MIRKA AutoChanger Communication Kit User Guide

: June 1, 2024
: MIRKA

Table of Contents

MIRKA AutoChanger Communication Kit
Product Information
Product Usage Instructions
Mirka AutoChanger
Technical Data
AutoChanger connection chart overview
Pneumatic settings
PROGRAMMING INSTRUCTIONS
OPERATOR INSTRUCTIONS
MAINTENANCE & TROUBLESHOOTING
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

MIRKA AutoChanger Communication Kit

MIRKA-AutoChanger-Communication-Kit-PRODUCT

Product Information

Specifications

Abrasive disc size: 77 mm & 150 mm
Abrasive disc capacity (per cassette): ~150 pcs (depending on abrasive type and grit size)
Abrasive change time: 10 s
Pneumatics:
- Fluid: Compressed Air, quality class [7:4:4] (ISO 8573-1)
- Compressed air supply connection (regulator not included): 0.2 – 0.25 MPa
- Recommended Magazine pressure (regulator included): 0.2 MPa
- Min. required air flow capacity: Supply air hose 10 mm (Push-in connector), Additional air hose 4 mm (Push-in connector)
Electrical Connections:
- Input voltage: 100–240 VAC
- Power supply: 24V DC at 5A
- Communication protocol: Ethernet/IP, Modbus TCP, Profinet RT/IRT
- Communication interface: IO-Link
Environmental:
- Ambient humidity: 20 ~ 90% RH (non-condensing)
- Storage temp.

Product Usage Instructions

Installation and Setup
To install the AutoChanger system, a qualified integrator with experience in automation and programming is required. Follow the instructions provided in the user manual and by the component manufacturer.

Camera Identification System
Implement a camera identification system to detect abrasive disc attachment and positioning on the sanding head. Ensure correct placement to avoid issues like folding or offsetting.

Pneumatic Settings
Maintain pressure balance between inlet and magazine pressure below 0.1 MPa for proper cylinder operation.

Programming Instructions

Programming Guidelines

Avoid pressing abrasive discs against bristles during pauses to prevent damage.
Utilize the three holes on the magazine’s top plate as coordinates for locating the center point easily.

Step 1:
Position AIROS over the magazine opening, with the pad/interface about 50 mm from the top. This is waypoint 1 with no pressure in the cylinder.

Frequently Asked Questions (FAQ)

Q: Can I install the AutoChanger system without professional help?
A: It is recommended to seek assistance from a qualified integrator to ensure safe and correct setup.
Q: What is the recommended air pressure for the system?
A: The compressed air supply connection should be maintained between 0.2 – 0.25 MPa.

The Mirka® AutoChanger is a revolutionary modular solution designed for the automated replacement of abrasive discs in various industrial sanding applications

Please read the full manual

Mirka AutoChanger

To install the AutoChanger system, the end customer should seek assistance from a qualified and experienced integrator. An understanding of automation and programming is required to setup the AutoChanger system safely and correctly.
In addition to the AutoChanger modules, it is recommended that the customer implement its own camera identification system. A camera identification system is needed to detect whether or not an abrasive disc has been attached to the sanding head. The camera system should also be able to identify whether the abrasive disc has been located correctly onto the interface or pad. Whether the abrasive disc has folded or is offset on the pad for example.
It is a responsibility of the integrator to carry out all installation and programming in accordance with the instructions in the user manual, as well as the instructions of the relevant component manufacturer. Mirka cannot provide additional support regarding installation and programming because of the differences in the final build of the various customers’ systems

Technical Data

$MIRKA-AutoChanger-Communication-Kit-FIG- $23$$

AutoChanger connection chart overview

$MIRKA-AutoChanger-Communication- Kit-FIG- $2$$

The simplified connection chart gives the integrator an overview of how the AutoChanger modules are supposed to be connected. $MIRKA-AutoChanger- Communication-Kit-FIG- $24$$

NOTE! *Included in the scope of delivery for a complete order of a minimum of one of each module. If one module is left out of the order this list will not be accurate.

Pneumatic settings

Important! The pressure differences between the inlet pressure and the magazine pressure should not be greater than 0.1MPa. If the pressure differences are > 0.1MPa, the cylinders will not operate properly.

