Nakanishi NR40 -5100 ATC Operation Manual

Automatic Tool Replacement Spindle
NR40 -5100 ATC
OPERATION MANUAL
Thank you for purchasing the Automatic Tool Replacement Spindle " NR40 - 5100 ATC ". The E3000 CONTROLLER,
Brushless Motor and Air Line Kit are required to drive this Spindle. Read this and all the associated component
Operation Manuals carefully before use. Always keep this Operation Manual in a place where a user can referred
to for reference at any time.
1 . CAUTIONS FOR HANDLING AND OPERATION
■ Read these warnings and cautions carefully and only use in the manner intended.
■ These warnings and cautions are intended to avoid potential hazards that could result in personal injury to the
operator or damage to the device. These are classi¿ed as follows in accordance with the seriousness of the risk.
Class Degree of Risk
A safety hazard could result in bodily injury or damage to the device if
WARNING
the safety instructions are not properly followed.
A hazard that could result in light or moderate bodily injury or damage
CAUTION
to the device if the safety instructions are not followed.
WARNING
① The Spindle is not a hand tool. It is designed to be used on CNC machines or special purpose
machines.
② Do not touch the cutting tool while it is running. It is very dangerous.
③ Wear safety glasses, dust mask, and use a protective cover around the Spindle whenever the
Spindle is rotating.
④ Never connect, disconnect or touch the Power Cord Plug or Motor Cord Plug with wet hands.
This may cause an electric shock.
⑤ Never operate or handle the Spindle and brushless motor until you have thoroughly read the
Operation Manuals and safe operation has been con¿rmed.
1 ) To prevent injuries / damages, check the Spindle, brushless motor and cutting tool for
proper installation, before operating the Spindle and brushless motor.
2 ) Before disconnecting the Spindle and brushless motor, always turn the control power off
and turn the compressed air supply to the CONTROLLER off. Then it is safe to remove the
Spindle and brushless motor.
⑥ When installing a Spindle to a ¿xed base, make sure the ¿xed base is grounded in order to
avoid the risk of an electric shock.
⑦ When installing a tool, tighten the collet correctly and check again the collet before use. Do not
over-tighten the collet. This may cause damage to the spindle.
⑧ Do not open and close the collet while the brushless motor is running.
⑨ Do not use bent, broken, chipped, out of round or sub-standard tools, as this may cause them
to shatter or explode. Tools with fractures or a bent shank will cause injury to the operator.
When using a new tool, rotate it in a low speed and increase speed gradually for safety.
⑩ Do not exceed the maximum recommended allowable tool speed. For your safety, use speeds
below the maximum allowable speed.
⑪ Do not apply excessive force. This may cause tool slippage, tool damage, injury to the operator
or loss of concentricity and precision.
CAUTION
① Do not drop or hit this Spindle, as shock can damage to the internal components.
② Do not connect this Spindle to the redutcion gear. This may cause collet breakage by overload.
③ Be sure to clean the collet, the inside of the spindle before replacing the tool. If ground
particles or metal chips stick to the inside of spindle or the collet, damage to the collet or
spindle can occur due to the loss of precision.
④ When cleaning a Spindle, stop the brushless motor and remove debris with a soft brush or a
cloth. Do not blow air into the end of spindle area (refer to section " 6 - 2 Outside View ") with
compressed air as foreign particles or cutting debris may get into the ball bearing.
⑤ Always clean the tool shank before installing the tool in the spindle.
⑥ When sizing the correct collet size to the tool shank diameter, a tolerance of +0 ~ - 0.01mm is
strongly recommended. A tool shank within the +0 ~ - 0.1mm range is mountable, however, this
may cause poor concentricity and or insuf¿cient tool shank gripping force.
⑦ Select suitable products or tools for all applications. Do not exceed the capabilities of the
Spindle or tools.
⑧ Do not stop the supplied cooling air to the brushless motor during operation of the machine.
Removing the air pressure from the brushless motor causes a loss of purging, allowing the
Spindle to ingest coolant and debris. This will cause damage to the Spindle.
⑨ Carefully direct coolant spray directly on the tool. Do not spray directly on the Spindle body.
If large amount spray directly on the Spindle, it may cause excess load of the Spindle rotation
with loss of durability to the Spindle.
⑩ Stop working immediately when abnormal rotation or unusual vibration are observed.
Immediately, please check the content of section " 14. TROUBLESHOOTING ".
⑪ Always check if the tool, collet, connection hose and supply air hose for damaged before and
after operating.
⑫ If the collet show signs of wear or damage, replace it before a malfunction or additional
damage occurs.
⑬ After installation, repair, initial operation, or long periods of non operation, please refer to
section " 12. BREAK-IN PROCEDURE " detailed in Table. 2. When checking the Spindle, no
vibration or unusual sound should be observed during rotation.
⑭ Do not disassemble, modify or attempt to repair this Spindle. Additional damage will occur
to the internal components. Service must be performed by NSK NAKANISHI or an authorized
service center.
⑮ When using this Spindle for mass production, please consider the purchase of an additional
Spindle to be used as a back-up in case of emergency.
2 . BASIC PACKAGE
When opening the package, check if it includes all items listed in " Table.1 Packing List Contents ".
In the event of any shortage, please contact either NAKANISHI (see the " 4. CONTACT US " section) or your local
dealer.
Table. 1 Packing List Contents
Spindle・・1pc. Collet
(CHB - 3.175)・・1pc.*
(For U.S. market
(CHB - 3.175))
OM-K0457E 003
Wrench (6.1 x 8), (9 x 11) Air Hose with Filter
・・1pc. Each.
