sauter BA 1130 User Manual

2012-01-24

Operating Instructions

BA 1130 en

Disc-Type Tool Turret

0.5.473.520

The present manual is part of the product.

• The manual should be kept in an easily accessible place during the product’s lifetime.

• The manual should be passed on to the next owner /user of the product.

• Make sure that any possible supplement received is duly added to the manual.

Manual Translation

Type plate on turret housing

1 Classification number (series, size)

2 Identification number

3 Order number

BA 1130 en

Classification number

Identification number

(series, size)

0.5.473.520

089 632 115 785 103 012 120 362 103 292 125 365 106 302 125 544 107 198 128 037 107 468 129 602 109 332 134 263 110 660 134 969 111 092 138 083 111 272 138 420 112 722 142 499 112 862 143 182 113 290 143 370 114 703 115 702

Table of contents

1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Use within specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Required skills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 Notes on product-specific risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Designation of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1 Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.3 Possible faults and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.1 Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.2 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.3 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.4 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.5 Aligning the tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.6 Adjusting the angular encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.7 Replacing the angular encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.8 Proximity switch S7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.9 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.10 Cooling lubricant valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Basis-BA 2012-01-19

BA 1130 3

Table of contents

Appendix

EP-870

Wiring diagram Disk-type tool turret

EP-855

Wiring diagram Tool drive

SK-919

Diagram of functions Disk-type tool turret

SK-920

Diagram of functions Disk-type tool turret

SK-940

Diagram of functions Tool drive

Contact/Order information

4 BA 1130

1 Safety notes

The turret corresponds to the state of the art and the recognized technical safety rules. Nevertheless hazards and risks can occur.

1.1 Use within specifications

➣ Install and operate turret only in machines complying with

the relevant regulations for workspace protection.

➣ Operate turret only in perfect condition and in compliance

with the Operating Instructions.

1.2 Required skills

Safe ty n o tes

• Work may only be performed on the turret by qualified staff. These are persons who are able to identify risks and to prevent possible hazards on the basis of their special training and their experience (IEC 60 201-1).

• All work on the electrical system is to be carried out by a qualified electrical engineer only.

• Only trained and competent personnel may work on the turret; this personnel must have been instructed in accordance with the Operating Instructions and directly on the tu rr e t.

1.3 Notes on product-specific risks

Setting tasks require a 24V DC power supply.

Clearing required prior to any work:

➣ Switch the machine off. ➣ Depressurize turret.

BA 1130 5

Safe ty note s

WARNING

In the event of a fault or a collision, unexpected rotation of the tool disk is possible. Injury hazard.

CAUTION

Do not attempt any further switching operati ons, if the turret is damaged, as otherwise considerable consequential damage may be caused.

➣ Call SAUTER Service.

CAUTION

Functional faults may be caused by an ingress of chips and contamination.

➣ Close open tool locations and cooling lubricant bores by

means of suitable closing plugs.

For manual operation, turn the motor shaft with the help of a hexagonal pin wrench, complete with T-grip.

WARNING

A reversal of the moment of the motor results in the accelerat io n of the moto r sh aft . The he x ago nal pin wr e nc h may thus be unexpectedly accelerated. Therefore, in order to avoid the ejection of the hex agonal pin wrench and resulting injuries, firmly grip the hexagonal pin wrench.

1.4 Disposal

➣ Comply with all national and regional disposal regulations

and laws.

6 BA 1130

2 Product description

2.1 Designation of parts

Product de s cr ipt ion

Design ation of parts

1 Locating disk 2 Tool drive: gear housing 3 Tool drive motor

4 Covering hood for electric components 5 Turret housing

1) not included in scope of delivery

BA 1130 7

Product de s cr ipt ion Designation of parts

6 Solenoid 7 Terminal box

(tool drive motor)

8 Flange plate

(tool drive motor)

9 Turret motor 10 Electric supply for turret 11 Angular encoder

12 Proximity switch S7

“Check pre-indexation”

13 Cooling lubricant

cartridge

14 Proximity switch S11

“Tool drive disengaged”

15 Proximity switch S10

“Tool drive engaged” 16 Solenoid 17 Tool drive coupling

8 BA 1130

Product de s cr ipt ion

Technical data 0.5.473.520

2.2 Technical data

Number of indexing positions 8 or 12 or 16

Perm. tangential torque

Nm 3,000 (turret locked) at calculated safety

Perm. mass moment of inertia of tool disk,

kgm

1.3

1.8 – 7.5

tool holders, and tools Perm. unbalance (load moment)

