Kitagawa TT200BE-01, Instruction Manual

Page 1: ...tions from experienced personnel the distributor or our company Before installing operating or maintaining this equipment carefully read this manual and the safety labels attached to the equipment Failure to follow these instructions and safety precautions could result in serious injury death or property damage Store this manual near equipment for future reference If any questions related to safet...

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Page 3: ...hich if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Indicates instructions which if not avoided could result in damage to the equipment or a shortened work life Liability and How to Use this Manual This unit is installed on the machining centers and suitable for indexing the angle of mac...

Page 4: ... Series TL Series TBX Series TUX Series TU Series LR Series TP Series TM Series TH Series TT Series TW Series Directives Machinery Directive 2006 42 EC EMC Directive 2004 108 EC The above product has been evaluated for conformity with above directives using the following European standards Machinery Directive EN ISO 12100 1 2003 A1 2009 EN ISO 12100 2 2003 A1 2009 EN ISO 14121 1 2007 EN 60204 1 20...

Page 5: ... CLAMP 8 3 AIR RELIEF 8 4 AIR PURGE 8 5 CHECKING DEVICE FOR CLAMP UNCLAMP 8 6 SOLENOID VALVE FOR CLAMP UNCLAMP 9 MOUNTING OF WORKPIECE 25 10 MAINTENANCE WORK 26 10 1 CORRECTIVE ACTION IN CASE OF FAILURE AND DISASSEMBLY 10 2 BEFORE PERFORMING MAINTENANCE WORK 11 BACKLASH ADJUSTMENT OF WORM GEARS 27 11 1 BACKLASH MEASURING METHOD OF WORM GEAR OF ROTATING AXIS 11 2 BACKLASH MEASURING METHOD OF WORM G...

Page 6: ...REMOVE CONNECTOR 17 2 TO MOUNT CONNECTOR 18 TROUBLESHOOTING 42 19 PARTS LIST 45 20 STORAGE 52 21 DISPOSAL OF NC ROTARY TABLE 52 22 REFERENCE DATA 53 22 1 CONVERSION OF ARC LENGTH AND ANGLE 22 2 COORDINATE CALCULATION OF TABLE CENTER FOR TILTING ANGLE 22 3 WORKPIECE INTERFERENCE AREA 23 PIPING DIAGRAM ON AIR HYDRAULIC SYSTEM 55 23 1 OUTSIDE VIEW OF CONNECTION PIPING SYSTEM 23 2 PNEUMATIC HYDRAULIC ...

Page 7: ...ssume responsibility for damage or accidents caused by misuse of the NC Rotary indexing tables through non compliance with the safety instructions Turn off the main power of the machine prior to maintenance check or repair of the unit Failure to do so may cause severe injury and or accident ON OFF OFF DANGER ...

Page 8: ...ghtening torque of the bolts Hex Bolt Size Torque N m M10 33 8 M12 58 9 M16 146 3 M20 294 3 Do not touch rotating object during operation Fingers or hand may be caught into gap Make sure the working area is clear of any foreign object and or hand when the unit is in operation to avoid any serious accident and or injury WARNING ...

Page 9: ...t The NC rotary table may malfunction Do not apply cutting force which exceeds the specification in this manual Failure to do so may cause severe injury and or damage to the unit Please consult your local distributor before attempting any modification of the unit NO WARNING Piping block ...

Page 10: ...he unit and any part of the machine Avoid bending the external cables and air tube of the unit Use a support steady rest or tailstock for heavy or long workpieces to prevent any injury and or accident Workpiece Steady Rest Tailstock WARNING ...

Page 11: ...mount the workpiece to or from the unit while the unit is clamped to avoid damage to the internal mechanism and diminished indexing accuracy of the unit When transporting the unit make sure to use eye bolts and a sufficient leash or wire Leash or Wire Eye bolt NO Pneumatic pressure Hydraulic pressure CAUTION ...

Page 12: ...n catcher The air supply port is on the motor case Apply air purge inside the motor case and be sure to provide dry air Periodically drain the water in air filter It is recommended to use the auto drain type OUT IN Air filter Drain Mist separator Regulator Drain catcher CAUTION ...

Page 13: ...face for motor case with liquid packing Because coolant is entered NC rotary table may be damaged Attach each O ring to motor case mounting face etc as shown in the following figure No damages on O rings Because coolant is entered NC rotary table may be damaged O ring O ring ...

