Tool Change
The TOOL CHANGE menu provides access to the pages that allow you to perform tool change operations on the machine, in both automatic and manual modes, and to select the tool loaded on the welding machine, if it has already been stored.
Tool change
The welding machine must be set to TOOL CHANGE, a status indicated by the flashing of the MANUAL CYCLE button located on the Touch Panel bezel. The tool change operation can be performed in either automatic or manual mode.
If changes have been made to the tooling parameters and the SAVE CHANGES button is flashing, a reminder banner will appear stating "Save the parameters to start the tool change procedure".
Automatic tool change
The automatic tool change is divided into two procedures: AUTOMATIC TOOL LOADING and AUTOMATIC TOOL UNLOADING.
Automatic tool loading
The AUTOMATIC TOOL LOADING procedure is initiated by the operator and allows tools to be loaded onto the machine autonomously and safely. The operator must follow the steps displayed on the operator panel screen, carrying out the required manual operations or confirming the prompts from the automatic procedure.
| TOOL LOADING |
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Automatic tool loading
| ICON | ACTION |
|---|---|
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The AUTOMATIC TOOL LOADING procedure is initiated by the operator and allows the tool to be loaded onto the machine independently and safely. The operator must follow the steps described by the procedure, which will appear on the Operator Panel screen, performing the essential manual operations required or verifying the requests of the automatic procedure. |
The various steps of the automatic tool loading procedure are listed in the table below.
| ICON | PHASE | ACTION |
|---|---|---|
| -- | START CYCLE | Start the TOOL LOADING procedure. |
| -- | TRANSLATING PLANE IN WELDING POSITION | The translating plane is placed in the welding position. |
| -- | GATE CLOSURE | The gate closes. |
| -- | TABLE IN TROLLEY COUPLING POSITION | The table moves to the correct position for the subsequent coupling of the trolley. |
| -- | GATE OPENING | The gate opens. |
| -- | TRANSLATING PLANE IN LOADING POSITION | The translating plane is placed in the loading position. |
| -- | PENDING TOOL LOADING | Couple the trolley to the welding machine. Load the tool correctly stacked on the welding machine and check that it is perfectly centred. After loading the tool, release the trolley from the welding machine. |
| -- | CENTRING DEVICES CLOSURE | The centring devices on the tool close or must be closed manually. |
| -- | CLAMPS CLOSURE | The clamps on the tool close or must be closed manually. |
| -- | CONNECTIONS CLOSURE | The connections on the tool close or must be closed manually. |
| -- | CODE DETECTION | After connecting the connections, the welding machine, starts detection of the installed tool code. |
| -- | PENDING TOOL IDENTIFICATION | Tool identification by the welding machine. If the tool is not stored, the procedure for saving in the welding machine starts. |
| -- | ACTUATORS | The actuators are placed in the basic position for tool change. |
| -- | TRANSLATING PLANE IN WELDING POSITION | The translating plane is placed in the welding position. |
| -- | GATE CLOSURE | The gate closes. |
| -- | TABLE IN THE ALIGNED TOOL POSITION | The table lifts up to the tool's aligned position, i.e. to the maximum height allowed by the tool's footprint. |
| -- | GATE OPENING | The gate opens. |
| -- | SCREW FIXING AND VACUUM CONNECTION | Verify centring of tool. Secure ALL the screws present on the upper fixture plate to the vibrating plate of the welding machine using a torque wrench. Tighten the screws to 90 Nm. The screws must not enter the vibrating plate by more than 20 mm. Connect the top vacuums to the machine. |
| -- | GATE CLOSURE | The gate closes. |
| -- | TABLE IN ZERO MACHINE POSITION | The table lowers to the zero machine position. |
| -- | GATE OPENING | The gate opens. |
| -- | TRANSLATING PLANE IN LOADING POSITION | The translating plane is placed in the loading position. |
| -- | COLUMNS REMOVAL | Remove the columns used for stacking the tools correctly and place them in the appropriate storage elements located at the sides of the lower fixture. |
| -- | CYCLE END | End of the TOOL LOADING procedure. |
Automatic tool unloading
The AUTOMATIC TOOL UNLOADING procedure is started by the operator and enables to unload the tool from the machine autonomously and safely. The operator must follow the steps described by the procedure, which will appear on the Operator Panel screen, performing the essential manual operations required or verifying the requests of the automatic procedure.
