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Matrix 0850 User Manual

External thread grinder
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0850/0850-T1 External Thread Grinder
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  • Page 1 0850/0850-T1 External Thread Grinder User Manual...
  • Page 2 +44 (0)2476 678 899 Email: aftersales@matrix-machine.com If you have any queries or suggestions regarding the 0850 User Manual, please contact our Technical Publications Department: publications@matrix-machine.com This manual describes the use of the 0850 External Thread Grinder. Any options taken or deviations from the standard are documented in each machines individual set of manuals.
  • Page 3 [JOG] JOG mode selection [MDA] MDA mode selection [AUTO] AUTO mode selection [TEACHIN] TEACHIN mode selection [SBLK] SINGLE BLOCK mode selection [RESET] RESET program cycle, alarm message [CYCLE CYCLE start request START] Matrix Machine Tool (Coventry) Limited 3 / 231...
  • Page 4 Acknowledge button used during setting and grinding cycle [FIN] instruction prompts or to confirm the completion of a setting cycle sequence [AUTO REF] Starts referencing all machine axes in a pre-defined order Matrix Machine Tool (Coventry) Limited 4 / 231...
  • Page 5 A axis select [W2] tailstock axis select Menu selection ">" is used to denote the sequence of softkey presses required to get a specific screen. Example: Matrix > Main Menu > Part Data Matrix Machine Tool (Coventry) Limited 5 / 231...

  • Page 6: Table Of Contents

    Manual Operation Procedure ......................56 9.3.2 Setting the tailstock advance and retract positions ................57 Taper Adjust Procedure ........................58 Workpiece probing (option) ......................59 10.1 Fitting the probe unit to the work table ....................60 Matrix Machine Tool (Coventry) Limited 6 / 231...
  • Page 7 19.3.3 Taper In/ Taper Out ..........................110 19.4 Thread Data (PMHMI) ........................112 19.4.1 Create New Thread ..........................112 19.4.2 Thread Parameter List ........................118 19.4.3 Thread Type 1 ............................. 119 19.4.4 Thread Type 2 ............................. 120 Matrix Machine Tool (Coventry) Limited 7 / 231...
  • Page 8 19.21.1 Procedure ............................172 19.22 Cycle Data - Grind Table ........................173 19.22.1 Procedure to edit Grind cycle variables ..................... 174 19.22.2 Grinding Zones ........................... 175 19.22.3 Explanation of parameters ......................... 176 Matrix Machine Tool (Coventry) Limited 8 / 231...
  • Page 9 Machine Diagnostic Screens ......................213 23.3 Alarm Messages ..........................217 23.4 Recovering from an axis software travel limit condition ..............228 23.5 Air conditioning unit alarm codes ...................... 229 23.6 Coolant System Technical Data ......................230 Matrix Machine Tool (Coventry) Limited 9 / 231...

  • Page 10: Health & Safety

    Operating section of this manual. Matrix Machine Tool has a safety record of which it is justly proud and in issuing this user manual they would like to bring to your operator’s attention to Section 7 of the Health & Safety at Work Act 1974, which requires that the supplied machine is designed and constructed as far as reasonably practicable to be safe and without risk to health.

  • Page 11: Understanding Safety Rules & Regulations

     run coolant on a stationary wheel.  modify the drive to get higher wheel speeds.  use special pulleys, high speed motors or speed control devices which have been altered or made inactive. Use standard wheel dressers. Matrix Machine Tool (Coventry) Limited 11 / 231...

  • Page 12: Electricity

    (both flushing with a chemical cleaner and physical cleaning) and preferably sterilising between changes. Industrial dermatitis can arise, especially amongst persons sensitive to skin irritations but a more fundamentally serious problem is the possibility of skin cancer of the scrotum. Matrix Machine Tool (Coventry) Limited 12 / 231...

  • Page 13: Cancer Of The Skin Caused By Oil

    Switch off the main isolator switch and report the problem to your supervisor. CAUTION DO NOT open the wheel guard while the grinding wheel is rotating DO NOT adjust the grinding coolant nozzles when the wheel is rotating Matrix Machine Tool (Coventry) Limited 13 / 231...

  • Page 14: Grinding Wheels

    Only grinding wheels with the following tolerances mounted on Matrix flanges must be used on this machine. Grinding wheels with a coarser and softer specification than 80L should not be used without reference to either Matrix or the grinding wheel manufacture.
  • Page 15  modify the drive to get higher wheel speeds  use special pulleys, high speed motors or speed control devices which have been altered or made inactive  force a wheel on to a wheel adaptor Matrix Machine Tool (Coventry) Limited 15 / 231...

  • Page 16: Machine User

    Repairs to the equipment must only be carried out by trained and qualified personnel in accordance with the servicing and maintenance guidelines. Machine warranty will become void if any repairs or modifications are made without the express permission of Matrix. Matrix Machine Tool (Coventry) Limited...

  • Page 17: Liability Exclusions

    Edition: 08/2013 2 Liability Exclusions Matrix Machine Tool (Coventry) Limited are excluded from all liability where the equipment supplied has been used in a manner other than intended OR has been modified without the express written permission of Matrix Machine Tool (Coventry) Limited which has subsequently resulted in the machine to malfunction, become damaged or caused injury to the user.

  • Page 18: Machine Overview

    Edition: 08/2013 3 Machine Overview The 0850 machine is a purpose built multi-axis CNC external thread grinder specifically designed for the precision grinding of many types of workpiece with an external thread or ballform requirement. The machine base, sub-slides and headstock are each constructed of single-piece high quality seasoned cast iron.
  • Page 19 9 Main electrical power isolator switch 10 Coolant system 11 Stage 1 coolant oil filtration 12 Stage 2 coolant oil filtration 13 High pressure lift pump 14 Coolant system control panel Matrix Machine Tool (Coventry) Limited 19 / 231...
  • Page 20 17 Operator/Setter sliding access doors (for wheel and dressing tool change) 18 Workhead chuck pneumatic services control panel 19 Return coolant oil sub-tank 20 Grinding and dressing spindles chiller unit Coolant system view (rear of machine) Matrix Machine Tool (Coventry) Limited 20 / 231...

  • Page 21: Axis Configuration

    Machine axis zero positions and software travel software limits are factory set and must NOT be altered otherwise the machine could get damaged and this is NOT covered by your machine warranty. Matrix Machine Tool (Coventry) Limited 21 / 231...

  • Page 22: Machine Configuration

    Manual Tailstock (standard) Traversing tailstock (option) Worktable is fitted with a servo drive sub-slide (W2 axis). Manual workpiece steady (standard) Power steady (option) Water cooled grinding spindle(S1) Wheelhead helix table (A) Dresser spindle (S2) Matrix Machine Tool (Coventry) Limited 22 / 231...

  • Page 23: Machine Floor Layout (With 800L Coolant System)

    0850/0850-T1 User Manual Edition: 08/2013 3.4 Machine floor layout (with 800L coolant system) Matrix Machine Tool (Coventry) Limited 23 / 231...

  • Page 24: Machine Floor Layout (With Optional High Pressure 3000L Coolant System)

    0850/0850-T1 User Manual Edition: 08/2013 3.5 Machine floor layout (with optional high pressure 3000L coolant system) Matrix Machine Tool (Coventry) Limited 24 / 231...

  • Page 25: Minimum Workshop Height Requirement

    0850/0850-T1 User Manual Edition: 08/2013 3.6 Minimum workshop height requirement The workshop floor-to-ceiling height where the 0850 machine and associated equipment is to be located must have a minimum room height of 4000mm. Matrix Machine Tool (Coventry) Limited 25 / 231...

  • Page 26: Technical Data

    5 arcsec (0.0014°) Workhead Spindle (C axis) – with power chuck Servo motor rating 154Nm @ 120rpm Programmable speed range 1 to 120rpm Encoder type Renishaw /Rotary / Incremental Positioning resolution 5 arcsec (0.0014°) Matrix Machine Tool (Coventry) Limited 26 / 231...
  • Page 27 Siemens PCU50.3 Drive system Sinamics S120 HMI display panel Siemens OP010 / 10.4” colour TFT / 640 x 480 pixels Program/jobfile storage media Hard disk USB port Connectivity Ethernet/LAN ANDON light stack Option Matrix Machine Tool (Coventry) Limited 27 / 231...
  • Page 28 HMI dialog programming and cycles package Standard ProfileMATE Thread profile software Standard ProfileMATE End-threading software function Option ProfileMATE Worm (ZI,ZA,ZN) profile software Option ProfileMATE Worm (ZK) profile software Option ProfileMATE Dual lead (duplex) worm function Option Matrix Machine Tool (Coventry) Limited 28 / 231...

