Rocketronics ELS 4 Basic Operating Instructions Manual Download Page 1

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ELS 4 BaSic

ENGLISH

Operating instructions

This manual describes the commissioning and use of

the cycle controller ELS 4 BASIC.

TrAnSLATIon of ThE orIgInAL
opErATIng InSTruCTIonS

Summary of Contents for ELS 4 Basic

Page 1: ...ELS 4 Basic ENGLISH Operating instructions This manual describes the commissioning and use of the cycle controller ELS 4 BASIC Translation of the original operating instructions ...

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Page 3: ...pensation All rights in the event of patent grant or utility model registration reserved All product designations mentioned in this manual are trademarks of respective companies Subject to technical changes without notice All safety regulations in particular the CE directives have been observed during pro duction The product was subjected to an extensive final inspection at the factory ...

Page 4: ...T EMITTING DIODED LED 24 Micro SD Card Slot 25 Programkey Settings reset 25 Inputs and outputs 26 Screwterminal data 27 Power supply 27 Extension connector 27 Grounding 27 Connection of encoder 28 Connection motordriver 30 Digital Inputs 32 Emergency Stop 33 Digital Outputs 35 Grounding cable and shielding 37 System connection diagram 38 SETUP 39 SETUP GeneraL 40 SETUP ENCODER 40 SETUP Z Motor 41 ...

Page 5: ...V 85 I RADIUS INTERNAL RADIUS CONVEX 87 I RADIUS INTERN RADIUS CONCAV 89 GROOVE 91 GRINDING 96 ANGLE 97 tips for use 98 Approach positions exactly 98 Set the zero point on the workpiece surface 98 Drive from waiting position to 0 98 Precise external turning made easy 98 Special dimensions by changing the settings 99 Moving the X axis manually in gear mode 99 Softwareupdate 100 Appendix 1 Definitio...

Page 6: ...ribed Nevertheless deviations cannot be excluded so that we do not assume any liability for the complete conformity However the information in this publication is checked regularly and necessary corrections are included in the following editions Addressee of the documentation This documentation is intended for machine tool users and installation personnel The bro chure describes in detail the info...

Page 7: ... not be changed removed or otherwise made unrecognizable 5 The customer may not reverse engineer decompile or disassemble the SOFTWARE Otherwise 69d 69e UrhG remain unaffected II warranty 1 The LICENSER warrants in accordance with the provisions of 434 ff BGB that the SOFTWARE complies with the specifications listed by Rocketronics in the associated program documentation and that it has been creat...

Page 8: ...ELS the user can cut threads in all pitches even tapered or multi threads It is possible to turn radii and cones inside and outside radii in concave or convex with cutting radius compensation Longitudinal and face cutting inside and outside are possible as well as parting and undercuts It indicates positions and allows the exact approaching of positions The ELS turns a manual machine into an autom...

Page 9: ...containing a component part manufactured by Rocketronics must include appropriate warnings and instructions for safe use and operation when handed over to the end user All warnings provided by Rocketronics must be passed directly to the end user The user of this control must ensure that all necessary safety precautions have been taken and that they have been checked for correct operation to ensure...

Page 10: ...rical industry Unqualified persons must not put the control unit into operation The control unit is designed for operating temperatures of 5 to 40 C and storage temperatures of 10 to 50 C The control unit must not be operated by unqualified persons It must be protected from high humidity vibrations and explosive gases Before opening the device it must be disconnected from the power supply Connecti...

Page 11: ... as well as careful operation and maintenance Do not use a damaged controller Switch off the device immediately if it shows noticeable deviations from normal operation Rocketronics de guarantees the proper function of the device only if no changes are made in mechanics electronics and software The opening of the device as well as adjustment maintenance and repair work may be carried out only by ap...

Page 12: ...re already present in many households and businesses For wall mounting we recommend the wall mount adapted to the ELS This is mounted to the ELS with two screws and available in our store ELS Basic Wallmount Power supply 12V 1A Micro SD Card Lathecontroller Basic Typ WH ELSBW Adjustable wall mount Power supply with 12V und 1A stabilized and short circuit protected 2 GB Micro SD Card for software u...

