface Screens


The Vision-FS Operator Screens contains the controls to operate the machine.

Select the Vision-FS Tab located on the left hand side of the machine to jump to this menu.

Item DescriptionMain Control This screen includes access to the most commonly used controls for the

Edge-SS.

Manual Servo Control Operate the machine manually by moving the servo motors.

Status For information,see “About the Status and Log Screens” on page 2-50.

Log For Information, see “About the Status and Log Screens” on page 2-50.

About the Vision-FS Main Control Screen

FIGURE 2-4. Vision-FS Main Screen


2-28


Home Machine

This button starts the home sequence on the machine, which scans to find a physical reference point on the frame. When this point is found, the position is stored and then used to calculate the location of all moves during the machine pro-cess.

The home sequence must be per-formed every time the machine is powered up or reset.

Vacuum Sleep

This button puts the vac-uum in sleep mode. Any door in process of lifting will hold its position. Reset PLC

If a fault occurs that cannot be cleared, press the Reset Machine button. This button will reset the machine to the start position. Press the Home button after resetting the machine

Pause/Resume

Select the Pause button to hold pro-cess of the door. Select again to Resume from the point where the pause was initiated.

Clear Sequence Machine

If a full machine reset is not wanted, press the Soft Reset button. Press the Home but-ton after resetting the machine

About the Main Control Menu

The Main Controls on the Feeder and the Stacker are the same and provide the same function or each machine.

Park

Press to park the lift of the machine in a safe place.

2-29



Door Quantity

Select and enter the number of doors to be processed.

Start Feeder

Press to start the process of machining a door from feed to finish. Ensure all machines in the pro-duction line are powered up, homed, and is clear to process.

Feeder Cycle Control

Control the quantity of doors and start the Process of machining doors in this menu.

Select Stack

Use drop down menu to select the starting point of the Feeder. One of three locations can be selected to be flexible for build process.

See Figure 2-5 below

Rotate Next Door

Press to rotate the next door to be fed into the machine. Rotates one time only

Scan OFF/ON

Press to turn On or Off the Scan function. The Scan feature is an optional feature that allows a bar-code to be scanned to deliver infor-mation about the doors being processed.

Auto Rotate ON/OFF

Press to initiate a cycle of auto rotating the doors.

22

2

1

1

1 2 3Stack Stack Stack

FIGURE 2-5. Locations of Stacks


2-30


Door Quantity

Select and enter the number of doors to be processed.

Start Move

Press to start the process of machining a door from feed to finish. Ensure all machines in the produc-tion line are powered up, homed, and is clear to process.

Move Control

Control the quantity of doors and start the Process of machining doors in this menu.

Stacker Control

Control where to place the doors with an option to rotate the door.

Rotate Next Door

Press to rotate the next door to be stacked

2-31



About the Vision-FS Servo Control Tab

Select the Manual Servo Control Tab to jump to the screen. Control the Gantry and the Infeed and Outfeed Tables manually.

FIGURE 2-6. Vision-FS Manual Control Screen


2-32


About the Table Control Sections

Select the Manual Mode Button to initiate

Table Buttons:

Press and hold the button to move the table motors in the desired direction.l

Feed Buttons

Forward: Into Table

Reverse: Out of Table

X-Feed Buttons

Forward: To Fence on the Table

Reverse: To the Door Stack

.

Gantry Buttons:

Press and hold the button to move the gantry in the desired direction. The but-ton will turn orange when active.

Clamp Button:

Press to Clamp a door. (Turns Suction on)

Un-Clamp Button

Press to Un-Clamp a door.

About the Gantry Control Section

Select the Manual Mode Button to initiate.

2-33


About the Face-SS interface Screens


The Face-SS Operator Screens contains the controls to operate the machine.

Select the Face-SS Tab located on the left hand side of the machine to jump to this menu.

Item DescriptionMain Control This screen includes access to the most commonly used controls of the

Machine.


Tool Config For information, see “About the Tool Config Tabs (Face-SS and Edge-SS)” on page 2-44.



About the Face-SS Main Screen

FIGURE 2-7. Face-SS Main Screen


2-34


About the Face-SS Main Control Section

Home Machine

This button starts the home sequence on the machine, which scans to find a physical reference point on the frame. When this point is found, the position is stored and then used to calculate the location of all moves during the machine process. The home sequence must be performed every time the machine is powered up or reset.

Reset Machine

If a fault occurs that cannot be cleared, press the Reset Machine button. This button will reset the machine to the start position.

Important: Press the Home button after resetting the machine

Setup Mode On/Off

Select Setup Mode to toggle on or off. In the On mode, a safe mode is active. The machine will go through normal sequences except the cutting motors will be inactive. Use this mode to check the machine operation without making a cut on the door. With the setup mode set to on, the button will change to an orange background.

In the Off mode the machine is in normal operation.

Abort Job

Select to stop (abort) the process of the door that is currently running.

About Speed Control

Routine Speed Percent

Adjust the speed of the cut. Press but-tons to use the graduated speeds or select box and enter a desired speed. The speed can be changed during real time processing.


2-35


About the Face-SS Manual Servo Control Tab

Select the Manual Servo Control Tab to jump to the screen. At this screen, the Main Head and Infeed and Outfeed Stop servo motors can be moved manually.

FIGURE 2-8.


2-36


Servo Position:

Press and hold the Forward or Reverse buttons to move the Head in the desired direction.

Z Axis

Forward: Moves Heads Down to the door cut

Reverse: Moves Heads Up and away from the door cut

Position of Encoder

Y Forward

Towards the Operator

Y Reverse

Away from the Operator

X Forward

To the Feeder

X Reverse

To the Edge-SS

About the Face-SS Head Servo Controls

These manual controls are designated by X, Y, and Z axises for the Main Head. (includes lower and upper tool sets as a unit). Press and hold the button (Forward or

Reverse) to move the head in the desired direction.

Servo Position:

Press and hold the Forward or Reverse buttons to move selected stops

About the Face-SS Stop Servo Controls

These manual controls move the Infeed and Outfeed stops.

Infeed Stop:

Outfeed Stop:

Reverse

Reverse Forward

Forward

2-37


About the Edge-SS Interface Screens


The Edge-SS Operator Screens contains the controls to operate the machine.

Select the Edge-SS Tab located on the left hand side of the machine to jump to this menu.

Item DescriptionMain Control This screen includes access to the most commonly used controls for the

Machine.


Tool Path Preview For information, see “About the Tool Path Preview Test Tab” on page 2-43.

Tool Config For information, see “About the Tool Config Tabs (Face-SS and Edge-SS)” on page 2-44.



About the Edge-SS Main Screen

FIGURE 2-9. Edge-SS Main Screen


2-38


About the Face-SS Main Control Section

Home Machine

This button starts the home sequence on the machine, which scans to find a physical reference point on the frame. When this point is found, the position is stored and then used to calculate the location of all moves during the machine process. The home sequence must be performed every time the machine is powered up or reset.

Reset Machine

If a fault occurs that cannot be cleared, press the Reset Machine button. This button will reset the machine to the start position.

Important: Press the Home button after resetting the machine

Setup Mode On/Off

Select Setup Mode to toggle on or off. In the On mode, a safe mode is active. The machine will go through normal sequences except the cutting motors will be inactive. Use this mode to check the machine operation without making a cut on the door. With the setup mode set to on, the button will change to an orange background.

In the Off mode the machine is in normal operation.

Abort Job

Select to stop (abort) the process of the door that is currently running.

About Speed Control

Routine Speed Percent

Adjust the speed of the cut. Press but-tons to use the graduated speeds or select box and enter a desired speed. The speed can be changed during real time processing.

2-39



About the Sequence Control Section

Start Sequence

• After templates and programs are loaded, the doors are in place to process, the machines is homed, Press the Start Sequence button to run the machine line.

Note: Pressing the Door Stop

Pedal will perform the same operation as the Start Sequence

Edge Toggle

• This button adds the flexibility to override the sequence and select the edge position. This button also allows the opportunity to repeat the selected cut.

• This control is also located at the machine control panel as a mechanical switch (but-ton)

Door Finished

Clears the job if user wants to finish the job before completing all cuts, or at the end of the job if Auto-Feedout is disabled. If the machine is working on the last side and Auto-

Feedout is enabled, a light will illuminate on this button. Pushing Door Finished will disable Auto-Feedout for that job only so the operator can inspect the door.

About Other Controls

Toggle Clamp

Press to toggle the door clamps UP or DOWN. This button is only available when a job is loaded in the machine.

Enable Feeler Adjust

Press to Enable or Disable the Feelers.

If this button is Disabled, the door mea-surements will be derived from the Door Job specifications.


