Tuesday, 10 November 2015 20:16

Crank-Arm Elevator: %Troubleshooting

Symptom:

It is not possible to lift or lower the Elevator.

Root Cause:
The drive motor is not controlled right
Remedial Action:
Check the control system
Root Cause:
Failure of the electric supply
Remedial Action:
Restore the electric supply
Root Cause:
The roller plunger limit switch on the crank-arm is defective
Remedial Action:
Check the roller plunger limit switch on the crank-arm and replace it if necessary
Root Cause:
The crank-arm is spinning on the output shaft
Remedial Action:
Tighten up the clamping set
Root Cause:
The system is mechanically locked
Remedial Action:
Remove the locking bolt

Symptom:

The motor does not stop when the Elevator reaches the upper / lower position

Root Cause:
Defect of the roller plunger limit switch; incorrect position or switching distance
Remedial Action:
Replace the roller plunger limit switch or either readjust or reposition it
Root Cause:
The roller plunger limit switch on the crank-arm is not connected as a safety switch
Remedial Action:
Connect the roller plunger limit switch as a safety switch

Symptom:

Incorrect transfer of the work piece / pallet

Root Cause:
The conveyor track on the Elevator is not correctly aligned with the adjoining ones
Remedial Action:
Adjust the heights by using the leveling feet

 

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All replacements of spare or wear parts have to be done by authorized technical personnel only and must be performed with all energy devices like electrical or pneumatic power shut down.
 
All the work described in the following chapter may only be carried out once the locking shaft has been put in manually as shown in the picture below! After finishing the work, the locking shaft must be removed to bring the Crank-Arm Elevator into operating mode. A sensor that checks the status of the locking shaft is available on request.
 
The locking bolt is mounted to the housing of the Crank-Arm Elevator and should be stocked there after finishing the maintenance work.
 

Crank Arm Elevator Preparatory work 1

Crank Arm Elevator Preparatory work 2

 
Before restarting the system, remove the locking bolt.
 
To better show the replacement of the crank-arm, the conveyor section is not shown in the images.
 
 
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To replace the drive motor, please proceed as follows:
  1. Bring the elevator in its center position and lock the carriage as described in previous chapter "Preparatory work for all replacements". If the motor and its brake are no longer functional, it is possible to loosen the motor brake manually. Thereby, the elevator has to be secured against lowering and the technician must adhere to the manufacturer’s instructions for the brake.
  2. Disconnect the system from the electrical supply and secure it against being switched on again.
  3. Remove the crank-arm as described in previous chapter "Replacement of the crank-arm".
  4. Remove the rear upper and lower plates of the Crank-Arm Elevator frame.
  5. Relieve the weight of the drive using a suitable lifting device as it is heavy and loosen the four mounting screws of the drive. Remove it through the rear of the frame.
  6. Re-install the new drive unit in reversed order.
  7. Re-install the rear upper and lower plates of the Crank-Arm Elevator frame.
  8. Re-install the crank-arm as described in chapter "Replacement of the crank-arm".
  9. Connect the drive motor to the electric supply according to the manufacturer's instructions.
  10. When unlocking the elevator, make sure that the carriage is put onto the crank-arm slowly.
  11. Make a test run without a pallet.
  12. Inspect the clamping set after 500 hours of operation and tighten it up again.
 

Crank Arm Elevator Replacing drive motor

 
Before restarting the system, remove the locking bolt.
 
To better show the replacement of the drive motor, the conveyor section is not shown in the image.
 
 
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To replace the cam roller, please proceed as follows:
  1. Bring the elevator in its center position and lock the carriage as described in previous chapter "Preparatory work for all replacements".
  2. Disconnect the system from the electrical supply and secure it against being switched on again.
  3. Remove the crank-arm according to chapter "Replacement of the crank-arm".
  4. Loosen the nut of the cam roller to the crank arm and remove it.
  5. The cam roller can be taken out (a gentle press may be necessary).
  6. Insert the new cam roller and bolt it back to the cam.
  7. Install the crank-arm according to the previous chapter "Replacement of the crank-arm".
  8. When unlocking the elevator, make sure that the carriage is put onto the crank-arm slowly.
  9. Perform a test run without a pallet.
  10. Inspect the clamping set after 500 hours of operation and tighten the bolts up again.
 

