Docstoc

Jed Pipe

Document Sample
Jed Pipe Powered By Docstoc
					Flower Pouch Flattener
           Sponsor:
 VanTimmeren Greenhouse Inc.




        Team Members:
           Pat Foley
           Jed Pipe
         Dale Slotman
       Mark ZurSchmiede

            7-22-04
TABLE OF CONTENTS
TABLE OF CONTENTS .................................................................................................. i

LIST OF FIGURES ......................................................................................................... iii

I.      INTRODUCTION..................................................................................................... 1
     A. General Specifications ............................................................................................... 1
     B. Description of Operation ............................................................................................ 1
     C. Important Precautions ................................................................................................ 1

II.      OPERATION ........................................................................................................... 2
     A. Machine Start Up ....................................................................................................... 2
     B. Adjust Speed .............................................................................................................. 2
     C. Height Adjustment ..................................................................................................... 2
     D. Stapling Mechanism ................................................................................................... 3
     E. Pouch Feeding ............................................................................................................ 3

III. MAINTENANCE & CLEANING .......................................................................... 4
     Recommended Maintenance Schedule ........................................................................... 4
     A. Chains and Sprockets ................................................................................................. 4
     B. Gearbox Lubrication .................................................................................................. 4
     C. Take-Up Bearings ...................................................................................................... 5
     D. Threaded Rod ............................................................................................................. 5
     E. Stapler Cable .............................................................................................................. 6
     F. Cleaning ...................................................................................................................... 6

IV. ADJUSTMENTS ...................................................................................................... 7
     A. Height Adjustment ..................................................................................................... 7
     B. Stapler Housing Adjustment ...................................................................................... 7
     C. Stapler Cable Adjustment........................................................................................... 7
     D. Guide Rail Adjustment............................................................................................... 7
     E. Conveyor Belt Slack Adjustment ............................................................................... 8

V.      TROUBLESHOOTING ........................................................................................... 9
     A. Mechanical ................................................................................................................. 9
     B. Electrical................................................................................................................... 10


                                                                    i
VI. REPLACEMENT PARTS .................................................................................... 11
   A. List of Replacement Parts ........................................................................................ 11
   B. Removal/Installation Procedures.............................................................................. 12

VII. PRINTS & SCHEMATICS................................................................................... 17
   A. Wiring Schematic ..................................................................................................... 17




                                                              ii
LIST OF FIGURES
Figure 1. Pinchpoints .......................................................................................................... 1
Figure 2. Motor Power Switch ............................................................................................ 2
Figure 3. Speed Control ...................................................................................................... 2
Figure 4. Height Adjustment............................................................................................... 2
Figure 5. Stapler Housing ................................................................................................... 3
Figure 6. Alignment ............................................................................................................ 3
Figure 7. Chain Guard Removed ........................................................................................ 4
Figure 8. Flattener Gearbox ................................................................................................ 5
Figure 9. Conveyor Gearbox............................................................................................... 5
Figure 10. Take-Up Bearing ............................................................................................... 5
Figure 11. Height Adjustment Rod ..................................................................................... 5
Figure 12. Stapler Housing ................................................................................................. 6
Figure 13. Height Adjustment............................................................................................. 7
Figure 14. Stapler Housing ................................................................................................. 7
Figure 15. Foot Pedal .......................................................................................................... 7
Figure 16. Guide Rails ........................................................................................................ 8
Figure 17. Take-Up Bearing ............................................................................................... 8
Figure 18. Main Replacement Reference.......................................................................... 11
Figure 19. Electrical Reference......................................................................................... 11
Figure 20. Chain & Sprocket Reference ........................................................................... 11
Figure 21. Wiring Schematic ............................................................................................ 17




