Operating Manual Honing Machine M641 1 27 · 2017-06-11 · 2.5.1 Material list 2-9 2.5.2 Workpiece list 2-10 2.5.3 Creating a new workpiece 2-11 2.5.4 ... 2-75 2.8.6 System parameters

M641englisch Version 1_27.doc / 19.10.09

M 641

Honing Machine for Heads and Inserts

MONNIER + ZAHNER LTD / CH - 2553 SAFNERN TELEPHONE +41 32 / 356 03 70 � FAX +41 32 / 355 26 54 m z @ m o n n i e r - z a h n e r . c h w w w . m o n n i e r - z a h n e r . c h

Monnier + Zahner AG

Table of contents

19.10.09 1

Table of contents

1 General aspects 1-1

1.1 Machine type and equipments 1-1

1.1.1 Machine type and technical characteristics 1-1

1.2 Equipment 1-3

1.3 Precaution / safety devices 1-4

1.4 Safety specifications and warnings 1-5

1.5 Starting-up 1-10

1.5.1 Transport and installation 1-10

1.5.2 Electric connection 1-10

1.6 Servicing and maintenance 1-11

1.6.1 Maintenance schedule 1-11

1.6.2 Cleaning 1-11

1.6.3 Lubricating instructions 1-11

1.6.4 Pneumatics 1-13

1.6.5 Hydraulics 1-14

1.6.6 Cooling 1-15

1.6.7 Maintenance service by Monnier + Zahner Ltd. 1-17

2 Operating 2-1

2.1 General aspects for the program operating 2-1

2.2 Training of the machine operators 2-1

2.3 Starting the machine 2-2

2.3.1 Moving to reference point 2-3

Monnier + Zahner AG

Table of contents

19.10.09 2

2.4 Description of the conversational screen datas 2-5

2.4.1 Initial page 2-5

2.5 Workpiece parameters 2-7

2.5.1 Material list 2-9

2.5.2 Workpiece list 2-10

2.5.3 Creating a new workpiece 2-11

2.5.4 Copying the workpiece 2-12

2.5.5 TCP/IP-Import 2-13

2.5.6 TCP/IP-Export 2-14

2.5.7 Import/Export data sets (files) 2-15

2.5.8 Calculating the start position of the swivel axis B - Head 2-16

2.5.9 Calculating the start position of the swivel axis B – Insert 2-19

2.5.10 Calculate the start position of the swivel axis B – spine products 2-22

2.5.11 Workpiece parameters (measuring unit) 2-23

2.5.12 Workpiece parameters (time) 2-25

2.5.13 Workpiece parameter (Position) 2-26

2.5.14 Workpiece parameters (2nd processing cycle) 2-28

2.5.15 Workpiece parameters (spray) 2-29

2.5.16 Workpiece parameters (dressing) 2-30

2.5.17 Dressing inserts 2-31

2.5.18 Workpiece parameters (loader) 2-33

2.5.19 Workpiece parameters (loader dressing parameters) 2-35

2.5.20 Workpiece parameters (Process controll) 2-36

2.5.21 Workpiece parameters (Drum magazine) 2-38

2.5.22 Approach parameters 2-40

2.5.23 Calculation of the clamping length of inserts 2-41

2.6 Setting-up 2-42

2.6.1 Description of the keys releasing a movement 2-43

Monnier + Zahner AG

Table of contents

19.10.09 3

2.6.2 Signification of the symbols 2-45

2.6.3 Resetting and zeroing of the measuring head 2-46

2.6.4 Multirange measuring head 2-53

2.7 Processing 2-57

2.8 System parameters 2-60

2.8.1 System parameters (reference distances) 2-61

2.8.2 System parameters (Teaching) 2-65

2.8.3 System parameters (force program) 2-67

2.8.4 System parameters (various) 2-69

2.8.5 System parameters (minimum and maximum values) 2-75

2.8.6 System parameters Marposs Unimar 2-76

2.8.7 System parameters (Loader) 2-77

2.8.8 System parameters (Security zones) 2-78

2.8.9 System parameters (Drum magazine) 2-79

2.8.10 Options printing 2-84

2.8.11 Options TCP/IP 2-85

2.9 Info 2-86

2.10 End 2-87

2.11 Data base 2-87

3 CNC Control 3-1

3.1 List of the M-Functions 3-1

3.2 Variable Timer 3-3

3.3 Machine in- and outputs 3-4

3.3.1 Inputs 3-4

3.3.2 Outputs 3-6

3.4 Errors and warnings 3-9

3.4.1 Machine status 3-15

Monnier + Zahner AG

Table of contents

19.10.09 4

3.5 Procedure after an emergency stop 3-16

3.6 Procedure after having moved on an axis limit 3-16

3.7 Connect M641 to the local area network (LAN) 3-17

3.7.1 Change the security properties for the following two directories 3-17

3.7.2 Announce the machine M641 in your domain. 3-18

3.7.3 Create a new user on your domain 3-20

3.7.4 Start the application M641 automatically 3-21

3.7.5 Adjust the MHIS 3-23

3.8 Software update 3-24

3.9 Modify CNC parameters 3-31

3.10 Operation panel CNC control 3-36

3.10.1 Operation panel 3-36

3.10.2 Operation panel CNC control 3-37

4 Diagrams

Pneumatics 641-03.90

Central lubrication 641-03.50

Electrics (In the electrical cabinet)

5 Prints

Layout and connection plan 641-00.04

Honing unit 641-01.200

Headstock 641-02.150

Measuring unit 641-04.00

Support 641-05.50

Monnier + Zahner AG

Table of contents

19.10.09 5

Dressing unit 641-06.00

Clamping-Unclamping device for heads 640-07.100

6 Manuals specific to apparatus

CNC – Control Fanuc Series210i-MB FANUC

Frequency converter Serie FVR-E11S-EN FUJI

Central lubrication unit LCH 2146 AIR 1-ABA BIJUR

Maintenance unit FRC-1/4-D-MINI FESTO

Chuck 100/3B-250 ROTOR

Measuring unit MHIS / P5 MARPOSS

Coolant aggregate MZA-T10.5632 TURBO SEPARATOR

Control board cooling unit KG 4266 SEIFERT

(In the electrical cabinet)

Electrostatic air filter RON/A 60 SV ELBARON ______________________________________________________________________________

MONNIER + ZAHNER AG General aspects

Operating manual 19.10.09

1-1

Operating Manual Honing machine for heads and inserts

M 641

1 General aspects

1.1 Machine type and equipments

1.1.1 Machine type and technical characteristics

The combined Head and insert honing machine M 641 is remarkable for its flexible use to hone both, heads and inserts. Heads or inserts can be honed by simply changing the tools, the clamping jaws and by selecting the corresponding operation mode of the CNC control Technical data Workpieces: Workpiece diameter: 22 - 60 mm [0.87 to 2.36 inch] Machine: workpiece clamping: pneumatic chuck max. speed workpiece-spindle: 2000 min

-1

drive workpiece-spindle: 1.5 kW max. speed tool-spindle: 5700 min

-1

drive tool-spindle 1.5 kW axis drive: longitudinal axis workpiece / way 120 mm [4.72 inch] / CNC longitudinal feed tools / way 140 mm [5.51 inch] / CNC swivel axis / setting angle / 40°/ CNC Airborne sound measuring: < 70 dB(A) Control: FANUC Series 210i-MB FANUC Series 320i A-4A-88 PC: CPU Card Pentium

® III, Windows

® 2000/XP Professional,

12.1" Color –Touch panel Dimensions: 2400 x 1650 x 1730 mm (l / w / h) [7.87 x 5.41 x 5.68 ft (l / w / h)] Weight: 1750 kg



1-2

Options: Various workpiece fixations (customized) Loading and unloading unit Dressing unit



1-3

1.2 Equipment

Axis drives: Drive workpiece motor: asynchronous LSMV 80L (head / insert) P=1.1 kW / n = 2850 min

-1

frequency converter type E82EV152-4B Lenze drive wheel motor side T5/z= 25 print number 641-02.04 drive wheel tool spindle side T5/z=75 print number 640-01.07 geared belt type 20 T5/610 Drive longitudinal axis: Servo motor FANUC Alpha M3/5000i (workpiece) ball screw HIWIN R20-4T4-RSI-195-322.5-0.03 print number 640-01.31 drive wheel motor side AT5/z= 40 print number 641-02.08 drive wheel workpiece spindle side AT5/z=40 print number 640-01.19 geared belt type 16 AT5/500 safety coupling FHW-F25 Ø 16 mm

[ ∅ 0.63 inch] Drive swivel axis Servo motor FANUC Alpha M3/5000i (workpiece) Harmonic drive: i = 1 : 160 HFUC 32-160-2UJ-P45-SP (31-0930) Drive tool: motor: asynchronous LSMV 80L P=1.1 kW / n = 2850 min

-1

frequency converter E82EV152-4B / Lenze / i = 1:1 drive wheel motor side T5/z= 40 print number 633-03.14 drive wheel tool spindle side T5/z=40 print number 640-02.22 geared belt type 20 T5/650



1-4

1.3 Precaution / safety devices

− The head and insert honing machine M 641 must only be set to work and operated by experts having been trained at Monnier + Zahner Ltd., or by technicians of Monnier + Zahner Ltd.

− The protecting cover is made of a steel plate, thickness 3 mm [0.12 inch]. The window in the door consists of Polycarbonate (Makrolon), thickness 5 mm [0.2 inch].

− In automatic mode and with tool and workpiece spindles running, the door is locked (electric and mechanical security).

− The safety door can only be opened in special operation. The door being open, the axis cannot be moved any more, if the bridging switch has not been actuated.

− The safety switch can be locked individually with three padlocks for servicing and maintenance work (diagnose functions are kept upright); it acts at all movements and energies causing danger.

− Not using the original spare parts may affect the security of the machine.

− Coolant oil vapors are separated by an electrostatic filter (option) and returned into the machine. If the machine is not equipped with an electrostatic filter, it has to be connected to a central filter unit in order to protect the user's health.

Monnier + Zahner AG is not reliable for damages resulting from improper maintenance and operation.



1-5

1.4 Safety specifications and warnings

Particular attention has to be payed to the following safety specifications and warnings that are important to the starting up and operation of the machine: General instructions:

Different safety risks apply during unloading, transport, installation, start-up and operation. The prevailing risks and their prevention are summarized in this chapter.

The Monnier + Zahner machines are quality products which are built in accordance with the recognized technical rules.

The machines are dispatched from the manufacturer’s premises in technically safe condition!

In order to maintain this condition, you have to operate the machine

� in accordance with the descriptions in this operator’s manual,

� in accordance with its designated use and with highest precision and

� to comply with the relevant safety and accident prevention regulations!

Work on and with the machine must be carried out by the corresponding qualified personnel only.

Make sure that all persons entrusted with the assembly, installation, operation and maintenance are adequately instructed in mechanical engineering, precision mechanics, pneumatics, electrical engineering and electronics!

Safety instructions - unloading and transport:

Due to the high weight of the machine, the unloading (e. g. from a truck) and transport of the machine constitute a risk to life and limb and the machine.

For unloading and transport, a suitable fork lift truck with adequate lifting capacity has to be used! Carrying force of at least 2.500 kg!

When using a fork lift truck for transport, make sure that the floor-load capacity is higher than the weight of the fork lift truck and the machine!

All transport paths must be even and secured!



1-6

Personal protection - transport by means of a fork lift truck:

Sliding of the machine or overturning of the for lift truck may cause fatal or severe injuries!

� Lift the machine at the provided points (center of gravity) only!

