Waldrich Siegen WS Roll grinding machine 1
Waldrich Siegen WS Roll grinding machine
INSTRUCTION MANUAL Type Year of No. To avoid excess, deploy when ordering spares or special equipment. for V4 ALDRICH-SIEGEN ROLL GRINDING MACHINE Type: WS Order No.: Year of construction: CONTENTS:
General remarks
Total view of the machine
Technical data and driving motors
Transport and assembly
Description and operation: Machine bed Headstock with driving gear Tailstock Steadies Grinding wheel carriage
Start-up of the machine
Dressing of the grinding wheel by means of diamond
Selection of grinding wheels
Maintenance of the electrical equipment
Annexures: Lubrication of the machine and lubrication chart General arrangement drawing Camber table Foundation drawing GENERAL REMARKS This machine is expected to maintain its reliability and precision over many years. However, these qualities cannot be guaranteed unless the instructions given in this manual for the operation and maintenance of the machine are always carefully observed. This instruction manual has been written for all persons directly interested in the machine, particularly for the operating personnel. In case defects are noticed during the period of guarantee, please inform our competent agent immediately and if possible give him details as to the defects noticed. Even after the period of guarantee has expired, it is recommendable to have eventual failures of the machine remedied by one of our specialists who will be sent to you in conformity with our general conditions. We are, of course, not liable for the unsatisfactory working of the machine resulting from repair and other measures taken by your people without our assistance and advice. Siegen/Westf. Faceplate speed 9-72 rpm Grinding carriage Feed, infinitely variable 60-300 mm/min = 2.4-118 Grinding wheel infeed 425 mm = 16.7 Rapid traverse by motor 400 mm/min = 15.7 Manual fine infeed on 0.0125 mm = 1 rev. = the handwheel 0.00049 = 1 rev. Manual coarse infeed on 0.25 mm = 1 rev. the handwheel 0.0098 = 1 rev. Continuous infeed by motor 0.0135-0.34 mm/min Final infeed by motor 0.01125-0.075 mm/stroke Grinding wheel Diameter 700 mm = 27.5 Width 70 mm = 2.75 Bore 305 mm = 12 For discharging the heaviest machine part, the bed, a crane of a lifting capacity of at least 40 t is required. For transporting the bed with the crane, pass round irons of 5-6 m length and approx. 70 mm diameter through the holes at either end of the bed and sling the lifting rope twice around the protruding ends of the irons. When lifting the bed, see to it that it is hanging in level position and put down carefully on the erection site.
Before erecting the machine, clean the bedways and bright machine parts of rust preventive agents. Before putting the bed on the foundation, insert the foundation bolts in the base of the bed and properly screw wedge blocks and foundation blocks. See to it that the wedge blocks are in the center position. Then the bed is put down on prepared auxiliary layers and adjusted according to ruler and spirit level. Now the foundation blocks are grouted in the anchoring holes. After 4-6 days, the auxiliary plates are removed and the beds are aligned and tightened. The final erection can then begin. H. A. WALDRICH G. m. b. H., GROSSWERKZEUGMASCHINEN SIEGEN. W. The starting drive functions are as follows: When pressing down button headstock start, the starting motor is engaged and drives the starting gear, while the Eldro device draws the tumbler lever with the driving pinion to the faceplate with internal gearing. At the moment of starting, the main headstock motor as the tumbler lever is kept in mesh and the gear rim by transmitting the torque max, specific of the starting drive is arranged to be smaller than the minimum normal headstock speed so that after some moments of simultaneous running, the main drive outstrips the starting drive, the tumbler lever being cut out of contact with the headstock gear rim. The starting motor is then stopped after a timing relay. The drive has the following advantages:
Transmission by Vee-belts
As it's no longer necessary to consider the high starting moment, the need not have extraordinarily large dimensions, like in the design of the machine for grinding, hack-up, and work recall.
