BSV-N 160/ 25 - 缓冲器，电磁阀，齿轮泵，气缸，液 … RULES • The tool turrets of...

03-99

M.I. 6431ISSUED

BSV-N 160/Series 25BIDIRECTIONAL TURRET

INSTRUCTIONS FOR USE AND MAINTENANCE

R

DUPLOMATICAUTOMAZIONE

GB

GENERAL RULES

• The tool turrets of Duplomatic design are provided for being incorporatedin numerically controlled turning machines, and they must be used only forthis purpose.The maximum performances of the turret are shown on the respectivetechnical data sheets.Any improper use or alteration of the turret relieves Duplomatic of any re-sponsibility for possible injury to persons and damage to property and willalso invalid any obligation for warranty.

• All necessary steps for the safety of the machine operator have to be ma-de by the machine builder who incorporates the turret in the tool machi-ne as prescribed by the European Machine Directive CE 89/392.

• Before installing and commisioning the turret, the technician and the ope-rator must have read carefully this Instructions Manual.

• For lifting the turret use only hoisting means which are suitable for theturret weight.

• Commissioning, adjustment and repair of the turret must be carriedout by skilled and authorized personnel who must follow the instruc-tions in this Manual for all necessary steps.

• Before any maintenance or repair job and before removing anysafeguard make sure that the machine's electric mains switch is on"OFF" position.It is absolutely forbidden to carry out any repair or maintenance job,when the turret is running.

• Duplomatic declines any responsibility for any accident or injuries to per-sons or damages to property due to non observance of the respective sa-fety rules and to the instructions shown in this Manual.

• The turret and its safety devices have been designed and built accordingto the following standards: "Machine Directives CE 89/392; 91/368; 93/44;93/68; 73/23; European standards EN 292/1-2; EN 60204-1.

M.I.6431-03991

INDEX sheet

1. TURRET IDENTIFICATION ............................................................................ 2

2. CHARACTERISTICS AND PERFORMANCES2.1 Technical data ........................................................................................................... 32.2 Loading capacity ....................................................................................................... 32.3 Duty performances ................................................................................................. 4/5

3. INSTALLATION3.1 Box removing and lifting ............................................................................................ 73.2 Turret placing on the machine................................................................................... 83.3 Assembling of the tool holder disc ............................................................................ 83.4 Coolant operation ...................................................................................................... 93.5 Electrical connections ............................................................................................. 103.6 Wiring diagram ........................................................................................................ 113.7 Cycle ....................................................................................................................... 123.8 Cycle description ..................................................................................................... 133.9 Flow chart ............................................................................................................... 13

4. SERVICE OPERATIONS4.1 Replacement and adjustment of locking control switch .......................................... 144.2 Replacement and timing of the angular position transmitter ................................... 164.3 Indexing control adjustment and replacement ........................................................ 164.4 Brake and motor replacement ................................................................................. 174.5 Solenoid pre-indexer ............................................................................................... 174.6 Shock absorber ....................................................................................................... 174.7 The turret's restart-up after an accidental or emergency shut-down ....................... 184.8 Operation checks to be carried out in case of accidental collision .......................... 194.9 Instructions for the checking of the mechanical parts ............................................. 204.10 Lubrication .............................................................................................................. 23

5. ASSEMBLY DRAWINGS AND PART LISTS5.A Main section ....................................................................................................... 24/255.B Back view ................................................................................................................ 265.C Coolant circuit ......................................................................................................... 275.D Shock absorber ....................................................................................................... 285.E Motor and gear box ................................................................................................. 295.F Table to determine the motor code and the gears .................................................. 30

6. RECOMMENDED SPARE-PARTS FOR BSV-N 160/25 .................................... 31

7. PREVENTIVE MAINTENANCE PROGRAMM FORINTENSIVE DUTY MACHINES ........................................................................... 32/33

8. TROUBLE SHOOTING .......................................................................................... 34/35

M.I.6431-03992

1 - TURRET IDENTIFICATION

1.a - Turret name plateThe details for turret identification are printed on a name plate fixed on turret housing.

OPTIONALS

SERIE 20 ÷ 29 (1)

POSITIONS CODE

Nr. 8 Pos. 8

Nr. 12 Pos. 12

SIZE CODE

160 160CODE FREQUENCY AND INERTIA

50 H 50Hz Fast

60 H 60Hz Fast

50 50Hz Standard

60 60Hz Standard

50L 50Hz Slow

60L 60Hz Slow

1.b - Model identification

(1) From 20 to 29 the performance and the overall dimensions do not change.

BSV-N * - * - * /2* - * - * - *

MOTOR VOLT. AND FREQUENCY

110 110 V - 50/60 Hz

220-380 220-380 V - 50/60 Hz

400-440 400-440 V - 50/60 Hz

model serial Nr.

matr.

cod.R

code Nr.

VERSION CODE

STANDARD —

AXIAL THROUGHT BORE PA

M.I.6431-03993

2 - CHARACTERISTICS AND PERFORMANCES

2.1 - Technical data

2.2 - Loading capacity

F3

F2

F1

b

b

b

Max. tangential torque F1xb Nm 1.600 1.600 1.600

Max. tilting torque to push F2xb Nm 1.900 1.900 1.900

Max. tilting torque to lift F3xb Nm 800 800 800

Unbalancing torque Nm 12

Transportable Masse Kg 60

Height h mm 80

Stations N° 8 ÷ 12

Version H STD L

Inertia of transportable masses Kgm2 0,55 0,90 1,80

30° s 0,41 0,48 0,58Indexing time

45° s 0,48 0,57 0,69

30° s 0,15 0,18 0,21Rotating time only

45° s 0,23 0,27 0,32

Indexing time 180° s 1,16 1,38 1,65

Indexing frequency α = 90° cycle/min 14 12 10

Indexing accuracy deg.° ± 6"

Repeatability accuracy deg.° ± 2"

Mass (without tooldisc) Kg 52

Size BSV-N 160

M.I.6431-0399

2.3 - Duty performances

F1 [N] Tangential force

F2 [N] Tilting force (to push)

F2

b

F1+

F1-

b

The diagram refers to F1 values which cause elastic yelding within the rates shown in the schedule.