� Make sure that the floor-load capacity over the whole transport path is sufficient for the weight of the machine and the fork lift truck!

� Avoid jerky acceleration and deceleration of the fork lift truck, in order to avoid tipping over of the fork lift truck!

� Do not lift the machine higher than it is necessary!

� Wear safety clothing (e. g. industrial clothing, helmet, safety gloves, safety boots and safety glasses)!

Collision between persons and fork lift truck or machine may cause fatal or severe injuries!

� Secure the whole transport path by means of e. g. barriers!

� Switch on the warning light of the fork lift truck!

� Make accompanying staff available to secure the transportation. Consider that the driver’s field of vision is blocked up by the machine!

� Make sure that the accompanying staff keeps a safety clearance to the machine or the fork lift truck!

� Always wear safety clothing (e. g. helmet, gloves, safety boots and safety glasses)!

Personal protection in case of a later inner-company transport

Prior to disconnecting the machine from the supply lines, some preliminary measures have to be taken. Disconnection from the electric supply lines. Touching live parts constitutes a risk of a hazardous electric shock! � Switch off all poles of the power supply of the building, before disconnecting

the machine from the mains!

� Use a voltage tester to check the terminals for the presence of power!

� If necessary, place a danger sign to avoid that the power supply is switched on unintentionally!

� Insulate the bare cable ends and protect the circuit breaker against unintentional switching on!

Disconnection from the pneumatic supply line Disconnecting the machine from the pneumatic supply line constitutes a risk of injury caused by a supply hose which is possibly still under pressure. � Close the stop valve at the end of the compressed-air supply line at the

building!

� Wait until the pressure in the supply hose has dropped!

� Wear safety clothing (e. g. safety gloves and safety glasses)!



1-7

Starting up:

Electric main connection

Before connecting the main connection, imperatively read point 1.5.2

connect electric main connection

control with rotating field measuring instrument the sense of rotation at terminals L1, L2, L3. The sense of rotation has to be clockwise (to the right hand side).

only now main switch ON!

Switching on machine

Main switch ON ⇒⇒⇒⇒ security switch ON ⇒⇒⇒⇒ switch to normal operation ⇒⇒⇒⇒ machine ON ⇒⇒⇒⇒ RESET emergency stop ⇒⇒⇒⇒ motors ON ⇒⇒⇒⇒ close safety

door⇒⇒⇒⇒ wait for set-up windows 2000 / XP ⇒⇒⇒⇒ control is initialising.

Operation: Personal protection - machine operation and setting up

When carrying out interventions in the work area during regular machine operation, there is a risk of injuries due to closing clamping systems and grippers and of cuts caused by sharp-edged tools and workpieces!

� Wear safety clothing (e. g. gloves and safety glasses)!

� Do not open the doors of the auxiliary area and/or the electrical cabinet!

� Never bypass the safety devices during regular machine operation (key selector II must be in OFF position and the key must be removed)!

� Inform the responsible skilled personnel when carrying out set-up, service and repair work!

When working in the work area, there is a risk of skin and eye irriations caused by splashing coolant.

� Wear safety clothing (e. g. gloves and safety glasses)!

� Consider that the coolant supply can also be activated while the protective door is open!



1-8

Caution! The operator is responsible that the machine control runs always in the correct machine mode

Danger of collision! The key on the switch for the protection of the system parameters has to be removed and may only be used to change the system parameters.

The significance of the symbols on the control keys is described in detail in the “list of symbols operating panel” or in the manual of the Fanuc control.

Definition of the workpiece and system parameters: see the following prints:

2.8 System parameters

When the doors are open, the axis can only be moved by pressing the bridging switch.

After an EMERGENCY STOP, determine the cause and clear, if necessary, the error before activating motors ON.

Caution!

If an EMERGENCY STOP has been produced, the EMERGENCY switch has to be released and the motors have to be switched on again. After an Emergency-stop the machine must be set into start-position prior to start the honing cycle again.

Danger of collision!



1-9

Servicing, maintenance and cleaning tasks:

Caution!

For servicing, maintenance and cleaning tasks the mainswitch has to be set to OFF and to be secured with a padlock. For servicing and maintenance tasks for which the electric tension has got to be kept upright, the security switch has to be set to OFF and to be secured with a padlock. By no means, servicing, maintenance and cleaning tasks must be performed without having taken one of these two measures!

Mechanical or electrical machine parts may only be exchanged by the manufactuer/authorized dealer or by an expert having received the corresponding professional training (e. g. technician)!

Incorrect and unauthorized work and interventions on machine parts constitute a risk of a hazardous electric shock!

� For any repair work, disconnect all poles of the machine from the mains!

� Work on electrical components must only be carried out in compliance with the manufacturer’s safety instructions!

� Do not reapair any (defective) electrical or mechanical machine parts! These parts have to be replaced by original spare parts of the manufacturer of the machine! The manufacturer cannot be held responsible for any personal injury and/or damages to property resulting from any unauthorized work of this kind!

When exchanging larger machine parts, there is a risk of severe injuries caused by possible uncontrolled sliding of the parts!

� Wear suitable safety clothing (e.g. industrial clothing, safety gloves and safety boots)!

� When working in the area of the containers, adhere to the “Personal protection - hazardous materials” set out in chapter 2.4!

� Do not carry out any heavy disassembly and assembly work by yourself! Use an adequate lift up unit, if necessary!



1-10

1.5 Starting-up

1.5.1 Transport and installation

− The transport has to be done with the utmost care.

− The machine may be transported on a palette trolley.

− It is suggested to set the machine on four shock absorbing plates.

1.5.2 Electric connection

CAUTION: Before the machine is connected to the electric circuit, it is absolutely necessary to check if the machine has been set to the existing tension. This is especially important if the location of the machine has been changed.

− Follow the electric diagram for the main connection.

− Total connection power of the machine: 9.5 kVA, 16 A protected.

− Control with the rotating field measuring instrument the sense of rotation at the terminals L1, L2, L3.



1-11

1.6 Servicing and maintenance

1.6.1 Maintenance schedule

Maintenance position Reference chapter

Maintenance term

To carry out by

Cleaning

chapter 1.6.2 daily Operator/ set-up technician

Central lubrication

chapter 1.6.3 weekly Operator/ set-up technician

Pneumatic maintenance unit

Control pression

chapter 1.6.4

weekly

Operator/ set-up technician

Coolant supply

Control filter tank pressure

Exchange coolant

chapter 1.6.5

daily

regularly customized

Operator/ set-up technician

Maintenance service by Monnier + Zahner AG

chapter 1.6.6 annually recommended

Service- technician

1.6.2 Cleaning

− Clean the machine at least once a week.

− Use the washing tube which has been supplied with the machine. Connect the washing tube with the coolant aggregate. Mind not to rinse under the guides and into the motors.

1.6.3 Lubricating instructions

Central lubricating unit BIJUR Type: LHC 2146 AIR 1 ABA (24 V) / 1.5 l Forced lubrication for all guide rollers, sliding bearings and satellite roller spindles.



1-12

Recommended lubricating oils for central lubrication

− Blasol 743 ISO VG68 / (HPL 68) (oil 5,5° E at 50° C)

− Mobil Vactra 2 ISO VG68 / (HPL 68) (oil 5,5° E at 50° C)

− Mobil DTE Oil Medium ISO VG46 / (HPL 46) (oil 4° E at 50° C) or lubricating oils of equal quality. Control: control weekly if oil has been used. Level and pressure control: If the pressure is not sufficient or if there is not enough oil in the container, an error message will be shown on the display. Specific unit manuals are added to the operating instructions.



1-13

1.6.4 Pneumatics

When the main switch is turned off, the air supply is interrupted by a stop valve. Adjustment of the air pressure:

− 1. Feeding pressure maintenance unit = 5.0 - 6.0 bar

− 2. Air barrier headstock, turret and coupling = 0.5 bar

− 3. Air barrier gear = 0.2 bar Function capability: The function capability of the machine was tested with the following maximum and minimum pressure values of the feeding pressure: Minimum feeding pressure maintenance unit = 4.5 bar Maximum feeding pressure maintenance unit 6.5 bar Control: Check pression weekly

Maintenance unit

1

2 3

Pneumatic connection 6 bar



1-14

1.6.5 Hydraulics

Only existing, when the machine is equipped with a hydraulic chuck. Hydraulic unit: HA20B/HV-L5/39-DS2-DW11-M1 Bachofen AG Recommended hydraulic oils:

− Mobil D.T.E 24 ISO VG32 / (HPL 32) (32 mm2/s, 40°C)

for warm countries:

− Blasol 158 ISO VG46 / (HPL 46) (46 mm2/s, 40°C)

or lubricating oils of equal quality The hydraulic oils has to be changed after 2 years or approx. 3'000 working hours. The oil filter has to be changed after 1'500 hours already. For further maintenance informations, see appendix. Pressure adjustment on the relief-valve jet:25 - 26 bar Pressure adjustment on the pressure reducing valvel: 18 - 20 bar The pressure can be controlled on the manometer of the hydraulic unit. Important: To take the pressure off the hydraulic unit, first motors OFF,

then open the discharge valve on the hydraulic unit (red text). Close the valve again.



1-15

1.6.6 Cooling

A coolant oil should be used. The customer chooses the type of coolant. At Monnier + Zahner Ltd., good results have been achieved with the following coolant: type: Honilo 981 Castrol (steel) Honilo 930 Castrol (ceramic) The coolant has to be changed regularly depending on the pollution. Filter cartridge unit (optional) (only when available) The filter cartridge on the filter cartridge unit also has to be changed regularely, at the latest when the pressure in the filter tank reaches 2.5 bar min. The input pressure amounts to approx. 4.8 bar. When the filter cartridges are new, the output pressure is equal to the input pressure. The output pressure diminuishes with increasing pollution of the filter cartridges. At a minimal pressure of 2.5 bar, a pressure detector signals that the filter cartridges have to be changed. This message is shown on the display of the Turbo separator equipment. When the filter cartridges are not changed, they might burst, and the coolant tank risks to be polluted. When switching on the coolant unit, the output pressure must show 3 bar at least. Control the filter tank pressure daily. Filter cartridge: Type: Flow Pac 718-5-8 0 53 (5 micron) Documentations specific to the the Turbo separator equipment are enclosed with the operating instructions.



1-16

input pressure P=4.8 bar

Output pressure Pmin. = 2.5 bar



1-17

1.6.7 Maintenance service by Monnier + Zahner Ltd.

In order to secure the operatability of the honing machine and to increase the production safety, we suggest a routine inspection and maintenance carried out by our service men on the components listed below: Honing unit – bearings and sealings of the spindle – slide: concertina (cover) – piping and cabling – lubrication tubes Headstock – bearings and sealings of the spindle – chuck – cabling and lubrication tubes All initial adjustments of the machine, such as measuring the machine geometry etc. will be checked and, if necessary, readjusted. To proceed to an efficient maintenance of the machine, the customer will have to stock spare parts or the parts suggested by MZ have to be ordered prior to servicing.

Only specialists of Monnier + Zahner Ltd. are allowed to perform these maintenance tasks.

IMPORTANT! The pressure has to be checked every 6 months and adjusted, if necessary.

MONNIER + ZAHNER AG Operating


2-1

2 Operating

2.1 General aspects for the program operating

On principle, the application M641 operates as a normal windows program. As, however, a touchscreen is used, there are a few special rules to be observed. If a parameter has to be modified, you tip the para-meter’s key and the following dialog screen appears:

2.2 Training of the machine operators

A training of the operators of the machine is planned at the plant of Monnier +Zahner Ltd. The machine may only be operated by persons having been trained at Monnier +Zahner Ltd. The training includes operating, setting-up, resetting, service and maintenance of the machine as well as breakdown repairs.

