0% found this document useful (0 votes)

850 views200 pages

3094 User Manual XP Kongsberg

Uploaded by

Rado

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

0% found this document useful (0 votes)

850 views200 pages

3094 User Manual XP Kongsberg

Uploaded by

Rado

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 200

User Manual

for

Kongsberg XP systems

Note
We remind you that only the Esko staff, or persons having received
appropriate training, are allowed to handle, manipulate or do repairs on the system.

A Publication of: Esko

Copyright © 1984-2014 Esko.

This copyright does not indicate that this work has been published.

All rights strictly reserved. Reproduction or issue to third parties in

any form whatever is not permitted without written authority from the publisher.

Esko reserves the right to change specifications without notice.

Esko-Graphics Kongsberg AS
www.esko.com
Document number: D3094 P.O.Box 1016, N-3601 Kongsberg, Norway
Status: 131128 Tel: +47 32 28 99 00 Fax: +47 32 28 85 15 / 32 28 67 63
User Manual, Kongsberg XP

Change record

07-07-2010 jhbe 3.4.13 added; Manual belt clamp.

29-09-2010 jhbe 7.4.3 Table top reference, one issue added.
07-02-2011 jhbe Rotation angle calculation chapter added
25-02-2011 jhbe Cutting thick materials chapter added
31-03-2011 jhbe XP using two vacuum pumps chapter added
Stop before use – chapter has been modified
22-05-2011 jhbe Acceleration is reduced during manual belt movement
03-10-2011 jhbe Tool configuration chapter has been upgraded
22-10-2011 jhbe Added chapter about Zefiro 75 vacuum cleaner for HSMU
08-06-2012 jhbe HPMU (High Power Milling Unit) – new tool head introduced
ARS chapter updated
General clean-up
23-06-2012 jhbe HPMU, some updates
24-08-2012 jhbe Forced tool height measurement chapter added
19-10-2012 jhbe About XP-Guide dialogs
24-10-2012 jhbe Extra lift height of tools added to Job setup
08-04-2013 jhbe Foam knife protection kit described.
10-07-2013 jhbe Chapter about chiller fuse replacement added
28-11-2013 jhbe Chiller error codes added

All rights reserved.

This material, information and instructions for use contained herein are the property of Esko. There are no
warranties granted or extended by this document.
Furthermore Esko does not warrant, guarantee or make any representations regarding the use, or the results of
the use of the system or the information contained herein.
Esko shall not be liable for any direct, indirect, consequential or incidental damages arising out of the use or
inability to use the system or the information contained herein.

The information contained herein is subject to change without notice. Revisions may be issued from time to time to
advise of such changes and/or additions.

No part of this system may be reproduced, stored in a data base or retrieval system, or published, in any form or
in any way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written
permission from Esko.

This document supersedes all previous dated versions.

Correspondence regarding this publication should be forwarded to:

Global Support
Esko-Graphics Kongsberg AS
Kirkegårdsveien 45
N-3616 KONGSBERG

2
User Manual, Kongsberg XP

Table of content

1. WELCOME ........................................................................................................................................................................ 6
1.1 LOCAL LANGUAGES ...................................................................................................................................................... 7
1.2 ABOUT XP-GUIDE DIALOGS ....................................................................................................................................... 7
2. SAFETY REGULATIONS ............................................................................................................................................ 8
2.1 INTRODUCTION ............................................................................................................................................................ 8
2.2 RESPONSIBILITIES ....................................................................................................................................................... 8
2.3 REQUIREMENTS TO BE MET BY OPERATORS ............................................................................................................... 8
2.4 DEFINITION OF USE ..................................................................................................................................................... 8
2.5 DANGER ZONES.......................................................................................................................................................... 10
2.6 WARNING SIGN EXPLANATION .................................................................................................................................. 11
2.7 SAFETY DEVICES ........................................................................................................................................................ 13
2.8 PROTECTIVE EQUIPMENT ........................................................................................................................................... 15
2.9 PROCEDURES IN CASE OF MALFUNCTIONS ............................................................................................................... 15
3. SYSTEM DESCRIPTION .......................................................................................................................................... 16
3.1 APPLICATION PROGRAMS AVAILABLE........................................................................................................................ 16
3.2 NAMING CONVENTIONS ............................................................................................................................................. 17
3.3 OPERATING ELEMENTS............................................................................................................................................... 19
3.4 OPERATORS PANEL..................................................................................................................................................... 20
3.5 HIGH PRESSURE AIR SYSTEM .................................................................................................................................... 24
4. HOW TO PROCEDURES ........................................................................................................................................... 25
4.1 INTRODUCTION .......................................................................................................................................................... 25
4.2 POWER ON SEQUENCE ............................................................................................................................................... 25
4.3 CONTINUE AFTER SAFETY BREAK .............................................................................................................................. 26
4.4 POWER OFF SEQUENCE ............................................................................................................................................. 26
4.5 PREPARING FOR A JOB ............................................................................................................................................... 27
4.6 OPEN AN INPUT FILE ................................................................................................................................................. 29
4.7 CORRUGATED PRODUCTION ...................................................................................................................................... 30
4.8 MILLING PRODUCTION .............................................................................................................................................. 30
4.9 HARD BOARD PRODUCTION ....................................................................................................................................... 31
4.10 CUTTING THICK MATERIALS ...................................................................................................................................... 32
4.11 MAKE A PEN PLOT ...................................................................................................................................................... 32
4.12 SET THE TABLE UP FOR MULTI PASS CREASING OR MILLING .................................................................................. 33
4.13 JOBS INCLUDING REVERSE SCORE............................................................................................................................ 34
4.14 WORK WITH DIFFERENT REFERENCE POINT SETTINGS............................................................................................ 34
4.15 WORK WITH SEQUENCING AND OPTIMIZATION ...................................................................................................... 35
4.16 WORK WITH REGISTER BAR ...................................................................................................................................... 36
5. WORK WITH ARS ...................................................................................................................................................... 39
5.1 INTRODUCTION .......................................................................................................................................................... 39
5.2 ARS - MODES OF OPERATION ................................................................................................................................... 40
5.3 WORK WITH ARS (AUTOMATIC REGISTRATION SYSTEM)..................................................................................... 44
5.4 CAMERA CALIBRATION ............................................................................................................................................... 53
5.5 ADJUST CAMERA OFFSET ........................................................................................................................................... 55
5.6 VERIFY CORRECT OFFSET ADJUSTMENT.................................................................................................................... 58
6. WORK WITH 123BOX .............................................................................................................................................. 59
6.1 INTRODUCTION .......................................................................................................................................................... 59
6.2 ARTIOSCAD, SHORT INTRODUCTION ...................................................................................................................... 59
6.3 CAD-X, SHORT INTRODUCTION ............................................................................................................................... 60
6.4 WORK WITH 123BOX ............................................................................................................................................... 60
7. SYSTEM SETUP ........................................................................................................................................................... 66
3
User Manual, Kongsberg XP

7.1 INTRODUCTION .......................................................................................................................................................... 66