Page 13: ... this later 2 Drive on X axis Tobeabletocontrolthetransverseaxis X asufficiently dimensioned controllable drive on the axis is necessary A stepper or servo motor must be mounted here 4 Safety device The complete machine must have an emergency stop device in which the ELS control must also be integrated The ELS has inputs and outputs for this purpose An automatic restart after the emergency stop ha...

Page 14: ...0 000 Example Speed 3000 rpm 400 pulses rev 3000x400 1 2000 000 which is fine If the pulse rate is too high this can overload the control The maximum possible speed can then be reduced The following pulse rates are recommended with a ratio spindle encoder of 1 1 and 2 1 Max Spindle speed Transmission Impulserate Encoder Settings in ELS Product 2000 1 1 500 500 1 000 000 3000 1 1 400 400 1 200 000 ...

Page 15: ...B B CHANNEL B CHANNEL 5V 5 V 5 V A A CHANNEL A CHANNEL X INDEX CHANNEL INDEX CHANNEL G GND GND T UNUSED N A AMT102 AMT103 Mating Connector AMP 3 640440 5 tin AMP 3 641237 5 gold Mating Connector Molex 50 57 9405 Housing Molex 16 02 0086 Terminals RESOLUTION SETTINGS 4 3 2 1 off 0 on 1 Example setting 500 PPR DIP switch 1 On 0 Off Resolution PPR Maximum RPM 1 2 3 4 2048 7500 0 0 0 0 1024 7500 0 0 1...

Page 16: ...f the ELS depends on the encoder pulses It is therefore naturally limited We recommend setting the motor output stages of the Z axis to 400 or 800 steps revolution The output stage of the X axis can be set to 800 1600 depending on the thread pitch of the spindle We recommend mounting a hybrid servo motor closed loop stepper motor on the Z axis and a stepper motor on the X axis Stepper motors are s...

Page 17: ...disadvantage being that the motor loses torque the smaller the step widths become and that the controller has to deliver more impulses for this With the ELS we use steps on the Z axis or i e 400 or 800 steps per revolution More is not necessary and only unnecessarily limits the maximum possible feed rate We can also use even finer steps on the X axis Motorcoils Stepper motors and hybrid servo moto...

Page 18: ...ques at higher speeds the curve drops sharply at higher speeds So if high speeds are required it is more of a disadvantage to trans late In the end they do not necessarily get more torque Pay attention to backlash free variants of timing belts e g a HTD profile Only use transmission in straight ratios 2 1 4 1 etc The step rate on the motor driver should then be selected accordingly see table below...

Page 19: ...m revolution is directly linked to the ratio of encoder pulses mo tor steps revolution and the thread pitch of the lead screw The maximum feed rate is decisive for the maximum thread pitch you can produce Please note however that threads with a pitch of more than 8 mm are very rarely turned 17 Screwpitch mm Transmission Steps Rev on motor Resolution per step mm 1 1 1 400 0 0025 2 1 1 400 0 005 3 1...

Page 20: ...halving the steps of the motor i e changing from half step to full step Unfortunately this cannot be done arbitrarily since at high speeds too many impulses are re ceived by the controller and it no longer follows with the processing of the control signals But up to a speed of 2000 rpm you should manage with 800 pulses rev for the encoder As you see there are a few settings which you can use to tu...

Page 21: ...r because the digital drivers offer better signal processing and thus control the motors even more efficiently We therefore recommend the use of digital motor drivers Connection of the drivers All drivers have a connection for a power supply which must be able to supply the required voltage and sufficient current for the motors Usually there are 24 36 or 48Volt with large driv ers it is also possi...

Page 22: ...te less heat when the drive is at rest This should be activated Please refer to the documentation of the manufacturers of the com ponents All components purchased from Rocketronics are accom panied by corresponding documentation and pin assignments 20 Emergency STOP The complete machine must have an emergency stop device in which the ELS control must also be integrated The ELS has inputs and outpu...

