Colibri Sander BOH 80 2.1 D 60 User Manual
Manual Book:
BOH 80 2.1 D 60
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In most respects aerostatic bearings are ideally suited for use in high-speed machines. Their low
friction provides high mechanical efficiency and minimizes bearing heating problems.
They are quiet and smooth running and do not add to sound and vibration levels of the machine in
the way that high-speed ball bearing do.
Applications
One of the most important fields of application of aerostatic bearings is undoubtedly on machine tools
where the range of machine tool application is very wide.
lmost all of the benefits result from three properties of aerostatic bearings: low friction, precise axis
definition, and the absence of wear. In comparison with spindles with ball or roller bearings, the lower
level of vibration of aerostatic bearings is an important advantage. This is particularly true in relation
to the production of good work piece geometry and surface finish, and in ensuring long life of the
cutting tool, drill or grinding wheel.
erostatic bearings have been employed in machines driven by most types of electric motors and
most types of turbines. They have also been employed in a wide range of machine tool spindles
driven by various types of belts and flexible couplings. In all these cases the driving torque is evenly
and smoothly applied, excepting the case of driving by means of a belt, the drive does not apply large
loads to the bearings. Aerostatic bearings are most successful when operating under these
conditions. They are much less likely to be successfully applied to machines with pulsating drives,
which impose large internal loads on the bearings.
Advantages
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CONTENTS
1. Fundamental Safety Instructions. 3
2. Warranty notice. 5
3. Attention – Daly Check Before starting the spindle 6
4. System general description. 7
5. Installing the spindle. 8
6. Specification for High – Speed Air Spindle. 9
7. Mechanical Constant. 10
8. Electrical Motor Specification. 11
9. Brushless DC Motor 12
10. Diagrams:
a) Torque & Power Vs. Rotation Speed 13
b) Final velocity Vs. Torque & Acceleration Time & External Inertia 13
c) Air Flow Vs. Air Pressure. 14
d) Inlet Air Flow Vs. Rotation Speed. 14
e) Water Flow Vs. Water Pressure. 14
f) Motors Temperature Vs. Rotation Speed & Cooling System 15
g) Motor Temperature Vs. Water Pressure 15
h) The Spindle Thermal Behavior 15
i) Shaft Extension Vs. Thermistor Resistance 15
j) Shaft Extension Vs. Motor Temp. 15
k) Radial Stiffness Vs. Air Pressure. 16
l) Axial Stiffness Vs. Air Pressure. 16
m) Radial Load Capacity Vs. Air Pressure. 16
n) Axial Load Capacity Vs. Air Pressure. 16
o) No Load Deceleration. 16
p) Mechanical Friction Losses. 16
q) Voltage Constant (BEMF). 17
r) Current Vs. Rotation Speed. 17
s) Torque Vs. Current. 17
t) Power Vs. Current & Rotation Speed. 17
u) Vibration Amplitude Vs. Rotation Speed. 17
v) Vibration Speed Vs. Rotation Speed. 17
w) Noise Level 18
x) Motor temperature Vs. Rotation Speed & Water Temperature 18
y) Torque Vs. Air Pressure 19
z) Load Vs. Axis Length & Air Pressure 19
aa) Torque Vs. Air Pressure 19
bb) Load Vs. Length & Air Pressure 19
cc) Brushes Pressure Vs. Length 20
dd) Brushes Wear Vs. Pressure 20
ee) Brushes Wear Vs. Length 20
ff) Brushes Lifetime Vs. Length 20
11. Raw Materials Data. 21
12. Spindle Modes. 22
13. Spindle Balancing. 23
14. Electrical System. 27
15. Electrical Connections. 28
16. Thermistor – 203GT-1. 29
17. Adapter for Power Cable and Signal Cable. 30
18. Remote Control. 30
19. Description of a Spindle Testing. 31
20. Cooling Water Sealing & Flow Test Circuit. 32
21. Flow Test Circuit. 32
22. Sensor Pressure Tuning. 32
27.Failure, Cause, Prevention. 33
28.Appendix
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FUNDAMENTAL SAFETY INSTRUCTIONS
1. Basic operation and designated use of the machine.
1.1 The machine has been built in accordance with state of the art standards and recognized safety rules.
Nevertheless, its use may constitute a risk to life and limb of the user and of the third parties, or cause
damage to the machine and to other material property.
1.2 The machine must only be used in technically perfect conditions in accordance with its designated
use and the instructions set out in the operation manual. Only safety-conscious persons who are fully
aware of the risks involved in operation the machine should operate it. Any functional disorders,
especially those affecting the safety the safety of the machine, should therefore be rectified
immediately.