7.2 REFERENCE POINTS AND COORDINATE SYSTEM ..................................................................................................... 67
7.3 SPEED SETUP ............................................................................................................................................................. 69
7.4 TABLE SETUP .............................................................................................................................................................. 71
7.5 SYSTEM OPTIONS ...................................................................................................................................................... 74
7.6 DISPLAY COLORS ....................................................................................................................................................... 77
7.7 JOB SETUP.................................................................................................................................................................. 78
7.8 JOB LAYOUT ............................................................................................................................................................... 85
7.9 TOOL CONFIGURATION AND ADJUSTMENT .............................................................................................................. 88
7.10 BOARD SIZE ............................................................................................................................................................... 95
7.11 CHANGE FLUTE/GRAIN DIRECTION ........................................................................................................................... 95
7.12 TRANSFORMATIONS ................................................................................................................................................... 96
7.13 STEP AND REPEAT...................................................................................................................................................... 98
7.14 COUNTER SETUP DIALOG ........................................................................................................................................... 99
7.15 VACUUM CONTROL ................................................................................................................................................... 100
8. TOOLING SYSTEM, INTRODUCTION............................................................................................................. 104
8.1 TOOL HANDLING AND CARE..................................................................................................................................... 104
8.2 TOOL CONFIGURATION ............................................................................................................................................ 105
8.3 HOW TO REPLACE A TOOL ....................................................................................................................................... 107
8.4 TWO OR MORE TOOLS OF THE SAME TYPE .............................................................................................................. 107
8.5 MEASURING STATION .............................................................................................................................................. 108
8.6 HDU - HEAVY-DUTY UNIT ..................................................................................................................................... 109
8.7 Ø150MM CREASE WHEEL ....................................................................................................................................... 110
8.8 V-NOTCH KNIFE TOOL ............................................................................................................................................ 112
8.9 HD KNIFE TOOL ...................................................................................................................................................... 116
8.10 FOAM KNIFE TOOL ................................................................................................................................................... 118
8.11 HSMU/HPMU ......................................................................................................................................................... 122
8.12 THE VIBRACUT KNIFE TOOL .................................................................................................................................... 147
8.13 RM KNIFE TOOL (RIGID MATERIAL) ..................................................................................................................... 150
8.14 THE HI-FORCE KNIFE TOOL .................................................................................................................................... 151
8.15 PRESSCUT KNIFE TOOL ........................................................................................................................................... 154
8.16 ROTACUT KNIFE TOOL ............................................................................................................................................. 157
8.17 DRILL / PEN TOOL ................................................................................................................................................... 161
8.18 DRILL TOOL.............................................................................................................................................................. 162
8.19 THE BALL POINT TOOL ............................................................................................................................................. 163
8.20 MEASURING FOOT .................................................................................................................................................... 164
8.21 LASER POINTER ........................................................................................................................................................ 164
9. MAINTENANCE .......................................................................................................................................................... 165
9.1 GENERAL................................................................................................................................................................... 165
9.2 DAILY MAINTENANCE ............................................................................................................................................... 165
9.3 WEEKLY MAINTENANCE ........................................................................................................................................... 165
9.4 MONTHLY MAINTENANCE ........................................................................................................................................ 166
9.5 MAINTENANCE, EXTERNAL EQUIPMENT .................................................................................................................. 167
10. FUSE REPLACEMENT ......................................................................................................................................... 168
10.1 MPU FUSES .............................................................................................................................................................. 168
10.2 X1 FUSE ................................................................................................................................................................... 169
10.3 X2 FUSE ................................................................................................................................................................... 170
10.4 Y FUSE ...................................................................................................................................................................... 171
10.5 Z1 / Z2 FUSES ........................................................................................................................................................ 172
10.6 FUSES: TOOL ROTATION / RECIPROCATING KNIFE............................................................................................... 173
10.7 HPMU CHILLER FUSE .............................................................................................................................................. 174
10.8 HPMU CHILLER HEATER FUSE ................................................................................................................................ 175
11. APPENDICES, INTRODUCTION ................................................................................................................... 176
12. APPENDIX - THE GRAPHICAL USER INTERFACE .............................................................................. 177
12.1 THE MAIN MENU ...................................................................................................................................................... 178

4
User Manual, Kongsberg XP

12.2 THE MAIN TOOLBAR FUNCTIONS ............................................................................................................................ 180

12.3 FILE VIEW ................................................................................................................................................................ 181
12.4 FILE VIEW TOOLBAR ................................................................................................................................................ 183
12.5 THE JOB VIEW ......................................................................................................................................................... 184
12.6 JOB VIEW TOOLBAR ................................................................................................................................................. 185
12.7 PREVIEW ................................................................................................................................................................... 186
12.8 STATUS BAR ............................................................................................................................................................. 187
12.9 CRITICAL WARNING DISPLAY ................................................................................................................................. 187
12.10 MESSAGE DISPLAY .............................................................................................................................................. 188
12.11 POSITION DISPLAY .............................................................................................................................................. 189
12.12 ACCELERATOR KEYS ............................................................................................................................................ 191
13. APPENDIX - INSTALL SOFTWARE ............................................................................................................. 192
13.1 INSTALL XP-GUIDE SYSTEM SOFTWARE ................................................................................................................ 192
13.2 INSTALL ARS SOFTWARE ........................................................................................................................................ 192
14. APPENDIX - CAD-X PREVIEW DIALOG ................................................................................................... 193
14.1 BOARD CODE ............................................................................................................................................................ 193
14.2 SIZE .......................................................................................................................................................................... 193
14.3 ZOOM FUNCTIONS.................................................................................................................................................... 194
14.4 FLUTE BUTTON ......................................................................................................................................................... 194
14.5 DESIGN SIDE DISPLAY ............................................................................................................................................. 194
14.6 UNIT DISPLAY ........................................................................................................................................................... 194
14.7 PRODUCE BOX .......................................................................................................................................................... 195
14.8 JOB SETUP ................................................................................................................................................................ 195
14.9 SAVE DESIGN ........................................................................................................................................................... 195
14.10 OPEN DESIGN ...................................................................................................................................................... 195
14.11 SHOW ALL LAYERS ............................................................................................................................................... 196
14.12 CREATE A NEW BOX ............................................................................................................................................. 196
14.13 RESIZE BOX ......................................................................................................................................................... 196
14.14 EXIT ...................................................................................................................................................................... 196
15. APPENDIX – ROLL FEEDER............................................................................................................................ 197
16. APPENDIX – ZEFIRO 75, VACUUM CLEANER ...................................................................................... 198
16.1 INTRODUCTION ........................................................................................................................................................ 198
16.2 FILTER SHAKING ...................................................................................................................................................... 198
16.3 REMOVE MATERIAL CONTAINER .............................................................................................................................. 199
16.4 USE PLASTIC BAG IN MATERIAL CONTAINER .......................................................................................................... 200

5
User Manual, Kongsberg XP

1. Welcome

Welcome to a long-lasting co-operation with Esko.

The intention of this User Manual is to provide information sufficient to:

 Understand the main principles of the XP system.
 Learn how to operate the XP table in order to produce the expected result.
 Learn about the XP safety rules in order to operate the system in a safe way.

The manual is divided into the following main sections:

 Safety regulations The main safety issues are described.

 System description A short-form description of the system. This section is divided into two
chapters:
 System description.
 Graphical User Interface (GUI). This part is available as context
sensitive help from the XP-Guide program. In addition, it is
available as Appendix A in this manual.