Automatic tool unloading
| ICON | ACTION |
|---|---|
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The AUTOMATIC TOOL UNLOADING procedure is started by the operator and enables to unload the tool from the machine autonomously and safely. The operator must follow the steps described by the procedure, which will appear on the Operator Panel screen, performing the essential manual operations required or verifying the requests of the automatic procedure. |
The various steps of the automatic tool loading procedure are listed in the table below.
| ICON | PHASE | ACTION |
|---|---|---|
| -- | START CYCLE | Start the TOOL UNLOADING procedure. |
| -- | PARTS REMOVAL | Verify the absence of welded or non-welded parts on the tool. If present, remove them. |
| -- | ACTUATORS | The actuators are placed in the basic position for tool change. |
| -- | TRANSLATING PLANE IN LOADING POSITION | The translating plane is placed in the loading position. |
| -- | COLUMNS INSERTION | IInsert the columns in the specific housings, taking them from the storage elements located at the sides of the lower fixture, for correct tool stacking. |
| -- | TRANSLATING PLANE IN WELDING POSITION | The translating plane is placed in the welding position. |
| -- | GATE CLOSURE | The gate closes. |
| -- | TABLE IN PIECE CONTACT POSITION | The table lifts up to the piece contact position. |
| -- | GATE OPENING | The gate opens. |
| -- | SCREWS REMOVAL AND VACUUM DISCONNECTION | Loosen ALL the screws present on the upper fixture plate from the vibrating plate of the welding machine using a torque wrench. Disconnect the top vacuums from the machine. |
| -- | GATE CLOSURE | The gate closes. |
| -- | TABLE IN TROLLEY COUPLING POSITION | The table moves to the correct position for the subsequent coupling of the trolley. |
| -- | GATE OPENING | The gate opens. |
| -- | TRANSLATING PLANE IN LOADING POSITION | The translating plane is placed in the loading position. |
| -- | CONNECTIONS OPENING | The connections on the tool open or must be opened manually. |
| -- | CLAMPS OPENING | The clamps on the tool open or must be opened manually. |
| -- | CENTRING DEVICES OPENING | The centring devices on the tool open or must be opened manually. |
| -- | PENDING TOOL UNLOADING | Couple the trolley to the welding machine. Unload the tool correctly stacked from the welding machine and check that it is perfectly loaded on the trolley. After unloading the tool, release the trolley from the welding machine. |
| -- | CYCLE END | End of the TOOL UNLOADING procedure. |
Tool change pop-up
Tool change, both during loading and unloading, is guided by the machine throughout all stages by means of the TOOL CHANGE POP-UP, an interface that shows all the operations performed by the machine autonomously or that must be performed by the operator.
Home
Pause the tool change procedure and return to the page to display the AUTOMATIC TOOL CHANGE page.
Previous page
View the previous page of the TOOL CHANGE POP-UP.
Next page
View the next page of the TOOL CHANGE POP-UP.
Tool change pop-up
Tool change, both during loading and unloading, is guided by the machine throughout all its steps via the TOOL CHANGE POP-UP, an interface that shows all the operations performed by the machine autonomously or that must be performed by the operator.
| ICON | ACTION |
|---|---|
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Home, to pause the tool change procedure and return to the AUTOMATIC TOOL CHANGE page. |
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Previous page, to view the previous page of the TOOL CHANGE POP-UP. |
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Next page, to view the next page of the TOOL CHANGE POP-UP. |
Tool change interrupted
| ICON | ACTION |
|---|---|
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Reset cycle, to reset the tool change cycle interrupted by closing the pop-up. |
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Resume cycle, to resume the tool change cycle interrupted by closing the pop-up, exactly from the point where it was paused. |
Reset cycle
Resets the tool change cycle interrupted by closing the pop-up.
Resume cycle
Resumes the tool change cycle interrupted by closing the pop-up, exactly from the point where it was paused.
Manual tool change
The MANUAL TOOL CHANGE procedure allows you to manually manage all stages of the tool change, enabling you to operate specific moving parts via the dedicated pages. From this page, you can upload and download tool data to the machine.
| ICON | ACTION |
|---|---|
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LOAD TOOLING: allows you to transfer data to the PLC of the tool that has been inserted and connected via a plug. |
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REMOVE TOOL: allows you to remove data from the tool’s PLC after disconnecting and removing it from the welding machine. |
Axes
The AXES card allows you to manoeuvre the main handling axes of the welding machine.
