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Alpha-cadman cnc Maintenance Manualeggnuts.weebly.com/uploads/2/1/3/3/21336138/maintenance_manual0… · Control system: Type Cadman cnc ... Maintenance manual punch press Alpha.

Jul 28, 2018

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  • Alpha-cadman cnc

    Maintenance Manual

    Last update 300804 Fdjo

    E-020315/02

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    Contents

    1 MACHINE TYPE: TECHNICAL SPECIFICATIONS ........................................................................................................ 3

    2 FIRST INSTALLATION OF THE MACHINE..................................................................................................................... 4

    3 MAINTENANCE SCHEDULE ............................................................................................................................................... 7

    3.1 DAILY MAINTENANCE .......................................................................................................................................................... 7 3.2 WEEKLY MAINTENANCE....................................................................................................................................................... 8 3.3 MONTHLY MAINTENANCE .................................................................................................................................................. 10 3.4 ANNUALY MAINTENANCE................................................................................................................................................... 11

    4 PUNCHING TECHNOLOGY: RECOMMENDED CLEARANCE BETWEEN PUNCH AND DIE............................ 12

    5 SECURITY .............................................................................................................................................................................. 13

    5.1 GENERAL ........................................................................................................................................................................... 13 5.2 FORESEEN USE OF THE MACHINE / WORKSTATIONS LIKELY TO BE USED BY OPERATORS ..................................................... 14 5.3 IDENTIFICATION AND CE-MARK......................................................................................................................................... 14

    6 APPENDIX A: NOISE LEVEL AND MEASUREMENT................................................................................................... 15

    7 APPENDIX B: LIST LUBRICANTS FOR HYDRAULIC GROUPS AND LUBRICATION .................................... 16

    Copyright 2004, LVD COMPANY NV. BELGIUM All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher. The information contained in this manual is subject to change without notice. This manual is property of LVD, no reproduction or access to third party is allowed without written permission.

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    1 Machine type: technical specifications

    Punch Press: Alpha Technical specifications: Machine type: Alpha cadman cnc.

    Type Hydraulics: H&L ECO 30 Control system: Type Cadman cnc

    Punching force: kN 300

    Sheet dimension max, X mm 2000 with repositionning

    Sheet dimension max, Y mm 1000

    Positionning speed, axis X m/min 15

    Positionning speed, axis Y m/min 15

    Positionning accuracy mm tolerance: +/- 0,1

    Repetition accuracy mm tolerance: +/- 0,05

    Repositionning system Yes

    Max, sheet thickness mm 8

    Hitrate: number of hits per min. n/min Tolerance +/- 5 %

    H&L: ECO 30 Tool B: Nibbling: X = 1 mm, Y = 0 mm 400 / min. Punching: X = 25 mm, Y = 0 mm 230 / min

    Toolholder type.

    Indexable tool, D station, Amada style.

    Indexable multitool, Amada style.

    Manual clamps Number: 2

    Main Motor kW 7,5

    Weight of the machine kg 8250

    General layout, Foundation drawing and general specifications, see drawing SA01000099.

    No special foundation required. See layout for air pressure connection and air consumption.

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    2 First installation of the machine

    This is the procedure for the first installation of the machine, which will be done by an LVD service engineer.

    1. Operator and maintenance manual are delivered with the machine.

    2. Take off the wooden support parts (used for transport) from the feet of the machine.

    3. Install the 3 dampers under the feet. Do the correct levelling of the machine.

    4. As the tables and X-Y beam, remains assembled on the machine, there is no mechanical assembly required. The maximum overall dimension left to right, with assembled tables = 2200 mm.

    5. Install the oil tank on the correct location

    6. Fill the oiltank, 150 liter. See oil list: LVD code H20W, appendix B.

    7. Connect air pressure circuit. Adjust pressure regulator on 5,5 bar.

    8. Open the electrical cabinets and check the voltages. Only LVD service engineers are allowed to perform this operation. Also check the accuracy of the 24V in the pedestal (max tolerance allowed = 10%)

    9. Start the hydraulic pump and check the direction of rotation.

    10. Make the reference of all axis, with feedrate on minimum value.

    11. Test the clampscan.

    12. Check the hydraulic system, by pushing the manual punch button. 13. Make a first test program, Nr9921 and run it without a sheet.

