Morii-Seiiki NH4000 DCG, NH5000, NH5000 DCG, NH6300 DCG, NH8000 DCG INSTRUCTION MANUAL

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INSTRUCTION MANUAL

Applicable Model

NH4000 DCG NH5000 NH5000 DCG NH6300 DCG NH8000 DCG NV4000

Applicable Specification

Carrier Pallet Pool System

Applicable NC Unit

MSG-501 MSG-502 MSX-501 MSX-501III MSX-502 MSX-502III MSX-701 MSX-701III MSX-711 MSX-711III

Before starting operation, maintenance, or programming, carefully read the manuals supplied by Mori Seiki, the NC unit manufacturer, and equipment manufacturers so that you fully understand the information they contain.

Keep the manuals carefully so that they will not be lost.

PPM-NHCPP-C1EN

• The contents of this manual are subject to change without notice due to

improvements to the machine or in order to improve the manual. Consequently, please bear in mind that there may be slight discrepancies between the contents of the manual and the actual machine. Changes to the instruction manual are made in revised editions which are distinguished from each other by updating the instruction manual number.

• Should you discover any discrepancies between the contents of the

manual and the actual machine, or if any part of the manual is unclear, please contact Mori Seiki and clarify these points before using the machine. Mori Seiki will not be liable for any damages occurring as a direct or indirect consequence of using the machine without clarifying these points.

whole or in part, is not permitted without the written consent of Mori Seiki.

The product shipped to you (the machine and accessory equipment) has been manufactured in accordance with the laws and standards that prevail in the relevant country or region. Consequently it cannot be exported, sold, or relocated, to a destination in a country with different laws or standards.

The export of this product is subject to an authorization from the government of the exporting country.

Check with the government agency for authorization.

990730

SIGNAL WORD DEFINITION

A variety of symbols are used to indicate different types of warning information and advice.

Learn the meanings of these symbols and carefully read the explanation to ensure safe operation while using this manual.

The warning information is classified into three categories, DANGER, WARNING, and CAUTION.

The following symbols are used to indicate the level of danger.

DANGER

WARNING

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or damages to the machine.

The information described following the caution symbol must be strictly observed.

Indicates the items that must be taken into consideration.

NOTE

Indicates useful guidance relating to operations.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

The information described in the DANGER frame must be strictly observed.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

The information described in the WARNING frame must be strictly observed.

Indicates the page number or manual to be referred to. The number in ( ) indicates the section number.

1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

2 SCHEMATIC DIAGRAM OF PALLET POOL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . P-2

3 PALLET TRANSPORT PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4

3-1 Pallet Transport Processing Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4

3-2 Pallet Transport Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6

3-3 Urgent Workpieces (Interruption Processing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-8

3-3-1 Interruption Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-8

3-3-2 Interruption Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-8

4 DATA SETTING SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-9

4-1 Screen Trees. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-9

4-2 PCMDI MENU Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-11

4-3 WORK NUMBER Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-11

4-3-1 Description of Pallet Statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-18

4-4 SETUP STATION PALLET CALL Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-21

4-5 WORK NUMBER (SUB) Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-22

4-6 PALLET DATA Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-23

5 SETUP STATION OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-24

5-1 Setup Station Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-24

5-2 Switches on the Operation Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-25

5-2-1 EMERGENCY STOP Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-25

5-2-2 LINK/INDE. Selection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-25

5-2-3 ALARM Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-25

5-2-4 ALARM RESET Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-25

5-2-5 SETUP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-26

6 STARTING THE APC AND PALLET POOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-27

6-1 Starting with the M02/M30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-27

6-2 Starting with the M60/M61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-28

6-3 Starting Using the APC START Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . P-28

6-4 Starting from the SETUP STATION PALLET CALL Screen . . . . . . . . . . . . . . . . P-28

6-5 Starting Using the Buttons on the Setup Station Operation Panel . . . . . . . . . . . P-28

6-6 SYSTEM LINK/INDE. Selection Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-29

6-7 Operation of the Setup Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-29

6-7-1 Single Pallet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-29

6-7-2 Multiple Pallet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-29

7 TABLE CLAMP/UNCLAMP FOOTSWITCH AT THE SETUP STATION . . . . . . . . . . . . P-30

8 SETUP STATION DOOR LOCK CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-30

9 AUTOMATIC POWER SHUTOFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-30

10 AUTO-COUPLER (OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-31

10-1 Operating the Auto-coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-31

11 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-31

11-1 Recovering Interrupted Pallet Pool Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . P-31

APPENDIX 1 HANDY OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-1

1-1 Manual Pallet Pool Operation Mode ON/OFF Switch . . . . . . . . . . . . . . APPENDIX-2

1-2 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-3

1-3 Selecting the Operation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-3

1-4 Registering Position Data of the A.G.V. and the Fork . . . . . . . . . . . . . . APPENDIX-6

APPENDIX 2 OPERATION USING MANUAL OPERATION SCREENS . . . . . . APPENDIX-9

2-1 Pallet Pool Operation Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-9

2-1-1 PCMDI MENU Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-9

2-1-2 MANUAL OPERATION Menu Screen. . . . . . . . . . . . . . . . . . APPENDIX-10

2-1-3 MANUAL OPERATION Screens . . . . . . . . . . . . . . . . . . . . . . APPENDIX-11

2-1-4 A.G.V. INDEX Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-13

2-1-5 MAINTENANCE DOOR Screen . . . . . . . . . . . . . . . . . . . . . . APPENDIX-14

2-1-6 ZERO RETURN Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-15

2-1-7 STATUS DISPLAY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-16

2-2 Pallet Pool Operation Using MANUAL OPERATION Screens . . . . . . APPENDIX-17

2-2-1 FORK CENTER Operation . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-19

2-2-2 FORK FORWARD Operation . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-19

2-2-3 FORK UP/FORK DOWN Operation . . . . . . . . . . . . . . . . . . . APPENDIX-19

2-2-4 SHUTTER OPEN/SHUTTER CLOSE Operation . . . . . . . . . APPENDIX-19

2-3 A.G.V. Indexing Using A.G.V. INDEX Screen . . . . . . . . . . . . . . . . . . . APPENDIX-20

2-4 Maintenance Door Locking/Unlocking Operation . . . . . . . . . . . . . . . . APPENDIX-21

2-4-1 MAINTENANCE DOOR LOCK Operation . . . . . . . . . . . . . . APPENDIX-21

2-4-2 MAINTENANCE DOOR UNLOCK Operation . . . . . . . . . . . . APPENDIX-21

2-5 Zero Return Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-22

2-5-1 A.G.V. ZERO RETURN Operation . . . . . . . . . . . . . . . . . . . . APPENDIX-22

2-5-2 FORK FOR./BACK ZERO RETURN Operation . . . . . . . . . . APPENDIX-23

2-5-3 A.G.V. + DIRECTION FEED Operation. . . . . . . . . . . . . . . . . APPENDIX-23

2-5-4 A.G.V. − DIRECTION FEED Operation . . . . . . . . . . . . . . . . . APPENDIX-24

2-5-5 FORK FOR./BACK + FEED Operation . . . . . . . . . . . . . . . . . APPENDIX-24

2-5-6 FORK FOR./BACK − FEED Operation . . . . . . . . . . . . . . . . . APPENDIX-25

2-6 Releasing Manual Operation Interlock . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-26

APPENDIX 3 MAINTENANCE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-27

3-1 Adjustment at Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-27

APPENDIX 4 OPERATION OF AUTO-COUPLER (OPTION) . . . . . . . . . . . . . APPENDIX-29

APPENDIX 5 PC-BASED (MCC-LPS) CONTROL (OPTION) . . . . . . . . . . . . . APPENDIX-30

5-1 Schematic Diagram of Pallet Pool System . . . . . . . . . . . . . . . . . . . . . APPENDIX-30

5-2 Station Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-31

5-3 Data Table Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-32

5-4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX-32

1OVERVIEW

The carrier pallet pool system operates according to the priority order determined by the operator for setup and machining. For an urgent request, the system is able to respond to the request by allowing the setup and machining for the urgent workpieces by interrupting the predetermined order.

The system is most appropriate for repetitive production of medium lot with medium variety of kinds of workpieces.

Since the pallet pool indexing is controlled in the random method, a total of "number of stockers + 1" pallets can be set in the system.

In this instruction manual, "one machine + one setup station + one pallet pool" system with PMC control is taken as an example for explanations.

P-1

Setup station

Machine setup station

Pallet pool electrical cabinet

Splash guard

Machine image (longitudinal arrangement specification)

P-2

2 SCHEMATIC DIAGRAM OF PALLET POOL SYSTEM

Machine

In-machine station

Standby station

31 34 35 36 37

Pallet

Setup station

A.G.V.

Machine

In-machine station

Standby station

Setup station

31 34 35 36 37

A.G.V.

P-3

Standby station

NOTE

A.G.V.

Setup station

In-machine station

Machine

1. The numbers given in the diagram above indicate the station numbers. Pallet transport is controlled according to these station numbers.

2. Depending on the system specification, the layout of the machine, stockers and the setup station may differ from the ones shown above.

3. When loading or unloading a pallet to or from the machine or a station, turn the A.G.V to the direction of loading or unloading the pallet. (The fork can only be moved in the positive direction to transfer a pallet.)

Machine

In-machine station

Standby station

31 34 35

Setup station

A.G.V.

P-4

3 PALLET TRANSPORT PROCESSING

3-1 Pallet Transport Processing Flowchart

A pallet is transported to the stations according to the flowchart given below.

Once the pallet transport processing is started, the pallets are continuously transported according to the flowchart until the processing is terminated.

START

A pallet in the

standby station?

An S-FIN pallet

in the system?

YES

A pallet in the setup station?

A C-FIN pallet in the system?

YES

A C-FIN pallet in the standby

station?

YES

The S-FIN pallet is transported to the standby station.