Table
The TABLE page allows you to move the welding machine’s table axis and displays a simplified diagram of the welding machine showing a simulation of the table’s movement.
Trolley position
Option
To load or unload tools from the welding machine safely, the table must be positioned at a specific height to allow the trolley carrying the tools to be correctly attached. The TROLLEY height can be adjusted directly on this page.
# Go in position
This allows you to position the axis at a specified height. The value entered is restricted by the limits defined in the MACHINE SETTINGS menu.
| Icon | ACTION |
|---|---|
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GO IN POSITION: the position is reached by holding down the button. The height is reached when the button lights up. |
Movement
| Icon | ACTION |
|---|---|
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The ARROW keys allow you to move the table up or down. The movement is performed by holding the key down. The destination elevation is shown above the arrow keys. |
Mirror
The MIRROR card allows to move the axis relating to the mirror on the welding machine.
Moving mirrors
| Icon | ACTION |
|---|---|
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The arrow keys allow you to move the IR mirrors forwards or backwards. You can move the mirrors individually by selecting L or R, or simultaneously by selecting R+L. Movement can only be performed if the key is held down. Next to the arrow keys is the target elevation of the mirrors, relative to machine zero. |
Gates
The GATES page allows you to operate the gates installed on the welding machine and displays a simplified diagram of the machine showing a simulation of the moving gate’s movement.
The OPEN and CLOSE buttons allow you to move the gate manually and must be held down to execute the movement.
If a two-hand control is installed on the welding machine, you must select the movement to be performed and start it using the physical START button.
Clamping
Option
The CLAMPING page allows you to operate the clamping devices, if fitted to the welding machine.
Definition of clamping
Option
The WORK and STOP buttons are used to move the clamping mechanism and must be held down to move it to the desired position. When the button is lit, the position has been reached; when the button is lit red, the clamping mechanism is in alarm mode. The position reached is determined by the set of clamping sensors, the number of which depends on the system installed on the machine and can be found on the wiring diagram.
Centerings
Option
The CENTRING card allows you to adjust the centerings fitted to the welding machine.
Centring definition
Option
Each centring device is assigned to an object bearing the identification name of the centring device itself. The object contains the in and out keys, which enable centring device movement. The keys must be kept pressed to engage or disengage the centring device. If the key LED is lit green, the position is reached.
Contacts
Option
The CONTACTS card allows you to control the actuators that operate the contacts fitted to the welding machine.
Definition of contracture
Option
The unit features in and out buttons, which are used to operate the contactor actuator and must be held down to engage or disengage the contactor. When the button is illuminated, the position has been reached; when the button is illuminated in red, the contactor is in alarm mode. The position reached is determined by the series of contactor sensors, the number of which depends on the system installed on the machine and can be found on the wiring diagram.
Product selection
This PRODUCT SELECTION page allows you to set and save the parameters of a tool so that they can be retrieved later.
Saved tools
On the left-hand side of the PRODUCT SELECTION page, a list of saved tools is displayed. You can save up to 63 tools, as long as the Add Icon is visible.
| Icon | ACTION |
|---|---|
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Adds a new tool. |
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Deletes the selected tool. The operation requires confirmation by the operator. |
Each tool is identified by a code (ID), a project number (serial number) and a brief description (description). To view the full list of stored tools, swipe your finger up from the bottom of the screen.
ID
Identification code assigned to the tool.
Serial number
Design number of the tool.
Description
Brief description of the tool.
Operating icons
At the bottom of the page, there are several icons that allow you to perform the following actions.
| ICON | DESCRIPTION |
|---|---|
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Edit the description of the selected tool. |
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Duplicates the configured settings of the selected tool for use on a new tool. When you press the button, a pop-up will ask for an ID for the new tool, a CEMAS NAME and a CUSTOMER NAME. |
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Import the configured settings of the selected tool from external storage. The illuminated icon indicates that the USB stick is connected correctly; the unlit icon indicates that the USB stick is not connected. |
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Export the configured settings of the selected tool to external storage. The illuminated Icon indicates that the USB stick is connected correctly; the unlit Icon indicates that the USB stick is not connected. Once the operation is complete, a confirmation message appears on a green background in the top right-hand corner of the screen. |
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Add a note to the selected tool. This can be useful for noting, for example, maintenance or a machine fault. |
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Saves the configured settings for the selected tool. When the button is pressed, you are prompted to enter a name to associate with the dataset, whilst the date and time are assigned automatically. Saving is only permitted if at least one tool parameter has been modified. |
Rename
Selected tool description change.
