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1、AIR ROD FEEDEROperation ManualSeki Kogyo Co.7-9 Miyauchi 4-choumeHatukaichi-shi Hiroshima-ken738-0034JAPAN Tel81-829-39-2211Fax81-829-39-22121Parts NumberSerial Number6M-4486DateThe table of contentsIntroduction Specifications Safety Manual Composition Structure：Main Body（Selector Assembly） ：Main Bo

2、dy (Case ) ：Nut Supply UnitAssembly ：L Shaped Bar Assembly ：Cover ：Kicker345 - 8910.111213 - 16161717（option）Manualtallation：Air Rod Feeder ：L-shaped Bar ：Air Piping：Nut Supply Hose Connection：Electric Wiring：Positioning of the jet pin and the guide pin181819192020.212122Control Panel Maintenancetru

3、ctionsThe Procedure of Part Replacements and Adjustments：Main Body（Selector） Selecting Point Bar Adjustment of the interval between Selecting Board and Magnet Holder：Nut Supply Unit Nut Supply Hose Hinge Cover Kick Spring Rod（or Cylinder） Jet pin TroubleshootingAir Sequence Diagram Timing ChartLayou

4、t DrawingAssembly DrawingParts List Electric Relation2323.2424.252626.2727.282930.313233.3435Block Diagram Ladder Diagram2IntroductionThank you for purchasing of the Air Rod Feeder.This operation manual designatesproper operation, structure and maintenance for our Air Rod Feeder. Please read this ma

5、nual completely and carefully in order to operate Air Rod Feeder efficiently. Unexpected accidents can be avoided by doing so. Also, be sure to keep this manual on record for future references.The unique serial number on the Air Rod Feeder is mentioned on the cover.Please inform us of this number wh

6、en ordering replacement parts, periodic maintenance, andoverhaul.Components may be changed to increase the efficiency ofyour Air Rod circumstance.Feeder.This document may differ in contentsinyourparticularPlease understand this situation beforehand.SincerelySeki Kogyo Co., LTD.3SpecificationsVoltage

7、 Current value Air pressureAverage selecting capability（for 1 minute） Suitable nutAC115V 50/60HZ 0.3A0.4Mpa (or 0.5Mpa)Sample nut that you supplied us.Supply Unit Cylinder Stroke200Yes300No400Others（）KickerLength of Nut Supply Hose is 2.5M when not specifying it.Volume with Cover depends on quantity

8、 of nut in bowl or the shape of nut.The capacity of the Bowl77LiterPLC model number is Mitsubishi FX1S-10MT or Mitsubishi FX1S-20MT when not specifying it.Metal Connector model number is NJC243-PM and NJC243-RF when not specifying it. Nut Supply Hose has 3 air vents. (150mm, 250mm and 350mm points f

9、rom the top of hose).Special Comments:4SafeguardsPlease read alltructions before you attach, adjust, maintain, or use the Air RodFeeder. Use it properly. The safety caution is leveled as Great Danger, Danger, andCaution in thesetructions. Precautions duringtallation！Never turn on the electrical powe

10、r, hydraulic/pneumatic power, or the water supply while performing tallation. Otherwise, such unexpected action could cause electrocution resulting in injury, or erious cases, lead to death. Before performing any operation, verify that electrical power, hydraulic/pneumatic power and the water supply

11、 are turned off.！To perform a safetallation, heed the following precautions:Never touch electrically charged areas. Otherwise, it could result in electrocution.Alwaystall the terminal cover.When replacing parts, always verify that the power is turned off. Otherwise, it could result in electrocution

12、or mis-operation.Verify that power cord connector is securely connected and the ground wire is grounded and ulated.Do not set the air rod feeder unit next to areas where intense magnetism occurs. The effects of magnetism could mis-operation or other problems.5！ Great DangerIf you failed to use the e

13、quipment properly, you may be at great danger and it may cause death or severe injury.！Dangerif you failed to use the equipment properly, you may be at danger and it may cause death and injury. ！Cautionif you failed to use the equipment properly, it maycause moderate injury or slight injury. It may

14、also cause material damage only. Connect wiring after verifying that the voltage for the welder pressurization valve and the voltage for the gun pressurization outputon the air rod feeder control is the same.If the wiring is notconnected under the same voltage conditions it could cause problems. To

15、prevent problem such as sudden movement, verify that a signal from the exterior is not input when the power to the feeder is turned on or air is supplied. ！If liquids such as water coolant spray out, it could cause electrical shorting or deterioration of control devices and unexpended mis-operation.

