Transcript
Machine Tools
HMC Maintenance (HP5100)
HP 5100
HP51MTE87
Contents 1. Disassembling and Assembling the Spindle Cartridge ........................ 3 1.1 Disassembling the Tool Unclamp Cylinder-------------------------------------- 3 1.2 Disassembling the Spindle Cartridge ------------------------------------------- 8 1.3 Assembling the Spindle Cartridge ------------------------------------------- 111 1.4 Assembling the Tool Unclamp Cylinder ----------------------------------------18 1.5 Rolling operation of the Main Spindle -----------------------------------------21
2. Disassembling and Assembling the Table ..........................................22 2.1 Disassembling the Table -------------------------------------------------------25 2.2 Disassembling the Table Cylinder----------------------------------------------26 2.3 Disassembling the Worm Shaft ------------------------------------------------28 2.4 Disassembling the Worm Wheel -----------------------------------------------30 2.5 Disassembling the Locating Cone----------------------------------------------33 2.6 Assembling the Locating Cone -------------------------------------------------34 2.7 Assembling the Worm Shaft and Worm Wheel --------------------------------35 2.8 Assembling the Table Cylinder -------------------------------------------------42 2.9 Assembling the Table (Pallet Base) --------------------------------------------44
3. Table Accuracy Work .........................................................................45 3.1 Disassembling the Table -------------------------------------------------------45 3.2 Temporary Assembly of theTable (Pallet Base) Body -------------------------48 3.3 Adjusting the Table Alignment -------------------------------------------------48 3.4 Setting the Table Accuracy ----------------------------------------------------49 3.5 Assembling the Table-----------------------------------------------------------49 3.6 Readjusting the Reference point of the B Axis --------------------------------50
4. Servo ATC Recovery ...........................................................................51 4.1 ATC Structure-------------------------------------------------------------------51 4.2 ATC Main Sequence ------------------------------------------------------------53 4.3 Troubleshooting -------------------------------------------------------------- 525 4.4 Centering the ATC --------------------------------------------------------------62 4.5 Important Notes on Troubleshooting the Servo Control ATC -----------------64 4.6 Troubleshooting ----------------------------------------------------------------65 1
HP 5100
HP51MTE87
5. Disassembling and Assembling the Ball Screw .................................. 66 5.1 Disassembling the X Axis Ball Screw-------------------------------------------66 5.2 Assembling the X Axis Ball Screw ---------------------------------------------71 5.3 Disassembling the Y Axis Ball Screw ------------------------------------------77 5.4 Assembling the Y Axis Ball Screw ---------------------------------------------82 5.5 Disassembling the Z Axis Ball Screw-------------------------------------------88 5.6 Assembling the Z Axis Ball Screw ---------------------------------------------93
6. Machine Accuracy work ..................................................................... 98 6.1 Straightness of the Z Axis -----------------------------------------------------98 6.2 Straightness of the X Axis --------------------------------------------------- 101 6.3 Straightness of the Y Axis --------------------------------------------------- 103 6.4 Straightness of the top of the Pallet----------------------------------------- 104 6.5 Perpendicularity between the Coordinate Axes ----------------------------- 105 6.6 Movement towards the X, Z Axes and Parallelism of the top of the Pallet- 108 6.7 Index Table Division Perpendicularity --------------------------------------- 111 6.8 Perpendicularity of the Edge Locator and Movement towards the X Axis-- 112 6.9 Distance between the Edge Locator Standard Side and the Rotation Central Line -------------------------------------------------------------------------------------- 1167 6.10 Pallet Exchange Repetition Location, Precision and Reciprocal Difference 118 6.11 Z Axis Movement and Parallelism with the Spindle Central Line---------- 119 6.12 Spindle Run-Out ------------------------------------------------------------ 119 6.13 Spindle Movement towards the Z Axis------------------------------------- 119 6.14 Leveling the Machine ------------------------------------------------------- 120
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HP 5100
HP51MTE87
1. Disassembling and Assembling the Spindle Cartridge 1.1 Disassembling the Tool Unclamp Cylinder ▣ Parts List for the Tool Unclamp Cylinder
410
900
1200, 1210 1220, 1230 1250 1260 1240
910
920, 930 940, 950
1270 1280 1290
990 1000
0420 0430
1490 1500
1010
1050 1060
1300, 1320 1330, 1340 1342
1070
1350, 1360 1450
1080 1090 1100
1460 1470 1480
1380, 1390 1400, 1420 1430, 1440
3
HP 5100 No.
HP51MTE87
Parts No.
Description
Material / Specification
Q'ty
410 C58011324
Spacer, Spring(3)
2
SCM435
420 C58011313B
Nut, Spring Clamp
1
SCM440
430 P80300013
O-Ring
1
S13
900 C58012124A
Collar, Distance
1
SM435
910 R11247
Bearing, Cyl. Roller
1
N1014KTNHA/SPVR
920 C58011082A
Housing, Rear Bearing
1
SM435
930 S8011250 940 C58011134A
O-Ring Wall
2 1
G125 SS41
950 S2201361
Bolt, Hex. Socket Head
1
BB4 ×6
990 C58011093
Support, R-Brg. Housing
1
SM45C
SKF
BB6 ×16
1000 S2204661
Bolt, Hex. Socket Head
1010 C58012134A
Collar, Distance(4)
1
SM435
1050 C58012153A
Bracket, Sensor
1
SM435
1060 P64008020
Key
2
KSP8×7 ×20
1070 R02120
Nut, Lock
1
YSR55×2
1080 C58012173A
Stopper, End
1
SM435
1090 S3524376 1100 S3520476
Screw, Set(Hex. S/Head) Screw, Set(Hex. S/Head)
2 2
BQY6×8 BQY8×10
1200 C58011041A 1210 P74060008
Cap, Motor Plug, Hex. Socket(S)
1 1
SM45C FPS-S1/4
1220 S2212261 1230 R35110
Bolt, Hex. Socket Head Connector, Male
8 1
BB10×30 L4N12×9-PT3/8
1240 R32152 1250 C51016233A
Tube, Nylon Bracket, Cylinder
1 1
N5-4-12X9 LMNSC2
1260 S2213661 1270 C51012463B
Bolt, Hex. Socket Head Cover, Cable
8 1
BB10×100 SCP1
1280 C51012474 1290 S22046461
Packing Bolt, Hex. Socket Head
1 4
Rubber(T1) BB6 ×12
1300 C58011203A 1320 C55342214
Body, Cylinder Bolt, Spring
1 4
SM435 SM45C
1330 184535 1340 S8001800
Spring O-Ring
4 1
PW2 P180
1342 R53286
O-Ring
1
P115
1350 C58011213A
Piston
1
SM435
1360 R53103 1380 C58011233A
O-Ring Cover, Cylinder
1 1
P120 SM435
NOK
1390 R53076
O-Ring
1
P110
NOK
1400 R53406
O-Ring
1
G125
NOK
1420 S2208861 1430 S5000501
Bolt, Hex. Socket Head Washer, Plain
8 8
BB8 ×20 ZP8
1440 S5100501 1450 R27053C
Washer, Spring Rotating, Union
8 1
ZS8 1129-018-137
1460 C58011223B
Cap, Piston
1
SM45C
1470 S8010450
O-Ring
1
G45
1480 S2204861
Bolt, Hex. Socket Head
4
BB6 ×20
1490 C58012254
Pusher, Spring
1
SM435
1500 S2204561
Bolt, Hex. Socket Head
4
BB6 ×14
4
12
Remarks
Duri(Ye-Joon)
NOK
Debulin.W/TSC
HP 5100
HP51MTE87
※ Preparations to Disassemble the Tool Unclamp Cylinder (1) Thoroughly clean the machine. (2) Pull out the Tool from the Spindle. (3) Return the Z Axis to its reference point, move the X and Y Axes to a convenient position (roughly the center) to work and turn off the power.
1) Remove the various parts (Hyd. Hose, Coolant Hose, Air Tube, Bracket, Nearby Switches, etc.) in order to disassemble the Tool Unclamp Cylinder.
2) Disassemble C58011223B Piston Cap with the R27053C Rotating Union.
Piston Cap
▪ 4-BB6×20 ▪ O-Ring : 1-G45 Rotating Union
3) Detach the C58011233A Cylinder Cover. ▪ 8-BB8×20, 8-ZP8
Cylinder Cover
▪ O-Ring : 1-P110, 1-G125
5
HP 5100
HP51MTE87
4) Detach the C58011231A Piston assembled
Piston
with the C58012254 Spring Pusher. ▪ O-Ring : 1-P120
Spring Pusher
5) Remove the two security Set-Screws on the C58012173A End Stopper, plug in the Washer and Bolts in the place of the Balancing Bolts (as shown right), and use a
Flat washer
BB8X20
“A”
chisel to remove the end stopper. ※ This is to prevent scarring the End Stopper. ▪ 2-BQY-6×8, 2-BQ8×10
Set-screw chisel “A” Detail End Stopper
6) Disassemble the C58011203A Cylinder Body. ▪ 4-C55342214 Spring Bolts ▪ 4-184535 Spring
Cylinder Body
▪ O-Ring : 1-P180, 1-P115
7) Remove the security bolts on the C51012463 Cable Cover, put the Cover aside, and disassemble the C51016233A Cylinder Bracket.
Cable Cover
▪ 8-BB10×100
Cylinder Bracket
6
HP 5100
HP51MTE87
8) Disassemble the BZ-Sensor, loosen the security bolts on the R02120 Lock-Nut,
BZ-Sensor
and use a chisel to remove the Lock-Nut.
Lock-Nut
9) Take out the C58012153A Sensor Bracket and remove the Key (2-KSP8×7×20). ※ You must not disassemble the C58011041
Motor Cap
Key
Motor Cap, because it will affect the concentricity of the position of the Main Spindle Bearing. Sensor Bracket
7
HP 5100
HP51MTE87
1.2 Disassembling the Spindle Cartridge ※ If the Spindle Cartridge is disassembled due to damage to the Main Spindle or Spindle Bearing, first disassemble the Spindle Tool Unclamp Cylinder as explained before and then disassemble the Spindle Cartridge in the front. ▣ Spindle Cartridge Parts List
680 690
740 750 760
640 650
810
120 130 140 150 160
510
520
530
800
300 330 340 360
360 370
540
200
700 710 830 840
500
No.
Parts No.
560
Description
Mat. / Specification
Q'ty
120
C58011031
Housing, Main Bearing
SM45C
130
P74060006
Plug, Hex. Socket(S)
FPS-S1/8
140
S8000110
O-Ring
P11
7
150
R53388
O-Ring
G150
3
160
S2215361
Bolts, Hex. Socket Head
BB12×35
8
200
C5801101B
Spindle, Main
SCM415
1
8
Remarks
1 13 NOK
HP 5100
HP51MTE87
Description
Mat. / Specification
No.
Parts No.
Q'ty
Remarks
300
C58011303A
Rod, Push(1)
SCM440
1
330
R56146
Ring, Wear
GP65-79L
1
Hansung
340
R55449
Ring, Quad
ORAR04216
2
BUSAK(Hansung)
350
R54363
Ring, Backup
BP3200280
2
BUSAK(Hansung)
360
C58011334
Base, Spring
SCM435
1
370
S8000180
O-Ring
P18
1
500
C48042124
Labyrinth(2)
SCM435
2
510
C48052114
Labyrinth(1)
SCM,435
2
520
R10432
Bearing, ANG. Contact Ball
XCM7014.t.P4S
1
530
C58011164
Spacer, Bearing(2)
SCM435
2
540
C58011173
Spacer, Long
SCM435
2
560
C42018073B
Nut, Lock
SM45C
1
640
C58011152B
Support, Main Bearing
650
P80300130
O-Ring
S130
1
680
S2208661
Bolts, Hex. Socket Head
BB8×16
8
690
R37260A
Nozzle, Coolant
SNM10-L20
6
700
C42018324
Ring, Front
SCM435
1
710
S8010850
O-Ring
G85
1
740
C58011183
Cover, Front
SM45C
1
750
P80300120
O-Ring
S120
1
800
C35056034A
Spacer, Collet
SM45C
1
810
R76441B
Collet(Din40)
Appvd Drow
1
830
C49046664
Key, Drive(BT40)
SM45C
2
840
S2204661
Bolts, Hex. Socket Head
BB6×16
2
1
1) Thoroughly clean the Spindle Head, then remove the Orientation Air Blow Tube with the Connector.
Connector
9
HP 5100 2) Remove the six R37260A Coolant Nozzles located in the Front Cover at the front of
HP51MTE87 Coolant Nozzle
the Spindle, then disassemble the C58011183 Front Cover. ▪ 8-BB5×20 ▪ O-Ring : 1-S120
Front Cover
3) Remove the security bolts (8-BB12X36) on the C58011031B Main Bearing Housing,
Bearing Housing
then plug in two M10 Stud Bolts (300mm or longer) in the Tap position (2-M12). Slowly and carefully remove the Spindle Cartridge taking care to maintain Balance. ▪ 8-BB12×36 ▪ O-Ring : 7-P11, 3-G150, 1-G115
4) When the Spindle Cartridge is nearly pulled out, use the Rope to completely separate it
and use a Crain to pull it out.
10
HP 5100
HP51MTE87
1.3 Assembling the Spindle Cartridge 1) Measuring the Pressure on the Rear Bearing and Collar on-site Grinding ① Wash and clean the Spindle thoroughly. ② Insert the R11247 Cylinder Roller Bearing(N1014) into the Spindle. Washing only inner Taper area is allowed. ③ Use the C58012134A Distance Collar(4)to hit a section of the inner rim
Distance Collar(4)
while making the outer rim touch the Roller lightly. The outer rim should be so
Collar On-site Dimension
that it moves slightly up and down with light pressure. At this point, the pressure on the Bearing can be seen as "0". After about five minutes' wait (allowing heat to transfer from your hand to the outer rim), rotate the outer rim to see if it still moves up and down with light pressure. ④ If the outer rim seems too loose, hit the Collar slightly to reduce looseness. However, if the outer rim is slipping at about 10 Kg.f pressure, it should be no problem as a preset pressure in the Field. ⑤ Measure the gap using the Block Gauge to verify the "Collar on-site Measure". ⑥ Grind the C58012124A Distance-Collar (3) according to the on-site measurement. (Measurement tolerance 0/-0.005; Parallelism under 0.005)
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HP 5100
HP51MTE87
2) Measuring the Tightness of the Rear Outer Rim Bearing and on-site grinding ① Measure the difference in height of the Outer Rims of the disassembled Bearing
Rear Bearing Support
Rear Bearing Housing Support
and the new Bearing on a plain measurement table. ② Determine the dimension of the C58011073A Rear Bearing Support ▪ Find the figures that add and subtract the height difference between the
Rear Bearing
detached Bearing and the new Bearing from the measurement of the Rear Bearing Support. ③ Grind the Rear Bearing Support from onsite Measure amounts found. (Margin +0.005/0, Parallelism under 0.005) Measuring the difference in height
3) Cleaning the Bearing and Applying Bearing Grease ① Remove all grease from the Bearing before applying the Grease (Use thinner or similar material to thoroughly clean the Bearing, then dry the Bearing for about an hour.) ▪ The shipped Bearing is stained with greaseproof material and other substances. Mixing ordinary lubricant with Grease will make the Grease useless. ② Apply enough Grease to cover 10~15% of the spatial area. The chart on the next page indicates the exact amount to be applied. ③ The Grease must be inserted evenly throughout the Bearing cylindrically and must be spread evenly to the bottom of
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Appropriate Grease Applying
HP 5100
HP51MTE87 the Ball.
④ After applying, rotate the Ball so that the Grease is applied on the entire Ball, and then put it into storage.
※ In the case of excess applying ▪ Leave only the amount needed for rotation ▪ Release the excessive grease to the outside ▪ Prevent any air influx ▪ Overheat the Bearing => Noisy/burnt down
Excessive Grease applying
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HP 5100
HP51MTE87
Standard Grease applying Amount for Main spindle Bearing Technology Production : 2008.09.04 Reference: NTN
Nominal
I.D (mm)
Scale : ㎤/EA
DoubleRow SingleRow Roller Roller Brg. NN30 Brg. N10
HS Thrust Angular Ball Brg.
6
30
0.6
0.4
BA,BT Series -
7 8
35 40
0.8 1
0.6 0.7
-
9 10
45 50
1.3 1.4
1 1.1
11 12
55 60
2 2.1
13
65
14 15
TAC Series -
Angular Contact Brg. 70 Series
72 Series
0.8
0.6
-
1 1.2
0.8 1.1
1.2
1.4
1.5 1.7
1.3 1.5
1.5 1.6
2 2
2 2.1
2.3 2.4
2 2
2.2
1.6
2.1
2.2
2.7
2.3
70
3.2
2.4
3
3.2
3.6
3.3
75
3.5
2.5
3.2
3.5
3.8
3.6
16 17
80 85
4.7 4.9
3.5 3.7
4.2 4.4
4.7 4.7
5.1 5.3
4.4 4.7
18
90
6.5
4.5
6
6.5
6.9
6.2
19
95
6.6
4.7
6.3
6.6
7.2
6.5
20 21
100 105
6.8 9.3
4.9 5.9
6.5 8.4
6.8 9.3
7.4 9.3
6.8 8.1
22 24
110 120
11 12.5
7.5 8.4
10.1 10.8
11 12.5
11.9 12.3
10.1 10.8
26 28
130 140
18 20
12.9 14
16.5 17.1
18 20
19.5 20.7
16.1 17
30
150
23
-
21.8
23
25.8
21.2
32 34
160 170
29 38
-
26.9 32.4
29 38
31.8 41.6
25.5 33.2
36 40
180 200
48 65
-
45.6 60.9
-
-
-
44 48
220 240
88 97
-
90
-
-
-
72 80
360 400
360 423
-
395
-
-
-
※: The amount of grease to be applied should be 12~15% of the spacial capacity for Angular Contact Bearings, and 10% of spatial capacity for Cylindrical Roller Bearings.