Input of the actual parameter. Elementary calculations can be made.

Minimum and maximum input value

Cancels the input

Capital/small letters shift

Deletes the sign at the right hand side of the cursor

Deletes the sign at the left hand side of the cursor

Cursor keys

Reject input value Take over input value

Result of the calculationW



2-2

2.3 Starting the machine

− Main switch ON

− Safety switch ON

− Switch to normal operation

− Press key Machine on

− Press RESET Emergency Stop

− Press key Motors ON

− Wait until Windows 2000 / XP has run up

− The control initializes

On the screen appears:

The field „user“ allows to select only the user. According to the user, the corresponding language is shown. Enter now the password in the corresponding field. The service number is shown for the user “admin” only. The service number is newly generated at each start of the program. With this number, you can ask for a password at Monnier + Zahner, which is valid one day. This password authorizes to change the machine configuration (see 2.8.4).

Specification of the keys see operating instructions chapter 3.10 CNC - control



2-3

2.3.1 Moving to reference point

The user having logged-on, the following screen page is shown: (Condition: the option „Machine has 6 axis (loader)“ is activated. See 2.8.4)

• Close the safety door

• Turn the rotary switch to „Automat“

• If the control field '� referencing axis in automatic mode’ is active, all four axis will be referenced automatically, after having tipped the key [referencing all axis]. The axis move to the reference point as follows:

Z-axis: longitudinal workpiece axis (feeding axis workpiece) X-axis: longitudinal axis tool (feeding axis tool) B-axis: swivel axis workpiece spindle



2-4

A-axis: tool turret U-axis: vertical loader axis V-axis: horizontal loader axis

• If the control field '� referencing axis in automatic mode' is deactivated, each one of the four axis has to be referenced manually. The sequence is the same as at the automatic referencing. To reference the axis one after the other, proceed as follows:

o set machine to reference mode o select the axis o activate the key '-' or '+' to start the reference course

• After having referenced all axis, the key [home position] becomes active and the key [referencing all axis] inactive.

• Actuating the key [home position], the machine moves to the home position and the main menu appears.

• Actuating the key [cancel], you go directly to the main menu. (However, a cycle can only be started, when the machine has been referenced.)



2-5

2.4 Description of the conversational screen datas

2.4.1 Initial page

WORKPIECE PARAMETERS In these windows you will find all workpiece specific parameters (see 2.5 parameter input).

SETTING-UP Call the set-up program (see 2.6 Setting-up).

PROCESSING To start the automatic cycle (see 2.7 Processing).

SYSTEM PARAMETERS Input of options for machine mode and reference distances (see 2.8 system parameters).



2-6

MOVING TO REFERENCE POINT (see 2.3.1 Moving to reference point)

OPTIONS Users and tokens are managed here. Select also the appropriate language. Worpiece parameters, system parameters and user data can be printed out by users possessing the necessary token. (See 2.8.9 Options)

INFO Shows all information about the installed software version. (see 2.9 Info)

END Set-back Windows (switch off machine), the user may log-out or the program may be terminated. (see 2.10 End) CHANGE TOOL SET If the process control is switched on (see 2.8.4), you can change from the actual tool set to the second tool set.



2-7

2.5 Workpiece parameters

After having selected the key [workpiece parameters] in the main menu, the display shows the following dialog:

Workpiece name Shows the current workpiece name; as soon as you tip the key [Save], the workpiece parameters are stored in the data base under this name. The key [workpiece list] allows to define new workpieces or to load existing ones. Material Shows the current material; as soon as you tip the key [material list], the display shows where new material can be acquired, deleted or selected (see 2.5.1).

Indicates the current workpiece name

Indicates the actual material

Acquiring and deleting material

Edits notes

Indicates the actual workpiece type

Input of the workpiece blank diameter

Input of the free clamping length

Acquiring, deleting, and copying new workpieces

Rejecting all modifications

All modifications are stored in the data base

All modifications are stored in the machine

Calculating the start position.

At the end of the cycle, the coolant may be switched on for a few seconds.

When teaching the insert, you may use a different clamping length to avoid collisions.



2-8

Note This input field allows to enter different comments referring to the current workpiece. Kind of workpiece Indicates if the current workpiece is a head or an insert. This parameter can only be selected for a new workpiece. Diameter [mm] Input of the diameter of the head or insert blank. Start position Calculating the start position of swivel axis B. see 2.5.8 and 2.5.9. Clamping length [mm] The clamping length is the distance between the shoulder of the workpiece holder and the center of the head or insert. (Calculation of the clamping length of heads see 0) (Calculation of the clamping length of inserts see 2.5.21) Clamping length teach [mm] Inserts with a large collar may cause collisions at teaching, as the run-off is different from grinding. In order to work these inserts all the same, we chose generally for teaching a longer clamping length than for the grinding process. This parameter appears only with inserts; as well in systems parameters „Various“ (see 2.8.4) the option [�� clamping length teaching for inserts] has to be active.



2-9

2.5.1 Material list

List of the existing materials

Actually selected material, will be allocated to the workpiece by tipping ok

Actually selected material is deleted in data base. This is only possible when the material has not yet been allocated to a workpiece.

Input field for new materials.

Adding the new material to the material list.

Back to workpiece parameters’ input without taking over the material.

Back to workpiece parameters’ input with take over of the actually selected material.



2-10

2.5.2 Workpiece list

Existing workpieces in data base

Actually loaded workpiece (if not yet stored, the background will be coloured in red)

Marked workpiece that can be loaded, deleted or copied.

Stores the currently loaded workpiece under the entered workpiece name

Loads the marked workpiece

Deletes the marked workpiece Copies the marked workpiece

Creates a new workpiece (head or insert)

Filter: Searches all workpieces having „sm“ in their names.

Import / export of the workpieces



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2.5.3 Creating a new workpiece

The new workpiece is created. All parameters are set back to the value 0.

For a new workpiece, the type of workpiece can be selected.

Enter the name of the new workpiece.

As soon as the new name has been entered, the workpiece can be created.

Cancel without creating a new workpiece.



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2.5.4 Copying the workpiece

Cancel without copiying the workpiece.

The marked workpiece is copied.

When copying, the kind of workpiece cannot be selected.

Enter the new workpiece name.

As soon as the new name has been entered, the workpiece can be copied.



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2.5.5 TCP/IP-Import

IMPORT: OVERWRITE DATA The control case being activated, eventually existing workpieces will be overwritten without inquiry, when importing. REMOTE MACHINE The datas of the remote machines are collected in the options under TCP/IP (see 2.8.11). Mention all machine names with which you wish to exchange datas. Look up the actual machine name for instance in the system parameters.

Data base filter

3. Import all marked workpieces.

1. Select the remote machine of which you wish to import datas and click connecting.

4. After having imported the datas, interrupt the connection.

2. As soon as you are connected with the remote machine, you will see the workpieces. Activate the control case of the workpieces that you whish to import.

Data base filter of the remote machine.



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2.5.6 TCP/IP-Export

REMOTE MACHINE The datas of the remote machines are collected in the options under TCP/IP (see 2.8.11). Mention all machine names with which you wish to exchange datas. Look up the actual machine name for instance in the system parameters.

Activate the control case of the workpieces to be exported.

Select all remote machines to which you wish to export the workpieces.

Export marked workpieces



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2.5.7 Import/Export data sets (files)

EXPORT: OVERWRITING DATA SETS The control case being activated, eventually existing data sets will be overwritten without inquiry, when exporting. IMPORT: OVERWRITING DATA SETS The control case being activated, eventually existing data sets will be overwritten without inquiry, when importing.

Activate the control case to export the workpiece to a data set.

Data base filter

Activate the control case to import the data set to the data base.

Actual path

Export selected workpieces.

Import selected data sets.

Select drive and path.



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2.5.8 Calculating the start position of the swivel axis B - Head

The start position is copied on the start position of all workpieces (first and second operation).




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There are two possibilities to calculate the start position of the swivel axis B. They can be selected on top of the window, to the left:

1. We assume that the honing tool has been determined to have the

ideal dimensions; this means that the phase of the honing tool runs over the pole above and over the edge of the workpiece below.

The inside and the outside diameter of the honing tool for head processing can be calculated with the following formulae:

2

22dAA

C−+

= CAF ×=

mmtoFOD 108+= mmtoFID 21−=

OD = Honing tool outside diameter ID = Honing tool inside diameter

2. If a honing tool is being used that does not exactly correspond to the dimensions of the workpiece, the phase of the tool runs over the pole, but the phase of the tool below outruns the edge.



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Parameter decription Diameter A Diameter of the head. Distance C As soon as distance C is known, the diameter d, the diameter F and the start position will be calculated. Diameter d As soon as diameter d is known, the distance C, the diameter F and the start position will be calculated. Diameter honing tool D means the inside diameter of an existing honing tool. Overlap e This parameter determines how much the phase of the honing tool should overrun the pole. At 0 mm, the inside diameter of the honing tool goes exactly through the pole. Start position The start position is being calculated automatically from the angle α and the angle XZ. These can be found in the system parameters under value axis (position of axis X and Z in zero position) The calculated start position can be taken over for all tools with the button “Assign values”.

Start postion = α - Angle XZ



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2.5.9 Calculating the start position of the swivel axis B – Insert





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There are two possibilities to calculate the start position of the swivel axis B. They can be selected on top of the window, to the left:

: 1. We assume that the honing tool has been determined to have the

ideal dimension; this means that the phase of the honing tool runs through the pole below in the insert and over the edge of the workpiece at the outside.

The inside and the outside diameter of the honing tool for insert processing can be calculated with the following formulae:

2

22dAA

C−−

= CAF ×=

mmtoFOD 21+= mmtoFID 76−=

OD = Honing tool outside diameter ID = Honing tool inside diameter

2. If a honing tool is being used that does not exactly correspond to the dimensions of the workpiece, the phase of the tool runs below in the insert through the pole, but the phase on the outside of the workpiece outruns the edge.



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Parameter description Diameter A Diameter of the insert. Distance C As soon as distance C is known, the diameter d, the diameter F and the start position will be calculated. Diameter d As soon as diameter d is known, the distance C, the diameter F and the start position will be calculated. Diameter honing tool D means the outside diameter of an existing honing tool. Overlap e This parameter determines how much the phase of the honing tool should overrun the pole. At 0 mm, the outside diameter of the honing tool goes exactly through the pole.. Start position Die start position is being calculated automatically from the angle α and the angle XZ. These can be found in the system parameters under value axis (position of axis X and Z in zero position) The calculated start position can be taken over for all tools with the button “Assign values”.

Start postion = α - Angle XZ



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2.5.10 Calculate the start position of the swivel axis B – spine products

This dialog appears only for inserts. As well, the option [�� start position: use formulas for spine products] has to be switched on (see 2.8.4 ).


Select workpiece



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2.5.11 Workpiece parameters (measuring unit)

Clamping length 1st processing. Only active when processing inserts This clamping length is used to polish the approach radius of the insert. The clamping length must be determined by tests. If the check box is not activated, the clamping length as described in chapter 2.5 workpiece parameters will be taken over.

Fix coupling means that the speed is active already before pressing.

Reject all inputs.

Store inputs in data base.

Take over inputs and store on machine.

Synchronous honing

Conventional honing Pressure at processing

Every 15 seconds the honing tool will be lifted off.

Sparking-out starts at 235µm

Processing stops at 220µm

Clamping length 1st. processing:for inserts only

Switch on tolerance switch point measure

Workpiece may have Maximum 220µm+50µm interfereing.