  • Page 29: Dresser System

    Never operate the dressing spindle with just the expanding collet fitted or the collet will be damaged. The dressing system also supports the Matrix designed single point diamond holder block (option) which installs over the spindle shaft without the expanding collet. The single point diamond block accepts standard diamond pen holders.
  • Page 30 Edition: 08/2013 Diamond disc/roll location face Coolant spray deflector Expanding collet Water cooled spindle motor Dressing tool Dressing tools supported: Diamond disc – sharp Vee, flat, radius Profiled Diamond Roll Single Point diamond Matrix Machine Tool (Coventry) Limited 30 / 231...

  • Page 31: Adjustable Helix Backplate (Option)

    However, it should be noted that this only applies when using a diamond roll dressing tool. It offers no benefit when wheel profile dressing is to be performed using a diamond disc or single point dressing tool. -ve helix angle +ve helix angle Dressing spindle helix range: +/- 45° Matrix Machine Tool (Coventry) Limited 31 / 231...
  • Page 32 0850/0850-T1 User Manual Edition: 08/2013 Helix position set/clamp screws M10x 30 with washers Helix pivot clamp grub screw +/- 45° scale (1div = 1°) Scale pointer clamping position holes Matrix Machine Tool (Coventry) Limited 32 / 231...
  • Page 33 4. Using an allen key turn the fine adjust grub screw to set to the helix angle. 5. Finally, tighten-up the 2x M10 position clamp screws and the pivot clamp grub screw. Matrix Machine Tool (Coventry) Limited 33 / 231...

  • Page 34: Dressing Spindle

    1. Using the supplied pin spanner hold the collet steady and then slacken the M6 screw using the 5mm allen key. 2. Carefully slide the dressing disc/roll off the collet without removing the collet. Matrix Machine Tool (Coventry) Limited 34 / 231...

  • Page 35: Single-Point Diamond Holder (Option)

    An alternative to the rotary truer system is the single point diamond system primarily used where wheel profiles demanding small profile radii (<= 0.1mm) are required. 30mm CAUTION The expanding collet must be removed before you fit the single point mounting block. Matrix Machine Tool (Coventry) Limited 35 / 231...
  • Page 36 4. Push the single-point diamond into to its location bore ensuring that it also locates to the machined flat on the holder. 5. Secure the diamond in place by tightening up the grub screw. Matrix Machine Tool (Coventry) Limited 36 / 231...

  • Page 37: Grinding Spindle

    Mounted directly above the grinding and to the fixed part of the wheel guard is the coolant oil manifold block into which can accept upto 3 flexible coolant nozzles. Spindle Chiller System The machine is supplied with a HF spindle chiller system as standard. Matrix Machine Tool (Coventry) Limited 37 / 231...

  • Page 38: Spindle Warm-Up

    Let the spindle continue to run uninterrupted for 20~30mins. Stop the spindle [SPINDLE STOP]. The spindle warm procedure is now complete. You can continue to use the machine as normal. Done. Matrix Machine Tool (Coventry) Limited 38 / 231...

  • Page 39: Grinding Wheel Speed Chart

    Using the expression below you can calculate the grinding wheel surface speed (M/s) for a given wheel diameter at a given rotational spindle speed (rpm): Matrix Machine Tool (Coventry) Limited 39 / 231...

  • Page 40: Handling Grinding Wheels

    Only grinding wheels with the following tolerances mounted on Matrix flanges must be used on this machine. Grinding wheels with a coarser and softer specification than 80L should not be used without reference to either Matrix or the grinding wheel manufacture.

  • Page 41: Checking The Grinding Wheel

    8 screws are tight enough to give a firm but not crushing pressure to the wheel. Matrix Machine Tool (Coventry) Limited 41 / 231...

  • Page 42: Workhead

    The direct drive 154Nm torque motor driven workhead spindle is supplied with a No.4 MT floating centre and workpiece driver arm assembly. Splined driving peg Driving arm Driving pin No.4 MT centre with carbide tip Floating centre Floating centre drive plate Matrix Machine Tool (Coventry) Limited 42 / 231...

  • Page 43: Power Operated Workhead Chuck (Option)

    Each chuck jaw is numbered uniquely to associate it with its mating actuator on the chuck body. The jaws are pneumatically operated and move simultaneously when opened or closed. 1 3x numbered jaws 2 Chuck open compressed air inlet port 3 Chuck close compressed air inlet port Matrix Machine Tool (Coventry) Limited 43 / 231...

  • Page 44: Opening And Closing The Chuck Manually

    2. Push down on the left-hand (LH) foot pedal [1] Chuck close procedure 1. Select [JOG] mode at the machine control panel. 2. Push down on the right-hand (RH) foot pedal [2] Matrix Machine Tool (Coventry) Limited 44 / 231...

  • Page 45: Powered Workpiece Support Steady (Option)

    Clamping range: Ø12 - Ø40 Working Pressure: 10 – 30 bar You can adjust the steady arms clamping pressure at the hydraulics power pack (see section 8.3.1) Matrix Machine Tool (Coventry) Limited 45 / 231...

  • Page 46: Operating The Steady

    3. The LED indicator above the button will flash as the steady arms retract. 4. The LED indicator will change to the steady OFF state when the steady arms have retracted inside the steady body. Matrix Machine Tool (Coventry) Limited 46 / 231...

  • Page 47: Fine Adjustment Screws

    Turn the screw counter-clockwise (CCW) to move the steady arms up. Turn the screw clockwise (CW) to move steady arms down. Y axis Y axis X axis Warning Never turn the fine adjuster screws when the steady is under load. Matrix Machine Tool (Coventry) Limited 47 / 231...

  • Page 48: Procedure For Fine Alignment Of The Steady Rest

    The maximum permissible adjustment travel of the steel bolt is +/- 2 to 3mm, depending on the size of the steady rest. Note 2: max movement of the steady centre is +/- 0.12 mm (120um). Matrix Machine Tool (Coventry) Limited 48 / 231...

  • Page 49: Steady Clamping Pressure

    Turn the adjuster screw (6) counter-clockwise (CCW) to reduce the oil supply pressure to the steady. To decrease steady pressure Turn the adjuster screw (6) clockwise (CW) to increase the oil supply pressure to the steady. Matrix Machine Tool (Coventry) Limited 49 / 231...

  • Page 50: Tailstock

    0850/0850-T1 User Manual Edition: 08/2013 9 Tailstock The basic 0850 model is offered with the manual type tailstock as standard. An optional semi- automated pneumatic version of the tailstock is also available for low to medium production applications. In addition, Matrix also offer a fully automated travelling tailstock which is better suited for high volume production applications of where the machine operation is entirely automated using a gantry type robot for part load and unload.
  • Page 51 0850/0850-T1 User Manual Edition: 08/2013 Tailstock body-to-table securing Taper adjust lock nut bolts Tailstock barrel centre No. 4 MT centre advance/retract lever Taper adjust wheel Tailstock spring tension adjuster (option) Matrix Machine Tool (Coventry) Limited 51 / 231...

  • Page 52: Pneumatic Tailstock (Option)

    This version of the tailstock is best suited to applications where the machine is intended to be used within an automation environment along with other automation options selected with the machine at the time of ordering. Matrix Machine Tool (Coventry) Limited 52 / 231...
  • Page 53 0850/0850-T1 User Manual Edition: 08/2013 Matrix Machine Tool (Coventry) Limited 53 / 231...

  • Page 54: Manual Operation Procedure

    As the tailstock moves the LED indicator above the key will change to the ‘flashing’ state to inform you that the tailstock barrel is moving. When the tailstock has stopped retracting the LED indicator changes from ‘flashing’ to ‘OFF’ state. Matrix Machine Tool (Coventry) Limited 54 / 231...

  • Page 55: Travelling Tailstock (Option)

    The tailstock has traversing of 360mm. Linear sub-slide (W2) Taper adjust wheel Servo motor with absolute Tailstock barrel centre position encoder advance/retract lever Matrix Machine Tool (Coventry) Limited 55 / 231...

  • Page 56: Manual Operation Procedure

    As the tailstock moves the LED indicator above the key will change to the ‘flashing’ state to inform you that the tailstock barrel is moving. When the tailstock has stopped retracting the LED indicator changes from ‘flashing’ to ‘OFF’ state. Matrix Machine Tool (Coventry) Limited 56 / 231...