14
HP 5100
HP51MTE87
4) Assembling the Spindle Rear bearing Parts R-Bearing Housing Support
① Thoroughly clean the Rear Bearing assembly parts ② Insert the Bearing that had been stored with NBU16 Grease on it. ③ Insert the previously on-site grinded
Rear Bearing Support
C58012124A Distance Collar into the C58011073A Rear Bearing Support and Rear Bearing
assemble it to the C58011082A Rear Bearing Housing. ▪ 6-BB6×16 ▪ O-Ring : 1-G85
5) Assembling the Spindle Cartridge ① Thoroughly clean the C58011021B Spindle Motor Body.
Distance Collar(3)
Spindle Motor Body
▪ Take special care to remove any remaining oil from the Motor Coil. ② Apply Grease thinly along the inside of the Spindle Motor Body. ③ Insert the O-Ring (3-P11, 2-G280) into the Main Bearing Housing and apply Grease around the O-Ring. ※ Prevent O-ring separation during Cartridge assembly by inserting the O-Ring after applying Grease to the 3-P11 O-Ring groove. ④ Lift up the Cartridge using clean linen Rope, then lay it on the interior of the Body using a crane. ⑤ Insert the Cartridge using 2-M12 Stud Bolts, then use 8-BB12×35 Bolts for security. ▪ If the Spindle strays into the rear part of the Bearing, insert the C58012134A Distance Collar(4) into the Spindle and use it to hit the Bearing and continue assembly.
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HP 5100
HP51MTE87
Spindle Cartridge
⑥ Use the C58012134A Distance Collar(4) to give shock to the Rear Bearing in order to
Distance Collar(3)
Distance Collar(4)
completely attach the Distance Collar(3) and the Rear Bearing to the Spindle section.
Rear Bearing
6) Clean the C58011183 Front Cover and assemble. ▪ 8-BB5×20 ※ Manually rotate the Spindle to check for any interference.
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Front Cover
HP 5100
HP51MTE87
7) Insert the parallel Key(2-KSP8×7×20) into the Spindle, assemble the C58012153A Sensor Bracket and secure with a Lock-Nut, and then
Motor Cap Key
tighten the Lock-Nut securing Set-Screws.
Lock-Nut Sensor Bracket
8) Assemble the BZ-Sensor. ※ Use a gap gauge to create a 0.1mm gap. If a gap gauge is not available, use a piece of paper to create the gap and remove the paper after tightening the BZ-Sensor
BZSensor
security bolts.
Lock-Nut
17
HP 5100
HP51MTE87
1.4 Assembling the Tool Unclamp Cylinder 1) Assemble the C51016233A Cylinder Cable Cover
Bracket. ※ Steadily remove the Motor Cable through the Cable Cover and store safely. ▪ 8-BB10×100
Cylinder Bracket
2) Assemble the C58011203A Cylinder Body.
Cylinder Body
※ Prevent damage to the O-Ring by applying Grease around the O-Ring. ▪ 4-C55342214 Spring Bolts ▪ 4-184535 Spring
1-P180
▪ O-Ring : 1-P180, 1-P115/NOK 1-P115
Spring Bolt
3) As shown right, insert the Flat Washer and Bolts into the Balancing Bolts location (to prevent scarring the End Stopper) and use a chisel to give shock to the C58012173A End Stopper until the Set-Screws seem to fit the Drill grooves (BQ Bolts grooves) made at the end of the Spindle. Then tighten the security Set-screws. ▪ 2-BQY-6×8, 2-BQ8-10 ※ In case no BQ Bolts grooves have been made ① Complete this process before assembling the Cylinder Body. ② First,tighten the End Stopper as strongly as possible. ③ Use the Ø5 Drill to make Drill marks at the place for Set-Screws (M6 Tap location). (Centering work) ④ Use the Ø4 Drill to make grooves about 3mm deep. 18
Flat A
W
BB8X2 0
2-BQY 6X8
chis el End Stopper
“A” Detail
HP 5100
HP51MTE87
4) Insert the O-Ring into the C58011231A 1-G125
Piston which the C58012254 Spring Pusher is assembled, and carefully assemble the Cylinder Body. ※ Apply grease around the O-Ring to
Piston
prevent damaging the O-Ring during assembly.
Spring Pusher
▪ O-Ring : 1-P120/NOK
5) Insert and assemble the O-Ring into the
1-G125
C58011233A Cylinder Cover and tighten the
1-P110
security bolts. ※ Apply grease around the O-Ring to prevent damaging the O-Ring during assembly. ▪ 8-BB8×20, 8-ZP8 ▪ O-Ring : 1-P110/NOK, 1-G125/NOK
Cylinder Cover
6) Use the R27053C Rotating Union to assemble the
Piston Cap
C58011223B Piston Cap. ▪ 4-BB6×20 ▪ O-Ring : 1-G45 1-G45 Rotating Union
※ Reference : Assembly of the Deublin-Rotating Union D1
Cap End
D2
Piston Field Simultaneo
Piston Cap Stub. Rotor
Rotating Union
19
HP 5100
HP51MTE87
① Separate the Piston Cap while there is no Tool in the Spindle. ② Measure the distance from the Piston section to the ceramic section of the Stub Rotor.(D1 Decision) ③ Measure the distance from the attached section of the Piston Cap to the ceramic section of the Rotating Union(D2) ④ Grind the attached section of the Piston Cap Rotating Union to make the difference between the two distances (D1 & D2) 2.3~2.5mm. Make sure that the attached section of the Rotating Union and the attached section which Piston Cap is attached to Piston are simultaneously machined. (Refer to the onsite machining in the picture) 7) Assemble the various Hyd. Hose, Coolant Hose, Air Tube, Bracket, proximity Switches, and Wires that had been removed to disassemble the Tool Unclamp Cylinder.
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HP 5100
HP51MTE87
1.5 Main Spindle Rolling Operation ※ When assembly is complete, check for any problems. If there are no problems, turn on the power and begin the spindle rolling operation after setting the reference point of each Axis. 1) The objective of rolling operation is to spread grease evenly throughout the Bearing and to make sure that the Bearing is securely in place. 2) Refer to the following program example for specific RPM and running times for rolling operation 3) Take appropriate measures to deal with miscellaneous strange sounds (interference noise). 4) The standard maximum temperature is room temperature (atomosphere temperature) + (40~50 degrees). ※ Example of Milling Spindle Bearing Rolling operation Program M03 S1000 ;
M03 S4000 ;
M03 S7000 ;
M03 S10000 ;
G04 X300. ;
G04 X300. ;
G04 X300. ;
G04 X180. ;
M04 ;
M04 ;
M04 ;
M04 ;
G04 X300.
G04 X300. ;
G04 X300. ;
G04 X180 ;
M03 S2000 ;
M03 S5000 ;
M03 S8000 ;
M03 S1000 ;
G04 X300. ;
G04 X300. ;
G04 X180. ;
G04 X300. ;
M04 ;
M04 ;
M04 ;
M04 ;
G04 X300. ;
G04 X300. ;
G04 X180. ;
G04 X300.;
M03 S3000 ;
M03 S6000 ;
M03 S9000 ;
M30 ;
G04 X300. ;
G04 X300. ;
G04 X180. ;
M04 ;
M04 ;
M04 ;
G04 X300. ;
G04 X300. ;
G04 X180;
21
HP 5100
HP51MTE87
2. Disassembling and Assembling the Table
96 97 98 99
104 105 106 107 108 109
127 128 129
49
117 118 119
120 121
122
5
123 124 125 126
111 112 113 114
115
100 101 102 103
41
44
42 43
146 147 148 149 150 151
45 46 47 48
136
137 138 139 140
133 134 135 131 132
93-6
51 52
143 144 145
61 54 55
84 85
62 62-3 92
60
93-2 93-3
57
83 88 89 91
22
62-2 53
141 142
93
50
59 86 87
82
93-8
56 60-3 60-5
HP 5100
No.
HP51MTE87
Parts No.
Material / Specification
Description
Q'ty
41
C50058283C
Piston
SM45C
1
42
R53131
X-Ring
Q4343-Xseal/Hansung
4
43
R54022
Ring, Back-Up
S52015-343/Hansung
8
44
R53129
O-Ring
P180/NOK
1
45 46
R53160 C50058303
O-Ring Plate, End
P140/NOK SM45C
4 1
47
S2215061
Bolts, Hex. Socket Head
BB12×25
6
48
S5110701
Washer, Spring
Special ZSS12
6
49
P57110032
Pins, Parallel(W/Tap)
SPB10×32
1
96
C51051554A
Cover
SS41
1
97
C51051574A
Packing
Cork
1
98
S2204661
Bolts, Hex. Socket Head
BB6×16
4
99
P74210008
Elbow, Street
HSE1/4
1
100
R55404
Seal, Dust
NBR-B2 807
2m
101 102
C58051153A S2209361
Gear, Ring Bolts, Hex. Socket Head
SCM440-F BB8×35
1 12
103 104
P51400008 C40052032
Washer, Conical Curvic-Coupling
ZC8 360320-230XV
12 1st
105 106
S2215261 P57213040
Bolts, Hex. Socket Head Pins, Taper(W/Tap)
BB12×30 TPB13×40
24 4
107 108
P57113040 S2212961
Pins, Parallel(W/Tap) Bolts, Hex. Socket Head
SPB13×40 BB10×65
4 2
109 111
P74060015 C58051143A
Plug, Hex. Socket(S) Cap, Cylinder
FPS-S1/2 SM45C
2 1
112 113
P74060006 S2212361
Plug, Hex. Socket(S) Bolts, Hex. Socket Head
FPS-S1/8 BB10×35
1 12
114 115
R53379 S8011850
O-Ring O-Ring
P135/NOK G185
1 1
117 118
C50058253 S8011450
Cap O-Ring
SS41 G145
1 1
119
S2204661
Bolts, Hex. Socket Head
BB6×16
6
120
S2212961
Bolts, Hex. Socket Head
BB10×65
12
121 122
P51400010 S8010900
Washer, Conical O-Ring
ZC10 G90
12 2
123
C50058263A
Shaft, Center
SM45C
1
124
P74060006
Plug, Hex. Socket(S)
FPS-S1/8
6
125 126
S8010950 S8011300
O-Ring O-Ring
G95 G130
1 1
127 128
R13003 R13005
Bearing, Needle Ring, Outer
NTB100135/IKO GS100135-IKO
1 1
129
R13008
Ring, Inner
WS100135/IKO
1
146
C58051132A
Housing, Piston
SM45C
1
147
S2221761
Bolts, Hex. Socket Head
BB16×55
8
148
P51400016
Washer, Conical
ZC16
6
149
S8012200
O-Ring
G220
4
150
S8000070
O-Ring
P7
1
Remarks
23
HP 5100 No. 151
HP51MTE87
Parts No.
Material / Specification
Description
Q'ty
S8000110
O-Ring
P11
2
50
C58051163A
Shaft, Gear
SM45C
1
51
C58056073
Housing, Bearing
SM45C
1
52
S2209361
Bolts, Hex. Socket Head
BB8×35
6
53 54
C58056083 S8010850
Liner, Adjust O-Ring
SS400 G85
1st 1
55
R10111
Bearing, Angular Ball
7008ADB/GNP4/NTN
1st
56
R03263
Nut, Lock
DZM40×1.5/K-Fukuda
1
57
C58051193A
Wheel, Worm
ALB2-F
1
59
C58056272
Key
SM45C
1
60
C58056284
Collar
SM45C
1
60.3 S6003660
Bearing, Radial Ball
#6206ZZ
1
60.5 S6500301
Ring, Retaining(Shaft)
RS30
1
Spacer
SS400
1st
62 C58056113 62.3 S2204661
Cap, Bearing Bolts, Hex. Socket Head
SS400 BB6×16
1 6
62.5 C58056094 82 C51056043
Collar Shaft, Worm
SS400 SCM440
1 1
61
C58056104
83 84
R03069 5000501
Nut, Lock Washer, Plain
DZM45×1.5/K-Fukuda ZP8
1 1
85 86
S2208661 C51056083
Bolts, Hex. Socket Head Bracket, Motor
BB8×16 SM45C
1 1
87 88
S2209861 C51056053
Bolts, Hex. Socket Head Housing, Bearing
BB8×60 SM45C
6 1
89 91
S2209061 S8010850
Bolts, Hex. Socket Head O-Ring
BB8×25 G85
1 1st
92 93
R55447 R10736
Seal, Oil Bearing Angular Ball
TC50×72×12/NOK 7009ADB/CNP4/NTN
1 8
93.2 C51056063 93.4 S2204661
Cap, Bearing Bolts, Hex. Socket Head
SS41 BB6×16
1 1
93.6 C51056074
Collar
STKM13A
1
93.8 S6154040
Bearing, Needle
RNA4904
1
94 95
P74151008 P74060008
Busing Plug, Hex. Socket(S)
HB3/8×1/4 FPS-S1/4
4 4
131
S8010750
O-Ring
G75
1st
132
R53259
O-Ring
P38(CO 0037)
1st
133 134
C51051383A C51051394
Con, Locating Liner
SCM415 SM45C
24 4
135 136
S2212061 C5006802A
Bolts, Hex. Socket Head Cap
BB10×25 SM45C
4 20
137
C50068013A
Collar
SCM415
4
138
S6250180
Ball, Steel
SBB3/8
4
139 140
R53260 R54333
Quad-Ring Ring, Back-Up
Quard04335 BP4900702
4 4
141 142
C50068044A C50068054
Quad, Spring Spring
SM45C PW2
4 4
143 144
C50068034A R53070
Shaft, Cap O-Ring
SM45C P40/NOK
4 4
24
Remarks
HP 5100
HP51MTE87
2.1 Disassembling the Table ※ If the Table is being disassembled, it is so important job that disassembly is carefully planned and carried out. ※ Preparations (1) A crane or chain block that can lift at least 1 ton (placed so that it can lift from the center of the Table) (2) Two M12mm eye bolts (3) Rope that can securely hold the balance (must be able to hold at least 1 ton) (4) L-Wrench Set, Pipe (5) Copper Hammer or Lead Lump (6) Appropriate amount of grease (7) Tools for removing pins (8) Miscellaneous tools necessary for basic machine maintenance (9) Spare parts that will need replacing (Example: O-Ring, etc.) ※ Preparations for Table Disassembly (1) Thoroughly clean the machine interior (take special care to wipe off all grease from the Sliding cover area in order to prevent slipping.) (2) Return the X, Y Axes to their reference points, Lift out the APC Pallet with a crane, and activate Pallet Change to lift out the Pallet to Machine outside. (3) Move the Z Axis to the around center for convenience, and turn off the power.
1) Disassemble the C50058253 Cap. ▪ 6-BB6×16
Cap
▪ O-Ring : 1-G145
25
HP 5100
HP51MTE87
2) Remove the Pallet Base security Bolts
security Bolts
(12-BB10×65/ZC10) from where the Cap was disassembled. 3) Remove the Set-Screw (2-BQ12×16) near the Pallet Base, insert eye bolts, tie a rope around this area an hang the rope on a crane.. ※ Be careful to maintain balance when hanging. ※ It is useful during assembly if the Pallet Base and Table Base are marked. 4) Slowly and carefully lift up the Pallet Base. ※ Maintain balance, sometimes hitting the Pallet Base evenly with a hammer or a wooden plank..
26
eye bolt
HP 5100
HP51MTE87
2.2 Disassembling the Table Cylinder ※ The Table Cylinder may have to be disassembled due to oil leakage around the Cylinder inside the Table. Disassembling the Table Cylinder involves disassembling most of the Table, and thus the process must be carefully prepared and executed. When making preparations or reassembling, be especially careful with cleanliness. 1) Remove the security bolts in order to disassemble the C58051143A Cylinder
Cylinder Cap
Cap. ▪ 12-BB10×35 ▪ O-Ring : 1-P135/NOK, 1-G185
2) Disassemble the Center Shaft and the
eye bolt
Cylinder Ass’y. ① Insert the M12 eye bolt in the Lift Tap location in the middle of the Center Shaft and tie the Rope. ② Carefully use the Crane to lift and disassemble. 3) Remove the C50058303 End Plate, and use
Center Shaft Cylinder Cap
a plastic hammer to disassemble individually the C50058283C Piston,
Needle Brg.
C50058263A Center Shaft, R13003 Needle Bearing, and the C58051154A Cylinder Cap. ※ Be careful not to damage the O-Ring
Piston End Plate
and the X-Ring. ▪ 6-BB12×25, 6-ZSS12
27
HP 5100
HP51MTE87
2.3 Disassembling the Worm Shaft 1) Return the X and Y Axes to their reference points , move the Z Axis as much as “-“ direction to a convenient location, and then turn off the power. 2) Remove the Cover security Bolts on the APC side of the Z Axis Sliding Cover, and push the Cover towards the APC. 3) Separate the B Axis Servo Motor Power Cable and the Feedback Cable from the Motor and store them inside the Table. 4) Remove the B Axis Servo Motor security Bolts and disassemble the Motor.
Motor Shaft
5) Disassemble the C51056083 Motor Bracket.
Motor Bracket
▪ 4-BB8×60
6) Remove the C51056053 Bearing Housing security bolts and turn the Worm Shaft
Bearing Cap
Bearing Housing
counterclockwise to disassemble the Worm Shaft Ass’y. ▪ 6-BB8×25 Worm Shaft
28
HP 5100 7) Loosen and remove the fastening set-
HP51MTE87 Lock-Nut
Worm Shaft
screws on the Lock-Nut side using a chisel, and separate the Worm Shaft from the Ass’y.
