SURFACE FX SPM1 MANUAL

SURFACE FX INC. 139 RYERSON RD. LINCOLN PARK, N.J. 07035 201-522-9038

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SURFACE FX SPM-1 /SPM-1C

POLISHING MACHINE MANUAL


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Table of contents

Introduction 3

Capacity 4

Slurry 4

Loading & Unloading 4

Programmable control features 5

Safety 5

External Supply Requirements 7

Installation 8

Operation 8

Operation II 8

Cleaning 10

Maintenance 11

Troubleshooting 15

Screen Shot descriptions 17

Parts List P

PLC Ladder Diagram 18


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Introduction

Introduction to the Surface Fx Model SPM-1/ SPM-1C Spherical Polishing Machine

The SPM1 Spherical Polishing Machine was designed specifically for the

biomedical industry to polish femoral cap heads and other spherical parts to

within a 0.1 micron finish. Although spherical truing is a by-product of the

operation, an out –of round condition will not be corrected. The basic purpose of

the machine is to bring a fine polish to the product. Operations take place on three

axes, two rotary, (supplied by variable speed controlled spindles) and one pivoting

axis.

Spindle speeds are definable from 10 revolutions per minute up to a maximum of

300 revolutions per minute. The pivot action is performed using a regulated

pneumatic cylinder with flow valves. These flow valves control the pivot speed,

and are preset from manufacture and only need adjustment during maintenance

procedures.

Overall control is performed using a Direct Logic PLC (Programmable Logic

Controller) coupled with a touchscreen interface with variable time and speed

constants to meet customers’ requirements.

The offset adjustment allows for various part offset diameters (as defined in

capacity). Offset is performed by using the offset arm located on the right hand

side of the machine with a calibration scale matched. The offset arm is connected

to the offset plates via rack and pinion for smooth and accurate positioning.

Cycle time is programmable (in minutes) from 1 minute through 13 minutes.

Elapsed time is displayed during operation and is controlled via the PLC internal

clock.


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Capacity

The capacity of the SPM-1 models for femoral caps ranges from a minimum

diameter of 12 mm to a maximum of 85mm, with an offset range of 28mm.

Slurry/ Polishing Media

Distribution of the slurry is performed using a six cartridge peristaltic pump. Slurry

drip rate is controlled in the program by way of the drip rate % input.

*Slurry removal is performed using a stainless steel hopper mounted below the

work area as a recovery tank. Slurry and water flow down into the tank and

accumulate. A two stage diaphragm pump is triggered every 5 machining cycles

by a pneumatic solenoid valve, purging to an external storage container provided

by the end user.

The slurry pump is controlled by a d.c drive unit located in the electrical enclosure.

*Optional

Part Loading & Unloading

The machine comes standard with one step push button loading and unloading.

Selection of the spindle to load or unload is performed from the touchscreen in the

load/unload menu. With the operator window open, and the part unclamp button

pressed, the part will be unclamped from the spindle selected. When the button is

released, the arbor will clamp again. The unit is designed to default to a clamped

condition in the event of a power failure, or other condition to protect the parts

mounted on the spindles.


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Programmable Control Features

The SPM-1C machine has upgrades incorporated which have been developed over

sixteen years of operations, improving uptime and lowering maintenance costs.

A touch screen is integrated into the PLC to display machine functions, and

eliminate rotary switches which are prone to failure in harsh conditions.

The result is a display which is weatherproof with all functions (status display and

inputs for speeds, time cycles, and maintenance features).

Status lights are outfitted on the machine to allow visual recognition of the

machine process status.

Safety

Safety Procedures for the SPM-1

The Surface Fx SPM-1 was created and designed using 24volt d.c. control voltages,

and a single 110volt GFCI outlet circuit for external inspection equipment (2amp

max). Interlocks are installed on all access points to protect both operators and

maintenance personnel from accidental exposure to risk. All motions are

pneumatically controlled, and will relax in a safe position should power be

interrupted, or interlock triggering.

The following guideline must be adhered to for continued safe operations:

A clean, low impedance ground must be connected to the machine and

supply ground (buss ground).

Shut the machine down, and disconnect power prior to performing

maintenance if guards will be removed, or when reaching into machine

beyond normal operation.

Do not attempt to bypass interlocks, (door interlocks, main disconnect)

which may present an unsafe operating condition.


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Safety, cont’d

Do not reach into any mechanical components such as belts pulleys etc.

while power is on.

Do not operate or maintain any component if machine power is on, or air

supply is connected.

Wear safety glasses and gloves during all operations, and maintenance

procedures to reduce chance of eye, or hand injury that may present itself.

Although this machine was designed with total safety in mind, it is the

responsibility of the purchaser to comply with safety guidelines set forth above.