Page 14: ...Cable Silencer Air hyd pressure unit Pneumatic supply port for air purge used by air hyd or oil hyd spec Cover Hyd oil supply port for air hyd unit Oil gauge for air hyd Lub oil supply port for tilting axis Oil gauge for tilting axis base Lub oil drain port for tilting axis Oil gauge for rotating axis Lub oil drain port for rotating axis Lub oil supply port for rotating axis Connector plate Cable ...

Page 15: ... axis min 1 33 3 Tilting axis min 1 16 6 13 Angle of tilting degree 35 110 14 Mass of Rotary Table kg About 170 15 Operating temperature range C 5 40 16 Operating humidity range 30 95 17 Operating altitude range above sea level m 1000 or lower 18 Storage temperature range C 10 60 19 Environmental pollution degree Degree 3 20 Noise level dB 79 The noise level is measured at a distance of 1m from th...

Page 16: ...ble value There is any case that the tailstock is required by the mass of workpiece shape cutting conditions etc For the conditions for using the table refer to the above specification columns and caution items Set each cutting condition so as not to exceed the allowance value CAUTION CAUTION CAUTION ...

Page 17: ...ble top face and mounting reference face tilting axis direction Total length 0 020 5 Parallelism of table top face and guide block center line Tilting angle 90 Total length 0 020 6 Parallelism of tilting axis center line and mounting reference face Total length 0 020 7 Indexing accuracy Rotating axis Cumulative 20 sec Tilting axis Cumulative 60 sec 8 Repeatability Cumulative 4 sec 1 2 3 4 5 6 7 8 ...

Page 18: ... unit against one side of the T slot to eliminate the gap 4 Securely fix the NC rotary table to the machine tool with the attached clamper Do not enter a part of your body under the NC rotary table during transportation Unexpected accidents such as a disengagement of lifting devices may cause the NC rotary table to drop on your body When mounting the NC rotary table to the machine tool check the m...

Page 19: ...rotary table is installed on the machine again unexpected accidents may occur If electric cables and working fluid piping cannot be disconnected secure them to the NC rotary table Flush the working fluid piping sufficiently before connecting it to the NC rotary table If foreign matter enters the piping route the product capability may not be exhibited Be sure to use the NC rotary table body in a h...

Page 20: ...ter position of oil gauge The shortage of oil leads to the insufficient performance of table Use the lubricating oil recommended in the table on the item 5 5 Use the hydraulic oil recommended in the table on the item 5 6 5 3 Required lubrication oil volume Unit liter Type TT200 Tilting axis 0 45 Gear box 0 15 Rotating axis 0 55 Filled with Daphne Multiway 32MT IDEMITSU before shipping 5 4 Required...

Page 21: ...idental drinking Consult a doctor immediately without vomiting forcibly If you are polluted in your mouth wash with water thoroughly For lubrication oils and hydraulic oils other than specified ones and antirust oils prepared by the customer refer to the safety information prepared for respective oils 5 7 3 Flammable characteristics Watch out for fire since lubricating oil and hydraulic oil are fl...

Page 22: ...unusual vibration and noise do not occur Body motor 7 Check unusual heating Body gear box motor Periodical inspection Inspect the following items every 6 month 1 Check the dirt degree of lubrication oil 2 Check the dirt degree of hydraulic oil 3 Check connectors are well mounted and cables are not damaged 4 Check wiring cables in the motor case do not corrode or are disconnected 7 Use of NC Rotary...

Page 23: ...rm wheel also will be damaged Clamped status is not canceled completely when residual pressure remains while unclamping Thus the table operation may continue under half clamped condition Since the above mentioned case leads to the seizing of worm gear and clamped part take extreme care of back pressure In case of especially hydraulic clamp design the circuit so that back pressure is less than 0 2 ...

Page 24: ... supply port is provided on the motor case See the external view attached for details Connection port is Rc1 4 3 Use this unit in the air pressure range of 0 45 to 0 6 MPa 4 If the air remains in the table clamp device the specified clamp torque cannot be attained Thus perform the air bleeding work Refer to section 8 3 8 2 2 Hydraulic clamp specifications 1 Connect the pipe exclusive for hydraulic...

Page 25: ...ecifications Do not change the mounting direction of the piping block When the piping block is removed hydraulic oil mixes with lubrication oil Moreover when the hydraulic oil is reduced a brake alarm occurs Piping block Fig 2 ...

Page 26: ... bubbles air contained in the oil After leaking the oil for a while once tighten the screw of with the table clamped 2 Repeat the clamp unclamp operations in this state At this time bubbles come out on the oil tank side The hydraulic oil is filled in the primary side piping line and air is discharged by repeating the clamp unclamp operations Check that bubbles on the tank side are eliminated by th...