    14. Install die and punch and run the test program with a sheet.

    15. Check the squareness of the X-axis in relation to the Y-axis. Use the special program made for this test. Program Nr 9901.

    a) Insert a 20x20mm punch and die with appropriate clearance (0,2mm) in the turret and load a sheet (1000x1000x1mm) correctly.

    b) Punch a row of holes at X = 470mm with an increment of dY = 100mm like shown on next drawing (holes 1 to x).

    c) Flip the sheet over and put it back in the clamps again. Let the program run once more, so you punch holes (n-4 to n).

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    d) Measure the distances between holes 1 and (n-4); 2 and (n-3); 3 and (n-2); etc If the X and Y axis are square, all those distances should be equal (maximum allowed deviation between largest distance and smallest distance = 0,1mm). In fact, with this method, you measure a double fault.

    e) As the tables and the beam have not been disassembled for transport, this test will be within the tolerances. We recommand to do this test. Something could happen during transport and unloading of the machine.

    f) Redoing this test on a regular time schedule, for accuracy test for example, it may happen, after using the machine ( crashes for example ) that the geometry of the machine has suffered. If for some reasons the squareness is not correct anymore you will have most probably one of following cases:

    Case A Case B

    In case B, the right side of the beam must move backwards, in case A the right side of the beam must move forwards.

    g) Put 2 dial indicators on the machine: one on the left side and one on the right side, so that youre able to measure the correction that you will enforce. The position of those dial indicators is important. Try to locate them so they are positioned symmetrically from the center of the punch press.

    h) Loosen the necessary bolts refering the fixture of the X beam, unless 1, which remains slightly tightened (number of bolts to loosen = 6 -1 = 5).

    i) With a wooden block, correct the position of the X beam and tighten all bolts.

    j) Redo the punch test and check whether the deviation is within tolerance.

    16. Install all covers on the machine, in case some covers have been disassembled.

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    17. Check the position, ( X position ) of the datum pin. Program 9914.

    a) Punch a 10 mm square hole.

    X = 40 mm.

    b) Check the dimensions X = 40. The maximum error = 0,1 mm.

    c) Correction of X dimension. Cadman cnc. Service mode. Parameter new plate. Correction of X dimension. Save the new X dimension. Activate. Restart.

    d) Redo the test again.

    X

    C1

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    3 Maintenance schedule

    3.1 Daily maintenance 1. Lubricate tools (engine oil : SAE80 or according to LVD Code: H40, see appendix B)

    2. Empty slug bin ( photo )

    3. Clean side tables

    4. Clean the die area and remove punching scrap. Remove all superfluous grease on lineair bearings and ball screws.

    ATTENTION: Never use compressed air to clean the die area.

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    3.2 Weekly maintenance 1. Take out the tools, punch and dies.

    2. Disassemble the tools completely. Clean and oil all tools. Regrind if necessary and check the OAL lengths.

    3. Disassemble, clean and oil/grease the toolholders (recommended: Strippit S-2000 grease).

    4. Grease the toollifters (recommended: Strippit S-2000 Grease).

    5. Clean the die area (use engine oil - see LVD oil list in appendix B, LVD-code : H40).

    6. Lubrication of the spring supported punch guide bushes (see LVD oil list in appendix B, LVD code: H40).

    7. Air filter-pressure regulator unit (photo)

    Check the air pressure, 5,5 bar.

    8. Clean the machine generally.

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    9. Weekly Greasing schedule. Handpump, once a week. Linear guides and ball screws.(See appendix B, Standard LVD oil and grease list. LVD-code: V2). Pump 3 times, once a week. Use the hand pump with the steel grease pipe. See pictures below. Linear guide X axis. 2 grease nipples. Linear guide Y axis. 2*2, grease nipples Clamps to be away from greasing holes.

    Y ball screw. 1 grease nipple. X ball screw, 1 grease nipple. Ball screw nut to be positionned in front of hole in the cover.

    Greasing of the indexes. Greasing with grease handpump. Pump 3 times, once a week.

    Upper index. 1 Grease nipple. Lower index. 1 grease nipple.

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    3.3 Monthly maintenance

    1. Hydraulic oil tank level.

    The oil level is electrically controlled, see also level indication on oil tank. The tank should be filled up if the level is below minimum level. Use hydraulic oil (See appendix B, Standard LVD oil and grease list. LVD-code: H20W).

    2. Hydraulic oil filter

    Observe the indicator on top of the oil filter. If the needle is in the red area, the filter element should be replaced.

    3. Datumpin assembly

    Lubricate with light machine oil (See appendix B, Standard LVD oil and grease list. LVD code: H20).

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    3.4 Annualy maintenance

    1. Hydraulic circuit.

    Dirt and dust do not go together with hydraulics. Therefore, be very careful in all working conditions and take the necessary precautions.