PROGRAMMING INSTRUCTIONS

Programming guidelines

Avoid pressing the stack of abrasive discs against the bristles during extended pauses, as it can damage the bristles.
Utilize the three holes on the Magazine’s top plate as coordinates to locate the center point easily. These instructions provide general guidance

STEPS

Step 1:
Position AIROS over the magazine opening, with the pad/interface about 50 mm from the top. This is waypoint 1. No pressure in the cylinder.
Step 2:
AIROS descends through the bristles until the pad/interface reaches the bottom. This is waypoint 2. Cylinder pressure remains off.
Step 3:
Open the 5/3-valve to pressurize the magazine cylinder and wait at waypoint 2 for the abrasive stack to reach the pad. Wait for 1-2 seconds.
Step 4:
Program an x-motion for AIROS when paper reaches the pad to ensure engagement. There is a 2mm tolerance between the pad and magazine.
Step 5:
After x-motion, AIROS moves back to waypoint 1 while sending a pulse to reverse the cylinder down for 0.1s. The solenoid valve returns to the closed position to prevent pushing abrasives out. The AIROS now has an abrasive disc attached. To pick a new disc, start from step 1. Reduce waiting time in step 3 for faster disc changes.

Removing abrasive discs

Important note! To reach knifes closed position, follow Festo’s homing command. Before executing the homing command, remove the sliding plate from the Remover. You can reattach it after completing the homing command. Failing to remove the sliding plate during homing will prevent the knife from making contact during operation.

Step 1:
Center the AIROS orbit by pressing the pad against the bumper on the Remover, first on the right and then on the left. Use the profiled edge of the bumper for alignment. $MIRKA-AutoChanger-Communication-Kit-FIG- $10$$
Step 2:
Ensure the edge of the abrasive disc makes contact with the grooves on the bumper to prevent folding.
Step 3:
Center the orbit, fold the disc edge down, and position the AIROS pad parallel to the sliding plate. Ensure the knife is at position 1.
Step 4:
Press AIROS against the sliding plate, causing it to spring back about 10 mm. This is waypoint 2.
Important! When an interface is in use, approach the remover carefully at 20 degree angle.
Step 5:
Move AIROS up to the knife; the disc separates from the pad, and the knife position changes to squeeze the disc in place (waypoint 3).
Step 6:
Tilt AIROS backwards 30-40 degrees to release the outer edges of the disc (waypoint 4).
Step 7:
Move AIROS at an angle to release the bottom part of the disc (waypoint 5).
Step 8:
Change the knife position from closed to fully open to release the disc, use an air nozzle to remove any residue, and return the knife to removing position (depending on abrasive thickness). $MIRKA-AutoChanger-Communication-Kit-FIG- $17$$
Step 9:
Re-center the orbit and follow the “Removing abrasive discs” process to pick a new disc.

OPERATOR INSTRUCTIONS

It is the responsibility of the customer to train operators in the AutoChanger system and provide them with sufficiently extensive training materials before they are allowed to operate the system.

Changing Cartridges:
When the system gives a warning that the Magazine is almost empty it is recommended to change the cartridge.

Step 1:
Switch the manual control on the front of the Magazine to the “unlock” position. This action will automatically lower and unlock the cartridge.
Step 2:
Carefully slide out the old cartridge from the magazine.
Step 3:
Remove the top lid of the new cartridge.
Step 4:
Insert the new cartridge into the Magazine. (Velour side up)
Step 5:
Rotate the manual switch to the “lock” position. The Magazine base will automatically rise and secure the new cartridge in place.

MAINTENANCE & TROUBLESHOOTING

Maintenance:
During any kind of maintenance to the AutoChanger system it is very important that the whole robot cell is shut off, in order to NOT put any maintenance personnel at risk.
Condition check
At least once a month check the condition of all AutoChanger modules. Ensure that none of the linear bearings are seized or making excessive noise. Check bristles for wear. Ensure that none of the pneumatic hoses are damaged or loose.
Cleaning
Sand and dust should be cleaned from the Magazine and Remover using compressed air at least once a day to prevent the premature wear of moving components. It is also important to remove all dust on the micro switch in the Magazine to prevent it from sticking.
Lubrication
No additional lubrication should be applied to any of the AutoChanger modules.

Troubleshooting $MIRKA-AutoChanger-Communication-Kit-FIG- $25$$