This manual is intended to be used by MachMotion Developers and MachMotion certifiedIntegrators

2000 Series Centerless Grinder Programming Manual2000 Series Centerless Grinder Operating Manual2000 Series Centerless Grinder Setup ManualGrinder Reg Wheel Calculator

Grinder - Centerless

Move the selected grinding axis through a series of moves and then Sparkout and retract.

1. Feed move to "Rapid End Position" at "Rapid Feedrate"2. Feed move to "Coarse End Position" at "Coarse Feedrate"3. Feed move to "Medium End Position" at "Medium Feedrate"4. Feed move to "Fine End Position" at "Fine Feedrate"5. Dwell for the Sparkout amount of time in seconds

Descriptions of parameters:

A - Rapid End PositionB - Rapid FeedrateC - Coarse End PositionD - Coarse FeedrateE - Medium End PositionF - Medium FeedrateH - Fine End PositionI - Fine FeedrateJ - Sparkout Time

Move the selected grinding axis to the retract position

1. Rapid move to "Retract Position" 

Descriptions of parameters:

R - Retract Position

2000 Series CenterlessGrinder ProgrammingManualGrind CyclesG241 In-Feed Grind Cycle

G246 In-Feed Retract Cycle

 

1. Rapid move Y to Machine Zero2. Rapid move X to Machine Zero

1. Rapid move X axis to X dress position plus wheel Clearance Front Side2. Rapid move Y axis to Y dress position plus wheel Clearance Circumference

Description

Checks to see if the wheel is below the minimum diameter after dressing.  If the wheel diameter isbelow the minimum diameter a Macro Alarm is created.

Examples

Wheel Diameter Check

 

Description

Checks to see if the wheel is below the minimum width after dressing.  If the wheel width is belowthe minimum width a Macro Alarm is created.

Grind Wheel Dress CyclesO9511 Rapid To Safety Position From Dresser

O9512 Rapid From Safety To Dresser Clear Position

O9513 Move X To Dresser Front

O9514 Move X To Dresser Back

O9515 Move Y To Dresser Safety

O9516 Move Y To Dress Position

O9517 Move Y To Dresser Clearance

O9521 Wheel Diameter Check

G65 P9521

O9522 Wheel Width Check

Examples

Wheel Width Check

 

T Cycle type number

Description

Changes the cycle type number to update the screen status indicator.

Examples

Change cycle type to Multiple Plunge Grind

 

S Cycle state number

Description

Changes the cycle state number to update the screen status indicator.

Examples

Change cycle state to Grinding Free Pass

 

H Sparkout Time (sec)

G65 P9522

O9523 Change Cycle Type

G65 P9523 T274

O9524 Change Cycle State

G65 P9524 S104

O9525 Sparkout Dwell

Description

Changes the state to Sparkout and then dwells and then restores the state back.

Examples

Sparkout 2 seconds

E Remaining Passes

Description

Update the remaining passes normally used for dress passes.

Examples

Update the remaining passes to 3.

 

1. Increment #9070

1. Zero #9070

1. Rapid move A to Machine Zero2. Rapid move Z to Machine Zero

G65 P9525 H2.0

O9528 Update Remaining Number Of Passes

G65 P9528 E3

O9530 Increment Dress Counter

O9531 Zero Dress Counter

O9532 Increment Dress Positions

 

Regulating Wheel Dress CyclesO9611 Rapid To Safety Position From Dresser

1. Rapid move Z axis to Z dress position plus wheel Clearance Front Side2. Rapid move A axis to A dress position plus wheel Clearance Circumference

1. Increment #9170

1. Zero #9170

 

Parameters:

T - Cycle Type

Parameters:

S - Cycle State

O9612 Rapid From Safety To Dresser Clear Position

O9613 Move Z To Dresser Front

O9614 Move Z To Dresser Back

O9615 Move A To Dresser Safety

O9616 Move A To Dress Position

O9617 Move A To Dresser Clearance

O9621 Wheel Diameter Check

O9622 Wheel Width Check

O9630 Increment Dress Counter

O9631 Zero Dress Counter

O9632 Increment Dress Positions

Internal SubsO9523 Change Cycle Type

O9524 Change Cycle State

Parameters:

H - Sparkout time in seconds 

Parameters:

E - Remaining Passes

0 Idle

1 Positioning

2 Spark-out

3 Finished

4 Free Passes

10 Retracting

11 Repositioning

100 Moving to Grind Position

101 Grinding

102 Gap Grinding

200 Moving to Dress Position

201 Dressing

202 Returning from Dress Position

203 Gap Dressing

O9525 Sparkout Dwell

O9528 Update number of passes remaining

AppendixCycle States

400 Rapid InFeed

401 Coarse InFeed

402 Medium InFeed

403 Fine InFeed

Global Memory

Pound Variable Description

#9040 GW Current Wheel RPM

#9045 GW Current Rotary Dresser RPM

#9065 GW Default Dress Amount

#9066 GW Default Dress Passes

#9067 GW Default Dress Feedrate

#9070 GW Dresser Parts Per Dress Cycle

#9071 GW Dresser Parts Since Last Dress

#9080 Current Cycle State

#9081 Current Cycle Type

#9082 Current Cycle Passes Remaining

#9140 RW Current Wheel RPM

#9145 RW Current Rotary Dresser RPM

#9165 RW Default Dress Amount

#9166 RW Default Dress Passes

#9167 RW Default Dress Feedrate

#9170 RW Dresser Parts Per Dress Cycle

#9171 RW Dresser Parts Since Last Dress

#9999 GW Dress program Sub number

#9998 RW Dress program Sub number

   

 

Grinding Wheel Memory (Wheel Number: 1)

