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OptiPro Systems eSX 300 CTS, User Manual

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OptiPro Systems eSX 300 CTS User Manual Download Page 92

User Manual – eSX

 

 

 

 

OptiPro Systems, LLC. 

Page 92 of 111 

Last Modified: 8/27/2014 

9.8

 

Replacing Existing Safety Windows 

 

 OptiPro  Systems  recommends  that  machine  enclosure  windows  made  of  polycarbonate  be  replaced 
every three (3) years with Makrolon AR2 brand polycarbonate 6mm thick. A longer term upgrade option 
is to replace existing polycarbonate panels with laminated glass complying with ISO 23125-B1 standard. 

Replacing the side windows: 

1.

 

Unbolt the left, right, and top brackets from the inside face of the window panel.  Unbolt the 
outer two screws first (the screws in the slots).  When removing the third (middle) screw, be 
sure to hold the bracket so it doesn’t drop when the screw is clear. 

 

 

                

 

 
 
 
 
 
 
 
 

 

Window Brackets 

Outer Bracket Screws 

Left and Top Brackets 

4mm Allen Wrench 

Side Window 

Summary of Contents for eSX 300 CTS

Page 1: ...User Manual eSX OptiPro Systems LLC Page 1 of 111 Last Modified 8 27 2014 OptiPro Systems LLC User Manual eSX...

Page 2: ...e 9 4 4 In An Emergency 10 5 Machine Overview and User Controls 11 5 1 Work Area and Machine Axes 13 5 2 Operator Panel Interface 14 5 2 1 Jog Panel 14 5 2 2 Jog Pendant 16 5 2 3 Door Interlock 17 5 2...

Page 3: ...1 6 3 Emergency Stop 31 6 3 1 When to press E STOP 31 6 3 2 Returning machine to normal operation 31 7 Software Interface 32 7 1 Screen Layout 32 7 2 G Series Submenu 33 7 3 Manual Jog Mode 34 7 4 Aut...

Page 4: ...85 8 1 1 Reading the Flow Monitor 85 8 1 2 Changing the Required Flow Rate 85 8 1 3 Cleaning if Necessary 86 8 2 Recovering from Error Messages 86 9 Machine Maintenance 89 9 1 Daily Maintenance 89 9...

Page 5: ...Tram B Zero Screen 101 10 1 4 Tram Spindles Aligned 101 10 1 5 Tram Center of B 103 10 1 6 Tram Pinch Test 104 10 1 7 Tram Tool Probe 105 10 1 8 Tram Lens Probe 106 10 1 9 Validation 106 10 1 10 Tramm...

Page 6: ...an Parkway Ontario NY 14519 Phone 585 265 0160 Fax 585 265 9416 Website www optipro com For Service and Parts Contact Service Coordinator Email Service OptiPro com For Sales Contact Sales Coordinator...

Page 7: ...tiPro Systems LLC Page 7 of 111 Last Modified 8 27 2014 3 Document Revisions The following is a summary of changes to this document Table 3 1 Document Revision Summary Release Dated Changes 2014 Augus...

Page 8: ...nt codes and regulations required by local or national regulatory bodies 4 2 General Safety Concerns 4 2 1 Personal Safety The following precautions should be taken when working in or around the machi...

Page 9: ...if applicable 4 3 Safe Operation of the Machine This machine includes many safety features however the following guidelines must also be observed Never operate the machine with any doors open or safet...

Page 10: ...on must then be pressed to clear the error bar found in the top right corner of the display IN AN EMERGENCY SITUATION Press the EMERGENCY STOP button In the case of serious injury fire or other hazard...

Page 11: ...e Overview and User Controls This section provides a brief description of the components controls and features this machine is available with Some of the features shown in this manual are options and...

Page 12: ...iew Figure 5 2 Left Rear Machine View Figure 5 3 Right Rear Machine View Main Air Entry Electrical Cabinet A C Main Power Disconnect Vacuum Pump Left Side Right Side Side Access Door Side Access Door...

