Oscillating andTangential Knife

Manual

Revised 10 April, 2019 © Multicam Systems Pty Ltd

All rights reserved. No part of this document may be reproduce or transmitted in any form or byany means, electronic, mechanical, photocopying, recording, or otherwise, without prior written

permission of Multicam Systems Pty Ltd.

Table Of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Health & Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Setting up the Tool Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Tool Heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Changing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Knife Origin and Knife Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Creating an NC File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Motor Drive Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Origin Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Function 24 - Set Knife Tool Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Valid Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Function 822 - Setting up Tangential Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Valid Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Tangential Maximum RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Tangential Knife Cycle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Tangential Knife Knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Proper Direction of Tangential Motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Stepper Motor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Skew Error Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Other Knife Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Setting Knife Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Tangential Knife NC Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Device Description and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Testing the PNP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Oscillating Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Oscillating Knife Service & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Oscillating Head Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Specifications of Oscillating Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3

Introduction

This manual is meant to be used in conjunction with the Multicam Machine Manuals provided withyour machine. This manual provides specific information on machines configured fortangential/oscillating knife devices.

Tangential devices are any device that uses a "W" axis to control a tangent of 1he XY motion andincludes:

1. Standard tangential knife head. 2. Oscillating knives head3. "Pizza wheel" Cutters4. Creasing wheels. 5. Sabre Blade Cutters6. Box Cutters7. Angled Blade Cutters

Most of the functionality is common with some differences that are pointed out in this manual.

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Health & Safety

This manual and the safety guidelines contained within it are designed to enable the user to obtainthe best performance from the machine over a long lifetime and to ensure the safety of theoperator. Each person who will operate the equipment, perform a service or maintenance, orsupervise its use must read the safety instructions in this manual. Please read it carefully beforeusing or working on the machine.

The machine is a 3-axis router designed to cut and shape a variety of materials using eithervacuum or manual clamping. The correct method of using these mechanisms is coveredelsewhere in the users manual.

Ensure that you have read and understood the operational and health and safety sections of themanual before beginning to use the machine.

The machine is not intended for use in an explosive environment.

ALWAYS CONSULT SEPARATE MANUALS FOR ADDITIONAL ANCILLARY DEVICES SUCHAS OSCILLATING TANGENTIAL KNIFE HEADS AND GANG DRILL HEADS FOR SAFE

OPERATION.

By their nature Knife cutting heads may use long, very sharp knife cutting blades. Due to theirconstruction these blades may break during use. It is important that the machine is not used ifthe supplied safety guards are not in place. Failure to follow this instruction can result inserious injury to the machine operator.

It is recommended that the operator, and other persons working in the vicinity of the machine, usethe following personal protective equipment in conjunction with the machine:

• Hearing protection• Eye protection• Gloves when handling materials to be machined or changing knife blade

ALWAYS REMOVE KNIFE BLADES FROM THE KNIFE HEAD WHEN NOT IN USE OR WHENCLEANING AND CARRYING OUT MAINTENANCE.

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Note: The supply and wearing of personal protective equipment is regulated by WorkCover.

• No liability will be accepted for damages which arise as a result of noncompliance with theoperating instructions or improper repairs or the use of non-original replacement parts. Themanufacturer reserves the right to make alterations which enhance technical performance.

• When using or servicing the machine, always wear eye protection.• When using the machine in a dusty environment always wear a breathing mask.• When using the machine always wear hearing protection.• Always wear suitable protective clothing.• Only connect the machine to the compressed-air supply when the valve is switched off and

tools installed.• Remove flammable materials and objects.• During operation, a flow pressure of 6 bar must under no circumstances be exceeded.• Installed cutters must under all circumstances be shielded against unintentional contact.• Watch out for the danger of dust or vapours being generated during the working of certain

materials. Use dust extractors and suitable protective equipment.• While working, watch out for the danger of certain materials generating dust or vapors

which could create an explosive atmosphere.• Before use, always read the attached safety notice.• Blow firmly through the compressed-air pipe (the compressed-air hose) before connecting

the machine to the compressed-air supply, in order to remove any particles of dirt whichhave may have accumulated.

• Before connecting the machine to the compressed-air supply, check your compressed airfor water content. Water, corrosion etc. in the pipe network cause rust inside the motor andtherefore severe wear or machine breakdown.

• Provide air quality in accordance with DIN ISO 8573-1, Quality Class 4.• Add a quality air compressor oil or robot 1 drops (1 drop = 1,5 mm3) per 4 working hour.• Over dimensioned tools can cause accidents.

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General User Guide

Setting up the Tool Map As in all machines, tools are managed using the tool map that is accessed using the A2MC AppsManager.

