SIMET AVIKO D INSTRUCTION MANUAL 1870

SORTING Solutions, Ltd.

1. TABLE OF CONTENTS 1. TABLE OF CONTENTS ................................................................................................... 1 2. INTRODUCTION............................................................................................................... 2

2.1. Application ............................................................................................................................................2 2.2. Operating Conditions...........................................................................................................................2 2.3. Electro - Optical Test (EOT).................................................................................................................2 2.4. Eddy Current Test (ECT)......................................................................................................................3 2.5. Vibration Test (EVT) .............................................................................................................................4

3.

ADJUSTMENT (BASIC) ................................................................................................... 5

3.1. EOT (Electro - optical Test) .................................................................................................................5 3.2. Eddy Current Test (ECT)......................................................................................................................5

3.2.1. Balancing ECT Sensors Asymmetry ..................................................................... 5 3.2.2. ECT Side Positioning and Adjusting the distance ECT sensor ............................. 5
3.3. Vibration Test (EVT) .............................................................................................................................5

4.

READJUSTMENT FOR DIFFERENT DIAMETERS......................................................... 6

4.1. Installation of Corresponding Parts ...................................................................................................6 4.2. Bridges ..................................................................................................................................................6 4.3. Lock Adjustment ..................................................................................................................................6 4.4. Axial Adjustment of the Roller ............................................................................................................6 4.5. Roller Revolution Sensor ....................................................................................................................7 4.6. Chute .....................................................................................................................................................7 4.7. ECT Sensor ...........................................................................................................................................7

4.7.1. Balancing ECT Sensor Asymmetry....................................................................... 7 4.7.2. ECT Side Positioning and Adjusting the distance ECT sensor ............................. 7
5. CONTROL ........................................................................................................................8
5.1. TESTERS ...............................................................................................................................................9

5.1.1. EOT TESTER ......................................................................................................10 5.1.2. EOT channel adjusting.........................................................................................10

5.1.2.1. EOT SETTING ..............................................................................................................11

5.1.3. EMT TESTER ......................................................................................................12

5.1.3.1. EMT channel adjusting .................................................................................................12 5.1.3.2. ECT SETTING (BALANCE) ..........................................................................................13 5.1.3.3. AUTOSTOP ..................................................................................................................15 5.2. SETUP..................................................................................................................................................16

5.2.1. LEFT or RIGHT SIDE ..........................................................................................16 5.2.2. TEST OUT ...........................................................................................................17

5.3. INFO .....................................................................................................................................................18 5.4. WEAR...................................................................................................................................................19 5.5. OSCILOSCOPE ...................................................................................................................................20

5.5.1. SELECT THE CHANNEL.....................................................................................21 5.5.2. TIME BASE..........................................................................................................21 5.5.3. RUN .....................................................................................................................22
6. ADJUSTING TABLES .................................................................................................... 23
6.1. Adjustment Table 1830 (left side of the machine) ..........................................................................23 6.2. Adjustment Table 3070 (right side of the machine)........................................................................24

7. 8.

ERROR MESSAGES...................................................................................................... 25 PICTURES PART ........................................................................................................... 26

8.1. Description of the pictures (right side for diameter range 30 up to 70) .......................................26 8.2. Description of the pictures (left side for diameter range 18 up to 30)..........................................30

2. INTRODUCTION
This manual contains the basic information which should be read before you start to operate this automatic sorting machine. For the users, who have already met with older types of the machines, some information will not be new. Nevertheless, even these users should read this manual carefully and especially the chapters dealing with the machine operation. The operating instructions contain some parts describing the acts which, if carried out incorrectly, might result in an injury of the operator or damage to the machine. Such parts are marked as follows:

2.1. Application SIMET AVIKO K 1870 D is an automatic machine designed for the defect detection on surfaces of bearing balls in the nominal range 18 up to 70 mm and actual range 18 up to 70 mm. Machine is separated to two sides. Left side of the SIMET machine is designed for diameter range 18 mm up to 30 mm and right side for checking range 31,75 mm up to 70mm. The detection is simultaneously carried out by three sensors - electro-optical, vibration, and eddy current sensors. Due to the control roller the entire surface of the ball is checked. Balls are sorted to three groups: good; repairable; irreparable. To the group of "repairable", balls are sorted by the electro-optical tests. To the group of irreparable, balls are sorted by the Eddy Current test and vibration test.