Page 13: ...ure 5 4 shows the direction for each axis and labels to spindles Figure 5 4 Machine Spindles and Axes NOTE If the machine is a twin spindle grinding machine then the left spindle is referred to as S1...

Page 14: ...8 27 2014 5 2 Operator Panel Interface The machine is equipped with a touch screen interface Figure 5 5 Operator Panel 5 2 1 Jog Panel Figure 5 6 Jog Panel 16 17 Not used on OptiPro equipment 15 21 22...

Page 15: ...7 Coolant Auto On Off Automatic coolant feed during cycle 8 Coolant Manual On Off Manually operates the coolant solenoid turning coolant on and off 9 Auto Mode Activates CNC Auto Mode for running prog...

Page 16: ...ove all axes X Y Z 4 or 5 When Axis Selection is on 4 the B axis can be rotated When Axis Selection is on 5 the work spindle S2 can be rotated Emergency Stop The EMERGENCY STOP E STOP button should be...

Page 17: ...Door Interlock Selector Switch 5 2 4 Emergency Stop The EMERGENCY STOP E STOP button should be used to stop the machine if there is any danger to the operator machine or process Once the button is pr...

Page 18: ...olant Recirc On Off USB ports 5 2 6 USB ports On the side of the Control Panel are standard USB ports Figure 5 10 that connect to the CPU These ports can be used just like on a personal computer to co...

Page 19: ...ctions throughout this manual Figure 5 11 Utility Control Panel The pneumatic panel houses all of the air regulators and switches machine They are set when your machine is first installed by OptiPro i...

Page 20: ...n will be lost at the work piece Be sure the machine is not running and that the work piece is adequately supported or removed from the machine before draining the vacuum drain tube Remember to close...

Page 21: ...nt Tank OptiPro requires that Deionized DI Water be used in the coolant Tank capacity is approximately 35 gallons Caution Verify that all motion on pump motors have stopped before attempting to servic...

Page 22: ...load particulate will accumulate at different rates It is recommended that the centrifuge be checked and cleaned regularly Failing to do so could result in the centrifuge spinning out of balance and...

Page 23: ...HILLER BEFORE ANY CHILLER SERVICE OR CLEANING AND BEFORE DISCONNECTING ANY CHILLER LINES THROUGHOUT THE MACHINE Figure 5 15 Spindle Chiller Unit 5 6 Electrical Cabinet A C unit The A C attached to the...

Page 24: ...s X Y and Z axes Replace the grease cartridge whenever necessary see Section 10 3 for part number The greaser is located on the base of the Z axis column near the pinch valve assembly The outer plast...

Page 25: ...HSK 63F style tool interface Only use tool holders conforming to the HSK 63F standard Figure 5 18 HSK 63F Tool Holder profile For machines NOT EQUIPPED with Coolant Through Spindle CTS only use tool h...

Page 26: ...tool holder and must never be exceeded Tools should be as short compact and light as possible Never exceed the tool manufacturer s recommendations for operating speed Hardware such as bolts and colle...

Page 27: ...within the following tolerance Shank Diameter either 25mm or 1 25 depending on customer option of h7 tolerance 0 m to 21 m or better OptiPro recommends 8 m to 18 m for best performance Length between...

Page 28: ...ith work and tool probing In the eSX the tool probe is located near the C axis and the work probe is typically located on the right side of the spindle Figure 5 22 Tool Probe mounting location Figure...

Page 29: ...ntegrated handheld spherometer is located on the utility tray on the front of the machine The spherometer can be used in correcting a radius Spherometer bells are interchangeable See Section 7 6 3 2 3...

Page 30: ...s found in the TRIPPED position turn the machine off and report this problem Once the control has booted up the G Series software will load automatically If for some reason the software fails to load...

Page 31: ...ol Panel 6 3 Emergency Stop The EMERGENCY STOP button shuts all energy to drives coolant pumps and spindles There should be no hesitation to use the E STOP button in an emergency situation Note that E...

Page 32: ...of the screen shows the G which indicates this machine is a grinder Double tapping on the G will bring up a sub menu as seen in Figure 7 2 Figure 7 1 Screen Layout 7 1 Operation and Navigation Button...