                                                               iii
I.     INTRODUCTION                             C. Important Precautions

                                                Operator safety was considered during
A. General Specifications                       the design of this machine, and
                                                preventable dangers have been guarded
This flower pouch flattener was                 against. As with any machine, however,
designed and built specifically for the         some dangers to the user still exist. Care
needs of VanTimmeren Greenhouse, Inc.           must be taken while operating this
of Allendale, Michigan. The flatter was         machine to minimize potential for injury.
designed to flatten 5.5” diameter, 20”          This manual is not a substitute for
long pouches filled with moist soil.            common sense.
Flattening heights vary from 2.0” to
4.0”. The flattener is 5’1” long, 14”           All chains have been guarded for
wide, and 5’2” tall at its highest point.       operator safety. At no time should the
Two 120 VDC motors with 30:1 gear               machine be operated without the chain
reduction power the conveyor and                guards in place.
flattening assembly. Power is supplied
using a U.S. standard 110VAC, 60Hz.             Pinch points exist where rollers are
outlet. When the machine is running at          turning. Keep hands away from these
the maximum speed, the machine uses             areas during operation.
440 Watts of power.


B. Description of Operation

This machine was designed to close and
flatten dirt filled pouches. The closing
of the pouches is performed using a foot
actuated stapler, and the flattening is
done using a tapered roller system. The
flattening assembly is powered by a ¼
HP 120VDC motor. The height of the
flattening assembly is adjustable from
2.0” to 4.0” by turning the hand crank
located at the front of the machine. The
speed of both motors is adjustable within       Figure 1. Pinchpoints
the range of 0 to 1.0 foot per second.
Pouches are transported through the
                                                Operating the machine with the
flattening assembly on a conveyor belt
                                                electrical panel door open increases the
driven by a ¼ HP 120VDC motor.
                                                risk of electric shock. The panel door
There is a removable storage cart
                                                should be left closed unless the machine
capable of holding 20 pouches.
                                                is unplugged.




                                            1
II.    OPERATION

A. Machine Start Up

Ensure that the switch located next to the
storage cart is off, and the speed control
knob is at the zero speed position. Plug
machine into a standard 110VAC, 60Hz
outlet. Turn switch on.



                                                 Figure 3. Speed Control

                                                 C. Height Adjustment

                                                 Flattening height is adjusted using the
                                                 crank handle located on the front of the
                                                 machine. Turning the crank clockwise
                                                 will raise the flattener; turning the crank
                                                 counterclockwise will lower the
                                                 flattener. Do not use excessive force on
                                                 the crank handle. If crank handle is
                                                 difficult to move, lubricate the
Figure 2. Motor Power Switch
                                                 threaded rod.


B. Adjust Speed

Turn the speed control knob clockwise
to increase motor speed and counter
clockwise to decrease motor speed until
desired motor speed is achieved.

After the speed control knob has been
adjusted, it does not need to be moved
unless the machine is unplugged.
Because unplugging the machine resets
the speed controller, the motors should
be turned off using the motor power              Figure 4. Height Adjustment
switch rather than by unplugging the
machine when possible.




                                             2
D. Stapling Mechanism

The stapling mechanism is operated
using the attached foot pedal. Pressing
down on the foot pedal will actuate the
trigger arms on the stapler housing,
causing the stapler to staple.

Pouches should be inserted into the
stapler jaws before pressure is applied to
the foot pedal.

Excessive force on the foot pedal may
cause slippage in the cable connection.
If this occurs, follow the instructions          Figure 6. Alignment
under stapler cable adjustment in section
IV.
                                                 As the pouch travels toward the
                                                 flattening assembly, the guide rails will
                                                 maintain the proper orientation during
                                                 flattening. For information on adjusting
                                                 the guide rails, see guide rail adjustment
                                                 in section IV.




Figure 5. Stapler Housing


E. Pouch Feeding

Stapled pouches are fed into the flattener
in the front of the machine. Pouches
should be set on the support plate, and
then lined up using the guide rails.
Pouches are to be fed open end forward
to minimize dirt loss during flattening.
Ensure that both tabs on bottom of
pouch rest above the guide rails as
shown.