Turret size 120 160 200 250 320 400

Max. elastic yelding mm 0,05 0,07 0,08 0,14 0,12 0,16

Distance from centre of measuring point mm 140 170 220 270 330 350

200000

10000080000

60000

40000

20000

100008000

6000

4000

2000

1000

0 100 200 300 400 500 b [mm]

BSV-N 400

BSV-N 320

BSV-N 250

BSV-N 200

BSV-N 160

BSV-N 120

200000

10000080000

60000

40000

20000

100008000

6000

4000

2000

1000

0 100 200 300 400 500 b [mm]

BSV-N 400

BSV-N 320

BSV-N 250

BSV-N 200

BSV-N 160

BSV-N 120

4

M.I.6431-0399

F3 [N] Tilting force (to lift)

F4 [N] Radial tilting force

F4a

F3

b

200000

10000080000

60000

40000

20000

100008000

6000

4000

2000

1000

0 100 200 300 400 500 b [mm]

BSV-N 400

BSV-N 320

BSV-N 250

BSV-N 200

BSV-N 160

BSV-N 120

200000

10000080000

60000

40000

20000

100008000

6000

4000

2000

1000

0 100 200 300 400 500 a [mm]

BSV-N 400

BSV-N 320

BSV-N 250

BSV-N 200

BSV-N 160

BSV-N 120

5

M.I.6431-03996

M.I.6431-0399

3 - INSTALLATION

3.1 - Box removing and lifting

Fig. 1

Eyebolt M12

7

M.I.6431-0399

Fig. 3

3.3 - Assembling of the toolholder discBefore assembling the toolholder disc the coolant outlet shown on page 9 must be properly positioned.Before locking the disc fixing screws it's necessary to adjust its angular position by checking the height of the tool position.When the disc is correctly positioned, lock the screws (according to the torque rates shown in the table) and put the referencepins between the toolholder disc and the turret.The pins could be removed to allow the disc movement in case of crash and re-utilized for an eventual further re-alignment.

Turret

Tool disc

3.2 - Turret placing on the machine

Make sure the fixing surface is clean and squared to ensure a proper tool alignment.Usually to bring the turret axis to the machine axis an adaptor plate (B) must be foreseen.Fix the turret to the machine's slide (A) by means of 8 appropriate screws (C) (high-resistant screws according to class 12.9 DIN912) and make sure that between the screw head and the turret the respective washer (D) of appropriate thickness (min. 8 mm)has been inserted.The reference pin (E) which is supplied together with the turret, is normally located at the opposite side of the working tool.Align the front surface of the disc in order to have it perpendicular to the spindle axis. Then lock the screws according to the torquerates shown in the table.In case of crash the turret may slip and turn around the reference pin. In this way any subsequent re-alignment will be facilitated.

Screws

Turret size

BSV-N 160

Type

M8 - 12.9

Tightening torque

[Nm]

34

Nr.

8

Reference pins

Nr.2 - ø10

��

��

�Screws

Turret size

BSV-N 160

Type

M10 - 12.9

Tightening torque

[Nm]

67

Nr.

8

ø D

20

ø d

10,5

S

8

Code fixing set

0424061

C

D

B

AE

0,01/100

8

Fig. 2

M.I.6431-0399

Fig. 4

425

426

417328

325

420324

323

418

408

424

419

418

422

421 B

2

A

424

+ α

− α

417

419

423

422

421

1

9

3.4 - Coolant operation (Fig. 4)

The coolant circuit is designed for supply only the tool in working position and for set the valve (417) in different positions, accordingto the disc requirements.The coolant pipe coming from the pump must be connected to the "A" or the "B" inlet on the turret housing. Throught an internalpath the coolant passes from the housing to the (408) manifold ring that, by means of an anular groove brings it to the exit points1 and 2.Normally, one of this outlet points is closed by a plug (418), while the other contains the coolant valve (417).The coolant valve (417) slides on the rear surface of ring (323), which rotates as one piece with the turret ring and the disc bydelivering the coolant to the working tool area.The coolant valve (417) can be positioned in any of the two positions provided by changing it with plug (418).The angular position of the coolant outlet can be modified by an amount of ± α as follows:

• Loosen screws (325) and turn ring (323). When the desired position has been reached, tighten screws (325) again.• Loosen screws (425) and turn collector (408) for moving the coolant valve (417) into the position of the hole at the outlet

on ring (323). Then tighten screws (425) again.It is furthermore possible to replace quickly the coolant valve (417) without any need to disassemble the disc after having loosenedscrews (424) and removed plug (421).

Coolant pressure:

• continuous supply: max 7 bar;• by pressure cut-off during turret rotation: max 14 bar.

M.I.6431-0399

Fig. 6

Fig. 5

3.5 - Electrical connections (Fig. 5)

The electric connection must be carried out according to diagram on page 11. The connection cable must be provided with fittingsand gaskets in order to avoid penetration of water into the turret.Figure 5 shows the exemple for correct electric connection.

A - Turret housingB - Copper gasket according to DIN 7603/DC - Fitting PG 13,5D - Armoured cableE - Hose clamp

A B C D E

PG 13,5 (DIN 40430)

10

M.I.6431-0399

3.6 - Wiring diagram

Fig. 7

ELECTRIC MOTOR CHARACTERISTICS

Turret size Minimum required power Short circuit power

BSV-N 160 KVA 1,10 KVA 1,60

(1) Other voltages on request.(2) The termal detector gives a signal only motor overheating.

Tab. 1 Tab. 2ELECTRIC MOTOR'S WIRING (1)

3

Indexing control switch

Indexing solenoid

Thermal detector

Electric motor (three phase)

Locking control switch

Angular positions transmitter

(absolute)

10-30 V D. C. (ripple) 10%350 mA (supply)50 mA/exit (load)OUTPUT - PNP

10-30 V D. C. (ripple) 10%200 mA (load)

OUTPUT - PNP - NO

24 V D. C.44 W

135 C 1,5A 250V

(1)

220-380 V 50/60 Hz(For other characteristics

see tab. 1)

10-30 V D. C. (ripple) 10%200 mA (load)

OUTPUT - PNP - NO

CHARACTERISTICS WIRING NUMBER COLOUR SIGNALCOMPONENTREF.

