Assembly instructions Change Double

Transcription

Assembly instructions
Change Double-Spindle Everest® engine
4140
Always on the safe side.
Sales:
KaVo Dental GmbH
Bismarckring 39
D-88400 Biberach
Tel. +49 7351 56-0
Fax +49 7351 56-1488
Manufacturer:
Kaltenbach & Voigt GmbH
Bismarckring 39
D-88400 Biberach
Assembly instructions Change Double-Spindle Everest® engine 4140
Table of contents
Table of contents
Table of contents ..............................................................................................................................................1
1 Exchanging the double spindle ......................................................................................................................2
1.1 Required tools and materials ...................................................................................................................2
1.2 Cause of failure of double spindle ............................................................................................................3
1.2.1 Mechanical check ...........................................................................................................................3
1.2.2 Check for noise, sealing air, and vibration ......................................................................................3
1.3 Removing a defective double spindle ......................................................................................................6
1.4 Mounting the double spindle ....................................................................................................................9
1.5 Adapting the spindle parameters ...........................................................................................................12
1.6 Calibrating the double spindle ................................................................................................................14
1.6.1 Affix the gauge ..............................................................................................................................14
1.6.2 Align the gauge with the calibration pin ........................................................................................15
1.6.3 Moving the Z axis and reading off the correction value ................................................................16
1.6.4 Determining the correction value ..................................................................................................16
1.6.5 Correcting the B axis .....................................................................................................................17
1.7 Saving the correction values for the B axis ............................................................................................18
1.7.1 Check which machine parameters are active ...............................................................................18
1.7.2 Changing machine parameters for the B axis ...............................................................................18
1.8 Saving and loading the machine and cycle parameters ........................................................................21
1.8.1 Save the machine parameters file under a new version number. .................................................21
1.8.2 Loading new machine parameters ................................................................................................21
1.8.3 Checking the new active machine parameters .............................................................................22
1.8.4 Check the calibration of the B-axis. ..............................................................................................22
2 Calibrating the engine ..................................................................................................................................23
2.1 Performing laser calibration ...................................................................................................................23
2.2 Adjusting the engine by milling the calibrating body ..............................................................................26
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1 Exchanging the double spindle | 1.1 Required tools and materials
1 Exchanging the double spindle
1.1 Required tools and materials
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A
Everest Milling Pin 1
Everest Milling Pin 3
Everest Insert
Everest positioner (16)
Everest T-Inplast
Mixing cup
Vaseline 250g
Everest Alloy Primer H&W
Everest T-Blank Set 10 units
Wax trimmer
Grindstone (oil stone)
Three-corner file
Micrometer screw
Holder for micrometer screw
Hair drier
Tweezers
Laser calibration pin
Digital dial gauge 1/1000mm
Gauge magnetic holder
Gauge mounting plate
Calibration pin for B axis
Torque wrench, 0-10Nm
Plug-in insert WAF 4
Small grindstone
Spindle alignment ring
Everest microswitch angle piece
Loctite 241
Molykote M55
Torx screwdriver TX 8
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Mat. No. 1.001.5998
Mat. No. 1.001.5999
Mat. No. 1.002.1759
Mat. No. 1.002.1762
Mat. No. 1.001.5996
Mat. No. 1.002.6216
Mat. No. 1.002.6215
Mat. No. 1.002.6217
Mat. No. 1.003.0256
Mat. No. 0.410.0132
Mat. No. 1.002.8714
Mat. No. 0.306.1430
Mat. No. 1.002.5839
Mat. No. 1.002.5840
Mat. No. 1.002.6224
Mat. No. 0.410.0162
Mat. No. 1.002.3770
Mat. No. 1.002.5841
Mat. No. 1.002.5842
Mat. No. 1.002.3779
Mat. No. 1.002.2421
Mat. No. 1.002.5846
Mat. No. 1.002.5873
Mat. No. 1.003.9581
Mat. No. 1.002.6101
Mat. No. 1.003.9717
Mat. No. 0.359.2056
Mat. No. 0.352.0422
Mat. No. 1.003.9336
1 Exchanging the double spindle | 1.2 Cause of failure of double spindle
1.2 Cause of failure of double spindle
The failure of the defective double spindle must be determined by the following tests
an entered in the “Everest double spindle investigation and test log” in the appendix.