  • Page 57: Setting The Tailstock Advance And Retract Positions

    0850/0850-T1 User Manual Edition: 08/2013 9.3.2 Setting the tailstock advance and retract positions Add content here! Matrix Machine Tool (Coventry) Limited 57 / 231...

  • Page 58: Taper Adjust Procedure

    1. Slacken-off the taper adjust lock nut 2. Turn the taper adjust wheel as required to correct the misalignment of the workpiece installed between the centres. 3. Tighten-up the lock nut when you have finished. Matrix Machine Tool (Coventry) Limited 58 / 231...

  • Page 59: Workpiece Probing (Option)

    Workpiece support block The measuring probe head is mounted onto a pneumatically operated sub-slide, which advances during the automatic probing cycle once the component has been orientated to the correct start position. Matrix Machine Tool (Coventry) Limited 59 / 231...

  • Page 60: Fitting The Probe Unit To The Work Table

    1. Locate and position the probe assembly directly onto the worktable across the Vee-and-Flat ways and secure it to the table by the 2x M16 T-nuts (1) and hexagon head bolts (2) provided. Matrix Machine Tool (Coventry) Limited 60 / 231...
  • Page 61 Plug the connector into the table mounted bulkhead socket (4). Probe assembly fitted in between the tailstock and workpiece steady rest (pic above) Matrix Machine Tool (Coventry) Limited 61 / 231...

  • Page 62: Enabling The Probe System Signal Interface

    1. Set the ORANGE Siemens Key to position 3 on the MCP. 2. Select [AUTO] and [SETUP] mode. 3. Select the Probe screen [Matrix] > [Main Menu] > [Setting Cycles] > [Set Work Datum] > [Probe Cycle] 4. Select the [Save Data] softkey to store the probe offset values to internal an system file.

  • Page 63: Procedure For Establishing Offsets

    3. Select [JOG] mode and position the centre of the grinding wheel so that it is aligned to the workhead centre tip (A) or the face of the chuck jaws (B) if a workhead chuck unit is fitted. Matrix Machine Tool (Coventry) Limited 63 / 231...
  • Page 64 A. If workhead fitted with a standard centre: align wheel middle to tip centre Grinding wheel Workhead centre B. If workhead fitted with optional 3-jaw chuck: align wheel middle to chuck jaw face Grinding wheel Workhead 3-jaw chuck Matrix Machine Tool (Coventry) Limited 64 / 231...
  • Page 65 You can enter a value in here if you wish or just leave it set as 0.000. 7. Select the [Advance Probe] button on the MCP to advance the probe slide. (Note: ensure the probe stylus is fitted!) Matrix Machine Tool (Coventry) Limited 65 / 231...
  • Page 66 9. Enter the Z axis position as displayed in the machine coordinate system (MCS) into the Probe 1 Offset input field. Matrix Machine Tool (Coventry) Limited 66 / 231...

  • Page 67: Part Offset

    3. Using the handwheel, manually pitch into the thread groove in X/Z in JOG mode. Note: you are not using the pitch-in cycle 4. Select the WORK DATUM screen and press the [Set Z start posn] key. Matrix Machine Tool (Coventry) Limited 67 / 231...

  • Page 68: Testing Auto Pitch-In And Correcting The Probe 1 Offset

    Z to make the wheel contact* on both flanks of the thread. *Rock the wheel back-and-forth by hand till you can feel that the wheel is touching the workpiece flanks. Matrix Machine Tool (Coventry) Limited 68 / 231...
  • Page 69 Increasing Probe 1 Offset applies offset bias towards the RH side of the groove (1) Decreasing Probe 1Offset applies offset bias towards the LH side of the groove (2) Matrix Machine Tool (Coventry) Limited 69 / 231...

  • Page 70: Automatic Doors (Option)

    0850/0850-T1 User Manual Edition: 08/2013 11 Automatic doors (option) In this version of the 0850 machine enclosure the two front operator access doors feature independently servo driven linear actuator mechanisms. The complete assembly is mounted externally to the top of the enclosure thereby providing easy access for maintenance purposes.

  • Page 71: Manual Door Operation

    If the machine is setup to operate without the supported automation features then the front door must be closed manually by the machine operator prior to starting the cycle. In this mode of operation the linear actuator assembly remains disabled. Matrix Machine Tool (Coventry) Limited 71 / 231...

  • Page 72: Two-Hand Auto Cycle Start (Option)

     Grind the workpiece Then at the end of the cycle the automation sequence would be as follows:  Open the power chuck jaws  Retract the tailstock centre  Open the access guard door(s) Matrix Machine Tool (Coventry) Limited 72 / 231...

  • Page 73: Procedure For Starting An Automatic Cycle Using Two-Handed Start Buttons

    3. Load the workpiece to be ground 4. Press in and hold together (within 0.5s) the LH and RH cycle start buttons until the door has fully closed. 5. The automatic cycle will now begin to operate. Matrix Machine Tool (Coventry) Limited 73 / 231...

  • Page 74: Andon Light (Option)

    GREEN Machine running in normal Machine running production mode production mode with FRO = 100% with FRO < 100% or operating in non- production mode Matrix Machine Tool (Coventry) Limited 74 / 231...

  • Page 75: Standard Coolant System (800L, Upto 5Bar Working Pressure)

    Main supply pump (max 8bar) to Main tank, 555L capacity machine (with pressure gauge + adjust tap) Coolant tank level sight glass Coolant oil chiller tank, 245L capacity Centrifuge unit Magnetic separator Matrix Machine Tool (Coventry) Limited 75 / 231...

  • Page 76: Switching On The Coolant System

    The main coolant delivery pump will only begin to operate after the machine has been started at the control station [MASTER START] and provided that the [COOLANT OFF] button indicator is not illuminated. Matrix Machine Tool (Coventry) Limited 76 / 231...

  • Page 77: Stage 1 - Magnetic Separator Filtration

    2°C below the ambient temperature. The cooled oil is mixed by natural convection as it get directed by baffle plates back to the main coolant pump. Matrix Machine Tool (Coventry) Limited 77 / 231...

  • Page 78: Stage 4 - Oil Distribution

    14.6 Stage 5 - Oil Return Oil flows from the machine back to the coolant system via oil return chutes and then the oil filtration and cooling cycle starts all over again from Stage 1. Matrix Machine Tool (Coventry) Limited 78 / 231...

  • Page 79: Optional Hp Coolant System (3000L, Upto 70Bar Working Pressure)

    15.1 Switching on the coolant system 1. Turn control panel main isolator switch (1) to the ON position. Reset the emergency stop button (2) at the control panel. Check the Power ON lamp (white) (3) is illuminated. Matrix Machine Tool (Coventry) Limited 79 / 231...
  • Page 80 7. Set the chiller system control switch (7) to the start position. 8. Check the temperature display panel (8) is registering the current oil temperature and no chiller fault lights are illuminated. Matrix Machine Tool (Coventry) Limited 80 / 231...
  • Page 81 11. Check that the Control ON lamp (green) (11) is illuminated. 12. Check that no alarms are being displayed on the user display panel (13). 13. The Coolant system is now ready for operation with the machine. Matrix Machine Tool (Coventry) Limited 81 / 231...

  • Page 82: Automatic Fire System (Option)

    Red coloured low-melting point located in void between machine pressurised tubing runs along the inner and LH side of the services cabinet roof section of the machine Matrix Machine Tool (Coventry) Limited 82 / 231...

  • Page 83: What Happens In The Event Of A Fire

    Maintenance of the Firetrace automatic fire extinguishing system is necessary to ensure system reliability and the periodic discharge requirements are comparable with standard portable fire extinguisher. Matrix Machine Tool (Coventry) Limited 83 / 231...

  • Page 84: Manual Triggering Of The Fire Extinguisher

    NOTE: The manual extinguishant release button is located on the side of the Services Cabinet. Manual pull tab (Yellow) Fire system pressurised indicator gauge Green = system is pressurised Red = system not pressurised Manual extinguishant release button (Red) Matrix Machine Tool (Coventry) Limited 84 / 231...

  • Page 85: Operator Console

    Machine area key Cursor and selection keys (blue) Recall (return) key Hot/shortcut keys Horizontal function select keys Data input key (yellow) Vertical function select keys Machine Control Panel (MCP) Etc/ menu extension key Matrix Machine Tool (Coventry) Limited 85 / 231...
  • Page 86 Program operating area area, the last alarms, messages, service displays or PLC status can be called. Access to Parameters operating Access to the Matrix Advanced area where the last tool offsets Programming and diagnostics are directly called. screens. Direct access to Program overview...

