Spindle Machining Unit Axis Gearbox Reference Points

Reference Files Tools Required Torque Chart
Note: Most common screw sizes shown. Always consult manufacturers recommendations.
Screw Size Grade Torque Specs Range
M5 12.9 7.7-10.3 N-m
M6 12.9 13.1-17.6 N-m
M8 12.9 32.1-42.6 N-m
M10 12.9 64-84 N-m
M12 12.9 110-146 N-m
M16 12.9 274-365 N-m
M20 12.9 534-712 N-m
M24 12.9 923-1231 N-m
Tools Required
1. Set of Metric Allen Wrenches
2. Set of Metric Open End Wrenches
3. HSK 100 Spindle Zero Tool #33.106962
4. Stop Angle (Square)

NOTE:

THIS PROCEDURE MUST ALWAYS BE CARRIED OUT IF THE MOTOR HAS BEEN REMOVED OR REPLACED, OR IF THE TOOL SPINDLE HAS BEEN REMOVED OR REPLACED WITHOUT FIRST ALIGNING AND LOCKING THE MACHINING UNIT GEARBOX.

OVERVIEW:

The gearbox of the machining unit as well as the tool spindle is offset from the spindle servo motor encoder zero mark by 180 degrees. It is therefore necessary to determine the machining unit's gearbox shifting points for 4:1 and 1:1 as well as determine the tool spindle 0.000 degree position when in 4:1 and 1:1.

Step 1: ECPL

Step 2:

Unclamp the spindle.

Step 3:

Open the work area safety door.

Step 4:

Insert the spindle zero tool.

Step 5:

Clamp the tool in the spindle.

Step 6:

Open the rear maintenance door.

Step 7:

Remove stud and locking nut from checking bore on the back of the unit

Check correct position of cover by means of the stamped mark

Step 8:

Manually switch gears into position 4: 1 By pushing the shift cylinder forward toward the machining area.

Step 9:

With spindle zero tool installed, manually rotate spindle to 180 degrees The German corner should in the lower right corner of spindle

Step 10:

On the rear of the spindle gearbox, the dimple should be aligned and the proximity switch should be on (proximity switch is aligned with internal cam)

Step 11:

If it is not aligned manually rotate the spindle until dimple of the intermediate shaft becomes visible in the checking bore.

Step 12:

Switch gears into position 1: 1, by manually pulling the cylinder to the back.

Step 13:

Determine the spindle error and rotate by half the error in the opposite direction beyond the zero position. In this example from A to B to C.

Step 14:

Manually switch gears into position 4: 1

Step 15:

Manually rotate the spindle until the dimple of the intermediate shaft becomes visible in the checking bore.

Step 16:

With spindle zero tool installed, manually rotate spindle to 180 degrees. The german corner shold be in the lower right corner of the spindle.

Step 17:

Clear position values in control 34100 and 35012, set MD active. Perform extended NCK reset.

Machine powers up

Spindle alignment position SPOS=0 is now set in the C1 axis machine data


N34100[0] $MA_REFP_SET_POS e.g. 180.033 (for 1:4 cylinder front) N34100[1] $MA_REFP_SET_POS e.g. 180.138 (for 1:1 cylinder back)


Gear shift position SPOS = 180 is now set in the C1 axis machine data N35012[1] $MA_GEAR_STEP_CHANGE_POSITION e.g. 180.456 (for 1:4 cylinder front) step 41-42 N35012[2] $MA_GEAR_STEP_CHANGE_POSITION e.g. 180.456 (for 1:1 cylinder front) step 42-41

Step 18:

In MDI Mode, enter:

M3S50

G4 F4

SPOS=0.

M30

Step 19:

Spindle will now be out of position. Around 180 degrees. Turn feedrate off, so you can manually rotate spindle. Use square to align spindle.
Control reads 181.311. Enter this value into 34100[0].
Motors off, perform another NCK extended reset.

In MDI Mode:
spos=0.
Spindle will now be at zero (laser Cart sticker at bottom)
Check alignment.

Step 20:

Next set shift position for 4:1 to 1:1

In MDI
M3S100

G4F4

SPOS=180

Run program and spindle will orient to 180 degrees Motors off, open maintenance door. Manually shift the cylinder from 4:1 to 1:1 until gear shifting in smooth by hand. Read spindle position from control (around 180) and enter into 35012[1] shifting position from 4:1 to 1:1 (M41-M42) Motors off, perform NCK extended reset.

Step 21:

In MDA

M3 S100 G4F4

SPOS=0

G4F1

M42

If everything is correct, the machine will shift gears to 1:1

M3 S100 G4F4

SPOS=0

Manually align spindle to zero. Read the position off the control (around 180 degrees) As an example 179.593. Enter value into 34100[1]

Perform an NCK extended reset.

Step 22:

In MDA:

M3

S100

G4F4

SPOS=0

Manually check alignment, German corner should be at upper left corner.
In MDA:

M3

S100

G4F4

SPOS=180

Motors off, open maintenance door. Manually shift cylinder from 1:1 to 4:1 (M42-M41) Shift until smooth. Read value from control (around 180 degrees) Enter value into 35012[2]

Perform NCK extended reset.

Step 23:

Test Program In MDA:

LOOP
M3 S100
G4F4
SPOS=0
G4F2
M41
G4F2
M3 S100
G4F4
SPOS=0
G4F2
M42
G4F2
ENDLOOP

Step 24:

Correct if necessary. For example when you rotate the spindle to zero and it reads 359.497, you must subtract 360.000 - 359.497 = 0.503 and add 0.503 to the value in 34100[0] or [1].