2-40


About the Edge SS Manual Servo Control Tab

Select the Manual Servo Control Tab to jump to the screen. At this screen, the Main Head and Table

servo motors can be moved manually. Table controls include moving the Feeler and the Feeder.

FIGURE 2-10. Edge-SS Manual Control Screen

About the Edge-SS Feeler Servo Controls

These controls operate the Thickness Feeler. The feeler uses encoder technology to accu-rately measure the thickness of a door. For information about the Feeler, see“About the Door Length Feeler” on page 6-8

LengthFeelerEncoder: Dis-plays the Count Position of the Feeler Encoder.

Feeler Forward: Press and Hold to move the feeler forward. (Toward from the door)

Feed Reverse: Press and Hold to move the feeler in reverse. (Away from the door)

Feeler Retracted: Press to toggle feeler contacts to and away from the door.

2-41



About the Edge-SS Feeder Servo Controls

These controls operate the optional feeder on the Edge-SS. The Feeder moves the door into the Vision-FS.

Feed Forward: Press and Hold to move the feeder. The Door will move toward the Stacker

Feed Reverse: Press and Hold to move the feeder. The Door will move away from the Stacker

Feed Fast: Press and hold to increase the feed speed.

Servo Position:

Press and hold the Forward or Reverse buttons to move the Head in the desired direction.

Y Axis

Forward: Moves Heads Down

Reverse: Moves Heads Up

Z Reverse

Away from the Door Cut

Z Forward

Towards the Door Cut

X Forward

X Reverse

To the Stacker

Position of Encoder

About the Edge-SS Head Servo Controls

The manual controls are designated by X, Y, and Z axises for the Main Head. Press and hold the button (Forward or Reverse) to move the head in the desired direc-tion.


2-42


About the Tool Path Preview Test Tab

Select the Tool Path Preview Test Tab to jump to the screen. At this screen, an animated path of the tool cutting pattern sequence can be obscured. Selected G-Code routines from Library of the Edge-SS can be viewed.

This sequence can be essential if troubleshooting, calibrating, or checking the wear of a tool. Dis-crepancies can be viewed before cutting into a door, saving product and time.

The figure below displays a sample of a good Deep Mortise Cut.

1. Select a G-Code routine form the drop down menu.

2. Select the Render Button

3. View the path of the tool on the screen.

Step 1 Step 2

Step 3

Circle represents the tool and the animation rep-resents the path

Center Point

2-43


About the Tool Config Tabs (Face-SS and Edge-SS)


The Face-SS and the Edge-SS interfaces contain tool configuration abilities.

At this screen, specifications of the tool, type of material being cut, and process is entered and saved to the database. This information is valuable to compute and provide the most precise cut available.

General Operating Controls

The Tool Config Screen contains a:

• List of the Main Head tools.

• Pop-up menus to enter information about each tool (Specifications, Router or Drill)

• The ability to enable or disable specific tool slots

• The ability to name the tools to familiar names.

• The ability to lock and unlock the ability to enter data.

Select Tab

Select Tab

List of Tools Available

Pop-Up Menus: enter tool data.(Router and Drill)

Unlock, Lock, and Save Data


2-44


Unlock the Tool Slot Configuration

The configuration screens are passwords protected. To unlock the screens, select the Unlock but-ton and enter the password in the password popup menu.

1. Select Unlock

2. Enter Password, Click OK

3. Ready to Enter Data

About the Tool Pop-up Screens

Each tool slot has versatility to choose between entering router information or drill information. Each tool can be enabled or disabled.

Drill Pop-up Drill Pop-up Disabled

2-45



Router Pop-up Router Pop-up Disabled

About Tool Locations (Edge-SS and Face-SS)

Tool locations are identified by slots. See the figures below for the locations and identifications.

Tool Slot 4:

Tool Slot 2:

Tool Slot 3

Tool Slot 1

Tool Slot 6:

Tool Slot 5

Edge-SS


2-46


Tool locations are identified by slots. See the figures below for the locations and identifications.

Face-SS

2-47



About Using Tool Configuration

1. Identify the tool that needs replace-ment.Measure tool dimensions and capture the data. (Use this informa-tion to populate the Drill or Router pop-up screens).

2. Select the Tool Slot from the desired Head (Hinge Head or Lock Head).

Note: Hinge Head 1 and 2 share the configured tool list. Each head tool should match in type and specifications.

3. Enter the data into the pop-up screen. (Router or Drill)

Measuring Tool Length

1. Measure the parameters listed below:

• Total Tool Length - The distance from the collet face to the tool’s tip

• Tool Cutting Length - The distance from start of the cutting area to the tip of the bit.

• Tool Point Length- From the point where the point starts to the end of the bit.

2. Update the data in the Tool Setup Group,

Important: The accuracy of the data Tool Setup Group is important. Any errors could damage tooling or product.

Tool Point Length

Cutting Length

Total Tool Length

About Entering Data into the Pop-up Menu

Insert specifications of the tools being used to make the cuts. Ability to name the tools to user defined descriptions. Customize the tools to reflect the actual tool parameters, making the most accurate cuts. Ability to define cut operation.


2-48


2-49


About the Status and Log Screens


The Machine has a Status and Log Screen. Information about each machine can be observed from these screens.

TIP: Right Click the Icon at the Bottom of the screen. Select Backup Logs to save all data from the machine operation. If needed, select Backup and Export Logs to send machine data to a text file. The file may be sent to Service Support if any issues occur.

About the Status Screen

From this screen, real time feedback during the operation of the machine can be viewed. The feedback includes times, dates, and machine status. Status includes a “True” flag if the assembly is in operation or a “False” flag if not in operation. Also status can include data and motor states (idle, operation). The data can be filtered to observe certain aspects of the operation of the machine. This tool is great for troubleshooting to locate faulty assemblies.

.

Filter Data

Status is listed by Location

List of Parameter of Door in Process

FIGURE 2-11. Status Screen


2-50


About the Log Screen

The Log screen displays all the tasks the Edge-SS performs. This screen can help with trouble shooting by associating the error code to machine sections or functions. The top line will have the most current routine that is running. The codes are color coded:

Red = ErrorGreen = Report is a non-issue

Yellow = Warning

If the machine issue can not be resolved, call KVAL Inc. (1-800-553-5825). Have any error code that is displayed, ready to give the KVAL representative. This will aid in troubleshooting and shorten down time.

FIGURE 2-12. Log Screen

2-51


Definitions

Definitions

Term Definition Library: Working database for stored cuts (which are stored in the Template Library) and

doors/jobs (which are stored in the Door Job Library)

Job Name: Name the Job that reflects the best description in your working environment.

Job Description: Additional text field to describe the job when similar names are being used.

Created: Date in which the feature or saved door/job was created.

Last Modified: Date in which the feature or saved door/job was last modified.

Face Material: Material that will be run on either Face of the door.

Hinge Material: Material that will be run on the Hinge Side of the door. Wood/FG is the only valid material type to run on the Hinge Side for this line.

Lock Material: Material that will be run on the Lock Side of the door.

Feature Group Also known as “Group” or “Template”, a Feature Group is a container in which indi-vidual or multiple features can be loaded and cut into a door. Feature Groups oper-ate at the root level of the feature tree, from which child features branch out.

All Feature Groups have their own L, T, and W location that is separate from the features contained inside. This allows the user to quickly move templates to new locations or to duplicate templates in multiple locations (by adding new locations to the group).

Feature Group Name:

This field is required when saving a new template.

Feature Features are created by adding children to a feature group. All features are specific cuts that can be made on a door. Feature Types for this line include Rectangle, Cir-cle, Hinge, Tee-Shape, and G-Code, each with their own parameters and valida-tion requirements.

Door Side: Selection for which side of the door that a feature will be run on.

L Axis: Located on the Door Preview Screen, the L (length axis) is represented visually with changes of door reference.

W Axis Located on the Door Preview Screen, the W (width axis) is represented visually with changes of door reference.

T Axis Located on the Door Preview Screen, the T (thickness axis) is represented visually with changes of door reference.

Expression: Inputted values by the user for an intended feature. The input is interpreted by the program and passed through a validation scheme for all machines in a line to determine if the intended cut is capable of being run (see validation).


2-52

Definitions

Validation All feature groups are analyzed by a validation routine before the software permits the operator to download the programmed cut to the machines for processing. The validation routine queries the capabilities of each machine and current tools loaded to determine if the programmed cuts can be performed by the line. If at least one machine in the line is capable of performing each cut / feature in the group, the group will be considered valid and the Add to Queue button will be enabled. If any feature or cut fails validation, however, a Orange or Red box will be highlighted over the faulty cut / feature for review and the Add to Queue button will be dis-abled. Red only appears if the expression cannot be interpreted to a real number for validation, while orange appears if the line cannot perform the cut.

