Doosan DVF5000 Owner's Manual
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Doosan DVF5000 Owner's Manual

Vmc installation and comissioning
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Manual for VMC Installation
and Commissioning
DVF5000
DOOSAN Machine Tool
MV0111ISE203

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Summary of Contents for Doosan DVF5000

  • Page 1 Manual for VMC Installation and Commissioning DVF5000 DOOSAN Machine Tool MV0111ISE203...

  • Page 3: Table Of Contents

    CONTENTS CONTENTS 1. Preparation Before Machine Shipping ..............4 1.1 Selection of Machine Installation site .............. 4 1.2 Foundation Work ..................7 1.3 Preparation Before Machine Arrival ..............10 2. Machine transport and checking of shipped items ..........11 2.1 Machine Transport ..................11 2.2 Checking of shipped items ................
  • Page 4 CONTENTS 6.10 C-axis centerline and Y-axis movement squareness ........62 6.11 Table top and X-axis feed parallelism ............66 6.12 Table top and Y-axis feed parallelism ............68 6.13 Spindle centerline and Z-axis feed parallelism ..........72 6.14 Run-Out of Spindle Cross Section ............... 76 6.15 Run-Out of Spindle Internal Diameter ............
  • Page 5 CONTENTS ♦ DVF5000...

  • Page 6: Preparation Before Machine Shipping

    1. Preparation Before Machine Shipping 1. Preparation Before Machine Shipping 1.1 Selection of Machine Installation site 1) Temperature at the place of machine installation Machine performance may be affected due to an irregularity of the lubrication system if the temperature is lower than the temperature range allowed for machine operation, or due to reduced cooling capacity of the oil cooler if the temperature at the place is higher.
  • Page 7 1. Preparation Before Machine Shipping Note 1) : Standard Machine Front View ※ ※ Note 2) : Standard Machine Top View...
  • Page 8 1. Preparation Before Machine Shipping ※ Note 3) : Standard Machine Right View...

  • Page 9: Foundation Work

    1. Preparation Before Machine Shipping 1.2 Foundation Work 1) Foundation Work Period and Inspection ① Ideally, it should take at least two months from completion of the foundation to installation of the machin. ▪ The concrete will need to be cured for a period of one month or more. ②...
  • Page 10 1. Preparation Before Machine Shipping ※ Detailed Drawings Side Anchor Styrofoam Concrete FL=0 Reinforces the ground by driving files if necessary Filing with quality rubbles and gravels and fully tamped down Reinforce concrete with diagonally placed steel bars ※ Main Values Machine Weight 7.5 ton Maximum weight of workpiece...
  • Page 11 1. Preparation Before Machine Shipping ※ Side Anchor Parts List Parts No. Description Mat./Specification Q ty Remarks ’ P88073613 Leveling Bolt S45C Level P88100036 Hex. Nut S45C Block 00201-04106 Leveling Block GC250 100203-01052 Clamp; Z S45C 120112-01428 Clamp Bolt HIT-C M20×320 Side S5101101 Spring Washer...

  • Page 12: Preparation Before Machine Arrival

    1. Preparation Before Machine Shipping 1.3 Preparation Before Machine Arrival 1) Marking the place of machine installation ① Please refer to the machine lay-out drawing and use a removable tape to mark the exact location of machine installation. ▪ Be sure to leave sufficient space for maintenance and door opening, installation and maintenance of the chip conveyor and the coolant tank, etc.

  • Page 13: Machine Transport And Checking Of Shipped Items

    2. Machine transport and checking of shipped items 2.1 Machine Transport The DVF5000, except for some peripherals that are separated and shipped separately, is transported after being assembled with the splash guard. Since the machine is heavy and the center of gravity is unstable, it is important to balance the machine as a whole when it is being moved by a crane or forklift, and to avoid bending or causing scratches etc.
  • Page 14 2. Machine transport and checking of shipped items Auxiliary rope for supporting option (TMG) weight 2) Using a forklift When using a forklift to transport the machine, use equipment with a rated load of 10 tons or more to ensure safety.
  • Page 15 2. Machine transport and checking of shipped items...