The completely filled out log should then be sent to the plant together with the double
spindle for further analysis and repair.
The procedure to trace the cause of failure is described below.
1.2.1 Mechanical check
Check the bearings by manually rotating the spindle shaft Are the bearings
▪ smooth? ❒
▪ rough? ❒
▪ sluggish? ❒
1.2.2 Check for noise, sealing air, and vibration
Note
This check cannot be performed when the spindle shaft is difficult to rotate in the
“Mechanical check.”
Note
A tool must be chucked when performing the check.
CAUTION
Danger of injury from open door
Since this test can only be performed when the door is open, there exists a danger
of injury.
▶ Be very cautious!
▶ Double-click KaVo Everest Engine Control to start the Everest Engine control
programs.
▶ Start the reference run by pressing the start button once on the control panel
The following error messages can be displayed:
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Malfunction
1503: Spindle speed not attained
Cause
Remedy
Bearing damage – it is not possible ▶ Send the double spindle back to
to rotate the shaft by hand.
the factory for inspection and/or
repair.
This test cannot be performed
on-site.
Milling tool is blunt or broken off.
▶ Check and if necessary replace
the milling tool.
1600: Spindle not ready for operati‐ Bearing damage – it is not possible ▶ Send the double spindle back to
on
to rotate the shaft by hand.
repair.
on-site.
Converter board defective.
▶ Send the double spindle back to
repair.
on-site.
1601: Converter overloaded
Fuse tripped on the back of the
▶ Check and if necessary replace
power supply.
the fuse.
1604: Motor phase interrupted
Cable connection in the spindle no‐ ▶ Tighten the locking screw.
se interrupted.
▶ Start the IBH CNC software
In the menu, select Machine Diagnosis CNC,
Select the AUTOmatik menu,
then select "Run program 1" (F1) and click "Manual NC" (F3).
▶ Open the safety door and bridge both door switches with the “Everest micro‐
switch angle piece” Mat. No. 1.003.9717.
▶ In the entry field, enter the value "N1S10000M3" and confirm with "OK".
4/26
▶ Press the start button on the control panel
The double spindle will then run at a speed of 10,000 rpm. Now you can determine
if the operating noise of the bearings is soft or loud, if sealing air at spindle shaft T1/
T2 is exiting evenly, and if vibrations can be determined at the spindle housing.
▶ Repeat the test at speeds of 30,000, 50,000 and 80,000 and document the re‐
sults in the test log.
▶ After checking, turn off the spindle with the command “N1M5”.
5/26
1 Exchanging the double spindle | 1.3 Removing a defective double spindle
1.3 Removing a defective double spindle
Note
The commands in the input window are only executed after confirming with "OK"
and then pressing the "Start button" on the control panel twice.
CAUTION
Damage from collision of the axes
Incorrect entries can cause the axes to collide.
▶ Recheck the entry of the commands!
▶ Always monitor the machine's performance.
▶ If necessary, press the "Stop“ button on the control panel and delete the entered
command by pressing "Crtl +C“!
Example phrase for NC programming:
N1 G1 F300 X30 =
N1 – set number
G1 – traversing of the axes with feed
F300 – feed per minute
X30 – end position in the X direction
▶ Perform a reference run.
▶ In the "Manual entry" menu (accessed via Automatic / Run program (F2) / Ma‐
nual entry (F3)), enter the command "N1G1F1000B0" and execute the com‐
mand (the A axis and the B axes move to 0°).
▶ Remove the gripping yoke.
nual entry (F3)), enter the command "N1G1F300X60Y0" and execute the com‐
mand.
nual entry (F3)), enter the command "N1G1F1000B-90" and execute the com‐
mand (tool change position).
