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Birmingham WSG1640AHD Operating Manual

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WSG1640AHD
SURFACE GRINDING MACHINE
OPERATING    MANUAL 

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Summary of Contents for Birmingham WSG1640AHD

  • Page 1 WSG1640AHD SURFACE GRINDING MACHINE OPERATING    MANUAL ...
  • Page 2 Ex-factory record: The machine is performing GB4022-83 《Horizontal Shaft &Rectangular Table Surface Grinder Precision》 standard Model of machine: WSG1640AHD Width of worktable: Length of worktable: The machine has been inspected being up to the standard and approved for delivery. Serial No.:...
  • Page 3 Operating manual Precision Inspection Register Geometrical precision Permissible Actual Items Diagram deviation deviation Full length: 0.01 Flatness of the table surface Local: 0.005/300 a. Parallelism of the table Full length: surface to its longitudinal 0.015 movement Local: b. Parallelism of the table 0.008/300 surface to its transverse movement...
  • Page 4 Operating manual Radial run out of the wheel 0.004 spindle nose Axial run out of the wheel 0.004 spindle Parallelism of the spindle center line to the table 0.025/300 surface Verticality of the spindle center line to the medina 0.015/300 slot Machining precision Permissible...
  • Page 5 Operating manual DISTRIBUTOR Do not transport the machine and start operation before reading the safety directions and the instruction manual. The below mentioned persons herewith confirm that they have read and comprehended the operation instructions before transport and appropriate use of the machine for their security and of third persons and the safety of the machine.