The C-FIN pallet is transported to the setup station.

An empty station

exists?

YES

The C-FIN pallet is unloaded from the standby station to the empty station.

Completion of Loading or Unloading

The C-FIN pallet is unloaded from the standby station to the setup station.

The pallet

in the setup station in

S-FIN status?

YES

An empty station

exists?

YES

The S-FIN pallet is unloaded from the setup station to the empty station.

The S-FIN pallet is unloaded from the setup station to the standby station.

END

P-5

NOTE

1. The S-FIN (setup finished) pallet includes the following pallets.

• The pallet where setup has finished.

• The pallet holding the urgent workpiece; setup has finished.

2. The C-FIN (cutting finished) pallet includes the following pallets.

• The pallet holding the workpiece which has been machined.

• The pallet holding the urgent workpiece which has been machined.

• The pallet holding the defective workpiece.

P-6

3-2 Pallet Transport Flow

The flow of pallet transport is explained.

An example of the pallet transport flow is shown below.

NOTE

No. Operation

1 The A.G.V. moves to the setup station.

Machine

Setup station

2 The setup station shutter is opened.

Stocker

3 The fork advances.

Setup station side

Rail

The fork is raised.

When the fork holds a pallet, the A.G.V.

NOTE

leans forward.

To prevent it from leaning forward, the rail is held and supported.

The rail is supported.

5 The fork retracts.

No. Operation

6 The fork is lowered.

The A.G.V. cannot move without

NOTE

releasing the rail.

Therefore, the fork must be lowered.

7 The setup station shutter is closed.

8 The A.G.V. moves.

• The pallet is moved while rotating 180

degrees.

P-7

9 The A.G.V. stops in front of the stocker.

10 The fork is raised.

When the fork holds a pallet, the A.G.V.

NOTE

leans forward.

To prevent it from leaning forward, the rail is held and supported.

11 The fork advances.

Stocker side

P-8

No. Operation

12 The fork is lowered.

The A.G.V. cannot move without

NOTE

releasing the rail.

Therefore, the fork must be lowered.

13 The fork retracts.

3-3 Urgent Workpieces (Interruption Processing)

3-3-1 Interruption Method

When the PRIORITY switch on the setup station operation panel is pressed, the "urgent request (EXPRES)" is assigned for the pallet presently located at the setup station. Once the "urgent request (EXPRES)" is assigned, the pallet is given the top priority to be transported to the machining center and after the completion of machining, it is also given the top priority to be returned to the setup station.

The "urgent request (EXPRES)" flag is cleared when the pallet is returned to the setup station again.

Setting of the "urgent request (EXPRES)" is also possible at the WORK NUMBER screen by setting the "urgent request (EXPRES)" flag at the STATUS column.

3-3-2 Interruption Operation

When the "urgent request (EXPRES)" is set, interruption operation is executed for pallet transport processing.

After the completion of presently executed pallet transport processing, pallet transport is executed for the pallet assigned the "urgent request (EXPRES)" flag. Then, upon completion of pallet transport for urgent request, the processing is continuously executed following the processing having been executed before interruption.

If the status of the pallet assigned the "urgent request (EXPRES)" is C-FIN, the pallet is transported to the setup station, and if it is S-FIN, the pallet is transported to the machining center (standby station).

4 DATA SETTING SCREENS

The data necessary for pallet pool system is set on the screens.

4-1 Screen Trees

P-9

OPERATION PANEL screen

SET-UP screen

PCMDI MENU screen

TOOL ENTRY screen

ATC MANUAL screen

PALLET DATA screen

APC MANUAL screen

SENSOR SETTING screen

P-10

WORK NUMBER screen

SETUP STATION PALLET CALL screen

WORK NUMBER (SUB) screen

PCMDI MENU screen

BLOCK DELETE screen

MANUAL OPERATION screen

A.G.V. INDEX screen

MAINTENANCE DOOR screen

ZERO RETURN OP. screen

STATUS DISPLAY screen

4-2 PCMDI MENU Screen

P-11

[PCMDI MENU]

1 WORK NUMBER 2 SETUP STATION PALLET CALL 3 WORK NUMBER (SUB) 4 5 MANUAL OPERATION

KEY IN NO. NUM =

Fig. 1

4-3 WORK NUMBER Screen

On this screen, the following information is checked, registered, or changed for each pallet.

Order of machining, setup order, pallet number, station (stocker) number, program number, and pallet status

[WORK NUMBER] ACT_No. M: 06 W: 05

No. <PLT> <ST> <WORK> <STATUS>

1 01 12 1001 CUTING EXPRES 2 02 31 1002 C-FIN 3 03 32 1003 S-FIN 4 04 1 1004 SETING 5 05 33 1005 S-FIN EXPRES 6 06 11 1006 S-FIN ST-HD

Press the function selection key (PRG-SEL/

CUSTOM) on the MDI operation panel at the pallet pool side.

This displays the PCMDI MENU screen (Fig. 1).

After keying in the number of the menu item for which

data should be set, press the (INPUT) key.

The screen used for setting the selected item is displayed.

On the PCMDI MENU screen (Fig. 1), press the following keys in order:

(INPUT)

The WORK NUMBER screen is displayed.

NUM =

Fig. 2

P-12

[EXIT]

When this soft-key is pressed, the screen returns to the PCMDI MENU screen.

[CLEAR]

This soft-key can clear either the machining priority data or all data.

When the [CLEAR] soft-key is pressed, the soft-keys shown in Fig. 3-1 are displayed for the selection of type of data to be cleared. Upon selection of the type of data to be cleared, the soft-keys shown in Fig. 3-2 or Fig. 3-3 are displayed; pressing the [YES] soft-key clears the selected data. Press the [NO] soft-key when the data should not be cleared.

SELECT TO KIND OF DATA

CUT-NO ALLCLR CANCEL

Fig. 3-1 Soft-keys for Data Clear Operation 1

CUTTING NUMBER CLEAR OK? (YES/NO)

YES NO

Fig. 3-2 Soft-keys for Data Clear Operation 2

WORK DATA ALL CLEAR OK? (YES/NO)

YES NO

Fig. 3-3 Soft-keys for Data Clear Operation 3

P-13

[ACT_NO]

By pressing this soft-key, it is possible to change the data of "M: " (machining priority number) and "W: ××" (setup priority number) of ACT_NO.

When the [ACT_NO] soft-key is pressed at the WORK NUMBER screen (Fig. 2), the soft-keys shown in Fig. 4 are displayed. Key in the "M: " or "W: ××" number to be changed and press

the corresponding soft-key ([M/C] soft-key for changing the machining priority number "M: " and [WSS] soft-key for changing the setup priority number "W: ××"). If the priority number is not changed, press the [CANCEL] soft-key.

When changing the number, it is not allowed to input a number greater than the registered

NOTE

maximum machining priority number.

When the power is turned off, both "M: " and "W: ××" are reset to "0".

M/C WSS CANCEL

Fig. 4 Priority Number Setting Soft-keys

[SET]

This soft-key is used to change the <STATUS> (pallet status) or (pallet sub status) data.

Pallet transport destination (machining center, setup station, stocker) is determined according to the pallet status and the pallet sub status. The pallet transport processing for the pallet and pallet sub statuses is described later.

On the WORK NUMBER screen (Fig. 2), press the [SET] soft-key after moving the cursor to the <STATUS> item, and the soft-keys shown in Fig. 5 are displayed.

S-FIN C-FIN SETING CUTING CLEAR

Fig. 5 Pallet Status Setting Soft-keys

On the WORK NUMBER screen (Fig. 2), press the [SET] soft-key after moving the cursor to the item, and the soft-keys shown in Fig. 6 are displayed.

EXPRES CUT-HD CLEAR

Fig. 6 Pallet Sub Status Setting Soft-keys

P-14

[N-SORT]

When this soft-key is pressed while the data is shown at random in terms of machining priority numbers, the data is arranged in the ascending order of machining priority numbers.

The soft-keys shown in Fig. 7 are displayed when the continuous menu key [+] is pressed on the WORK NUMBER screen (Fig. 2).

N-SORT CHANGE

Fig. 7 [N-SORT] and [CHANGE] Soft-keys

[CHANGE]

By using this soft-key, it is possible to change the machining reserved status pallets (CUT-HD) to the S-FIN status pallets in batch.

When the [CHANGE] soft-key is pressed, the soft-keys shown in Fig. 8 are displayed. Press the [YES] soft-key to execute global change. To cancel the operation, press the [NO] soft-key.

DATA CHANGE OK?

YES NO

Fig. 8 Change Function Soft-keys

<ACT_NO M: W: ××>

<M: >

The machining priority number of the pallet which is or which has been at the standby station.

Transport of the S-FIN pallets to the standby station (machine) is controlled based on this number.

For the procedure used for changing this number, refer to <Description of the soft-keys> on page P-12.

<Example: M: 04>

The system executes "search" for the S-FIN status pallets in the ascending order of the machining priority numbers beginning with "5". If a S-FIN pallet is found, that pallet is transported to the standby station. As soon as the pallet transport begins, the data for ACT_NO is updated to "M: 06", for example if the machining priority number of the transported pallet is "6".

P-15

If no S-FIN status pallet is found when search is made up to the pallet assigned the largest machining priority number, the search is repeated from the smallest machining priority number. If no S-FIN status pallet is found in this search, executed to the machining priority number of "3", pallet transport processing is not executed.

The ACT_NO data is not changed if interruption processing for the urgent request is being

NOTE

executed.

<W: ××>

The setup priority number of the pallet which is or which has been at the setup station.

Transport of such a pallet as the C-FIN status pallet and NG status pallet to the setup station is controlled based on this number.

For the procedure used for changing this number, refer to <Description of the soft-keys> on page P-12.