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Page 24: ...ates In the manual buttons are addressed with a symbol e g START and with the following designation Settings X Axis off Z Axis off LED2 Display START STOP Key LEFT UP Z STEP RIGHT KNOB DOWN X STEP Power ON OFF Zero position Zero Z Axis Zero X Axis SLOW JOG X and Z axis FAST JOG X and Z axis FN KEY Programkey Settings reset Micro SD Card LED3 LED1 ...

Page 25: ...y pressing the knob push button function or turning and simultaneously pressing the but ton push button function The input resolution can be reduced by pressing the FN key This allows you to enter values in steps of 1 0 1 or 0 01 In some cycles the step by step is sensibly adjusted to 0 1 0 01 and 0 001 LEFT Switches the cycles to the left RIGHT Switches the cycles to the right UP ZSTEP Moves the ...

Page 26: ... Z axis was switched off with ZOFF LED3 lights up if the X axis was switched off with XOFF LED1 flashes during a software update If the update fails LED2 lights up after the update process The cursor shows the current value that can be changed with the rotary knob It corresponds to the cursor on the computer screen The cursor can be moved with the up and down keys Move it to e g the first line to ...

Page 27: ...y cards of 2 32GB with FAT32 formatting are compatible Programkey Settings reset On the right side of the housing there is also a small button For a software update this button is kept pressed when switching on Factory Reset In normal operation this button can also be used to set the settings to factory defaults The button is held for 7 seconds A warning message in the display must be confirmed to...

Page 28: ...RJ45 and screw terminal 2 inputs for 1 X axis drive system RJ45 and screw terminal ATTENTION Either use RJ45 OR terminals not both 1 supply voltage input for 12V round plug 4 digital inputs for emergency stop circuit limit switches and error signals 4 outputs for 12 or 24V external for switching purposes 1 SUB D 15 Expansion connector for an external control unit 1 Ground connection All screw term...

Page 29: ... connector Signals for an external control unit are output via a SUB D 15 HD socket The signals are used to control a 16 bit I O expander that is addressed via a specially adapted 3 3V I2C bus The assignment is suitable for the offered ELS expansion modules Grounding A 6 3mm flat plug is available for grounding the housing The earthing should always be connected to ensure good interference immunit...

Page 30: ... RJ45 connection using a commercially available Ethernet patch cable and the differential line driver is designed to match To ensure the interference immunity of the signals the signal must be transmitted differential ly recognisable by the connections A A B and B Normal signals can be converted into a differential signal with the Rocketronics differential line driver An index signal is not neces ...

Page 31: ...vides a very cost effective simple shielded connection The line driver can be soldered directly to encoders of type HEDS or AMT103 Encoder Setings Some encoder types can be set in the pulse rate e g the type AMT103 V Please refer to the section on the encoder in this manual and set the desired pulse rate Other encoders have a fixed pulse rate and cannot be set For example The PIB408 Encoder alread...

Page 32: ...ut stages are FET open drain outputs which connect to ground Maximum switching voltage 30V Maximum switching current 200mA Maximum pulse length 12 microseconds adjustable Connection Use either screw terminals or RJ45 jack for connection The RJ45 connector is compatible with Rocketronics RJ45 driver adapters and allows clean connection of motor drivers with commer cially available Ethernet patch ca...

Page 33: ...ivers and copies thereof These are connected directly to the driver connectors and then provide a suitable RJ45 connector Connect drivers and controls with an Ethernet patch cable very simple and create a clean and shielded connection The adapters are also available for ES DHxxxx servo drivers Schematic representation of the output stages and connection to drivers ...

Page 34: ...al assignment Both normally closed and normally open contacts can be used or inductive proximity switches PNP or NPN 12V Terminals 9 and 10 GND can be used to connect the control ground to external power supplies or sensors Input 1 ESTOP The input must be activated in the settings Input for emergency stop signal Connect a po tential free contact here e g an emergency stop mushroom button or a rela...