U1 WhiteV1 GreenW1 BlackU2 WhiteV2 GreenW2 Black

See tab. 2

(2)1 Brown

2 Brown

5 Blue

6 Brown

7 Brown + V D. C.8 Black EXIT9 Blue 0 V D. C.

7 Brown + V D. C.10 Black EXIT9 Blue 0 V D. C.7 Brown + V D. C.9 Blue 0 V D. C.

11 White Bit 112 Yellow Bit 213 Green Bit 3

14 Violet Bit 415 Black Strobe16 Pink Parity chech

Green/Yellow Ground

1

2

4

5

6

7

Brake24 V D. C.

BSV-N 120/160=8WBSV-N 200/400=12W

3 Green

4 Green3

U1V1W1U2V2W2 WIRING

U1V1W1U2V2W2(380 V) WIRING (220 V)

4

3

5 1 2 3

7

6

11

M.I.6431-0399

3.7 - Cycle

cw—

—

——

c

cw

12

34

56

78

910

1112

10

10

10

10

10

10

01

10

01

10

01

10

00

01

11

10

00

01

00

00

00

01

11

11

11

01

00

11

00

10

11

11

11

11

11

11

1 B

IT

2 B

IT

3 B

IT

4 B

IT

PA

RIT

Y C

HE

CK

ST

RO

BE

PO

SIT

ION

STa

b. 1

TU

RR

ET

SIZ

E16

0Ta

b. 2

ALL

OW

ED

LA

G T

IME

MA

X

50 200

40 40 40

Sta

ndar

d

Slo

w

Sta

ndar

d

T1

(ms)

T2

(ms)

R1

(ms)

40S

low

R2

(ms)

PR

OG

RA

MM

ING

TIM

E

1 5 6 7

CC

W

CW

01

PO

S. 1

(S

TAR

T)

ELE

CT

RIC

MO

TO

R1

AN

GU

LAR

PO

SIT

ION

TR

AN

SM

ITT

ER

(AB

SO

LUT

E)

1 B

IT

2 B

IT

3 B

IT

4 B

IT

PA

RIT

Y C

HE

CK

ST

RO

BE

PO

S. 2

(S

TAR

T)

R1

R2

R1

T1T1

PO

S. 1

2 L

ocke

d tu

rret

NO

TE

:

For

the

T1-

T2-

R1-

R2

valu

e se

e T

ab. 2

Inde

xing

pin

mec

h.po

sitio

n

For

pos

ition

cod

ese

e T

ab. 1

01B

RA

KE

3

01

IND

EX

ING

SO

LEN

OID

4

01IN

DE

XIN

G C

ON

TR

OL

SW

ITC

H

01LO

CK

ING

CO

NT

RO

LS

WIT

CH

01 01 01 01 01 01

T2PO

S. 2

Loc

ked

turr

et

PO

S. 1

T2 R2

12

FU

NC

TIO

N

M.I.6431-0399

3.8.a - SignalsTo get a change of positions on the BSV-N turrets, thecontrol equipment (usually a N.C. equipment) must controlthe components mentioned below according to a welldefined sequence (see wiring diagram on page 11).• Motor (1)• Brake (3)• Indexing solenoid (4)The following output signals from the turret are providedfor driving the positioning cycle:— Angular position given by the angular position tran-

smitter (7)— Indexing control switch (5)— Locking control switch (6).

3.8.b - Description of the operating sequenceThis description refers to sequence cycle: the first partgives the sequence to pass from position 1 to position 2with clockwise rotation, the second part gives the sequenceto pass from position 2 to position 12 with counterclockwiserotation.As indicated by the cycle the controls are to be performedaccording with the following sequence:

• De-energize the brake (3) and start motor rotation in thedesired direction.

• If, as in the case shown by the diagram, the next position(pos. 2) is the Stop position, when the strobe signalreached a zero level, the solenoid (4) is to be energized.In case of passage from position 2 to position 12, wait forthe reading signaling the passage on pos. 1 then, sincethe next one is the Stop position, wait until the next strobesignal reaches a zero level and (at that time only) energizethe solenoid (4).N.B.: The maximum lag time between the reading of thestrobe signal and the excitation of the solenoid (4) cannotexceed the R1 values indicated in the table.• The turret goes on rotating until the indexing pin, pushedby the solenoid (4), enters into the mechanical stop slot.This movement is detected by the sensor (5) which mustimmediately stop the motor that, once expired the T1 timewill re-start rotating in the opposite direction.• During this phase the turret is locking and its lockedposition is detected by the sensor (6) and this signal isused to stop the motor (1). The maximum lag time betweenthe signal of the sensor and the stopping of the motor mustnever axceed the R2 value shown in the table. At this pointthe machine can be started, in order to go on working.• The solenoid (4) is to be de-energized after the expirationof the T2 lag time starting from the moment when thesensor (6) signal is read.

N.B.: The T1, T2, R1, R2, times must be understood asreal times execution of the controls and the signals checkedon the terminal board of the turret.For an accurate detection and measurement of the abovementioned values it is advisable to use adeguateinstrumentation such as an oscilloscope with memory andcurrent sensing devices.

3.8 - Cycle description 3.9 - Flow chart

(*) See tab. 2 sheet 12 ( Cycle ).

TURRETSTART CYCLE

DE-ENERGIZE BRAKEAND SET ROTATION

1 BEFORE GOAL POSITION-STROBE

SET INDEXmax. allowed lag time

R1 = (*)

INDEX CONTROLSWITCH = 1

STOP ROTATION

SET TIMER T1 (*)

DELAY TIMER T1EXPIRED

LOCKING CONTROLSWITCH = 1

SET REVERSEROTATION

CONCIDENTPOSITION

START TOTHE MACHINE WORK

STOP MOTORmax. allowed lag time

R2 = (*)

SET BRAKE

YES

NO10

YES

NO

YES

NO

NO

YES

YES NO

YES

FAULT

13

M.I.6431-0399

4 - SERVICE OPERATIONS

4.1 - Replacement and adjustment of locking control switch (Fig. 8 - 9)This switch is operated by the part (141) in correspondance of the locking position.The turret is locked when the part (141) is moved to the top dead point or at least at a max. distance of 0.5 mm from it.The switch point of the proximity switch, to be used to stop the motor, must be adjusted with an advance to ensure that the motoris stopped in the zone of the locked turret.This advance is provided the counteract the R2 lag time or stated values (see table page 12).The switch point, size "B", is shown in the fig. 9 page 15.