<Example: W: 04>

The system executes "search" for the pallets such as C-FIN status pallets which should be transported to the setup station in the ascending order of the machining priority numbers beginning with "5". If such a pallet is found, that pallet is transported to the standby station. As soon as the pallet transport begins, the data for ACT_NO is updated to "W: 06", for example if the machining priority number of the transported pallet is "6".

If C-FIN status pallet or pallets in the status to be transported to the setup station are not found when search is made up to the pallet assigned the largest machining priority number, the search is repeated from the smallest machining priority number. If no pallet to be transported to the setup station is found in this search which is executed to the machining priority number of "3", pallet transport processing is not executed.

The ACT_NO data is not changed if interruption processing for the urgent request is being

NOTE

executed.

P-16

<NO.>

Displays the machining priority number.

• Setting is possible in the range from 0 to 99.

• The machining priority number must be unique and it is not allowed to set the same

number for more than one pallet.

<PLT>

Displays the pallet number.

• Setting is possible in the range from 0 to 99.

• The pallet number must be unique and it is not allowed to set the same number for

more than one pallet.

<ST>

Displays the station number of the station where the pallet is stored.

• The station number must be unique and it is not allowed to set the same number for

more than one pallet.

• The number assigned to an empty station cannot be used.

• Setting should be made using the following numbers:

1: Setup station

11: Standby station

12: In-machine station

31: Stocker number 31

32: Stocker number 32

<WORK>

Displays the program number corresponding to the individual pallets <PLT>.

• This number indicates a program number of the program used for machining the

workpiece(s) mounted on the pallet. Setting is possible with up to a four-digit number.

Displays the status of the individual pallets.

• To change the present setting for <STATUS>, move the cursor to the <STATUS>

column and press the [SET] soft-key, then the status setting soft-keys are displayed. Press the required one for changing the status.

• When changing the <STATUS> data, entry of a pallet status is not possible unless the

station number is set for the pallet for which the status should be changed.

• The following four status items are provided:

S-FIN, C-FIN, CUTING, and SETING

• For the display of <STATUS> items for the individual pallet statuses, refer to Table 1.

Displays the sub information of the individual pallet status items.

• To change the present setting for , move the cursor to the column and

press the [SET] soft-key, then the sub status setting soft-keys are displayed. Press the required one for changing the status.

• The sub status includes the following. Note that it is not possible to set "NG" in this

screen.

EXPRES, CUT-HD, and NG

• For setting the sub status of "EXPRES", the <STATUS> item must be either "S-FIN" or

"C-FIN".

• For setting the sub status of "CUT-HD", the <STATUS> item must be "S-FIN".

• For the display of items for the individual pallet statuses, refer to Table 1.

P-17

P-18

4-3-1 Description of Pallet Statuses

The pallet pool controls pallet transport according to the status of a pallet.

Table 1 shows the pallet statuses and the corresponding STATUS and SUB items displayed on the screen. The pallet transport processing for the individual pallet statuses is explained below the table.

Table 1 Pallet Status and Display

Pallet Status

Display Items

Setup finished pallet S-FIN

Machining finished pallet C-FIN

Machining hold pallet S-FIN CUT-HD

Urgent request pallet with unmachined workpiece S-FIN EXPRES

Urgent request pallet with machined workpiece C-FIN EXPRES

Pallet with workpiece being machined (in-machine) CUTING

Urgent request pallet with workpiece being machined (in-machine)

CUTING EXPRES

Setup pallet (setup station) SETING

Error pallet with workpiece being machined CUTING NG

Error pallet with machined workpiece C-FIN NG

Error pallet loaded to setup station SETING NG

Empty pallet

The <STATUS> item of the pallet which is located at the standby station (station number

NOTE

11) lights.

1. Setup finished pallet

This indicates the status in which all workpieces and related parts are mounted to the fixture and setup is completed.

If necessary conditions are satisfied, the pallet is transported to the machining center and machining starts for the mounted workpieces.

Setting of this status is possible either at the WORK NUMBER screen or the setup station operation panel.

2. Machining finished pallet

When the APC is executed after the completion of machining (completed correctly), the pallet status is automatically changed to this status.

The pallet assigned this status is transported to the stocker or the setup station.

In addition to automatic setting as indicated above, it is also possible to set this status at the WORK NUMBER screen.

P-19

3. Machining hold pallet

This indicates the status in which machining should not be started although setup has been finished (hold status).

The pallet in this status is transported to the stocker but not to the machine or setup station.

Setting of this status is possible either at the WORK NUMBER screen or the setup station operation panel.

4. Urgent request pallet

If this status is assigned, interruption processing is executed independent of the present machining priority number or setup priority number.

Setting of this status is possible either at the WORK NUMBER screen or the setup station operation panel.

When setting this status at the WORK NUMBER screen, the <STATUS> of that pallet must be either "S-FIN" or "C-FIN".

5. Machining pallet

This indicates the status in which the pallet is loaded into the machine and machining program is presently executed.

When the pallet is loaded to the machine, the pallet status is automatically changed to this status.

In addition to automatic setting as indicated above, it is also possible to set this status at the WORK NUMBER screen.

On-screen setting is possible only when the <ST> (station number) of this pallet is "12".

NOTE

6. Setting pallet

This indicates the status in which the pallet is loaded to the setup station and setup is being carried out for that pallet.

When the pallet is loaded to the setup station, the pallet status is automatically changed to this status.

In addition to automatic setting as indicated above, it is also possible to set this status at the WORK NUMBER screen.

On-screen setting is possible only when the <ST> (station number) of this pallet is "1".

NOTE

P-20

7. Error pallet

This indicates that the machined workpieces held in the pallet are defective.

Make a program so that "1" is set for #1105 if the result of measurements accomplished by such as a sensor is defective.

O××××;

#1105 = 1;

G4 X5.;

#1105 = 0;

Once the "NG" display is given while the workpiece is inside the machine, it remains displayed until the pallet is loaded to the setup station and then unloaded from it.

Although it is possible to clear the "NG" display on the screen, setting the "NG" status is not possible.

8. Empty pallet

Empty status is set for pallets which will not be used.

The pallet assigned the empty status is unloaded to the stocker and, after the unloading to the stocker such pallet is not transported to the setup station or the standby station until the status is changed on the screen.

4-4 SETUP STATION PALLET CALL Screen

By the operation on the SETUP STATION PALLET CALL screen, it is possible to call a pallet to the setup station.

[SETUP STATION PALLET CALL]

CALLED PALLET NO. 00

SET PALLET NO. THEN PRESS [EXEC.] SOFT KEY NUM =

Fig. 9

For transporting a pallet to the setup station, the following conditions must be satisfied.

On the PCMDI MENU screen (Fig. 1), press the following keys in order:

(INPUT)

The SETUP STATION PALLET CALL screen is displayed.

When the [EXIT] soft-key is pressed, the screen returns to the PCMDI MENU screen.

After keying in the pallet number of the pallet to be transported to the setup station, press the [EXEC.] soft-key and the specified pallet is transported to the setup station.

P-21

1. The setup station table is at the zero point.

2. The setup station door is closed.

3. Neither pallet transport cycle nor APC cycle is executed.

4. The fixture in the setup station is in the clamped state (auto-coupler specification).

The pallet call operation is possible independent of the setting of the LINK/INDE. selection

NOTE

switch on the setup station operation panel.

P-22

4-5 WORK NUMBER (SUB) Screen

On the WORK NUMBER (SUB) screen, the station number of empty station is set.

[WORK NUMBER (SUB)]

EMPTY STATION 1 0031 EMPTY STATION 2 0036

NUM =

Fig. 10

After moving the cursor to the number of the data item to be changed, key in the required number

and press either the [SET] soft-key or the (INPUT) key.

If the [CLEAR] soft-key is pressed, "NONE" is displayed.

After moving pallets in manual operation, make sure to check the EMPTY STATION data whether it is correct. Change the registration if necessary.

On the PCMDI MENU screen (Fig. 1), press the following keys in order:

(INPUT)

The WORK NUMBER (SUB) screen is displayed.

When the [EXIT] soft-key is pressed, the screen returns to the PCMDI MENU screen.

Set the weekly timer work number at the WORK NUMBER screen of the machining center.

NOTE

An empty station number means the number of the stocker where a pallet is not stored.

Setting: 31 and above

CAUTION

Empty station number must not be changed unless necessary for the purpose of maintenance.

Usually, the empty station number is automatically updated as pallets are transported.

The numbers registered as <ST> number on the WORK NUMBER screen cannot be set.

Setting is possible for up to two station numbers.

If there is no empty station, "NONE" is displayed.

4-6 PALLET DATA Screen

On the PALLET DATA screen, whether a pallet exists in the machining center or not is set.

Usually, the setting is "ON" which means that a pallet exists in the machining center.

Change the setting to "NONE" if there is no pallet in the machining center.

[PALLET DATA]

MACHINE PALLET : NONE ON

NUM =

Fig. 11

P-23

Input the code number of the PALLET DATA screen at the PCMDI MENU screen of the machining center and press

the (INPUT) key.

INPUT

The PALLET DATA screen is displayed.

Setting can be changed by using the cursor control keys.

When the [EXIT] soft-key is pressed, the screen returns to the PCMDI MENU screen.

The PALLET DATA screen is the machining center

NOTE

side screen.

P-24

5 SETUP STATION OPERATION PANEL

5-1 Setup Station Operation Panel

5-2-5 "SETUP Switches"

5-2-3 "ALARM Indicator"

5-2-2 "LINK/INDE. Selection Switch"

SETUP

READY NO SET

PRIORITY RESERVE

Arrangement of the switches on the operation panel will differ from the panels shown

NOTE

above.

ALARM LINK INDE.

EMERGENCY

STOP

ALARM RESET

5-2-1 "EMERGENCY STOP Button"

5-2-4 "ALARM RESET Switch"

5-2 Switches on the Operation Panels

5-2-1 EMERGENCY STOP Button

The EMERGENCY STOP button has the same function as provided by the emergency stop button on the machine operation panel. Entire system operation stops when this EMERGENCY STOP button is pressed.