                                             3
III. MAINTENANCE & CLEANING

Recommended Maintenance Schedule

Maintenance Period              Required Maintenance
Every 3 months                  Lubricate chains and sprockets using standard chain oil.
Every 6 months                  Inspect gearbox lubrication. Fill, if necessary, using
                                instructions below.
Every year                      Grease take-up bearings on conveyor belt
As needed                       Lubricate threaded rod on flattening height adjustment
                                using a dry lubricant if crank handle becomes difficult to
                                turn.
As needed                       Lubricate stapler cable using a dry lubricant if stapler does
                                not return to original position on its own.
As needed                       Clean machine (for looks only), not necessary for normal
                                operation.

Note: this maintenance chart assumes continuous use. If the machine is in seasonal use, ensure
that all components are properly lubricated before seasonal operation begins to prevent wear.
Also ensure that chains, sprockets, and threaded rod are properly lubricated before machine is
put into storage to prevent rusting.


A. Chains and Sprockets

   1.   Turn machine off.
   2.   Remove chain guards by removing screws.
   3.   Spray chain with chain oil.
   4.   Replace chain guards.




                                                       Figure 7. Chain Guard Removed

B. Gearbox Lubrication

   1.   Turn machine off.
   2.   Drain gear oil by unscrewing drain and fill plugs.
   3.   Replace drain plug.
   4.   Fill gearbox with 85W-140 gear oil (or comparable) until oil is visible in fill hole.
   5.   Replace fill plug.


                                              4
Figure 8. Flattener Gearbox                    Figure 9. Conveyor Gearbox




C. Take-Up Bearings

   1. Locate grease fittings in take-up bearings
   2. Using a standard grease gun, fill bearings
      with grease.




                                                   Figure 10. Take-Up Bearing


                                 D. Threaded Rod

                                    1. Turn crank until flattener is in lowest position.
                                    2. Spray threaded rod with a dry lubricant.
                                    3. Turn crank until flattener is back in desired
                                       position.




Figure 11. Height Adjustment
Rod




                                           5
E. Stapler Cable

   1. Remove stapler from housing.
   2. Spray exposed stapler cable with a dry
      lubricant on both stapler and foot pedal ends.
   3. Work lubricant into cable housing by stepping
      on foot pedal multiple times.
   4. Replace stapler.

                                                        Figure 12. Stapler Housing

F. Cleaning

Cleaning dirt from the machine is not required for normal operation. It is recommended that dirt
be removed from the machine periodically. It is recommended that an air stream be used to
clean off any loose dirt that might accumulate. If water is to be used, unplug the machine first.

WARNING: DO NOT DIRECTLY SPRAY THE ELECTRICAL ENCLOSURE OR MOTORS
WITH WATER. IF WATER IS SPRAYED ON ELECTRICAL ENCLOSURE OR MOTORS,
ENSURE THAT SUFFICIENT DRYING TIME IS ALLOWED BEFORE MACHINE IS
PLUGGED IN AGAIN.




                                            6
IV.    ADJUSTMENTS
A. Height Adjustment

The height of the flattening assembly is
controlled using the crank handle located
at the front of the machine. Turning this
crank handle moves the threaded rod in
and out of the threaded plate. This
movement forces the flattener support
arms to move forward or backward,
according to the direction that the crank        Figure 14. Stapler Housing
handle is turned. The motion of the
arms raises and lowers the flattening            C. Stapler Cable Adjustment
assembly.
                                                 To adjust the tension in the stapler cable,
                                                 loosen the adjustment retainer nut
                                                 located on the foot pedal. Turn the
                                                 adjustment bolt until cable is at desired
                                                 tension. Tighten the retainer nut to
                                                 secure adjustment bolt.




Figure 13. Height Adjustment

B. Stapler Housing Adjustment

The stapler housing may be brought
forward or back by loosening the
thumbscrew located on the left side of           Figure 15. Foot Pedal
the stapler housing shaft. Once the
stapler housing is at the desired location       D. Guide Rail Adjustment
tighten the thumbscrew.
                                                 To adjust the width of the guide rails
                                                 loosen the adjustment knobs located on
                                                 the sides of the machine. Slide the guide



                                             7
rails in or out until desired position is
achieved. Tighten the adjustment knobs
to secure the guide rails.

