ALFA-MOTION TECHNOLOGY (M) SDN BHD

Users manual








Auto Capping Machine 2
ALFA-MOTION TECHNOLOGY (M) SDN BHD.
46, Lorong Asasjaya 3,
Kawasan Perindustrian Ringan Asasjaya,
Permatang Tinggi, 14000 Bukit Mertajam,
Pulau Pinang. Malaysia.
Tel : 604- 5872207 Fax :604-5873834
Email : sales@alfamotion.com.my
Webside : www.alfamotion.com.my
Programmer : M. Hairie
Designer : Idzwan Hazree




A vast range of industrial automated system.

For last 11 years, ALFA-MOTION has gained considerable experience in the industrial automated
system domain.

In adapting to the main automated system development for SEMICON PICK/PLACE,
CONNECTOR ASSEMBLY, AUTOMOTIVE TEST, ASSEMBLY INDUSTRIAL and MEDICAL
PRODUCT HANDLING PROJECT.


ALFA-MOTION has developed many systems and associated Process in a big number of applications.



SEMICON

- LED Dispensing system, Trim & Form System, Hard Disk Polishing,
Function Tester, Laser Marking System, Vision Checking System,
Loading & Unloading Station and Etc

CONNECTOR
ASSEMBLY

- Pins Inserting System, Connector Function Checker, Connector
Vision Checker, Tape & Reel Packing System, Trimming Station,
Tube Unloaded, Tube Packing and Etc...

AUTOMOTIVE
INDUSTRIAL

- Components for air conditioning systems, compressor, evaporators,
airbags, systems of injection, tanks, radiators, pressure sensor, steering
for leak test, calibration & function test, as well as automated
assembly.

PROCESS FACTORY
AUTOMATION

- Dipping and Washing System for Medical Product, Aluminum Recycle
System,
- Different packaging; the performances of the helium leak test
technique to provide an effective and reliable test line.




This long experience permits Alfa-Motion to propose to customers designs suitable to their
application, also the necessary know-how to design the better solution.


Table of Contents

Acknowledgement i
C HA P T E R A
SAFETY
Location of Safety Equipment A10
Function of Safety Equipment A20
Safety Precautions A30
Mechanical A30A
Electrical A30B
Lockout / Tag-Out Procedure A30C
C HA P T E R B
THEORY OF OPERATIONS
System Overview B10
Description of the machine B10A
C HA P T E R C
INSTALLATION
Facility Requirement C10
Electrical Power C10A
Pressurized Air C10B
Moving Of Machine C20
Installation of Equipment C30

CHAPTER D
POWER UP & DOWN PROCEDUCE
Power Up Checklist D10
Power Down Checklist D20
Power Up Procedures D30
Shut Down Machine D40

CHAPTER E
SETUP
Set Up Under Normal Condition E10
Set Up After Emergency Shut Down E20


CHAPTER F
AUTOMATIC OPERATION
Start Production Procedures F10
Pause Production and Continue F20

CHAPTER G
MANUAL OPERATIONS
Setting Page G10
Step Mode G20A
Manual Device Trigger G20B
Change Password G30

CHAPTER H
MACHINE ALIGNMENT / CALIBRATION
System Configuration H10
Sensor Calibration H20
Cylinder Speed Adjustment H30
Teaching the Stepper Motor H40
Reed Switch Adjustment H50

CHAPTER I
Appendix
IO Table I10
Circuit Diagrams I20
Ladder Diagram I30
Mechanical Drawing I40
List of Figures I50





A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .












SAFETY
A 10
Location of Safety Equipment
afety of equipment normal can as RED MUSHROOM HEAD
LATCHING buttons with the label of EMO. Besides, ELCB, MCB and
Main Control Valve also apart of safety equipment.













Figure 1: Safety equipment location (front & back view)
Chapter
A
S
EMO EMO
Back View
Main Air
Valve
Front View
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
A 20
Function of Safety Equipment




Figure 2: Shows (a) EMO, (b) Main Valve, (c) MCB
EQUIPMENT FUNCTION & DESCRIPTION
EMO (Emergency Mechanical Off)

When it is pressed, all mechanical motion will stop
immediately. The button can be released by rotating
the knob clockwise.

Main Valve

On / Off pressurized air supply.
Turn off the main air supply to free all the pneumatic
parts when mechanical hazards occur.