8) Disassemble the C51056063 Bearing Cap and separate the Bearing and Oil Seal from
Bearing Cap
Bearing Housing
the C51056053 Bearing Housing. ▪ 8-BB6×16
29
HP 5100
HP51MTE87
2.4 Disassembling the Worm Wheel ※ You must disassemble the Table before disassembling the Worm Shaft. Prepare the materials below and follow the instructions in detail. ※ Preparations (1) Crane or chain block that can lift at least 1 ton (placed so that it can lift from the center of the table) (2) 2 each of M12mm, 16mm eye bolts (3) Rope that can securely maintain the balance of the various parts (must be able to lift at least 1 ton) (4) L-Wrench Set, Pipe (5) Brass Hammer, or lump of lead (6) Appropriate amount of Grease (7) Tools for removing pins (8) Basic Tools needed for basic machine maintenance 1) Disassembling the Table ※ Preparations for disassembling the Table (1) Thoroughly clean the interior of the machine and return the X and Y Axes to their reference points. Remove the Pallet inside the machine or lift it from the APC and rotate it to a right-angle position. (2) Move the Z Axis to the around center to make disassembly easier, and turn off the power.
① Disassemble the C50058253 Cap. ▪ 6-BB6×16 ▪ O-Ring : 1-G145
30
Cap
HP 5100
HP51MTE87
② Disassemble the C58051021B Pallet
Security bolt
Base. ▪ 12-BB10×65 ※ Useful during assembly if kept at the Pallet Base and TableBase.
Eye bolt
③ Remove the Pallet Base security bolts (12-BB10×65, 12-ZC10) in the place where the Cap has been disassembled. ④ Remove the Set-Screw (2-BQ12X16) near the Pallet Base, insert eye bolts, tie the rope here and hang onto a Crane. ⑤ Carefully and slowly lift up the Pallet Base. ※ Be sure to maintain balance, sometimes hitting evenly with a hammer or baulk while lifting.
2) Remove the C58056073 Bearing Housing security Bolts and disassemble the Worm Wheel Ass’y by removing the Pins from the Tap holes in the center of the C58051163A Gear Shaft.
Removing Pins
Bearing Housing
31
HP 5100
HP51MTE87
3) Use the exclusive tool to remove the Retaining-Ring at the bottom of the Worm Wheel Ass’y and disassemble the Bearing.
Worm Wheel Collar LockNut
Retaining Pin
4) Loosen and remove the security set-screws
near the Lock-Nut using a chisel, then disassemble (in order) the Collar, Worm Wheel, Key, and Spacer.
Spacer
Key
Worm Wheel Collar Lock-Nut
5) Hit and disassemble the C58051163 Gear
Gear Shaft
Shaft.
6) Remove the C58056113 Bearing Cap Security Bolts (6-BB6×16) and detach (in
Collar
order) the C58056113 Bearing Cap,
Bearing Housing
Angular Ball Bearing, C58056104 Spacer, Bearing, and the C58056094 Collar from the C58056073 Bearing Housing.
32
Spacer
Bearing Cap
HP 5100
HP51MTE87
2.5 Disassembling the Locating Cone ※ The Locating Cone Ass'y may need to be disassembled to handle oil leakage around the O-Ring inside the Table Locating Cone, or to repair internal parts. Since the Locating Cone Ass’y has many O-Rings attached, cleanliness is important. Also take care not to cause damage from the corners of O-Ring parts or Oil grooves. ※ Preparations for Disassembling the Locating Cone (1) L-Wrench Set (2) Appropriate amount of Grease (3) 8mm Bolts(2EA) (4) Basic tools necessary for machine maintenance 1) Disassemble the C51051383 Locating Cone. ① Remove the Locating Cone security Bolts(6-BB10×25). ② Disassemble the Locating Cone by alternating inserting and tightening M8 bolts in the Tap location. Locating Cone
Removal Tap
2) Disassemble the C50068014A Collet,
Cap
Collet
C50068024 Cap, and C50068054 Spring. Spring
3) Remove the C50068044A Spring Guide
6mm L-Wrench use
using a 6mm L-Wrench and disassemble the C50068034A Cap Shaft. Spring Guide
Cap Shaft
33
HP 5100
HP51MTE87
2.6 Assembling the Locating Cone ※ Clean all parts needed for assembling the Locating Cone and clean the surrounding areas as well. ※ O-Ring List needed for assembling the Locating Cone No.
Parts No.
Material / Specification
Description
Q'ty
131 132
S8010750 R53259
O-Ring O-Ring
G75 P38(CO 0037)
4 4
139
R53260
Quad-Ring
Quad04335
4
140
R54333
Ring, Back-Up
BP4900702
4
144 145
R53070 S8010300
O-Ring O-Ring
P40/NOK G30
4 4
Remarks
1) Assemble the C50068044A Spring Guide 6mm L-Wrench use
and the C50068034A Cap-Shaft. ① Insert the O-Ring into the Cap Shaft and insert into a groove in the Table Base body. ※ Apply grease on the lower O-Ring groove in advance to prevent O-Ring
Spring Guide
Cap Shaft
separation during assembly. ▪ O-Ring : 1-P40/NOK, 1-G30 ② Assemble the Spring Guide and secure using a 6mm wrench. 2) Insert the C50068054 Spring into the C50068044A Spring Guide, and assemble the C50068014A Collet that already has C50068024 Cap attached.
Inserting Steel Ball
Collet Cap
Spring
※ Apply grease to the O-Ring and Quad Ring to prevent damage during assembly. ▪ 1-Quad Ring (QRAR04335) ▪ 1-Back-Up Ring (BP4900702) 3) Apply Grease to the hole in the C50068014A Collet and insert the SBB 3/8 Steel Ball.
34
Spring Guide
HP 5100
HP51MTE87
4) Insert the O-Ring into the C51051383 Locating Cone. Slowly assemble while keeping an eye on the Steel Ball attached to the Collet, insert the C51051393 Liner when there is about 10 mm left, and tighten the security bolts. ※ Apply grease around the O-Ring to prevent damage during assembly. ▪ 6-BB10×25 ▪ O-Ring : 1-G75, 1-P38(CO 0037)
2.7 Assembling the Worm Shaft and Worm Wheel 1) On-site machining of the C58056113 Bearing Cap A
① Measure distance "A" from the end of the C58056073 Bearing Housing to the assembling portion of the Bearing. ② Piling up the Angular Ball Bearing,
B
Spacer, and Bearing in order and measure distance "B". ③ Measure “C”= (“A”-“B”) + 0.05mm
Collar
and on-site machine the Bearing Cap accordingly.
C Space r
2) Assembling the Bearing Housing Ass’y ① Apply Grease to the 7008ADB Angular
Bearing Housing Bearing Cap
Collar
Ball Bearing. (Hold the inner rim of the Bearing and insert Grease while rotating the outer rim so that Grease is applied evenly throughout the Bearing Ball.) ② Assemble (in order) the Collar, Bearing,
Space r
Bearing Housin g Bearing Cap
Spacer, and Bearing to the Bearing Housing, taking care to match the correct direction. Assemble the machined Bearing Cap and secure with Bolts.
▪ 6-BB6×16 35
HP 5100
HP51MTE87
3) Fitting the Worm Wheel Key
Gear Shaft
① First try to assemble the WormWheel without the Key in the Gear Shaft.
Key
Worm Wheel
※ If assembly is difficult, abrase the problem area with rope or sandpaper to aid assembly. ② Try assembling again, this time with the Key in the Gear Shaft. ※ If assembly is difficult, abrase the problem area with file or sandpaper to aid assembly. ③ If temporary assembly goes smoothly, disassemble again and clean all parts thoroughly. 4) Assemble the Gear Shaft to the previously assembled Bearing Housing Ass’y. Bearing Housing Ass’y Gear Shaft
5) Assemble (in order) the C58056284 Spacer, Key, C58051193A Worm Wheel, C58056284 Collar, secure the Lock-Nut Worm Wheel
strongly, and tighten the security SetScrews.
Spacer Key
36
Collar LockNut
HP 5100
HP51MTE87
6) After assembling the #6206ZZ Radial Ball Bearing, use snap ring nipper to insert the RS30 Retaining Ring. ※ After inserting the Retaining Ring, apply shock towards the Retaining Ring Axis with a screwdriver, etc. to check if it is securely in place in the groove.
7) Insert the O-Ring (G85) into the Gear Shaft Ass’y. Assemble slowly to the Table
Retaining Ring
Bearing
Adjust Liner
Base, and when there is about 10 mm left insert the C58056083 Adjust Liner, insert the rest of the body, and tighten the
O-Ring
security Bolts. (Simply connect the Bolts for now, the Adjust Liner will be adjusted after the Worm Shaft is assembled.) ※ Apply Grease around the O-Ring to prevent O-Ring damage during assembly. ▪ O-Ring : 1-G85 8) Assembling the C51056053 Bearing Housing ① On-site machine the Bearing Cap according to Measurement "C" [(Height of the Adjusted C51056063 Bearing Cap “C”= (Bearing Housing Depth “A”- Bearing Width “B”)+0.05mm.] ② Apply Grease to the 7009ADB Angular Ball Bearing. (Hold the inner rim of the Bearing and insert Grease while rotating the outer rim so that Grease is applied evenly throughout the Bearing Ball.) ③ Assemble the Bearing, matching up the direction with the Bearing Housing, and then assemble the Bearing Cap. ▪ 8-BB6ⅹ16, 1-Oil Seal(TC50×70×12/NOK)
37
HP 5100
HP51MTE87 B
C
A
9) Attach the C51056043 Worm Shaft to the
Collar
Worm Shaft
previously assembled Bearing Housing, insert the C51056074 Collar, and fasten the Lock-Nut.. ※ Use a chisel and hammer to securely fasten the Lock-Nut, then tighten the security Set-Screw.
LockNut
10) Assemble the RNA4904 Needle Bearing to the Table Base and apply Grease. Needle Bearing
11) Assemble the Gear Shaft Ass’y to the Table Base. ① Insert the O-Ring (G85) into the Bearing Housing and apply Grease. ② Slowly insert the Gear Shaft by turning it clockwise fitting the previously assembled Worm Wheel Ass’y. ③ Assemble the last Needle Bearing part, taking care not to damage the Bearing. ④ When the Bearing Housing reaches the
38
O-Ring
HP 5100
HP51MTE87 Table Base, tighten the Bearing Housing security Bolts(6-BB8×26).
① Remove the Bearing Housing security
B
12) Adjusting the Worm Wheel Center Line
A
▪ 6-BB8×26, O-Ring : 1-G85
bolts (6-BB8×35) on the Gear Shaft Ass’y and pull out the C58056083 Adjust Liner. ② Move the entire Gear Shaft Ass’y to measure the lowest (ⓐ) and highest(ⓑ) height. (“A” or “B”) ※ “A” : Measured with a Block Gauge
Center Line
“B” : Measured with a Depth Gauge or Vernier Calipers ③ Calculate the on-site machining dimension of the Adjust Liner from the measurements above, and grind the Adjust Liner. ※ ⓒ = ⓐ + (ⓑ - ⓐ) ÷ 2 ④ Grind the Adjust Liner according to the on-site machining dimension above. ※ On-site grinding tolerance : ± 0.01 ⑤ Insert the grinded Adjust Liner under the Bearing Housing and tighten the security Bolts. ▪ 6-BB8×35 ※ After assembly ,manually rotate the Worm Shaft to check or any problems. If there are none, move forward to the next step. 13) Assemble the C51056083 Motor Bracket.
Motor Bracket
▪ 4-BB8×60
39
HP 5100
HP51MTE87
14) Assembling the B Axis Servo Motor ① Insert the Key into the B Axis Servo Motor Shaft. ② Carefully assemble the Motor to the Motor Bracket and tighten the security Bolts. ③ Assemble the various Servo Motor Cables that were previously disassembled.
Key
Motor Shaft
15) Assembling the Table (Pallet Base)
O-Ring
① Apply Grease evenly on the disassembled O-Ring(2-G90) (part of the Table's inside diameter) and the Dust Seal (part of the Table Base's outer diameter) to prevent damage to the O-Ring during assembly. ② Clean the Curvic Coupling as thoroughly as possible by blowing all substances
Dust Seal
away with air. ③ Lift up the Table (maintaining proper balance) and lower it onto the marked line made during disassembly. If the Table becomes caught in the Base, hit evenly over the surface with balk or copper hammer to direct it to the proper position. ※ Verifying the proper positioning of the Table There is a Plug(FPS-S3/4) near the Table Base. If you remove this Plug and provide worklight, you can see the Coupling assembly position inside the Table through the Plug holes.
40
Plug
HP 5100
HP51MTE87 ④ If the Table secured without problems,
Cap
connect the Table security Bolts (12BB12×65), assemble the C50058253 Cap, and connect the security Bolts(6BB6×16). ▪ 12-BB12×65, 6-BB6×16
Table security bolt
O-Ring : 1-G145 16) Assemble the various Plugs that had been removed, after wrapping them with Tefron. The last step is executing the Pallet Change and setting the Pallet on the APC.
41
HP 5100
HP51MTE87
2.8 Assembling the Table Cylinder ※ To assemble the Table Cylinder, thoroughly clean the Table Base assembly area and the disassembled Table Cylinder parts, and clean the surrounding area. ※ Reference : The types of O-Rings needed for Table Cylinder assembly No.
Parts No.
Description
Material / Specification
Q'ty
42
R53131
X-Ring
Q4343-Xseal/HANSUNG
4
43
R54022
Ring, Back-Up
S52015-343/ HANSUNG
8
44
R53129
O-Ring
P180/NOK
1
45
R53160
O-Ring
P140/NOK
4
114 R53379
O-Ring
P135/NOK
1
115 S8011850
O-Ring
G185
1
118 S8011450
O-Ring
G145
1
122 S8010900
O-Ring
G90
2
125 S8010950
O-Ring
G95
1
126 S8011300
O-Ring
G130
1
149 S8012200
O-Ring
G220
4
150 S8000070
O-Ring
P7
1
151 S8000110
O-Ring
P11
2
1) Insert the various O-Rings, X-Rings, and
Cylinder Cap
Back-Up Rings into the C50058283C Piston
Remarks
Needle Bearing
and C58051143A Cylinder-Cap. Apply grease to the surrounding area. Assemble the Inner Ring from among the Piston Needle Bearings and set on top the
Piston
greased Needle. ▪ O-Ring : 4-P140/NOK, 4-X-Ring(Q4343) ▪ 8-Back-Up Ring(S52015-343) ▪ 1-P180/NOK, 1-G185, 1-P135/NOK 2) After assembling the Needle Bearing-Outer to the C50058263A Center Shaft, assemble to the Piston, and assemble the C50058303 End Plate.
Center Shaft
Needle Bearing Piston
※ Be sure to apply clean grease around the O-Rings and X-Rings to prevent damage during assembly.. ▪ 6-BB12×25, 6-ZCC 12 ▪ O-Ring : 1-G95, 1-G130
42
End Plate
HP 5100
HP51MTE87
3) Assemble the pre-assembled Piston Ass’y to the Piston Housing and fasten the
Piston Housing
Cylinder Cap
Cylinder Cap's security Bolts(12BB10×35). ※ Make sure to apply clean Grease around the O-Ring and X-Ring to prevent damage. ▪ 12-BB10×35
43
HP 5100
HP51MTE87
2.9 Assembling the Table (Pallet Base) 1) Apply Grease evenly on the disassembled ORing (2-G90) (part of the Table's inside diameter) and the Dust Seal (part of the Table Base's outer diameter) to prevent damage to the O-Ring during assembly. 2) Clean the Curvic Coupling as thoroughly as possible by blowing all substances away with air. 3) Lift up the Table (maintaining proper balance) and lower it onto the marked line made during disassembly. If the Table becomes caught in the Base, hit evenly over the surface with balk or copper hammer to direct it to the proper position.
O-Ring
Dust Seal
※ Verifying the proper positioning of the Table There is a Plug (FPS-S3/4) near the Table Base. If you remove this Plug and provide worklight, you can see the Coupling
Plug
assembly position inside the Table through the Plug holes. 4) If the Table secured without problems,
Cap
fasten the Table security Bolts (12BB12×65), assemble the C50058253 Cap, and tighten the security Bolts (6-BB6×16). ▪ 12-BB12×65, 6-BB6×16
Table security Bolts
▪ O-Ring : 1-G145
5) Assemble the various Plugs that had been removed, after wrapping them with Tefron. The last step is executing the Pallet Change and setting the Pallet on the APC.
44
HP 5100
HP51MTE87
3. Table Accyracy work ※ If a large shock has been applied to the Table in the direction of rotation due to collision, etc., the parallelism between the Edge Locator and the moving Axis could be deviated. This is because Curving Coupling within the Table was deviated by shock and may cause problems when assembling fixture. The Table should be disassembled and the Curvic Coupling must be realigned. This process requires the following preparation. ※ preparations (1) Crane or Chain Block that can lift at least 1 ton (positioned to lift from the center of the Table) (2) 2 each of M12mm, 16mm eye bolts (3) Rope (able to lift over 1 ton) that can hold the balance of machine parts (4) Gauge (Test Indicator, Magnetic Stand etc) that can measure the parallelism of the Edge Locator (5) L-Wrench Set and Pipe (6) Copper Hammer or Lead bundle. (7) Appropriate amount of Grease (8) Tool for pulling out Pins (9) Basic tools needed for basic machine maintenance
3.1 Disassembling the Table ※ Preparations for disassembling the Table (1) Thoroughly clean the interior of the machine. Send X and Y Axes to their reference points. Lift out the Pallet from inside the machine or lift from the APC and rotate it 90 degrees. (2) Move the Z Axis to the center for convenience work, and turn off the power.
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① Disassemble the C50058253 Cap.
Cap
▪ 6-BB6×16, O-Ring : 1-G145
2) Disassemble the C58051021B Pallet Base.