1.3 The machine is designed exclusively for drilling, grinding and milling operations. Using the machine
for purposes other than those mentioned above is considered contrary to its designated use. The
manufacturer cannot be held liable for any damage resulting from such use. The risk of such misuse
lies entirely with the user. Operating the machine within the limits of its designated use also involves
observing the instructors set out in the operation manual and complying with the inspection and
maintenance directives.
2. Organizational measures.
2.1 The operating instructions must always be at hand at the place of use of the machine.
2.2 In addition to the operating instructors, observe and instruct the user in all other generally applicable
legal and other mandatory regulations relevant to accident prevention and environmental protection.
Those compulsory regulations may also deal with the handling of hazardous substances, issuing
and/of wearing personal protective equipment.
2.3 The operations instructions must be supplemented by instructions covering the duties involved in
supervising and notifying special organizations, working sequences or the personal entrust with the
work.
2.4 Personal entrust with the work on the machine must have read the operating instructions and in
particular the chapter on safety before beginning work. Reading the instructions after work is too late.
This applies especially to persons working only occasionally on the machine e.g. during setting up or
maintenance.
2.5 Check whether personal is carrying out the work in compliance with the operation instructions and
paying attention to risks and safety factors.
2.6 For reasons of security, long hair must be tied back or otherwise secured, garment must be close
fitting and no jewelry, such as ring, may be worn. Injury must result from being caught up in the
machinery or from rings catching on moving parts.
2.7 Use protective equipment whenever required by the circumstances or by law.
2.8 Observe all safety instructions and wearing attached to the machine.
2.9 See to it that safety instructions and wearing attached to the machine are always complete and
perfectly legible.
2.10 In the event of safety-relevant modifications or changes in the behavior of the machine during
operation, stop the machine immediately and report the malfunction to the competent person.
2.11 Never make any modifications, additions or conversions, which might affect safety without the
suppliers’ approval. This also applies to the installation and adjustments of safety devices and valves.
2.12 Spare parts may comply with the technical requirements specified by the manufacturer. Spare parts
from original equipment manufacturers can be rely to do so.
2.13 Never modify the software of programmable control systems.
2.14 Adhere to prescribe intervals or those specified in the operating instructions for routine checks and
inspections.
2.15 For the execution of maintenance work, tools and workshop equipment adapted to the task on hand
are absolutely indispensable.
2.16 A portable fire extinguisher must be placed within immediate reach.
2.17 Observe all fire warning and fire-fighting.
3. Selection and qualification of personal-basic responsibilities
3.1 Any work or and with the machine be executed by reliable personnel only. Statutory minimum age
limits must be observed.
3.2 Employ only trained or instructed stuff and set out clearly the individual responsibility of the personnel
of operation, set-up, maintenance and repair.
3.3 Make sure that only authorized personnel work on or with the machine.
3.4 Define the machine operators’ responsibilities – giving the operator the authority to refuse
instructions by third parties that are contrary to safety.
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3.5 Do not allow persons to be trained or instructed or persons taking part in a general training course to
work on or with the machine without being permanently supervised by an experienced person.
3.6 Work on the electrical system and equipment of the machine must be carried out only by a skilled
electrician or by instructed person under the supervision and guidance of a skilled electrician and in
accordance with electrical engineering rules and regulations.
4. Safety instructions governing standard operation
4.1 Avoid any operational mode that might be prejudicial to safety.
4.2 Take the necessary precautions to ensure that the machine is used only when in a safe and reliable
state.
4.3 Operate the machine only if all protective and safety oriented devices, such as removable safety
devices, emergency shut-off equipment, sound proofing elements and exhausts, are in place and
fully functional.
4.4 Check the machine at least once per working shift for obvious damaged and defects. Report any
changes (including changes in the machine’s working behavior) to the competent person
immediately. If necessary stop the machine immediately and lock it.
4.5 In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified
immediately.
4.6 During start-up and shutdown procedures, always watch the indicators in accordance with the
operating instructions.
4.7 Before starting up or setting the machine in motion, make sure that nobody is in risk.
4.8 Never switch off or remove suction and ventilation devices when the machine is in operation.
5. Safety instructions governing special work in conjunction with utilization of the machine and
maintenance and repair during operation; disposal and consumable parts.
5.1 Observe the adjustment, maintenance and inspection activities and intervals set out in the operation
instructions, including information on the replacement if parts and equipment. Skilled personnel may
execute those activities only.
5.2 Brief operation personnel before beginning special operations and maintenance wok, and appoint a
person to supervise the activities.
5.3 If any work concerning the operation, conversing or adjustment of the machine and its safety oriented
devises or any work related to maintenance, inspection and repair always observe the start-up and
shutdown procedures set out in the operating and the information on maintenance work.
5.4 Ensure that the maintenance area is adequately secured.
5.5 If the machine is completely shut-down for maintenance and repair work, it must be secured against
inadvertent starting by:
- Locking the principal control elements and/or
- Attaching the “warning signal” sign to the main switch.
