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Rocketronics ELS 4 PRO Operating Instructions Manual

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ELS 4 PRO
Operating instructions
TRanSLaTiOn Of ThE ORiginaL
OPERaTing inSTRucTiOnS
This manual describes the commissioning and use of
the cycle controller ELS 4 PRO.
ENGLISH

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Summary of Contents for Rocketronics ELS 4 PRO

  • Page 1 ELS 4 PRO Operating instructions TRanSLaTiOn Of ThE ORiginaL ENGLISH OPERaTing inSTRucTiOnS This manual describes the commissioning and use of the cycle controller ELS 4 PRO.
  • Page 2 The distribution and reproduction of this document, its use and communication of its con- tents is strictly prohibited. not permitted, unless expressly conceded. Contraventions obligate to Compensation. All rights in the event of patent grant or utility model registration. reserved. All product designations mentioned in this manual are trademarks of respective companies.

  • Page 3: Table Of Contents

    INHALT .......................... 4 Disclaimer .....................  4 Addressee of the documentation ........................ 4 Safety instructions ...... 5 Licence conditions for software of the electronic leadscrew control system Notes ............................ 6 Scope of delivery and accessories .................. 10 Pro requirements ........................ 11 ..........................
  • Page 4 ..................  48 Implementation of the commissioning BASIC functionality .......................  52 .....................  54 Selection of cutting passes Possible Modes ........................ 56 ........................ 57 GEARBOX LEFT ........................ 57 GEARBOX RIGHT .......................... 58 TURNING .......................... 60 Example .......................... 62 BORING .......................... 64 FACING ..........................

  • Page 5: Disclaimer

    DISCLAIMER We have checked the contents of this publication for conformity with the hardware and soft- ware described. Nevertheless, deviations cannot be excluded, so that we do not assume any liability for the complete conformity. However, the information in this publication is checked regularly and necessary corrections are included in the following editions.

  • Page 6: Licence Conditions For Software Of The Electronic Leadscrew Control System

    LICENCE CONDITIONS FOR SOFTWARE OF THE ELECTRONIC LEADSCREW CONTROL SYSTEM In the following the company Rocketronics.de, owner Louis Schreyer is referred to as „LICENSER“ of the software. I. Rights of Use 1. The LICENSER grants to the Customer a royalty-free, perpetual and non-exclusive right to use (license) the SOFT- WARE contained in this archive (hereinafter referred to as „SOFTWARE“).

  • Page 7: Notes

    NOTES The ELS controls are simple cycle controls that allow fully automatic cycle machining with a conventional lathe. For this purpose, drives must be mounted on the axes of the ma- chine and a rotary encoder for position feedback must be mounted on the main spindle. Equipped with these components, the machine can then be controlled in 2 axes.
  • Page 8 All products containing a component part manufactured by Rocketronics must include appropriate warnings and instructions for safe use and operation when handed over to the end user. All warnings provided by Rocketronics must be passed directly to the end user.
  • Page 9 Qualified personnel Qualified personnel must be able to correctly interpret and implement the safety instructions and warnings. They must also be familiar with the safety concepts of automation technology and have received appropriate training. Non-qualified interventions in the devices or failure to observe the warning notices in this documentation or the warning notices displayed by the device may result in damage to property or personal injury.
  • Page 10 ● Switch off the device immediately if it shows noticeable deviations from normal operation. ● Rocketronics.de guarantees the proper function of the device only if no changes are made ● in mechanics, electronics and software. The opening of the device as well as adjustment, maintenance and repair work may be ●...

  • Page 11: Scope Of Delivery And Accessories

    SCOPE OF DELIVERY AND ACCESSORIES The scope of delivery of the ELS Pro includes a control unit. Various components are available as accessories. Manual ELS PRO This Manual Lathecontroller PRO OPTIONAL OPTIONAL OPTIONAL Wallmount Micro-SD-Card Power supply 24V/1A 2 GB Micro-SD-Card for An adapter plate is available Power supply with 24V und for mounting to a VESA wall...

  • Page 12: Pro Requirements

    PRO REqUIREMENTS Lathe The machine must have a lead screw and a cross slide. It must be possible to equip these spindles with drive motors. Simple so-called mechanic lathes are therefore not optimally suitable. The size is not limited. Rotary encoder on main spindle Make sure that an encoder with quadrature signals is connected to the main spindle.