Crank Arm Elevator Replacing cam roller 1

Crank Arm Elevator Replacing cam roller 2

 
Before restarting the system, remove the locking bolt.
 
To better show the replacement of the cam roller, the conveyor section is not shown in the images.
 
 
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To replace the crank-arm, please proceed as follows:
  1. Bring the elevator in its center position and lock the carriage as described in previous chapter "Preparatory work for all replacements".
  2. Disconnect the system from the electrical supply and secure it against being switched on again.
  3. Loosen the bolts of the clamping set at the crank-arm and twist the crank-arm on the motor shaft until the cam roller is no longer connected to the tread carriage plate so that the arm can be removed through the cut-out in the carriage plate.
  4. Now the crank-arm can be removed from the motor output shaft.
  5. Re-install the crank-arm in reverse order. Pay attention to the positioning of the crank-arm on the motor output shaft; furthermore, the clamping set has to be mounted as described in the manufacturer’s manual. The safety switch must be put on the control disc again.
  6. When unlocking the elevator, make sure that the carriage is put onto the crank-arm slowly.
  7. Perform a test run without a pallet.
  8. Inspect the clamping set after 500 hours of operation and tighten the bolts up again.
Ensure that the roller plunger limit switch isn't damaged when removing the crank-arm.
 

Crank Arm Elevator Replacing crank arm 1

Crank Arm Elevator Replacing crank arm 2

 
Before restarting the system, remove the locking bolt.
 
To better show the replacement of the crank-arm, the conveyor section is not shown in the images.
 
 
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Tuesday, 10 November 2015 19:37

Crank-Arm Elevator: %General Maintenance


All LOGO!MAT Components are developed to make very little preservative maintenance necessary but all components will last way longer if the following tasks get do in the shown intervals. The maintenance and inspection work listed below is to be carried out at the listed intervals to keep the warranty and to follow up constantly if the LOGO!MAT Component is working well. Any defects found must be documented and fixed before operating again. All time specifications are based on single-shift operations.

With an interval of one (1) month the following preservative maintenance should be carried out:
  1. Inspect every component for damages and wear.
  2. Visual and acoustic check.
  3. Inspect the clamping set of the crank-arm and re-adjust it if necessary.

With an interval of six (6) month the following preservative maintenance should be carried out:

  1. Lubricating and cleaning of the carriages (if necessary).
  2. Inspection of all detachable connections and connection elements; retighten loose bolt connections.
  3. Inspection of the cam roller and its running surface.
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The Crank-Arm Elevator must be controlled automatically. 
 
This should be as follows:
  1. The pallet moves onto the conveyor section of the Crank-Arm Elevator. A sensor confirms that the pallet has moved onto the track and sends a signal to the controls, which switches the drive unit off. An additional stop unit or a pawl can secure the pallet.
  2. After the control system receives the signal that the pallet is on the conveyor and the motor is switched off, it starts the drive motor of the crank-arm that lifts the track section. The direction and extent of movement is defined by the stature of the upper and lower switch.
  3. By reaching the second limit switch the motor stops automatically so that the track section on the Crank-Arm Elevator aligns the adjoining conveyor.
  4. After reaching the end position, the drive motor of the conveyor starts in the direction of flow and the pallet can be released as soon as there is no other pallet on the adjoining track section.
  5. A high level sensor on the stationary conveyor clears the area. After the pallet has completely left the elevator, it is unlocked and can take the next pallet.
This description is a recommendation only and does not take up every control action. The operator has to decide how the application takes place on-site. This also depends on the local conditions. LOGOMAT automation systems, Inc. is not responsible for damages of any kind that may arise from the controls system.
 
 
 
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Tuesday, 10 November 2015 19:28

Crank-Arm Elevator: %Electrical Installation


Electrical adjustments may only be made by authorized technicians and only when the Crank-Arm Elevator is mechanically locked and disconnected from its electrical supply.

To guarantee a safe and efficient operation, the LOGO!MAT Crank-Arm Elevator must be equipped with the specified sensors or their equivalent.