Validation Report

Validation will only work if the information that is fed to the machine line is accu-rate. Inaccurate information that is downloaded from Tool Configurations, Calibra-tions, or Libraries (e.g. material types) will produce unexpected or potentially harmful results to the machine and/or operator.

Some cuts in fringe cases may pass validation that result in non-conforming cuts (cut does not match visual representation).

Validation Report identifies particular faults that would cause a feature to fail vali-dation. Each feature has its own validation tests and will fail if the tests for a valid feature are not satisfied. Clicking on a specific test will provide an explanation of the test being performed so that the user can correct the mistake.

Term Definition

2-53


Definitions


2-54

CHAPTER 3 Calibration of the Vision Line

This chapter describes steps to use the interface to calibrate the Machine Line.



About Calibration Descriptions of the Calibration Menus. Tips to look for before calibrating.

page 3-2

About the Calibration Tabs

Descriptions of the Calibration Tabs. page 3-3

How to Enter Calibration Data

Descriptions of how to use the calibration screens

page 3-5

About the Edge-SS Calibration Screen

Descriptions of the calibration available. page 3-8

3-1


About Calibration

About Calibration

Calibration is all about the confidence in the end results of your manufacturing process. Calibra-tion assures you that your cut parameters are accurate and within the specified limits.

If slight discrepancies in the machining of a door are observed, the built in KVAL calibration can adjust the tooling to fix the issue.

In troubleshooting, calibration can be an essential step in solving the issue.

About the Calibration Menus and the Calibration Reference Cut

This chapter describes the Calibration Menus and to how to perform a Calibration Reference Cut.

In the Calibration Menus, offsets are entered to calibrate assemblies in the machine. See “About the Calibration Tabs” on page 3-3.

The Calibration Reference Cut delivers a calibration cut for the Hinge Heads and for the Lock Head. Use the Calibration Menus to adjust the tool sets from information taken from the calibra-tion cuts.

1. Hinge Cut: Performs a cut to verify the Predrill, Hinge Router, and the CounterRotate Router.

2. Lock Cut: Performs a cut to verify the Predrill, Counter Rotate Router, PlungeRouter, Plate Router, and the Deep Mortise Router.

Before you Calibrate

Before you start calibration, check for the following common issues.

1. Is the loaded setup correct for the current cut?

2. Check tools for wear.

3. Is the correct Calibration loaded?

4. Are the stops set up correctly?

5. When did the problem first start? during a run, at start up.

6. When was the last calibration?

7. Is the Door True?

8. Use Router Bit Depth Gauge (PN: 432C) to check depth.

9. Check for sawdust build-up, which may affect depth.

Note: KVAL recommends that a test door is run first and checked for specificationsbefore a full run is started.


3-2



The calibration tabs contain access to screens to adjust servo motors in the machine.These soft-ware adjustments are designed to fine tune the servos for optimum accuracy. The maximum adjustment is 0.50 inches for all calibrations.

Note: If more than 0.50 inches of adjustment is needed, there is a high probability that another issue may be causing a problem. Perform a visual check of the assembly to be calibrated and check the Status Screens and Log Screens for error reporting. Finding errors from these screens will help localize problem areas.

Note: If the machine issues can not be resolved, call KVAL Inc. (1-800-553-5825). Have any error code that is displayed, ready to give the KVAL representative. This will aid in troubleshooting and shorten down time. See “Getting Help from KVAL” on page 1-17.

Access to the Calibration Adjustments

Buttons to unlock access to calibration, save a calibration, and restore calibration are located here. Lists of assemblies to calibrate are in the main body of the page.

Calibration Tab:

Select to enter the calibration screen

Calibration Lists:

Select to access calibration adjust-ments

Calibration Buttons:

Unlock a Calibration

Save a Calibration

Restore a Calibration

FIGURE 3-13. Calibration Header

3-3



Unlock the Calibration (Option)

Access to the calibration is password protected. (Optional)

1. Select the Unlock button

2. At the Password pop-up, enterthe password and select OK tocontinue.

3. The calibration message willchange from a red ''Calibration isLocked '' to a green Calibration isUnlocked”.

Enter a Positive or Negative Number?

Determine when to enter a positive of negative number by using your Left Hand. Use the cut on the door as a reference. Hold out the left hand with the first finger pointed at the door cut, second finger and thumb at right angle to each other. The first finger represents the positive direction of the ‘Z” axis, the thumb represents the positive direction of the ‘Y” axis, then second finger rep-resents the positive the direction of the ‘X’ axis.

Point at cut on door

+ X

+ Y + Z


3-4



Adjustment menus are located in the setup screens. In these menus, you can add negative or posi-tive adjustments to move a servo to desired positions to compensate (calibrate) for any deviation’s from the expected cut. The calibration can then be stored.

Below are general instructions to perform a calibration.

1. Check for deviations between the expected machining and actual machining. Mea-sure the offset from the expected result. Use this number to enter into the offset boxunder the inaccurate parameter.

Note: Maximum offset is 0.50 inches. If more than 0.50 inches of adjustment is needed, there is a high probability that another issue may be causing a problem. If issues can not be resolved, contact the KVAL Service Center KVAL Inc. (1-800-553-5825). See “Getting Help from KVAL” on page 1-17.

2. Enter the offset positive or negative number in the whitebox below the Offset title to adjust the servos in the X,Y, and Z directions.

3. The Base display box keeps a running total of dataentered to help keep track of the changes.

4. The Combine button merges the offset number to thebase to adjust the servo.

5. Run a test door again to verify the offset correction was successful.

6. Keep running a test door and adjusting the offset until satisfied with the result

7. After satisfied, click the Save button to store the calibration.

About Restore PointsRestore Points can be created to store a calibration point for recall.

To create a Restore Point:

1. Select the Restore Points button

2. Select the Save Current button from the pop-up windowsave current calibration

3. Name and enter to save

To Load or Delete a Restore Point:

1. Select the restore point from the menu

2. Select the Load button to use the calibration. Select the Load button to load

3. Select the Delete button to delete the point.

3-5


About the Vision-FS Calibration Screen


The Vision-SS Calibration Screen contains a list of calibration adjustments. Select the Vision-FS

Tab located on the left hand side of the machine, then select the Calibration Tab to jump to this menu. Enter adjustments according to “How to Enter Calibration Data” on page 3-5. Ensure Cali-bration is unlocked.

Vision-SS Calibration Screen

The Vision-FS calibration routines adjusts the Lift Head location to align to each Door Stack (1,2,and 3). The Infeed and Outfeed Tables can be adjusted for horizontal and vertical movements. The Outfeed Table also includes adjustable eye span and table centering.

Summary of Available Calibrations

TABLE 3-1. Description Summary of Face- SS Calibrations

Calibration Unit Assembly Description

Door Stack #1

Door Stack #2

Door Stack #3

Lift Head For each stack adjust the vertical low point and hori-zontal points.

Feeder Table Table Servo Motor Adjust the table horizontal location.

Adjust the table height.

Stacker Table Table Servo Motor Adjust the table horizontal location.

Adjust the table height.

Photo Eye Adjust the arm attached to the centering photo eye.

Table Servo Motor Centers the door on the table

Gantry Gantry Adjust Clamp Time (Set the period of time)

Scan Location


3-6


Adjust Lift Head Location

Visually check the desired locations for stacking the doors. Use the Calibration Door Stack #1, Door Stack #2, and Door #3 to adjust the pickup and placement of the doors. Adjust until satis-fied with locations.

Gantry Calibrations:

Scan Location is the vertical or horizontal position that the gantry goes to for scanning.

Clamp Time is the amount of time that the gantry waits before it decides to lift the door up to allow clamping to occur

Adjust until satisfied with operation.

+ + +-- -

Door Stack #3Door Stack #2Door Stack #1

+

-

Adjust Feeder And Stacker Tables Parameters

Visually check the desired placement of the door on the tables. Adjust the Feeder Table for horizontal location and table height. Adjust until position of the door on the table meets require-ment.

Adjust the Stacker Table for height and horizontal position as done for the Feeder Table. Also centering can be adjusting by using the Photo Eye and Table Servo Motor calibration routines.

Feeder Table

Stacker Table

+

_

+

_

_

+

+

_

3-7


About the Face-SS Calibration Screen


The Face-SS Calibration Screen contains a list of calibration adjustments. Select the Vision-FS Tab located on the left hand side of the machine, then select the Calibration Tab to jump to this menu. Enter adjustments according to “How to Enter Calibration Data” on page 3-5. Ensure Calibration is unlocked.

Face-SS Calibration Screen

Summary of Available Calibrations

TABLE 3-2. Description Summary of Face- SS Calibrations

Calibration Unit

Assembly Description

Main Head Face Car-riage Axes

Adjust the location of the 3 axes (X,Y,and Z) of the Hinge Carriage Heads.