The power of the headstock motor is not determined by the starting moment but by the power required for the proper grinding operation. Clamping of the V-belts in the headstock Uff. S 10703 The V-belts are clamped by swiveling the pinion shaft 1 by means of adjusting screws 2 at the right-hand side of the headstock. The clamping of the belts can be checked after removal of the cover at the headstock housing. Deviations of the V-belt sets from the calculated length as well as different extensions of the front and rear set of belts are compensated by eccentric 3. The eccentric is turned after loosening the screws in the flange according to the size of the machine, either by a hook spanner or a crank over worm. The tailstock is guided with its base on the workpiece bed and is traversed along the bed by means of a ratchet. It is secured in its working position by a pawl which engages in the rack cast on the bed between the guideways. The upper part of the tailstock can be moved transversely across the base. The very rigid tailstock spindle has a long guide, is traversed longitudinally by means of a handwheel and a worm gear, and locked in the working position by a clamp handle or a nut. A tapered bore on the front side of the spindle carries the center, which can be removed by a forcing-off nut. Fixed to the front of the tailstock casing is a wheel dressing device. The steadies serve for supporting the roll when grinding necks and barrels. Each steady is equipped with two large and radially adjustable bearing pads which are designed to allow grinding of the necks while the roll is rotating in the steadies. The exact position of the roll in both planes is ascertained by a special measuring device supplied with the machine. For certain kinds of rolls, we supply steadies with semi-round bearing pads or for long slender rolls, a kind of supporting jack which is put underneath the center of the barrel. The grinding wheel carriage consists of the saddle, center part, top part, and feed gearbox. It is guided on the bed without vibrations. The lubrication of the guideways is done by a circulation type lubrication system by means of a pump and a filter. The capacity of the oil pump allows feeding all greasing spots in the saddle in addition to the guideways. The filter must be cleaned once per month. Operator's control station and arrangement of the operating elements Drawing Off. S 10770
Handwheel for the coarse adjustment of the grinding wheel
Handwheel for the precision adjustment of the grinding wheel
Control panel
Lever for immediate stop of the longitudinal motion of the grinding carriage
Dial
Buttons for automatic and continuous infeed
Scale for setting the camber measurements
Locking of shifting block for cambering gears
Square for lifting the grinding head. During cylindrical grinding, also to be used for precision adjustment.
Handwheel for adjusting the desired camber measurement
Hexagon for loosening the cam
Square for turning the cam
Change wheel housing
Cutting speed indicator
Feed indicator
Ammeter for grinding wheel motor
Oil stream control switch H. A. WALDRICH GROSSWERKZEUGMACHINEN Drawing Off. S 10771 The longitudinal traverse of the grinding carriage is done by means of an electric motor and the feed gearbox which is mounted on the saddle. The coarse adjustment of the stroke is made on lever , the fine adjustment on disc E by setting the reversing dogs A. Reversing is effected by changing the direction of rotation of the carriage traverse motor.
In addition to this automatic procedure, the grinding carriage can be reversed in any desired position by operating a push-button switch on the control panel. The grinding carriage traverse speed is adjusted by means of electrical push-buttons on the control panel. In addition to the automatic carriage traverse, the carriage is provided with fine feed adjustment by handwheel H. The wheel head slides on prismatic guideways and consists of a lower and upper part. The lower part contains the cambering device, the upper part contains the grinding spindle with bearings, the operating elements, and measuring instruments. The following motions can be given to the wheel head:
Rapid traverse to and from the workpiece
Coarse feed adjustment by hand to and from the workpiece
Precision feed adjustment by hand to and from the workpiece
Movement for camber grinding
Automatic infeed towards the workpiece
The rapid traverse of the wheel head is done by a special electric motor by operating push-buttons on the control panel. The wheel head travels to or from the workpiece as long as the push buttons are pressed down.
The coarse adjustment of the wheel head is accomplished by operating handwheel 1, which works on a threaded spindle. One revolution of the handwheel equals a feed motion of mm.
The precision adjustment allows for setting feeds in thousandths of millimeters. The precision adjustment cannot be done by traversing the whole wheel head because of its great adhesive friction. It is therefore done on the same principle as camber grinding, i.e., by swiveling the wheel head around a fixed point. For this purpose, handwheel 2 is turned, and the feed rate set is indicated on dial 5, which is also used for camber grinding. One turn of the handwheel equals mm so that the above-mentioned amounts can be obtained without.
For cylindrical grinding, precision adjustment is done by handwheel 9 provided that hand 7 points on cylindrical.
In case you want to proceed as described above, turn hand 7 by means of handwheel 10 to zero and put the cambering device out of operation by taking off the change wheels for the cambering device on the operator's stand on the grinding carriage. Then follows the same procedure as described above.
Setting of the required convex or concave measurement is done by turning handwheel 10 until hand 7 points on the figure read from the camber table supplied with the machine.
The automatic infeed and the continuous one are initiated from a small motor installed in the upper control panel on the wheel head. The feed is engaged with each reversal of the grinding carriage. The desired feed size is set on button.
The continuous infeed has the purpose of compensating for the grinding wheel wear during the cut and thus preventing the motor load from dropping so that the grinding performance is kept constant. A second advantage of this system is that the machine is able to obtain better cylindricity so that machining times for finish grinding are reduced.
This system functions in the following way: The D. C. motor with a range of 1:100 is adjusted by means of a push-button; as to keep the load of the grinding wheel motor at a constant level. The load may be read on the ammeter 16 on the grinding carriage. The infeed rates are adjustable between 0.0135 and 0.34 mm/min.