To adjust the height of the guide rails
loosen the guide rail bracket bolts. Slide
the brackets up or down until the desired
height is achieved. Tighten the bracket
bolts to secure the guide rails.




                                                 Figure 17. Take-Up Bearing




Figure 16. Guide Rails

E. Conveyor Belt Slack
   Adjustment

Turn the belt tensioning rob on the take-
up bearings located on the front sides of
the machine. The belt should be taut at
all times for proper motion.




                                             8
V.     TROUBLESHOOTING

A. Mechanical

Problem                       Possible Cause                Solution
Pouch is too flat             Flattener is too low          Turn height adjustment
                                                            crank handle clockwise
Pouch does not get flattened Flattener is too high          Turn height adjustment
enough                                                      crank handle
                                                            counterclockwise
Foot pedal does not actuate   Cable has become              Reattach cable to foot pedal
stapler                       disconnected from foot
                              pedal
                              Cable has become              Reattach cable to stapler
                              disconnected from stapler     housing
                              housing
                              Cable has slipped on either   Turn adjustment bolt on
                              stapler housing or foot       foot pedal out to take slack
                              pedal                         out of the cable. If not
                                                            enough slack can be taken
                                                            out using the adjustment
                                                            bolt, cable must be loosened
                                                            and reattached.
                              Cable has broken              Remove and replace cable
Height adjustment handle      Setscrew has come loose       Tighten setscrew in handle
turns freely without
adjusting height
Conveyor belt is slipping     Conveyor belt is too loose   Tighten conveyor using
                                                           take-up bearings
Pouch does not align          Guide rails are not adjusted Adjust guide rails using
properly                      correctly                    method described in section
                                                           III.C.
Height adjustment handle      Height adjustment has        Turn handle in opposite
will not turn                 reached upper or lower limit direction




                                            9
B. Electrical

Problem                   Possible Cause                Solution
Both motors do not turn   Machine is not plugged in     Plug power cord into wall
                                                        outlet.
                          Power switch is in off        Turn switch to on position.
                          position
                          Speed control knob is at      Turn knob clockwise until
                          zero position                 desired speed is achieved.
                          Motor speed controller        With machine plugged in
                          needs to be reset             and turned on, turn speed
                                                        control knob counter
                                                        clockwise to zero speed
                                                        position and then turn
                                                        clockwise until desired
                                                        speed is achieved.
                          One or both fuses are blown   Unplug machine and
                                                        replace fuses.
                          Thermal relay is tripped      Turn the power switch to
                                                        the off position and firmly
                                                        press the switch to reset the
                                                        thermal relay.
                          Motors are disconnected       Refer to wiring schematic to
                                                        reconnect motors.
                          Motor controller is           Refer to motor controller
                          damaged                       installation to replace
                                                        controller.
One motor does not turn   Motor is burnt out            Refer to motor installation
                                                        to replace motor.
                          Motor is disconnected         Refer to wiring schematic
                                                        and motor installation
                                                        section to reconnect motor.




