南通恒康数控机械股份有限公司

User Manual
CNCHK-9.2

Nantong Healthcare Machinery Co.,Ltd

Dingyan Town,Rugao City, Jiangsu Prov.,China

TEL:0086-513-88532596

FAX:0086-513-88532599

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Index
1. Introduction………………………………………………3

2. Machine construction……………………………………3

3. Installation………………………………………………5

4. Operation ………………………………………………15

5. Software…………………………………………………20

6. Repair & Maintenance…………………………………32

7. Electric drawing…………………………………………34

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Product Introduction
1) Application and Content
This manual apply to Healthcare Foam cutting machine-Continuous blade (CNCHK-9.2) for
users, including installation, operation, parameters setting and maintenance.

2) Specification
Weight (T) 5T CNC Type Industrial computer

Power 10KW,380V,50HZ Display LCD

Machine size (mm) 9200X4600X2400 Controller Motion control card

MAX. Foam size(mm) 2200X2200X1200 O.S XP2000 or above

Blade(mm) 11590x3.5x0.6 Programmable Axis X,Y,Z,φ

Speed 0～40 Min. Radius(mm) 10

Accuracy(mm) ±1 Self Test Installed

Min. Cutting size(mm) 5 Blade broken alarm Installed

Machine Construction & working principle

1) Machine construction
The machine includes: Main frame, working tables and control cabinet.

2) Working principle
The knife holder device can rotate ±180degree (between +180°and -180°) controlled by servo
system and also can move up and down, working together with the movement of X-axis (Machine
body moves back and forward) to get 2D contour cutting.
CNCHK-9.2 has one rotate table, it can do contour cutting for a whole block for the first time, and
cut again after turning the table 90degree to make a simple 3-D products.
CNCHK-9.2 also has 3 tables, one for loading, the middle one for cutting,and another one for
unloading. When the machine cuts, the tables do not move, the machine body drives the blade to
move back and forward together. During cutting, the operator can prepare another foam block on the
loading table, and when finish cutting, can move the tables together to transport the foam to the
unloading table, and continue the packages process, and then move another block from loading table
to unloading table for another cutting.

3) Layout of the machine

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Installation
1) Safety information during handling and installation
The staff must understand and master the safety information during handling, the most
important thing is to ensure the safety of the staff, and secondly is to ensure the machine is not
damaged.
a) Operation should follow the command, unified scheduling.

b) Prepare and pack the installation tools before and after installation/handling.

c) During machine handling, the staff need to protect each other and Strengthen mutual
supervision. Before using the forklift or crane to lift the machine, need to do the trial run
first and observe the force/balance, then lift/move the machine after confirming the safety
and reliability. When move the machine with the forklift/crane, please put something (such
as the wooden plate or cushion) between the forklift/crane and machine, to avoid any
damage to the paint.

d) Lower the machine slowly and smoothly, the staff should follow the unified command and
cooperate. When the machine is close to the ground, need to hold and adjust it if necessary
to ensure it’s put in the right place .

e) The smaller parts can be removed by hand, but please be careful and handle them gently, to
avoid any damage on the parts.

2) Handling instructions
a) Use the forklift to place the base plates (4pcs) for the machine frame to required position, as
below

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b) Use the forklift to move the machine frame to the required position, see below.
Note: Pay attention to the point/position for the forklift, do NOT lift other position.

c) Move the platform for conveyor tables wit forklift, as below.

Note: Pay attention to the guide rail, linear bearing/sliders and also the connecting part
for the cutting table (in the middle.)

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d) Move the cutting table (the middle one--rotate table with conveyor belt) with forklift.
Note: Please use 2 ropes to lift the table, to avoid any damage on this table, as below.
Be careful and pay attention to the conveyor belt and also the connecting part on the
bottom.

e) Move the loading and unloading table with the forklift, as below.
Note: Be careful and pay attention to the conveyor belt.

f) Move the smaller parts by the staff.

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3) Select the proper position for the machine

The size of the machine is 9200mm long, 5000mm wide and 3700mm high. The area for the
machine should be larger than the machine size, and must leave at least 1m wide as side walk for the
staff. The machine should be installed in a ventilated and dry area.