Security Bolt
▪ 12-BB10×65 ※ It is useful during assembly if the Pallet Base and Table Base are marked. ① Remove the Pallet Base security Bolts
Eye bolt
(12-BB10×65/ZC10) from where the Cap was disassembled. ② Remove the Set-Screw (2-BQ12×16) near the Pallet Base, insert eye bolts, tie a rope around this area and hang the rope on a crane. ③ Slowly and carefully lift up the Pallet Base. ※ Maintain balance, sometimes hitting the Pallet Base evenly with a hammer or a wooden baulk. 3) Adjusting the Curving Coupling assembled to the Table Base Body ① Loosen the Curvic Coupling security Bolts (12-BB12×30). ② Pull out the Curvic Coupling Positioning Pins (2-SPB13 ×40) and check for any problems. ③ If there are no problems with the Pins, reassemble. If there are problems, replace with new Pins and assemble after reaming into the Pin hole again. ④ Fasten the Curvic Coupling security Bolts (12-BB12×30) as strongly as possible.
4) Preparation for Adjusting the Curvic Coupling 46
Curvic Coupling
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HP51MTE87
attached to the Table(Pallet Base) Body ① Loosen the Curvic Coupling security Bolts(12-BB12×30). ② Remove the Plug(2-FPS-S1/2) attached in the Curvic Coupling Positioning Pins(2TPB13×40) location, and pull out the Taper Pins. ③ Tighten the Curvic Coupling security bolts with about 1/3 force equally.
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3.2 Temporary Assembly of the Table (Pallet Base) Body 1) Apply Grease evenly on the Table's inner ORing (2-G90) and the Table Base's outer Dust Seal to prevent O-ring damage during assembly. 2) Lift up the Table (maintaining proper balance) and lower it onto the marked line made during disassembly. If the Table becomes caught in the Base, hit evenly over the surface with baulk or copper hammer to direct it to the proper position. 3) Fasten the Table security Bolts (12BB12×65). ※ Verifying the proper positioning of the Table There is a Plug (FPS-S3/4) near the Table Base. If you remove this Plug and provide light, you can see the Coupling assembly position inside the Table through the Plug holes. 4) Remove the Table's upper Plug (2-FPS-S1/2) and loosen the 2-BB10×65. ※ These Bolts are exclusive bolts necessary for aligning the Table.
3.3 Table Accuracy Adjustment 1) Put in the power and Set the Indicator on the Edge Locator by attaching it to the Spindle. 2) Move the X Axis and measure the parallelism between the X Axis and the grinded face of the Edge Locator. 3) Turn off the oil pressure by pressing the emergency stop Switch. Use a hammer or wooden baulk to hit the end of the Pallet and move the Table towards the rotation direction, matching up the parallelism. 4) Reset the Machine Ready and measure the 48
Curvic ass’y State check Curvic ass’y Plug hole State check Plug hole
Curvic Fixed Curvic Bolt Plug Fixed Bolt Plug
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HP51MTE87
parallelism. Repeat the above process until the parallelism comes below the optimal measure. ※ Optimal Measure: 0.01mm/250mm 5) When the optimal parallelism is achieved, tighten the loosened 2-BB10×65.
3.4 Setting the Table Accuracy 1) Disassemble the Table, referring to the "1) Disassembling the Table” section above. 2) Individually fasten the Curvic Coupling security Bolts(12-BB12×30) diagonally using even strength, and tighten as strongly as possible. 3) Even out the Taper Pins location with 13mm taper reamer, then push in new pins. ▪ 2-TPB13×40 4) Assemble the Plug(FPS-S3/4) in the place where the Taper Pins are attached (the Plug should not protrude more than the Coupling face).
3.5 Assembling the Table 1) When the Curvic Coupling is secure, blow out all
Cap
foreign substances from both the upper and lower Curvic Coupling with air. Assemble the Table, referring to the "2) Table(Pallet Base) Body Temporary Assembly” above. 2) Referring to the “3) Adjusting the Table Alignment” above, measure the parallelism between the X Axis and the adjusted side of the Edge Locator. If the measurement falls within the margin, complete final assembly. ① Assemble the C50058253 Cap. ▪ 6-BB6×16, O-Ring : 1-G145 ② Wrap the various Plugs with Tefron and assemble.
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3.6 Readjusting the B Axis Reference Point ※ The B Axis Reference Point must be readjusted in the following circumstances: when the B Axis Servo Motor has been disassembled and reassembled, when the B Axis location changes after executing CW or CCW, and when the “2073 Pallet Or Table CL/UNCL Switch Alarm” is activated. 1) Set the B Axis to 0 degrees and unclamp the Table. ※ MDI” Mode : G90 B0.; M11; 2) Attach the Test Indicator to the Spindle Head, and move the X Axis to fit the parallelism of the Edge Locator. ① Set the Mode to "Handle" and Set the Axis Selection Switch at B-Axis, 0.01. ② Rotate the Handle incrementally to set the parallelism between the Edge Locator and the X Axis as accurately as possible. 3) When the parallelism is set, set Parameter #1815's Bit (APZ) #4 to "0". Reset it to "1" and turn off the power. ※ When the Parameter #1815's Bit (APZ) #4 is changed, “P/S Alarm 000 Must Turn Off Power” and “P/S Alarm 300 nAxis Need ZRN”will be set off. 4) When the power is turned back on, the
Angle Indicator
alarm will be released and the screen's B Axis Position will changed to 0. 5) Verify the accurate position of the Table Clamp. ① With B Axis as 0 degrees, activate from 90 degrees to 0 degrees, and from -90 degrees to 0 degrees. When the Table becomes clamped (when the Curvic Coupling teeth fit together), check the amount that the Table moves through the Angle Indicator. ② After Unclamping the Table, use the handle to move the B Axis towards the direction that the B Axis moves when Clamping after executing CW or CCW (ex: ±0.03∼0.05 degrees). Then repeat 3) and 4) above. 6) Continue repeating this process until the amount that the B Axis Moves when Clamping is the same on the opposite side. ※ The amount of movement here is simply Backlash from the machine itself. 50
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4. Servo ATC Recovery 4.1 ATC Structure -
Magazine Servo Motor With Brake - Reduction Gear
- Tool Pot Guide & Clamp Device
Changer Arm Home Position Detection Proximity S/W
Unique Tool Locking Device
Spline Shaft Air Cylinder
Reduction Gear ATC Servo Motor Drive Cam Ass’y
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4.2 ATC Main Sequence ☞ Initial Condition ① Arm & Servo Home Position ② 2nd Reference Point & M19 ③ Pot Spindle Side & Clamp ④ Arm Pins Release
Changer Arm Home X8.7(SX53) CAHP.M X7.0(SX5A) WPSS.M X7.2(SD32) WPCL.M X15.5(SD56) ATAR.M Gripping Tool
☞ Spindle Tool Unclamp ▪ Output: Y4.3(TUCR.R), YV11, Output Module Slot 3 (Pins 5)
On
▪ Completion: X6.4(TCL.M), SX11, Input Module Slot 8 (Pins 31)
Off
X6.5(TUCL.M), SX12, Input Module Slot 8 (Pins 47)
On
Spindle Tool Unclamp
Arm Pins Locking ☞ Changer Arm Pin Locking ▪ Output: Y4.7(ATAL.R), YV55, Output Module Slot 3 (Pins 10)
On
▪ Completion: X15.3(ATAL.M), SD56, Input Module Slot 8 (Pins 43)
On
X15.5(ATAR.M), SD53, Input Module Slot 8 (Pins 37)
Arm Out & Rotation
Off Tool Change Arm In
☞ Spindle Tool Clamp ▪ Output: Y4.3(TUCR.R), YV11, Output Module Slot 3 (Pins 5)
Off
▪ Completion: X6.4(TCL.M), SX11, Input Module Slot 8 (Pins 31)
On
X6.5(TUCL.M), SX12, Input Module Slot 8 (Pins 47) Off
Spindle Tool Clamp
Arm Pins Release ☞ Changer Arm Pin Release ▪ Output: Y4.7(ATAL.R), YV55, Output Module Slot 3 (Pins 10)
On
▪ Completion: X15.3(ATAL.M), SD56, Input Module Slot 8 (Pins 43)
On
X15.5(ATAR.M), SD53, Input Module Slot 8 (Pins 37)
On Changer Arm Home
☞ Changer Arm Home Position ▪ Input Signal: X8.7(CAHP.M), SX53, Input Module Slot 8 (Pins 37)
52
Arm Forward
On
HP 5100
HP51MTE87
4.3 Trouble Shooting 1) Operating the Maintenance Screen (Manual Operation of the ATC) ① Select the "JOG” Mode from the Main O.P. ② Press the” CUSTOM” Key. ⇒ The” CUSTOM WINDOW” appears on the screen.
`
③ Press "MANUAL" (Function Key). ⇒ The ATC, APC Manual screen appears.
④ Press “ATCON”. ⇒ The “ATC MANUAL MODE” is turned on.
※ Selecting a Step: use the cursor keys to move the cursor up and down and select. ⑤ Manual Control: Select the appropriate process and press Cycle Start. The corresponding Process will be activated. When "*" appears in the Status line on the right, the process has been completed.
Initial Condition
Status
2) Canceling the AL2065 (Verifying the Arm Home Position) ① Meaning of the Alarm : The alarm becomes activated when there is a change in t he Main Changer Arm Home Position due to the Servo System or from other causes. That is, the case where there is a difference between the reference point (X7.6) memorized in the servo system and the reference point that recognizes 53
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proximity switches (X8.7) by the present arm position. ② Objective of the Alarm: The alarm aims to increase the stability of the Servo Mechanisms (e.g. Clamping/Unclamping), which must work based on the Arm's actual location, by maintaining the same Arm position setting regardless of continuous tool exchanges. ③ Troubleshooting the Alarm ☞ Checking for Problems with the Changer Arm Home Position Detection Proximity S/W After
checking
for
problems
with
switch
looseness/
Dog
looseness/
contamination/firing range, proceed normally.
☞In case of alarm, when the changer arm home dog is deflected or even if the position is normal, observe inside the Cam to see if the Turret Can Follower Bearing is positioned on the Cam's Center area. Since this area is very small, it is convenient to use a mirror and worklight. Is the Cam Follower Bearing in the middle of the central area? A
Central
Mirror
Area
A
☞After verifying the Cam Follower Bearing location, use those observations to release the #2065 Alarm by Origin Initialization from the Servo Drive.. A≒B
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HP 5100
Case A B
HP51MTE87 Cam Follower
S/W & Dog align
Solution
Normal Normal Faulty Faulty
Faulty Normal Normal Faulty
Reorder the Switch, secure, and Initialize Initialize Realign the Changer Arm using Inching, reorder the Switch, and Initialize
▶Case “A” ① Press the "MODE" Key once on the Servo Drive start screen [r 0000]
② Press the "DOWN" Key once on the [rd-oFF] screen
③ Press the "SET" Key for five seconds on the [Or9.S--] screen. The letters will blink, then complete Servo Origin Initialization.
④ Power Off → On
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HP 5100
⑤ Move back to Maintenance Mode. Execute the remaining Recovery processes. Verify normal ATC activity, and close Maintenance Mode. ▶Case “B” ① Press the MODE Key once and the "DOWN" Key four times on the Servo Drive start screen[r 0000] to display the [JOG run]. Press the "SET" Key once to display the [Jr.0000].
② Appropriately use the "UP/DOWN" Key (which drives the Arm 20rpm every time it is pressed) to position the Cam Follower Bearing in the center of the middle section. If necessary, reorder the S/W and press the "Set" Key once to exit to the [JOG run] screen.
③ Press the "UP" key three times on the [JOG run] screen.
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HP51MTE87
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HP51MTE87
④ Press the "SET" Key for five seconds on the
[Or9.S--] screen. The letters on the screen will blink, and then complete the Servo Origin Initialization.
⑤ Power Off → On
⑥ Move back to Maintenance Mode. Execute the remaining Recovery processes. Verify normal ATC activity, and close Maintenance Mode.
3) Ordinarily, ATC related trouble shooting that could possibly occur during ordinary arm driving Case 1 2
Status Power interruption before unclamp or after clamp, emergency situation Power interruption during arm driving after unclamp and before clamp, or emergency situation Power interruption during unclamp or right after clamp, emergency
3
situation Arm gets jammed during unclamp or right after clamp (in most cases)
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▶ Case “1” ① Power On⇒Machine Ready Control ② Maintenance Mode On ③ Use the Reverse Step Control to recover the Arm Home Position ※ If the problem occurred after Clamping, use the available Forward Step control. The point at which the problem occurred can be judged based on the Forward Step control's availability. On the PMC G.Data Table, it is the D450 = D452 status.
Case “1”
④ Maintenance Mode Off ⑤ Check for AL2065 activation and take appropriate steps. ⑥ If there is a record of turning off Power, manually recover the reference point (unnecessary in the case of emergency). ⑦ M19 / G91 G30 X0 Y0 Z0 in MDI Mode ⑧ Check the tool number (D450 / D452) on the PMC G.Data Table and make any necessary changes. ⑨ Maintenance Mode On ⑩ Execute 1 Cycle several times to accurately judge the cause of the problem, and to check for any additional problems. ⑪ Maintenance Mode Off ⑫ Insert the tool that was to be exchanged before the problem arose. Recheck the program, and continue the original process.
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▶ Case “2” ① Power On⇒Machine Ready ② Maintenance Mode On ③ Use the Reverse Step Control to recover the Arm Home Position ※ Detach all tools attached to the Changer Arm, and use the Reverse control. Removing tools from the "A" location (shown below) is dangerous; be sure to remove tools from the "B" location. ④ Maintenance Mode Off ⑤ Check for AL2065 activation and take appropriate steps ⑥ If there is a record of turning off Power, manually recover the reference point(unnecessary in the case of emergency). ⑦ M19 / G91 G30 X0 Y0 Z0 in MDI Mode ⑧ Check the tool number (D450/D452) from G.Data Mode and make any necessary changes. ⑨ Maintenance Mode On ⑩ Execute 1 Cycle several times to accurately judge the cause of the problem, and to check for any additional problems. ⑪ Maintenance Mode Off ⑫ Insert the tool that was to be exchanged before the problem arose. Recheck the program, and continue the original process.
A
① ②
B Case “2”
①
②
Press the Locking Pin in the back of the Arm, and remove the tools attached to the Arm Check the rotation and abrasion level of the Roller and take any necessary actions
CT/DIN Shape
▶ Case “3” (Mechanically Jammed) Trouble Shooting Process Case
Tool Data
Status
3-1
D450≠D452
3-2
Cannot rotate Changer Arm because it is D450=D452 jammed in tools after Clamping.
Cannot pull out tools after Unclamping.
Case “3”
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※ It is recommended to judge based on the location of the Changer Arm Home Position Dog in these two situations. Case 3-1
Case 3-2
C. Arm Home Position Dog is under the switch. ▶ Reverse Control
C. Arm Home Position Dog is above the switch ▶ Forward Control
① Power On ⇒ Machine Ready Control ※ Even if it is not due to a power interruption, due to a machine jam ,An AL2009 can occur in the Servo System. Since an AL2009 is due to Overload and is a Power Off Level, it is necessary to toggle Power Off/On in order to release the alarm. ② Maintenance Mode On ③ Identify the Cause and Troubleshoot accordingly. Case
Tool Data
3-1
D450 ≠ D452
3-2
D450 = D452
Status ▪ If the Changer Arm falls out easily during Reverse Step Control, return it to the Cam Home Position and execute the next step. ▪ If the Arm does not fall out and the Overload Alarm(#2009) is set off, after Power Off==èOn, and press the Changer Arm Roller using a screwdriver. Carefully recover using Reverse control and execute the following step. ▪ If the Changer Arm falls out easily during Forward Step Control, return it to the Cam Home Position and execute the next step. ▪ If the Arm does not fall out and the Overload Alarm(#2009) is set off, after Power Off==èOn and press the Changer Arm Roller using a screwdriver. Carefully recover using Forward control and execute the following step.
④ Finding the cause of jamming and Troubleshooting (see below) ⑤ Maintenance Mode Off
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⑥ Finding the reason for AL2065 activation and appropriate measures ⑦ If there is a record of turning off Power, manually recover the reference point(unnecessary in the case of emergency). ⑧ M19 / G91 G30 X0 Y0 Z0 in MDI Mode ⑨ Verify the tool number(D450 / D452) on the PMC G.Data Table and make necessary changes. ⑩ Maintenance Mode On ⑪ Execute 1 Cycle several times to accurately judge the cause of the problem, and to check for any additional problems. ⑫ Maintenance Mode Off ⑬ Insert the tool that was to be exchanged before the problem arose. Recheck the program, and continue the original process. ※ Important Notes Concerning Removing Jams ① When Unclamping manually, be careful of tools falling from the Spindle. ② If the tool had not fallen due to weak Kicking amount, send the Arm to its home position. Carefully hit with a rubber hammer and repeat the manual unclamping process to pull out the tool. After completion, reset the tool Kicking amount. ③ Loosen the Collet and check for any damage/abrasion/loosening. ④ Recheck the ATC Alignment using Centering tools in order to check the M19, change in the 2nd reference point, and change or Slip in the Changer Arm. ⑤ Check for any abrasion, dents, or scratchers on the Changer Arm Roller. Also check the spring strength of the Release Pin.