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Micrometer adjustment workpiece axis Z A clamping length correction can be entered for both the first and the second operation (±0.02mm). The clamping length correction is added to to the clamping length in the workpiece window „Data base“. The tool length is not teached anew. The micrometer adjustment can be used for heads and inserts (see also Fehler! Verweisquelle konnte nicht gefunden werden.).



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2.5.12 Workpiece parameters (time)

SPARKING-OUT OVER A PERIOD

Force [N]

Time [s]

Processing time [s]

Sparking-out [s]

Time switch point [s]

Pressure force [N]

Sparking-out force[N]

Processing stops after 60s

Two processing cycles with the same tool.

Parameters of the second processing.

From start postition ± 8 degrees oscilation at a speed of 500 degrees/min.



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2.5.13 Workpiece parameter (Position)

The X-axis is moving to this absolut position. The honing cycle ends, when the contouring error is 0.

A dwell time can be programmed for the „spark out“.



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As soon as the tool is teached one time in the set up mode, the teach position appears here. By the means of the teach button, this value can be taken over and, for example, being reduced by 0.2mm.



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2.5.14 Workpiece parameters (2nd processing cycle)

The parameters of the second processing cycle are identical with the ones of the first processing cycle. Clamping length 2nd processing Only active when processing inserts This clamping length is used to polish the face of the insert. The distance must be determined by tests. If the check box is not activated, the clamping length as described in chapter 2.5 workpiece parameters will be taken over.

Clamping length 2nd operation For inserts only!



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2.5.15 Workpiece parameters (spray)

A spray cycle can be defined for each tool. The spray cycle is identical for the first and the second operation. The above example shows that the tool lifts off the workpiece every 15 seconds and that it sprays for 1 second. After 9 seconds of polishing, the coolant switches on again. Spray 3 is an option (see 2.8.4).

Spray every 15 seconds.

Spray during 6 seconds.

9 seconds after polishing start, the coolant will be switched on.

Spray with spray 1 and 2



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2.5.16 Workpiece parameters (dressing)

Clamping length for dressing see 0

Speed for simultaneous dressing

Pressure force at dressing.

Start position for dressing

Duration of dressing cycle

After n workpieces, the message appears that the tools have to be dressed.

Set counter to 0 (0 workpieces have been ground).

Dressing of the tool with a distance.



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2.5.17 Dressing inserts

Contrary to the dressing of the tool when processing heads, which allows a constant dressing of the tool, a dressing cycle must be programmed when processing inserts. This dressing cycle is only allowed when working with a fix coupling.



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Honing tool for processing inserts Workpiece

(Insert)

Dresser



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2.5.18 Workpiece parameters (loader)

GENERALITIES Change machine with rotary switch to automatic mode. It is always possible to move to JOG mode with the axis and to teach them. CAUTION: danger of collision, when activating button [STEP FORWARD] afterwards. The loading parameters are blocked during automatic cycle.

[START POSITION] The machine moves to start position, and the mode „Loader set-up“ is activated. The four buttons [STEP FORWARD], [STEP BACKWARD], [CARRY OUT LOADING CYCLE] and [END SET-UP] are now active. [STEP FORWARD] The action shown in the label message is being carried out.

If this checkbox is marked, the remote control is switched on.

If this check box is marked, the machine is in automatic mode.

All positions can be teached.

Position workpiece turret head, when loading a new workpiece.



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[STEP BACKWARD] The step indicated on the display in the message label is set back to the preceding step. This step can be carried out by pressing [STEP FORWARD]. [CARRY OUT LOADING CYCLE] As soon as the loader is set-up, a complete loading cycle can be carried out. [END SET-UP] Ends the set-up mode, and machine returns to start position.



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2.5.19 Workpiece parameters (loader dressing parameters)

These set-ups can be checked out in set-up with the button [DRESSING (LOADER)]. The dressing cycle is active in automatic mode only.

Dressing cycle ON / OFF

The dressing tool has a special dressing length. See 0 / 2.5.21

For each tool, the dressing cycle can be switchen ON / OFF.

Indicates number of processings of the tool.

Set number of processings to 0.

Speed for dressing synchronous honing

Pressure force when dressing

The tool will be dressed after XX number of workpieces.

Dressing time in seconds.



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2.5.20 Workpiece parameters (Process controll)

Two identical tool sets can be programmed with the process control. In the example above, the first tool set consists of tool 1 and 2. The second tool set consists of tool 4 and 5. Each tool set processes 50 workpieces. When the desired number of workpieces has been ground with the first tool set, the machine switches automatically to the second tool set. After the processing with the second tool set, the message appears to change the tools. After having changed the tools, the counter must be reset to 0. The process control functions in manual and automatic operation.

Switch ON / OFF process control

First tool set: consisting of tool 1 and 2.

Second tool set: consisting of tool 4 and 5.

Number of workpieces processed with one tool set.

Number of workpieces processed with the first / second tool set.

The number of workpieces is set to 0.



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Calculation of the clamping length of heads Calculate as follows: 1. Determine head measure. 2. See head diameter on working plan. Clamping length = head measure – ½ head diameter Example: Measured head measure = 43.37 mm [1.7075 inch] Head-Ø = 28.00 mm [1.1024 inch] Clamping length = 43.37 – ½(28) = 29.37 mm [1.7075 – ½ (1.1024) = 1.1563 inch]

7

Clamping length

½ head diameter

head measure



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2.5.21 Workpiece parameters (Drum magazine)

GENERALITIES Change machine with rotary switch to automatic mode. It is always possible to move to JOG mode with the axis and to teach them. CAUTION: danger of collision, when activating button [STEP FORWARD] afterwards. The loading parameters are blocked during automatic cycle.

[START POSITION] The machine moves to start position, and the mode „Loader set-up“ is activated. The four buttons [STEP FORWARD], [STEP BACKWARD], [CARRY OUT LOADING CYCLE] and [END SET-UP] are now active. [STEP FORWARD] The action shown in the label message is being carried out.

If this check box is marked, the machine is in automatic mode.

All positions can be teached.

Number of workpieces to be machined if drum magazine cycle is on.



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[STEP BACKWARD] The step indicated on the display in the message label is set back to the preceding step. This step can be carried out by pressing [STEP FORWARD]. [PERFORM DRUM CYCLE] If a workpiece is clamped in the chuck, the drum magazine is rotating to the next free position. If the chuck is empty, the drum magazine is rotating to a occupied position. [CARRY OUT LOADING CYCLE] As soon as the loader is set-up, a complete loading cycle can be carried out. [END SET-UP] Ends the set-up mode, and machine returns to start position.



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2.5.22 Approach parameters

APPROACH SPEED Speed with which the tool approaches the workpiece. APPROACH DISTANCE The X-axis moves in quick motion in front of the workpiece, switches to approach speed and traverses the approach distance + 0.5 mm. Afterwards, a contouring error is built up that corresponds to the minimum contouring error.

Distance covered with approach speed. If the approach parameters are deactivated, the teach parameters are active when approaching.



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2.5.23 Calculation of the clamping length of inserts

Calculate as follows:

1. Determine the insert measure. 2. See axis distance on working plan. Clamping length = insert measure – axis distance Example: Measured insert = 17.10 mm [0.673 inch] Axis distance = 1.00 mm [0.0394 inch] Clamping length = 17.10 – 1.00 = 16.10 mm [0.673 – 0.0394 = 0.6339 inch]

Clamping length

Axis distance

Insert measure



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2.6 Setting-up

These input fields release a movement, depending of the active tool. The safety door has to be closed manually.

First processing of tool 1 is active.

Starts the program 'Marposs Human Interface Software'. Used to adjust the measuring heads.

Set the workpiece counter to 0.



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2.6.1 Description of the keys releasing a movement

HOME POSITION The machine moves to home position. This procedure is possible in any situation. MOVE TO START POSITION The machine moves to start position. The swivel axis B first moves to start position. After that, the Z-axis moves with the center of the head / insert into the center of the B-axis. HONING TOOL FORWARDS The tool moves to the head. The pressure corresponds to the value entered in the workpiece parameter “pressure force”. The tool has got to be teached-in. HONING TOOL BACKWARDS The tool goes back to home position. MEASURING The machine being in home position, you move to the start position (B- and Z-axis). After that, the measuring grippers move to the head / insert. You have now two possibilites:

• Tip a second time the key [Measure], the workpiece turns and is measured. The measured value is shown under measure in µm.

• The measuring unit can be calibrated by pressing the key

[Calibrate]. • Tipping the key [MHIS], the Marposs program will start. This

program is used to adjust the measuring heads (see chapter 2.6.3).

• If no calibrating or measuring should be made, tip the key [Home position] to run the machine into home position.

CALIBRATING When the master part is in the chuck and when the measuring grippers are on the head / insert, the measuring unit can be calibrated with this function. TEACHING THE CURRENT HONING TOOL Determination of the length of the current workpiece. TEACHING ALL HONING TOOLS Determination of the length of all tools with active processing.



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DRESSING The swivel axis B moves to the reference distance After that, the Z-axis moves with the center of the head / insert to the center of the B-axis. Now, the actual length is always teached first. After these procedures follows the proper dressing process, which can only be stopped by pressing the key [Cycle stop]. DRESSING INSERT Starts the dressing cycle for insert processing. See also 2.5.17. DRESSING (LOADER) Starts the dressing cycle with the dressing tool. See also 2.5.19. START The safety door closes automatically and the machine performs the processing cycle of the active tool. CYCLE STOP The machine stops the current operation and moves to the home position.



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2.6.2 Signification of the symbols

The tool is weared out. Change it.

The tool length is unknown.

The tool length has been teached.

The tool is switched off (no processing) To verify the tool lengths, tip the key [Tool lengths].



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2.6.3 Resetting and zeroing of the measuring head

In fact, the resetting from heads to inserts or vice-versa is very time-consuming. We therefore try to describe it here more precisely. 1. Exchanging honing tools and felt:

Select the honing tools so that the exterior diameter of the stones reach in the correct setting angle, on the one hand, slightly over the pole and, on the other hand, slightly over the edge of the head or insert. The dressing edge prevents the honing tool to damage the workpiece, the clamping tool or the measuring probes. The dressing edge allows to choose the exterior diameter of the honing tool as large as necessary to prevent a deformation of the tool.

2. Entering the workpiece parameters:

The setting angle "Swivel axis B start position“ has to be entered, so that the swivel axis moves to the correct position when setting-up.

3. Mounting the measuring head on the support: For processing heads and inserts, there is one measuring head each.



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Measuring head for head processing: (probe for exterior measuring)

Measuring head for insert processing: (probe for interior measuring)



2-48

4. Set back the setting slides of the support for the measuring head to prevent a collision of the probes with the workpiece when running-in (with screw 1 in longitudinal direction, with screw 2 in transversal direction).

5. Clamp now the master part (calibrating diameter) into the workpiece

holder. Heads: The master part should have a diameter that is

slightly smaller than the measure at the lower tolerance limit of the workpieces to be processed.

Inserts: The master part should have a diameter that is

slightly larger than the measure at the upper tolerance limit of the workpieces to be processed.

Set now the probe by pressing the key “Measuring” (window “setting-up”) to measuring position. Go to the MHIS first page by pressing the key MHIS.



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MHIS first page

Indicates the current measuring result.

Mechanical zeroing



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Mechanical zeroing

6. Move now the measuring head into measuring position: use the two

screws described under point 4. Measure very precisely as close as possible to the exterior edge of the insert. Heads: measure the largest diameter.

probe T1

probe T2

Electrical zeroing to lift-off / lower the probes.