2.2. Operating Conditions To achieve optimal sorting results, the machine must work in a clean, dust-free and, if possible, at least partially air-conditioned environment. Under no circumstances may the temperature quickly change and exceed the range of +18C up to +28C, and the machine must not be exposed to direct sunshine. To employ the higher sensitivity of the EOT inspection, it is important that the balls for sorting are as clean as possible. Impurities produce useless rejection of certain percentage of good balls and soil the sorting machine. The best suitable balls for sorting are those directly coming from the final production operations, leaving as little as possible dirt on the balls. Alternatively, an additional cleaning device can be used. Larger stuck impurities can even cause rejection by the vibration test. The balls and the elements of the inspecting point must not be magnetized. This would produce disturbing signals during the eddy current test, thus deteriorating its results, because a lower sensitivity would have to be used. The batches containing higher percentage of balls with gross shape defects are not suitable for testing, because they might cause operation failures and even reduce the life of functional elements of the inspecting point. The operators must perfectly know the functions of the automatic sorting machine and be trained in its adjustment. 2.3. Electro - Optical Test (EOT) The electro-optical sensor /2/ emits a convergent beam with the cross-section in the output 1x10 mm, which is concentrated in the center of the ball being tested. The tested part of the surface of the ball is illuminated, the size of which is determined by the beam cross-section and convergence and the ball diameter. Reflected light returns in the same way and goes through a receiving diaphragm. The increased resolution for semi-polished and polished-in form defects is caused by a deflection of the reflected light beam due to the defect and its restriction by the receiving diaphragm. As a source of light, laser diode is used, which belongs to class l (output power is about 1mW). In balls with all diameters the surface size 0.11x1.2 mm is scanned.
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EOT scale indicating the setup sensitivity level is calibrated directly in per cent of the reflected light drop due to a defect (0 up to 100 %). Depending on the processing quality and soiling of the surface, the defect resolution is from 5 % of the reflected light drop. Step for adjusting the level of sorting is 2%. The EOT evaluates the defects in three working modes, which can be selected by push-buttons: Evaluation of spot defects with suppression of differing ball polish. Evaluation of spot defects including reduced polish by comparing with the polish of preceding balls. c) Evaluation of reduced polish by comparing with the polish of preceding balls and with suppression of spot defects (not expected to be usually used). d) Evaluation of reduced polish (not by comparing with the polish of preceding balls but absolutely) New EOT unit uses two channels (allowed us to sort the steel balls using two working modes simultaneously). Older generations AVIKO machines (type E and type C) can use only one working mode at the same time and gave us only three working modes. This advantage brings us better way for sorting. We can adjust level of sorting separately for each channel. For the first channel we can choose one of the first two sorting modes (a or b), for the second channel one of the last two sorting modes (c and d). Of course, its possible switch one of this channels or both. 2.4. Eddy Current Test (ECT) ECT sensor /1/ consists of a differential probe proper, its holder and cable with a connector. The advantages of ECT module consist in the possibility of analyzing both the defect signal amplitude and phase. Thus the signal of some types of defects can be highlighted against the other types or the material noise caused by the non-homogeneity of its electric and magnetic conductivity due to defects in the crystal lattice. The module has two preset selection phases: a) Evaluation of cracks with optimal suppression of the material noise. b) Evaluation of cracks with the highlighted signal of shape defects and compromised suppression of the material noise. c) Evaluation of shape defects. The miniature probe is especially designed for elimination of the influence of non-direction orientated prolonged defects (cracks) on the evaluation of the signal. ECT scale indicates the preset sensitivity level and is calibrated directly in the depth of the material crack (0 up to 100 m). If the probe is correctly positioned against the ball surface in the distance of 0.1mm, the cracks deeper than the preset sensitivity should be rejected. Depending on the material noise, cracks deep 10 m and more and flat-type shape defects deep 5 m or more can be rejected. Magnetized balls interfere with the process. The new ECT unit (inside EMT unit) uses two channels (allowed us to sort the steel balls using two working modes simultaneously). Older generations AVIKO machines (type E and type C) can use only one working mode at the same time and gave us only three working modes. This advantage brings us better way for sorting. We can adjust level of sorting separately for each channel. For the first channel we can choose one of the first two sorting modes (a or b), for the second channel only the last sorting mode (c). Of course, its possible switch one of this channels or both. Suggested values for the ECT channels are: 111 DEGREE for evaluation of cracks with optimal suppression of the material noise 150 DEGREE for evaluation of cracks with the highlighted signal of shape defects and compromised suppression of the material noise 69 DEGREE for evaluation of shape defects (Values of phase selections can be changed according to material properties.) The sensitivity for various types of defects you can see in the graph. The next advantage of the new ECT unit is the important function the unit helps us adjust the distance between the ECT sensor and the ball in the inspection point. The new design of the body of ECT sensor and its holder and the solution of electronic circuits inside ECT unit bring us this new function. Directly on the screen we can see this distance during adjusting the ECT sensor. The correct use of this function decreases the danger of the damaging of ECT sensor. a) b)