▶ Remove milling tools T1 and T2 from the double spindle
▶ In the Manual entry menu, enter the command: "N1G1F1000B0" and execute
the command (B axis to basic position).
▶ Remove the four screws 1-4, and the metal housing 5.
▶ Remove the coolant feed (6) by pressing the plastic ring of the instant plug-in
connector downward.
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▶ Undo the four screws (7) and take off the coolant distribution (8).
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▶ Undo the four screws (9) of the double spindle and carefully remove the double
spindle (10) by pulling it forward.
▶ Disconnect the cable connections.
Note
Send the defective double spindle together with the completed repair report back
to the factory.
8/26
1 Exchanging the double spindle | 1.4 Mounting the double spindle
1.4 Mounting the double spindle
Note
Use extreme caution when mounting the double spindle to keep from damaging
the spindle nose and spindle bearing.
▶ Debur and clean the contact surfaces of the spindle nose (1) and the contact
surface of the double spindle (2) with a grindstone (Mat. No. 1.003.9581).
▶ Clean the sealing ring (3) of the double spindle (Mat. No. 1.004.4119) or replace
it, and then grease it with Molykote M55 (Mat. No. 0.352.0422).
9/26
▶ Connect the connection cable and ground cable to the double spindle.
▶ Carefully place the double spindle on the spindle nose so that the position of the
locating pin (1) of the double spindle corresponds with the hole in the spindle
nose (2).
Note
When mounting the double spindle, make sure not to damage the contact surface
of the spindle nose with the positioning pin. Also make sure that the ground cable
or connection line is not clamped between the spindle and spindle nose.
10/26
▶ Secure the double spindle with the four cylinder head bolts. Secure the bolts with
Loctite 241 (Mat. No. 0.359.2056) and tighten them with the torque wrench
(Mat. No. 1.002.5846) to a torque of 6 Nm.
▶ Note the serial number and distance dimension for parameter P70 (e.g. 75.931
mm) for the new double spindle.
▶ A test run is now required to check the direction of rotation of the spindle shaft
and the sealing air.
nual entry (F3)), enter the command "N1S10000M3" and execute the command
(spindle runs at 10,000 rpm).
▶ The spindle shaft should now rotate clockwise, and air should exit uniformly at
positions T1 and T2.
▶ In the entry window, enter the value "N1M5" and execute the command.
The spindle is switched off.
11/26
1 Exchanging the double spindle | 1.5 Adapting the spindle parameters
1.5 Adapting the spindle parameters
The previously noted distance dimension for parameter P70 now needs to be ad‐
apted in the control. To change the parameter you need to select the cycle para‐
meter list:
▶
▶
▶
▶
▶
Change to the "DATA" menu.
Click on "Data selection".
Click on "Parameters" and then "DATA" again.
Click on "Change" F5.
Select P0070 and enter the previously noted value in µm, then click on "OK" to
confirm.
Example: A value of 75.869 mm for example needs to be entered as follows in µm.
P0070 =+0.75869000000 E+005
12/26
1 Exchanging the double spindle | 1.5 Adapting the spindle parameters
Spindle dimension P70:
13/26
1 Exchanging the double spindle | 1.6 Calibrating the double spindle
1.6 Calibrating the double spindle
After the double spindle is exchanged, the new one must be adjusted.
The correction value first needs to be determined and then changed via the software.
The following procedure must be followed:
1.6.1 Affix the gauge
nual entry (F3)), enter the command “N1G0A0”.
▶ Remove the gripping yoke.
N1G1B0X60Y0F300 Spindle moves to mid-position X60mm.
▶ Secure a mounting plate for the dial gauge (Mat. No. 1.002.3779) ① to the righthand gripping yoke mounting.
▶ Secure a magnetic dial gauge holder (Mat. No. 1.002.5842) with a 1/1000mm
digital dial gauge (Mat. No. 1.002.5841) ② onto the mounting plate ①.
▶ Clamp a calibrating pin for the B axis (Mat. No. 1.002.2421) ③ into position T1.