Pound Variable Description

#9000 Diameter

#9001 Width

#9003 Minimum Diameter

#9004 Minimum Width

#9014 Maximum RPM

#9015 Wheel SFM

#9016 RPM

#9017 Dresser Diamond Type

#9018 1 Dress Position

#9019 2 Dress Position

#9024 Tip Radius Diamond 1

#9030 Safety Position In-Feed

#9031 Safety Position 1

#9032 Safety Position 2

#9033 Clearance Circumference

#9034 Clearance Front Side Of Wheel

#9035 Clearance Back Side Of Wheel

#9041 Wheel Dress SFM

#9042 Rotary Dresser Roll Diameter

#9043 Rotary Dresser SFM

#9044 Rotary Dresser RPM

#9047 Rotary Dresser Maximum RPM

#9048 Wheel SFM Mode

#9049 Rotary Dresser SFM Mode

#9050 Rotary Dresser Direction

#9053 Wheel Dress RPM

#9054 Wheel Command Source

#9055 Max Surface Feet Per Min

#9065 Part Loader Memory Tracking Part

   

 

Regulating Wheel Memory (Wheel Number: 2)

Pound Variable Description

#9100 Diameter

#9101 Width

#9103 Minimum Diameter

#9104 Minimum Width

#9114 Maximum RPM

#9115 Wheel SFM

#9116 RPM

#9117 Dresser Diamond Type

#9118 1 Dress Position

#9119 2 Dress Position

#9131 Safety Position 1

#9132 Safety Position 2

#9133 Clearance Circumference

#9134 Clearance Front Side Of Wheel

#9135 Clearance Back Side Of Wheel

#9141 Wheel Dress SFM

#9142 Rotary Dresser Roll Diameter

#9143 Rotary Dresser SFM

#9144 Rotary Dresser RPM

#9147 Rotary Dresser Maximum RPM

#9148 Wheel SFM Mode

#9149 Rotary Dresser SFM Mode

#9150 Rotary Dresser Direction

#9153 Wheel Dress RPM

#9154 Wheel Command Source

#9155 Max Surface Feet Per Min

   

   

1900 Upper or Lower Slide Selected. Upper = 0, Lower = 1

1902 Enabled Axes Bits.  Bit0 = X, Bit1 = Y...

1903 Upper Slide Axis ID

1904 Lower Slide Axis ID

1910 Wheel Diameter Lock (1 = Lock, 0 = Unlock)

1911 Wheel Width Lock (1 = Lock, 0 = Unlock)

1912 In-Feed Cycle Incremental or Position Default isIncremental (0 = Incremental, 1 = Diameter)

1915 Grinding Wheel Dresser Diamond In-Feed Axis Direction (1= Standard, -1 = Reversed)

1916 Regulating Wheel Dresser Diamond In-Feed Axis Direction(1 = Standard, -1 = Reversed)

1917 Fixed Blade Machine (0 = Standard, 1 = Fixed BladeMachine)

1920 In-Feed Cycle Repeat (1 = On, 0 = Off)

1921 Part Loader Enabled (1 = On, 0 = Off)

1922 Thru-Feed Cycle Start Wheels and Coolant (1 = On, 0 =Off)

1923 Grind Wheel Dress Use Cutter Comp (1 = On, 0 = Off)

1924 Park Grinding Wheel Dresser in the Rear (1 = On, 0 = Off)

1925 Park Regulating Wheel Dresser in the Rear (1 = On, 0 =Off)

1926 Turn Off Coolant at end of cycle (1 = On, 0 = Off)

1927 Disable Interlock that forces the Regulating wheel to be onbefore the grinding wheel

1928 Start and stop Regulating wheel and coolant during In-Feed Cycle (1 = On, 0 = Off)

1929 Disable Wheels Starting Automatically in Cycles (1 = On, 0= Off)

 

GCode Parameters

1930 Part Loader - Stop Regulating Wheel and Main Coolant (1 =On, 0 = Off)

1931 GW Dress Cycle Number, If not set the default is 260

1932 RW Dress Cycle Number, if not set the default is 360

 

 

 

This manual is designed to give the operator a working understanding of how to operate your newCNC Centerless Grinder. The control is designed to simplify the operation of your CenterlessGrinders high-end features. We have elected not to use g-codes to manipulate the servo axis.Instead, we use the combination of a simplified data entry routine with a graphic interface that theoperator will find extremely easy to use.

Each page contains items that are used specifically for the function of the individual screen likestarting and stopping motors, changing cycle modes, entering new feedrates and positions, etc.

There are other items that are used globally. This means that the same items are found on all ofthe pages. Primarily they are the machine state, cycle time, and date and time at the top of thescreen, the axis position, cycle status, current feedrate, and wheel speed on the right side of thescreen.

The following is a description of the Operator Panel and it's functional devices. The numberedballoons point to the object.

2000 Series CenterlessGrinder Operating Manual 

Introduction

Operator Panel Overview

1. Computer HMI. Consists of screens designed to control the machine functions andfeedback information on the machine state.

2. Emergency Stop Button. Used to stop process and motors in the event of anemergency, by turning off all active output logic.

3. Cycle Start Button. Used to initiate an automatic cycle and confirm actions.4. Feedhold Button. Used to pause an automatic cycle in place.5. Cycle Stop Button. Used to stop an automatic cycle in place.6. Reset Button. Used to clear or reset machine faults and enable system servo motors.7. Rapid Speed Control Buttons. Used to change the speed the machine moves during

rapid moves.8. Feedrate Override Knob. Used to change the speed the machine moves during feed

moves.9. Spindle Control Buttons. Used to start and stop the wheel and change the speed

override value.10. Programmable Function Buttons. Used to customize the control.11. Jog Control Buttons. Used to manually jog servo axes while the machine is not in a

cycle.12. Jog Speed Knob. Used to control the speed during manual jog moves.