Adjust if all tools are out of specification

Edge Car-riage Axes

Adjust the location of the 3 axes (X,Y,and Z) of the Edge Carriage. Includes 3 and 0 degree options for the Z and Y axes.

Adjust if all tools are out of specification

Lock tools Adjusts each tool set individually within the Edge Carriage Head. Includes each Chisel.

Face Tools Adjusts each tool set individually within the Face Carriage Head. Adjust Diameters of routers Adjust router and drill depths from the top and from the bottom.

Door Feed Setup

Door Stops Adjust the location of the Infeed and Outfeed Stops located on the table.

Bottom Feeler Adjusts the Feeler


3-8


Face-SS: Full Calibration

Follow the order of the steps below when performing a full calibration for the Face-SS.

1. After the machine is homed and is parked, measure the distance between the for-ward and reverse limit eyes. The head should be directly between the two eyes. Adjust the HEAD X to move this position.

2. Make a cut using the main router using the outfeed stop. Measure the location of the cut. Note: it is recommended to use a global Z axis cut to capture all the tools.

3. X adjustments to cut is made in the Out Feed Stop calibration. (See “Using the Door Stops Calibration” on page 3-9.)

4. Y adjustment to cut is made to Head Y Axis calibration.(See “Using the Face Car-riage Axes Calibration” on page 3-10.)

5. Depth adjustments are made to the tool Top Depth and Bottom Depth calibration. (See “Using the Face Tools Calibration” on page 3-11.

6. Do the same with the Infeed Stop.You should only need to adjust the “In-Feed Stop” calibration.(See “Using the Door Stops Calibration” on page 3-9.)

Now look at the log screen. You should be able to go back and see the clamp event for both doors. It will show how much difference there was between where the feed target was and where the door feeler actually found the door. This number should be close to 0. Adjusting the Infeed Eye calibration will change this number. For Log Screen Information, see “About the Log Screen” on page 2-32.

Using the Door Stops Calibration

The Door Stop adjusts In-Feed and Out-Feed fences on the machine.

Process: If door is not centered in machine, adjust the stops to correct.

Enter a positive offset to move toward the Out- Feed

Enter a negative offset to move toward the In-Feed.

See Figure on page for assembly designation and direction of adjustments.

3-9



Out -Feed StopIn-Feed Stop In-Feed 2nd

Stop Spacing

Out-Feed 2nd Stop Spacing

+_ _+

FIGURE 3-14. Stops Calibration

Using the Face Carriage Axes Calibration

The Carriage Axes calibration treats the entire tool set within the carriage as one unit. Therefore, if all parameters or a particular cut are out of specifications, use this calibration adjustment.

1. Identify the cut out of specification.

2. Select Face Carriage Axes

3. Measure the cut and follow the instructions in “How to Enter Calibration Data” on page 3-5.


3-10


Using the left hand rule, point down to the cut on the face of the door. All assemblies are moved together in the selected direction.

+ X

-X

+ Y

- Y

- Z

+ Z

FIGURE 3-15. Direction of Cutting Head

Using the Face Tools Calibration

1. Identify the cut that is out of specification.

2. Select the Tool that is out of specification from the Main Head


4. For direction of cut see “How to Enter Calibration Data” on page 3-5.


3-11



With the Main Head -Face Tools Calibration, top and bottom tool sets are adjusted in-tandem. This keeps the bottom and top tool aligned.

Axis: Identification axes (X,Y, Z, and Diameter Offset)

Diameter Offset is available on the rout-ers only.

(Customer Assigned Name): Identification of tool

Tool Slot: Identifica-tion tool Location


3-12


Router Tools

The Router calibra-tion routines are grouped in a top and bottom arrangement for the X axis Y axis, and diameter offset. The top and bottom drills will move in tandem.

The depth parameter is 180 degrees out. The positive depth always point to the door cut.

For information about diameter offset, see page 3-23

Operator Side

Operator Side

+ X

+ Y

+ Z

+ Z

+ Z

+ Z+ Z

+ Z

+ X

+ Y

Router Set 2

Router Set 1

3-13



Drill Tools

The Drill calibration routines are grouped in a top and bottom arrangement for the X axis Y axis. The top and bottom drills will move in tan-dem.There is no cali-bration for diameter offset for the drills.

The depth parameter is 180 degrees out. The positive depth always point to the door cut.

Operator Side

Drill Set 1

+ Z

+ Z + Z

+ Z

+ X

+ Y

+ X

+ Y

Drill Set 2

Operator Side


3-14


About Edge Carriage Calibration (Face-SS)

The edge tooling is an option on the Face-SS. The Edge Carriage Axes treats the entire tool set within the carriage as one unit. The tool set includes router and chisels.

Note: If all parameters are out of specifications, use this calibration adjustment

.

+ X

- X

+ Y

- Y

+ Z

- Z

Perform separate calibrations for 3 degree and 0 degree doors of Y and Z axises. The X axis is univer-sal.

+ Z

+ Y+ Y+ Z

3-15



About Lock Tools Calibration (Face-SS)

The Lock Tools Calibration individually adjusts the router and each chisel in the head assembly.

Plate Router Calibrations

This calibration adjusts the plate router. For examples of cuts that might require this calibration, see “Typical Edge-SS Adjustments” on page 3-23.

+ X

+ Y

- Y

- Z- X

+ Z

Chisels Calibrations

This calibration adjusts each indi-vidual corner chisel on the Edge

Carriage. Each chisel is adjusted in the Z, Y, and X axis. Use this calibration of a corner is out of specification, such as misalign-ment from the corner edge.

To identify the corner to be cali-brated, see “Identifying Chisel Locations” on page 3-17.

+ X

+ Y

- Y

- Z

- X

+ Z


3-16


Identifying Chisel Locations

The figure below identifies the corner locations of the calibration routine. The refer-enced point is looking at the edge cut.

Lower Right Chisel (X,Y, and Z axes)

Upper Left Chisel (X,Y, and Z axes) Upper Right Chisel (X,Y, and Z axes)

Lower Left Chisel (X,Y, and Z axes)

1 2

43

1 2

3 4

FIGURE 3-16. Corner locations of Chisel Calibrations

3-17




The Edge-SS Calibration Screen contains a list of calibration adjustments. Select the Edge-SS Tab located on the left hand side of the machine, then select the Calibration Tab to jump to this menu. Enter adjustments according to “How to Enter Calibration Data” on page 3-5. Ensure Calibration is unlocked.

Edge-SS Calibration Screen

TABLE 3-3. Description Summary of the Edge- SS Calibrations

Calibration Unit Assembly Description

Main Head Carriage Axes Adjust the location of the 3 axes (X,Y,and Z) of the Hinge Carriage Heads

Tools Adjusts each tool set individually within the Hinge Car-riage Head

Feed and Measurement

(Perform First)

Feelers Adjusts the Length Feelers next to the Hinge and Lock Head In-feeds and Out-feeds

Y-X Axis Positive movement

Z Axis Positive movement

Y Axis Positive movement

Z -

X -

Y + Z +

X +

FIGURE 3-17. Left Hand Rule Front Section


3-18


(First Calibration) Calibrating the Feelers

Door Feelers is the first calibration that should be checked or performed. This calibration adjusts the encoders located in the machine. These calibrations are a starting reference for all calibrations.

Process:

1. Measure a known good door.

a.The door should be true and be considered a calibration reference

b. Door should be sturdy enough to survive multiple passes through machine.

c..Capture the width, length, and thickness measurements. (These measure-ments are used to compare feed backs from the encoders.)

2. Ensure the Set-Up Mode is Enabled (no cut-ting).

a.Select the Edge-SS-Main Control Tab

and under the Main Control Section

select the Setup Mode button.

3. Feed a Test Door into the machine.

4. After the door has been fed in, Check the measurements fed back from the encoders

a.. Select the Log Tab from the Edge-SS Screen check the latest feedback from encoder.

5. Get averages of the feedback. Capture the measurements.

a.Run the door and re-feed it at least 3 times. (Each time capturing the measure-ments from the Log Screen)

b.Reverse the door and re-feed it at least 3 times. Repeat data collection.

6. Compute the averages of the fed-back measurement.

7. Enter the data derived from the averages

a.Go to the Edge-SS Calibration, select Feelers-

b.Subtract measured data to adjust for the difference

3-19



Identify the Hinge and Lock Head Designations

If the Hinge Pockets and Lock Pockets are out of the expected results, select the desired Head Cal-

ibrations from the list to adjust. The figure below identifies the carriage heads to match to the cal-ibration list.

Hinge Head

FIGURE 3-18. Carriage Designators

Using the Carriage Axes Calibrations

The Carriage Axes calibration treats the entire tool set within the carriage as one unit. There-fore, if all parameters or a particular cut are out of specifications, use this calibration adjustment.