  • Page 6: Safety Directions

    Operating manual SAFETY DIRECTIONS To guarantee an optimal, trouble-free operation at lowest possible endangering this machine should only be operated, maintained and repaired by persons familiar with it and list operation. For these reasons the instruction directions must be read and be followed exactly before transport and start of operation.
  • Page 7 Operating manual INDEX Description page Chapter 1. Safety instruction general safety instruction safety regulation of the machine Chapter 2. Summary of the machine concise statement on the machine field of application construction identification main specification Chapter 3. Machine installation instruction Diagram of machine floor space demand of foundation foundation construction and machine setting...
  • Page 8 Operating manual INDEX Description page select perfect method of variously grinding inspection of the grinding wheel wheel dressing & correct use of wheel dresser Balancing wheel Chapter 6. Daily maintenance daily inspection (oil & water) daily inspection (test list before operating) daily inspection (test list after work) Chapter 7.
  • Page 9 Operating Manual Chapter 1 Safety instruction 1.1. general safety instruction (1) The operator must be trained and passed the operating and maintaining test. (2) The user should educate the operator according to local law of industrial safety and hygiene. (3) The user should warn operator about unsafe operating. (4) Read the manual before using the machine, and note danger mark and content stuck on the machine.
  • Page 10 Operating Manual and glove. (2) Don’t lean against the machine in working range (3) Don’t adjust the grinding wheel cover, right or left travel limit control block, nozzle with hand or tools when the machine is running. (4) Don’t blow out scrap or dust with compressed air to protect operator’s eyes.
  • Page 11 Operating Manual before driving the machine. (10) Must inspect if the spindle rotating direction is correct before driving the spindle motor. Begin to grind work-piece after not less than 5 minutes since driving the machine. (11) Please clean the magnetic chuck surface before using, if there is scuffing or scar on the surface, please grind it again.
  • Page 12 Operating Manual (9) Must not wearing metal garnish to avoid electric shock when inspecting electrical parts, and hang up warning mark to avoid someone operating the machine. (10) Forbid to fixed short & over-thin work-piece or complicated shape, precarious CG work-piece directly on the magnetic chuck. (11) When grinding, any other goods are permitted to place on the table but the fixed work piece.
  • Page 13 Operating Manual Chapter 2 Summary of the machine 2.1 concise statement on the machine “十” saddle is adopted in the design, all these three guide way is lined with TF wearable material and lubricated by intermittent forced oil pump, the column have double walls.
  • Page 14 Operating Manual 2.3 construction identification Name Name Grind wheel Saddle cross moving hand Electro lubricate pump wheel Table longitudinal moving Saddle hand wheel Table Wheel head lifting hand wheel Column Cabinet Elevating motor (only for R/A Wheel guard model)
  • Page 15 Operating Manual 2.4 main specification Main specification of WSG1640 Series Model Unit Item Table size (W×L) 16×40 Table longitudinal move speed in/min 275.5~906 Max. Distance from table surface to spindle centerline Max. Loading capacity ( include chuck) Auto intermittent feed 0.004~0.3 Table Rapid speed...
  • Page 16 Operating Manual Chapter 3 Preparation before machine installation diagram of machine floor space size model WSG1020 89” 68” 85” WSG1224 110” 82” 87” WSG1240 173” 128” 87” WSG1632 142” 104” 94” WSG1640 173” 128” 94” Limit position drawing...
  • Page 17 Operating Manual demand of foundation 1) Installation of the machine will effect deeply efficiency and precision, don’t place the grinder between the milling machine and planer, etc, because there is shock when these machine are running, the shock will be transferred to the grinder and make wave mark on the grinding surface.
  • Page 18 Operating Manual completely and the function of electric circuits proved to be securely safe and reliable, can the wheel of the machine be tested for geometrical complete, started and operated. UNIT: inch size model WSG1640 WSG1632 WSG1240 WSG1224 WSG1020 Machine ground diagram...
  • Page 19 Operating Manual Carriage and lifting machine Use equipment to lift the machine as following. Lifting: first fasten the sling bolts on the machine base, then set the wire cables on the sling bolts and the hook. Remove the setting plates In order to avoid damage during transporting, the movable parts have been locked.
  • Page 20 Operating Manual 2. Move up the wheel head then get off the wooden block 3. Remove the antirust paper covered around hydraulic piston rod. Clean the saddle slide way. Clean the machine All the machines are provided with anti-rust treatment. The moving parts are lubricated with grease and fixture point and dye black portions are applied with anti-rust oil.
  • Page 21 Operating Manual Connect the hydraulic pipe to oil tank. Right side is the oil Out the tank with high pressure, left one the oil back to the oil tank. Each one pipe connecting to the each point is Ok! Fill in suitable oil (32# Hydraulic oil) through the top of the tank.(capability of tank is about 110L) Hydraulic Oil recommended: (32# hydraulic oil )
  • Page 22 Operating Manual 2. Fill in oil until marking at oil gauge is reached. 3. Oil types are recommended according to the above list. 4. The oil filter should be changed for the first two month after starting operation of the machine at the latest. After that changing the filter in the oil changing cycle of two times a year in case of one shift operation is sufficient.
  • Page 23 Operating Manual 3. Assemble the pipe to the coolant pump and tighten it. You can put the pipe into hot water for a few minutes, make it easy to install Filter box. The coolant should flow back into the box at first Power wire connect to the electrical box power supply...
  • Page 24 Operating Manual Connect suitable power according to the rated voltage Connect the coolant pump and oil pump power wire to the electrical box. For coolant pump For oil pump The electric connections must be carried through by an approved electrical engineer only. Before connecting the supply line, it has to be checked if the stated operation voltage of the machine corresponds to the available power supply voltage.
  • Page 25 Operating Manual In a short starting testing, the grinding wheel spindle must rotate clockwise.

  • Page 26: Chapter 4 Trial Running

    Operating Manual Chapter 4 Trial running 4.1 preparation before trial running 4.1.1 Lubrication A. Lubrication set 1) In order to maintain mechanical performance and life, choice correct lubrication oil for lubrication system is necessary. 2) When the machine is on work, the lubrication pump auto intermittently feed oil to all the lubrication points.
  • Page 27 Operating Manual Lubricating Lubricate point Lubricant Times mode 32＃ slide way oil V slide way of saddle Auto lubricating Adjustable 32＃ slide way oil Cross feed screw Auto lubricating Adjustable 32＃ slide way oil Lifting feed screw/nut Auto lubricating Adjustable Front slide way of 32＃...
  • Page 28 Operating Manual TIME(the range from 2min to 30min). the shortest stop time should not less than 2min. after setting, push the RESET button for confirm. THE TIME HAS BEEN ADJUSTTED WELL BEFORE DELIVERY. Lubricant recommended （32＃ slide way oil） China Brand MOBIL CASTROL ESSO...
  • Page 29 Operating Manual 4) Check the spindle rotating and make sure the direction is clockwise. Before check the spindle rotating direction, please remove the wheel, because the spindle turning unticlockwisly is very dangerous. 5) Conform the oil tank is full enough. 6) Make sure the speed control valve is taken off.