ELCB (Earth Leakage Circuit
Breaker)

Earth leakage protection.
MCB (Miniature circuit breakers) Protection and control of circuits against overloads
and short circuits in domestic equipment.
(a)
(b) (c)
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
A 30
Safety Precaution


A30A Mechanical
Wear proper attire, do not operate or service the system while wearing neckties,
necklaces, loose garments & etc.

Wear necessary protection gears, e.g. gloves, cap, goggles & etc.

Always self-discipline and follow the safety.

Do not operate the machine, if you are not ready to do so.

Do not bypass the safety interlocks except the qualified personnel.

Always STOP all moving parts before performing any operation inside machine.

A30B Electrical
The power panels and terminal blocks of this machine present an electrical
hazard. Only qualified or trained maintenance personnel are allowed to
perform troubleshooting, voltage and current measurement, on-line alignment or
carry out the maintenance of the machine. Always turn OFF main power and
isolate from the incoming supply.

Check and ensure the machine/system is properly grounded. Regular
maintenance will not only ensure consistent and reliable operation, it will also
prolong the life span of the machine.

Standard safety procedure should be followed to carry out any servicing
operation within the equipment.

Understand and remember the location of all the safety switches such as EMO,
MCB, RCCB & etc.
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
A 30
Safety Precaution


A30C Lockout / Tag-out Procedure
Physically lock the main power supply of the machine to prevent
unauthorized person from switching on/off the machine.

Place several highly visible labels around the machine to indicate that this
machine is currently in service.

One of the highly visible labels should have this information:
1. Name of person that is servicing this machine.
2. Department name
3. Necessary danger warning


A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .



THEORY OF OPERATIONS
B 10
System Overview


Auto Capping Machine consists of Vibrator Bowl, Loading Station, Unloading Station,
Cap Insert Station and Cap Tightening Station. Vibrator Bowl will guide cap into track
and stop when the track full. After part inserted into Loading Station, moving conveyor
will transfer to Cap Insert Station to perform cap insert process. In Tightening Station,
motor will apply tightening process on cap depend on our desired torque. Unloading
Station will release part from conveyor.




Figure 3: Location of each station on machine
Chapter
B
Tightening Module
Conveyor
Cap Insert Module
Vibrator Bowl
Loading Module
Unloading Module
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
B 10A
Description of the Mechine



Vibrator Bowl - Move and guide cap into track
Loading Station - Clamp part to ensure stay static on jig
Cap Insert Station - To perform cap insert process
Cap Tightening Station - To perform cap tightening process
Unloading Station - To release part from conveyor











A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .



Installation
C 10
Facility Requirement
Facility Requirement for equipment normally will be provided forms the customer
facility group. Facility equipment to run the equipment normally will including of
dimension of production floor when the equipment sited, electrical supply for the
equipment, compressor air, and etc...


Chapter
C
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
C 10A
Electrical Power







Figure 4: Location of (a) PLC, (b) MCB.



Incoming power supply: AC 1-phase 240V, Max 25A, and 50/60HZ.
Power Supply Input:
(a) (b)
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
C 10B
Pressurized Air




Figure 5: Main air supply



Main air supply:
5 bar ~ 6 bar


A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
C 20
Moving of Machine.



he machine was packed onto a wooden pallet and fully covered with a
wooden crate. Inside the wooden crate, the machine again is wrapped
up using stretch film. The machine was packed with silica gel to maintain a dry
environment and prevent moisture from damaging the parts during transportation.

Procedures for moving and unpacking:

STEP ACTIONS
1 Unpack the wooden crate to unload the machine before moving it into the
production floor.

2 Move the machine to the located place in the production floor.

3 Place the bubble level meter on the machine base plate.

4 Adjust the foot mount (leveler) to level the machine before locking the entire
foot mount.

5 Remove all the silica gel from the machine.



CAUTION: Be cautious not to lean on side and to shake when lifting up and getting
down the shuttle.



DANGER: Be sure when transferring the machine using lifter and must not draw it
sloped passage
T
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
C 30
Installation of Equipment.










STEP ACTIONS
1 Connect compressed air pipe to air supply unit located on back of the machine.
2 Adjustment of regulator - set the regulator handle to have proper input.
Air input pressure: 5bar ~ 6bar
3 Connect the Single-phase AC 240V main power supplies.

4 Connect all cables to its connector as labeled accordingly. All connectors are
located at back of the machine.

A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .



POWER UP & DOWN PROCEDURE
D 10
Power Up Checklist





No What To Check? O.K / Not O.K
1
Ensure the main power supply is correctly matched the machine
requirement, which is Single-phase 240VAC 50/60Hz.


