sauter BA 892 User Manual

Operating Instructions

for

Disk-type tool turret

0.5.473.520 107 468

110 660 111 092 111 432 112 862 115 702

BA 892 e

2007-03-27

125 365

Product data as per nameplate on the housing

1. Classification number (series, size)

2. Identification number

3. Order number

4. Gear ratio

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x.x.xxx.x xx

xxx xxx xx-xxx-xx-xx

xxx

Basis-BA: 06-10-23 Manual translation

  

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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.

Table of contents

Interpretation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Use within specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Required skills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.3 Notes on product-specific risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.5 Liability and warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.1 Designation of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.3 Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4 Repairs after fault conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.5 Aligning the tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.6 Replacing the cooling lubricant valve . . . . . . . . . . . . . . . . . . . . . . . 26

4.7 Adjusting the angular encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.8 Replacing the angular encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.9 Proximity switch S7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.10 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Replacement parts for turrets (without tool drive) Replacement parts tool drive for turret

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Survey: Disk-type tool turret 0.5.480.5..

Table of contents

Appendix

Diagram of functions: Disk-type tool turret . . . . . . . . . . . . . . . . . . . . . . . . . SK - 919

Diagram of functions: Disk-type tool turret . . . . . . . . . . . . . . . . . . . . . . . . . SK - 920

Wiring diagram: Disk-type tool turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EP - 870

Diagram of functions: Tool drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SK - 940

Wiring diagram: Tool drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EP - 855

Contact/Order information

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Interpretatio n o f symbols

Interpretation of symbols

Warning notes

WARNING

This warning de sig n ate s a potentially hazardous sit ua tio n which may lead to serious injuries, or even death.

WARNING

Risk of electric shock due to high voltages!

CAUTION

This caution designates a potentially hazardous situation in which the produ ct or p rop erty in its environment could be damaged.

IMPORTANT

For application notes and other useful information.

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Clearing

Clear machine before carrying out any further work!

1) Classification of signal wo rd s acc. to ANSI Z535.4

Interpretation of symbols

Symbols for action instructions

Designates an a cti on in stru c tion

Designates the result of an action

Designates a c ro ss -ref ere nc e

Tools required: here, hexagonal pin wrench complete with Tgrip

Use M10 bolts, qua lity 1 2. 9; u s e M o S marked, tightening torq ue 7 0 Nm.

M10 - 12.9 MoS

Abbreviations

max. maximum perm. permissible Fig. figure if nec. if necessary approx. approximately acc. according (to) incl. inclusive (of)

to lubricate th e po ints

70 Nm

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1 Safety notes

The turret correspon d s t o th e sta te of the art and the recognized tech nic a l s afe ty rul es. Ne ve rth el ess h a za rds a nd risks can occur.

1.1 Use within specifications

Install and op era te turre t o nl y i n m a ch ines complying with the relevant regulation s for worksp ace pro tecti on.

Operate turret only in perfect condition and in compliance with the Operating Instructions.

1.2 Required skills

Safety note s

• Work may only be pe rfo r me d on the tu rret by qualified staff. These are person s w ho are a ble to id en tif y ri sk s an d t o

prevent possibl e h az ard s on th e b as is o f th ei r sp ec ia l 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 personn el m us t h av e be en instructed in accordance with the Operating Instructions and directly on the turret.

1.3 Notes on product-specific risks

Setting tasks require a 24V D C power sup ply.

Clearing required prior to any work:

Switch the machine off.

Push the motor pro te cti on switch for the turret into the OFF po s itio n.

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Safety note s

WARNING

In the event of a fau lt or a collision, unexpected rota tio n of t he tool disk is pos si ble. Injury hazard.

CAUTION

Do not attempt any further switching operations, if the turret is damaged, as otherwise considerable conseq uential damage may be cause d.

Call SAUTER Service.

CAUTION

Functional fau lts m ay b e c a us ed by a n ing r es s of ch ip s and contamination.

Close open too l l oc ations and cooling lubrica nt bo res by means of suitable closing plugs.

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

WARNING

A reversal of the m om e nt of the m oto r re su lts in th e acceleration of the mot or shaft . The hexag onal pin wr ench may thus be unexpectedly accelerated. Therefore, in order to avoid the ejection of the hexagonal pin wrench and resu lti ng in ju ries , firmly grip the hexagonal pin wrench.

1.4 Disposal

Comply with all national and regional disposal regulations and laws.