  • Page 16: Checking Of Shipped Items

    2. Machine transport and checking of shipped items 2.2 Checking of shipped items The following units and parts are disassembled at the factory and transported to the site for installation. Make sure that all items have been shipped in good condition so that no delay occurs due to missing or damaged items.
  • Page 17 2. Machine transport and checking of shipped items ( Pallet Bundle for AWC ) ( Jig for machine feed level measuring ) ( AWC (Automatic Workpiece ( Pallets for AWC that are Changer)) unfolded )
  • Page 18 5. Machine Leveling ※ Note) Thickness adjustment for L/M Guide Block Liner (Y-Z) (1) Refer to the “Y-Z squareness”above to measure the exact squareness. (2) Calculate the amount of Liner polishing by calculating the length of square ruler and the distance between the Z-axis L/M Guide’s two Blocks. ▪...

  • Page 19: Machine Anchoring Operation

    3. Machine Anchoring Operation 3. Machine Anchoring Operation 3.1 Machine Homing Operation 1) Marking the machine installation site Mark the exact installation location of the machine using a tape that can be removed once the machine has been installed. 2) Machine Transport After transporting the machine to the place of installation, determine the exact position of installation and place the machine on the factory floor.

  • Page 20: Machine Anchoring Operation

    3. Machine Anchoring Operation 3.2 Machine Anchoring Operation 1) Items to be prepared for anchoring For the anchoring required to secure the machine on the factory floor, first prepare the various parts and other essentials. ① Hammer Drill ② Hammer drill bit for making a hole with a diameter of 22mm and a depth of 150mm or more.
  • Page 21 3. Machine Anchoring Operation 2) Anchor position marking ① Install a screw jack in front of the 4 leveling bolts (out of the 6 leveling bolts on the bed), put the Z-clamp on it against the bed, adjust the Z-clamp so that it is parallel to the ground surface by adjusting the height of the jack screw, and insert the clamp bolt into the groove of the Z-clamp and place it in the upright position when it touches the ground.
  • Page 22 3. Machine Anchoring Operation 4) Anchor drilling ① Attach a 22mm bit to the hammer drill and make a hole at the center of the circle marked as the anchor position. ▪ As a lot of dust is generated when making a hole in concrete, remove the dust with the vacuum cleaner from the entrance of the hole.
  • Page 23 3. Machine Anchoring Operation 5) Moving the machine back to the installation position ① Move the machine back to the required position. ② Make sure that the ends of 4 of the 6 leveling bolts (exclude the 2 bolts in the middle) protrude by about 25mm and put down the leveling block.
  • Page 24 3. Machine Anchoring Operation 6) Setting up the chemical anchor ① Prepare the items required to set up the chemical anchor. ▪ Full Thread Clamp Bolt (HIT-C M20ⅹ320) with one end cut by 45° ▪ Chemical Anchor ▪ Manual Dispenser for Chemical Anchor Manual dispenser for chemical...
  • Page 25 3. Machine Anchoring Operation ④ Set up a screw jack in front of the leveling bolt, place the Z-clamp on it against the bed, adjust the height of the screw jack until the Z-clamp is parallel to the ground surface or the screw jack’s side is a little higher, and insert the washer and nut. ▪...

  • Page 26: Machine Power-Up

    4. Machine Power-up 4. Machine Power-up 4.1 Oil Cooler Connection Place the oil cooler to its originally intended position which was removed from the machine unit at the time of shipping and separately transported, and connect various hoses and wires that were removed for the shipping. 1) Placing the Oil Cooler to its original position ①...
  • Page 27 4. Machine Power-up ④ From among two cables wound around the oil cooler, find the temperature detection sensor cable and connect the cable into the connector removed inside the machine splash guard. Censor Cable Connector ⑤ Find the hoses and attach them to the hydraulic connector on the “...