Nm 63 caused by tool holders and tools

Indexing times Theoretical cycle time

(unlock/turn/lock)

41 α+

----------------

× 017,× 01,+

at rotating angle α [degrees]

Gear ratio i see turret type plate

Motor speed n rpm see motor rating plate

Perm. indexing frequency min

-1

10 – 5.5

Operating voltage/m ains frequ ency see motor rating plate

Degree of protection IP 65

Turret mass

kg approx. 70 (wit h o ut tool di s k)

Perm. ambient temperature range °C

°F

Operating pressure for cooling lubricant

+10 ... +40 +50 ... + 104

Cooling lubricant valve – standard version constant supply externally switched supply

Medium pressure valve (option)

1) The perm. loads refer to processing without load shocks. Whenever processing is subject to intermittent cuts , shocks or impacts, a significa ntly reduction in the values needs to be taken into account.

2) De pending on gea r rat io an d ma in s f re qu e n cy

3) In order to achieve an extended service life of the cooling lubricant valve, it is advisable to filter the cooling lubricant by ≤ 100µm. Post-connected loads (spindle units with internal coolin g lubricant guide a.o.) may require a higher degree of filter fineness. Note and comply with the manufacturer’s instructions!

bar bar

bar

14 25

BA 1130 9

Product de s cr ipt ion Technical data 0.5.473.520

Tool drive

Mass (without any motor) kg

Gear ratio

Perm. speed

Max. perm. torque

on tool drive coupling n

2) 3)

perm

approx. 40

41/ 41 41/ 31 41 /27 41/21

rpm 4000

Nm 32

on tool drive coupling

Transferable power

perm

Suitable for spindle units coupling profile 17 × 14 DIN 5482

1) Th e da t a st ate d he re may dif fer on sp ec ia l versions.

2) M

3) The permissible torque can be utilized for non-pulse machining operations.

is the pe rmissible peak load for the gears.

perm

The torque must be limited on the motor freque ncy converter to the va lue indicated, while adhering to the gear ratio involved! The us eful power data depend on the performa nce characteristic curve of the motor type used.

For strongly pulsed machining operations - e.g. inserted tooth milling cutters and others only a significantly reduce d drive torque should be applied to protect the gears again s t any overloads.

10 BA 1130

3 Manual mode

In manual mode, the mechanical functions of the disk-type tool turret will be checked:

• following initial assembly to the machine

• during troubleshooting

• after a renewed setup following fault conditions

Clearing required prior to any work:

➣ Switch the machine off. ➣ Depressurize turret.

1. Undo fixing screws of covering hood, withdraw covering hood to rear. If necessary, use push-off screw.

Manual mode

2. Remove screw plug on motor housing.

Unlock turret

3. Use a hexagonal pin wrench, complete wi t h T-gr ip, to rotate the moto r sh af t. ➪ If the disk-type tool turret is locked, the locating disk (or

tool disk) does not co-rotate; the centre position of the lock can be felt.

BA 1130 11

Manual mode

WARNING

4. Keep the same direction of rotation, continue to rotate. ➪ The disk-type tool turret unlocks; a reversal of the moment

on the motor shaft can be felt.

Rotate tool disk

5. Keep direction of rotation, continue to rotate disk until loca ting dis k (o r tool dis k) starts to tur n as we ll.

6. Keep direction of rotation, continue to rotate disk until locati n g dis k (o r tool disk ) has re ac h ed th e po s iti o n re qu i r ed , then pre s s in the keep er by mean s of a scr ewd ri ver.

➪ The preindexing bolt engages into a hole. ➪ The tool disk c annot be rotated any further.

12 BA 1130

Manual mode

Lock turret

7. Reverse direction of rotation on the motor shaft whilst simultaneously pressing in keeper. ➪ The disk-type tool turret locks.

The lock resis tance can be felt when rotation is conti nued. The locking process ends, if the centre position of the lock can be felt.

On completion of setup or maintenance work:

8. Screw in plug an d fit c over ing hoo d. Note po siti o n of cables in order to avoid any pinc hin g of the same.

Lock turret in position 1

IMPORTANT

For some setup and maintenance work the disk-type tool turret has to be locked in position 1.