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4.4 ATC Centering work ※ If the Tool Change is not smooth directly after installation or during use, the ATC and Main Spindle must be aligned (centered). ※ Centering Tools for ATC Centering work
Tool 3 Tool 2 Tool 1
1) Preparations for ATC Centering ① Remove the tool from the Main Spindle to empty the Spindle, and remove the two Driving Keys attached on the side of the Spindle. ② Attach the Centering Tool (1) to the Spindle. ③ Send each Axis to the Tool Change Position.. ⇒ B Axis : X, Y, Z Axis : 2nd reference point (G91 G30 X0. Y0. Z0.) ④ Activate the Spindle Orientation. ⇒ M19 ; ⑤ Check the empty Pot numbers from the Tool Magazine and recall the appropriate tools. ⇒ ex) Tool No. 15 : “MDI” Mode T15 ; “Cycle Start” ⑥ Open the ATC Door. ⇒ ex) “MDI” Mode M222 ; “Cycle Start” 2) Insert the ATC Centering Tool(2) into the Changer Arm Gripper. ① Manually operate the ATC from “Maintenance” Mode. ② Select “JOG” Mode. ③ Press the “CUSTOM” Key. ④ Press the “MAN” Key (Function Key). ⑤ Press “ATCON”. ⑥ Manually select the Toggle S/W from the manual ATC menu ⑦ Use the arrow keys to move the cursor to “ATC ARM FORWARD STEP,” then press the 'Cycle Start‘ button to rotate the Changer Arm towards the Spindle until just before the Arm Out position. 62
HP 5100
HP51MTE87 ⑧ Insert the Centering Tool(2), matching it up with the Arm Gripper Key
3) Check the Alignment between the Changer Arm and the Spindle.
Centering Tool (2)
① Measure the gap between Tool (1) and Tool(2) by using a gap gauge. ▪ Goal : DIN : 3.2mm,
BT : 2.0mm
② Insert Tool(3) into the middle hole and
Centering Tool (3)
check if the position of Tool(2) and Tool(1) are correct.
Area for gap measurement
4) Adjusting the gap between Tool(1) and Tool(2) : Set the gap both in front of and behind the Changer Ass'y. ▪ Goal: DIN : 3.2mm, BT : 2.0mm 5) Adjusting the Center location of Tool(2) and Tool(1) ① If Centering is not correct, remove Centering Tool(3) and change Keep Relay K7.6 from “1” to “0”. Use MPG to move minutely the X, Y Axis and check Centering. ▪ Do not use Keep Relay K7.6 “0”→ ATC. ② When Centering is complete, input the coordinates into the X, Y 2nd reference point. ▪ 2nd Reference Point Parameter : #1241 ③ After removing Centering Tool(3), again change the Keep Relay K7.6 from “0” to “1”. ④ Return the Changer Arm to Home Position using Forward Step, then remove Centering Tool(1) from the main spindle. ④ Execute tool exchange once in “MDI” Mode, then manually move the Changer Arm to ‘tool exchange’ position and recheck Centering.
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4.5 Important Notes Concerning Troubleshooting the Servo Control ATC ① Cam home position check ② Second reference point/orientation check ③ Tool kicking amount check ④ C. arm gripper roller check ⑤ Tool pot spindle side check ⑥Tool size/specification and state check ⑦ Arm centering check ⑧ Tool loading state check ⑨ Remove tool during recovery ⑩ Servo drive check and initialization ⑪ Tool data check
64
Is the turret cam follower bearing located at the center area of the cam center section? Is the alignment of changer arm gripper and spindle drive key normal? During unclamp, is the shift amount insufficient or excessive? Are there any abnormal rotation, over-wear, flaw, corrosion and is the release pin tension normal? Is the feedrate adequate and is the In/Out positioning and clamp confirm accurate? Is the shank / pull stud of the tool normal standards and are there any loosening or damage? When checking with step operations, is there any strain or slip caused by collision during use? In the case of CT / DIN tool, is the direction inserted correctly in the magazine? During maintenance, removing the stuck tool is the general rule. Be sure to understand the alarm release method during AL2009 alarm and initialization method during AL2065 alarm After step operation, must check tool data and prevent collision and machining error, etc.
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HP51MTE87
4.6 Trouble Shooting 1)Operating the Maintenance Screen (Manual Operation of the ATC) ① Select the "JOG” Mode from the Main O.P. ② Press the “CUSTOM” Key. ⇒ The “CUSTOM WINDOW” appears on the screen. ③ Press "MANUAL" (Function Key). ⇒ The ATC, APC Manual screen appears.
④ Press “ATCON”. ⇒ The “ATC MANUAL MODE” is On.
※ Choosing a Step: Use cursor keys from the Main O.P to move up and down and select. ⑤ Manual control : Press Cycle Start after selecting an order. When an "*" appears in the 'Status' Line on the right, the process has been completed.
Initial Condition
Status
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5. Disassembling and Assembling the Ball Screw 5.1 Disassembling the X Axis Ball Screw 31 32 33 34
30
21 22 23
36
37 38 39 40
29 35
18 19 20
27
6 7 8 9
24 25 26
1 2 3 4 5
66
41
28
10 11 12 13
14 15 16 17
HP 5100 No.
HP51MTE87
Parts No.
Description
Q'ty
Material/Specification
Remarks
1
C58023013
Ball Screw (X)
1
W4510Z-312PSS-C3Z20
NSK
2 3
S2212461 P72130004
Bolt, Hex. Socket Head Adaptor, Elbow
10 1
BB10×40 PH4
4
R462945
Connector, Hose
1
C4N8×6-PT1/4
NITTA MOORE
5
R462946
Connector, Elbow
1
L4N×86-PT1/4
NITTA MOORE
6 7
C58021052A S2221961
Bracket, Motor Bolt, Hex. Socket Head
1 8
GC300 BB16×65
8
P51400016
Washer, Conical Spring
8
ZC16
9
P57208056
Pin, Taper(Tap)
2
TPB8×56
10 11
C58021062A S2221961
Bracket. Support Bolt, Hex. Socket Head
1 6
GC300 BB16×65
12
P51400016
Washer, Conical Spring
6
ZC16
13
P57208056
Pin, Taper(Tap)
2
TPB8×56
14 15
C58021072A S2222061
Support, Bearing Bolt, Hex. Socket Head
1 4
SM45C BB16×70
16
P51400016
Washer, Conical Spring
4
ZC16
17
C58021084
Liner, Adjusting
4
SS400
18 19
C58021094A S2202961
Cover Bolt, Hex. Socket Head
1 4
SCP1(t2.0) BB5×12
20
S5000201
Washer, Plane
4
ZP5
21
C58021103A
Damper, Motor
1
Urethane, Rubber
22 23
S2209461 S5000501
Bolt, Hex. Socket Head Washer, Plane
3 3
BB8×40 ZP8
24
C58021113A
Damper, Motor
1
Urethane, Rubber
25
S2209061
Bolt, Hex. Socket Head
4
BB8×25
26
S5000501
Washer, Plane
4
ZP8
27
P72130004
Adaptor, Elbow
2
PH4
28
C58021124
Liner
1
SM45C
29
R18721
Coupling, Rigid
1
Ø35×Ø30
30
R10712
Ang. Contact Ball Brg.
1
35TAC72BDBDC10PN7A
31
C49021524C
Cap. Bearing
1
SM45C
32
S2209261
Bolt, Hex. Socket Head
6
BB8×30
33
P51400008
Washer, Conical Spring
6
ZC8
34 35
C42036094 R02119
Collar Nut, Lock
1 1
SM45C KSN 7
36
R10712
Ang. Contact Ball Brg.
1
35TAC72BDBDC10PN7A
37
C49021524C
Cap. Bearing
1
SM45C
38 39
S2209261 P51400008
Bolt, Hex. Socket Head Washer, Conical Spring
6 6
BB83×0 ZC8
40
C42036094
Collar
1
SM45C
41
R02119
Nut, Lock
1
KSN 7
NSK
NSK
67
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1) Move the X Axis to the center in order to easily detach the X Axis Ball Screw, and turn off the power. 2) Detach the C58021094A Cover from the
Cover
C58021052A Motor Bracket, and remove
Lubricant Pipe
the lubricant pipe, and the Servo Motor Power (Power and Feedback Cable) Connector. Motor Connector
Motor Bracket
3) Loosen the bolts on the R18721 Rigid Coupling by manually unscrewing the Ball Screw, then carefully detach and remove the Motor by removing the Servo Motor Fixing Bolts.
4) Detach the Lock-Nut on the opposite bracket. ▪ Loosen the Security Set-Screws on the Lock-Nut, and remove the Lock-Nut by using the chisel or hammer.
LockNut
68
LockNut
HP 5100
5) Move the Ball Screw Nut area lubricant pipe and cooling pipe to the side. Remove the
HP51MTE87
Cooling Pipe
Nut security Bolts (10-BB 10×40).
Ball Screw Nut
6) Remove the Motor Bracket security Bolts
8Security Bolts
(8-BB16×65) and Positioning Pins (2TPB8×56). Motor Bracket
2-Taper Pins
7) Lift out the Motor Bracket and the Ball Screw Ass’y from the machine.
8) Loosen the C58021072 Bearing Support security Bolts (4-BB16×70) and disassemble the Bearing Support Ass’y.
69
HP 5100
HP51MTE87
9) Disassemble the Motor Bracket Lock-Nut. ▪ Loosen the Lock-Nut security Set-Screws and remove the Lock-Nut by applying shock with a chisel or hammer.
Lock-Nut
10) Separate the Motor Bracket and Ball Screw.
11) Disassemble the C49021524C Bearing Cap from the Motor Bracket and detach the Ball Screw Bearing. ▪ 6-BB8×30
70
Bearing Cap
HP 5100
HP51MTE87
5.2 Assembling the X Axis Ball Screw 1) Assemble the Angular Contact Ball Bearing (35TAC72BDBDC10PN7A) to the C59021072A Bearing Support. ① Assemble the 35TAC Angular Contact Bearing to the Bearing Support, making sure to maintain the right direction. Measure the depth between the end of the Bearing and the section of the Bearing Support. ("B") ② Calculate the on-site dimension of the C49021524A Bearing Cap and machine accordingly. ※ Bearing Cap on-site dimension (Field Adjustment Measure) “A” = “B” - 0.05mm ⓒ Assemble the on-site machined Bearing Cap to the Bearing Support. ※ Make sure to connect all bolts with the same amount of strength. ▪ 6-BB8×30 Bearing Cap Bearing Support
35TAC Bearing
2) Insert the C58021084 Adjust Liner into the C58021072A Bearing Support, assemble to the opposite Support from the Motor Bracket, and connect the security Bolts.
“B”
“A”
Adjust Liner Bearing Cap
▪ 4-BB16×70 ※ Replace the four Adjust Liners to their places as marked number when disassembling.
Bearing Support
71
HP 5100
HP51MTE87
3) Assemble the Angular Contact Ball Bearing (35TAC72BDBDC10PN7A) to the C58021052A Motor Bracket. ① Assemble the 35TAC Angular Contact Bearing to the Motor Bracket, making sure to maintain the right direction. Measure the depth between the end of the Bearing and the section of the Bearing Support. ("B") ② Calculate the on-site dimension for the C49021524C Bearing Cap and adjust accordingly. ※ Bearing Cap on-site dimension (Field Adjustment Measurement) “A” = “B” 0.05mm ③ Assemble the machined Bearing Cap to the Motor Bracket. ※ Try to fasten all security Bolts with the same amount of strength. ▪ 6-BB8×30 “B”
35TAC Bearing “A”
Bearing Cap Motor Bracket
4) Stand up the Motor Bracket with the Bearing assembled, assemble the Ball Screw, insert the C42036094 Collar and fasten the Lock-
Collar
Nut. ▪ Simply tighten as much as possible; the Ball Screw Run-Out will be finally set later on.
Lock-Nut
5) Carefully push the Ass’y with Ball Screw and Motor Bracket assembled in through the Column’s X Axis Ball Screw location.
72
HP 5100
HP51MTE87
※ When assembling the Ball Screw to the opposite Bearing Support, be careful not to hit the screw against something and scar it.
6) Fasten the Motor Bracket security Bolts and Positioning Pins. ▪ 8-BB16×65, 8-ZC16, 2-TPB16×65
7) Release the security bolts (4-BB16 x 70) from the C58021072A Bearing Support assembled to the Support opposite from the
Pull out the Liners Collar
Motor Bracket and pull out the four Adjust Liners. ▪ Mark the four C58021084 Adjust Liners to prevent their locations from being
Lock-Nut
switched during assembly. 8) Insert the C42036094 Collar and secure the Lock-Nut. ▪ Simply tighten as much as possible, the Ball Screw Run-Out will be finally set later on.
73
HP 5100
HP51MTE87
9) Ball Screw Pre-Tension ① Measure the gap between the Bracket Support and Support Bearing with a Block Gauge. ② Measure six places with the Block Gauge and add Pre-Tension (0.08mm) to the
Gap Measure ment
measurements. Do on-site machining of the Adjusting Liner accordingly. ※ Liner Dimension = Gap Measurement + 0.08mm 10) When the on-site machining is complete, loosen the Lock-Nut. Widen the gap between the Bearing Support and the
Adjust Liner Lock-Nut
Support Bracket, insert according to the numbers previously marked, and secure the security Bolts. ▪ 4-BB16×70 11) Use a chisel again to secure the Lock-Nut. ▪ Simply tighten as much as possible; the Ball Screw Run-Out will be finally set later on. 12) Fit the Ball Screw Run-Out. ① Set the Indicator at the end of the Ball Screw. ② Rotating the Ball Screw, read the Indicator. At the highest point, hit with a hammer towards the direction of locking the Lock-Nut ③ When the Ball Screw Run-Out on both sides fall below 0.01mm, tightly fasten the Lock-Nut security Set-Screws. 13) Rotate the Ball Screw Nut to move it to its correct position, then secure the security Bolts. ▪ Since precise fix is required after turning the power on, for now loosely secure the Bolts. ※ Final Securing of the Nut after Power On 74
Support Bracket
HP 5100
HP51MTE87
① Send the X Axis to the“X0”position. ② Fasten the Nut security Bolts with increasing tightness, taking care to apply equal strength to all bolts, and finally tightly secure all Bolts. (It is also possible to tightly secure to diagonal Bolts, loosen them, then tighten all bolts.) 14) Assemble the X Axis Servo Motor (with R10712 Rigid Coupling assembled) to the Motor Bracket by inserting it into the Ball Screw, being careful of the Rigid Coupling. Tighten the security Bolts.
Motor Bracket
15) Fastening the R10712 Rigid Coupling ① Use a Wrench to lightly fasten the four bolts in diagonal order. ② Gradually increase tightness.
Rigid Coupling
③ Set the Indicator on the Rigid Coupling. Manually rotate the Ball Screw to measure the Run-Out. Repeat until the measurement falls under 0.03mm, then secure the bolts. ※ The Run-Out must fit all three rings of the Rigid Coupling. 16) When assembly is complete, assemble the
Cover
C58021094A Cover of the Motor Bracket,
Lubricant Pipe
and assemble the lubricant pipe, and Servo Motor Wire (Power and FeedbackCable)
Connector
that
had
been
disassembled. Motor Connector
Motor Bracket
※ After reassembling the X Axis Ball Screw, you must reset the X Axis reference point.
75
HP 5100
HP51MTE87
※ Resetting the X Axis Reference Point 1) Insert the Test Bar into the Spindle. 2) Send the X Axis to the center (X425.) of the Stroke, the Z Axis to the Z115. position, and the Y Axis to the Y250. position. 3) Install the Indicator on top of the Table. Set the Gauge Needle at about 30 mm away from the end of the Test Bar. Move the Y Axis up and down along Handle
180˚ Rotation
Mode and set "0" at the highest point. 4) Turn the Spindle to stop it in the middle of the Run-Out of the Test Bar, and set the gauge to “0.” 5) Order the setting G91 Y100.; B180. ; Y100.; in MDI mode. ▪ Use the Override to decrease the speed of the Test Bar when down in Y-100.; in order to reduce the shock hitting the gauge. 6) Move the X Axis half of the distance measured by rotating the Table 180˚, then measure again using 5) above and set it so that it falls below 0.005mm. 7) According to the measurement shown on the CRT screen's Machine Position. input into the Parameter if it is + 425., enter "+," if it is -, enter "-". ▪ After editing the Parameter, you must power off and restart the machine. ※ X Axis Reference Point Parameter : NO. #1850 X ▪ Add or subtract the above measurement from the original Parameter and enter “INPUT,” or enter the above measurement with a sign, as “+INPUT”. 8) Reset the machine reference point, and measure 1)∼7) again repeatedly until the measurement falls below 0.005mm.
76
HP 5100
HP51MTE87
5.3 Disassembling the Y Axis Ball Screw ※ To disassemble the Y Axis Ball Screw, it is best to disassemble the X Axis Sliding Cover. However, since it is too difficult to disassemble the Sliding Cover, disassemble the Z Axis sliding cover and detach the Ball Screw Lock-Nut from the bottom.
29 11 12 13
17 18 19
22 23 24 25 26
28
6 7 8
21 20
9 10
27 14 16 16 32 33 30 31 40
34 35 36 37 38 39
1 2 3 4 5
77
HP 5100
No.
HP51MTE87
Parts No.
Description
Material / Specification
Q'ty 1
Remarks
1
C58033013
Ball Screw (Y)
2
S2212461
Bolt, Hex. Socket Head
3
P72130004
Adaptor, Elbow
1
PH4
4
R462945
Connector, Hose
1
C4N8 ×6-PT1/4
NITTA MOORE
5
R462946
Connector, Elbow
1
L4N8 ×6-PT1/4
NITTA MOORE
6
C58031042A
Bracket, Motor(Y)
1
GC300
7
S2221961
Bolt, Hex. Socket Head
8
BB16 ×65
8
P51400016
Washer, Conical Spring
8
ZC16
10
W4509Z-450PSS-C3Z20 NSK BB10 ×40
9
C58021084
Liner Adjusting
8
SS400
10
P57208056
Pin, Taper(Tap)
2
TPB8 ×56
11
C58031094
Cover
1
SCP1(t2.0)
12
S2202961
Bolt, Hex. Socket Head
8
BB5 ×12
13
S5000201
Washer, Plane
8
ZP5
14 15
C58031133A S2212461
Damper, Motor Bolt, Hex. Socket Head
1 3
Urethane, Rubber BB10 ×40
16
S5000501
Washer, Plane
3
ZP8
17
C58021094A
Cover
1
SCP1(t2.0)
18 19
S2202961 S5000201
Bolt, Hex. Socket Head Washer, Plane
8 8
BB5 ×12 ZP5
20
R10712
Ang. Contact Ball Brg.
