Anode Press Manual 2 D

AXIAL ANODE PRESS MANUAL
INDEX
SYSTEM DESCRIPTION ------------------------ 2
SENSORS ------------- 15
WIRE SUPPLY LOOP
MANUAL MODE OPERATION ---------------------------------- 15
POWDER SHOE SENSOR
MACHINE SETUP ------------------------------- 4-6

CONTROL ------------- 16
ANODE TRAY LEVEL
AUTOMATIC OPERATION --------------------------------------- 16-17
SERVO MOTOR SYSTEM
7-8
COUNTERS -------------------------------------- 8
CODES ------------ 17-18
SERVO MOTOR ALARM
MANUAL STEP OPERATION ------------------------------------------- 18-24
ALARM MESSAGES
COMPACTION POSITION MONITOR ----COOLING ------------ 24
10
ELECTRICAL CABINET
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MOTOR PARAMETER SETTINGS ----------------------------------------------- 24-25
11-12
AIR SUPPLY
PUNCH MOTION TESTING ------------------------------------------------- 25
12
SYSTEM POWER
LIGHT TOWER ---------------------------------- 12

POWER -------------- 25
CONTROL INTERFACE
WIRE CUTTER SETUP ------------------------- 13-14

LOADCELL ---------------- 26
FORCE PRESSURE
ANODE CUT SENSOR PH4 ------------------- 14

------------------------- 26
SYSTEM CONTROLLER
SYSTEM DESCRIPTION
Tantalum powdered metal is pressed into slugs for processing into tantalum capacitors.
This machine is designed to perform that task while inserting a tantalum solid wire into
the slug while the metal powder is being compacted.
The process is handled with nine Yaskawa servo motors
connected to a central control system. The controller
has an operator interface using a RedLion touchscreen
HMI providing access to process or motor parameters
and control buttons for the various motor functions.
Below the HMI screen there are three additional
switches. The left one is a key switch used to disable the
machine guards in the event access is required to
operate the system while accessible. At the center there
is an illuminated pushbutton switch with multiple functions. This switch is only active
when the indicator light is on. It is used to jog selected enabled servo motors, single step
the pressing sequence, and reset various process settings and counters. Additional
details of this pushbutton functions will be provided later in this manual. To the far right
side there is the Emergency Stop pushbutton. This is used to shut power off to all servo
motors preventing their operation. An indicator light is illuminated when active. When the
system is to be shut down for any extended period it is a good idea to use this shut off
function.
When the system is powered on the HMI will come up to the Main screen. This is the
normal running screen used while the system is producing anodes. Each screen page on
the HMI has a name associated with it along with a numerical value that is displayed on
the right top corner. These numbers are provided as a reference to aid the identification
of various screen pages used. These page numbers will be indicated in this document to
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ensure clarity of its intended functions. The left side of the HMI has a vertical row of six
buttons, to the right there is an additional row of vertical buttons shown on the screen.
Both rows of buttons have the same functions and operations.
On all HMI screen pages at the bottom there is a white area showing alarm or status
messages. When an alarm is detected a red alarm indicator will be displayed to the
bottom right. At the same time the light tower will illuminate the yellow light. An Alarm
Reset button is to the left of the white text area. This button
clears all alarm conditions and prepares the system to run again.
When multiple alarms are present then the Alarm Reset
pushbutton may need to be pressed more than once. Each alarm
message contains a date, time value, number identifier and
description, example: 9/5/10 10:14 Alm106> Wire Supply Move
Up Overtime. Details concerning the various alarm messages
and actions are described later in ALARM MESSAGES. Some
alarm messages are not associated with fault conditions but only
to indicate the status of the system and display a time of when a
condition was present.
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MANUAL MODE OPERATIONS

Manual motor control is provided for each motor allowing position indexing and jog
functions. It is selected using the Manual Functions pushbutton. This is useful when
making adjustments or verifying their operations. When selected a screen will be
displayed showing four system motor areas. Each area is grouped to associated items
with their function descriptions.
On any of the four screen groups a set of pushbuttons surrounded by a yellow box contain
the Jog functions. The Jog functions have two types of operation modes. One mode allows
selection to move a motor in either direction using the top and bottom buttons while
another uses the lower center pushbutton below the
HMI screen. The screen yellow box center pushbutton
labeled Jog Button: Enable is used to engage the
center bottom pushbutton on the HMI enclosure
previously mentioned. While enabled this function and
the HMI pushbutton will light up and the motor jog
direction will be indicated. Pressing the top or bottom
yellow boxed pushbutton will set the desired direction
of the control of this function. Pressing the center
yellow box Jog Button: Enable will disable it and the
pushbutton illumination will turn off.
Additional functions are also provided to
enable the motors to be moved to the
various programmed positions used during
cycling. A description of each position is
given along with the positional value below.
These motor positions are setup with the
password protected screens or by the
process settings of the part type dimensions
presently entered in the process setup
screen. The actual motor position value is
displayed at any given time even when
jogging the motor. Also a percentage torque
value is shown at the bottom of the jog
direction yellow box previously mentioned. This value can be a positive or negative
number as it relates to the motor shaft direction and the load applied to it.
Data is also included on these screens to indicate the amount of time the motor takes to
make its move during an indexed or programmed move. As the speed percentage value
of the system is adjusted, in percentage (10-100%), the time to make a motor move will
also be affected. The manual positioning uses the same speed values as the normal
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cycling but does not include any jogging operations. Those settings are contained in the
screens that are password protected. Other data is present on the manual screens
including: Distance between punches, Load Cell Force (Lbs.), Limit Switch Status, Peak
Torque Values (+-%), Wire Length Measurement, and Servo Status (On/Off).
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MACHINE SETUP
Preparation to run a batch on this machine requires installing a tooling set comprised of
two punches and a cylindrical dieset corresponding to the diameter of anodes to be
processed. These are selected in sets as their parts are very precise in fit and diameters
of the different anode sizes required.
Pressing the Manual Functions pushbutton
brings up the Jog and Manual Positioning Select
screen. Select Press Top and Bottom Punch
Drive. This will bring up the Press Punches
screen providing controls to manually move the
press punches. The screen includes both Top
and Bottom press punches. Two of jog controls
are available for the Top Punch. Two servo
motors are used with each one having a
specialized function. The top left set of controls
is the Top Punch Low Force High Speed (LF/HS).
This servo is used to provide a high speed
positioning of the punches. Next to it on the right screen side another set of controls
labeled Top Punch High Force Low Speed (HF/LS). At the bottom of the screen is the
Bottom Punch set of controls.
Using the Bottom Punch Jog pushbuttons press and hold the Down button while watching
the bottom punch move down. Move it down low enough for the punch to fully clear the
dieset. Also use the Top Punch Jog pushbutton to move the Top Punch up to give room to
access the punch for removal. When both punch mechanisms are clear of the dieset then
the punches are ready to be changed out. Press the Emergency Stop pushbutton to
ensure the mechanism will not move during the change out process.
Using an a 3/16 inch allen wrench loosen the pinch bolt for each punch and dieset
component then remove it and store it away in the storage container. Install the new
tooling set components while making sure they are properly seated in their positions. The
dieset tooling must be installed with its top even with the powder shoe sliding surface.
This may take several attempts to get this even. By using a flat edge of a scale or similar
item will aide in this setting
With the tooling installed a Homing Operation will need to be done. Returning to the Main
screen select Process Setup then on that screen select System Homing. Reset the
Emergency Stop pushbutton pressed earlier when the tooling was being changed out. A
Gauge Block will be used to home the punches. The thickness of this block is shown on
this screen and can be adjusted if different thickness blocks are used in the homing
operation.
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On the System Homing screen near the right upper corner