  • Page 30: Chapter 5 Operation Instruction

    Operating Manual Chapter 5 Operation instruction 5.1. Control panel instruction 5.1.1 Control panel 1) AHD Series control panel（WSG818AHD ~ WSG1640AHD）...
  • Page 31 Operating Manual 5.1.2 control panel instruction： 1) AHD Series SB0：Emergency switch SB1：Power on push button / indicator lamp SB6：Wheel head rapid down push button SB7：Wheel head rapid up push button SB8：Table cross rapid moving backward push button SB9：Table cross rapid moving forward push button SA2：Table cross movement mode (Manual/ Auto.) selecting knob SA4：Wheel head down feed mode (rapid elevating/ jog feed /Auto.
  • Page 32 Operating Manual c. creep age d. transformer is bad. 2. Table longitudinal movement a） Start the oil pump: turn the SA5 to “ magnetized “ position, the electric magnetic chuck engaged, waiting for a moment then push Key F6 on HMI, the oil pump start, Push F2, the oil pump stop. when push the F6, the oil pump not start, may be cause by: a.
  • Page 33 Operating Manual If the table reversing dog D1/D2 bump against table direction control arm C due to operator’s error operating or an long times using, control arm will lost the correct position then cause the table unable to travel automatically. In such case adjusting the control arm position as follows: Turn L (speed controller) to close position to stop table movement.
  • Page 34 Operating Manual and left by right hand (about 15-20 degrees), if this can’t make the table move right and left, reset C at other position and try again, by this way, you can find the right position for C. ATTENTION: be care for not clamping fingers by dogs and control arm.
  • Page 35 Operating Manual The cross intermittent feed is control by AC motor controller in the cabinet. On the Ac motor controller Panel, the “ set” key is for set the feed rate. There are 4 shift !~4, feed rate: shift 1: 0.08~6mm; shift 2: 0.3~12mm;...
  • Page 36 Operating Manual feed. if the grinding mode is set to “PLUNGE GRINDING” mode the table couldn’t make cross rapid or intermittent feed. 4. Wheel head vertical up / down movement a) AH model: the wheel head can only up/down by manual and handwheel. b) AHR model: push the SB6 “...
  • Page 37 Operating Manual make rapid up moving. Note: the when the machine is set on “ Jog-feed “ function, the elevating Servo motor will be “ power on”, IT IS FORBIDED MOVING THE WHEEL HEAD BY MANUAL (HAND WHEEL) ! 3. Auto feed Turn the SA4 to “...
  • Page 38 Operating Manual wheel head make Spark out grinding, when all the feed is finished, the wheel head would lift up (the travel can be set) auto and the spindle motor and hydraulic pump motor are power off. During the auto feed working, push “emergency switch” end the program, the new auto down feed working should be reset again.
  • Page 39 Operating Manual 4. Auto down feed stop and reset while the autodown feed program is going, stop the working table by speed control lever , the table and wheel head move stop, restart the workig table longitudinal moving, the program resatart too. While the autodown feed program is going, turn the knob SA4 to “jog feed”...
  • Page 40 Operating Manual On the HMI panel there are 16 soft keys, F1~F8 can take effect by pressing directly, F9~F16 take effect by pressing “SHIFT” key at first and then pressing one key of them. “SHIFT”: shift key, used to make F9~F16 take effect 1) Functions of soft keys: F1—spindle motor stop F5--- spindle motor start...
  • Page 41 Operating Manual TD 400C SIEM ENS F R C N C surface grinder. SHIFT ENTER (default menu) Set feed times for different feed rate ...
  • Page 42 Operating Manual Press F4, HMI will show above menu, press arrow↑、↓to turn page, press “ENTER”, the fist data will shining, the feed times can be set by press arrow↑、↓ to increase or decrease times. Pressing “ENTER” to confirm the data and then the second data shining, repeat the same operating step to set the grinding times.