2.5. Vibration Test (EVT) EVT has the contactless sensor /3/, frequency-dependent amplifier, circuit creating an absolute value of the signal, decision storage circuit with an adjustable level and DEFECT LED indicating its state, and circuit for its resetting. EVT test is used only to reject large shape defects which could disturb the regularity of the ball rolling and cause not scanning of the entire surface by ECT and EOT sensors. The sorting sensitivity level is setup using the arrow push-buttons, located below the text LEVEL. The inspection is provide by the reliable contactless vibration sensor which automatically follows an optimal working position when the mechanism is being adjusted, as well as due to the additional device rejecting the balls which are not rotating regularly due to large shape defects or smaller diameter. This is provided for by an advanced contact switch (less dependent on the soiling of contact surfaces).

3. ADJUSTMENT (BASIC)
3.1. EOT (Electro - optical Test) Depress EOT push-button (SCREEN 2). Depress SETTING push-button (SCREEN 3). Insert a clean and good ball to the lock. Using arrow push-button choose item 2 (SCREEN 5). Adjust diameter of ball of EOT holder. Adjust the lock using the supporting roller lever /4/ to the maximum deflection on EOT module display (maximum of the received light flux). Use GAIN potentiometer (front panel of the ELECTRONIC UNIT setup the deflection on EOT display at 8090 % (SCREEN 6). Depress OK push-button to exit the adjustment mode. 3.2. Eddy Current Test (ECT) 3.2.1. Balancing ECT Sensors Asymmetry

(the ball is not in the lock)

Depress EMT push-button (SCREEN 2). Depress BALANCE push-button (SCREEN 7) Using arrows push-button choose item 2 (SCREEN 11). Use DC potentiometer (front panel of the electronic unit) set the deflection to zero. Using arrows push-button choose item 3 (SCREEN 12). Use AC potentiometer (front panel of the electronic unit) to set the deflection to zero.

Note: If a large correction was made, repeat the procedure. After repeated choosing item 2 and item 3 value on the scale must at 0 ( 1 is permissible).
3.2.2. ECT Side Positioning and Adjusting the distance ECT sensor

(the ball is in the lock)

Loose the arresting screw of ECT sensor /19/ Check the position of ECT sensor and the ball (the axis of ECT sensor goes throw the ball) move with the ECT holder /6/ down or up. Choose item 4 (SCREEN 13). For the right results the first step is push the ECT sensor to the ball in the inspecting point (necessary be in the contact with the ball). Pull the ECT sensor back from the ball (on the display you see distance between the sensor and the ball). First adjust value between 200-250 m. Moving the ECT sensor /1/ left or right set the deflection approximately to zero (it is permissible if the deflection is in the range 50 m). Simultaneously adjust the distance (should be approximately 150 m 20 m) and side position of the ECT sensor. Depress OK push-button to exit the adjustment mode.

3.3. Vibration Test (EVT)

In case of this unit, only the sorting sensitivity to shape defects is adjusted.
Depress EMT push-button (SCREEN 2). Choose channel 3 (SCREEN 7). Using the arrow push-buttons adjust the level sensitivity. Depress OK push-button to exit the adjustment mode.

4. READJUSTMENT FOR DIFFERENT DIAMETERS

1. 2. 3. 4. 5. 6. 7. Installation of corresponding parts. Bridges. Lock adjustment. EOT sensor Axial adjustment of the roller. Supply line. ECT sensor.