 How to‟s.. Typical tasks are described in detail.

 Preparing for a job What do I have to prepare before the start of a job. This is a part of
the „How to‟ chapter.

 Work with ARS The Automatic Registration System is covered by a separate chapter.

 System setup A description of all parameters to be set and how to set them.

 Tooling system A complete description of the XP tooling system.

 Maintenance What maintenance is required in a short and long term.

 Appendices

Some definitions used in this document:

Name or style Description

This is the dialog that appears when you click the Right mouse
Pop-up dialog
button.
Start button The italic style indicates this is a button on the Operator panel.
The bold style indicates this is a button or function in the XP-Guide
OK
user interface.
Options->System Option Menu selection: From the Options menu, select System Option
123 is the page number where the actual function is described. It is
(123) also a hyperlink; a mouse-click on the number will bring you directly
to the issue.

6
User Manual, Kongsberg XP

1.1 Local languages

This manual is available in a wide range of local languages. When the document is translated into a
local language, the screen pictures, some illustrations and the content in the Appendices remains in
English language.

1.2 About XP-Guide dialogs

To exit from any XP-Guide dialog, use the
control buttons available.
Using the cross in upper right corner is not
recommended and the consequence is un-
predictable.

7
User Manual, Kongsberg XP

2. Safety regulations

2.1 Introduction
The Kongsberg table is designed to conform to safety regulation standards.
Nevertheless, operating the table can involve hazards if the operator does not follow the operating
instructions or uses the table for non-intended purposes.
The safety regulations described below are supplemented with safety warnings in the respective
topics.

2.2 Responsibilities

2.2.1 The manufacturer

The manufacturer is responsible for delivering the system according to safety regulation standards.

2.2.2 The customer

The customer is responsible for:
 Ensuring that the system is used for it's intended use only
 Allowing that only authorized and trained personnel operate the system
 Preventive maintenance as described in the Maintenance manual.
 The local regulations regarding installation and operation are fulfilled.

2.2.3 The operators

The operators are responsible for:
 Operating the system only when it is in a flawless state.
 Ensuring that no unauthorized persons come close to the system.

2.3 Requirements to be met by operators

The personnel operating the system must:
 Be adequately trained.
 Have read and understood the instructions described in "Safety regulation" as well as any
other safety warnings.

2.4 Definition of use

The intended use is described in the „How to..‟ chapter. Any other use is considered non-intended
use.

Examples of non-intended use:

 Operation by operators not meeting the requirements as described above.
 Unauthorized modifications (bridging safety devices, removing covers etc.)
 Utilizing accessories other than those specified by Esko.
8
User Manual, Kongsberg XP

Non-intended use may cause:

 Health hazards and injuries.
 Damage to the system.
 Incorrect functionality.
 Damage to work materials.

Esko is not liable for any damage resulting from such non-intended use.

9
User Manual, Kongsberg XP

2.5 Danger zones

2.5.1 Moving parts, laser radiation and high voltage

The area around the moving parts should be considered to be a danger zone.

2.5.2 Noise level

Hearing protection should be used by any personnel exposed to the noise from the XP table.
10
User Manual, Kongsberg XP

2.5.3 Ejection of parts

Potential risk when running the HSMU/HPMU:

Personnel hit by breaking milling bit or small

pieces of processed material.

Eye protection should be used by any personnel

working with HSMU/HPMU on XP.

2.6 Warning sign explanation

Knife blades are extremely sharp.

Used in this documentation to indicate operations with knife
blades and milling bits.

Potential areas with a risk of being squeezed are marked with

the 'do not touch' sign. These areas are:
 Between Y carriage and rack
 When the Y carriage moves towards traverse ends.
 Between the table top and the moving traverse.
 Underneath the tool head.

The Hearing Protection symbol indicates areas where the use of

hearing protection is compulsory.

11
User Manual, Kongsberg XP

The Eye Protection symbol indicates areas where the use of eye
protection is compulsory.

Potential areas with a risk of being hit by moving parts are

marked with the 'Moving Parts' sign. These areas are:
Moving parts  Both traverse ends.
 Y carriage.
 Tool head(s).

WARNING The main power unit contains main voltage and may only be
Do not remove cover before
mains is disconnected opened by authorized personnel. The main power unit is
High voltage controlled from marked with the 'voltage' warning sign.
external source inside

CAUTION
LASER RADIATION Laser radiation. The tool head is equipped with a class II laser
pointer.
DO NOT STARE INTO BEAM

DIODE LASER
MAX OUTPUT 1 mW
WAVELENGTH 650-660nm Avoid laser light into your eyes.
EN 60825-1: 1994+A11:1996
CLASS II LASER PRODUCT

AVOID EXPOSURE
Laser radiation emitted from this aperture

12
User Manual, Kongsberg XP

2.7 Safety devices

2.7.1 Overview

Y 4

2
3

1 The Main power switch

2 Emergency stop
3 Yellow / black tape on the floor to indicate attention area
4 Warning lamp
5 Dynaguard

2.7.2 The Main power switch

The Main power switch turns power to the table on/off.

13
User Manual, Kongsberg XP

2.7.3 Emergency stop button

When hit, the Emergency stop button switches off all power to the table.

Note: Activating the emergency stop button does not provide a guarantee
against injury!
Due to the high kinetic energy of moving parts do not underestimate
stopping distances of traverse, Y carriage and tool head.

2.7.4 Yellow / black tape

The yellow / black tape indicates the warning area. This area is restricted to operators and other
trained personnel.

2.7.5 Warning lamp on top of Y carriage

Light is Description
Off Servo power is off
On Servo power is on, Safety system is enabled, table is in operation
Blinking Safety system is activated. Reset Safety system to continue operation

2.7.6 DynaGuard Safety System

The Photocell safety system consists of two light beams in front of the traverse and two behind. In
addition, there is a stop mechanism mounted on each end of the traverse.
Machine movement will stop and servo power will be switched off if:
 One of the light beams is broken.
 The stop mechanism is activated, for instance when a person is standing too near the table.

To continue operation after the Safety system has been activated, do:
 Reset the Safety system by pressing Stop on Operators panel
 Press Start to continue operation

14
User Manual, Kongsberg XP

2.8 Protective equipment

For the operator(s), Esko recommends the following protective equipment:

 Close-fitting clothes to avoid being caught by the beam or the tool head
which can cause injuries.

 Gloves to protect against cuts from materials with sharp edges

 Eye protection should be used by any personnel working with

HSMU/HPMU on XP.

 Always use hearing protection when working with the machine for a
longer period of time.
The acoustic noise level will vary with the type of operation and tooling,
but a typical average level is 78.5 – 83.5 dBA and a maximum level of
98.5 dBA.

2.9 Procedures in case of malfunctions

Trouble-shooting and repair shall only be executed by authorized personnel.
Contact the Esko Service Organization.

15
User Manual, Kongsberg XP

3. System description

3.1 Application programs available

After installation of XP-Guide, the following application programs are available:

XP-Guide Control program for the XP - table

SysLoad Program for download of updates to CU – modules.
HWT900XP Hardware test program, see separate HWT900XP User Manual.
FaceMill A program for face milling. Prepared for HSMU/HPMU (145).
FaceCut A program for simple cut out of squares. Prepared for knife or milling (145).