Precondition

• Numeral 1 of the locating disk has reached its 12 o’clock position relative to the turret base area.

• Position 1 of the tool disk is in working position.

1. Use a hexagon al pin wre n ch, comp let e with T-grip, and rotate the motor shaft until position 1 has been reached.

2. Press i n the k eeper b y means of a scr ewd rive r an d rotat e th e motor shaft until the disk-type tool turret locks (see above).

BA 1130 13

4 Operation

4.1 Survey

Changing

Tools

Clearing faults

4.2 Tools

→

Page 15

→

Page 16

Operation

Survey

CAUTION

Risk of machine damage due to changing a driven tool incorrectly: Impacts on the tool holding fixture can damage the turre t drive train.

Therefore, always change driven tools as follows: ➣ When loosening/clamping the tool holding fixture, always

support it with a second spanner.

➣ Remove spindle unit, change tool and refit spindle unit.

BA 1130 15

Operation Possible faults a nd remedies

4.3 Possible faults and remedies

Clearing required prior to any work:

➣ Switch the machine off. ➣ Depressur ize turret .

Fault Cause Remedy Who carries out

this task?

Turret

Incorrect center heigh t, tool disk offset relative to locating disk

Tool disk does not rotate

Tur ret is diffic ult to operate

(Thermo protection device has respon de d)

Turret no lo nger l ocks or the pre-indexing bolt gets caught

Tool disk does not stop in the selected po s i t io n

Collision when turret is locked

Gearwheels are defective

Proximity switch S11 does not switch

Insufficient oil in the gearbox chamber

Contactor is defective Check motor drive

Collision during pivoting

Angular encoder is not correctly adjusted or defective

Turn back tool disk in the annular groove and align

SAUTER Service

Check pro ximity s witch S11; if necessary, set or replace

Check oil

SAUTER Service

Check angular encoder , set or replac e if necessar y

User

→

Page 23

User

→

Page 35

User

→

Page 20

User

→

Page 24 , page 26

Proximity switch S7 does not switch

Too l di sk s top s i n between two positions

Leakage oil escapes Seals are defective SAUTER

Chips between tool disk an d turret

Check pro ximity s witch S7, se t or replace if necessary

Remove tool disk, remove chips

Service

User

→

Page 31

User

16 BA 1130

Operation

Possible faults and remedies

Fault Cause Remedy Who car ries out

this task?

Cooling lubricant is not being transferred

Cool in g l ubricant escapes between tool disk and turret

Tange ntial play of tool disk when turret i s locked

Tool drive

Tool drive does not engage

Cooling lubricant valve is defective

Cool in g l ubricant va lve/

line is blocked

Cooling lubricant valve is defective

Collision while turret is locked

Wear due to lack of oil

To ol d is k is disp lace d Align tool disk

Tool drive coupling is defective

Replace cooling lubricant valve

Blow cooling lubricant valve/lin e clear

Replace cooling lubricant valve

SAUTER Service

User

→

User

→

Page 37

Page 23

Pinion sh aft i s def ec ti v e Repla ce def ect iv e

Solenoid is defective Replace solenoid and

Tool is not driven Gear wh eels are

defective

Tool drive motor is defective

Proximity switch S10 does not switch

part, adjust solenoid

adjust

SAUTER Service

Replac e tool drive motor

Check proximity switch S10, se t or replace if necessary

User

→

User

→

Page 34

Page 35

BA 1130 17

Maintena nce Survey

5 Maintenance

Safety notes

→

Page 5

5.1 Survey

Planne d preventive maintenance Repairs a f ter fault conditio ns

→

Page 19

→

Page 16

5.2 Se rvi ce life

The service life of the turret is approx. 8 million switchings or approx. 5 years.

The service life of the tool drive unit is approx. 8000 operating hours.

These values apply to

• collisio n-f ree op er ation ,

• compliance with the specified operating conditions and the permissible loads,

→

Technical data, page 12

18 BA 1130

5.3 Service intervals

Plan your tasks careful ly in order t o provide for troublefree ope ration and reduce necessar y d owntimes to a m inimum.

IMPORTANT

➣ Maintenance intervals must be adapted

to the operating conditions involved.

if required Clean to o l d rive coupling. User

Maintena nc e

Service intervals

Check tool drive coupling for damage, replace if necessary.

after 4 0 00 operating hours of the machine respectively

Check cooling lubr i ca nt valve for wear and leak a ge. Replace any defective parts.