  • Page 13: Encoder

    The pulse rate delivered to the ELS per spindle revolution must be entered in the control ● settings before starting operation. Encoders can be connected directly to terminals or via the Rocketronics „Incremental Line ● Driver“ with an Ethernet patch cable (CAT5 or better, S-FTP e.g.) to the RJ45 connector. See...
  • Page 14 Encoders either have a fixed pulse rate or can be set. The frequently used adjustable encoder type AMT 103-V has 4 small switches to set the pulse Additional Resources: Product Page 3D Model rate. The manual contains a table showing the assignment of the pulse rate to the switch combination.

  • Page 15: Axle Drives

    AXLE DRIVES Drive motors must be mounted on the X and Z axes. ● In order to be able to move the axes, the installed threaded spindles must be moved using ● stepper or servo motors. These are available in various sizes which must be selected to suit the machine.
  • Page 16 tween the steps, which leads to very precise drives. And the best thing is: step losses are ex- cluded. All in all a very recommendable drive for the ELS. The disadvantage here, too, is the higher price. The ELS generates step and direction signals for motor drivers. A step pulse drives the stepper motor 1/200 revolution further, the direction signal determines in which direction the motor rotates.

  • Page 17: Selection Of Right Motor

    SELECTION OF RIGHT MOTOR The stepper motor must provide sufficient torque to turn the lead screw in all positions. De- pending on the machine, more or less power is required. In general it can be said that the nec- essary forces are smaller than e.g. on a milling machine. For normal hobby machines with 400-600mm distance a Nema24 motor with 3-4A current should be sufficient.
  • Page 18 Recommendation for step rate on the motor driver with direct drive 1:1 of the Z-axis Steps/Rev Resolution per step Screwpitch [mm] Transmission on motor [mm] 0,0025 0,005 0,0075 0,010 0,005 0,00625 0,0075 0,010 Recommendation for step rate on the motor driver with ratio 2:1 of the Z-axis Steps/Rev Resolution per step Screwpitch [mm]...

  • Page 19: Maximum Feed Speed

    MAXIMUM FEED SPEED The maximum feed rate in mm/revolution is directly linked to the ratio of encoder pulses, mo- tor steps/revolution and the thread pitch of the lead screw. The maximum feed rate is decisive for the maximum thread pitch you can produce. Please note, however, that threads with a pitch of more than 8 mm are very rarely turned.

  • Page 20: Motor-Drivers

    MOTOR-DRIVERS To convert the control signals supplied by the ELS into motor current, we need a motor driv- er or motor output stage. These are small electronic devices that generate suitable signals to move the motor. Most types have step and direction inputs, 4 output terminals for the motor connection and +VDC and GND connections for the supply volt- age.
  • Page 21 This should be activated. Please refer to the documentation of the manufacturers of the com- ponents. All components purchased from Rocketronics are accom- panied by corresponding documentation and pin assignments!

  • Page 22: Emergency-Stop

    EMERGENCY-STOP The complete machine must have an emergency stop device in which the ELS control must also be integrated. The ELS has inputs and outputs for this purpose. An automatic restart after the emergency stop has been triggered must be safely prevented! An emergency stop of category 1 - controlled shutdown while maintaining the power supply - is required to carry out the shutdown.

  • Page 23: Controlelements

    CONTROLELEMENTS FRONT SIDE The ELS keyboard has buttons for operation. In the manual, buttons are addressed with a sym- bol, e.g. START, and with the following designation: Mikro-SD-Card-Slot Programmiertaste/ Resettaste ON/OFF Settings Parameters SUBMODE RIGHT LEFT Spindle DOWN ZSTEP ZOFF KNOB XOFF XSTEP...

  • Page 24: Key Functions

    KEY FUNCTIONS START Start of a cycle. Most cycles do not start until the spindle is already turning! PAUSE Pauses a cycle when possible STOP Stops a running cycle. Sets the selected input value to 0, e.g. feed rate, ZP or XP. Sets the current Z position to 0, zeros the axis.

  • Page 25: Display-Elements

    DISPLAY-ELEMENTS The LCD display shows the data on 4 lines. The standard display before the start of a cycle shows the Pro data. The display changes depending on the mode. Parametermenü available Selected mode CURSOR Cutter-radius und Infeed-depth CURRENT X POSITION XP= X Endposition Diameter CURRENT Z POSITION XP= X Endposition as Radius...

  • Page 26: Micro-Sd-Card-Slot

    Further down, the cutting radius and infeed depths Ap Finishing and Ap Roughing set in the parameter menu are displayed. In the bottom line there is the display for cycle status: RUN= Started, STOP= Stopped. In addition, you can see the status of the power stages: ZOFF = Z axis switched off (with the ZOff key) XOFF = X axis switched off (with the XOff key) In addition, it is indicated whether one of the axes is in step mode:...