Page 33: ...olant Vacuum Vacuum Monitoring and Enable Disable C axis mode Tool Library Navigates the user to the Tool Library where all tools will be input and pulled from for each process Section 7 5 RDS Calcula...

Page 34: ...Always reduce Feed Rate Override FRO to 0 before pressing CYCLE START and increase slowly in MDI mode to reduce the risk of collisions See Section 10 2 for additional information regarding MDI command...

Page 35: ...to reflect the override Figure 7 4 Automatic Mode 7 4 1 Motion Stop for non emergencies In Emergencies Press the E STOP button on the Jog Panel Figure 5 9 in any situation in which the operator feels...

Page 36: ...execute programs that are generated offline not with the G Series software These files are usually manually typed out or generated with a CAD CAM application CAUTION G Series software has built in saf...

Page 37: ...sed for performing asphere grinding edging and beveling operations Ball Section 7 5 4 Ball tools or hemispherical tools are used for creating aspheres Edge Section 7 5 5 Edge tools have a cylindricall...

Page 38: ...ary screen any unsaved changes to the Tool parameters will be discarded 7 5 3 Ring Tools Figure 7 6 Tool Library Ring Tools Table 7 4 Ring Tool Parameters and Descriptions Ring Tool Parameters Descrip...

Page 39: ...ool Parameters and Descriptions Ball Tool Parameters Description Name A descriptive name that differentiates one tool from another Description Additional information that can be used to describe the t...

Page 40: ...other Description Additional information that can be used to describe the tool Outside Diameter Measured outside diameter of the tool Probe Diameter Defines the diameter at which the tool should be pr...

Page 41: ...Tool Library End Mill Tools Table 7 7 End Mill Tool Parameters and Descriptions End Mill Tool Parameters Description Name A descriptive name that differentiates one tool from another Description Addit...

Page 42: ...e that differentiates one tool from another Description Additional information that can be used to describe the tool Outside Diameter Measured outside diameter of the tool Probe Diameter Defines the d...

Page 43: ...FID Tool Parameters Description Name A descriptive name that differentiates one tool from another Description Additional information that can be used to describe the tool ID Number A serial number tha...

Page 44: ...Tool Parameters Description Name A descriptive name that differentiates one tool from another Description Additional information that can be used to describe the tool Outside Diameter Measured outside...

Page 45: ...Load Job button from any screen 2 Select a job from the dropdown menu For the job highlighted the Lens Blank Parameter fields will be populated with the data that was last saved in that job file The...

Page 46: ...ping DELETE will permanently deleted the job selected in the dropdown list 7 6 3 Creating a New Job The steps involved in creating a new job include defining the shape of the starting lens blank and d...

Page 47: ...sag face of the upper side of the blank leave empty if there is no sag face Lower Shape The shape of the lower side of the blank options include Convex Concave and Plano Lower Radius Radius of the low...

Page 48: ...ens Blank Parameters use the probing sequence to set the reception height automatically a Secure the blank in the work spindle b Tap PROBE at the bottom of the Lens Blank screen Always use caution whe...

Page 49: ...ex 100mm CC Grind Rough Tool 3 Define the shape to be cut using the Lens Parameter fields and verify with the graphical representation provided Figure 7 16 Spherical Process Lens Definition Screen Ta...

Page 50: ...indle Head Angle Calculated based on tool and part geometry Outer Diameter Imported from Library Outside diameter of the tool Inner Diameter Imported from Library Inside diameter of the tool Tool Radi...

Page 51: ...one exists Clean Up CT Calculated Maximum Center Thickness CT to ensure entire surface is cut Finished CT User inputted final Center Thickness CT for this process Safety Height Rapid Feed threshold of...

Page 52: ...m Monitoring Optional If active will monitor for vacuum loss during a processing cycle SPC Monitoring Optional Will broadcast time date stamped part count information across a network 9 Advance to the...

Page 53: ...tap LEFT NIB or RIGHT NIB in the Function Bar Note that the images will reflect if the current process is convex or concave 13 Enter the diameter of the nib in the field 14 Tap APPLY to accept the ch...