Check oil of the turret g ea rbox chamber; if necessary, replenish oi l.

Check grease condition of tool drive unit; if necess a ry, replenish grease.

after 2½ years respectively Check all elect r ical lines an d

connec ti ons for mechanical d ama ge a s well as embrittlement. Replace any defective parts.

after 8 0 00 operating hours of the machine respectively

Change the oil of the turret gearbox chamber.

The service life of the tool drive unit may possibly be reached, depending on the operating conditions involved. A general overhaul is recommended for furt her trouble-free operatio n.

User SAUTER Service

User

→

Page 37

User

→

Page 20

User

→

Page 22

User Specialist electrical

engineer

User

→

Page 20

SAUTER Service

after a p prox. 2 –3 mil lion indexing operations respectively

The service life of the turret may possibly be reached, depending on the operating conditions involved.

SAUTER Service

A general overhaul is recommended for furt her trouble-free operatio n.

1) These ar e pe rso ns w ho ar e ab le t o id en tif y ri sk s and t o pr e v en t pos sib le ha zard s on the basis of their special training and their experience (IEC 60 201-1).

BA 1130 19

Maintena nc e w ork Tu rret gearbox chamber

5.4 Maintenance work

Turret gear b ox ch amber

The turret gear box chamber has to be ser viced after 4, 000 operating hour s.

Clearing required prior to any work:

➣ Switch the machine off. ➣ Depressur ize turret .

IMPORTAN T

Improperly disposed used oil is a danger for our environment. ➣ Pay attention to the legal regulations for the waste disposal

of used oil.

In line w ith the setup position of the disk-type tool turret, the following apertures (1) for draining or replenishing oil are provided:

Checking the oil

➣ Carefully unscrew oil drain plug and drain the oil

(max. 10 cm

) into a suitable container.

20 BA 1130

Tu rret gearbox chamber

Assess oil c ondit ion

Condition Cause Action

Maintena nc e wo rk

Oil black or brown, without metallic abrasio n

Oil black or brown, with metallic abrasio n

Oil white, mixed with cooling lubricant

Natural consumption –

Internal parts of turret are damaged

Turret sealings are damaged

None oil left Turret sealings are damaged

Changing the oil

➣ Open oil drain plug, drain waste oil. ➣ Close oil drain plug. ➣ Remove screw plug from oil charging hole.

Fill oil

300cm

Request SAUTER Service!

lubricating oil C acc. to ISO 6743/6 viscosity ISO VG 46 acc. to DIN 51562

➣ Screw in screw plug.

BA 1130 21

Maintena nc e w ork Tool dr iv e

Tool drive

• The product is lubricated with grease. Lubricant used:

CENTOPLEX CX4/375 (KLÜBER)

• Lubrication must be checked after 4,000 operating hours respectively.

Clearing required prior to any work:

➣ Switch the machine off. ➣ Depressur ize turret .

➣ Clear access to opening on tool drive. ➣ Remove screw plug off opening. ➣ Rotate gear and assess grease condition:

Condition Cause Measure

Grease: black or brown, without metallic abrasion

No grease visible on gear Natural consumption

Grease: black or brown, with metallic abr a si o n

Grease: white, mixed with cooling lubricant

Grease mixed with oil

Trace of natural wear –

Internal parts of turret are damaged

Turret sealings are damaged

➣ Replenish grease.

approx. 1 05 c m CENTOPLEX CX4/375

➣ Request SAUTER Service!

➣ Re-insert screw plug.

22 BA 1130

5.5 Aligning the tool disk

Preparation

➣ Lock turre t .

→

Manual mode, page 11

Aligni ng

Repairs after fault conditions

Aligning the tool disk

➣ If necessary, undo screws (1). ➣ Align the locating hole to center height of the machine;

use a plug gauge (2) if required.

➣ Tighte n sc rews (1 ).

M10 - 12.9 77 Nm

MoS

BA 1130 23

Repairs aft e r f a ult c onditions Adjusting the angular encoder

5.6 Adjusting the angula r encoder

IMPORTAN T

Setting tasks require a 24V DC power supply.

Preparation

➣ Lock disk-type tool turret in position 1.

Manual mode, page11

→

➣ Undo claws by means of a hexagonal pin wrench.

Adjustin g

➣ Rotate a ngular enc ode r out of pos itio n unt il il lumi nat ed di ode

lights up.