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7. Zeroing of the measuring head: Traverse to the master part with the probes.

Meas. head for interior measuring: Meas. head for exterior measuring:

8. Release screw 2 and 3. 9. Shift screw 1 on probe T1 so that the display of the measuring unit

shows zero (± 10 µm), then tighten screw 2. 10. Do the same with probe T2.



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Often, it is necessary that the probes can be lifted and lowered. Especially when processing inserts, the space between probe and honing tool is very small, when the probe is lifted. The following function allows to lift-off and lower the probes: Lift-off / lower the probes

Lifting-off / lowering probe



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2.6.4 Multirange measuring head

Air supply pneumatic reset multirange measuring head UNIMAR

Socket multirange measuring head UNIMAR

Socket measuring head MINIALSAR

Multirange measuring head UNIMAR



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To change from measuring head MINIALSAR to the multirange measuring head UNIMAR, proceed as follows: Activate the check-box „Machine equipped with a multirange measuring unit“ on the display. (Systemparameter (Various) 2.8.4 ) Enter the minimum workpiece diameter on the display (Systemparameter (Marposs Unimar) 2.8.6)

In the workpiece parameter set the Diameter for example to 40mm. This is Part 2 and cycle 3 if the Minial Diameter is 38mm. Press key „Home position“ in the Setup to take over all values.



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Start MHIS Programming measuring head

When the measuring head is changed, the type of the measuring head must be selected: (Module 1 for MINIALSAR; Module 2 for UNIMAR)

Programming measuring head



2-56

If you use the Unimar measuring head select Head 2, T1, T2. If you use the Minialsar measuring head select Head 1, T1, T2. Switch machine OFF Change measuring head (connect plug as described above), switch machine ON again and move to home position. Retraction treshold acquisition. Proceed according to the operating manual Marposs chapter 6.2. Mechanical null balance of the contacts as described above.



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2.7 Processing

Having selected the key [Processing] in the main menu, the display shows the following dialog:

HOME POSITION The machine moves to home position. This procedure is possible in any situation. START Pressing the key [Start] or the key [Cycle Start] on the operator’s panel the cycle will be started. CYCLE STOP The cycle will be stopped, the machine moves to home position. AUTOMATIC STOP The workpiece will be completely processed. The loading cycle stops afterwards.



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OPERATING START WITH TOOL The cycle starts with the preselected tool and ends with the tool having been programmed as the last one. After operating, the first active tool will be preselected. CHANGE PARAMETERS DURING PROCESSING The workpiece parameters can be changed during processing. The cycle stops and waits until the processing panel is active. Then the new parameters are entered. The loading parameters cannot be changed during processing.



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Measure and time

Tool 1: Processing with measuring unit and sparking-out Tool 2: Processing with measuring unit and without sparking-out Tool 3: Processing with time, without sparking-out Tool 4: No processing Tool 5: Two processings with time, both without sparking-out



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2.8 System parameters

Contrary to the workpiece parameters, the system parameters can only be modified on the machine. The system parameters will be stored in the data base under the corresponding computer name, for example: M641-010803 CAUTION: If you change the name of the computer, the system parameters have to be reentered.



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2.8.1 System parameters (reference distances)

REFERENCE DISTANCE X-AXIS Distance between turret head and center of swivel axis B, when X-axis is in home position. REFERENCE DISTANCE Z-AXIS Reference distance between clamping jaws and center of the swivel axis B, when Z-axis is in home position. REFERENCE DISTANCE B-AXIS Angle between reference switch point and home position B-axis. REFERENCE DISTANCE A-AXIS Angle between reference switch point and turret head, when turret head is in position „tool 1“. REVOLVER OFFSETS Correction of the height of centers and the radial position of the tool spindles. ANGLE XZ This angle is used for the calculation of the start position.



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Head processing

Head processing ( angle XZ=0 )



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Insert processing

Insert processing ( angle XZ=0 )



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Reference distance A-axis



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2.8.2 System parameters (Teaching)

SPEED FOR CONTACTING Speed of the tool to contact the workpiece. DISTANCE FOR CONTACTING The X-axis moves in quick motion in front of the workpiece, switches to speed for contacting and moves forwards the distance for contacting + 2 mm. There results a position deviation of approximately 2 mm.

CAUTION This value must not be modified, as it would also modify the pressure force. The entered values would be incorrect.



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RELEASE WAY As soon as the honing tool is lifted off the workpiece, the position deviation will be set to 0 and then the honing tool moves away by the distance of the release way. Using flexible couplings, this method secures that the honing tool does not lie any more on the workpiece. This is important for sparking-out, as a new pressure force will only be correct, when the tool contacts the workpiece with the defined contacting speed. POS. DEVIATION AMOUNT MINIMUM The position deviation amount should at least be 1 mm. It is necessary to check if the honing tool has contacted the workpiece. PRESSURE FORCE Pressure force teaching the tool. LONGEST TOOL (HEAD / INSERT) When a tool’s length is not yet known (not yet teached), the X-axis moves in quick motion to the position of the longest tool and moves then in slow motion (250 mm/min) [9.84 inch/min] the distance for contacting in direction workpiece. After each stop, the position deviation amount will be checked and it will thus be checked if the honing tool contacts already the workpiece. The position deviation amount becoming bigger than the ‘position deviation amount minimum’, the length of the honing tool will be determined. SHORTEST TOOL (HEAD / INSERT) The length of the shortest tool serves to determine if a honing tool is used up.



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2.8.3 System parameters (force program)

Procedure to adjust force program 1. Establish a new head program. 2. Mount the pressure cell on a tool. 3. Measure the tool length adapt it in the system parameters (longest tool, shortest

tool. 4. Teach the pressure cell (in set-up program). 5. Change to system parameters (force program). 6. Enter in the field „second torque limit minimum“ the value 60. 7. Enter in the field „second torque limit maximum“ the value 255. 8. Enter in the field „measuring minimum“ 1N. 9. Enter in the filed „measuring maximum“ 200N. 10. Press key „measuring maximum“. 11. The measurement has to be 200N. Should you measure a higher value than 200 N,

reduce the parameter 2060. Should you measure an inferior value than 200N, increase the parameter 2060. This parameter should have a value of approx. 1500 to 2000.

12. Return to set-up dialog. 13. Enter a pressure force of 20N. 14. Press „honing tool forwards“ and read the measured value.

Go to home position.

Select tool with mounted pressure cell.

Carries out a movement of the X axis in rapid motion.

Change with this key to status conversation.

Carry out measuring with the maximum pressure.



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15. If the measured value is inferior than 20N, return to the system parameters and increase the value „second torque limit minimum“. Repeat the steps 12, 13 and 14 until you measure 20N. If the measured value is higher than 20N, return to the system parameters and reduce the value „second torque limit minimum“. Repeat the steps 12, 13 and 14 until you measure 20N.

IMPORTANT: Check power adjustment approx. every 6 months.



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2.8.4 System parameters (various)

TOOL RPM FOR CONTACTING Centering speed of the tool, centering the tool on the head / insert when moving forwards. These numbers of revolutions are only valid when using flexible couplings. Using fix couplings, processing will always be with the nominal number of revolutions mentioned in the workpiece parameters. WORKPIECE COUNTER General workpiece counter. The finished parts are counted until the counter is set back to 0. CYCLE WITH MEASURING UNIT Working with a measuring unit, the cycle will stop after the indicated time. This secures that the cycle stops even when no material will be removed any more. This time refers to a processing with sparking-out. MHIS-PATH The machine being equipped with a measuring unit, the path to the MHIS program is entered here.



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SOFTWARE OPTIONS CHANGE OF FANUC PARAMETERS PERMITTED Mark this check box and confirm with OK. The Fanuc system parameters can now be changed, e. g. parameter 2060 for the force program. DRESSER: DISPLAY INSERT DRESSING Activates the dressing cycle for dressing tools when processing inserts. SHOW DRESSING PROGRAM If the tools have to be dressed with a dressing stone, the control board has to be activated. THE MARPOSS UNIT IS EQUIPPED WITH A MULTIRANGE HEAD The machine being equipped with a multirange head, the control case has to be activated. INSERT: COLLISION FREE PROCEDURE MULTIRANGE MEASURING HEAD The movement is changed so that the contacts do not touch the tool. TEACHING CLAMPING LENGTH FOR INSERTS For inserts with a large collar, a separate clamping length for teaching can be entered. SEPARATE CLAMPING LENGTH FOR TOOLS 1…5 (INSERTS) A separate clamping length can be entered both for the first and the second processing. The clamping length is independant of the clamping length in the workpiece window „Data base“. When the clamping length is altered, the tool length must be teached anew. This function is needed to polish the approach radius and the face. START POSITION: USE FORMULAS FOR SPINE PRODUCTS When calculating the start position of inserts, a dialog for spine products appears. FINE ADJUST WORKPIECE AXIS Z A clamping length correction can be entered for both the first and the second operation (±0.02mm). The clamping length correction is added to to the clamping length in the workpiece window „Data base“. The tool length is not teached anew. CHUCK FOR INTERNAL CLAMPING If there is a Chuck for internal clamping, mounted, this control board has to be activated.



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SPINE (FEEDING TO AN ABSOLUT POSITION!) This option is only useful honing spine products in combination with tools having very little wear in the process. If this option is activated, the modus position appears within the workpiece parameters. The tool honing until the axis has reached an absolute position



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CONFIGURATION OF THE MACHINE The following parameters can only be altered when asking for a password from Monnier + Zahner with the service number shown in the Login display. This special password is always valid one day. THE CLAMPING CHUCK IS HYDRAULIC The machine is equipped with a hydraulic aggregate for the clamping chuck. THE MACHINE IS EQUIPPED WITH SPRAYS If the machine is equipped with sprays, the control board has to be activated. THE MACHINE HAS GOT 3 DIFFERENT SPRAYS SPRAY CYCLE: LIFT OFF TOOL The control case being activated, the tool lifts off the workpiece before spraying. The coolant switches off before spraying and switches on again delayed.



2-73

THE MACHINE IS EQUIPPED WITH DRESSING UNIT If the machine is equipped with a dressing unit, the control board has to be activated. THE MACHINE IS EQUIPPED WITH A MEASURING UNIT. If the machine is equipped with a measuring unit, the control board has to be activated. FLOW CONTROL It is possible to install a flow control fort he coolant. SAFETY DOOR AUTOMATIC MODE The control case being marked [�� Safety door automatic], the safety door will automatically be closed by tipping the key [Start] in the set-up or processing mode. SECURITY ZONE AXIS B If this check box is marked, the machine has a large swivel angle. The security zone protects the measuring unit from collisions. When teaching the tools, the swivel axis B moves to 0 degrees and not to the reference distance axis B. THE MACHINE IS EQUIPPED WITH 6 AXIS (LOADING UNIT) The machine is equipped with a handling system. EVALUATE EMERGENCY STOP FOR / OF FOREIGN MACHINE If the check box is marked, the machine passes an emergency stop on to other machines. The machine also reacts to an emergency stop of a third machine. COMMUNICATION WITH CONVEYER BELT ACTIVE If the check box is marked, the machine communicates with the conveyer belt. DO NOT CENTER CENTERING ARBOR IN START POSITION The centering arbor of the turret head has not returned. Used for setting up the machine (adjustment of the axis parameters) PEDAL ACTIVE IN SPECIAL MODE ONLY (VACUUM) When a vacuum head is clamped to the workpiece chuck, the chuck may not be opened to avoid unclamping of the vacuum head. INDICATE PROCESS CONTROL Indicates process control for several tool sets. WORKPIECE WITH ROBOT LOADING / UNLOADING Activates the communication interface robot - machine.



