Rapid-Air SA3, SD User Manual

Straightener / rapid-roll

operating inStructionS

MODELS

SA3 - SD WITH COMPACT CONTROL

(5-07)

RAPID-AIR CORPORATION

4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925

Phone: (815) 397-2578

• Fax: (815) 398-3887 • Web Site: www.rapidair.com

table of contentS

Straightener Layout Sheet SBX ............................................................................................................... pg. 3

Straightener Layout Sheet SCX ................................................................................................................ pg. 4

Platen Adjustment Bulletin ...................................................................................................................... pg. 5

Speciﬁcations ............................................................................................................................................. pg. 6

Installation ................................................................................................................................................... pg. 7

Start-Up Procedure .................................................................................................................................... pg. 8

Electrical Controls Layout ........................................................................................................................ pg. 9-10

Dancer Arm Adjustment Explanation ..................................................................................................... pg. 11

Standard and Optional Components ....................................................................................................... pg. 12

Operations.................................................................................................................................................... pg. 13

Maintenance ............................................................................................................................................... pg. 13

Troubleshooting Guide .............................................................................................................................. pg. 14

Taut Stock Explanation .............................................................................................................................. pg. 15

RAMM Board Explanation ........................................................................................................................ pg. 16-19

Warranty ....................................................................................................................................................... pg. 20

Electrical Schematics ............................................................................................................................... pg. 21-23

Mechanical Parts List SBX ................................................................................................................... pg. 24-27

Mechanical Parts List SCX .................................................................................................................... pg. 28-33

Typical Stamping Layout ........................................................................................................................... pg. 34

Straightener SA3 - SB4 ............................................................................................................................. pg. 35-36

Rapid Roll .................................................................................................................................................... pg. 37-38

3 4 5

If the straightener is made to correct a clockwise curvature, it is often impossible to correct a counterclockwise curvature. The only available adjustment is the variation of the degree of bend at each station. This is true even for straighteners that have banked upper rolls that pivot for two-point adjustment.

To more easily explain the concept, Figure 8 shows a three-roll combination with the upper roll forward and Figure 9 shows a three-roll combination with the upper roll to the rear.

Figure 8 Figure 9

Adjustable Platen

Stock Straighteners

vs.

Straighteners with

Traditional

Vertical Roll

Adjustment

CONCEPT: The concept behind a movable platen containing the upper bank of rolls for straighteners can be somewhat difﬁcult to grasp, but once the principles are understood the superiority of this system becomes obvious. To explain the differences between the adjustable platen system and one that uses traditional single-point vertical roll adjustment, we are describing both types of systems here.

VERTICALLY ADJUSTABLE UPPER ROLLS: For centuries the bending of materials has been done by variations of a three-roll arrangement as illustrated in Figure 1.

Figure 1

Downward curvature of material

to remove coil set

Bending occurs when one roll is forced into the space between the other two rolls for downward curvature of the material to remove coil set. Pressroom straighteners add multiple three-roll combinations in order to level the material in small increments at each stage. This method can provide acceptable results for some materials, but is limited because correction of material curvature is effective in only one direction as illustrated in Figure 2.

Figure 2

SIX-WAY UPPER ROLL ADJUSTMENT: After manufacturing straighteners with vertically adjustable rolls for many years, Rapid-Air developed and patented the adjustable platen type straightener as illustrated in Figure 3.

Figure 3

Forward/Back

Up/Down

Up/Down Slant

This design mounts the upper rolls in a platen which can be adjusted for degree of bend as illustrated in Figure 4 and Figure 5

Figure 4

Light material distortion

Figure 5

Heavy material distortion

Less deﬂection

Deeper deﬂection

and for curvature direction as shown in Figure 6 and Figure 7.

Figure 6

Rolls forward – curve up

Figure 7

Notice that the sharpest bend occurs where two rolls are in close proximity. When the upper roll is forward, the curvature will be up and when the forward roll is adjusted to the rear, the bend will be down. The degree of bend can be adjusted by a combination of vertical and horizontal adjustments.

ADVANTAGES: The high degree of ﬂexibility afforded by the adjustable platen design provides a predictable straightening method for a wide variety of materials and takes a lot of the “Black Magic” out of pressroom straightener setup. The reduction in the ﬂexing and distortion of the strip of material and the reduction of the straightening power required allows effectiveness with heavy materials. Additionally, the ability to place rolls in a proper close proximity allows effective straightening with very thin materials.

