Beruflich Dokumente
Kultur Dokumente
OPERATING INSTRUCTIONS
VERTICAL PROCESSING CENTRES BAS03-12 and BAS03-22 (A3)
Machine type: .................................... CNC control: ...................................... Order number: ................................... Machine no.: ...................................... Year of manufacture: .........................
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0.1 Product
Standard processing centres "BAS03-x2" are 3 axle drilling and milling centres with two processing areas, vertical spindles as well as an automatic tool magazine for the automatic execution of CNC work programmes. Currently there is a one spindle model (BAS03-12) and model with a "double spindle" (BAS03-22). The two work areas are integrated in a swivel support system and hold customerspecific workpiece carriers (e.g. tensioning bar or tensioning frame). Every workpiece holder is considered its own independent work room, which offers the advantages of main time parallel loading and unloading. The machines are controlled via the CNC control panel. The proper operation of the machine requires skilled personnel. Significant deviations from the standard model, based on customer-specific requirements, are listed in Chapter 10.
0.2 Manufacturer
Schwbische Werkzeugmaschinen GmbH Seedorfer Strae 91 78713 Schramberg (Ortsteil Waldmssingen), Germany Phone: 0 74 02 / 74-0 Fax: 0 74 02 / 74-211 Service department: Phone: 0 74 02 / 74-240 Fax: 0 74 02 / 74-195
0.3 Supplier
0.4 Copyright
The copyright for the presented documentation belongs to "Schwbische Werkzeugmaschinen GmbH" as well as partially ot the suppliers of the external documentation. The information contained therein are intended exclusively for the operators of the machine supplied by us and may not be modified, expanded, copied saved/distributed to data processing devices or used for purposes that are not in our interest. There is no claim made regarding the completeness of the information contained in the documentation. We have done our utmost to present the content regarding our products correctly and in an up-to-date fashion. However, we cannot guarantee that this document is free of errors. Especially in photos and other illustrations, components could be shown that are not part of the standard scope of delivery (optionen) or parts that have been modified in the meantime. We reserve the right to make modifications based of further developments or "state-of-the-art". Copyright "Schwbische Werkzeugmaschinen GmbH", 2007
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Damages caused by illegal use voids any warranties granted by "Schwbische Werkzeugmaschinen GmbH".
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0 OPERATING INSTRUCTIONS
0.1 Product 0.2 Manufacturer 0.3 Supplier 0.4 Copyright 0.5 Intended use 0.6 Machine dangers 0.7 Environmental influences 0.8 Warranty / Liability 0.9 Total table of contents
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0-2 0-2 0-2 0-2 0-3 0-3 0-4 0-5 0-6
1-1
1-2 1-3 1-10 1-10
2 GENERAL DESCRIPTION
2.1 Preliminary information 2.2 Description of the mechanics 2.2.1 General 2.2.2 Special machine features 2.3 CNC control: 2.3.1 Control type
2-1
2-2 2-3 2-3 2-6 2-7 2-7
3 PICTORIAL PART
3.1 Preliminary information 3.2 Machine photographs 3.2.1 Total view
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3-2 3-3 3-3
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3.2.2 Work room / loading room (two locations) 3.2.3 Tool magazine 3.2.4 Groups 3.2.5 Units 3.2.6 Individual components
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4-3 4-5 4-7 4-7 4-8 4-9 4-9 4-11 4-12 4-13 4-13 4-13 4-15 4-15 4-16 4-19 4-20 4-21 4-22 4-22 4-22 4-23 4-24 4-25 4-25 4-26 4-27 4-29 4-29 4-30 4-31 4-32 4-33 4-34 4-35 4-35 4-36 4-36 4-37
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4.9 Environmental influences 4.10 Shutting down and storing the machine
4-39 4-41
5-1 6-1
6-2 6-8
7 UNITS / DEVICES
7.1 Pneumatic system 7.1.1 Function 7.1.2 Adjustment elements 7.2 Cooling lubricant system (option) 7.2.1 Function 7.2.2 Option Interior cooling lubricants 7.2.2.1 High-pressure pump / filter for interior coolant supply 7.2.3 Adjustment elements 7.3 Central lubrication / minimum oil quantity lubrication 7.3.1 Function 7.3.1.1 Central lubrication: 7.3.1.2 Minimal oil lubrication 7.3.2 Adjustment elements 7.4 Hydraulic system 7.4.1 Function 7.4.2 Adjustment elements 7.5 Central cooling unit 7.5.1 Function 7.5.2 Adjustment elements 7.6 Option: Emulsion vapor separator system / compact electric filter 7.6.1 Function 7.6.2 Adjustment elements
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7-3 7-3 7-5 7-9 7-9 7-9 7-10 7-10 7-15 7-15 7-15 7-15 7-16 7-19 7-19 7-20 7-23 7-23 7-24 7-27 7-27 7-27
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9-2 9-6 9-9 9-9 9-10 9-10
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9.2.3 roller blinds 9.2.4 Work room safety window (only with two station models) 9.2.5 Work room grid 9.2.6 Magazine loading door (only with two station models) 9.2.7 Cassette walls 9.2.8 Panels 9.2.9 Switch cabinet doors 9.3 Cleaning 9.3.1 General instructions 9.4 List of lubricants BAS-03 9.4.1 Lubricant list for SW machines 9.5 Tips for the use of cooling lubricants 9.6 Maintenance / service 9.6.1 Lubrication schedule 9.6.2 Fill volumes 9.6.3 Maintenance schedule 9.7 Maintenance photos 9.8 Service 9.8.1 Safety windows 9.8.1.1 Exchanging the polycarbonate window on the work room door 9.8.1.2 Replacing the polycarbonate windows of the work room door 9.8.2 roller blind covers 9.8.2.1 Replacing the "roller blind spindle unit" (X axle) 9.8.2.2 Replacing "roller blind loading room cover" 9.8.2.3 Replacing the "side roller blind roof sled" 9.9 Troubleshooting
9-11 9-12 9-13 9-13 9-14 9-14 9-14 9-15 9-15 9-17 9-18 9-20 9-21 9-23 9-24 9-25 9-32 9-39 9-39 9-39 9-39 9-40 9-40 9-41 9-41 9-43
10-1 11-1
11-3 11-3 11-4 11-4 11-7 11-7 11-7 11-8 11-9 11-10 11-11 11-11 11-11 11-12
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11.2.2.1 Siemens machine control panel 11.2.2.1.1 SW function keys with LED 11.2.2.1.2 Axle selection 11.2.2.2 Additional control panel SW 11.2.2.2.1 BAS03-11 / -21 11.2.2.2.2 BAS03-12 / -22 11.2.2.3 SW magazine control panel 11.2.2.3.1 BAS03-x2 11.2.3 Two station processing 11.3 Operation 11.3.1 Switching the machine on 11.3.1.1 Switching on 11.3.1.2 Roof sled drive synchronisation 11.3.1.3 Switching the machine off 11.3.1.4 Turning the swivel support in the JOG mode 11.3.1.5 Roof sled 11.3.1.6 Reference points 11.3.1.7 Selecting programmes 11.3.1.8 Test stop 11.3.2 Tools and magazine 11.3.2.1 Basics 11.3.2.2 Oversized tools 11.3.2.3 Loading the tool magazine BAS03-x1 11.3.2.3.1 New tool 11.3.2.4 Loading the tool magazine BAS03-x1 11.3.2.4.1 New tool 11.3.2.5 Unloading the magazine 11.3.2.5.1 Unload tool 11.3.2.6 Programming notes for tool management 11.3.2.6.1 Tool change 11.3.3 Tool monitoring 11.3.3.1 Standstill monitoring 11.3.3.2 Quantity monitoring 11.3.4 Tool magazine 11.3.4.1 Basics about the tool magazine 11.3.5 Teleservice (Option) 11.4 HMI masks 11.4.1 SW 11.4.1.1 Tool breakage 11.4.1.2 Machine 11.4.1.2.1 NC programme 11.4.1.2.2 Assigning NC programmes 11.4.1.2.3 Machine control panel 11.4.2 Preparation 11.4.2.1 Type preselection 11.4.2.2 Adjustment 11.4.2.2.1 Lubrication 11.4.2.2.2 Chip conveyor / input 11.4.3 Manual operation 11.4.3.1 Individual movement of tool changer 11.4.3.2 Individual movement tensioning device, table 1 11.4.4 Processing
11-12 11-13 11-15 11-17 11-17 11-21 11-23 11-23 11-24 11-25 11-25 11-25 11-26 11-27 11-27 11-28 11-28 11-29 11-30 11-31 11-31 11-32 11-33 11-33 11-35 11-35 11-37 11-37 11-38 11-38 11-39 11-39 11-39 11-41 11-41 11-43 11-45 11-46 11-46 11-47 11-47 11-48 11-49 11-51 11-51 11-52 11-52 11-53 11-54 11-55 11-56 11-57
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11.4.4.1 Tension layer 11.4.5 Diagnosis 11.4.5.1 Carrier round table 11.4.6 Documentation 11.4.6.1 Workpiece counter 11.5 SW masks / expansions 11.5.1 Loading axles / setup positions 11.5.2 Selecting the device 11.6 Tool and magazine masks (Siemens) 11.7 Control tips, tables, lists 11.7.1 BAG's and channels 11.7.2 Coordinate system/axle designations/drive distances 11.7.3 Special functions / BAS03 11.7.3.1 Error messages 11.7.3.2 M functions / overview 11.7.3.3 H functions 11.7.3.4 Extended M functions 11.7.3.5 L functions 11.7.3.6 G commands 11.8 Programming / examples 11.8.1 Clamping of round axles 11.8.1.1 Round axles from NCK status 6.4 11.8.1.1.1 G1 standard (without round axle interpolation) 11.8.1.1.2 G1 with 4 or 5 axle interpolation 11.8.1.1.3 Programming of A or U axle parallel to the tool change. 11.8.1.1.4 Axle-neutral programming of the round axles A or U 11.9 Appendix / Option 11.10 ePS network manufacturer's documentation 11.11 Groove cycle 11.11.1 Groove cycle (option) 11.11.1.1 Inner groove 11.11.1.1.1 Entering workpiece parameters 11.11.1.1.2 Input of tool parameters 11.11.1.1.3 Adjustments for interior circulation 11.11.1.2 Outer groove 11.11.1.2.1 Entering workpiece parameters 11.11.1.2.2 Input of tool parameters 11.11.1.2.3 Adjustments for exterior circulation
11-57 11-58 11-58 11-59 11-59 11-61 11-61 11-63 11-65 11-67 11-67 11-68 11-69 11-69 11-69 11-71 11-72 11-72 11-72 11-73 11-73 11-73 11-73 11-74 11-75 11-75 11-76 11-76 11-76 11-77 11-78 11-78 11-81 11-82 11-83 11-83 11-86 11-87
12 UPGRADING
12.1 Safety instructions 12.2 Loading with crane / handling systems 12.2.1 One station machines 12.2.2 Two station machines
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12-2 12-5 12-5 12-6
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13 DISPOSAL
13.1 Safety instructions 13.2 Disposal options
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13-2 13-3
14 FIRES
14.1 General Information on Fire Procedures
14-1
14-2
14.2 Opening the force locked protective doors when there is no power supplied to the machine 14-3 14.3 Opening the safety separating window when there is no power supplied to the machine
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15 EXTERNAL DOCUMENTATION 16 ELECTRICAL DOCUMENTATION 17 SPARE PARTS AND WEAR PARTS, DRAWINGS, ILLUSTRATIONS
17.1 Usage instructions for the electronic spare parts and wear parts lists 17.2 Drawings, illustrations Technical specifications are subject to change.
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Impending danger for body, life and property. If these instructions are not observed, this can cause health problems or even lifethreatening injuries, as well as damages to the equipment and property value.
Important note for the proper handling of the machine. If these notes are not observed, this can lead to damages to the equipment and property value - and sometimes - harbour an injury risk for employees.
Impending danger by electric current. If these instructions are not observed, this can cause health problems or even lifethreatening injuries caused by electric current, as well as damages to the equipment and property value. Impending danger caused by thermal influences. If these notes are not observed, this can lead to burns and scalding by coming into contact with liquids, surfaces and objects (e.g. motors, pumps, hydraulic and cooling units, valves, etc.)
Impending danger by strong magnetic fields. If these instructions are not observed, this could lead to life-threatening affects on humans (e.g. pacemakers, electr. health systems) as well as injuries by magnetic tools and damage or destruction of electronic devices.
Useful tips and work-releated information. These instructions contain information that allows for a better handling of the machine.
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1.2 General
The machine is state-of-the-art; the design and manufacturing is performed under observance of the general regulations and legal directives of the machine industry. The highest possible operation safety is only achieved, however, if the machine is used solely by trained, respsonsible personnel and is only used for its intended purpose. Every person that is responsible for the transport, installation, operation, maintenance and supervision of the machines manufactured by "Schwbische Werkzeugmaschinen GmbH as well as the master or department manager, under whose supervision the machine is erected, must have read and understood the chapter "General safety and accident prevention instructions. Theother country-specific regulations and law, which apply to special handling, must be observed as well and have priority over our instructions. A non-dangerous and flawless performance of activities and interventions is only warranted if special skills are present for these activities and if the information and instructions in our machine documentation as well as the components' instructions are taken into consideration. The cautionary measures required in the documentation of the "Schwbische Werkzeugmaschinen GmbH do not claim to be complete and refer solely to the use of our products. If unauthorised personnel acts/intervenes without extensive know-how, these situations could result: - Dangers to body and life, - dangers to the machine and other property assets, - danger to the efficient operation of the machine, - danger to the environment. The responsibility of having only trained/skilled personnel work on certain activities lies with the different supervisors of the employees in charge as well as with the safety officer of the operator.
Prior to performing certain tasks, all relevant information as well as the special safety instructions in the respective machine documentation chapter must be observed.
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The operator bears the responsibility for the internal transport of the machine even if the employees of the "Schwbische Werkzeugmaschinen GmbH are present - and he must ensure that the safety and accident prevention instructions are adhered to. Depending on the activities to be performed, the respective personal safety equipment must be worn (e.g. protective gloves, safety shoes, helmet, protective eye goggles, etc.). Machine or panel parts with sharp edges in the access area of the transport workers must be covered by covers (upholstery material). The prescribed end positions for the load pickup devices must be used.. The products to be transported must be secured against movement, tilting, rotating or swivelling of individual parts prior to and during transport. The respective measures must be taken to achieve this (observing the gravity center as well as securing with: positioning rings, chains, securing wooden wedges, screw connections, etc.). The transport must be slow, controlled and no other objects must be touched. If the machine and machine parts are not transported properly, this will endanger your health and life! Neverstep underneath raised loads; secure transported goods sufficiently; when turning/moving the transported goods in small areas, ensure a sufficient safety distance (crushing and severing danger of the head, body and extremities)!
Machinesmanufactured by "Schwbische Werkzeugmaschinen GmbH are equipped with various safety systems; e.g. doors and windows (work room, machine room, tool magazine, etc.) are all monitored and locked via the machine control.
The operator is responsible for the machine not being operated if safety systems (such as panel parts) are open, removed, bypassed or taken out of operation - life-threatening danger!
Panel parts and cab sheet metal parts and switch cabinet doors are not monitored.
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With automatically operated doors / windows / openings, there is always a risk of crushing. Persons close to the machine must be warned of this danger by the operator. The operator must check the proper fastening of the tensioning devices, their power supplies (electric, pneumatic, hydraulic) as well as the proper functioning of the tools / tool holders and the processing programme; a walk around the machine as well as an inspection of the machine interior must be conducted to ensure that no persons are within the immediate machine area and that the machine is not colliding with any objects prior to starting the machine. With machinesthat allow the use of two "separate" processing locations by a common spindle performing the processing alternatively, only the work room is monitored or locked, where the processing spindle is located. The other work room can be opened for loading/unloading without having to interrupt the work process in the opposite work room. The serial work room separating wall which is equipped when the two work room model is used must not be removed - life threatening danger! Reaching across or climbing from the free work room into the active work room is prohibited; danger of injuries by cuts and loss of limbs all the way to life-threatening injuries
Depending on the machine model, certain machine functions or operation settings are protected by key switchesThese key switches are located in the control panel or directly on the respective functional unit. The machine must be set up so that only the required activities are performed by the respective employees. The operator is obliged to remove the key and keep the device locked from unautorized persons. The key switch installed on some machine (e.g. in the control panel), which can interrupt the protective door monitoring, may only be used for setup, maintenance and repair procedures.
As long as the protective door monitoring is disabled, a life-threatening danger exists; axle drives can be activated while the protective door is open.
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The operator must inform himself extensively about the location and the function of the "EMERG OFF" key(s).
If the safety is breached, or if a situation is detected that might lead to a safety breach, the "EMERG OFF" key must be activated immediately.
When the "EMERG OFF" key is pressed, all machine movements are stopped; depending on the situation, this can cause damage to the tools, the work piece and perhaps to the machine. The operator must immediately inform the responsible party of all modifications on the machine that may lead to safety-relevant issues. The CNC controlled machines are equipped with diagnostics system; with functional errors or operational errors, error messages will be generated.The causes of the errors must be eliminated. Severe errors will lead to a shut down of the machine, just like pressing "EMERG OFF". There is no check of the customer-specific processing programmes regarding these operation errors.. Every operator is responsible for not using commands in programmes that might cause safety issues for persons and materials (e.g. work piece and tool dimensions, advances, speeds, depth of cut). The operator is responsible for the compliance with work and environmental protection when using hazardous and auxiliary substances.The machines require oils, greases, cooling lubricants and refrigerants, air, hydraulics and electrical energy for their proper operation.The operator is also responsible for choosing the proper manufacturer/supplier as well as for clarifying the safety-relevant issues. Oils, greases, cooling lubricants, detergents and solvents and other materials used for operation contain biological and chemical substances, which may cause hazards to your health if used improperly (toxic and/or flammable vapors, acidic or skin-irritating additives, etc.). Furthermore, the mixing of these materials may create new compounds that may also negatively impact not only human health but also the machine's product life. Generally the information and use instructions of the manufacturer (material safety data sheet) and the applicable national regulations and laws that are binding for the machine's location must be adhered to prior to using auxiliary materials and additives.