1
35TAC72BDBDC10PN7A
21
C42036094
Collar
1
SM45C
22 23
C49031123B S8000007
Cap. Bearing O-Ring
1 1
SM45C P7
24
S2209261
Bolt, Hex. Socket Head
6
BB8 ×30
25
P51400008
Washer, Conical Spring
6
ZC8
26 27
S3522282 P72130004
Screw, Set (Hex Socket) Adaptor, Elbow
1 1
BQD5 ×6 PH4
28
R02119
Nut, Lock
1
KSN 7
29
R18721
Coupling, Rigid
1
Ø35 ×Ø30
30
C57031044
Spacer
1
SM45C
31
S8010350
O-Ring
1
G35
32
C57031053
Spacer
1
SM45C
33
P80300060
O-Ring
1
S60
34 35
R10712 C49021524C
Ang. Contact Ball Brg. Cap. Bearing
1 1
35TAC72BDBDC10PN7A SM45C
36
S2209261
Bolt, Hex. Socket Head
6
BB8 ×30
37
S2209261
Bolt, Hex. Socket Head
6
BB8 ×30
38 39
C42036094 R02119
Collar Nut, Lock
1 1
SM45C KSN 7
40
P72130004
Adaptor, Elbow
1
PH4
78
NSK
NSK
NSK
HP 5100
HP51MTE87
1) Move the X and Y Axes to the center, the Z Axis to its reference point (for convenience of disassembling Y axis ball screw) and turn off the power. ※ To prevent the Spindle Head from falling when disassembling the Y Axis Servo Motor, support between the Column and Spindle Head with a baulk and turn off the power. (Make sure to position the baulk so that it will not interfere during Ball Screw disassembly.) 2) Detach the C58021094 Cover(1) and C58031094 Cover(2) from the C58031042A
Cover(1)
Motor Bracket(Y), and remove the lubricant
Cover(1)
pipe and Servo Motor Cable(Power and Feedback -Cable) Connector.
Lubrican t Pipe
3) Manually rotate the Ball Screw of the R18721 Rigid Coupling security Bolts to loosen them, then remove the Servo Motor security Bolts and carefully detach and lift out the Motor.
Rigid Coupling
4) Disassemble the Lock-Nut from the bottom Bracket. ① Disassemble the Z Axis Sliding Cover near the Column. ② Loosen the Lock-Nut security Set-Screw through the bottom of the Cover. Hitting with a chisel and hammer to remove the Lock-Nut. ×
Lock-Nut
Lock-Nut
79
HP 5100
HP51MTE87
5) Disassemble the lubricant pipe and cooling
Lubricant Pipe
pipe near the Ball Screw Nut. Remove the Nut security Bolts. Hold the Nut and rotate the Ball Screw to slightly pull the Nut out from the main body.
Ball Screw Nut
6) Remove the Motor Bracket security Bolts
Motor Bracket
(8-BB16×70) and Positioning Pins (2-
security Bolts
TPB8×56).
Taper Pins
7) Lift out the Motor Bracket and Ball Screw Ass’y from the machine.
8) Remove the security bolts from the C58021072A Bearing Support (4-
Spacer
Spacer
BB16×70) and the C49021524C Bearing Cap security bolts(6-BB8×30) attached to the Support opposite from the Motor Bracket, then disassemble the parts. ※ Mark the four C58021084 Adjust Liner according to location to prevent their positions from switching during assembly.
80
Collar
Bearing Cap
HP 5100
HP51MTE87
9) Disassemble the Motor Bracket Lock-Nut. ※ Loosen the Lock-Nut security Set-Screws
Lock-Nut
and use a hammer to hit and remove the Lock-Nut. 10) Separate the Motor Bracket and the Ball Screw. 11) Disassemble the C49021524C Bearing Cap from the Motor Bracket and separate the Ball
Bearing Cap
Screw Bearing. ▪ 6-BB8×30
81
HP 5100
HP51MTE87
5.4 Assembling the Y Axis Ball Screw 1) Assemble the Angular Contact Ball Bearing (35TAC72BDBDC10PN7A) to the bottom of the Ball Screw Bracket. ① Apply Grease and insert the O-Ring (G35) and Spacer (1) into the Bracket, and assemble the 35TAC Angular Contact-Bearing taking care to keep the correct direction. ② Measure the depth of the end side of the Bearing and the section of the Bracket (“B) ③ Calculate the on-site dimension of the C49021524C Bearing Cap and do the onsite machining. ※ Bearing Cap on-site dimension “A” = “B” – 0.05mm ④ Assemble the machined Bearing Cap to the Bracket. ※ Make sure to use all Bolts tightened with the same amount of force. ▪ 6-BB8×30 Spacer(2)
Spacer(1)
“A”
“B”
Bearing
Bearing Cap
2) Assemble the Angular Contact Ball Bearing(35TAC72BDBDC10PN7A) to the C58031042A Motor Bracket(Y). ① Assemble the 35TAC Angular Contact Bearing to the Motor Bracket, taking care to match up the directions well, and then measure the depth between the end of the Bearing and the section of the Motor–Bracket. (“B) ② Calculate the on-site dimension of the C49031123B Bearing Cap and do the onsite machining. ※ Bearing Cap on-site dimension “A” = “B” – 0.05mm ③ Assemble the machined Bearing Cap to the Motor Bracket, fitting it to the O-Ring grooves. ※ Make sure to use all Bolts tightened with the same amount of force. ▪ 6-BB8×30, 6-ZP8, 1-P7
“A”
“B”
Motor Bracket
82
Bearing Cap
35TAC Bearing
HP 5100
HP51MTE87
3) Stand up the Motor Bracket with the Bearing attached, assemble the Ball Screw, insert the C42036094 Collar and secure the Lock-Nut. ▪ First,secure as tightly as possible. 4) As shown below, use an Indicator to measure the end of the Ball Screw (Coupling assembly area), the area near the Bearing, and the Ball Screw Nut area, and fit the Run-Out. ▪ To adjust the Run-Out, rotate the Ball Screw while reading the Indicator, and at the highest point hit with a hammer towards the direction of locking the Lock-Nut.
300mm
A B
Collar C
Lock-Nut
5) Hang the Ass'y (with Ball Screw and Motor Bracket assembled) onto a crane with a rope, and carefully push through the Y Axis Ball Screw position from above the Column.
※ When assembling the Ball Screw to the opposite Bracket area, be careful not to hit and scar the lift out screw area near the end of the ball screw.
83
HP 5100
HP51MTE87
6) Lightly plug in the Motor Bracket Positioning Pins(2-TPB8×56) to position them, then insert the collar into the Bracket below and fasten the Lock-Nut. ▪ Simply tighten as much as possible; the Ball Screw Run-Out will be finally set later on.
Collar
Lock-Nut
7) Setting the Ball Screw Pre-Tension Bracket and the upper side of the Column using a Block Gauge. ② Measure the nine Adjusting Liner assembly areas with a Block Gauge. Add the PreTension (0.03mm) to the measurement, and accordingly grind each Adjusting Liner. ※ Liner Measurement = Gap Measurement + 0.03mm 8)
When
the
Liner
on-site
grinding
is
complete, loosen the Lock-Nut, widen the gap
between
the
Motor
Bracket
and
Column a little, insert the liners according to their locations as previously marked, and fasten the security bolts and positioning pins. ▪ 8-BB16×70, 8-ZC16, 2-TPB8×56 9) Use a chisel and hammer again to fasten the Lock-Nut. * Simply tighten for now, you must set the Ball-Screw Run-Out again later.
84
Gapmeasure
① Measure the gap between the Motor
HP 5100
HP51MTE87
10) Fit the Ball Screw Run-Out. ① Set the Indicator at the end of the Ball Screw. ② Rotate the Ball Screw while reading the Indicator. At the highest reading, hit with a chisel in the direction of locking the Lock-Nut. ③ When both Ball Screw Run-Outs fall below 0.01mm, tightly secure the LockNut security set-screws. 11) Rotate the Ball Screw Nut back to its original location, fasten the security Bolts, and assemble the lubricant pipe and cooling pipes. ▪ Since accurate fix should be done after turning on the power, for now loosely connect the security Bolts. ▪Final Nut Fix after turning on the Power On ① Send the X Axis to the "X0" position. ② Fasten the Nut security Bolts with increasing tightness, taking care to apply equal strength to all bolts, and finally tightly secure all Bolts. (It is also possible to tightly secure to diagonal Bolts, loosen them, then tighten all bolts.)
Ball Screw Nut
12) Insert the Y-Axis Servo-Motor with the R10712 Rigid Coupling attached into the Ball Screw, being careful not to hit the Rigid Coupling. Assemble to the Motor Bracket and tighten the security bolts.
13) Fastening the R10712 Rigid Coupling ① Use the Wrench to lightly secure the four bolts, in diagonal order. ② Gradually increase the fastening force on the bolts. ③ Set an Indicator inside the Rigid Coupling. Manually rotate the Ball Screw to measure Run-Out repeatedly until the figure comes
Rigid Coupling
85
HP 5100
HP51MTE87
under 0.03mm, then firmly secure the bolts. ※ The Run-out must match all three rings of the Rigid Coupling. 14) When assembly is complete, assemble the Motor Bracket's Cover(1) and Cover(2), and assemble the lubricant pipe and
Cover(1) Cover(2)
Servo Motor Wire Connector previously disassembled..
Lubricant Pipe
※ After reassembling the Y Axis Ball Screw, the Y Axis Reference Point must be reset. ※ Resetting the Y Axis Reference Point 1) Insert the Test Bar into the Spindle. 2) Set the Block Gauge(over 150mm) on top
Indicator Test Bar
of the Pallet and install the Indicator on top of the Pallet to set the Block Gauge's height at “0” Setting.
Block Gauge
3) Send the Y Axis to the position corresponding to the measurement found from the formula below.
Pallet
Y Axis position ＝ Block Gauge height － (Test Bar Radius ＋ 50) ▪ In case of HP-5100, when Y is Y0. the distance from the top of the Table to the center of the Spindle is 50mm. Ex): If the Block Gauge height is 150mm: 150 - (30 + 50) = 70. Therefore, Y70. 4) With the Indicator at the highest point of the Test Bar, rotate the Spindle so that it stops in the center of the Test Bar's Run-Out. 5) Move the Y Axis to set the Indicator needle at "0”. 6) Enter the Parameter according to the measurement shown on the CRT screen's Machine Position. If it is + the location found in 3), enter "+," if it is -, enter "-". ▪ After editing the Parameter, you must power off and restart the machine. ※ Y Axis Reference Point Parameter : NO. #1850 Y ▪ Add the above measurement from the original Parameter and enter “INPUT,” or enter the above measurement with a sign, as “+INPUT”. 7) Set the reference points again and measure 1)∼6) repeatedly until the figure comes under 0.005mm.
86
HP 5100
HP51MTE87
5.5 Disassembling the Z Axis Ball Screw ※ To disassemble the Z Axis Ball Screw, disassemble the Z Axis Sliding Cover and place it in the center for convenience, and turn off the power. 36
31 32 33 34
41
30
37 38 39 40
29 35
18 19 20
6 7 8 9
27
21 22 23
24 25 26
28
10 11 12 13
14 15 16 17
1 2 3 4 5
87
HP 5100
No.
HP51MTE87
Parts No.
Description
Material / Specification
Q'ty
Remarks
1
C58023023
Ball Screw (Z)
1
W4509Z-451PSS-C3Z20 NSK
2
S2212461
Bolt, Hex. Socket Head
10
BB10 ×40
3
P72130004
Adaptor, Elbow
1
PH4
4
R462945
Connector, Hose
1
C4N8 ×6-PT1/4
NITTA MOORE
5
R462946
Connector, Elbow
1
L4N8 ×6-PT1/4
NITTA MOORE
6
C58021052A
Bracket, Support
1
GC300
7
S2221961
Bolt, Hex. Socket Head
8
BB16 ×65
8
P51400016
Washer, Conical Spring
8
ZC16
9
P57208056
Pin, Taper(Tap)
2
TPB8 ×56
10
C58021062A
Bracket. Support
1
GC300
11
S2221961
Bolt, Hex. Socket Head
6
BB16 ×65
12
P51400016
Washer, Conical Spring
6
ZC16
13
P57208056
Pin, Taper(Tap)
2
TPB8 ×56
14 15
C58021072A S2222061
Support, Bearing Bolt, Hex. Socket Head
1 4
SM45C BB16 ×70
16
P51400016
Washer, Conical Spring
4
ZC16
17
C58021084
Liner, Adjusting
4
SS400
18 19
C58021094A S2202961
Cover Bolt, Hex. Socket Head
1 4
SCP1(t2.0) BB5 ×12
20
S5000201
Washer, Plane
4
ZP5
21
C58021103A
Damper, Motor
1
Urethane, Rubber
22 23
S2209461 S5000501
Bolt, Hex. Socket Head Washer, Plane
3 3
BB8 ×40 ZP8
24
C58021113A
Damper, Motor
1
Urethane, Rubber
25
S2209061
Bolt, Hex. Socket Head
4
BB8 ×25
26 27
S5000501 P72130004
Washer, Plane Adaptor, Elbow
4 2
ZP8 PH4
28
C58021124
Liner
1
SM45C
29
R18721
Coupling, Rigid
1
Ø35 ×Ø30
30
R10712
Ang. Contact Ball Brg.
1
35TAC72BDBDC10PN7A NSK
31
C49021524C
Cap. Bearing
1
SM45C
32
S2209261
Bolt, Hex. Socket Head
6
BB8 ×30
33
P51400008
Washer, Conical Spring
6
ZC8
34 35
C42036094 R02119
Collar Nut, Lock
1 1
SM45C KSN 7
36
R10712
Ang. Contact Ball Brg.
1
35TAC72BDBDC10PN7A NSK
37
C49021524C
Cap. Bearing
1
SM45C
38 39
S2209261 P51400008
Bolt, Hex. Socket Head Washer, Conical Spring
6 6
BB8 ×30 ZC8
40
C42036094
Collar
1
SM45C
41
R02119
Nut, Lock
1
KSN 7
88
HP 5100
HP51MTE87
1) To disassemble the Z Axis Ball Screw, disassemble the Z Axis Sliding Cover and place it in the center for convenience, and turn off the power. 2) Disassemble the C58021094A Cover from the C58021052A Motor Bracket. Remove the lubricant pipe and Servo Motor Wire (Power and Feedback Cables) Connector.
Cover
Lubricant Piping Motor cable
Motor Bracket
Cable Connector
3) Loosen the R18721 Rigid Coupling bolts by manually rotating the ball screw. Remove the Servo Motor security Bolts and carefully detach and remove the Motor.
4) Disassemble the opposite C58021072A Bearing Support Lock-Nut. * Loosen the Lock-Nut security Set-Screws and remove the Lock-Nut using a chisel and hammer. Lock-Nut Lock-Nut
89
HP 5100 5) Disassemble the Ball Screw Nut Area's lubricant pipe and the cooling pipe and
HP51MTE87 Cooling Pipe
remove the Nut security Bolts(10-BB 10×40). Ball Screw Nut
6) Remove the Motor Bracket security
Security Bolts
Bolts(8-BB16×65) and Positioning Pins(2TPB8×56). Motor Bracket
Taper Pins
7) Remove the Motor Bracket and Ball Screw Ass’y from the machine.
8) Loosen the C58021072A Bearing Support security Bolts(4-BB16×70) and disassemble the Bearing Support Ass’y.
90
HP 5100
HP51MTE87
9) Disassemble the Motor Bracket Lock-Nut. * Loosen the Lock-Nut security Set-Screws and remove the Lock-Nut by hitting with a
Lock-Nut
chisel and hammer. 10) Separate the Motor Bracket and Ball Screw.
11) Disassemble the C49021524C Bearing Cap from the Motor Bracket and separate the Ball Screw Bearing. ▪ 6-BB8×30
Bearing Cap
91
HP 5100
HP51MTE87
5.6 Assembling the Z Axis Ball Screw 1) Assemble the Angular Contact Ball Bearing (35TAC72BDBDC10PN7A) to the C59021072A Bearing Support. ① Assemble the 35TAC Angular Contact Bearing to the Bearing Support, making sure to put it in the correct direction, then measure the depth of the end of the Bearing and the section of the Bearing Support. (“B”) ② Measure the on-site dimension of the C49021524A Bearing Cap and do the on-site machining accordingly. ※ Bearing Cap on-site dimension “A” = “B” - 0.05mm ③ Assemble the machined Bearing Cap to the Bearing Support. ※ Make sure to apply the same strength to all bolts while securing. ▪ 6-BB8×30 Bearing Cap Bearing Support
35TAC Bearing
2) Insert the C58021072A Bearing Support and the C58021084 Adjust Liner into the Support opposite from the Motor Bracket, and secure the security bolts. ▪ 4-BB16×70
“B”
“A”
Adjust Liner Bearing Cap
※ Insert the four Adjust Liners according to their positions as marked during disassembly.