  • Page 28: Disassembling The Shipping Fixtures

    4. Machine Power-up 4.2 Disassembling the Shipping Fixtures Disassemble and take out the shipping axis fixture assembled at the time of machine shipping to prevent the table or column from slipping. 1) Removing the X-axis(Column) fixture ① Disassemble and take out the Front Maintenance Cover on the side of the machine. Maintenance Cover ②...
  • Page 29 4. Machine Power-up 3) Removing the Z-axis (Spindle Head) fixture Disassemble and take out the Z-axis (spindle head) shipping fixture secured to the column and spindle head. Z-axis fixture Z-axis fixture 4) Disassembly of the B-axis (Tilting Table) fixing jig Disassemble and take out B-axis (Tiling Table) shipping fixture which secures Tilting Table s fixed part and rotation part.
  • Page 30 4. Machine Power-up 6) Removing the O.P (Operation Panel) fixing jig Disassemble and take out the O.P. shipping fixture which secures the O.P. and the splash guard. O.P fixture O.P fixture 7) Removing the AWC (Automatic Work Changer) fixing jig (Option) Disassemble and take out the AWC Gantry Loader and the Pallet Support fixture.

  • Page 31: Main Power And Pneumatic Input

    4. Machine Power-up 4.3 Main Power and Pneumatic input 1) Main Power connection Connect the power line and earth line from the factory switchboard to the terminal block of the main NFB. ▪ Power capacity: 60KVA ▪ Wire sectional area: 220V : 35㎟, 360 ∼...
  • Page 32 4. Machine Power-up 3) Checking the factory voltage applied Switch the switchboard of the factory to "ON" and measure the voltage of the factory side power on the main NFB using an electric tester to see if there is any irregularity. ▪...
  • Page 33 4. Machine Power-up 4) Turning On the Main NFB After fully checking the main power connection and voltage, assemble the NFB terminal block lid and turn the main NFB to “ON” after checking once again that the various hydraulic hoses, wires and connectors are properly connected. Terminal Block lid 5) Machine Ready...

  • Page 34: Machine Leveling

    For the DVF5000, which is designed with one Bed, machine absolute level operation shall be performed on the basis of Table along with feed level operation based on the Spindle Head, and both shall be satisfied.

  • Page 35: Machine Absolute Level Operation

    5. Machine Leveling 5.1 Machine absolute level operation Note) Matters to be noted when performing the level operation ※ Prior to starting absolute level operation for 5-axes machine, be sure to check the table top accuracy in advance, and correct in case of any irregularity. ▪...
  • Page 36 5. Machine Leveling 2) Level installation ① Send the machine to X0. Y0. Z400. position. ② Clean the table top thoroughly and install the levels to which Absolute Level “ ” Setting was completed in X- and Y-axis respectively such that the table top center comes to the middle of the level.
  • Page 37 5. Machine Leveling After accurately adjusting the absolute level by adjusting 4 level bolts, tighten the ③ remaining 2 bolts with optimum torque by letting them make contact with the leveling block. ▪ Lastly, make a final adjustment to ensure accurate level with a torque as equal as possible being applied to each of 6 level bolts.

  • Page 38: Machine Feed Level Operation

    5. Machine Leveling 5.2 Machine Feed Level Operation 1) Machine feed level operation jig installation and reference point setting ① Prepare the level installation jig which is one of the basic items shipped and assemble and secure the jig on the front cover surface under the spindle in Y-axis direction.
  • Page 39 5. Machine Leveling ② Repeat the leveling operation as described above and write down the level amount on a piece of paper. How to record the level on a piece of paper (example) ※ Y225. X-direction: 20 direction Y-direction: 20 X direction Y-225.

  • Page 40: Machine Accuracy Measurement And Adjustment

    6. Machine Accuracy Measurement and Adjustment 6. Machine Accuracy Measurement and Adjustment ※ Sample of DVF5000 Test Report GEOMETRICAL TEST (기하학적 정밀도) Straightness (진직도) Unit : mm Tolerance (허용 공차) Result Item (검사 항목) Diagram (측정 방법) (측정 결과) DOOSAN...
  • Page 41 6. Machine Accuracy Measurement and Adjustment GEOMETRICAL TEST (기하학적 정밀도) Squareness (직각도) Unit : mm Tolerance (허용 공차) Result Item (검사 항목) Diagram (측정 방법) (측정 결과) DOOSAN Checking of squareness between X-axis XY plane motion and 0.020/500 0.010/300 the Y-axis (XY평면)
  • Page 42 GEOMETRICAL TEST (기하학적 정밀도) Parallelism & Run out (평행도 & 흔들림) Unit : mm Tolerance (허용 공차) Result Item (검사 항목) Diagram (측정 방법) (측정 결과) DOOSAN Checking of parallelism between X-axis XZ Plane motion and 0.020/500 0.010/300 the table (XZ평면)