Any number of different types of tangential tools or knives can be assigned on a machine. Simplygive each one of them its own tool number. They just become tangential tools.

Tool Heights Although tangential knives are two dimensional devices they still need to know where the surfaceof the table is so tool heights are required. For tangential devices either function 24 or function 25can be used.

Generally using function 24 is more convenient and in the case of an oscillating knife it isnecessary to use function 24 instead of function 25. Also for machines with gantry mount function25 sensors the knife heads sometimes cannot reach the sensor.

Changing Tools Tangential devices and knives can be changed manually just like a collet spindle provided that: 1. Knife blades are extremely sharp! Use extreme caution when handling.2. Each tangential knife used is assigned a tool number. 3. The tangential knife has a tool height programmed as described above

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Knife Origin and Knife Angle The knife origin is knife angle equal to zero degrees which is defined as the knife edge pointingdirectly along the positive X axis.

The tangential device will automatically seek its origin when: 1. Function 12 is entered. The tangential origin seek will occur right after the Z origin seek. 2. Function 31 tool change will seek the tangential origin if the select tool is a tangential tool.

If the knife does not appear to align directly along the positive X axis then use function 822 toenter a tangential origin offset. There is a set up section in the last half of this manual.

When the current tool is a tangential tool function 42 allows the user to program the tangentialangle.

Values between -180 and + 180 are valid: 0 degrees is along the positive X axis. 90 degrees is along the positive Y axis. 90 degrees is along the negative Y axis.180 or + 180 is along the negative X axis.

Creating an NC File Tangential knife jobs are necessarily two dimensional jobs. A sample file is shown below:

GOX1OY10 Move to position X=10, Y=10 M6T15 Select tangential tool, knife will seek origin M3 If oscillating knife this will turn the knife on GOZ1 Rapid move down to Z=1 G1Z0 Knife will align to next move, it will set knife top to Z= 1, and will move down

to cut G1X20 Knife will be aligned to 0 degrees and cut along X axis G1Y19 Knife will lift to Z = 1, rotate to 90 degrees, go down and cut along Y axis G3X19Y20119J19 Knife will not lift and just track around curve G1X10 Knife just continues to move along negative X GOZ1 Cut ends and knife lifts M5 Turn off oscillating knife M6T15 Seek origin and check for tracking error M30 End job

Some restrictions and hints on tangential knife jobs: 1. Use an initial G 1 Z move to set the lift height for the tangential knife to lift and turn on

sharp corners. If there is no G1Z the default lift will be 6mm. 2. If there are any G1,G2, or G3 Z moves during a knife cut the knife will stop rotating for that

move regardless of any associated X and Y moves. The A2MC cannot track the knife anddo a Z move at the same time.

3. Putting an extra M6 at the end of a job will check if there was a tangential tracking error.M6 commands can be put in where ever there is concern about a tracking error.

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Machine Setup

Overview There are two main parts to a tangential knife set up: 1. The tangential knife works using a motor that is in the tangential device itself. The motor

drive card is in the control box. 2. The tangential knife requires a sensor to find the knife origin (knife angle = 0).

Motor Drive Setup The tangential drive system uses the Z4 motor output therefore any machine with a tangentialdevice can only have three Z axis (Z1, 12, and 13) rather than the usual four. The tangential drivewill always be plugged into Z output number 4. All tangential devices are set up to have four motor rotations for one knife rotation. The drives areset up to operate at 1600 steps per revolution of the motor so that wiD be 6400 steps per kniferevolution.

Origin Sensor The origin sensor input is on the carriage board and only machines with carriage boards canoperate a tangential knife. This sensor input is only enabled when the tangential device is actuallyseeking the origin and is turned off at all other times. There is an indicator light on the edge of the carriage board that will show if the sensor is detected.Function 822 will enable the tangential sensor input so it can be manually tested.

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Function 24 - Set Knife Tool Height

OverviewThis function is an alternative to function 25 and is used specifically for setting the tool heights oftangential knife heads. Knife heads are two dimensional devices and it is often inconvenient touse the function 25 sensor. Oscillating knives in particular do not function well with the function 25sensor so function 24 should be used instead.

Valid EntryFunction 24 must specify the tool that it applies to so the entry should be FUNC 24.1, 24.2, etc.The function will only work if the specified tool is a tangential of oscillating knife head, otherwise itwill show "F24 not applicable."

