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Related Manuals for Knuth Roturn 400 C
Summary of Contents for Knuth Roturn 400 C
- Page 1 Operation and Maintenance Manual Roturn 400 C Part No. 180 633 2304...
- Page 2 MACHINE TOOLS OPERATION AND MAINTENANCE MANUAL Manufactured in (year): ......Serial number: ........We reserve the right to modify any construction, equipment and fittings if necessary to promote development. No claim shall be raised with reference to details indicated, figures, drawings or descriptions.
- Page 5 Instructions Users shall carefully read the operation manual before using the lathe, completely understand all the content, install, use and maintain it according to the requirements and operate after thoroughly understand the content of various safety signs and warning so as to avoid the equipment damage or personnel injuries. Users can’t make the speed of mainshaft larger than the allowable maximum speed of the fixture during the process and pay attention to the safety protection and guarantee the personal safety.
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Page 6: Table Of Contents
Table of contents 1 Summary........................1 1.1 Product introduction..................1 1.2 Precision of the lathe..................2 1.3 Service environment of the lathe...............2 1.4 Influence of the lathe on the environment............3 2. Instructions for the safety protection................3 2.1 Requirements on the operators and maintenance personnel......4 2.2 Basic operation requirements................4 2.3 Requirements before power-on................. - Page 7 3.7 Final adjustment of the lathe bed level............24 3.8 Maintenance of the early installation.............. 24 4 Main technical parameter of the lathe............... 26 5. Lathe structure......................28 5.1 Lathe travel and tool interference drawing............. 28 5.2 Main drive system................... 29 5.3 Feed system.....................30 5.4 Clamp system....................
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Page 8: Product Introduction
1 Summary 1.1 Product introduction C400K horizontal-type ramp CNC lathe is mainly used for the processing of Rot ur n 400 C various shaft and disk parts, which can turn the internal and external curved surfaces of various threads, arcs, circular cones and solid of revolution and it can satisfy the high-speed cutting requirements of ferrous metal and non-ferrous materials. -
Page 9: Precision Of The Lathe
more internal operation space, which can realize the processing of large parts. It expands the applicable scope of the lathe and customers can obtain more benefits. The lathe body is with the inclination of 45°, which has the merits of smooth chip removal. -
Page 10: Influence Of The Lathe On The Environment
The installation position shall be far away from the vibration source and flammable& explosive goods as well as the electromagnetic interference. 1.4 Influence of the lathe on the environment The noise SPL of the lathe is not higher than 83dB during the idle running, no emission of noxious gas or liquid occurs, so it won’t produce bad effect on the environment. -
Page 11: Requirements On The Operators And Maintenance Personnel
2.1 Requirements on the operators and maintenance personnel Operators of the lathe shall be the ones who have receive relevant training and obtain the qualification. Operators shall carefully read the Operation Manual before the operation, completely understand the content and obtain the capacity of operating the lathe. - Page 12 The coordinated signal shall be stipulated at each operation step when one task needs to be completed by two or more personnel, and the next step must be performed after the stipulated signal is given and accepted. Use the recommended hydraulic oil, lubrication oil, grease or recognized oil or grease with the same performance.