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Escaped liquids (leakages) as well as worn or used auxiliary materials must be removed immediately and disposed of as determined by the work and environmental protection regulations. Wear protective clothing. The service and maintenance staff is expected to be familiar with the general legal accident prevention measures; the responsibility lies with the safety officer of the user or rather with the supervisor of the maintenance and service staff.
Prior to beginning maintenance and repair procedures, the machine must be disconnect from the power supply and the pressure must be relieved; furthermore, the non-operational stastus of the machine must be reported by means of "Caution Signs". After disconnecting the electrical energy (main switch OFF), enough residual energy may remain in the different supply systems - e.g. electrical, electronic, hydraulics, pneumatics - which could lead to hazardous situations, some with fatal consequences - if not handled by an expert.
Hydraulic and pneumatic systems may only be disconnected from the main line and the system pressure may only be released after it has been ensured that this will not cause any uncontrollable mechanical reactions (snapping back of spring-loaded tensioning systems or cylinders in idle positions; dropping of tools; sliding off of advance and movement units by the lack of weight balancing, etc.). Prior to removing e.g.motors with built-in brakes, toothed gears, couplings or other movement-inhibiting components, the respective movement units must be secured (supported or hung up) so that these inadvertent movements are prevented. When working on hard to reach places as well as units that are not clearly visible for design or functional reasons (e.g. chip conveyor, chip box, cooling agent containers, submersion pumps, tool magazine, etc.) there is a danger of cuts, crushing, abrasion and burn injuries. To prevent accidents, you must wear protective clothing during these procedures.
Maintenance, repair and adjustment procedures on active systems must be performed using extreme caution. If the necessary caution is not applied, there is a danger of injuries or even death!
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Maintenance and repair work that requires adjustments that is only possible while all systems are ready to operate or by removing or deactivating special safety equipment, must be monitored by responsible employees located near the "EMERG OFF" and "main switch" keys; if danger arises, the machine must be shut down.
The electric switch cabinet may only be opened by qualified and authorised personnel. After disconnecting the machine from the electrical supply (main switch OFF), the following parts still feature life-threatening current: - on the main switch - in the switch cabinets on the terminals L1, L2, L3 - on the connecting cable between the main switch and the terminals - on the power supply line - on electric regulators and their supply modules - on all areas marked with a warning label
Switched interventions to modify the hardware or software, as well as electrical and mechanical modifications of the machine's design may only be performed by service technicians of "Schwbische Werkzeugmaschinen GmbH"; the information in the operating instructions is for informational purposes only. The operator/owner is liable for any damage caused by unauthorized intervention. After completing maintenance or repair work, the supervisor of the maintenance/service personnel must verify the unlimited operation readiness of the machine. This includes: the proper fastening of all panel parts and protective equipment, checking the proper installation of all parts, connections, etc. loosened or removed in the course of the work performed the proper filling and pressure application a function test of the machine with the result, that the machine/its components are functioning properly and within the prescribed NOMINAL values. the correct function of the protective equipment and the EMERG OFF key checking the processing programme, if the executed procedures may have affected it in any way. A walk around the machine as well as an inspection of the machine interior must be conducted to ensure that no persons are within the immediate machine area and that the machine is not colliding with any objects prior to starting the machine. Only then may the production operation be released.
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All safety-relevant equipment (e.g. EMERG OFF function, light curtains, safety rails, floor mats, door monitors, error current switch, etc.) must be checked for proper function on a regular basis. Here, the respective applicable laws and regulations apply that are legally binding for the operating site.
Adhere to legal regulations: Hydraulic hoses must be regularly checked by an expert for their safe function; the max. use is 6 years - as per the "Safety regulations for hydraulic hoses" (incl. storage time).
Due to the material aging of polycarbonate, the retaining capacity (protection from foreign object impact) of the work rooom protective windows is decreased. Another reduction of safety is caused by mechanical damage, temperature influence, radiation and the contact with chemical and biological auxiliary materials and additives. The usage period of work room protective windows is limited, see Chapter "Maintenance Damaged polycarbonate windows must be replaced immediately.
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2 GENERAL DESCRIPTION
2.1 Preliminary information 2.2 Description of the mechanics 2.2.1 General 2.2.2 Special machine features 2.3 CNC control: 2.3.1 Control type
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Currently, there is a differentiation between a one station model (with a swivel table, BAS03-x1) and a model with a "double swivel table" (BAS03-x2), which can be called a two station model. The swivel tables are used as machine tables for the placement of workpieces or the tensioning devices; they are fashioned as horizontal NC axle. Generally, both models can be supplied with one (BAS03-1x) as well as with two (BAS03-2x) vertically arranged motor spindles and they are equipped with an automatic tool magazine.
The following information refers to the two station model of the processing centres BAS03, with either one or two spindles BAS03-12 BAS03-22 (one spindle, two station model) (two spindle, two station model)
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The basis is the fixed, stiff U-shaped machine stand made of welded steel with cross strut in the rear roof area. The Y sled in "Gantry style" for the lengthwise movement, the X sled for the horizontal movement and the Z sled for the vertical movement of the work spindle(s) are also located in the roof area and make up the three axle unit (as a box in box system). The different sleds are connected to each other via linear guide rails with roller guides. The advance of the individual drive axles (X, Y, Z) is realized via ball roll spindles and servo drives.The distance measuring is done via absolute, direct measuring systems (glass scales). The Gantry system of the Y sled with two drives and two separate distance measuring sytems ensures a regulated, sled-parallel advance movement. Underneath the three axle unit, there is the work room. The machines have two swivel tables with counterbearings, which are defined as independent horizontal NC axles by the control (A1 / U1). This allows processing outside the three main machine axles (room angle processing) without additional effort.The optional planet round tables provide additional NC round axles (C / W); see figure. The swivel tables are built into a swivel support system and make up two areas separated by safety windows.While one table for parts processing is located in the work room, the other table is located in the loading room (main time parallel loading and unloading), so that you could consider this to be a two-station processing. By turning the entire swivel support system by 180, the two swivel tables change their positions between work and loading room. The chips that are generated during processing (as well as the cooling lubricant - if used) are discharged via declined surfaces into the foot area of the machine stand. As a choice, a chip cart or a cooling lubricant system with chip conveyor - which are adapted to the opening contours in the machine leg - must be used.
If operating without adapted chip catch container (e.g. with central disposal), the operator is obliged to close the foot area of the machine so that there is no bottom access to the hazardous areas of the machine.
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The encapsulated tool magazine is located behind the work room. The automatic tool change takes place on the border of the work room via the pickup principle.
Assembly photo The tool magazine is loaded and unloaded via the magazine loading station on the left long side of the machine.
Synchronuous motor spindles are used as work and tool spindles. Their performance data along with the low mass moment of inertia allow for an economic tool use. The tool tensioning takes place automatically; the release is hydraulic. For the use of tools with "interior coolant supply", the tool tensioner is equipped with a rotating feedthrough (option).
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3 PICTORIAL PART
3.1 Preliminary information 3.2 Machine photographs 3.2.1 Total view 3.2.2 Work room / loading room (two locations) 3.2.3 Tool magazine 3.2.4 Groups 3.2.5 Units 3.2.6 Individual components
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3-2 3-3 3-3 3-7 3-9 3-11 3-15 3-24
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Control panel
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Device room
Switch cabinet
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Rear view
Hydraulic unit
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Control panel
EMERG OFF
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Swivel support Loading room door Option: Device / planet tables (round tables)
Option: Rinse nozzles loading (Cover removed) Option: Rinse nozzles work
Work spindle Magazine door (lifting door) Lock Safety discs Work room safety disc (open)
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Drain funnel bed rinsing Spring bearing Tool magazine Pneumatic cylinder Tool change Cover of the magazine drive
Pneum. cylinder Loading station BERO, Magazine pliers open BERO, Magazine position Magazine opening (to the work room)
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Magazin e drive
Magazine door
Safety it h
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3.2.4 Groups
Two location machine View from the left
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Standard hydraulic components Mounting plate for optional equipment Counter bearing swivel support
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3.2.5 Units
(Device room)
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3-15
Pressure reducer, air purge, motor spindles, round table, counter bearing, etc.
Switching valve Central / minimum oil lubrication Central lubricating unit, (Central lubrication / minimum oil lubrication)
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A8003Agb
3-16
Hydraulics Accumulator
Pressure switch system pressure Motor with pump Valves tool tensioner Temperatur e display
(Rear) Heat exchanger hydraulic unit Tank installation filter with fill level limit switch Fill opening
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A8003Agb
3-17
Temperature display
Circulating p mp
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A8003Agb
3-18
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A8003Agb
3-19
Spindle box (Roof area) Oil filter and pneum. pressure switch, minimum quantity lubrication Pneumatic valves Minimum quantity lubrication plan Regulator valve plan system Lubrication pressure monitoring
Lubrication distributor Minimum quantity lubrication Pressure adjuster / manometer / ventilation, for pneum. weight balancing
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A8003Agb
3-20
Activation coolant valves Connectors, coded; (chip conveyor, filter systems, additional pumps) Interior cooling lubricant, Coolant lubrication supply Additional blowoff function via rinse nozzles in the loading room Supply of coolant gun chip conveyor, Pneum. controlled coolant valves
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A8003Agb
3-21
Link belt
Setup screw
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A8003Agb
3-22
Switch cabinet
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A8003Agb
3-23
Gantry drive left; Roll circulation guide, motor, ball roll spindle, glass scale
Roof rollo
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A8003Agb
3-24
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A8003Agb
3-25
Rinse rail
Drain funnel
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A8003Agb
3-26
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A8003Agb
3-27
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A8003Agb
3-28
4-1
4-3 4-5 4-7 4-7 4-8 4-9 4-9 4-11 4-12 4-13 4-13 4-13 4-15 4-15 4-16 4-19 4-20 4-21 4-22 4-22 4-22 4-23 4-24 4-25 4-25 4-26 4-27 4-29 4-29 4-30 4-31 4-32 4-33 4-34 4-35 4-35 4-36 4-36 4-37 4-39 4-41
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4-1
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A8004Agb
4-2
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A8004Agb
4-3
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A8004Agb
4-4
4.2 Dispatch
For the dispatch, the processing centres are treated with anti-rusting agents, moving parts and units are locked into place / removed and sent in two transport units (machine as well as a pallet with small parts). The crane transport takes place via attachment eyes (rotating transport eyes). Depending on their size and weight, options and accessories are enclosed with the usual transport units or packaged separately (see delivery note).
In accordance with the "environmental" and "hazardous materials transports" rules and regulations, the contents of the units are limited to a permitted volume.
The operating instructions for the machine are packaged in separate boxes and are sent along with the small parts.
BAS03-x2 (Two station machine) 2.44 x 3.37 x 2.75 m approx. 8,000 kg 1.2 x 3.75 x 1.4 m approx. 750 kg 1.00 x 1.30 x 0.45 m approx. 250 kg
Decreasing these dimensions can only be achieved by the elaborate removal of machine parts.
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A8004Agb
4-5
With seaworthy packaging, all transport units are wrapped with a sealed aluminium foil and are dispatched in transport crates with pallet floors. Dispatch data for seaworthy packagaing Machine (WxDxH) Weight Chip conveyro (option)
(WxDxH)
BAS03-x1
BAS03-x2
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A8004Agb
4-6
4.3 Transport
You can use a crane, forklift and rolling transport cart to transport the machine and the different packaging units.
Generally, machines and other machine-related parts (e.g. hydraulic units, filter units, cooling and air conditioning units, etc.) may only be transported in their upright position or the position they are used in.
The transport must take place taking into consideration the country-specific requirements and laws regarding accident prevention and transport.
The safety switches with locks are constructed so that a forced lock will be performed on the respective door when there is no power to the machine. The manual opening of a forced lock may only be performed when the machine poses no dangers.
After removing the lock screw, a bushing with a front cross groove will be exposed and can be accessed.By turning this bushing by approx. 5 degrees counter clockwise, the lock in the safety switch is released and the machine access can be opened by hand. After closing it once again, the forced lock is reactivated.
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A8004Agb
4-7
Safety separating window (only for 2 station models) There is a safety window between the loading room and the work room on both sides of the swivelling support.This safety window can be manually folded open when working in the work room. The lock is activated by two monitored pneumatic cylinders. If the control is turned ON and by pressing the key "safety window", the locks are released.
Loading the magazine The access to the tool magazine on the left side of the machine (only with two station machines) is locked / monitored by a safety switch. In conditions without power, the lock remains active. The safety switch can be accessed beneath the opening - after removing the cabin panel.
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A8004Agb
4-8
The rear threaded borings for the attachment eyes are located to the right or left of the motors for the longitudinal drive (y axle) of the sled unit.
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A8004Agb
4-9
The borings for the two attachment eyes in the front part of the machine are located next to the guide rails of the sled unit. Caution: These attachment eyes must be removed after the crane transport; otherwise there will be a collision with the attachment eyes (or with the roof sled) when the sled unit is moved.
You must check that the attachment eyes are properly screwed in and that they are able to move freely.
The transport ropes are attached to the attachment eyes with clevises.
Prior to as well as while lifting the machine, the rope guides and the rope stop postions must be checked to guarantee a stable transport without the danger of tipping over or damaging the machine. The transport must take place taking into consideration the labor assiocations regulations regarding accident prevention and transport.
The front attachment eyes must be removed after the crane transport; otherwise there will be a collision with the attachment eyes or with the roof sledwhen the sled unit is moved.
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A8004Agb
4-10
> 3.0 m
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A8004Agb
4-11
The steerable heavy load rolls are positioned under the front right and left machine pedestal so that a proper, safe connection can be made via the anchor hole of the machine stand (e. g. by a screw / bolt) with the heavy load rolls.
At the rear of the machine, two heavy load rolls are attached via a spacer and connected with suitable connection elements by means of the anchor holes to the machine stand.
If the heavy load rollers are not properly connected to the machine stand or if there is an uncontrolled transport situation, there is a risk of crushing or cutting for body parts and limbs by slipping or tipping of the machine.
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A8004Agb
4-12
Generally, we recommend having the foundation and the floor checked by an architect or a structural engineer prior to erecting the machine.
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A8004Agb
4-13
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A8004Agb
4-14
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A8004Agb
4-15
Never put your hands under the machine to position any parts!
Install the remaining fixator components and tighten the fastening screws to the indicated torque.
4.5.2 Alignment
In the roof area, next to the Y guide rails, there are ground surfaces to attach the measurement devices. We recommend: 2x machine level (accuracy 0.02 mm/m) 2 x ground spacer blocks (> 140 mm) 1x ground strip (machine ruler) l = > 1400 mm Horizontal deviation: Place the spacer blocks onto the ground surfaces next to the Y-guide rails and position the machine ruler and the level.
Vertical deviation: 2. Position the machine level next to the left Y-guide rails.
Read the horizontal deviation in the vertical and horizontal direction and note it with respect to the four machine erection points.
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A8004Agb
4-16
The machine is aligned horizontally using the four fixators. Generally, the machine is always aligned upward. This means that the machine corners that lie the lowest according to the determined deviations compared to the other corner points are lifted to the level of the highest corner point. The horizontal alignment must be performed by repeatedly checking the vertical and horizontal deviations until the horizontal deviation is 0.02 mm/m.
After the machine is ready to use, we recommend measuring the tension bridge in the X direction with the machine axle. The permissible deviations can be found in the machine protocol.
If - in spite of the correct static alignment of the machine - there is an excessive deviation from the horizontal alignment during the test run, one can assume that the foundation has been deformed and is therefore not suited. A repeated adjustment would deform the machine bed and would not influence the test run.
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A8004Agb
4-17
____________________________________________________________________________________________________________
A8004Agb
4-18
Assembly sequence after the transport Transportation locks Check / install units Cleaning Initial fill Connection Check / fill / ventilate systems Option; e.g. chip conveyors, tensioning devices, etc. Startup
Disassembly for the transport see information "Shutdown / Storage" see "Dispatch" and "Transport" see "Concluding the transport preparation" Observe options; chip conveyor / devices Positioning movement units Cleaning Transportation locks / crane eyes Disconnect remaining connection, also to foundation (see "Erection") Empty systems Disconnect connections
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A8004Agb
4-19
In the roof area of the machine, there are the transporation locks for the X axle as well as the two transportation locks for th Y axle. If the front attachment eyes are still there, these must be removed! All transportation locks are accessible from above. The disassembly of the transportation locks is done by removing the socket head screws.
The transportation lock for the left Y axle is mounted to the left horizontal side of the machine.
The transportation lock for the right Y axle is located on the right side of the machine, behind the switch cabinet (top view)
Switch cabinet
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A8004Agb
4-20
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A8004Agb
4-21
4.6.1.3 Transport position of swivel support (only for two station machines)
The swivel support is driven by a "brake motor" with a subsequent gear. For transport, we recommend setting the swivel support (Q) to one of the two working positions (0 or 180). Without applied power, the motor brake is active and prevents the self-turning of the swivel support - in combination with the gear.
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A8004Agb
4-22
The startup / ventilation of the hydraulic system is only possible after connecting the machine to the power supply; see chapter "initial fill.
The hydraulic system is connected to safety functions of the machine that only function properly with a correctly adjusted system.
Disassembly In accordance with the laws and regulations for "environmental protection" and "transporting hazardous goods", the contents of the hydraulic unit and the accumulator must be kept at a permissible quantity for dispatch The emptying and the depressurising must only be performed by skilled personnel. The respective documentation of the component manufacturers must be adhered to.
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A8004Agb
4-23
In accordance with the "environmental protection" and "hazardous materials transports" rules and regulations, the contents of the units are limited to a permitted volume.
Disassembly There is no disassembly required for the transport. If you are planning a dispatch, we recommend checking the valid legal situation regarding "Environmental protection" and "transport of hazardous goods" with the forwarding agent; reduce contents to a permitted value if necessary.
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A8004Agb
4-24
Disassembly There is no disassembly required for the transport. If you plan a dispatch, we recommend emptying the consumer circuit; (anti-freeze).
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A8004Agb
4-25
Disassembly Pull the chip cart out of the machine. Clean cooling lubricant container if necessary.