Page 27: ...with rags to prevent the plug from flying out and the hydraulic oil from spilling out Be careful that a steel ball jumps out when the plug is removed 2 Once some air has been removed leave it in clamp unclamp for five seconds or longer and then remove the air again until there is none left 3 When you loosen the air relief plug leave it in clamp mode until the plug is tightened again If you switch ...

Page 28: ...n lightly the air relief plug with a hexagonal wrench key and with the plug covered with rags loosen the plug a little to bleed the air 3 When bubbles air mixed with oil does not run over the air relief plug tighten the air relief plug under a clamp state 4 Then bleed the air by means of air relief plug by the same procedure 5 Repeat the procedure until no bubbles are found in the leaking oil even...

Page 29: ...form the air relief work on both the rotating axis and tilting axis 5 After finishing the air relief cleanly wipe oil spilled around the unit with a waste cloth 6 Take care so as not reduce pressure during clamp 8 3 4 Maintenance inspection 1 Air may mix in oil during operation because the piping joint each plug etc are loosened At this time bleed the air according to the procedures of the above 2...

Page 30: ...closed condensed drops are not exhausted and pressure is kept in the motor cover as is thus causing in motor case damaging and motor malfunction Therefore never close the air purge exhaust port When exhausting air although any exhaust sound occurs there is no problem Hydraulic pressure system Since an exclusive supply port for air purge is provided be sure to supply clean air as well as the type o...

Page 31: ... the solenoid valve is not incorporated When the solenoid valve is mounted outside of NC rotary table route cable at the above specification 9 Mounting of Workpiece Mount the workpiece securely to increase accuracy If the workpiece is not mounted securely accuracy becomes not only worse but also the machine and tools are damaged Therefore take extreme care because it also causes an accident result...

Page 32: ...usting valve of air combination that supplies the air to the NC rotary table to 0 MPa or shut off the power of the air compressor to exhaust the compressed air so as to stop the supply of the working fluid Perform the maintenance work with the workpiece removed Performing the work with the workpiece left on the table may cause the workpiece to be dropped out resulting in injuries Appropriate value...

Page 33: ... Adequate Backlash TT200 Circular arc length at peripheral table position μm Converted angle sec Rotating axis 14 42 29 86 Tilting axis 8 17 14 29 When adjusting the backlash measure the current backlash by the following method After that adjust it This adjustment affect the indexing accuracy and worm wheel durability thus it is strongly recommended that a skilled technician should do the adjustme...

Page 34: ...screwed in tap holes on the table back face with worm wheel gear tooth attached At this time for the torque added to the tilting body refer to the list created later Next rotate the tilting body under the same condition in the reverse direction to read the value of dial gauge This difference of measured values is the backlash See Fig 7 T F L T Torque N m F Effort force N L Distance from table cent...

Page 35: ...mm drill hole the backlash becomes small 6 After adjusting the backlash fix the bearing case and tighten the lock nut securely Then measure the backlash again and check that it is proper 7 After checking that the backlash is proper mount the cover again to the original position with hexagon socket head cap screws and washer Each interval between the hole and the hole of periphery of bearing case i...

Page 36: ...gon socket head cap screws to the same amount the bearing case advances and the backlash becomes small The rotating angle of adjusting screw to reduce the backlash to 0 01mm is as follows Type TT200 Return angle About 90 When adjustment is finished mount the workpiece jig etc by the reverse procedures as the above and tighten bolts securely After mounting measure the backlash again on the peripher...

Page 37: ...ts which fix the motor 4 Move the motor in the arrow direction so that the backlash becomes zero 0 approximately 5 Move the motor by pushing it up in the opposite direction of step 4 so that the backlash of the gear falls within the adequate range 0 02 mm 0 04 mm At this time check the motor movement with the dial gauge attached to the motor side 6 Tighten four mounting bolts that loosened slightl...

Page 38: ... operate it to lower the motor position until the backlash becomes zero 0 approximately 4 Insert a rod approximately φ5 a bar wrench may also be used in the hole located below the motor and operate it to move the motor until the backlash falls within the adequate range 0 02 mm 0 04 mm At this time check the motor movement with the dial gauge attached to the motor side 5 Tighten four mounting bolts...

Page 39: ...tery on the machine side or controller runs down When the servo motor encoder or encoder cable is replaced or repaired 13 1 Dog type zero point return device OPTION OPTION The contents of this section is applicable to the NC rotary table with the dog type zero point return specification 13 1 1 Rotating axis ZRN Zero Return device See Fig 12 1 The dog for ZRN deceleration is mounted inside of table...