16
User Manual, Kongsberg XP

3.2 Naming conventions

3.2.1 Table

1 Cutting table 6 Emergency stop button

2 Traverse 7 Operator panel
3 Y carriage 8 Main power on/off switch
4 Tools 9 Traverse safety stop switches
5 Main Power Unit (MPU)

3.2.2 Axes

X1 Z1 Z2 X2

17
User Manual, Kongsberg XP

3.2.3 The Graphical User Interface

The XP Graphical User Interface (GUI) contains these main elements:

1 Main Menu 5 Preview

2 Main Toolbar 6 Job View Toolbar
3 File View Toolbar 7 Job View
4 File View 8 ARS Toolbar
9 Status Bar

18
User Manual, Kongsberg XP

3.3 Operating elements

The table is equipped with the following operating elements:

 Main power switch

 Emergency stop switch

 Operators Panel

3.3.1 Main power switch

On XP, the Main power switch is located on the Front Panel or Revolving Work Station.

Switch positions:

0 - the main power to the machine is switched OFF.

I - the main power to the machine is switched ON.

3.3.2 Emergency stop switch

On XP, the Emergency stop switch is located on the Front Panel or Revolving Work Station.

Switch positions:

UP - the main power to the machine is switched ON.

DOWN - the main power to the machine is switched OFF.

19
User Manual, Kongsberg XP

3.4 Operators panel

3.4.1 Power on

Lit when Main power is on

3.4.2 Start button

Press this button to start operation.

3.4.3 Stop button

Press this button to stop operation.

20
User Manual, Kongsberg XP

3.4.4 Vacuum On/Off button

Press this button to switch Vacuum On/Off.

3.4.5 Init Button

Press this button to:
 Initialize the system, i.e. give variables pre-set values.
 Set Panel Reference Point.

If Fixed Reference Point is disabled, the current position of the Laser Pointer is
set as the new Reference Point.

3.4.6 Table Zero / Forced tool height measure

Press this button, then the Start button, to move the tool head to Zero
Reference Point, which corresponds to origin in the Coordinate System. The
Table Zero Mode is automatically selected at Start-Up. The button remains lit
until the Zero Position is reached.

If Forced tool height measuring mode is enabled, this button will start a Tool
height measuring sequence. For more information, see (38).

3.4.7 Servo On/Off

Press this button to switch the Servo on/off. The servo power is on when the
lamp is lit.

3.4.8 Jog buttons

Press the Jog buttons to move the tool head in the desired direction.
The system must be in Stop mode, i.e. the Stop button must be lit, for
these buttons to be operative.
Note: It is possible to configure the jog direction, see Option, System
setup.

21
User Manual, Kongsberg XP

3.4.9 Continuous Jog

Press a Jog button to manually move the tool head with constant speed.
The X and Y Jog buttons can be operated both individually and simultaneously.

Press the single arrow for low jog speed.

Press both symbols for medium jog speed.

3.4.10 Incremental Jog / Forced tool height measure

Press this button to select the Incremental jog / Forced tool height
measuring mode.
Press the button a second time to disable the Incremental jog / Forced tool
height measuring mode.
For information about Forced tool height measure, see (38).

Press the two arrows to move the tool head a large step.
Press the single arrow to move the tool head a small step.

The size of the incremental movement can be changed from Option-> System
setup.

3.4.11 Tool Down

Press this Tool Down button to manually operate the machine with a tool in the
down position.
Cancel by pressing Tool Down a second time.

3.4.12 Vacuum release mode

For details about this function, see separate chapter 'Vacuum control' (100).

22
User Manual, Kongsberg XP

3.4.13 Manual belt clamp

In order to manually drag material onto the cutting table using the conveyor
belt, the Manual Belt clamp function is available.

The Manual Belt Clamp function is enabled after the Vacuum release button has
been kept down for more than 2 secs.

The Manual Belt Clamp function is active as long as the Vacuum release button is
kept down.
As long as the Manual Belt Clamp function is active, the following actions are
carried out:
 The belt clamps are activated.
 The feeder paws are activated.
 The operator panel jog buttons are available for manual movement of the
traverse / conveyor belt. All other possible actions on the machine are
inhibited.
 Acceleration is reduced during belt movement.

23
User Manual, Kongsberg XP

3.5 High pressure air system

3.5.1 General
The High Pressure Air System supplies the valves and tooling with compressed air.

For details regarding air supply requirements, see 'Site Preparation manual'.

3.5.2 Air regulator settings

Air
regulator

The compressed air is connected to a combined pressure regulator valve/water trap.

The air pressure should be adjusted to minimum 6 bar (6 kg/cm2, 6*105 Pa). Recommended
pressure level is 7 bar (7 kg/cm2, 7*105 Pa).

24
User Manual, Kongsberg XP

4. How to procedures

4.1 Introduction
Keep away from moving parts during operation.

Do not lean on racks, guide ways or traverse during operation as this may cause personal
injury.
Before starting operation, make sure that:
the table is free from obstructions
no unauthorized personnel come close to the table

All procedures for how to run the machine, except „Power on‟ is based upon the following
assumptions:
 The user interface is up and running.
 The actual tools are properly mounted and adjusted.

4.2 Power on sequence

Follow these steps to power up the system and get ready to work:

4.2.1 Front End PC

Switch on the PC and the monitor.

4.2.2 Table Power

Switch the table on using the Main Power switch.
Note: After power off, wait minimum 5 sec. before the system is switched on again.

4.2.3 XP-Guide
Use the mouse, double-click the icon for XP-Guide. Check that no error message indicates faulty
conditions.

4.2.4 Safety system

Reset the Safety system by pressing the Stop pushbutton.

4.2.5 Servo Power

Press the Servo on pushbutton. The Warning lamp on top of the Y carriage should be on without
flashing.

25
User Manual, Kongsberg XP

4.2.6 Table zero sequence

Press Start pushbutton to complete the table zero sequence. The machine will move to current
selected reference point.

The table is now ready for operation.

4.3 Continue after safety break

If the Safety system is activated, all movements on the table are stopped and the Warning lamp on
top of the Y carriage starts flashing.
To continue operation, proceed as follows:
1. Ensure the table is free from obstructions and ready for operation.
2. Reset the Safety system by pressing the Stop pushbutton.

4.4 Power Off sequence

When power off, follow this sequence:

4.4.1.1 Servo power off

Press the Servo on pushbutton to switch servo power off.

4.4.1.2 Table Power

Switch Table power off using the Main Power switch.

4.4.1.3 Front End PC

To switch off the PC, use the Operating system shutdown procedure.

26
User Manual, Kongsberg XP

4.5 Preparing for a job

Keep away from moving parts during operation.

Do not lean on racks, guide ways or traverse during operation as this may cause
personal injury.
Before starting operation, make sure that:
 the table is free from obstructions
 no personnel come close to the table

Use this chapter as a check – list when changing from one job to another.

4.5.1 Job Setup

Job Setup is a table that links

Logical tool numbers (P - numbers)
in the Input File to physical tools on
the machine and describes their
behavior (78).

The Job Setup information is stored

as a file on the front end PC.

Select Job Setup file from the Job

Setup drop down list.