5.6 To avoid the risk of accidents, individual parts and large assemblies being moved for replacement
purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically
perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under
suspended loads.
5.7 For carrying out overhead assembly work, always use specially designed or otherwise safety-oriented
ladders and working platforms. Never use machine parts as a climbing aid. Wear a safety harness
when carrying out maintenance work at greater heights.
5.8 Keep all hardens, steps, handrails, platforms landing and ladders from dirt.
5.9 Clean the machine especially connections and threaded unions, of any trace of oil, fuel, or
preservative before carrying out maintenance. Never use aggressive detergents. Use lint-free
cleaning rags.
5.10 Before cleaning the machine, cove or tape all openings, which for safety and functional rezones, must
be protected against water, steam, or detergent penetration. Special care must be taken with electric
motors and switchboard cabinets.
5.11 Always tighten any screwed connections that have been loosened during maintenance work.
5.12 Any safety devices removed for set-up, maintenance or repair purpose must be ratified and checked
immediately upon completion of the maintenance work.
5.13 Ensure that all consumable and replaced parts are disposed safely and with minimum environmental
impact.
6. Warning of special dangers:
6.1 Use only original fuses with the specified current rating. Switch off the machine immediately if trouble
occurs in the electrical systems.
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6.2 Work on the electrical system or equipment may only be carried out by a skilled electrician himself or
by specially instructed personnel under the control and supervision of such electrician and in
accordance with the applicable electrical engineering rules.
6.3 If provided for in the regulations, the power supply to parts of machine, on which inspection,
maintenance and repair work has to be carried out, must be cut off. Before starting any work, check
the de-energized parts for the presents of power and ground or short-circuit in addition to insulating
adjacent live parts and elements.
6.4 The electrical equipment of machine is to be inspected and checked at regular intervals. Defects such
as loose connectors or scorched cable must be rectified immediately.
6.5 Necessary work on live parts and elements must be carried out only in the presence of a second
whom can cut off the power supply in case of danger by actuating the emergency shut-off or main
power switch. Secure the working area with a red-and-white safety tape and a warning sign. Use
insulated tools only.
6.6 Check all lines, hose and screwed connections regularly for leaks and obvious damage. Repair
damage immediately.
6.7 Depress all system sections and pressure pipes to be removed in accordance with the specific
instructions for the unit concerned before carrying out any repair work.
6.8 Compressed air lines must be laid and fitted promptly. Ensure the no connections are interchanged.
The fittings, length and quality of the hoses must comply with the technical requirements.
7. Mobile machinery and equipment
7.1 Cut off the external power supply of the machine even if only minor changes of place are envisage.
Properly reconnect the machine to the supply mains before restarting.
7.2 For restarting process only in accordance with the operating instructions.
We warrantee this spindle to be free of material and workshop defects. This warrantee is conditional
upon proper use in the applications of which this spindle is designed to. Warrantee is void if damaged caused
due to improper use, installation, negligence, accident, inadequate maintenance to the spindle or the machine
in which it is installed. This warrant is also void if customer did not follow the complete manual and caused
damage.
In any case of damage, failure analysis will be perform by Plasel to determine the cause of the failure.
Warrant is void if damaged caused by inadequate machine maintenance or improper use ex. Leaky valves, Zaxis leakage wear, contained air supply, lower/higher air presser, inadequate vacuum, using the spindle to
work on material that is too hard, drilling into anything other then the right material.
WARRANTY NOTICE
5
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DAILY CHECK BEFORE OPERATING THE SPINDLE
1. For first time installation, look at “Installing the spindle”
paragraph.
2. Check air supply (5-6 bar.)
3.
Check water supply (4-5 bar.) Check water supply (4-5 bar.)
4. Check ventilation exits.
5. Check for free movement of the shaft.
6. The spindle must be securely clamped to the machine and clea
from any distraction.
7. Check for electric connections and command (community
grounding).
8. Start the spindle.
ATTENTION
6
General Description
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INSTALLING THE SPINDLE
1. Remove the spindle from its package.
2. Follow the machine’s safety and installation instructions.
3. Clamp the spindle to the machine - using 5 screws (M6 or 1\4” UNF socked head – minimal
length 15 mm).
4. Remove plugs from water, air and brushes ventilation connections (5).
5. Connect inlet air pipe Ø6 mm to “AIR IN” (AI).
6. Connect outlet air pipe Ø5 mm to “AIR OUT” (AO).
7. Connect inlet water pipe Ø8 mm to “WATER IN” (WI).
8. Connect outlet water pipe Ø8 mm to “WATER OUT” (WO).
9. Connect
10. Remove black plastic nut from the end of the shaft.
Ø 4 mm pipe to brushes ventilation hole (BV).