4.1. Installation of Corresponding Parts Install the parts corresponding to the given ball diameter as per table. Control roller /7/ - (outer bearing holder - see that the adapted end of the roller fits into the outer bearing screw EOT sensor /2/ 4.2. Bridges Loosen the chute arresting screw /11/. Loosen the screw /12/ to lower down the bridges. Insert a ball between at the bridges. Using the adjusting screw /12/, elevate the bridges until the ball just cannot go through. Tighten the arresting screw /11/. 4.3. Lock Adjustment

(!!! Remove ECT probe from the supporting roller lever!!!) Adjustment Using EOT
Depress EOT push-button (SCREEN 2). Depress SETTING push-button (SCREEN 3) Using arrow push-button choose item 2 (SCREEN 5). Loosen the arresting screw /8/) of EOT sensor. Adjust EOT sensor to the given diameter. Slightly tighten the arresting screw of EOT sensor. Loosen the arresting screw /14/ of the supporting roller lever /4/ - slide the supporting roller lever to the rear position (by loosening the adjusting screw /15/). Insert a ball between the control roller /7/, driving disk /16/, and support roller /9/. Adjust the control roller lever so that the control roller touches the ball (using the micrometer screw /17/). Using the adjusting screw /15/, draw the supporting lever /4/ near the driving disk and read the deflection on EOT scale. Using the arresting screw /14/, fix the supporting roller lever in the position where EOT deflection is the highest. Using the micrometer screw /17/, elevate the control roller lever (simultaneously rotating the driving disk) up to the position where LED the contact switch on the side starts flashing . From this position lower down by 0,05 mm (using the contact switch micrometer screw /17/) - LED of the contact switch on the side turns off. Use the screw /18/ to fix the vibration sensor lever /3/. Use GAIN potentiometer (front panel of the electronic unit) setup the deflection on EOT display at 8090 % (SCREEN 6) Depress OK to exit the adjustment mode. 4.4. Axial Adjustment of the Roller Depress EOT push-button (SCREEN 2). Depress SETTING push-button (SCREEN 3) Using arrow push-button choose item 2 (SCREEN 5). Insert a ball to the lock and slightly push the control roller lever /5/ towards the control roller axis to find out whether EOT deflection increases or decreases. The control roller should be shifted in the direction of the increasing EOT deflection (move the control roller to the position with the maximum EOT deflection). Repeat the last step until EOT deflection decreases when the roller is pushed towards both directions.
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Depress OK to exit the adjustment mode. 4.5. Roller Revolution Sensor Insert the revolution sensor into the outer bearing holder (if the control roller is correctly turned, the LED on its casing turns on). Pull out the sensor by about 0.4 mm (the LED on the casing of the revolution sensor is still on and the control roller can be easily rotated). Slightly tighten the screw fixing the revolution sensor in the bearing holder. 4.6. Chute Position the supply line so that balls freely enter the bridges (using the adjusting screw). 4.7. ECT Sensor

!!! Do not position the probe in the supporting roller lever before the passage through has been checked!!! (That means, verify at first that the ball correctly goes through the machine and that ECT probe cannot be damaged by balls being darted out of the lock.)
4.7.1. Balancing ECT Sensor Asymmetry

(to be carried out without a ball in the lock)

Depress EMT push-button (SCREEN 2). Depress BALANCE push-button (SCREEN 7) Using arrows push-button choose item 2 (SCREEN 11). Use DC potentiometer (front panel of the electronic unit) set the deflection to zero. Using arrows push-button choose item 3 (SCREEN 12). Use AC potentiometer (front panel of the electronic unit) to set the deflection to zero.

Note: If a large correction was made, repeat the procedure. After repeated choosing item 2 and item 3 value on the scale must at 0 ( 1 is permissible).
4.7.2. ECT Side Positioning and Adjusting the distance ECT sensor

(the ball is in the lock)

Loose the arresting screw of ECT sensor /19/ Check the position of ECT sensor and the ball (the axis of ECT sensor goes throw the ball) move with the ECT holder /6/ down or up. Choose item 4 (SCREEN 13). For the right results the first step is push the ECT sensor to the ball in the inspecting point (necessary be in the contact with the ball). Pull the ECT sensor back from the ball (on the display you see distance between the sensor and the ball). First adjust value between 200-250 m. Moving the ECT sensor /1/ left or right set the deflection approximately to zero (it is permissible if the deflection is in the range 50 m). Simultaneously adjust the distance (should be approximately 150 m 20 m) and side position of the ECT sensor. Depress OK push-button to exit the adjustment mode.