▶ Horizontally position the dial gauge at the lower end of the calibrating pin so that
a path of 30 mm can be traversed on the calibrating pin along the Z axis.
14/26
1.6.2 Align the gauge with the calibration pin
▶ Determine the highest point (middle of the calibration pin) on the calibration pin.
Move the axis in the Y direction until the largest value shows on the gauge.
15/26
nual entry (F3)), enter the command “N1G1Y1F100”.
▶ After pressing the start button twice, watch the gauge and see if it goes up or
down.
▶ Change the Y axis in the + or - direction until the highest point is reached on the
calibration pin.
▶ After approaching the middle of the calibration pin, set the gauge to zero.
1.6.3 Moving the Z axis and reading off the correction value
▶ Now the double spindle must be corrected vertically; move the Z axis to do this.
▶ In the manual entry menu, enter the command “N1G1Z100F300”.
▶ Read off the measured value from the dial gauge and make a note of the value.
1.6.4 Determining the correction value
16/26
1.6.5 Correcting the B axis
Calculating the B-correction
tan α = GK / AK
tan α = 2.082 mm / 30 mm
tan α = 0.0694
B α = 3.97°
▶ Enter the correction via the "Manual entry" menu (via Automatic / Run program
(F2) / Manual entry (F3)), e.g. N1G1F100B3.97.
Moving the Z axis and checking the correction
▶ Reset the dial gauge to 0, enter e.g. N1G1F300Z130 and execute the command.
▶ Read off the measured value and recalculate the correction value.
▶ Repeat this process until a value < 3 is obtained when traversing along the Z
axis (traversing range from 130 to 100).
17/26
1 Exchanging the double spindle | 1.7 Saving the correction values for the B axis
1.7 Saving the correction values for the B axis
1.7.1 Check which machine parameters are active
▶ In the IBH CNC software program, go to the menu “INFO”
▶ Click on "Version", then read off the "Active machine parameters" and make a
note of them on a form.
Example: 7371101.MPF
1.7.2 Changing machine parameters for the B axis
In order the change machine parameters for the B axis, open the MP Tool window
again.
▶ Change to the "SETUP" menu.
▶ If you are requested to enter a password, enter "IBHAJ" and click on "OK" to
confirm.
▶ Click on "Machine settings“ F2 and then on "Machine parameters" F1.
▶ A new window opens when you click on "MP Tool".
▶ Now compare the version opened at the top left with the "Active machine para‐
meters". Otherwise, open the active version via the "Open" menu (F3).
▶ In the list on the left open the submenu "ReferencePointCycle" (click on the "+"
symbol) and click on "ReferencePositionDistance".
18/26
The following list of µm values is read out (the numbers are examples):
Index 1
-32100
Index 2
20289
Index 3
-700
Index 4
-189970
Index 5
with a coloured
background
-112621
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Value for the X axis Never change this
value.
Value for the Y axis Never change this
value.
Value for the Z axis Never change this
value.
Value for the A axis Never change this
value.
Value for the B axis Recalculate this va‐
lue. !
Example
▶ Read off the index, e.g. -112621.
▶ Calculate the new machine parameters. To do this, you will first need to convert
the correction value for the B axis and then add the old machine parameter to
the correction value.
Examples: Conversion of the correction value:
Ex. 1: Bcorr = +3.970° which corresponds to +3970’’’
Ex. 2: Bcorr = +2.853° which corresponds to +2853’’’
Examples: Calculation of the new machine parameters
Ex. 1: Index value 5 = -112621 +3970 = -108651
Ex. ": Index value 5 = -112621 +2853 = -1098768
Bcorr = +3.970° (conversion: move the decimal point three places to the right, e.g.
0.25° = 250’’’ )
Bcorr = 3970’’’ (’’’ = Tertien)
BMpold = (current machine parameters for the B axis)
BMpnew = BMpold + Bcorr
BMpnew = -112767’’’ + 3970’’’
BMpnew = 108797’’’
20/26
1 Exchanging the double spindle | 1.8 Saving and loading the machine and cycle parameters
1.8 Saving and loading the machine and cycle parameters
1.8.1 Save the machine parameters file under a new version number.
▶ Click on the "Save" button or press F2.