    2. Because of the little oil volume, we strongly recommand to change the oil once a year. Keeping the machine running with the oil in excellent condition will increase lifetime of cylinder seals and will be of benefit for maintenance for the hydraulic equipment.

    See appendix B, Standard LVD oil and grease list. LVD-code: H20W.

    In case you decided NOT to change the oil every year, please have the oil checked on all specifications.

    3. Replace the hydraulic pressure filter once a year. See chapter 3.3 item 2

    4. Never let the pump run without oil or in the opposite direction. 5. Take off the covers from the X axis and clean the complete X axis. Look for any damage at the

    cable guides and the mechanical drive for the axis. Grease the spindle.

    6. Clean the complete Y axis. Look for any damage at the cable guides and the mechanical drive for the axis. Grease the spindle.

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    4 Punching technology: Recommended clearance between punch and die

    Punch and die clearance is a function of the sheet thickness and material.

    Total clearance = Factor in % x Material thickness.

    Material Minimum Best Maximum

    Copper (1/2 hard) 8 12 16

    Brass (1/2 hard) 6 11 16

    Mild steel 400 N/mm 10 15 20

    Mild steel 500 N/mm 12 18 24

    Aluminum (Soft) 5 10 15

    Stainless steel 12 18 24

    1. Calculation: punch and die clearance

    Example: Sheet thickness 2 mm, steel 500 N/mm2. Punch diameter 40 mm. Die diameter = 40 + ( 0,18 x 2 ) = 40,36 mm.

    2. When using a die with incorrect clearance to punch thicker materials, the stress caused on the punch tip will cause the cutting face to chip and break down much earlier than usual.

    3. Slug pulling can be caused by too small or too large die clearance. If the clearance is too small, a vacuum is created between the punch cutting face and the material causing the slug to pull out of the die as the punch is retracted. If the die clearance is too large, the slug wraps itself around the punch tip, resulting in the same conclusion.

    4. Note: As material thickness increases approaching 4 mm, the maximum die clearance percentage should be selected from the table rather than the best die clearance percentage.

    5. Insufficient clearance = Double Fracture. Material is squeezed between punch and die, the result is an hardened burr which is costly to remove and causes significant risk to get injured.

    6. Excessive clearance = Large Burr.

    ATTENTION: Always degauss the tools after grinding in order to eliminate the remanent magnetism due to the

    grinding, e.g. due to clamping on magnet table.

    MINIMUM CLEARANCE:

    Index stations: 0,2 mm

    Fixed stations: 0,15 mm

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    5 Security

    5.1 General

    The punch press is designed according to the latest security regulations.

    The user of the machine has to take care of the security regulations and the manufacturer will not take any responsibility when modifications have been made at mechanical, electrical or hydraulic components and/or security equipment, so that the machine becomes unsafe.

    Maintenance and adjustments have to be done by well trained people, having correct knowledge of the machine.

    To garantee the safety of the operator, the people around the machine and also the punch press, following instructions have to be complied:

    1. To garantee the optimal working of the punch press, the recommendations on layout and fundation drawing and the instructions in the operator and maintenance manual have to be followed.

    2. The environment where the machine is placed, has to be organized, that optimal working conditions can be garanteed (passage ways, lightening, installation of pipes and tubes).

    3. The electrical connection has to be made according to the regulations.

    4. Never let the motorpump run when the machine is not used.

    5. New operators on the punch press must be fully trained. This training includes the proper working of the machine and the specific risks for this machine.

    6. The front door must be closed during working of the punch press. It is never allowed to take off this protection door. Protections on the hydraulic group, are not allowed to be taken off during operation with the punch press.

    7. During maintenance, we strongly recommand to lock the main switch and to show danger - do not switch on ! on it.

    8. The hydraulic safety valve must be adjusted according to the information on the hydraulic drawing.

    9. Malfunction of the machine has to be reported immediately. Repairing or maintenance can only be done under full safety conditions.

    10. It is always forbidden to repair and to do maintenance while the machine is in operation.

    11. Unloading parts or sheets, is always done with the machine in rest position.

    12. Safety devices that are protecting the working zone, may not be removed while the machine is under operation (for ex. lightguards, fences, ...).

    13. Never overload the punch press.

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    5.2 Foreseen use of the machine / workstations likely to be used by operators

    The punch press is used to punch holes, to create forms and to cut into material.