4) Installation
a) Firstly, confirm the installation position, place the 4 base plates for the machine frame.
After placing the base plates, to measure the diagonal line with the tape measure, make sure
the corner is 90degree.
Use the Laser infrared to calibre the base plates, to ensure the 2 guide rails are in the same
horizontal level, and the same as the horizontal line of the infrared.

b) Install the machine frame.

Put the machine frame on the slider/linear bearing of the base plates. Use the laser infrared
to adjust the level of the machine frame according to the level of guide rails. Then fix and
tighten the screws after vertical alignment.

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c) Install the struts for the press plates.

Put the strut in the correct position, fix the screws. Adjust the vertical alignment for the
struts with the infrared according to the vertical line of infrared, then tighten the screws. Fix
the motor and drive shaft. Then install the timing belt, the cover, drag chain and the electric
box.

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d) Install the tables

Including: loading table, cutting table, unloading table and the platform for the tables.
Put the platform for the tables on the foundation, adjust the horizontal level with infrared,
to ensure the level of 6 wheels are in the same level.

Install the connecting part /retainer plate (4pcs) on the metal frame for placing the
conveyor belt tables.

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Put the conveyor belt tables on the platform, and install the connecting parts.

As below.

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Note: When install the middle table (rotate table/cutting table), please pay attention to
the connecting parts of the rotation shaft.

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e) Install the roller table without power.

f) Connect the wire/cables inside the control cabinet, and also the wires/cables for the
motors.

5) Power supply requirement

3Phase, 4wires (380V,3Phase wire, one ground wire).
The wire should be at least 2.5mm².
The power should be no less than 10KW.

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6) Connect the power

The transformer converts the power from 380V to 200V.
380V should be connected with the power from the factory. (3 Phase wire, 1 ground wire)
220V should be connected with the machine. (3Phase wire, 1 ground wire)

Note: Before connecting the power to the machine (Control cabinet), please measure the
voltage between every 2 phase wires.
Pin 2 & 3, Pin 3 & 4 and also Pin 2 &4. The voltage must be around 200V.

7) Connect the air compressor

Install the air compressor, connect the power. Check idling and rotation direction before
connecting to the machine.
The compressed air should be around 4-5.5KG.

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Operation
1) Preparation before running the machine
a) Check the power. Make sure no lack of phase, no too high voltage nor too low. Before
connecting the machine with the power supply from the factory, please measure the
voltage between pin 2&3, pin 2&4 and pin 3&4 on the plug (This plug is connected to the
control cabinet, and another side of this cable is connected with 220V/200V on the
transformer.) as the picture below, the voltage should be around 220VAC/200V.

b) Adjust the air pressure. Check if the air compressor works well and if the air pressure is
normal, also the air tube from air compressor to the machine. The pressure for tension
the blade is about 4KG-5.5KG.

c) Connect the wires/cables. Check if any wire between computer and the display, mouse,
keyboard, motion control card get loose. Check all the cables/plugs//wires under the
machine frame. Also the plugs on the servo motors.

d) Mechanical part.
Check if the knife is installed properly. The knife should be on the wheels without twist,
and check the direction of the knife edge. The angle of the left and right knife holder
devices should be the same in the range between -180 degree and +180degree. The gap
between the knife and bearings should be properly.
Check if there is any dust on the tables, any dust on the table will affect the cutting
accuracy directly, even damage the conveyor belt.
The tension of the timing belt and pulley should be properly. If too loose, it will affect the
cutting accuracy obviously. If too tight, the timing belt will be damaged easily. Make sure
no dust between pulley and timing belt, especially the hard material such as the screws
and bolts, otherwise the timing belt will be easily damaged.

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2) Operation sequence

Power supply ON

Turn on power for air compressor Switch on the power for control cabinet

Turn on computer

Open Program

Click ‘RUN ALL’ and then go to cutting software interface

Control ON

Switch on valve to tension the knife

Open calibration window

Click Zero till the data of C axis becomes normal

Run knife

Move the knife

Start Cutting

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3) Control cabinet

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Note:

After you switch on the valve, please check if the wheel and knife is tensioned.

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4) Warning Plate
a) This machine has warning symbols attached on it as shown below to ensure proper and safe
operation.
These symbols are used on the machine to indicate points or instances of specific danger to
operating personnel.
Make sure to memorize these symbols and bring them to the attention of others as and when
necessary. Do not remove safety symbols from the machine.