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Page 13: Requirements Before Power-On
avoid the accidents. Hands can’t directly touch the iron turning during the cleaning. Confirmation in advance must be performed before operating the switches and mistakes are forbidden, or accidents will be easily produced. Don’t randomly touch the switches. The workbench nearby the lathe shall be firm so as to prevent the articles from sliding or workbench damage and avoid the accidents. -
Page 14: Requirements After Power-On
total power switch of the lathe shall have enough sectional area so as to satisfy the requirements of the electric power transmission. The cable exposed on the ground shall have the water-proof, cutting-proof, wearproof and other protective measures. The sundries and anti-rust oil shall be cleaned if it’s used for the first time or it’s restarted after long-term stop before the devanning of the lathe, each lubrication point shall be oiled again and lubricated according to the lubrication requirements. -
Page 15: Routine Inspection
operation manual. 2.5 Routine inspection Warning Never stretch out the fingers to the space between the belt and the belt pulley when you check the tightness of the belt, which easily crush the finger. Attention Check if the reading on the pressure meter of the hydraulic system is correct and meet the requirements of the operation manual. -
Page 16: Temperature Rise
2.6 Temperature rise Attention Temperature rise shall be non-load performed under the automatic operation status of the lathe and make the lathe rotate for 10~20 minutes with half or 1 third of the maximum speed so as to let the lathe reach the stable temperature. Each moving parts on the lathe shall be automatically operated according to the procedure during the automatic operation and meanwhile check the movement conditions of each moving parts, which shall be smooth and no abnormal noise. -
Page 17: Precautions In The Work
The processing area shall be with good illumination for the convenience of security detection. The tools or other goods at the surrounding of the lathe shall be kept orderly and stable, the environment cleanness and smooth channel shall be kept. Tools, workpiece and any other goods can’t be placed at the spindle box, knife rest, mainshaft, carriage and other similar part so as to avoid the accidents. - Page 18 Adjust the nozzle of the cooling liquid under the shutdown status. Don’t use hands or let the clothes touch the rotating workpiece and mainshaft. Don’t open the protective door or cover of the lathe during the automatic processing. The chip accumulation shall be avoided during the heavy load processing, because the hot chip may cause fire disaster, the thermal accumulation will also cause the thermal deformation of the lathe and it will affect the processing accuracy.
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Page 19: Processing Interruption
Use hairbrush to clean the turnings on the tool bit, can’t use hands to directly clean. Operators shall wear the gas mask during the processing of magnesium alloy; you need to wear the gauze mask and other protective tools when the materials with big dust are processed. -
Page 20: Safety Protection Device
Check the dosage of the cooling liquid, hydraulic oil and lubrication oil, which need to be added once it’s insufficient. Clean the filter at the position of the iron turning box so as to avoid the obstruction. The power switch, main circuit switch of the lathe and the power transmission switch on the operation panel shall be turned off when the work off and leave the lathe. -
Page 21: Maintenance Operation
Carefully read and completely understand the safety protection measures stipulated in the operation manual. Carefully read the relevant content in the operation manual and understand the correlated principles and the precautions included. 2.13 Maintenance operation Danger The personnel unrelated to the maintenance can’t operate the main circuit switch or the control power switch on the operation panel. -
Page 22: Treatment After The Maintenance
2.14 Treatment after the maintenance Warning Clean and arrange the working environment after the maintenance is completed so as to provide good working environment. The dismantled parts and the waste oil and water cleaned out shall be kept away from the lathe and treated according to relevant provisions. The maintenance personnel shall check if potential risk exists in the lathe operation after the maintenance is completed. -
Page 23: Transportation And Installation
3. Transportation and installation 3.1 Transportation and storage of the lathe Rain-proof package is adopted for the lathe, the anti-rust oil is painted to the key parts, certain anti-vibration and shock resistance measures are adopted for the packing box, which can guarantee the safe transportation and storage within the temperature scope of －... -
Page 24: Main Power
at the surrounding of the lathe for the antivibration if the vibration source exists nearby the position of the lathe installation. Prevent the lathe from being placed at the soft ground as possible, piling or similar measures must be adopted to strengthen the supporting ability of the soil layer if the ground is too soft so as to avoid the sink or inclination of the lathe. - Page 25 inversion. The soft object shall be cushioned at the contact point between the wire rope and the lathe so as to avoid the damage of the lathe appearance. Warning: the inclined angle of the lifting rope can’t be larger than 60°. The forklift transport is recommended to adjust the position of installation, the groove part at the bottom of the pedestal is specially designed, convenient and safe.
- Page 26 lathe shall be fastened, the protective door shall be properly fixed, the mobilizable articles of the lathe as well as some accessories and the goods not belong to the lathe shall be taken down. The steel wire rope shall be adopted for the lifting according to the lifting signs outside of the packing box during the lifting of packing box, the steel wire rope shall neither seriously squeeze the packing box nor contact the lathe, the impact and vibration suffered by the packing box shall be reduced...