  • Page 87: Machine Control Panel (Mcp)

    JOG / MDA / AUTO rotary switch (0 - 100%) JOG increment selection INC 1, 10, When a key is pressed on the MCP the corresponding status indicator above the key is illuminated. Matrix Machine Tool (Coventry) Limited 87 / 231...
  • Page 88  All electro-mechanical valves/actuators Recovering the machine from an emergency stop 1. Ensure that all emergency stop buttons are in their released state. 2. Press the Master Start button on the MCP. Matrix Machine Tool (Coventry) Limited 88 / 231...

  • Page 89: Cnc Operating Modes

    Select this function if you want to execute part program commands one block at a time in MDA or AUTO mode. Single Block can be de-selected at any time during program execution and the cycle continued un-interrupted by pressing the [CYCLE START] button again. Matrix Machine Tool (Coventry) Limited 89 / 231...

  • Page 90: Program Cycle Start/Reset

    De-select [BLOCK SKIP] and then press the [CYCLE START] key to resume the grinding cycle. RESET Press the reset key at any time to abort (reset/rewind) the active program OR to clear an active alarm message when a cycle is not executing. Matrix Machine Tool (Coventry) Limited 90 / 231...

  • Page 91: Axis Selection And Speed Controls

    Press the [-] key to jog the selected axis in its negative direction axis in JOG mode. To jog the selected axis faster press and hold the [RAPID] key together with jog direction key [+] or [-]. Matrix Machine Tool (Coventry) Limited 91 / 231...
  • Page 92 Set the switch at 100% (or above) to allow the machine axes to move at the programmed feedrate. FEED START/STOP Feed start/stop functions are not selectable. The feed stop function is always disabled. The feed start function is always enabled. Matrix Machine Tool (Coventry) Limited 92 / 231...

  • Page 93: Axis Reference

    AXIS REFERENCE MODE The axis reference function can only be select when JOG mode is active. Manual axis referencing is not necessary. Therefore, this function should not be used establish machine axis datums. Matrix Machine Tool (Coventry) Limited 93 / 231...

  • Page 94: Grinding Spindle Controls

    ON: spindle is operating at its commanded speed. OFF: spindle is stopped. SPINDLE STOP Select JOG mode and then press this key to stop the spindle. Indicator status meaning: ON: spindle is in stopped state OFF: spindle is running. Matrix Machine Tool (Coventry) Limited 94 / 231...

  • Page 95: Command Functions

    Hand held unit ON/OFF toggle. Press this key if you want to use the hand held unit functions. The indicator above the key is illuminated when the handheld unit function is enabled. Matrix Machine Tool (Coventry) Limited 95 / 231...
  • Page 96 PROBE ADVANCE/RETURN (option) Probe slide advance/retract toggle key. Press this key to advance or retract the probe slide. The indicator above the key illuminates when the probe slide has moved to the advanced position. Matrix Machine Tool (Coventry) Limited 96 / 231...
  • Page 97 Used in conjunction with the Matrix cycles, to acknowledge dialog prompt messages that presented during cycle execution. FINISH ACKNOWLEDGE Used in conjunction with the Matrix cycles, to acknowledge the completion of a setup cycle sequence. SETUP MODE Setup mode ON/OFF toggle.
  • Page 98 Once initiated, the warm-up cycle will run for 60mins and then stop. However, you can interrupt the cycle at any time be pressing the [RESET] key. The indicator above the key illuminates whilst the warm-up cycle is running. Matrix Machine Tool (Coventry) Limited 98 / 231...

  • Page 99: Handheld Unit

    1. Whilst the handheld unit is in use axis selection at the machine control panel (MCP) is inhibited. 2. The handwheel cannot be used on the travelling tailstock axis (W2) if this option is fitted to the machine. Matrix Machine Tool (Coventry) Limited 99 / 231...

  • Page 100: Automatic Wheel Balancer (Sbs 4500)

    Due to wear and frequent dressing of the wheel periphery, the rotational dynamics of a grinding wheel are always changing. Therefore, dynamic balancing of the grinding wheel is considered to be an essential step in the production process. 18.1 Block diagram Matrix Machine Tool (Coventry) Limited 100 / 231...

  • Page 101: Integral Balancer Unit

    Non-contact sender unit motorised weights) Receiver unit There are two moving weights inside the integral balance unit which are electronically controlled to compensate for any imbalance to the grinding wheel during running. Matrix Machine Tool (Coventry) Limited 101 / 231...

  • Page 102: Vibration Sensor Location

    1. Locate the sensor in the same direction as the centreline between the grinding wheel and the workpiece. 2. Locate the sensor on a rigid part of the wheelhead assembly. If possible the 0850 machine should be installed away from other sources of vibration that would generated by surrounding machinery. Matrix Machine Tool (Coventry) Limited...

  • Page 103: Control Panel

    The balancer control panel is accessed from the HMI screen. Select [MENU SELECT] > [Balancer] to launch the control panel display. For specific setup and operating instructions please refer to the SBS user manual supplied in addition to this manual. Matrix Machine Tool (Coventry) Limited 103 / 231...

  • Page 104: Dialog Programming

    19.1 Displaying the Main Menu [Custom > Matrix > Main Menu] Press the [CUSTOM] key on the HMI panel to display the Matrix HMI menu screen then select the [Main Menu] softkey to display the main menu screen as shown below:...

  • Page 105: Work Piece Manager

    Edition: 08/2013 19.2 Work piece Manager [Custom > Matrix > Workpiece Manager] Before you can run any setup cycle or start to do any grinding on the machine you must load a workpiece (sometimes called a job file) to the NC. If there are no existing workpieces listed in the workpiece folder (Machine >...

  • Page 106: Load An Existing Workpiece

    3. To unload the active workpiece enter the name of the active workpiece in the input field and then select the [Unload NC > HD] softkey. 4. Select the [Return] softkey to return to the main menu screen. Matrix Machine Tool (Coventry) Limited 106 / 231...

  • Page 107: Part Data

    Edition: 08/2013 19.3 Part Data [Custom > Matrix > Main Menu > Part Data] The Part Data screen defines the workpiece thread profile requirement to the machine. Before proceeding to grind a workpiece thread you must enter part data about the workpiece that is to be ground by the machine.

  • Page 108: Explanation Of The Input Parameters

    If you are using a diamond disc then enter the name of the dress profile program that you created with the Ball Profile software which has already been copied and loaded to the Sub-Programs folder in the PCU50. Leave this field blank if you are using a diamond roll. Matrix Machine Tool (Coventry) Limited 108 / 231...
  • Page 109 Select this function if you are want to use the probing system to automatically determine the pitch-in position of the grinding wheel to the workpiece thread groove. Barelling Input selection: OFF or ON Select this if you want to use the barrelling function (see section Matrix Machine Tool (Coventry) Limited 109 / 231...

  • Page 110: Taper In/ Taper Out

    Select the [Barrel Data] vertical softkey in the Part Data screen if you want to define the point at which the grinding wheel enters and exits the workpiece thread to be ground. input fields become visible when the BarrelData key is selected Matrix Machine Tool (Coventry) Limited 110 / 231...
  • Page 111 The amount of taper to apply to the grinding wheel moving in the X direction can be calculated using the following expression: Z Taper In / Z Taper Out The amount of taper to apply to the grinding wheel moving in the Z direction is generally determined as follows: Matrix Machine Tool (Coventry) Limited 111 / 231...

  • Page 112: Thread Data (Pmhmi)

    0850/0850-T1 User Manual Edition: 08/2013 19.4 Thread Data (PMHMI) [Matrix] > [Main Menu] > [Thread Data] 19.4.1 Create New Thread 1. Select the [Thread Data] softkey from the main menu screen to access the PMHMI thread and tool menu screen.
  • Page 113 Select [Upright To Axis] softkey if the thread pitch dimension is specified axially to the workpiece (see fig 1 below) followed by selecting the [Next] softkey to continue. Fig.1 thread specified upright to the axis Matrix Machine Tool (Coventry) Limited 113 / 231...
  • Page 114 If the workpiece is parallel then you can select either [Upright To Axis] or [Upright To Cone] softkey followed by selecting the [Next] softkey to continue. Note: the selection you make is highlighted in green. Matrix Machine Tool (Coventry) Limited 114 / 231...
  • Page 115 Some axial thread types (such as API spec 5B BCSG sizes 16 and above) are actually defined such that the tip and root of the thread are parallel to the workpiece axis. Select [Parallel To Axis] followed by [Next] softkey to continue. Matrix Machine Tool (Coventry) Limited 115 / 231...
  • Page 116 [Next] softkey to continue. The angle can be specified as a positive or negative value. Fig.3 below shows the affect that positive major/minor angle has on the thread profile. Fig.3 user defined major/minor angles Matrix Machine Tool (Coventry) Limited 116 / 231...
  • Page 117 Highlight the thread type that you want to create using the blue cursor buttons on the HMI panel and then press the [Select] softkey to continue. Matrix Machine Tool (Coventry) Limited 117 / 231...