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Machine External Supply Requirements

The Surface Fx SPM-1 Requires the following:

Electrical:

Voltage 208- 240 volts A/C

Amperage 20 Amps

Ground Low Impedance Building or System Buss

Pneumatic Supply:

Clean dry 60 – 100 P.S.I. @2CFM

Air supply must be run to machine to the right rear corner where the Pneumatic

regulator is located. Connection can be made via flexible hose, or hard plumbing.

The air regulator uses a ¼” NPT fitting. Customer must install a service disconnect

in line with pneumatic supply.

Rinse Water

Used at customers convenience for rinsing parts, or machine cleaning.


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Operation

Power on Sequence

Verify main air pressure supply is set to 80 psi (located rear right corner of

machine).

Turn main power switch to “ON” position (located on the electrical

enclosure cabinet on the right side of the machine) verify that the display

comes up at the login screen.

Release Emergency Stop button, and press Reset button for 2 seconds.

Verify that arbors and laps are properly selected and prepared for operation

(See Maintenance section for Arbor installation and removal).

Select the proper offset as determined for the part size and offset (The

offset arm is located on the right side of the machine and has a graduated

scale above it).

Arbor RPM and Lap RPM should be set in the program written for the

corresponding part to be polished (Setting in program mode in “Screen

Functions” section).

Load part onto Arbor (“Part Loading and Unloading”).

Verify that Cycle time, Slurry %, Spindle RPM and Lap RPM are correct for

the part to be polished (Program screen).

Prime slurry pump ( if beginning of shift) using the “Maintenance”

screen(Setting in program mode in “Screen Functions” section).


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Power on Sequence cont’d

Wet down laps for first operation to prevent friction to part and lap pad

failure.

Close Operator window

Select “Auto Mode”

Press the “Cycle Start” button on the front panel.

Verify that lap pressure regulator is set for approximately 45 PSI (regulator

is located on right side of machine).

Verify spindles are rotating, and slurry is dripping at expected rates.

Verify that pivot is moving.

When the Cycle end lamp flashes, the parts are completed.

At this point, the machine has been setup for parts run in Auto Mode. All

additional cycles of same part sizes will only require part changing and “Cycle

Start”.


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Machine Cleaning and Waste Removal

Waste is removed from the machine by a pneumatically powered

diaphragm pump,* in between cycles.

The machine stainless enclosure and interior surfaces should be gently

washed down, or wiped down at the end of shift.

NOTICE:

WHEN MACHINE IS NOT RUNNING ALL SPINDLE STATIONS, OR IS

SPRAYED WITH WATER FOR CLEANING, THE SUPPLIED YELLOW

COVERS MUST BE COVERING THE OPEN LAP SPINDLE LOCATIONS!

AT END OF SHIFT OF DURING POWER OFF, LEAVE OPERATOR

DOOR/WINDOW OPEN TO REDUCE HUMIDITY LEVELS IN MACHINE.

POLISHING ABRASIVE MAKES GOOD PARTS, BUT IS EXTREMELY BAD

FOR MECHANICAL COMPONENTS, AND MAY VOID WARRANTY

REPAIRS ON ASSOCIATED COMPONENTS IF NOT PROPERLY

FOLLOWED.

Monthly inspection of Slurry tank should be performed for buildup of

solidified Slurry, and removed if so by reducing with water, and agitating

while pumping out using the “waste button” (located on front operator

panel).


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Maintenance

Proper maintenance of the SPM-1 is as important as proper operation.

Under normal operating conditions, the machine will require inspection, and

maintenance to insure reliable operation.

o Daily Clean Arbors to prevent buildup of abrasives

o Daily Clean interior stainless enclosure

o Monthly inspection of Belts (Arbor and Lap)

o Monthly inspection of spindle pulleys for possible slurry contamination

o Monthly grease Lap spindle housings (1 pump each with grease gun)

o Monthly inspect slurry tubing at pump heads for flat spots, or clogging

o Annual inspection of gearboxes for proper lubrication level


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Maintenance cont’d

Arbor removal:

Open operator window

Select spindle arbor to be removed

Press “Part Unclamp” button on front panel and unscrew center wedge of

arbor with flat blade screwdriver

Release button

Using a wrench, unscrew arbor (standard threads, counter clockwise to

remove)

To install reverse procedure

Clamping adjustments are made by tightening or loosening the wedge

Pivot Cover Removal:

Remove power from machine at disconnect switch

Open rear doors of machine

Verify no person is near the pivot ,or in the operator area

On the slide and pivot solenoids, activate the manual override

The slide and pivot will activate to a convenient position for access

Open front hinged operator panel

Remove operator window cover (door interlock cable must be unscrewed)