1. Identify the cut out of spec-ification.

2. Select Carriage Axes

3. Measure the cut and followthe instructions in “How toEnter Calibration Data” onpage 3-5.


3-20


Y: + Offset

X: +Offset

Y: -

X:-

Hinge 1 or Hinge 2Lock Head

Samples of Carriage Axes Calibrations

A Positive ‘X’ Offset will move the entire pocket as shown

A Negative ‘X’ Offset will move the entire pocket as shown

A Positive ‘Z’ Offset increases depth

A Negative ‘Z’ Offset decreases depth

A Positive ‘Y’ Offset will move the entire pocket in the up direction

A Negative ‘Y’ Offset will move the entire pocket n the down direction

Y: + Offset

X: +

Offset

Y: - Offset

X: - Offset

Note: Reference is looking directly at the cut using the Left Hand Rule.

About Tools Calibration

With the Tools Calibration, each tool assembly within the Head can be adjusted individually. The tools are identified with a slot number, axis (or diameter of tool) and the customer assigned name. Chisels are identified by X-Y coordinate and axis

1. Identify the cut that is out of specification.

2. Select the Tool that is out of specification from the Main Head


4. For direction of cut see “How to Enter Calibration Data” on page 3-5.


3-21



(Customer Assigned Name): Identification of tool

Tool Slot: Identifica-tion tool Location

Axis: Identification axes (X,Y, Z, and Diameter Offset)

Diameter Offset is available on the rout-ers only.

Tool Slot Identification

Tool Location Assembly ParameterTool Slot 1 Main Plate Router Axis Y

Axis X

Axis Z

Diameter Offset

Tool Slot 2 Counter Rotate Router

Tool Slot 3 Deep Mortise Router

Tool Slot 4 Small Plunge Router

Tool Slot 5 Deep Drill

Tool Slot 6 Point to Point Drill Axis Y

Axis X

Axis Z

Chisels Chisels Axis Y, Axis X, and Axis Z of each discrete corner.


3-22


Tool Slot 4:

Tool Slot 2:

Tool Slot 3

Tool Slot 1

Tool Slot 6:

Tool Slot 5

Typical Edge-SS Adjustments

Below are simplified examples of how the cut will change with calibration.

Y: - Offset

X: - Offset

In this case the router pocket is out of specifica-tion. Negative offsets should be entered into the Y and X axis calibration to bring into specifica-tion. If there are any issues with lip depth use the Z axis calibration. (positive number to increase depth negative number to decrease depth)

3-23



In this case a lock hole is out of specification by location. Positive offsets should be entered into the Y and X axis calibration to bring into specifi-cation. If there are any issues with hole depth use the Z axis calibration. (positive number to increase depth negative number to decrease depth)

Y: + Offset

X: + Offset

In this case a lock hole is out of specification by diameter. Positive offsets should be entered into the Diameter Offset calibration to bring into spec-ification.

The chisel calibrations, adjust each corner of the square cut pocket.

For more information, see “Identifying Chisel Locations” on page 3-17.


3-24

CHAPTER 4 Tour of the Vision-FS

This chapter describes components, assemblies, and the user interfaces of the KVAL Vision-FS



page 4-2

Identification of Key Parts of the Vision-FS

A tour of the Machine. Description of assemblies on the machine

page 4-3

About the Lift Assembly A tour of the Lift Assembly page 4-4

About the Infeed and Outfeed Tables

Descriptions of the Infeed and Outfeed Tables page 4-6

About the Safety Curtain What to do if a field is broken and how to resume operation

page 4-10

About the Electrical Panels

Identification of components within the electrical panels

page 4-12

About the Vision-FS Description of the Feeder and Stacker within the Vision Line

4-1


About the Vision-FS

About the Vision-FS

The Vision-FS does double duty as a feeder and a stacker. A feeder takes a door from a stack and inputs it into a door machine for processing. A stacker is located at the end process and takes the door from the door machine and stacks them to get ready for the next step in manufacturing. The operation of the feeder and stacker is controlled and synchronized by the PLC/programming of the machine.

Stack 2 Stack 3Stack 1

FIGURE 4-19. Movement of Door Through the Vision-FS


4-2



This section describes the key parts of the Vision-FS.

Vision-FS Top View

Vacuum Pump Motor

Up and Down Motor

Motor and Belt Drive: Drive over to door and back to Rollers

Local Control: Light Curtain:

Side Loading of Doors

Door Lifting Pads

Infeed Door Roll Table

Outfeed Door Roll Table

Light Curtain:

Front Loading of Doors

Light Curtain:

Front Unloading of Doors

Light Curtain:

Side Unloading of Doors

Local Control

FIGURE 4-20. Top View of the Vision-FS

4-3


About the Lift Assembly


The Lift assembly is the key of moving doors effectively into process and out to stack after pro-cess. The control is a combination of sensors and programming to create a smooth transfer. This section identifies the main parts on the Carriage assembly.

Boom Assembly

Below are key components of the Boom Assembly.

Option Rotate Door: Some Vision-FS have a gear drive to rotate doors.

Up and Down Servo Motor assembly: Drives Grabber to pick up and place door on rollers

Vacuum Pads: Uses suction to move a door.

Vacuum Motor Sys-tem: Provides suc-tion to Lifting Pads

FIGURE 4-21. Components on thew Boom Assembly


4-4


Carriage Assembly

Below are key components located on the Carriage Assembly.

Vacuum Motor: Motor

Vacuum Input

Rotation Gear:

Rotates Door 180o

Vacuum Motor Filter:

Vacuum Pads Adjustment: DO NOT Adjust unless trained

Vacuum Pads: Three Pads

Horizontal Servo Motor

Vertical Servo Motor:

Air Manifold: Con-trols Pneumatics in Carriage

Vertical Brake Gear Box

FIGURE 4-22. Components on the Lift Assembly

4-5




The Infeed and Outfeed tables are synchronized with the Carriage, the Face-SS, and the Edge-SS.The combination of sensors and programming combine to create timing to load, unload, and rotate the door.

Infeed Table

Infeed Area to Stack Doors

Outfeed Area to Stack Doors Outfeed Table

Sensors

FIGURE 4-23. Locations of the In-feed and Outfeed Tables


4-6


Table Componentsbelow are key components of the Tables.

Pop-Up Cylinders: (x4)

Elevates rollers to move door to the fence

Cross Feed/ and Feed Motor: When cross feed belts pop-up this motor moves the door to the fence.

When cross feed cylin-ders re retracted, door is fed into table.

Feed Rollers: Moves door into Table

Cross Feed Belts (X2): Moves door to the fence.

Servo Motor (Outfeed Table Only): Motor feeds in the door from the Edge Lift table

FIGURE 4-24. Components of the Table

4-7


About Controls on Vision-FS


These controls are normally located at the door staging area. The controls are designed for safety during the operation of the machine. The controls can pause the machine to allow safe entry, dis-able the lift, reset the lift, and apply emergency stop.

Vision-FS Main Control

The Vision-FS controls are located on the Main Control Panel. For detailed information about the start-up process, see Chapter 2.

Control Transformer: Energize and De-Energize the machines

Start Machine Button: Wakes up the machine, similar to a boot-up

Stop Machine Button: Puts the machine to sleep.

Pause/Resume Lift: Press to pause lift. Pull-out the button to Resume Oper-ation. The action in process will be paused and maintained. Note: If enter-ing the staging area use the Request Access buttons located on the Staging area frames. For details on using the Request Access button, see page 4-9.

Start Sequence: After templates and programs are loaded, the doors are in place to process, the machines is homed, Press the Start Sequence but-ton to run the machine line.


4-8


Staging Area Controls

To Enter Staging Area (Request Access):

1. Push the blue Request Access button IN

2. A blue light will blink and the lift will move a door over therollers.

3. After door is over rollers, enter the Staging Area

4. After completed task, EXIT staging area

To Exit the Staging Area

1. After task is completed, exit the door staging area and PULLOUT the Request Access Button

2. Press the Reset Light Curtain Button to continue with the pro-cess (Note: These buttons must be used On initial start-up ofthe machine line.)

Emergency Stop: Press the Emergency button to stop machine. Will maintain clamp and lift. To restart machine, see “About Emergency Shutdown and Recovery” on page 2-7.

Pause/Resume Lift: Press to disable or pause the process cycle. To re-start process, pull OUT the button.

Feeder Controls

4-9


About the Safety Curtain


The Safety Curtain provides safety for personnel who enter the defined area when the machine is active. If any part of an operator’s body is detected in the defined area, the machine stops the operation.The machine must be reset from the operators station to continue machining.