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Page 27: How To Install
excessively incline the lathe. Firstly check the external conditions of the lathe when the packing box is dismantled, and check if the accessories and tools are complete according to the packing box. 3.4 How to install The installation method of the lathe has great influence on the function and performance of the lathe, inappropriate installation can’t make the lathe reach the required processing precision or the long-term precision requirements can’t be kept. - Page 28 3.4.2 Foundation installation drawing...
- Page 29 Diagram C400K Foundation Rot ur n 400 installation Fix the attached foot screw to the flat concrete foundation according to the diagram of the foundation installation, use the level meter to adjust it after the lathe is placed on it and then fix it. The position of the lathe installation shall be flat, decide the installation space according to the stipulated arrangement environment and the foundation diagram and prepare the foundation.
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Page 30: Inspection On The Connection Of The Internal Device
3.4.3 Temporary level adjustment Lift or fork the lathe, and penetrate the iron bolt of the adjustable pad into the foundation bolt hole of the pedestal. Then slowly put down the lathe and guarantee the even contact. Rotate the adjustable bolt of the shim, use the level meter to check the level of the lathe so as to make the longitudinal level not exceed 0.06/1000 and the horizontal level not exceed 0.03/1000. -
Page 31: Final Adjustment Of The Lathe Bed Level
The sliding surface of the lathe and some metal parts are painted with a layer of anti-rust oil for the rust protection during the delivery, it will suffer environment pollution during the transportation process, the anti-rust oil must be cleaned before the use, or it will damage the sliding surface. The cloth shall be dipped with oil before the cleaning and the lubrication shall be performed according to the requirements after the cleaning. - Page 32 solidification of the foundation, which will severely affect the lathe precision. On the other hand, the reason of the initial wear as well as the pollution suffered by the lathe will easily cause the change of the lathe performance. Therefore, please perform initial maintenance according to the following methods: Test run: the initial test run must be very careful after the lathe installation is completed and the foundation is completely solidified.
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Page 33: Main Technical Parameter Of The Lathe
4 Main technical parameter of the lathe C400K Technical parameter Rot ur n 400 C Item Unit Specification Notes Maximum rotating diameter of the lathe bed Maximum rotating diameter of the sliding bed Maximum turning length Type and code of the spindle nose A2-6 Spindle bore Maximum diameter of penetrating... - Page 34 Servo motor torque of X axis Servo motor torque of Z axis Travel of X axis Travel of Z axis Form of guide rail Rolling guide Form of knife rest 8 work station hydraulic servo turret Tool size Outer circle knife 25 ×25 Boring blade diameter Form of chip cleaner...
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Page 35: Lathe Structure
5. Lathe structure The inclination-type overall cast iron bed with higher rigidity is adopted for this kind of lathe, the bed rigidity is largely improved through reasonable layout of the internal stiffener, the stability and earthquake resistance of the lathe is increased so as to improve the lathe precision;... -
Page 36: Main Drive System
Tool interference drawing 5.2 Main drive system The mainshaft movement is directly driven by the main motor of the lathe. With simple structure, convenient maintenance and high reliability, the gear change mechanism is canceled in the spindle box. The speed change is driven by the servo mainshaft motor or the variable frequency motor through the main motor, which can realize the stepless speed. -
Page 37: Feed System
deformation and high precision through the careful assembly of the mainshaft so that the mainshaft can keep relative stability of various precision during the long-term operation. Distribution diagram of the mainshaft drive system and bearing 5.3 Feed system The feed movement of X axis and Z axis is directly connected to the ball screw by the servo motor through an elastic coupling, then it’s delivered to the big and small carriage by means of the ball screw. -
Page 38: Clamp System
Distribution diagram of servo feed system and bearing 5.4 Clamp system The hydraulic system is adopted as the power source for the workpiece clamp mechanism that’s equipped to the lathe, and the actuator is the hydraulic chuck. The hydraulic chuck is connected to the angling cylinder by means of the pull rod or stay tube, the wedge-shaped parts in the hydraulic chuck will push the jack catch tighten or loosen when the piston in the angling cylinder is moved forwards or backwards under the force of hydraulic pressure. - Page 39 that the workpiece can still be reliably clamped when the electric power is suddenly interrupted or the hydraulic source suddenly fails. The hydraulic chuck is suitable for clamping the workpiece with larger diameter or the workpiece with special requirements. Structural Diagram Of Hydraulic Chuck Clamp System 1.