  • Page 27: Inputs And Outputs

    INPUTS AND OUTPUTS Various inputs and outputs are available for connection to the machine. 2 inputs for 1 incremental encoder (RJ45 and screw terminal) 2 inputs for 1 X-axis drive system (RJ45 and screw terminal) 2 inputs for 1 X-axis drive system (RJ45 and screw terminal) (ATTENTION: Either use RJ45 -OR- terminals, not both!) 1 supply voltage input for 24V round plug + 1 screwterminal 4 digital inputs for emergency stop circuit, limit switches and error signals...

  • Page 28: Screwterminal Data

    SCREWTERMINAL DATA The screw terminals are pluggable and can accept cables with the following cross-sections: Solid (rigid) 0.14 mm² - 1.5 mm² AWG 28-16 Flexible 0.14 mm² - 1.5 mm² AWG 28-16 Flexible with wire end sleeve 0.25 mm² - 1.0 mm² Stripping length: 7.0 mm Maximum current:...

  • Page 29: Connection Of Encoder

    To ensure the interference immunity of the signals, the signal must be transmitted differential- ly, recognisable by the connections A+, A-, B+ and B-. Normal signals can be converted into a differential signal with the Rocketronics „differential line driver“. An index signal is not neces- sary and is not used.
  • Page 30 Encoder connection to differential line driver Many encoders deliver only one non-differential signal, which has many disadvantages. To con- vert it into a differential signal you can use the differential line driver. This converts the AB signal into an A+A-B+B signal and thus significantly increases interference immunity. Another advantage of the driver is the possibility of connecting the encoder to the controller via a com- mercially available Ethernet patch cable.

  • Page 31: Connection Motordriver

    Connection: Use either screw terminals or RJ45 jack for connection. The RJ45 connector is compatible with Rocketronics RJ45 driver adapters and allows clean connection of motor drivers with commer- cially available Ethernet patch cables. Terminal assignment screw terminal for X and Z axis:...
  • Page 32 We offer small adapters for easy connection of leadshine drivers (and copies thereof). These are connected directly to the driver connectors and then provide a suitable RJ45 connector. Connect drivers and controls with an Ethernet patch cable very simple and create a clean and shielded connection.

  • Page 33: Digital Inputs

    DIGITAL INPUTS The controller has 4 digital inputs that can be loaded with up to 24V. For easy connection, 24V is available next to each input terminal. If external power supplies are used, the earth terminals next to the input terminals can be used for the earth connection between the power supply and the controller.

  • Page 34: Emergency Stop

    EMERGENCY STOP The controller must be integrated into an emergency stop circuit in order to implement an emergency stop function. DANGER A non-existent or malfunctioning emergency stop circuit can result in death or serious injury. Ensure that the entire machine is in a safe state in the event of an emergency stop before using or handing over the machine.
  • Page 35 Input 3: Z LIM The input must be activated in the settings! Input for limit switch of the Z axis. You can use potential-free contacts of a mechanical limit switch or inductive proximity switches (see below) When the input is activated, the control switches to a safe state and ends running cycles until a release has been given with the STOP key.

  • Page 36: Digital Outputs

    DIGITAL OUTPUTS The controller has 4 digital outputs which can be used for control purposes. Output voltage: Identical with voltage at OUTPOW IN, maximum 24V. Maximum output current: 500mA per output. All outputs are short-circuit proof. Resistive and inductive loads can be switched, on inductive loads a flyback diode is mandatory!. The output stages switch DC voltage which is applied to OUTPOW IN.

  • Page 37: Spindle Control With Frequency Converter

    SPINDLE CONTROL WITH FREqUENCY CONVERTER: The control has 3 outputs for spindle control: spindle left, spindle right and an analogue 0-10V output for the speed reference. Standard frequency inverters have inputs for these signals, these must be parameterised so that a signal on spindle left starts a counterclockwise run, cor- responding to a signal on spindle right a clockwise run.

  • Page 38: Grounding, Cable And Shielding

    GROUNDING, CABLE AND SHIELDING Use cables of sufficient length, but shorten overlong cables if possible. The cross-section of the cables should be sufficiently dimensioned, especially the cables between driver and motor, where high currents flow. 1.0 mm reaches up to 10A current 1.5 mm reaches up to 15A current 2.5 mm...

  • Page 39: System Connection Diagram

    SYSTEM CONNECTION DIAGRAM The system consists of controller, motor systems, encoder, power supply units and safety ele- ments is wired as shown below (schematically shown).. Encoders and motor drivers can be connected directly with patch cables as well as with mul- ti-core cables.