2-74

Blow workpiece clean: Duration dry blowing of the workpiece before unloading. SET AXIS B TO INITIAL POSITION AFTER OPERATING After operating, the axis B moves to the initial position. DRESSING UNIT IS ONLY ACTIVE AT CLOSED DOOR The dressing unit is only active when the door is closed (hand operated on panel). FUJI FREQUENCY CONVERTER The machine is equipped with a Fuji frequency converter. DRUM MAGAZINE The machine is equipped with a drum magazine. CLAMPING LENGTH MESURE The clamping length is measured and corrected individually for each workpiece. CHUCK FOR INTERNAL CLAMPING The machine is equipped with a chuck for internal clamping. INCH MACHINE Indicates if the machine is displayed for INCHES. This parameter is set at delivery and must not be modified. ONLY DESKTOP PROGRAM (SEE M641.INI DESKTOP=1) This parameter allows to control if the program M641.EXE is performed on a machine tool or on a Desktop-Computer. This parameter can only be modified with a text editor.



2-75

2.8.5 System parameters (minimum and maximum values)

Any entered value will be checked within a valid range. This range can be adjusted in dialog. To do so, tip the field with the minimum or maximum value and adjust it. For take-over of these inputs, tip the key [OK].

Tip this field to adjust the minimum diameter of the workpieces.



2-76

2.8.6 System parameters Marposs Unimar

MINIMUM DIAMETER [MM] Define here the start diameter, for instance 38 mm. The measuring range is now defined from 37.5 mm up to 62.499 mm. Note that the Marposs unit has to be adjusted to this diameter range, too.

Define the start diameter here.



2-77

2.8.7 System parameters (Loader)

LOADING SPEED [Z] The Z axis crosses the workpiece. UNLOADING SPEED [Z] The Z axis drives away from the workpiece. LOADING SPEED IN THE MACHINE [V, U] High speeds can be selected in the machine to speed up the loading process. LOADER SPEED AT CONVEYER BELT [V, U] Select low speeds at the conveyer belt. These speeds are also used when setting up the loader and at start position. BLOW WORKPIECE CLEAN The workpiece is blowed clean for a while during unloading.



2-78

2.8.8 System parameters (Security zones)

The security zones avoid a collision between the loader and the measuring unit e. g. This means that it is not possible to approach these security zones in JOG and automatic mode when the security zone is switched ON. PROCEDURE

1. Deactivate check box [�� Security zone aktive]. 2. Confirm with OK. 3. Recall system parameters. 4. Teach points 1 - 7 in JOG mode. CAUTION danger of collision! 5. Activate check box [�� Security zone aktive].

Important: If there are axis in the security zones, you can switch to JOG mode at

any time and leave the security zone with the U axis in positive direction (U +).



2-79

2.8.9 System parameters (Drum magazine)

LOADING SPEED [Z] The Z-axis is moving to the Drum magazine. UNLOADING SPEED [Z] The Z-axis is moving away from the Drum magazine. MAXIMUM CORRECTION If the clamping length is measured and corrected with the measuring unit, the maximum correction per measure can be determined with this parameter. POSITION SWIVEL AXIS B B-axis position during the measuring of the clamping length.



2-80

ACCESS AUTHORISATION

� Modify workpiece parameters The user can modify the workpiece parameters

� Read data base The user can read workpieces in the data base.

� Write data base The user can store workpieces in the data base.

� Delete data base The user can delete workpieces in the data base.

� Read system parameters The user can see system parameters, but not modify.

� Write system parameters The user can modifiy system parameters.

� Add user The user can acquire new users.

� Delete user The user can delete acquired users. � User change password The user can modifiy passwords. But

first he has to enter the old password.

Actually logged-on user

Modify password of the marked user. Enter first the old password, then the new one.

The marked unser will be deleted after acknowledgement. The userr 'admin' and the logged-on user cannot be deleted..

Acquire new user with name and password.



2-81

� Change access authorisation user

The access authorisations can be modified.

� Change language user The language can be modified. � Options record Not implemented � Options print Workpiece paramters, system paramters

and user data can be printed out. � Write loading parameters The loading parameters can be

changed. � Set-up man: determine limits The set-up man determines for which

workpiece parameters limits can be defined. Afterwards, the limits for the operator for each determined parameter can be entered.

� Operator: limits are active The operator can only change the parameters with the defined limits.

The system edifies the user 'admin', it cannot be deleted. As well, it is not possible to modify the access authorisations of the user 'admin'. Use of limits

Parameter Einheit Werkstückparameter � Diameter [mm] Data base � Clamping length [mm] Data base � Clamping length teaching [mm] Data base � Follow-up time coolant [s] Data base � Switch point measure [µm] WZ1..WZ5 � Processing time [s] WZ1..WZ5 � Speed workpiece [1/min] WZ1..WZ5 � Speed tool [1/min] WZ1..WZ5 � Pressure force [N] WZ1..WZ5 � Spark out measure [µm] WZ1..WZ5 � Switch point [s] WZ1..WZ5 � Spark out time [s] WZ1..WZ5 � Spark out force [N] WZ1..WZ5 � Start position [Grad] WZ1..WZ5 � Oscillation [Grad] WZ1..WZ5 � Oscillation speed [Grad/min] WZ1..WZ5 � Oscillation [s] WZ1..WZ5 � Spray frequency [s] Spray parameters: WZ1..WZ5 � Spray time [s] Spray parameters: WZ1..WZ5 � Coolant retardation [s] Spray parameters: WZ1..WZ5 � Clamping length dressing [mm] Dressing parameters � Dressing speed [1/min] Dressing parameters � Tool Speed [1/min] Dressing parameters � Pressure force dressing [N] Dressing parameters



2-82

All selected parameters have additional limits that the set-up man can determine. . These limits are defined in the workpiece parameters.

Determine limits for the switch point measure.

The set-up man can check the limits when this check box is switched on.



2-83

The set-up man can limit the input as well as the minimum and the maximum input value for the operator. Select the corresponding edit field before entering the value.

The button „assign value“,assignes the value 85 to the field maximum input value.

The operator can change the switch point measure only between the limits 75 and 85.



2-84

2.8.10 Options printing

To print, the machine has got to be connected to a network and a network printer has to be installed. Workpiece parameters, system parameters and user data can be printed.

Cursor keys for workpiece selection

Mark actual workpiece

Remove all markings

Mark all workpieces

Filter: Searches all workpieces having „He“ in the workpiece name.



2-85

2.8.11 Options TCP/IP

REMOTE MACHINES Collect here all machines with which you wish to exchange datas over TCP/IP.

All acquired machines (maximum 10)

Delete marked machines

Acquire datas of a new machine.



2-86

2.9 Info

This window shows the information regarding the software version.



2-87

2.10 End

2.11 Data base

There are three data bases, one for the workpiece parameters, one for the system parameters and one for the languages. The data bases communicate over the ODBC-driver. Data source name

Description

M641 Contains the workpiece parameters M641Sys Contains the system parameters M641Text Contains the languages

The ODBC-Data Source Administrator allows to determine a new storage location.

Back to main menu.

The program shuts down..

Logout the user. The login dialog appears again.

Windows are shut down and the machine will be switched off after two minutes. The machine will only be switched off when the FANUC control is switched on.

MONNIER + ZAHNER AG CNC Control


3-1

3 CNC Control

3.1 List of the M-Functions

M03 CW workpiece M04 CCW workpiece M05 workpiece spindle off M08 coolant on M09 coolant off M30 reset and rewind M33 CW tool spindle M35 tool spindle off M40 move PMC-axis V in position M41 move PMC-axis U in position M42 loading grippers upwards M43 loading grippers downwards M44 open loading grippers M45 close loading grippers M46 open unloading grippers M47 close unloading grippers M49 blow workpiece clean M50 release pedal M51 clamp into collet / block pedal M52 open sliding door M53 close sliding door M57 switch PMC axis to CNC M58 switch PMC axis to PMC M60 open workpiece collet (chuck) M61 close workpiece collet (chuck) M62 spray M63 measuring unit longitudinal forwards M64 measuring unit longitudinal backwards M65 measuring unit transversal forwards M66 measuring unit transversal backwards M67 dressing unit swivel forwards M68 dressing unit swivel backwards M69 couple honing tool M70 desengage coupling honing tool M72 calibrate mesuring unit M73 measure measuring unit M76 centering pin forwards M75 control workpiece present



3-2

M77 centering pin backwards M80 lock sliding door M81 unlock sliding door M83 set torque limit of X-axis M85 drum magazine cycle start M86 lock manual door M87 unlock manual door M88 swivel in arm drum magazine M89 swivel out arm drum magazine M90 drum magazine divide forward M91 drum magazine divide backwards M92 drum magazine positionning forward M93 drum magazine positionning backwards M94 drum magazine start rotatinge



3-3

3.2 Variable Timer

TIMER M-Code Function Default

No. 0003 M60 open chuck 384 0004 M61 close chuck 384 0007 stand-by lubrication 1500000 0009 lubrication time out 15000 0010 stop lubrication cycle 20000 0011 spindle speed achieved (workpiece) 1000 0012 spindle stopped (workpiece) 1000 0013 spindle 2 speed achieved (tool) 1000 0014 spindle 2 stopped (tool) 1000 0015 M45 close loading grippers 1000 0016 M47 close unloading grippers 1000 0017 control coolant flow monitoring 15000 0019 M88 drum magazine swivel in 0 0020 M89 drum magazine swivel out 0 0026 workpiece spindle speed too slow (FUJI) 1000 0027 toll spindle speed too slow (FUJI) 1000 0028 M94 drum magazine positionning forward 0



3-4

3.3 Machine in- and outputs

3.3.1 Inputs

Type • S = standard machine

• L = machine with loader

• R = machine with robot interface

• T = machine with drum magazine

Type Input Symbol Description Checked Date Initials S,L,R X0030.0 1A0 Limit 1. axis –X �

S,L,R X0030.1 1A1 Limit 1. axis +X �

S,L,R X0030.2 1A2 Reference point 1. axis X �

S,L,R X0030.3 1A3 Limit 2. axis –Z �

S,L,R X0030.4 1A4 Limit 2. axis +Z �

S,L,R X0030.5 1A5 Reference point 2. axis Z �

S,L,R X0030.6 1A6 Limit 3. axis –B �

S,L,R X0030.7 1A7 Limit 3. axis +B �

S,L,R X0031.0 1B0 Reference point 3. axis B �

S,L,R X0031.1 1B1 Reference point 4. axis A �

S,L,R X0031.2 1B2 Security door closed �

S,L,R X0031.3 1B3 Security door manually locked �

S,L,R X0031.4 1B4 Security switch, motors ON �

S,L,R X0031.5 1B5 Special mode �

S,L,R X0031.6 1B6 Safety switch �

S,L,R X0031.7 1B7 Security strip �

S,L,R X0032.0 2A0 Checking coolant �

S,L,R X0032.1 2A1 Pression central lubrication �

S,L,R X0032.2 2A2 Level central lubrication �

S,L,R X0032.3 2A3 Checking workpiece spindle �

S,L,R X0032.4 2A4 Checking tool spindle �

S,L,R X0032.5 2A5 Key cycle start �

S,L,R X0032.6 2A6 Pedal �

S,L,R X0032.7 2A7 Checking air pressure �

S,L,R X0033.0 2B0 Measuring head set back �

S,L,R X0033.1 2B1 Request performed �

S,L,R X0033.2 2B2 Alarm measuring system �

S,L,R X0033.3 2B3 Measure automat �

S,L,R X0033.4 2B4 Measurement works �

S,L,R X0033.5 2B5 Ext. remote setup in progress �

L,R X0033.6 2B6 Checking motors ON �

S,L,R X0033.7 2B7 Limit ready �

S,L,R X0034.0 3A0 Measuring unit longitudinal forward �

S,L,R X0034.1 3A1 Measuring unit longitudinal backw. �

S,L,R X0034.2 3A2 Measuring unit transversal forward �



3-5

Type Imput Symbol Description Checked Date Initials S,L,R X0034.3 3A3 Measuring unit transversal backw. �

S,L,R X0034.4 3A4 Swivel dressing unit forward �

S,L,R X0034.5 3A5 Swivel dressing unit backward �

S,L,R X0034.6 3A6 Coupling connected �

S,L,R X0034.7 3A7 Coupling disconnected �

S,L,R X0035.0 3B0 Centering mandrel forward �

S,L,R X0035.1 3B1 Centering mandrel backward �

S,R X0035.2 3B2 Flow control coolant �

L X0035.2 3B2 Reference point 5. axis U �

L X0035.3 3B3 Reference point 6. axis V �

R X0035.3 3B3 Security door open �

L X0035.4 3B4 Limit 5. axis -U �

R X0035.4 3B4

Security door locked automatic mode

�

L X0035.5 3B5 Limit 5. axis +U �

R X0035.5 3B5 Automatic mode �

S,R X0035.6 3B6 Checking hydraulic pression �

L X0035.6 3B6 Limit 6. axis -V �

S,R X0035.7 3B7 Checking hydraulic motor �

L X0035.7 3B7 Limit 6. axis +V �

L X0036.0 8A0 Loading grippers upwards �

L X0036.1 8A1 Loading grippers downwards �

L X0036.2 8A2 Loading grippers open �

L X0036.3 8A3 Loading grippers empty (no piece) �

L X0036.4 8A4 Loading grippers open �

L X0036.5 8A5 Loading grippers empty (no piece) �

L X0036.6 8A6 Mode automatism �

L X0036.7 8A7 Orientation spindle �

L X0037.0 8B0 Remote control ON/OFF �

L X0037.1 8B1

Remote control preselection axis V/U

�

L X0037.2 8B2 Remote control step forward �

L X0037.3 8B3 Remote control step backward �

L X0037.4 8B4 Remote control start position �

L X0037.5 8B5 Remote control JOG + �

L X0037.6 8B6 Remote control JOG - �

L X0037.7 8B7 Security door open �

L X0038.0 9A0

Security door locked automatic mode

�

T X0038.0 9A0 Manual door locked �

L X0038.1 9A1 Flow control coolant �

T X0038.1 9A1 Protection door left open �

L X0038.2 9A2 Dressing unit longitudinal forward �

T X0038.2 9A2 Protection door right open �

L X0038.3 9A3 Dressing unit longitudinal backw. �

T X0038.3 9A3 Spindle 1 rpm achieved �



3-6

Type Imput Symbol Description Checked Date Initials

T X0038.4 9A4 Spindle 2 rpm achieved �

L X0038.6 9A6 Workpiece on loading positione �

L X0038.7 9A7 Work piece on unloading position �

L X0039.0 9B0

Workpiece carrier in unloading position MZ

�

R X0039.0 9B0 Loader in automatic mode �

T X0039.0 9B0 Presence control clamping chuck �

L X0039.1 9B1

Workpiece carrier in loading position MZ

�

R X0039.1 9B1 Close clamping device �

T X0039.1 9B1 Arm drum magazine swiveled in � L X0039.2 9B2 Data taken over �

R X0039.2 9B2 Open clamping device �

T X0039.2 9B2 Arm drum magazine swiveled out �

L X0039.3 9B3 Transfer belt works �

R X0039.3 9B3 Robot outside danger area �

T X0039.3 9B3 Drum magazine divide forward

L X0039.4 9B4 Emergency stop of foreign machine �

R X0039.4 9B4 Start processing �

T X0039.4 9B4 Drum magazine divide backwards �

R X0039.5 9B5 Malfunction robot �

T X0039.5 9B5

Drum magazine positionning forward

�

T X0039.6 9B6

Drum magazine positionning backwards

�

T X0039.7 9B7 Presence control drum magazine �

3.3.2 Outputs

Type • S = standard machine

• L = machine with loader

• R = machine with robot interface

Type Output Symbol Description Checked Date Initials S,L,R Y0030.0 4A0 Lock security door manually �

S,L,R Y0030.1 4A1 Start workpiece spindle �

S,L,R Y0030.2 4A2 Start tool spindle �

S,L,R Y0030.3 4A3 Slow down workpiece spindle �

S,L,R Y0030.4 4A4 Slow down tool spindel �

S,L,R Y0030.5 4A5 Central lubrication �

S,L,R Y0030.6 4A6 Coolant �

S,L,R Y0030.7 4A7 Stop air �

S,L,R Y0031.0 4B0 Open sliding door �

S,L,R Y0031.1 4B1 Close sliding door �

Type Output Symbol Description Checked Date Initials



3-7

S,L,R Y0031.2 4B2 Measuring unit longitudinal forward �

S,L,R Y0031.3 4B3 Measuring unit longitudinal backw. �

S,L,R Y0031.4 4B4 Measuring unit cross forward �

S,L,R Y0031.5 4B5 Measuring unit cross backward �

S,L,R Y0031.6 4B6 Swivel dressing unit forward �

S,L,R Y0031.7 4B7 Swivel dressing unit backward �

S,R Y0032.0 5A0 Pneumatic chuck �

L Y0032.0 5A0 Dressing unit longitudinal forward �

S,R Y0032.1 5A1 Coupling honing tool �

L Y0032.1 5A1 Dressing unit longitudinal backward �

S,R Y0032.2 5A2 Polish spray head 1 �

L Y0032.2 5A2 Pneumatic chuck �

S,R Y0032.3 5A3 Centerin mandrel forward / backw. �

L Y0032.3 5A3 Coupling honing tool �

S,R Y0032.4 5A4 Polish spray head 2 �

L Y0032.4 5A4 Centering mandrel forward / backw. �

S Y0032.5 5A5 Polish spray head 3 �

L,R Y0032.5 5A5 Blow off workpiece �

T Y0032.5 5A5 Presence workpiece �

S,R Y0032.6 5A6 Unscrew hydraulic chuck �

L Y0032.6 5A6 Open security door �

S,L,R Y0032.7 5A7 Amplifier ready �

S,L,R Y0033.0 5B0 Head retraction �

S,L,R Y0033.1 5B1 Zeroing measuring head �

S,L,R Y0033.2 5B2 Cycle request �

S,L,R Y0033.3 5B3 Measure automat �

S,L,R Y0033.4 5B4 Enable remote setup �

S,L,R Y0033.5 5B5 Marposs clear alarm �

S,L,R Y0033.6 5B6 Machine OFF �

S,L,R Y0033.7 5B7 Switch OFF PC �

S,R Y0034.0 6A0 Selection workpiece bit 0 �

L Y0034.0 10A0 Loading grippers upwards �

T Y0034.0 8A0 Selection work piece BIT0 �


L Y0034.1 10A1 Loading grippers downwards �



L Y0034.2 10A2 Open loading grippers �


L Y0034.3 10A3 Open unloading grippers �


S,R Y0034.4 6A4 Selection cycle Bit 0 �

L Y0034.4 10A4 Blow off piece �

T Y0034.4 8A4 Selection cycle BIT 0 �

S,R Y0034.5 6A5 Selection cycle bit 1 �

Type Output Symbol Description Checked Date Initials



3-8

L Y0034.5 10A5 Lock security door automat �



L Y0034.6 10A6 Release break axis U �



S,R Y0034.7 6A7 Selection cycle BIT 3 �


L Y0035.0 10B0 Unload piece not OK �

L Y0035.1 10B1 Unload piece OK �

L Y0035.2 10B2 Data appear stable �

L Y0035.3 10B3 Foreign machine works �

L Y0035.4 10B4 Entrance stand-by �

L Y0035.5 10B5 Emergency stop for foreign machine �

L Y0035.6 10B6 No piece on workpiece carrier �

S,L,R Y0037.0 Y-BI08 Temporary bit 08 �




S,L,R Y0039.0 YTBI08 Temporary bit 08 spindle2 �




R Y0040.5 10A5 Lock security door �

T Y0040.5 10A5 Lock manual door �

R Y0040.7 10A7 Reset security relay �

R Y0041.0 10B0 Machine ready for work �

R Y0041.1 10B1 Workpiece clamped �

T Y0041.1 10B1 Arm swivel in �

R Y0041.2 10B2 Workpiece unclamped �

T Y0041.2 10B2 Arm drum magazine swivel out � R Y0041.3 10B3 Automatic door open �

T Y0041.3 10B3 Drum magazine divide forward �

R Y0041.4 10B4 Automatic door closed �

T Y0041.4 10B4 Drum magazine divide backwards �

R Y0041.5 10B5 Workpiece finished �

T Y0041.5 10B5

Drum magazine positionning forward

�

R Y0041.6 10B6 Start loading cycle �

T Y0041.6 10B6

Drum magazine positionning backwards

�

R Y0041.7 10B7 Rejected workpieces �



3-9

3.4 Errors and warnings

Message Description M641 Ok Everything o.k. MM Machine! Adjust parameters! A metric machine has not duly been changed to

INCH mode. INCH Machine! Adjust parameters! An INCH machine has not duly been changed to

metric mode. Caution: oil level central lubrication is low!

Refill oil

Close safety door! Close safety door. Reference X-axis [REF] [X] [+/-] Reference axis manually Reference Z-axis [REF] [Z] [+/-] Reference axis manually Reference B-axis [REF] [B] [+/-] Reference axis manually Reference A-axis [REF] [A] [+/-] Reference axis manually Reference U-axis [REF] [U] [+/-] Reference axis manually Reference V-axis [REF] [V] [+/-] Reference axis manually Reference course X-axis Is shown when referencing automatically Reference course Z-axis Is shown when referencing automatically Reference course B-axis Is shown when referencing automatically Reference course A-axis Is shown when referencing automatically Reference course U-axis Is shown when referencing automatically Reference course V-axis Is shown when referencing automatically Traverse to home position System moves to home position Special operation active The flip switch for special operation is active Coupling not coupled The coupling was not able to couple after 10 trials Change tool The tool is used up The head is already too small The head was already too small before honing The insert is already to large The insert was already too large before honing Cycle has been stopped The user has interrupted the cycle Expired time (measuring unit) The honing cycle was too long Remove workpiece and leave collet open

The workpiece has not been removed from the collet for the dressing cycle

M46 Open unloading grippers Next step in loader set-up M47 Close unloading grippers Next step in loader set-up Unloading position conveyer belt horizontal [V]

Next step in loader set-up

Unloading position conveyer belt vertical [U]


M42 Swivel loading grippers upwards Next step in loader set-up M43 Swivel loading grippers downwards




3-10

M44 Open loading grippers Next step in loader set-up M45 Close loading grippers Next step in loader set-up Loading position conveyer belt horizontal [V]


Loading position conveyer belt vertical [U]


Position swivel axis [B] Next step in loader set-up Position headstock horizontal [V] Next step in loader set-up Position headstock vertical [U] Next step in loader set-up M52 Open sliding door Next step in loader set-up Waiting position horizontal [V] Next step in loader set-up Waiting position vertical [U] Next step in loader set-up M61 Close workpiece collet Next step in loader set-up M60 Open workpiece collet Next step in loader set-up Unloading position Z axis [Z] Next step in loader set-up Loading position Z axis [Z] Next step in loader set-up M49 Blow workpiece clean Next step in loader set-up M19 Orientate workpiece spindle Next step in loader set-up Switch ON automatic mode and close manual door


Close manual door! Next step in loader set-up Wait for signal WC in loading position

Machine waits for a WC in loading position.