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A8004Agb
4-26
Disassembly Disconnect the electrical connections between the chip conveyor / coolant system as well as the optionally installed devices (filter, cooling unit, high-pressure pumps, etc.). Suction the cooling lubricant from the storage containers (chip conveyor / coolant filter) Loosen the screw connections of the cooling lubricant lines to pumps and coolant distributors (as well as the coolant gun in the front area) Lower the chip conveyor / cooling lubricant system onto the transport rolls by loosening the articulating legs Pull the chip conveyor / cooling lubricant out of the machine Clean cooling lubricant container if necessary.
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A8004Agb
4-27
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A8004Agb
4-28
The units belonging to a serial machine and the included units must be installed (filled) according to the intended operation; otherwise there will be a danger of destruction of the unit as well as its connected components (e.g. dry run protection on pumps and bearings, overheating of spindle units, malfunctions of hydraulic units).
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A8004Agb
4-29
Prior to starting up a machine, the units and the accumulators must be checked regarding their contents and might have to be filled / ventilated by trained staff.
The processing centres are standard equipped with a hydraulic unit that is built into the device room (at the left long side of the machine) above the rail guides. Further hydraulic components (for basic functions and optional devices) are installed into the accessory devices room on the right side of the machine.
The startup / ventilation of the hydraulic system is only possible after connecting the machine to the power supply. Check the fill level in the unit, fill / refill / ventilate if necessary Check the accumulator fill, ventilate / refill if necessary. In addition to the accumulator on the unit, there can be more accumulators; see hydraulic diagram. Check the tightness of the hydraulic lines and connections Check the safe fastening of all hydraulic components
The information listed in the manufacturer's documentation is mandatory. Also see Chapter "Specifications" as well as "Maintenance/Service".
Safety functions are connected with the hydraulic system on the machine (e.g. weight balancing, etc.) that only function flawlessly with a properly configured system.
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A8004Agb
4-30
Ventilation: The ventilation may only be performed by skilled personnel (service employees). (loosen the lubrication lines from lubrication location and multiple triggering of lubrication intervals).
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A8004Agb
4-31
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A8004Agb
4-32
Filling (switch control off) Create the mechanical and electrical connections (see Chapter "Connections") Check on the cooling lubricant container whether all hose/pipe connections as well as the electrical connections have been properly connected; open shutoff valves to the connected components (e.g."interior coolant" or "coolant guns') if necessary. Fill the cooling lubricant container via an automatic mixing device (injector mixing device) with the desired emulsion concentrate. If no automatic mixing device is available: Mix the required amount of cooling lubricant concentrate (see Chapter "Maintenance/Service") with approx. 5 parts water. Fill the premixed emulsion into the cooling lubricant container. Fill the cooling lubricant container with water; see fill level indicator Check the concentration Check the fill level several times during the first days after the machine startup; fill up water if necessary.
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A8004Agb
4-33
All loose parts have either been removed from the machine or properly stowed. All panel parts, cables and hose lines, etc.are attached correctly and cleaned up. All switch cabinet doors are closed; panels / sheet metal plates are either secured or removed. All machine parts that are subject to the risk of damage during transport, are protected accordingly (e.g.control panel, etc.) All keys have been removed It is ensured that the loading can be performed without danger. After loading the machine, the removed panels are reattached for transport or packed into transport boxes.
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A8004Agb
4-34
4.7.1 Pneumatics
The connection for the pneumatic supply is located inside the device cabinet, on the left long side of the machine. Prior to installation activities, the connection point to the onsite pneumatic supply must be relieved of pressure. Create the connection between the onsite pneumatic connection point and the machine connection (maintenance unit) via a suitable pressure hose. Connect the hose with a hose clamp. Supply the connection line with compressed air and check the pneumatic system for leaks. Set the required operating pressure (see Chapter "Specifications") on the manometer. Check the pressure settings of the other manometers; sealing air; weight balancing, options, see pneumatic diagram
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A8004Agb
4-35
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A8004Agb
4-36
4.8 Startup
The proper startup procedure requires extensive mechanical and control skills, which are not included in this documentation! The startup may only be performed by a person trained by us (Schwbische Werkzeugmaschinen GmbH) in mechanics and the control for the respective machine type. After switching on the control, all units and devices (control, pneumatics, cooling lubricant system, cooling system, lubrication, hydraulics, etc.) must be checked for correct function and correct settings of the operational values. The hydraulic systems and the lubrication units must be ventilated. Check the limit positions and the interplay of the individual machine cycles (test programmes). Test the safety and control units for safe operation. Perform customer-specific sample programmes without processing as a test; also see: Operation and programming instructions of the manufacturer of the control Supplemental operation and programming instructions of the "Schwbische Werkzeugmaschinen GmbH in Chapter "Operation
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A8004Agb
4-37
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A8004Agb
4-38
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A8004Agb
4-39
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A8004Agb
4-40
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A8004Agb
4-41
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A8004Agb
4-42
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A8005Agb
5-1
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A8005Agb
5-2
6-1
6-2 6-8
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A8206Agb
6.0 Specifications
6-1
ELECTRICAL POWER CONNECTION Connected voltage Total connection value PNEUMATIC CONNECTION Compressed air quality as per ISO 8573-1 Operating pressure Connected pressure average air requirement at 5 bar Connection dimensions DIMENSIONS ( L x W x H ) [m] erection room (without emergency exit paths) Transport dimensions WEIGHT Machine ready to operate Transport weights EMISSIONS Noise level with nominal operation (without chip removal) electromagnetic emissions AMBIENT CONDITIONS perm. geographical height perm. ambient temperature perm. humidity Atmosphere
3 x 400 V / 50 Hz, grounded, TN-S or TN-C net no error current protective switch approx. 70 kVA
approx. 78 dB(A)
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A8206Agb
6-2
6.0 Specifications
WORK SPINDLES Number of spindles spindle layout spindle distance Design Cooling lubricant (standard) Cooling lubricant (option)
BAS03-12 BAS03-22 (one spindle) (two spindle) 1 2 vertical vertical, side by side -300 mm Motor spindle, liquid cooled, AC-SYNCHRONOUS technique Nozzles on the work spindle Interior coolant supply
SPINDLE DRIVE
BAS03-12
BAS03-22
Model 17500 HSK (Siemens / SW) Torque range Output Torque Startup time to: Main spindle Main spindle seat Spindle lubrication Tool interface Tool tensioner tension / release
0 - 17500 1/min 15.5 kW each (at 2500 1/min) (S6/40% ED) 15.5 kW each (at 3500 1/min) (S6/100% ED) 60 Nm each (S6/40% ED) 42 Nm each (S6/100% ED) 15000 1/min approx. 1.65 s 70 mm 3-fold Minimum oil quantity lubrication Hollow shaft cone DIN 69893-HSK-A63 Retraction force > 18 kN; mechanical / hydraulic
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A8206Agb
6.0 Specifications
6-3
BAS03-12
BAS03-22
X Y Z X Y Z X Y Z
AC technique, digital L 1 75,000 mm, L 1 75,000 mm, L 1 75,000 mm, 4,500 N 4,500 N 4,500 N 10 m/s 10 m/s 10 m/s X, Y, Z axle direct, absolute BAS03-12 BAS03-22 (one spindle) (two spindle) 600 mm 300 mm 400 (650) mm 400 mm
Advance force
Distance measurement
DRIVE PATHS X axle Y axle (change position) Z axle ACCURACY Position tolerance Tp
0.010 mm
These values can be warranted by the operator as long as our foundation requirements have been met and were determined at a reference temperature of 20C using the pendulum step procedure as per VDI/DGQ 3441.
TOOL MAGAZINE Chain magazine Tool storage Numbering max. tool diameter max. tool length max. tool weight TOOL CHANGE Tool change principle medium chip to chip time
BAS03-21 (two spindle) 2 x 20 tools (2 x 32 tools) location encoded 2 x 1-20 (2 x 1-32) 70 mm (160 mm with unused adjacent locations) 275 mm (see tool data sheet) 7.5 kg
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A8206Agb
6-4
6.0 Specifications
WORK AREA Model Swivel support with two-sided plan teeth max. transport load Swivel time (0 - 180 degrees) Main time parallel workpiece loading Swivel table as an independent horizontal NC axle (round table with counterbearing) Driving torque Plan disc speed Distance measurement Splitting accuracy (angle seconds) max. moment of mass inertia Tangential moment hydr. clamped max. transport load max. Dimension workpiece / tensioning bridge Illumination Luminous flux
BAS03-x2 (two station) Swivel support with 2 separate swivel tables to hold tensioning bridges 1 1,100 kg approx. 3.5 sec yes 2
200 Nm max. 100 1/min direct, absolute +/- 5 18 kgm 2,000 Nm 400 kg 450 x 830 mm diam.
2 x 13 2 x 900 lumen
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A8206Agb
6.0 Specifications
6-5
Vogel MFE 5 27 bar 0,5 dm / min. (counter pressure 5 bar) 2.7 liters via solenoid valve
1,800 s (approx. 2/h) self-initiating adjustable via PLC 10 s (after pressure build-up) approx. 1.9 cm/interval see Chapter Units / devices
after 600 s spindle run time (n>20 1/min), selfinitiating, adjustable via PLC 10 s (after pressure build-up) continuously by air flow approx. 0.1 cm/interval see Chapter Units / devices
Hydraulic system Max. operating pressure Fill volume hydraulic tank Oil quality Supplied devices
Central cooling unit (water return cooler) Cooling performance recommended temperature setting Refrigerant type Fill weight Cooling water container Cooling water additive (corrosion protection) Nominal volume flow - water circuit Supplied devices
approx. 5.2 KW at 25 C ambient temperature 25 C (with middle-European climate) R134a 1.9 kg approx. 40 liters Tyfocor ( 20 Vol.% ) approx. 22 dm / 3 bar see Chapter Units / devices
A8206Agb
____________________________________________________________________________________________________________
6-6
6.0 Specifications
Pneumatic system Filter regulating valve: autom. condensate drain / filter Operating pressure Filter insert Pressure switch Sealing air: Filter regulating valve: Minimum oil quantity lubrication: System pressure Weight balancing: Filter regulating valve: Supplied devices
5 m 5.5 bar 0.01 m 4.5 bar 0.5 bar = Operating pressure approx. 4 bar see Chapter Units / devices
(Option) chip conveyor / cooling lubricant system Cooling lubricant Chip conveyor Model max. chip length Ejection height Separation of chips / coolant Cooling lubricant system Fill volume Feed volume Supplied devices Interior cooling lubricant supply Pressure Feed volume (at 40 bar) Cooling lubricant cleaning Filter insert Pure water container
Emulsion
Scraper belt conveyor with coolant container 150 mm, no chip balls approx. 1,000 mm Full stream filtering 200 m, suction pump
approx. 400 dm 200 l/min (at 3 bar) see Chapter Units / devices
adjustable, max. 70 bar 28 l/min Backwash filter Steel structure 60 m approx. 100 dm, integrated into the coolant container
Emulsion vapor separator (option) Medium / contaminants Air volume Operating temperature Supplied devices
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A8206Agb
6.0 Specifications
6-7
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A8206Agb
6-8
6.0 Specifications
7-1
7-3 7-3 7-5 7-9 7-9 7-9 7-10 7-15 7-15 7-16 7-19 7-19 7-20 7-23 7-23 7-24 7-27 7-27 7-27
Access by non-authorised persons without extensive knowledge of the machine can cause extensive damage to the machine and, in extreme cases, can lead to dangers for body and life. As a rule, the enclosed documentation by the supplier / manufacturer must be adhered to.
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A8007Agb
7-1
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A8007Agb
7-2
The pneumatic system is used for the following applications: Opening the magazine position pliers during manual loading/unloading of the tool magazine Opening the magazine pliers during automatic tool change and simultaneous blowing off of the groove in the tool pickup, by nozzles in the magazine pliers Blowing off the tool bevel and blowing off the work spindle during the automatic tool change Placing / lifting off the blow cylinder on/from the work spindle Blowing off the spindle tools during the automatic tool change, prior to placing them into the tool magazine Supply to the minimum oil quantity lubrication Sealing air supply to the round axles (A, U, Q), work spindles, gear, tool magazine and measuring systems, and switching the individual coolant valves on and off Option: Plan system control (monitoring for correct tool seating in the spindle) Option: Contact control (monitoring for correct positioning of workpieces in the tensioning unit) Unlocking the work room safety disc (only two station machines) Weight balancing on the vertical unit (only with two spindle machine) Roof sled release (only one station machines)
7.1.1 Function
The connection for the pneumatic supply is located inside the device cabinet, on the left long side of the machine. The oil-free dry compressed air is routed to the air preparer (water separator, pressure reducer with manometer and filter) via a hose or pipe line. The operating pressure is set at the pressure reducer, see pneumatic diagram. After the fine filter, the compressed air is further distributed to the different application locations. Here, further setting and monitoring elements can be integrated. During the tool change, a pneumatic cylinder is docked within the work spindle.This will be used to supply the compressed air to clean the spindle interior and tool. Another pneumatic cylinder with air supply opens the magazine pliers in the tool magazine and transfers the compressed to blow off the pliers and the tool pickup. For the minimum quantity oil lubrication which is used to lubricate the main spindle bearings, the compressed air is used as a transport medium for the lubricant. The sealing air creates an increased air pressure (overpressure) within certain systems, which largely prevents contaminants from entering. Motor spindles, round table motors, counterbearings and the measuring systems of the linear axles and the round axles (swivelling table / swivel support) are supplied with sealing air. One station machines with common work / loading rooms are equipped with an automatic roof sled with a pneumatically actuated release. ______________________________________________________________________________
A8007Agb
7-3
Two-spindle machines are equipped with an additional pneumatic weight balancing system (pneumatic cylinder and accumulator) to balance the gravity on the spindle boxes.
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A8007Agb
7-4
Two-spindle model
Spindle box Pressure adjuster / manometer / ventilation, for pneum. weight balancing
Pneumatic diagram and device list for the different machine types can be found on the following pages.
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A8007Agb
7-5
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A8007Agb
7-6
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A8007Agb
7-7
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A8007Agb
7-8
Avoid any kind of skin contact with these cooling lubricants and wear the necessary personal protection gear. Please observe the country specific guidelines and laws
7.2.1 Function
After switching on the machine control, the cooling lubricant pump starts up and supplies the cooling lubricant gun.The direct cooling on the spindle is selected by manually pressing the key "Coolant on" or by programming the respective M function. Furthermore, machine-related and optional applications such as "Rinse package ALU" depend on the customer-specific requirements. The added cooling lubricant and the chips arrive in the chip conveyor through an opening.The cooling lubricant and chips are separated from each other via perforated sheets and sieves.The cooling lubricant flows back into the storage container and the chips are transported to another location. The electrical connection of the different cooling lubricant components takes place via encoded connectors.
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A8007Agb
7-9
For tools with interior cooling lubricant supply, you must use hollow shaft cones as per DIN 69893-HSK-A63 with a cooling lubricant pipe.
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A8007Agb
7-10
Further information can be found in the manufacturer's documentation Cooling lubricant diagram and device list on the following pages.
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A8007Agb
7-11
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A8007Agb
7-12
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A8007Agb
7-13
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A8007Agb
7-14
7.3.1 Function
Lubrication cycle on the lubricating unit: Start the pump motor (prelubricating) until the set operating pressure is reached (see central lubrication diagram) Start of the trail time (lubrication duration) Start of the set interval time (break time) After the interval time has elapsed, a new lubrication cycle will start.
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A8007Agb
7-15
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A8007Agb
7-16
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A8007Agb
7-17
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A8007Agb
7-18
7.4.1 Function
After pressing "Control ON / Hydraulic system ON, the pressure oil is available for the following hydraulic systems: Open / close lifting door tool magazine Loosen tool tensioner Lock / lift off swivel support (two station model only) Swivel table (round table axle) - lock / lift off; clamp counterbearing Oil distributor for customer-specific applications Options: expanded, customer-specific hydraulic system Heat exchanger to cool the hydraulic system The sequence of hydraulic functions is regulated via the machine control. The monitoring takes place via pressure switches, Beros, etc.(A direct activation of the valves, e.g.during service calls, is only possible by means of special interventions into the machine control and by using special functions.) Error messages are shown on the control panel display and evaluated by the machine control. Prior to switching off the hydraulic system, all devices connected to it must be in stable condition; hydraulic devices can still move after switching off the oil supply (e.g.lowering the lift cylinders, opening/closing tensioning devices, etc.); also see "Safety instructions".
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A8007Agb
7-19
For customer-specific functions (e.g. tensioning devices), the serial hydraulic unit is expanded.
The hydraulic diagrams and device lists for the basic unit and its expansions are listed on the following pages.
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A8007Agb
7-20
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A8007Agb
7-21
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A8007Agb
7-22
7.5.1 Function
Standard use: Cooling of the motor spindles (The housing of the motor spindles is connected to the consumer circuit.) Cooling the switch cabinet air (The switch cabinet is connected to the consumer circuit via an air water exchanger) Athermostat regulates the connection to the consumer circuit. Cooling of the round table motor (A / U axle) (The drive of the swivel tables is connected to the consumer circuit).
Optional use: Cooling of hydraulic oil (An additionally installed heat exchanger on the hydraulic unit is connected to the consumer circuit and cools the hydraulic oil) A thermostat regulates the connection to the consumer circuit. Cooling the cooling lubricant (The cooling lubricant is exchanged via a plate exchanger that is installed in the chip conveyor.) A thermostat regulates the connection to the consumer circuit.
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A8007Agb
7-23
Switch cabinet heat exchanger The air water exchanger for the switch cabinet is mounted in the floor area.
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A8007Agb
7-24
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A8007Agb
7-25
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A8007Agb
7-26
7.6.1 Function
The unit is connected to the grid sieve in the work room via a hose and pipe line and routes the contaminated air to the filter system. Permissible ambient temperature approx. 5 - 45 C. The condensate that is emitted during cleaning is routed to the drain funnel (in the roof area) via a hose line and is discharged into chip carts / chip conveyors. The solid particles remain in the filter.
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A8007Agb
7-27
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A8007Agb
7-28
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A8008Agb
8-1
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8-2
9-1
9-2 9-6 9-9 9-9 9-10 9-11 9-12 9-13 9-13 9-14 9-14 9-14 9-15 9-15 9-17 9-18 9-20 9-21 9-23 9-24 9-25 9-32 9-39 9-39 9-40 9-43
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9-2
In order to prevent injuries and machine damage, the machine should be properly cleaned prior to maintenance and service work.