The "File selection" window is opened. This file contains all currently saved ver‐
sions of the machine parameters.
▶ Select the number of the old machine parameters file which was previously read
out and written down on the form.
▶ Increase the serial index number by one and save. To do this, change the "File
name" accordingly and click on "OK" to confirm.
Example:
▪ Old file name: "3482501.MPF" (index: 01)
▪ New file name: "3482502.MPF" (index: 02)
1.8.2 Loading new machine parameters
For the changed machine parameters saved under the new version number to be
active, they first must be loaded into the control memory.
Requirement
The machine must be in emergency off mode.
▶
▶
▶
▶
Change to the "AUTOmatic" menu.
Click on the button "Run program 1".
Click on the button "Manual NC".
In the entry window, enter the value "N1M93" and click on "OK" to confirm.
21/26
1 Exchanging the double spindle | 1.8 Saving and loading the machine and cycle parameters
▶ Press the start button on the machine twice.
Note
The following steps will need to be repeated if the transfer is not successfully com‐
pleted at the first attempt.
▶ Change to the "SETUP" menu to load the new machine parameters.
▶ If you are requested to enter a password, enter "IBHAJ" and click on "OK" to
confirm.
▶ Click on the "Machine settings" button.
▶ Click on the "Parameters" button.
▶ Click on the "Load" button.
The "Program directory" list is opened with at least two versions of the machine
parameters file.
▶ Select the file saved before with the new version number and click on "OK" to
confirm.
The message "Transfer completed successfully" is shown. If this message is not
shown then the steps for loading the new machine parameters will need to be re‐
peated..
1.8.3 Checking the new active machine parameters
▶ Change to the "INFO" menu.
▶ Click on the "Version" button.
▶ Check the name of the "Active machine parameters" file.
1.8.4 Check the calibration of the B-axis.
Now check the calibration of the double spindle. Do a reference run for the B-axis:
In the main menu "Manual", select the submenu "Run reference" (F4). Now select
the "B-axis" (F5). All of the other axes must be deactivated. (Only the B-axis may
have a green background)
Note
The gauge and calibration pin do not have to be removed for this reference run.
Now repeat the process from section 1.6.3 and check whether the B axis is within
the tolerance band of less than 3 µm.
22/26
2 Calibrating the engine | 2.1 Performing laser calibration
2 Calibrating the engine
2.1 Performing laser calibration
Note
After converting the laser, the machine must undergo a calibration/function check.
▶ In the "AUTOmatic" menu click on the "Program process 1“ button (F2).
▶ Click on the "Sequential selection" button (F1).
▶ Select the "AUTOmatic" menu again.
▶ Click on the "Program blocks" button (F1).
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▶ Click on the "Program number" button (F1).
▶ Go to the program directory "C:\IBHData\NCProg\Calibr\".
▶ Click the subdirectory "Calibr" button or press F5.
24/26
▶ Select program "P955051" and confirm with "OK".
Note
If the directory "Calibr" is not in the bar, you can open it by clicking the button "...".
First click on a different directory (with the exception of "CNC"), and then click the
button "...". A window opens in which the directory can be linked. The directory then
appears in the right bottom menu bar.
▶ Press the Start function key on the control panel.
▶ Upon the programs request, insert calibration pin into T2.
After 10 minutes, the laser calibration program should be successfully concluded.
Note
Exit the IBH software, and restart "KaVo-Everest Engine Control" for the change
to become active.
25/26
2 Calibrating the engine | 2.2 Adjusting the engine by milling the calibrating body
2.2 Adjusting the engine by milling the calibrating body
Now the engine has to be adjusted by milling the calibration piece. This process is
described in the assembly instructions "Everest engine calibration".
Note
The housing of the engine must be installed before the calibration is performed.
26/26
*.***.***** · kb · 20070917 · en

Assembly instructions Change Double

Transcription

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