  • Page 118: Thread Parameter List

    θ Right Hand Flank Angle θ Effective Diameter Starts Taper Rate Number of Ribs This is the number of ribs you want to put on the grinding wheel with the same profile Matrix Machine Tool (Coventry) Limited 118 / 231...

  • Page 119: Thread Type 1

    Note: You can input the data in any order that you want. Just use the TAB key to switch into the required input field. 4. After you have finished inputting the thread data select the [Save] softkey to continue. Matrix Machine Tool (Coventry) Limited 119 / 231...

  • Page 120: Thread Type 2

    Note: You can input the data in any order that you want. Just use the TAB key to switch into the required input field. 4. After you have finished inputting the thread data select the [Save] softkey to continue. Matrix Machine Tool (Coventry) Limited 120 / 231...

  • Page 121: Thread Type 3

    Note: You can input the data in any order that you want. Just use the TAB key to switch into the required input field. 4. After you have finished inputting the thread data select the [Save] softkey to continue. Matrix Machine Tool (Coventry) Limited 121 / 231...

  • Page 122: Thread Type 4

    Note: You can input the data in any order that you want. Just use the TAB key to switch into the required input field. 4. After you have finished inputting the thread data select the [Save] softkey to continue. Matrix Machine Tool (Coventry) Limited 122 / 231...

  • Page 123: Thread Type 5

    Note: You can input the data in any order that you want. Just use the TAB key to switch into the required input field. 4. After you have finished inputting the thread data select the [Save] softkey to continue. Matrix Machine Tool (Coventry) Limited 123 / 231...

  • Page 124: Thread Type 6

    Note: You can input the data in any order that you want. Just use the TAB key to switch into the required input field. 4. After you have finished inputting the thread data select the [Save] softkey to continue. Matrix Machine Tool (Coventry) Limited 124 / 231...

  • Page 125: Create New Tool

    0850/0850-T1 User Manual Edition: 08/2013 19.5 Create New Tool [Matrix] > [Main Menu] > [Thread Data] 1. Select the [Thread Data] softkey from the main menu screen to access the PMHMI thread and tool menu screen 2. Select the [Tool] softkey You are now prompted to create a new tool or edit an existing one.
  • Page 126 Select the TAB key to switch into the next input field and continue to enter data until all input field have been filled. Note: You can input the data in any order that you want. Just use the TAB key to switch into the required input field. Matrix Machine Tool (Coventry) Limited 126 / 231...
  • Page 127 0850/0850-T1 User Manual Edition: 08/2013 6. After you have finished inputting the thread data select the [Save] softkey to continue. 7. Select the [Home] softkey to return to the home screen. Matrix Machine Tool (Coventry) Limited 127 / 231...
  • Page 128 11. Press the [TAB] key again to highlight the Tool field. 12. Using the blue up/down arrow keys scroll down the list and choose the tool that you want to use to dress the profile onto the wheel. Matrix Machine Tool (Coventry) Limited 128 / 231...
  • Page 129 Analyse the returned message and try again! 15. Press the [Use] softkey > [Home] softkey > [Back] softkey to return back to the main programming dialog screen. Matrix Machine Tool (Coventry) Limited 129 / 231...

  • Page 130: Grinding Cycle Overview

    0850/0850-T1 User Manual Edition: 08/2013 19.6 Grinding Cycle Overview [Custom > Matrix > Main Menu > Grinding Overview] This overview screen displays updated information related to the grinding cycle as each grinding stage (G1 – G5) completes. With the exception of Cycle Hold and Restart at current diameter, all visible fields are for information only.

  • Page 131: Part Counter (Option)

    Edition: 08/2013 19.6.1 Part Counter (option) [Custom > Matrix > Main Menu > Grinding Overview > Part Counter] In the Part Counter screen you can set the quantity of workpieces that are to be processed by the machine. You can also set the grinding wheel re-dress interval based on the number of parts processed.

  • Page 132: Dressing Cycle Overview

    Edition: 08/2013 19.7 Dressing Cycle Overview [Custom > Matrix > Main Menu > Grinding Overview > Dress Cycle Overview] Select the [Dress Overview] vertical softkey in the grinding cycle overview screen. This screen automatically updates to show the active dressing cycle sequence as the cycle progresses through each defined zone (G1 –...

  • Page 133: Setting Cycles Menu

    Align the formed grinding wheel to a blank, non-pre-cut component (X axis). 4. Steady Rest Setting Cycle This cycle option is NOT available on 0850 series thread grinding machines. 5. Next Wheel Utility Cycle This cycle option is NOT available on 0850 series thread grinding machines.
  • Page 134 2. Select [AUTO] and [SETUP] mode from the MCP. 3. Select the Setting Cycles menu screen [Custom > Matrix > Main Menu > Setting Cycles] In general you are expected to at least execute the following setup cycles in the order listed below:...

  • Page 135: New Wheel Cycle

    Edition: 08/2013 19.9 New Wheel Cycle [Custom > Matrix > Main Menu > Setting Cycles > New Wheel] This cycle is used establish the relationship between the grinding wheel and the dressing tool ie to teach the machine the relative position of the grinding wheel to the dressing disc or roll.

  • Page 136: Explanation Of The Input Parameters

    Number of seconds that the diamond roll shall remain in contact with the grinding wheel at its current incremental position before the next radial dress increment is applied. THIS ONLY APPLIES WHEN A DIAMOND ROLL is used. If a diamond disc is used then this parameter is ignored. Matrix Machine Tool (Coventry) Limited 136 / 231...
  • Page 137 Grinding wheel advanced Grinding towards dressing tool Wheel using the handwheel In NEW WHEEL the dressing box cycle will continue to run until you have selected the [FIN] key to terminate the cycle Matrix Machine Tool (Coventry) Limited 137 / 231...
  • Page 138 Touch-on point Touch-on point Once the New WHEEL cycle has completed should then use the AUTO DRESS cycle to condition the wheel until the profile has been completely formed on the wheel. Matrix Machine Tool (Coventry) Limited 138 / 231...
  • Page 139 Select YES if the dresser system is set to helix. With fixed helix (0°) dresser system always set to NO. When using dressing disc or single point diamond dressing media then this field must be set to NO. Matrix Machine Tool (Coventry) Limited 139 / 231...
  • Page 140 For a diamond roll this is the profile diameter at the root. For a single point diamond this is the 2x radial distance from dressing spindle centreline to the diamond tip. Diamond roll Diamond disc Single point diamond Matrix Machine Tool (Coventry) Limited 140 / 231...

  • Page 141: Procedure For Executing The New Wheel Setting Cycle - If Diamond Roll Fitted

    X and then stop. 9. New Wheel cycle complete! You can now use the AUTO DRESS cycle to dress the wheel to full form with the profile on the diamond roll. Matrix Machine Tool (Coventry) Limited 141 / 231...

  • Page 142: Procedure For Executing The New Wheel Setting Cycle - If Diamond Disc Fitted

    X axis i.e the safe position. 16. New Wheel cycle complete! Upon completion of the NEW WHEEL setting cycle if you think that the wheel still requires more dressing then you use the AUTO-DRESS cycle if required. Matrix Machine Tool (Coventry) Limited 142 / 231...

  • Page 143: Work Datum Setting Cycle

    Edition: 08/2013 19.10 Work Datum Setting Cycle [Custom > Matrix > Main Menu > Setting Cycles > Set Work Datums] This setting cycle is used to set the Z axis start and end grind positions (this does not include the X and Z taper in/out moves when the grind sequence commences).

  • Page 144: Setup Method 1 - Grind Direction From Right-To-Left

    You should select this method of work datum setup if you are grinding a left-hand threaded workpiece. The sketch above illustrates the start and end setting positions of the grinding wheel relative to the workpiece. Matrix Machine Tool (Coventry) Limited 144 / 231...

  • Page 145: Procedure For Executing The Work Datum Setting Cycle

    1. Set the orange keyswitch to position 3 on the MCP 2. Select [JOG] mode on the MCP 3. Load the Work Datum setting cycle [Custom > Matrix > Main Menu > Setting Cycles > Set Work Datums] 4. Using handwheel or JOG buttons [+][-] manually position the grinding wheel to the start grind position.