  • Page 43: Axis Movement Straightness

    6. Machine Accuracy Measurement and Adjustment [1] Straightness 6.1 X Axis Movement Straightness 1) X - Z plane ① Measurement Place two blocks whose height is equal in the X-axis direction on the table and place a straight edge over it in the upright position, and then set up an indicator on the spindle head and set it to at both ends of the upper side of the straight edge, and “...
  • Page 44 6. Machine Accuracy Measurement and Adjustment 2) X - Y plane ① Measurement Place a straight edge by laying down on the table in X-axis direction, set the indicator on both ends of the straight edge by setting up an indicator on the spindle head “...

  • Page 45: Y Axis Movement Straightness

    6. Machine Accuracy Measurement and Adjustment 6.2 Y Axis Movement Straightness 1) Y - Z plane ① Measurement Place two blocks whose height is equal in the Y-axis direction on the table and place a straight edge over it in the upright position, and then set up an indicator on the spindle head and set it to “0 ”...
  • Page 46 6. Machine Accuracy Measurement and Adjustment 2) Y - X plane ① Measurement Place a straight edge by laying down on the table in the Y-axis direction, set the indicator to “0 ” at both ends of the straight edge by setting up an indicator on the spindle head, and then measure the maximum difference (i.e.

  • Page 47: Straightness Of Z Axis Movement

    6. Machine Accuracy Measurement and Adjustment 6.3 Straightness of Z Axis Movement 1) Z - Y plane ① Measurement Place a square ruler in the upright position on the table in the Y-axis direction at the B0. position, set the indicator to “0 ” at the end of the vertical plane on the square ruler by setting up an indicator on the spindle head, and then measure the maximum difference (i.e.
  • Page 48 6. Machine Accuracy Measurement and Adjustment 2) Z - X plane ① Measurement Place a square ruler in the upright position on the table in the X-axis direction at the B0. position, set the indicator to “0 ” on the end of the vertical plane on the square ruler by setting up an indicator on the spindle head, and then measure the maximum difference (i.e.

  • Page 49: X-Z Axis Cross-Squareness

    6. Machine Accuracy Measurement and Adjustment [2] Squareness 6.4 X-Z axis cross-squareness 1) Measurement Place a square ruler in the upright position on the table in the X-axis direction at the B0. position, set the indicator to “0 ” at the end(ⓑ) of the vertical plane on the square ruler by setting up an indicator on the spindle head, and then measure the maximum difference of the other end(ⓐ) while moving the Z-axis.
  • Page 50 6. Machine Accuracy Measurement and Adjustment (4) Loosen the Y-axis Ball Screw nut fixing bolt. (5) Put a Screw-Jack between the Saddle and the Column, and slightly lift the Column until the Liner can be taken out. (6) Take out the Adjusting Plate, perform polishing operation for the amount calculated in “(2) ”, and then reassemble it.

  • Page 51: Y - Z Axis Cross Squareness

    6. Machine Accuracy Measurement and Adjustment 6.5 Y - Z axis Cross Squareness 1) Measurement Place a square ruler in the upright position on the table in the Y-axis direction at the B0. position, set the indicator to “0 ” at the end(ⓑ) of the vertical plane on the square ruler by setting up an indicator on the spindle head, and then measure the maximum difference of the other end(ⓐ) while moving the Z-axis.
  • Page 52 6. Machine Accuracy Measurement and Adjustment Note) L/M Guide Block Liner thickness adjustment (Y-Z) ※ (1) Refer to the “Y-Z squareness” above to measure the exact squareness. (2) Calculate the amount of the Liner polishing by calculating the length of the square ruler and the distance between the Z-axis L/M Guide’s two blocks.