4.5.2 Board Setup

Position the material for the job on the

table.
Select Board Size from the Board Size
drop down list.

Note: Board size information is used for

calculating Step & Repeat. If Step &
Repeat is not used, this setup is optional.

27
User Manual, Kongsberg XP

4.5.3 Open an input file

From File View, open files in one of following ways:

Double click on a file.

Select a file and click the Open button.

Click on a file, hold the left mouse button down, drag the file into Job View and release
it.

When Auto Open is enabled and activated the files will be opened automatically.

4.5.4 Set flute direction

Use the Toggle Flute Direction button to set

correct direction for the actual job.

4.5.5 Vacuum Section Setup

From the Vacuum Section setup – dialog,

configure a suitable vacuum area for the job.

4.5.6 Select proper speed

The machine speed during execution will have important impact on the final result.
For some combinations of tools and materials, you can run with full speed, for other combinations,
the speed and/or the acceleration has to be reduced.
For this purpose, the following alternatives are available:
 Select between High Quality, Normal or High Speed mode (75).
 Reduce the overall acceleration (69).
 Reduce the speed and acceleration for the Job setup line (80)

28
User Manual, Kongsberg XP

4.5.7 Run the job

Verify that the display of the job in Job View is reasonable.

Ensure that all settings are proper.

Press Vacuum on to start the vacuum pump (If you are running with Automatic vacuum control
enabled, the pump will start automatically when Start is pressed).

Press Start to execute the job.

4.6 Open an Input File

From File View, open Input Files in one of following ways:

Double click on a file.

Select a file and click the Open button.

Click on a file, hold the left mouse button down, drag the file into Job View and release
it.

When Auto Open is enabled and activated the files will be opened automatically (183).

The formats available are:

File
Description
extension
Kongsberg acm – format. This is the default input format for Kongsberg XP. Described
.acm
in the Technical Reference manual for XP.
.plt HPGL. Described in the Technical Reference manual for XP.
.dxf DXF. See Appendix about DXF input tuning (193).
.ard ArtiosCAD. See Appendix about the ArtiosCAD module CAD-X (193).
.cf2 CF2. See Appendix about the ArtiosCAD module CAD-X (193).
.ddes DDES. See Appendix about the ArtiosCAD module CAD-X (193).

The format is selected from the System Setup dialog (74).

Standard file extensions will be automatically recognized.

29
User Manual, Kongsberg XP

4.7 Corrugated Production

Take care:
 Knife blades are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use hearing protectors.

1. Ensure that the tool configuration is correct for the job and corresponds with the Job Setup
information.
2. Ensure that the knife blade is sharp and proper.
3. Ensure that the Job Setup information is correct for the material. If not, select Job Setup
file.
4. From File View, select the Input File.
5. Retrieve information about required sheet size from Job View.
6. Position a sheet of material against the left ruler. Retrieve information about the flute
direction from the Job View window and position the material accordingly.
7. Configure vacuum zones according to the material size.
8. Switch Vacuum on.
9. Ensure that you run with a suitable Program Reference point.
10. Execute the job by pressing Start.
11. To repeat the job, press Init and repeat this procedure from point 5.

4.8 Milling Production

Take care:
Milling bits are extremely sharp.
Keep away from all moving parts.
Ensure all other personnel stays in a safe distance from all moving parts.
Use hearing protectors.

Milling jobs should be executed in High Quality mode (75).

1. Ensure that the tool configuration is correct for the job and corresponds with the Job Setup
information.
2. Ensure that the router bit is sharp and proper for the job.
3. Ensure that the Job Setup information is correct for the material. If not, select Job Setup
file.
4. From File View, select the Input File.
5. Retrieve information about required sheet size from Job View.
6. Position a sheet of material against the left ruler.
7. Configure vacuum zones according to the material size.
8. Switch Vacuum on.
9. Ensure that you run with a suitable Program Reference point.
10. Execute the job by pressing Start.
11. To repeat the job, press Init and repeat this procedure from point 6.

30
User Manual, Kongsberg XP

4.9 Hard board production

Take care:
 Milling bits are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use hearing protectors.

To prepare hard board materials, the procedure

is as follows:

1. Mill through the top layer using

HSMU/HPMU.

2. Cut through the mid-section using the

HF VibraCut knife tool.

3. Mill through the bottom layer using

HSMU/HPMU.

1. Ensure that the tool configuration is correct for the job and corresponds with the Job Setup
information.
2. Ensure that the router bit is sharp and proper for the job.
3. Ensure that the knife blade is sharp and proper for the job.
4. Ensure that the Job Setup information is correct for the material. If not, select Job Setup
file.
5. From File View, select the Input File.
6. Retrieve information about required sheet size from Job View.
7. Position a sheet of material against the left ruler.
8. Configure vacuum zones according to the material size.
9. Switch Vacuum on.
10. Ensure that you run with a suitable Program Reference point.
11. Execute the job by pressing Start.
12. To repeat the job, press Init and repeat this procedure from point 6.

31
User Manual, Kongsberg XP

4.10 Cutting thick materials

Take care:
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use hearing protectors.

When preparing materials with thickness between 45 – 50 mm (1¾ - 2 in.), the following rules
apply:

 No camera operations are available.

 Disable Measure material thickness.
 In Job setup, use T-function to specify the cutting depth.
 This function is for knife tools only.

Disable Material thickness measurement:

Job setup->More Cutting depth using T-function:

T-20
T0

Note: This function is useful for all materials with an un-even surface.

4.11 Make a pen plot

Take care:
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use hearing protectors.

1. Ensure that the tool configuration is correct for the job and corresponds with the Job Setup
information.
2. Ensure that the Ball point pen is proper for the job.
3. Ensure that the Job Setup information is correct for the material. If not, select Job Setup
file.
4. From File View, select the Input File.
5. Retrieve information about required sheet size from Job View.
6. Position a sheet of material against the left ruler.

32
User Manual, Kongsberg XP

7. Configure vacuum zones according to the material size.

8. Switch Vacuum on.
9. Ensure that you run with a suitable Program Reference point.
10. Execute the job by pressing Start.
11. To repeat the job, press Init and repeat this procedure from point 6.

4.12 Set the table up for multi pass creasing or milling

Take care:
 Knife blades are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use hearing protectors.

Multi pass creasing is beneficial if you want a deeper crease pattern. This is achieved by running one
pass with for example 50% depth and a second pass with 70% dept.

Multi pass milling is beneficial if you want to mill through a material where the thickness is bigger
than the router bit diameter.

Multi pass creasing or milling is available by modifications in the Job Setup file. Proceed as follows:
1. Open the Job Setup file for editing.
2. Identify the crease or milling line where multi pass is wanted.
3. Add one or more new lines with the same logical tool number and specify the same tool and
desired depth.
4. When executing the job with this Job Setup file selected, the multi pass function will be
carried out for the specified logical tool(s).
5. The multi pass lines will be executed in the same sequence as they appear in the Job setup
dialog.

This picture shows a Job Setup with double pass creasing with logical tool no 22:

33
User Manual, Kongsberg XP

4.13 Jobs including reverse score

Take care:
 Knife blades are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use hearing protectors.

A typical use of reverse score is when you want to add a crease line on the front side of a
material that you normally prepare from the rear side.