Bearing Support
3) Assemble the Angular Contact Ball Bearing (35TAC72BDBDC10PN7A) to the C58021052A Motor Bracket. ① Assemble the 35TAC Angular Contact Ball Bearing to the Motor Bracket, making sure to put it in the correct direction, then measure the depth of the end of the Bearing and the section of the Bearing Support. (“B") ② Measure the on-site dimension of the C49021524C Bearing Cap and do the on-site machining accordingly. ※ Bearing Cap on-site dimension “A” = “B” - 0.05mm ③ Assemble the machined Bearing Cap to the Motor Bracket. ※ Make sure to apply the same strength to all bolts while securing. ▪ 6-BB8×30 92
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35TAC Bearing “A”
Bearing Cap Motor Bracket
4) Stand up the Motor Bracket with Bearing attached, assemble the Ball Screw, insert the C42036094 Collar, and fasten the Lock-
Collar
Nut. ▪ Simply tighten as much as possible; the Ball Screw Run-Out will be set later on. Lock-Nut
5) Carefully push in the Ass'y (with Ball Screw and Motor Bracket attached) through the X Axis Ball Screw position on the Column.
※ When assembling the Ball Screw to the opposite Bearing Support, be careful not to hit the screw against something and scar it.
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6) Fasten the Motor Bracket security Bolts and
8securit
Positioning Pins. ▪ 8-BB16×65, 8-ZC16, 2-TPB16×65 Motor Bracket
2-Taper Pins
7) Remove the security bolts (4-BB16 x 70) from the C58021072A Bearing Support attached to the Support opposite from the
Pull out the Liner Collar
Motor Bracket and pull out the four Adjust Liners. ▪ Mark the four C58021084 Adjust Liners to prevent their locations from being switched
Lock-Nut
during assembly. 8) Insert the C42036094 Collar and secure the Lock-Nut. ▪ Simply tighten as much as possible; the Ball Screw Run-Out will be finally set later on. 9) Setting the Ball Screw Pre-Tension ① Use a Block Gauge to measure the gap between the Bracket Support and the Support Bearing. ② Measure six places with the Block Gauge, add the Pre-Tension amount (0.04mm) to the measurements,and grind the Adjusting Liner accordingly. ▪ Liner Measurement = Gap Measurement + 0.04mm
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10) When grinding is complete, loosen the Lock-Nut and widen the gap between the Bearing Support and the Support Bracket. Insert according to the numbering and tighten the security Bolts. ▪ 4-BB16×70 11) Use a chisel and hammer to fasten the Lock-Nut again. ▪ Simply tighten as much as possible; the Ball Screw Run-Out will be finally set later on. 12) Set the Ball Screw Run-Out. ① Set the Indicator at the end of the Ball Screw. ② Rotate the Ball Screw while reading the Indicator. At the highest reading, hit with a chisel in the direction of locking the Lock-Nut. ③ When both Ball Screw Run-Outs fall below 0.01mm, tightly secure the LockNut security set-screws.
Adjust Liner Lock-Nut
Support Bracket
13) Rotate the Ball Screw Nut to move it to its correct location, then fasten the security Bolts. ▪ Since accurate fixing should be done after turning on the power, for now loosely connect the security Bolts.. ※ Finally Securing the Nut after Turning on the Power ① Send the Z Axis to the “Z0”position. ② Fasten the Nut security Bolts with increasing tightness, taking care to apply equal strength to all bolts, and finally tightly secure all Bolts. (It is also possible to tightly secure to diagonal Bolts, loosen them, then tighten all bolts.) 14) Insert the Z Axis Servo Motor (with R10712 Rigid Coupling attached) into the Ball Screw and assemble to the Motor Bracket. Fasten the security bolts.
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Motor Bracket
15) Fastening the R10712 Rigid Coupling ① Use a Wrench to first lightly fasten the four Bolts in diagonal order. ② Gradually increase tightening force. ③ Set the Indicator on the Rigid Coupling. Manually rotate the Ball Screw to measure Rigid Coupling
the Run-Out, repeating until the measurement falls below 0.03mm. Secure the Bolts. ※ The Run-Out must fit all three Rings of the Rigid Coupling.
16) When assembly is finished, assemble the Motor Bracket C58021094A Cover. Assemble the lubricant pipe, cooling pipes, and Servo Motor Cable (Power and Feedback Cable) Connector that were previously disassembled. Cover
Lubricant Pipe
Motor Bracket
Motor Cable Connector
※ When reassembling the Z Axis Ball Screw, you must reset the Z Axis Reference Point.
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※ Resetting the Z Axis Reference Point 1) Set the X Axis Reference Point (refer to "Resetting the X Axis Reference Point") and set the Indicator at "0" setting. ▪ Machine coordinates: X425. Z115., Y Axis is near Y250. 2) Command G91 Z100.; B90.; Z-100.; in
“0” Setting
MDI Mode. ▪ When the last Test Bar hits the gauge, use Override to slow it down and reduce the shock hitting the gauge.
Measur ement
▪ When the reference very different, set 맞춘다. 닿지않으면 point 핸들로isX축을 움직여 위치를
90˚ Rotation
the last Z-100. at about Z-95. and send the Z Axis over to the gauge using Handle Mode. ▪ If the Test Bar does not reach the gauge because of the difference in Table position, use the Handle to move the X Axis and position it. 3) Move the Z Axis to set the Indicator needle at “0”. 4) Enter the Parameter according to the measurement shown on the CRT screen's Machine Position. If it is + Z115., enter "+," if it is -, enter "-". ▪ After editing the Parameter, you must power off and restart the machine. ※ Z115. is for when the Test Bar's length(L) is 310mm, and diameter(D) is 60mm. Z = L - (200 + D/2),
Z = 310 - (165 + 30) = 115
In the case of HP-5100, when Z is Z0. the distance between the center of the Table to the Spindle Gauge Line is 200mm. ※ X Axis reference point Parameter : NO. #1850 Z ▪ Add the measurement to the original Parameter and enter “INPUT,” or enter the above measurement with a sign, as “+INPUT”. 5) Set the Z Axis reference points again, send the Z Axis to Z115., and repeatedly measure with Indicator until the figure comes under 0.005mm.
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6. Machine Accuracy Work 6.1 Straightness of the Z Axis X-Axis
1) X－Y Plane ① Measurement Install the Level in the center of the top of the Pallet in the X Axis direction to set the reference point. Divide the Z Axis Stroke into three equal parts and transfer them, measuring the greatest difference in level change. ▪ Measurement position : Z0. Z375. Z750. ▪ Permitted Range : 0.025mm / Entire Length
Z Axis transfer
② Adjustment
Z-Axis
If the machine transfer level is incorrect, it can effect the Z Axis X-Y straightness. Make sure to level the machine first (refer to "Leveling the Machine").
X-Axis
2) Y－Z Plane ① Measurement Stand up a Straight Edge on the Pallet in the Z Axis direction, and install the Indicator on the Spindle Head to set both ends of the Straight Edge as "0." Move the Z Axis to measure the largest difference. ※ If a Straight Edge is not available, a side of a perpendicular ruler may be used to measure the Y-Z straightness. ▪ Measurement position : Both ends and center of the Straight Edge. ▪ Permitted Range : 0.005mm / 300mm ② Adjustment If the machine transfer level or the Z Axis L/M Guide is incorrect, it can effect the Z Axis YZ straightness. First level the machine first (refer to "Leveling the Machine"), and if the problem persists, repair or replace the L/M Guide.
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Z Axis Transfer Z-Axis
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3) X－Z Plane ① Measurement Lay the Straight Edge on the Pallet in the Z Axis direction, and install the Indicator to Spindle Head to set both ends of the Straight Edge as "0." Move the Z Axis to measure the largest difference. ※ If a Straight Edge is not available, a side of a perpendicular ruler may be used to measure the X-Z straightness. ▪ Measurement Location : Both ends and center of the Straight Edge.
X-Axis
▪ Permitted Range : 0.005mm / 300mm
② Adjustment If the machine transfer level or the Z Axis L/M Guide are incorrect, it can effect the Z Axis Y-Z straightness. First level the machine first (refer to "Leveling the Machine"), and if the problem persists repair or replace the L/M Guide.
Z Axis Transfer Z-Axis
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6.2 Straightness of the X Axis 1) X - Y Plane ① Measurement
X Axis Transfer X-Axis
Stand up a Straight Edge on the Pallet in the X Axis direction, and install the Indicator on the Spindle Head to set both ends of the Straight Edge as "0." Move the X Axis to measure the largest difference. ※ If a Straight Edge is not available, a side of a perpendicular ruler may be used to measure X-Z straightness. ▪ Measurement Location : Both ends and center of the Straight Edge. ▪ Permitted Range : 0.005mm / 300mm
Z-Axis
② Adjustment If the machine transfer level or the X Axis L/M Guide are incorrect, it can effect the X Axis X-Y straightness. First level the machine first (refer to "Leveling the Machine"), and if the problem persists, repair or replace the L/M Guide.
①Measurement Install the perpendicular magnetic level on a
X Axis Transfer
section of the Spindle in the Z axis direction so that the level needle can be read, then divide the X Axis stroke into three equal parts and transfer, measuring the largest difference in level. ▪ Measurement Position : X0. X425. X850. ▪ Permitted Range : 0.025mm / Entire Length ② Adjustment If the machine transfer level is incorrect, it can effect the X Axis straightness. Make sure to level the machine first (refer to "Leveling the Machine").
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Z-Axis
X-Axis
2) Y - Z Plane
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3) X - Z Plane ① Measurement Lay the Straight Edge on the Pallet, in the direction of the X Axis. Install the indicator on the Spindle Head and set both ends of the straight edge to "0". Move the X Axis and measure the greatest difference. ※ If a Straight Edge is not available, a side of a perpendicular ruler may be used to measure X-Z straightness. ▪ Measurement position : both ends and center of the Straight Edge. ▪ Permitted Range : 0.005mm / 300mm ② Adjustment
X Axis
If the machine transfer level or the X Axis L/M
Transfer X-Axis
Guide are incorrect, it can effect the X Axis X-Z straightness. First level the machine first (refer to "Leveling the Machine"), and if the problem persists, repair or replace the L/M Guide.
Z-Axis
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6.3 Straightness of the Y Axis 1) X - Y Plane ① Measurement Set up a perpendicular ruler on the Pallet in the X Axis direction. Install the indicator on the Spindle Head, and set both ends of the straight edge as "0." Measure the central area. ▪ Measurement Position : both ends and
Indicator
Perpen dicular Ruler
Y-Axis
center of the straight edge. ▪ Permitted Range : 0.005mm / 300mm ② Adjustment If the X Axis L/M Guide is incorrect, it can effect the Y Axis X-Y straightness. Repair or replace the L/M Guide. 2) Y - Z Plane ① Measurement Stand up a perpendicular ruler on the Pallet in the X Axis direction. Install the indicator on the Spindle Head, and set both ends of the straight edge as "0." Measure the central area. ▪ Measurement Position : both ends and center of the straight edge. ▪ Permitted Range : 0.005mm / 300mm ② Adjustment If the X Axis L/M Guide is incorrect, it can effect the Y Axis X-Y straightness. Repair or replace the L/M Guide.
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Y-Axis
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6.4 Straightness of the Top of the Pallet 1) X - Y ① Measurement
XDirection
Place a Straight Edge on top of the Pallet and attach the indicator to the block. Measure the straightness of the top of the straight edge to find the greatest difference. ※ If a Straight Edge is not available, it is also
Spindle
Straight Edge
possible to attach an indicator to the
Block
spindle head and to measure the top of the pallet by manually moving the Axis.
Pallet
▪ Measurement Position: both ends and center, 9 positions in the X direction ▪ Permitted Range : 0.015mm / 500mm ② Adjustment Since this is the straightness of the top of the Pallet itself, it is impossible to adjust. If the problem is serious, the top of the Pallet should be regrinded. 2) Y - Z ① Measurement
ZDirecti on
Place a Straight Edge on top of the Pallet and attach the indicator to the block. Measure the straightness of the top of the straight edge to find the greatest difference. ※ If a Straight Edge is not available, it is also
Spindle
Straight Edge
possible to attach an indicator to the
Block
spindle head and to measure the top of the pallet by manually moving the Axis.
Pallet
▪ Measurement Position: both ends and center, 9 positions in the Z direction ▪ Permitted Range : 0.015mm / 500mm ② Adjustment Since this is the straightness of the top of the Pallet itself, it is impossible to adjust. If the problem is serious, the top of the Pallet must be regrinded. 103
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6.5 Perpendicularity between the each Coordinate Axes 1) X - Y Perpendicularity ① Measurement Place a perpendicular ruler on the Pallet in the X Axis direction. Install an Indicator 축 on the Spindle Head and measure in the X- and Y-Axis direction to find the greatest difference. ▪ Measurement : Set ⓑ and ⓒ (shown in the photo) as "0.”Add +/- signs to the ⓑ－ⓐ measurement and the ⓒ－ⓓ measurement. If ⓐ and ⓓ are the same sign, the measurement is the sum of the two axes; if they are different signs, the measurement is the smaller number subtracted from the larger number. ▪ Permitted Range : 0.01mm/300mm ② Adjustment X-Y perpendicularity adjustment is possible by adjusting the thickness of the X Axis L/M Guide Liner. ⓐ Refer to“X-Y Perpendicularity”above to accurately measure the perpendicularity. ⓑ When measuring, calculate the length of the perpendicular ruler and the distance between the two L/M Guide Sliders to find the grinding amount of the Liner. ⓒ Remove the L/M Guide Slide security bolts and loosen the X Axis Ball Screw Nut security Bolts. ⓓ Insert a screw-jack between the Bed and Column, and lift the column a little until the Liner can be removed. ⓔ Pull out the Liner, grind the amount found in“②,”and reassemble. ⓕ When reassembling the Ball Screw Nut, move the X Axis to the outermost position(X0.) and then secure the bolts one by one, tightening them equally. ⓖ Measure the perpendicularity repeatedly until a satisfactory figure is reached.
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b
a
c
d
security Bolts
Liner
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2) Y - Z Perpendicularity ① Measurement Place a perpendicular ruler on the Pallet in the Z Axis direction. Install an Indicator on the Spindle Head and measure in the Z- and Y-Axis direction to find the greatest difference. ▪ Measurement : Set ⓑ and ⓒ (shown in the photo) as "0.”Add +/- signs to the ⓑ－ ⓐ measurement and the ⓒ－ⓓ measurement. If ⓐ and ⓓ are the same sign, the measurement is the sum of the two axes; if they are different signs, the measurement is the smaller number subtracted from the larger number. ▪ Permitted Range : 0.01mm/300mm
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② Adjustment Y-Z perpendicularity adjustment is possible by adjusting the thickness of the X Axis L/M Guide Liner. ⓐ Refer to“X-Y Perpendicularity”above to accurately measure the perpendicularity. ⓑ When measuring, calculate the length of the perpendicular ruler and the distance between the two L/M Guide Sliders to find the grinding amount of the Liner. ⓒ Remove the L/M Guide Slide security bolts and loosen the X Axis Ball Screw Nut security Bolts. ⓓ Insert a screw-jack between the Bed and
b
Column, and lift the column a little until the Liner can be removed.
a
c
ⓔ Pull out the Liner, grind the amount found in“②,”and reassemble. ⓕ When reassembling the Ball Screw Nut, move the X Axis to the outermost position(X0.) and then secure the bolts
d
one by one, tightening them equally. ⓖ Measure the perpendicularity repeatedly
security Bolts
until a satisfactory figure is reached.
Liner
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3) X - Z Perpendicularity ① Measurement Lay a perpendicular ruler on the Pallet, and move the indicator in the X Axis direction to set both ends of the ruler to "0" (hit high points with the handle of a screwdriver to set the parallelism of the X Axis). Measure the parallelism towards the Z Axis to find the greatest difference. ▪ Measurement : Set ⓐ-ⓑ(shown in the photo) to“0,”and find the difference ⓒ－ ⓓ. ▪ Permitted Range : 0.01mm/300mm ② Adjustment It is unlikely that the perpendicularity will be altered after setting the X-Z perpendicularity. However, if the X-Z perpendicularity should be adjusted, the X- or Z-Axis L/M Guide itself should be realigned.
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6.6 MovementTowards the X, Z-Axes and Parallelism of top of the Pallet 1) Measurement Install the Indicator onto the Spindle Head, then find the two points on either side of the Pallet, 150 mm away from the Pallet’s center. Use the measurement Block to measure the four points on the Pallet, then rotate the B Axis 90° and repeat the process to find four new points. Repeat this process to find a total of 16 points, then record the measurements into a chart like the one below. ※ 1,2,3,4 : Table Direction : (Fixed Position) A,B,C,D : Pallet Direction (Position changes with Table Index) 2) Calculation ① Sum : Sum of 4 figures, each horizontally and vertically ② Average : Sum divided by 4 ③ Precision Calculation Pallet
ⓐ X Axis direction : The larger difference from between Averages 2,3 and Averages 1,4 ▪ Permitted Range : 0.012mm / 300mm
3
4
ⓑ Z Axis direction : The larger difference from between Averages 1,2 and Averages
C
D
B
A
3,4 ▪ Permitted Range : 0.012mm / 300mm ⓒ Run-Out : From A, B, C, and D, subtract the smallest figure from the largest figure ▪ Permitted Range : 0.010mm 1P A B C D Sum Avg.
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1
2
3
4
Su Avg. m
2
1 Spindle
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3) Adjustment Measure Pallet No. 1 and No. 2 at the same time. Compare and calculate to see which area should be adjusted. ① A,B,C,D : When the height distribution for Pallet No. 1 and No. 2 are similar, grind the Liner inside the Table Locating Pin. When they are different, pull out the liner from the Locating Bush under the Pallet and grind and adjust. ② 1,2,3,4 : The alignment can be corrected by grinding the X Axis L/M Guide Liner. ※ Adjusting the Table Locating Pins Liner, Pallet Locating Bush Liner ① Refer to“Parallelism of the top of the Pallet”and accurately measure the parallelism. ② Calculate the grinding amount of the Liner according to the measurement. ③ Loosen the Locating Pins or Locating Cup security Bolts. ④ Insert two M8 Bolts into the Tap holes of the Locating Pins or the Locating Cup Lift, and slightly tighten until the Liner can be removed.