Combination of automatic and continuous infeed For most grinding work, both feed motions are used together, i.e., continuous infeed while grinding the barrel and automatic infeed at the barrel end.
Preselection of automatic infeed This device eliminates the necessity of intermediate measurements when grinding to exact measure. The preselection range lies between feed rates from 0 to 2 mm, i.e., 0 and 4 mm on the diameter. When having reached the preselected measure, the automatic infeed is cut out. In case the preselection device is not used but grinding is done with automatic infeed, knurled knob IN is put on letter E. When switching to A, the automatic infeed is cut off. Setting of the device: After some grinding passes, the scale ring II and knurled knob III are set on zero by means of handwheel I. In order to measure the diameter already ground, the grinding wheel is withdrawn from the roll, using handwheel I, the revolutions required being counted on the knurled button III. A measurement of the diameter ground reveals how much stock has still to be taken off to arrive at the desired diameter. The preselection of this value, for example, mm on the diameter = infeed of mm, is done as follows: The grinding wheel is returned to its initial position by means of handwheel 1, i.e., advanced until the scale ring II and the knurled button II3 are again on zero. One handwheel revolution equals a feed rate of mm so that in order to take off 0.4 mm, the scale ring II has to make a full turn and after that has to be set on -0.4 mm by turning the ring to the left. The full turn of the scale ring is done by turning the knurled button III on figure 1. When having arrived at the preselected measure, the automatic infeed is stopped. Grinding spindle and bearings: The rigid grinding spindle is made of high-grade steel. It has been subject to a nitriding treatment at the bearing points and is ground to an excellent surface quality. Our grinding spindle bearings are self-aligning bearings which are designed in accordance with the latest findings of lubrication techniques. Two-thirds of the bearing are immovable while the remaining third adjusts itself to the most favorable backlash. Greasing of the bearings is by a circulation type lubrication. A gear pump with a special motor sends the oil by means of a magnetic filter installed in an oil sight glass to the bearing bushings, the oil in the oil grooves assuring a perfect centering of the spindle. The oil film adapts itself to the prevailing working conditions. As a metallic contact between spindle and bearings does not exist, the wear in the bearing bushings is extraordinarily small and the working temperature of the bearings remains practically unchanged. In case of a defective oil pipe or a failure of the pump, an oil circuit control switch cuts out the main driving unit or together with the wheel carriage traverse motor so that the wheel is withdrawn from the workpiece by about 20 mm. The same occurs when the button grinding wheel off is operated. The oil level in the top head has to be controlled from time to time. The speeds of the grinding spindle are infinitely variable. The speeds and the cutting speeds for the different wheel diameters can be read on the control station of the machine. When starting the grinding wheel, the oil pump is first put into operation. After 10 to 15 seconds, the push-button has to be pressed once again, and only then does the grinding wheel rotate. The grinding wheel motor is mounted on a separate base plate beside the wheel head with which it is traversed synchronously. Its center of gravity lies very deep and just above the bedway so that vibrations from the motor - as far as these can occur with our carefully balanced motors - cannot be transmitted to the spindle and the wheel. Our roll grinders are normally equipped with D.C. variable speed motors to allow, beside infinite variation of the workpiece speed, a precise regulation of the circumferential speed of the grinding wheel so that the most favorable speed ratio between the grinding wheel and roll may be adjusted without difficulty. This is of special importance for achieving perfect surface quality and high grinding output. The cambering device allows for grinding rolls to any desired curve independent from wheel and barrel diameter and barrel length. The desired curve is obtained by the longitudinal travel of the grinding carriage simultaneously with a small transverse motion of the grinding wheel controlled by a cam driven by a special gear incorporated in the bottom of the carriage. This cam lifts the rear part of the wheel head, swinging it around its fixed front bearing. When lifting the wheel head, the grindstone approaches the workpiece by a small amount which can exactly be determined, and when lowering the wheel head, the grindstone is withdrawn by the same amount. Patented cambering device crowning device: Our patented cambering device is designed to produce always the same grinding curve with the same setting independent from the roll and wheel diameters. This is of special importance for abnormal concave and convex curves. The cambering device is set in accordance with the table supplied with the machine. The different barrel lengths of the rolls are shown on the upper part of the table. The concave and convex measurements are specified left-hand. The lower part of the table shows those figures on which the index plate has to be set by means of a handwheel in order to obtain the desired camber. As these figures are approximate values, the curve must be checked after having roughly ground the desired camber on the roll barrel, and if there is a deviation from the nominal measure, i.e., from the pitch of the curve, an additional adjustment has to be made at the index plate. A disk marked concave - convex has to be set accordingly depending on the curve which has to be ground. For camber grinding, the grinding wheel is set exactly against the middle of the barrel. Hexagon 11 is then to be turned to the left by means of a wrench, whereby the friction coupling is loosened. The disk 17 marked concave and convex is set to concave and convex. Then the friction coupling is retightened again by hexagon 11.