2
Check the incoming air supply (main valve) setting to make sure that the
setting is suitable for the machine normal operation (not less than 5 bar air
pressure).


3
Clean the machine to remove all part and dirt to prevent any mechanical
hazard.


4
All the doors and covers on moving parts must be nicely closed.

5
Follow the power up procedures correctly.





Chapter
D
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
D 20
Power Down Checklist




No What To Check? O.K / Not O.K
1 Ensure the machine already stops or finish operation, then only can
proceed with power off procedures.

2 Remove the entire unfinished product from the machine before power off
the machine.

3 All the doors and covers on moving parts must be nicely closed.
4
Follow the power off procedures correctly.

5 Always check that the main power supply is already off before leaving the
machine/after the power off procedures.




A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
D 30
Power Up Procedures



STEP ACTIONS
Connect the Main Power Supply.
Connect Machine Air Supply Hose to Air Supply Line.
Turn ON all Main Circuit Breaker (MCB) and Earth Leakage Circuit Breaker
(ELCB).
Close the control panel door and turn ON the isolator switch.
Please wait until a screen as shown below appears on the touch screen. Then
press Start Up Button.


Figure 6: Touch screen (Start up)
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
D 30
Power Up Procedures



The system will begin initializing the Operating System.

Figure 7: Touch screen (System initialize)
Station
Progression
Status
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
D 30
Power Up Procedures



Main Menu will appear after initialization is completed. The machine is ready for
operation.

Figure 8: Touch screen (Main menu)
Device Function/Description
1 MANUAL MODE Manually Trigger Device Single or Full Step
2 AUTO MODE Machine Auto Mode Running
3 SETTING Move to Setting Page
4 CHANGE PASSWORD Change Password Page
5 ALARM HISTORY Display Alarm History






1
4
2
3
5
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
D 40
Shut Down Machine



STEP ACTIONS
1 Wait until all stations finish its cycle.
2 Turn Off the isolator switch.
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .


SETUP
E 10
Set up Under Normal Condition

STEP ACTIONS
1. Remove the remaining part at Auto Capping Machine.
2. Power up the machine as shown in previous chapter
3. Enter setting page and make sure all variables are exactly same with desired
value.


Figure 9: Setting Value

4. Main Screen will appear after initialization is completed. The machine is ready
for operation.


Chapter
E
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
E 20
Set Up After Emergency Shut Down




After emergency shutdown, the following set up procedures needs to be followed:
STEP ACTIONS
1. Remove the remaining part at Auto Capping Machine.
2. Release EMO.
3. Press the RESET button for system initialization.


Figure 10: Critical Error

4. Main Screen will appear after initialization is completed. The machine is ready
for operation.
Press RESET
button
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .


Chapter
F
AUTOMATIC OPERATION
F 10
Start Production Procedures


STEP ACTIONS
1. At the main menu, press the AUTO MODE Button.

Figure 11: Touch screen (Auto Mode button at main menu)
2. Machine will call system initialize module before Auto Mode to ensure all station is
in right condition.
3. Press the START Button. The machine will wait part at loading station. Loading
station will NOT clamp the parts if area sensor detects the presence of
human/object at loading station door. Station Condition Massage will display the
current condition of each station.
Press AUTO
MODE button
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
F 10
Start Production Procedures



Figure 12: Touch screen (Start Auto Mode)
Press START
button to start
fully automatic
operation
Station Condition
Massage
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D .
F 20
Pause Production and Continue


STEP ACTIONS
1 To stop the machine, press the STOP button. Servo motors and cylinders will
stop immediately.


Figure 13: Touch screen (Stop Auto Mode)

2 To start again, press the START button and the machine will continues process.
Press STOP
button
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D


Chapter
G
MANUAL OPERATION
G 10
Setting Mode

STEP ACTIONS
1. At the main menu, press the SETTING Button. Password page will appear
before user can access into setting page.

Figure 14: Touch screen (Setting Button at main menu)
2. Setting page allows user to change the value of these variable:

Vibrator Bowl Stop Time
Track Time Up
Tightening Time
Torque for tightening section (Min: 0.01 N.m, Max: 0.35 N.m)

Door switch could be disabled at setting page.

Press SETTING
button
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

G 10
Setting Mode



Figure 15: Touch screen (Setting page)
Press this button to
disable or enable
door switch
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

G 20A
Step Mode


STEP ACTIONS
1. Two section in Manual Mode which is STEP MODE and MANUAL DIVICE
TRIGGER.