Page 40: ...off use the proximity switch as a target when the dog position is adjusted 13 1 2 Tilting axis ZRN device See Fig 12 2 1 The ZRN deceleration dog and the proximity switch are contained into the rotating axis motor case 2 In the standard specification the horizontal table face position is regarded as an origin The proximity switch detects dog Set screw Cover Dog Cover Proximity switch 0 75mm Fig 12...

Page 41: ...an the limited angle 14 2 Adjusting methods of dog for vertical over travel 1 When the customer will change position of dog A according to the shape of workpiece and jig loosen hexagon socket head cap screw which fix the dog A Once remove the dog A 2 Rotate the tilting axis to the tilting angle to be set in the minus direction with the manual pulse generator or the Manual axis feed key checking th...

Page 42: ...e the dog B in the reverse direction counterclockwise CCW before fixing until the over travel alarm lamp lights Tighten hexagon socket head cap screw that loosened slightly 5 After fixing the dog B rotate the tilting axis again with the manual pulse generator or the Manual axis feed key and check that the tilting axis stops at the desired tilting angle position and alarm lamp lights 6 After adjust...

Page 43: ...slowly with the motor case raised Connect the air hose correctly and take care so as not to bend it 15 2 Countermeasures for waterproof To prevent the motor from coolant penetration O rings are used to the mounting faces on the motor case and the connector plate and also liquid packing 1216 made by THREE BOND are used on connection parts among the motor case and covers When reassembling the motor ...

Page 44: ...ves 2 Mount the O ring and mount the motor by the reverse procedure as the above removing 3 After mounting the motor adjust the backlash of spur gears according to item 12 Mount the motor to the spur gear carefully after cleaning so that the spur gears are not damaged When mounting the motor take extreme care so that O ring is not damaged because lubrication oil may enter into the motor case Conne...

Page 45: ...ring and mount the motor by the reverse procedure as the above removing 3 After mounting the motor adjust the backlash of spur gears according to item 12 Mount the motor to the spur gear carefully after cleaning so that the spur gears are not damaged When mounting the motor take extreme care so that O ring is not damaged because lubrication oil may enter into the motor case Connect the connector a...

Page 46: ...licon system or molybdenum system or oil and grease including an extreme pressure additive agent 2 Insert the washer locking element spacer and spur gear in order 3 At this time attach the locking element Generic name for inner ring and outer ring so as to pressurize the inner ring 4 Tighten bolts on each diagonal line equally in order so that the end face of spur gear and the flange end face of m...

Page 47: ...r 1 Mate the plug housing to the receptacle housing as shown in the following figure 2 Insert the receptacle housing into the plug housing securely until a clicking noise occurs 3 After mounting pull the receptacle housing slightly and check that it does not draw out Check that connectors and cables are not damaged before connecting Connect cables so as not to be bent or crushed Do not apply any l...

Page 48: ... rotary joint make the load torque larger than the motor torque Compare the specification of NC rotary table with the work condition to make improvement Use of unit out of specified temperature range Adjust ambient temperature within specified temperature range Symptom Table does not rotate but generates a noise Possible causes Corrective actions Motor makes a howling sound to try to rotate Seizur...

Page 49: ...djustment Readjust Fault due to damaged NC rotary table or expired life of components Stop the use of NC rotary table immediately Please contact the sales agent Fault occurs only during continuous cutting Lack or deterioration of lubricating oil blocks smooth rotation Check oil level viscosity and date of last change of lubricating oil Adjust backlash amount to appropriate value Inappropriate back...

Page 50: ...ero point and zero point shift amount Faulty zero point dog position adjustment Adjust the zero point dog Faulty zero return deceleration signal device Check the zero return deceleration signal device and replace the proximity switch Faulty clamp operation See Symptom Inappropriate backlash amount Adjust the backlash Inappropriate backlash compensation amount Change the backlash compensation amoun...

Page 51: ...ing G80 1 07 Hexagon socket head cap screw Special low head SSH M5 10 4 08 Hexagon socket headless set screw Flat Point M8x8 4 09 Steel ball 6 3 4 10 Cover 2 1 11 O Ring S90 1 12 Machine screw M5x25 2 13 Machine screw M5x8 6 14 Seal washer 5S1 5 15 Hexagon socket head cap screw M6x30 4 16 Hexagon socket headless set screw Flat Point M8x20 4 17 Cover 3 1 18 O Ring G40 1 19 Plug MPG14 1 Pisco 20 Hex...