FunctionalityThe function works by the operator jogging the head down such that the tip of the knife ispositioned at the desired cut depth. The recommended procedure is:

1. Lay a piece of paper on the cutting surface.2. Jog the knife head over the piece of paper.3. Enter function 24. 4. If using an oscillating knife with automatic controls the knife will come on automatically

otherwise turn it on manually.5. Adjust the air pressure to the desired knife frequency.6. Jog down until the knife tip punctures the paper. 7. Press . The head will return to the Z top.

The knife tool height will stored such that the set height will be Z=0 for the knife tool.

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Function 822 - Setting up Tangential KnivesThis function sets up the RPM and RPM/second parameters of tangential or oscillating knives.Also see function 24 for further tangential knife settings.

Once the settings are done you can choose to run a tangential knife cycle test.

Valid Entry

A tangential knife can be:

Standard tangential knife.“Pizza wheel” knife.Creasing wheel.Oscillating knife.

The tangential parameters used are the same for all these devices.

Tangential Maximum RPM

The tangential maximum RPM is the maximum revolutions per minute that the knife will rotate at.The knife is driven by a stepper motor with a gear ratio of four to one so every revolution of theknife will be four motor revolutions.

Generally maximum RPM should be set to 50. That will work in most applications and isconsidered medium speed. Setting it up to 75 RPM will run the knife quicker whereas 25 RPM willrun it slower.

Once the RPM and RPM/second is set the knife will seek its origin and should go to 0 degreeswhich is pointing along the positive X direction. The display will show:

If the knife is not aligned with the positive X axis select YES to set the knife. If it is then you can

select NO as setting the knife origin is not required. If YES use the and keys to jog

the knife clockwise and counter clockwise until it is aligned with the positive X direction. You can

use the key to slow it down.

Max RPM: 50

Set Knife? YES

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Once this is done the knife will go to +90 degrees and display:

Check that the knife is actually at +90 degrees which means that the knife blade is pointing in thepositive Y direction. If it is pointing in the positive Y direction simply press ENTER as that is thecorrect direction. If it is pointing in the negative Y direction it is rotating backwards and you mustselect NO. The knife will reset itself again and again you must check if it goes to 0 degrees, if notselect Set Knife again and reset it back to 0 degrees. Again it will go to +90 and ask you to confirmthat it is at +90. This time it should be.

Knife set up is complete.

Tangential Knife Cycle TestThis feature is offered at the end of the function 822:

If “YES” the knife will run 100 test cycles which consists of swinging the knife 360 degreesclockwise then360 degrees counterclockwise at full speed. After each cycle the tangential sensorwill be checked to see if the knife has lost position.

The knife should pass all 100 test cycles. If there is a failure it will show the failure count on thedisplay.

Knife at +90? YES

Test Knife? YES

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Tangential Knife Knowledge

Proper Direction of Tangential MotionIt is fairly easy to wire the tangential knife in reverse. In order to know if the knife is working in theright direction select the tangential knife as the current tool and select function 42.

Function 42 sets the spindle speed if the current tool is a spindle but it allows the operator to setthe knife angle if the current tool is a tangential knife. Set the angles for 90, 180, •]90, and 0 andcheck that the knife is actually positioned as shown below:

If the knife is operating backwards the 90 and •]90 directions will be reversed. Generally thismeans the motor wiring is reversed.

Motor SettingsThe tangential knife heads have a 34 frame sized motor and the oscillating knives will have amuch smaller 23 frame sized motor. Both run off the same drive and the settings are:

1600 steps per revolution5.5 Amps

The 23 frame motors on the oscillating knife will get quite hot, often to 100 degrees Celsius! Theyare inside an enclosure but if it’s open don’t touch the motors!

Skew Error CheckingThe tangential knife does not have a real time feedback loop so if the knife operates faster than itcan handle or the knife gets jammed the knife direction will become skewed. If it gets skewed theknife will cut off angle and if it’s off angle enough it will usually break the knife.

The A2MC will check and straighten out the knife every 50 knife “lifts”. The errors are recorded inthe activity log so if there is suspicion that there are skewing problems simply upload the activitylog and take a look. A properly operating tangential knife will have knife errors of less than 0.5degrees. If the error exceeds 1 degree then the A2MC will display an error 726 and show theactual skew error in degrees.

Other Knife ErrorsThere are three error codes associated with the tangential and oscillating knives:

Error 724 Knife Error ResetError 725 Knife Error SetupError 726 Knife Skew Error

Error 724 is caused when the knife cannot find the tangential sensor. The knife sensor is pluggedinto the carriage board. If this error is occurring then either the sensor is not working, the wiring iswrong, or the carriage board is either faulty or not connecting to the A2MC.

Error 725 is a set up error indicating that a tangential knife is set up where there is no tangential(W) axis.

Error 726 The knife skew error is already covered in the previous section.