  • Page 53: X-Y Axis Cross-Squareness

    6. Machine Accuracy Measurement and Adjustment 6.6 X-Y axis cross-squareness 1) Measurement Place a square ruler lying on the table top, set the indicator at both ends while moving the indicator in the X-axis direction( ), and adjust the X-axis direction parallelism ⓐ...
  • Page 54 6. Machine Accuracy Measurement and Adjustment ※ Note) L/M Guide Block realignment operation (X-Y plane) (1) Refer to the “X-Y squareness” above to measure the exact squareness. (2) Calculate the amount of the Liner polishing by calculating the length of the square ruler and the distance between the Y-axis L/M Guide’s two slide blocks.

  • Page 55: Spindle Centerline And X-Axis Movement Squareness (X-Z Plane)

    6. Machine Accuracy Measurement and Adjustment 6.7 Spindle centerline and X-axis movement squareness (X-Z plane) 1) Measurement ① Install the indicator hold on the end of the spindle and bend so that the needle is about 150mm from the spindle center and place the axis near Y0., X150. ②...
  • Page 56 6. Machine Accuracy Measurement and Adjustment Note) Spindle Housing Vertical Adjustment (12,000rpm spindle) ※ (1) By referring to “Spindle centerline and X-axis movement squareness” above, measure the exact squareness to calculate the amount of polishing on the liner. ▪ Since the outer diameter of the spindle housing is 250mm, multiply the squareness measurement by 0.8.
  • Page 57 6. Machine Accuracy Measurement and Adjustment ④ Loosen two bolts diagonally from among the Bearing Housing Fixing Bolts (6-BB10ⅹ45), insert two M10 full thread screws into each M10 Nut and insert them to the positions from which the fixing bolts have been removed diagonally, place one nut at a point 40mm away from the housing entrance, with the other positioned very close to the entrance, and then loosen all other fixing bolts that have not been disassembled.
  • Page 58 6. Machine Accuracy Measurement and Adjustment ※ Note) Spindle Housing Vertical Adjustment(18,000rpm spindle) (1) By referring to “Spindle centerline and X-axis movement squareness” above, measure the exact squareness. (2) Calculate the amount of Liner polishing by calculating the length of the square ruler and the outer diameter of the spindle housing.

  • Page 59: Spindle Centerline And Y-Axis Movement Squareness (Y-Z Plane)

    6. Machine Accuracy Measurement and Adjustment 6.8 Spindle centerline and Y-axis movement squareness (Y-Z plane) 1) Measurement ① Install the indicator hold on the end of the spindle and bend so that the needle is about 150mm from the spindle center and place the axis near X0., Y150. ②...
  • Page 60 6. Machine Accuracy Measurement and Adjustment ※ Note) Spindle Housing Vertical Adjustment(12,000rpm spindle) (1) By referring to “Spindle centerline and Y-axis movement squareness” above, measure the exact squareness to calculate the amount of polishing on the liner. ▪ Since the outer diameter of the spindle housing is 250mm, multiply the squareness measurement by 0.8.
  • Page 61 6. Machine Accuracy Measurement and Adjustment ④ Loosen two bolts diagonally from among the Bearing Housing Fixing Bolts (6-BB10ⅹ45), insert two M10 full thread screws to each M10 Nut and insert them to the positions where the fixing bolts have been removed diagonally, place one nut at a point 40mm away from the housing entrance with the other positioned very close to the entrance, and loosen all other fixing bolts that have not been disassembled.
  • Page 62 6. Machine Accuracy Measurement and Adjustment (4) Reassemble the Tubes, Connecter and Hoses, Fitting Cover, etc. (5) Reassemble the bearing housing, measure the squareness and repeat the process until a satisfactory result has been obtained. ※ Note) Spindle Housing Vertical Adjustment (18,000rpm spindle) (1) By referring to “Spindle centerline and Y-axis movement squareness”...

  • Page 63: C-Axis Centerline And X-Axis Movement Squareness

    6. Machine Accuracy Measurement and Adjustment 6.9 C-axis centerline and X-axis movement squareness 1) Measurement ① Place the block in the X-axis direction at a point about 150mm from the table top center, set up an indicator on the spindle end at the “X-150., Y0.” position and set the block to “0 ”.