a pushbutton labeled Home Punch Press Servo Motor.
Pressing this pushbutton will start the homing process and a
status indicator will then show up indicating the ongoing
operations. First the Top and Bottom Punches will move
away from the center dieset to reach the end of travel limit
sensors. When reaching their limit positions their position
data will be zeroed and the punches will then move toward
the center dieset and stop before reaching it. The status will then prompt: Place Gauge
Block On Dieset Top. Lay the Gauge Block on top of the dieset flat across and evenly
spaced from center.
After placing the Gauge Block press the pushbutton marked
Place Block On Lower Punch Acknowledge Placement. The
two punches will then move together picking the gauge up
with the Bottom Punch with the Top Punch pressing against
it. Both punches will then move down until the bottom side
of the gauge block is pressing against the top of the dieset
tooling. The status will then display: Punches Zero Position
Value Set. Then it will display: Punches moving to Retracted
Position.
The Gauge Block will now need to be removed and the
status indicator will display: Confirm Block Removed From
Dieset. Another pushbutton will appear marked Remove
Block On Lower Punch Acknowledge Removal. Press this
pushbutton after removing the Gauge Block and the homing
operation will be done. If the dieset was pushed down
during the homing operation then it may be necessary to repeat this operation again
after correcting its position.
Homing of the other motors can be done on this screen by pressing the Home
pushbutton associated with the mechanism. Each motor will move to its end position limit
reaching a positive stop. When a motor hits its limit the controller will reset the motor
position counter and set its zero position. After setting its zero position the motor will
move to a retracted or rest position ready to operate. A status message box is provided
for each motor. Homing is not required after cycling the power to the system. All positions
are backed up with a battery for each motor axis. One point to note is to not disconnect
any of the servo motors from its cable! Doing so will lose the motor configuration data
and require reprogramming to restore operation.
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Process parameters, of a batch of parts to be made,

can be entered using the Process Setup select
pushbutton, shown on the Main screen. The Process
Setup screen has the process data divided into
three areas. First: Anode Anode Diameter, Anode
Length, Anode Weight, Top Compaction Percentage,
and Compaction Speed. Second: Wire Wire
Insertion Percentage, Outside Length, Wire
Diameter, Cylinder Enable/Disable (Wire Feed), Wire
Release Percentage, and Cut To Dieset Top Distance
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(Wire Cutter cut line to Top of Dieset distance). Third: Powder Binder Percentage, Osc.
Strokes Done (Times the Powder Shoe shakes while filling the Dieset), Scott Density, Press
Density, Fill Depth and Overfill.
Batch setup operation is next with
information about the run to be entered by
using the Batch Setup select pushbutton,
shown on the Main screen. On the Batch
Setup screen left side there are areas to enter
count numbers of the batch. Each batch is
composed of a quantity of Levels with a
preset number of anodes to be placed in each
one. Entering the level quantity along with
the number of levels has the system calculate
the total number of anodes to be made for
the given batch. The count value totals will
need to be cleared before starting another
batch. Below each count box there is a reset pushbutton (Reset Batch Count and Reset
Level Count). When pressing any of these two pushbuttons the center pushbutton below
the HMI will illuminate. By pressing that pushbutton and the reset pushbutton on the
screen the count will reset to zero.
As the data is entered from the Batch Router Sheet the
system will calculate and set the press punch positions
required to start an initial run. Tantalum powder is loaded
on the Bulk Powder Feeder unit and Tantalum Wire spool
is placed and threaded through the wire straightener
mechanism, upper loop area and then down to the Top
Punch area. Moving the Top Punch to the Stage
position will make it easier to access and thread the wire
into the mechanism. A lever is provided to release the
wire from the drive wheel pinch roller set. The wire is to
be threaded thru the Top Punch center hole. Allow the
wire to extend beyond the end of the punch.
A flat item such as a brush wooden handle can be used
to gently push the wire up flush with the punch end while
holding the release lever. When flush then release the
lever and the wire is all set. Whenever the wire needs to
be reset this method can be used. A possible instance
would be after manually cutting an anode from the end
of the wire with some snips.
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AUTOMATIC OPERATION
With tooling changed, product
parameters setup, counters reset
and materials loaded the system is
ready to run. Selecting the Main
screen batch count information can
be viewed. On the right side of the
screen there is a Time and Date
Display.
The Main screen center area
contains pushbuttons to operate the
system in automatic. Areas
surrounding the Stop and Start
Pushbuttons provide a colored
surround that is only active when
the process is operational. A prompt is shown below the Start pushbutton indicating
Ready To Start status along with the pushbutton background. If the Emergency Stop
pushbutton is pressed or if an alarm condition is detected then this color box and prompt
area message becomes invisible. This makes it easy to identify if the system is in running
condition. Also while the system is cycling a prompt is shown indicating System
Running.
Stopping the system operating is normally done using the Cycle Stop pushbutton unless
there is a need to discontinue running mid cycle. This pushbutton is only visible while the
system is running. The cycle can be stopped anywhere by pressing the Stop pushbutton
and can be resumed by pressing the Start pushbutton again. If a cycle is stopped mid
cycle and the system switched to Manual Mode then the process cycle will be reset to
start at the beginning when restarted. The Auto/Manual Mode status is shown in the
upper right corner of all screens.
When making anodes some adjustments are necessary to compensate for variances in
materials and machine conditions including flexing under compaction loads. Selecting
Adjust Dimension from the Main screen brings up four adjustment parameters. The left
two items are associated to the Anode Length and Weight. While the right two
parameters are associated to Wire Outside Length and Overall Length. Anytime the part
dimensions are changed in the Process Setup the adjusted dimensions are restored to
an initial value determined from the system calculations from that entered data.
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A Single Cycle pushbutton is visible when the system

is ready to run on the top right screen corner. Pressing it
causes the system to cycle and make a single anode
without adding its count of one to the Active Level
Quantity value. Its purpose is for making physical
checks of an anode that is removed from a normal run.
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Anodes produced are measured and if