The control supports an In-Feed cycle for plunge grinding and a Thru-Feed cycle for bar grinding.  Italso supports Grind Wheel and Regulating Wheel Dressing (Truing) with up to 2 coordinated axeseach. 

Control Overview

Easily navigate the 5 pages of the screen using the tab menu at the bottom of the screen.  Thecontrol will seamlessly switch operating modes following the active page and update the AxisPosition group to only show the relevant axes for that operation.

Screen Navigation

1. StatusStatus - Displays any current messages (Home All Pressed, Cycle Start Pressed, etc.)State - Displays the current state of the machine (Run, Feed Hold, etc)Cycle Time - Displays how long the GCode has been runningDate - Date and time of the timezone of the control

2. Operation PagesIn-Feed Cycle Page

Thru-Feed Cycle Page

Grind Wheel - Setup and Dressing Page

Regulating Wheel - Setup and Dressing Page

Service

Maintenance and Support

Dashboard

Machine I/O

Grinder Settings

Program

3. Operation DisplayAxis Position DisplayCycle StatusFeedrate DisplayGrind Wheel DisplayRegulating Wheel Display

4. Grinder DashboardConfigurable Dashboard with Widgets for machine auxiliaries (Hydraulics, MistCollectors etc.)

5. Side Bar DashboardConfigurable Dashboard with Widgets for productivity

The In-Feed Grinding cycle begins at the Load Position and rapids to the start of the Coarse grindand continues through Medium and Fine with optional Feedrates and pauses until it reaches theFinish Position and pauses to spark-out.  Then rapids to the Retract Position and completes thecycle at the Load Position. 

In-Feed Cycle

Retract Position: The position the slide will move to at the end of the cycle to drop oreject the part.  When the Retract Position is not needed set the make it equal the LoadPosition.

In-Feed Cycle ParametersPosition Parameters

Load Position: This is the first and last slide position in the cycle.Finish Position: This is the final grind position and the position that Fine, Medium andCoarse grind amounts are referenced from.  The Finish Position can be set to a diameteror 0 depending on the setup.

Coarse GrindCoarse Grind Amount: The amount to be removed at the Coarse FeedrateCoarse Feedrate: The Feedrate used during Coarse grindT1: Optional Delay at the end of the Coarse grind

Medium GrindMedium Grind Amount: The amount to be removed at the Medium FeedrateMedium Feedrate: The Feedrate used during Medium grindT2: Optional Delay at the end of the Medium grind

Fine GrindFine Grind Amount: The amount to be removed at the Fine FeedrateFine Feedrate: The Feedrate used during Fine grindT3: Optional Delay at the end of the Fine grind, sometimes referred to as SparkoutTime

Retract DelayT4: Optional Delay at the Retract position to allow the part to drop between theRegulating Wheel and Grinding Wheel

Load DelayT5: Optional Delay at the end of the cycle.  This is normally used along with CycleRepeat to allow time to load the next part.

Comp is used to adjust the part diameter.   For more info see Compensation.

Cycle Parameters

In-Feed Comp

For info on Grind Position calibration see Grind Position Calibration

Thru-Feed Grinding will rapid the slide to the Grind Position and stay there. 

Cycle Start button is used to start the In-Feed cycle.

At any point Cycle Stop or Retract buttons will cause the slide to Rapid to the RetractPosition.

Thru-Feed Cycle

Retract Position: The position the slide will move to when Cycle Stop or Retract areused.Finish Position: This is the position the slide will move to when the cycle is ran.

When the slide is at the Grind Position and Comp offset is applied the slide will move back to theGrind Position.  When the slide is at any other position than the Grind Position the slide willapply the offset without any movement.  For more info see Compensation.

Thru-Feed Cycle Position Parameters

Thru-Feed Comp

For info on Grind Position calibration see Grind Position Calibration

The Grind Wheel Page is where the Grind Wheel parameters and dress parameters are configured. Depending on the enabled options of the machine some of these parameters will be hidden. 

Use the following figure for Grind Wheel dimensions and clearances

Cycle Start button is used to start the Thru-Feed cycle.

At any point Cycle Stop or Retract buttons will cause the slide to Rapid to the RetractPosition.

Grind Wheel

Diameter: The current wheel diameter.  The dressing cycle automatically updates thewheel diameter.  When a new wheel is mounted on the machine this parameter should beupdated. Minimum Diameter: When the wheel is dressed to this diameter the control will notallow any more dress cycles to complete.  The operator will get a alarm messages statingthat the wheel is to small.Width: The current width of the wheel, used in the straight dressing cycles.Minimum Width: When the wheel is side dressed to this width the control will not allowany more dress cycles to complete.  The operator will get a alarm messages stating thatthe wheel is to narrow.Clearance Circumference: This is used in the dress cycle, the diamond will rapid to thisclearance position and then switch to a feedrate move before touching the wheel.Clearance Front Side: This is used in the dress cycle, the diamond will rapid to thisclearance position and then switch to a feedrate move before touching the wheel.Clearance Back Side: This is used in the dress cycle, the diamond will rapid to thisclearance position and then switch to a feedrate move before touching the wheel.Max Wheel RPM: Max RPM the wheel can be commanded to run.  Check the wheel specsand keep this number under it.Wheel SFM: The commanded Surface Feet Per Minute or (SFM).  There are buttons justbelow that set the mode, RPM Mode or SFM Mode.Wheel RPM: The commanded Rotations Per Minute or (RPM).  There are buttons justbelow that set the mode, RPM Mode or SFM Mode.Wheel Speed Mode: RPM Mode or SFM Mode switch the command source betweenWheel RPM and Wheel SFM modes.