  • Page 64: C-Axis Centerline And Y-Axis Movement Squareness

    6. Machine Accuracy Measurement and Adjustment 6.10 C-axis centerline and Y-axis movement squareness 1) Measurement ① Place a block in the Y-axis direction at a point about 150mm from the table top center, set up an indicator on the spindle end at the “Y-150., X0.” position and set the block to “0 ”.
  • Page 65 6. Machine Accuracy Measurement and Adjustment ※ Note) Table Ass’y vertical/horizontal adjustment (1) When the B-axis is turned to B90, make a note of the direction and error amount by measuring the heights of the Y-axis and the table top. (2) Set up two indicators on the spindle head, perform “0 ”...
  • Page 66 6. Machine Accuracy Measurement and Adjustment Adjust Adjust Block Block Hook Wrench 2-Bolt If the hook wrench was not prepared, use a bolt and rod. (4) Turn the B-axis to B90. and measure the parallelism of the erected table with the Y-axis by moving the Y-axis with the indicator placed against the erected table top.
  • Page 67 6. Machine Accuracy Measurement and Adjustment (6) Set up two indicators on the spindle head, perform “0 ” setting while the needle makes contact with the T-groove side of the table end and table top, and then secure the bearing body. ①...
  • Page 68 6. Machine Accuracy Measurement and Adjustment [3] Parallelism & Run Out 6.11 Table top and X-axis feed parallelism 1) Measurement ① After setting up an indicator on the spindle, transfer the X-axis to X-150. ② Perform “0 ” setting on the indicator set up to the spindle at a table surface about 150mm away from the table center in the Y-axis “-”...
  • Page 69 6. Machine Accuracy Measurement and Adjustment ※ Note) Resetting the B-axis reference point (1) By referring to “Table top and X-axis feed parallelism” above, measure the exact parallelism. (2) Measure the table top in the X-axis direction while moving the B-axis in the “Handle”...
  • Page 70 6. Machine Accuracy Measurement and Adjustment 6.12 Table top and Y-axis feed parallelism 1) Measurement ① After setting up an indicator on the spindle, transfer the T-axis to -150. ② Perform “0 ” setting on the indicator set up to the spindle at a table surface about 150mm away from the table center in the Y-axis “-”...
  • Page 71 6. Machine Accuracy Measurement and Adjustment ※ Note) Table Ass’y vertical/horizontal adjustment (1) When the B-axis is turned to B90, make a note of the direction and error amount by measuring the height of the Y-axis and table top. (2) Set up two indicators on the spindle head, perform “0 ” setting while touching the needle on the T-groove side on the table end and table top, and then loosen the 160601-02056C Bearing Body Fixing Bolts (4- BB8ⅹ...
  • Page 72 6. Machine Accuracy Measurement and Adjustment Adjust Block Adjust Hook Wrench Block 2-Bolt If the hook wrench was not prepared, use a bolt and rod. (4) Turn the B-axis to position B90 and measure the parallelism of the erected table with the Y-axis by moving the Y-axis with the indicator placed against the erected table top.
  • Page 73 6. Machine Accuracy Measurement and Adjustment (6) Set up two indicators on the spindle head, perform “0 ” setting while the needle makes contact with the T-groove side of the table end and table top, and then secure the bearing body. ①...

  • Page 74: Spindle Centerline And Z-Axis Feed Parallelism

    6. Machine Accuracy Measurement and Adjustment 6.13 Spindle centerline and Z-axis feed parallelism 1) Measurement Set up a test bar on the Spindle and an indicator on the Table. Contact the gage at the highest point at the end of the test bar. Measure the spindle run-out by rotating the spindle by hand.
  • Page 75 6. Machine Accuracy Measurement and Adjustment ※ Note) Spindle Housing Vertical Adjustment (12,000rpm spindle) (1) By referring to “Spindle centerline and Z-axis feed parallelism” above, measure the exact parallelism to calculate the amount of polishing on the liner. (Measured amount and amount of polishing 1:1) (2) Lower the spindle housing by about 30mm-35mm.
  • Page 76 6. Machine Accuracy Measurement and Adjustment ④ Loosen two bolts diagonally from among the Bearing Housing Fixing Bolts (6-BB10ⅹ45), insert two M10 full thread screws into each M10 Nut and insert them into the positions from which the fixing bolts have been removed diagonally, place one nut at a point 40mm away from the housing entrance, with the other positioned very close to the entrance, and then loosen all other fixing bolts that have not been disassembled.
  • Page 77 6. Machine Accuracy Measurement and Adjustment ※ Note) Spindle Housing Vertical Adjustment (18,000rpm spindle) (1) By referring to “Spindle centerline and Z-axis feed parallelism” above, measure the exact parallelism to calculate the amount of polishing on the liner. (Measured amount and amount of polishing 1:1) (2) Disassemble and take out the spindle head cover and loosen the spindle housing fixing bolts (8-BB10ⅹ30).