Press this button when stopping the pallet pool and the machine.

5-2-2 LINK/INDE. Selection Switch

When this switch is placed in the LINK position, a pallet is automatically transported to the setup station. A pallet is not transported to the setup station if the switch is placed in the INDE. position.

Calling a pallet to the setup station using the SETUP STATION PALLET CALL screen is always possible independent of the setting of the LINK/INDE. selection switch.

Pallet transport from the setup station is also possible independent of the setting of the LINK/ INDE. selection switch.

P-25

5-2-3 ALARM Indicator

The [ALARM] indicator is lit only when an alarm related with the pallet pool occurs.

5-2-4 ALARM RESET Switch

If this switch is pressed after an occurrence of a pallet pool related alarm, the alarm is cleared.

Pallet transport does not stop even when this button is pressed while a pallet is being transported.

P-26

5-2-5 SETUP Switches

The following four SETUP switches are provided:

READY, PRIORITY, NO SET, and RESERVE

To unload a pallet from the setup station to transport it to a stocker or the machining center after the completion of setup or removal of a finished product at the setup station, press any of the following switches:

READY, PRIORITY, NO SET, and RESERVE

If any of these switches is pressed when the following conditions are satisfied, the indicator in the switch is lit. After the completion of pallet unloading from the setup station, the indicator goes off. If the indicator is not lit and pallet unloading does not start even when the switch is pressed, check the following conditions if all of them are satisfied.

If the switch, which has been pressed, is pressed again while the indicator is lit and before the pallet unloading has not started from the setup station, the indicator goes off and pallet unloading request is canceled. Pressing any other switch causes the indicator in the pressed switch to be lit and the pallet is unloaded from the setup station under the state corresponding to the pressed switch. Once the pallet unloading cycle starts, pressing the switch is ignored and the started cycle is continuously executed even if the switch is pressed.

The switch is valid when the following conditions are satisfied.

1. There is a pallet in the setup station.

2. The setup station table is at the zero point.

3. The setup station door is closed.

4. There is no error alarm occurred related with the pallet pool.

5. A pallet loading/unloading cycle is not executed at the setup station.

6. The fixture in the setup station is in the clamped state. (Auto-coupler specification)

Press this switch to transport the pallet, which has been unloaded to the setup station, to the stocker or the machining center after finishing the setup for that pallet.

Press this switch to carry out machining for the urgent request pallet by interruption processing.

The pallet for which this switch is pressed is registered as the urgent request pallet and it is transported to the machining center at the highest priority after the completion of present machining.

Press this switch to store a pallet which is not used to the stocker.

Once this flag is set for the pallet, the pallet stays stored in the stocker until the flag is changed on the screen.

Press this switch for the pallet which should be stored to the stocker after the completion of setup without conducting machining.

6 STARTING THE APC AND PALLET POOL

Once pallet indexing is started, pallet transport is continuously executed until there is no pallet to be transported to the standby station, setup station, stocker, etc. The pallet transport is controlled according to the flowchart given in 3-1 "Pallet Transport Processing Flowchart".

If pallet transport is started on the SETUP STATION PALLET C A L L s creen, only the specified pallet is called to the setup station and no further pallet transport is executed.

6-1 Starting with the M02/M30

When the M02/M30 command specified in a program is read in memory mode operation with the Z-axis at the 2nd zero point and the B-axis at the zero return position, the pallet assigned the highest priority for machining is selected among the S-FIN status pallets and transported to the standby station; APC cycle is then executed. After the completion or at the start of APC cycle, the program to be used for machining of workpiece(s) mounted on that pallet is searched and automatic operation is started.

The pallet unloaded from the machining center is assigned either the C-FIN status or NG status and transported to the setup station or the stocker. After the completion of transport of the pallet unloaded from the machining center, the system searches the setup finished (S-FIN) status pallet to be machined next and transports it to the standby station.

If there is no S-FIN status pallet when the M02/M30 command is read, the system searches the pallet to be loaded to or unloaded from the setup station to execute transport processing.

P-27

O1234;

G91;

G28 B0;. . . . . . . . . . . . . . . . . . . . . . . . . B-axis zero return

G30 Z0;. . . . . . . . . . . . . . . . . . . . . . . . . Z-axis 2nd zero return

M02 (M30); . . . . . . . . . . . . . . . . . . . . . . (Pallet change cycle, work number search)

P-28

6-2 Starting with the M60/M61

When the M60/M61 command is read, the pallet given the highest priority among the S-FIN status pallets is transported to the standby station and APC cycle is executed.

The M60/M61 command (pallet change) can be specified only in the MDI mode.

1. The M60/M61 command cannot be specified in the memory or tape mode.

2. When pallet change operation is executed in the memory mode, work number search is executed either at the completion of pallet change cycle or at the start of it. However, if pallet change cycle is executed in response to the M60/M61 command, work number search is not executed.

3. If M60/M61 command is executed while there is no S-FIN status pallet, an alarm occurs.

6-3 Starting Using the APC START Switch (Option)

Pallet change cycle can be started by pressing the APC START switch on the machine operation panel.

The switch has completely the same function as the M02 (M30) command specified in a program. For the operation using this switch, the following interlocks are provided.

1. Memory mode is selected.

2. The system is not in the program cycle start state.

3. The APC is not operating.

If there is no S-FIN status pallet when the APC START switch is pressed, the system searches the pallet to be loaded to or unloaded from the setup station to execute transport processing.

6-4 Starting from the SETUP STATION PALLET CALL Screen

It is possible to call the required pallet to the setup station by using the SETUP STATION PALLET CALL screen.

6-5 Starting Using the Buttons on the Setup Station Operation Panel

The SET FIN or NO SET button on the setup station operation panel can be used for starting the pallet transport operation.

When an S-FIN status pallet is transported to the standby station by the pressing of the button, APC cycle is not executed after the pallet is transported to the standby station. Even in this case, if the M02/M30 indicator is lit, the APC cycle is executed.

6-6 SYSTEM LINK/INDE. Selection Switch

P-29

SYSTEM

LINK INDE.

6-7 Operation of the Setup Station

6-7-1 Single Pallet Operation

When repeating setup and machining of workpieces only with a single pallet, operate by the following method.

• Use another pallet as a dummy pallet and run a program consisting of M02 (M30).

6-7-2 Multiple Pallet Operation

Workpieces on multiple pallets are machined in order of pallet unloading from the setup station. The pallets are automatically returned to the setup station. Remove the finished workpieces from the pallet, set up unmachined workpieces, unload the pallet from the setup station, and carry out machining as described below.

The switch is provided at the machine operation panel.

LINK: Pallets are automatically transferred into the

machine.

INDE.: Automatic transfer of pallets into the machine is

not possible.

1) Check that the shutter between the setup station and the A.G.V. is closed.

2) Turn the handle at the right door of the setup station 45° to the right to unlock the door.

3) Open the right door and then the left door, and remove the finished workpieces.

Turn the table if necessary.

The table can be turned as described below.

a) Step on the foot switch to unclamp the table.

b) Turn the table to the desired direction (at every 45°) and step on the foot switch again

to clamp the table.

4) Set up unmachined workpieces.

5) Align the table to the zero point (shown with an arrow in red) and step on the foot switch to clamp the table.

6) Close the left door and then the right door.

7) Turn the handle at the right door 45° to the left to lock the door.

8) Press any of the READY, PRIORITY, NO SET or RESERVE switch.

9) Repeat 2) to 8).

When carrying out unmanned operation, store the pallets loaded with workpieces to be machined temporarily in the stocker by pressing the RESERVE switch. Press the [CHANGE] soft-key to change the machining reserved pallets to the setup finished pallets at one time and start unmanned operation.

P-30

7 TABLE CLAMP/UNCLAMP FOOTSWITCH AT THE SETUP

STATION

The footswitch is used to operate the table lock pin at the setup station.

When the footswitch is stepped on while the table is clamped, the table is unclamped. Conversely, if the footswitch is stepped on while the table is unclamped, the table is clamped.

After completing setup, clamp the table at the home position.

The buttons and switches on the setup station operation panel are invalid unless the table is clamped at the home position.

1. The setup station door is open.

2. Pallet loading/unloading cycle is not executed at the setup station.

8 SETUP STATION DOOR LOCK CONDITIONS

The following five combinations of the setup station door lock conditions are provided.

The setup station door is locked when it is closed in the following cases.

1. Pallet loading/unloading cycle is executed at the setup station.

2. There is no pallet in the setup station.

The LINK/INDE. selection switch on the setup station operation panel is placed in the LINK position.

3. There is a pallet in the setup station.

The indicator in the SET FIN or NO SET button on the setup station operation panel is lit.

4. The setup station shutter is opened.

5. The pallet pool is in the manual (ON) mode.

(The manual pallet pool operation mode ON/OFF switch is provided on the handy operation panel.)

9 AUTOMATIC POWER SHUTOFF

By executing automatic power shutoff at the machine, automatic power shutoff is executed at the pallet pool.

The automatic power shutoff function becomes valid under the condition that there is no S-FIN status pallet at the stocker, setup station, and standby station.

Whether or not the automatic power shutoff sequence is executed is determined by the setting for PC parameter K2.7 at the pallet pool side.

K2.7 1: Automatic power shutoff function is invalid if there is a pallet in the setup station (during

setting up).

0: Automatic power shutoff function is valid even if there is a pallet in the setup station

(during setting up).

10 AUTO-COUPLER (OPTION)

Conventionally, a workpiece is fixed to the fixture with such as bolts. If an auto-coupler is used, it is possible to clamp or unclamp a workpiece to the fixture on the pallet by using the footswitch for the auto-coupler installed at the setup station.