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Setting Knife DepthTangential and oscillating knives require tool height settings just like spindle tools.Tangential knives can use function 25 and they can be automatically set exactly the same as arouter tool. The tangential knife will automatically rotate to 90 degrees for the automatic sensing ofthe knife tip. This is required to clear the waste board on some configurations of machines.

Oscillating knives are more problematic because their length changes when the oscillation is on.Do not try to use function 25 with an oscillating knife. The knife will break!

Use function 24 instead:! The surface of the table needs to be some sort of padded material such as foam

matting. This provides the knife space under the material.! Lay a piece of paper on the foam matting.! Enter Function 24. The oscillating knife will come on.! Lower the knife until it is punching holes in the paper. Press enter and the A2MC

will properly calculate the oscillating knife length.

Tangential Knife NC CodeTangential knives do not need a specific NC code or special post. The A2MC will calculate all therequired lifts and rotations on its own. Actually it better if specialized posts are not used as theycan mix everything up!

M3 and M5 will turn on and off the oscillating knife. S (spindle speed) commands are ignored.Tangential knives will ignore M3 and M5.

The tangential knife will automatically lift and rotate as required to manage a clean cuttingprocess. The height it lifts is the “most recent G0Z height”. For example:

G91G20 Absolute co-ordinates in mmG0X10Y10G0Z20 G0Z = 20mmG1Z0 Knife rotated to 0 Cut depth is 0G1X20 Cut from X=10 to X=20Y20 Lift to 20mm, rotate to 90, lower and cut to Y = 20X10 Lift to 20mm, rotate to 180, lower and cut to X = 10G0Z30 G0Z = 30mmG0X30Y20G1Z0 Knife rotated to 90 Cut depth is 0G1Y30 Cut from Y=10 to Y=20X20 Lift to 20mm, rotate to 0, lower and cut to X = 20

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Oscillating Knife Service & Maintenance

LubricationThe Oscillating Knife must be lubricated with 1 drop (1 drop = 1.5mm3 ) of high quality air toollubricant or robot oil per 4 working hours. Failure to do so will result in damage to the mechanism.

DO NOT over lubricate the mechanism as this will cause premature failure and clogging and willbe evidenced during repairs.

The use of automatic oilers IS NOT recommended as these can provide to much oil to the unit,which will cause premature failure.

Air SupplyMaximum flow pressure - 6 bar (600kPa or 85PSI). Exceeding this pressure will significantlyreduce the service life of the unit and void warranty.

Multicam machines are equipped with air filters to help provide clean dry air. However a waterseparator and air filter are highly recommended where customer’s compressor produces anexcessive amount of moisture and air particles. Provide air quality in accordance with DIN ISO8573-1, Quality Class 4.

Reducing the air supply will affect the number of strokes per minute. Generally you want to keepthe number of strokes as low as possible to reduce wear and tear. However reducing the numberof strokes will also mean a corresponding reduction in feed rate must be made.

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Pneumatic Oscillating Head Parts

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List of replacement parts for pneumatic Cylinder

Pos. QTY Part description Part No. Service

1 OSZ-110 OSZ110 cutting drive 1101100

1 2 Lubricating nipple M6x1 SW7 4000001

2 1 Cover 4000002 YES

3 1 Guide plate 4000003 YES

4 1 Counter sank bolt M4 x 10 4000004 YES

5 1 Locking screw M6 x 5 4000005 YES

6 1 Piston shaft 6 mm Ø6mm 4000006 YES

7 1 Spring, thin,long 4000007 YES

8 1 Spring,thick, short 4000008 YES

9 1 Piston ring D30 4000009 YES

10 1 Spacer ring 4 x 42 4000010 YES

11 1 Compressed air supply G ¼" 4000011

12 1 Ball 4000012 YES

13 1 Cylinder 4000013

14 1 Holding ring 4,1 x 1,6 4000014 YES

15 1 Piston ring D26 4000015 YES

16 1 O-Ring 25,12 x 1,78 4000101 YES

18 1 Piston 5000002

17 1 Housing 5000001

The following replacement parts should be examined within a period of approx. 1,000 operatinghours:

ball (4000012) piston ring (4000009)piston ring (4000015) spring (4000007)guide (4000003)shaft and cover must be checked; if there is a small difference, the cover (4000002) and shaft(4000006) must replaced.

Specifications of Oscillating Head

Overall Length 200mmWeight 1.05kgMaximum Air Pressure 600kPaNo. of strokes 9000/minLength of strokes 8mmConsumption of compressed air 120litres per minMaximum Tool capacity 6mmNoise level 77 dB(A)Vibration value 2m/s2

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