CONTROLLED AUTOMATION, INC.

2AT-175 PLATE PUNCH

MACHINE CALIBRATION

INITIALLY SETTING THE CONSTANTS

The constants should be already set close enough to where the machine will initialize and the grippers will move to the load position for a part run..

FINE TUNING PUNCH LOCATION

1. Program and run any small part. After the grippers move to the load position, the computer will display the left gripper location. This is the dimension from the outside (left) edge of the left gripper to the zero pin (on the table) in the X axis. Adjust the XYTX_SRVINT, INITVAL constant so the measured dimension is the same as the displayed dimension.

Increase the constant if the measured distance is the less than the displayed distance.

Decrease the constant if the measured distance is more than the displayed distance.

2. Initialize the machine, program and run a part with one mark at XPOS = 1” and UPOS = 3”. If the Punch doesn’t make the mark, use the manual switch to the punch and make the mark before moving the grippers.

3. If the gauge is not correct (gripper edge to hole), adjust the XYTY_SRVINT, INITVAL constant.

Increase the constant if the measured gauge is the less than programmed gauge.

Decrease the constant if the measured gauge is more than programmed gauge.

4. If the X measurement is not correct (end of material to mark), adjust the XYT_OFF, ZPINOFF constant.

Increase the constant if the measured distance is the more than programmed gauge.

Decrease the constant if the measured distance is less than programmed gauge.

5. Change the location of the programmed mark, initialize the machine after changing the constant(s) and run again to check accuracy.

SETTING THE MAXIMUM TRAVEL

1. Create a part 12’ long with 1 hole with a gage of 1” and an X position of 11’11” .

2. Run the part. You do not need to have material in the machine.

3. The grippers will go as far to the right as they think they can to load the material. Adjust the XYT_OFF, MAXRTTRVL so that the grippers will come within about ¼ inch of the right overtravel limit switch.

4. When the MAXRTTRVL (maximum right travel) is set correctly, continue running the part. The grippers will move as far to the left as they think they can before shuttling. Watch how close the grippers come to the left overtravel limit switch and adjust the XYT_OFF, MAXLFTRVL so that the grippers come within about ¼ inch of this limit switch.

ADJUSTING THE ENCODER MARK POSITION

1. Create a part with one hole and another part with one layout.

2. Run the part with the hole with no material. This initializes the encoder.

3. Run the part with the layout with material.

4. If the layout is too deep, make the XYT_TLCYC, MARKPOS and MARKPRSPOS more negative. If the layout is too light make them less negative. Run the part again with the layout in a different place.

5. Once you have the layout the depth that you want it, enter into the diagnostics.

6. Write down the counter value for the punch encoder. You will use this to calculate the XYT_OFF, PNCHTODIE.

7. Exit the diagnostics and go into the constants.

8. Find the XYT_TLCYC, CPIN.

9. Divide the number you wrote down for the counter value by the CPIN.

10. Write down the whole number on the left of the decimal point. This is the inches value in the XYT_OFF, PNCHTODIE.

11. Subtract the whole number so you only have the decimal part.

12. Multiply the decimal part by 64.

13. The whole number on the left of the decimal of your answer is the fraction part of the XYT_OFF, PNCHTODIE, measured in 64ths.

14. Input the XYT_OFF, PNCHTODIE that you calculated and exit from the constants.

15. Press the INIT key and run the part with the layout mark. The layout should be very close.

16. If the layout is too deep, decrease the XYT_OFF, PNCHTODIE. If the layout is too light increase it. Hit the INIT key and run the part again with the layout in a different place.

ADJUSTING THE SQUARING PINS

1. Get a piece of long flatbar (nearly as long as the table) and put it on the table. Make sure the flatbar has a very straight edge.

2. Get into the Diagnostics and extend the Squaring pins (Ctrl-F2).

3. Move the grippers all the way apart and directly in front of the punch.

4. Center up the flatbar with the punch and load it flush against the squaring pins. Grip it.

5. Run the flatbar to the right until the left squaring pin is in front of the punch and make a layout mark by extending the punch with the manual switch.

6. Run the flatbar to the left until the right squaring pin is in front of the punch and make a layout mark by extending the punch with the manual switch.

7. Measure the gauge on both layout marks.

8. If the gauge on the right layout mark is greater than the left layout mark, the left squaring pin should be moved toward the back of the gripper or the right squaring pin should be moved toward the front of the gripper. The squaring pins should move the distance that the gages don’t match.

9. If the gage on the right layout mark is less than the left layout mark, move the pins opposite of what is described above.

10. Repeat the steps above until the layout marks are exactly the same gauge.

11. Program the flatbar with layout marks 3” apart all the way down the part with a 2” gauge.

12. Run the part and check the gauge on the layout marks.

13. If the layouts are not consistent adjust them as in steps 8 and 9, then move the layouts in the part and run again.

14.