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Page 40: Knife Rest And Tailstock
clamped, or it will easily cause the human injury due to the separation of the jack catch. 5.5 Knife rest and tailstock 6 work station hydraulic servo turret is adopted for the lathe. The transposition of electronic knife rest is driven by the servo motor, the hydraulic locking device installed in the knife rest will fasten the cutter after the tools reach the designated position. - Page 41 Hydraulic schematic diagram With compact structure and little pollution, the hydraulic oil tank is placed at the back of the lathe pedestal, the hydraulic pump and hydraulic control valve are installed at the cover of the oil tank. Variable vane pump is used to provide pressure oil in the hydraulic system, each loop is individually equipped with the reducing valve in the oil hydraulic circuit that can separately adjust the pressure;...
- Page 42 oil is preserved in the oil cylinder, the oil pressure is passive pressure, which won’t add excessive pressure to the mainshaft bearing and it prolongs the service life the mainshaft bearing. 5.6.2 Main parameters of the hydraulic system: Motor: 2.2KW 1430r/min Hydraulic pump: VP-SF-30-D (the pressure and flow can be adjusted) Working pressure range: 0.8～4.5MPa Output volume: 30L/min...
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Page 43: Lubrication System
5.7 Lubrication system 5.7.1 Schematic diagram of lubrication system Schematic diagram of lubrication system 5.7.2 Maintenance of lubrication system Please use high quality ISO #32 anti-wear lubricating oil. It is adopted for both ball screw and linear guide rail, the positive displacement automatic lubrication system is applied, the long-term even and effective supply can be guaranteed for the lubricant no matter where the position is;... -
Page 44: Bearing Lubrication
consumption of the lubricating oil so as to reduce the environment pollution. Notice: the positive displacement automatic lubrication system is adopted for the lathe, please replace the parts of corresponding types if the parts of lubrication system need to be replaced, the use of incorrect parts will cause unusual lubrication so as to lead to the lathe parts damage or shorten the service life of the lathe. -
Page 45: Lathe Use And Safety Protection
6 Lathe use and safety protection 6.1 Lathe use Operation procedure, shutdown operation procedure, operation method and precautions as well as the occurred false operation and preventive measures during the process of lathe start and operation refer to the Electrical Operation Manual of the lathe. - Page 46 travel limit switch can also be set according to the requirements so that the lathe will stop and NC system will give a alarm once the knife rest presses on the limit switch along with one direction. Most of iron turnings can be filtered through the gauze filter when the cooling liquid reflows to the water tank.
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Page 47: Set Necessary Safety Warning Signs
manual. 6.3 Set necessary safety warning signs Even though lots of safety protection measures have been adopted for the lathe, but some potential and unobvious risks still exist, the lathe sets necessary safety warning signs in order to notify the operators, please don’t violate the notice during the use. -
Page 48: Lathe Maintenance And Troubleshooting
7 Lathe maintenance and troubleshooting 7.1 Routine inspection Examina Part of tion Content of inspection inspection period Routine inspection Lubrication Check the oil pointer and lubrication pump and mechanism of the manually use oil to lubricate the guide rail before guide rail the use each day. -
Page 49: Maintenance Of The Numerical Control System
be at about 3 months, one time for six months after that; check if the belt is fractured or scrapped Wash various valves and filter, clean the bottom of the oil tank, the hydraulic oil shall be completely Hydraulic oil-way replaced after it’s used for 3 months after the first use, it’s replaced for one time each 6 months after that... -
Page 50: Driver Maintenance
the lathe of long-term stop, it shall be operated for 4 hours each month, which can prolong the service life of the numerically control lathe. The CMOS elements are adopted for the parameter storage of some numerically control system, the storage content is kept by the battery during the outage. The battery shall be replaced for one time within a year, and it must be performed under the condition that the numerically control system is power-on, or the storage parameter will lose and it will lead to that the numerically control system can’t work. - Page 51 industrial products is good and the selected range is big, the elements may not be good; taking capacitance for example, one or two power leakage won’t affect the normal use, but the service time will definitely be shortened, the whole machine maybe scrapped, so it must be carefully maintained so as to finally guarantee the good condition of the wind fan and the smooth of the air flue.