ROLL DIAMETER: The smaller the roll diameter in a straightener the better it is able to remove distortions in the strip of material, but this factor is compromised by the requirement of larger rolls in wider models of straighteners in order to prevent deﬂection of the rolls themselves. Rapid-Air straighteners are designed to optimize all factors (including number of rolls, diameter and position) within the published material capacities and speciﬁcations for each model.

SWING-OPEN TOP: Rapid-Air developed and introduced the swing-open top for straighteners in order to facilitate the cleaning of rolls and the threading of a new strip of material through the straightening rolls. For convenience and safety, each top is counterbalanced and held in the open position until it is clamped for operation. Roll adjustment settings are maintained when the top is closed and locked.

AVAILABILITY: All models of Rapid-Air straighteners are presently available with the adjustable platen design with an expanded range of models being introduced in the coming months.

Material curvature is effective

in only one direction

Rolls back – curve down

Series

SpecificationS

SBX

Series

SCX

Series

Material Straightening Speed Rolls Rolls (2) Motor Power Model Width Range per min Speed No., Dia. Dia. (HP) (vac/ph)

SA3 3” (76mm) .002” - .030” (.051-.76mm) 700” (1778cm) Standard 11, 3/8 (9.53mm) 1-1/2 (38.1mm) 1/4 115/1 SA3M 3” (76mm) .002” - .030” (.051-.76mm) 1,400” (3556cm) Medium 11, 3/8 (9.53mm) 1-1/2 (38.1mm) 1/2 115/1

SB4 4” (102mm) .003” - .050” (.076-1.27mm) 700” (1778cm) Standard 11, 5/8 (15.86mm) 1-1/2 (38.1mm) 1/2 115/1 SB4M 4” (102mm) .003” - .050” (.076-1.27mm) 1,400” (3556cm) Medium 11, 5/8 (15.86mm) 1-1/2 (38.1mm) 1/2 115/1

SBX4 4” (102mm) .004” - .080” (.10-2.03mm) 825” (2100cm) Standard 9, 7/8 (22.23mm) 1-3/4 (44.45mm) 3/4 115/1 SBX8 8” (203mm) .004” - .070” (.10-1.78mm) 825” (2100cm) Standard 9, 7/8 (22.23mm) 1-3/4 (44.45mm) 3/4 115/1 SBX12 12” (305mm) .004” - .060” (.10-1.52mm) 825” (2100cm) Standard 9, 7/8 (22.23mm) 1-3/4 (44.45mm) 3/4 115/1

SBX4M 4” (102mm) .004” - .080” (.10-2.03mm) 1,650” (4200cm) Medium 9, 7/8 (22.23mm) 1-3/4 (44.45mm) 1 115/1 SBX8M 8” (203mm) .004” - .070” (.10-1.78mm) 1,650” (4200cm) Medium 9, 7/8 (22.23mm) 1-3/4 (44.45mm) 1 115/1 SBX12M 12” (305mm) .004” - .060” (.10-1.52mm) 1,650” (4200cm) Medium 9, 7/8 (22.23mm) 1-3/4 (44.45mm) 1 115/1

SCX6 6” (152mm) .006” - .100” (.15-2.54mm) 825” (2100cm) Standard 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 1 115/1 SCX12 12” (305mm) .006” - .090” (.15-2.29mm) 825” (2100cm) Standard 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 1 115/1 SCX18 18” (457mm) .006” - .080” (.15-2.03mm) 825” (2100cm) Standard 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 1 115/1 SCX24 24” (610mm) .006” - .065” (.15-1.65mm) 825” (2100cm) Standard 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 1 115/1

SCX6M 6” (152mm) .006” - .100” (.15-2.54mm) 1,650” (4200cm) Medium 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 2 230/1 SCX12M 12” (305mm) .006” - .090” (.15-2.29mm) 1,650” (4200cm) Medium 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 2 230/1 SCX18M 18” (457mm) .006” - .080” (.15-2.03mm) 1,650” (4200cm) Medium 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 2 230/1 SCX24M 24” (610mm) .006” - .065” (.15-1.65mm) 1,650” (4200cm) Medium 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 2 230/1