Remove cap nuts and seal washers on pivot cover

Lift closest edge of cover, then slide cover towards rear of the machine

while lifting cover off

Reverse procedure to reinstall


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Removal of Lap belt:

Remove pivot cover as outlined

Loosen belt tensioner plate bolts (4)with a 3/16 Allen wrench (Tensioner is

located on lower right of the slide unit)

Remove serpentine belt (No components need to be removed to change

belt)

Inspect pulleys and spindles for free rotation

Replace belt

Tension plate against bolt head using a large screwdriver for leverage

Belt tension should be measured by ½” deflection midway between the

gearbox and tensioner

Removal of Arbor Belt:

Open rear doors

Loosen but do not remove tensioner hubs located on left and right frame

verticals

Remove belt

Reverse operation to install (tensioners will return proper tension)


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Removal of Drawbars:

Remove Arbors

Power machine off

Open rear doors

Remove ejector cylinder brackets and move away (leave tubing

attached)

Pull drawbars out

Inspect Belleville washers in drawbar cup for collapse, or over

compression (Replace if necessary)

Reverse to re install


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Troubleshooting

During machine operation, at times it will be necessary to troubleshoot

operational problems, and determine causes of malfunctions.

The SPM1 has been in service since 1999 with over 12 units Installed.

During this time, re-engineering and control upgrades have added to the

dependability of the unit.

The basic mechanical function remains the same.

Most common items for troubleshooting are listed below.

Machine will not power up: Possible Remedies:

Is the main power switch on?

Did anyone plug a device into

the outlet of the machine?

Is the interior work light on?

No response from push buttons:

Are access doors closed?

Are status lights flashing?

Is the Emergency Stop button

depressed?

R.P.M. is not displayed on display:

Has the tachometer sensor

been disturbed?

Does the display vary much?

Main disconnect fuses, Transformer

fuse (2amp), power supply.

Faulty Button, Emergency Stop

depressed

Check gap on tachometer sensors

Test by waving metal shim in front of

sensor, Replace switch.


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Troubleshooting cont’d

During operation, a jumping sound

or vibration is felt or heard:

Are Lap and Arbor Belts

adjusted and in good

condition?

Is there buildup of Slurry on

pulleys?

Is the offset correct, and Lap

pressure below 60p.s.i. ?

During operation a squeaking noise

is heard:

Are the Laps dry?

Is the offset correct?

Does it happen without Lap

pressure applied?

During operation, Laps or Arbors do

not rotate:

Is the belt broken?

Do drive units have a fault

alarm?

No Pivot motion during cycle:

Is the piston stuck up/ down?

Is there air pressure to

machine?

Did the piston move at all?

Possible Remedies:

Tension improper on belt, belt failure,

contamination, binding on spindle /

pulleys, bearing, improper offset or

lap pressure settings

Dry Lap, Improper settings, bearing

issue

Belt failure, Binding, Drive failure,

Gearbox failure.

Pivot switches need adjustment /

replacement, flow valves clogged, low

or no supply air pressure


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Screen Shots, and Descriptions

Operator Panel:

Part Unclamp: Pushing the button releases the part,

Releasing the button clamps the part.

Waste Pump: If option is installed, pushing the button

manually pumps the waste.

Slurry Prime: Pushing the button manually operates the

slurry supply pump.

Cycle Start: In auto mode pushing the button starts the

automatic cycle.

Cycle Stop: In auto mode pushing the button stops the

automatic cycle.

Reset: Resets the drives after Emergency Stop has

been released

Emergency Stop: Pressing Stops all machine movement and

powers off all motion control. Turn clockwise to release


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Screen Shots cont’d

Login Screen:

(Touchscreen Display)

The Login screen is the first screen that appears on power up.

By touching the “Login” prompt, The “Access code “ screen will appear.

Default access code from Mfg. is “11111”


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Operation Selection Screen:

Load/Unload mode allows you to load and unload parts, when selected “Spindle

Select” screen appears.

Touching spindle # allows you to clamp/unclamp from “Unclamp” operator button

on Operator Panel.


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Program screen:

When the “Program” selection is made, the program screen is displayed.

Arbor speeds can be set, Lap speeds, Cycle time, and Slurry drip rate.

Cap and Cup should always default to Cap.


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Auto Mode screen:

The “Auto Mode” screen displays programmed speeds and cycle times.

When “Cycle Start” on the operator panel is pressed, the “Actual” results will be

displayed.


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Maintenance mode screen:

The Maintenance screen is intended for maintenance personnel to test operations

of the machine.

Functions include:

Moving the slide forward/ Back

Moving the pivot up/ down

Jogging the spindles

Jogging the slurry pump

A Login screen will appear prior to being able to view this screen.

SURFACE FX SPM1 MANUAL

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