                                       10
VI. REPLACEMENT PARTS
A. List of Replacement Parts




                       Figure 18. Main Replacement Reference




     Figure 19. Electrical Reference      Figure 20. Chain & Sprocket Reference




                                        11
  Table 1. Replacement Parts
Item #   Description                             Part #     Vendor                     Website/Phone #
    1    Motor, 1/4 hp, 130V DC                  10-1860    Surplus Center             www.surpluscenter.com
    2    Gear Reducer 30:1, 56C Face                        Gezon Industrial Surplus   (616)454-7600
    3    Stapler                                 Arrow P-22 Allendale True Value
    4    Flange Mount Bearings                   1F550      Grainger                   www.grainger.com
    5    Potentiometer Knob                      6094K23 McMaster                      www.mcmaster.com
    6    Aluminum Crank Handle                   6473K78 McMaster                      www.mcmaster.com
    7    Caster 4" Swivel with Brake             5UX89      Grainger                   www.grainger.com
    8    Caster, 4" Rigid                        4W890      Grainger                   www.grainger.com
    9    Plastic Rod Mount                       9268K37 McMaster                      www.mcmaster.com
   10    Fuse, 15A                               1CT81      Grainger                   www.grainger.com
   11    Motor Speed Controller                  11-2449    Surplus Center             www.surpluscenter.com
   12    12 Tooth, 5/8 Bore, 40 Pitch Sprocket   1L109      Grainger                   www.grainger.com
   13    Chain, #40 ANSI (10' LG)                2W093      Grainger                   www.grainger.com
   14    Chain Link Connect                      5X293      Grainger                   www.grainger.com
   15    Thermal Unit                            5B640      Grainger                   www.grainger.com
   16    U-Joint                                 6445K6     McMaster                   www.mcmaster.com
   17    Ball Lock Pin                           92490A733 McMaster                    www.mcmaster.com
   18    12 Tooth, 3/4 Bore, 40 Pitch Sprocket   1L110      Grainger                   www.grainger.com
   19    10' Brake Cable                                    Freewheeler Bikeshop       (616)451-8011
   20    5k Potentiometer                                   T&W Electronics
   21    4" Diameter Crowned Pulley              5706K21 McMaster                      www.mcmaster.com
   22    Take-Up Bearing                         6029K21 McMaster                      www.mcmaster.com
   23    Fuse Block, 30A                         4XC31      Grainger                   www.grainger.com
   24    Take-Up Frame                           6029K41 McMaster                      www.mcmaster.com
   25    Conveyor Belting and Lacing                        Mol Belting                (616)454-2484
   26    Guide Rail Clamps                       9268K51 McMaster                      www.mcmaster.com
   27    Tapped Mounting Rod, 10" Length         9268K77 McMaster                      www.mcmaster.com
   28    Conveyor Guide Rail                     9268K41 McMaster                      www.mcmaster.com

  NOTE: Not all items are shown in the reference pictures.

  B. Removal/Installation Procedures

  1) Motor:

  The following instructions will guide you through the process of removing either of the two
  motors attached to the pouch flattener. To reinstall the motor reverse the order of the removal
  instructions paying careful attention to the wire connections AC1 and AC2. If the motor is
  spinning in the wrong direction reverse the wires. As a reference, use wiring schematic shown in
  figure 21.

          1) Unplug machine from wall outlet.
          2) Remove wiring box faceplate from motor.
          3) Disconnect wire leads AC1 and AC2.


                                                  12
       4)   Disconnect motor chassis ground.
       5)   Remove conduit retaining nut.
       6)   Pull conduit out and away from motor.
       7)   Remove the 4 motor face bolts attaching motor to gearbox.
       8)   Pull motor straight back careful not to damage motor.

2) Motor Controller:

The following instruction will guide you through the process of removing the motor controller
unit from the electrical panel. To reinstall reverse the order of the removal instructions paying
careful attention to the wire connections on the controller and chassis ground. Refer to the
wiring schematic in figure 21 for assistance.

       1) Unplug machine.
       2) Carefully disconnect all spade terminals from controller unit.
       3) Remove 4 screws attaching the inner panel to the electrical enclosure.
       4) Pull inner panel out far enough to gain access to the nuts holding the controller unit in
          place.
       5) Remove the 4 nuts and bolts from the control unit.

WARNING: DUE NOT PLUG MACHINE IN WITH ELECTRICAL ENCLOSURE DOOR
OPEN AND/OR WIRES NOT CONNECTED.

3) Stapler:

The following instructions will guide you through the process of removing the stapler from its’
housing. To reinstall the stapler reverse the order of the removal instructions paying attention to
the direction in which the stapler is facing.
        1) Pull stapler handle retaining pin out.
        2) Remove cylindrical insert.
        3) Slide stapler out the top of the housing.