4.1.a - Replacement of the switch (Fig. 8)Remove the cover (146) to reach the proximity switch (105). To replace the switch disconnect the wires from the terminal board,unscrew the screw (321) of the block (306) and remove the switch.Once replaced and re-connected the new switch adjust the position as follows:

— With the screw (321) unscrewed, introduce a 1 ÷ 1,2 mm spacer (A) between the switch and the part (141).

— Push the switch against the spacer (A) (as shown on the figure) then lock in place with the screw (321).

— Remove the spacer (A).

Fig. 8

A

1 ÷ 1,2

141

142

304

118

116

139

140

307

306

105

321

166

305

14

M.I.6431-0399

4.1.b- Adjusting procedure (Fig. 8 - 9)

a) With the turret correctly lock part ( (141) on the Nr. 3 position) energize the low voltage circuit only, do not apply mains voltageat this stage.

b) Loosen the two screws locking the support (306) and move it in the direction indicated by the arrow (4) until the switch is de-energized (verify this condition on the relevant Led of the electrical interface equipment).Move the support (306) forwards (direction indicated by the arrow (5) ) the exactly, find the point where the switch is re-energized. Starting from this position move the support (306) forward again (direction indicated by the arrow (5) ) of a distancecorresponding to the B value. To better check the displacement (B), it is advisable to use a dail as indicated on figure 9.

Note: The "top position" can be slightly different changing the position (scattering "n" in figure 9)For the right adjustment please refer to the most external top position.

Fig. 9

B = 0,7mm ± 0,2

Lower position (Unlocked turret)1

Switching point2

Top position (Locked turret)3

scattering "n"

141

5 4

105

306

15

M.I.6431-0399

Fig. 10

4.2 - Replacement and timing of the angular position transmitter (Fig. 8)

To replace this element remove the cover (146); the angular position transmitter is the component (116). Disconnect the wiresfrom the terminal board, unloose the two screws and remove the two fixing pieces (118). At this point it is possible to remove itfrom the turret. For the re-assembly proceed according to a reverse sequence, but before locking it, set the timing operations asfollows:

— Lock the turret at any position.

— Set an approximate positioning by rotating the unit to get corresponding position code (check by means of a voltmeter oron the led of the machine PLC).

— Perform an accurate adjustment by rotating the unit until the strobe signal passes from 1 to 0; mark the position of the angularposition transmitter against its support then rotate in the opposite direction until the strobe signal passes again from 1 to0 and mark this new position.In such a way it is possible to determine the area where the strobe signal is 1; the width of this area will be 20°.Rotate 10° backwards the angular position transmitter so that the reference mark is halfway the angle found with thepreviously described procedure and tighten the screws of the fixing pieces (118).

4.3 - Indexing control adjustment and replacement (Fig. 10)

To reach the indexing control first remove the solenoid assy as shown on page 17.The switch (105) is locked by means of a block (106).To replace the switch disconnect the wires from the terminal board, loosen the cable clamp (145), unscrew the two screws (457)and remove the switch together with the block, simultaneously pushing the wire through the cable clamps (145).Once replaced the switch and before connecting the wires to the terminal board, provide for the adjustment of this position asfollows:

— Lock the screw (457).

— Once locked the screw (457/B) proceed as follows:- take a 0,9 ÷ 1,1 mm thick spacer.- introduce the spacer (A) between the pin (158) and the switch.- push the switch against the space (as shown by the figure) then lock it with the screw (457/B).- remove the spacer, connect the wires, tighten the cable clamp and re-assemble the solenoid.

A0,9 ÷ 1,1

158 106 457 105 145

457/B

16

M.I.6431-0399

Fig. 11

4.4 - Brake and motor replacement (Fig. E)

The motor and the brake form a single assy which can be reached after removal the rear cover (146) of the turret. To disassemblethe unit, first disconnect the cables of the brake and the motor from the terminal board then unscrew the screws (147) and removethe motor assy together with ist shaft.The brake (228) is fixed by means of screw (229) and in case of replacement verify that the air gap (B) value is 0,2 ± 0,05 mm(de-energized brake). If the (B) value doesn't correspond to the above, replace the spacer (235) with the new one supplied togetherwith the brake. The new spacer has a haiger thickness and it is therefore possible to machine it to get the (B) point at the desideredvalue.

4.5 - Solenoid pre-indexer (Fig. 11)

4.5.a - Solenoid pre-indexer

The solenoid pre-indexer is the component shown by the number 4 on the sequential cycle and is the unit which, lifts or lowersthe pre-indexer pin, pre-sets the turret for its rotation (beginning of cycle) or for shut-down (end of rotation).To check this assy proceed as follows:• Remove the rear cover of the turret (146), disconnect the solenoid wires from the terminal board, loosen the cable clamp

and push the cable inwards.• Unscrew the screws (178) and remove the spacers (177).• Remove the cap (193) after having unscrewed the screws (190) then remove the solenoid (157) (see fig. 11 and fig. 12).

4.5.b - Checks to be performed on the pin

Manually push the pin (158) and let it be pushed back by the springs to verify that it runs smoontly.In case of problems, completely remove the pin and check the springs (180) for correct condition and verify that the flats couplingof the cam (128) is not damaged.

175

171

180

170

174

170

128

176

172

194

171

173

172

173

157193

158

178

177

174

181

159 190

180

179

4.6 - Shock absorber (Fig. 11)

The shock absorber (173) as be designed to absorb the shocks caused by the turret pivoting part when stopping it by means ofthe pin (158).As it can be seen on the drawing, the shaft (181) is axially positioned by means of two shock absorbers (173) allowing a cushionedstopping of the disc.

17

M.I.6431-0399

4.7 - The turret's restart-up after an accidental or emergency shut-down

This operation is required in case the turret stops during rotation due to lack of electricity or sequential cycle mismanegement.This turret-up after an accidental or emergency shut-down must be performed in the same rotation direction which it hadat the moment of shut-down.

4.7.a)Operate one of the turret's positioning cycles. In the case that the controller doesn't accept the positioning command, becausethe point of departure is wrong and the turret is not locked, see point (4.7.b)

4.7.b)In order to return to the normal turret positioning, it is necessary to have at one's disposal a set of manual commands (push-buttontype) to manually start up the individual cycle phase for each component in order to operate the solenoid, motor and brake in anindipendent manner, accordimg to the opportune sequences. To reset the turret's normal condition, follow these steps:

— De-energize the brake (3).

— Energize the indexing electromagnet (4).