    The sheet is taken by 2 clamps, which are clamping the sheet pneumatically

    Operating the machine happens via the Cadman cnc control system, which is placed outside the zone protected by the light guards.

    One operator is sufficent to control the machine. This operator has to be outside the security zone during operation.

    5.3 Identification and CE-mark

    Machine: Punch Press

    Type:

    Serial number:

    Please, always mention the serial number of the machine in your correspondence, when you order spare parts or when you need information. Type of inspection: CE

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    6 Appendix A: Noise level and measurement Equivalent continuous A-weighted sound pressure level Leq at workstations (measured at a distance of 1 meter from the surface of the machinery and at a height of 1,60 metres from the floor). Measurement-method and measured values are accordingly following standards: EN ISO 9614-1 EN ISO 3747 Measurement-tool: Brul en Kjaer Sound Level Meter Type 2237 Conform with following standards: IEC651 (1979) and 804 (1985) Type 2; ANSI S1.4 1983 and Draft S1.43, 6th September, 1992 Type 2; BS5969 and BS6698 Type 2

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    7 Appendix B: list lubricants for hydraulic groups and lubrication

    LVD- Code

    H10 H20W H20S H20 H30 H40 H50 V1 V2 - V3

    Merk(*) Type

    VG32 VG46 VG46 VG68 VG100 VG150 VG320 V1 V2-V3

    BP ENERGOL HLP 32

    ENERGOL HLP 46

    BARTRAN HV 46

    ENERGOL HLP 68

    ENERGOL HLP 100

    ENERGOL GR-XP 150

    ENERGOL GR-XP 320

    ENERGOL GR 3000-2

    ENERGREASE LS EP2

    CASTROL HYSPIN AWS 32

    HYSPIN AWS 46

    HYSPIN AWH 46

    HYSPIN AWS 68

    HYSPIN AWS 100

    ALPHA SP150

    ALPHA SP320

    GRIPPA 60 S

    SPHEEROL EPL 2

    ELF ELFOLNA DS 32

    ELFOLNA DS 46

    HYDRELF DS 46

    ELFOLNA DS 68

    ELFOLNA DS 100

    REDUCTELF SP 150

    REDUCTELF SP 320

    CARDREXA DC 1

    EPEXELF 2

    ENGEN TOH 20/32

    TOH 20/46

    GENMARINE HV 46

    TOH 20/68

    TOH 20/100

    GENGEAR 150

    GENGEAR 320

    GENSTIC M GENLITE EP22

    ESSO NUTO H 32

    NUTO H 46

    UNIVIS HP 46

    NUTO H 68

    NUTO H 100

    SPARTAN EP 150

    SPARTAN EP 320

    SURETT FLUID 4k

    UNIREX N2

    FINA HYDRAN LZ 32

    HYDRAN LZ 46

    HYDRAN HV 46

    HYDRAN LZ 68

    HYDRAN LZ 100

    GIRAN L 150

    GIRAN L 320

    CABLINE 2750 FLUID

    MARSON EPL 2

    MOBIL DTE 24 DTE 25 DTE 15M DTE 26 DTE 27 MOBILGEAR 629

    MOBILGEAR 632

    MOBILTAC D MOBILUX EP 2

    MOLUB ALLOY

    TRIBOL 771

    TRIBOL 772

    TRIBOL 943 AW-46

    TRIBOL 773

    TRIBOL 775

    TRIBOL 1100 ISO 150

    TRIBOL 1100 ISO 320

    882 HEAVY

    TRIBOL ET 4020

    O8 HAYDN 32 HAYDN 46 HANDEL 46 HAYDN 68 HAYDN 100 GOYA 150 GOYA 320 GIOTTO FLUID 3

    REMBRANDT EP2

    SHELL TELLUS OIL S 32

    TELLUS OIL 46

    TELLUS OIL T 46

    TELLUS OIL 68

    TELLUS OIL 100

    OMALA OIL 150

    OMALA OIL 320

    MALLEUS FLUID C

    ALVANIA GREASE EP 2

    TEXACO RANDO OIL HD 32

    RANDO OIL HD 46

    RANDO OIL HDZ 46

    RANDO OIL HD 68

    RANDO OIL HD 100

    MEROPA 150

    MEROPA 320

    CRATER 2x FLUID

    MULTIFAK EP 2

    TOTAL AZOLLA ZS 32

    AZOLLA ZS 46

    EQUIVIS ZS 46

    AZOLLA ZS 68

    AZOLLA ZS 100

    CARTER EP 150

    CARTER EP 320

    ENS/EP 700 MULTIS EP 2

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