Grind Wheel Parameter Descriptions

1. Using the Jog buttons or MPG, Jog the GD (X) axis so the diamond is just touching thefront side of the wheel.

Grind Wheel Diamond Setup

2. Press the yellow Teach button for X.3. Using the Jog buttons or MPG, Jog the GD (Y) axis so the diamond is just touching the

circumference of the wheel.

4. Press the yellow Teach button for Y.

Diamond Comp can be used at anytime and during a dress cycle to move the diamond in closer tothe wheel.  Sometimes the wheel will wears a lot between dress cycles, and this can be use toreduce the number of dress passes.  For more information see Compensation.

The control supports two dress cycles for the wheels, Standard Dress and New Wheel Dress.  Bothof these cycles are very similar and allow you to store two sets of parameters, one for normalproduction (Standard Dressing) and one set of parameters for shaping a wheel (New Wheel Dress). 

Use the following table to compare the dress cycles:

Dress Cycle Features Standard Dress New Wheel Dress

Y Diamond Comp

Dress Cycles

Dress Rate Yes Yes

Dress Passes Yes Yes

Dress Amount Yes Yes

Spark-Out Passes (Free Passes) Yes No

Changing the profile of the wheel No Yes

The Standard Dress is the default dress cycle and would be used after the wheel has been shapedand is ready for production.  Standard Dress will use whatever profile was selected on the NewWheel Dress page. 

Dress Rate: The feedrate the diamond will travel across the wheel.Dress Passes: The number of passes the diamond will make across the wheel.Dress Amount: The amount mount of wheel to remove per pass.  The amount is in radiusof the wheel so 0.001 will change the wheel diameter by 0.002.

Standard Dress

Standard Dress Parameters

Spark-Out Rate: The feedrate the diamond will travel across the wheel during the Spark-Out Pass or Free Pass.Spark-Out Passes: The number of passes the diamond will make across the wheelwithout in-feeding the diamond into the wheel.  Sometimes this type of pass is called aFree Pass.In-Feed Parts Per Pass: This is only used in the In-Feed Cycle and will cause the controlto automatically call a dress cycle after the number of cycles is greater than the value inthis parameter.  A value of 0 disables this feature. 

The New Wheel Dress is the cycle used to create the profile in the wheel and to rough the wheelinto shape.

Dress Rate: The feedrate the diamond will travel across the wheel.Dress Passes: The number of passes the diamond will make across the wheel.Dress Amount: The amount mount of wheel to remove per pass.  The amount is in radiusof the wheel so 0.001 will change the wheel diameter by 0.002.Custom Profile: When the Custom Profile is off the dress profile will be a straight profileand use the Grind Wheel Parameters to make the profile.  When Custom Profile is on therewill be a subroutine with a profile that the diamond will follow.

New Wheel Dress

New Wheel Dress Parameters

The control supports Straight Profile and Custom Profile.  The straight profile uses the data from theGrind Wheel Parameters and the custom profile uses the Grind Wheel Profile Dressing dialog todraw any custom profile.  To switch between the straight and custom profiles turn the CustomProfile on or off.

When the Custom Profile is off the dress profile will be a straight profile and use the Grind WheelParameters to make the profile.

When the Custom Profile is on the the dress cycle will use the Subroutine that is created with theprofile number.

Profile Number shows the selected Profile to use. To change the profile press Open.There are 3 buttons for creating opening and editing the custom profiles. 

New will open the Grind Wheel Profile Dressing dialog with blank profile.Open will open a File Browser dialog and allow you to select a profile.Edit will open the current profile in the Grind Wheel Profile Dressing dialog.

Cycle Start button is used to start the Dress cycle.

Wheel Profiles

New Wheel Dress - Straight Profile

New Wheel Dress - Custom Profile

Custom Profile

Grind Wheel Profile Dressing

The Grind Wheel Profile Dressing is where you create your custom dress profile for the wheel.  Theprofile can be a mixture of lines and arcs.  There are four columns Type, X Position, Y Position andRadius showing the data for the given line or arc segment. The example below has profile number2005 loaded.

Use the Add button to add an new line or arc.  The new segment values will be copied from theprevious segment.  Use the Type field to change between a line or clock wise (CW) and counterclock wise (CCW) arcs.  All positions can be modified at any time, click on a value and it willhighlight to green to show it can be changed.

Use the Remove button to remove any line segment.

Open: Open a different dress profile

Add: Add new line segment to the dress profile

Remove: Remove a line segment from the dress profile

Save As: Save the profile with a new name

Add Line Segment

Remove Line Segment

Profile Operations

Save: Save the current profile

The Regulating Wheel Page is where the Regulating Wheel parameters and dress parameters areconfigured.  Depending on the enabled options of the machine some of these parameters will behidden. 

Use the following figure for Regulating Wheel dimensions and clearances

Diameter: The current wheel diameter.  The dressing cycle automatically updates thewheel diameter.  When a new wheel is mounted on the machine this parameter should beupdated. 

Regulating Wheel

Regulating Wheel Parameter Descriptions

Minimum Diameter: When the wheel is dressed to this diameter the control will notallow any more dress cycles to complete.  The operator will get a alarm messages statingthat the wheel is to small.Width: The current width of the wheel, used in the straight dressing cycles.Minimum Width: When the wheel is side dressed to this width the control will not allowany more dress cycles to complete.  The operator will get a alarm messages stating thatthe wheel is to narrow.Clearance Circumference: This is used in the dress cycle, the diamond will rapid to thisclearance position and then switch to a feedrate move before touching the wheel.Clearance Front Side: This is used in the dress cycle, the diamond will rapid to thisclearance position and then switch to a feedrate move before touching the wheel.Clearance Back Side: This is used in the dress cycle, the diamond will rapid to thisclearance position and then switch to a feedrate move before touching the wheel.Max Wheel RPM: Max RPM the wheel can be commanded to run.  Check the wheel specsand keep this number under it.Wheel SFM: The commanded Surface Feet Per Minute or (SFM).  There are buttons justbelow that set the mode, RPM Mode or SFM Mode.Wheel RPM: The commanded Rotations Per Minute or (RPM).  There are buttons justbelow that set the mode, RPM Mode or SFM Mode.Wheel Speed Mode: RPM Mode or SFM Mode switch the command source betweenWheel RPM and Wheel SFM modes.