  • Page 43 Operating Manual feed” mode again, push the button SB6 , the program will going on again. While the auto down feed program is going, push soft KEY F8, the program will be cancel, and the grind head will lift up auto. 3) Other operating Under the default menu, press “...
  • Page 44 Operating Manual after up steps, if the spindle motor would not start, please check the undercurrent rely and oil pump control circuit and spindle motor control circuit. NOTE: There is a micro switch fixed on the inside of Wheel guard, if the door have not been closed, the spindle motor could not start.
  • Page 45 Operating Manual 5.2. Operating caution： 1) Before install of remove the wheel, shut off the power in advanced. 2) Don’t operate the grinding machine which have no wheel cover, it is forbidden that opening the wheel cover while working. 3) Not move the work piece or put hand on the table before the wheel stop 4) Make sure that work piece is fixed on the table substantially.
  • Page 46 Operating Manual reduce the motor speed. 15) Confirm the direction of wheel turning is same as indicated on the wheel cover. 16) Confirm all the switch and button are on the shut off position before start the machine. 17) Stop the table while adjusting the longitudinal travel. 18) Shut off the grinding head motor before cleaning the table after working.
  • Page 47 Operating Manual NOTE: of the wheel must be higher than Peripheral cutting velocity limit speed of the wheel. of the grinding wheel (m/s) Peripheral cutting velocity =3.14×D(dia. Of wheel, mm)×N(spindle speed, r/min)÷60000 5.3.3 ABRASIVE All the abrasives have themselves physics character, their hardness and tenacity is deferent, choice proper wheel according to work-piece material.
  • Page 48 Operating Manual Sort of abrasive and using range Name Code Color Using Range Grinding carbon steel, general alloy steel, malleable cast iron, hard bronze etc. Brown emery A (GZ) Brown especially suit grinding steel without quenched & quenched and tempered steel, suit rough grinding too.
  • Page 49 Operating Manual general way, the grit size is smaller, the surface ground is better. APPLICATION RANGE OF SERIES WHEEL GRIT SIZE Application range Grit size of gain 14-24 Grinding steel ingot, iron burr, cutting off billet 36-60 Grinding general surface 60-100 Fine grinding and grinding edge 120-W20...
  • Page 50 Operating Manual GRINDING CONDITION AND CHOICE OF HARDNESS Soft grad hard Hard and brittle work-piece material soft and ductile width interface narrowness fast linear speed slow Slow work-piece moving speed fast Better mechanical precision badness Experience operator inexperience 5.3.6 STRUCTURE Express volume proportion among grain, bond, pore, separate three kinds of structuredense structure, middle structure, open structure, 15 degree.
  • Page 51 Operating Manual Divide bond into: (1) Vitrified bond, its purpose is abroad, combine degree and structure is easy to adjust, chemical performance is better. (2) Resinoid bond, is propitious to high speed rotate, has a bit stretch. (3) Rubber bond, has stretch, is propitious to thin wheel (4) Metal bond, is mainly propitious to make the wheel whose abrasive is over-hard.
  • Page 52 Operating Manual d. operator’s skill ★ If ground material is steel or alloy, the abrasive usually be oxide, if it is iron, non-ferrous metal or nonmetal, abrasive would be carbide. Fine grit size abrasive is propitious to soft, high ductility material. Hard grinding wheel grinds soft material, soft grinding wheel grinds hard material.
  • Page 53 Operating Manual the wheel and supports the wheel, then lightly knock the wheel with wooden bar, the wheel would have voices, if the wheel has broken, it would have different voice, even we don’t see with our eyes. The perfect wheel’s voice is very clear.
  • Page 54 Operating Manual d) Then fix two other balancing weights at symmetrically place, which is at the same periphery and isogonal of the first one position, then rotate the wheel 90° one times, test the wheel whether balance, if not, remove the two balancing weight until the wheel comes to an entire standstill at any place.