Page 54: ...following ways d Measure the CT offline and type the value in the Measured CT field e Measure the CT with the onboard part probe by tapping PROBE CT to initiate the automated probing sequence Always u...

Page 55: ...or performing a radius correction Direct offline measurement integrated Spherometer measurement if equipped or Manual measurement a Direct method Figure 7 22 Spherical Process Radius Correction Screen...

Page 56: ...alibration plate to be used 2 Ring Diameter Diameter of the spherometer ring or bell to be used For convex parts use the inner diameter of the ring for concave parts use the outer diameter of the ring...

Page 57: ...anual i If using a manual spherometer enter the information required in the screen above ii Tap APPLY to accept the correction 22 Tap APPLY to accept the changes and return to the main Spherical Proce...

Page 58: ...stment is used to make small alignment changes to the Y axis as required The graphic will let the operator know if the machine requires positive of negative adjustment After making an adjustment tap A...

Page 59: ...ons Asphere Parameters Definition Diameter Diameter of the asphere Shape Convex or Concave asphere RoC Radius of Curvature of the asphere K Conic constant A1 through A20 Asphere deformation constants...

Page 60: ...perture The specified diameter to start the extension Extension Radius Used to define the convex or concave radius of the extension 4 The button is a global sign converter that is used to ensure the c...

Page 61: ...er Imported from Library Outside diameter of the tool Inner Diameter Imported from Library Inside diameter of the tool Tool Radius Imported from Library Lip radius of the tool Grit Imported from Libra...

Page 62: ...alue greater than the step cut Safety Height Rapid Feed threshold offset from lens surface Since position of tool lens contact is calculated and does not account for imperfections in lens or blocking...

Page 63: ...files for form correction Total Corrections Displays all active corrections Nib Diameter Displays the active nib correction diameter CT Adjust Displays the active center thickness CT adjustment Asphe...

Page 64: ...CT and form correction 16 Tap OK to accept the new or modified process and return to the HOME screen 17 Save the changes to the job by tapping SAVE JOB 7 6 3 4 Edge Process Setup The following steps...

Page 65: ...s Imported from Library Lip radius of the tool Grit Imported from Library Grit rating of the abrasive material of the tool Tool Length Probed tool length automatically filled after probing Opposite To...

Page 66: ...ack in X to the final diameter It then feeds in the Z direction to finish the cycle This safety distance prevents the work piece s bottom edge from being damaged during the edging process Feed Type Se...

Page 67: ...eed into the part during grinding Final Feed Rate Rate at which the tool will use for the finishing portion of the process i e Feed Rate for final pass Z DOWN Z axis feed Z UP and retract X OUT Coolan...

Page 68: ...34 Edge Process Corrections Screen Table 7 22 Edge Process Correction Parameters and Descriptions Correction Parameters Description Predicted Diameter Imported The diameter defined from the Edge Proce...

Page 69: ...on Bar 2 Provide a name for the process ex FIRST SIDE BEVEL 3 Input Lens Parameters to define the bevel Figure 7 35 Bevel Process Lens Definition Screen Table 7 23 Bevel Parameters and Definitions Bev...

Page 70: ...r Diameter Imported from Library Inside diameter of the tool Tool Radius Imported from Library Lip radius of the tool Grit Imported from Library Grit rating of the abrasive material of the tool Tool L...

Page 71: ...itch from Rapid Feed to the commanded Feed Rate at this distance Use a larger safety height for initial job setup to help prevent collisions Lens RPM Rotational speed of the work spindle Tool RPM Rota...

Page 72: ...7 38 Bevel Process Corrections Screen Table 7 26 Bevel Process Correction Parameters and Descriptions Correction Parameters Description Predicted Width Imported The bevel width defined from the Bevel...

Page 73: ...f the lens to be vacuumed Figure 7 39 Fixture Process Lens Definition Screen Table 7 27 Fixture Parameters and Definitions Fixture Parameters Definition Diameter Outside diameter of lens to be held in...