Regulating Wheel Diamond Setup

1. Using the Jog buttons or MPG, Jog the RD (Z) axis so the diamond is just touching thefront side of the wheel.

2. Press the yellow Teach button for Z.

3. Using the Jog buttons or MPG, Jog the RD (A) axis so the diamond is just touching thecircumference of the wheel.

4. Press the yellow Teach button for A.

The control supports two dress cycles for the wheels, Standard Dress and New Wheel Dress.  Bothof these cycles are very similar and allow you to store two sets of parameters, one for normalproduction (Standard Dressing) and one set of parameters for shaping a wheel (New Wheel Dress). 

Use the following table to compare the dress cycles:

Dress Cycle Features Standard Dress New Wheel Dress

Dress Rate Yes Yes

Dress Passes Yes Yes

Dress Amount Yes Yes

Spark-Out Passes (Free Passes) Yes No

Changing the profile of the wheel No Yes

The Standard Dress is the default dress cycle and would be used after the wheel has been shapedand is ready for production.  Standard Dress will use whatever profile was selected on the NewWheel Dress page. 

Dress Cycles

Standard Dress

Dress Rate: The feedrate the diamond will travel across the wheel.Dress Passes: The number of passes the diamond will make across the wheel.Dress Amount: The amount mount of wheel to remove per pass.  The amount is in radiusof the wheel so 0.001 will change the wheel diameter by 0.002.Spark-Out Rate: The feedrate the diamond will travel across the wheel during the Spark-Out Pass or Free Pass.Spark-Out Passes: The number of passes the diamond will make across the wheelwithout in-feeding the diamond into the wheel.  Sometimes this type of pass is called aFree Pass.In-Feed Parts Per Pass: This is only used in the In-Feed Cycle and will cause the controlto automatically call a dress cycle after the number of cycles is greater than the value inthis parameter.  A value of 0 disables this feature. 

The New Wheel Dress is the cycle used to create the profile in the wheel and to rough the wheelinto shape.

Standard Dress Parameters

New Wheel Dress

Dress Rate: The feedrate the diamond will travel across the wheel.Dress Passes: The number of passes the diamond will make across the wheel.Dress Amount: The amount mount of wheel to remove per pass.  The amount is in radiusof the wheel so 0.001 will change the wheel diameter by 0.002.Custom Profile: When the Custom Profile is off the dress profile will be a straight profileand use the Regulating Wheel Parameters to make the profile.  When Custom Profile is onthere will be a subroutine with a profile that the diamond will follow.

The control supports Straight Profile and Custom Profile.  The straight profile uses the data from theRegulating Wheel Parameters and the custom profile uses the Regulating Wheel Profile Dressingdialog to draw any custom profile.  To switch between the straight and custom profiles turn the Custom Profile on or off.

When the Custom Profile is off the dress profile will be a straight profile and use the RegulatingWheel Parameters to make the profile.

New Wheel Dress Parameters

Cycle Start button is used to start the Dress cycle.

Wheel Profiles

New Wheel Dress - Straight Profile

When the Custom Profile is on the the dress cycle will use the Subroutine that is created with theprofile number.

Profile Number shows the selected Profile to use. To change the profile press Open.There are 3 buttons for creating opening and editing the custom profiles. 

New will open the Regulating Wheel Profile Dressing dialog with blank profile.Open will open a File Browser dialog and allow you to select a profile.Edit will open the current profile in the Regulating Wheel Profile Dressing dialog.

The Regulating Wheel Profile Dressing is where you create your custom dress profile for the wheel. There are four columns Type, Z Position and A Position showing the data for the given linesegment. The example below has profile number 3010 loaded.

New Wheel Dress - Custom Profile

Custom Profile

Regulating Wheel Profile Dressing

Use the Add button to add an new line.  The new segment values will be copied from the previoussegment.   All positions can be modified at any time, click on a value and it will highlight to greento show it can be changed.

Use the Remove button to remove any line segment.

Open: Open a different dress profile

Add: Add new line segment to the dress profile

Remove: Remove a line segment from the dress profile

Save As: Save the profile with a new name

Save: Save the current profile

Add Line Segment

Remove Line Segment

Profile Operations

Before running parts on the control, be sure the following steps have happened after starting thecontrol software:

Machine is homed.Part setup is complete.The Grind Position has been calibrated.The In-Feed Cycle Parameters or Thru-Feed Cycle Position Parameters cycle parametersare set.Starting the cycle:

In-Feed Cycle: Press "Cycle Start" while the In-Feed page is active.Thru-Feed Cycle: Press "Cycle Start" while the Thru-Feed page is active.

Before dressing the wheels, be sure the following steps are complete:

Machine is homed.Mount the wheels on their respective spindles.Set the regulating wheel to the proper angel.Follow the Grind Wheel Diamond Setup and the Regulating Wheel Diamond Setup.Configure the dressing profiles for both the Grind Wheel and Regulating WheelStarting the cycle:

Grind Wheel Dress: Press "Cycle Start" while the Grind Wheel page is active. Make sure to select between a Standard dress or a New Wheel dress.Regulating Wheel Dress: Press "Cycle Start" while the Regulating Wheel page isactive.  Make sure to select between a Standard dress or a New Wheel dress.