When working on hard to reach places as well as units that are not clearly visible for design or functional reasons (e.g. chip conveyor, chip box, cooling agent containers, submersion pumps, tool magazine, etc.) there is a danger of cuts, crushing, abrasion and burn injuries. Never clean the machine with compressed air, high-pressure devices or steam. An uncontrolled spreading of solid, liquid or gaseous substances can cause them to permeate the system components, which may lead to malfunctions (short circuit, contamination, lack of oil, corrosion, etc.). Do not use cleaners containing solvents, which themselves or in combination with other substances, liquids, atmospheres (gases), can lead to fire or explosion hazardous. Do not change or dissolve, etc. the used materials.
Oils, greases, cooling lubricants, detergents and solvents and other materials used for operation contain biological and chemical substances, which may cause hazards to your health if used improperly (toxic and/or flammable vapors, acidic or skin-irritating additives, etc.). Furthermore, the mixing of these materials may create new compounds that may also negatively impact not only human health but also the machine's product life. Generally the information and use instructions of the manufacturer (material safety data sheet) and the applicable national regulations and laws that are binding for the machine's location must be adhered to prior to using auxiliary materials and additives.
Escaped liquids (leakages) as well as worn or used auxiliary materials must be removed immediately and disposed of as determined by the work and environmental protection regulations. Wear protective clothing.
Prior to beginning maintenance and repair procedures, the machine must be disconnect from the power supply and the pressure must be relieved; furthermore, the non-operational stastus of the machine must be reported by means of "Caution Signs".
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9-3
After disconnecting the electrical energy (main switch OFF), enough residual energy may remain in the different supply systems - e.g. electrical, electronic, hydraulics, pneumatics - which could lead to hazardous situations, some with fatal consequences - if not handled by an expert. Hydraulic and pneumatic systems may only be disconnected from the main line and the system pressure may only be released after it has been ensured that this will not cause any uncontrollable mechanical reactions (snapping back of spring-loaded tensioning systems or cylinders in idle positions; dropping of tools; sliding off of advance and movement units by the lack of hydaulic weight balancing, etc.). Prior to removing e.g. motors with built-in brakes, toothed gears, couplings or other movement-inhibiting components, the respective movement units must be secured (supported or hung up) so that these inadvertent movements are prevented.
Maintenance, repair and adjustment procedures on active systems must be performed using extreme caution. If the necessary caution is not applied, there is a danger of injuries or even death! Maintenance and repair work that requires adjustments that is only possible while all systems are ready to operate or by removing or deactivating special safety equipment, must be monitored by responsible employees located near the "EMERG OFF" and "main switch" keys; if danger arises, the machine must be shut down. The electric switch cabinet may only be opened by qualified and authorised personnel. After disconnecting the machine from the electrical supply (main switch OFF), the following parts still feature life-threatening current: - on the main switch - in the switch cabinets on the terminals L1, L2, L3 - on the connecting cable between the main switch and the terminals - on the power supply line - on electric regulators and their supply modules - on all areas marked with a warning label Switched interventions to modify the hardware or software, as well as electrical and mechanical modifications of the machine's design may only be performed by service technicians of "Schwbische Werkzeugmaschinen GmbH"; the information in the operating instructions is for informational purposes only. The operator/owner is liable for any damage caused by unauthorized intervention.
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9-4
After completing maintenance or repair work, the supervisor of the maintenance/service personnel must verify the unlimited operation readiness of the machine. This includes: the proper fastening of all panel parts and protective equipment, checking the proper installation of all parts, connections, etc. loosened or removed in the course of the work performed the proper filling and pressure application a function test of the machine with the result, that the machine/its components are functioning properly and within the prescribed NOMINAL values. the correct function of the protective equipment and the EMERG OFF key checking the processing programme, if the executed procedures may have affected it in any way. A walk around the machine as well as an inspection of the machine interior must be conducted to ensure that no persons are within the immediate machine area and that the machine is not colliding with any objects prior to starting the machine. Only then may the production operation be released.
Please inform us about extraordinary malfunctions / errors in the course of the product observation.
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9-5
The operator is responsible for the machine not being operated if safety systems (such as panel parts) are open, removed, bypassed or taken out of operation - life-threatening danger! The separating protective equipment (work room door, loading room door, magazine loading door/panels/cassette walls) are used to keep away the chips, cooling lubricants and ejected material and tool parts - thus to protect the operator. All protective equipment must be fully functional and properly fastened. Repair and service work on the safety equipment may only be performed by SW personnel.
All safety-relevant equipment (e.g. EMERG OFF function, light curtains, safety rails, floor mats, door monitors, error current switch, etc.) must be checked for proper function on a regular basis. Here, the respective applicable laws and regulations apply that are legally binding for the operating site.
Depending on the machine model, certain machine functions or operation settings are protected by key switches These key switches are located in the control panel or directly on the respective functional unit. The machine must be set up so that only the required activities are performed by the respective employees. The operator is obliged to remove the key and keep the device locked from unautorized persons. The key switch installed on some machine (e.g. in the control panel), which can interrupt the protective door monitoring, may only be used for setup, maintenance and repair procedures.
As long as the protective door monitoring is disabled, a life-threatening danger exists; axle drives can be activated while the protective door is open.
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Due to the material aging of polycarbonate, the retaining capacity (protection from foreign object impact) of the work rooom protective windows is decreased. Another reduction of safety is caused by mechanical damage, temperature influence, radiation and the contact with chemical and biological auxiliary materials and additives. The usage period of work room protective windows is limited, see Chapter "Maintenance Damaged polycarbonate windows must be replaced immediately.
Option: Automatic loading room doors Depending on the customer requirements, the loading room doors can be opened and/or closed automatically. The activation takes place via the function keys on the control panel. To protect against crushing of body parts, the closing edges are covered with rubber strips. If an obstacle is encountered, a safety feature will interrupt the door movement (also see manufacturer's documentation).
There is a risk of crushing on the closing edge and in the "rear driving range".
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9-8
Green lamp:
Safety switch circuit closed; protective function is active Safety switch circuit interrupted, no protective function In case of an interruption of power, releasing this aux. release will open the mechanical lock.
Red lamp:
Aux. release:
After removing the lock screw, a bushing with a front cross groove will be exposed and can be accessed. By turning this bushing by approx. 5 degrees counter clockwise, the lock in the safety switch is released and the respective mechanical system can be moved (opened). After closing it once again, the forced lock is reactivated.
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9-9
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Two roller blinds are located left and right of the spindle unit (X axle). (The illustration shows the roller blinds in premounted condition)
Only for one station machines Lateral roller blind cover (roof sled open)
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9.2.4 Work room safety window (only with two station models)
There is a risk of crushing when opening the two prefriction locks of the work room safety window.
Independent of their visual condition, safety windows must be replaced at least every three years. An immediate replacement is necessary, if the holdback capacity is decreased by damage (scratches or cracks) or if the proper visibility is not longer ensured. There is a safety window between the loading room and the work room on both sides of the swivelling support. The safety window consists of a steel sheet metal frame and a polycarbonate window. This safety window can be manually folded open when working in the work room. The locks / monitoring function via two safety switches each. If the control is turned ON and by the pressing the "Safety window" key, this window will be unlocked and can be opened by hand. The safety switches with locks / monitoring of the safety windows installed between the work and loading rooms, can be accessed from the left and right machine sides - after removing the panelling.
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When operating without a chip conveyor / cart, the openings in the machine pedestal must be closed by different means - suitable metal sheets - so that the access from below to the work and loading rooms is prevented.
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9-13
The prefriction locks must always be closed; the cassette walls must always be installed flush with each other, so that there will be no gaps and all cassette walls can be installed.
9.2.8 Panels
The machine parts that must be worked on directly, are protected by fixed panels.The panels consist of steel sheet metal and are fastened to the prefriction locks by screws. Prefriction size: 8 mm square
Make sure that the panels and their fasteners are completely and properly fastened.
Always keep all switch cabinet doors closed, if you are not working directly in the switch cabinet for inspection, maintenance or service reasons.Remove the keys.
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9-14
9.3 Cleaning
A regular cleaning of the machine not only preserves its value - but also allows for early detection of wear and tear and damages. Therefore we recommend (independent of the requirements listed in the maintenance schedule) cleaning the machine thoroughly at least twice a year (after removing covers and panel parts).
In order to prevent injuries and machine damage, the machine should be properly cleaned prior to maintenance and service work.
Do not use cleaners containing solvents, which themselves or in combination with other substances, liquids, atmospheres (gases), can lead to fire or explosion hazardous. Do not change or dissolve, etc. the used materials.
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9-15
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9-16
Manufacturer
Esso Shell Mobil ARAL BP Spartan EP 68 Omala-l 68 Pressure oil KLP 68C Deol BG 68 Emergol HLP-D68
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A8009Bgb
9-17
Contact surface oil Viscosity as per DIN 51519 ID as per DIN 51502 ISO VG 220 220 mm/s (cSt) at 40C CG LP 220
Lubricating oill / hydraulic oil ISO VG 10 10 mm/s (cSt) at 40C C LP 10 (H-LP 10)
Manufacturer
ARAL ARAL AVIA BP CASTROL DEA Esso FINA FUCHS MOBIL MOBIL SHELL SHELL TEXACO Zeller+Gmelin Q8 DEGANIT B 220 DEGANIT BW 220 AVILUB RSL 220-SU MACCURAT 220 D MAGNAGLIDE D 220 NOVAN CGLP 220 FEBIS K 220 HYDRAN G 220 RENEP 5 K VACTRA Oil 4 track oil 20 TONNA T 220 TONNA TX 220 WAY LUBRICANT 220 Divinol T 12 EP Q8 Wagner 220 DEGANIT B 68 DEGANIT BW 68 AVILUB RSL 68-SU MACCURAT 68 D MAGNAGLIDE D 68 NOVAN CGLP 68 FEBIS K 68 HYDRAN G 68 RENEP 2 K VACTRA Oil 2 track oil 68 TONNA T 68 TONNA TX 68 WAY LUBRICANT 68 Divinol T 6 EP Q8 Wagner 68 VITAM GF 10 VITAM DE 10 AVILUB RSL 10 ENERGOL HLP-HM10 HYSPIN SP 10 HYSPIN AWS 10 ASTRON HLP 10 NUTO H 10 GIRAN L 10 RENOLIN B5 DTE 21 TELLUS 10 RANDO Oil HD A 10 Divinol DHG 10 Q8 Haydn 10
NOTE: The data in the different product descriptions in the lubricant list is entered because of the capability information of the respective mineral oil supplier, with reference to the required DIN qualities. We did not perform a capability test.
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Hydraulic oil Viscosity as per DIN 51519 ID as per DIN 51502 ISO VG 68 68 mm/s (cSt) at 40C H LP 68
Manufacturer
ARAL ARAL AVIA BP BP CASTROL CASTROL DEA Esso FINA FUCHS MOBIL MOBIL SHELL SHELL TEXACO Zeller+Gmelin Q8 VITAM GF 68 VITAM DE 68 AVILUB RSL 68 ENERGOL HLP-HM 68 HYSPIN SP 68 HYSPIN AWS 68 ASTRON HLP 68 NUTO H 68 HYDRAN 68 RENOLIN B 20 DTE 26 TELLUS 68 RANDO Oil HD C 68 Divinol HLP ISO 68 Divinol DHG ISO 68 Q8 Haydn 68 VITAM GF 46 VITAM DE 46 AVILUB RSL 46 ENERGOL HLP-HM 46 HYSPIN SP 46 HYSPIN AWS 46 ASTRON HLP 46 NUTO H 46 HYDRAN 46 RENOLIN B 15 DTE 25 TELLUS 46 RANDO Oil HD B 46 Divinol HLP ISO 46 Divinol DHG ISO 46 Q8 Haydn 46 VITAM GF 22 VITAM DE 22 AVILUB RSL 22 ENERGOL HLP-HM 22 HYSPIN SP 22 HYSPIN AWS 22 ACTIS HLPD 22 NUTO H 22 HYDRAN 22 RENOLIN B 5 DTE 22 TELLUS 22 HYDROL DO 22 RANDO Oil HD A 22 Divinol HLP ISO 22 Divinol DHG ISO 22 Q8 Haydn 22
NOTE: The data in the different product descriptions in the lubricant list is entered because of the capability information of the respective mineral oil supplier, with reference to the required DIN qualities. We did not perform a capability test.
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9-19
The machine is designed to use "low water mixture, mineral oil containing cooling lubricants". The cooling lubricant concentrate should have a mineral oil content of approx. 40 %. To mix a useable emulsion, the water must be mixed with at least 6% lubricant or coolant concentrate. When selecting suitable cooling lubricants and their maintenance and care, we recommend using the consulting services of the suppliers. Special attention must be paid to the compatibility with the other aux. materials, such as lubricating oil, track oil, gear oil, greases, cleaners, etc., which have been shown to contaminate the cooling lubricant.Therefore, we cannot make any recommendations regarding certain cooling lubricants. We do not recommend using fully synthetic or mineral oil-free cooling lubricants, as the machine is equipped with a loss lubrication system, where used lubricant is channeled into the cooling lubricant.
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9-20
Maintenance and repair work may only be performed by trained and authorised skilled personnel. The service and maintenance staff is expected to be familiar with the general legal accident prevention measures; the responsibility lies with the safety officer of the user or rather with the supervisor of the maintenance and service staff. Generally, all activities must be performed while the machine is turned off, if there is not an immediate need for the machine to be turned on for control or adjustment purposes.
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Machine parts BAS03 No of the invention location Pictoral symbol of the intervention Type of intervention Lubricant as per DIN 51502 Check / fill (h) Fill (h) Clean (h) Replace (h)
Oil air lubrication Main spindle Hydraulic unit *3 Cooling lubricant *4 Central cooling device *5 Tooth crown Q axle 6
*2
H LP 46
Emulsion
Grease
(KE2K)
100
4800 4800
400
40
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9-23
BA S03-xx
Central lubricating / minimum oil quantity lubrating unit
Lubricant Mineral oil with EP additives-Zustzen (MoS2 additives mixed oils are not approved) Hydraulic oil see manufacturer's documentation (Tyforop, Hamburg) see manufacturer's documentation see manufacturer's documentation see manufacturer's documentation
H LP(D) 46 ISO VG 46 Water with 20 Vol.% corrosion protection (Tyfocor) CLP PG ISO VG 220 (Tribol 800/220) KLBER Klberplex BEM 34/132
12 dm approx. 40 dm 0.16 dm
Magazine gear (SEW) Swivel support gear; Q axle (Neugart) Chip conveyor gear motor
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9-24
No.
Illustratio n
Object / activity
Note
According to the applicable laws, relevant devices such as EMERG OFF function, light curtains, safety rails, floor mats, door monitors, error current switch, etc. must be checked for their function at least once a year. 20 General Check the condition and function of protective devices / roller blinds. If damages are detected, the machine may only be used after these damages have been fixed and the protective equipment is fully functional. W110 Loading room / work room (Option) door drive safety strip perform functional test. By applying force to the telescoping doors during the automatic movement (e.g. holding them) and light tapping on the safety strip on the closing edge (e.g. with the handle of a screwdriver), the movement must be interrupted and the doors must open automatically. Work room / tool spindle Cooling lubricant rotating feedthrough visual inspection; with permanent leakage flow, an immediate exchange of the tool spindle rotating feedthrough is necessary to avoid spindle and subsequent damages! Documentation "Kessler
20
20
W120 * W121
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No.
Illustratio n
Object / activity
Note
Aux. materials, such as lubricants and coolants have chemical, biological and synthetic characteristics, which can cause influences that are negative for health and environment. The work and environmental protection regulations must be adhered to; wear protective gear. 20 * Cooling lubricant system (Option) paper band filter; check filter fleece for correct transport and damage. Documentation Knoll / Interlit
The oil filling for lubrication and hydraulic applications must be done with a filter rating of 10 m. 100 * Coolant system Documentation (Option) chip conveyor / coolant container "KNOLL" / Interlit Check the function of chip conveyor, pumps as well as the proper function of the filter systems. Dirt freight max. 40 mg/l Check the cooling lubricant as well as its contamination level (dirt freight). Remove the chips as well as residue in the sieve box. Check the gear motors (chip conveyor) oil level. During the functional control of the chip conveyor, there is a risk of cutting, crushing and severing for fingers, hands and limbs by the circulating conveyor system. Interventions are only permitted while the machine is turned off. When replacing the cooling lubricant, all contamination, such as chips, sludge and other residue from all the cooling lubricant containers must be removed; otherwise, there is a risk of damaging the motor spindles, the rotating feedthroughs, valves and other active and passive components. 100 W130 W131 W132 Work room / additional device room (Option) suctioning system Clean the suction location in the work room Check/clean exhaust air sieve insert in the additional device room (optional on the opposite side of the machine). Hydraulic unit Check / clean / replace the oil return filter Central cooling unit Check the fill level in the consumer circuit / fill water Documentation "Lotz hydraulics" Documentation Lahntechnik
400 400
W140 * W150 *
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9-26
No.
h 400
Object / activity Work room and roof area General check of all components for fastening, damages, leakages and contamination. Position the X and Y axle at the largest and smallest values, respectively.Check the roller blinds for contamination and damage. Clean the roller blinds and the scrapers in the work room and the roof area; retension or replace if necessary. Remove chips / contamination from the scrapers of the X and Y axles.
The functional check of the tool tensioner and the tool magazine can only be performed while the machine is running. This results in an increased risk of injury due to automatic processes and the functional readiness of the work spindle and the advance units. Activities of this kind must be monitored by a second person positioned by the EMERG OFF key. Otherwise there is a risk of collision, cut, crushing and severing injuries for the fingers, hands and other body parts. 400 * Work room, tool spindle Documentation "Kessler Check the spindle cone and tool pickup for damage. Clean the tensioning set of the tool tensioner - do not use compressed air - for function and wear; replace if necessary. Replace the grooved ring in the tensioning set(Viton O-ring to seal for interior cooling lubricant supply). Do not apply oil, grease the clamping spigot pickup / sliding parts with high-performance grease. Measure the retraction force and document it; max. 27kN; min. 15 kN. Check the adjustment dimension of the tensioning unit in the loosened position (see spindle drawing, with HSK63 = 10,5 mm +/- 0,1). Pneumatic system Check function / adjustments. Sealing air: Check function / adjustments. Pneumatic system Cylinder weight balancing: Check / replace muffler. Documentation "Festo" Heidenhain Documentation "Festo"
1200
1200
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9-27
No.
