AXIS Series OPERATION MANUAL

Designed & Manufactured By

Dispense Works Inc.

2

Axis Series Robotic Dispenser

Dispense Works Inc

4071 Albany Street McHenry IL 60050

815-363-3524 815-363-8089

www.dispenseworks.com info@dispenseworks.com

Always wear safety glasses while working with or near this machine Copyright © 2015 Dispense Works Inc. All rights reserved. In the interest of constantly improving our product, Dispense Works Inc. reserves the right that these products including without limitation product features, specifications, designs, availability and pricing are subject to change by Dispense Works Inc., at any time without notice. R150610

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Machine & Operation Manual

Table of Contents

SECTION 1.0 ...............................................................................GENERAL DESCRIPTION Machine Structure

Machine Connections Dispenser Description

Electrical Controls SECTION 2.0 ..............................................................................................................SETUP

Machine Preparation Fixture / Tooling Mount Machine Initialization

SECTION 3.0 .....................................................................................................CONTROLS Control Description Modes of Operation

Tool File Setup File

Set Tool (tip) Height Run Machine

SECTION 4.0 ..........................................................................PROGRAMMING EXAMPLES Jog and Teach

Manual Command Entry CAD File Import

SECTION 5.0 ..................................................................................................SCHEMATIC

Electrical Diagram

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SECTION 1.0 GENERAL DESCRIPTION

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Machine Structure The dispensing system consists of a multi axis X/Y/Z robot that can be programmed to perform virtually any type of motion path geometry in the envelope of its physical travel. The X/Y and Z axes are driven with pre-loaded leadscrews and hardened & ground slides for accuracy and repeatability to satisfy most dispensing applications. Physical limit sensors are provided on the machine for the purpose of homing (initializing) the machine as well as protecting the robot from over-travel. In addition or in place of this, software limits are also provided to limit the travel. The base of the machine is used to mount and support fixturing and tooling that will “hold” product in place during the dispensing application.

Machine Connections

The below list may vary slightly from machine to machine.

• Power: 110-240 VAC 50-60 Hz 2.5A • Pneumatic: Based on application • Keyboard (ps-2) • RS-232 (serial) ports • Network (LAN) • Foot Pedal (mini-din) 3 position • Rotary Axis (din) 5 position • Auxiliary (based on application)

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Dispenser Description Syringe The simplest method for dispensing fluid onto a product is filling a syringe with fluid and using air pressure to push the material via a piston out of a controlled sized orifice (dispensing tip). This may be done for a time duration to create patterns such as dots or the syringe may be maintained in its “on” position during the motion of the machine to create a pattern such as a gasketing operation. The dispenser’s digital timers creates a very accurate time value that results in accuracy and repeatability to suit many applications. The syringe mounts to an adjustable block that provides quick removal for change over. The syringe receiver plugs directly into the valve on the Z axis head. All control is done through software. Programmable Auger Valve This method uses a motorized auger valve which consists of a miniature lead-screw that acts as an Archimedes screw to force the material out of a dispensing nozzle during the rotation of the above screw. This can “meter” materials in a controlled fashion that will provide more accuracy and repeatability than air pressure. Another advantage of this concept is the fourth axis that controls the auger screw is “tied” into the X/Y/Z vector speed of the robot. This means as the robot slows down or speeds up the screw will proportionally slow down and speed up, resulting in a more consistent volume of material from the dispensing tip. The auger valve connects to a 9 pin connector on the side of the Z axis head. A pneumatic valve is also provided for the syringe which feeds into the auger valve. Positive Displacement Syringe This method replaces the pneumatic portion of a syringe dispenser with a programmable motor/lead-screw mechanism that controls the plunger movement positively with software rather than fluctuating air pressure. This method uses a motor that will follow the X/Y/Z robot movement to speed up and slow down the valve accordingly, resulting in consistent material volume. This system connects to a 9 pin connector on the side of the Z axis head. This system also has a “home” limit to allow retracting the syringe plunger.

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Electrical Controls The machine’s electrical components are divided into two parts, the power components and the control components. A power supply generates DC voltage to the motor drivers / amplifiers. These in turn control the motor positions by receiving signals from the controller. A single AC line supplies the components. Miscellaneous pneumatic valves, sensors, and other other peripheral devices are also tied to the main system for real time control. The controller features a dual memory processor with Compact Flash Card memory storage digital I/O card At the top of the machine an electrical panel houses any pneumatics and electronics that need to move with the X/Y/Z axis. Terminations for Z axis motors, limits, etc. are also located here. The operator interface is a pendant which is connected to the machine via a 25 pin connector. The control section is explained in more detail in Section 6.0 in the KwikPro Software manual. The system operates with a dual memory processor including a Compact Flash Card. No external PC or controller is required. Communications are provided by an RS-232 and Ethernet (LAN) connection. The optional Windows Software Suite (KwikPro) may be used to program the system by way of a graphical operator interface. Dozens of features and utilities are included in the KwikPro software. See Section 7.5 Examples in the KwikPro manual.