Reverse score is available by modifications in the Job Setup file. This function requires that the
table is equipped with left and right rulers. Proceed as follows:

1. Open the Job Setup file for editing.

2. Identify line for reverse score or add a line for this function.
3. Open the More dialog for this line, enable Reverse score.
4. When executing the job with this Job Setup selected, the Reverse score function will be
carried out for the specified logical tool(s).
5. Follow the instructions displayed when executing the job.

The picture shows a Job Setup with reverse creasing using logical tool no 1:

4.14 Work with different reference point settings

To define or modify reference point settings, go to the Set Reference point wizard (72).
Reference points are selected from the Job View Toolbar (185).

34
User Manual, Kongsberg XP

4.15 Work with Sequencing and Optimization

4.15.1 Sequencing disabled

Input file
P1, crease

P2, knife
P1, crease

P2, knife
Execution
P2, knife P1, crease P2, knife P1, crease P2, knife P1, crease

The input file is executed as is.

4.15.2 Sequencing enabled

Input file
P1, crease

P2, knife
P1, crease

P2, knife
Execution
P2, knife P2, knife P2, knife P1, crease P1, crease P1, crease

All crease lines are executed before knife cuts. The sequence is: pen, crease, v-notch knife, milling,
knife, drill.

4.15.3 Sequencing and knife before crease enabled

Input file
P1, crease

P2, knife
P1, crease

P2, knife
Execution
P1, crease P1, crease P1, crease P2, knife P2, knife P2, knife

All knife cuts are executed before crease lines. The sequence is: pen, milling, knife, crease,
V-notch knife, drill.

35
User Manual, Kongsberg XP

4.16 Work with Register bar

The Register bar is an aid when the material needs registrations that fits the requirements of a
specific printing press or die cutter.

On XP, the register bar is mounted along the X -

axis as illustrated at left.
Register bar - Register bar fixed to the table.
Material - Sheet of material with pre-punched holes
that fit the Positioning pins on the Register bar.
Positioning pins. Use these pins to fix the sheet of
material in a correct position on the table. When
the sheet is fixed and vacuum is switched on, you
must remove the pins.
Cutting underlay - Cutting underlay.
Area not available for tools - This area is outside
the working area of the machine.

4.16.1 Work flow

Take care:
 Knife blades are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use hearing protectors.

Place the sheet of material onto the cutting table

and align the holes in the material with the
positioning pin holes.
Insert the positioning pins.

When both positioning pins are in place, the sheet is

correctly positioned.

36
User Manual, Kongsberg XP

Switch vacuum on.

IMPORTANT: Remove the Positioning pins.

Now, the machine is ready for operation.

4.16.2 Reference point setting

When working with register bar, select one of the

available Reference points ( Option->Table options )
and set a reference point in a fixed position relative
to one of the Positioning pins
(R in the illustration).
This position should be used as origin during
geometry design and cam file generation.

When preparing the job in the CAD - system, use

the same Reference point as origin.

This work flow ensures exact positioning of the

geometry relative to the Positioning pins.

37
User Manual, Kongsberg XP

4.16.3 Forced tool height measurement

Follow these steps to start a tool height measuring sequence:

1) Enable Incremental Jog.

2) Select the Table Zero sequence.

3) Press Start to execute the height measuring sequence (as part of the Table
zero sequence).

38
User Manual, Kongsberg XP

5.Work with ARS

5.1 Introduction
XP offers different levels of automation for Registration mark reading:

1- Manual reading of 2 registration marks by use of laser pointer (standard).

ARS 2- Manual reading of 2 registration marks by use of camera as pointing device (option).
3- Automatic reading of up to 4 registration marks. Linear transformation (option).

This chapter will cover all ARS – related issues.

The camera solution used in ARS is based upon a Scorpion software package.

Thus, it is a pre-requisite that Scorpion is properly installed and configured together with XP-Guide
in order to make ARS work.

Note: The Job layout function is not available when running ARS.

39
User Manual, Kongsberg XP

5.2 ARS - modes of operation

5.2.1 Introduction
All settings described in this chapter are available from the Registration setup dialog, available from:

XP-Guide->Option->Registration setup

Job view toolbar -> Enter ARS registration setup dialog

The button change face depending upon if ARS is running or not.
XP-Guide is running with ARS enabled.

Job view toolbar -> Enter ARS registration setup dialog

No ARS functions are enabled.

The mode of operation is specified by 3 (4) parameters as illustrated above:

 Register mark input / position input
 Work flow
 Transformation
 Registering tool
 Camera operations

40
User Manual, Kongsberg XP

5.2.2 Registering tool

From the drop down menu, select the tool to use for registration
or No registration.

5.2.3 Register mark input

Specify how the location of the register marks is specified to the system:

5.2.3.1 From input file

The location of the register marks is specified in the input file, provided by the CAD – system.

5.2.3.2 Manual

The location of the register marks is entered manually.

5.2.3.3 Register mark position

Press the Register mark position button to enter the dialog:

If your Register mark input is from input file, If your Register mark input is Manual, enter
enter A/B values. A/B/C/D values.

41
User Manual, Kongsberg XP

5.2.4 Camera operation

Use this setting to select between a manual or automatic mode of operation:

5.2.4.1 Manual detection of register marks

Pointing with laser

A wizard will guide you from one register mark to the next.
Place the laser pointer in the center of the register mark and press Start.

Viewing with camera

This is a manual, visual detection of register marks.
A wizard will guide you from one register mark to the next.
Place the camera (cross in the view) in the center of the register mark and press Start.

5.2.4.2 Automatic detection of register marks

Automatic detection
The system will, by means of a camera picture, automatically detect the position of the register
mark.

Circle or cross as register mark

Specify if the register mark is a cross or a circle.
The geometry requirements are:

2 mm < L < 12 mm
1 mm < T < 0.5 * L
L
T 0.08 in. < L < 0.47 in.
0.04 in. < T < 0.5 * L

2 mm < R < 12 mm

R
0.08 in. < R < 0.47 in.

Search
If no register mark is detected inside the camera picture, the system will try to search for a register
mark around the expected location (twice the size of the camera picture).

42
User Manual, Kongsberg XP

5.2.5 Workflow

5.2.5.1 Register on – First sheet only

Reading register marks will be carried out on the first sheet in a job. For the subsequent sheets, no
register mark reading will take place.
The compensations calculated for the first sheet will be used for all sheets in the job, that is, until a
new file is opened.

5.2.5.2 Register on – All sheets

Reading register marks will be carried out for every sheet of material in a job.

5.2.5.3 Continue with last found register mark set

If, for any reason, reading register marks fails, the job will continue, using the last register mark
information available.

5.2.6 Transformation

5.2.6.1 Offset and rotation only

The design is offset and rotated. No scaling is applied. To calculate

rotation minimum two marks are required.

5.2.6.2 Common X/Y scale (Uniform)

In addition to offset and rotation, the system will calculate a scale

factor.
Both axes are scaled with the same factor.

5.2.6.3 Different X/Y scale (non-uniform)

With this option, offset, rotation and scale is calculated, allowing

different scale factors for the main design axes. Minimum three register
marks are required.

43
User Manual, Kongsberg XP

5.3 Work with ARS (Automatic Registration System)

5.3.1 The camera window

This window is available from:
 Registration setup->Camera setup
 It pops up each time a register mark is searched for / detected.