In order to select the correct figure to be set on the torque index plate for a given parallel and camber, select the barrel length on the top table and the camber measurement on the left-hand side. However, identical cambers can be found in one and same barrel length by means of changes, slight corrections of the curve towards both ends are possible. The figure to be set will be found on the intersection point of the line of the camber measurement and the vertical line of the barrel length. After having loosened the clamping, hand has to be set on this figure by means of handwheel. Then the device is again reclamped. For convex grinding, the figure shown on dial should lie slightly above zero. For concave grinding, the value shown on the dial should be somewhat higher than the desired measurement. This adjustment can be done with handwheel for precision adjustment and serves to provide a sufficient margin for precision adjustment which is also necessary for camber grinding. For cylindrical grinding, hand has to be set at zero. In order to assure an exact working of the cambering device, it is essential that the gear, consisting of worm and worm wheel - driving the cam and raising and lowering the wheel head during camber grinding - runs without any backlash. Should in the course of time arise some play between worm and worm wheel, the worm has to be readjusted. For this purpose, the rotor is formed as a differential worm.
Drawing Off. S 10773 The sequence of operations is as follows:
Let off oil through an oil outlet screw provided under the cambering gear housing.
Remove cover on the right-hand side of the cambering gear housing.
Adjust cross hole nuts 3 and by turning the rear square 18 in such a way that the safety screws can be loosened.
Loosen safety screws on both cross hole nuts.
Turn left cross hole nut 3 to the left side. Turn right cross hole nut 4 with worm to the left side until the play of worm and worm wheel is eliminated. Turn then left cross hole nut 3 to the right against the worm.
After that, retighten both nuts and close the cover. The cam supplied with the machine is made for a given form of curve. The cambering equipment is so designed that other cams can easily be installed if different types of curves have to be pro- duced. The same applies to higher camber measures. In order to grind also rolls with short barrel and relatively great concave or convex measure, several transmissions are pro- vided in the gear for the cambering device. These transmissions allow giving the cam a smaller or greater rotating motion and thus flattening or steepening the curve somewhat towards the barrel ends. To obtain other transmissions, the change gear wheels are exchanged. The change gear wheel housing is placed on the control station. Exchanging of wheels can thus be done without trouble. The necessary wheel combinations for the different transmissions are shown on the camber table. Concentrating of backlash To obtain exactly symmetrical cambers, there must be a synchronism between longitudinal travel of the grinding carriage and the trans- verse motion of the grinding wheel so that at any point of the barrel the correct distance between roll centre and grinding spindle axis is assured. A lag of one motion behind the other results in a distorted curve. Such a lag of motion becomes conspicuous when the grinding wheel cuts only on one side of the barrel up to the barrel centre and does not grind on the other half of the barrel or vice versa. To ensure simultaneous engagement and continuation of both motions, the gear for the cambering device is provided with a compensation of backlash.
Drawing Off. S 10674 Functioning of backlash compensation: The drive of the grinding carriage motion and that of the cambering device is effected from a joint shaft. The drive of the grinding carriage is transmitted over worm worm wheel 3 and rack pinion 4 gearing in the bed rack. The drive of the cambering device is transmitted from shaft 1 over conical wheels , change gear wheels 6 and two worm gears to the cam which performs the raising and lowering of the wheel head. When reversing the carriage motion, worm 2 changes its sense of rotation and travels without moving the carriage against the fixed stop 7. If this stop has been reached, the worm wheel 3 with pinion 4 are again turned and the carriage feed motion begins. In the moments when the carriage remains without longi- tudinal motion, the gear for the cambering device continues running. The distance between worm 2 and the stop has been chosen in such a way that the carriage is not reversed until the dead play in the gear has been eliminated. This assures a synchronous running of the grinding carriage and the cambering device so that an absolutely symmetrical curve is obtained. For fixing the distance between worm and stop, the counter bearing 7 has to be adjusted on shaft 1 by means of worm 8 and worm wheel 9 with the aid of a square wrench. When turning the square wrench clockwise, the distance is increased, and it is decreased when turning the wrench counterclockwise. This allows later on to compensate for an eventual wear of the gear parts by means of the adjustable counter-bearing 7. Furthermore, the ar- rangement of the counter-bearing offers the advantage of being able to adjust the distance between worm and stop while the car- riage is in operation.