16、II Precautions When Performing Adjustment/Maintenance WorkIf injuries or machine damage occur during operations, stop operations immediately.When performing replacement of worn parts and repairing damage to equipment, always turn off the power and air.！To perform correct adjustment and maintenance,

17、heed the following precautions:Do not touch terminals during energizing. Otherwise, it could cause electrocution or mis-operation.When performing program changes, forced output, or RUN/STOP control operations, read the accompanying sequencer manual and ensure sufficient safety.When supplying air to

18、the welder, do not allow your hands or head to come near the cylinder moving area. Otherwise, it could result in unexpected injury.Do not perform modifications or disassembly under your own accord. Otherwise, it could cause an accident or mis-operation.When supplying air to the air rod feeder, do no

19、t allow your hands or head to come near the cylinder moving area. Otherwise, it could result in an unexpected injury.When performing operations on areas which are driven by the motor,always turns off the power. unexpected injury.Otherwise, it could result in anDuring recovery, verify that the startu

20、p signal from the exterior is not input.6III Precautions on UseAir supplyAn appropriate amount of air and air pressure is required to operate the air rod feeder. Heed the following precautions. Verify that the air supply hose is properly fitted and securely tightened. Verify that the nut supply hose

21、 is properly routed and locked in a position where it is connected safely. ！ Do not place objects between the feeder rod and other apparatus. Otherwise, it could result in injury or damage to the machinery. Also, be careful not to contact electrical parts in which electrical current is flowing. To p

22、revent unexpected injuries, be careful of the following points. Do not place hands or objects near the nut separator (motor revolving area, kicker area) or the supply unit. When removing the protection cover or cleaning, verify air and power are turned off assuredly.Do not use unspecified nuts. Othe

23、rwise, it could cause problems.！To maintaafe operation, the following personnel should not performfeeder operation.Personnel with psychiatric disorders.Personnel not having full use of hands, feet, eyes and ears. Personnel on medication (including narcotics).Personnel who have consumed alcohol. Pers

24、onnel fitted with pacemakers.Personnel not wearing protective clothing.Unqualified personnel (without sufficient equipment).Personnel with long hair (hair not banded). Personnel not wearing protective glasses.trainingin operationof7 ！Air rod feeder operators are required to adequately understand the

25、 following points.The contents of thistruction manual shall be understood.The precautionary items shall be understood. The required protective clothing shall be worn.In case of an emergency, contact locations and contact person(s) shall be made clear.Methods of handing injured persons and locations

26、of first aid equipment and materials shall be verified.The method for turning off the switch during an emergency and the method for restarting operation shall be verified.Equipmentpection methods shall be understood.Sufficient knowledge and understanding of feeder operation are required.To understan

27、d feeder operations, sufficient knowledge of resistance welding is required. ！To prevent fire and explosions, heed the following points. (Spatter and weld matter occurring during welding can cause fires). Do not perform operations near combustible gas or flammable objects. An electric protective dev

28、ice is not equipped on the bolt feederequipment.tallation of overload protection equipment such as aground leak breaker is recommended. Do not place products which have just been welded near flammable objects. Have fire extinguishers put in appropriate places in preparation for unexpected accidents.

29、 ！Use the air rod feeder correctly and perform welding work safely.To protect your eyes from spatter and welding matter occurring during welding, wear protective glasses.Wear protective clothing such as protective gloves, long-sleeved clothing and a leather apron.tall a protective curtain around the

30、 work area to prevent spatter and welding matter from dispersing.Use ear protection in the event of loud noise.If signals such as the snap switch are input without informing operators during operations, it could cause an accident or breakdown. Do not place hands or objects around the fingers or elec

31、trical terminals during startup.Alwaystall grounding.Turn off the power when opening the control panel.CompositionThe Air Rod Feeder consists of the following components.Refer to the “Parts List” section for further details on specific contents.L shaped BarAssemblyCoverMain Body (Selector)Supply Uni

32、t AssemblyOperation Manual9StructureThe following parts sort the nuts into reverse ones and the front ones.BowlBowl holds the nuts.Selecting Board AssemblyNuts are moved on selecting board by magnetic force, and then are sorted into reverse ones and front ones by the selecting bar.Selecting BarNut P

33、assageNut SendingAir Tube ConnectorEntranceBoard10 ： Main Body （Selector Assembly）Structure of Nut SelectorA nut is sorted as shown in the above drawing. If the nut is on its reverse side, the selecting bar will make it drop back into the bowl again.Refer to “the Procedure of Parts Replacements and

34、Adjustments” section to learn abouthow to adjust the Selecting Point Bar.Magnet Holder AssemblyMagnet holder assembly is connected with the axis of the motorand is rotated by motor. It moves nuts by magnetic force. is fixed at the selecting board not to interfere.ItRefer to “the Procedure of Part Re

35、placements and Adjustment” (pages 23-24) to adjust space between Magnet Holder and Selecting Board Assembly.（Basically, no need to adjust.）Cross CoverThe cross cover connects the selecting board with main body.A magnet holder assembly rotates between the selecting board and the cross cover.（Basicall

36、y, no need to adjust.）11NUTfront sideCan not passthroughpass throughNUTreverse sideCaseThe case consists of the control box, control panel and the air pressure equipment. The Selector Assembly is attached above the case.Electric parts are described in a separate volume “Electric relation”.Air Pressu

37、re EquipmentRefer to “Air Sequence Diagram” (pages 32) or “Air Piping”(pages 18-19) about all air connections.Refer to separate volume “Assemblythe use of the equipment.Set the air pressure at 0.4Mpa.drawing-Partslist”about12 ： Main Body（Case）The supply unit assembly extracts the rod and supplies th