5.3.2 Camera control

Three different camera control views are available from the tabs on top of window:
This is the default view where the camera picture is shown. In the picture there
is a red marker to indicate the centre of the picture.
Image The green circle indicates that high accuracy area. If a register mark is detected
outside this area the machine moves the camera centre over the register mark and
takes a second picture.
This tab defines which camera to be used and also which camera that creates the
Image.
Camera
The only time the operator needs to use this tab is when a new camera is installed
(1).

Misc This tab is used when entering the license code (1).

(1) For more information, see Installation Guide for XP available on the XP-Guide CD.

44
User Manual, Kongsberg XP

5.3.3 Other camera controls

Camera info Informational messages from the camera control.

Press this button to enable live video. The camera picture will be continuously
Live Video
updated.
One single picture will be taken. If a register mark is available in the picture, it will
Snapshot
be detected.

Adjust offset Run wizard in order to adjust the offset of the camera.

Calibrate
Run wizard to calibrate the camera.
Camera

45
User Manual, Kongsberg XP

5.3.4 Pre-defined register marks

ArtiosCAD

When the position of the register marks is included in the Input file to XP-Guide, we call it pre-
defined register marks.

From ArtiosCAD, a maximum of 4 pre-defined register marks can be added to the design.
A description on how to generate register marks in ArtiosCAD is available from the document
ServiceGuide_ArtiosCAD - Kongsberg on the XP-Guide CD.

46
User Manual, Kongsberg XP

5.3.5 Reading pre-defined register marks automatically

Take care:
 Knife blades are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use ear protection.

Select this alternative if:

 An ARS – camera is available.

 Standard register marks are available on the upward face of the material on the cutting
table, visible to the camera.
 Coordinates for the registration marks are defined in the input file. ArtiosCAD and Digital
Flexo Suite are able to do so.

5.3.5.1 Procedure

 Prepare for the job as described in the User manual for XP.
 Select Automatic operation and options as described in chapter „ARS – modes of operation‟
(40).
 During execution, the register marks are examined one by one and compensations are
calculated before the job is completed.
 If, for any reason, the register mark is not detected, the execution will stop and a picture is
displayed in the GUI. The following alternatives are available:
1. If the register mark is visible inside the picture frame, position the mouse pointer in the
center of the register mark and click the mouse.
2. If the register mark is not visible, move the machine by manual jog until the register
mark is inside the picture and press Start.
3. Select Ignore this mark (this register mark) and press Start.

47
User Manual, Kongsberg XP

5.3.6 Reading pre-defined register marks manually

Take care:
 Knife blades are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use ear protection.

Select this alternative if:

 Register marks are available, but the marks can not be recognized by the camera due to
shape or lack of contrast.
 Automatic register mark detection is not available.
 Coordinates for the registration marks are defined in the input file. ArtiosCAD and Digital
Flexo Suite are able to do so.

5.3.6.1 Procedure using camera

 Prepare for the job as described in the User manual for XP.
 After Start, the execution will stop for each register mark and the camera picture is displayed
in the GUI. Two alternatives are available:
1. Use the register mark by mouse click
 By manual jog, move the camera to a position where the register mark is
inside the picture.
 In the picture, move the cursor over the center of the register mark and press
the left mouse button.
 If the mouse-click was inside the green circle, the machine will move to the
next register mark and the procedure is repeated.
If the mouse-click was outside the green circle, the machine will move until the
“click-position” is close to the center of the green circle. Now, move the cursor
over the center of the register mark and press the left mouse button once
more.

2. Use the register mark by jog

 By manual jog, move the camera until the centre cross is exactly on top of the
register mark.
 Press Start to continue execution.

 After the last register mark is found, the compensation parameters are calculated and the job
is completed.

48
User Manual, Kongsberg XP

5.3.6.2 Procedure using laser pointer

 Prepare for the job as described in the User manual for XP.
 After Start, the execution will stop for each register mark.
 By manual jog, move the laser pointer into the center of the register mark.
 Press Start to move to the next register mark and repeat the procedure.
 After the last register mark is found, the compensation parameters are calculated and the job
is completed.

5.3.7 Reading manually defined register marks

Take care:
 Knife blades are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use ear protection.

Select this alternative if:

 No pre-defined register marks are available in the input file.

5.3.7.1 Procedure

 Specify Manual Register mark input and other Registration setup parameters as described
in chapter ARS – modes of operation (41).
 Enter the X/Y distance from the register mark to design blank, see (41).
 Depending upon the selected mode of operation, follow one of the procedures for reading
pre-defined register marks as found in chapter „Work with ARS‟ (44).

49
User Manual, Kongsberg XP

5.3.7.2 Manually defined register marks - key parameters

This chapter describes the work flow from Structural design through Graphical design and print and
finally to Corrugated production and how the register marks are treated in the different steps:

Structural design
The structural design is prepared
using a design software tool, as
ArtiosCAD.
The two register marks are
positioned symmetric and in a
known position relative to the
design (Rx and Ry).
In a company working with this
system, one should standardize
these values and use the same
offset (Rx and Ry) in all designs. Ry Ry
Rx Rx

Graphical design and print

The graphical design is prepared
G raphics

using a graphical design software

G raphics

tool.
The structural design template
(output from the CAD system) is
used to correctly position the
graphics and the register marks
relative to the structural design.

Corrugated production
On the Cutting table, the offset
values Rx and Ry must be entered
into the system.
When the position of the register
marks is obtained, offset Rx, Ry is
used to position the structural
design relative to the register
marks.
Ry Ry
Rx Rx

Rx, Ry - distance from Register mark to design blank

50
User Manual, Kongsberg XP

5.3.8 How to make the register mark visible on the up-ward side of the
material
 A typical use of this alternative is when the register mark is on the down-ward side of the
material.
 Use this procedure to make the register mark visible on the up-ward side of the material:

This is the Register mark, which in this

case will be on the down-ward side of
the sheet when cutting and creasing is
carried out.

Place the sheet on a soft surface, and

use an awl to make a hole through the
material.

Keep the awl vertical as you apply

pressure.

51
User Manual, Kongsberg XP

On the rear side, use the awl to round

the hole.
Now, you have transferred the Register
mark to the opposite side of the sheet.
Repeat the procedure for the second
Register mark.

52
User Manual, Kongsberg XP

5.4 Camera calibration

Take care:
 Knife blades are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use ear protection.

5.4.1 Introduction
To achieve maximum accuracy when using ARS, the camera should be calibrated relative to the
laser pointer.
Camera calibration is a three-step process:

Knife tool used 1) The knife tool to be used for camera

for calibration calibration is calibrated relative to the laser
Camera to pointer.
be calibrated 2) The camera is calibrated relative to the knife
tool.
3) The camera position relative to the laser
pointer is calculated based upon the previous
two calibrations.
Laser pointer

Knife tool calibration is not included in this procedure; it is available in the Tool section.
It is important that the knife tool calibration procedure is completed before this procedure is carried
out:

53
User Manual, Kongsberg XP

5.4.2 Procedure
Select the camera calibration wizard:
Option->Registration setup (Alt+R)->Camera setup->Calibrate camera.