Clamp and unclamp of a workpiece on the pallet which has been loaded to the machining center are possible using M codes (M108 for clamp, and M109 for unclamp).

10-1 Operating the Auto-coupler

1) Transport the pallet where the fixture compatible with the auto-coupler is mounted to the setup station.

2) The footswitch is used in the following manner.

If it is stepped on while the fixture is clamped, the fixture is unclamped.

If it is stepped on while the fixture is unclamped, the fixture is clamped.

P-31

1. The setup station door is opened.

2. There is no error occurred related with the setup station.

3. The STATUS indicator [MRDY] is lit on the pallet pool electrical cabinet.

11 MAINTENANCE

11-1 Recovering Interrupted Pallet Pool Operation

If pallet pool operation is interrupted during pallet pool cycle or APC cycle, recover the operation manually.

After recovering the operation manually, or after the occurrence of an alarm which does not require manual operation recovery, make sure to check the data related to pallets.

1. On the WORK NUMBER screen, check the station number and the status of the pallet recovered manually.

2. On the WORK NUMBER (SUB) screen, check or change the empty station numbers.

If pallet transport is carried out with incorrect data, it causes an alarm and malfunctioning

NOTE

of the pallet pool.

APPENDIX

This appendix deals with the procedure for operating the pallet pool manually.

The handy operation panel is used to carry out manual operations of the pallet pool.

APPENDIX 1 HANDY OPERATION PANEL

A handy operation panel provided at the setup station side of the pallet pool is used to operate the carrier pallet pool.

The switches on the handy operation panel are used for mounting and removing workpieces to and from the pallet pool.

Manual pallet pool operation mode indicator

PMGE 1

1. ALARM

2. STOP

3. START

MANUAL

8. HP

AXIS HP

10. M-OPE

11. MDI

ONOFF

APPENDIX-1

Manual pallet pool operation mode ON/OFF switch

Emergency stop button

PMGE 1

APPENDIX-2

The indicators on the pallet pool handy operation panel indicate that the pallet pool is in the following status.

LED Indicator Status

LED01

LED02

LED03

LED04

LED05

LED06

LED07

LED08

LED09

LED10

LED11

NOTE

1. ALARM

2. STOP

3. START

Lights (red) if an alarm occurs.

Lights (red) in the feed hold state.

Lights after cycle start.

7. MANUAL

8. HP

9. AXIS HP

10. M-OPE

11. M D I

Lights when the manual mode is selected for the pallet pool.

Lights when all axes are at the home position.

Lights when the X-axis of the pallet pool is in the specified operation enabled range.

Lights when the keyboard is in the M-OPE mode.

Lights when the keyboard is in the MDI mode (normal status).

Usually, the keyboard of the handy operation panel is used in the MDI mode. If the mode

indicator showing the M-OPE mode is lit, press the function selection key (M-OPE/

MDI) to turn ON the indicator [MDI].

1-1 Manual Pallet Pool Operation Mode ON/OFF Switch

OFF ON

Switch Position Function

OFF

When the switch is placed in this position, the pallet pool operates in the automatic operation mode.

When the switch is placed in this position, the manual pallet pool operation mode indicator (fifth LED from the bottom) is lit and the pallet pool can be operated manually.

NOTE

Even if the switch is placed in this position during the automatic operation of the pallet pool, the manual pallet pool operation mode indicator dose not light. The indicator lights when the automatic operation of the pallet pool is completed.

The manual pallet pool operation mode ON/OFF switch is used to select whether the pallet pool is operated automatically or manually.

1-2 Emergency Stop Button

1-3 Selecting the Operation Mode

When operating the pallet pool, select the operation mode first using the handy operation panel.

Select the operation mode of the pallet pool, following the steps below.

APPENDIX-3

The emergency stop button has the same function as that available with the emergency stop button on the machine operation panel.

Pressing the emergency stop button on the handy operation panel turns off the power to the circuits that control the axis movements and spindle rotation, stopping the machine as well as the pallet pool operation.

The operator must be able to press this button any time at any place while operating the machine.

1) Press the function selection key (OFFSET/SETTING).

2) Press the menu selection key .

3) Press the [OPR] soft-key. The mode selection items are displayed at the screen.

OPERATOR'S PANEL O0105 N00340

MODE

MODE : MDI AUTO EDIT STEP JOG ZRN

HNDL FEED : DISABLE X Z

H/S MULTI. : (HNDL : ＊ 100 STEP : ＊ 1000)

RAPID OVRD. : 100% 50% 25% F0

JOG OVRD. : 100%

＊＊

FEED OVRD. : 100%

＊＊＊＊＊＊＊＊＊

ACTUAL POSITION (ABSOLUTE)

X 0.000 Z 0.000

STEP ＊＊＊＊＊＊＊＊＊＊ ALM 17 : 49 : 23

[ MACRO ] [ MENU ] [ ] [ ] [ ]

ALM

OPR

Fig. 1 OPERATOR'S PANEL

4) Select the desired mode by pressing the menu selection key or .

APPENDIX-4

Operation Mode Description

To input the parameter

To punch out the parameter

To move an axis by the pulse handle

MDI To input the parameter, set "1" for the "PARAMETER WRITE

ENABLE" item at the SETTING screen.

If PS100 alarm occurs, press the (INPUT) key while pressing

the (CAN) key and the alarm is cleared.

After completing parameter input operation, press the

NOTE

function selection key (AUTO/POS) to select the

AUTO mode (the AUTO mode indicator lights).

EDIT

STEP <Operation procedure>

1) Connect the cable of the manual pulse handle box that is provided in the pallet pool electrical cabinet to the connect (XP-XS593) of the pallet pool electrical cabinet.

2) Select manual pallet pool operation mode. (The fifth indicator from the bottom in the LED display lights.)

3) Set the axis to be moved and the feed amount per pulse using the axis selection switch and the magnification selection switch at the handy operation panel.

X: A.G.V traveling direction

Z: Fork axis forward/backward diction

4) Move the selected axis using the manual pulse generator on the manual pulse handle box.

5) After completing the axis movement, disconnect the cable of the manual pulse handle box.

Operation Mode Description

APPENDIX-5

To move an axis in jog feed operation

To return an axis to the zero point

JOG or ZRN

When moving an axis in jog feed operation or returning an

NOTE

axis to the zero point, make sure that the conditions below are satisfied.

1. The manual mode is selected for pallet pool operation. (The fifth indicator from the bottom in the LED display lights.)

2. The presently displayed screen is not the PCMDI MENU screen or the manual pallet pool operation screen.

3. The pallet pool is not operating.

1) Select the M-OPE mode (the indicator [M-OPE] lights) by

pressing the function selection key (M-OPE/MDI).

2) Press the axis feed switch of the axis to be moved while

pressing the (SHIFT) key.

A.G.V. traveling direction: (+J1) (−J1)

Fork extending/retracting direction: (+J2) (−J2)

3) After completing axis movements, press the function selection

key (M-OPE/MDI) to select the MDI mode (the indicator

[MDI] lights).

NOTE

1. The keys used for selecting CNC screens are not operative unless the pallet pool mode is returned to the MDI.

2. Use this function only for returning operation. Please note that no interlock is imposed.

APPENDIX-6

1-4 Registering Position Data of the A.G.V. and the Fork

Since the pallet pool system uses servomotors for driving the A.G.V. and for driving forward/ backward movement of the fork and the servomotors operate based on the position data registered in the PLC, it is necessary to register position data properly for each station.

Call the A.G.V. INDEX screen from the PCMDI MENU screen to register the position data.

By pressing the [WRITE] soft-key on the A.G.V. INDEX screen, the coordinates of the present position are written automatically to a data table in the PLC as the position data of the fork and the index position of the A.G.V. It is also possible to set data directly to the data table.

Follow the procedure below to register the position of the fork and the index position of the A.G.V.

1) Adjust the position of the A.G.V. and the forward movement position of the fork by performing A.G.V. feed operation and fork forward/backward feed operation.

2) Press the function selection key (PRG-SEL/CUSTOM).

3) The PCMDI MENU screen is displayed.

[PCMDI MENU] I98079B01

1 WORK NUMBER 2 SETUP STATION PALLET CALL 3 WORK NUMBER (SUB) 4 5 MANUAL OPERATION

KEY IN NO.

[ 1 ] [ 2 ] [ 3 ] [ ] [ 5 ]

Fig. 2 PCMDI MENU screen

4) Enter "94" and press the input key (INPUT).

The A.G.V. INDEX screen is displayed.

[A.G.V. INDEX]

APPENDIX-7

INDEX STATION NO. 031

X −49.999 D0324 = −50000 Z −499.980 D0724 = −900000

XI % = 0

ZI % = 0

PRESS THE [WRITE] SOFT-KEY

EXIT ¹²½– SET

WRITE

Fig. 3 A.G.V. INDEX Screen

031

The coordinates of the current position of the A.G.V. and the fork are displayed on the left side of the screen.

5) Set the number of the station where the position data should be registered

The address of the set station and the registered values are displayed on the right side of the screen.

The values "XI %" and "ZI %" indicate the intensity of an electrical current by the ratio to

NOTE

the maximum current load and 100% corresponds to the maximum current load of the servo amplifier.

APPENDIX-8

6) Press the [WRITE] soft-key.

[A.G.V. INDEX]

INDEX STATION NO. 031

X −49.999 D0324 = −50000 Z −499.980 D0724 = −900000

XI % = 0

ZI % = 0

DO YOU WANT TO WRITE THE DATA? (YES/NO)

YES NO

Fig. 4 A.G.V. INDEX Screen

031

7) Press the [YES] soft-key.

The coordinates of the current positions of the A.G.V. and the fork are written to the data table in the PLC.

Always check if the position data are property set in the data table after registering position

NOTE

data. The following table shows which data table contains the position data for which station.