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1.5 Liability and warranty

The information contained in these Operating Instructions is in conformity with the k no wledge at the point of printing . Subject to modifica tio ns wh ich o cc ur with in the fra m ewo rk of continuous further development.

All liability an d w a rran ty sh a ll be excluded if

• the notes and instructions contained in these Operating Instructions are not complied with,

• the product is not used as directed,

Use within specific at ion s, pa ge 7

• the product including accessories is in correctly operated,

• the product including accessories is in competently repaired and maintained,

• conversions and f unctional cha nges are imp lemented witho ut approval by the manufacturer,

• no suitabl e sp in d le uni t s are us e d as st ipulated in SAUTER Product Informat io n PI 14.2, for examp le ,

• no suitable tool disks and tool holders are used,

• no original replacement parts are used.

Liability and warra nt y

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Product description Designation of parts

2 Product description

2.1 Designation of parts

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

4 Covering hood for electric components 5 Turret housing

1) not included in scope of delivery

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Product description

Designation of parts

6 Solenoid 7 Terminal box:

tool drive motor

8 Flange plate:

tool drive motor

9 Turret motor

10 Electric connection:

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

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Product description 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) caused

Nm 63 by tool holders and tools

Indexing times Theoretical cycle time

41 α+

----------------× 017,× 01,+ n

(unlock/turn/lock) 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/mains frequency see motor rating plate Degree of protection IP 65 Turret mass

kg approx. 70

(without tool disk) Perm. ambient temperature range °C

°F

Operating pressure for cooling lubricant

Cooling lubricant valve – standard version constant supply externally switched suppl y

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 significantly reduction in the values needs to be taken into account.

2) Depending on gear ratio and mains frequency

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 cooling lubricant guide a.o.) may require a higher degree of filter fineness. Note and comply with the manufacturer’s instructions!

bar bar

bar

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

14 25

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Product description

Technical data 0.5.473.520

Tool drive

Mass (without any motor) kg approx. 40

Gear ratio i 41/41 41/31 41/27 41/21

Perm. speed

on tool drive coupling n

Max. perm. torque

2) 3)

perm

rpm 4000

Nm 32

on tool drive coupling Transferable power

perm

kW 10

Suitable for spindle units coupling profile 17 × 14 DIN 5482

1) The data stated here may differ on special versions.

2) M

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

is the permissible peak load for the gears.

perm

The torque must be limited on the motor frequency converter to the value

indicated, while adhering to the gear ratio involved! The useful power data depend on the performance characteristic curve of the motor type used.

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

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Manual mode

3 Manual mode

In manual mode, the me chanical 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.

Push the motor prote cti on s witc h f or t he tu rret i nto th e OFF p os ition.

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

2. Remove screw plug on motor housing.

Unlock turret

3. Use a hexagonal pin wrench, complete with T-grip, to rotate the motor shaft.

If the disk-type tool turret is locked, the locating disk (or tool disk) does no t co-rotat e; the centre position of t he lock can be felt.

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Manual mode

WARNING

A reversal of the m ome nt o f t he m oto r re su lts in th e acceleration of the motor shaft. The hexagonal pin wrench may thus be unexpectedly accelerated. Therefore, in order to avoid the ejection of the hexagonal pin wrench and resu lti ng in juri es , fi rm ly grip the hexagonal pin wrench.

4. Keep the same direction of rotation, continue to rotate.

The disk-type tool tur ret unlo cks; a r eversal o f the mo ment on the motor shaft can be felt.

Rotate tool di sk

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5. Keep direction of rotation, continue to rotate disk until locating disk (or tool disk) starts to turn as well.

6. Keep direction of rotation, continue to rotate disk until locating disk (or tool disk) has reached the position r equired, then press in the keeper by means of a screwdriver.

The preindexing bolt engages into a hole.

The tool disk cannot be rotated any further.

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 resistance can be felt when rotation is continued. The locking process ends, if t he centr e pos ition o f the lock can be felt.

On completion of setup or maintenance work:

8. Screw in plug and fit covering hood. Note position of cables in order to avoid any pinching of the same.

Lock turret in position 1

IMPORTANT

For some setup and mai nte nanc e work th e disk -type tool tu rret 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 hexagonal pin wrench, complete with T-grip, and rotate the motor shaft until position 1 has been reached.

2. Press in the keeper by means of a screwdriver and rotate the motor shaft until the disk-type tool turret locks (see above).

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4 Maintenance

Turret maintenance compri ses the followin g tasks:

• Cleaning,

• Checking,

• Setting and

• Repair.