— Operate the motor's rotation in order to turn the turret in the same direction that it turned at the moment of interruption.Cut off the motor's feed as soon as the indexing pin stops the rotation.

— Reverse the motor's rotation in order to lock the turret, cutting of the feed as soon as you have the locking microswitch signal.

— Energize the brake (3).

— De-energize the electromagnet (4).

— The turret, at this point, is normally indexed and locked in position and ready to go in an automatic cycle.

4.7.c)If the re-timing — as described in point (4.7.a) and (4.7.b) — doesn't work because the necessary manual commands are notavailable or because the rotation direction at the time of shut-down wasn't known, the following manual re-timing procedure becarried out:

— Desconnect the turret's electrical connections. This operation serves to electrically isolate the turret with a resultantde-energizing of indexing solenoid and brake.

— Remove the solenoid cover (193).

— Remove the rear cover (146).

— Push by hand down wards the part (192) and contemporally, by means of a key as stated in Fig. 12 rotate the motor.

— Rotate the motor shaft until the part (192) will push the pin (158) inside the slot relevant to an indexing position andkeep always pushed the part (192).

— For locking the turret, rotate the motor shaft (during this step keep part (192) pushed), into the direction where lessresistance is felt (rotation into the opposite direction is impossible).

— If the rotation direction is the right one you can see the ring (141) page 14 is moving towards the outside signallingthat the turret is going to be locked. Right locking is got when the ring (141) is in the top position (before starting torecover); in this situation the proximity switch (105) must be energized.

— Now the turret is ready to start again in the automatic cycle.

18

M.I.6431-0399

Fig. 12

4.8 - Operation checks to be carried out in case of accidental collision

This inconvenience presents two different conditions:• The collision between the disc and the machine occurs while the disc is locked.• While the disc is unlocked. The most frequent condition is the collision while the disc is locked and, normally, the following

operations are to be performed for re-starting the machine:

— Loosen the screws locking the disc.

— Introduce the suitable setting pin supplied with the machine.

— Tighten the screws and remove the setting pin. Repeat the above sequence also for the screws locking the turret to thesaddle.

Having completed the above operations, the turret usually is aligned again and ready to be operated.Should the collision occur while the disc is unlocked, or in case of malfunction after the re-alignment operations previouslydescribed, the mechanical parts are to be checked in conformity with the procedure illustred in the next chapter.

190

193

192

146

19

M.I.6431-0399

4.9 - Instructions for the checking of the mechanical parts

This check is to be performed in the following cases:

— Accidental collision with the lathe, when after retiming the turret does not work correctly.

— Misfunctions which cannot be eliminated after checking the motor, the brake, the encoder, the turret timing and the max.lag times of the electrical equipment of the machine.

4.9.a-Disassembly instructions (see Fig. A-B)

— Remove the toolholder disc from the turret.

— Remove the ring and seal complete (408) from the turret and check the condition of the seal (123).

— Remove the rear cover of the turret (146).

— Remove the encoder (116).

— Remove the proximity switch (105) and its support (306).

— Remove the motor support (350).

— Remove the snap ring (138).

— Remove the screws (101) and the relevant pins.

— At this point, even with the turret locked, the wholemechanical group can be removed through the front of the turret.

— The various components of the mechanical assy can be dismantled further after removing the locking nut (135).

4.9.b-Checks to be performed on the mechanical elements.

— Check the conditions of the bearing (131).

— Check that the three roller and pins (130) are not damaged.

— Check that the surface of the cam (128) is not damaged.

— Check that all sliding surfaces are in good condition and that all gaskets are undamaged.

4.9.c-Assembly instructions

— Carefully clean and wash the various components before reassembly. The assembly must be carried out in thereverse sequence of the above disassembly instructions and the turret on the mechanical assy must be unlocked.

— Before locking the collar (135) check the preload of the springs, proceeding as follows (Fig. 13):Assembly the spacer (134)Screw the collar (135) until it touches the springs (133).Then tighten the collar and makesure that the springs are compressed in according with the X-Y values indicatedin the table of Fig. 13, if necessary modify the spacer (134).

— After assembly check, with the turret unlocked, the 0,1 mm backlash on the main shaft (311); in the opposite casemodify the ring thichness (320) to get the right clearance.

20

M.I.6431-0399

Fig. 13

LENGHT AFTER PREOLADING

UNLOADED LENGHT

BSV-N 160 5,4 1,0 ± 0,05

Turret size Normall value

X [mm] X-Y [mm]

134

135

311

308

133

X

Y

21

M.I.6431-0399

Fig. 14

4.9.d - Check of the right mechanic locking of turretAfter re-assembling of the turret or in case you suspect the toolholder disc is not mechanically locked(also if the electrical indexingcycle is properly operating).A rod (313) allows to inspect the right shifting of the locking inside parts and the consequent application of the power given bythe cup-springs (Fig. 13).Shifting remark must be executed in the following way:

— Position a dial gauge as per Fig. 14.

— Unlock the turret manually driving the motor as shown at page 18 - 19.

— Push the rod (313) towards the inside up to the touching.

— Reset the dial gauge.

— Manually get the locking and check the rod has got the shifting stated in Fig. 14.If the checked vaule "Z" is not corrisponding to the stated one the reasons could be the following ones:• Wrong assembly of inside parts.• Excessive wearing of the rollers (130) or of the cam (128) or of the toothing (111-112).• Presence of dirt between the contact surfaces.

N.B.: After prolungated working time it is possible to inspect a lower value; min. acceptable value is 0,05 mm.

313 165 314

400 Z = 0,10 ÷ 0,15 mm

22

M.I.6431-0399

4.10.b - Recommended lubricant

FLUID GREASECENTOPLEX GLP 500 - KLüBER LUBRICATION

4.10 - LubricationThe mechanical part of the turret is supplied with permanent lubrication and therefore it does not require periodical refillings orlubricant changes.The lubricant is to be changed only in case of complete disassembly of the turret.The lubricant is to be filled before assembling the solenoid (157) and the pin (158) pouring it through the pin seat.