OperationsRunning Grinding Cycle

Dressing the Wheels

AppendixStart-Up Sequence

1. Apply power to the control2. Press the Reset button on the operator panel. The control will go through it's start-up

sequence. Allow time for the computer to start up.3.  Start the Mach4 application from the shortcut on the desktop. Allow time for the system

to initialize.4. Press Cycle Start when the control requests to Enable and Home the servo axes.

Most machines are configured with a Enable and Home dialog that will be shown on startup.

Press the Cycle Start button on the dialog or the Cycle Start button on the operator panel.  Themachine will enable the servos and home to the switches.

If for some reason this dialog is not shown you can manual enable the machine by pressing Resetand then navigate to the Service page.

Homing Machine

Home each axis individually or press Home All to home all axes.

Part Setup can very from machine to machine, so this is a very general outline to part setup.  Thefollowing drawing is a setup with the work height above centerline.

Part Setup

 

A Centerless grinder has three main components: a grinding wheel, a regulating wheel and aworkblade.

1. Select the blade of proper material, thickness and top angle.2. Clamp the workblade with the correct relationship of the part center height above the

wheel’s centerline.3. Clamp the workrest to the lower slide.4. Mount the wheels on their respective spindles.5. Set the regulating wheel to the proper angel.6. Dress Regulating Wheel7. Dress Grinding Wheel8. Select the proper regulating wheel speed.9. Set the regulating wheel distance to the workblade.

10. Entrance/exit guide alignment.

Part Calibration should be done after the Part Setup steps have been complete.

1. Place a part on the Workblade and if needed start the Regulating Wheel and Grind Wheel.2. Using the Jog buttons or MPG, Jog the slide in so the part is just touching the Grind Wheel.3. Press the grey Edit Offsets button. When this is active the Edit Offsets button will change

to yellow.

Grind Position Calibration

Calibration

4. When Edit Mode is active the Position DROs will be editable and there will be Zero buttonsnext to the DROs.

5. Press the Zero button or click into the DRO and Input the desired position and pressEnter.

6. Press the yellow Edit Offsets button to lock the offsets.

Now the Grind Position should be calibrated.

Compensation or Comp is used to adjust the slide offsets to maintain the part diameter as thewheel breaks down and wears.  It can also be used to adjust the diamonds closer to the wheelwhile dressing.  Comp acts differently depending on the grinding mode.  See the table below to seehow Comp is applied.

Grinding Mode Adjust slide offsets? Moves to position afteradjustment?

In-Feed Grinding Yes No

Thru-Feed Grinding at Grind Position Yes Yes

Thru-Feed Grinding not at GrindPosition Yes No

Use Compensation to make small adjustments to the Grind Position

Compensation

There are Comp buttons on the screen, and some machines have buttons on panels for applyingComp.  Coarse and Fine Comp buttons allow the operator to choose between two definedincrement sizes.

Total Comp is for the operator to track how much Comp as been applied.  Resting the Total Compwill only zero the Total Comp indicator.

Coarse and Fine Comp amounts are configurable on the Service / Grinder Settings page.

When Comp is being applied and the slide is moving away from the grinding wheel the control canmake an extra move to take up any loss of motion from backlash in the slide.  To enable this optionopen the Interface Config dialog from the Service page and search for Backlash.  Modify thefollowing parameters.

Backlash Move Enabled: This enables and disables the Backlash moveBacklash Move Distance: This is the distance the slide will move when applying Comp

To command a movement using the MDI feature, press the [MDI] button.

Total Comp

Configure Comp Amount

Backlash Move

MDI Programmed Movement

Enter the desired gcode command into the field and press [Cycle Start] to execute thecommand(s). The up/down arrow buttons will scroll through the history of cycled commands. Clickthe [X] or the [MDI] button to close the MDI window.

MachMotion warranty policy is subject to change. Updated information is available at our website:https://machmotion.com/warranty

 

The MachMotion Teamhttp://www.machmotion.com14518 County Road 7240, Newburg, MO 65550(573) 368-7399 • Fax (573) 341-2672

 

Warranty Information

Below is the standard setup for any 2000 series centerless Grinder:

 

Axes Directions

Grind Dress - Moving toward the wheel is negative. 

Comp Directions

Grind DressComp In should make the dresser move toward the wheel the next time you cyclethe dress cycle. When you press Comp In, the machine doesn't move. It only updatesthe grind dress offset which causes the Y axis value to increment.Comp Out should make the dresser move away from the wheel the next time youcycle the dress cycle. When you press Comp Out, the machine doesn't move. It onlyupdates the grind dress offset which causes the Y axis value to decrement.

 

Apollo III Output Name Function (Alsodescription IO in Mach4) Configuration in Mach4 Mach4 Signal

Assignment 

Y0 Y0CR - Lube   Output0

Y1 Y1CR - Unused   Output1

2000 Series CenterlessGrinder Setup Manual

Axis Setup

Basic IO SetupOutputs

Y2 Y2CR - Hydraulic Pump PMC with time delay afterenable turns off Output2

Y3  Y3CR - Grind WheelContactor (if applicable) MM plugin - Grind wheel On Output3

Y4 Y4CR - Reg WheelContactor (if applicable) MM plugin - Reg wheel On Output4

Y5 Y5CR - Coolant Pump Config-> coolant Coolant

Y6 Y6CR - Grind Wheel Coolant MM plugin - lube - on withspindle Output6

Y7 Y7CR - Unused   Output7

 

Apollo III InputName

Function (Alsodescription IO inMach4)