NOTE:
Any differences in the sensitivity of ECT sensors can be corrected by means of changing the distance from the ball (the difference can be identified by repeated testing with only one ball in STAY mode gradually on one side and then on the other side).

5. CONTROL
For the control the main functions of the machine we use push-buttons on the front display. Other adjusting is provided by switches and potentiometers on the rear panel and left or right side plates of the machine. The five push-buttons on the top the display are designed for choose the main functions oscilloscope, setup, info, wearing parts and testers. The seven push-buttons under screen have the special functions (function of each push-button is described directly on the screen of display function is changing in according the menu). Thats why these push-buttons arent described. The six push-buttons down on the display are for the control motors of both sides and start the working cycle of the machine motor, run, one/stop and stay.

SCREEN 1

5.1. TESTERS
As soon as the machine is connected to the mains and main switch on the front panel of the sorting machine is turned on, the initialization takes place. The main display (TESTERS) is as follows:

SCREEN 2
Display is split to the basic blocks. These blocks agree with the correspondence electronic units and functions of the machine (EOT tester, EMT /ECT and EVT/ tester, AUTOSTOP). On the screen we can see parameters which are adjusted, separately for the right and left side the machine. On the top of the screen we can find preset diameters, number of tested balls (also number OK and BAD balls). Beside these we can see which control roller should be used for this diameter (including the colour code of this control roller). In the block OPTICAL TESTER we can see two scales (one for each channel). On the left side of the corresponding scale is the symbol for the sorting mode: Evaluation of point /spot/ defects with suppression of differing ball polish Evaluation of point /spot/ defects including reduced polish (shine) by comparing with the polish of preceding balls Evaluation of reduced polish /shine/ by comparing with the polish of preceding balls and with suppression of spot defects (not expected to be usually used) Evaluation of reduced polish /shine/ (not by comparing with the polish of preceding balls but absolutely) In the block EMT TESTER (ECT and EVT) we can see three scales (one for each channel). The first two channels are for the ECT tester and third for EVT tester. On the left side of the corresponding scale is the symbol for the sorting mode: Evaluation of cracks with optimal suppression of the material noise Evaluation of cracks with the highlighted signal of shape defects and compromised suppression of the material noise Evaluation of shape defects Vibrations In the block AUTOSTOP we can see the number of OK, bad or missing balls.
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The scales of individual channels indicate the working modes, the current levels of sorting, and the autostop scale shows the preset number of bad or missing balls. The automatic stop mode watches for the number of OK, bad or missing balls. As soon as the preset number is achieved, the machine stops (this condition is also signalled by the beacon). If we want change some parameters or adjust EOT, EMT or AUTOSTOP we should depress the corresponding push-button directly under screen EOT TESTER, EMT TESTER or AUTOSTOP. 5.1.1. EOT TESTER After depress push-button EOT TESTER (left or right side) we can see this screen. We can setup first or second channel of EOT unit, choose setting mode of this unit or return back to main screen.

SCREEN 3
5.1.2. EOT channel adjusting In this mode we can change the sorting mode and adjust the level of sorting. After choosing the first or second channel we see this screen:

SCREEN 4
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Using arrows we can decrease and increase the level of sorting. Next push-buttons are designed for changing sorting mode or switch off this channel.
5.1.2.1. EOT SETTING

This mode allows us adjust the correct position between the EOT sensor and the ball in the inspecting point. Using arrow we choose the next step (according the instruction on the screen).

SCREEN 5
After choose second step you can see this screen:

SCREEN 6
On the screen is scale shown us value of the light, which is reflected from the ball back to the EOT sensor.

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5.1.3. EMT TESTER After depress push-button EMT TESTER (left or right side) we can see this screen. We can setup first or second channel of ECT unit, choose setting mode of this ECT unit (BALANCE), setup the EVT (third channel of EMT unit) unit or return back to main screen.

SCREEN 7
5.1.3.1. EMT channel adjusting

In this mode we can change the sorting mode and adjust the level of sorting. After choosing the first or second channel we see this screen:

SCREEN 8
Using arrows we can decrease and increase the level of sorting. Next push-buttons are designed for changing sorting mode or switch off this channel.