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Page 52: Faq And Reasons
FAQ and reasons 7.3.1 The cooling liquid can’t flow out If the cooling liquid switch setting on the operation panel is normal; if fault occurs in the M order. If the suction inlet of the cooling pump completely insert into the cooling liquid. If the filter of the chip tray and the filter at the pump suction inlet are obstructed. - Page 53 The pretightening force setting of the ball screw bearing is not appropriate. The lubrication of the guide rail is not appropriate. The coupling bolt is loosen. 7.3.6 The lathe can’t normally work NC device displays the alarm signal. Some part of the lathe maybe damaged. 7.3.7 The workpiece can’t be clamped Manual three jaw chuck: Three jaws can’t be at simultaneous motion.
- Page 54 7.3.9 Taper occurs in the finish machining When the panel type is processed: the centering of the mainshaft is not appropriate When the shaft type is processed: the centering of the tailstock is not appropriate The gap of the guide rail is too big. 7.3.10 The tailstock sleeve can’t be moved Oil leakage exists in the oil cylinder of the drive tailstock sleeve.
- Page 55 The coupling is loosen. The lubrication on the guide rail is not good. 7.3.14 No oil in the lubrication system or the lubrication point If the oil-way caution is normal. The oil in the lubrication oil tank is very little. The oil-way of the lubrication point is obstructed.
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Page 56: Catalogue Of Accessories And Tools
8 Catalogue of accessories and tools Catalogue of accessories Name Size Qty. Notes Foot switch Lathe foot-pad Hydraulic chuck and stay tube Angling cylinder Three jaw chuck Optional Collet and stay tube Optional 8.2 Catalogue of tools Name Size Qty. Notes 1 for Open spanner... - Page 73 Table of contents 1. Summary................................1 2. Main technical parameters..........................1 2.1 Power Parameters..........................1 2.2 Spindle System..........................1 2.3 Feed drive System........................... 1 2.4 CNC System............................1 2.5 Auxiliary drive............................ 2 2.6 Other..............................2 3. Machine Control Panel..........................2 3.1 MODE Selection Mode ......................2 3.2 Panel Operation Button Instruction....................
- Page 74 Attention 1.The user may supply the machine power: voltage deviation, frequency deviation, minimum rated capacity must be consistent with the requirements of this machine. If not, the user must to be change the wrong electrical power. Wrong input power can damage the machine, the company is not responsible for this situation.
- Page 75 Machine power phase sequence adjustment Access to power the machine,before the first run, phase sequence adjustment should be carried 1 Add the lubricant to the centralized lubricating oil tank 2 Machine on power 3 NC on power, elimination machine alarm 4 Machine work in JOG 5 Before the machine is not installed the turret Press the start button to observe the direction of rotation of cooling pump.