out of tolerance their measurements are
entered in the Adjust Dimension screen.
After the data is entered again switch
back to the Main screen and make some
additional anodes to be measured. If
additional adjustments are needed then
go back and enter the new
measurements and repeat until the
dimensions are within tolerances. If the
measured dimensional values become
worse and it is decided to restart the
adjustment process then to initial values
can be restored for that given
adjustment.
Below each adjustment box there is a blue pushbutton labeled Adjustment Reset with
its function noted. Pressing any of these four pushbuttons will make the center
pushbutton below the HMI illuminate. By pressing that pushbutton and the Adjustment
Reset pushbutton on the screen the initial setting is restored.
COUNTERS
Press Tooling along with the Wire
Cutter and other consumable items
will wear out in a number of cycles. A
counter screen is provided to enter an
item name along with a count preset
number. This can be accessed from the
Main screen by pressing System
Counter selection pushbutton. Ten
different items are available for
counting. Each one has a label that
can be modified with a text message
detailing the purpose of that counted
item. To modify the text touch the
white message line and a keyboard will be displayed allowing editing it. Once the
message is prepared the count preset value will need to be entered. Press the message
associated Preset count and enter a number desired. If the preset value is set to zero
then the message will be disabled and not function.
Each time the system cycles the count will increment by one. When the count value is
reached by a given counted item the system will stop and the entered message will be
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displayed below in the alarm message box at the bottom of the screens. The system will
not restart and the count alarm will not clear until the counter is reset again or count
preset changed to a higher value. The counter can be reset to zero by pressing the
Count Reset and the center pushbutton below the HMI . By pressing that reset
pushbutton and one below the HMI screen the count will reset to zero.
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MANUAL STEP OPERATION

Checking the operation of the system it
becomes important to be able to step the
machine cycle through its sequence. A
mode is provided to allow this function.
Access to the Sequence Step Mode is
provided through the Compact Graph
selection on the Main screen. When
selected the screen contains a list of motor
position values along with two sequence
counter displays. Counter A relates to the
press control movements while counter B
relates to the wire cutter and anode drop
off operations. These two counter displays
are also provided on the Main screen. These two counters are useful in tracking the
process and an aide in troubleshooting the systems operation. In the event there is a
problem with the system then it would be useful to spot the program area running at that
point. The program is written using these count values in its sequence.
When this function is enabled then the center pushbutton will be illuminated. Each time it
is pressed the sequence will be stepped. Holding the pushbutton in will not make the
sequence keep cycling. Some of the steps will not result with actual motion of the
mechanisms. The steps without motion are there as an operation necessary for the
sequence to process the cycle. As the steps are made the sequence numbers can be
seen.
During the step operation the Wire Supply does not cycle to keep the overhead loop feed.
A pushbutton is provided to manually cycle the Wire Supply unit if additional wire is
needed for the manual stepping operations. Another pushbutton is also provided to open
and release an anode when needed from the wire cutter holding an anode. This allows
catching the anode for further checking of the cutter or clearing out the cutter to resume
normal cycle operations.
The system is capable of cycling without actually making anodes by selecting the Dry Run
mode. A pushbutton enabling this function is provided. When this mode is enabled the
pushbutton will show Dry Run Operation Selected. The Main screen will also indicate
this operational mode. While cycling the system in this mode the Powder shoe will not
move fully out to center the punch dieset. It does this to keep from filling it preventing it
from making any anodes. The wire feed will also be disabled during this time.
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COMPACTION PUNCH POSITION MONITOR

Making anodes with the proper density of
tantalum powder compaction relies on both Top
and Bottom Punches moving together to a
central point. To ensure this operation is correct
and working properly a screen is available to
check this process operation. From the Main
screen the Compact Graph can be selected.
The screen has graph showing the punch travel
distance positions during the compaction phase
of processing. Top punch movements are shown
in red while the Bottom punch is in blue. To the
right a percentage value is shown indicating the
error between the two punches for a given position set point. Fifteen different check
points can be adjusted for the overall punch distances to move to. Touching the Check
Setting value brings up the keypad allowing position set points to be modified. The
values are in inches and can be set to position points within the length of anodes
processed. A graph on the right center of the screen displays the fifteen position error
percentage values to make it more clear how the process is operating. Maximum error
percentage limit can be set on the top left of the Process Setup screen. If the limit value is
exceeded then the system will have an alarm with associated message.
CONTROL INPUT/OUTPUT MONITOR
There are several sensor inputs and output items
controlled by the system. Functions are given to allow
monitoring and manual control to them. After selecting
the Manual Functions screen then select Control I/O.
This screen will display the status of all of the
controllers Inputs and Outputs. Two rows of sixteen
items are shown along with a description of each one.
colored square next to each one shows its status of Off
On.
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While on that screen select Output Control and the

listed output items will then be shown to the left side of
the screen along with lines connecting to Toggle
Output pushbuttons. Here any of the outputs can be
manually controlled to check their operation and the
device connected to it. When leaving this screen
selection process items used will be reset to their
correct state. Other items not used will remain as set
during this manual operation.
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MOTOR PARAMETER SETTINGS

The mechanics of this system are composed of nine servo
motors each controlled by a central unit connected together
by a network. Motor parameters including position and speed
set points are accessible through the HMI. The data
adjustment areas on the HMI are password protected to
restrict unauthorized personnel access.
The nine servo motors have various settings necessary to
control their movements of both speed and position. This
servo data along with other related data is accessible in the
Password protected areas. Access to this is made by
selecting the Motor Axis Setup pushbutton. Here the
password screen will show. A block will appear Press To
Enter Password:. When the block is pressed a keypad will
pop up allowing the password number to be entered. After
entering the password then press the block Press to goto
Motor Selection. From there a screen will display giving all of
the selections available.
When the password is entered and the selection made to go
to the motor selection a screen will display eight pushbutton
blocks of motor selections and two other items. Each motor axis is indicated along with
its function. By touching a block selection the screen will change to that motor and axis.
Each motor axis screen contains an upper blue box
indicating the motor units, example: inches, the motor
position data settings use. The range of the motor
movements and settings are also provided to help
ensure proper settings are used. Selecting a data field
to adjust is done by touching the line containing the
data twice. A keypad will display allowing entering a
new value into that selected item. After
touching the Enter the data will be written
into the display. Be sure of what setting is
being changed and why it is being modified.
Most data entry items are checked to be
within a limited entry number. If out of this
range the data will not be written into the
selection and the display will give a beep
sound.
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The bottom left pushbutton selection of the