➣ Clamp in angular encoder by means of the claws.

24 BA 1130

Repairs after fault conditions

Adjusting the angular encoder

Checking the setup for symmetry

1. Use hexagonal pin wrench with T-grip for rotating the motor shaft.

2. Rotate motor shaft until illuminated diode on the angular encoder or the ind ic ati on “Positio n 1” on th e ma c hin e are extinguished.

3. Note the T-grip position.

WARNING

A reversal of the moment of the motor results in the acceler ati on of t he mo tor s haf t. The hexagonal pin wrench ma y thus be unexpectedly accelerated. Therefore, in order to avoid the ejection of the hexagonal pin wrench and resulting injuries, firmly grip the hexagonal pin wrench.

4. Carefully continue to rotate until a moment reversal can be felt on the moto r sha ft .

5. Note the T-grip position.

The distance between the two grip positions characterizes the angle range.

6. R ep ea t ste ps 1 to 5 w i th reverse dire ctio n of rot at ion . The

α must be the same for both directions of rotation!

angle

By turning the angular encoder out of position, any dissymmetry can be removed.

BA 1130 25

Repairs aft e r f a ult c onditions Replacing the angular encoder

5.7 Repl acing the angular encoder

The location of t he angular enc oder depe nds on the disk -type tool turr et version (without/with fluid rotary feedthrough).

IMPORTAN T

Setting tasks require a 24V DC power supply.

Angular encoder, centrally positioned

Preparation

➣ Lock disk-type tool turret in position 1.

→

Manual mode, page11

➣ Note the position of the cable outlet (2) on the

angular encoder (1), remove attachment.

➣ Undo cables (3) on terminal strip (note where they are

connected).

➣ Undo claws by means of a hexagonal pin wrench.

26 BA 1130

Repairs after fault conditions

Replacing the angular encoder

Replacing

➣ Undo setscrew. ➣ Carefully withdraw angular encoder. ➣ Connect new angular encoder electrically.

Wiring diagram EP-870 in the appendix to these

→

Operating Instructions

➣ Rotate shaft of the angular encoder until the illumin ation of

the LED on the angular encoder indicates the “Position 1” setting.

This indication must remain w hilst the following steps are carried out.

IMPORTANT

The LED is used only to indicate position 1 during the adjustment work. It is no position indicator during operation.

BA 1130 27

Repairs aft e r f a ult c onditions Replacing the angular encoder

➣ Ensur e th at the cabl e outle t is in its cor r ect posi t ion . ➣ Insert the shaft of the angular encoder into the bore of the

➣ Use setscrew to attach the angular encoder to the shaft. ➣ If necessary, check the adjustment of the angular encoder.

flexible shaft and introduce carefully until the angular encoder is in contact with the plate. Ensure that the claws are in their correct position!

Page 25

→

➣ Use claws to secure the angular encoder. ➣ Fit covering hood. Note position of cables in order to avoid

any pinching of the same.

28 BA 1130

Repairs after fault conditions

Replacing the angular encoder

Angular e ncoder, in side positio n

Preparation

➣ Lock disk-type tool turret in position 1.

→

Manual mode, page 11

➣ Note the position of the cable outlet (2) on the angular

encoder (3), remove attachment.

➣ Undo cables (1) on terminal strip (note where they are

connected).

Replacing

➣ Undo claws by mea ns of a hex ag on al pin wr en ch . ➣ Carefully withdraw angular encoder.

On the shaft of the angular encoder, a disk is located which is fixed in position by means of a setscrew.

➣ Undo setscrew and remove disk. ➣ Connect new angular encoder electrically.

Wiring diagram EP-870 in the appendix to these

→

Operating Instructions

BA 1130 29

Repairs aft e r f a ult c onditions Replacing the angular encoder

➣ Rotate shaft of the angular encoder until the illumination of

➣ Fit disk in its correct posi tion.

the LED on the angular encoder indicates the “Position 1” setting.

This indication must remain whilst the following steps are carried out.

➣ Ensur e th at the cabl e outle t is in its cor r ect posi t ion . ➣ Insert the angular encoder into the opening of the plate,

note the position of the claws!

➣ If necessary, check the adjustment of the angular encoder.

Page 25

→

➣ Use claws to secure the angular encoder. ➣ Fit covering hood. Note position of cables in order to avoid

any pinching of the same.

30 BA 1130

+ 83 hidden pages