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SECTION 2.0 SET UP

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Machine Preparation

Select a steady work bench or machine base to support the Dispense Works machine. Because of the high speeds and accelerations during operation, a solid top such as butcher block maple or metal works best. The work area should have adequate open space for the machine clearance, cabling, etc.

Carefully remove the Dispense Works machine from its box, place it on the bench and inspect the unit in general to verify that no damage has taken place during shipment.

If required, assemble the filter/regulator/gage unit to the machine.

When the Dispense Works machine and accessories are in position at your work area, begin the following procedures:

1 Turn off power switch before plugging the unit into your power outlet. 2 Connect the ps-2 keyboard to the mini-din receptacle located on the side of the machine. 3 Connect a clean and filtered air line to the pneumatic air prep input of the machine. The input

fitting is 1/8th NPT thread. This is directly connected to the filter, gauge and regulator. 4 Plug the power cord to your power source. Power requirement is: 115-240 VAC, 50-60 Hz,

2.5 Amp service. Check to confirm the values if the equipment is in use out of the USA.

Your connections both electric and pneumatic should now be complete.

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Fixture / Tooling Mount

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Machine Initialization

After the connections are complete, turn the machine on. The machine’s LCD display will show a “welcome” screen in about 20-30 seconds. This lasts only 3 seconds. The main menu will appear in about 25-35 seconds after power-up. (Main Menu is: “RUN JOB” screen)

Adjust the regulator (if required) to suit the pressure requirements of the job at hand. Be sure the tooling / fixturing is secure on the base prior to attempting any dispensing operation. HOME the Machine: Always “HOME” the machine after power up by pressing the HOME key on the machine’s keypad. This will move the axes to their limit sensors in the following sequence: • Move the Z axis UP • Move the X axis LEFT • Move the Y axis BACK This routine is important as it resets internal counters and initialize the machine. The home position is fixed, but does include “offset” values that can be set in the machines Setup File. Set the ORIGIN:

It is desirable to have a physical “Origin” to which you may line-up your tip to for its X Y Z position.

This may be a unique corner, edge, hole, etc of the part or an “Origin Pin” pressed into your fixturing. The distance from this origin to the dispense pattern should be a known value. This provides a convenient reference point when setting the needle or tip. Using the Blue Arrows on the Keypad, jog the tip to the desired position directly over this Origin. On the front panel, select Set Origin. This will set the current position as the machine’s Origin. It also “writes” the position to the machine’s setup file to retain it even if the machine is powered off. This will remain the Origin until changed by the user.

ons Manual

TIP: Software Manual: Section 6.0 Page: 9 – Cartesian Coordinate System

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SECTION 3.0 CONTROLS

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Control Description This is a file based system. It runs using an executable file, within an operating system. This means software upgrades and modifications are available. This is the best insurance against obsolescence. Because of the above, several files are required to operate the system. They are listed in the KwikPro software manual Section 7.0. Required: JOB job file is a G Code file SET setup file controls the machines settings, resolution, mode(s) of operation, (over 600 items) Optional: TJB the job box controls several job files and text files TOL tool file controls the “tool” or dispenser, speed, Z height, digital timer, early shutoff, etc FIX fixture file sets up the step & repeat, rotary axis for cylindrical or indexing modes FIL fill file for controlling peristaltic pumps TGT target file for vision system operation PAL pallet file for pallet based programming FNT font file for marking application PMP pump file works with the fill files fot peristaltic pump control DM data matrix file for marking 2-D bar coding CSV mapping file for laser output

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Modes of Operation There are two modes of operation: Standard Mode, where all events are programmed manually, and Tool File Mode, where the Tool File controls the machine. Consider the following example: Dispense material on three “frames” all at different levels, at different speeds. Standard Mode The machine will run with simple G & M code commands (and several custom commands and functions). See Section 6.5 pages: 12-30 in the KwikPro software manual. This mode will require the user to input each function including turning outputs on & off, entering timer values, programming the Z axis up & down motions, etc. This is simple step by step (flow) programming. This gives the user total machine control, but is much more time consuming to program and to edit, especially redundant information.