The service life of the turret is approx. 2–3 million switchings or approx. 5 years.

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

These values appl y to

• collision-free operation,

Maintenance

Safety note s

• compliance with the specified operating conditions and the permissible loa ds ,

Technical data, page 12

4.1 Safety notes

Page 7

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Maintenance Service intervals

4.2 Service intervals

Plan your tasks car efully in order to provide fo r troublefree o peration an d reduce necessar y downtimes to a minimum.

IMPORTANT

Maintenance intervals must be adapted to the operating conditions involved.

if required

after 4000 operatin g hours of the machine respectively

after 2½ years respectively

after 8000 operating hours of the machine respectively

Clean tool drive coupling. User

Check tool drive coupling for d amage,

User

replace if necessary.

SAUTER Service

Check cooling lubricant valve for wear and leakage. Replace any defective parts.

Check oil of the turret gearbox

User

Page 26

User

chamber;

if necessary, replenish oil.

Check grease condition of tool drive unit; if necessary, replenish grease.

Check all electrical lines and

Page 19

User

Page 21

User connections for mechanical damage as well as embrittlement. Replace any defective parts.

Change the oil of the turret gearbox

Specialist electrical

engineer

User chamber.

Page 19

after approx. 2–3 million indexing operations respectively

The service life of the tool drive unit

SAUTER Service may possibly be reach ed, depend ing on the operating conditions involv ed. A general overhaul is recommende d for further trouble-free operation.

The service life of the turret may

SAUTER Service possibly be reached, depending on the operating conditions involved. A general overhaul is recommende d for further trouble-free operation.

1) 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).

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4.3 Maintenance work

Turret gearbox chamber

The turret gearbox chamber ha s to be service d after 4,00 0 operating hou rs.

Clearing required prior to any work:

Switch the machine off.

Push the motor pro te cti on switch for the turret into the OFF po s itio n.

IMPORTANT

Improperly disposed used oil is a danger for our environment.

Pay attention to the le ga l re gu lat ion s for the waste disposal of used oil.

Maintenance work

Turret gearbox chamber

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

Checking the oil

Carefully unsc rew o il dra in plu g and drain the oil (max. 10 cm

) into a suitable co ntainer.

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Maintenance work Turret gearbox chamber

Assess oil condition

Condition Cause Action

Oil black or brow n, w ith ou t metallic abrasi on

Oil black or brown, with metallic abrasi on

Oil white, mixed with cooling lubricant

Natural consum p tion –

Internal parts of turret are damaged

Turret sealings are damage d

None oil left Turret sealings are damaged

Changing the oil

Open oil drai n p lu g, 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.

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Maintenance work

Tool drive

The tool drive is lubricated with grease. The grease needs t o be checked a fter 4,000 h ours of opera tion of the tool drive.

Clearing required prior to any work:

Switch the machine off.

Push the motor pro te cti on switch for the turret into the OFF po s itio n.

Preparation

Provide access to the ap e rtu re (1) on the tool drive.

Tool drive

Checking the grease condit ion

Unscrew screw plug on aperture (1).

Rotate gear and assess grease condition:

Condition Cause Measure

No grease visible on gear Natural consumption Replenish grease. Grease: blac k or b r own ,

without metallic a bra s ion Grease: blac k or b r own ,

with metallic abra si on

cooling lubrican t

Traces of natural wear – Internal parts of turret are

damaged Turret sealings are damag ed

Request SAUTER Service!Grease: whi te, mixed with

Grease mixe d wi th oil Turret sealings are d am ag ed

Replenishing the grease

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Close aperture (1) by means of screw plug.

ISOFLEX NBU 15max. 20cm

(KLÜBER)

Repairs after fault conditions Possible faults and remedies

4.4 Repairs after fault conditions

Clearing required prior to any work:

Switch the machine off.

Push the motor prote cti on sw itc h f or t he tu rret i nto th e OFF p os ition.

Fault Cause Remedy Who carries out

this task?

Turret

Incorrect center height, tool disk offset relative to locating disk

Tool disk does not rotate

Turret is difficult to operate

(Thermo protection device has responded)

Turret no longer locks or the pre-indexing bolt gets caught

Tool disk does not stop in the selected position

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 proximity switch S11; if necessary, set or replace

Check oil

SAUTER Service

Check angular encoder, set or replace if necessary

User

Page 25

User

Page 37

User

Page 19

User

Page 27, page 29

Proximity switch S7 does not switch

Check proximity switch S7, set or replace if necessary

User

Page 33

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