Motor Select & Force Loadcell screen
brings up a screen allowing the set
adjustments of the upper and lower
pressure limits measured by the loadcell
during the Compaction cycle. If the loadcell
pressure, during a compaction cycle, is not
within the two set limits then an alarm
condition is set and message displayed
describing it. An offset value is also
adjustable to zero the loadcell output when
no load is actually pressing on it. The weight
of the bottom punch and its tooling and be
subtracted from the readings.
PUNCH MOTION TESTING
On the bottom right side of the Motor
Select & Force Loadcell screen there is a
function called Motion Test Of Punch
Servo. This is used to operate the Top or
Bottom punch servo motors to move up and
down for a preset number of cycles. A set of
Stop and Start pushbuttons is provided to
give manual control to the test operation.
Delay times in seconds for each move
direction can be set by touching the
associated data lines. Number of cycles can
be adjusted with a maximum of one
hundred along with cycles completed is
shown. Selecting the Top or Bottom punches to run the Motion Test can be made with the
pushbutton above the cycle count box. A speed setting in percentage can be modified by
touching the data display line. It can be adjusted from 10 to 125 percent. This speed
setting is used for the Manual and Automatic operations of this system. The normal
setting for making anodes is 100 percent but under some conditions this could be
changed.
LIGHT TOWER
A three position light tower is included in this system to indicate the operation status
from a distance. If needed the light tower can be operated using the Control I/O
functions.
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RED System Stopped in Automatic Mode

YELLOW Alarm condition present with message showing
machine fault
GREEN System operating normally without alarms
WIRE CUTTER SETUP

Wire Cutting is done with two motors, one to position a
cutter assembly (Cutter Swing) and a second one to
move the cutter tooling (Wire Cutter) to perform the
cutting operation. The wire cutter tooling has a width of
cutter blade that needs to be utilized across its inside
area to extend the
number of cycles it can
be used. A function is
programmed to move
the cutter placement back and forth automatically.
Three parameters are used in this operation. A position
value is set as the inside starting point of the cutter
tooling nearest the center of the mechanism. This can
be set by having the Top Punch in the Wire Cut position
with a wire extended from the punch low enough for the
wire cutter to reach it. Jogging the Cut Swing arm
toward the Top Punch the wire position related to the
cutter blade can be established. Noting the Cut Swing
actual position value when this position is found it can
be entered thru the Motor Setup area as the Cut Edge
Pos. The second parameter is the active cutting blade
cut area set as Cutter Width. This can also be entered
when the edge position is setup. The third parameter is the amount of index distance the
cutter needs to move for the next cutting operation. This value comes from the Wire
Diameter parameter setting. This way the cutter indexes one wire width each cycle until
it reaches the outside cutter width setting then it returns back to the starting point of the
cutting operation.
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As the Cutter Swing moves from the Cut to the Anode Release position the cut
position is recalculated for the next move to the cut position. Using the Manual Wire
Cutter controls the positioning controls can be
checked and verified. As shown in the picture on
the right there is the Cutter Swing Start Cut Pos.
To the right three parameters are shown. A Cut
Offset value is shown that is two wire diameter
indexes past the starting position. The Cut New
Pos indicates the position the cutter will move on
its next move to cut a wire off at the Top Punch.
The index value can be changed for verification
but the value setting will be automatically reset
when the system is running. Moving the Cut
Swing back and forth between the two positions between cutting and drop off will
indicate how it operates during normal operation cycling.
If the cutter is damaged and a section needs to be bypassed then the Starting point and
the Cutter Width values can be adjusted to have the system operate until the tooling
issues can be addressed. By adjusting the starting point position of the Cutter Swing and
the Cutter Width movement can be restricted from a damaged or worn out area of the
cutter tooling.
To monitor the number of cut cycles a counter can be programmed with the cutter name
and a preset value of machine cycles. When the number is reached then an alarm will
signal the event alerting the operator that the tooling needs attention. Additional details
can be found in the Counter section of this document.
ANODE CUT SENSOR PH4
A sensor is provided to detect anodes cut and moved
to drop into the Level Trays. The sensor is a reflective
type using a fiber cable connecting to a Keyence
sensor amplifier. Below the cutter assembly a bracket
is provided to allow adjustment of the sensor end to
align it with an anode being held in the cutter wire
holding jaws. Light reflected back from the sensed
anode is picked up and sent back to the sensor
amplifier where it converts it to a numerical value and
compares it against an adjusted setting. When the received value meets or exceeds the
setting then the anode sensed is present.
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During normal operation the Cut Swing arm moves the

Wire Cutter into position after an anode is formed and
the Top Punch is in the Wire Cut position. After the
Wire is cut the Cutter Swing arm starts moving back
away to clear the punch. As the arm moves back the
Anode Sensor (PH4) starts checking for the presence
of an anode in the Cutter. If the anode is not there the
system will stop and alarm: Alm30> Anode Not
Detected After Cut Sensor PH4. The pressed anode
may have not been dropped, wire bent making the cutter miss cutting, or sensor
misadjusted. To ensure the sensor is operating correctly its output status is checked when
the system is started and during the operation cycle. If the sensor output is on at the
wrong time the system will stop and alarm: Alm31> Anode Cutter Sensor PH4 Fault.
If either one of the two alarm messages come up then check the situation to confirm the
fault and take corrective actions. When an anode is missed at the cutter the cause could
be from tantalum wire having a curve moving it away from the cutter tooling. This could
be caused by the wire straightener not being properly
adjusted or wire kinked during setup. Other problems can
result from sensor misalignment or contamination of the
fiber detection ends.
Access to the adjustment of the sensor amplifier PH4 can
be done by opening its cover by swinging it up. Two
numerical values are displayed. The green one is the set
point while the red is the value received back from the
fiber pair. Adjust the green LED set point at least twice the value shown in the red LED
without any anode present.
WIRE SUPPLY LOOP SENSORS - PH1 (LOW) PH2 (HIGH)

Wire fed from the Wire Supply Hitch Feed mechanism
travels in a loop between two lexan panels over above
the Top Punch assembly down to the Wire Feed drive
unit. Wire within the top loop section is monitored to be
within two extreme positions. The two sensors are
mounted on the back side of the rear lexan panel. Both
sensors point forward. Placing a hand on the front side
of this panel adjacent to a sensor will activate it. When
the system is cycling in automatic mode this sensor
pair is also activated and used to control the Wire Supply.
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Wire reaching the lower sensor PH1 starts the Wire

Supply cycle while the upper high sensor PH2 stops it.
The sensor interface to the system controller can be
checked by accessing the Control I/O screen.
POWDER SHOE SENSOR PH3

A thru beam sensor is attached to the Powder Shoe
to control the level of powder contained in the
vessel. An adjustment clamp is provided to allow
adjustment to set the height of the powder filling
it. While the system is cycling the sensor is
checked and when below the sensor beam line.
The Bulk Powder Feeder is signaled to operate at
that time for a programmed rotation and again the
sensor checks the powder level. This will repeat
several times until full or if the filling time goes
into overtime and an alarm message is displayed:
Alm74> Powder Shoe Charge Overtime Low
Powder. The sensor operation can be verified using the Control I/O screen.
ANODE TRAY LEVEL CONTROL