Figure 16: Touch screen (Manual Mode)
Choose STEP MODE to perform step-by-step or complete step for each
module. Choose MANUAL TRIGGER DIVICE to perform single device.
2. STEP MODE page allows user to perform step-by-step and full process for
singulator, track blower and tightening module. Select module and press either step
or full step.

Figure 17: Touch screen (Step Mode)
Select module
before perform
either STEP or
FULL STEP
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

G 20B
Manual Device Trigger


3. Manual device trigger page allows user to activate a single device for maintenance
purpose.

Figure 18: Touch screen (Manual Device Trigger)
4. Singulator Module:

Figure 19: Touch screen (Singulator Module)
PRESS CAP: Trigger cap insert cylinder up or down
SINGULATOR IN: Trigger cap insert singulator cylinder extend or retract
CAP GUIDE: Trigger cap insert guide cylinder up or down


A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

G 30
Change Password


STEP ACTIONS
1. Press CHANGE PASSWORD button at Main Menu page. Make sure to enter
the old password.

Figure 20: Touch screen (Change Password)



A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

Chapter
H
MACHINE ALIGNMENT
/ CALIBRATION
H 10
System Configuration
Hardware Software
PLC
- Mitsubishi (FX3u-128M)
- AD (FX2n-2AD)
- DA (FX2n-2DA)
PLC
- GX Developer (MELSOFT)
Touch Screen
- GOT 1000
Touch Screen
- GT Designer 3
Motor Driver
- RY401F5-VV2 (M1)
- RY201F5-VV2 (M2)
- RY201F5-VV2 (M3)
Motor Driver
- ALPHA5 Series Loader
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

H 20
Sensor Calibration





















Figure 21: Reed switch location on cylinder
STEP ACTIONS
1 P R E S S S T O P B U T T O N T O S T O P A L L M E C H A N I C A L
M O T I O N .
2 Go to Manual Mode and press the Single device trigger. Select the station where the sensor is
located for adjustment.
3 Trigger the cylinder to move forward and backward and check the reed switch.
4 Loosen the reed switchs mounting screw and move the reed switch either slightly inwards or
outwards until the indicator ON.
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

H 30
Cylinder Speed Adjustment




Figure 22: Air valve fitting
STEP ACTIONS
1 P R E S S S T O P B U T T O N T O S T O P A L L M E C H A N I C A L
M O T I O N .
2 Go to Manual Mode and press the Single device trigger. Select the station where the cylinder is
located for adjustment.
3 Trigger the cylinder to move forward and backward and check speed of cylinder.
4 Adjust the hand wheel of speed controller until the cylinder achieves the desired speed.
Hand Wheel
Lock Nut
Release Sleeve Body
A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

H 20
Sensor Calibration


A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D



Chapter
I
APPENDIX
I 10
IO List










A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

H 20
Sensor Calibration

A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 10
IO List



A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 10
IO List



A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 10
IO List




A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram




A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram







A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram




A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram





A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram





A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram









A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram





A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram








A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram








A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram







A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram



A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram




A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram




A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram




A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram




A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 20
Electrical Circuit Diagram

A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 30
Ladder Diagram


A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 40
Mechanical Drawing




A L F A - M O T I O N T E C H N O L O G Y ( M ) S D N . B H D

I 50
List of Figures



Figures
No.
Descriptions Topic
1 Safety equipment location (front & back view)
A10
2 Shows (a) EMO, (b) Main Valve, (c) MCB
A20
3 Location of each station on machine
B10
4 Location of (a) PLC, (b) MCB
C10A
5 Main air supply
C10B
6 Touch screen (Start up)
D30
7 Touch screen (System initialize)
D40
8 Touch screen (Main menu)
D40
9 Setting Value
E10
10 Critical Error
E20
11 Touch screen (Auto Mode button at main menu)
F10
12 Touch screen (Start Auto Mode)
F10
13 Touch screen (Stop Auto Mode)
F20
14 Touch screen (Setting Button at main menu)
G10
15 Touch screen (Setting page)
G10
16 Touch screen (Manual Mode)
G20A
17 Touch screen (Step Mode)
G20A
18 Touch screen (Manual Device Trigger)
G20B
19 Touch screen (Singulator Module)
G20B
20 Touch screen (Change Password)
G30
21 Reed switch location on cylinder
H20
22 Air valve fitting
H30