Lift Bolts Position
Security Bolts
⑤ Pull out the Liner, grind the amount found in “②,”and reassemble. ⑥ Strongly tighten the Locating Pins or Locating Cup Security Bolts.
Liner
Table
⑦ Measure the parallelism again and repeat until a satisfactory figure is reached.
Liner
※ Adjusting the thickness of the Z Axis L/M
Security Bolts
Security Bolts
Guide ① Refer to “Parallelism of the top of the Pallet” to measure the accurate
Pallet
Liner
parallelism. ② Calculate the measured distance of the Pallet(300mm) and the distance of the two L/M Guide Sliders(약 450mm) to find the grinding amount of the Liner. ③ Remove the L/M Guide Slide Security Bolts and loosen the Z Axis Ball Screw Nut Security Bolts. ④ Insert a Screw-Jack between the Bed 109
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and Table, and lift up the Table until the Liner can be removed. ⑤ Pull out the Liner and grind the amount found in “②.” Reassemble. ⑥ When reassembling the Ball Screw Nut, send the Z Axis to its reference point, then tighten the security Bolts individually with the same strength. ⑦ Measure the parallelism repeatedly until a satisfactory figure is reached.
6.7 Index Table Division Perpendicularity 1) Measurement ① Lay a perpendicular ruler on the Pallet and move the X Axis to match the parallelism between the X Axis and the perpendicular ruler. ② Clamp so that the perpendicular ruler will not move during B Axis Index.
90˚ Index
③ Index the B Axis 90˚at a time. Measure the parallelism of the X Axis and find the largest figure. ▪ Permitted Range : 0.012mm / 300mm 2) Adjustment The degree division of the machine's Index Table is based on the Curvic Coupling, which is extremely precise. However, if there is a large margin of error despite accurate measurement, there is probably a foreign substance stuck in the Curvic Coupling inside the Table or a faulty part due to damage or wear. The parts must be replaced with new parts.
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6.8 Parallelism of the Edge Locator and Movement towards the X Axis 1) Measurement Install the Indicator onto the Spindle Head. Move the grinding side of the Edge Locator attached on the side of the Pallet in the X Axis direction and measure the greatest difference.
Edge Locator
▪ Maximum Amount : 0.010mm 2) Adjustment This area has been twisted when the B Axis has collided with something and the Curvic Coupling inside the Table has received shock. Refer to "Aligning the Table" and adjust accordingly. ※ T-Groove and Parallelism of Movement towards the X Axis (T-Groove Pallet) 1) Measurement Install the Indicator on the Spindle Head. Set a gauge on the Pallet T-Groove and measure while moving it towards the X
T-Groove
Axis to find the greatest difference.
Pallet
▪ Permitted Range : 0.010mm 2) Adjustment This area has been twisted when the B Axis has collided with something and the Curvic Coupling inside the Table has received shock. Refer to "Aligning the Table" and adjust accordingly. ※ Table Accuracy work
※If a large shock has been applied to the Table in the direction of rotation due to collision of tools, etc., the parallelism between the Edge Locator and the Removal Axis could have been twisted. This is due to shock to the Curving Coupling within the Table and may cause problems when coming into contact with tools. The Table must be disassembled and the Curvic Coupling must be realigned. This process requires the following preparation and precise work.
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※ Preparations (1) Crane or Chain Block that can lift at least 1 ton (positioned to lift from the center of the Table) (2) 2 each of M12mm, 16mm eye bolts (3) Rope (able to lift over 1 ton) that can hold the balance of machine parts (4) Gauge (Test Indicator, Magnetic Stand etc) that can measure the parallelism of the Edge Locator (5) L-Wrench Set and Pipe (6) Copper Hammer or Lead bundle (7) Appropriate amount of Grease (8) Tool for pulling out Pins (9) Basic tools needed for machine maintenance 1) Disassembling the Table ※ Preparation for disassembling the Table (1) Thoroughly clean the interior of the machine. Move X and Y Axes to their reference points. Lift out the Pallet from inside the machine or lift from the APC and rotate it 90 degrees. (2) Move the Z Axis to the center for convenience, and turn off the power.
① Disassemble the C50058253 Cap. ▪ 6-BB6×16, O-Ring : 1-G145
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Cap
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② Disassemble the C58051021B Pallet Base.
Security Bolt
▪ 12-BB10×65 ※ It is useful during assembly if the Pallet Base and Table Base are marked. ⓐ Remove the Pallet Base security Bolts (12-
Eye bolt
BB10×65/ZC10) from where the Cap was disassembled. ⓑ Remove the Set-Screw(2-BQ12×16) near the Pallet Base, insert eye bolts, tie a rope around this area and hang the rope on a crane. ⓒ Slowly and carefully lift up the Pallet Base. ※ Maintain balance, sometimes hitting the Pallet Base evenly with a hammer or a wooden baulk. ③ Adjusting the Curving Coupling assembled to the Table Base Body ⓐ Loosen the Curvic Coupling security
Curvic Coupling
Bolts(12-BB12×30). ⓑ Pull out the Curvic Coupling Positioning Pins(2-SPB13 ×40) to check for any problems. ⓒ If there are no problems with the Pins, reassemble. If there are problems, replace with new Pins and assemble after reaming into the Pin hole again. ⓓ Fasten the Curvic Coupling security Bolts(12-BB12×30) as strongly as possible. ④ Preparation for Adjusting the Curvic Coupling attached to the Table(Pallet Base) Body ⓐ Loosen the Curvic Coupling security Bolts(12-BB12×30). ⓑ Remove the Plug(2-FPS-S1/2) attached in the Curvic Coupling Positioning Pins(2TPB13×40) location, and use the appropriate tool to pull out the Taper Pins. ⓒ Tighten the Curvic Coupling security bolts about 1/3 force of the way each.
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2) Temporary Assembly of the Table (Pallet Base) Body ① Apply Grease evenly on the Table's inner O-Ring(2-G90) and the Table Base's outer Dust Seal to prevent O-ring damage during assembly. ② Lift up the Table (maintaining proper balance) and lower it onto the marked line made during disassembly. If the Table becomes caught in the Base, hit evenly over the surface with a piece of lead or copper hammer to direct it to the proper position. ③ Fasten the Table security Bolts(12BB12×65). ※ Verifying the proper positioning of the Table There is a Plug(FPS-S3/4) near the Table Base. If you remove this Plug and provide light, you can see the Coupling assembly position inside the Table through the Plug holes. ④Remove the Table's upper Plug (2-FPSS1/2) and loosen the 2-BB10×65.
2-Curvic Security Bolt Plug Curvic Assembly Confirmation
※ These Bolts are necessary for adjusting the Table accuracy. 3) Adjusting the Table accuracy ① Put in the power and Set the Indicator on the Edge Locator by attaching it to the Spindle as shown. ② Move the X Axis and measure the parallelism between the X Axis and the grinded section of the Edge Locator. ③ Turn off the oil pressure by pressing the emergency stop Switch. Use a hammer or wooden baulk to hit the end of the Pallet and move the Table towards the rotation direction, matching up the parallelism. ④ Reset the Machine Ready and measure the parallelism. Repeat the above process until the parallelism is within the optimal measure. 114
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※ Optimal Measure 0.005mm/Entire Area ⑤ When the optimal parallelism is achieved, tighten the loosened 2-BB10×65. 4) Setting the Table Accuracy ① Disassemble the Table, referring to the "1) Disassembling the Table” section above. ② Individually fasten the Curvic Coupling security Bolts(12-BB12×30) diagonally using even strength, and tighten as strongly as possible. ③ Even out the Taper Pins location with 13mm taper reamer, then push in new pins. ▪ 2-TPB13×40 ④ Assemble the Plug(FPS-S3/4) in the place where the Taper Pins are attached (the Plug should not protrude more than the Coupling). 5) Assembling the Table
Cap
① When the Curvic Coupling is secure, blow out all foreign substances with air from both the upper and lower Curvic Coupling. Assemble the Table, referring to the "2) Table(Pallet Base) Body Temporary Assembly” above. ② Referring to the “3) Adjusting the Table Accuracy” above, measure the parallelism between the X Axis and the grinded section of the Edge Locator. If the measurement falls within the margin, complete final assembly. ⓐ Assemble the C50058253 Cap. ▪ 6-BB6X16, O-Ring : 1-G145 ⓑ Wrap the various unraveled Plugs with Tefron and assemble.
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6.9 Distance Between the Edge Locator Reference plane and the Rotation Central Line 1) Measurement ※ This area should be measured using
X Axis
customized tools, but since it is difficult to find such tools ,another method will be used. This method involves adding up the machine’s position accuracy with Back-lash margin, and is not accurate. It should only be used for reference (the measurement
“0” Setting
can also be done using the Z Axis). ① Send to X150. B90. in MDI mode. ② Install an indicator on the spindle head and mark the center of the edge locator with a pen. Set the Indicator to “0.” Setting. ③ Command G91 Y100. in MDI mode. ④ Command G90 X650. B180. ⑤ Command G91 Y－100. (Slowly
X Axis
approach the point marked with the Pen) ⑥ Half of the The figure being found above is measurement. ※ Measure separately the long and short measures of Pallet #1 and Pallet #2. ▪ Permitted Range : 0.010mm 2) Adjustment Disassemble the Edge Locator. When the measurement is “－,” grind the tool attachment side, and when the measurement is “＋”grind the Pallet attachment side according to the measurement.
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180˚ Index
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6.10 Repetition Position Precision of Pallet Exchange and Reciprocal Difference 1) Measurement ① Send the X, Y, Z Axes to the center of the Axis Stroke (X400. Y350. Z375.). ② Install three indicators on the Spindle Head. Set the X, Z Axis directions on the Edge Locator and the Y Axis directions on top of the Pallet. ③ Create and execute the following program. G91 G28 Y0; G91 G28 X0 Z0; M60; G90 G00 X400. Z375.; Y350.; M01; M99; ※ When the Indicator hits the Pallet at Y280.; above, adjust the override to slow it down and reduce the error margin caused
Z
by shock. ④ Measure the X, Y, Z Axes simultaneously, and measure P#1, p#2 at least four times
X
Y
each to find the greatest difference. ▪ Permitted Range : 0.020mm 2) Adjustment The Table Locator Pins or Cup are most likely to be faulty. Clean them again and attempt to measure again. If the problem is still existing, replace with new parts.
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HP 5100
HP51MTE87
6.11 Z Axis Movement and Parallelism with the Spindle Central Line 1) Measurement Insert the Test Bar into the Spindle and move the Z Axis from the entrance to
X-Z면
300 mm away to measure parallelism. Find the greatest figure.
Y-Z면
※ Measure the Test-Bar Run-out and stop the Spindle in the middle of the found measurement, and find the reading. ▪ Permitted Range : Y－Z Side 0.012mm/300mm X－Z Side 0.012mm/300mm 2) Adjustment Adjust the Y Axis L/M Guide Liner. ※ Adjusting the Y Axis L/M Guide Liner
security bolt
Thickness ① Refer to "Z Axis Movement and Parallelism with the Spindle Central Line" to accurately measure the parallelism.
Liner
② Using the measured distance and calculating the four L/M Guide Sliders' distances, calculate the grinding amount of the Liner. ③ Remove the L/M Guide Slider security Bolts and loosen the Y Axis Ball Screw Nut security Bolts. ④ Pull out the Liner, grind the amount found in“②,”and readjust. ⑤ When reassembling the Ball Screw Nut, move the Y Axis to "0" and then individually tighten the security Bolts, using the same amount of strength for each. ⑥ Measure the parallelism again and repeat until a satisfactory figure is reached.
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HP 5100
HP51MTE87
6.12 Spindle Run-Out 1) Measure Insert the Test Bar into the Spindle. Set the indicator at the entrance and at 300 mm from the entrance, and rotate the Spindle at low speed to measure shaking. Find the greatest amount of shaking. ▪ Permitted Range : At the entrance :0.005mm From 300 mm: 0.012mm 2) Adjustment It is probable that the side of the Spindle Taper has been dented. Pull out the Pull Stud using a Test Bar or a new tool, and thinly apply red lead or red seal-ink on the Taper. Use sandpaper to get rid of the dents caused by Taper sides rubbing against each other. ※ Do not use a grinder. When the Taper is severely damaged, you must regrind the Spindle.
6.13 Spindle Movement towards the Z Axis 1) Measurement
Steel Ball
Insert the Test Bar into the Spindle. Attach the Steel Ball to the center of the end of the Test Bar. Set the Indicator against the highest point of the X, Y Axes and rotate the Spindle to find the greatest amount of shaking. ▪ Permitted Range : 0.003mm 2) Adjustment If the Spindle moves towards the Z Axis, it is a problem with the Spindle Main Bearing. Replace the bearing.
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HP 5100
HP51MTE87
6.14 Leveling the Machine Leveling the machine has a direct influence on the machine’s accuracy and is very important. It is recommended to accompany this process with the machine accuracy work. ※ Preparations. ▪ two Perpendicular Levels(150×150 ) ▪ Perpendicular Ruler (Rectangular 350×350) ▪ Test-Indicator(0.002mm) ▪ Magnetic Stand ▪ Test-Bar ▪ Tools for Leveling (Spaner : 30mm, 50mm, 58mm) ▪ Pipe(1", 1.5m-long) Anchor Bolts(BA20) Washer(ZP20) Leveling Bolts Nut Bed 80mm이상
Leveling Plate Anchor
(With Foundation)
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(Without Foundation)
HP 5100
HP51MTE87
1) Move to the X400. Y700. Z375. position. 2) Clean the top of the Pallet and set the center of the Pallet with the center of the Level to "Set the Original Level".
※ Setting the Level Reference point (1) Place the Level at the center of the Pallet and read the accurate measurement on the side of the Level water droplets. (2) Rotate the Level 180˚ in the same spot and read the measurement of the water droplets in the same direction. (3) Turn the Level Adjustment Screw to move halfway between the first and second water droplet measurements (halfway between the two directions). (4) Repeat steps (1)∼(3) so that the water droplets come in the same location even after being rotated to either side. ※ Reading the Level(example)
“-”
“+”dirc
(Location of the Right Water drop’s Edge ＋ Left Water drop’s Edge) ÷ 2 ＝ Level Measurement (-50 + -40) ÷ 2 ＝ -45 ※ The above level’s left side is 45μ/m higher 3) Send the Z Axis to Z0, Z375., Z750., locations while adjusting the Level Bolt to approximately set the Level. (Set both X,Z-Directions at about 0.04/m.) ▪ It is more convenient to set up a Program before Leveling. Example) O 001; G90 G00 Z0.; M01; Z375.; M01; Z750.; M01; Z375.;
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HP 5100
HP51MTE87
M01; M99; ※ Cautions during Leveling work ① Make sure that the pressure with which the Level Bolt hits the Level Plate is the same overall. ▪ If any one Level Bolt touches the level Plate with lower or higher pressure, the entire Level will be thrown off balance. ② Make sure to stop Level Bolts in a locking direction. ▪ If possible, level while pulling up the machine. 4) When the Z Axis Level has been approximately set, move the Z Axis to the Z375. location. To begin work on the X Axis, use a Magnet to flatten the level all over the Spindle Head, and set the Level at “0.” 5) Through the same process as the Z Axis, set the X Axis level by moving the X Axis through the X0. X400. X800. locations. ※ When working on the X Axis Level, keep in mind that the Z Axis Level may change. (Keep a Level towards the X Axis on the Table and check periodically.) ▪ It is more convenient to set up a Program before Leveling. Example) o 002; G90 G00 X0.; M01; X400.; M01; X800.; M01; X400.; M01; M99; 6) As explained above, repeat the Level process for the X and Z Axes and record the Levels so that the overall levels do not differ by more 0.02/m. ※ Recording the Level Values ① Format of recording the Levels (example) Z-axis
X-direction
10
20
Z-direction
X-axis
Z-direction
15
10
X-direction :20 Z-direction : 15
30 20
20
30
30
(With Foundation)
※ The method above is the standard way of reading the absolute level. When 122
HP 5100
HP51MTE87 installing the machine center, straightness must be read. Therefore, it is easier to read only one side and then to calculate by comparing the three measurement areas. ▪ In the case of the chart above, the right side is 30μ higher. Therefore, there is an arrow pointing to the right with the number 30. Other areas are measured and recorded in the same way, and the Level amount is found by subtracting the smallest number from the largest number. ② When reading the Level scale, make sure that your eye is perpendicular to the Level. ※ Since there is distance between the Level scale and the waterdrops, reading from different angles can yield different readings.
7) Lock the Anchor Bolts, beginning with the X Axis Anchor Bolts. (At this point ,the Level Accuracy should be about what is reached when the above alignment process is complete.) ※ Locking the Anchor Bolts ① Lock the level bolts which had been locked with the same strength about ¼ turn(90˚) tighter, then lock all bolts with moderate strength (begin with the X Axis) ② Measure the Level Accuracy again and use the Level Bolts to further adjust the alignment. ※ If the bolts were locked with similar strength at first, there won't be a large need for adjustment. 8) Tighten the Z Axis Anchor Bolts in the same manner. 9) Measure the Z and X Axis Levels again. Lock the Anchor Bolts tightly and lock the Level Bolts' Nut, then measure the Z and X Axis Levels again. ※ Since the machining center(milling machine)'s Anchor Bolts simply hold the foundation and the Level Bolts, the Level Bolts' backlash creates a slight gap with the machine's main body. Therefore, the Anchor Bolts cannot completely do it’s anchor role. When the Level Bolts' Nut is locked, the Level Bolts and the main body are held together, so it is likely that the anchor bolts hold the machine main body.
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