Page 74: ...Left Spindle or Right Spindle Outer Diameter Imported from Library Outside diameter of the tool Tool Length Probed tool length automatically filled after probing Description Imported from Library Addi...

Page 75: ...n every pass Safety Height Rapid Feed threshold offset from lens surface Since position of tool lens contact is calculated and does not account for imperfections in lens or blocking or any input error...

Page 76: ...Fixture Process Corrections Screen Table 7 30 Fixture Process Correction Parameters and Descriptions Correction Parameters Description Predicted Lens Dia Imported The diameter defined from the Fixtur...

Page 77: ...in the Navigation Bar 15 Provide a name for the process ex Scoop 16 Input Lens Parameters to define radius to be scooped Figure 7 43 Scoop Process Lens Definition Screen Table 7 31 Scoop Parameters a...

Page 78: ...of the tool Inner Diameter Imported from Library Inside diameter of the tool Grit Imported from Library Grit rating of the abrasive material of the tool Tool Length Probed tool length automatically fi...

Page 79: ...account for imperfections in lens or blocking or any input errors the machine will switch from Rapid Feed to the commanded Feed Rate at this distance Use a larger safety height for initial job setup...

Page 80: ...new or modified process to the job file 24 Enter Scoop correction parameters as necessary Figure 7 46 Scoop Process Corrections Screen Table 7 34 Scoop Process Correction Parameters and Descriptions C...

Page 81: ...e position of tool lens contact is calculated and does not account for imperfections in lens or blocking or any input errors the machine will switch from Rapid Feed to the commanded Feed Rate at this...

Page 82: ...tool lengths and part reception height before processing Once they have been setup and checked by a qualified operator the job is ready to run 3 Once a job has been created or loaded and the tools an...

Page 83: ...7 7 1 Settings Page 1 Figure 7 49 G Series Settings Page 1 Table 7 36 Settings Section Descriptions Page 1 Settings Section Description Machine Configuration Factory set hardware configuration for th...

Page 84: ...ogram for part loading unloading Linked Process Is used with extreme caution to link multiple spherical part programs together to reduce overall cycle time Should only be used by an experienced operat...

Page 85: ...point When this switch point LED changes to orange then the flow requirement has been met Figure 8 1 Coolant Flow Meter Display and Controls The relative flow is indicated by the number of green LEDs...

Page 86: ...ravel may cause error messages to appear on the user interface Press the RESET button to clear messages after action to correct the error has been taken For example If you see a low air pressure error...

Page 87: ...42 SPINDLE CHILLER TEMP OR FLOW FAULT M43 SPINDLE CHILLER MOTORS RUN FAULT M44 COOLANT CHILLER TEMP OR FLOW FAULT M45 COOLANT CHILLER MOTORS RUN FAULT M50 TOOL NOT IN LEFT SPINDLE FAULT M51 TOOL NOT I...

Page 88: ...C AXIS WORK SPINDLE NOT REFERENCED M59 COOLANT SYSTEM CENTRIFUGE OR STIRRER OFF M64 B AXIS CLAMPED M93 LEFT TOOL IS OK BUT WON T RELEASE M97 RIGHT TOOL IS OK BUT WON T RELEASE M99 PROBE CONTACT DETECT...

Page 89: ...K WITHOUT A PRECISION STEM FULLY INSERTED see Section 5 9 for additional information Ensure the tool holder and spindle tapers are clean and free of burs See Section 9 9 9 1 2 End of Shift Remove any...

Page 90: ...e Section 10 3 9 4 Semi Annual Maintenance Check the machine tram and re tram if necessary See Section 10 1 9 5 Yearly Maintenance Drain and replace the chiller fluid with approximately 4 gallons of 3...

Page 91: ...that are circled in yellow and remove the top as seen in the Figure 9 1 Make sure to take note of the dowel circled in red Figure 9 1 Centrifuge Catch Basin 4 Remove the rubber liner by gripping its s...

Page 92: ...erm upgrade option is to replace existing polycarbonate panels with laminated glass complying with ISO 23125 B1 standard Replacing the side windows 1 Unbolt the left right and top brackets from the in...