All roller plunger limit switches have to be mounted at their respective positions and have to be adjusted in height as well as in their switch distance. All cables must be protected against scrubbing and accidental removal. The upper and lower limit switches turn the drive motor off when activated. As soon as the limit switch that protects the Crank-Arm Elevator from overrunning is activated it must stop the drive motor immediately. Thereby, a cable break or contact problems will stop the motor for safety reasons. It must be ensured that all sensors have the correct switching distance to their target. The overrun protection must be connected to a separate electrical system. If this activation is broken, the drive unit of the Crank-Arm Elevator has to stop immediately to protect the system against overrunning.

The Crank-Arm Elevator is driven by a three-phase motor with brake. The motor and the brake must be connected correctly to the electric supply according to the manufacturer’s documentation. Since the function of the motor and the Crank-Arm Elevator may be adversely affected when handled improperly, the brake must be activated even when the drive is switched off.

If no LOGO!MAT ITB is included in the scope of delivery, the complete control system has to be provided by the customer. In this case, it is the customer's responsibility to ensure that the Crank-Arm Elevator is controlled correctly and safely. Since the control our customers’ needs, no general information is provided.

Crank Arm Elevator Electrical inst

 

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The clamping set, which mounts the crank-arm to the drive shaft, is installed with the mandatory torque of 41 Nm per mounting bolt when it gets delivered.

After loosening the mounting bolts, this torque must be applied again (use a torque wrench) to prevent the crank-arm from spinning. Furthermore, it is necessary to check the torque approximately every 500 hours of operation and it must be re-adjusted if necessary.

Further information and details about the clamping set and its adjustments can be found in the manufacturer’s documentation (KTR).

Crank Arm Elevator Adjustments

 

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Tuesday, 10 November 2015 17:23

Crank-Arm Elevator: %Mechanical Installation


The installation of the Crank-Arm Elevator may only be performed by authorized and qualified personnel. If there are any damages caused by the transportation of the Crank-Arm Lift, log these damages and inform LOGOMAT automation systems, Inc. immediately. Do not operate or install the Crank-Arm Elevator if there are any damages. 
 
Move the Crank-Arm Elevator to one of its stop positions (up / down) and make sure that it sits on the ground solidly. 
 
For the installation of the Crank-Arm Elevator, please proceed as follows:
  1. Place the conveyor and the Crank-Arm Elevator on the floor according to the layout.
  2. Place the Crank-arm Elevator so that the distance between the track section on the elevator and the adjoining track section is not more than 57 mm (side frame to side frame).
  3. Adjust the height and level the elevator horizontally and vertically with the leveling feet. To guarantee a safe and correct pallet transfer, ensure that the conveyor section on the Crank-arm Elevator has exactly the same height as the adjoining track section. Check that those two conveyor sections align.
    The lift of the Crank-Arm Elevator is unalterable. In the event there is a height difference between the elevator track and the adjoining conveyor track, adjust the height of the elevator or conveyor track using the leveling feet. If there are height differences between only one adjoining track or the spacing between the two assembly line tracks is off, please contact LOGOMAT technical support.

    Crank Arm Elevator Mechanical inst

  4. After everything has been adjusted, anchor the Crank-Arm Elevator to the floor at the intended positions.
  5. Connect the Crank-arm Elevator to the electric supply and install all sensors and safety switches. Ensure that the motor brake is correctly wired according to the manufacturer’s manual.
  6. Before starting a test run, make sure that the Crank-Arm Elevator is not mechanically locked and only start the test run under supervision. Check that the elevator is not blocked and that there is no pallet on the conveyor.
  7. Test the controls through every possible situation and make adjustments if necessary.

    Crank Arm Elevator Mechanical inst anchoring points

For proper function, the Crank-Arm Elevator must be installed and aligned correctly.
 
Ensure that the pallet cannot move as it stops on the elevator mounted conveyor track. This can be done by either switching off the drive, or by using a stop unit or a mechanical return stop.
 
Crank-Arm Elevator operates automatically. However, the control is not in the scope of delivery. Since the programming of the Crank-Arm Elevator may have major influence on the function of the elevator, the safety instructions must be observed.
 
 
 
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