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Page 53: ... 2 1 40 Cover 3 1 41 Connector plate 1 1 42 O Ring S112 1 43 Machine screw M5x14 8 44 Cable connector 1 1 45 Hexagon socket head cap screw M4x8 8 46 Washer 4 8 47 Connector plate 2 1 48 O Ring S130 1 49 Cable connector 2 1 50 Bulkhead connector KQ2E06 02 1 SMC Booster 51 Bulkhead connector KQ2E06 03 2 SMC Booster KQ2E06 01 1 SMC Hydraulic 52 Seal washer 14S1 3 Booster 1 Hydraulic 53 Hexagon socket...

Page 54: ...48 When the specification is 4th and 5th axises the motor case and the cable are different from the above figure For detailed models refer to attached outside view ...

Page 55: ... 64 Pressure switch for clamp detection 176 112 200 2 SKF 65 Pressure switch for unclamp detection 176 120 400 2 SKF 66 Cover 1 67 Machine screw M5x8 8 68 O Ring G85 1 When the specification is different the model and the installation position of the solenoid valve and the pressure switch are different from the above figure For detailed models refer to attached wiring diagram ...

Page 56: ...K NAME TT200 Q ty Recital 81 Proximity switch FL7M 3K6H 2 Azbil 82 Holder for Proximity switch 1 83 Seal washer DT 1 12 1 Mitsubishi Cable 84 O Ring P16 1 85 Machine screw M6x8 1 86 Washer 6 1 No proximity switch is provided for the M signal type ...

Page 57: ...3 92 Clamp 4 93 Hexagon head bolt M16x65 4 Strength Dimension 8 8 94 Washer 16 4 95 T slot nut 1816 4 When the specification is different the clamping parts and guide block are different from the above figure For detailed models refer to attached outside view ...

Page 58: ...nd case or lap it with the wooden cover or vinyl cover etc When using the wooden base and box avoid the wooden base and the green wood Since the green wood is not chemically neutral use the wood moistened with paraffin 21 Disposal of NC Rotary Table Dispose of this unit in accordance with the laws and regulations of your country You may suffer punishment if you disposed of this unit without follow...

Page 59: ...he table circumference mm 1 60 60 360 D L 2 10 125 4 60 60 360 5 D L D L 3 10 424 2 60 60 360 6 D D L Examples Assuming the diameter of the workpiece is 100mm and by using formula 3 the cumulative indexing accuracy of 20 seconds as linear length at table circumference will be mm L 004848 0 10 100 20 424 2 6 Therefore the length is approximately 0 0048mm And converting the cumulative pitch error of...

Page 60: ... 0 X 70sinθ Z 70cosθ 70 22 3 Workpiece interference area Since the following shows standard specifications take care in case of special specifications Interference with the clamp device is not considered Tilting range may be reduced due to fit the Jig or Chuck onto Face plate Refer to the back of the Instruction Manual drawing and the outside view Set a soft limit by the parameter to prevent inter...

Page 61: ...6 Unions Y φ6 Straight φ6 IN 457 170 Solenoid valve Upper for tilting Solenoid valve Lower for rotating Silencer for tilting Silencer for Rotating Soft nylon tube φ6 Piping Diagram Excitation Clamp Spec Piping Diagram Excitation Unclamp Spec Solenoid valve Upper for tilting Solenoid valve Lower for rotating Silencer for tilting Silencer for Rotating Silencer for rotating Pneumatic supply port Conn...

Page 62: ...Excitation Clamp Spec Unclamp CHECK 0 40MPa Booster Solenoid valve Oil pot Booster Solenoid valve Table CLAMP Clamp CHECK 2 20MPa Unclamp CHECK 0 40MPa Oil pot Booster Solenoid valve Fixed throttle for air purge Inside of rotary table is shown in frame dotted line Customer shall arrange Silencer Air combination Air filter Mist separator Regulator Drain catcher ...

Page 63: ... CLAMP Clamp CHECK 2 20MPa Unclamp CHECK 0 40MPa Fixed throttle for air purge Fixed throttle for air purge Table CLAMP Clamp CHECK 2 20MPa Unclamp CHECK 0 40MPa Inside of rotary table is shown in frame dotted line Solenoid valve Solenoid valve Solenoid valve Air combination Air filter Mist separator Regulator Drain catcher Excitation Unclamp Spec Excitation Clamp Spec Solenoid valve Customer shall...

Page 64: ...58 25 Outside view of Air Hydraulic Part SKY packing 16 Gear box Base To cylinder Oil pan Oil route 4 in total Pneumatic Specifications Penta seal PS16 O ring G40 ...

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