4) Stapler Cable:

The following instructions will guide you through the removal of the stapler cable. To reinstall
reverse the order of the removal instructions with an addition of pulling the cable taut at the
stapler housing before tightening the cable clamp located on the staple housing. This will ensure
proper alignment and cable tension.

Stapler Housing:
        1) Cut ferrules (cable crimps) off end of cable.
        2) Unbolt cable retaining clamp.
        3) Slide cable through guide holes.

Foot Pedal:
       Refer to the instructions for stapler housing.



                                            13
5) Height Adjustment Assembly U-Joint:

The following instructions will guide you through the removal of the height adjustment rod u-
joint. To reinstall reverse the order of the removal instructions.

       1) Place flattening box in lowest flattening position. Ensure that the support arm rests
          on the lower limit rod.
       2) Loosen setscrew on both ends of the u-joint.
       3) Turn crank handle counterclockwise to separate the two rods.


6) Conveyor Roller:

The following instructions will guide you through the removal of the conveyor rollers. To
reinstall, reverse the order of the removal instructions.

Non-driven roller:
      1) Unplug machine.
      2) Loosen setscrews holding shaft to bearings on both sides of roller.
      3) Remove guide rails.
      4) Use a rod with a diameter less than the roller shaft and a hammer to gently pound out
          the shaft.
      5) Lift roller and conveyor belt up and remove roller.

Drive roller:
       1) Unplug machine.
       2) Remove chain guard.
       3) Refer to chain/sprocket removal to remove the drive chain and sprocket from the
           roller shaft.
       4) Loosen setscrews holding shaft to bearings on both sides of roller.
       5) Use a rod with a diameter less than the roller shaft and a hammer to gently pound out
           the shaft.
       6) Lift roller and conveyor belt up and remove roller.

7) Flattening Rollers:

The following instructions will guide you through the removal of the flattening rollers. To
reinstall, reverse the order of the removal instructions.

       1)   Unplug machine.
       2)   Raise flattening box to highest setting.
       3)   Remove chain guards from both sides of flattening box.
       4)   Refer to chain/sprocket removal to remove the drive chains and sprocket from rollers.
       5)   Loosen setscrews holding shaft to bearings on both sides of roller.




                                            14
         6) Use a rod with a diameter less than the roller shaft and a hammer to gently pound out
            the shaft.
         7) Once shaft is removed roller should drop out of the flattening box.

Note: To gain easier access to roller bearings the storage cart may be removed. Refer to storage
cart removal for this procedure.

8) Chain and Sprocket:

The following instructions will guide you through the removal of the chain and sprockets. To
reinstall reverse the order of the removal instructions.

Chain:
         1)   Unplug machine.
         2)   Remove chain guard.
         3)   Remove master link from chain.
         4)   Pull chain off of sprockets.

Sprocket:
      1) Remove chain.
      2) Loosen setscrew holding sprocket onto shaft.
      3) Remove sprocket.

Note: When reinstalling the sprocket ensure that the key is replaced between the shaft and the
sprocket.

9) Storage Cart:

The following instructions will guide you through the removal of the storage cart. To reinstall
reverse the order of the removal instructions.

         1) Place supports underneath storage cart frame near the bolt flanges.
         2) Remove retaining bolts from flanges.
         3) Separate the storage cart from the rest of the machine.

10) Conveyor Belt:

The following instructions will guide you through the removal and installation of the conveyor
belt.

         Removal:
         1) Run machine until lacing is accessible.
         2) Unplug machine.
         3) Remove lacing rod.
         4) Pull belt away from machine.




                                               15
Installation:
1) Wrap belt around rollers.
2) Interweave lacing.
3) Push lacing rod through lacing.
4) Refer to conveyor slack adjustment to tighten belt.




                                    16
VII. PRINTS & SCHEMATICS

A. Wiring Schematic




Figure 21. Wiring Schematic


                              17

				
DOCUMENT INFO
Shared By:
Categories:
Tags:
Stats:
views:25
posted:8/10/2011
language:English
pages:21