The Safety Curtain is composed of an EZ-Screen emitter and receiver. The emitter has a row of synchronized light-emitting diodes (LEDs) that send signals to the receiver. The receivers have a a matching row of synchronized photo detectors that read the signal from the emitter. When the signal is blocked of any field, the machine stops. To continue machining, push the Start button

Important: The EZ-Screen system is aligned at the factory. Do not move the emitter or receiver modules. This may cause misalignment, if the system is mis-aligned the machine will not start

Emitter Receiver Emitter Receiver

Machine in operationBreaking of any field stops the machine

FIGURE 4-25. Operation of Safety Curtain

If the Field is Broken

If the field is broken, the machine will shut down. This is safety feature performs the same func-tion as an Emergency Shutdown (E- Stop). For information on the E-Stop function, see Chapter 2.

To Resume Normal Operation after an Field is Broken

If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved:


4-10


Location of Fields on the Vision-FS

The Vision-FS offers the versatility to load and unload doors from the front or sides.Safety Cur-tains are located on the sides and the front of the Vision-FS.

Stacker and Feeder Loading/Unloading Safety Curtain

Side Loading

Front Unloading Front Loading

Side Unloading

Feeder Loading Safety CurtainStacker Unloading Safety Curtain

4-11




Warning: High Voltage is present in this panel at the top of the Three Phase input even with the disconnect off. If working on the panel, follow disconnect protocol. See Chapter 1.

This section is an overview of the electrical components in the Main Electrical Panel. Refer the machine's electrical prints for in-depth information.

The Main Electrical Panel:

• Supplies voltages to the machine

• Contains the PLC (Programmable Logic Controller)

• Contains VFD’s (Variable Frequency Drives) and Servo Drives

Relays

24 VDC Supply

24 VDC,110 VAC Light Curtain Terminals

Thermal Resistor

VFD Feeder Motors

Out Feed

Cross Feed

Vacuum

Servo Drivers

Carriage Vertical

Carriage Horizontal

Infeed (Stacker)

Transformer

High Voltage Input

Fuses

PLC (Vision-FS), Electrical Outlet,

Vision-FS

FIGURE 4-26. Electrical Box for Vision-FS


4-12


4-13


CHAPTER 5 Tour of the Face-SS

This chapter describes components, assemblies, and the user interface of the KVAL Face-SS Sys-tem. The content is geared to help operators understand the basic operation of the Face-SS



About the Face-SS page 5-2

Identification of Key Parts of the Face-SS

A tour of the Machine Description of assemblies on the machine. Includes the Out-Feed, In-Feed, and Cutter Head.

page 5-2

Front View of the Face-SS A tour of the Operators Side of the Machine page 5-4

Back View of the Face-SS Descriptions of the Cutter Head and Tools page 5-7

Servo Motors and Valve Bank Locations

Illustrates locations of the servo motors and the valve banks

page 5-10


Descriptions of the Electrical Panels of the Face-SS. Includes: Nodes

page 5-13

About the Electrical Nodes

Location of nodes on the machine page 5-15

Description of the Face-SS within the Vision Line

5-1


About the Face-SS

About the Face-SS

The Face-SS is the second machine in line with the Vision System Process. machine

Opt: Op Station Location

FIGURE 5-26. Door Movement in the Face-SS


5-2



This section takes you on a tour of the Face-SS machine.

Top View

The figure below shows locations of selected areas, parts, and assemblies on the machine.

Electrical Panel # 2


Cutter Head

Sensors Located Throughout Machine

Roll Table

Clamps, Fence and Stops

Opt: Bolt Drill with chisels

Air System and Valve Bank: Air system deliv-ers CDA and lubricated air to valve banks and air cylinders, The valve bank: door stops and air blow off,

FIGURE 5- 1. Top View of the Face-SS

5-3


Front View of the Face-SS


At the front of the machine the operator controls the door through the process. This includes load-ing templates of the cut to be performed, controlling the path of the door, positioning the door, and feeding the door thorough to the next machine. The Figure below identifies major assemblies and controls.

Cutting Head: Work Horse. Servo Driven Tool Carriage to rout and drill the face of a door.

Operator Station:

The Operator’s Station includes a touch screen and keyboard to run the program that operates the machine.

Note: Multiple machine controls may combined in one station (Machine Combinations are Cus-tomer Definable)

Foot Pedal Controls:

Door Stops

Door Clamps

Emergency Stop

Fence, Clamps, Stops:

The Fence acts like a reference to align the door. The clamps hold the door in place in processing. Stops are located both sides of the table and are identified by software. Fence, Clamps, Stops

Door Rollers

Start Button: locally located start button that mimics the start button at the Op Station

Call Door: Press to load the door from the Feeder

FIGURE 5-2. Location of Assemblies on the Front Section


5-4


Foot Pedal Control

The Foot Pedal is centrally located and controls the Door Stops and the Door Clamps. Press the pedals once to engage, press again to disengage.

An Emergency Stop is also located on the pedal. Press the pedal to shut down the machine in a dan-gerous or risky situation.

Note: These controls can also software buttons the Operator’s Station.

Operator’s Station

The Operator’s Station includes a touch screen and keyboard to run the program that operates the machine. Machine power, and other controls are also centrally located at the station. Multiple machine controls may combined in one station (Machine Combinations are Customer Definable).

Touch Screen:

Face Controls:

Control Power

Start and Stop

E-Stop

Indicator Light

The indicator light monitors the process of the cutting routine. The visibility of the light allows observation of the progress of the machining in a factory environment.

TABLE 5-1. Indicator Light Descriptions

Color Description of Process

RedMachine in Error State

Yellow -Low Air Pressure

Green-(Solid) un Cutting Routine

-(Blinking) Ready to Start

Blue-No Remaining Work on the Door

5-5



Face-SS Fence, Clamps, and Stops

The Door is pressed against the Fence and Stops. After the door is secure, clamp the door with the foot pedal.

Retracted Stop: Stops are extended by manual food pedal

Door Clamps

Door Fence

Laser Safety Scanners

The Laser Safety Scanner generates a field to protect the operator during cutting a door. if the field is broken during cutting the machine will stop.

If field is broken

1. Push the START MACHINE button on the operator's station.



5-6

Back View of the Face-SS


At the front of the machine the operator controls the door through the process. This includes load-ing templates of the cut to be performed, controlling the path of the door, positioning the door, and feeding the door thorough to the next machine. The Figure Below identifies major assemblies and controls.

Air Bank

Y Axis Servo Motor

Fence, Clamps

X Servo Motor: Controls the movement of the car-riage in the X axis direc-tion.

Z Axis Servo Motor: Controls the tools up and down movement

Electronic Node: Con-tains connections from PLC and Power Supplies From the Electrical Boxes

Cutter Head: Work Horse. Servo Driven Tool Carriage to rout and drill the face of a door.

Opt: Four Corner Chisels

FIGURE 5-3. Location of Assemblies on the Back Section

About the Cutter Head

There are eight tools available, 4 that machine the top face of the door and 4 that machine the bot-tom face of the door. Options can include a Face Plate Router and 4 chisels. Holes or slots can be processed simultaneously from top and bottom with the cutting tools almost touching in the mid-dle of the door. This process is fast and eliminates tear-out or chipping of the door face. The top

5-7



and bottom tools are mirror images of each other. Software templates will automatically chose a tool based on door face, top or bottom, and cut size.

13 5 7

9

24 6 8

FIGURE 5-4. Cutter Head

Chisels and Face Plate Router (Option)

The Chisels and Face Plate Router work together to machine a faceplate on the edge of the door. The router drills the bolt hole and the air driven chisels corner the 4 edges of the faceplate. The router and chisels are attached to the same metal plate and are driven in axis by a servo motor. For location of the servo motor, see Figure 5-6 on page 5-10.

Figure 5-5 below shows the orientation of the chisels and the face plate router


5-8


FIGURE 5-5. Orientation of Chisels and Face Plate Router

5-9


Servo Motor and Valve Bank Locations


This section shows the locations of the servo motors and the valve banks. For detailed information about wiring, voltages, and parameters, refer to the Electrical Schematic that is shipped with the machine. These figures may be used in conjunction with the schematics to locate the assembly.

Servo Motor Locations

Figure 5-6 shows the locations of the servo motors on the machine. The motors interact with the Template, PLC, and servo drivers. They are highly accurate in movement and position.The motors are part of the calibration of the machine. See the calibration chapter for axis direction. See Ser-vice Manual for motor part numbers

Face Plate Axis (OPT):

Moves the Face Plate Drill and Chisel Plate

View from back sec-tion of machine

X-Axis Servo MotorY-Axis Servo Motor

Z-Axis Servo Motor

Right Stop Axis Servo Motor

Left Stop Axis Servo Motor

FIGURE 5-6. Location of Servo Motors

Valve Bank Locations

Figure 5-7 shows the locations of the valve banks on the machine. The valve banks include con-trol valves (solenoids) that drive cylinders to move different loads in the machine. The solenoid if


5-10


controlled by the PLC by applying a high voltage or a low voltage to a control coil. Controls for example are: extending and retracting router, drill, clamping a door.