  • Page 146: Barelling Function (Option)

    Edition: 08/2013 19.11 Barelling function (option) [Custom > Matrix > Main Menu > Setting Cycles > Set Work Datums > Barelling] With the barrelling function enabled you can apply fine positional adjustments to the grinding wheel infeed (X) axis at various points along the workpiece length as the grinding wheel moves along it.

  • Page 147: Explanation Of The Input Parameters

    Input Range: 0 – 380 mm Total length over which the length correction will be applied during workpiece grinding. Z Length Input Range: 0 – 380 mm Length between adjacent correction points. Matrix Machine Tool (Coventry) Limited 147 / 231...

  • Page 148: Probe System Setup (Option)

    19.12 Probe system setup (option) [Custom > Matrix > Main Menu > Setting Cycles > Set Work Datums > Probe Cycle] If the machine is fitted with the probe system option then a number of offset values relating to the unit must be set in the probe setup screen before the probing system can be used in the automatic machine cycle.

  • Page 149: Procedure For Setting Up The Probe System

    4. Make a note of the Z axis position as displayed on the screen in the machine coordinate system (MCS). 5. Select the Probe Cycle screen [Custom > Matrix > Main Menu > Setting Cycles > Set Work Datums > Probe Cycle] and enter the value you made a note of in the previous step into the Fixture Offset input field.
  • Page 150 23. Go back to the WORK DATUM setup screen and complete the procedure to set the end grind Z position. 24. Test the probe cycle in [SETUP] mode to confirm that the workpiece can be probed correctly. 25. Probe system setup is complete! Matrix Machine Tool (Coventry) Limited 150 / 231...

  • Page 151: Pitch-In Setting Cycle

    0850/0850-T1 User Manual Edition: 08/2013 19.13 Pitch-IN Setting Cycle [Custom > Matrix > Main Menu > Setting Cycles > Pitch-in Cycle] Use this setting to synchronise the grinding wheel to the pre-cut thread or non-threaded workpiece. 19.13.1 Explanation of the Input Parameters Work Speed Input Range: 0 –...

  • Page 152: Pitch-In To Workpiece With A Pre-Cut Thread

    Using the handwheel in X,Z and C, align the formed grinding wheel to the pre-cut component. 19.13.3 Pitch-in to a blank or non-threaded workpiece Using the handwheel in X,Z and C, align the tip of grinding wheel to OD of the workpiece. Matrix Machine Tool (Coventry) Limited 152 / 231...

  • Page 153: Procedure For Executing The Pitch-In Setting Cycle

    3. Select [AUTO] and [SETUP] mode 4. Select the Pitch-In setting cycle from the setting cycles menu screen [Custom > Matrix > Main Menu > Setting Cycles > Pitch-In] 5. Press the [CYCLE START] key and wait for the message prompt “Enter data in data field and press input –...

  • Page 154: Next Wheel Setting Cycle (Option)

    0850/0850-T1 User Manual Edition: 08/2013 19.14 Next Wheel Setting Cycle (option) [Custom > Matrix > Main Menu > Setting Cycles > Next Wheel] Option is not available with the machine. Matrix Machine Tool (Coventry) Limited 154 / 231...

  • Page 155: Auto Dress Utility Cycle

    Edition: 08/2013 19.15 Auto Dress Utility Cycle [Custom > Matrix > Main Menu > Setting Cycles > Auto Dress] This is a stand-alone cycle that can be used to dress the grinding wheel independently of the grinding cycle. Auto wheel dressing can be executed whenever you like provided that the New Wheel cycle or Next Wheel (option) cycle has been run previously.

  • Page 156: Explanation Of Input Parameters

    Number of seconds that the diamond roll shall remain in contact with the grinding wheel at its current incremental position before the next radial dress increment is applied. THIS ONLY APPLIES WHEN A DIAMOND ROLL is used. If a diamond disc is used then this parameter is ignored. Matrix Machine Tool (Coventry) Limited 156 / 231...

  • Page 157: Procedure For Using The Auto Dress Cycle

    Procedure for using the Auto Dress cycle 1. Select [AUTO] and [SETUP] mode 2. Select the AUTO DRESS setting cycle [Custom > Matrix > Main Menu > Setting Cycles > Auto Dress] 3. Press [CYCLE START] and wait for the message prompt ”Enter DRESS DATA in data field -...

  • Page 158: Correction Utilities Menu

    Edition: 08/2013 19.16 Correction Utilities Menu [Custom > Matrix > Main Menu > Setting Cycles > Correction Utilities] In the correction utilities menu you can select the type of correction to be applied to the machine. Matrix Machine Tool (Coventry) Limited...

  • Page 159: Lead Correction

    Nominal length over which the lead error has been measured The error length must always be a positive value. Also, the length along the workpiece where the lead is checked does not matter. Matrix Machine Tool (Coventry) Limited 159 / 231...
  • Page 160 0850/0850-T1 User Manual Edition: 08/2013 Matrix Machine Tool (Coventry) Limited 160 / 231...

  • Page 161: Procedure

    Procedure To add Lead Correction 1. Select [AUTO] and [SETUP] mode 2. Select the Correction utilities screen [Custom > Matrix > Main Menu > Setting Cycles > Correction Utilities] 3. Select the [Lead Correction] softkey. 4. Input the measured lead error (microns) followed by pressing the yellow [Input] key.

  • Page 162: Applying Lead Correction

    +ve then enter a positive value into the lead error field The lead error value can be +ve or –ve but the error length must always be a positive value. Matrix Machine Tool (Coventry) Limited 162 / 231...

  • Page 163: Taper Correction

    1. parallel workpiece ground thread was measured and found to be showing a positive or negative taper 2. taper workpiece ground thread was measured and found to be showing a positive or negative taper Matrix Machine Tool (Coventry) Limited 163 / 231...

  • Page 164: Explanation Of Input Parameters

    Taper Error input field. Active Corr. (radial) Read only field Currently active radial taper correction applied to the machine. Active Taper (radial) Read only field Currently active taper value applied to the machine. Matrix Machine Tool (Coventry) Limited 164 / 231...

  • Page 165: Positive Taper Error

    A negative taper means that more stock than required is being removed from the workpiece by the grinding wheel as it moves along the workpiece where the grinding direction is from right to left. Matrix Machine Tool (Coventry) Limited 165 / 231...

  • Page 166: Procedure

    Procedure To add Taper Correction 1. Select [AUTO] and [SETUP] mode 2. Select the Correction utilities screen [Custom > Matrix > Main Menu > Setting Cycles > Correction Utilities] 3. Select the [Taper Correction] softkey. 4. Input the measured taper error (mm/mm) followed by pressing the yellow [Input] key.

  • Page 167: Diameter Correction

    Error between the measured diameter and the active machine diameter Tooth Error Input Range: 0 - 999 microns Error between the measured tooth width and required tooth width. This input field only applicable when grinding dual-lead worms. Matrix Machine Tool (Coventry) Limited 167 / 231...

  • Page 168: Applying Diameter Correction

    Procedure To add Diameter Correction 1. Select [AUTO] and [SETUP] mode 2. Select the Correction utilities screen [Custom > Matrix > Main Menu > Setting Cycles > Correction Utilities] 3. Select the [Diameter Correction] softkey. 4. Input the measured diameter error (mm) followed by pressing the yellow [Input] key.

  • Page 169: Profile Correction

    The adjustment is applied at the profile mid-point on completion of the right hand profile and prior to execution of the left hand profile. Note: This is only applicable to diamond discs. Matrix Machine Tool (Coventry) Limited 169 / 231...

  • Page 170: Explanation Of Input Parameters

    0850/0850-T1 User Manual Edition: 08/2013 19.20.1 Explanation of input parameters Width Error Input Range: +/- 300 microns Adjustment of profile width Radial Error Input Range: +/- 300 microns Adjustment of profile height Matrix Machine Tool (Coventry) Limited 170 / 231...

  • Page 171: Procedure

    Procedure To add Profile Correction 1. Select [AUTO] and [SETUP] mode 2. Select the Correction utilities screen [Custom > Matrix > Main Menu > Setting Cycles > Correction Utilities] 3. Select the [Profile Correction] softkey. 4. Input the width and/or radial error (microns) followed by pressing the yellow [Input] key.

  • Page 172: Barrelling Correction

    To make corrections at barrelling points 1. Select [AUTO] and [SETUP] mode 2. Select the Barrelling corrections screen [Custom > Matrix > Main Menu > Setting Cycles > Correction Utilities > Barrelling] 3. Press the [Set Barrelling] soft key and enter the required values in the table followed by pressing the yellow [Input] key after each entry.