  • Page 78: Run-Out Of Spindle Cross Section

    6. Machine Accuracy Measurement and Adjustment 6.14 Run-Out of Spindle Cross Section 1) Measurement Disassemble and take out the driving key from the spindle cross section, perform “0 ” setting while placing the indicator against the spindle, and then take the maximum run- out value as the measurement value by rotating the spindle at low speed.

  • Page 79: Run-Out Of Spindle Internal Diameter

    6. Machine Accuracy Measurement and Adjustment 6.15 Run-Out of Spindle Internal Diameter 1) Measurement Install the test bar on the spindle and turn the spindle at low speed or manually, with the indicator touching the entrance and at 300 mm from the entrance. Rotate the spindle manually or at low speed to measure the run-out, and take the maximum run-out as the measured value.

  • Page 80: Run-Out Of Table Top Surface

    6. Machine Accuracy Measurement and Adjustment 6.16 Run-Out of Table Top Surface 1) Measurement In the B0. condition, install an indicator on the spindle, set the indicator to “0 ” while a gage is making contact with the table top at a point 150mm away from the center, and take the maximum difference in height as the measured value by rotating the C-axis in the Handle Mode.

  • Page 81: Adjustment Of Reference Points Of Respective Axes And Manual Tcp Adjustment

    7. Adjustment of reference points of respective axes and manual TCP adjustment 7. Adjustment of reference points of respective axes and manual TCP adjustment 7.1 X- and Y-axis reference point resetting Reset the X-axis or Y-axis reference point with the Grid Shift adjustment. ▪...
  • Page 82 7. Adjustment of reference points of respective axes and manual TCP adjustment Grid Grid Grid Reference point mark - direction + direction Grid Shift (Parameter No. 1850) Starting position Y-axis Y-axis X-axis reference fixing X-axis feed reference point mark reference reference point mark point mark...

  • Page 83: Z-Axis Reference Point Resetting (Z-Axis Stroke: 400Mm)

    7. Adjustment of reference points of respective axes and manual TCP adjustment 7.2 Z-axis reference point resetting (Z-axis Stroke: 400mm) 1) Insert a test-bar into the spindle, set up a block gage (around 100mm) so that the measurement can be made from the bottom, and set the indicator to “0.”...
  • Page 84 7. Adjustment of reference points of respective axes and manual TCP adjustment Grid Grid Grid Reference point mark - direction + direction Grid Shift (Parameter No. 1850) Starting position Z-axis Z-axis fixing reference reference point mark point mark Z-axis feed reference point mark...
  • Page 85 7. Adjustment of reference points of respective axes and manual TCP adjustment ※ Note) Forced reference point setting of the Z-axis (1) Use the Test Bar, Indicator, Block Gage, etc. to measure the distance from the table top to the Spindle Gage Line. (Refer to “Z-axis reference point resetting”...

  • Page 86: B-Axis Reference Point Resetting (B-Axis Stroke : B-30° ~ B110°)

    7. Adjustment of reference points of respective axes and manual TCP adjustment ∼ 7.3 B-axis reference point resetting (B-axis Stroke : B-30° B110°) The axis B is subject to the absolute zero-point setting method, so the zero point should be reset by the parameter setting.

  • Page 87: C-Axis Reference Point Resetting (C-Axis Stroke : C0° ~ C359.999°)

    7. Adjustment of reference points of respective axes and manual TCP adjustment ∼ 7.4 C-axis reference point resetting (C-axis Stroke : C0° C359.999°) Reset the absolute reference point of the C axis by setting up the parameters. 1) X-axis and Table T-groove parallelism adjustment Install an indicator on the spindle, set the the indicator to while the indicator makes...