Illustratio n
Object / activity
Note
A high amount of pressure energy remains in the hydraulic circuits even after the machine has been turned off. Unauthorised, improper interventions can cause oil to be expelled with high pressure and can result in severe, deep injuries, even death. Oil hydraulic systems may only be worked on by trained specialists, after the system has been depressurised. Prior to that, it must be checked whether this pressure relief did not cause any undesired movements, such as the backlash of tensioning systems or the sliding off of moving units. 1200 W140 W141 W142 W123 * Hydraulic unit Check the hydraulic components for contamination / clean. Clean the heat exchanger Perform a safety inspection of the accumulator / hydraulic hoses / safety valves, etc. Check the accumulator for gas pretension pressure; refill if necessary. Central cooling unit Check the concentration of the corrosion protection agent with a full unit; minimum volume 25%. Clean the airways on the central cooling device; remove the metal filter walls and clean them; replace if necessary. Roof area Remove chips and residue behind the 3-axle unit and the drain funnel; check the function of the rinse bars. End limit switch, limit and measuring key Check the fastening as well as the function - remove dust or chips. Check all "EMERG OFF" keys and safety equipment for their proper function (door lock, etc.). General cleaning of the machine In case of wear / damage, consult SW. The work spindle(s), ball thread drive, guide rails, rotary encoders, etc. must be visually and acoustically checked for scratch or abrasion traces as well as external noise development. Pipes and hoses of pneumatics, coolant, cooling lubricant, central lubrication and hydraulics must be checked for leakage and proper fastening / function. W126 Loading room / work room Clean / check the door guide. (Option) automatic door drive Clean the drive, toothed belt, mechanical connections as well as the safety rail and check them for function and damages. Documentation "Lotz hydraulics"
1200
W150 *
Documentation Lahntechnik
1200
W125
1200
2400
2400
2400
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A8009Bgb
9-28
No.
h 2400
Illustratio n
Object / activity Work room, tool spindle Check the axial and radial play as well as the circulation. Check the function of the pneumatic blowout as well as plan position control (option); detection from 0.04 mm distance.
Note
2400
W170 W171
Machine room Energy supply / Q axle (Remove the left sheet metal insert; open the additional device room); check the energy supply lines for damage, leakage and correct routing. Check energy chain. Check measurement systems / rotary distributors (A / U and Q axle), clean if necessary. TOOL MAGAZINE Magazine locations; check the lock for damage and function as well as guide rollers; clean if necessary. (Machine rear) replace defective elements. Pneumatic system Replace the very fine filter for "sealing air measurement systems". Central lubrication system Check the function of the central lubrication unit; check the lubricant metering via the lubricating oil distributors (central lubrication) and on the metering units (minimum oil lubrication). Hydraulic system Take an oil sample from the unit, replace the hydraulic oil if is dirty or worn; clean the return filter and tank interior if necessary. Documentation "Heidenhain" Documentation "Vogel
2400
2400
2400
2400
Documentation "Lotz"
Oberve the notes issued by the labor associations: Hydraulic hoses must be checked for their safe operation at least once a year by an expert; max. use is 10 years - as per the "Safety regulations for hydraulic hoses" (incl. storage time). 2400 * (Option) suction / air filtering system Maintenance as instructed by the manufacturer (e.g. emulsion vapor separator or compact electric filter Replace/clean filter. Coolant system (Option) chip conveyor; chain tension, drive shaft, guide rollers, removal strips and scrapers must be checke for function and wear / adjusted / replaced. Documentation Losma
2400
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No.
h 4800
Object / activity
Note
Pneumatic system Documentation Maintenance unit; replace prefilter and fine filter of the "Festo" main maintenance unit; clean the water separator (filter) (observe chemical durability; check function. Tool spindle / roof areas Replace the cooling lubricant rotary feedthrouhgh on the work spindle. Switch cabinet / control Check the ventilator of the PCU, NCU, regulator package and heat exchanger for function and contamination; clean. Test the motor protection triggering device: Press the reset / test key for > 2 sec, red LED will illuminate. Press the reset / test key briefly, red LED will turn off. Save data and create NC and PLC archives; we recommend saving the hard drive to a CD once per year. Control "OFF", turn main switch on switch cabinet OFF = "0". Discharge voltage / watch for time of drive assemblies! Connections of current rail, intermediate circuit, connections and bus connections, regulator board and I/O. Check the regulator board for contamination, clean if necessary Check the serial terminals (random sample) Documentation "Kessler
4800
4800
4800
W170*
9600
Swivel support (only two station machines) Clean / grease the tooth crown of the Q axle. Gear Q axle; check the shaft seal rings for tightness, replace if necessary (check grease content). Cover / guides / drive spindles Remove the covers / roller blinds, check for function; slightly oil the metal covers; checking sealing lips. Remove chips (also on the ball thread drives). Check the guide rails as well as the ball thread drives and lightly oil them after the cleaning.
Documentation "Neugart"
9600
W140*
Documentation Hydraulic unit "Lotz hydraulics" Replace hydraulic oil Have the hydraulic hoses / pressure lines checked by an expert
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9-30
No.
h 9600
Illustratio n W175 *
Object / activity Tool magazine gear Check the grease filling and fill if necessary (for grease type - see manufacturer's documentation).
14400
Independent of their visual condition, safety windows must be replaced at least every three years. An immediate replacement is necessary, if the holdback capacity is decreased by damage (scratches or cracks) or if the proper visibility is not longer ensured.
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9-31
W110
Safety strip
W120
W121
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9-32
W122
W123
W124
W125
W126
W127
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9-33
W130
W131
W132
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9-34
W140
W141
Return filter
Fill neck
W142
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9-35
W150
W160
W161
W162
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9-36
W170
W171
W172
W173
W174
W175
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9-37
W180
W181
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9-38
Independent of their visual condition, safety windows must be replaced at least every three years.
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9-39
9.8.2 roller blind covers 9.8.2.1 Replacing the "roller blind spindle unit" (X axle)
The two roller blinds are located to the right and left of the work spindles. Replace the roller blind as follows: 1. Open the loading room doors all the way 2. Unlock the work room door and fold toward the front 3. Remove the aperture, two-part, galvanised zinc, left and right from the Z sled 4. Loosen 3 screws on each side of the scrapers 5. Remove the toothed belt for synchronising 6. Unscrew the top support angle of the roller blind 7. Pull the roller blind out of the bottom bearing 8. Refit the toothed belt disc and the bearing to the new roller blind 9. Install the new roller blind with the top holder and affix loose end to the scraper 10.Reinstall the belt 11.Manually retension the roller blind spring by hand and tighten tensioning set 12.Install the aperture
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9-40
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9-41
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9-42
9.9 Troubleshooting
Error messages are displayed as PLC errors and PLC operation messages on the screen. The error message mainly points out the cause (e.g. protective door open) or can be derived from this. See Chapter 11 and the control manufacturer's operating instructions.
A correct troubleshooting procedure is part of SW's operator training and therefore may only be performed by a personnel trained by SW.
If errors cannot be clearly identified / localised, please contact our service department to clarify the error cause and eliminate the error. Please inform us about extraordinary malfunctions / errors in the course of the product observation.
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9-44
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A8010Agb 10.0
10-1
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A8010Agb
10-2
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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11 Machine operation
Please consult the user documentation and operating instructions we furnish to operate the control. The proper operation of the machine requires the knowledge of the operating and programming instructions issued by the control manufacturer as well as a programming training by the "Schwbische Werkzeugmaschinen GmbH".
11 MACHINE OPERATION
11.1 General safety and accident prevention notes 11.1.1 Explanation of symbols 11.1.2 General information 11.1.3 Use and operation 11.1.4 Training 11.1.4.1 Training skilled personnel 11.1.4.2 Training for production operation 11.1.5 Operating and programming instructions 11.2 Operating elements 11.2.1 Overview Main operating panel 11.2.1.1 Siemens control panel 11.2.1.2 Siemens machine control panel 11.2.1.3 Additional operating panel Schwbische Werkzeugmaschinen GmbH 11.2.2 Switches, keys, signal elements 11.2.2.1 Siemens machine control panel 11.2.2.2 Additional control panel SW 11.2.2.3 SW magazine control panel 11.2.3 Two station processing 11.3 Operation 11.3.1 Switching the machine on 11.3.1.1 Switching on 11.3.1.2 Roof sled drive synchronisation 11.3.1.3 Switching the machine off 11.3.1.4 Turning the swivel support in the JOG mode 11.3.1.5 Roof sled 11.3.1.6 Reference points 11.3.1.7 Selecting programmes 11.3.1.8 Test stop 11.3.2 Tools and magazine 11.3.2.1 Basics 11.3.2.2 Oversized tools 11.3.2.3 Loading the tool magazine BAS03-x1 11.3.2.4 Loading the tool magazine BAS03-x1 11.3.2.5 Unloading the magazine 11.3.2.6 Programming notes for tool management 11.3.3 Tool monitoring 11.3.3.1 Standstill monitoring 11.3.3.2 Quantity monitoring 11.3.4 Tool magazine 11.3.4.1 Basics about the tool magazine 11.3.5 Teleservice (Option)
11-1
11-3 11-3 11-4 11-4 11-7 11-7 11-7 11-8 11-9 11-10 11-11 11-11 11-11 11-12 11-12 11-17 11-23 11-24 11-25 11-25 11-25 11-26 11-27 11-27 11-28 11-28 11-29 11-30 11-31 11-31 11-32 11-33 11-35 11-37 11-38 11-39 11-39 11-39 11-41 11-41 11-43
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11.4 HMI masks 11.4.1 SW 11.4.1.1 Tool breakage 11.4.1.2 Machine 11.4.2 Preparation 11.4.2.1 Type preselection 11.4.2.2 Adjustment 11.4.3 Manual operation 11.4.3.1 Individual movement of tool changer 11.4.3.2 Individual movement tensioning device, table 1 11.4.4 Processing 11.4.4.1 Tension layer 11.4.5 Diagnosis 11.4.5.1 Carrier round table 11.4.6 Documentation 11.4.6.1 Workpiece counter 11.5 SW masks / expansions 11.5.1 Loading axles / setup positions 11.5.2 Selecting the device 11.6 Tool and magazine masks (Siemens) 11.7 Control tips, tables, lists 11.7.1 BAG's and channels 11.7.2 Coordinate system/axle designations/drive distances 11.7.3 Special functions / BAS03 11.7.3.1 Error messages 11.7.3.2 M functions / overview 11.7.3.3 H functions 11.7.3.4 Extended M functions 11.7.3.5 L functions 11.7.3.6 G commands 11.8 Programming / examples 11.8.1 Clamping of round axles 11.8.1.1 Round axles from NCK status 6.4 11.9 Appendix / Option 11.10 ePS network manufacturer's documentation 11.11 Groove cycle 11.11.1 Groove cycle (option) 11.11.1.1 Inner groove 11.11.1.2 Outer groove
11-45 11-46 11-46 11-47 11-51 11-51 11-52 11-54 11-55 11-56 11-57 11-57 11-58 11-58 11-59 11-59 11-61 11-61 11-63 11-65 11-67 11-67 11-68 11-69 11-69 11-69 11-71 11-72 11-72 11-72 11-73 11-73 11-73 11-76 11-76 11-76 11-77 11-78 11-83
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11.1 General safety and accident prevention notes 11.1.1 Explanation of symbols
The operating instructions include graphic symbols to alert the machine operator about special safety and operating situations. The different symbols have the following meaning: Direct danger for life and health. Non-adherence to these notes will have severe health effects as well as possibly life-threatening injuries. Threat for body, life and property assets. Non-adherence to these notes can lead to health risks as well as possible lifethreatening injuries and damage to the equipment and property assets. Important note for the proper handling of the machine. Non-adherence to these instructions can cause damage to the equipment and the property assets and - in some cases - might lead to injuries of the employees.
Threatening danger by electrical energy. Non-adherence to these notes can lead to health risks as well as life-threatening injuries and damage to the equipment and property assets caused by electrical energy. Impending danger by thermal influences. Non-adherence to these instructions can cause burns and scalding by contacting liquids, surfaces and objects. (I.e. motors, pumps, hydraulic and cooling units, valves, etc.) Impending danger by strong magnetic fields. Non-adherence to these instructions can lead to life-threatening situations for humans (e.g. pacemakers, electrical health care equipment) as well as danger of injuries by magnetic tools and damages or even destruction of electronic devices. Helpful hints and work-related information. These hints contain information regarding better handling of the machine.
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The cautionary instructions required in the documentation of the "Schwbische Werkzeugmaschinen GmbH" do not claim to be complete and refer solely to the handling of our products. The national and international regulations and laws that extend beyond these and that are valid for specific actions must also be adhered to and must take priority over our instructions.
During setup, different motions can be initiated with open workroom doors. NC axles as well as working spindles can be driven at reduced speeds. Danger of cutting, crushing and burning injuries by tool and advance movements as well as by thrown chips and workpieces.
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Panel parts such as cabin sheet metal panels with locks and switch cabinet doors are not monitored as a standard.
The user is responsible for the machine not being operated while safety equipment (including panel parts) are open, removed, bypassed or taken out of operation; life-threatening danger! Automatically operated doors/windows/openings represent a crushing hazard; persons present in the machine vicinity must be informed of this danger by the operator. Prior to starting work, the operator must check the proper attachment of the tensioning devices, the energy supply (electrical, pneumatic, hydraulic) and their function as well as the tools/tool holders and the processing programme; a walk around the machine and a check within the machine must be conducted to ensure that nobody is locked inside the machine when it is started and that no collision with non-machine parts can take place. On machines, whose use is possible from two "separate" processing locations working with one common spindle, only the work area with the working spindleis monitored or locked. The other workroom can be opened for loading/unloading without interrupting the processing in the other workroom. The workroom separating wall installed during two-location operation must never be removed: life-threatening danger! The intervention or entering of the occupied workroom is prohibited; danger of cut injuries and loss of limbs or even life-threatening injuries.
The operator must learn about the location and the function of the EMERG STOP key(s).
If a safety hazard occurs, or if a situation is recognised which may indicate a safety risk, the EMERG STOP key must be activated immediately.
When activating the EMERG STOP key, all movements of the machine are stopped; depending on the situation, this can cause damage to the tools, workpiece and possibly to the machine. All changes on the machine that cause safety-technical hazards to it, must be immediately reported to the supervisor by the operator.
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The CNC-controlled machines have a diagnostics system; in case of malfunctions or operator errors, error messages will be displayed. The reasons for these errors must be eliminated. Severe errors will lead to an interruption of operation, just like when activating EMERG STOP. There will be no check of the customer-specific processing programmes in relation to operation errors. Every operator is responsible for not using commands in the programmes, which may lead to safety hazards for personnel or machine based on environmental conditions (e.g. workpiece and tool dimensions, advances, chip depth).
The operator is responsible for the adherence to the work and environmental protection when using hazardous and auxiliary equipment. The machines require oils, greases, cooling lubricants and refrigerants, air, hydraulics and electrical energy to function properly. The selection of the proper manufacturer/supplier as well as the clarification of the safety-relevant connections is handled by the operator.
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11.1.4 Training
In the course of the start-up of the machine, SW will conduct a training session, which will include the following content:
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BAS03-12
BAS03-22
Depending on the additional equipment and the work task at hand, the control and the control panel were customised to the customer's specifications. The symbols found here may include functions that your machine is not equipped with, or your machine might have functions that are not depicted here. If the machine should differ, you will find supplemental information as an enclosure of these operating instructions; see chapter "Additions/supplements". The standard operation takes place according to the current operating and programming instructions of the control manufacturer. This chapter includes exerpts of the operating instructions for the Siemens 840D control. We will not be held liable for the completeness and up-to-dateness of this information!
Mandatory prerequisites for the safe and accident-free operation of the processing centre as well as its programming are: Knowledge of the operating and programming instructions of the control and component manufacturers. Knowledge of the SW operating instructions. The participation in a operator and programmer training session at SW. The use of the machine and control by exclusively skilled and trained personnel familiar with the functions of the machine, the control and the work task at hand so that errors and hazards can be avoided.
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C/W
A/ U
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To operate and program the machine, the control panel is subdivided into several operating fields or function groups.
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EMERG OFF KEY Press the red key in emergency situations: if human lives are in jeopardy, if there is a danger of the machine or the component being damaged. Generally, all drives will be stopped with the highest possible braking effect when EMERG-OFF is initiated.
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Test stop After "main switch ON" as well as after the time span set by the control (> 8 operating hours) and selecting the operating mode "JOG", the request to conduct the test stop function will be placed via the control display. Acknowledgment load/unload tool After the menu-guided loading/unloading of tools, the key "tool acknowledgment" must be pressed. Interior cooling lubricant/high-pressure pump The cooling lubricant dispensing via the processing tool will be turned on or off.Suitable tools and tool pickups are required. The system can be switched on while the NC programme is running. Following a programme interruption (NC stop), the settings that were valid before the interruption, will be restored. Cooling lubricants/spindle nozzles The cooling lubricant dispensing via nozzles on the work spindles is switched on or off. The system can be switched on while the NC programme is running. Following a programme interruption (NC stop), the settings that were valid before the interruption, will be restored. Cooling lubricant/rinsing The cooling lubricant dispensing via additional rinsing nozzles will be turned on or off. The system can be switched on while the NC programme is running. Following a programme interruption (NC stop), the settings that were valid before the interruption, will be restored.
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Chip conveyor By activation, the chip conveyor will be turned on and off During its activation, the chip conveyor is driven back (time-limited) The system can only be switched on while the NC programme is running. Following a programme interruption (NC stop), the settings that were valid before the interruption, will be restored. Home Position Option: Reserve/home position Stop after end of programme Special function with automatic loading/unloading By switching on the function, the tensioning device remains in the workroom after the CNC programme is ended. The automatic swivel support movement in the loading room will not be executed. Lamp test By activating the key in the operating mode "JOG", all signal lamps on the control panel are switched on for testing. Rotate swivel support Only with two station model: By activating the key in the operating mode "JOG", the swivel support is rotated by 180.This will switch the tables (1 and 2) or the round axles (A and U) positions between the workroom and the loading room. Caution: Collision hazard between spindle tool and swivel support or device Tool changer - basic position By pressing the key (several times) in the operating mode "JOG", the tool change basic position is driven, e.g. after terminating a tool change or after a long standstill. The basic position is reached when the respective LED is turned off. Safety window Only with two station model: The safety protection window between the loading room and the workroom is locked by two monitored pneumatic cylinders. When the key is pressed, the lock is released and the safety window can be opened. Prerequisite: operating mode JOG or .AUTO no spindle/advance movement (NC STOP is active) Channel
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By first activating the shift key, the second function is selected with doublefunction keys.