  • Page 40: Setup

    • ESTOP-FOLLOW DELAY SETUP • COOL ACTIVE? • COOL DELAY • 0..10V OUTPUT MAX RPM OUTPUTS • I/O INFORMATION INPUTS OUTPUTS • FIRMWARE VERSION ELS 4 PRO SETUP • SELFTEST RESULT INFORMATION • ON-THRESHOLD TIME • ON-THRESHOLD COUNTER • OFF-THRESHOLD TIME •...

  • Page 41: Setup General

    SETUP GENERAL Element Description LANGUAGE Language selection, German or English MODE LOCK DURING SPIN- If „ON“ is selected, the cycle cannot be changed while the DLE ROTATION spindle is turning. If „OFF“, this is allowed. It is recommend- ed to use „ON“ otherwise the cycle may be changed acci- dentally while the spindle is turning.

  • Page 42: Setup Z-Motor

    SETUP Z-MOTOR Element Description Spindle pitch This is the pitch of the lead screw of the machine. In case of doubt, this must be remeasured. Backlash The backlash of the sled. Those who do not have an exact ball screw on their lathe will almost certainly have a back- lash.

  • Page 43: Setup X-Motor

    SETUP X-MOTOR Element Description Spindle pitch This is the pitch of the lead screw of the machine. In case of doubt, this must be remeasured. Backlash The backlash of the sled. Those who do not have an exact ball screw on their lathe will almost certainly have a back- lash.

  • Page 44: Setup Data

    SETUP DATA Element Description Step Size Fine The step size in mm that is moved during the large step-by- step movement of the axes. In the step mode of the X or Z axis, the rotary knob must be turned WITHOUT the knob being pressed.

  • Page 45: Setup Inputs

    SETUP INPUTS Element Description ESTOP Input active Input for emergency stop circuit, switch or relay contacts ESTOP Activate or deactivate input ESTOP Input polarity Standard: Open Active (NC). Can be set to Closed Active (NO). X LIMIT Input active Input for X limit switch Activate or deactivate limit switch input X LIMIT Input polarity Standard: Closed Active (NO).

  • Page 46: Setup Outputs

    SETUP OUTPUTS Element Description Spindle Output active Activate spindle left and right outputs. The SPINDLE LEFT output is activated when the spindle key is pressed briefly, the SPINDLE RIGHT output is activated when the spindle key is pressed long. Spindle Runnup Duration Spindle run-up time in milliseconds.

  • Page 47: Commissioning

    COMMISSIONING PREPARATIONS Mounting the control Mount the controller on the wall, a support or on the machine so that you can operate the keys without moving the case. Optionally, you can purchase a suitable wall mount bracket for the ELS. Connection Connect the emergency stop circuit, the motor output stages and the encoder to the rear terminals.

  • Page 48: Checklist Before Commissioning

    CHECKLIST BEFORE COMMISSIONING To facilitate commissioning, please check the following items in advance: The pulse rate of the encoder must be set correctly on the encoder, 400 pulses per spindle revolution are usually optimal. This pulse rate must also be adopted in the settings of the ELS (SETTINGS -> SETUP ENCODER ->...

  • Page 49: Implementation Of The Commissioning

    IMPLEMENTATION OF THE COMMISSIONING Please make sure that the motor and encoder parameters are correctly set in the settings be- fore proceeding. The correct number of steps of the motors and the correct pulse rate of the encoder must be set. DANGER When moving, make sure that there is enough free travel so that the machine is not damaged! Use all protective measures of the machine as prescribed...
  • Page 50 -> Now snap the lock nut into place! If the spindle turns to the left, the slide should move in the direction of the chuck. If it does not, the encoder is set the wrong way round. Remedy: Switch to SETTINGS -> SETUP ENCODER -> REVERSE DIRECTION and change the direc- tion there.
  • Page 51 If you have any problems, please feel free to contact us at info@rocketronics.de . It is best to write down the setting values as well..
  • Page 52 What to do if the measured path deviates from the set path? Small deviations of a few hundredths are normal, because the spindles are more or less accu- rate, and even ex works their deviations can have. If the deviation to 50 mm is more than 0.1 mm, something is wrong, check: ●...

  • Page 53: Basic Functionality

    BASIC FUNCTIONALITY The Electronic Leadscrew Control (ELS) is a cycle control for lathes and allows the automatic execution of turning operations and the free selection of the feed rate. Relative travel distances In contrast to many industrial controls, the ELS operates in a relative mode: The operation to be performed always starts from the zero point of the tool, i.e.
  • Page 54 moves the axes slowly, FAST JOG moves the axes fast (rapid traverse). How fast and how slow can be set in the settings. Move to positions You can approach exact positions: The Z axis always stops moving from right to left at 0 and at ZP.