The pressed anodes are dropped into a tray known as
a Level. After the anodes are cut and removed from
the Top Punch tooling they get placed into a container
for further processing. The system has the option of
using a Level or other types of catch containers. The
typical Level tray used is placed on a motor driven
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rotary turntable. Several controls are provided to adjust the actions of the drive motor.
Accessing the Motor Axis Setup by entering the password the Motor Select & Force
Loadcell screen is shown. Selecting the Wire Cutter Axis 6 will bring up that screen. On
the bottom right side there is a box labeled Pressed Anode Tray Turntable Motor Control.
Two sets of adjustments are provided with the top one setting the number of cycles
Anode Tray Cycles to Turn to start the turntable motor running. If the value is set to zero
then the turntable motor will never start. Below that the amount of time the tray needs to
rotate is set with Anode Tray Turn Seconds. If the tray needs to continuously turn then
enter zero to this setting.
The motor can also be manually turned on for checking or
setup purposes by using the Control I/O accessible from
the Manual Function selection. After reaching the
control screen select the Output Control pushbutton.
Output 11 can then be toggled to switch the output on
and off as needed.
SERVO MOTOR SYSTEM
Axis 1 Bottom Punch, Axis 2 Top Punch Low Force/High Speed (LF/HS), Axis 3 Top
Punch High Force/Low Speed (HF/LS), Axis 4 Powder Shoe, Axis 5 Bulk Powder
Feeder, Axis 6 Wire Cutter, Axis 7 Wire Cutter Swing, Axis 8 Wire Feed, Axis 9
Wire Supply
Nine servo motors are used in the system with each one
setup and tuned to a specific function. It is not advised to
interchange the motors or drives. During machine setup
each drive module and servo motor was loaded with a set of
parameters specifying how that motor was to function with
the mechanical load attached. Each motor has two sets of
cables attached to it connecting to the drive module located in the main electrical
enclosure. The cables connecting them have a battery
backup in them located near the drive end of them. This
battery keeps the data stored in the motor active and also
keeps the motors encoder shaft position updated. Under no
circumstances should any motor cable be disconnected
from a motor. If it is disconnected then all servo
configurations and motor shaft position data will be lost.
Restoring the motor configuration will require reloading the
servo parameters by connecting the drive to a computer
using a Yaskawa program called SigmaWin+.
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Having the
motors fitted
with a battery
backup the
system does
not need to be
homed when
the main
power is
switched off.
This holds true
even if the
motor shafts
are turned in
the off
condition. Rehoming is only
necessary
after
disassembling
a mechanism that upsets the mechanisms position relative to the motor shaft rotation
angle.
Each servo motor drive has a setting address that identifies it on a network called
Mechatrolink. A set of rotary switches are located on each drive to setup them. Details
on each ones setting can be found in the electrical schematics. The motors are each
numbered with an Axis number from one to nine. Number labels are placed on each
motor to help identify them and referenced in the various screen pages as to their
function names given them. The motor drives also have a number label to identify them.
Drive placement in the electrical enclosure does not follow a
sequential order but is grouped with its wattage power rating.
In the event a servo motor fails and stops working an alarm
message code will result. On the upper part of each servo drive
there is an LED readout that will flash signal codes identifying
its status. Reading the code will reveal the reason the motor
has stopped working. However not all alarm codes will stop the
motors operation. Some of the code signal conditions indicate intermittent motor torque
overloading and other detected occurrences not favoring ideal running operations. The
three servo motors used to drive the press punch tooling have motor alarm readouts
shown on the Batch Setup and Punch Motion Testing HMI screens. When no alarm is
present then the red code readout box will not appear.
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SERVO MOTOR ALARM CODES

The following list contains the more common Alarm conditions that will be encountered
on this system. Other alarms not listed can be found in the Yaskawa Motion Module Users
Manual in the Troubleshooting section 10 on Table 10.2.
Code
Alarm Name
A400
Overvoltage
deceleration
A410
Undervoltage
A510
Overspeed
Alarm Content
Incoming Power Input Voltage High or motor
setting too high
Incoming Power Input Voltage Low.
The servo Speed is too High.
A710
Overload (Instantaneous The Servo Motor ran with a torque exceeding its
rated torque
Maximum Load)
for several or more seconds.
A720
Overload (Continuous
at torque ratings
Maximum Load)
A7A0
or
Heat Sink Overheat
The servo motor is operating continuously

exceeding its rating.
The servo driver is Overheated. Motor overloaded

or electrical enclosure cooling filter blocked.
A810
Encoder Backup Alarm
encoder cable
disconnected from the motor.
The servo motor encoder data lost by weak

battery or the cable was
A830
Encoder Battery Alarm
and needs replacing
The battery in the encoder cable is weak
A860
Encoder Overheat
motor being
ACA0
The servo motor encoder is overheated from

overloaded without enough cool off time.
Encoder Parameter Error The servo motor encoder data is corrupted
ALARM MESSAGES
The alarm messages are numbered and identified with that number in the control
program. When a problem exists with a given alarm use the reference number when
contacting machine support. As each alarm is shown it is also logged into a screen for
viewing. Selecting the Adjust Dimension screen and then selecting Revision and Alarm
Data Log the logging screen is active. Here all alarm and machine condition messages
are shown. As each item changes condition from active to inactive the message line
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becomes a different color. A red message line shows when the

status or alarm condition occurred while a green one shows
when the alarm or status was cleared. Two left pushbuttons
allow scrolling thru the messages. Clearing the Alarm Data is
done by pressing the illuminated center pushbutton and the
Clear screen pushbutton. Both items must be done together
to do this.
During an alarm condition the Light Tower will
have the Yellow signal illuminated. If the system
was in automatic running operating mode then
the Red tower light will also be illuminated.
Alm1>
E-Stop Pushbutton Pressed

Emergency Stop Pushbutton
Pressed Power to servo drives shut off.
Alm2> Guard Interlock
Open
Machine Guard Door
Open Interlock Switch circuit open.
Alm3> Guard
Override Active
Key
Switch in Guard Override Position Guards Disabled Allowing Operation.
Alm4> System Sequence Jog Mode Active
Pressing Operation Step Mode Active Process Sequence
Testing
Alm5> Cycle Stopped
System in Automatic Mode and Stopped
System Not Running
Alm6> Cycle Started
System in Automatic Mode and Running System Running
Alm7> Manual Mode Selected
System in Manual Mode Manual Mode Active
Alm8> Punch Initialization Active to
Home Servo Motors
Top and Bottom Punch
Servo Motors Homing Punch Home Sequence Active
Alm9> Powder
Shoe Initialization Started
Powder Shoe Motor Homing Powder Shoe Home Sequence Active
Alm10> Wire Supply Initialization Started
Wire Supply Motor Homing Wire Supply Home
Sequence Active
Alm11> Wire Cutter Swing Initialization
Started
Wire Cutter Swing Motor
Homing Wire Cutter Swing Home Sequence Active
Alm12> Wire Cutter
Initialization Started
Wire Cutter
Motor Homing Wire Cutter Home Sequence Active
Alm13> Place
Punch Initialization Spacer Block
Place Spacer Block on Top of Dieset Prompt Punch Initialization Active
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Alm14> Remove the Punch Spacer Block