..
Axle selection and directional keys The desired axle is selected by pressing the respective key X, Y, Z, etc. .
..
Moving the selected axle in the positive or negative direction. Other occupied axles are moved in the same manner. If an NC function is set, only one increment is moved when the direction key is pressed (cursor key) - no matter if it is pressed briefly or for a long time (1/10/100/1000/10000 Inc., depending on the setting). If no INC function is selected, the presetting "continuous" will prevail. The axle will be moved as long as the directional key is pressed. If the safety locks are open, only the simple movement movement via the JOG keys or or via the handwheel is possible (also see agreement key). Quick run overlap If this key is activated together with one of the keys described above, the axle is driven in rapid gear (not in setup mode).
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Confirmation key By pressing this continuously, axle movements can be performed with the workroom open. Prerequisite: Key switch (15) on setup (1); operating mode "JOG", axle selected. While using this in connection with the "plus or minus" keys, the selected axle is driven. Axle movements are limited to 2,000 mm/min. Close door The open roof area is closed when activating this key; see chapter "roof sled". With the optional extension "automatic workroom door", this door will be closed. Tensioning The function depends on the application: e.g.: close tensioning device or tension the workpiece. Prerequisite: Device is in basic position and work or loading room door is closed.
0
Basic position of round axle Turns the NC axles (and possibly setup planets) in the loading room (workroom) into the basic position. (The determination of the basic positions is done in the SW menu)
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Cycling the C axle Option: Rotates the planet (C) by a previously set angle value. (The determination is made in the SW menu) Magazine position Loading and unloading of the tool magazine takes place first at the control in the control panel; including magazine location selection. By activating the key, the previously selected magazine location is automatically driven to the loading or the unloading position. Circling Special operating mode: By switching this on, the work spindle can be rotated by hand. Prerequisite: Key switch (15) on setup (1); operating mode "JOG". Control ON Drive regulator, pumps, valves as well as connected aux. units are switched on. Performance components that are monitored by safety equipment only become active, if certain safety instructions (such as workroom doors closed) are fullfilled. Equipment acknowledgment Acknowledges the completed equipment and starts the automatic operation. (With active automatic loading cycle, automatic functions such as: open door, release, keep cycling, etc. can be run. After the equipping is completed, the automatic loading cycle is terminated and this will lead to e.g. tensioning, closing door and finished message to the control.) Unlock/open door By activating the key, the loading room door is unlocked; (with optional extension "automatic loading door", additionally opened automatically). At the same time, the roof area will open - depending on the Y position of the work spindle; see also chapter "roof sled". Release The function is application-dependent; e.g. open tensioning device or release workpiece. Prerequisite: Device is in basic position and work or loading room door is closed.
7
0 1
10
11
12
Cycling A axle Rotates the round axle (A) by a previously set angle value. (The determination is made in the SW menu) Rinsing Option: The function depends on the device. Possibilities include: Rinsing the device with cooling lubricant; cleaning the device with compressed air; switch on oil minimum lubrication volume; etc. Magazine cover The magazine door (between the workroom and the tool magazine) is alternately opened/closed.
13
14
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15
0 1
Setup Special operating mode: In connection with the confirmation key, the different advance axles can be moved with the workroom door open. Prerequisite: Key switch on setup (1); operating mode "JOG", axle selected. Control OFF Drive regulator, pumps, valves as well as connected aux. units are switched off. Unlocking magazine location For the manual tool change the magazine location is unlocked using the foot switch. A tool can be inserted or removed while this switch is pressed.
16
18
Functions involving a higher safety risk are protected by the Siemens key switch and deactivated selection options (greyed out soft keys). Also see the menu "machine control panel" and the listed selection options.
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C/W
A/U
Confirmation key By pressing this continuously, axle movements can be performed with the workroom open. Prerequisite: Key switch (15) on setup (1); operating mode "JOG", axle selected. While using this in connection with the "plus or minus" keys, the selected axle is driven. Axle movements are limited to 2,000 mm/min. Close door Option: By pressing this key, the loading room door is closed automatically. Tensioning The function depends on the application: e.g.: close tensioning device or tension the workpiece. Prerequisite: Device is in basic position and work or loading room door is closed.
0
C/W
Basic position round axles / planets Turns the NC axles (and possibly setup planets) in the loading room into the basic position. (The determination of the basic positions is done in the SW menu) Cycling the C/W axles Option: Turns the planets (C/W) in the loading room by a preset angle value. (The determination is made in the SW menu) Circling Special operating mode: By switching this on, the work spindle can be rotated by hand. Prerequisite: Key switch (15) on setup (1); operating mode "JOG".
7
0 1
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Control ON Drive regulator, pumps, valves as well as connected aux. units are switched on. Performance components that are monitored by safety equipment only become active, if certain safety instructions (such as workroom doors closed) are fullfilled. Equipment acknowledgment Acknowledges the completed equipment and starts the automatic operation. (With active automatic loading cycle, automatic functions such as: open door, release, keep cycling, etc. can be run. After the equipping is completed, the automatic loading cycle is terminated and this will lead to e.g. tensioning, closing door and finished message to the control.) Unlock/open door By activating the key, the loading room door is unlocked; (with optional extension "automatic loading door", additionally opened automatically).
10
11
Release The function is application-dependent; e.g. open tensioning device or release workpiece. Prerequisite: Device is in basic position and work or loading room door is closed.
A/U
12
Cycling A/U axle Turns the round axle in the loading room(A/U) by a preset angle value. (The determination is made in the SW menu) Rinsing Option: The function depends on the device. Possibilities include: Rinsing the device with cooling lubricant; cleaning the device with compressed air; switch on oil minimum lubrication volume; etc. Setup Special operating mode: In connection with the confirmation key, the different advance axles can be moved with the workroom door open. Prerequisite: Key switch on setup (1); operating mode "JOG", axle selected. Control OFF Drive regulator, pumps, valves as well as connected aux. units are switched off.
13
15
0 1
16
Functions involving a higher safety risk are protected by the Siemens key switch and deactivated selection options (greyed out soft keys). Also see the menu "machine control panel" and the listed selection options.
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11.3 Operation
A prerequisite for an economic processing method is the skill to use the operating processes as well as the understanding of the memory organisation. See Siemens operating instructions "managing programmes and NC data".
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Synchronising
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Main switch
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Depending on the Y position of the work spindle, the roof sled can take on three different positions:
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VSK1
NCPROG
VSK5
VSK6
NCPR_EG
VSK2 The existing programme allocation is deleted VSK3 "table release" can only be changed in the loading room. With a deactivated table release, the programme assignment becomes ineffective and the table is skipped during the subsequent programme execution. start programmes With two-station processing centres: The area/table that is to be processed, must be located in the workroom; (possibly "turn swivel table"). Select the operating mode "AUTO"; the CNC programme run is started via "CYCLE START". Acknowledgment key By pressing the acknowledgment key, the control will receive the release for a new automatic programme start - after a successful programme sequence. With two-station machines: After the CNC programme for one of the tables in the work room is completed, the swivel support is rotated automatically and the CNC processing of the other table is started. More automatically run functions (loading cycles) can be executed for the table in the unloading station after the end of processing via separate programmes ("device selection").
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On the machine control panel, there is a key with an LED to initiate the TEST STOP function. After "main switch ON" as well as after the time span set by the control (> 8 operating hours), the request to conduct the test stop function will be placed via the control display. Operating message: 700248 perform TEST STOP (key); (A currently running NC programme is not interrupted by this. After switching operating modes, or after "main switch ON", the safety doors remain locked until the test stop function is completed.) Prerequisite: Operating mode "JOG" Doors / safety protection windows (with two-station models) closed Position of the Y axle < 0 mm Process: Using the "test stop" key; during the run of this function, the LED on the keys are illuminated. After the LED turns off, the self test is completed.
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11.3.2.1 Basics
Before a tool can be used for automatic processing, its tool data must be transferred to the tool management/machine control. The entered tool data is saved in a database, the individual values/parameter can be modified via different masks. Basically, only one tool magazine or one spindle tool is managed via the machine control, regardless whether one or two processing spindles are used. With two-spindle processing centres, identical tools will have to be used in both processing spindles. This also applies to the tool loading of the samename magazine locations. Only use clean and undamaged tools. The tools must be inserted into the tool magazine in the correct position (see label on the insertion position). Observe the permissible tool diameters, tool weights, tool lengths and revolutions. The retaining capacity of the protection devices used as standard (protection doors, separating walls, panels) meets the requirements of the DIN prEN 12417. If you wish to use larger tools, such as for open side locations in the tool magazine, please keep in mind that the protection devices might have to be reinforced (larger diameter, higher revolution speed).
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By using oversized tools, the additional locations in the tool magazine are blocked/covered and can no longer be used for other tools; collision hazard.
Additional limitations (with two-spindle processing centres) arise from the designrelated placement sequence of the different tools. Some of the direct additional locations might differ by up to 3 magazine location numbers. When using several oversized tools, you must generally make sure that the next oversized magazine location is different from the previous one by at least 4 magazine location numbers. Magazine locations to be preferred for the placement of oversized tools include: 2,3, 6,7 10,11, 14,15, 18,19, etc. (with a distance of 4 each). If the control suggests other magazine locations, we recommend placing the selection marker (cursor) on the subsequent magazine location and to conduct a new empty location search. The check for open additional locations must be performed during loading.
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"Magazine list"
WBEL-F
VSK5
VSK8
WBEL-LS
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Press the key "magazine cover" (14) on the "additional SW control panel"; the magazine door between the workroom and the tool magazine will open. Press the key "magazine position" (6) continuously; the magazine will drive the previously found free magazine location to the loading position automatically and will stop. Press the key "unlock workroom door" and open the workroom door at the same time. Press the footswitch "unlock magazine" - the magazine location lock will be opened Insert the tool properly into the magazine location Release the footswitch Press the key "tool acknowledgment" (on the SW function key block) to acknowledge the completion of the manual tool loading. Close the workroom door; the tool loading is complete.
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"Magazine list"
WBEL-F
VSK8
WBEL-LS
VSK8
press "Start"; the entries will be checked WBEL-DE and transferred into the machine. "Loading/unloading active" will appear in the alarm/message line on the control panel. At the same time "tool movement running" will appear in the dialog line and the key "tool acknowledgment" will illuminate on the additional SW function block.
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Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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The further tool loading (manual placement of the tools into the tool magazine) must take place directly on the magazine loading station, via the magazine control panel. Site change on the magazine control panel Switch on the key switch "release magazine" on the SW magazine operating panel. Press the key "magazine forward" continuously; the magazine will drive the previously found free magazine location to the loading position automatically and will stop. Press the key "unlock magazine door" and open the magazine door at the same time. Continuously press the key "unlock magazine location"; the magazine location in the loading position will be unlocked. Insert the (first) spindle tool properly into the unlocked magazine location Release key check correct tool locking (pull on tool) Close magazine door
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Only with two-spindle machines: Press the key "magazine back" continuously; the magazine will drive the previously found free magazine location to the loading position of the second tool automatically and will stop. Press the key "unlock magazine door" and open the magazine door at the same time. Continuously press the key "unlock magazine"; the magazine location in the loading position will be unlocked. Insert the second spindle tool properly into the unlocked magazine location Release key check correct tool locking (pull on tool) Close magazine door
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Press the key "tool acknowledgment" to acknowledge the completion of the manual tool loading Switch off the key switch "release magazine"
0 1
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By unloading, the data of a tool are removed from the magazine list. Here, you can select whether the tool data including their usage data (standstill time, corrections, etc.) should remain in the "tool list", be moved to the "tool cabinet" or be completely deleted. HSK4 Mark the desired tool with the cursor keys Press "unload" Select the unloading function: WENT VSK4 Unload the tool from the magazine and archive the respective tool data in the cabinet VSK6 Unload the tool from the magazine and delete the tool data VSK8 Unload the tool from the magazine and move the tool data to the tool list
The selected unloading function is executed. "Loading/unloading active" will appear in the alarm/message line on the control panel. At the same time "tool movement running" will appear in the dialog line and the key "magazine position" will illuminate on the additional SW control panel.
Depending on the machine model (with or without magazine loading station), the manual unloading from the magazine takes place.
Without magazine loading station: (1-station machine)
The further tool unloading (manual removal of the tools) is controlled via the keys on the "SW additional control panel". Press the key "magazine position"; the magazine will drive the tool to be unloaded to the loading/unloading position automatically and will stop. Open the loading door Open the magazine door Press the (foot) switch "unlock magazine" and remove the tool; release the (foot) switch. Press the key "acknowledge load/unload tool" to acknowledge the manual tool loading Close the loading door; the tool loading is complete.
With magazine loading station: (2-station machine)
The further tool loading (manual removal of the tools into the tool magazine) must take place directly on the magazine loading station, via the magazine control panel. Switch on the key switch "release magazine" on the SW magazine operating panel. Press the key "magazine forward"; the magazine will drive the tool to be unloaded to the loading/unloading position automatically and will stop. Press the key "unlock magazine door" and open the magazine door at the same time. Keep the tool in the load/unload position, press the key "unlock magazine" and remove the tool; release key, close magazine door. Press the key "magazine back" and repeat the unloading process for the second tool. Press the key "acknowledge load/unload tool" to acknowledge the completion of the manual tool loading; switch off the key switch"release magazine".
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L6 parameter
Via the function "T00", an existing spindle tool is placed into the magazine, without changing in a new tool. After the placement, the tool spindle remains in the tool changing position.
With a tool change with "speed transfer", the work spindle will already be started in the work spindle. Disadvantage: With contaminated tools, the particles are spread around the magazine room and can cause malfunctions.
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With the SETPIECE function, the user can update the quantity monitoring data of the tools used for the processing sequence. All tools are captured, which were replaced since the last update of SETPIECE.
If the "actual value piece" reaches or does not reach the value "0", this tool is considered used and is blocked for future use; marked in Maglist-3 by a "G". If desired, a prewarning can be issued prior to blocking the tool. If the remaining standstill time does not reach the value entered under "warn time", the tool is marked accordingly in the Maglist-3 with a "V". As an option, customer-specific functions can be derived.
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All tools in the tool magazine must be properly registered in the machine control. A manual new placement, adding or removal of tools without the support of the control's tool management, can lead to collisions between tools and machine or device parts. Furthermore, there is a danger of injuries for the employees caused by blown off / broken parts.
With multi-spindle machines, you must ensure that the same tools are in the same tool locations. By using different tools on the work spindles, there is a danger of damages to the tool, the workpiece and the tensioning device, as only one tool is defined per magazine location in the tool management and only one can be corrected.
Depending on the machine type, the magazine loading is conducted via the operator station or via the magazine loading station, which is located on the left long side of the machine.
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Workroom door
Magazine door
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Step 2 Now start the ePS Network Services by pressing the soft key "online services". The function of the soft key video is described in the following under "login instructions".
Step 3 Now enter your access data on the login page and press the soft key "OK". You will receive the access data by the responsible service organisation. If you enter false information three times, your access will be denied for safety reasons. To unblock your access, you must contact the respective eP dynamic administrator. Further information regarding the "ePS network" can be found in the appendix to this chapter 11.
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The horizontal soft keys of the HMI masks feature two lines. Main menus are listed on the bottom line, the respective selections for the main menus are pictured above, in the first line.
Depending on the setup level of the machine/control, only certain menus or menu paths are displayed.
Standard assignment Horizontal Soft Keys: HSK HSK HSK HSK HSK HSK 1 2 3 4 5 8
WERKZBR
Operating area "SW" Operating area "Preparation" Operating area "Manual operation" Operating area "Processing" Operating area "Diagnosis" Operating area "Documentation"
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WERKZBR
Selection:
A prerequisite for the use of the mask is the expansion of the machine by an external tool breakage monitoring system. After a tool breakage message via the external monitoring system, the processing programme is automatically interrupted by "NC STOP" and the tool breakage mask is displayed on the control panel display. The message must be acknowledged by means of the vertical soft keys. Function keys: Tool Ok. The control receives the signal that the message "tool breakage" is an erroneous alarm and can be ignored. The automatic processing can be restarted via "NC START". The tool breakage is acknowledged. The processing programme should be interrupted and the damaged tool should be replaced. If the process is continued by pressing "NC START" without eliminating the error, the spindle tool will be marked as "invalid" by the control.
Tool broken
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11.4.1.2 Machine
11.4.1.2.1 NC programme This mask is used to assign NC programmes and table releases to the work tables for production.
NCPROG
"HMI" "SW" "machine" "NC Prog" "Assign programme"; a new mask will open (see following page). "Delete programme"; causes the deletion of the programme assignment for the displayed table. The entry for the directory and the programme path will be "without assignment" after the deletion. Changing the "table release"; with deactivated table release, the programme assignment is invalid. The CNC programme for this table/area is not executed. "Switch table"; display switching between table 1 and table 2.
VSK 4
VSK 7
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11.4.1.2.2 Assigning NC programmes This mask lists the NC programmes present on the control. Pressing the respective keys will transfer or terminate the programme assignment.
NCPR_EG
Selection:
Function keys: VSK VSK 6 7 Terminating the input Transfer the entered data.
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11.4.1.2.3 Machine control panel In addition to the mechanical key switches, certain user functions can be switched on/off via this menu. The consideration of protective levels/authorisations to change individual functions can be saved in the control.
MSTT
Selection:
"HMI" "SW" "Maschine" Key switch MSTT" You can page up and down using the keys "PageUp" and "PageDown". The selection of the desired function is made via two arrow keys. The listed functions have two switch positions (ON/OFF). Effective functions (ON) are marked in green.
Function keys: VSK 1 The switch position is changed via this key.