Page 93: ...t when it comes unstuck 3 Place the new piece of glass or polycarbonate into the window frame Holding the window in place reinstall the bottom bracket Install the screws in the middle unslotted holes...

Page 94: ...re there is space enough to place the door once it is removed 1 Remove the two clips on the bottom of the door holding the door to the rail shown with an Allen wrench 2 Remove the plate on the left in...

Page 95: ...ously up and outwards 4 Follow the directions for removing the windows from the side doors to remove the window from the front doors If the silicone bead in the machine comes out with the window remov...

Page 96: ...Lift the window back into the lower channel in reverse of step 3 ensuring that the bearings on the top inside face of the door are seated correctly in the rail and replace the two brackets removed in...

Page 97: ...oling liquid oil or metallic particles nor traces of oxide or scale See the figures below Figure 9 2 Tool Holder taper 1 and stop 2 must be clean Figure 9 3 Spindle taper 1 and stop 2 must be clean Us...

Page 98: ...t be periodically lubricated See Section 10 3 for MetaFlux part number 1 Lightly spray MetaFlux in the grooves between the fingers of the drawbar on the tool spindle Figure 9 4 2 After applying the Me...

Page 99: ...tram operation The tram screens will actively set the fixture offsets G54 for single grinding spindle G54 G55 for twin grinding spindles and update probe locations in the settings page A single spind...

Page 100: ...ck should be between 0 2 m If the run out is greater than 2 m then the chuck needs to be adjusted If the chuck needs to be adjusted 1 Slightly loosen the four M8 bolts holding the chuck to the table 2...

Page 101: ...or the F4 key to start the tram procedure 10 1 3 Tram B Zero Screen The purpose of this screen is to align the angle of the tool spindle and work spindle center lines so that they are parallel This is...

Page 102: ...e this operation follow the instructions on the screen see Figure 2 You should move to the previously found B zero and spindles aligned position by tapping MOVE LEFT or MOVE RIGHT for each tool spindl...

Page 103: ...bly as necessary To remove the probe tip or probe assembly use the spanner wrenches provided in your tram kit The instructions on the screen will guide you through performing this task see Figure 3 Ut...

Page 104: ...h a 0 127mm 0 005 thick metal feeler gage and 25 4mm 2 precision gage block that should be used for touching off the HSK tool Pin also in the tram kit on the tram ball and the Schunk face If the gages...

Page 105: ...ool pin that is placed in the tool spindle over the top of the tool probe tip This can be done by manually jogging the machine over this location or by tapping MOVE L or MOVE R and pressing CYCLE STAR...

Page 106: ...e last known alignment positions Once in place tapping ALIGN will execute an automated probing routine Figure 10 7 guides you through this process If the old B axis number is not correct you can place...

Page 107: ...80 micron move the axis 10 15 micron Work on one axis at a time Very often there is a combination error adjust the axis with the greatest error first With practice this method will speed up the entir...

Page 108: ...Work Spindle S2 counterclockwise rotation Right Tool Spindle S1 clockwise rotation 5 Stop spindle rotation M5 S1 M5 S2 6 Perform Tool Change T5M6 T1 8 7 Turn on Thru the Tool Spindle Coolant 8 Turn on...

Page 109: ...CW One Pocket Synchronous 2 Arm ATC and Synchronous No Arm ATC 103 TC Gripper Open Synchronous 1 Arm ATC 103 TC Magazine Rotate CCW One Pocket Synchronous 2 Arm ATC and Synchronous No Arm ATC 104 TC...

Page 110: ...r rotary axes EXAMPLE G55G1X0F100 move x axis to 0 position at 100mm min 10 2 3 Spindle Command S spindle number rpm M spindle parameter spindle number command tool or work spindle 1 Left Tool Spindle...

Page 111: ...MC AFM30P 060AS 1 Air Prep Regulator Filter Bowl OptiPro 63164A SMC C3SF 1 Air Prep Mist Separator Bowl OptiPro 63164A SMC C3SF 1 Work Spindle Rotary Union OptiPro 69284A SMC KXH08 03S 1 Centrifuge Li...

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