4.10.a - Recommended capacity of lubricant used

Turret size Lubricant quantity

cm3 Kg

BSV-N 160 300 0,28

23

AustraliaKlüber LubricationA Division of Freudenberg (Australia) Pty. Ltd.14 Daniel StreetP. O. Box 164, Botany N S W 2019, SydneyTel. (02) 666-5744, Telex 26121 lesco

Bundesrepublik DeutschlandKlüber Lubrication Munchen KGGeisenhausenerstrasse 7, Postfach 70 10 47D-8000 Munchen 70Tel. (089) 78 76-0, Telex 523 131Telefax 3a (089) 78 76 333

Schweiz / SuisseKlüber Lubrication AG (SCHWEIZ)Thurgauer Strasse 39, CH-8050 ZurichTel. (01) 302 79 79, Telex 823 194 klub ch

BrasilKlüber Lubrication Industria e Comércio Ltda.Rua Sao Paulo, 345Distrito Industrial de Alphaville06400 Barueri - Sao PauloTel. 421 5511/421 5155/421 5150Telex (011) 39209

BelgiqueKlüber Lubrication Belge S. A.95 Rue Cardinal Mercier, B-7760 DottigniesTel. (056) 48 98 71, Telex 0046-57059,Telefax 0032-56 48 98 49

NipponNOK Klüber Co. Ltd.Seiwa Building, 1 - 12 - 15 Shiba-DaimonMinato-ku, Tokyo 105Tel. (03) 432-4211, Telex 242-2152 nok tokTelefax 0081/34 36 59 68

ArgentinaKlüber Lubrication Argentina S. A.Bdo. de Irigoyen 566 - 2° D1072 Buenos AiresTel. (01) 37-6371, Telex 22832 laqui ar

Republic of KoreaKlüber Lubrication (KOREA) Ltd.Head Office/Factory:1132, jung ri-dong suh-gu,P. O. Box 146, Daegu 630Tel. (053) 529160/1/2, Telex klkco k 54384

Republic of the PhilippinesKlüber Lubrication International Ltd.6th Floor Rediffusion House822 Lai Chi Kok RoadKowloon, Hong KongTel. (02) 3-741 42 29, 3-741 42 30Telex (02) 38337 fvi hxTelefax 3-7453667

United States of AmericaKlüber Lubrication Corp.Grenier Industrial Airpark, Manchester,New Hampshire 03103Tel. (0603) 669-7789, Telex 94-3494Telefax (603) 627-3718

Republic of South AfricaKlüber Lubrication (Pty) Ltd.Harpur House, 1 Dover StreetP. O. Box 3924, Randburg 2125Tel. (011) 789-3242, Telex 4-22 455 sa

EspañaKlüber Lubrication Iberica S. A.Carretera Nacional 152 km 22Parets del Valles (Barcelona)Tel. (03) 562 17 11, 562 17 90, 562 18 00Telex 93659 Klub e

FranceKlüber Lubrication France S. A.10-16 Allee E. Ducretet Z IBP1437, F-26014 Valence CedexTel. (75) 44-02-34, Telex 345 637

Great BritainKlüber Lubrication Great BritainLtd.Hough Mills, Halifax, West Yorkshire, HX3 7BNTel. (0422) 205115, Telex 517197

Hong KongKlüber Lubrication International Ltd.6th Floor Rediffusion House822 Lai Chi Kok RoadKowloon, Hong KongTel. (02) 3-741 42 29, 3-741 42 30Telex (02) 38337 fvi hxTelefax 3-7453667

ItaliaKlüber Lubrication Italia S.R.L.Via Monferrato Sesto Ulteriano,20098 S. GiulianoCasella postale 13.104, I-20130 MilanoTel. (02) 98.81.121 Telex 316090Telefax 0039/29 88 11 24

JOsterreichKlüber Lubrication Austria Ges. m. b. H.Franz-Wolfram-Scherer-Strasse 32, SalzburgPostfach 49, A-5101 Bergheim.Tel. (0662) 52 705-0, Telex 0047-633326

A DanmarkKlüber Lubrication A/SSoenderlandsgade 11, DK-7500 HolstebroTel. (07) 42 46 20, (07) 42 42 77, Telex 0055-66424

DK

AUS E RA

B

BR

CH

D

F ROK

GB RP

HK USA

I ZA

M.I.6431-0399

5. ASSEMBLY DRAWINGS AND PART LISTS

5.A - Main section

101 Screw M6x16 A12.9 0530294 12

105 Proximity 0661254 1

106 Switch holder 0327459 1

108 Key 0323963 2

109 Screw M10x25 A12.9 0531173 6

110 Spring 0115271 4

111Toothings 0425927 1

112

114 Pin 10x28 0550599 4

Encoder 8 pos. 0661256116 1

Encoder 12 pos. 0661246

117 Screw M4x8 0530019 2

122 O-Ring OR 2.161 0591399 1

123 Gasket 0591406 1

124 O-Ring OR 2.162 0590375 1

125 O-Ring OR 2.151 0591405 1

126 O-Ring OR 2.161 0591399 1

127 Key 0324092 1

Cam 8 pos. 0328673128 1

Cam 12 pos. 0328674

129 Screw M4x8 0530480 3

130 Roller 0422684 3

131 Bearing AR 95 070.4 0631635 1

133 Spring 0324045 1

134 Spacer 0550767 1

135 Ring nut 0324090 1

(1) See Fig. 10

138 Snap ring 0550766 1

139 O-Ring OR 2100 0590308 1

140 O-Ring OR 3131 0590492 1

141 Ring 0324085 1

142 Spring 0110985 1

145 Cable gland 0671722 2

146 Rear cover 0323992 1

147 Screw M5x16 0530032 3

150 O-Ring OR 2.261 0591408 1

151 Rod 0324091 1

152 Cam 0323975 1

166 Screw M4x8 0530385 1

304 Encoder holder 0325669 1

305 Coupling 0325596 1

308 Plate 0325671 1

311 Main shaft 0325707 1

315 Rollholder 0328200 1

320 Spacer 0323171 1

400 Housing 0326273 1

409 O-Ring OR 3225 0590397 1

439 Screw M5x16 0530032 5

457 Screw M4x16 0530022 2

Ref. Description Code Q.ty Ref. Description Code Q.ty

(1)

24

N.B. When ordering any spare part, please state both the reference number of the part and the complete name and code numberof the BSV-N.