Valve banks are normally located near the load that they drive.

Note: Labels on the solenoids identify loads they control.

View from back section of machine

Out Feed Valve Bank

In Feed Valve BankEdge Face Plate Valve Bank (OPT)

Top Head Valve Bank

Bottom Head Valve

FIGURE 5-7. Location of Valve Banks

Typical Valve Bank Controls

The table below lists the typical loads controlled by the valve banks.

Note: The values in this table are typical. To verify check the labels on the solenoids and the air schematic.

TABLE 5-2.

Valve Bank Loads (Cylinders)

Inside Stop, Outside Stop, and Clamp

1/2'' Router #2, 3/8'' Router #4, Drill #6, Drill #8, Anti Crash and Blow-Off

1/2'' Router #1, 3/8'' Router #3, Drill #5, and Drill #7

0/3 Degree, Router Extend, Left Chisel Extend, Right Chisel Extend, Door Feeler

Inside Stop, Outside Stop, and Clamp

In Feed Valve Bank

Bottom Head Valve

Top Head Valve Bank

Edge Face Plate Valve Bank (OPT)

Out Feed Valve Bank

5-11



About Sensors

On the Face-SS, sensors provide input to the PLC as part of the automation of the door cutting process, including feed through, door clamping, and door location. It is important to keep the sen-sors cleaned and aligned to keep the door process running smoothly. There are two classifications of sensors on the Face-SS: Photo Electronic and Inductive Proximity Sensor.

Photo Eye Detector Emitter and Receiver in one package

Proximity Detector Senses metallic objects

Proximity Sensors Used on Cylinders

FIGURE 5-8. Examples of Sensor


5-12



Warning: High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off. If working on the panel, follow disconnect protocol.

The Face-SS has a Main Electrical Panel, a High Frequency Panel and Nodes on the Cutter Head and the Frame. This section is an overview of the electrical components. Refer the machine's elec-trical prints for in-depth information

.



• Contains the PLC (ProgrammableLogic Controller)

• Contains servo drives to interact withthe servo motors.

The High Frequency Panel


• Contains the PLC interface seriallyconnect from Main PLC

• VFDs (Variable Frequency Drives) tointeract with the cutter motors

PLC (Face-SS)

24 VDC and 110 VAC Terminals

Relays

24V DC Supplies

Servo Drives

X Axis

Y Axis

Z Axis

Left Stop Axis

Right Stop Axis

Face Plate Router and Chisels Axis (Opt)

Transformer

High Voltage Input

Fuses

Face-SS Main E-Panel

FIGURE 5-9. Main Panel

5-13




Relays

VFDs

Router1 (Top)

Router2 (Bottom)

Router3 (Top)

Router4 (Bottom)

Drill Motor 1 (Top)

Drill Motor 2 (Bottom)

Drill Motor 3 (Top)

Drill Motor 4 (Bottom)

Face Plate Router (Opt)

High Voltage Input

Fuses

Face-SS High Freq Panel

Power Outlet

PLC (Face-SS)

FIGURE 5-10. High Frequency


5-14

About the Nodes

About the Nodes

Nodes are interfaces from the Main E Box. Node contain inputs and outputs of PLC and power connections. For example, door sensors, width adjusts, and tool interfaces.

PLC Interface

Top Ethernet cable is from PLC

Bottom Ethernet goes to Cutter Node

Inputs and Outputs

Interconnect Bar

FIGURE 5-11. Sample of a Frame Node

Typical Block Diagram of Network Connections

FIGURE 5-12. Block Diagram of the Network on a Face-SS

5-15


About the Nodes

Illustration of Node Connections

Cutter Node

Frame Node

High Freq Box

Main E Box:

Contains Servo Drives

Network Connec-tions, power, and Inputs/Outputs originate from this box and are con-nected to Nodes.

Net

wor

k C

onne

ctio

ns

Power Dis-tributed to Points in the machine

FIGURE 5-13. Locations of the Nodes on the Face-SS


5-16

About the Nodes

5-17

KVAL Operation/Service Manual

CHAPTER 6 Operation of the Edge-SS Line

This chapter describes components, assemblies, and the user interface of the KVAL Edge-SS Sys-tem. The content is geared to help operators understand the basic operation of the machine. Included are instructions to calibrate the machine and process a door.



About the Edge-SSDescription of the Feeder and Stacker within the Vision Line

page 6-2

Identification of Key Parts of the Edge-SS

A tour of the Machine. Description of assemblies on the machine

page 6-3

Front View of the Edge-SS A tour of the Operators Side of the Machine page 6-4

Assemblies on the Main Cutter

Descriptions of the tools located on the Cutting Head

page 6-10

Servo Motors and Valve Bank Locations

Illustrates locations of the servo motors and the valve banks

page 6-11


Identification of components within the electrical panels

page 6-13

About the Electrical Nodes Location of nodes on the machine page 6-15

6-1


About the Edge-SS

About the Edge-SS

The Edge-SS is a computer-controlled router designed to machine architectural doors for hinge pockets, T-strikes, concealed closures, flush bolts, leaf and European hinges, end pivots, as well as edge work for either cylindrical or deep pocket locks. Many customers also use the Edge for re-railing & re-stiling operations.

Opt: Op Station Location

FIGURE 6-1. Edge-SS in Vision System


6-2



This section takes you on a tour of the Edge-SS machine.

Top View

Control

Roll Table

Operators Station #2



Rails

Door Clamps

Main Cutter Head

Clamps

Door Feeler

OPT: Pop-up Power Rollers

FIGURE 6-2. Top View of Edge

6-3


Front View of the Edge-SS


At the front of the machine the operator controls the door through the process. This includes load-ing templates of the cut to be performed, controlling the path of the door, positioning the door, and feeding the door thorough to the next machine. The Figure below identifies major assemblies and controls.

Cutting Head: Work Horse. Servo Driven Tool Carriage to rout and drill the edge of a door.

Operator Station:


Note: Multiple machine controls may combined in one station (Machine Combinations are Cus-tomer Definable)

Foot Pedal Controls:

Door Stops

Door Clamps

Emergency Stop

Fence, Clamps:

The Fence acts like a reference to align the door. The clamps hold the door in place in processing.

Stops: Stops are located both sides of the table and are identified by software.

Lift Table:

At the end of the pro-cess this table lifts the door and deliver to the stacker portion of the Vision-FS

Machine Controls

Edge Pos Lights

Start Seq. Button

Edge Toggle

‘Door Finished

FIGURE 6-3. Front view of Edge-SS


6-4


Edge-SS Controls

This section describes the controls on the Edge-SS.

Main Machine Controls

Start Sequence: After templates and programs are loaded, the doors are in place to process, the machines is homed, Press the Start Sequence but-ton to run the machine line.

Door Finished: Clears the job if user wants to finish the job before com‐pleting all cuts, or at the end of the job if Auto-Feedout is disabled.

Edge Toggle: Door edge selection

This button adds the flexibility to over-ride the sequence and select the edge position. This button also allows the opportunity to repeat the selected cut.

Edge Position Lights: Indicates the selected door edge.

Foot Pedal Control

The Foot Pedal is centrally located and controls the Door Stops and the Door Clamps. Press the pedals once to engage, press again to disengage.

An Emergency Stop is also located on the pedal. Press the pedal to shut down the machine in a dan-gerous or risky situation.

Note: These controls can also software buttons the Operator’s Station.

6-5



Operator’s Station (Vision Line)

The Vision Line includes a free standing Operator’s Station. The interface on the Edge is a clone from the free standing station and operations can be executed from both stations.

Startup power controls for the Vision-FS and the Face-SS are located on this station. The Edge-SS power-up Controls are located on the Edge Station.

Indicator Light

The indicator light monitors the process of the cutting routine. The visibility of the light allows observation of the progress of the machining in a factory environment.

TABLE 6-1. Indicator Light Descriptions

Color Description of Process

RedMachine in Error State

Yellow -Low Air Pressure

-X Axis Auto Greaser Empty

Green-(Solid) un Cutting Routine

-(Blinking) Ready to Start

Blue-No Remaining Work on the Door

Operator’s Station on the Edge-SS



6-6


Touch Screen Interface: Main Control of Entire Machine Line. Download G-code and Templates to set the specifications of door machining. Manually control the door path and process through the line. Machine diag-nostics are included, as well as internet sup-port and connectivity for remote support via our Service Support.