Active Low Configuration inMach4

Mach4 SignalAssignment

X0 Drive Fault - Do NotUse Low Active GMS - disable Input0

X1 X1 - Lower SlideHome     motor 5 home

X2 X2 - Lower Slide Limit     motor 5 limit - +

X3 X3 - Upper SlideLimit      Input3

X4       Input4

X5       Input5

X6       Input6

X7       Input7

X8 X8 - Main CoolantFlow Okay   GMS - disable Input8

Inputs

X9 X9 - HydraulicPressure Okay  

GMS - warning ifhydraulics on(Output# 10) for 5seconds

Input9

X10       Input10

X11       Input11

X12 X12 - Air PressureLow   GMS - disable Input12

X13 X13 - Way LubePressure Low   GMS - disable Input13

X14 X14 - Way Lube LevelLow   GMS - warning Input14

X15 X15 - Overloads Okay   GMS - disable Input15

 

 

PLC Output NameFunction (Alsodescription IO inMach4)

Safety Relay Configuration inMach4

Mach4 SignalAssignment 

Q00.0 7201M - HydraulicPump (Q00.0)   MM plugin -

hydraulics  Output# 10

Q00.17202M - Coolant And/ Or Filter Pump(Q00.1)

  Config-> coolant??? Coolant

Q00.2

7203M - Grind WheelDress MotorContactor (Optional)(Q00.2)

  MM plugin - Grindwheel if used Output# 12

Q00.3 Q00.3 - Reg WheelForward   MM plugin - Reg

wheel on Output# 13

 

Advanced IO Setup with PLCOutputs

Q00.4 Q00.4 - Reg WheelEnable  

PMC -> enable (adddelay so it will enablecorrectly)

Output# 14

Q00.5 Q00.5 - Work Light(Above Safety Circuit) Above MM plugin - Work

light Output# 15

Q00.6 Q00.6 - Unused(Above Safety Circuit) Above   Output# 16

Q00.7Q00.7- Unused(Above Safety Circuit) 

Above   Output# 17

Q01.0Q01.0- Unused(Above Safety Circuit) 

Above   Output# 18

Q01.1 Q01.1- Unused(Above Safety Circuit) Above   Output# 19

         

Q08.0 7501CR - Lube(Q08.0)  

MM plugin - lube - onwith machineenabled; event

Output# 20

Q08.17502CR - GrindWheel Coolant(Q08.1)

  MM plugin - Grindwheel coolant Output# 21

Q08.27503CR - RegDresser Coolant(Q08.2)

  MM plugin - regwheel coolant Output# 22

Q08.37504CR - GrindDresser Coolant(Q08.3)

  MM plugin - grinddresser coolant Output# 23

Q08.4 7506CR - GrindWheel Lube (Q08.4)   PMC -> enable Output# 24

Q08.5 7507CR - Main Air(Q08.5)   PMC -> enable Output# 25

Q08.6 7508CR - Unused(Q08.6)     Output# 26

Q08.7 7509CR - Unused(Q08.7)     Output# 27

         

Q09.0 7511CR - GrindDresser Front (Q09.0)   MM Plugin -

centerless Output# 28

Q09.1 7512CR - GrindDresser Back (Q09.1)   MM Plugin -

centerless Output# 29

Q09.27513CR - GrindDresser Diamond(Q09.2)

  MM Plugin -centerless Output# 30

Q09.3 7514CR - RegDresser Front (Q09.3)   MM Plugin -

centerless Output# 31

Q09.4 7516CR - RegDresser Back (Q09.4)   MM Plugin -

centerless Output# 32

Q09.57517CR - RegDresser Diamond(Q09.5)

  MM Plugin -centerless Output# 33

Q09.6 7518CR - Unused(Q09.6)     Output# 34

Q09.7 7519CR - Unused(Q09.7)     Output# 35

 

PLC InputName

Function (Alsodescription IOin Mach4)

Active Low Configurationin Mach4

Mach4 SignalAssignment 

MachMotinoModbusDevice

I00.0 I00.0 - Unused     Input #20 Input0

I00.1 I00.1 - OverloadsOkay   GMS - disable Input #21 Input1

I00.2 I00.2 - AirPressure Low   GMS - disable Input #22 Input2

I00.3 I00.3 - Way LubePressure Low   GMS - disable Input #23 Input3

Inputs

I00.4 I00.4 - Way LubeLevel Low   GMS - warning Input #24 Input4

I00.5 I00.5 - CoolantFilter Dirty   GMS - disable Input #25 Input5

I00.6 I00.6 - HydraulicFilter Dirty   GMS - disable Input #26 Input6

I00.7I00.7 - GrindWheel HydraulicFilter Dirty

  GMS - disable Input #27 Input7

I01.0 I01.0 - CoolantFlow Okay   GMS - disable Input #28 Input8

I01.1

I01.1 - HydraulicPressure Okay /Bearing atPressure

 

GMS - warning ifhydraulics on(Output# 10) for5 seconds

Input #29 Input9

I01.2 I01.2 - Reg WheelAxis Drive Fault   GMS - disable Input #30 Input10

I01.3I01.3 - Reg WheelResistor Fault(Optional)

  GMS - disable Input #31 Input11

I01.4I01.4 - GrindWheel ResistorFault (Optional)

  GMS - disable Input #32 Input12

I01.5 I01.5 - Unused     Input #33 Input13

           