SCX6H 6” (152mm) .006” - .080” (.15-2.03mm) 4,100” (10400cm) High 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 3 230/1 SCX12H 12” (305mm) .006” - .070” (.15-1.78mm) 4,100” (10400cm) High 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 3 230/1 SCX18H 18” (457mm) .006” - .060” (.15-1.52mm) 4,100” (10400cm) High 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 3 230/1 SCX24H 24” (610mm) .006” - .055” (.15-1.40mm) 4,100” (10400cm) High 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 3 230/1

Max Effective Max Straightening Pinch Drive Input

SD6 6” (152mm) .006” - .125” (.15-3.18mm) 825” (2100cm) Standard 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 2 230/1 SD12 12” (305mm) .006” - .125” (.15-3.18mm) 825” (2100cm) Standard 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 2 230/1 SD18 18” (457mm) .006” - .100” (.15-2.54mm) 825” (2100cm) Standard 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 2 230/1 SD24 24” (610mm) .006” - .090” (.15-2.29mm) 825” (2100cm) Standard 9, 1-3/8 (34.93mm) 1-3/4 (44.45mm) 2 230/1

A right-to-left material ow direction is standard for above models –– left-to-right optional at no additional cost.

SC4 4” (102mm) .015” - .085” (.38-2.13mm) 825” (2100cm) Standard 9, 1-1/4 (31.75mm) 1-1/4 (31.75mm) 1 115/1

Model SC4 Straightener with individually adjustable upper rolls. This 4” x .085” capacity straightener with its counterbalanced swing-open top is a Rapid-air original and continues to be available due to customer acceptance and demand. Dial-type indicators for roll settings are optional.

Model SC4

A NOTE ON ROLL DIAMETER AND QUANTITY: The smaller the roll diameter in a straightener the better it is able to remove distortions in the strip of material. Rapid-Air straighteners are designed to optimize all factors (including number of rolls, diameter and position) within the published material capacities and speciﬁcations for each model.

inStallation

Operating Instructions For Straighteners / Rapid Roll

Align the Rapid Roll with the feed allowing sufﬁcient space for free stock for the feed. The loop control arm roller rests on the stock between the Rapid Roll and the press. The Rapid Roll should be bolted to the ﬂoor, especially when used to pull stock from a non-powered reel.

The pinch rolls must be parallel in the lateral (horizontal plane to insure that there will be equal pinch force along the full width of the stock). An upper pinch roll adjustable eccentric trunion is slotted with a locking screw in

its center. Adjust parallelism of the rolls by loosening the center screw and rotating the trunion through 180 degrees. A wide blade screwdriver and allen wrench may be used. Use a feeler gauge to check for equal spacing on either side of the pinch rolls.

Perform a visual check by lifting the cover and placing a white piece of paper in front of the pinch rolls to reﬂect light through the space between. Tighten the pinch roll knob so the rolls just touch. Observe the slit of reﬂected light between the rolls and make

any ﬁnal adjustment. Tighten the trunion lock screw. Raise the pinch roll to allow clearance for the next setup procedure.

The main control unit is located behind the side access cover. On pages 9 & 10 is an illustration of the layout of the control panel. This diagram lists all the components and the approximate location of each that could be used for troubleshooting the machine if a problem should occur. The reel is shipped with

- 120 vac (1 phase) input. Visually check all electrics before starting the reel.

Start up procedure

Prior to applying power to the straightener, all the controls on the machine should be reviewed. A brief summary is listed below.

Main Console And Controller

The main control console with controls is mounted on the cabinet of the straightener. Located on the face of the console are five switches, one potentiometer, one push-button and one or two circuit breaker reset switches, which are explained below.

1. ON/OFF SWITCH

This illuminated switch is the main power switch for the controller. On the 120 VAC straighteners, it will be a toggle switch and on the 230 VAC version it will be a mushroom push-button. It must be “ON” for the straightener to function.

2. RESET BUTTONS (circuit breaker)

120 VAC. a. 15 amp – This is the main circuit

breaker for the straightener. b. 3 amp – This is the main circuit breaker for the “D-SUB” (25 pin) connector. Any shorting or overloads would trip this breaker.

240 VAC. a. 3 amp – This is the main circuit

breaker for the “D-SUB” connector. Any shorting or overloads would trip this breaker.