  • Page 55: Wheel Dressing

    Operating Manual the wheel by take-down flange is uneconomical. We advise contact with manufacturer of wheel flange, special order wheel flanges according your condition. 5.6. WHEEL DRESSING & CORRECT WHEEL DRESSER 1) The dresser can be fixed on the magnetic chuck or the table, inclination between axis of diamond tool and vertical axis of the wheel is 5°, because the wore part of diamond must be toward rotate direction of the wheel, so as to the diamond keep sharp.
  • Page 56 Operating Manual handle the well wheel-dressing technic, and make sure the wheel get the high performance at any time. 7) The wheel dressing is the process of making the wheel sharp. In this process, we need to remove the agglutinant and the grains,so that the grains will come out from the agglutinant and form the sharp tool.
  • Page 57 Operating Manual 12) In the wheel dressing, please let the diamond pen do the movement in constant speed. If the roughness of the wheel require more low, the speed will be more slow. The total quantity of the wheel dressing is 0.1mm in single section, and repeat several times.
  • Page 58 Operating Manual racket. As shown: 1. Let the wheel rolling on the stand freely to find out it is gravity center “S” and mark it with chalk. 2. Insert a balancing weight on the opposite “G” of “S”, rotate the wheel 90°to find out “S” or “G” side is heavier. 3.

  • Page 59: Chapter 6: Daily Maintenance

    Operating Manual Chapter 6: Daily maintenance 6.1. daily inspection (oil & coolant) 警告 工作台运动中，禁 止操作人员探头进入工 作区观看工件，以免造 成挤压的危险。 Oiling inspection position Oil advised remark model time oil for Lubricate unit daily 32# oil for guide-way guide-way Hydraulic unit Hydraulic oil monthly 32#hydraulic oil Heat-resista Spindle...
  • Page 60 Operating Manual 2) Clean oil filter of the oil tank half year. (exchange if need) 3) Clean and exchange cooling water of the coolant tank according your condition (exchange every three months at least) 6.2. daily inspection (test list before operating) Machine state Test Test...
  • Page 61 Operating Manual 6.3. daily inspection (test list after work) Machine state Test Test Test content Test standard Item period Power Running Lubricating oil is over 1 Lubrication unit √ visual daily lower limit 50mm more 2 Spindle motor √ visual daily work-piece Urgent...
  • Page 62 Operating Manual Chapter 7: Setting, Adjusting and trouble shooting 7.1. there are ripples on the work piece Cause : 1) The wheel is not well balanced — balance again. 2) The abrasive is not suitable to the work piece material — select suitable wheel again.
  • Page 63 Operating Manual 7.3. The spindle don’t run. Cause: 1) The electro magnet doesn’t work 2) The fault of the power switch 3) The wheel guard is not closed well. 4) The control wire is loosened. 5) The coupling of the spindle is broken 6) The fault of spindle motor 7) The lubricating pump is short of oil.
  • Page 64 Operating Manual Parts list of Electrical circuit No  Code  Name  Spec.  Qty  Remark  1  QM1  Breaker  3UV1340‐1MN00(14‐20A)  1  Siemens  2  QM2  Breaker  3UV1340‐1NL00(8‐13A)  1  Siemens  3  QM3  Breaker  3UV1340‐1MF00(0.6‐1A)  1  Siemens  4  QM4  Breaker  3UV1340‐1MJ00(2.4‐4A)  1  Siemens  5  QM5  Breaker  DZ47‐63/2P D6 ...
  • Page 65 Operating Manual LA38‐11/203 绿  23  SB7‐8  Button  2  Changjiang  24  SA2  Knob  LA38‐31X2/203  2  Changjiang  25  SA4  Knob  LA38‐21X3/203  1  Changjiang  26  SA5  Knob(auto reset)  LA38‐20XL3/203  1  Changjiang  Waveband  27  SA6  DPN01N‐30°  1  Dongce  switch  28  HL1‐3  Indicator lamp  AD11‐16/21‐6GZ(绿)  4  Changjiang  29 ...
  • Page 66 Operating Manual Circuit diagram...
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  • Page 75 Operating Manual Table assembly structure Parts name Machine model Parts Code name WSG1225 FSG3063R-30-304 WSG1632 FSG4080R-30-308 Table extend guard WSG1240 FSG30100R-30-311 WSG1640 FSG40100R-30-301 WSG1020 FSG2550R-30-303 WSG1225 FSG3063R-30-303 Splashing guard WSG1632 FSG4080R-30-301 WSG1240 FSG30100R-30-303 WSG1640 FSG40100R-30-300 WSG1020 FSG2550R-30-100 WSG1225 FSG3063R-30-100A Table WSG1632 FSG4080R-30-100 WSG1240...
  • Page 76 Operating Manual Column structure Code Name FSG4080R-12-300 Fixed Guard FSG4080R-12-304 Movable guard FSG4080R-12-301 Dust-proof plate FSG4080R-12-500 Bellow Plastic guard FSG4080R-12-303 Dust-proof clamping strip FSG2550R-12-100 FSG4080R-12-101 Grinding spindle housing FSG30100R-12-100 FSG4080R-12-305 Upper cover-plate FSG4080R-12-100 column Column rear guard...
  • Page 77 Operating Manual Table longitudinal manual feed structure Code Name FSG-30100R-23-302 Gear shaft FSG-4080R-23-305 FSG-3063R -30-300 FSG-2550R -30-300 Rack FSG-4080R -30-300 FSG-30100R -30-300A Deep-furrow ball bearing 61204－2Z(17×30×7)GB/T276-94 (61204) FSG-30100R -23-101 Manual shaft bracket FSG-4080R -23-103 longitudinal FSG-30100R -23-304 Driven shaft sleeve FSG-4080R -23-311 Spring FSG-2050M-23-306...
  • Page 78 Operating Manual Cross feed structure Code Name FSG-4080R-23-313 Washer FSG-2050M-23-503 Hand wheel FSG-2050M-23-302 Bearing cover FSG-4080R-23-316 Feed dial M818-10-312 Knurling set screw FSG-4080R-23－307 Spacer FSG-2050M-23-304 Sleeve FSG-4080R-23-104 Vernier dial plate M20×1.5/J14-4B Round nut 3204A (47×20×20.6)/GB/T292-94 Bearing FSG-2050M-23-106 Small timing pulley FSG-2050M-23－105 Big time pulley 187L075/GB11616-89...
  • Page 79 Operating Manual Elevating structure...
  • Page 80 Operating Manual Parts list of elevating structure Code Name FSG-4080R-23-313 Washer 17*250/HY8313.7 Hand wheel FSG-3063R-10-310 Vertical feed dial FSG-3063R-10-315 Vernier dial FSG-4080R-10-311 Dial sleeve FSG-4080R-10-315 Spacer 50/GB893.1 Retaining washer Deep-furrow ball bearing 6204－2Z(20×47×14)GB/T281-94 (6204) FSG-4080R-10-314A Bearing base Cover plate FSG-4080R-10-103 transmission box FSG-3063R-10-102 Vertical belt pulley(big)