1. Select the tool to be used when

making a circle. Use a knife tool.
2. Press Start to make the circle.
3. Press Finish.
4. Press Close to continue.
5. Remove the material from inside the
circle.

The camera dialog will be shown with the circle inside the picture:

1. If camera focus has to be adjusted, do

it now by turning the camera lens in or
out.
2. Click the Snapshot – button and the
machine will move to the next point.
3. Continue to click Snapshot until all
points are completed and the dialog
disappears.
4. The camera is now calibrated.

54
User Manual, Kongsberg XP

5.5 Adjust camera offset

Take care:
 Knife blades are extremely sharp.
 Keep away from all moving parts.
 Ensure all other personnel stays in a safe distance from all moving parts.
 Use ear protection.

Follow this procedure to calibrate the camera position relative to the other tools in the tool holder:

5.5.1 General
 As the camera is mounted outside the tool head cover, it is important that this
test is carried out with the cover mounted.
 All test files to be used are available from the folder: c:\xp-guide\iat
 From Options->Table options, select Manual Vacuum control to ensure
vacuum stays on during the complete procedure.

 From Main Toolbar->Application selection, select Corrugated.

 From Job View Toolbar-> Select Reference point, select Panel Ref. point.

 For this procedure, use a thin sheet of carton (500 x 600 mm) as test material.
 To continue in next chapter

55
User Manual, Kongsberg XP

5.5.2 Procedure

Select Options->Registration setup->Camera setup->Adjust camera offset:

The wizard will create a circle, which will be used for offset adjustment.

From the drop-down menu in the dialog, select the tool to be used, preferably a knife.

With a sheet of material on the table, switch Vacuum on.

Jog to a proper position on the sheet and press Start. Note: In this case, the position is the position
of the camera.

The cross is made and the camera is positioned above the cross. The following dialog appears:

56
User Manual, Kongsberg XP

By Jog and Incremental jog, move the camera until the red marker is exactly in the center of the
circle.

In the dialog, press Finish.

In the Continue Adjustment dialog, press Close.

Switch Vacuum off.

Now, the camera offset is properly adjusted.

57
User Manual, Kongsberg XP

5.6 Verify correct offset adjustment

5.6.1 Draw the test figure

1 Select No registration:
Option->Registration setup (Alt+R)->No registration.
2 Open the file regtestd.acm
3 Place a sheet of carton, 400 x 400 mm, on the table.
4 Switch Vacuum on to keep the sheet in a stable position.
5 Configure Job setup to have a pen tool for line 1, 2 and 5.
6 Jog to a start position (laser pointer) in the –X, -Y corner of the sheet.
7 Press Init.
8 Press Start to draw the file.

5.6.2 Draw the test figure using registration marks

1 Select Register mark input from input file and Camera detection:
Option->Registration setup (Alt+R)->From input file.
Option->Registration setup (Alt+R)->Camera detection.

2 Open the file regtest.acm using the same Job setup (pen tool for line 1, 2 and 5).

3 Move the machine to approximate the same position as used when the test figure
was prepared and press Init.
4 Press Start.
5 The program will automatically read 4 registration marks and execute the file.
6 Inspect the final result. Requirement:
The angles prepared by this file should be positioned exactly on the two registration
marks prepared by the first file.

58
User Manual, Kongsberg XP

6. Work with 123Box

6.1 Introduction
123Box is an add-on to the XP-Guide control software for Kongsberg cutting tables.

The purpose of the program is to offer a simple work flow for preparation and production of standard
corrugated and folding carton boxes.
The solution is based upon a CAD-X implementation using ArtiosCAD functions to select a design
from a library, enter dimensions and generate a cut-file.
The cut-file is automatically opened in XP-Guide, ready to be cut on the Kongsberg cutting table
(for description of ArtiosCAD and CAD-X, see separate chapters).

It is a pre-requisite for this function that ArtiosCAD is installed and configured for CAD-X on the
front end PC.
In Service Guide for 123Box, chapter 3 and 4, you will find a description of how to install and
configure the ArtiosCAD software.

A license key is required for ArtiosCAD to run properly.

6.2 ArtiosCAD, short introduction

Design, Manufacturing and Communication for Packaging.

 ArtiosCAD is the world‟s most popular structural design software for packaging design.
 With dedicated tools specifically designed for packaging professionals for structural design,
product development, virtual prototyping and manufacturing, ArtiosCAD increases
productivity throughout your company.
 ArtiosCAD is the ideal product for all corrugated, folding carton and POP display designers.
Artios CAD's Design Modules are the best there are today.
 The design and drafting tools of ArtiosCAD include functions that structural designers need to
get their job done accurately and efficiently.
 The tool alignment and snapping features provide graphical feedback, helping both
experienced and new users immediately become more productive.
 Complete 3D integration allows for quick prototyping of designs and presentations,
eliminating communication errors and reducing design review cycles.
 ArtiosCAD‟s layout and tooling design features can be used to create plate layouts and die
tooling – optimized for the production equipment that will be used in manufacturing.
 The integrated database and reporting features enhance communication within your company
as well as with external suppliers. ArtiosCAD‟s Adobe® Illustrator® plug-ins truly creates the
first round-trip workflow for structural and graphic designers.

Key benefits

 Superior drafting tools increase packaging designer productivity

 Smart Standards save time and reduce errors
 3D modeling and design provide fast prototyping and presentations
 Powerful and efficient layout and tooling design reduce production costs
 Relational database offers flexible library searches and reports

59
User Manual, Kongsberg XP

6.3 CAD-X, short introduction

 CAD-X is a software module that makes it possible for other programs to use functions from
within ArtiosCAD.
 The CAD-X software is installed as part of XP-Guide.
 It is a pre-requisite for CAD-X to run properly that ArtiosCAD is installed on the PC before
installing XP-Guide.

6.4 Work with 123Box

6.4.1 Introduction
The 123Box workflow can be illustrated as follows:

XP-Guide Select and define CAD-X preview - XP-Guide

settings a new box select Job setup file execution

This chapter will describe each step in detail.

When all default settings are correct, the complete workflow is just a few steps illustrated as:

XP-Guide Select and define CAD-X preview - XP -Guide

settings a new box select Job setup file execution

Press Select and define Press Press

Create a Box a new box Produce Box Start

60
User Manual, Kongsberg XP

6.4.2 XP-Guide settings

For 123Box, the following XP-Guide
settings are necessary:

From Option->System setup:

• Enable CAD-X: must be enabled.

From Main menu->File, select

Create a box… or..

..press the
Fileview toolbar->Create a box button.

61
User Manual, Kongsberg XP

6.4.3 Select and define a new box

From the Create a box – function, the
Standards catalogue dialog is displayed.
Select Corrugated or Folding Carton.

From the list of standard boxes, select the

wanted standard (template) and press
OK.

Select the board to use and press OK.

For setting of default parameters, see

ServiceGuide_123Box, Chapter 3, Boards.

62
User Manual, Kongsberg XP

Enter the dimensions to use.

Press Next to enter the next setup menu.

Note:
The number of menus and parameters
depends upon the actual standard
selected.
Pressing OK will bring you directly to the
CAD-X preview dialog.
This is the recommended choice if you
know that the default settings are correct
for the rest of the parameters.