Table 1 Position Data Registration Address for Each Station

Address Name (X-axis, A.G.V. Traveling Axis) Address Name (Z-axis, Fork Axis)

D204 Position of setup station 1 for A.G.V. D604 Position of setup station 1 for fork

D244 Position of machine 1 for A.G.V. D644 Position of machine 1 for fork

D324 Position of station 31 for A.G.V. D724 Position of station 31 for fork

D328 Position of station 32 for A.G.V. D728 Position of station 32 for fork

D332 Position of station 33 for A.G.V. D732 Position of station 33 for fork

D336 Position of station 34 for A.G.V. D736 Position of station 34 for fork

D340 Position of station 35 for A.G.V. D740 Position of station 35 for fork

D344 Position of station 36 for A.G.V. D744 Position of station 36 for fork

D348 Position of station 37 for A.G.V. D748 Position of station 37 for fork

APPENDIX-9

APPENDIX 2 OPERATION USING MANUAL OPERATION SCREENS

2-1 Pallet Pool Operation Screen

2-1-1 PCMDI MENU Screen

The PCMDI MENU screen is called out when the function selection key (PRG-SEL/CUSTOM)

on the MDI operation panel at the pallet pool is pressed.

[PCMDI MENU]

WORK NUMBER

2 SETUP STATION PALLET CALL

3 WORK NUMBER (SUB)

MANUAL OPERATION

NUM =

[ 1 ] [ 2 ] [ 3 ] [ 4 ] [ 5 ]

Fig. 5 PCMDI MENU Screen

The MANUAL OPERATION menu screen is displayed when the (INPUT) key is pressed after

pressing the key or when the [5] soft-key is pressed.

APPENDIX-10

2-1-2 MANUAL OPERATION Menu Screen

Operation to perform is selected from among manual pallet pool operation, A.G.V. operation, and maintenance door lock operation at the MANUAL OPERATION menu screen.

With NH4000 or NH5000, item 3 at the MANUAL OPERATION menu screen is displayed

NOTE

as "3 " since the maintenance door lock mechanism is not provided.

[MANUAL OPERATION]

1 MANUAL OPERATION

2 A.G.V. INDEX

3 MAINTENANCE DOOR

4 ZERO RETURN OP.

5STATUS DISPLAY

NUM =

[ EXIT ] [ ] [ ] [ ] [ ]

Fig. 6 MANUAL OPERATION Menu Screen

After keying in the number of the menu item for which data should be set, press the (INPUT)

key.

The screen used for setting the selected item is displayed.

Pressing the [EXIT] soft-key returns the screen to the PCMDI MENU screen (Fig. 5).

2-1-3 MANUAL OPERATION Screens

For the carrier pallet pool systems, traversal and longitudinal configurations are available.

APPENDIX-11

[MANUAL OPERATION]

1 FORK FORWARD TO + SIDE

2FORK CENTER 3 FORK FORWARD TO − SIDE

4FORK UP

5FORK DOWN

KEY IN NO.

[ EXIT ] [ NEXT ] [ ] [ SELECT ] [ EXEC. ]

Fig. 7 MANUAL OPERATION Screen (1/2)

[MANUAL OPERATION]

6 WSS 1 SHUTTER OPEN

7 WSS 1 SHUTTER CLOSE

8 WSS 2 SHUTTER OPEN

9 WSS 2 SHUTTER CLOSE

PAGE 1/2

PAGE 2/2

KEY IN NO.

[ EXIT ] [ PREV ] [ ] [ SELECT ] [ EXEC. ]

Fig. 8 MANUAL OPERATION Screen (2/2)

APPENDIX-12

[MANUAL OPERATION]

1 FORK FORWARD TO + SIDE

2FORK CENTER 3 FORK FORWARD TO − SIDE

4FORK UP

5FORK DOWN

6 A.G.V. CW

7 A.G.V. CCW

KEY IN NO.

[ EXIT ] [ NEXT ] [ ] [ SELECT ] [ EXEC. ]

Fig. 9 MANUAL OPERATION Screen (1/2)

[MANUAL OPERATION]

8 WSS 1 SHUTTER OPEN

9 WSS 1 SHUTTER CLOSE

10 WSS 2 SHUTTER OPEN

11 WSS 2 SHUTTER CLOSE

PAGE 1/2

PAGE 2/2

KEY IN NO.

[ EXIT ] [ PREV ] [ ] [ SELECT ] [ EXEC. ]

Fig. 10 MANUAL OPERATION Screen (2/2)

After inputting a number using the data entry, heading the required operation, press the

(INPUT) key or the [SELECT] soft-key, and the number of the selected item begins blinking with the following message displayed on the screen.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the selected operation is executed.

Page APPENDIX-17 (APPENDIX 2-2)

When the status is established, the characters of the selected operation item are highlighted.

Pressing the [EXIT] soft-key returns the screen to the MANUAL OPERATION menu screen (Fig. 6).

"3 FORK FORWARD TO − SIDE" is not used with NH4000 DCG.

NOTE

Note that the guidance display for 6 and 7 shows "6 CW" and "7 CCW", respectively.

2-1-4 A.G.V. INDEX Screen

[A.G.V. INDEX]

INDEX STATION NO. 31

APPENDIX-13

KEY IN NO.

[ EXIT ] [ ] [ ] [ SET ] [ EXEC. ]

Fig. 11 A.G.V. INDEX Screen

After inputting the station number of the station where the A.G.V. should be moved using the data

entry key, press the (INPUT) key or the [SET] soft-key, and the following message is

displayed on the screen.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the A.G.V. moves to the specified station.

Page APPENDIX-20 (APPENDIX 2-3)

Pressing the [EXIT] soft-key returns the screen to the MANUAL OPERATION menu screen (Fig. 6).

APPENDIX-14

2-1-5 MAINTENANCE DOOR Screen

[MAINTENANCE DOOR]

1 MAINTENANCE DOOR LOCK

2 MAINTENANCE DOOR UNLOCK

KEY IN NO.

[ EXIT ] [ ] [ ] [ SET ] [ EXEC. ]

Fig. 12 MAINTENANCE DOOR Screen

After inputting a number using the data entry key, heading the required operation, press the

(INPUT) key or the [EXEC.] soft-key, and the number of the selected item begins blinking with the following message displayed on the screen.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the selected operation is executed.

Page APPENDIX-21 (APPENDIX 2-4)

When the status is established, the characters of the selected operation item are highlighted.

Pressing the [EXIT] soft-key returns the screen to the MANUAL OPERATION menu screen (Fig. 6).

This screen is not displayed for NH4000 DCG or NH5000 or NH5000 DCG.

NOTE

2-1-6 ZERO RETURN Screen

[ZERO RETURN OP.]

1 A.G.V. ZERO RETURN

2 FORK FOR./BACK ZERO RETURN

3 A.G.V. + DIRECTION FEED 4 A.G.V. − DIRECTION FEED

5 FORK FOR./BACK + FEED 6 FORK FOR./BACK − FEED

[MACHINE] A.G.V. (X) 77777.777

FORK F/B (Z) 33333.333

KEY IN NO.

[ EXIT ] [ ] [ ] [ SET ] [ EXEC. ]

APPENDIX-15

Fig. 13 ZERO RETURN OP. Screen

After inputting a number using the data entry key, heading the required operation, press the

(INPUT) key or the [SET] soft-key, and the number of the selected item begins blinking with the following message displayed on the screen.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the selected operation is executed.

Press the function selection key (M-OPE/MDI) and select the M-OPE mode (the indicator

[M-OPE] lights).

Press the axis feed key that corresponds to the axis to be moved while holding down the

(SHIFT) key.

: The A.G.V. moves in the positive direction.

: The A.G.V. moves in the negative direction.

: The fork moves in the positive direction.

: The fork moves in the negative direction.

After completing the axis movement, press the function selection key (M-OPE/MDI) to set the

operation mode back to the MDI mode (the indicator [MDI] lights).

When the status is established, the characters of the selected operation item are highlighted.

Pressing the [EXIT] soft-key returns the screen to the MANUAL OPERATION menu screen (Fig. 6).

APPENDIX-16

2-1-7 STATUS DISPLAY Screen

[STATUS DISPLAY]

A.G.V. ZERO POINT MEMORY

FORK ZERO RET.

ESTABLISH A.G.V. INDEX FIN.

WSS1 AUTO COUPLER CLAMP FIN.

[ EXIT ] [ ] [ ] [ ] [ ]

Fig. 14 STATUS DISPLAY Screen

When the status is established, the characters of the selected operation item are highlighted.

Pressing the [EXIT] soft-key returns the screen to the MANUAL OPERATION menu screen (Fig. 6).

"AUTO COUPLER CLAMP FIN." item is displayed only for the auto-coupler specification

NOTE

setup station.

2-2 Pallet Pool Operation Using MANUAL OPERATION Screens

Manual pallet pool operation using the MANUAL OPERATION screens is allowed in the state indicated below.

• The MANUAL OPERATION indicator is lit with the MANUAL/AUTO selection switch on the

operation panel set in the MANUAL position.

The following conditions must be satisfied for operating the pallet pool manually using the MANUAL OPERATION screen.

• Not during APC cycle or pallet pool indexing cycle

• The maintenance door is closed and locked.

• The setup station shutter is closed or the setup station door is closed and locked.

• The APC rotating door of the machine is in the home position.

• The pallet pool is in the ready state.

• There are no errors occurring with the pallet pool.

APPENDIX-17

APPENDIX-18

• Standby station:

Station No. 11

• In-machine station:

Station No. 12

• Setup station:

No. 1

Machine

No. 1

Machine

1st Station

Station No. 1

• Stocker:

Stocker 1 Stocker 2 Stocker 3 Stocker 4 Stocker X

Station No. 31 32 33 34 30 + X

Standby station

A.G.V.