  • Page 173: Cycle Data - Grind Table

    Edition: 08/2013 19.22 Cycle Data - Grind Table [Menu Select > Matrix > Main Menu > Cycle Data > Grind Data] The Grind R variables screen presents you with a data table in which you can enter data to define how the workpiece is to be ground.

  • Page 174: Procedure To Edit Grind Cycle Variables

    Procedure to edit Grind cycle variables 1. Select [AUTO] and [SETUP] mode 2. Select the Grind Data screen [Custom > Matrix > Main Menu > Cycle Data > Grind Data] 3. Enter data in each zone field as required. 4. Press the [UPDATE TABLE] vertical softkey and check the total stock to remove in each zone (G1 to G5) you defined.

  • Page 175: Grinding Zones

    G4 to clean-up any small amount of material (if any) still remaining the workpiece. Sometimes, sparkout passes are used to eliminate possible wheel deflection that may have occurred during grinding. Note: Dressing cycles are not permitted during sparkout passes. Matrix Machine Tool (Coventry) Limited 175 / 231...

  • Page 176: Explanation Of Parameters

    Workpiece rotational speed Grind Inc Input range: 0 – 499 microns Amount of stock to remove on diameter per grinding pass Wheelspeed Input range: 0 -70 M/sec The grinding wheel surface speed during grinding Matrix Machine Tool (Coventry) Limited 176 / 231...
  • Page 177 Grind pass #10 (for start 2) Dress If you don’t want to do any dressing in the selected zone then enter dress frequency to a value greater than the value in the No. of cycle field. Matrix Machine Tool (Coventry) Limited 177 / 231...

  • Page 178: End-Threading Parameters

    Workspeed required for end-threading as a percentage of the thread grinding speed Thread Grind Input range: toggle ON/OFF Global thread grinding function enable If this parameter is set to OFF then the threading grinding cycle will not be performed on the workpiece. Matrix Machine Tool (Coventry) Limited 178 / 231...

  • Page 179: How To Set The Start And End Points For End-Thread Grinding

    0850/0850-T1 User Manual Edition: 08/2013 19.22.5 How to set the start and end points for end-thread grinding Matrix Machine Tool (Coventry) Limited 179 / 231...

  • Page 180: Cycle Data - Dress Table

    Procedure to edit Dress cycle variables 1. Select [AUTO] and [SETUP] mode 2. Select the Dress R variables screen [Custom > Matrix > Main Menu > Dress R Variables] 3. Enter data in each zone field as required. 4. Finally, press the [SAVE Data] vertical softkey to save the dressing cycle data to the workpiece data file.

  • Page 181: Explanation Of Parameters

    Number of seconds that the diamond roll shall remain in contact with the grinding wheel at its current incremental position before the next radial dress increment is applied. THIS ONLY APPLIES WHEN A DIAMOND ROLL is used. If a diamond disc is used then this parameter is ignored. Matrix Machine Tool (Coventry) Limited 181 / 231...

  • Page 182: Load And Run The Grind Cycle

    Edition: 08/2013 19.24 Load and Run the Grind Cycle Select the Grind Overview screen [Menu Select > Matrix > Main Menu > Grinding Overview] 1. Set the ORANGE Siemens Key in position 3. 2. Select [LOAD CYCLE] softkey. This will load the grind program into the NC ready for execution.

  • Page 183: Cycle Stop/Interrupt

    Should there be a need to interrupt or abort the active grind cycle it is recommended that you select the [BLOCK SKIP] function at the machine control panel to bring the cycle to a controlled stop. Matrix Machine Tool (Coventry) Limited 183 / 231...

  • Page 184: Procedure For Cycle Interrupt

    “Select required option using vertical buttons” to appear. 3. Select the [Cycle Options] screen [Custom > Matrix > Main Menu > Grinding Overview > Cycle Options] 4. You can now inspect the workpiece or make a correction to the diameter if required.

  • Page 185: Resume The Cycle

    Make a correction to the diameter and then resume the cycle Select this option if you want to make a correction to the diameter before resuming the cycle. 1. Select the Diameter Correction screen [Custom > Matrix > Main Menu > Setting Cycles > Correction Utilities] 2.

  • Page 186: Access Level Key Switch

    Full access to the HMI panel is allowed. Position 3 (Orange Key) Maintenance All manual functions are available. Protection level 4 - 7 Full access to the MCP is allowed. Limited access to the HMI panel. Matrix Machine Tool (Coventry) Limited 186 / 231...

  • Page 187: Programming M/S/T Codes

    (i.e handwheel off) cancel handwheel selection in cycle set handwheel overlay to X axis set handwheel overlay to Z axis set handwheel overlay to C axis select TEACHIN mode set VAR increment Matrix Machine Tool (Coventry) Limited 187 / 231...
  • Page 188 S3=nnnn dressing spindle CW speed, where nnnn is the grinding wheel speed in rpm S4=nnnn dressing spindle CCW speed, where nnnn is the grinding wheel speed in rpm Matrix Machine Tool (Coventry) Limited 188 / 231...

  • Page 189: Maintenance

    The machine is fitted with a positive displacement lubrication unit and is factory preset to automatically displace a 12sec oil shot every 15 mins to the various lubrication points around the machine via small plastic lube feed lines. Oil Distribution Layout Matrix Machine Tool (Coventry) Limited 189 / 231...

  • Page 190: Electrical Control Cabinet (Ecc)

    As standard the ECC if fitted with a door mounted air conditioning unit to maintain the internal cabinet temperature at 35°C. Matrix Machine Tool (Coventry) Limited 190 / 231...

  • Page 191: Services Cabinet (Sc)

    0850/0850-T1 User Manual Edition: 08/2013 22.3 Services Cabinet (SC) The machine service cabinet located to side of ECC and contains gauges and switchgear for monitoring the air supply to the machine’s pneumatically operated equipment. Matrix Machine Tool (Coventry) Limited 191 / 231...

  • Page 192: Fume Extractor

    Power to the fume extraction is connected via a junction box located at the base machine and the extractor unit operates automatically when the machine is started. Matrix Machine Tool (Coventry) Limited 192 / 231...

  • Page 193: Recommended Oils/Fluids/Additives

    Fully synthetic water-miscible corrosion protection concentrate for anti-corrosion additive spindle cooling systems. Colour: yellow fluorescent Density @ 20°C: 1.15 pH value: 8.8 pH value 5 % in water 8.4 – 8.6 temperature range : 4 - 80°C Matrix Machine Tool (Coventry) Limited 193 / 231...
  • Page 194 0850/0850-T1 User Manual Edition: 08/2013 Matrix recommend using neat cutting oil for all types of thread grinding applications. A wide range of modern cutting oils are available from a number of suppliers. Details of oils which give good results are listed below.

  • Page 195: Coolant System

    Filling the coolant system 1. Remove the filling point cover 2. Pump 750 ~ 800 litres of neat cutting oil into the tank through the filling point 3. Replace the filling point cover Matrix Machine Tool (Coventry) Limited 195 / 231...

  • Page 196: Preparing The Spindle Chiller Unit

    2. Using a suitable funnel first pour in 10L of normal tap water. 3. Now pour in 1.75L of anti-corrosion concentrate. 4. Finally top up with water until the sight glass is showing the tank full. 5. Replace the filling point cover. Matrix Machine Tool (Coventry) Limited 196 / 231...

  • Page 197: Oil Cooler Unit

    SV °C: Displays the current set value. Operation Lamp: PUMP: Indicates if the mixing motor (optional) starts operating. COOL: Indicates if cooling process starts. WARM: Indicates if heater (optional) starts operating. Matrix Machine Tool (Coventry) Limited 197 / 231...
  • Page 198 Clean internal cooler body avoiding any water splashes on the electrical components. Use dry materials to clean electrical components. Check the condenser is not clogged with any contaminants. Use a long brush or compressed air to remove dust from condenser. Matrix Machine Tool (Coventry) Limited 198 / 231...
  • Page 199 Oil Filter - Regularly clean the oil filter installed at the inlet point of the cooler unit. This will help prevent any build up of cutting powder on the cooling coil. Leakage - Leaks from the oil hose can be fixed by tightening the tube clips or replacing. Matrix Machine Tool (Coventry) Limited 199 / 231...

  • Page 200: General Maintenance Schedule

    22.8 General Maintenance Schedule The recommended maintenance intervals are based on assumptions that the machine is used for 40 hours per week. For more intensive use of the machine, consult Matrix Machine Tool (Coventry) Ltd for a maintenance schedule. Daily 1.
  • Page 201 0850/0850-T1 User Manual Edition: 08/2013 fig. 1 fig.3 Note: do not exceed the tank capacity (3L) when filling with oil (VG68) fig. 2 fig. 4 Lubrication nipples Matrix Machine Tool (Coventry) Limited 201 / 231...