The wet grinding device is fed by a pump of considerable capacity. The coolant is pumped from a container arranged in the foundation. and pressed through the cable drag chain to the steel jet. The returning coolant flows back to the main container. When grinding, see to it that the coolant flow is always directed on the grindstone and not away from it. Before being mounted on the grinding spindle, the grinding wheel has to be exactly balanced by displacing the segments installed in the grinding wheel holder. The segments are secured in their position by threaded pins. When fixing the grinding wheel in its holder, put paper 1 to 2 mm thick on either side of the wheel. This prevents distortions of the wheel and helps to compensate differences in width. After having fitted the wheel holder with the wheel on the grinding spindle, the wheel has to be dressed with the diamond dressing device attached to the tailstock. See page Dressing of grinding wheel by means of diamonds. START-UP OF THE MACHINE Before setting the machine into operation, supply all greasing points with a sufficient quantity of oil according to lubrication scheme. Further details about the lubri- cation of the machine, such as oil quantity required, recommended lubricants, and frequency of lubricating, are contained in the attached lubrication chart. Operate all motions first at lowest speeds and traverse grinding carriage and wheel head by hand to their end position. Be careful when starting the grinding spindle. Do not switch to continuous service right from the beginning. Warm up the spindle gradually by repeated engaging and disengaging of the spindle motions. Dress the grinding wheel. See paragraph Dressing of the grinding wheel. Fill coolant in the water pit of the foundation. All commercial grinding salts and oils can be used as supplements for the cooling water. When using crystalline soda, 3-5 kg are necessary for 100 l of water.
DRESSING OF GRINDING WHEEL WITH DIAMOND The lifetime of dressing diamonds can be substantially increased by paying attention to the following points: The wheel should be dressed only with sharp edges; for a blunt diamond, set parallel to the peripheral surface of the wheel does not cut the wheel but exerts a pressure on it, gets heated up, and is used in a very short time. It is therefore absolutely necessary to turn the diamond holder very frequently and to put the diamond on the wheels always at another angle so that the wheel is dressed only with edges but not with faces. When the diamond end projecting from the holder has been used up so far that it can no longer be placed at an angle with the wheel face, advance the diamond somewhat and continue dressing as before. The diamond has to be fitted somewhat below the grinding wheel axis; for if set above the axis it might happen that with a wrong fitting of the diamond in the holder, the diamond jams and is pulled out. Please note that dressing has to be done with a good flow of coolant to avoid excess heating and dust formation. In order to spare the diamond, there is nothing to say against using ordinary dressing tools with rotating steel disks, floating fibers, or something else which generally meets the requirements during roughing a roll.
SELECTION OF GRINDING WHEELS What the roll grinder has to know Apart from an appropriate machine, the quality of the surface finish depends to a great extent on the selection of the grinding wheel to be used for a particular operation. The wheel has to be chosen with regard to grit, hardness, and bond in order to unite a high chip removal rate with short grinding times and a minimum degree of wheel wear. The operator's choice should be guided by the following principles: a) The harder the roll surface, the softer the grinding wheel. b) If the grinding wheel wears down too fast, the wheel is too soft for this particular operation. The result can be improved by: Increasing the circumferential speed of the wheel, Increasing the feed per revolution of the roll up to 3/4 of the wheel width. Decreasing the circumferential speed of the roll. If after these measures no improvement is noticed, the grinding wheel is not suitable. c) In case the wheel has the tendency to clog or to smear and in case burns appear on the grinding surface, the wheel is too hard. The grinding conditions are improved by decreasing the wheel speeds and increasing the roll speeds. d) For all grinding operations, especially when using hard wheels, a sufficient supply of coolant is required to avoid heating up of the roll surface. For chilled cast iron rolls, use only silicon carbide wheels, for hardened and unhardened steel rolls corundum wheels. The coolant we recommend is a 3-5% soda solution which has excellent cooling qualities and provides a certain protec- tion against rust. On the attached list figure a number of grinding wheels which have been tested on rolls of different material and can therefore be used as standard values for similar jobs. Wheel speeds:
The circumferential speed of the grinding wheel is normally For polish grinding, it is most advantageous to use low speeds even lower than 20 m/sec.
The circumferential speed of the roll should be for rough grinding 30-50 m/min for finish grinding 15-30 m/min for relatively slender and long rolls, use the smaller speed, for calender rolls of great length and small barrel diameter, speeds down to 10 m/min.
The carriage feed per revolution of the roll can be for rough grinding 2/3 to 3/4 of the wheel width for grinding 1/4 to 1/2 of the wheel width
The infeed of the wheel per grinding carriage stroke can be to mm for rough grinding, depending on the material of the roll and the roll diameter. For harder and larger rolls, we recommend using smaller feeds. For finish grinding, use feeds of to mm For polish grinding, some thousandths of millimeters are usual. LIST OF GRINDING WHEELS tested on rolls of different material Roll material Wheel.