In-machine station

Machine

Setup station

2-2-1 FORK CENTER Operation

Press the (INPUT) key or the [SET] soft-key after inputting the code number heading the

"FORK CENTER" item using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the fork moves to the central position.

The conditions required for the fork movement to the central position are indicated below.

• The fork is at the upper or lower end level position of a loading/unloading station.

• Zero return has completed with the A.G.V. and fork forward/backward operation.

2-2-2 FORK FORWARD Operation

Press the (INPUT) key or the [SET] soft-key after inputting the code number heading the

"FORK FORWARD" item using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

APPENDIX-19

Press the [EXEC.] soft-key, and the fork moves to the forward end position.

The conditions required for the fork movement to the forward position are indicated below.

• The fork is at the upper or lower end level position of a loading/unloading station.

• Zero return has completed with the A.G.V. and fork forward/backward operation.

2-2-3 FORK UP/FORK DOWN Operation

Press the (INPUT) key or the [SET] soft-key after inputting the code number heading the

required fork up/down level number using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the fork moves up or down to the required level.

The condition required for the fork up/down operation is indicated below.

• The fork is at the forward or backward end position (either machine side or opposite to the

machine side).

2-2-4 SHUTTER OPEN/SHUTTER CLOSE Operation

Press the (INPUT) key or the [SET] soft-key after inputting the code number heading the

required shutter operation (open or close) using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the shutter opens or closes according the selected operation.

The condition required for the fork up/down operation is indicated below.

• The fork is at the backward end position.

APPENDIX-20

2-3 A.G.V. Indexing Using A.G.V. INDEX Screen

It is possible to move the A.G.V. to the position in front of the station of the specified number.

At the A.G.V. INDEX screen, press the (INPUT) key or the [SET] soft-key after inputting the

station number of the station where the A.G.V. should move using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the A.G.V. moves to the position in front of the station of the specified number.

Manual A.G.V. operation using the A.G.V. INDEX screen is allowed in the state indicated below.

• The MANUAL OPERATION indicator is lit with the MANUAL/AUTO selection switch on the

operation panel set in the MANUAL position.

The following conditions must be satisfied for operating the pallet pool manually using the A.G.V. INDEX screen.

• Not during APC cycle or pallet pool indexing cycle

• The maintenance door is closed and locked.

• The setup station shutter is closed or the setup station door is closed and locked.

• The APC rotating door of the machine is in the home position.

• The pallet pool is in the ready state.

• There are no errors occurring with the pallet pool.

• The fork is at the central position.

2-4 Maintenance Door Locking/Unlocking Operation

To lock or unlock the maintenance door, the following conditions must be satisfied.

• Not during APC cycle or pallet pool indexing cycle

• There are no errors occurring with the pallet pool.

• The pallet pool is in the ready state.

2-4-1 MAINTENANCE DOOR LOCK Operation

Press the (INPUT) key or the [SET] soft-key after inputting the code number heading the

"MAINTENANCE DOOR LOCK" item using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the maintenance door is locked.

2-4-2 MAINTENANCE DOOR UNLOCK Operation

APPENDIX-21

Press the (INPUT) key or the [SET] soft-key after inputting the code number heading the

"MAINTENANCE DOOR UNLOCK" item using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

Press the [EXEC.] soft-key, and the maintenance door is unlocked.

When the maintenance door is unlocked, power supply is shut off for the A.G.V. drive

NOTE

motor, the fork operating motors, and the motor driving the APC of the machine.

APPENDIX-22

2-5 Zero Return Operation

Zero return operation using the ZERO RETURN OP. screen is not allowed unless the manual operation interlock is released.

For the procedure to release manual operation interlock, refer to page APPENDIX-26 (APPENDIX 2-6).

CAUTION

For operations which are executed on the ZERO RETURN OP. screen, interlock is not valid or only a minimum requisite interlock is valid. Accordingly, the operations using the ZERO RETURN OP. screen requires your special attention to ensure safe operation.

When zero return operation is executed in the state the zero return position has been established, the A.G.V. and the fork return to the respective zero point at a rapid feedrate.

If zero return operation is performed when the zero return position has not been established, the operation establishes the zero point.

To change the zero return point which has already been established, set "0" for parameter 1815, bit 4 before executing the zero return operation.

Before executing the zero return operation, it is necessary to move an axis (A.G.V. or fork) either in rapid feedrate or jog feedrate and switch off the power supply to the NC once. This operation is required so that the NC reads one grid of a motor. If this step is skipped, an alarm (code 90) occurs. If alarm 90 occurs even if zero return is executed after this step, set a larger value for parameter 1425 (FL speed for zero return operation).

2-5-1 A.G.V. ZERO RETURN Operation

1) Press the (INPUT) key or the [SET] soft-key after inputting the code number heading

the "A.G.V. ZERO RETURN" item using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

2) Press the [EXEC.] soft-key.

3) Press the function selection key (M-OPE/MDI) and select the M-OPE mode (the

indicator [M-OPE] lights).

4) Press the axis feed key while holding down the (SHIFT) key.

The A.G.V. moves toward the zero position (in the positive direction).

5) After completing the axis movement, press the function selection key (M-OPE/MDI) to

set the operation mode back to the MDI mode (the indicator [MDI] lights).

The condition required for the A.G.V. zero return operation is indicated below.

• The fork is at the central position.

CAUTION

When you perform unmanned operation with the carrier pallet pool system of longitudinal configuration, make sure that the fork position is located at 0° or 180° position (with the fork facing toward the setup station or the pallet stocker) before starting. If the fork is started from the 90° position, it will collide with the 90° positioning unit somewhere between the normal traveling position to the travel zero point.

2-5-2 FORK FOR./BACK ZERO RETURN Operation

1) Press the (INPUT) key or the [SET] soft-key after inputting the code number heading

the "FORK FOR./BACK ZERO RETURN" item using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

2) Press the [EXEC.] soft-key.

3) Press the function selection key (M-OPE/MDI) and select the M-OPE mode ((the

indicator [M-OPE] lights).

4) Press the axis feed key while holding down the (SHIFT) key.

The fork moves toward the zero position (in the positive direction).

5) After completing the axis movement, press the function selection key (M-OPE/MDI) to

set the operation mode back to the MDI mode (the indicator [MDI] lights).

APPENDIX-23

To execute zero return in the state the zero point has not been established, move the fork manually forward to the machine side before executing zero return; the zero point of the fork in the forward/backward direction is near the center of the forward/backward stroke. If zero return is executed with the fork positioned near the center or at a position opposite to the machine side, the fork moves backward to the end position opposite to the machine side and zero return operation cannot be executed.

2-5-3 A.G.V. + DIRECTION FEED Operation

1) Press the (INPUT) key or the [SET] soft-key after inputting the code number heading

the "A.G.V. + DIRECTION FEED" item using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

2) Press the [EXEC.] soft-key.

3) Press the function selection key (M-OPE/MDI) and select the M-OPE mode (the

indicator [M-OPE] lights).

4) Press the axis feed key while holding down the (SHIFT) key.

The A.G.V. moves in the positive direction.

5) After completing the axis movement, press the function selection key (M-OPE/MDI) to

set the operation mode back to the MDI mode (the indicator [MDI] lights).

The A.G.V. does not move unless the fork is at the central position.

NOTE

APPENDIX-24

2-5-4 A.G.V. − DIRECTION FEED Operation

1) Press the (INPUT) key or the [SET] soft-key after inputting the code number heading the "A.G.V. − DIRECTION FEED" item using the data entry key, and the following message

is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

2) Press the [EXEC.] soft-key.

3) Press the function selection key (M-OPE/MDI) and select the M-OPE mode (the

indicator [M-OPE] lights).

4) Press the axis feed key while holding down the (SHIFT) key.

The A.G.V. moves in the negative direction.

5) After completing the axis movement, press the function selection key (M-OPE/MDI) to

set the operation mode back to the MDI mode (the indicator [MDI] lights).

The A.G.V. does not move unless the fork is at the central position.

NOTE

2-5-5 FORK FOR./BACK + FEED Operation

1) Press the (INPUT) key or the [SET] soft-key after inputting the code number heading

the "FORK FOR./BACK + FEED" item using the data entry key, and the following message is displayed.

"THEN PRESS [EXEC.] SOFT KEY"

2) Press the [EXEC.] soft-key.

3) Press the function selection key (M-OPE/MDI) and select the M-OPE mode (the

indicator [M-OPE] lights).

4) Press the axis feed key while holding down the (SHIFT) key.

The fork moves in the positive direction.

5) After completing the axis movement, press the function selection key (M-OPE/MDI) to

set the operation mode back to the MDI mode (the indicator [MDI] lights).

2-5-6 FORK FOR./BACK − FEED Operation

1) Press the (INPUT) key or the [SET] soft-key after inputting the code number heading the "FORK FOR./BACK − FEED" item using the data entry key, and the following message is

displayed.

"THEN PRESS [EXEC.] SOFT KEY"

2) Press the [EXEC.] soft-key.

3) Press the function selection key (M-OPE/MDI) and select the M-OPE mode (the

indicator [M-OPE] lights).

4) Press the axis feed key while holding down the (SHIFT) key.

The fork moves in the negative direction.

5) After completing the axis movement, press the function selection key (M-OPE/MDI) to

set the operation mode back to the MDI mode (the indicator [MDI] lights).

APPENDIX-25

APPENDIX-26

2-6 Releasing Manual Operation Interlock

The following message is displayed when the (INPUT) key is pressed after inputting "98" at

the PCMDI MENU screen using the data entry key:

"RELEASE MN INTERLOCK? (YES/NO)"

To release the manual operation interlock, press the [YES] soft-key.

The manual operation interlock release state is cleared once you exit the screen.

CAUTION

In the state the manual operation interlock is released, interlock is not valid or only a minimum requisite interlock is valid. Accordingly, operations to be executed in such a state requires your special attention to ensure safe operation.