  • Page 81: Hydraulic Cylinder

    Operating Manual HYDRAULIC CYLINDER...
  • Page 82 Operating Manual HYDRAULIC CYLINDER Code Name M16×1.5/J11-1B Hexagonal nut SG-4080AHR-53-300 Washer SG-4080AHR-53-500 Cushion SG-4080AHR-53-301 Driven base M12×40/J21-9B Socket head cap screw 12/J54-1B Spring washer SG2550AHR-53-301 SG3063AHR-53A-301 Piston rod SG-4080AHR-53A-302 SG30100AHR-53-301 M6×20/J21-9B Socket head cap screw 6/J54-1B Spring washer SG-4080AHR-53A-301 End cap AD48-20×28×5.3 Dust-proof ring MA30-20×28×6.3...
  • Page 83 Operating Manual Spindle unit Parts list spindle unit Name Grinding wheel shield Lock screw Balancing block Grinding wheel Spindle Plug Spindle housing Coupling connect to motor shaft Clamping plate Motor assembling flange AC motor Plastic insert Coupling connect to the spindle Plug Wheel flange base Wheel flange clamping cover...

  • Page 84: Packing List

    Packing List PACKING LIST Name G.W. WSG1640AHD 3800KG Name Oil tank Coolant tank 3. Accessories Name Code Remark Balance arbor FSG2550R-86-301/302 In the tool box Wheel dresser In the tool box base Wheel Flange Suit for 350*40*120 1 set In the carton...
  • Page 85 Packing List 4. Optional accessories Name Code Balance stand Parallel wheel dresser Digital readout Magnetic separator Paper filter Diamond pen 5. Documents Name Operating manual 1 copy Packing list 1 copy Inspector：...