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Page 76: Main Technical Parameters
1. Summary The machine structure to achieve the mechanical and electrical integration, easy to operate. Electrical control, using the SIEMENS 828D Absolute Value control system, the system has integrated programmable controller. servo motors feeding axis (3 Phase) control the drivers. AC servo spindle motor (three-phase asynchronous motor) to drive the spindle motor, realize stepless spindle. -
Page 77: Auxiliary Drive
The system also has a good self-diagnosis function ,and use M,S,T function&stable constant cutting speed &linear and circular interpolation when you are programming. In the operation and programming, the program can be manually input, or via PC transmission .Using circular interpolation to program the arc radius ,coordinate rotation , zoom function , parameter programming, with a variety of cycle subprogram. -
Page 78: Panel Operation Button Instruction
3.2 Panel Operation Button Instruction Cycle Start: Program starts. Press this button to start the program running. (Green button) Feed Hold: Program pause. Press this button to pause the program in the program running, when press the “CYCLE START", the program is continuous.(Red Button) EMG-Stop: Press the EMG-Stop button when the machine is running, the control enters the EMG-Stop state, then the machine stop move immediately, the spindle rotation and coolant also to be turn off. - Page 79 Spindle forward: Spindle forward in manual mode. Spindle stop: Spindle stop in manual mode. Spindle reversal: Spindle reversal in manual mode. Single block: Single block. Check the program through execution of the program piece by piece. Dry Running: Dry running. Press this button in Automatic or DNC mode, Each axis (not the programmed speed) move by the speed that the Parameter setting speed multiply by feed override, this function is used to check the tool movement without the workpiece.
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Page 80: Operation
4. Operation 4.1 The introduction of power After the machine is installed , check the integrity of components in the electrical cabinet , and make sure the components are normal and reliable . Check the all cables and wires , make sure they are tight . After make sure the earthing system ,start the power. -
Page 81: Cooling Control
b In manual mode, press the spindle forward button, the spindle forward; Press the spindle stop button, spindle stopped; Press the spindle reversal button, spindle reversal. 4.4.2 Manual Axis Control Handheld Unit/MPG moving axis In the handheld mode ,select the axis(X-Axis/Z-Axis) you want to move and set the value ( Hand encoder grid represents the amount of movement of 0.001mm, 0.01mm, 0.1mm), move the axis by the handwheel. - Page 82 14510-2 14510[2] Knife lock delay (10 ms) 14510-3 14510[3] Tailstock retreat delay (10 ms) 14510-4 14510[4] Spare 14510-5 14510[5] Spare 14510-6 14510[6] Spare 14510-7 14510[7] Spare Back 14510-8 14510[8] Spare 14510-9 14512[0] Spindle measurement / low oil level / tailstock / external alarm / lubrication 14510-10 14512[0].0 =1 The second spindle measuring system is on 14510-11...
- Page 83 Key Definition K1 Hand wheel K4 Lubrication K5 Coolant K6 Tailstock Forward / Backward K8 Inner/ Outside Chuck Select(INT.EXT. Button in the panel) K9 Chuck Clamp / Release K12 Turret forward rotating K13 Turret Reversal M-Code M07/08: Coolant ON Coolant OFF M10 Tailstock Forward M11 Tailstock Backward M12 Chuck Clamp...
- Page 84 700000 Oil level is low 700001 Safety Door is not Closed 700002 24V/110V Overload 700003 220V Overload 700004 Hydraulic Pump Overload 700005 Coolant Pump Overload 700006 Hydraulic pressure low 700007 Chips overload 700008 User Alarm 1 700009 User Alarm 2 700010 Turret overheated 700011 Lubrication Pump Overload 700012 Please start the hydraulic pump...
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Page 85: Manually Tool Change
start running until you close the safety door, if not, the feed-axises will be not working. Manually Tool Change 4.7.1 Press the “Tool Change”，clockwise turn one tool , also you can change tool T****in MDI mode, T****means the tool number and position Lubrication The machine use electronic timing automatic lubrication system.After the power on , the machine will automatically lubricate the machine every once in a while. -
Page 86: System Parameter
The following are the tips a: Make sure the earthing system have the good continuity , to ensure the safety of person and equipment b: Check the circuit breakers , contactors, relays ,and other components periodically . If the wiring is loose , or noisy , find the reason and solve it. c: Make sure the heat vent and fan shaft work normally, if there is a problem, it may cause the damage of components. -
Page 87: Spare Parts
(for KNUTH only) You would assist us grately in this matter. Yours sincerely, KNUTH Werkzeugmaschinen GmbH KNUTH - Customer-No. ____________________________________ Company __________________________________________________________________________ Adress __________________________________________________________________________ __________________________________________________________________________ Your personally name __________________________________________________________________________ Phone-No.
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