APPENDIX 3 MAINTENANCE OPERATION

3-1 Adjustment at Start-up

The following describes the procedure to be followed when starting up the pallet pool or extending the pallet pool capacity.

1) Set the number of stockers, machines, and setup stations.

↓

2) Execute zero return of the A.G.V. and fork.

(This step may be skipped if the zero return position has already been established.)

↓

3) Enter the position data of the A.G.V. and the fork corresponding to stockers, machines, and setup stations.

↓

4) Check the correctness of the data by manually moving the A.G.V. and the fork.

APPENDIX-27

↓

Completion

APPENDIX-28

1) Setting the number of stockers, machines, and setup stations

Press the function selection key (SETTING) on the operation panel, and then press the

SETTING

[CUSTOM] soft-key to display the PCMDI MENU screen.

Key in "97" at the PCMDI MENU screen and press the (INPUT) key. Then, the screen

shown below will be displayed. Set the number of stockers, machines, and setup stations meeting the actual configuration.

To change the values already set and displayed on the screen, password "76543210" must be input at the PCMDI MENU screen.

[BYTE DATA SETTING]

NUMBER OF STOCKER 10

NUMBER OF MACHINE 1

NUMBER OF WSS 2

[ EXIT ] [ ] [ ] [ ] [ SET ]

Fig. 15 BYTE DATA SETTING Screen

2) Executing zero return of the A.G.V. and fork

Execute zero return of the A.G.V. and the fork according to the procedure explained in APPENDIX 2-5 "Zero Return Operation".

3) Enter the position data of the A.G.V. and the fork corresponding to stockers, machines, and setup stations according to the procedure explained in APPENDIX 1-4 "Registering Position Data of the A.G.V. and the Fork".

4) Checking the correctness of the data by manually moving the A.G.V. and the fork

Check the correctness of the entered data by actually moving the A.G.V. and the fork according to the procedure explained in APPENDIX 2 "OPERATION USING MANUAL OPERATION SCREENS".

APPENDIX-29

APPENDIX 4 OPERATION OF AUTO-COUPLER (OPTION)

Installation of an auto-coupler simplifies clamping of a fixture in setting up steps.

For clamping/unclamping a fixture, a footswitch is installed at setup stations. The footswitch toggles - stepping on the footswitch while the fixture is clamped causes the fixture to be unclamped and stepping on the footswitch while the fixture is unclamped causes the fixture to be clamped.

To clamp or unclamp the fixture, all of the conditions indicated below must be satisfied.

• The setup station door is closed.

• The MRDY indicator is lit.

• The SET FIN or NO SET indicator is not lit.

The FIXTURE CLAMP indicator is lit when the following conditions are satisfied.

• The fixture is clamped.

• The workpiece correct holding signal is on (only when the correct holding check switch is

used).

Conditions required to unload a pallet from the setup station are indicated below.

• To transport a pallet after setting up a workpiece on it, the fixture must be clamped with the

workpiece correct holding signal ON. Unless these conditions are satisfied, the SET FIN indicator in the SET FIN button does not light even if the button is pressed and thus the transport of a pallet does not start.

• To transport a pallet without setting up a workpiece on it, the fixture must be clamped.

Unless the fixture is clamped, the NO SET indicator in the NO SET button does not light even if the button is pressed and thus the transport of a pallet does not start. In this case, the status of the workpiece correct holding signal is disregarded.

APPENDIX-30

APPENDIX 5 PC-BASED (MCC-LPS) CONTROL (OPTION)

PC-based (MCC-LPS) control of the linear pallet pool system is possible. PC-based control enables the use of flexible functions tailored to actual conditions: for example you can reliably ascertain the system operating status and machining record using simple operations, and deal with interruption processing of urgent workpieces.

5-1 Schematic Diagram of Pallet Pool System

Machine

In machine

Machine side

APC rotary door

Buffer station

NOTE

A.G.V.

31 33 35 36 37 38 1

Fork

Opposite to the machine side

Fig. 16 Schematic Diagram of Pallet Pool System (Carrier Pallet Pool)

Shutter

Setup station operation panel

113432

Setup station

Control panel

1. Actual arrangement of the equipment varies according to the pallet pool system configuration.

2. The numbers given in the diagram above indicate the station numbers.

5-2 Station Numbers

Max. number of stations and machines

• Machines . . . . . . . . . 2

• Setup stations . . . . . 2

• Stocker. . . . . . . . . . . 30

• Buffer station (for 2 machines):

APPENDIX-31

No. 1

machine

Station No. 11 14

• In-machine station (for 2 machines):

No. 1

machine

Station No. 12 15

• Setup station (for 2 setup stations):

1st station 2nd station

Station No. 1 2

• Stocker:

Stocker 1 Stocker 2 Stocker 3 Stocker 4 Stocker X

No. 2

machine

No. 2

machine

Station No. 31 32 33 34 30 + X

APPENDIX-32

5-3 Data Table Numbers

The data table numbers of the data table where the fork position data corresponding to the individual stations is entered are described in Table 2.

Table 2 Power Mate iH Control

Station

No.

Station Name

X Coordinate

(Traveling axis)

Address

Z Coordinate

(Fork axis)

Address

A.G.V. Rotation

Direction

Address

1 Setup station 1 D204 D604 D1101

2 Setup station 2 D208 D608 D1102

11 Machine station 1 front D244 D644 D1111

14 Machine station 2 front D256 D656 D1114

31 Stocker 1 D324 D724 D1131

32 Stocker 2 D328 D728 D1132

30 + a

Stocker 3

Stocker a

Stocker 100

"A.G.V. Rotation Direction" is used for the turn type A.G.V. specification.

NOTE

D332

D(320 + a × 4)

D440

D732

D(720 + a × 4)

D840

D(1130 + a)

Set "1" for turning the A.G.V. CW, and "0" for turning the A.G.V. CCW for each station.

D1133

D1160

5-4 Parameters

Table 3 Related Parameters

Correspondence with MCC-LPS

Parameter No. Description

D101.4 D106.4

For both: 1: PMC control 0: MCC-LPS

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061110

Morii-Seiiki NH4000 DCG, NH5000, NH5000 DCG, NH6300 DCG, NH8000 DCG INSTRUCTION MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual

SIGNAL WORD DEFINITION

CONTENTS

1OVERVIEW

2 SCHEMATIC DIAGRAM OF PALLET POOL SYSTEM

3 PALLET TRANSPORT PROCESSING

3-1 Pallet Transport Processing Flowchart

3-2 Pallet Transport Flow

3-3 Urgent Workpieces (Interruption Processing)

3-3-1 Interruption Method

3-3-2 Interruption Operation

4 DATA SETTING SCREENS

4-1 Screen Trees

4-2 PCMDI MENU Screen

4-3 WORK NUMBER Screen

4-3-1 Description of Pallet Statuses

4-4 SETUP STATION PALLET CALL Screen

4-5 WORK NUMBER (SUB) Screen

4-6 PALLET DATA Screen

5 SETUP STATION OPERATION PANEL

5-1 Setup Station Operation Panel

5-2 Switches on the Operation Panels

5-2-1 EMERGENCY STOP Button

5-2-2 LINK/INDE. Selection Switch

5-2-3 ALARM Indicator

5-2-4 ALARM RESET Switch

5-2-5 SETUP Switches

6 STARTING THE APC AND PALLET POOL

6-1 Starting with the M02/M30

6-2 Starting with the M60/M61

6-3 Starting Using the APC START Switch (Option)

6-4 Starting from the SETUP STATION PALLET CALL Screen

6-5 Starting Using the Buttons on the Setup Station Operation Panel

6-6 SYSTEM LINK/INDE. Selection Switch

6-7 Operation of the Setup Station

6-7-1 Single Pallet Operation

6-7-2 Multiple Pallet Operation

8 SETUP STATION DOOR LOCK CONDITIONS

9 AUTOMATIC POWER SHUTOFF

10 AUTO-COUPLER (OPTION)

10-1 Operating the Auto-coupler

11 MAINTENANCE

11-1 Recovering Interrupted Pallet Pool Operation

APPENDIX 1 HANDY OPERATION PANEL

1-1 Manual Pallet Pool Operation Mode ON/OFF Switch

1-2 Emergency Stop Button

1-3 Selecting the Operation Mode

1-4 Registering Position Data of the A.G.V. and the Fork

APPENDIX 2 OPERATION USING MANUAL OPERATION SCREENS

2-1 Pallet Pool Operation Screen

2-1-1 PCMDI MENU Screen

2-1-2 MANUAL OPERATION Menu Screen

2-1-3 MANUAL OPERATION Screens

2-1-4 A.G.V. INDEX Screen

2-1-5 MAINTENANCE DOOR Screen

2-1-6 ZERO RETURN Screen

2-1-7 STATUS DISPLAY Screen

2-2 Pallet Pool Operation Using MANUAL OPERATION Screens

2-2-1 FORK CENTER Operation

2-2-2 FORK FORWARD Operation

2-2-3 FORK UP/FORK DOWN Operation

2-2-4 SHUTTER OPEN/SHUTTER CLOSE Operation

2-3 A.G.V. Indexing Using A.G.V. INDEX Screen

2-4 Maintenance Door Locking/Unlocking Operation

2-4-1 MAINTENANCE DOOR LOCK Operation

2-4-2 MAINTENANCE DOOR UNLOCK Operation

2-5 Zero Return Operation

2-5-1 A.G.V. ZERO RETURN Operation

2-5-2 FORK FOR./BACK ZERO RETURN Operation

2-5-3 A.G.V. + DIRECTION FEED Operation

2-5-5 FORK FOR./BACK + FEED Operation

2-6 Releasing Manual Operation Interlock

APPENDIX 3 MAINTENANCE OPERATION

5-1 Schematic Diagram of Pallet Pool System

5-2 Station Numbers

5-3 Data Table Numbers

5-4 Parameters