11. Turn air supply on, spin the shaft by hand and make sure that the shaft is rotating freely.
12. Check for air pressure ( 4.5-5.5 [bar].)
13. Check for airflow ( 35-55 [lpm].)
14. Connect signal cable to the driver.
15. Connect power cable to the driver
16. Connect brushes cable to the spindle.
17. Open water pressure on to derivate water leaks.
18. Check for water pressure (4-5 bar)
19. Check for water flow (2.5 – 3.5 [lpm])
20. Turn the driver on and spin the spindle. Start at low speed (5000 rpm for 5 minutes) and slowly
increase up to 60 Krpm.
21. Check for motor current at 5000 rpm, less 0.5 Amp.
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SPECIFICATION FOR HIGH-SPEED AIR SPINDLE
Rotation speed – 2K ~ 75K [rpm
Air supply
]
Pressure :5~7 [bar]
Flow rate :45-55 [lpm]
Filtering :0.01 [µm]
Dew point :lower then 15 [
C]
Oil residue :lower then 0.1 [ppm]
PCW (Pure Clean Water – pure H2O)
Coolant Water
Pressure (max) : 5 [bar] (72.5 psi)
Flow rate (min) :1-3.5 [lpm]
Temperature :20 ~ 25 [oC]
Variation range :within 1 [oC]
Static run-out of the rotor
Radial direct.(max) :0.35 [µm]
Thrust direct (max) :0.35 [µm]
Dynamic run-out of the rotor
Radial direct(max) :1 [µm]
Thrust direct.(max) :1 [µm]
Radial direct. Fluctuation between peaks :0.3 [µm]
Thrust direct. Fluctuation between peaks :0.3 [µm]
Rigidity of the rotor
Radial direct. :14 [N/µm]
Thrust direct. :9 [N/µm]
Load capacity
Radial direct. :60 [N]
Thrust direct. :100 [N]
General
Shaft Axial Extension @ Tm = 40 [oC] :4 [µm]
Spindle Weight :6.7 [Kg]
Rotor Inertia :6.5E-5 [Kg*m2]
Noise level 0 up to 10 Krpm (max) :70 [db a]
Resistance between shaft & frame :1 [MΩ]
Balance:G0.4 @ ISO 1940 :0.03 [gmm]
CE standard : corresponding
Floating Point : 2 [bar]
Cables` length: Power cable :1.25 [m]
Signal cable : 1.3 [m]
Brushes cable : 1.15 [m]
Brushes life-time@ 30-40 Krpm : 2500 [hr]
Mechanical Coefficient
Air Flow Coefficient :A
Water Flow Coefficient :W
Still Air Cooling Efficiently :C
Air Flow Cooling Efficiently :C
Shaft Extension Coefficient :E
Mechanical Friction Coefficient :F
Stiffness & Load Coefficient :S
Thermal Behavior Coefficient :B
Radial Stiffness Coefficient :S
Axial Stiffness Coefficient :S
Radial Load Coefficient :L
Axial Load Coefficient :L
= 38.14
f
= 2.84
f
= 28.8
s
= 54
a
= 0.055
S
= 0.043
L
= 0.417
L
= 3.6-4
t
= 16.487
r
= 10.06
a
= 71.54
r
= 91.84
a
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MECHANICAL COEFFICIENT
Af Air Flow Coefficient
A
= 43*e
f
W
W
Water Flow Coefficient
f
= 0.9+1.4*In {Pw} @ Pw = 4 [bar]
f
C
C
Still Air Cooling Efficiency:(Water Flow Cooling/Still Air Cooling)@60 Krpm
s
=80*e
s
-0.002*Vsp
-0.017*Vsp
@ Vsp = 60 [Krpm]
Ca Air Flow Cooling Efficiency: (Water Flow Cooling/Air Flow Cooling)@60Krpm
C
= 82.3*e
a
Bt Thermal Behavior Coefficient
B
= [(Tr-Tf)2 + (Ts-Tf)2 + (Ts-Tr)2 ]
t
-0.007*Vsp
-1/2
@ Tm = 100 [Cº]
Es Shaft Extension Coefficient
Es = (0.236*Tm – 5.426)-1 @ Tm = 100 [cº]
Sr Radial Stiffness Coefficient
Sr = 13.642*In(Ps)-7.956 @ Ps=6
Sa Axial Stiffness Coefficient
Sa = 6.425*In(Ps)-1.454 @ Ps=6
Lr Radial Load Coefficient
Lr = 64.39*In(Ps)-43.832 @ Ps=6
La Axial Load Coefficient
La = 67.664*In(Ps)-29.4 @ Ps=6
Fl Mechanical Friction Coefficient
Fl = (6.5*10-3*Vsp2)-1 @ V = 60 Krpm
Sl Stiffness & Load Coefficient
Sl = 7*10-4[4(Sr+Sa)+3(Lr+La)] Sl = 0.417
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