Remove the Spacer Block on Top of Dieset Prompt
Punch Initialization Active
Alm15> Punch Initialization Spacer Block
Removed
Confirmation the Spacer Block
is Removed Prompt Punch Initialization Active
Alm16> Servo Power
Manual Shut Off Active
Servo
Power Shut Off using Manual Control Manual Output Control Active
Alm17> Air Pressure Low
Incoming Air Pressure Low Air Pressure Switch PS1 Detects Low Air
Pressure
Alm18> System Not Homed Home System
Servo Motors Not Homed Homing
Operations Needed
Alm19> Punches Not Homed
Home Punches
Punch Servo
Motors Not Homed Punch Homing Operation Needed
Alm20>
Powder Shoe Not Homed Home Powder Shoe
Powder Shoe Motor Not Homed Powder Shoe Homing Operations Needed
Alm21> Wire Supply Not Homed Home Wire Supply
Wire Supply Motor Not Homed Wire Supply
Homing Operations Needed
Alm22> Unused
Alm23> Wire Cutter Swing Not Homed
Home Cutter Swing
Wire Cutter Swing Motor
Not Homed Wire Cutter Swing Homing Operations Needed
Alm24> Wire
Cutter Not Homed Home Wire Cutter
Wire Cutter Motor Not Homed Wire Cutter Homing Operations Needed
Alm25> Unused
Alm26> Wire Feed Inhibited Wire At Loop Upper Sensor (PH2)
Wire Loop Upper Sensor Active Wire Supply Cycle
Inhibited
Alm27> Wire Feed Drive Not Tracking
Encoder to Motor
Wire Not Moving Correctly
While Feeding to Top Punch Wire Slipping or Kinked
Alm28> Unused
Alm29> Unused
Alm30> Anode Not Detected After Cut Sensor PH4
Anode Cut from End Of Top Punch Missing After Moving
Back Cutter or Sensor Trouble
Alm31> Anode Cutter Sensor PH4 Fault
Anode Sensor PH4 Output On when it
should be Off Check Sensor and Fiber Cable
Alm32> Unused
Alm33> Bottom Punch Axis#1
Position Error
Bottom Punch
Servo Motor Alarm Present Reset Alarm to Clear
Alm34> Bottom
Punch Jog Up Limit Position
Bottom Punch Jogged Up and Reached its Upper Limit Switch Sensor
Alm35> Bottom Punch Jog Down Limit Position
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Bottom Punch Jogged Down and Reached its Lower Limit

Switch Sensor
Alm36> Bottom Punch Top Of Dieset
Position Overtime
Bottom Punch was
Moving to Top Of Dieset Position but did not make it in time
Alm37>
Bottom Punch Overfill Position Overtime
Bottom Punch was Moving to Overfill Position but did not make it in time
Alm38> Bottom Punch Fill Position Overtime
Bottom Punch was Moving to Fill Position but did not
make it in time
Alm39> Bottom Punch 0.05 Inch Position
Overtime
Bottom Punch was Moving to
0.05 Inch Position but did not make it in time
Alm40> Bottom Punch
Anode Eject Position Overtime
Bottom Punch was Moving to Anode Eject Position but did not make it in time
Alm41> Top Punch LF/HS Axis#2 Position Error
Top Punch Low Force/High Speed Axis #2 Servo
Motor Alarm Present Reset Alarm to Clear Alm42> Top Punch HF/LS Axis#3
Position Error
Top Punch High
Force/Low Speed Axis #3 Servo Motor Alarm Present Reset Alarm to Clear Alm43>
Top Punch Jog Up Limit Position
Top Punch Jogged Up and Reached its Upper Limit Switch Sensor
Alm44> Top Punch Jog Down Limit Position
Top Punch Jogged Down and Reached its Lower Limit Switch
Sensor
Alm45> Top Punch LF/HS Stage Position Overtime
Top Punch was Moving to Stage
Position but did not make it in time
Alm46> Top Punch LF/HS
Top Of Column Position Overtime
Top Punch
was Moving to Top Of Column Position but did not make it in time
Alm47>
Top Punch LF/HS Compact Release Position Overtime
Top Punch was Moving to Compaction Release Position but did not
make it in time
Alm48> Top Punch LF/HS Wire Cut Position Overtime
Top Punch was Moving to Wire Cut
Position but did not make it in time
Alm49> Compaction Force
Is Low
Compaction Force
was Below Lower Set Limit Value
Alm50>
Compaction Force Is High
Compaction Force was Above Upper Set Limit Value
Alm51> Compaction Cycle Overtime
Compaction Sequence did not finish its cycle in time
Alm52> Top Punch HF/LS Servo Torque Excessive
Monitored Motor Torque Exceeded its
Set Limit Value
Alm53> Top Punch LF/HS Motor
Hold Off Active
Top Punch Low
Force/High Speed Axis #2 Servo Hold Torque Released to Freewheel
Alm54> Top Punch HF/LS Motor Hold Off Active
Top Punch High Force/Low Speed Axis #3 Servo Hold Torque
Released to Freewheel
Alm55> Bottom Punch Motor Hold Off Active
Bottom Punch Axis #1 Servo Hold
Torque Released to Freewheel
Alm56> Unused
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Alm57> End Of Batch