Page 35: ...is activated in the control running cycles are aborted immediately pulse generation is stopped and the drives are stopped If the spin dle of the machine is operated via an inverter it can be stopped in a controlled manner via the simultaneously switched SPINDLE STOP OUTPUT thus slowing down the spindle faster than if the voltage is simply interrupted After an adjustable time ESTOP FOLLOW DELAY the...

Page 36: ...t switch of the Z axis You can use potential free contacts of a mechanical limit switch or inductive proximity switches see below When the input is activated the control switches to a safe state and ends running cycles until a release has been given with the STOP key Input 3 X LIM Like Z LIM only for X axis Input 4 ERROR The input must be activated in the settings input for an error signal e g fro...

Page 37: ...cify a delay time in the settings then this output switches delayed after the emergency stop to switch off the power supply completely for example after braking the drives Settings Outputs ESTOP FOLLOW Delay See also EMERGENCY STOP Output 2 SPINDLE STOP This output is used to switch off the spindle It is activated at the end of a cycle and after an emergency stop The output is activated immediatel...

Page 38: ...starts Settings Outputs COOL OUTPUT DELAY Output 4 AUX Not used yet NOTE All outputs are deactivated at the factory and must first be activated in the settings The voltage applied to OUTPOW IN is switched to the outputs If the terminal is not con nected no voltage is output at the outputs Connect OUTPOW IN with 12V or another DC voltage up to max 24V CAUTION Only apply DC voltage to the voltage in...

Page 39: ... throughs available that allow the use of shielded patch cables If you use other cables please make sure that they are shielded The shield is optimally con nected to the control ground on one side only There are several terminals with GND available which can be used for the shield connection At the back of the housing there is also a 6 3mm flat plug for grounding connect a cable for grounding the ...

Page 40: ...ers 38 System connection diagram The system consists of controller motor systems encoder power supply units and safety ele ments is wired as shown below schematically shown Encoders and motor drivers can be connected directly with patch cables as well as with mul ti core cables Driver error outputs can be connected to the error input Please observe the notes on encoders and motor systems i ...

Page 41: ...R IMPULSES PER REV REVERSE DIRECTION SETUP Z MOTOR SPINDLE PITCH BACKLASH mm STEPS REV ACCELERATION F SLOW F FAST REVERSE DIRECTION SETUP X MOTOR SPINDLE PITCH BACKLASH mm STEPS REV ACCELERATION F SLOW F FAST REVERSE DIRECTION AVAILABLE SETUP DATA STEP SIZE FINE STEP SIZE COARSE Z Ap FINISH Z Ap ROUGH Z RESTPOSITION X Ap FINISH X Ap ROUGH X RESTPOSITION SETUP INPUTS ESTOP INPUT ACTIVE ESTOP INPUT ...

Page 42: ...RATION OF STEP PULSE The duration of the pulses sent to the stepper motor output stage Normally 4µs are sufficient if required also 8 and 12 µs are possible X AXIS KEYS INVERT This allows you to reverse the operation of the X axis trav erse keys useful for inclined bed machines MEMORYPROFILE The settings can be stored in 2 profiles which can be select ed here The default profile is A B can be used...

Page 43: ...his value cannot be calculated but must be determined by test Stepper motors cannot be switched from 0 to 100 then they would inevitably block The electronic lead screw therefore moves all movements with an adjustable acceler ation ramp Values between 50 and 150 should be tried at the begin ning F Slow The slow feed rate in mm min This is used when the Z axis is approaching material in automatic p...

Page 44: ...eration The acceleration of the stepper motor in mms2 This value cannot be calculated but must be determined by test Stepper motors cannot be switched from 0 to 100 then they would inevitably block The electronic lead screw therefore moves all movements with an adjustable acceler ation ramp Values between 50 and 150 should be tried at the begin ning F Slow The slow feed rate in mm min This is used...