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TYPVORW
Selection:
"HMI" "Preparation" "Type preselection" The tensioning devices on the workpiece carriers are assigned tension layers. A max. of 8 tension layers are possible on one table. Each tension layer on table 1 or table 2 can be assigned its own workpiece type. Without this assignment, the workpiece counting will not work!
Select the desired workpiece type using the cursor key and enter the table and tension layer number in the input field for the respective workpiece type. The "to the right". selected type is transferred to the input field with the key Input: Table numbers Tension layer numbers values 1 to 2 are permitted values 1 to 8 are permitted
After an entry, the soft key+ must be pressed to assign the workpiece to the corresponding table and the respective tension layer. With the soft key- this assignment can be reversed. The tension layers with their assigned workpiece types are listed in the mask "process tension layer". ______________________________________________________________________________
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11.4.2.2 Adjustment
The following masks show the adjustments for the lubrication times and the chip conveyor. 11.4.2.2.1 Lubrication The setup interval times for spindle lubrication and central lubrication as well as the counter status are displayed. Changes to the factory defined values are not possible in this mask.
EIN_SCHM
Lubrication
Operating area "lubricating spindles and central lubrication" (preset) The counter value shows the remaining time until a new lubrication pulse is initiated (in seconds) and is constantly updated. When "0" is reached, a lubricating pulse is initiated and the counter status will restart at the preset adjustment value. Operating range "chip conveyor".
Chip conveyor
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11.4.2.2.2 Chip conveyor / input The selected run and stop times are displayed that the chip conveyor processes periodically after it has been switchd on. The remaining time until the change into the other operating mode (ON/OFF) is constantly updated and shown as a counter display.
EIN_SPAE
Selection:
"HMI" "Preparation" "Adjustment" The run and stop times are entered in seconds (0 ...9998 /9999) via the keyboard; Run time = 0 no run Stop time = 0 no stop, continuous run with run time >0 The yellow Siemens input key transfers the values into the display.
Function keys: Lubrication operating area "lubricating spindles and central lubrication" (preset) Operating range "chip conveyor".
Chip conveyor
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WKZBW1
Selection:
"HMI" "manual operation" "WKZW EZB" The signal conditions are distinguished by coloured markings: Signal OK / normal Signal disturbed background grey, font colour black background red, font color white
With multi-page menus, the previous or subsequent pages are displayed by paging through them using (Page up / down).
An identical status for the return messages of the two adjustment possiblities of a movement unit (e.g. top and bottom, tensioned and released, front and back) is not realistic and indicates that there is a malfunction (pair monitoring). To use the special operating mode "individual movement", the lateral soft keys (cursor keys) in the mask "machine control panel" must be released via the function "INDIVIDUAL MOVEMENT".
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EZBW_VS1
Selection:
The operation takes place in the same way as with the "individual movement of tool changer"
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SPANNLAG
Selection:
The tensioning devices on the workpiece carriers are assigned tension layers. A max. of 8 tension layers are possible on one table. Table Tension layer Quantity OK vorh. beab. Workpiece here, you will find the descriptors for tables TI_1 (table_1) and TI_2 (table_2). contains the numbering of the tension layers (1..8) for table_1 and (1..8) for table_2. the number of workpieces per tension layer is displayed here. (in order) shows whether the parts were processed properly. (existing) displays whether there are parts in the tension layer. (processed) displays whether the parts in the respective tension layer have been processed. shows the current workpiece types.
Each tension layer on table 1 or table 2 can be assigned its own workpiece type in the mask type preselection. Entries: Select the desired workpiece type using the cursor key and enter the table and tension layer number in the input field for the respective workpiece type. Enter the number of workpieces per tension layer into the quantity column! This value is used as an increment during the workpiece counting! Without this assignment, the workpiece counting will not work!
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TR_RUNDT
Selection:
In this mask, the status of the carrier round table (raised or lowered) and the table position (0 or 180 degrees) is displayed.
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WERK_ZAE
Selection:
"HMI" "Documentation" "Workpiece counter" The counter field can be selected using the arrow keys to the left and right
Function keys:
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BELAD_A
Select the desired table area (A/U) via the soft keys. Depending on the selected device, the values for the used setup positions are displayed. The designation "ABL1_" refers to the first device programme; ABL2_ to the second, ABL3_ to the third, and so forth. You can switch between the input fields via the arrow keys (cursor keys); additional explanations will be displayed in the header line. Values can be changed via the keyboard. The displayed input fields depend on the machine equipment and the customer requirements.
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Example: Setup positions ABL1_A_POS1 ABL1_A_POS2 A axle, basic position 1, (degrees) A axle, basic position 2, (degrees)
ABL1_A_ROBPOS1 A axle, basic position 1 with robot ON, (degrees) (with robot OFF, POS1 is used) ABL1_C1_POS1 ABL1_xx_INK C1 axle, basic position 1, (degrees) xx axle, angle value for "rotate round axle"; can be predetermined for table and/or additional axle (A, U, C, W)
ABL1_U_ARBPOS1 U axle, preset for work position (degrees) (Prepositioning for more rapid work start after swivelling)
When using "loading cycles", the saved positions must be considered with regard to the selected device.
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Vor_Anw
Up to 8 device programmes with the respective setup positions for loading axles can be selected via the mask (also see "loading axles/setup positions" and "loading cycles") By selecting these, saved command sequences (e.g. drive to setup position, rinse device, open door, open device, etc.) are executed following CNC processing when the device is located in the loading room. The activation/deactivation of a device only becomes effective by the next "NCK POWER ON" or with the next "CONTROL ON". You can switch between the input fields (nominal) via the arrow keys (cursor keys). The select key is used to activate/deactivate the device. (The device programme is saved in the PLC) If necessary, every device programme can be marked with a designation; entries are transferred via "input".
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EPS_01
MAGL_1
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BAG, channels
The SW two-station processing centres use exclusively BAG 1 with one channel: BAG 1, channel 1 for NC-programmes/applications
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X1
= horizontal, transverse to the operator position, to the left = minus, to the right = plus. = horizontal, lengthwise to the operator position, forward = plus, backwards = minus. = Gantry axle to Y1 = vertical axle, up = plus, down = minus = work or tool spindle, tool rotation, to the right = plus, to the left = minus = work or tool spindle, tool rotation, to the right = plus, to the left = minus
X1 Y2 Z1 SPIND_1 SPIND_2
MAGAZINE = tool magazine; magazine location increasingn = plus Q A/U C.. / W.. = swivel support (only with 2-station machines) = swivel table (U only for 2-station machines) = planets on swivel table A/U (option)
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Description Stop like M 00, but selectable Programme end Right rotating spindle Left rotating spindle Stop spindle Tool change Coolant 2 ON (inner cooling) *see H function Coolant 1 ON (exterior cooling) Coolant 1 +2 OFF Clamping ON (monitoring ON)/axle: A / U Clamping OFF (monitoring OFF)/axle: A / U Open clamping until the end of next drive command A /U Clamping ON (monitoring ON)/axle: C C2 / W W2 Clamping OFF (monitoring OFF)/axle: C C2 / W W2 Open clamping until the end of next drive command C C2/W W2 Subprogramme end Adjust spindle Tension circuit / device 1 open Tension circuit / device 2 open Tension circuit / device 3 open Tension circuit / device 4 open Rapid gear limit 30%: OFF Programme end Tension circuit / device 1 tension Tension circuit / device 2 tension Tension circuit / device 3 tension Tension circuit / device 4 tension M function 1 with external return (advance and reading stop) M function 1 with external return (advance and reading stop) M function 1 with external return (advance and reading stop)
BAS 03
(09/07)
Option
Option
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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M 38 M 39 M 40 M 41 M 42 M 43 M 44 M 45 M 46 M 47 M 48 M 49 M 50 M 51 M 52 M 53 M 54 M 55 M 56 M 57 M 58 M 59 M 60 M 61 M 62 M 63 M 64 M 65 M 66 M 67 M 68 M 69 M 70 M 71 M 72 M 73 M 74 M 75 M 76 M 77 M 78 M 79 M 80 M 81 M 82 M 83 M 84 M 85 M 86
M function 1 with external return (advance and reading stop) Rapid gear limit 30%: ON Deletion position M 41 / M 42 (reserved system) Main spindle star operation (reserved system) Main spindle triangle operation (reserved system) reserved system reserved system reserved system Tension hydraulics circuit 1 Tension hydraulics high-pressure circuit 1 Tension hydraulics low pressure circuit 2 Tension hydraulics high-pressure circuit 2 Tension hydraulics low pressure circuit 3 Tension hydraulics high-pressure circuit 3 Tension hydraulics low pressure circuit 4 Tension hydraulics high-pressure circuit 4 used Open tool magazine cover (premature) Flow monitor OFF until tool change IK (M7) Flow monitor OFF until tool change AK (M8) Pressure monitor OFF until tool change IK (M7) Measuring key 2 ON (door open, if available) Measuring key ON (door open, if available) Rinse bed ON Rinse shutter ON Blockage air angle drill head ON Blockage air angle drill head OFF Device rinse ON workroom Device rinse OFF workroom reserved system All measuring keys OFF (door open, if available) Rinsing OFF Minimum volume lubrication ON Minimum volume lubrication OFF ARTIS monitoring ON ARTIS: Monitoring OFF ARTIS: Monitoring only ON with G 01 ARTIS: Oscillation monitoring ON ARTIS: Oscillation monitoring OFF Tool breakage control: ON/test Tool breakage control: Measuring 1 Tool breakage control: Measuring 2 Device rinse start, when table is on loading side reserved EPS Part finished processing Start loading/unloading robot
Option Option
Option Magazine sheet metal Option Option Option Option Option Option Magazine sheet metal Option Option Option Option Option Option Option
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M 87 M 88 M 89 M 90 M 91 M 92 M 93 M 94 M 95 M 96 M 97 M 98 M 99 M 100 M122 M123 M125 M126 M140 M150 M152 M156 M158 M160 M186
Increment workpiece counter Close cover Open cover (depending on Y position) Loading door open Open workpiece grabber 1 Open workpiece grabber 2 Close workpiece grabber 1 Close workpiece grabber 2 Adaptive regulation ON Adaptive regulation OFF Coolant pumps ON Home cycle end Safe programme end Ensure H function Rinse valve loading side ON (channel 2 only) Rinse valve loading side OFF (channel 2 only) Open loading door (channel 2 only) Close loading door (channel 2 only) Set equipping acknowledgment (channel 2 only) Start: Release, total (channel 2 only) see M60= Finished message: Tensioned, total (channel 2 only) see M63= ERV ON ERV OFF Message output: Loading axle not in release position PREStart robot
Option
impossible
11.7.3.3 H functions
Code H 01 H 02 H 03 H 04 H 05 Description ASI-Bus H1=1 ... H1=100 possible in steps % Programme number on ext. device (Telesis / Roboter / .. Prop value 1 tensioning device (standardisation in bar) Prop value 2 tensioning device (standardisation in bar) MDE-BDE - INTERFACE BAS 03 Option Option Option Option
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11.7.3.5 L functions
Code L6 L 20 L 21 L 23 L 29 L 30 Description Tool change with free drive / BA03: with T0 without free drive Query swivel table in position Query axle name round axles (A/U) Query current table Thread coupling ON Thread coupling OFF BAS 03 impossible possible possible possible possible
11.7.3.6 G commands
The G commands are listed in the original machine documentation issued by the control manufacturer (programming guide).
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If the movement capability (interpolation) of the round axles is not needed during a process, these must be clamped.
This clamping can be executed with or without monitoring and also in connection with "reading stop". Depending on the software status of the control, the newer models include clamping sequences which used to have to be activated/selected via M functions in the previous software versions.
If the automatic clamping/monitoring of the round axles is active, an error message will be generated with "G1 + interpolation of main and round axles". Rapid gear (G0) will be executed automatically and time-optimised with the interpolation of the main and round axles. With G64 (track control operation), the clamping for a later drive command is opened prematurely (up to 2 G0 sets earlier). The G0 movements of the main axles are driven without round axle clamping; after G1, the clamping, monitoring as well as the further processing will take place. Example: G0 G64 Z-200 X-300 A=0 Z-50 X-200 A=90 Z-200 G1 F2000 X-220 M30 Comment G64 is mandatory Clamping of A will be opened prematurely clamping A will close automatically advance = 0% until A is clamped
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11.8.1.1.2 G1 with 4 or 5 axle interpolation If the G1 interpolation of main and round axles is required for a process, this interpolation opportunity must be released via a PLC-MD (machine date).
The automatic clamping/monitoring of the round axles is no longer effective, after the G1 interpolation of main and round axles has been released.
For a processing without moving round axles, the respective clamping/monitoring must be switched on via the following M functions A- / U axle M 10 (default) C- / W axle M 13 (default) Function Clamping is closed and monitored. During the function execution a "reading stop" applies. A set change is prevented until the return message of the clamping has taken place. (Reset by Reset / M30) The clamping is permanently open. (Serves i.e. for the interpolation between the 4th axle and the main axles - or to process items that do not require clamping).
M 11
M 14
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11.8.1.1.3 Programming of A or U axle parallel to the tool change. DO POS [U]=DC (180) FA[U]=36000 Txy L6 Load GUD variable with position value of the axle (e.g.180) Start axle Retrieve tool xy Conduct tool change
11.8.1.1.4 Axle-neutral programming of the round axles A or U N30 L21(_AU,_CW,_CW2) N20 L23(_ATISCH) DO POS [_AU]=DC(0) FA[_AU]=10000 DO POS [_CW]=DC(180) FA[_CW]=10000 DO POS [_CW2]=DC(180) FA[_CW2]=10000 N180 T1 N190 M6 N250 g0 g54 g95 AX[_AU]=DC(0) AX[_CW]=DC(180) AX[_CW2]=DC(180) S2000 M3 N320 G1... IMPORTANT: Check round axle position
if present if present
Processing
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Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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The processing sequence "circular interpolation" can be compared to a lathe, in spite of the "fixed workpiece". Two semi-circle tracks are created with the tool spindle by interpolating X and Y advance. At the same time, the tool is turned by a coupled spindle speed so that the tool blade always has the same angle (orthogonal) to the circular track. A chip removal (advance of the tool blade) is created (like with a lathe) when the interpolated circular track is continuously changed with regard to the radius and the tool blade enters the workpiece in a spiral fashion. Depending on the tool and the used parameters, interior and exterior grooves can be created. The workpiece/groove parameters and blade data with regard to the radial conditions are defined via the following masks. The cycle retrieval takes place in the CNC programme by "groove" [groove number (1...8)], [tool number (1...8)] and controls the automatic creation of the groove depending on the saved values. Prerequisite: Tool blade is aligned to 3 o'clock in the tool pickup (looking at the tool; when viewing from the tool spindle, the blade will be positioned at 9 o'clock) Tool type and length were properly saved in the tool administration during tool loading (e.g. special tool 900). Tool was replaced in the tool spindle prior to cycle retrieval Groove position was addressed prior to cycle retrieval via the CNC programme
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03G11AGB
11-77
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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INZIRK
Selection: Operating mode JOG Function keys: HSK1 HSK2 VSK1/2 VSK7 VSK8
Mask groove tool / tool parameter circulate on the outside / circulate on the inside Paging groove + / groove Transferring the changed values Reading back the most recently saved values
Entries: If the input limits are exceeded or not reached, a message is displayed in the bottom status line. N NUT Count number 1-8; max. 8 different grooves can be defined
D_BOHR
drilling diameter / opening in the workpiece, via which the tool will arrive at the groove position without collision. nominal diameter of the groove (indicated value = drawing dimension)
D_EINST
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03G11AGB
11-78
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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D_KORR V_SCHRUPP
correction value for nominal diameter; e.g. to balance tool displacement (with long shaft), tool wear or tolerances. Roughing speed (interpolation torque = circular track speed of the blade) assignment of roughing; advance or chip depth per circular track (360 )
AP_SR
U_ENTSPAN
factor for cut interruption / empty cut. Depending on the blade advance, the machine will need a certain number of circular movements/rotations until the required groove depth has been reached. This value is calculated internally. The factor "U_ENTSPAN" subdivides the calculated numbers of rotations and results in a (rounded) rotation limit value. Everytime this limit value is reached, a rotation without advance is executed to release. Example: U_ENTSPAN = 3, required rotations = 120. Therefore, 120 / 3 = 40; after every 40 roations, an empty step is performed. Number of rotations for speed adaptation between V_SCHRUPP and V_FERTIG Inertia, drive system and mechanical circumstances can lead to a change in diameter of the blade track (groove depth) in case of abrupt changes in the track speed (circular interpolation) and thus destroy the blade. The numeric value "U_UEBERG" indicates how many circular tracks are available to the control in order to perform the speed change. Example: U_UEBERG = 4; V_SCHRUPP = 8000mm/min, V_FERTIG = 1000 mm/min. The acceleration/delay is selected on the control so that the new web speed (1000 mm/min) is achieved after four rotations.
U_UEBERG
V_SCHLICHT
Smoothing speed (interpolation speed = circular web speed of the blade); also see "T_SCHLICHT" assignment of smoothing; advance or chip depth per circular track (360 ) Material difference to the groove diameter (D_EINST), which is chipped by smoothing. (With "0", only roughing takes place during the processing)
AP_SL
T_SCHLICHT
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03G11AGB
11-79
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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X_OSZ
Distance for the oscillating centre point migration; serves for chip removal - depending on the material properties - or for the clearing during roughing. This value must not exceed 70% of "AP_SR". Number of oscillation movements per circular web
U_OSZ
U_FERTIG
Number of rotations for final lathing. The numeric value "U_FERTIG" determines how many circular webs the tool blade will execute after the nominal diameter has been reached (D_EINST) in order to form the groove. Finished rotated speed (interpolation speed = circular web speed of the blade), which is used to form the groove after the nominal diameter (D_EINST) has been reached. Driving out speed (interpolation speed = circular web speed of the blade) that is used to exit the groove.
V_FERTIG
V_Z
AP_Z
assignment of driving out; advance or chip depth per circular track (360 ) Is used in connection with "V_Z" to create a smoothing surface with a shallow rough depth on the groove flanks when "driving out". Number of rotations for speed adaptation to drive out speed "V_Z" The numeric value "U_ABH" indicates how many circular tracks are available to the control in order to reach the drive out speed.
