1.

AUM-We have problems when producing Reflectors(the smallest size of plate)

the material is bending too much when it’s going through the white plastic
reel(the reel used as a sensor for automatic uncoiling of the plate). Probably
it’s too heavy, and it’s also trying to pull the material to the side. Than the
plate is not going perfectly into the straightening reel.

We will design another arm that will take care of this problem.

Velux: Arm has to be lighter and not so wide

2. ATMM-We have a lot of hydraulic oil leakages under the hydraulic cylinders
on the punch station(the big one) and on the shear station.

Is it possible to have more specific indicators

on the leaks? The leak could be from several sources; hoses, fittings,
distribution block or cylinders. It would be a real help if we would know as exact
as possible from where the oil is coming. Solvent and wiping dry the entire area
will provide an opportunity to observe the start of the leak(s). A photograph of
the start of the leak would be helpful.

Velux:

Leakeages are from 3 cylinders and fittings as well! Leaks comes directly under
cylinders.
3. ATMM-Sometimes the plate is bending too much inside of the machine when
it’s stopping the movement (all the way between the straightening reels and
the shifting reel)

You’ll need to support the material over the

length (not diagonal as you show in the picture). We’ll provide two parts made of
plastic plates to solve this problem.

Velux: ensure such a support on every black reel.

4. ATMM-when we put the shifting reel all the way down to the plate(we loose
the lifting screws completely) than it’s pulling the plate to the side. It’s
pushing the plate towards the small leading wheel on the side and it’s
making the plate curly on this side.

This is the result of not having correct

alignment of the material being supplied to the machine. It is possible that the
un-coiler (AUM) is not positioned correctly to provide the material in alignment
with intended path through the machine (ATMM).

Velux: uncoiler is aligned almost perfectly (+- 2 mm difference in diagonals).

When you were here it was set up +- 2 cm.
5. ATMM-We are not able to produce the Elbow without changing the original
adjustments of machine. I mean we needed to move the whole material 2mm
towards to control panel to get the right dimensions.

This problem has the same solution as the

previous problem.

Velux: Don’t agree, see point above.

6. ATMM- sometimes when the plate goes out of the shear unit ,it hits the
orange colour rollers on the next station. The idea to flatten the plate with
the straightening reels doesn’t work all the time.

This picture shows that you are running Top and Bottom elbow material without
the “Keyway Guard – Bottom Shear Blade” part number 40888, in place (refer to
figure next to the photo). This part was provided with the machine and is
intended to be used whenever you do not use the profile knife for the shear. It
will be very difficult for the material to go easily on the conveyor rollers, without
this part. And you are correct, whether the material is straightened or not will
not affect this problem very much.

Velux: We lost Keyway Guard – Bottom Shear Blade. Could you send a drawing,
and we will ensure a new one.
7. ATMM-When we have to add the additional shear to the shear unit
(production of telescopic tubes) after cutting, the plate holds on the shear
and it doesn’t continue. (It’s like sticked on the shear)

The material is sticking here on the shear.

We will provide two guides that will increase the friction between the material
and the rollers. The material will then be pulled from the shear blade.
Additionally, the guides will dampen the material from bouncing at the entrance
of the conveyor.

Velux: ok, please provide it.

8. AAM- A lot of fittings on the hydraulic hoses are not tighten enough and than
we have the leakages of the oil.

Please determine the color of the oil that is leaking. If it is red in appearance
then it is a hydraulic system leak. In this case tightening the hoses will likely
solve the oil leaks. If the oil is not red, it is spent lubricant used in forming
the elbow. Used lubricant oil can be captured with small pan under the
machine.

Velux:

9. AAM- sometimes when the operator removes the finished part, the machine
tries to start again without operators command.
This is a very serious issue. We need more information regarding how and when
this occurs. Can you provide more details on this situation? We need to know if
the problem is repeatable or occurs at random. Please record the exact
conditions when this occurs. For example, the machine is in automatic mode or
setup mode, or after an emergency stop, or right after setup mode and switched
to automatic mode. You mentioned that the machine “tries to start”, what
movements do you see on the machine?

Velux: Happened only sometimes. It happends when operator is using foot

switch (pedal) for fixing elbow, when he wants to turn it after fininshing. Machine
is in automatic mode and machine tries to start again, but it switch off
automaticaly because of lights curtains. It happends not after pressing
emergency button or whatever else. Just it happends, during removing final
elbow.

10.ATMM- we have problems with this small spindle that is missing a cotter pin

and it has a tendency to jump out.

The defective part will be replaced.

11.ATMM- In last week we had a problem with broken punch pin on the small
punch station. It happened two times. We found the reason for this problem-a
tiny film of aluminum was sticked on the punch pin and also inside of the hole
for punching. When there was too much of aluminum, the punch pin was
blocked inside of the hole and didn’t come up. Than the machine moved the
plate and broke it.

A good solution to prevent this damages would be to add some kind of

sensors on the hydraulic cylinders(on both of them).Those sensors will
always detect the position of the piston. If it will stick inside like it happened
here, it will not allow the machine to continue.

And for that problem with the tiny film of aluminum we will try to spray the
punches with oil more often. But still we need any suggestions how to avoid
these damages with the sticky aluminum.

Sticked together after

disassembling
This issue is still in discussion. We will provide a solution soon.