Simple program created for Standard Mode

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Tool File Mode This is the most common mode for dispensing applications. The only programming required is the X & Y motion path. The tool file does the rest. This allows “recording” the motion pattern by just following the x & Y geometry. No outputs to turn on & off. No Z axis moves to teach. No timers or early shutoffs to define. No speeds to enter.

Simple program created for Tool File Mode Note the M06Tn commands. These are standard tool change commands. These are the only control commands required. This “tells” the machine when to change to the tool number according to the Tool File settings:

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Press the Tool View button to display the pattern showing tool paths

Tool File The Tool File actually controls the entire machine. Many obvious advantages. The tool file has 16 tools, each definable as the diagram below:

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Several Tool Files may be saved in the KwikPro Windows Suite, but only one resides in the machine at a time. See section 6.0 page in the KwikPro software manual. If using Jog & Teach to create programs, do not be concerned with the tip height, speed, timer settings, etc, during the operation, as this will be entered in the Tool File later. As long as the machine is set to Tool File mode, even if you jog the Z axis during teaching it will not be “captured” as a move, but only ignored. Do not set outputs, as these are automatically turned on when a G01, G02, G03 (line, cw arc, ccw arc) is executed. They are automatically turned off when a G00 is executed. Just enter the output number in the A/F Out (autofeed output) column in the Tool File. NOTE: All programs, regardless how they were created, may always be edited in the KwikPro Software Suite. If the machine is connected to the PC during Jog & Teach mode, it may be set to draw the path on the monitor during the teaching operation. This becomes a legitimate G Code program just as if it were imported from a CAD file. To Access the Tool File:

• Connect machine to PC via RS-232 (or LAN) • Set machine to Main Menu (Run Job screen) • Select Setup from the KwikPro pull down menu • Choose Tools

The Tool File will be displayed on the monitor. See above image.

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Setup File The machine’s Setup File has hundreds of settings and parameters to give the system a “personality”. There are several Tabs, each controls different sections and parameters of the machine. To Access the Setup File:

• Connect machine to PC via RS-232 (or LAN) • Set machine to Main Menu (Run Job screen) • Select Setup from the KwikPro pull down menu • Choose Modify

The Setup File will be displayed on the monitor. Go to the Settings Tab and check the Use Tool File checkbox to enable Tool File mode.

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Tool Clearance Pos:ORIGIN use previousENTER set newClearance= 0

Tool Height / Clear:Tool Height = 0.275Clearance = 0.110Press any key

Tool Height:ORIGIN goto prevENTER to AcceptZero= 0

Run Job Run Fixture>Set Tool Height Edit Tool File

Set Tool (tip) Height

The system must “know” the height or Z position of the tip. This is set with the machine’s front panel keypad as follows:

• Scroll to Set Tool Height • Press ENTER

• Jog the tip to the desired dispense height over the part • Press ENTER

The next screen will display the Clearance height setting:

• Jog the tip to the desired clearance (travel) height • Press ENTER

The next screen will display the Zero and Clearance heights:

• Press ENTER to accept The above is repeated if the tip is changed (longer or shorter) or if the part height changes.

Run Machine

Select Run Job Select the File (alphabetically) desired

Press Start

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SECTION 4.0 PROGRAMMING EXAMPLES

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Jog and Teach First Home the machine, next jog the tip to the Origin point. This is where your program will start from. This may be a pin, corner of the part, or any unique point. Line it up as accurately as possible. From the Main Menu, scroll down to Set Origin. Press Enter. This will write the current X, Y & Z position to the Setup File. This will always be the machine’s Origin point until you change it. Next you enter the Jog & Teach mode on the machine as follows:

• Plug in the keyboard (ps-2)

• Scroll to New on the machine menu using the machine keypad. Press Enter.

• Select Jog & Teach. Press Enter.

• Type a Name when prompted (8 alphanumeric characters max). Press Enter. The LCD screen will now display status, machine position, etc. From this point, you will use the keyboard. See Section 6.5 Pages 8 thru 12 in the KwikPro software manual. Jog the tip from the Origin to the beginning of the dispense pattern. Either of the following methods may be used. Remember, The F6 key will toggle between standard and relative mode. You may switch back & forth during the teaching process.