  • Page 55: Selection Of Cutting Passes

    You can also turn off the spindle during a cycle in progress, and after restarting the spindle, ● the machining will continue. Please keep in mind that the tool can be damaged, especially ceramic inserts often do not survive this undamaged. Thread cutting is possible up to 1200 rpm, all other modes run up to 3000 rpm (exceptions: ●...
  • Page 56 Display before the cut: The control shows you clearly the data and the number of passes before the cut, these can then be adjusted very easily and quickly with the rotary knob. Below are examples of threading as a tapered thread, or for external turning:...

  • Page 57: Possible Modes

    POSSIBLE MODES The following modes are available: Gearbox Left - Electronic gear Left ● Gearbox Right- Electronic gear Right ● Turning - External long turning ● ● Boring- Internal long turning Facing ● Parting ● Undercut ● External thread - Straight or tapered thread External ●...

  • Page 58: Gearbox Left

    GEARBOX LEFT Electronic gear with freely selectable feed rate. The motor is driven at the set feed rate, the spindle stops -> the motor also stops. This is identical with the condition before the conversion of the machine, the gear is now replaced by the ELS. If the spindle turns to the left, the carriage moves to the left, if the spindle turns to the right, the carriage moves to the right.

  • Page 59: Turning

    TURNING Straight chip removal in the longitudinal direction towards the chuck to reduce the diameter of a workpiece. Moving axes and directions: • X towards the chuck (-X) • Z towards the chuck (-Z) Required data: • Feed F in mm/U •...
  • Page 60 IMPORTANT: ALWAYS MAKE SURE THAT THE ZERO POINT IS SET CORRECTLY! There are three possible variants: ZP = 0 and XP = 0 In this case, the movement after the START signal goes after a safety query to X 0,00 and then in -Z direction until the STOP key is pressed. START-STOP operation is possible while the vehicle is moving.

  • Page 61: Example

    EXAMPLE External turning in several passes Example: Selected are ZP= -40,00 and XP = -10,000 It should therefore remove 10mm of material, over a length of 40mm. After starting the spindle and pressing START, the control first calculates the number of passes required.
  • Page 62 The value for „Finish Feedrate“ can be set in percent of F or as a discrete value in mm/sec. With the turning knob you can change the value which is then valid for all cycles. In the above example, 0.99 mm is to be removed in 10 passes, the last pass is made with a finis- hing thickness of 0.10 mm.

  • Page 63: Boring

    BORING This mode is used to remove material in the longitudinal direction, but from the inside. Starting from the zero point, the lathe tool moves to -XP, then to -ZP, where the length corresponds to the depth of the material removed. ATTENTION: -X is ALWAYS in the removal direction, in this case -X is towards the oper- ator! This is the other direction as with external turning! To zero the X axis, always ap- proach the operator and then set it to 0.
  • Page 64 Limitations in dimensions: None Maximum speed: 3000 rpm The speed can be freely changed during the cut. A stop can be made at any time by pressing the STOP button. There are three possible variants: ZP = 0 and XP = 0 so there are no endpoints at all specified, in which case the movement after the START signal goes to X 0,00 after a safety query and then in the -Z direction until the STOP key is pressed.

  • Page 65: Facing

    FACING This mode is used to remove material from the face of the part. From the zero point, the turn- ing tool moves to -Z, then to -X. ZP, corresponds to the depth of the material to be removed (ap) XP is the radius by which the part becomes smaller (r).
  • Page 66 Limitations in dimensions: None Maximum speed: 3000 rpm The speed can be freely changed during the cut. A stop can be made at any time by pressing the STOP button. There are three possible variants: ZP = 0 and XP = 0 so there are no endpoints at all specified, in which case the movement after the START signal goes to Z 0,00 after a safety query and then in the -X direction until the STOP key is pressed.

  • Page 67: Parting

    PARTING This mode is used to cut round workpieces. Starting from the zero point, the lathe tool travels here to -X after XP in the direction of the diameter center. ZP values in the Z direction are ig- nored! ATTENTION: -X is ALWAYS in the removal direction, in this case -X is therefore away from the operator.

  • Page 68: Undercut

    UNDERCUT This mode is used for the automatic turning of undercuts according to DIN 76-1. Turning is done with pointed inserts, e.g. type VCGT.. An undercut is optimal at the bottom of threads. The undercut according to DIN 76-1 is initiated by a 30°...
  • Page 69 Moving axes and directions: • X towards the chuck (-X) • Z towards the chuck (-Z) Required data: • Feed F in mm/U • ZP: Machining length in Z direction, must be zero or negative • XP: Cutting depth in X-direction, must be zero or negative. Available parameters in the parameter menu: The parameter menu allows quick access to useful settings.