Batch
Count Preset Reached

Preset Quantity of Anodes Produced and System Stopped
Alm58> System Count = Preset Check Message Below
Count Preset Value Reached Set point Related to Programmed
Message
Alm59> End Of Level Accept or Reject Anodes
Level Tray Count Preset Value
Reached Press Button to Accept or Reject Anodes
Alm60> Quality Inspection
Accept or Reject Anodes
Quality
Check Count Preset Value Reached Press Button to Accept or Reject Anodes
Alm61> Compaction Punch Tolerance Error
Punch Position During Compaction Was Incorrect Causing a
Position Error
Alm62> Unused
Alm63> Unused
Alm64> Servo Motor Communications Failure
Servo Motor Communications Network Not Functioning
Check Power Status
Alm65> Powder Shoe Home Overtime
Powder Shoe Homing
Operation did not finish its cycle in time
Alm66> Bulk Powder Feeder Axis #5 Position Error
Bulk Powder Feeder Servo Motor Alarm Present Reset Alarm to
Clear
Alm67> Powder Shoe Axis #4 Position Error
Powder Shoe Servo Motor Alarm Present Reset Alarm to Clear
Alm68> Powder Shoe Jog Forward Dieset Limit Position
Powder Shoe Jogged Forward as Far as Possible
Alm69> Powder Shoe Jog Away From Dieset Limit Position
Powder Shoe Jogged Backward as Far as Possible
Alm70> Powder Shoe Standby Position Overtime
Powder Shoe Did Not Reach the Back Standby Position in Time
Alm71> Powder Shoe Dieset Position Overtime
Powder Shoe Did Not Move Forward to Dieset Position in Time
Alm72> Powder Shoe Osc Forward Position Overtime
Powder Shoe Did Not Move Forward to the Osc Forward Position in Time
Alm73> Powder Shoe Osc Back Position Overtime
Powder Shoe Did Not Move Backward to the Osc Back Position in Time
Alm74> Powder Shoe Charge Overtime Low Powder
Powder Shoe Cycled to Load Powder Shoe but Timed Out
Alm75> Powder Shoe Motor Hold Off Active
Powder Shoe Servo Hold Torque Released to Freewheel
Alm76> Powder Shoe Anode Eject Position Overtime
Powder Shoe Did Not Move Forward to Anode Eject Position in Time
Alm77> Bulk Powder Feeder Position 1 Overtime
Bulk Powder Feeder Did Not Move to Position 1 in Time
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Alm80> Bulk Powder Feeder Motor Hold Off Active
Bulk Powder Feeder Servo Hold Torque Released to Flywheel
Alm81> Wire Cutter Swing Home Overtime
Wire Cutter Swing Homing Operation did not finish its cycle in time
Alm82> Wire Supply Home Overtime
Wire Supply Homing Operation did not finish its cycle in time
Alm83> Wire Cutter Home Overtime
Wire Cutter Homing Operation did not finish its cycle in time
Alm84> Wire Supply Axis #9 Position Error
Wire Supply Servo Motor Alarm Present Reset Alarm to Clear
Alm85> Wire Feed Axis #8 Position Error
Wire Feed Servo Motor Alarm Present Reset Alarm to Clear
Alm86> Wire Cutter Swing Axis #7 Position Error
Wire Cutter Swing Servo Motor Alarm
Present Reset Alarm to Clear
Alm87> Wire Cutter Axis #6
Position Error
Wire Cutter Servo
Motor Alarm Present Reset Alarm to Clear
Alm88> Wire
Cutter Swing Jog (CW) Away From Dieset Limit Position
Wire Cutter Swing Jogged Clockwise as far as Possible
Alm89> Wire Cutter Swing Jog (CCW) To Dieset Limit Position
Wire Cutter Swing Jogged Counter Clockwise
as far as Possible
Alm90> Wire Cutter Jog Closed Limit
Position
Wire Cutter Jogged
Closed as far as Possible
Alm91> Wire Cutter
Jog Open Limit Position
Wire
Cutter Jogged Open as far as Possible
Alm92>
Wire Supply Jog Down Limit Position
Wire Supply Jogged Down as far as Possible
Alm93> Wire Supply Jog Up Limit Position
Wire Supply Jogged Up as far as Possible
Alm94> Wire Feed Wire Size Selected Non
Standard
Wire Size Entered is Not one on
the List Check Wire Size Entry Value
Alm95> Wire Supply Motor
Hold Off Active
Wire Supply Servo
Hold Torque Released to Flywheel
Alm96> Wire
Cutter Swing Motor Hold Off Active
Wire Cutter Swing Servo Hold Torque Released to Flywheel
Alm97> Wire Cutter Swing Staging Position Overtime
Wire Cutter Swing Did Not Move to Staging Position in
Time
Alm98> Wire Cutter Swing Cut Position Overtime
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Cut Position in Time

Drop Position Overtime
Swing Did Not Move to Anode Drop Position in Time
Wire Cutter Swing Did Not Move to

Alm99> Wire Cutter Swing
Wire Cutter
Alm100> Wire Cutter Swing Back Position Overtime

Wire Cutter Swing Did Not Move to Back Position in Time
Alm101> Wire Cutter Swing Sample Position Overtime
Wire Cutter Swing Did Not Move to
Sample Position in Time
Alm102> Wire Cutter Grip Cut
Position Overtime
Wire Cutter Did
Not Move to Grip Cut Position in Time
Alm103> Wire
Cutter Release Cut Position Overtime
Wire Cutter Did Not Move to Release Cut Position in Time
Alm104> Wire Cutter Release Anode Position Overtime
Wire Cutter Did Not Move to Release Anode Position in
Time
Alm105> Wire Supply Move Down Overtime
Wire Supply Did Not Move to Down
Position in Time
Alm106> Wire Supply Move Up
Overtime
Wire Supply Did Not
Move to Up Position in Time
Alm107> Wire Feed
Insert Overtime
Wire Feed
Did Not Move to Insert Wire Position in Time
Alm108>
Wire Feed Cut To Punch Overtime
Wire Feed Did Not Move Wire Back Up to Cut to Punch Position in Time
Alm109> Wire Feed Servo Release Overtime
Wire Feed Servo Not Responding to Release Torque
Command
Alm110> Wire Feed Servo Engage Overtime
Wire Feed Servo Not
Responding to Restore Torque Command
Alm111> Wire
Feed Outside Length Overtime
Wire Feed Did Not Move to Outside Length Position in Time
Alm112> Wire Cutter Motor Hold Off Active
Wire Cutter Servo Hold Torque Released to Flywheel
Alm113> Wire Feed Motor Hold Off Active
Wire Feed Servo Hold Torque
Released to Flywheel
Alm114> Unused
Alm115> Punch Movement Blocked by Wire Cutter Swing Position
Punch Motion Controls Disabled due to Wire Cutter Swing
Position
Alm116> Powder Shoe Not Back When Jogging
Press Punches
Punch Motion Controls Disabled
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due to Powder Shoe Position