Wait for signal WC in unloading position

Machine waits for a WC in unloading position.

Wait for signal data taken over Machine waits until the conveyer belt has taken over the data.

Wait for signal WC leaves loading position

Machine waits until WC leaves loading position.

Wait for signal WC leaves unloading position

Machine waits until WC leaves unloading position

Process control: Tool change The tools must be changed Dress all tools manually! The tools must be dressed manually. Reset

counter to 0 in the workpiece parameters (Dressing).

M88 Arm swivel in Set up next movement in drum magazine.

M89 Arm swivel out Set up next movement in drum magazine.

M90 Drum magazine divide forward Set up next movement in drum magazine.

M91 Drum magazine divide backwards

Set up next movement in drum magazine.

M92 Drum magazine positionning vorward


M93 Drum magzine positionning backwards


Drum magazine must have an empty position!

The drum magazine must have an empty position, if there is a work piece in the gripper.

Time overrun drum cycle The drum cycle could not be finished.



3-11

No workpiece loaded No work piece has been loaded. M86 Lock manual door Lock manual door M87 Unlock manual door Unlock manual door Drum magazine not in initial position As long as this alarm is active, the machine will

not execute the reference points.

Protection door open! The protection door must be opened. Divide and position the drum The drum magazine is rotated to the next

position. Gripper is open! No work piece is in the gripper!

Close gripper and load work piece correctly, if there is one.

Drum magazine is empty! No workpieces in the drum magazine The machining process is finished. All work pieces out of the drum magazine are

machined Maximal correction is exceeded! If the clamping length is measured with the

measuring device, the correction value maid be to big.

Mode Description Wait Machine waits for a user’s input Select reference When starting the machine for the first time, you

may select in reference dialog if the axis should be referenced automatically.

Automatic reference The axis will be referenced automatically Reference axis separately The axis have to be referenced individually and

manually. Traverse to home position The machine moves to home position Cycle start processing A cycle has been started in processing dialog. Cycle start in setting-up A cycle has been started in setting-up dialog Emergency stop pushed An emergency stop was made, the machine has

to return to home position. Traverse to start position workpiece B-axis and Z-axis move to start position Advance honing tool The honing tool moves to the workpiece Honing tool backward The honing tool returns to home position Measure measuring unit The measuring unit measures the workpiece Calibrate measuring unit The measuring unit is calibrated Teach current honing tool Definition of the tool length of the currently

selected tool Teach all honing tools Definition of the length of all active tools. Teach and dress current honing tool Definition of the tool length of the currently

selected tool and consecutive dressing. Teach and dress actual honing tool Teaches and dresses the actual honing tool

(dressing by hand) Test minimum torquelimit Force program



3-12

Measure force Force program Carry out loading cycle Carries out a loading cycle Carry out dressing cycle (loader) Carries out a dressing cycle Set-up loader The loader can be set-up Set up drum magazine The drum magazine can be set up

MODE Description MDI The machine is in MDI-Mode MEM The machine is in MEM-Mode EDIT The machine is in EDIT-Mode JOG The machine is in JOG-Mode INC The machine is in INC-Mode REF The machine is in REF-Mode

RUN Description RESET Reset key is pushed STOP Cycle start key is not active HOLD Cycle has finished START Cycle has started

MSTB Description FIN Carrying out a M-function

EMG Description EMG An emergency alarm is pending

ALM Description ALM A general alarm is pending. Tip this key for detailed error message, i.e.

which axis has contacted the stop position. BATTERY Change the battery.

ALARM Description 1001 Workpiece spindle alarm Alarm of the workpiece spindle 1002 Tool spindle alarm Alarm of the tool spindle 1003 Windr/w : data [i240,d96] error [i220,d98] Error at writing the Torque limit. Surveillance coolant motor Triggers no Emergency Stop; the

processing cycle stops, and the machine returns to start position. Control the fuses of the coolant pump motor

1006 Surveillance air pressure Triggers no Emergency Stop; the processing cycle stops, and the machine returns to start position. The air pressure is too high/low

1007 Alarm measuring unit The measuring unit is in alarm status.



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See detailed error message In the MHIS program.

1008 Automatic / Special / Manual mode The mode may not be changed during processing.

1009 Measuring unit head not retracted. The measuring head could not be set back.

2000 Battery alarm Battery has to be replaced. 2002 Programmed spindle 1 speed too high Number of revolutions workpiece spindle

1 is too high 2003 Programmed spindle 2 speed too high Number of revolutions tool spindle 2 too

high

When loading an existing program, it may happen that the activated system parameters do not correspond to the program. 1. Clamping length teaching

2. Separate clamping length for tool 1…5 (Inserts) or Fine adjust workpiece axis Z



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3.4.1 Machine status

The last three M-functions carried out.

Deletes the alarm list. This is only possible if there is no alarm in line at present.

Here you can see the inputs and outputs of the machine.



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3.5 Procedure after an emergency stop

Caution!

If an EMERGENCY STOP has been produced, release the key EMERGENCY STOP and switch on the motors again. After an emergency stop move to the home position to continue processing.

Danger of collision!

3.6 Procedure after having moved on an axis limit

− Turn and hold key switch "limit" ⇒ press RESET, until no warnings stand in line on the display.

− ⇒ (JOG) ⇒ move off with the respective axis in the corresponding direction (off the switch EMERGENCY STOP).



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3.7 Connect M641 to the local area network (LAN)

Connect a PS2-keyboard and a PS2-mouse to the machine. Login as local administrator. User administrator Password M641 (or no password) Domain e.g. M641-060605

3.7.1 Change the security properties for the following two directories

C:\program Files\Monnier + Zahner C:\program Files\Marposs With the explorer you search those directories and click the right mouse button and choose properties.

1.) Highlight the entry: Users (M641-060605\Users)

2.) Activate the checkbox Fulll Control.



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3.7.2 Announce the machine M641 in your domain.

1.) Highlight the entry: Users (M641-060605\Users)

2.) Activate the checkbox Fulll Control.



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1.) Click the Sytem Icon.

2.) Click on the Change… button

Attention: The computer name may not be changed.

1.) Click on Domain and enter your domain name with the keyboard.

2.) Click on OK and restart your computer.



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3.7.3 Create a new user on your domain

• Create a new user M641 with password M641 on your domain server.

• Login as local administrator. User administrator Password M641 (or no password) Domain e.g. M641-060605

Click on Start, RUN... and write “regedit” with the keyboard and click on OK. The Registry editor appears.

1.) Search this directory: HKEY_LOCAL_MACHINE\SOFTWARE\Microsoft\Windows NT\CurrentVersion\WinLogon

2.) The following entries you must register or change: AutoAdminLogon = 1 DefaultDomainName = Your domain name DefaultUserName = M641 DefaultPassword = M641

3.) Close the Registry Editor and restart the computer.



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3.7.4 Start the application M641 automatically

1.) Click with the right mouse button on the NCBOOT32 Icon and click on OPEN.

3.) Click on Settings… 2.) Switch this checkbox off.

4.) Click on New…

5.) Change to the directory: C:\program Files\Monnier-Zahner\M641

6.) Highlight the file M641.EXE

7.) Click on Open.



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8.) Click on Ok.

8.) Click on Close.



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3.7.5 Adjust the MHIS

1) Click

2) Click

3) Activate „Touch Screen“ and „On line“



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3.8 Software update

• Unpack the ZIP file and copy the files on a SRAM card or on a CDRW.

• Switch off machine.

• Open the cover of the operating panel.

• Connect a keyboard and a mouse to the machine.

Mouse

Keyboard



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• Open the cover of the control board.

Turn this switch to 0.



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• Switch on the machine.

• On the display, the following dialog appears:

(1) Click on this button to select the source drive.

(2) Click on this button to load the files.



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• The following dialog appears:

(1) Click on file M641.CRD (3) Click on file M641.MEM

(2) Load file M641.CRD (4) Load file M641.MEM

(5) Close the dialog.

(1) Close the dialog.



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• The following dialog appears:

(1) Enter a 0 over the keyboard and confirm with key ENTER.

(1) Enter a 1 over the keyboard and confirm with key ENTER.



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• Open the Windows explorer

• Copy the file M641.EXE on C:\Program files\Monnier + Zahner\M641

• Copy the file M641Text.MDB on C:\Program files\Monnier + Zahner\M641\Database

Finish the program

Finish the program.



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Set the turning switch again to 1 and take off mouse and keyboard.



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3.9 Modify CNC parameters

• Reference machine

• Finish M641 program

• Start the program CNC-Screen Display Functions

The screen shows the following:

Activate the Function Keys, if they do not appear.



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• Press the key reset on the panel

• Switch the machine to MDI-Mode.

• Enter a 1 and confirm with Enter.

• An error message appears on the screen (100 parameters overwritable)

Press the key OFST.

(2) Position the cursor over the keyboard on this line.

(1) Press on „settings“

Press the key SYS.



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The following screen appears:

Enter the parameter number over the keyboard, for instance 2060. DO NOT CONFIRM WITH ENTER!

Press the key NO. SRH.



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The following screen appears

Enter the new value over the keyboard, for instance 1600 and confirm with Enter.

Press the key OFST.



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• Enter a 0 and confirm with Enter.

(2) Position the cursor over the keyboard on this line.

(1) Press on „settings“



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3.10 Operation panel CNC control

3.10.1 Operation panel

2 1 3 4 5 6 7 8

10 11

12

13

14

9

12xx

10xx

12 11xx

Legend: 1. Machine ON 2. Machine OFF 3. Motors ON 4. Motors OFF 5. Reset EMERGENY STOP 6. Key switch for normal / special operation 7. Key switch limitation 8. Cycle start 9. EMERGENCY STOP 10. Override for axis’ movements 11. Key switch for system parameters 12. Operation panel for CNC control 13. Bridging switch

13



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3.10.2 Operation panel CNC control

Only the keys occupied with a function are explained: Key functions:

Automatic – mode

Editing - mode

MDI – mode

Single Block – mode

Cycle stop

+_

X 1 X 10 X 100 X1000 X Z

TÜRE

ZU

TÜRE

OFFEN

B

A

RESET

ZYKLUS

STOP

SPRAY 1 SPRAY 2

ZYKLUS

STOP



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Cycle – start

Cycle - stop

Reference traverse – mode

JOG - mode

Step by step – mode

Factor for step by step – mode → 0.001 x 1 = 0.001 mm step [0.000039 inch step]




OPEN safety door

CLOSE safety door

X 1

X 10

X 100

X1000

TÜRE

AUF

TÜRE

ZU



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Spray 1 ON

Spray 2 ON

Coolant OFF

Coolant ON

Dressing unit FORWARDS

Dressing unit BACKWARDS

Engage tool drive

Desengage tool drive

Centering pin FORWARDS

Centering pin BACKWARDS

RESET - key

SPRAY 1

SPRAY 2

RESET



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A , Z , B , X ,– axis – selection key

- Direction – selection key for JOG – and step by step - mode

+ Direction – selection key for JOG – and step by step – mode

Rapid feed for JOG . mode (has always to be pushed together with the direction-selection key)

A

_

+

Documents

Operating Manual Honing Machine M641 1 27 · 2017-06-11 · 2.5.1 Material list 2-9 2.5.2 Workpiece list 2-10 2.5.3 Creating a new workpiece 2-11 2.5.4 ... 2-75 2.8.6 System parameters