  • Page 70: Making Threads

    MAKING THREADS The electronic lead spindle transforms your conventional lathe into a universal thread lathe. If you have motorized both axes, you can turn threads of all kinds, inside and outside, fully auto- matically. It doesn‘t matter which flank angle you cut, or which type of thread. In addition to metric threads, imperial threads are also possible, as well as trapezoidal threads or pipe threads.
  • Page 71 CUTTING STRATEGY The ELS can turn threads with 4 different infeed methods: Radial infeed with gradually decreasing infeeds Simple flank infeed with even infeeds Modified flank infeed with even infeeds Alternating flank infeed with even infeeds These are the methods currently used in industry, the last three are actually only feasible on CNC machines, or with the ELS! Simply explained, for radial infeed the machine only feeds in X, i.e.
  • Page 72 Radiale infeed Smaller infeed increments Ÿ Multi-tooth plate inserts Ÿ Infeed only in X direction Ÿ For fine threads P<1.5mm Ÿ The most frequently used heavy-duty chip control Ÿ High to very high cutting forces Ÿ Uniform tool wear Ÿ Flankinfeed Uniform cut depths Ÿ...
  • Page 73 External threads Starting from the zero point, the lathe tool moves to -X, then to -Z. ZP = Thread length, XP = the thread depth (ap), F = the thread pitch. ATTENTION: -X is ALWAYS in the removal direction, in this case -X is so away from the server! To zero the X axis, always approach the workpiece and set it to 0 to ensure that the backlash is taken into account.
  • Page 74 INTERNAL THREADS This mode is used for automatic turning of internal threads. This mode moves beyond 0 when resetting in Z direction! Attention: Maximum speed is 1200 rpm! Starting from the zero point, the turning tool moves to -X, then to -Z. ZP = Thread length, XP = the thread depth (ap), F = the thread pitch.
  • Page 75 THREAD <0 This mode is used for the automatic turning of threads. This mode does NOT go beyond 0 when resetting in Z direction! Attention: Maximum speed is 1200 rpm! This mode is like „external thread“, except that the Z axis is never moved beyond 0. Since the stepper motor on the Z-axis requires a certain distance to accelerate to the nominal feed rate, it needs a „start-up“...
  • Page 76 Re-Cut thread at full depth If the thread does not quite fit after the cut, you can start a new pass and simply turn the number of passes to 1, then another pass is made at maximum deptch, often this is enough to remove the missing last hundredths and make the thread fit.
  • Page 77 MULTI-START THREADS Proceed as follows to produce a multiple-start thread: 1. Set the angle to 0 in ANGLE MODE. 2. Switch to thread mode and cut the first thread. 3. Switch back to angle mode and manually rotate the chuck to the desired angle. This would be 180°...
  • Page 78 TAPERED THREADS The ELS can also turn tapered threads inside and outside. To do this, the raw material must first be transformed into a taper using the taper function. Usually, taper threads are defined by a cone ratio in addition to pitch and flank angle, e.g. 1:16. For the definition of the cone ratio see the appendix.

  • Page 79: External Cone

    EXTERNAL CONE This cycle is used to cut external cones at any angle. The X and Z axes are moved simultaneous- ly. The Z-Axis moves from left to right when cutting cones. -Z +Z The cuttings of external cones is only possible with a drive on the X axis. The control compen- sates the radius of the cutting edge of the tool.
  • Page 80 Procedure for cone turning: • Turn the raw material to diameter d1 before starting. Use this to zero the X-axis by jogging the X-axis to the depth you just cut after the cut with the jog-keys. Since the last depth reached is still set in XP, the X-axis stops there.

  • Page 81: Internal Cone

    INTERNAL CONE This mode is used to cut inner cones at any angle. The X and Z axes are moved simultaneously. -Z +Z The cutting of inner cones is carried out in the same way as the turning of external cones. Only the reversal of direction of the X-axis has to be considered here, as always with internal turning -X is here again in the direction of the removal, i.e.
  • Page 82 Procedure: 1. Before starting, turn the raw material to diameter d2. 2. Then zero the X axis to the inside of the material. Always approach the operator. 3. Then return to the end of the material and zero the Z axis. Always drive from right to left to compensate for the backlash! 4.