Operation Manual・・1set
OPERATION MANUAL
3 . WARRANTY
We provide a limited warranty for our products. We will repair or replace the products if the cause of failure is due
to the following manufactures defects. Please contact us or your local distributor for details.
① Defect in manufacturing.
② Any shortage of components in the package.
③ Where damaged components are found when initially opening the package.
(This shall not apply if the damage was caused by the negligence of a customer.)
4 . CONTACT US
For your safety and convenience when purchasing our products, we welcome your questions.
If you have any questions about operation, maintenance and repair of the product, please contact us.
Contact Us Contact Us
For U.S. Market
Company Name :
Industrial Div.
Business Hours : 8:30am to 17:00pm (CST)
(closed Saturday, Sunday and Public Holidays)
U.S. Toll Free No. : 800-585-4675
Telephone No. : 847-843-7664
Fax No. : 847-843-7622
Web Address : www.nskamericacorp.com
For Other Markets
Company Name :
Business Hours : 8:00am to 17:00pm
(closed Saturday, Sunday and Public Holidays)
Telephone No. : +81 (0) 289-64-3520
e-mail Address : webmaster-ie@nsk-nakanishi.co.jp
5 . FEATURES
① The tools can be replaced automatically by putting ON - OFF the air.
② The Spindle housing is made from precision ground, stainless steel (SUS) with outside diameter of
③ The collet size is 2.0mm, 3.0mm,
6 . SPECIFICATIONS AND DIMENSIONS
6 - 1 Speci¿cations
Model
Maximum Motor Rotation Speed
Spindle Accuracy
Applicable Motor
*This Spindle can not use the reduction gear.
Milling Capacity
(Cutting or Milling PC boards with an end mill.)
Noise Level at 1m distance
Weight
* You may need to lower feed rate (mm / min) depending on the shape of tools being used or the thickness of work.
Always check the milling condition before working.
3.175mm Bar Wrench (K - 236)・・1pc.
3.175mm
Inspection Card・・1pc.
( 6mm x 2m)・・1pc.
Inspection Card
* The collet is attached to the Spindle.
40mm.
3.175mm, 4.0mm.
NR40 - 5100 ATC
50,000min -1 (rpm)
Within 2 m
EM - 3060, EM - 3060J / EM - 3060J - 2M
EM - 3030J / EM - 3030J - 2M
End Mill Size : Less than 2.0mm
Wo r k : PC board (ex. Glass Epoxy Resin)
Thickess : Less than 1.6mm
F : Less than 3,000mm / min
Less than 70 dB (A)
740g
Temperature Humidity
Operation Environment 0 - 40°C MAX.75% (No condensation)
Transportation and Storage
-10 - 50°C 10 - 85%
Environment
<Option>
Collet (CHB - □□ ) 2.0 mm, 3.0 mm, 3.175mm, 4.0 mm
6 - 2 Outside View
End of Spindle Area
3
(6.1)
8 82
(109.1)
Fig. 1
7 . CONNECTION OF THE SPINDLE TO THE BRUSHLESS MOTOR
CAUTION
Make sure your hands and all interlocking parts of the Spindle and brushless motor are clean
before connecting the Spindle to the brushless motor. This is critical in preventing contaminants
from entering the Spindle or brushless motor.
Align the thread on the front end of the brushless
motor and the rear of the Spindle, and turn the
Spindle clockwise. If the drive shaft of the brushless
motor does not engage properly to the drive dog
on the Spindle, it may only turn aprroximately two
threads before stopping.
DO NOT FORCE THEM TOGETHER. Loosen
the Spindle from the brushless motor, rotate the
Spindle shaft by hand then re-try. The drive shaft
and the drive dog must be fully engaged. When
fully engaged, secure the brushless motor and
Spindle using the provided 27mm wrench (Fig. 2).
8 . CONNECTION OF AIR HOSE AND AIR SUPPLY
CAUTION
Securely connect the air hose to the brushless motor and air line kit to avoid accidental
disconnection and injury to the operator during use.
① Connect the provided 6mm Air 6mm Air Hose with Filter
Hose with ¿lter and 3-way valve to
Air Inlet Joint
Air Inlet Joint shown in Fig. 3.
② Supply clean air from air
compressor through air ¿lter or air
dryer to the 3-way valve at the set
air pressure : from 0.55 - 0.6MPa
(79.8 - 87psi).
9 . CHANGING THE TOOL
WARNING
Do not open and close the collet while the brushless motor is running.
CAUTION
・ When the air is supplied to the inlet joint of the Spindle, the tool will be pushed out by
exhausting the coolant air of brushless motor from the edge of Spindle. Be careful not to be
damaged to the tool or be injured.
・ Use the air on-off valve through which the air can be exhausted. Do not use 2 way valve,
because the 2 way valve is not echausted and the collet is not closed.
・ Do not open and close the collet before the tool is not installed. Because this will cause damage
to the collet or loss of precision.
RECOMMENDATIONS
Please set the cutting tools to minimize the overhang amount. 13mm is the maximum amount of
overhang to maintain high accuracy and safety.
① Stop the motor (Or check if the motor is stopped).
② Supply air pressure: from 0.55 - 0.6MPa (79.8 - 87psi) to Air Inlet Joint through 3-way valve. Then, the chuck
will be opened. At the same time, the tool is pushed out by the air exhaust for the coolant of motor. So, need
the tool holder not to be damaged to the tool.
③ Replace the tool.
④ Exhaust the air through 3-way valve. The collet will be closed and the tool can be ¿xed.
Atmospheric Pressure
800 - 1,060hPa
500 - 1,060hPa
10
(13)
Transmission Clutch
Tighten
Turn
Fig. 2
3-way valve
Air Release
Air Supply
Dry Air
(Supply Side)
Fig. 3