3. RUN/STOP/JOG SELECTOR SWITCH

a. If “RUN” was selected and the dancer control arm was raised, the straightener rolls would rotate. If “STOP” was selected then none of the functions would work. If “JOG” was selected then the jog button has to be depressed to have the straightener rolls rotate.

4. JOG BUTTON

Used for intermittent movement of the straightener rolls and mainly for setup. The jog speed can be adjusted by rotating the R3 potentiometer on the 69100079 board in the control sub panel.

5. % SPEED POTENTIOMETER

The % speed potentiometer adjusts the maximum speed that the straightener rolls can rotate regardless of the dancer arm height. It should be set to maintain a constant material feed rate through the straightener.

6. DANCER ARM LOOP HEIGHT AND RANGE ADJUSTMENT

a. Loop Range – The loop range

switch adjusts the amount of travel that the dancer arm will move to provide the full range of speed on the straightener. It has three positions with a “0” as the least travel from slowest to fastest speed and a “2” has the most movement between slowest to fastest speed.

b. Loop Height – The loop height switch is used for setting the start position of the control arm. It has three positions with the “0” setting having the start position at the dancer arm rest position and the “2” having the start position somewhat higher than the dancer arm rest position. This setting will determine the dancer arm angle that the reel will start turning. This function is used to accommodate different thickness of material which

would have a different bend radius thus requiting the dancer arm to be at a height somewhat above the home position when at rest.

7. LOOP ARM / EXTERNAL SWITCH

This switch is used to select whether the material loop is controlled by the dancer arm or an external loop control. If LOOP ARM is selected then the control will monitor the dancer arm movement. If EXTERNAL is selected then the control will monitor whatever is plugged into the “D-SUB” (25 pin) connector.

8. REMOTE INTERFACE PORT “D” CONNECTOR

This 25 pin connector, located on the lower portion of the console is used to communicate with external loop equipment. The RSB, RTB, & RTA will plug into the port and can immediately be implemented.

CAUTION: Never plug any type of computer or non Rapid-Air equipment into this plug or severe damage could result. Always consult the factory when installing different external controls for advice on compatibility and wiring information.

9. PANEL MOUNTED ELECTRICAL COMPONENT DESCRIPTION

69100034 board – proportional control board 69100076 board – component interface board 69100014 board – (RAMM) D.C. motor control board [120 VAC, 1 PH] 69100038 board – (RAMM) D.C. motor control board [240 VAC, 1 PH]

dancer arm loop

Dancer Arm Loop Height Adjustment

Three different loop sensing arm operating positions are selected manually during set-up. By selecting the higher number, the zero point of the dancer arm is raised from its rest position to the angle shown (as indicated 0-2). The dancer arm will move from rest position to the angle selected before the straightener rolls begin to rotate.

Dancer Arm Loop Range Function

30 degree — Loop sensing arm travels through a full 30 degree arc to vary

rotation speed from slow to full speed as controlled by % speed pot.

20 degree —Loop sensing arm travel through a 20 degree arc to vary speed from slow to full speed as controlled by % speed pot.

10 degree — Loop sensing arm travels through a 10 degree arc to vary rotation speed from slow to full speed as controlled by % speed pot.

Standard Straightener componentS

Curve Up/Down Adjustment

Some applications have dies that cannot accept anything but ﬂat stock and other dies run better with the material curving up or down to miss the built in edge required in the die. Before this feature was added, operators would under straighten or over straighten the material to suit their needs but in doing so would severely change the material entering the die. This not only caused feeding problems but part quality problems. With this feature, curve up or down can be accomplished by changing the position of the rolls without stressing the material.

optional Straightener componentS

Entrance Cascade Roll

The entrance cascade roll assembly is used to maintain a support arc for stock entering a feed. The cascade roll has three extra rollers to help the material ﬂow better.

Exit Cascade Roll

The straightener is shipped with the exit side pre-drilled for the cascade roll or guide roll block. The entrance and exit use the same components.

Entrance Guide Roll Block

All straighteners are shipped with an entrance guide roll. This contains a roller and two adjustable edge guides.

Angle Bracket

Rapid-Air offers this accessory that mounts between the straightener head and the base. It angles the exit side of the straightener twelve degrees lower than the entrance side. This feature works very well when using the straightener to pull off a non-powered reel.

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