38、e nut to the target point.MotionWith start signal on, the rod begto extract.The jet pin keeps a nut by inhaling the air. Air blow is turned off by DU bush. That frees a nut from air pressure and a nut falls onto the guide pin.The rod will remain extracted for a while (T33). The welding signal is out

39、putted for a while (T32) after the extract switch of supply unit is turned on.With this hole blocked, The wall of air is lost13 ： Nut Supply Unit AssemblyStructureWhile the rod extracts, air is infused to the blow entrance.Air which enters from the blow entrance is jetted out reversely from the jet

40、pin.The blow entrance is plugged by DU bush before the rod extracts fully.That frees a nut from air pressure and a nut falls onto the guide pin.DU BushBlow MouthTypeSupply unit consists of the following parts.Supply hoseNutsupply proximity SwitchCylinder ASSYSupply Unit Bracket ASSYPoint Block ASSY1

41、4Bent typeStraight typethe rod has come outthe rod has returnedPoint Block AssemblyPoint blockA nut is set on the point block.Mixing dust or spatter at this partcould cause a trouble.Alsoert the supplyhosetotheback,otherwise a trouble will occur.Kick springThe kick spring is fixed on the hinge cover

42、.If it breaks or deteriorates, a trouble will occurHinge coverThe hinge cover prevents a nut from dropping.Cylinder AssemblyJet pinThe jet pin holds a nut by jetting air reversely.15RodThe rod connects the jet pin with the cylinder.It has the hole to supply air to the jet pin.Nut proximity detector

43、switch AssemblyThis part detects whether there is proper quantity of nuts in the supply hose, and then its signal is sent to the control.This is not used with the kicker.Supply unit bracketThe supply unit bracket is fixed to welding machine through the L shaped bar.This part connects the supply unit

44、 with the welding machine. shaped barped bar bracketunit bracket16 ：L shaped bar assemblyThe cover guards the bowl from mixing a foreignobject.It is also effectiveoundproofing.The kicker supplies a nut to the supply unit one by one. It needs to betalledwhen the plural nuts cannot be kept simultaneou

45、sly (or nuts pile)ide the supply hose.Motion The upper piston rod retracts at initial state. With the power on, the lower piston rod retracts and the upper piston extracts. The upper piston prevents the plural nuts being sent to the supply unit at the same time. Air blows at the same time, and then

46、a nut is sent to a supply unit. The lower piston rod extracts and the upper piston rod retracts. The lower piston prevents the nut being sent.17Nut detect proximity switchNut supply air tube connectorKicker Main BodyKicker coverUpper piston cylinderUpper pistonLower pistonLower piston cylinder ： Kic

47、ker (option) ： Covertallation ManualPlease be sure to confirm the following items beforetalling.Turn off all welding, control, and motive power.Turn off air pressure and cooling water sources.Turn off all air pressure and cooling-water circuits.tall it on even ground.Secure the exclusive ground.Dril

48、l the hole on the side of the welding machine, then connect the L shaped bar bracket and the L shaped bar with welding machine.L shaped barLshapedbar bracketunit bracketFix the unit bracket to the L-shaped bar.Fix the supply unit assembly to the unit bracket.（Adjust them after all parts are fixed.）C

49、onnect air pipes at the supply unit. Other pipes have been connected already.Please refer to “Air Sequence Drawing” (pages 32) for details.183. Air piping2. L shaped barAIR RODFEEDER1. Main bodyABConnect the supply unit and main body with the supply hose.Air passi ng hol esCaution ：Connect the hose

50、taking care of the direction of nut.Ensure the hose iserted to the back of the point block.If the hose creates a small Radius, a nut may get stuck there. that nuts move smoothly.Check the hose that air passing holes are opened.Adjust the hose so194.Connection of Nut Supply HoseRetract rod when the p

51、ower supply off.Conducting electric wiring, confirm that the welding, the control, and the motive power supplies are turned off. Check that none of these should be turned on the way.In order to allow the Air Rod Feeder to work properly, the following signals need to be exchanged.20Side viewConnect t

52、he extension line of a jet pin, and open a gap 2-3mm. These should not touch.Front viewAdjust to unite the central point of each pin.30 - 60 angles1. Positioning of the jet pin and the guide pinNut proximity detect switchThe feeder start signalfeeder extract rod cylinder switchweld timers start sign

53、al5. Electric wiringXHHX Control paneltructions Power lamp /the light will be turned on when a power supply is turned on. Power OFF/ON command switch Weld only/ Parts feed & weld command switchParts feed & weldfeeder and a welding machine is operated. Weld onlyOnly a welding machine is operated.Rod

54、test OFF/ON command switch/ for the positioning of the vacuum head and a guide pin.21Side viewThe bottom of the jet p hould agree horizontally with the peak of the guide pin. Pull in the direction of a vertical axis the length of X (which about the half the height of a nut).Front viewAdjust to unite the each central point.From 15 to 30 degreesMaintenance22A YEAR Replace the hinge cover (pages 26). Replace the Stainle