M.I.6431-0399

Fig

. A

400

(157

)10

8

(158

)

106

105

152

151

150

145

(350

)

147

(160

)

146

142

166

116

305

304

139

141

140

138

439

320

135

134

133

308

131

315

130

129

128

126

112

(408

)

124

(323

)

409

101

117

(325

)

(324

)

109

110

311

111

127

114

125

122

123

(328

)

25

M.I.6431-0399

Fig. B

5.B - Back view

105 Proximity 0661254 1

115 Elect. block 0490146 1

118 Encoder holder 0113203 2

120 Elect. block 0490147 1

Plug 0671182 4121

O-Ring OR 2068 0590301 4

162 Name plate 0328080 1

163 Rivet 0530521 4

(1) See Fig. 8

(2) See Fig. 14

165 O-Ring OR 2010 0590561 1


307 Screw M5x20 0530034 1

313 Rod 0325670 1

314 Screw M5x8 0531028 1

321 Screw M4x12 0530021 1

410 Board holder 0325598 1

411 Reference pin 0326336 1


(2)

(1)

(1)

26


��

��

��

��

��

��

��

��

��

��

��

M.I.6431-0399

Fig. C

5.C - Coolant circuit

425

426

417328

325

420324

323

418

408

424

419

418

422

421 B

2

A

424

+ α

− α

417

419

423

422

421

1

Coolant ring 8 pos. 0324128323 1

Coolant ring 12 pos. 0324129

324 Holder 0323910 2

325 Screw M5x10 0530030 2

328 O-Ring OR 2050 0590298 8/12

408 Coolant flange 0327487 1

417 Coolant valve 0326399 1

418 Plug 0326398 1

419 O-Ring OR 114 0590172 2

420 Spring 0319956 1

421 Plug 0326397 2

422 O-Ring OR 2043 0590297 2

423 Plug 0326400 1

424 Screw 0323851 2

425 Screw M5x20 0530313 4

426 Holder 0326394 4


27


M.I.6431-0399

5.D - Shock absorber

Fig. D

Ref. Description Code Q.ty

157 Solenoid 0425883 1

158 Pin 0324097 1

159 O-Ring OR 3268 0590525 1

170 Screw M5x10 0530030 12


178 Screw M6x10 0530043 2

179 Pin 6x28 0550196 1

180 Spring 0324080 2

194 O-Ring OR 2.34 0591411 1

177 Holder 0323833 2

176 Screw M5x25 0530035 1

181 Shaft 0323958 1

190 Screw M3x8 0530267 4

171 O-Ring OR 2.30 0591404 2

193 Plate 0328079 1

172 Cover 0323959 2

173 Shock absorber 0323962 2

174 Spacer 0323960 2

175 Bush 0837062 1

175

171

180

170

174

170

(128)

176

172

194

171

173

172

173

157193

158

178

177

174

181

159 190

180

179

28


M.I.6431-0399

5.E - Motor and gear box

Fig. E(1) See sheet 30

160 Braked motor (see sheet 30) – –

220 Gasket 0591108 1

221 Snap ring 0550395 1

222 Spring 0550425 1

223 Bearing 6003 0630158 1

227 Key 0550044 1

228 Brake 0324227 1

231 Bearing 6000-2RS 0630769 1

235 Spacer 0324226 1

251 Bearing 6000 0631571 2

253 Bearing DL 30 16 0630823 1

254 Bearing DL 10 12 0630282 1

255 Bush 0324114 4

256 Screw M6x20 0530318 4

257 Washer 0324113 4


260 Pin 6x20 0550490 1

261 Gear 0324112 1

264 Plate 0631641 1

265 O-Ring OR 3175 0590323 1

350 Gear box 0325667 1

351 Gasket 0325668 1

Z3Gears (see sheet 30) – –

Z4


265

221

223

256

260

350

351

220

226

Z3 (1)

253

255

Z4 (1)251

264

261

254

222 232

224 225

231

234

230

233

257

258

260228

229

0,2 ± 0,05

227

235

160 (1)

29


M.I.6431-0399

Fig. F

5.F - Table to determine the motor code and the gears (Fig. F)

MOTORZ3

Z4

400/440 V

0425988

MOTOR

50 Hz H 0328212 0324105

60 Hz H 0328213 0324106

50 Hz 0328213 0324106

60 Hz 0328214 0324107

50 Hz L 0328214 0324107

60 Hz L 0328983 0325837

BSV-N 160/25

SIZE

Z3 Z4 110 V 220/380 V

0425933 0425932

VERSION GEARS

30

M.I.6431-0399

6 - RECOMMENDED SPARE-PARTS FOR BSV-N 160/25

105 Proximity 0661254 2


Encoder 8 pos. 0661256116 1

Encoder 12 pos. 0661246

122 O-Ring OR 2.161 0591399 1

123 Gasket 0591406 1

124 O-Ring OR 2.162 0590375 1

125 O-Ring OR 2.151 0591405 1

126 O-Ring OR 2.161 0591399 1

139 O-Ring OR 2100 0590308 1

140 O-Ring OR 3131 0590492 1

150 O-Ring OR 2.261 0591408 1

159 O-Ring OR 3268 0590525 1

171 O-Ring OR 2.30 0591404 2


194 O-Ring OR 2.34 0591411 1

220 Gasket 0591108 1

228 Brake 0324227 1


265 O-Ring OR 3175 0590323 1

328 O-Ring OR 2050 0590298 8/12

409 O-Ring OR 3225 0590397 1


418 Plug 0326398 1

419 O-Ring OR 114 0590172 2

420 Spring 0319956 1

422 O-Ring OR 2043 0590297 2


31


M.I.6431-0399

7 - PREVENTIVE MAINTENANCE PROGRAMM FOR INTENSIVE DUTYMACHINES

The number of working hours mentioned in the following paragraphs are valid for a turret use at an average indexingfrequency of 300 ÷ 400 cycles/h.

7.a EVERY 3.000 ÷ 3.500 hours:Check and replacement, if necessary, of the coolant valve (see sheet 27).

Needed parts:


419 O-Ring OR 114 0590172 1

420 Spring 0319956 1

422 O-Ring OR 2043 0590297 1


(1) Replace only if the check of the part is negative.For the replacement procedures see chapter 4.4 and 4.5.