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After choosing the third channel we see this screen:

SCREEN 9
Using arrows we can decrease and increase the level of sorting. Next push-buttons are designed for switch off/on this channel.
5.1.3.2. ECT SETTING (BALANCE)

Using BALANCE push-button we can start adjust ECT unit. After depress this push-button next screen follows:

SCREEN 10

13

After choose the second step you can see this screen:

SCREEN11
In this mode we adjust ECT unit with upper potentiometer on the side plate. The value on the scale should be 0 ( 2). After choose the third step you can see this screen:

SCREEN 12
In this mode we adjust ECT unit with lower potentiometer on the side plate. The value on the scale should be 0 ( 2).

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After choose the fourth step you can see this screen:

SCREEN 13
In this mode we adjust ECT sensor position against the ball in the inspection point(together distance and side position).
5.1.3.3. AUTOSTOP

If we depress this push-button this screen follows:

SCREEN 14
Using arrows we can decrease and increase the number of bad or missing balls. Next push-buttons are designed for switch off/on this channel.

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5.2. SETUP This mode is designed for changing the working parameters of the machine. After depress pushbutton SETUP we can see this screen:

SCREEN 15
On the screen we can see the main adjusted parameters and see the number of revolutions of control roller. If we want to change something we should choose left or right side. The push-button TEST OUT is designed for the testing the magnets, motors and beacon. 5.2.1. LEFT or RIGHT SIDE After choosing left or right side we can setup the diameter of sorted balls, setup the batch counter, setup the main parameters of ECT TESTER and disable individual checks. The screen looks like this:

SCREEN 15
Using the push-buttons PREVIOUS ITEM and NEXT ITEM we choose the parameter which we want to adjust. After choosing the parameter we can setup it using push-buttons -/OFF and +/ON. For adjusting the BATCH SIZE we can use also use the push-buttons -200 and +200 for more
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comfortable setting. The batch size is designed for customer who directly put the sorted balls to the boxes (it allowed preset the number of balls rejected by OK channel). After this number is achieved, the machine stops. 5.2.2. TEST OUT In this mode we can check the right function of the magnets, motors and beacon. The screen is this:

SCREEN 16
For testing we have to choose left or right side. After choosing the side the next screen is like this:

SCREEN 17
Using the push-buttons PREVIOUS ITEM and NEXT ITEM we choose the part which we want to check. After choosing the part we can check it using push-buttons CHOOSE ITEM.

17

5.3. INFO After depressing the push-buttons INFO we can see the statistics of the sorting. Follow the next screen.

SCREEN 18
If we want reset the statistics we can choose left or right side. Follow the next screen.

SCREEN 19
In this mode we can reset the statistics.

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5.4. WEAR This possibility allows us watch the lifetime of basic parts. The screen looks like this:

SCREEN 20
After depressing left or right side we can reset the working hours of each part. Follow the next screen:

SCREEN 21
Using the push-buttons PREVIOUS ITEM and NEXT ITEM we choose the part. After choosing the part we can reset it using push-buttons RESET ITEM.

19

5.5. OSCILOSCOPE

NOTE: At this moment this function is not available at machine 1870.

After depressing push-button SCOPE we can use integrated oscilloscope. The oscilloscope allowed us se the process of checking cycle. The screen looks like this:

SCREEN 22
The red vertical line at the zero position represents the start of measuring cycle. On the right side near the screen of the oscilloscope we can see the basic parameters (time base, unit which is displayed and side which is displayed). The push-buttons left and right side allowed us choose the channel which we want to display. The push-button time base is designed for changing time base of the oscilloscope. The push-button RUN is designed for starting the working cycle of the oscilloscope. The push-button TIME BASEE is for editing the working cycle (measuring and exchanging time and working cycles of magnets).

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5.5.1. SELECT THE CHANNEL After depressing left or right side we can choose the channel which will be displayed. The screen looks like this:

SCREEN 23
Using the push-buttons we can select the channel which we want to see on the screen. 5.5.2. TIME BASE After depressing push-button time base we can change the time base of the oscilloscope. The screen looks like this:

SCREEN 24
For changing we use push-buttons down on the display (for example 50 ms).

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5.5.3. RUN After depressing RUN oscilloscope displays us the next working cycle of the channel which we did choose.