U_ABH
X_KORR
Correction dimension of the X axle to balance the centre point migrations of the blade trajectory Correction dimension of the Y axle to balance the centre point migrations of the blade trajectory
Y_KORR
L_LAENGS
Distance difference/drive path to widen the groove (= groove width minus blade width) or to create a contour Axial advance per circular web (360) to widen the groove or to create a contour Cutting speed (interpolation speed = circular web speed of the blade)
AP_LAENGS
V_LAENGS
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03G11AGB
11-80
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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INZIRK_W
Selection: Operating mode JOG Function keys: HSK1 VSK1/2 VSK7 VSK8
mask workpiece / groove parameter Paging tool number + / Transferring the changed values Reading back the most recently saved values
Entries: If the input limits are exceeded or not reached, a message is displayed in the bottom status line. WZ_NR W_SCHN1 Count number 1-8; max. 8 different tools (tool sets) can be defined Positioning angle of blade in spindle 1; viewed from the tool spindle, the tool blade should be aligned with 9 o'clock. An entered angle value causes a turning counter clockwise. Positioning angle of blade in spindle 2; see above Positioning angle of blade in spindle 3; see above Positioning angle of blade in spindle 4; see above
With 2-spindle machines, the value -1 (not present) must be entered into W_SCHN3 and W_SCHN4!
WZ_RADIUS PKD_TIEFE
tool radius; distance between the rotating point and the blade tip Blade depth; is max. groove depth.
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03G11AGB
11-81
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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1 20 21
Groove tool number Positioning angle blade spindle_1 Positioning angle blade spindle_2 Positioning angle blade spindle_3 Positioning angle blade spindle_4 Tool radius Blade depth
1 -1 -1 -1 -1 10 1
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03G11AGB
11-82
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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AUZIRK
Function keys: HSK1 Mask groove tool / tool parameter HSK2 circulate on the inside / circulate on the inside VSK1/2 Paging groove + / groove VSK7 Transferring the changed values VSK8 Reading back the most recently saved values
Entries: If the input limits are exceeded or not reached, a message is displayed in the bottom status line. N NUT Count number 1-8; max. 8 different grooves can be defined
D_AUSSEN
outer diameter / bolt diameter, via which the tool will arrive at the groove position without collision nominal diameter of the groove (indicated value = drawing dimension)
D_EINST
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03G11AGB
11-83
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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D_KORR V_SCHRUPP
correction value for nominal diameter; e.g. to balance tool displacement (with long shaft), tool wear or tolerances. Roughing speed (interpolation torque = circular track speed of the blade) assignment of roughing; advance or chip depth per circular track (360 )
AP_SR
U_ENTSPAN
factor for cut interruption / empty cut. Depending on the blade advance, the machine will need a certain number of circular movements/rotations until the required groove depth has been reached. This value is calculated internally. The factor "U_ENTSPAN" subdivides the calculated numbers of rotations and results in a (rounded) rotation limit value. Everytime this limit value is reached, a rotation without advance is executed to release. Example: U_ENTSPAN = 3, required rotations = 120. Therefore, 120 / 3 = 40; after every 40 roations, an empty step is performed. Number of rotations for speed adaptation between V_SCHRUPP and V_FERTIG Inertia, drive system and mechanical circumstances can lead to a change in diameter of the blade track (groove depth) in case of abrupt changes in the track speed (circular interpolation) and thus destroy the blade. The numeric value "U_UEBERG" indicates how many circular tracks are available to the control in order to perform the speed change. Example: U_UEBERG = 4; V_SCHRUPP = 8000mm/min, V_FERTIG = 1000 mm/min. The acceleration/delay is selected on the control so that the new web speed (1000 mm/min) is achieved after four rotations.
U_UEBERG
V_SCHLICHT
Smoothing speed (interpolation speed = circular web speed of the blade); also see "T_SCHLICHT" assignment of smoothing; advance or chip depth per circular track (360 ) Material difference to the groove diameter (D_EINST), which is chipped by smoothing. (With "0", only roughing takes place during the processing)
AP_SL
T_SCHLICHT
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03G11AGB
11-84
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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X_OSZ
Distance for the oscillating centre point migration; serves for chip removal - depending on the material properties - or for the clearing during roughing. This value must not exceed 70% of "AP_SR". Number of oscillation movements per circular web
U_OSZ
U_FERTIG
Number of rotations for final lathing. The numeric value "U_FERTIG" determines how many circular webs the tool blade will execute after the nominal diameter has been reached (D_EINST) in order to form the groove. Finished rotated speed (interpolation speed = circular web speed of the blade), which is used to form the groove after the nominal diameter (D_EINST) has been reached. Driving out speed (interpolation speed = circular web speed of the blade) that is used to exit the groove.
V_FERTIG
V_Z
AP_Z
assignment of driving out; advance or chip depth per circular track (360 ) Is used in connection with "V_Z" to create a smoothing surface with a shallow rough depth on the groove flanks when "driving out". Number of rotations for speed adaptation to drive out speed "V_Z" The numeric value "U_ABH" indicates how many circular tracks are available to the control in order to reach the drive out speed.
U_ABH
X_KORR
Correction dimension of the X axle to balance the centre point migrations of the blade trajectory Correction dimension of the Y axle to balance the centre point migrations of the blade trajectory
Y_KORR
L_LAENGS
Distance difference/drive path to widen the groove (= groove width minus blade width) or to create a contour Axial advance per circular web (360) to widen the groove or to create a contour Cutting speed (interpolation speed = circular web speed of the blade)
AP_LAENGS
V_LAENGS
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03G11AGB
11-85
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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AUZIRK_W
Selection: Operating mode JOG Function keys: HSK1 VSK1/2 VSK7 VSK8
mask workpiece / groove parameter Paging tool number + / Transferring the changed values Reading back the most recently saved values
Entries: If the input limits are exceeded or not reached, a message is displayed in the bottom status line. WZ_NR W_SCHN1 Count number 1-8; max. 8 different tools (tool sets) can be defined Positioning angle of blade in spindle 1; viewed from the tool spindle, the tool blade should be aligned with 9 o'clock. An entered angle value causes a turning counter clockwise. Positioning angle of blade in spindle 2; see above Positioning angle of blade in spindle 3; see above Positioning angle of blade in spindle 4; see above
With 2-spindle machines, the value -1 (not present) must be entered into W_SCHN3 and W_SCHN4!
WZ_RADIUS PKD_TIEFE
tool radius; distance between the rotating point and the blade tip Blade depth; is max. groove depth
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03G11AGB
11-86
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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[mm/min] Advance for finished rotation [mm/min] Maximum drive out speed [mm] [n] [mm] [mm] [mm] [mm] Assignment for driving out Slowly lift off rotations Correction measure X axle Correction measure Y axle Longitudinal rotation incremental Z axle Assignment longitudinal rotation of Z axle
[No.]
1 -1 -1 -1 -1 10 1
[degrees] Positioning angle blade spindle_1 [degrees] Positioning angle blade spindle_2 [degrees] Positioning angle blade spindle_3 [degrees] Positioning angle blade spindle_4 [mm] [mm] Tool radius Blade depth
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03G11AGB
11-87
Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx
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03G11AGB
11-88
12 UPGRADING
12.1 Safety instructions 12.2 Loading with crane / handling systems 12.2.1 One station machines 12.2.2 Two station machines
12-1
12-2 12-5 12-5 12-6
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A8012Agb
12.0 Upgrading
12-1
Prior to performing certain tasks, all relevant information as well as the special safety instructions in the respective machine documentation chapter must be observed.
The operator is responsible for the machine not being operated if safety systems (such as panel parts) are open, removed, bypassed or taken out of operation - life-threatening danger!
Panel parts and cab sheet metal parts and switch cabinet doors are not monitored.
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A8012Agb
12-2
12.0 Upgrading
If the safety is breached, or if a situation is detected that might lead to a safety breach, the "EMERG OFF" key must be activated immediately.
Prior to beginning maintenance and repair procedures, the machine must be disconnect from the power supply and the pressure must be relieved; furthermore, the non-operational stastus of the machine must be reported by means of "Caution Signs". After disconnecting the electrical energy (main switch OFF), enough residual energy may remain in the different supply systems - e.g. electrical, electronic, hydraulics, pneumatics - which could lead to hazardous situations, some with fatal consequences - if not handled by an expert. Hydraulic and pneumatic systems may only be disconnected from the main line and the system pressure may only be released after it has been ensured that this will not cause any uncontrollable mechanical reactions (snapping back of spring-loaded tensioning systems or cylinders in idle positions; dropping of tools; sliding off of advance and movement units by the lack of hydaulic weight balancing, etc.).
The refitting of workpieces, tools, tensioning devices and work procedures that were not designed for the respective machine, is prohibited; also prohibited are interventions that could cause direct or indirect hazards.
In order to avoid damages caused by chips, etc. , we recommend cleaning the machine before upgrading it.
Wear the required protective gear for cleaning and upgrading, e.g. protective gloves, safety shoes, protective eye goggles, etc.
Use transport help devices for the transport of large, heavy or bulky objects. The products to be transported must be secured against movement, tilting, rotating or swivelling of individual parts prior to and during transport. The respective measures must be taken to achieve this (observing the gravity center as well as securing with: positioning rings, chains, securing wooden wedges, screw connections, etc.). No do stand under suspended loads and avoid hazardous areas
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A8012Agb
12.0 Upgrading
12-3
Switched interventions to modify the hardware or software, as well as electrical and mechanical modifications of the machine's design may only be performed by service technicians of "Schwbische Werkzeugmaschinen GmbH"; the information in the operating instructions is for informational purposes only. The operator/owner is liable for any damage caused by unauthorized intervention.
The responsible party must be immediately informed of all modifications on the machine that may lead to safety-relevant issues.
Upgrade procedures that require adjustments that is only possible while all systems are ready to operate or by removing or deactivating special safety equipment, must be monitored by responsible employees located near the "EMERG OFF" and "main switch" keys; if danger arises, the machine must be shut down.
After concluding the work, the unlimited operation readiness of the machine must be checked and confirmed by a responsible party appointed by the operator. This includes: the proper fastening of all panel parts and protective equipment, checking the proper installation of all parts, connections, etc. loosened or removed in the course of the work performed the proper filling and pressure application a function test of the machine with the result, that the machine/its components are functioning properly and within the prescribed NOMINAL values. the correct function of the protective equipment and the EMERG OFF key checking the processing programme, if the executed procedures may have affected it in any way. A walk around the machine as well as an inspection of the machine interior must be conducted to ensure that no persons are within the immediate machine area and that the machine is not colliding with any objects prior to starting the machine. Only then may the production operation be released.
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A8012Agb
12-4
12.0 Upgrading
12.2 Loading with crane / handling systems 12.2.1 One station machines
One station machines (BAS03-x1) are generally equipped with an automatic roof sled. When opening the work room door - depending on the Y position of the work splindles - the roof area of the machine will also open and will thus allow unobstructed access to the work room (also for crane and handling systems). Depending on the Y position of the work spindle, the roof sled can take on three different positions. Y position Work spindle Y = 0 to -399 mm (work room) Y = -400 mm (work room limit) Tool magazine change area (L36) Opening the work room door Roof area remains closed Roof area opens to centre position Roof area opens completely
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A8012Agb
12.0 Upgrading
12-5
If a crane loading process is required, the panel sheet metal can be removed in the roof area by opening the prefriction locks.
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A8012Agb
12-6
12.0 Upgrading
13 DISPOSAL
13.1 Safety instructions 13.2 Disposal options
13-1
13-2 13-3
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A8013Agb
13.0 Disposal
13-1
The machine, its contents and the packaging material must be disposed of in an environmentally friendly manner and as demanded by the current regulations.
Please observe the applicable environmental regulations as well as the requirements put into place by the labor association(s) and the material safety data sheets and the safety and accident prevention instructions in this operating manual! Please wear you personal protective gear, such as safety gloves, safety goggles and a respiratory protection, if needed.
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A8013Agb
13-2
13.0 Disposal
Material
Aluminium components free of oil 12 01 03 Lubricating oil (nonchlorinated) 13 02 xx Processing emulsions (free of halogens) 12 01 09 Hydraulic oil 13 01 xx Contents of oil/water separators 13 05 xx Water return cooler Refrigerant R 134A Antifreeze / corrosion protection TYFOCOR Protective discs polycarbonate Please adhere to the enclosed data sheets and the data provided by the supplier! Please adhere to the enclosed data sheets and the data provided by the supplier! Please adhere to the enclosed data sheets and the data provided by the supplier! Please adhere to the enclosed data sheets and the data provided by the supplier!! Please adhere to the enclosed data sheets and the data provided by the supplier! Please adhere to the enclosed data sheets and the data provided
16 05 05
12 01 05
The indicated codes are not binding and refer to "pure substances". By mixing the substances (mixing leakage oil and cooling lubricant), these disposal key codes can change.
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A8013Agb
13.0 Disposal
13-3
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A8013Agb
13-4
13.0 Disposal
14 FIRES
14.1 General Information on Fire Procedures
14-1
14-2
14.2 Opening the force locked protective doors when there is no power supplied to the machine14-3 14.3 Opening the safety separating window when there is no power supplied to the machine 14-4
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A8014Agb
14.0 Fires
14-1
The machine contains: Hydraulic oil in the cooling system: the non-chlorinated refrigerant R134a Cooling lubricant Lubricants
Fill volumes are listed in the Specifications and the external documentation of the manufacturers!
Based on the safety concept, the closed protective doors remain closed when the machine is not powered.
The protective doors in the work room or the loading room also offer resistance against exterior attempted access. In case of a fire, the power supply to the machine must be interrupted. Extinguishing attempts into the work room from the front are difficult due to the locked protective door; but the protective doors can be opened manually (see next chapter). With critical materials and processes, we recommend using a fire extinguishing system.
When fighting a fire, you must wear a respiratory mask with independent air supply. Fire fighters must wear the respective gear to protect their eyes and skin.
The decomposition products of polycarbonate (protective windows) are mainly H2O and CO2 when burned, as well as small amounts of CO (depending on the oxygen content).
Please adhere to the material safety data sheets for the used liquids, oils as well as to the respective legal requirements!
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A8014Agb
14-2
14.0 Fires
14.2 Opening the force locked protective doors when there is no power supplied to the machine
(The door can be opened by hand if the main switch is turned on and the "EMERG OFF" key is activated.) In a no power state (main switch off), the lock is active. The safety switches with locks / monitoring of the: Work room door (with one station machines BAS03-x1) Loading room door (with two station machines BAS03-x2) are built in above the doors behind a metal panel. The two signal lamps are visible through two punchouts (switch status display), which also allow access to the lock screw. In conditions without power, the lock remains active.
After removing the lock screw, a bushing with a front cross groove will be exposed and can be accessed. By turning this bushing by approx. 5 degrees counter clockwise, the lock in the safety switch is released and the machine access can be opened by hand. After closing it once again, the forced lock is reactivated.
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A8014Agb
14.0 Fires
14-3
14.3 Opening the safety separating window when there is no power supplied to the machine
Safety separating window (only for 2 station models) There is a safety window between the loading room and the work room on both sides of the swivel support. The respective safety window to the active work room can be opened manually. If the "Control is ON" (JOG or AUTOMATIC with NC stop), the locks are released if the "Safety window" key is pressed. (The locking is done via two monitored pneumatic cylinders, which are installed on the left and right machine sides.The lock blocks that are located on the support of the safety window, are the counter pieces.) With no power to the machine (main switch OFF), the safety windows are locked.
Another way to open the work room window is to remove the two lock blocks.
1. Open the protective door of the loading room (see previous chapter)
2. Remove the two socket screws from the support of the safety window in the right and left lock block. 3. Hold the safety window and remove the lock blocks. 4. Press the cylinder rod of the pneumatic cylinder in until flush and open the safety window.
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A8014Agb
14-4
14.0 Fires
15 External documentation
The following pages show the documentation of the component manufacturers. Basically, the information and the described procedures of the manufacturers apply to work on units, unless this is expressly stated otherwise in these operating instructions.
Pneumatics Very fine filter LFM / manometer Pressure switch PEV Regulating valve LRP Switch on valve CP valve island Central lubrication Central lubricationr unit MFE5 Pressure switch DS-W Hydraulics see Chapter 7 Measuring systems Rotary encoder, RCN 220 EnDat Length measuring system, LC481 EnDat Pressure sensor, PN7, PN5 Erection elements Fixator Cooler Central cooling device, LM040-19
Vogel Vogel
Lotz
Bertuch
Lahntechnik
Air filter (option) Oil vapor separator, Darwin 600 Cooling lubricooling system (option)
Losma
Neugart Heynau
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A8015Agb
15-1
Safety safety switch TZ Motors Synchronous motor TMA 210/100 (xxxxxxx) Torque servo motor 1FK6 (xxxx) Synchronous installation motors 1FE1 - Minicoder GEL244 Other devices / options Door drive Motor spindle - Spindle drawing - Spindle / tensioner detail - Tool tensioning system - Rotary feedthrough
Euchner
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A8015Agb
15-2
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A8016Agb
16-1
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A8016Agb
16-2
17-1
17-2 17-3
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A8017Agb
17-1
17.1 Usage instructions for the electronic spare parts and wear parts lists
The spare and wear parts lists are compiled by our electronic data processing centre and they are laid out as trees. The interpretation of these lists takes some getting used to, but it has the advantage that also the installation site or rather the superior assemblies can be taken from the electronic lists. For its use, there are these column headers: "Pos / Stuf" and "Id-Nr / EK" (Item/level and ID no. / Purchasing). (Pos) Item number within the parts list level value or structure position in reference to the total machine: 0 = total machine, 15 = single part in the lowest structure. The combination of several installation parts, e.g. of level 5 will make up one installation part (assembly) of the next higher level 4; level 4 is part of level 3, level 3 is part of level 2, etc. ID no. or data processing number issued by "Schwbische Werkzeugmaschinen GmbH S/W Part: column for spare or wear part identification; the abbreviations have the following meaning: "EE" = Ersatzteil (spare part) "EV" = Verrschleiteile (wear part)
In spite of the data processing supported spare parts management, we ask you to indicate the follwing information when ordering individual parts or in case of questions Order / machine number issued by "Schwbische Werkzeugmaschinen GmbH". When in doubt, this will give us the opportunity to adapt your order to the machine in question (possible upgraded by service calls).
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A8017Agb
17-2
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A8017Agb
17-3
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A8017Agb
17-4