139 O-Ring OR 2100 0590308 1

140 O-Ring OR 3131 0590492 1

150 O-Ring OR 2.261 0591408 1

124 O-Ring OR 2.162 0590375 1

123 Gasket 0591406 1

122 O-Ring OR 2.161 0591399 1

159 O-Ring OR 3268 0590525 1

171 O-Ring OR 2.30 0591404 2

180 Spring 0324080 2

194 O-Ring OR 2.34 0591411 1


328 O-Ring OR 2050 0590298 8/12

351 Gasket 0325668 1

409 O-Ring OR 3225 0590397 1

157 Solenoid 0425883 1(1)


7.c Other checks to be carried out after 4.500 ÷ 5.000 working hours:• Lack of coolant inside the protection cover of the turret and/or inside the mechanism.

(Remove the solenoid Ref. 157).

• Check of the mechanical locking of the turret as per instructions of chapter “4.9.d” and "procedure for the checkof the worn cam" attached.

In case of negative result of one of these checks a detailed check of the inside mechanism is requested.

• Lack of angular play on the toolholder disc, with locked turret. Check the toolholder disc fixing on the turret.

32

7.a EVERY 4.500 ÷ 5.000 hours:Parts to be checked and replaced, if necessary:

M.I.6431-0399

N.B.: The checking Rodin the locking posi-tion return of the"ZA" value respectto the elevation re-marked in the checkoperation.

(1) Measurement taken in the worst position, in CW and CCW direction.

Reference Values

Z = 0,10 ÷ 0,15

ZA = 0,05 ÷ 0,06

Minimum values acceptedon worn condition (1)

[mm]

Z = 0,05

ZA = 0,03

In case of sure worn ("Z" and "ZA" values at minimum acceptable) the opening of the inside mechanism and thereplacement of the following parts are requested:

(2) Replace only in case of a defective original part.

(3) Check also the entirety of the Roller Holder Ref. 315 code 0328200 and the key Ref. 127 code 0324092.


131 Bearing AR 95 070.4 0631635 1

134 Spacer 0550767 1

308 Plate 0325671 1

130 Roller 0422684 3

129 Sprig M4x8 0530480 3

Cam 8 pos. 0328673128 1

Cam 12 pos. 0328674

(2)

Z ZA

313 165 314

400

Maximum elevation

Locking position

Unlocked turret

7.d PROCEDURE FOR CHECKING OF A WORN CAM AND ROLLER HOLDER

33

M.I.6431-0399

8 - TROUBLE SHOOTING

FAILURE

1) Unlocked turret(after indexing cycle lockingswitch signal = 0)

1.1 Faulty locking switch1.2 Faulty motor supply1.3 Faulty motor1.4 Faulty mechanism1.5 Wrong adjustment of locking

switch1.6 R2 lag time too long

1.1 Check and if necessary replacethe proximity switch

1.2 Check the 3 phase of motor andfeeding voltage

1.3 Check the motor winding and ifnecessary replace

1.4 It's necessary an internal check(see sheet 20). Please contact theService Center

1.5 Adjust the locking switch as shownon sheets 14-15

1.6 The lag time must be reduced tothe limit indicated on sheet 12

PROBABLE CAUSES HOW TO DO

2) Unlocked turret(after indexing cycle, the turret ismechanically unlocked but lockingswitch signal = 1)

2.1 Faulty locking switch2.2 Sticking bush (see sheet 14

ref. 141)2.3 Wrong adjustment of locking

switch

2.1 Check and if necessary replacethe proximity switch

2.2 Please contact the Service Center2.3 Adjust the locking switch as shown

on sheets 14-15

3) The tool disc doesn't rotate 3.1 Faulty indexing switch(signal always = 1)

3.2 Indexing solenoid always ener-gized

3.3 Indexing device sticking3.4 Faulty motor supply3.5 Faulty motor3.6 Turret rotating in wrong direction

after an unlocking for accidentalreasons

3.7 Faulty mechanism

3.1 Check and if necessary replacethe indexing switch

3.2 Check the relevant electric circuit3.3 Check both pin, springs (ref. 180)

and solenoid (see sheet 17)3.4 Check the 3 phase of motor and

feeding voltage3.5 Check the motor winding and if

necessary replace3.6 Reverse the rotation or re-timing

as per sheet 183.7 It's necessary an internal check

(see sheet 20). Please contact theService Center

4) The tool disc goes on rota-ting without indexing

4.1 Faulty angular position transmitter4.2 Missed supply of indexing solenoid4.3 Faulty index solenoid4.4 Indexing device sticking

4.1 Check the angular position signals4.2 Check the solenoid feeding voltage4.3 Check the solenoid winding and if

necessary replace4.4 Check both pin, springs (ref. 180)

and solenoid (see sheet 17)

5.1 Indexing device sticking5.2 Lag time R1 too long

5.1 Check both pin, springs (ref. 180)and solenoid (see sheet 17)

5.2 The lag time must be reduced tothe limit indicated on sheet 12

5) Turret indexed in wrongposition

34

M.I.6431-0399

FAILURE

6) Excessive bounce at theindexing

6.1 Excessive inertia6.2 Faulty shock absorbers

6.1 Verify the inertia (it cannot exceedthe values indicated on sheet 3)

6.2 Check the shock absorbers(see sheet 17)

PROBABLE CAUSES HOW TO DO

7) Disc rotation is not smooth,action is jerky

7.1 Excessive unbalance torque 7.1 Verify unbalance torque (it cannotexceed the values indicated onsheet 3) if necessary add or remo-move tool holders to counterbalan-ce the disc

8) Thermal detector signalsmotor overheating

8.1 Excessive frequency of turret cycle8.2 Faulty motor supply8.3 Faulty motor8.4 Turret restarting in wrong direction

after an unlocking for accidentalreasons

8.5 Faulty mechanism

8.1 Verify the admitted value of toolchange frequency (see sheet 3)and if necessary reduce the fre-quency

8.2 Check the 3 phase of motor andfeeding voltage

8.3 Check the motor winding and ifnecessary replace

8.4 Reverse the rotation or re-timingas per sheet 18

8.5 Manually rotate the motor shaft tocheck for free mechanism

35

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DUPLOMATIC AUTOMAZIONE S.p.A.20025 LEGNANO (MI) - ITALY

P.LE BOZZI, 1TEL 0512-55177726

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BSV-N 160/ 25 - 缓冲器，电磁阀，齿轮泵，气缸，液 … RULES • The tool turrets of...

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Transcript of BSV-N 160/ 25 - 缓冲器，电磁阀，齿轮泵，气缸，液 … RULES • The tool turrets of...