Duplicate
Duplicates the configured settings of the selected tool so that they can be used on a new tool. When you press the button, a pop-up window will ask for an ID for the new tool, a CEMAS NAME and a CUSTOMER NAME.
Import
Option
Imports the configured settings for the selected tool via an external USB drive. If the button is lit, the USB stick is connected correctly. If the button is off, the USB stick is not connected.
Export
Option
This allows you to export the configured settings of the selected tool to an external USB drive. The button lights up when the USB drive is connected correctly. If the export is successful, a message on a green background appears in the top-right corner of the screen to confirm that the export has been completed.
Note
Add a note to the selected tool. This can be useful for noting down, for example, maintenance work or a machine breakdown.
Save
Saves the configured settings for the selected tool. When the button is pressed, you will be prompted to enter a name for the data set; the date and time are assigned automatically. Saving is only permitted if at least one tool parameter has been changed.
Tool Information
By selecting a tool from the list, you can view on the right-hand side of the page the list of notes entered and saves made.
| EXAMPLE NOTE | EXAMPLE SAVE |
|---|---|
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By selecting the arrow at the side of each save, the save note can be expanded.
Save icon
| ICON | ACTION |
|---|---|
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Compare with current values, i.e. display the comparison between saved values and the values currently in use. |
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Restore, i.e. retrieve the values configured and saved in the selected save. |
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View changes, i.e. display values that have changed since the previous save. |
Compare with current values
View the comparison between the saved values and values currently in use.
Restore
Retrieves the values configured and saved in the selected save file and loads them into the PLC so that the tools can be used.
View Changes
Displays the values changed compared to the previous save.
Tool Wizard
By selecting the Add button in the tools list, you can configure and save a new tool. By pressing the Remove button, you can delete the tool from memory. This operation requires confirmation from the operator.
| Icon | ACTION |
|---|---|
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Adds a new tool. |
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Removes the selected tool. |
Tool configuration is carried out via the TOOL WIZARD, an interface that guides the operator through the selection of the functions required to configure the tool correctly, without having to access the TOOL SETTINGS menu. This function is particularly useful when the tool parameters to be set are already known.
The TOOL WIZARD consists of five pages: 1. CONFIGURATION page: see TOOL SETTINGS/CONFIGURATION. 2. ACTUATORS AND SENSORS page: see TOOL SETTINGS/ACTUATORS AND SENSORS. 3. POSITIONS page: see TOOL SETTINGS/POSITIONS. 4. CYCLE PROGRAMMING page: see TOOL SETTINGS/CYCLE PROGRAMMING. 5. WELDING LIMITS page: see TOOL SETTINGS/WELDING LIMITS.
| Icon | ACTION |
|---|---|
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Displays the previous page of the TOOL WIZARD. |
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Displays the next page of the TOOL WIZARD. |
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Confirm and complete the configuration, saving the tool settings to memory. |
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Close the TOOL WIZARD without saving the changes made. |
Duplicate tools
By selecting the Duplicate button from the icons at the bottom of the page, you can duplicate the configured settings of the selected tool and use them to create a new tool. When you select the Duplicate button, a pop-up appears asking you to specify the details of the new tool: the tool’s CEMAS name, the customer name and the ID that identifies the tool. You can confirm or cancel the details entered using the Confirm or Cancel buttons located in the bottom right-hand corner of the pop-up.
Import tools
Option
By selecting the Import button from the icons at the bottom of the page, you can import the configured settings for the selected tool from an external storage device. A lit icon indicates that the USB stick is connected correctly; a dimmed icon indicates that the USB stick is not connected.
Edit import
Option
Once you have selected the tool to be imported, a new pop-up window appears, allowing you to edit the configuration details: the tool’s CEMAS name, the customer name and the ID that identifies the tool. You can confirm or cancel the details entered using the Confirm or Cancel buttons located in the bottom right-hand corner of the pop-up.