  • Page 83: Radius Turning In General

    RADIUS TURNING IN GENERAL The ELS can also turn radii. Convex and concave inner and outer radii are possible. The radii may be circular or elliptical in shape. Thus a lot of curvatures are possible, there are no limits to the imagination. The radius of the tool is compensated when turning radii.

  • Page 84: External Radius Konvex

    EXTERNAL RADIUS KONVEX This mode is used to create convex outer radii. The X and Z axes are moved simultaneously. In addition to round radii, elliptical radii are also possible. The cutting radius correction requires that this process is carried out beyond XP and ZP! The exact procedure is shown below, for clarification with a round insert: Pr = cutting radius Tool is moved beyond XP by the amount of the cutting radius.
  • Page 85 The radius is defined here by the values ZP and XP: Circular radius: XP=ZP Elliptic radius: XP≠ ZP So you can adjust the shape of the Radii by selecting the values for XP and ZP. Circular radii are achieved by equal values of XP and ZP. XP can also be larger than ZP, resulting in a flat elliptical radius.

  • Page 86: External Radius Concav

    EXTERNAL RADIUS CONCAV This mode is used to rotate concave outer radii. The X and Z axes are moved simultaneously. In addition to round radii, elliptical radii are also possible. This operation does not go beyond XP and ZP. For clarification, the exact route is shown below: Pr = cutting radius 1.
  • Page 87 So you can adjust the shape of the Radii by selecting the values for XP and ZP. Circular radii are achieved by equal values of XP and ZP. XP can also be larger than ZP, resulting in a flat elliptical radius.

  • Page 88: Internal Radius Convex

    INTERNAL RADIUS CONVEX This mode is used to rotate convex inner radii. The X and Z axes are moved simultaneously. In addition to round radii, elliptical radii are also possible. The cutting radius correction requires that this process is carried out beyond XP and ZP! The exact procedure is shown below, for clarification with a round insert: Pr = cutting radius Tool is moved beyond XP by the amount of the cutting radius.
  • Page 89 The radius is also defined here by the values ZP and XP: Circular radius: XP=ZP Elliptical radius: XP≠ ZP XP may also be larger than ZP, resulting in a flat elliptical radius. Procedure: 1. Turn the raw material to the desired diameter before starting. 2.

  • Page 90: Internal-Radius Concav

    INTERNAL-RADIUS CONCAV This mode is used to rotate convex outer radii. The X and Z axes are moved simultaneously. In addition to round radii, elliptical radii are also possible. This operation does not go beyond XP and ZP. For clarification, the exact route is shown below: Pr = cutting radius 1.
  • Page 91 So you can adjust the shape of the Radii by selecting the values for XP and ZP. Circular radii are achieved by equal values of XP and ZP. XP can also be larger than ZP, resulting in a flat elliptical radius.

  • Page 92: Groove

    GROOVE This mode allows a circular or elliptical groove to be cut on a shaft. It can be used to produce, for example, rope pulleys or track rollers. ATTENTION: Machining is only possible with round inserts! We recommend the type MRMN with e.g. 1 mm cutting radius. Important settings: The correct setting of the backlash of the X-axis is very important, other- wise a paragraph may appear at the bottom of the groove.
  • Page 93 Cutting strategy for groove The cut is carried out in several infeeds, as usual adjustable in the other modes. The roughing contour is roughly traversed line by line and then the final contour is turned in one pass in the last pass.
  • Page 94 Available parameters in the parameter menu: The parameter menu allows quick access to useful setting values. • TOOL CORnER RADiUS - The radius of the cutting edge, very important for correct radius compensation. • X AP FiniSh - Depth of the last finishing pass in mm. • FiniSh FEED RATE - Speed of the finishing pass, either as a percentage of the feed rate set, or if it continues to exceed 100%, also in discrete values in mm/revolution.
  • Page 95 Zeroing is done as follows: ZERO ZERO Possible grooves:...

  • Page 96: Straight Groove (Version 9 And Higher)

    STRAIGHT GROOVE (VERSION 9 AND HIGHER) This mode allows a straight groove to be cut on a shaft, with a selectable slope of the sides of the groove. It can be used to produce, for example, V-Belt pulleys. -Z +Z α...
  • Page 97 Available parameters in the parameter menu: (Access the parameter menu by pressing the PARAM-Button) • V-BELT TYPE - Type of V-Belt, either SPZ, SPA, SPB or SPC, with 34° or 38°. You can select the type with the turning knob. If you dial further that the last predefined type you will see a custom angle, starting with 0°.
  • Page 98 Zero the cutter as shown here: -Z +Z Phase 1: Clear groove α X Ap Rou Zero cutter Included Standard V-Belt Types and sizes: Type Width (ZP) Depth (XP) Flank-Angle SPZ 34° 9.70 11.00 34° SPA 34° 12.70 13.80 34° SPB 34°...
  • Page 99 DRILLING This mode is used for drilling with the tool holder. To do this, a drill bit must be centered in the tool holder and clamped, i.e. it is NOT drilled with the quill as usual. Apart from the somewhat time-consuming centering, this has many advantages, as in this mode it is possible to drill very precisely and, by using the setting parameters in the parameter menu, to drill with different retraction strategies.