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The below is the Key sequence on the keyboardto program the diagram shown at left:

Example Jog & Teach

Rear of Machine

Front of Machine

.7501.500 M1.000 Space1.000 Space.500 Space.500 Space.500 M.500 SpaceT1.000 Space.500.500 Space1.000 Space.500 Space2.000.500 SpaceESC

GO TO ORIGIN (On Machine)

Rear of Machine

Front of Machine

A

B C

DE F

G

H

I

JK

L

ORIGIN

The below is the Key sequence on the keyboardto program the diagram shown at left:

JOG to A MJOG to B SpaceJOG to C SpaceJOG to D SpaceJOG to E SpaceJOG to F MJOG to G SpaceTJOG to H SpaceJOG to I SpaceJOG to J SpaceJOG to K SpaceJOG to L LeftJOG to L Back SpaceESC

GO TO ORIGIN (On Machine)

If the dimensions are known, you may press F6 to enter Relative mode. An R will appear in the INC= line. Now when youtype a value, just press the arrow key, and the machine will move. You may switch back & forth duri ng the teaching process. F6 will toggle relative mode.

.75

1.75

2.25

2.75

3.25

1.00

1.50

2.50

3.75

3.25

1.25

2.00

1.50

1.00

.000

.50

.000

Standard Mode

Relative Mode

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The above image was created from the Jog & Teach function described above. To display it, Select Graphic from the pull down menu then choose Edit Code. A list of all files in the machines will appear alphabetically. Choose the desired file. Note: The motion path may be displayed on the monitor, during the teaching operation, if the PC is connected to the machine. Select the Graphic pull down menu then choose Jog Teach Viewer.

Manual Command Entry See entire command set in Section 6.5 Pages: 12 to 30 of the KwikPro software manual. Any command may be inserted into the program.

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CAD File Import

One advantage of Tool File mode is that you may import a CAD type file (since only the X & Y geometry is required) and there is no programming required. Just enter the desired properties into the Tool File. Your CAD drawing layers will also be assigned tool numbers automatically: DXF files: Layer number becomes the tool number PLT files: Pen number becomes the tool number This means you may “draw” a pattern in layer 1 (RED) for dispensing at a certain height, then a pattern in layer 2 (YELLOW) for dispensing at different height.

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Consider the following: From the Graphic pull down menu select Import Choose Glue.DXF. Note the random motion as defined by a “raw” CAD file. Too many start/stop points to be effective. Press the Optimize button.

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SECTION 5.0 ELECTRICAL DIAGRAM

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AXIS Series

POWER SUPPLY24 & 5 VDC OUT

+24VDC

+5 VDC

0V

TS6*

TS7*

TS3*

L

N

G

L

N

G

115-22050-60 HzVAC (IN)

SSRINPUT OUTPUT- ++

WHT/BLUTs2

BLK

SOLENOID24 VDC VALVE

Ts6

PORT-1/ 15

TSGRN

SSR WHT/BLUSOL

1

4

* 0V (IN)

2

LCD DISPLAYPC/104

X/Y PROX

X/Y PROX

LCD DISPLAY

PC/104

FAN

FAN

* +5VDC (IN)

SOLENOID

* +24VDC (IN)

5

6

7

8

9

10

11

3

WHT

GRN

ORG

BRN

TOPORT-1

29

25

33

21

BLK

BLK

WHT

GRY

BRN +24 VDC

WHT DIR R

BLU 0V

GRY STP R

BLK +5 VDC

VIO 47 (In 1)

BLK 50

GRY 48 (Gnd)

3 PIN MINI-DIN PLUG

RECEPTACLE

DIGITAL I/O CARD

PORT-1

PORT-2

1 50

50 123

RED

BLUTs7

Ts3

OU

TPU

T 9

16-PIN CONNECTOR TO LCD DISPLAY

1 16

46-0

V49 21 19 17 915 13 11

+ -

7 5 3 1

4745

3937

VIOGRN

WHTVIO

TOPORT-1

Y AXIS PROX SWITCH

Z AXIS PROX SWITCH

BLKBLUBRN

Ts5

BLKBLUBRN

Ts6

Ts5Ts6

Z AXIS DRIVERX AXIS DRIVER

GRN2527293133353739

WHT

TOPORT-1

8 PIN CONNECTOR

16 KEY TOUCHPAD TRACE 1 NOT USED

FOOT SWITCH

RED

MOTORZ

33K

RE

DW

HT

GR

NBL

K

MOTORX

RED

WH

TG

RN

BLK

33K

BLUE DISPLAY: 8.2 OHMGREEN DISPLAY: 3.3 OHM

MINI-RELAY

Schematic Diagram02-26-2007

3 PIN MINI-DIN

+5 V

DC

0V

CHASSIS

Y AXIS DRIVER

MOTORY

33K

RE

DW

HT

GR

NBL

K

4341

ORGBRN

X AXIS PROX SWITCH

BLKBLUBRN

Ts5Ts6

12GRN35

GRY

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NOTES: