Afm Afe

AccuForm 3Dx-T
Reference Guide
Version 1.3, June 2007
502 S. Vista Addison, IL 60101-4423 Phn(+1) 630-458-0008 Fax(+1) 630-458-0730

U.S.A. : http://www.aim-inc-usa.com Support@aim-inc-usa.com
Europe : http://www.aim-inc-europe.com Support@aim-inc-europe.com
In the U.S.A.: http://www.aim-inc-usa.com
Or in Europe: http://www.aim-inc-europe.com
Published by:
Automated Industrial Machinery, Inc.
502 S. Vista Addison, IL 60101 U.S.A.
All rights reserved. No part of this document may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or
computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without the prior written
consent of Automated Industrial Machinery, Inc., except for the inclusion of brief quotations in a review.
Copyright © 1992-2007 by Automated Industrial Machinery, Inc.
First Edition 1998
Printed in the United States of America by Automated Industrial Machinery, Inc., Addison, IL.
Trademarks
T CO/Session and Session/XL are trademarks of Trion Technologies Inc. Other product names are Trademarks of their respective companies.
Table of contents
Chapter 1
Safety . 1-1
Owners Responsibility . . . . .1-1
Lock -Out/Tag-Out .............. .1-1
Steps to Lockout/Tagout . . . .1-2
Machine Modification . . . . .1-3
........................................... .1-3
Safety Hardware and Software .1-3
Installation .......................... .1-6
Maintenance ....................... .1-6
Operators responsibilities . . . .1-7
Training .............................. .1-7
.1-7
.1-7
Clothing and Other Apparel ................................... .1-7
Personal Care ........................................................ .1-7
Tooling ................................................................... .1-7
Travel Limits .......................................................... .1-8
Running production ................................................ .1-8
WARNING ............................................................. .1-8
Subsystem Failure ................................................. .1-9
Pneumatics ............................................................ .1-9
Electrics ................................................................. .1-9
.1-9
Hydraulics.' .'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.' .1-9
Fire Prevention and Fighting ................................. .1-9
Electro-mechanical Failures and Overheating .1-9
Chapter 2
Description - Concept............................ . 2-1
The machine ................................ .2-1
Straightening unit ......................... .2-3
Feeding and Measuring Units. .2-4
Bending Unit ................................ .2-4
Control Cabinet ............................ .2-5
Buttons ........................................ .2-5
Indicators & Connectors . . . .2-6
Touch Screen Computer . . . .2-6
Looking Inside.............................. .2-8
Chapter 3
Installation ................ . 3-1
Machine Location. .3-1
AccuForm Modular 3DX-T i

Electrical Setup ................................................................................................................................................................. 3-1
Chapter 4
Adjustments * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * . 44
Straightening the wire ............................................................................................................. .4-1
Usage & adjustment instructions for the Anti-Torsion Device ANT-x. (Optional). .4-5
.4-5
Installing theANT-x on the AF-xDl CNC Bender..' .' .' .' .' .' .' .' .' .' .' .' .' .' .' .' .'
.4-6
Passing the wire through the ANT-x ........................................................................................
.4-6
Adjusting the pressure of the measuring roller........................................................................
.4-6
Adjusting the bender's home position ......................................................................................
.4-7
Adjusting the cutter limit switches ............................................................................................ .4-8
Adjusting the feeder belt ......................................................................................................... .4-9
Chapter 5
Operation ............................................ . 5-4
Feeding wire ............................ .5-4
Changing the bending tools. .5-2
Chapter 6
Bending Tools Defined ....................... . 6-4
Bending tool description . . .6-1
Standard Bending Tool Data .6-2
Chapter 7
Turntable Option ......................................................... . 7-1
Description-Concept........................................ .7-1
The Rotating Base .......................................... .7-2
The Guide Arm................................................ .7-2
The Fixed Body ............................................... .7-2
The Rotating Assembly ................................... .7-3
The Electric Motor ........................................... .7-3
The Gearbox ................................................... .7-4
Operation Of P270 Turntable .......................... .7-4
Adjusting Acceleration and Deceleration. .7-4
Service & Maintenance Schedule ... . .7-5
Inspection ....................................................... .7-5
Lubrication ...................................................... .7-5
ii AccuForm Modular 3DX-T
Chapter 8
Hydraulic System. 8-1
Chapter 9
Pneumatic System 9-1
Chapter 10
Tooling Catalog 10-1
Chapter 11
Maintenance 11-1
Chapter 12
Troubleshooting. 12-1
AccuForm Modular 3DX-T iii

Chapter 1
Safety
This section is included to address the safety hazards normally encountered with the
intended use and the foreseeable misuse of the AccuForm wire bending line. This
product was intended to be used by trained operators. These programmers run the part
programs to required specifications. While running the machine, the operators must
use their experience and training to make any necessary adjustments and improve the
efficiency of their programs.
This safety section describes common problems seen by AIM representatives with
suggestions for avoiding or dealing with the problems in a safe manner. However, this
information is not an exhaustive description of all of the possible misuses of the
machine nor is it a substitute for operator training, skill, and good judgment. AIM inc
does not accept any liability for operator error.
Owners Responsibility
The AccuForm CNC wire bender owner has several responsibilities regarding safety.
First, the owner must read this section of the manual and implement the safety
requirements described. Then the owner must be certain that the operators in the shop
are properly trained and are using the machine as it was intended to be used. The owner
must be certain that the operator assigned to run the AIM AccuForm machine is a AIM
trained operator.
The owners must ensure that the machine is setup in a way that it complies with all
local safety regulations. Anyone who works with machine in production or
maintenance must be trained to adhere to the local safety regulations. AIM provides
many safety mechanisms to aid in our customer's compliance with their local safety laws
and it is the owner's responsibility to make sure they are utilized.
The owner must establish proper procedures to prevent fires and provide approved fire
extinguishers to put out small fires. Of course, large fires must be extinguished by
professional fire fighters. As a safety precaution, many shops have regular fire drills so
that all employees know their responsibilities during an emergency situation.
Lock -Out/Tag-Out
The following is a procedure for lockout of energy sources that could cause
injury to personnel. All employees need to comply with a procedure that is in
accordance with local requirements and this example. AIM equipment needs to
be locked out to protect against accidental or inadvertent operation when such
operation of the equipment and/or circuitry could cause injury to personnel. AIM
recommends the strictest enforcement of this logout / tag out procedure
regardless of the situation.
1 -1
AccuForm Modular 3DX-T
PROPRIETARY AND CONFIDENTIAL: THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF AIM, INC.
ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE EXPRESS WRITTEN CONSENT OF AIM, INC IS STRICTLY PROHIBITED.
Figure 1.1: Lock-Out/Tag-Out
■ All equipment will be locked-out or tagged-out to protect against accidental or inadvertant

operation, when this operation could cause injury to personnel.
■ Do not attempt to operate any switch, valve or other energy isolating device where it is
locked or tagged-out
Steps to Lockout/Tagout
1. Notify all affected employees and customer that a lockout is required and the reason
therefore. The authorized employee shall identify the type and the magnitude of the energy that
the machine and/or equipment utilizes, understand the hazards of the energy, and know the
methods of how to control the energy lockout. 1,2
2. If the equipment is in operation, after obtaining approval, shut it down by the normal stopping
procedures. 1,2
3. Operate the switch, valve, or other energy isolating devices so that all energy sources
(electrical, mechanical, hydraulic, etc.) are disconnected or isolated from the equipment and/or
circuits. Stored energy, such as that in capacitors, springs, elevated machine members, rotating
flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc., must also be
dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down,
etc. 1,2
4. All affected employees are then required to lockout the energy devices with their individual
lock. 1,2
5. After insuring that no personnel are exposed and as a check on having disconnected the
energy sources, operate the push button or other normal operating controls to make certain the
equipment will not operate. In the event that electrical circuits have been locked out, insure that
the circuits are de- energized by applying an appropriate voltage tester that itself has been
tested on live circuits. Be sure to return all operating controls to the neutral position. 1,2
6. The equipment and/or circuits are now locked out. 1,2

1-2
Machine Modification
Modifications may cause safety hazards that may injure the operator and damage the
machine. The owner is fully responsible for any accidents resulting from unauthorized
modifications.
Safety Hardware and Software

If the owner or an operator modifies the hardware or software by removing, altering,
disabling, or tampering with any safety circuit, safety switch, or any safety operation
and then continues to operate the machine with those modifications, such operation is
extremely hazardous, and considered a misuse of the machine. If the owner or an
operator finds that such modifications have been made, that person must immediately
switch off the machine and prevent use of the machine until it has been repaired. The
owner must then contact a AIM service representative for assistance in restoring the
machine to safe operation.
In many locales, machine hardware or software modification to override safety protections
and continued operation of such a modified machine is illegal and punishable with a fine
and /or other legal action.
On the AFM-3DxT and AFE-3DxT machines the main safety hardware that arrives
with machine includes a safety gate, straightener covers, and various safety interlocks.
The safety gate arrives unassembled with an assembly drawing. It is the responsibility
of the owner to ensure the gate is installed in a manner that complies to local safety
codes. Regardless of the local safety code AIM safety interlocks should never be
disabled for any reason. Disabling the interlocks can result in serious and/or fatal
injuries. These interlocks should be inspected on a regular basis to verify their
functionality.
Figure 1.2 below shows an example of how the AFM/AFE 3D safety Gate should look
after assembly. It should be bolted to the floor and the safety switch needs to be
mounted on the door.
Figure 1.2: Overview of Safety Gate on AFM 3D machine
AccuForm Modular 3DX-T 1 -3
Figure
1.3 below
shows
the front
entrance
of the
safety
gate.
Figure 1.3: Front View Arm Safety Gate with Label
Figure 1.4 below shows the interlock switch for the 3D Safety Gate (Arm Gate Door).
The switch is designed to kill power to the portion of the machine responsible for any
motion. The switch has 2 contacts, one for the logic controller and the other that acts
as direct shutoff switch to bus (motion) power. The switch should be installed similarly
to Figure 1.4 and should also be tested before operating the machine. It is the owner's
responsibility to ensure this switch is mounted and functioning properly as part of the
install of the machine.
Figure 1.4: Safety Gate interlock Switch
As well as making sure the arm (Z-axis) is safe for production it is important to make
sure the feeder, straightener and turntable are all inspected as well. Figure 1.5 below
shows how the straightener wheels should be isolated to prevent injury. It is the
owner's responsibility to make sure these wheels are isolated to prevent injury. If you
would like assistance in guarding your feeder rollers don't hesitate to contact AIM for
help.
Figure 1.5: Straightener roller guarding Figure 1.6 below shows the feeder cover safety switch that is
mounted and calibrated at the factory. This mounting should not be modified. The function of the
switch should be tested regularly.
Figure 1.6: Feeder Cover Safety Switch
AccuForm Modular 3DX-T 1 -5
The mounting of the male switch is shown in Figure 1.7.
Figure 1.7: Male end of Feeder Cover Safety Switch
It strongly recommended to implement a guarding system to the payoff unit. The

turntable is a powerful machine and it is strongly suggested to add protection. If
assistance is needed don't hesitate to call AIM for support.
Installation
The owner is responsible for proper site preparation before the machine is installed as
described in the installation instructions. This location must not be subject to
uncontrolled cabinet temperatures or unfavorable work environmental conditions that
could cause electronic component failure.
If the owner decides later to move the machine from its installed location, AIM
recommends that the owner call AIM for assistance. If this is not possible, AIM urges
that the owner use a competent rigger with the necessary equipment to move the
machine to the desired location.
Maintenance
The owner must be certain that the shops maintenance personnel are trained.
This machine must not be serviced, repaired or maintained by unqualified and untrained
personnel.
If at any time the operator or owner determines that the electrical cabinet must be
opened, the power must be shut off to the machine in accordance with OSHA or other
regulatory agencies before the doors are opened.
The only exception to his rule is when the machine is being serviced for electrical
problems. Under those circumstances, only a competent electronics technician directed
by AIM technical support should perform the work.
See Chapter 12 for maintenance details.
Operators responsibilities
To avoid serious personal injury, damage to the machine, and unproductive down-time,
the operator must pay careful attention to safety precautions and proper maintenance of
the machine. CNC wire forming operation is often a dangerous task, so operators must
stay alert and be aware of potential hazards. Operators must also follow the safety
regulations of their shops.
Training
All operators must be trained AIM AccuForm CNC operators in order to operate the
AccuForm wire bending line, operators who are going to run the machine must be
trained by AIM before attempting to operate the machine. The operator should study
the supplied manual(s) and become familiar with the machine functions and safety
features. The manual should be kept at the machine for quick reference.
If training is conducted by the owner, the owner thereby assumes responsibility for
providing training on the safe operation of the machine, and should keep appropriate
training records.
While studying the manual, the operator should make special note of the caution and
warning messages in the manuals and all warning and instruction plates/decals on the
machine tool.
Clothing and Other Apparel

Operators should always wear eye protection and safety shoes while in the work area.
Safety glasses with side shields are recommended. The operator should not wear items
such as loose fitting clothing, watches, necklaces, rings and neckties that could become
caught in the moving parts of the machine. Long hair should be tied back and worn
under a hat, hairnet or tied in a bun.
Personal Care
Operators and maintenance people should also avoid frequent or prolonged skin contact
with oil and other hazardous chemicals/materials. Some operators wear gloves or use a
special hand cream to protect their hands from these chemicals.
For complete information about handling industrial chemicals used in forming,
cleaning and storage, refer to the international Control of Substances Hazardous to
Health (COSHH) materials or MSD sheets from the chemical suppliers.
Tooling
Operators should never modify tooling without authorization from AIM. If the
operator is unsure on how to program a specific wire form please consult AIM
technical support. If the owner decides to manufacturer there own tooling, AIM
should be contacted for drawings and recommendations for manufacturing. AIM is
not responsible for any tooling not made by AIM.
Operators must stow away all loose objects before starting the machine. Remember
AccuForm Value Line 1-7
that loose objects, such as wrenches and Allen keys, can become flying projectiles if not
removed from the table before the machine is started. Operators should also be aware of
protruding machine members (such as conduit, hoses, moving external components) when
working around the machine.
Travel Limits
Safety limit switches and interlocks provided for each machine must not be bypassed or
removed in order to obtain more travel or take short cuts. Serious damage to the machine
and personal injury to the operator may result from such actions. Use caution when an
attached part (table) to the Z-Axis of an AccuForm 3D wire bender is in operation.
Running production
Operators should always know the location of the Emergency Stop button on the electrical
cabinet. Operators should use caution when retrieving parts after they are formed. To
prevent injury, the wire form should be clear from any moving parts. In addition when
changing out tooling please disconnect the air and turn off the electricity to the machine.
Under no circumstances should the operator attempt to retrieve parts or clean the moving
components while the machine is in operation.
WARNING
When running part programs, operators should always follow these rules:
■ Never press the F1 run button without knowing exactly what the machine will do!
■ Never run the machine without homing it first.
■ Stand away while the machine is running a part program.
■ Be aware of situation(s) that may occur when and unattended machine is in operation.
I Operating the machine unattended is not considered good safety practice and, therefore, not
recommended.
The operator should work within reach of the Emergency Stop button and be able to observe
the operation of the bender. If the operator is running a part program and cannot reach the
Emergency Stop button or observe the bender, this is considered unattended operation of
the machine and presents possible safety hazards such as but not limited to the following:
■ Tool breakage may occur due to loosening of hardware.
■ If tool breakage does occur wire may be fed uncut.
■ Loss in production due to damaged tooling.
■ Hydraulic leaks may cause damage to components of the unit.
■ Electrical fires due to loose, broken wires or an introduction of unwanted fluids.
AIM will not be held responsible for any damage to machines, property or personnel from
unattended machine operation or operating the machine without the proper safety features
installed or bypassed. Warrantees may also be voided since unattended operation and
safety features that are disabled or not installed is considered misuse or improper use of the
machine. Running the machine without properly trained personnel and/or safety features is
done solely at the owners’s risk.
1 -8
Subsystem Failure
Maintenance personnel and trained operators need to understand the maintenance
requirements and possible problems associated with the AIM inc AccuForm wire
bender. They can become familiar with the subsystem maintenance requirements by
attending a AIM training class or reviewing the manual.
Pneumatics
Air cylinders on the machine need to be free of water and oil to operate at peak
efficiency. If excess water or air enters the system the cylinders and valves are subject to
failure.
Electrics
Clean AC source power, as defined in the ANSI/NFPA 79 standard, is essential to the
successful operation and continued reliability of the machine. Therefore, the machine
must be properly connected to its power source as described in detail in the Installation
Instructions. The machine must be attached to a dedicated, fused, and isolated line with
incoming power that matches the specified, factory-wired, power cabinet voltages, and
current requirements of the machine.
If the machine is not properly connected to its power source, there may be noise on the
line that will affect machine safety, performance, and the warranty. In addition, brown-out
conditions may occur in the shop, and the machine’s electrical components may fail and
require replacement.
Hydraulics
The hydraulic unit is an independent unit supplied with power for the electrical cabinet. To
assure the phases are connected properly check the rotation of the fan on top of the
hydraulic unit. If it is connected properly the rotation will match the arrow on the side of the
stack.
Fire Prevention and Fighting

There are some obvious causes of fires that should be avoided in all shops:
■ Storing or handling flammable materials near heat sources.
■ Failure to keep the work area clear of debris such as shop clothes, cartons, and other
shop supplies that could catch fire.
Electro-mechanical Failures and Overheating

It is also dangerous to leave a machine unattended since heavy machinery is subject to
electrical or mechanical component failure that could cause a fire. For example, a drive
motor might overheat or a bearing may fail and cause an overheating condition. The
feeder might stall causing a belt to slip and overheat the amplifier. Of course keeping the
work area free of debris and watching the machine during operation reduces the possibility
of a fire form these failures.
AccuForm Value Line 1-9
Chapter 2
Description-Concept
Figure 2.1 AccuForm Modular 3D-T
The machine
The AccuForm 3Dx is a Modular line of programmable CNC steel wire bending
machines that are capable of two and three dimensional bending of steel wire fed
directly from a spool. There are three models:
AccuForm 3D1-T for wire diameter 2.7 mm - 10 mm (0.106”-0.312”)
AccuForm 3D2-T for wire diameter 4.0 mm - 12 mm (0.157”-0.472”) and the
AccuForm 3D3-T for wire diameter 6.4 mm - 16 mm (0.250”-0.629”)
The Accu-Form 3Dx (Fig 2.1 ) in general consists of the following major
components:
1.1 The straightening unit.
1.2 The feeding unit.
1.3 The measuring unit.
2 -1
1.4 Computer
1.5 The bender arm rotating unit.
1.6 The Bender Unit

1.7 The Cutting Unit.
2-2 AccuForm Modular 3DX-T
H3 H2
2A | |
2.1
2.2 2.3
FIGURE 2.2 TWO PLANE STRAIGHTENER
Straightening unit
The two-plane straightening unit (Fig. 2.2) consists of two assemblies (2.1 and 2.3)
that are mounted on a 90 degree angle to each other. Each assembly consists of two
sets of freely rotating rollers: five lower rollers and four upper rollers (numbers may
vary depending on the model). The adjustor screws for the upper rollers of each
assembly are mounted on a steel bar that can be lifted, so that wire can be inserted
without having to readjust the unit. The upper rollers are individually adjusted by
tightening or loosening the bolts (2.4) located at the top of each assembly. The lower
rollers are stationary and they do not need adjustment.
When wire passes through the unit it is being pressed between the upper and lower
rollers and thus it is subject to plastic deformation. Due to this deformation in two
planes (one for each assembly) at 90 degrees to each other, the steel wire is
straightened. More details on the wire straightening procedure can be found in Chapter
3.
AccuForm Modular 3DX-T 2-3
FIGURE 2.3: FEEDING & MEASURING UNIT
Feeding and Measuring Units

The steel wire is “pulled” from the coil, through the straightening unit by the feeding
unit (Fig. 2.3). This unit consists of two sets of rollers: the two lower rollers (3.1) and
the two upper (3.2) rollers. All four rollers are grooved along the circumference on the
surface that comes in contact with the steel wire. The lower rollers are stationary and
the upper rollers can be moved along a vertical axis to the wire to allow insertion of the
steel wire as discussed later. Two pneumatic cylinders provide pressure that pushes the
upper rollers towards the lower ones and snug the wire between them. The pressure
can be adjusted for different wire diameters by a pressure relief valve located below the
unit. The feeding unit is driven by a brushless servo motor as discussed later.
The measuring unit (Fig. 2.3) is located to the right of the feeding unit. It consists of
two rollers: the lower (3.4), and the upper measuring roller (3.3), freely rotating but at
adjustable positions along a vertical axis to the steel wire. A pneumatic cylinder
provides the pressure that pushes both rollers towards the wire and snug the wire
between them. This measuring device also includes a hub, a rotary encoder and a
shaft-coupler that are discussed later.
Be sure not to exceed the pressure on the encoder over 30 psi. Excessive pressure will
cause inconsistent lengths.
Bending Unit
The bending unit (Fig. 2.4 ) consists of two bending pins (1a ,1b). Both the bending
pins can facilitate a hard pin, roller pin (for generation of radii), cutter tool or offset
pins for special configurations. The Center tool is referred to as the “Tool Cluster”
(2a). The Tool Cluster has many different radii, in turn the user can select what type or
radii they can bend around. The Cluster is mounted onto the turret shaft (2b). The
turret shaft pops up and down and is able to index four positions. Respectively, as the
shaft changes positions so does the tool cluster changing the radii configuration every
time.
The bender operates when wire arrives over the bending unit. The Turret “pops up”
2-4
Figure 2.4: Bending Unit
around the wire, when this happens the bending pin “pops up’ as well. The bending
pin (1a or 1b) proceeds to applies force on the wire around one of the pins on the Tool
cluster(2a). After the move is complete the Bending Pin (1a or 1b) offsets to allow the
wire to move forward and then retracts. If a bend angle is to the opposite direction of
the previous one, the bending pin retracts and the entire bending head assembly rotates
to position while the proper length of wire is fed. Once in position the bending pin
pops up and then the entire assembly rotates again to continue with the bending of the
wire. The bending pin’s up and down motion is driven by a pneumatic cylinder
connected to the pin and rotating with the entire bending head assembly. When the
bending has been completed, the side cutter slides and shears the wire, afterwards the
bending head returns to the “Zero position”. The bending unit is driven by a brushless
servo motor as discussed later.
Control Cabinet
The controls that operate the AccuForm 3D are the following:
The MAIN SWITCH which is located on the back of the Electrical Panel. By turning
the switch to the “ON” position we supply the machine with three-phase power.
The control unit doors cannot open with the main switch at the “ON” position.
NEVER BYPASS THIS SAFETY FEATURE!
Control Panel
START This green colored button starts the electric motor of the hydraulic unit and powers
up the servomotors.
EMERGENCY STOP This red colored “mushroom” button is located on the front panel to the right of the monitor.
When pressed, the power to the electric motor of the hydraulic unit and to the
servomotors is cut off and therefore stops all operations. This button should be used
only when the machine is idle. To stop the machine or execute any other command
during normal operation the keyboard must be used.
To resume operation of the machine after the switch is pressed we have to pull the switch out
and then press the START button.
CONTROL POWER A green colored LED located at the front of the control panel indicates that the servo motor
controller has power and is ready to operate.
ERROR A red colored LED located at the front of the control panel indicates that the servo motor
controller had an error and the motion stopped.
This LED usually goes on because the front feeder cover is open. To resume operation close the feeder
cover.
GREEN LIGHT This light is located on the right side of the control panel above the buttons. It serves as a visual
indicator that the servomotors and the electric motor of the hydraulic unit are powered up.
PIECES COUNTER This is a battery operated LCD up counter which counts the number of pieces the machine has
produced while running the current data file. It serves as a backup to the software program’s down
counter in case of power failure. It is supplied with a lithium battery that has a life expectancy of
about ten years.
Every time starting a new production, reset the counter.
Touch Screen Computer

Computer and Touch screen is one complete unit and has the CD-Rom drive and floppy located
on the right side of the unit. All of the connections are located on the back of the unit.
A view of the computers connections which are located along the back side of the computer.
A view of the computers CD-ROM drive along with the floppy drive located on the side of the computer.
Looking Inside...
FIGURE 2.5: LOOKING INSIDE...
2-8
The heavy metal body frame of the machine protects all the electrical, mechanical,
1 Modular body hydraulic, and pneumatic devices and provides steadiness for the proper operation of
frame the machine. It must be fastened to the ground by four 5/8-11 U.N.F. screws as
discussed in Chapter 3.
The positioning of the feeding unit rollers is controlled by a brushless servo motor with
1a. Feeding unit servo
high torque drive belts. As it will be discussed in the service chapter, it is recommended
motor &
that the belt be changed every 2-3 years, depending on the total working hours.
speed
reduction unit
The positioning of the Arm assembly is controlled by a brushless servo motor with a
1b. Arm’s Belt and precision gear attached at the face of the servo motor.
Servo
motor
The positioning of the bending head assembly is controlled by a brushless servo motor
with a right angle precision planetary gear head attached at the face of the servo motor.
1c., Bender’s servo
The output shaft of the gear head is linked to the bending head by a high torque drive
motor, gearbox and
belt with an S-Curve profile.
belt
There is no adjustment for the belt. The center distances of the bending head and the
drive are fixed and require no adjustment.
As it will be discussed in the service chapter, it is recommended that the belt be changed
every 2-3 years, depending on the total working hours.
The Turret shaft is driven by a brushless servo motor and is held in position by a four
1d. Turret Shaft, Motor position key (up position). When the Turret shaft is in the down position the servo
and motor is able to rotate the shaft to the next programmed position. After it goes to the
Cylinder programmed position the pneumatic cylinder sends the shaft to the up position
locking it in the keyway. When locked the Turret shaft can not turn in any direction,
allowing wire to be formed around the Tool Cluster mounted on the shaft.
This two plane straightener allows the wire to flow through the rollers and
2a. Two Plain be formed into a perfectly straight piece of wire so that it may be bend in
Straightener the correct fashion to obtain the desired part necessary to use.
Two pneumatic cylinders at the top of the Feeder unit serve as the pressure agents for
2b. Feeding unit’s the two upper rollers. The shaft extension of each cylinder is adjustable, so that when
pneumatic cylinders the cylinders are energized the upper rollers do not touch the lower rollers. Any
adjustments on the shafts are done when the cylinders are bolted on the blocks of the
upper rollers.
The measuring unit monitors the length of steel wire that is fed from the feeding unit.
2c. Measuring unit with This device consists of two rollers, a hub, and a rotary encoder. The encoder monitors
rotary the amount of wire fed thought the machine.
encoder
2d, 2e. Slip Ring
All the cables that transfer power and signals to the bender are connected
to a “Slip ring” which allows the “Z-axis” to rotate an unlimited amount of
revolutions. Also the hydraulic hoses that transfer pressures to the cutter
2f. Z-Axis Precision are routed though the “slip ring”. Access to this slip ring can be obtained
Gear by opening the side access door.
The Z-Axis Precision Gear allows the Z-Axis Motor to turn the arm in a
2g. Cutter hydraulic negative or positive direction based on degrees of movement. The arm
cylinder & limit switches can be rotated to any specific degree of direction with the input into smart
editor.
The cutter’s hydraulic cylinder is driven by the hydraulic unit and it is controlled by
the positioning controller. This is a double-acting cylinder and on the back of it there
2g. Bending head
are two proximity switches. These switches define the limits of the cylinder’s shaft
travel and inform the controller on the position of the cutter.
The bending head assembly is one of the most important units of the
machine. Its construction allows a maintenance-free operation. Two heavy
duty shielded tapered bearings provide protections against any operation
abuse.
2h. Hydraulic unit
This is the hydraulic unit’s reservoir which has to be filled with a premium grade fluid. We
recommend Mobil DTE 24 or Valvoline AW-ISO 32 hydraulic fluid to achieve the best
performance and extend the unit’s operating life. Extended specifications of the fluid that we
used can be found in Appendix A. Fluid must always cover the hydraulic pump inlet, which is
located inside the oil tank, to prevent air entrance. The fluid level side gauge indicates the
proper level ranges. The fluid level should be maintained so that it is always visible in the
sight gauge. This is of the utmost importance for the proper operation of the hydraulic unit. A
maximum temperature of 150° Fahrenheit (65.6° C) is considered safe for proper operation.
At higher temperatures, difficulty is often experienced in maintaining reliable and consistent
hydraulic control, component service life is reduced, hydraulic fluid deteriorates, and a
potential danger to operating personnel arises. For industrial machine applications at
pressures of up to 1500 psi and temperatures of up to 130° Fahrenheit a fluid viscosity of
150 SSU @100° Fahrenheit is permissible. For higher pressures and temperatures (with a
maximum of 150° Fahrenheit) a fluid viscosity in the range of 225 to 325 SSU @100°
Fahrenheit will provide maximum pump operating life. When using high viscosity fluids (325
SSU or above) a heater must be used to heat the oil to a minimum of 80° Fahrenheit before
start up. For cold start up applications at temperatures as low as 0° Fahrenheit, automatic
transmission fluid Type A will usually prove satisfactory.
It is of great importance to maintain the hydraulic fluid clean. In order to achieve the best possible filtration, the machine is
equipped with a Textron filtration system which removes water and solid contaminants to assure total system cleanliness.
The filter absorbs water, whose presence increases differential pressure and decreases flow. Such condition indicates to the
equipment operator, through a gauge, that the cartridge must be changed. The media inside the filter, when fully saturated
with water, swells shut, preventing further flow and causes the integral bypass valve to open until the element is changed.
The hydraulic unit is equipped with a 3-phase/460V AC electric motor. For further specifications please refer to Appendix
A. The junction box for the wiring of the hydraulic unit’s electric motor is located at the side of the motor. If servicing is
needed, only experienced personnel may do so.
DO NOT OPEN THIS BOX UNLESS POWER IS SHUT OFF. Always check the nameplate on the motor to determine
I proper wiring. If the plate or decal is missing, make inquires to the manufacturer.
Chapter 3
Installation
The manufacturer of AccuForm 3Dx does not bear any responsibilities if
the installation is performed by an unauthorized person. Also, the
manufacturer does not bear any responsibility if damage is done due to
improper handling of the machine or failure to follow installation procedure.
Your machine was shipped either by boat, train, or by truck. No matter what the case would be
we have to make sure that we inspect the machine before we start working with it and there is no
visual evidence of any damage. If you see any damage please document it immediately,
preferably take a picture and please submit to your freight contractor / insurer. Also Inform our
office immediately so that we can make sure that no further damage will be done and so that we
can guide you or provide you with any spare parts needed.
If your machine was shipped by sea, please clean all of the excess oil and grease that was
applied before shipment.
The following are some basic inspection points and rules:
1. Machine Ground & Isolation transformer
a. Machine Electrical Ground: Ground the machine on a single location. A large
ground terminal is provided inside the electrical cabinet.
b. Don’t introduce ground loops. Ground loops are created whenever a ground
reference is established at more than one location.
c. If ground is not available, use CE/CSA/UL Listed Ground rods next to installed
equipment.
d. Use heavy gauge ground conductors. Please consult your local electrical for wire
sizing and always use certified electricians to connect power of the machine. The
machine plate with ratings is located on the door of the electric cabinet.
e. If the machine is installed on a highly electrical-noisy environment, an isolation
transformer must be installed.
f. Do not share the power supply with an electric welder or electrical discharge
machine. When the servo amplifiers are placed near a high frequency oscillator,
install a noise filter on the input side of the power supply line. Use a noise
suppression filter to prevent noise generated by the power supply line. The filter also
reduces the amount of noise generated by the servo amplifiers that are transferred to
the power line. Install a noise filter on the power supply line if other peripheral
equipment are connected to the same line.
g. All grounds must be made to only one point in the system as mentioned above.
2. Check Machine Power cables.
a. Use properly sized cables. Please consult your local electrical for wire sizing and
always use certified electricians to connect power of the machine. The machine plate
with ratings is located on the door of the electric cabinet.
b. Check for poor connections to the power cables on both sides. At your disconnect
switch, (usually on the wall next to the machine) and inside the electrical Cabinet.
Make sure all wires connections are tight. Sometimes these connections are getting
loose because the copper is getting compressed. Tighten all screw terminals.
3. Check Cabinet wiring.
a. Screw terminals can get loose after about six months from their installation. We at
AIM, Inc are trying to install spring-clamp terminals in all of the electrical connections
but there are certain manufacturers that do not offer them. Disconnect power on the
machine and tighten all screw terminals.
b. Inspect for short circuits: Most common problem is on a multi-stranded wire where
one or more of the strands is not correctly inserted to the wire terminal. Our policy for
the inspection of this problem is very strict and we have not experienced this problem
since 1995 but it does not hurt to check.
c. On machines manufactured before 2003 we used a 60 pin flat cable from the back
of the computer to the front of the servo controller fan-out board. This cable has a
black jacket, which carries the shield, and it is connected to the FG (Frame Ground)
at the back of the computer using a screw ring terminal. We have seen cases that
users might remove the computer for servicing and then forget to reconnect the
shield ground.
4. Check Encoder Cables and Connectors.
a. The device that provides position feedback to the Servo controller is the encoder.
All of the servomotors have an encoder usually mounted inside the motor at the back
of its housing. In addition we use an external encoder for the wire feed length. We
also have to state that we never had a feeder encoder malfunction except one case
that a heavy tool accidentally hit the encoder (a hammer).
First we have to check if the encoder connectors are tight on both sides of the
encoder cables. All the motor encoders are connected on the servomotor side to the
servo - amplifiers except the feeder encoder unit, which is connected directly to the
servo controller fan-out board, using a DB15 style connector.
b. If these connectors look tight and we still have a problem then we check inside the
connectors for disconnected or shorting wires, usually on the axis that we have the
problem. This fault could only be from excessive pull force on the encoder cable. In
the past we have seen cases where someone is disassembling the feeder encoder
unit and let it hanging from the cable!
c. Check the encoder Coupler. This is pertinent to machines shipped prior to 2004.
The encoder coupler is “coupling” the encoder shaft with the measuring wheel shaft.
One has to examine the coupler very closely because it is very difficult to determine if
it is broken. It might be broken but NOT completely and this could cause positioning
errors.
Please refer to “Encoder Unit Maintenance.pdf” document for more details on the
Encoder.
5. Check Servo Motor Power Cables and Connectors.
a. The servo amplifiers and motors generate a large amount of electrical noise themselves
and improper grounding and shielding could cause feedback problems. Before the year 2001
the recommended from YASKAWA® motor power connection was that the shield of the motor
power cable was only grounded on the amplifier side. On years after 2001 and because noise
problems were introduced, along with the CE directives, YASKAWA® recommended that the
shield of the motor power cable has to be connected to the FG (Frame Ground) on both sides.
With the main power disconnected, open the power plug connectors, on the motor side,
and check if the shield is attached to the clamp of the MS connector. If the shield is not
connected we have to carefully splice the cable until we can see about 8 mm (3/8”) of the
shield, attach a thick (8 AWG) green wire using a screw terminal or a metallic clamp, and
connect this wire to the connector clamp or a screw on the servo motor. Make sure that we
have good electrical contact to the FG: If you connect this ground wire to one of the screws of
the motor most of the times we have to clean the metallic surface from the paint.
Electrical Setup
Electrical
DANGER: Please follow Electrical Safety Rules. Do not touch powered
cables, disconnect from source before you work and always wear isolation
gloves. Use approved electrical tools. Use professional and experienced
services
Remember: Safety first.
The machine must be connected to a 460 Volts AC /3-phase/50-60Hz OR 380 VAC /3-phase/50-
60Hz (for European models-unless different configuration has been ordered) fused switch
(disconnect) box. Check with the machine plate mounted on the electrical box, which defines the
electrical requirements.
Please consult your local electrician for appropriate wire size and fuses using the placard on
the machine. Check with the regulations of the electric code in your city / state / country
regarding power connections.
1. Pass the power cable on the top left of the Electrical cabinet box. Do not forget the ground!
The key(s) for the modules are in a plastic bag in the box containing tooling.
NOTE: To achieve maximum performance it is recommended to connect the power lines of the
AccuForm in separate lines than your welding equipment if present.
Figure 1. Feeder and Bender Module
Connecting the Turntable P270 to the Machine
1. Connect the Air hoses to the nipple on the machine cabinet.
2. Connect the 16 pin connector on to the machine cabinet door.
Hydraulic Setup
Very the level of the Hydraulic Tank, it should be filled at least ¾ of the gauge. If you need to refill
the tank use a premium grade fluid. We recommend Mobil DTE24 or Valvoline AW-ISO 32
hydraulic fluid.
Failure to use the proper fluid will cause damage to the hydraulic unit resulting in poor performance
and shortened operating life.
Figure 3. Parker-
Hydraulic
Unit Rotation
1. After connecting the machine to the electric service box and inspecting the oil tank level close
and lock all the cabinet doors. Turn on the wall disconnect switch and then turn on the power of the
machine with the main switch at the back door of the control cabinet. Observe the electric motor on
the hydraulic unit. Look for the "ARROW" label on the topside of the electric motor that defines the
rotation of the motor.
2. Observe the computer monitor. When the screen prompts for a Login password (make sure the
login name reads either AIM or Administrator) enter “chi” (without the quotes and press enter.
SmartEditor program should come up on the screen. By default the login for SmartEditor program
is enabled. On the bottom of the SmartEditor window you can see if the machine is Ready to start.
Chapter 4
Adjustments
Straightening the wire
Straightening steel wire with the use of a two plane straightening system requires just
logical thinking along with some elementary knowledge on steel wire behavior. We will
make an attempt to describe the easiest and simplest way to adjust the straightening
system. Ultimately, it will be the experience that the end user will attain through time
that will provide the best tool in accomplishing this task effortlessly.
Figure 4.1 Example of straightener setup
Figure 4.2
Two-Plane Straightener
The purpose of the two-plane straightener is to straighten the wire as it is pulled

through the machine. The straightener has three sections:
1. Horizontal Axis – Controls the “left and right” memory of the wire
2. Vertical Axis – controls the “up and down” memory of the wire
3. Anti – Torsion Device – controls the “twist” of the wire
Figure 4.1 is the vertical two-plane straightener. The principal is to deflect off of one roller onto
another giving the wire different direction. There are different size straighteners for different capacity
machines. The sizes are as follows:
- S1 Wire range (.080” - .312”)

- S2 Wire range (.125” - .500”)
- S3 Wire range (.250” - .625”)
The S1 and S2 straightener have two different size rollers (as shown in figure 4.1) to take care of all
the different wire diameters for that capacity.
On the S1 the larger rollers are used for .125” and above. The smaller ones are used for anything
below .148”. The S2 smaller rollers are for .312” and below.
Below are two examples of what adjustments need to be made dependent on the direction of the wire
as it is coming out of the machine. Use Figure 4.2 to assist in the examples.
Example #1
Problem: If the wire is going up towards the ceiling (away from the floor).
Corrective Action: Apply pressure on #4 forcing the wire down to #2 forcing it up to hi #5 deflecting it
back down (towards the floor). Be sure not to put too much pressure so it hits #3.
Example #2
Problem: The wire is going down towards the floor.
Corrective Action: Apply pressure on #5 forcing the wire to hit #3 deflecting it back up again.
The two examples above are the most common situations that occur. Be sure to only change one axis
at a time. Sometimes what you do on the horizontal axis will affect what happens on the vertical axis.
The Anti – Torsion device is used to counteract the “twist” in the coil. The device can be used on all
wire diameters sizes. Depending on how severe the torsion is it may not remove all the twist. If this
occurs and it affects the quality of your part, remove the coil and try a new one.
Figure 4.4 Straight Setup
The pressure of the upper rollers of the feeding unit must be checked and adjusted if
necessary. The pressure should be enough to pull the wire from the coil and through
the straightening unit, but neither excessive so that the wire develops flat spots nor
insufficient so that the feeding rollers spin when the FORWARD button is pressed.
Likewise the tension of the upper roller of the measuring unit should be enough to
push the wire against the lower roller, but not excessive so that the wire develops flat
spots or marks.
To check and adjust the pressure of the rollers of either the feeding or the measuring
unit please consult the appropriate sections.
When changing spools of wire with the same wire diameter, all of the adjustments for
all the units do not need to be repeated. However, it is recommended that you check to
see if the wire is straight or if it is being scarred and make appropriate adjustments if
necessary.
4-4
Figure 4.5 Antitorsion Concept
Usage&adjustment instructions for the

Anti-Torsion Device ANT-x. (Optional)
In the majority of the wire forming we notice a tendency of the wire to rotate on its
own axis. This is caused mainly by the impurities of the steel and the way that the wire
is processed. When the steel wire passes through a die while on the drawing machine,
the diameter changes according to the diameter of the die. It is very rare that the
eccentricity of the wire is perfect due to the reason that the friction involved on the
drawing process is very large which of ‘course causes the wear of the die. The ware of
the die is never eccentric because the wire composition is never equally distributed to
the material, causing a change on the diameter and the eccentricity of the wire. That
change on the dimensional properties causes the rotation of the wire when we use a
roller feeding mechanism which results to a distorted part. In other means our parts do
not lay perfectly “flat” on a flat surface.
In most cases the wire tends to rotate only in one direction. These are the cases that we
can use the Anti-Torsion device in order to counterbalance the effect. And we say
“counterbalance” because a simple way to overcome the problem of the wire turning is
to force it to turn to the opposite direction, “balancing” the two forces thus resulting a
“straight” feed.
The theory behind the Anti-Torsion device is very simple. Take a bolt with a nut and
hold just the nut. Now try to push the bolt through the nut (it takes a large force...).
What is going to happen?: The bolt will turn while moving towards the direction that
we are pushing. The opposite will happen if we try to pull the bolt or if we use a left
threaded nut.
The same principal stands for our Anti-Torsion device. We adjust the angle that the
wire passes through the V-grooved rollers accomplishing the rotation of the wire and
counterbalancing the force that makes the wire rotate the other way.
Installing the ANT-xonthe AF-xD1 CNC Bender...
In order to install the ANT-x on our CNC bender we have to move the horizontal
plane straightener about ten inches to the left. When we dismount the straightener we
can see that we have two extra holes on the C-channel. The ANT-x mounts in between
the two straighteners with two ½-13 x1½" bolts.
Passing the wire through the ANT-x

The ANT-x is a small straightener as well. To begin the adjustments we pass the wire
through the rollers so that when we push or pull the wire it forces the rollers to turn.
Then, depending on the wire diameter and composite we press the rollers towards the
wire by adjusting the top fully threaded 5/16-18 (item #20 on the assembly drawing)
so that we “snug” the wire without forcing an excessive bend. Notice that the rollers
have to be parallel with the wire.
Then we adjust the height of the rollers the same way as we adjust a plain straightener
(described earlier on the manual).
When we finish straightening the wire we enter a program on the computer that has a
feed of approximately four inches, a ninety (90) degrees bend and a feed of fourteen
inches. When we run the program we have to observe the feed after the bend. This
way we will be able to tell the direction that the wire rotates.
If the wire rotates to the right, (the part tends to go inside the machine), we adjust the
top rollers to the opposite direction (left). Accordingly we have to turn the top rollers
to the right if the wire tends to rotate to the left (the part tends to go outside the
machine). We can turn the top rollers by adjusting the position of the threaded rod on
the top of the ANT-x (item #5) and then securing it with the two hex jam nuts.
Adjusting the ANT-x is a “cut and try” procedure and requires some experience. We
would have to write a huge book if we would have to give analytical data regarding
angle and pressure adjustments because of the wide variety of wire properties and
diameters.
Adjusting the pressure of the measuring roller

Proper operation of the measuring unit (5.9) depends on the pressure adjustment of the
cylinder that operates the measuring rollers. The pressure adjustment valve is located
on the front panel just below the feeder unit. By turning this knob clockwise we
increase the pressure on the measuring rollers and therefore the pressure that the rollers
exert on the wire. By turning this knob counterclockwise we decrease the pressure.
The pressure on the rollers should be adequate to secure the wire between them SO
THAT WE CANNOT TURN THE ROLLERS BY HAND. If the tension is insufficient
the unit will not function properly and the measurements of the wire lengths, that
are being fed will not be accurate. If the tension is excessive, the wire will either be
scarred or it will not be straight.
4-6
Figure 4.6 Program “HomeAdj”
Adjusting the bender's home position

The bender’s home position is always referenced from the home proximity switch
located on the bender channel. When we issue a “home” command from the keyboard,
the bender rotates clockwise until it reaches the home proximity switch and then turns
counterclockwise until the position reaches the number of degrees stated at the Home
Offset parameter. If the position of the bender is further than the home proximity
switch then the bender will travel to the right limit and then home.
The easiest way to adjust the Benders Home position is with the program on figure ,
above. This program will produce two right angle pieces: one with a right bend and
one with a left bend. We have to straighten the wire and then run this program
comparing the two angles. If they are both equal then the home position is good.
Then we press <Ctrl> <F10> to get to the Servo Parameters window. This window
is password protected and should be accessed only by authorized personnel. The cursor
defaults at the Bender Offset position. We press <Ctrl> <F1> and the machine
homes and then produces two parts. You have to remember which one is made with
right-hand bend (in our example the first one) and which one is made with left-hand
bend. We set these parts one on top of the other and we check if the angles are the
same. If they are not the same then we know that we have to adjust the home offset.
Let us say that the part with the right-hand bend is about 100 degrees and the part
with the left-hand bend is about 80 degrees. This means that the bender home
position is located further to the right of the zero position and that results to a larger
right-bend. The best way to figure out our difference is to measure the two angles,
subtract them and divide the difference by two.
Therefore, in our example, we have to adjust our home position to be about 10
degrees towards the left. We locate the cursor on the Benders Home Offset line, we
press <Del> in order to delete the old value and we enter the new one. If in our
example the old value was -28 degrees, our new value will be -38 degrees. This value
is calculated as follows:
Original value = -28
Angle Difference between Left and Right Angle = 100 - 80 = 20
Angle Difference between Home and Bend = 20 / 2 = 10
Direction multiplier = -1
NOTE: use -1 when the right-hand Bend is larger than the left-hand Bend use 1 when
the left-hand Bend is larger than the right-hand Bend
New Home Offset Value = Original value + (Direction multiplier * Angle Difference
between Home and Bend), where:
New Home Offset Value = -28 + (-1 * 10) = -28 -10 = -38 degrees
For further details regarding the program please read the parameters section at the
SmartEditor chapter
Chapter 5
Operation
To properly operate the AccuForm 3D-T CNC wire bender and produce one particular
product you must proceed with the following general guideline:
1. Choose the appropriate tooling and make any necessary changes.
2. Turn the power on with the main switch located on the back door of the control
cabinet.
3. Press the Green Button above the touch screen and start the motors.
4. Feed wire through the machine and straighten it.
5. Setup tool file or load saved tool file.
6. Enter the positioning data or load a data file from the memory.
7. Start production and terminate the process when desired.
8. Shut down Windows and turn the power off with the main switch located
on the back door of the feeder module.
Refer to appropriate sections for instructions on how to perform each step.
Feeding wire
The Feeder Module drives the wire to the bender to be formed. The feeder is driven
by a servo motor and clamping pressure on the wire is applied by pneumatic cylinders. The feeder rollers are
used to drive the wire to the bender. The clamping force of the feeder rollers are controlled by pneumatic
cylinders which can be adjusted by the pressure gauge above the unit. A variety of parts and wire diameters
require different pressures on the feeder.
Chapter 6
Bending Tools Defined
Tooling Files
The tool files are used to notify SmartEditor of what tools are installed on the machine. Without the tool files
many of the options and compensations can not be used from SmartEditor. The following will cover how to
load/save and configure the tooling on an Accuform CNC Wire Bender. For further information on tool files
reference the SmartEditor and Machine Reference Manual(s).
Identifying Tool files

The tool file for each individual tool is etched on the bottom of the tool cluster. The same number is also the
part number for that tool.
Loading Tool Files

1. In order to load tool files (turret files) access the Parameters Window (F5). The Parameters Window
(Bender Geometry Tab) has all the values for the tools.
FIGURE 2.9 BENDER GEOMETRY TAB
2. Click on Load Turret File (Figure 3.0)

3. Highlight the tool file etched on the bottom of the cluster installed on the machine and click open.
4. Save Parameters as Default and click OK.
FIGURE 3.0 LOAD PARAMETER WINDOW
Configure Tool Files –Zero Bender

The following steps are used to configure the machine to run at peak efficiency.
1. Program SmartEditor (Figure 3.1) to make a left and right hand bend with the same radius. The cut flag (C)
is inserted between the two bends to compare them after they are bent.
FIGURE 3.1 LEFT AND RIGHT BEND
2. Compare the two angles. If the right one (positive) is bent more than the left one (negative) than the bender
is positive of the Zero position.
3. Access the Parameter screen and go to the Servo Tab. The bender homes by moving positive till it hit the
“home switch” and moves back the amount of degrees specified in the Bender Home Offset (Figure 3.2). For
example: If the positive angle is bent more than the negative the Bender Home Offset value needs to be
increased.
FIGURE 3.2 BENDER HOME OFFSET
4. After the value is change click the button “Home with New Values”. This action will re-home the bender
with the new Bender Home Offset value.
5. Run the angle program and compare the angles. Repeat the process till the two angles are equal.
6. Save Parameters as Default and resave the tool file loaded on the machine. The Bender Home Offset value
is carried with the tool file. So next time the tool file is loaded the above operation is not required.
The following steps are used to calibrate the tool file with the diameter wire and tensile of the material. Before
starting this calibration access the Bender Geometry tab (Figure 2.9) and confirm the Wire diameter (Line 2)
and the Wire Hardness (Line 3). Change the values if necessary.
1. Program a positive 90 degree bend with tools P1, T1.
2. Run the part and measure the angle bent.
3. Type the angle measured on line 13.
FIGURE 3.3 ANGLE COMPENSATION
4. When this value is increased the bender will bend less and when the value is decreased the bender will bend
more.
5. Repeat the process till a 90 degree bend is made.
6. Continue the calibration for the next tool configuration (P1, T2 then P1, T3 etc.)
7. After all of the calibrations are complete, resave the tool file and Save Parameters as Default.
8. Once this process is finished and saved next time the file is loaded the only compensation that needs to
change is the Wire Hardness. For example: If the wire form is under bent, increase the wire hardness.
Chapter 7
Turntable Option
Description-Concept
The P270 is a fully automatic powered payoff unit (turntable) that was specifically designed
to compliment the and ACCU-FORM CNC programmable steel wire benders. The P270's
function is to hold coils (spools) of steel wire and assist the CNC benders with the feeding of
the wire. The turntable accommodates the speeds demanded by and ACCU-FORM allowing
simultaneous operation and effortless feeding of steel wire. The P270 operates at variable
speeds with extremely fast response time to accelerations / decelerations. It is driven by a
gearbox that is attached to an electric motor whose speed is controlled by a transistorized
inverter. The inverter is regulated by a dancer arm. The P270 consists of the following (see
Figure 8.1):
■ The rotating base where the coil rests
■The fixed body frame.
Turntable P270-x
Figure 8.1
The Rotating Base
The rotating base consists of a round frame with four axles attached in an assembly that
resembles a cartwheel. Each axle is equipped with a vertical arm whose position is
adjustable along the axle. This way the four arms can be placed up against the inside of
the coil (spool) keeping it stationary and secure. The rotating base is attached to a
rotating assembly that is inside the fixed body frame.
Figure
8.2
Turntable P270-x Top View
The Guide Arm

There is one arm that guide the wire as it de-reels from the spool into the Straightening
Unit of the ACCU-FORM CNC wire bender. This arm is a dancer arm that sways
forwards and backwards. It is attached to one end of a rotating shaft that is affixed to a
plate at the middle of the left side of the turntable. The other end of the rotating shaft
is connected through a flexible coupler to a radius block, which in turn is measured by
a analog proximity, the distance is sent to the transistorized inverter that serves as the
main controller of the turntable. The Dancer arm uses air pressure to adjust for
different tension, so that the arm can move back to its idle position. On the plate in
either side of the dancer arm, there are two proxies, the START and STOP, whose
function are to provide, along with the analog proximity, reference points in
controlling the output of the inverter and therefore the speed of the turntable. One
pulley is attached at the arm, through which the wire is passed. There are two
more pulleys around the side of the turntable to guide the wire into the machine.
The Fixed Body

The fixed body of the T270 turntable (see Figure 8.3) contains the electric motor (#2)
and its power brake (#1), the gearbox (#4), and the turning assembly (#6). They are
all mounted on the bottom base of the unit. The rotating assembly includes a sprocket
around which the chain that connects the assembly to the gearbox wraps, and a greaser
for a simple and clean method of lubricating the rotating assembly. The gearbox and the
electric motor that is directly attached to the input shaft of the gearbox are mounted on
a base whose position can be adjusted. By moving the gearbox, adjust the tension of
the chain that wraps around the sprocket on the output shaft of the gearbox and the
sprocket of the rotating assembly. It is very critical that the chain remains tight and does
not sag. For proper operation of the turntable, full rotating power must transfer from
the gearbox to the rotating assembly. Therefore, periodic inspection of the chain is
necessary, especially during the first six months of operation. To adjust the tension of
the chain, loosen the four mounting bolts (#5) that hold the plate (#3) on which the
gearbox sits on. Pull the plate towards the edge of the base by tightening and loosening
the two screws that touch against the side of the plate. Then, tighten the four mounting
screws of the plate.
Figure 8.3 Turntable P270-x Adjusting the chain
The Rotating Assembly

The rotating assembly requires no adjustments and should never be tampered with.
However, it should be lubricated once every month. The recommended lubricant is
synthetic grease with Teflon, NLGI #2. To properly lubricate the assembly, clean the
tip of the Alemite fitting and apply the grease gun. Use 5 to 6 full strokes. The chain
that connects the rotating assembly with the gearbox should also be greased once every
month. Use any industrial synthetic grease.
The Electric Motor

The electric motor is a 5 HP High Efficiency electric motor. It is a ball bearing
motor and the bearings have been given initial lubrication at the factory. The motor is
pre-greased normally with Shell Oil Company's "Dolium R". Several equivalent
greases, which are compatible with the factory-furnished grease, include Chevron Oil's
"SRI No. 2" and Texaco Inc.'s "Premium RB". The lubrication intervals listed in the
Maintenance & Service Schedule are suggested as a guide for long operating life. To
properly lubricate the motor, clean the tip of the Alemite fitting and apply the grease
gun. Use 1 to 2 full strokes. Over-greasing bearings can cause premature bearing
failure.
CAUTION: Keep grease clean. Lubricate motor at standstill. Do not mix petroleum
grease and silicone grease in motor bearings.
The Gearbox
The gearbox is a Worm Gear Speed Reducer. The Maintenance & Service Schedule
indicates the type and viscosity of the recommended lubricant for this particular speed
reducer. It is important to use the proper type of oil since many oils are not suitable for
the lubrication of worm gears. Different types of gears require different lubricants. The
lubricant must remain free from oxidation and contamination by water or debris, since
only a very thin film of oil stands between efficient operation and failure. To ensure
long service life, the speed reducer should be periodically drained (preferably while
warm) and refilled to the proper level with recommended gear oil. The recommended
lubricant is a synthetic lubricant that allows extended lubrication intervals because of its
increased resistance to thermal and oxidation degradation. Under normal environmental
conditions, oil changes are suggested after the first 1500 hours of operation, and
thereafter at regular intervals of 5000 hours. Periodic inspection of all mounting bolts is
also recommended.
CAUTION: Speed reducers must be lubricated more frequently when operated at high
ambient or operating temperatures, in unusually contaminated environments, or with high
loads.
Operation Of P270 Turntable

When the wire is fed to the ACCU-FORM CNC wire bender, as it comes off the coil
(spool) it passes through the pulleys on the arms. Originally, the dancer arm is
resting backwards at an angle against a stopper. The START proximity sensor is
sensing the dancing arm and disables any motion. As the Feeder Unit starts pulling
the wire, the arm is pulled forwards disabling the START proximity switch, thus
commencing the rotation of the turntable. The wire is pulled at variable rates and
therefore the dancer arm changes positions relative to these rates.
The analog proximity switch measures a small radius block coupled to the dancer arm,
as the dancer arm changes positions the speed changes. The analog proximity is
connected to the transistorized inverter providing a frequency reference input signal. As
the variable resistor changes, the input of the inverter varies regulating the output
frequency signal. The inverter is connected to an electric motor whose speed is
controlled by the output of the inverter. As the output frequency signal of the inverter
varies, so does the speed of the motor.
The output shaft of the motor is connected to a gearbox whose output shaft is
connected, with a chain, to the rotating assembly upon which the rotating frame rests.
As the speed of the motor varies, so does the speed of the rotating assembly and
rotating frame. Therefore, the rotation of the frame is relative to the rate that the wire is
being pulled. If the wire gets tangled or there is a problem with the turntable the dancer
arm is pulled to the forward most position triggering the STOP switch that dictates the
turntable and the bending machine to stop. When there is no demand for wire, the
dancer arm springs back to the backward most position (rest) disabling the START
switch and therefore, stopping any rotation.
Adjusting Acceleration and Deceleration.

Please consult the manual attached, in order to adjust the acceleration or deceleration of
the drive.
If the turntable is bought with one of our CNC steel wire benders then the controls of
it are in an electrical connection box is mounted on the backside of the turntable.
Service&Maintenance Schedule
Inspection
Service / Suggested
Unit Description
Maintenance Interval
Gearbox Check mounting bolts of gearbox and plate

Periodic
Inspection Check to see if the chain is tight and if
Chain
Inspection necessary move the gearbox
For detailed information on inspection,

Controller servicing, and maintenance refer to the end of the
controller section
Lubrication
Service / Unit Suggested Interval Recommended Lubricant (or
Maintenance equivalent)
Lubrication Electric Hours of Operation Per Shell Oil Co.
Motor Year "Dolium R"
5000 hours 5 years
Continuous Normal 2 years

Application
Seasonal Service Motor is 1 year (beginning of

idle for 6 months or more season)
Continuous high ambient, 6 months

dirty or moist locations, or
high vibrations
Gearbox First 1500 hours of Mobil Oil
operation Co.SHC 634
Synthetic
Every 5000 hours of

operation
Rotating Assembly Every month Synthetic
Grease with
Teflon, NLGI
#2
8-5
Chain Any industrial
grease
Chapter 8
pter 11
Hydraulic System
The following drawings are inserted for your convenience and for your own use. You are
not allowed to manufacture any of these components unless they are made for your own
use.
Chapter 9
Pneumatic System
The following drawings are inserted for your convenience and for your own use. You are
not allowed to manufacture any of these components unless they are made for your own
use.
Chapter 10
Tool Catalog
The following drawings are inserted for your convenience and for your own use. You are not allowed to manufacture
any of these components unless they are made for your own use.
This page was intentionally left blank
Chapter 11
Maintenance
The machine's design and fabrication guaranties a simple and easy maintenance. The
instructions below have to be followed to achieve the maximum operating life. They
cover the entire AccuForm 3D line.
The Planetary Gearbox used for the Bender and the Arm Servo is sealed.
Component Type of inspection Interval Corrective Action Number

1. Physical Damage Remove gouge or burr with
40 Hours fine sandpaper
Turret Shaft/ 2. Surface Corrosion Remove corrosion with fine
Bender Head sandpaper
3. Proper Lubrication Clean off old oil and dirt and
apply light oil (Spline Shaft AFT2-BC-00
4. Missing teeth and tears 480 Hrs Oil)
on belts
Cutter Cylinder 1. Leaks on cutter housing Replace O-Rings/ call AIM
for support
2. Surface Damage on 1. Remove foreign
cutter slide 160 Hrs material AFT2-CC-00
2. Cutters may cause
rubbing, check width
of cutters
Encoder 1. Shaft Concentricity Replace Shaft

2. Groove on the shaft If encoder shaft is loose or
3. Bearings had a hard spot replace ENC-00-V4
4. Coupler Damage (if bearings
applicable) 480 Hrs Replace
5. Loose Coupler (if Tighten screws
applicable)
Feeder 1. Missing teeth and tears
on belts 480 Hrs FD10-00
2. Damaged Bearings
Computer 1. Wipe down screen Spray glass cleaner onto
2. Lightly blow out dust Daily rag, then wipe down screen
Machine Fans 1. Inspect filters 160 Hrs Wash filter or replace
Z- Axis 1. No Lubrication in container Yearly Add new lubrication grease

Lubrication
Feeder Pulley’s and belt replacement guide
1.Release two screws

located on the both
sides of the idler
bracket
2.Remove idler
retainer bracket.
PROPRIETARY AND CONFIDENTIAL: THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF AIM, INC. Note: If any problems
please call Aim
5. Unscrew and remove
all of the washers
holding down the
pulleys.
6. Remove belt.
NOTE: If any problems

please call Aim Technical
Support.
9. Using existing holes
and screws, mount new
idler support bracket.
Make sure that the
bracket is squared with
the front face of the
feeder upper plate.
Use thread locker #242

(blue) to tight screws!
10.Install new idler

bracket.
Do not tighten screws
yet; make sure that
idler bracket is in the
lowest possible
position.

Support.
11.Put spacers on the
shafts.
12.Now you can put

the pulleys on the
shafts as you see in the
picture.

Support.
.
19.Fasten screws on
the idler mounting
bracket.
20.Put on the drive

shaft the last spacer
(5/8 high)

Support.
.
21.Set the bushing on

the shaft to bottom out
on the spacer. Tighten
the setscrews on the
bushing to lock its
position.
22.Install feeder back

onto machine then
install the large driven
pulley and tighten
using the torque
wrench to approx 15
ft-lbs.

Support.
Turret ONLY – Replacing O-Ring(s) in
the Bender Manifold
1. Remove top cover of

the 3D arm.
2. Remove the four

bolts holding down
the cutter assembly.
3. After removing the
cutter from the four
bolts place it on the
2X4 as shown in the
picture.
This will prevent any

obstruction from occurring.
4. Remove the main

pulley
This will allow no tension

on the bender
5. Remove the turret
shaft
6. Remove the bending
pin housing(s)
NOTE:
Disconnect Air to
machine
7. Remove the two

screws circled in
the picture.
8. After the screws
and small blocks
are removed the
slotted ring will be
able to turn.
NOTE:
Be sure to mark
reference points
before unscrewing
the ring.
9. After the slotted
ring is removed the
plate surrounding
the bender.
10. Pull the
bender out to
expose the manifold
(3 green arrows).
NOTE:
Beware of surround
components when
removing this section.
11. Remove and Replace

all of the O-Rings on
the manifold and the
ring on top, don’t forget
about the one at the
base around the
tapered bearing.
NOTE:
Be sure to lubricate all of
the O-Rings prior to
installation.
After installation lubricate
the whole assembly.
Removine and installing the Turret
Shaft
REMOVING THE TURRET SHAFT
1. REMOVE AIR SUPPLY FROM THE

MACHINE. Then, loosen the screw
holding tension on the collet.
2. Unthread the collet from the bottom

of the turret shaft
3. Rotate the shaft in the DOWN

position till T1 is in line with the wire.
If the key way is not perpendicular to
the wire line the turret shaft will not
slide out
4. Pull the turret shaft up away from the

floor.
Lubricating the Turret Shaft
After removing the turret shaft clean with light spindle oil. Do NOT
apply grease to the shaft. If available apply an anti seize lubricant to
the turret shaft. For specifications on the anti-seize lubricant browse
to the web page below:
INSTALLING THE TURRET SHAFT
1. Install the turret shaft the same way

it was removed
2. If a tool cluster is installed, be sure
when homing the machine to check if
T1 is in the correct position.
3. Be sure the Turret Shaft is all the
way down and re-install the collet.
4. When tightening the collet be sure to
place the washer in front of it.
NOTE: TIGHTEN the collet until it will not

move any more and back it off ¼ of a
turn to allow the turret shaft to rotate.
5. Tighten the set screw on the collet
6. Cycle the turret shaft to assure

smooth operation
Chapter 12
Troubleshooting
Control “power on” F0 - main fuses blown: Check that machine is connected to proper input line voltage.
indicator will not light See cabinet wiring diagram.
(first make sure power
Defective “power on” light: Replace light.
is on)
Hydraulic motor thermal protection engaged: Reset OR1 (overload relay) and check
for possible overloads for the hydraulic system motor.
Defective switch: Replace switch.
We have power on the F4 - fuse is blown: Reset fuse.

control cabinet but the Loose cables: Check the two cables that connect the monitor to the computer.
monitor is not on
Monitor switch is off: Open the top door of the control unit and check if the monitor
switch is on.
When I press any of the Feeder cover is open: Close feeder cover.
buttons on the control Rollers switch is off: Turn on the rollers switch (after you place the wire in the right
panel nothing happens position). Make sure you are pushing and holding down Ctrl, along with the other
button. If machine is not on hit the “?” button.
Turntable has error: Reset turntable controller.