  • Page 100: Grinding

    GRINDING This mode is used for grinding, where up and down is moved in Z direction, the path is defined by ZP, the feed speed by F. Set the Z axis to 0, then enter the desired path at ZP. Press START to start the process, press STOP to stop it.

  • Page 101: Angle

    ANGLE In this mode, the angle of the lathe chuck is displayed. This can be used to use the lathe chuck as a dividing head, but also for multiple threads. The angle is reset to zero with P0. Proceed as follows to produce a multiple-thread thread: 1.

  • Page 102: Tips For Use

    TIPS FOR USE APPROACH POSITIONS EXACTLY: With the ELS, it is very easy to move to a certain position: To do this, set the end position to the desired value and then move manually with the travel keys < > << >> coming from the right. The axis then stops at the end position, even if it is set to 0.

  • Page 103: Special Dimensions By Changing The Settings

    SPECIAL DIMENSIONS BY CHANGING THE SETTINGS Sometimes it is necessary to produce something out of line, e.g. a screw conveyor with a very high pitch. In such cases, you can „play“ with the settings to get there. For example, in the settings you can temporarily halve the number of encoder pulses to double the feed rate.

  • Page 104: Softwareupdate

    SD card, the controller can remain connected. 1. From the website https://www.rocketronics.de/en/updatepro you can download the latest software as a package. There you will also find the changes that have been made.

  • Page 105: Appendix 1: Definition Of Cone Ratio

      Seit Version 10.11 ist es möglich kegelige Gewinde zu drehen. Es sind dabei Innengewinde als auc   Dazu muss das Rohmaterial natürlich zuerst mit der Kegelfunktion in einen Kegel verwandelt wer kegeliger Form möglich!  Dazu muss das Rohmaterial natürlich zuerst mit der Kegelfunktion in einen Kegel verwandelt wer APPENDIX 1: DEFINITION OF CONE RATIO werden Kegelgewinde neben Steigung und Flankenwinkel durch ein Kegelverhältnis definiert, z.B   werden Kegelgewinde neben Steigung und Flankenwinkel durch ein Kegelverhältnis definiert, z.B Das Kegelverhältnis C beschreibt den Unterschied zwischen größtem und kleinstem Durchmesser Dazu muss das Rohmaterial natürlich zuerst mit der Kegelfunktion in einen Kegel verwandelt wer Das Kegelverhältnis C beschreibt den Unterschied zwischen größtem und kleinstem Durchmesser V � V � � The cone ratio V describes the difference between the largest and smallest diameter of the   � werden Kegelgewinde neben Steigung und Flankenwinkel durch ein Kegelverhältnis definiert, z.B  ...

  • Page 106: Appendix 2: Wall Mounting

    APPENDIX 2: WALL MOUNTING On the back there are 2 brackets with suspension holes. An optional VESA adapter plate is available to attach the controller to a 3D adjustable wall bracket. A standard VESA wall bracket can also be used.

  • Page 107: Appendix 3: Technical Data

    APPENDIX 3: TECHNICAL DATA Dimensions ca. 196x220x94 mm Weight 350 g Operating voltage 24V DC stabilized Current consumption Max. 1 A Max. speed 3000 RPM Max. speed threading 1200 RPM Smallest step size 0,01mm Way in Z- und X-direction Smallest possible thread pitch 0,001mm Max.

  • Page 108: Disposal

    Of course you can also dispose it completely. CONTACT US: Manufacturer is Rocketronics.de Dipl.-Ing (FH) Louis Schreyer Hugo-Grotius-Str. 18 27404 Zeven GERMANY Tel: 04281 50 79 78 2 Mo-Fr. 14-18 Uhr Email: info@rocketronics.de USt.-IdNr: DE813546414 WEEE-Reg. Nr. DE 35691149...
  • Page 109 Changes for Software version 9 or higher • 35: Added description of flyback diodes for outputs • 39: Added new settings section for handwheel extension • 56: Added new cycle Straight groove • 57: Added new parameter menu description for gear mode •...

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