  • Page 202: Pressurised Air Supply To Machine

    The micro-filter located in the services cabinet should be inspected at regular intervals (at least once a week) and changed when it becomes clogged up. Matrix Machine Tool (Coventry) Limited 202 / 231...

  • Page 203: Cleaning The Coolant System Centrifuge

    Therefore, regular maintenance cleaning of the centrifuge drum must be carried out to ensure trouble free operation. Matrix Machine Tool (Coventry) Limited 203 / 231...
  • Page 204 Cleaned oil exit pipe outlet feeding to lock lever clean oil tank Removable inspection panel Lift pump to transfer oil from main tank to the centrifuge Debris collection bin on castors Lift pump flow adjust valve Matrix Machine Tool (Coventry) Limited 204 / 231...
  • Page 205 0850/0850-T1 User Manual Edition: 08/2013 Debris catch plate positions Catch plate shown in the normal operating position Catch plate shown in the maintenance position Set to this position when cleaning the drum. Matrix Machine Tool (Coventry) Limited 205 / 231...
  • Page 206 THE DRUM LOCK WHILST THE DRUM IS STILL ROTATING OTHERWISE THERE IS A RISK OF PERSONAL INJURY AND THE LOCKING PIN WILL GET DAMAGED. Cut out switch Fig 6 Drum Lock Drum Pulley Matrix Machine Tool (Coventry) Limited 206 / 231...
  • Page 207 Normal position (the bar is horizontal) 9. Close the drum switch access panel and secure with the hexagon cap head.. 10. Start-up the centrifuge unit as normal from the coolant system control panel. Matrix Machine Tool (Coventry) Limited 207 / 231...

  • Page 208: Power Chuck Maintenance

    4. Maintenance intervals: Depending on the conditions of use, but not later than after the specified periods. We recommend using Rohm special grease F80. Matrix Machine Tool (Coventry) Limited 208 / 231...

  • Page 209: Troubleshooting Guide

    Change cooler unit to a larger cooling capacity . Replace the oil temperature sensor. Contact the refrigeration technician for refrigeration system failures. Explanation There is a pressure fault within the refrigeration system. Matrix Machine Tool (Coventry) Limited 209 / 231...
  • Page 210 Has the temperature controller failed? Solution Reconnect the power cable with the correct phase. SV °C Three phase cooling unit should be connected to a three phase power source. Replace faulty components. Matrix Machine Tool (Coventry) Limited 210 / 231...
  • Page 211 The process load is above the cooler unit’s capacity. Poor heat dissipation. Leakage of refrigerant. Thermostat failure. Inspection Is the cooler unit’s capacity suitable for the process load? Is cooler unit’s internal temperature too high? Matrix Machine Tool (Coventry) Limited 211 / 231...
  • Page 212 Is the thermostat connection ok? Is the power supply still working? Has the thermostat failed? Solution Set circuit breaker back on. Reconnect any loose wires on the remote control and thermostat. Replace faulty components. Matrix Machine Tool (Coventry) Limited 212 / 231...

  • Page 213: Machine Diagnostic Screens

    0850/0850-T1 User Manual Edition: 08/2013 23.2 Machine Diagnostic Screens Select [Custom > Matrix > Main Menu > Maintenance Menu] from the HMI screen panel to access the machine specific diagnostics. Maintenance diagnostics sub-menu Digital Inputs Matrix Machine Tool (Coventry) Limited...
  • Page 214 Using the blue arrow keys on the HMI panel cursor onto a bit field. Observe the message text in the lower status panel to give you specific indication of the area of the problem. Matrix Machine Tool (Coventry) Limited 214 / 231...
  • Page 215 0850/0850-T1 User Manual Edition: 08/2013 Machine Overview Wheel balancer system diagnostic screen Matrix Machine Tool (Coventry) Limited 215 / 231...
  • Page 216 0850/0850-T1 User Manual Edition: 08/2013 Coolant system diagnostic screen Setup Data (Restricted Access) This screen is only accessible at the manufacturer password level. Matrix Machine Tool (Coventry) Limited 216 / 231...

  • Page 217: Alarm Messages

    Remove the switch from the ECC and put it into a refrigerator for 20minutes to get it back to the reset state. Re-fit the switch inside the ECC and check that the alarm clears. Matrix Machine Tool (Coventry) Limited 217 / 231...
  • Page 218 The axis drives ready signal was not set by the Siemens drive system when the machine was master started. This could be because of an internal fault within a SINAMICS power module or the infeed power supply module. Remedy: Refer to the Siemens SINAMICS drives documentation for troubleshooting instructions. Matrix Machine Tool (Coventry) Limited 218 / 231...
  • Page 219 Check which circuit breaker has tripped inside the ECC and ensure that the current overload trip setting has been set in accordance with the FLC of the device being protected. Reset the circuit breaker. Matrix Machine Tool (Coventry) Limited 219 / 231...
  • Page 220 The grinding spindle failed to start within 4 seconds after the user request to start the spindle or change to the programmed speed whilst operating in cycle. Remedy: Contact your authorized Matrix Service representative for assistance to troubleshoot this fault. 700028 Air conditioning cooling unit fault K1 700029 Air conditioning cooling unit fault K2 Cause: The air conditioner unit fitted to the door of the electrical cabinet has developed a fault.
  • Page 221 700033 Programmed wheel speed is too high Cause: The programmed wheel speed is above the maximum wheel speed defined in the Matrix Setup Data screen Remedy: Reduce the programmed wheel speed to below the maximum wheel speed. Wheel Speed changes should only be Performed while the wheel is Stopped.
  • Page 222 The 220VAC power supply is not connected or fuse has blown. Remedy: Top-up the oil in the lubrication tank. Check pump motor. Operate the lubrication unit manually to confirm operation and the green indicator is illuminated. Matrix Machine Tool (Coventry) Limited 222 / 231...
  • Page 223 The minimum grinding wheel speed is set to a higher value than the maximum grinding speed. Remedy: Check the maximum and minimum grinding wheel speed settings in Menu Select > Matrix > Setup Data Min speed should be >=500rpm but less than the max speed...
  • Page 224 The coolant high level float switch could have become stuck. Remedy: Check the amount of coolant oil in the tank and siphon off excess coolant from the tank if necessary. Check the high level float switch operates correctly or replace it. Matrix Machine Tool (Coventry) Limited 224 / 231...
  • Page 225 6 = FIFO full - Job must be repeated since queue is full 7 = Option not set - OB100 parameter "NCKomm" is not set 9 = Transmission occupied - Job must be repeated Matrix Machine Tool (Coventry) Limited 225 / 231...
  • Page 226 The minimum dresser spindle speed is set to 0 or >= the maximum grinding speed. Remedy: Check the maximum and minimum dresser spindle speed settings in Menu Select > Matrix > Setup Data Min speed should be >=100rpm but less than the max speed...
  • Page 227 2 seconds after the position was detected. state change from 0 to 1 is seem within 2 seconds. Remedy: With the workpiece supported between centres adjust the tailstock pressure regulator until the pressure signal state changes to 1. Matrix Machine Tool (Coventry) Limited 227 / 231...

  • Page 228: Recovering From An Axis Software Travel Limit Condition

    3. If the axis is on the positive software limit then press the [-] jog button until the alarm message disappears 4. If the axis is on the negative software limit then press the [+] jog button until the alarm message disappears Matrix Machine Tool (Coventry) Limited 228 / 231...

  • Page 229: Air Conditioning Unit Alarm Codes

    Result is stored in the log file. Display message Connection problem between display Reset: Switch power supply off, then switch on And controller board. Again after approx 2 sec. Cable defective; connection loose. Exchange the Boards. Matrix Machine Tool (Coventry) Limited 229 / 231...

  • Page 230: Coolant System Technical Data

    MA-12 capacity: 120 l/min power: 380/440V, 3ph, 50/60Hz Oil Cooler Unit Habor HK-2RMSB power: 380/415V, 3ph, 50/60Hz, 6.5A compressor: 380/415V, 3ph, 50/60Hz, 5.2A, 2.48kW temp. control: RT +/- 10°C refrigerant: R-407C 1.8kg Matrix Machine Tool (Coventry) Limited 230 / 231...
  • Page 231 0850/0850-T1 User Manual Edition: 08/2013 Space for your notes Matrix Machine Tool (Coventry) Limited 231 / 231...

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