Roughly translated text with corrected spelling:
Rindin operation = :material6 grit_ _ _ ιάrine: s bond
Chilled cast iron rolls rough grinding silicon carbide 24/30 K ceramic Steel rolls rough grinding normal or refined corundum 46/60 H-L ceramic grinding 500 M
Rubber rolls hard and soft rough grinding silicon carbide 24/30 I-K ceramic polish grinding 30 4
Granite rolls silicon-carbide 16/24 Jbt, K ceramic
Fiber rolls green grain RG 60 I-7 paper glazing carborundum or calenders silicon-carbide emery paper glued to wooden wheel
Maintenance of the Electrical Equipment The electrical motors have to be protected against dirt, dust and a high degree of humidity. In case the machine is installed in dusty surroundings, it is recommended to clean the motor windings from dust at regular intervals by means of bellows or dry compressed air. Special attention has to be paid to the rotors of the slipring motors. Keep their surface perfectly clean. Stains which might, appear after some time of service must be removed immediately by polishing. Carbon brushes which are worn down have to be renewed in time. They don't require any kind of lubrication. The only thing to do is clean them from dust and dirt once a month together with the sliprings and brush holders with a cloth soaked in spirit. Motors with roller bearings are supplied ready for service with a grease filling which in general need not be renewed before the machine has been in operation for 2 to 3 years. Only then fill the bearings with a certain quantity of grease while the motors are running. Please note that too much grease is just as detrimental as too little grease. After several years of service, the anti-friction bearings have to be disassembled, residues of old grease to be removed and the space between the bearing rings to be filled up to 1/3 with roller bearing grease. Regarding the sliding bearing motors, check the oil level in the bearings constantly and renew the oil every 6 months. Use only non-resinous and non-acid medium-heavy oil 4-5o Engler at 50o C. The electrical control gear has to be checked every 6 months as to consumption of the contacts and formation of burn blisters. The contacts can be cleaned with a fine emery file and the control gear lubricated with pure burner oil. Recommendations for lubricants to be used for WALDRICH-SIEGEN Heavy Duty Roll Grinding Machine Kind of Filling quantity Oil change Lubrication spot lubrication liters working hours Mobilux Alvanía all three months Headstock - Anti-friction bear-tr-1q central lubrication 0.7s ng Grease No. 2 grease 3 to grease
Starting drive immersion lubrication 1000/ L 000 Headstock - Displacement oil filling to central lubrication control daily
Superposed gear immersion lubrication DT ViresL - Oil Heavy-Medium 33 Tailstock - top part 4.9 / 50 immersion lubrication 5.5/50,000 / 4000 5 Tailstock - base part immersion lubrication Tailstock - displacement oil filling to central lubrication control daily CENTRAL LUBRICATION ECO 966 6078 Neu-Isenburg, Hugenottenallee 173 Groups Groupes Gruppos Grupos P-20 - P-150 DESCRIPTION, INSTALLATION INSTRUCTIONS DESCRIPTION, DIRECTIVES OF MONTAGE E FUNCTION AND OPERATION Le pompe con le valvole della forma 6 sono pompe d'applicazione esterna per serbatoi d'olio separati. La valvola di entrata viene fornita in questo caso avvitata solo leggermente; Pumps with valves of form 6 are external application pumps for separate oil reservoirs. The inlet valve is supplied in this case screwed only slightly; Model 181 avec tefoulement à droite. Otherwisе an Fig. 2. INLET VALVE is screwed in; it can only be mounted when the pump has been, essa può venir fissata solamente dopo il montaggio della Model 181 with right displacement. Otherwise, the same execution as in Figure 2. is provided; INLET VALVES are screwed in; it can only be mounted when the pump has been, it can only be mounted when the pump has been, éxecution de môme que 1a figure 2. sOUPAPES D'ASPIRATION the return flow led off. 10 scarico deve venir derivato. Le pompe con le valvole della Execution as in Figure 2. SUCTION VALVES the return flow led off. The discharge must be derived. Pumps with valves of the Exécution comme sur la fígure 2. SOUPAPES D'ASPIRATION le scarico deve venír derívato. L olio deve venir immesso, Execution as in Figure 2. SUCTION VALVES the discharge must be derived. The oil must be introduced, Service Instructions I. The balancing of grinding wheels II. The Electrodynamic system III. Preparations on the machines IV. Adjustment of the instrument V. The balancing by the Electrodynamic instrument A. Rough balancing B. Fine balancing VI. Some remarks The balancing of grinding wheels Only by grinding wheels, balanced very precisely, the high demands which are today required of the surface finish can be satisfied. Ex- periences have shown that generally the necessary balancing quality cannot be obtained by the procedure used until now, to oscillate the grinding wheel put on an auxiliary arbor on an unrolling de- vice. As per the influence of the friction, occurring during the os- cillation, only a very limited accuracy may be obtained. Moreover, balancing faults which are caused by the heat of the auxiliary arbor as well as by the inevitable tolerance clearance between the taper of the grinding spindle and the taper of the auxiliary arbor, effect that the grinding wheel not compensated in the machine will run after the installation from the first with unbalance. Furthermore, it must be considered that a grinding wheel becomes unbalanced when dressed several times.