Page 45: ...in two steps several roughing passes and one final finishing pass the thickness of the finishing pass in mm being indicated here Z Ap Rough In automatic operations such as long turning cutting is always carried out in two steps several roughing passes and one final finishing pass The maximum thickness of the roughing passes in mm is indicated here Z restposition The waiting position in Z direction...

Page 46: ...switch input Z LIMIT Input Polarity Standard Closed Active NO Can be set to Open Active NC ERROR Input active Input for error signal Motor drive Activate or deactivate input ERROR Input Polarity Standard Closed Active NO Can be set to Open Active NC SETUP INPUTS ATTENTION ATTENTION The activation of an input takes effect immediately after leaving the settings the control reacts accordingly When th...

Page 47: ...ump activated at cycle start COOL output delay Delay for starting a cycle This time is waited after activa tion of the COOL output until a cycle is started This en sures that the coolant has arrived at the tool before the cut starts SETUP Outputs Element Description I O Information Shows the state of the inputs and outputs ELS 4 Firmware Version Firmwareversion SELFTEST RESULT Shows the results of...

Page 48: ...o the correct voltage 12V and polarity The voltage input is protected against reverse polarity and fused 1 3 Connection Switch on Connect the emergency stop circuit the motor output stages and the encoder to the rear terminals Refer to the previous chapters for details Switch on the ELS Basic at the power switch by pressing the button for approx 1 second To switch it off press the button for appro...

Page 49: ...d For acceleration first start with 50 slow and fast travel with 300 mm min or 1500 mm min 0 0 Set the pitch of the threaded spindles on the Z and X axes SETTINGS SETUP Z X MOTOR SPINDLE PITCH Very important Set the encoder pulse rate on the encoder AND in the settings of the ELS Set the step rate of the stepper motors on the motordrivers AND in the settings of the ELS Setting the thread spindle p...

Page 50: ...irection in the settings under SETTINGS X MOTOR REVERSE DIRECTION 3 Correct encoder direction In some cases it may be necessary to reverse the direction of rotation display of the encoder To check this proceed as follows Use the LEFT key or to change to the GEARBOX LEFT cycle 1 Use the UP and DOWN keys to move the cursor to F feed rate 2 Set the feed rate with the knob to a value of 0 20 mm 3 Move...

Page 51: ...ly tested 1 Switch to the ANGLE cycle 2 Mark a point on the lathe chuck and set the angle on the control with P0 to 0 3 Now let the spindle run for a while at medium speed max 1000 rpm 4 Stop the spindle and turn the chuck manually in the direction of rotation up to the mark 5 Here the control must now display approximately 0 If it deviates strongly there is something wrong with the encoder Is the...

Page 52: ...he acceleration of the Z motor 1 Stop the spindle 2 Change to the settings and set the value for F rapid traverse of the Z stepper motor to a value around 1000 3 Move the Z axis a few times to the left and right using the traverse keys 4 If you notice that the motor is blocking you must try to adjust it using the acceleration and rapid traverse values If the motor blocks at the end of the accelera...

Page 53: ...mber of motor steps for the axes correct If there are slight deviations which are different each time steps may be lost loosen all axle clamps reduce the acceleration further as a test and check again Are the motors slip free on the shafts Grub screws don t always hold this tight better are keyslots with keys Is there a transmission in the powertrain that may not have exact round numbers Then adju...

Page 54: ... about that later With the three input values F ZP and XP the ELS can now be used to run any cycle that is offered Example A piece of raw material with a diameter of 50 14 mm is to be turned down to 40 00 mm over a length of 30 00 mm So the material changes in diameter by 10 14 mm in radius by 5 07 mm We then enter 30 00 for the path in ZP but 5 07 mm for the path in XP since the decrease in X cor...

Page 55: ... than 1 second to switch to the step mode of the Z axis Press and hold the STEPX key to switch to the step mode of the X axis You can then move step by step with the rotary knob in 0 1mm increments press the rotary knob while turning you move in 0 01mm increments Manual movement We recommend to leave the handwheels mounted because then you can still drive manually To allow this you can deactivate ...