Touch Screen Interface: Main Control of Entire Machine Line. Download G-code and Templates to set the specifications of door machining. Manually control the door path and process through the line. Machine diag-nostics are included, as well as internet sup-port and connectivity for remote support via our Service Support.

Keyboard: Enter data and interact with Touch Screen.

FIGURE 6-4. Operator’s Station

Operator’s Screen Layout

The Operator’s Screen contains the following:

The left side

• Contains a visual representation of the machine and the door placement.

• Shows the path of the door mir-rored by the operating template.

The right side

• Contains the Operator’s Inter-face.

Examples Door Placement (Left Side of Screen)

6-7



Edge-SS Fence, Clamps, Stops, and Feeler

The Door is pressed against the Fence and Stops. After the door is secure, clamp the door with the foot pedal.

Door Clamps

Door Fence

Door Stops

About the Door Length Feeler

The Door Length Feeler accurately senses the length of the door.

After the door has been fed in to the door stop, the feelers “feel’ the other end of the door. The location of the stop and the machine encoders are combine to calculate the exact length of the door.


6-8


Laser Safety Scanners

The Laser Safety Scanner generates a field to protect the operator during cutting a door. if the field is broken during cutting the machine will stop.

If field is broken

1. Push the START MACHINE button onthe operator's station.


About Sensors

On the Edge-SS, sensors provide input to the PLC as part of the automation of the door cutting process, including feed through, door clamping, and door location. It is important to keep the sen-sors cleaned and aligned to keep the door process running smoothly. There are two classifications of sensors on the Face-SS: Photo Electronic and Inductive Proximity Sensor.

Photo Eye Detector Emitter and Receiver in one package

Proximity Detector Senses metallic objects

Proximity Sensors Used on Cylinders

FIGURE 6-5. Examples of Sensor

6-9


Assemblies on the Main Cutter Head

Assemblies on the Main Cutter Head

Point to Point: Drills pilot holes for insertion of screws on the door

Counter Rotate Hinge Router: Routs the hinge pocket providing a clean cut.

Cylinders:

drives tools In and Out the door

Deep Drill Z-Axis Servo Motor

Plunge Router: Routs the lock hole in the door

Main Plate Router: Routs the Face plate pocket

Deep Mortise Router: Routs a deep pocket.

Zero/Three Degree Cylinder Toggles the Head for 3 and 0 degree cuts

X-Axis Servo Motor

Y-Axis Servo Motor

Electronic Node: Connections from the Electrical Panel

Auto Lubricators: Auto lubri-cates the X-Axis Gear and rail.

Opt: Chisels X4

Deep Drill: Drills a deep cut

FIGURE 6-6. Locations of Assemblies on the Cutter Head


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This section shows the locations of the servo motors and the valve banks. For detailed information about wiring, voltages, and parameters, refer to the Electrical Schematic that is shipped with the machine. These figures may be used in conjunction with the schematics to locate the assembly.

Servo Motor Locations

Figure 6-7 shows the locations of the servo motors on the machine. The motors interact with the Template, PLC, and servo drivers. They are highly accurate in movement and position.The motors are part of the calibration of the machine. See the calibration chapter for axis direction. See the “Vision System Service Manual” for motor part numbers

X-Axis Servo Motor

Y-Axis Servo Motor

Z-Axis Servo MotorDeep Drill Z-Axis Servo Motor

Feeler Servo Motor

FIGURE 6-7. Location of Servo Motors

6-11



Valve Bank Locations

Figure 6-8 shows the locations of the valve banks on the machine. The valve banks include con-trol valves (solenoids) that drive cylinders to move different loads in the machine. The solenoid if controlled by the PLC by applying a high voltage or a low voltage to a control coil. Controls for example are: extending and retracting router, drill, clamping a door.

Valve banks are normally located near the load that they drive.

Note: Labels on the solenoids identify loads they control.

Typical Valve Bank Controls

Table Valve Bank 2

Table Valve Bank 1

Cutter Head Valve Bank

Deep Drill Valve Bank

FIGURE 6-8. Location of Valve Banks

The table below lists the typical loads controlled by the valve banks.

Note: The values in this table are typical. To verify check the labels on the solenoids and the air schematic.

TABLE 6-2. Valve Bank Descriptions

Valve Bank Loads (Cylinders)

Extend and Retract: Stops, Feeler, Dust Hoods, Lower Door

Extend and Retract:; Clamps, Lift Table

Extend and Retract: Chisels (X4),Hinge Router, Router, CR Router, Deep Mortise

Extend, Retract., and Lift, Air Inject for Deep Drill

Table Valve Bank 1

Table Valve Bank 2

Cutter Head Valve Bank

Deep Drill Bank


6-12



Warning: High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off. If working on the panel, follow disconnect protocol.

The Face-SS has a Main Electrical Panel, a High Frequency Panel and Nodes on the Cutter Head and the Frame. This section is an overview of the electrical components. Refer the machine's elec-trical prints for in-depth information

.



• Contains the PLC (Programmable Logic Controller)

• Contains servo drives to interact with the servo motors.

The High Frequency Panel


• Contains the PLC interface serially connect from Main PLC

• VFDs (Variable Frequency Drives) to interact with the cutter motors

PLC (Edge-SS)


Relays

24V DC Supplies

Servo Drives

X Axis

Y Axis

Z Axis

Feeler

Deep Drill Z

High Voltage Input

Fuses

Edge-SS Main E-Panel

Transformer

FIGURE 6-9. Main Panel

6-13




Relays

VFDs

Plate Router

Point to Point

Feed #1

Feed #2

Plunge Router

Counter Router

Deep Mortise

Deep Drill

High Voltage Input

Fuses

Edge-SS High Freq Panel

Power Outlet

PLC (Edge-SS)

FIGURE 6-10. High Frequency


6-14

About the Nodes

About the Nodes

Nodes are interfaces from the Main E Box. Node contain inputs and outputs of PLC and power connections. For example, door sensors, width adjusts, and tool interfaces.

PLC Interface

Top Ethernet cable is from PLC

Bottom Ethernet goes to Cutter Node

Inputs and Outputs

Interconnect Bar

FIGURE 6-11. Sample of a Frame Node

Typical Block Diagram of Network Connections

FIGURE 6-12. Block Diagram of Network Connections

6-15


About the Nodes

Illustration of Node Connections and Power Distribution

Net

wor

k C

onne

ctio

ns

Main E Box:

Contains Servo Drives

Network Connec-tions, power, and Inputs/Outputs originate from this box and are con-nected to Nodes.

Frame Node

Cutter Node

Power Dis-tributed to Points in the machine

Power

Power

FIGURE 6-13. Location of Nodes on the Edge-SS


6-16

About the Nodes


6-18

Index
AAbort Job2-35, 2-39adjustment menus
how to use3-5

Bback section group

description2-35, 2-39Backup and Export Logs2-50Backup Logs2-50base

readout description3-5

CCalibration

about the tabs3-3enter a positive of negative number?3-4entering data3-5menus

reference cutsbefore you calibrate3-2

unlock3-4Clear Remaining Quantity2-35, 2-39contact information1-2control power indicator light description2-5control transformer switch

power up2-4, 2-6, 4-8customer service1-2

DDoor Length Feelers

description of6-8

Eelectrical panels

description4-12, 5-13, 6-13emergency shutdown

description2-7e-stop light

description2-5

Hhigh frequency panel

description5-13, 6-13hinge spec group

description2-40Home Machine2-35, 2-39

Iinductive proximity sensor5-12, 6-9

KKVAL, getting help1-13

Llocation of Door Length Feeler6-8lockout and tagout Guidelines1-11lockout procedure1-9log screen

description2-51

Mmain electrical panel

description4-12, 5-13, 6-13manual operation

interface2-41, 2-43menu map2-13

Ooverload relay light description2-5

Ppower

lock out procedure1-9powering

up and down machine2-4preset selection

description2-40product return procedure1-13

Rremote operation, setting up machine for1-15reset machine button

description user interface2-29, 2-35, 2-39Restore Points

createload

delete3-5return material authorization (RMA)1-13returning the product to Kval1-13


IndexRight Hand Rule3-4Routine Speed Percent2-35, 2-39

SSafe Mode Enabled/Disabled2-35, 2-39safety guidelines1-4Safety Sign Off Sheet

Safety Concerns1-18sensors

types5-12, 6-9service center, contacting information1-13six light panel

description2-5sequence list2-5

start light description2-5start machine button

power up2-4, 4-8Start Sequence2-35, 2-39stop light description2-5

Ttagout procedure1-9Toggle Clamp2-40Toggle Stop2-40

Zzero-energy start-up

clean up1-11inspect1-11


Notes:

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Customer Service

Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

Contacting KVAL

Phone and Fax:

In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

Email: [email protected]


vision line operation - kval inc

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