The mentioned difficulties are only to be avoided if the grinding wheels are balanced in the machine, that means, balanced when mounted and under service conditions. For this purpose, our Eltrodyn-instruments N1 or N1/m have been developed. It has to be operated as follows: One vibration pick-up as well as one indicating instrument and one measuring electronic N1 have to be mounted at the grinding machine and connected. When the instrument has correctly been adjusted - this is to be done only once at the starting - the amount of unbalance is directly indicated on the measuring instrument of the indicating device. The light point of the grinding wheel is directly to be read on the wheel by means of the stroboscope handlamp. Now it is possible to add the compensation weights on the correct point of a new grinding wheel or to improve the balancing quality by displacing the weights on a grinding wheel already balanced. At the type N1/m, the indicating device has been mounted into the measuring electronic. Moreover, for the general function and handling, the same is valid as at the type N1 with the separately mounted or installed indicating instrument. The high measuring sensitivity and other very important qualities of the instrument allow a very accurate balancing and by this, mostly an important improvement of the surface finish. Moreover, an extremely high saving of time is obtained, as the usually necessary by-works pulling off and mounting of the wheel, transport to the balancing equipment, pulling up on the auxiliary arbor are avoided. II. The Eltrodyn system By the unbalance of the grinding wheel, vibrations synchronously to the spindle speed are caused. The vibration pick-up for these vibrations has to be mounted where the unbalance vibrations usually appear in a most excessive way. In other words: the mounting has to be executed near the wheel-side spindle bearing. As the vibration pick-up does only react upon vibrations in the direction of its longitudinal axis, the longitudinal axis must always be arranged vertically to the spindle arbor. The centrifugal forces act vertically to the rotation axis. The vibration pick-up transforms the mechanical unbalance vibrations into a corresponding electric voltage. During the balancing, this voltage is led via a cable to the measuring electronic. Here, the voltage is sufficiently amplified and all particles not resulting from the unbalance are eliminated by a filter, tuned to the corresponding spindle speed. If the filter is correctly tuned, only the unbalance vibrations are indicated on the measuring instrument. After having correspondingly chosen the sensitivity, the angle where the two compensation weights have to be added may directly be read on the instrument. The position angular where the two compensation weights have to be added may be determined by a stroboscopic handlamp, connected to the indicating device. This lamp is controlled by the unbalance vibrations and flashes shortly at each rotation of the grinding wheel so that the wheel seems to stand still in spite of the rotation stroboscopic effect. Especially the numbers, marked on the wheel flange, may be read during the run. It may be proved that the light point of the wheel does always appear in the same direction. If this direction is found and fixed by a reading pointer, the number read under the pointer signifies the light point of the wheel compared. Design on the following page. I want to explain once more the balancing procedure on a new grinding wheel by a scheme: For the balancing of a new grinding wheel - mounted without any compensation weights - the sensitivity switch at the indicating device has to be commutated to . The number 3 is to be seen by the handlamp in the direction of the reading pointer, while the measuring instrument indicates the angle of 45°. After having stopped, two normal weights, beginning from the direction of the number 3, have to be added each in 45°, according to the designed.
Adjust a deflection of about 600 by means of the adjustability regulator P1. If necessary, increase the deflection by the regulator P2. Now search the mark on the wheel by the handlamp. The marked place is the light point of the wheel, and mark the direction with a reading pointer fastened to the machine. As you have started from a wheel balanced only approximately, the direction of the reading pointer as well as the adjusted sensitivity is not still definitive. After adding the standard weight back to its original place, the wheel has to be balanced precisely. Finally, the explained procedure of taking off a weight, adjustment to 600, and fastening of the reading pointer has to be repeated.