SCREEN 25
The oscilloscope displays us the signal from the EOT sensor. The first peak (near the -50 ms) shows to us the ball coming to the inspecting point. After this the signal quickly jumps down (ball coming to the inspecting point need some time to be calm). In a few milliseconds we can see the next jump up and down (the time between peaks is shorter). Then we can se only small peaks it is reflected light from the ball in the inspecting point (the ball is already moving calm). This small peaks are the defects on the surface the steel ball (or impurities on the surface bad cleaning the steel balls).

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6.

ADJUSTING TABLES

6.1. Adjustment Table 1830 (left side of the machine)

BALL
Mm inch

CONTROL ROLLER
Number code Revolutions h1

SET VALUES (mm)

h2 h3 / (t)

MAGAZINE
Pin Outlet

DISTANCE OF EOT SENSOR FROM BALL

Mm

18,0

1 2 3 4 5 6 17 7 8 9 10 11 12 13 14 15 16

30 30 31 32 32 34 34 35 36 37 39 40 41 41 43 46 48

0,046 0,049 0,059 0,069 0,071 0,078 0,081 0,085 0,092 0,098 0,103 0,107 0,108 0,109 0,111 0,109 0,103 2 0,04 0,08 0,1 / (0,13) 46,0+0,5 1 1 0

18,256 23/32 19,05 3/4

19,844 25/32 20,0 -

20,638 13/16 21,0 -

21,431 27/32 22,225 7/8

23,019 29/32 23,813 15/16 24,606 31/32 25,0 25,4 26,988 28,575 30,163 1 1 /16 1 /8 1 /16
3 1 1

2 3

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6.2. Adjustment Table 3070 (right side of the machine)

BALL Mm 31,75 33,338 34,925 36,516 37,306 38,100 39,688 40 41,27 42 42,862 43,656 44,45 45 46,038 47,625 48,419 50 50,8 53,97 55 55,562 57,15 58,738 59 60 60,32 63,5 65 66,675 70 21/8 19/8 5/2 35/16 9/4 37/16 2 17/8 29/16 15/8 61/32 27/16 21/8 7/4 13/8 Inch 5/4 21/16 11/8 23/16 47/32 3/2 25/16 CONTROL ROLLER Nr. Code 1 2 3 4 5 6 7 7 8 17 17 30 9 9 18 19 20 10 10 13 21 21 11 22 22 14 14 12 15 23 16 SPEED 49 52 54 56 58 59 61 62 64 65 66 67 69 69 70 72 75 77 78 83 85 86 88 91 91 93 93 98 101 104 108 SET UP VALUES (mm) h1 0,26 0,25 0,24 0,23 0,215 0,2 0,180 0,182 0,171 0,15 0,146 0,149 0,154 0,152 0,138 0,136 0,137 0,146 0,147 0,154 0,154 0,157 0,168 0,177 0,179 0,187 0,189 0,217 0,233 0,259 0,3 24 0,05-0,08 h2 FORCE OF THE MAIN LEVER SPRING N 17 18 18,5 19,5 20 20,5 22 22 23 23 24 24 24 24 24,5 25 25,5 26 26 27 28 28,5 29 29 29,5 30 30 32 33 33,5 35 46,0+0,5 DISTANCE OF EOT SENSOR FROM THE BALL Mm

7. ERROR MESSAGES

The following error messages can appear during the operation (unless their indication is disabled, error messages are followed by the machine stop): LOW ROLLER COUNT! This error message signals the fault in the ball rolling out
Ensure that the driving belt of the driving disk is not broken or worn. Check the axial clearance of the control roller in bearing screws (that it has a characteristic run-out after being rotated, but its clearance does not exceed 0.1mm). Ensure that the mechanical adjustment is correct. Check the functionality of the roller revolution sensor and its correct positioning towards the roller (also check for the clamp being not torn off the control roller due to the incorrect positioning of the revolution sensor).

Note: After checking the right rolling, it is possible to compare the real number of revolutions with the number stated in the adjustment table, which determinates the minimal number of revolutions of the control roller ensuring the inspection of the whole surface of the ball. The real number of revolutions can be checked during the operation after the selection speed rollers from the menu SETUP (SCREEN 11). LEVER SWITCH ERROR! This error message signals the fault in the contact switch of control roller lever
Clean the switch contacts.