Alm117> Cut Swing Not
Back When Jogging Press Punches
A Prompt to
Indicate Cut Swing in Punch Area While Jogging Press Punches
Alm118>
Bot Punch Manual Move Inhibit Check Top Punch Pos
Bottom Punch in Danger of Hitting Top Punch Move Top Punch Up
Alm119> Top Punch Manual Move Inhibit Check Bot Punch
Pos
Top Punch in Danger of Hitting Bottom Punch
Move Bottom Punch Down
Alm120> Top Punch Hold Off
Preventing the Bottom Punch Moves
Prompt to
Notify Why the Bottom Punch will Not Move Machine Safety
Alm121> Unused
Alm122> Unused
Alm123> Unused
Alm124> Unused
Alm125> Unused
Alm126> Unused
Alm127> Unused
Alm128> Side Guard Door Open
System Guard Door Open Status Active When Guard Override Not
Active
ELECTRICAL CABINET COOLING
All of the servo motor drives
have a built in cooling fan.
There are no filters employed
in
the drives so the surrounding
air should be clean to reduce
the amount of dust buildup
within them. The electrical
enclosure has a single four
inch cooling fan with a filter unit to clean the air as it enters it. Air directed to come in low
thru the filter fan unit and exit on the opposite side top corner.
Access to the filter can be made by pulling the bottom edge of the louvered cover
snapping it out. Pull off the filter and clean or replace it as necessary. After cleaning
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replace it into the fan filter frame and snap the cover back on with the louvers pointing
down.
AIR SUPPLY
Pressurized air is used in
the system on two air
cylinders used to hold
tantalum wire. The
incoming air connection is
fitted with a quick
disconnect coupling. A
manual air control valve
placed between the air
supply and pressure regulator contains an air dump feature to exhaust all pressure
contained in the system.
A filter regulator unit is provided employing a gauge indicating the regulator setting. The
regulator should be set to 65 PSI. On the output side of the regulator unit a pressure limit
switch is attached. When the air pressure is below its setting setpoint the switch goes off
indicating a problem with the air supply. From there the air line connects to a multiple
electrically controlled solenoid bank unit feeding to the air cylinders.
SYSTEM POWER
Power to the system is connected
to a single twist lock connector
located to the right side of the
system next to the lower cooling
fan air intake. The system is
designed to run on a single phase
circuit of 208 to 240 Volts AC. The
maximum peak current load is
approximately 12 Amps. A lockable
rotary power switch is fitted mid
way up the right side of the
electrical enclosure. When in the
OFF position a padlock can be
attached to prevent the system to
be operated. After the switch is a
dual circuit breaker for protecting the various circuits.
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Each servo motor drive has a pair of circuit breakers along with additional ones to protect
the other devices connected to power. These circuit breakers are operated by pushing in
the blue end button to reset or switch on and off. The circuit power is Off when the
actuator button is in the out position.
When the Emergency Stop pushbutton is pressed or an activated Safety Guard is
breached then the 240 Volt AC power is disconnected from the servo motor drives. Two
contactor relays are used to switch this power and can be seen between the power circuit
breakers on the electrical panel in the enclosure.
CONTROL INTERFACE POWER
An Omron 24 Volt power supply is
used to operate all of the sensors,
HMI touch screen, air valves, relays
and servo motor brakes. The unit
employs a switchable readout that
will display the power supply output
voltage or load current amps. Four
circuit breakers are used to protect the circuits connected to it. Each of the 24 Volt power
distribution block employ an LED indicator attached to indicate 24 Volt power.
Two 24 Volt circuits are present providing Switched and Un-switched DC power. The
Switched 24 Volt circuit is controlled by the Emergency Stop switch and the Safety
Guards. If either of these is activated then the power will be cut off.
FORCE PRESSURE LOADCELL

A loadcell is coupled in series with the press
mechanism to provide a feedback of the anode
compaction and ejection cycles. It has a maximum
rating of 7,000 Lbs. Signals from the loadcell are
connected to a conditioning amplifier fitted with a
excitation circuit necessary to drive it. The amplifier
unit is analog and has an output signal voltage
proportional to the amount of force load on the
loadcell. This voltage signal is connected to the
Yaskawa controller where it is scaled into a number for
display.
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Calibration of the
an external calibrated
readings at low and
readings match. If this
calibration data
used. An external
match values indicated
document and the
Span adjustments are
systems loadcell is done using

loadcell and comparing the two
high scale points until the
is not available then the
supplied with the loadcell is
voltage source is used to
in the sensors calibration
loadcell amplifier Offset and
made to get it set.
SYSTEM CONTROLLER
All of the machine controls are handled with a
Yaskawa MP-2200 series controller. The
programs are written in a Ladder Format with
several subroutines. All control bits and
registers are Tag Based items defined such to
help identify program area and function used by
it. The program structure is broken into two
classifications of High and Low speed programs.
High speed programs deal with the process
cycle and actions of msto of the servo motors.
Low speed programs handle the operator
interface, alarm checking, motor homing and
certain calculations.
Software used to program the controller is Yaskawa MPE720 Version 6. Connection is
made between the programming computer and the controller using a regular USB cable
plugged into the CPU module. A flash memory is used to store the program and user
variables. Indicator lights are on the CPU and associated modules to alert of their status
and possible alarm conditions.
To the right of the CPU module there are additional modules. The servo motor
communications network Mechatrolink module. A serial communications module was
included allowing the addition of bar code reading or any other type of expansion. For
sensor and output device interface a Digital I/O module with 16 points each type. This
module also has a counter input used to collect the Wire Feed encoder input. On the end
there is an Analog module to interface the Loadcell output.
Ver1.1
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AXIAL ANODE PRESS MANUAL

WIRE SUPPLY LOOP

MANUAL MODE OPERATION ---------------------------------- 15

POWDER SHOE SENSOR

MACHINE SETUP ------------------------------- 4-6

ANODE TRAY LEVEL

AUTOMATIC OPERATION --------------------------------------- 16-17

SERVO MOTOR SYSTEM

SERVO MOTOR ALARM

MANUAL STEP OPERATION ------------------------------------------- 18-24

COMPACTION POSITION MONITOR ----COOLING ------------ 24

Innovation Center Anode Press

MOTOR PARAMETER SETTINGS ----------------------------------------------- 24-25

PUNCH MOTION TESTING ------------------------------------------------- 25

LIGHT TOWER ---------------------------------- 12

WIRE CUTTER SETUP ------------------------- 13-14

ANODE CUT SENSOR PH4 ------------------- 14

Innovation Center Anode Press

Innovation Center Anode Press

MANUAL MODE OPERATIONS

Innovation Center Anode Press

Innovation Center Anode Press

Innovation Center Anode Press

Innovation Center Anode Press

On the System Homing screen near the right upper corner

Innovation Center Anode Press

Process parameters, of a batch of parts to be made,

Innovation Center Anode Press

Innovation Center Anode Press

Innovation Center Anode Press

Innovation Center Anode Press

A Single Cycle pushbutton is visible when the system

Innovation Center Anode Press

Anodes produced are measured and if

Innovation Center Anode Press

Innovation Center Anode Press

MANUAL STEP OPERATION

Innovation Center Anode Press

Innovation Center Anode Press

COMPACTION PUNCH POSITION MONITOR

Innovation Center Anode Press

While on that screen select Output Control and the

Innovation Center Anode Press

MOTOR PARAMETER SETTINGS

Innovation Center Anode Press

Innovation Center Anode Press

The bottom left pushbutton selection of the

Innovation Center Anode Press

RED System Stopped in Automatic Mode

WIRE CUTTER SETUP

Innovation Center Anode Press

Innovation Center Anode Press

During normal operation the Cut Swing arm moves the

WIRE SUPPLY LOOP SENSORS - PH1 (LOW) PH2 (HIGH)

Innovation Center Anode Press

Wire reaching the lower sensor PH1 starts the Wire

POWDER SHOE SENSOR PH3

ANODE TRAY LEVEL CONTROL

Innovation Center Anode Press

Innovation Center Anode Press

Innovation Center Anode Press

SERVO MOTOR ALARM CODES