At first, the fine balancing: 1 Start the wheel together with the standard weight added to the correct place. Commutate the sensitivity commutator to F and note the deflection. 2 Note the number seen by the handlamp in the direction of the reading pointer. The light point number is engraved on the flange. Stop the grinding wheel. 3 For the compensation, now displace the standard weight situated nearest to the direction square to the light point, a little toward its light point. The enclosed design shows further details of displacement of the compensation weights at the fine balancing. If the compensation weights are situated symmetrically, both weights must be displaced by the same amount toward the light point. 4 Restart the wheel and determine the success of compensation by the reduced deflection of the index. If necessary, repeat the procedure until no constant image appears when regarding stroboscopically.
With the previously balanced wheel, the sensitivity and the reading pointer are fixed as follows: 1 Take off one standard weight after having marked its exact position and commutate the measuring electronic device to . Then adjust the sensitivity regulator to a deflection of 600. 2 The direction in which the light point, the marked point on the grinding wheel, may be seen has to be determined by the handlamp. The reading pointer has to be arranged in this direction. Now all adjustments are finished. The measuring electronic device may be closed and finally fastened. Also, the cable may now be correctly wired.
The balancing by the Electrodyn-Instrument: For newly mounted wheels, we recommend first the rough balancing described in paragraph B. The balancing quality may be improved according to paragraph B, fine balancing. The fine balancing may also be used for wheels balanced several times.
The measuring electronic device, however, is always necessary at the corresponding machine. The measuring electronic device has to be connected to the main supply, connection, handlamp, and has to be adjusted to the corresponding balancing speed, selection commutator of the filter.
A. Rough Balancing: 1 Commutate the sensitivity commutator to Y. 2 Start the wheel, determine the light point under the reading pointer by the stroboscopic handlamp, operate the push-button at the lamp handle, read the angle on the measuring instrument's upper scale. 3 Stop the grinding wheel and balance. For balancing, two standard weights have to be added symmetrically to the light point. The read angle has to be counted from the light point in both directions. In other words, the two weights augment the double angle. If the measuring instrument indicates an entire deflection, a standard weight has to be added first at the light point, and the measurement has to be repeated.
B. Fine Balancing: If the unbalance is so small that the deflection may not easily be read, the sensitivity has to be increased, and the compensation must be improved by displacing the standard weights. 1 Commutate the sensitivity commutator to F; clean the slot at the wheel's flange. 2 Start the grinding wheel, determine the light point by the lamp, note the deflection on the measuring instrument's lower scale. 3 Stop the grinding wheel. Displace the standard weights towards the light point according to the design shown for displacement of the compensation weights at the fine balancing. 4 Repeat the measurement and the compensation until a constant image no longer appears within the stroboscopic light.
VI. Some remarks: 1 Adjustment of the grid-to-tension for the stroboscopic valve handlamp: If, despite great unbalance, no constant image should appear when regarding stroboscopically, reasons like aging of the valves, alteration of the main supply, or the standard voltage of the valves may be adjusted without opening the instrument. The regulator can be found on the front plate of the instrument, in the connection for the handlamp, and can be operated with a screwdriver. For operation, press softly the screwdriver's friction clutch. Moreover, the position of the regulator has to be changed if necessary so that an exactly constant voltage appears in the stroboscopic light. This presupposes a clear unbalance and a correct filter adjustment to the balancing speed of the spindle. 2 An unbalanced driving motor may, especially if its speed is near the spindle speed range, influence the exact balancing of the grinding wheel's fluctuations of the pointer. If this should happen, first the motor has to be balanced exactly. 3 If the Electrodyn-Instrument shall be mounted at another machine, please pay attention to the new spindle speed. If the spindle speed is still in the speed range, only the new adjustment has to be found out, filter, sensitivity, reading pointer. If the spindle range indicated on the valve guarantee card does not cover this spindle speed, a new filter plug has to be obtained for this new spindle speed. To change the plugs, please open the measuring electronic and remove the filter plug located above the filter regulator P3. The new plug may now be put on the socket like a valve. After this is done, the instrument may be adjusted. 4 If nothing else has been agreed, the mains voltage is 220 Volts. If necessary, the electronic device may be commutated for 110/110 and 240 Volts by soldering the primary side of the transformer. At 100/110 Volts, you have to safeguard with 1 A, at 220/240 Volts with 0.5 A. The fuse is inside the instrument, unscrew the front plate located in the lower part, approximately in the middle. 5 The measuring electronic device has been equipped with the following valves: ECC 85, E 80 CF, EC 92, and 6201 (4 valves). The handlamp is fitted with one stroboscopic valve NSP-1 Ferranti. Furthermore, one stabilizer 150 B 2 has been mounted. The valves and the stabilizer are products of VnLVO. To change the valves, it is only necessary to loosen the front plate of the measuring electronic device. It must be ensured that after changing the valves, the plug connection at the chassis cable connection between the front plate and the chassis are still properly set up.