When I press RUN the
wire moves and one of The measuring unit does not function properly: Check if you have pressure on the
the red indicators on measuring roller and if the wire goes through the measuring unit. Check to see if the
the front of the control encoder roller has a grove in it.
panel is lit or the Check the shaft coupling of the encoder.
accuracy of the lengths
is not within The turntable does not turn: Check if the wire is tangled or if the straightening unit
specifications. rollers are pressed too much.
The feeding unit rollers do not have enough pressure and they “spin” on the wire:
Make sure that you have the correct set of rollers for the wire used and increase the
The red LED on the front pressure on the upper rollers of the feeding unit.
of the control panel is
on. We have a positioning error: Check the rotary encoder coupling (if Applicable)
and replace if broken, OR the encoder does not have enough pressure.
The servo amplifiers have an overload error: Turn the machine off, and check for
possible overload causes (stuck wire, broken belt, loose pulley). Restart the machine.
Call technical support if problem persists.
Communication error between the PC and the servo controller: Issue any command
from the Run window. For example press QUIT (<F2>) and then the RUN button.
Check the pieces counter on the top-right of the screen and set the number of pieces. If
the machine is producing wire parts and the counter is “1" then the computer thinks
that the machine did not stop at the appropriate time.
The machine does not cut If the machine does not cut the wire after it produced a part please check the line “Cut
the wire. at the end of program” at the program Parameters window (Press <F5> at the main
screen). The value should be “1“ in order for the machine to cut at the end of the
program.
The cutter’s proximity switches are not properly adjusted: Adjust the cutter’s proximity
switches following instructions on Chapter 3.
The system hydraulic pressure is not enough: Go into the I/O screen and press
cutter up to create pressure in the system, open the gauge valve so that you can
monitor the pressure, and turn the pressure relief valve clockwise to increase the
pressure of the hydraulic unit (½ turn at a time). WARNING! Never set the system
pressure more than 1,750 psi. When done, shut off the gauge valve.
The cutter is broken: Replace the cutter.
Air in the hydraulic lines: Press <Ctrl> + <F8> (Cutter up valve) to increase the
pressure of the system. Slowly loosen the front hydraulic fitting of the cutter cylinder
until you see “foam” coming out. When the “foam” stops, tighten the fitting. Remove
the upper proximity switch and press <Ctrl> + <F8> to cut. Repeat the above
procedure with the lower hydraulic fitting. Adjust the cutting travel and remount the
proximity switch. Call technical support if problem persists.
The wire comes out with flats Worn out rollers in the straightener or feeder: Replace rollers.
or marks. Excessive pressure on the upper feeder rollers: Adjust roller pressure on upper feeder
rollers.
The shape does not Straightener not properly adjusted: Adjust straightening unit.
come out straight. Excessive pressure on the upper feeder rollers: Adjust pressure on upper feeder rollers.
The cutter does not Worn out cutter or bending head top: Replace cutter or bending head top.
retract after a cut. Proximity switch not properly adjusted: Follow instructions on Chapter 3 to properly
adjust the cutter proximity switch.
Malfunctioning hydraulic valve: Clean cutter hydraulic valve. Replace if necessary.
Bad wiring connections: Check continuity of cutter’s proximity switch cables.
Adjusting the cutter limit switches
The hydraulic cylinder (figure , above) for the cutter is located under the bending unit. The cutter limit
switches are located on the side of the hydraulic cylinder, and they provide information to the controller
about the position of the cutter. These proximity switches do not have any moving parts and require no
contact with any moving part. They “sense” the piston of the hydraulic cylinder. When the cutter is
retracted, the lower cutter switch is on. When the cutter is activated, the lower switch turns off, the rod
extends up until the upper switch turns on and then the cylinder retracts until the lower switch is on
again. This is the “Cut cycle” and it takes place whenever we need to cut the wire, either manually or
automatically during production.
When we need the cutter to extend further during a “cut cycle”, all we need to do is move the upper
cutter switch, towards the bender top. We do so by un-tightening the Phillips screw and moving the
switch along the slot on the cylinder wall.
DO NOT use excessive force while tightening the mounting screw. It will be damaged!
Usually the cutter does not have to travel more than one third (1/3) of the diameter of
the wire. Therefore, for small diameters of wire we can reduce the cutters' travel,
increasing production time and efficiency of the machine.
A red LED is located at the back of each proximity switch, which is very useful when
we adjust the switches. When the light is ON it means that the switch is ON.
Figure 15.2 Adjusting the Feeder Belt
Adjusting the feeder belt

All four feeding rollers are driven by a combination of three belts. The belt that is located at the back
of the rollers is the only one that needs to be adjusted. Looking at the back of the feeding unit we see that
the top belt drives six (6) pulleys; four attached to the feeding rollers and two idler pulleys, which serve the
role of tension idlers. As we see at the figure , above, in order to adjust the tension of the belt, we have to
move the top idler pulleys. We can do so, by un-tightening the two lock bolts, at the center of the top
bracket and screwing the two tightening screws, located at the sides of the top bracket.
Before tightening the belt make sure that the rollers are at the working position (down or ON).
When the rollers are at the relaxed position (up) the belt should not be tight.
Remote Diagnostics-“Dial-A-Service”
What is“Dial-A-Service”?
“Dial-A-Service” is a feature that allows AIM’s Technical Support Department to access any machine worldwide; it is a
remote communication via a modem between the computer of the AccuForm 3D-T and AIM’s Technical Support
Department. This communication link is established with the use of a remote communication software used on the
internet called www.Logmein.com.
From this online program AIM Technician can access the computer on the machine from any pc that has an
internet connection and be able to assist you in fixing your problem with the machine.
LogMeIn, Inc. (formerly 3am Labs, Inc.) offers a suite of remote access and support solutions that provide
instant, secure connections between remote PCs over the web. Powered by the LogMeIn Gateway, the service
has applications for desktop remote control, data backup, file sharing, remote system administration, and on-
demand customer support.
index
A 2-7 2-9
Anti-Torsion 4-5
FLOPPY DRIVE PIECES COUNTER 2-6
Frame Pneumatic System 12-1
Pneumatics 1-9
B POWER 2-6
H PRINTER 2-6
Bender 2-10 HARD DRIVE 2-7

Bending 2-4 home position 4-7 R
Buttons 2-5 HOURS COUNTER 2-6 RESET Rotary Encoder 2-5,2-7
Hydraulic Setup 3-2 2-10
c
Cabinet
CD ROM DRIVE 2-5
Hydraulic System
Hydraulic UNIT
11-1
2-9
S
Safety 1-1
2-7 Hydraulics 1-9 Safety Hardware and Software

1-3
Clothing and Apparel
Other START Straightening 2-5
1-7
Straightening the Wire 2-3
Computer 2-6 Indicators 2-6
4-1
Connectors 2-6 Installation 3-1
Cutter 2-10
K
Cutter Limit Switches 4-8
D KEYBOARD LOCK 2-7

T
Dial-A-Service 6-1
M Training 1-7
Fire Prevention and Fight
1-9
Troubleshooting 15-1
Machine Location 3-1 Turntable 8-1
E Maintenance 1-6,14-1
Electrical Drawings 10-1 Measuring 2-4 Acc
uFor
Electrical Setup
Electrics
3-1
1-9
measuring roller
Measuring Unit
4-6
2-10
wWARNING 1-8
m
Mod
ular
3DX
EMERGENCY 2-6 Mechanical Drawings 9-1
-T
Energy Chain 2-10
ERROR 2-6
Operation 5-1
F Operators responsibilities 1-7
Failures 1-9 Owners Responsibility 1-1
Feeder Belt 4-9
Feeding 2-4
P

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AccuForm 3Dx-T

502 S. Vista Addison, IL 60101-4423 Phn(+1) 630-458-0008 Fax(+1) 630-458-0730

First Edition 1998

AccuForm Modular 3DX-T i

AccuForm Modular 3DX-T iii

■ All equipment will be locked-out or tagged-out to protect against accidental or inadvertant

6. The equipment and/or circuits are now locked out. 1,2

Safety Hardware and Software

Figure 1.2: Overview of Safety Gate on AFM 3D machine

AccuForm Modular 3DX-T 1 -3

Figure 1.3: Front View Arm Safety Gate with Label

Figure 1.4: Safety Gate interlock Switch

Figure 1.6: Feeder Cover Safety Switch

AccuForm Modular 3DX-T 1 -5

Figure 1.7: Male end of Feeder Cover Safety Switch

It strongly recommended to implement a guarding system to the payoff unit. The

See Chapter 12 for maintenance details.

Clothing and Other Apparel

AccuForm Value Line 1-7

■ Never run the machine without homing it first.

■ Stand away while the machine is running a part program.

■ Tool breakage may occur due to loosening of hardware.

■ If tool breakage does occur wire may be fed uncut.

■ Loss in production due to damaged tooling.

■ Hydraulic leaks may cause damage to components of the unit.

■ Electrical fires due to loose, broken wires or an introduction of unwanted fluids.

Fire Prevention and Fighting

■ Storing or handling flammable materials near heat sources.

Electro-mechanical Failures and Overheating

AccuForm Value Line 1-9

Figure 2.1 AccuForm Modular 3D-T

1.6 The Bender Unit

2-2 AccuForm Modular 3DX-T

FIGURE 2.2 TWO PLANE STRAIGHTENER

AccuForm Modular 3DX-T 2-3

Feeding and Measuring Units

Every time starting a new production, reset the counter.

Touch Screen Computer

FIGURE 2.5: LOOKING INSIDE...

Figure 1. Feeder and Bender Module

1. Connect the Air hoses to the nipple on the machine cabinet.

2. Connect the 16 pin connector on to the machine cabinet door.

AccuForm Modular 3DX-T

Figure 4.1 Example of straightener setup

AccuForm Modular 3DX-T

The purpose of the two-plane straightener is to straighten the wire as it is pulled

AccuForm Modular 3DX-T 4-2

- S1 Wire range (.080” - .312”)

Problem: The wire is going down towards the floor.

Usage&adjustment instructions for the

AccuForm Modular 3DX-T 4-5

Passing the wire through the ANT-x

Adjusting the pressure of the measuring roller

Adjusting the bender's home position

AccuForm Modular 3DX-T

Angle Difference between Left and Right Angle = 100 - 80 = 20

Angle Difference between Home and Bend = 20 / 2 = 10

4. Feed wire through the machine and straighten it.

5. Setup tool file or load saved tool file.

7. Start production and terminate the process when desired.

Refer to appropriate sections for instructions on how to perform each step.

Bending Tools Defined

Identifying Tool files