Electric shock Rotating object warning Danger

b) This machine is provided with one red emergency stop button, located on the control panel.
This button is to press whenever an emergency situation arises, causing the machine to stop
immediately in order to protect the equipment and the operator. The machine needs to be
reset for restart.

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Software
1) Drawing software: CAD
The drawing software is secondary developed based on CAD, the operator needs to have
some knowledge of CAD graphic drawing skill. After making one drawing, change to Polyline
(Locate the cutting path. The direction of Polyline is the knife cutting path, the drawing must be
Polyline instead of Line, because when we create path, the software need to identify the direction
of Polyline, while Line has no direction.). Then create path and save the drawing. Select the
drawings which you need, and transfer to cutting software to start cutting.

2) Loading program/tool
a) RUN ALL: After creating path for the drawing, it will trasnfer to cutting software by this
command.

b) RUL SEL: In one drawing (after creating the path), we can select one single pattern and cut it.
This can be used when something abnormal happens occasionally. After the
machine recovers, select the pattern which is not finshied and then transfer to
cutting software to continue the cutting.

c) Creat P.: Create the path for the drawing which is drawn with Polyline, and this path will be
the knife path during cutting.

d) Cancel P.: Use this command to cancel the path when you find any mistake on creating it.
But after you use this command, you must exit the drawing software CAD, delete
the wrong memory and create the path again.

e) Setting: Parameter setting for creating path.

f) Preview: After drawing and creating the path, use this function to check if there is any
mistake; Or you can preview in the cutting software, use the command
‘Simulation’ to preview the cutting path, and simulation cutting speed is
adjustable.

g) Function: Some special functions for creating path.

h) About: Software version can be displayed.

Note: It’s better not to modify the created path. If necessary, please cancel the path first, save it
and exit, and then open the drawing again to create the new path.

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3) Cutting software
Interface

a) Prg.: Select the drawing with path from CAD, click ‘RUN ALL’ to transfer to cutting
software. The switch between cutting and drawing software can be done by the
command ‘Prg.’ in cutting software and ‘RUN ALL’ in CAD.

b) Sim.: This command can simulate the cutting path, it’s similar to ‘Preview’ in the cutting
software.

c) Break: When no break, this button turns gray and not available. When the limit switch of
X-Axis or Y-Axis is touched, or after click ‘Pau.’ and then ‘Stop’, the function of this
button can continue the cutting from the pause point. But need to clear the limit
and confirm the knife position, and also zero the knife to make sure the knife
angle is correct.

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d) Set.: All the parameters and some function can be set by this command.
Description will be listed below.

e) Cal.: Display the position of X-Axis, Y-Axis and those 4 servo motors of C-Axis. If the value
is difference from the real position, then need to calibrate.
Calibration Interface

Zero position, the left and right side knife holder device and the knife direction
should be as below, which means 180degree. Knife without twist.

After you confirm the real position of all the axis is correct, then click ‘Zeroing_C’, and
then Exit.
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f) Step: In ‘AUTO’mode, click ‘Step’, the machine will pause after running one step, and run
another step after clicking ‘step’ again. The machine will continue the cutting
after clicking ‘AUTO’.

g) Pau.: In ‘AUTO’ mode, the machine will pause after you click ‘Pau.’. Axis-X, Y, Z will pause,
but the blade will not stop running. The machine will continue the cutting after
you click ‘AUTO’.

h) AUTO: After zero the blade, move the foam block to the proper position, the machine
will cut automatically with this command.

i) Stop: Under ‘Jog’ condition, the machine will stop running if you click ‘Stop’. In AUTO
mode, Axis- X, Y, Z will stop working, and the blade will also stop running if click
‘Stop’. Cannot continue the cutting by clicking ‘AUTO’ directly. If you want to
continue the cutting, do not click ‘Stop’ directly, please click ‘Pau.’ and then click
‘Stop’, then can continue the cutting with the function of ‘Break’.

j) Roat_cx: In Manual mode, to adjust the angle of C-axis a little bit by using those 2 rotation
arrows together.

k) XY FAST: When move the blade up/down or move the machine frame left/right in Manual
mode, you can choose higher speed or lower speed with this command. When
this button turns gray, the function of ‘FAST move’ is not available, click the
button again, it turns black and means fast move. This function can be use
together with the command ‘Jog’. That’s to say, when use ‘Jog.’ and ‘XY FAST’, if
click the direction arrows, the blade and machine frame will move the required
distance with a faster speed.

l) Jog.: Click the button ‘Jog.’, it turn gray means the function is not available, click it again, it
turns black which means the function is enabled. Input the value you need. The
value means the distance that you move the knife or machine frame.
Note: After you use ‘Jog.’, it’s better to disable this function, and change to a
smaller value, in case of any accidents.