If this does not help, the defect is in the electronic part. EOT/EMT COMM ERROR Communication error between the EOT or EMT unit and ECP unit (display)
Restart the machine (switch the machine off/on)

ECU COMM ERROR! Communication error between the ECU unit and ECP unit (display)
Restart the machine (switch the machine off/on)

BAD RESET RESPONSE! During initialization the software wasnt load correctly to the EOT or EMT unit
Restart the machine (switch the machine off/on)

BOOT ERROR! During initialization the software wasnt load correctly to the EOT or EMT unit
Restart the machine (switch the machine off/on)

UNIT RESET! Unit was reset critical error.

Restart the machine (switch the machine off/on)

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8. PICTURES PART
8.1. Description of the pictures (right side for diameter range 30 up to 70) Attention: Pictures are used from standard full machine 4070 (booth sides range 40 up to 70mm). For current situation of this machine you need to perceive these pictures side mirrored.

Position /1/ /2/ /3/ /4/ /5/ /6/ /7/ /8/ /9/ /10/ /11/ /12/ /13/ /14/ /15/ /16/ /17/ /18/ /19/ /20/ /21/ /22/ /23/ /24/ /25/ /26/ /27/ /28/ /29/ /30/

Description Eddy-current sensor (ECT sensor) Electro-optical sensor (EOT sensor) Electro-vibration sensor (EVT sensor) Supporting roller lever Control roller lever Holder of the ECT sensor Control roller Arresting screw of EOT sensor Support roller Screw of the supporting roller Arresting screw of the bridges-assembly Positioning screw of the bridges-assembly Separator segment Arresting screw of the supporting roller lever Adjusting screw of the supporting roller lever Driving disc Micrometer screw of the contact switch Arresting screw of the contact switch Arresting screw of the ECT sensor Work stop (upper stop) of the supporting roller lever Work stop (lower stop) of the supporting roller lever EOT connector ECT connector EVT connector Sorter Outlet Flap of the sorter Supply line Cover of the supply line Feeding unit (lift)

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Pic. 1

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Pic. 2.

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Pic. 3.

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8.2. Description of the pictures (left side for diameter range 18 up to 30) Pic. 4: Side bar Position Description /1/ EOT sensor holder with EOT sensor /2/ Module of the supporting roller lever /3/ Module of control roller lever /4/ Sorter /5/ Bridges-assembly /6/ Feeder /7/ Control LED of the contact switch /8/ Driving disk

Pic. 5: Module of the control roller lever Position Description /1/ EVT sensor /2/ Micrometer screw of the contact switch /3/ Arresting screw of the contact switch /4/ Inner bearing screw /5/ Control roller /6/ Outer bearing screw /7/ Roller revolution sensor /8/ Control roller lever /9/ Fixing screw of the revolution sensor /10/ Lever of the vibration sensor /11/ Case of the module Pic. 6: Module of the supporting roller lever Position Description /1/ Working position /2/ Rest position /3/ Arresting screw of the supporting roller lever /4/ Adjusting screw of the supporting roller lever /5/ Arresting screw of ECT sensor /6/ ECT sensor /7/ Arm of ECT sensor /8/ Supporting roller /9/ Screw of the supporting roller /10/ Supporting roller lever

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Pic. 7: Bridges assembly Position Description /1/ Rear screw /2/ Front screw /3/ Adjusting grooved screw /4/ Arresting screw /5/ Adjusting screw of the position /6/ Rotary electromagnet of the separator /7/ Separating segment /8/ Screw of the separating segment Pic. 8: EOT sensor holder with EOT sensor Position Description /1/ EOT sensor holder /2/ Fork of the EOT sensor /3/ EOT sensor /4/ Adjusting micrometer screw /5/ Arresting screw /6/ Screw of the cover /7/ Screws of the fork /8/ Outer adjusting screw /9/ Adjusting screw of the inclination (parallel with the side bar) /10/ Cover of the holder /11/ Screws of the holder /12/ Adjusting screw of the inclination (perpendicular with the side bar) Pic. 9: Adjusting the distance between probe and ball (scheme) Lock adjustment (scheme)

Values t, h3 (see the adjustment table). Values h1 a h2 (see the adjustment table). Position S labile position; position S ball in the lock.

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Pic. 4: Side bar

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Pic. 5: Module of the control roller lever

Pic. 6: Module of the supporting roller lever

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Pic. 7: Bridges assembly

Pic. 8: EOT sensor holder with EOT sensor

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Pic. 9: Adjusting the distance between probe and ball (scheme) Lock adjustment (scheme)

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Graph of ECT sensitivity in dependence on phase selections

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