I08.0 I08.0 - GrindDresser Front   MM Plugin -

centerless Input #34 Input16

I08.1 I08.1 - GrindDresser Back   MM Plugin -

centerless Input #35 Input17

I08.2 I08.2 - RegDresser Front   MM Plugin -

centerless Input #36 Input18

I08.3 I08.3 - RegDresser Back   MM Plugin -

centerless Input #37 Input19

I08.4I08.4 - WheelGuard 

  GMS - warning  Input #38 Input20

I08.5 I08.5 - WheelBalancer Fault   GMS - disable

  Input #39 Input21

I08.6 I08.6 - Unused     Input #40 Input22

I08.7 I08.7 - Unused     Input #41 Input23

I09.0I09.0 - GrindDresser SpeedLow Push Button

  MM Plugin -centerless Input #42 Input24

I09.1

I09.1 - GrindDresser SpeedMedium PushButton

  MM Plugin -centerless Input #43 Input25

I09.2I09.2 - GrindDresser SpeedHigh Push Button

  MM Plugin -centerless Input #44 Input26

I09.3I09.3 - GrindDresser Out PushButton

  MM Plugin -centerless Input #45 Input27

I09.4I09.4 - GrindDresser In PushButton

  MM Plugin -centerless Input #46 Input28

I09.5I09.5 - GrindDresser FrontPush Button

  MM Plugin -centerless Input #47 Input29

I09.6I09.6 - GrindDresser BackPush Button

  MM Plugin -centerless Input #48 Input30

I09.7I09.7 - DresserCoolant FlowOkay

 GMS - disable ifcoolant on for 5sec

Input #49 Input31

Hydraulics

 

 

 

 

Wire up the regulating wheel to Analog Output 0 or Analog Output 1 of the PLC as shown here:Siemens PLC - Wiring SM1234 Analog Card .

Set up the regulating wheel in MachMotion Parameters as shown:

Regulating Wheel SetupSiemens PLC Setup

 

Set Max Speed Range 0 to the max RPM. 

Command the regulating wheel to go max RPM for Speed Range 0 and use a tachometer to confirmit goes the correct speed. If it doesn't, calculate the new Regulating Wheel Max Speed Range 0 asfollows:

Actual RPM / Commanded RPM * Range 0 = New Regulating Wheel Max Speed Range 0

 

This is for when using the X15-02-10 adapter board.

To change the accel and decel you must change these Yaskawa drive parameters:

Pn305 = acceleration

Yaskawa Servo Reg Wheel Speed

Pn306 = deceleration 

Pn300 Speed Reference Input Gain 0.01V/rated speed.  Some systems we need to adjust this tomake the servo go the correct speed.  Current Max RPM / Desired RPM * Value in Pn300.  Example:3000/4625*1000 = 648.  Changing Pn300 from 1000 to 648 increased the motor speed to 4625RPM from 3000 RPM.

1. Copy in the UserModule that is attached to this document to the Profiles\Grinder-Centerless\Macros\Scripts\

2. Map RegulatingWheelSpeedRegister to MachMotion UserValue25.3. Make sure the spindle speed for pulleys in mach matches the spindle speed for the Reg

Wheel

Pn000 digit 0 sets motor direction.

Change it from 0 to 1 if the wheel is spinning backwards

Using the Analog output from Apollo 3 to control theRegulating wheel speed

Reg wheel Direction

Set Control Source to Auxiliary. You must restart Mach4 before proceeding after making thischange.

Set the V1000 Auxiliary Control Max RPM to the max RPM you want the grind wheel to go. 

Next set the Grind Wheel Max Speed Range 0 to the same as the Auxiliary Control Max RPM.Configure the other parameters as follows:

Parameter Name Value Description

Grind Wheel Enabled Yes Enables the grind wheel.

Grind Wheel Input IO -> Yaskawa-V1000_0->Motor_At_Speed

Tells the control when the grind wheelis up to speed.

Grind Wheel Output Speed Mode RPM Tells the grind wheel to send a RPMvalue to the V1000. 

Grind Wheel Output Speed Multiplier 1 Should always be 1. 

Grind Wheel Output IO -> Yaskawa-V1000_0_Auxiliary->FWD Tells the V1000 to start rotating

Grind Wheel Speed Register Register -> Yaskawa-V1000_0_Auxiliary->Command_RPM

Tells the V1000 what speed to rotateat.

 

Grind Wheel SetupV1000 Setup

Now test the grinding wheel speed. Enter in a speed command and monitor the actual speed with atachometer. Make sure your Max Wheel RPM is high enough to allow the commanded speed youwant to command. 

If it isn't correct, calculate the new Max RPM as follows:

Actual RPM / Commanded RPM * V1000 Auxiliary Control Max RPM = New Max RPM. 

Now set the V1000 Auxiliary Control Max RPM and the Grind Wheel Max Speed Range 0 to the newMax RPM. 

Load Meter Setup

 

Grind Wheel Speed Calibration

1. Find out what the max speed they want to command on the wheel is2. Set the "Yaskawa V1000 Auxiliary Control Max RPM", "Grind Wheel Max Speed Range 0",

and the on-screen maximum grind wheel speed to this value.3. Command a speed of half of the maximum RPM and get a tachometer reading to see if it

is going too slow or fast compared to commanded. This is necessary so we don't over-speed and explode the wheel.

If the actual speed is faster than commanded, jump to step 5, then return to step 4.4. Command the full speed and record the tachometer reading.5. Set "E1-04 Max Output Frequency" to its current value multiplied by commanded speed /

actual speed.

 

To enable the Auto Loader, set the pound variable AutoLoaderEnabled in the gcode file to1. Also, setup user button 6 to set the pound variable AutoLoaderEnableButton to 1 or 0 toactivate it or turn it off. 

 

 

 

Hz = "Yaskawa V1000 E1-04 Max Output Frequency" parameter

NewHz = CurrentHz * CommandedSpeed / ActualSpeed

Auto Loader

Reg Wheel Calculator (regwheel):

See attachments on this page for how to calibrate the commanded speed of the Yaskawa drive tomatch the actual speed of the Reg wheel. On any system that is not a 1 to 1 gear ratio, thiscalculator must be used.  

 

Keywords: 14514

 

Grinder Reg WheelCalculator