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m) Sharping_off: You can set the sharpening time, and also the time interval accordingly.
You can use AUTO mode for sharpening when the machine is working.
Note: When you use tooth knife, do not use the sharpen function. Sharpening is
only for knife without tooth.

n) Random Zero: Click this button, the default of zero position (180degree) will be the
current knife angle.
Note: No need to use this command during normal operation.

o) Straight.: Bevel function. This is seldom used during normal operation.

p) More details

1) For adjusting the cutting speed in the range of 20%-160%. Increase/ Decrease 20%
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when click the arrow once.

2) Direction arrows.
After zero, the blade will up/down by holding the up/down arrow and will stop once
release it; The machine frame will move forward and back by holding the left/right
arrow and will stop once release it.
If the function ‘Jog.’ is enabled, and also after zero, the machine will move the required
distance (the value you input after Jog.) after the blade rotates to the correct angle.
Also can use XY FAST at the same time.

3) Rotate the blade angle. The blade will rotate in clockwise or anti-clockwise direction by
these 2 arrow.

4) Run the blade. Left arrow is for reducing the blade speed; right one is for increasing
the speed.

q) Parameter settings

1) Cutting speed in Manual mode. Speed is faster if the value is bigger.

2) X Y C Pulse: These parameters determine the cutting accuracy. If X and Y axis is not

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accurate, need to adjust the X Y pulse. The value is inversely

proportional to the distance. NO need to change the value of C axis.
3) The parameters for Cutting speed in AUTO mode.

4) Set the bevel between arc & line, and arc & arc, and also line & line.
If we set the bevel between line & line to ‘2’, that’s to say, when the real bevel is
smaller than 2degree, the machine will cut smoothly without short stop .
If we set the bevel between acr & line to ‘10’, that’s to say, when the real bevel is
smaller than 10 degree, the machine will cut smoothly without short stop; but if it’s
bigger than 10degree, speed up/down and short stop will appear.
If we set the bevel between arc & arc to ‘30’, that’s to say, the machine will cut
smoothly without short stop when the real bevel is smaller than 30degree; but
bigger, speed up/down and short stop will appear.

5) This parameter is the ratio between fast move speed and normal speed. ‘1.28’ means
the fast move speed is 1.28 times the normal speed.

Note: Pulse setting and trial run

1) Check if all the rotation/transmission parts work smoothly without any block/jam.
If not smoothly, must power off to check and find out the problem. To resolve the
problem by adjust the gap between the parts and lubricate it. Then retry again.
Test if all the limit switches and travel switches work in good condition.

2) Set the X-Pulse

Use the command ‘Jog.’ to move the machine 1000mm manually, the measure the
real distance that the machine moves (for example 995mm), then you can calculate
the correct X-Pulse for the machine. The correct X-Pulse=The current X-Pulse (for
example: 0.00488) × the real distance (995mm)/ the value you input after Jog.
(1000mm), then it will be 0.00466.

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4) Motion control card

Installation instructions (850card or 8940A1 card) as below
Step 1

Step 2

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Step 3

Step 4

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Step 5

Step 6

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Step 7

Step 8

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Step 9

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Maintenance
No Description Picture Cycle

Clean the drag chain, wheels,

1 timing belt and also the ground Everyday

under the tables

Air pressure should be around

2 Everyday
4-5.5KG/cm3

Check if anything (dust/hard items)

3 Everyday
on the conveyor tables

After the blade is tensioned, rotate

the drive wheel by hand, check if

4 Everyday
the knife is in the middle of all the

wheels.

Rotate the drive wheel by hand,

5 check if there is any abnormal Everyday

noise, and if smoothly.

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Check these 4 twisted wheels of

6 each knife holder device, if the Everyday

wheels rotate smoothly and freely.

Drain the water from the air

7 regulator by pressing the bottom Every week

part up.

Lubricate guide rails and slider.

8 Every week
Also clean the dust/hard material.

Clean the dust proof foam of the

9 Every month
computer

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