  • Page 88: Dcp-I Compensation

    It uses a touch probe and a mast ball to automatically measure the measurement and compensation and to minimize geometric errors. ▪ DCP-i : DOOSAN Rotation Axis Center Point Compensation-Inteli 1) DCP-i Main Screen ①...
  • Page 89 7. Adjustment of reference points of respective axes and manual TCP adjustment ⑧ By moving the cursor to the stored Table, it is possible to enter the measurement value stored to the NC. ⑨ A function used to “LOCK” the stored measurement table value. It is displayed as “L” when activated.
  • Page 90 7. Adjustment of reference points of respective axes and manual TCP adjustment ② Use the MPG to traverse the Z axis so that the stylus of the touch probe can be positioned 10 to 20 mm above the datum ball. ③...
  • Page 91 7. Adjustment of reference points of respective axes and manual TCP adjustment 5) Measurement ① Change to the [ MEM ] Mode. ② Press the [TCP MEASURE START] soft key and the Cycle Start button to start the measurement automatically. “...
  • Page 92 7. Adjustment of reference points of respective axes and manual TCP adjustment ③ After completion of the measurement, the message “MACHINE PARAMETER SAVE OK? Y OR N!” appears in the figure area ( “D ”) below. Upon entering “Y” and pressing the [INPUT] key, the error value is automatically compensated and the parameter is entered.
  • Page 93 7. Adjustment of reference points of respective axes and manual TCP adjustment “ ” “ ” “ ” “ ” “ ”...

  • Page 94: Atc Alignment And Finishing Operation

    8. ATC Alignment and Finishing Operation 8. ATC Alignment and Finishing Operation 30/40 Tools 60 Tools 90 Tools 120 Tools...

  • Page 95: Tool Change Position Resetting

    8. ATC Alignment and Finishing Operation 8.1 Tool Change Position Resetting 1) Preparing the ATC Alignment ① Preparing the Centering Jig Prepare a centering jig suitable for the spindle taper of the machine spindle in question. ▪ Jig 1: Jig for Changer Arm ▪...
  • Page 96 8. ATC Alignment and Finishing Operation ② Rotate the ATC Changer Arm by hand so that the Arm Gripper can fully grip the tool inserted into the Waiting Pot. Waiting ATC Arm Tool ③ Insert “Jig 1” into the Spindle-side Gripper. “...
  • Page 97 8. ATC Alignment and Finishing Operation ⑤ Check Z-axis position a. Remove “Jig 1” from “Jig 2”, gripper, inserted to the spindle and insert a tool into the spindle. Tool Tool b. Rotate the ATC Changer Arm by hand, but stop rotating it just before the Arm Gripper fully grips the tool.

  • Page 98: Coolant Tank Installation

    8. ATC Alignment and Finishing Operation 8.2 Coolant Tank Installation 1) Correct Position of Coolant Tank ① Untie the various cables and hoses wound around or tied to the back of the machine and move them aside, then clean the installation position of the coolant tank. ②...
  • Page 99 8. ATC Alignment and Finishing Operation 3) Connection of Coolant Hoses ① Flood Coolant Hose Connection Flood Coolant Pump Coolant Cable Hose Duct Motor Cable ② T.S.C Coolant Hose Connection T.S.C Coolant Pump Coolant Hose 4) Finishing Work Once the coolant tank is in position, tighten the coolant tank fixing bolts until they touch the floor in order to secure the tank.

  • Page 100: Assembling The Covers

    8. ATC Alignment and Finishing Operation 8.3 Assembling the Covers Assemble the various covers disassembled for shipping and install them in the intended positions. 1) Maintenance Cover Assembly Assemble the maintenance cover (disassembled to perform various operations inside the machine) in the intended position. Maintenance Cover 2) Air Service Unit Acrylic Cover Assembly...
  • Page 101 8. ATC Alignment and Finishing Operation...
  • Page 102 Revision Revision Record VMC Maintenance Manual DVF5000 (MV0111ISE203) Version Date Revision History Prepared by 2020. 03 Document creation S. Y. Chung...

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