Page 56: ... of cutting passes So that the tool or the material is not overloaded cutting is usually carried out in several in feeds we speak of passages Before each pass the cutting edge is driven into the material by a certain amount in order to chip the material layer by layer The cutting depth during machining is called ap in the display we use Ap For rough roughing we use Ap Rough for fine finishing we u...

Page 57: ...aves time on longer operations Possible cycles The following cycles are available Gearbox Left Electronic gear Left Gearbox Right Electronic gear Right Turning External long turning Boring Internal long turning Facing Parting Undercut External thread Straight or tapered thread External Internal thread Straight or tapered thread Internal Thread 0 External thread Never exceeding 0 External taper Int...

Page 58: ...ple the beginning of a thread is found correctly again in the thread cycle After changing to this cycle the feed must first be started with START for safety reasons The STOP key can be used to stop and restart the feed at any time GEARBOX RIGHT The same but the other way round e g for left hand threads Tip In these GEARBOX cycles the X axis can be deactivated with XOFF to be able to feed man ually...

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Page 60: ...an be selected before the start of the process Available parameters in the parameter menu X Ap Finish depth of the last finishing pass in mm Finish feed rate Speed of the finishing pass either as a percentage of the feed rate set or if it continues to exceed 100 also in discrete values in mm revolution The roughing pass is then carried out at the feed rate F set in the cycle the last finishing pas...

Page 61: ... Here the movement goes directly after the START signal WITHOUT safety query to X 0 00 and then in Z direction to the end point Z P Then a reset to X 0 2 and back to Z 0 00 takes place then the position for X and Z changes to the hold position 3 ZP 0 and XP 0 so the values for length and depth are given here The control cuts fully automatically in several passes After the START signal the control ...

Page 62: ...n mm revolution L 10 00 The length of the cut in Z direction ap 5 00 The total decrease of material thickness in X direction nap 10x 0 49 0 10 The number of roughing passes and the strength of the last finishing pass nap n x Ap So here 0 49mm are to be removed in 10 passes the last pass is done with a finishing thickness of 0 10 mm In total this results in a value of ap 5 00 mm The total number of...

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Page 64: ... X Z towards the chuck Z Required data Feed F in mm U ZP Machining length in Z direction must be zero or negative Optional data XP Cutting depth in X direction must be zero or negative If XP 0 the material is only fed in the Z direction e g for manual feed in the X direction If XP 0 the number of cutting passes can be selected before the start of the process Available parameters in the parameter m...

Page 65: ... STOP button is pressed after which X and Z are reset to the stop position 2 ZP 0 XP 0 therefore only one end position for Z is specified no depth Here the movement goes directly after the START signal WITHOUT safety query to X 0 00 and then in Z direction to the end point Z P Then a reset to X 0 2 and back to Z 0 00 takes place then the position for X and Z changes to the hold position 3 ZP 0 and...

Page 66: ...d data Feed F in mm U ZP Machining length in Z direction must be zero or negative Optional data XP Cutting depth in X direction must be zero or negative If XP 0 the material is only fed in the Z direction e g for manual feed in the X direction If XP 0 the number of cutting passes can be selected before the start of the process Available parameters in the parameter menu X Ap Finish depth of the las...

Page 67: ... Z are reset to the stop position 2 ZP 0 XP 0 therefore only one end position for Z is indicated no depth Here the move ment goes directly after the START signal WITHOUT safety query to Z 0 00 and then in X direc tion to the end point X P Then a reset to Z 0 2 and back to X 0 00 takes place then the position for X and Z changes to hold position 3 ZP 0 and XP 0 so the values for depth and radius ar...

Page 68: ...r negative There are two possible variants 1 XP 0 so no end point is specified in which case the movement after the START signal goes in the X direction after a safety query until the STOP key is pressed START Stop operation is possible while the vehicle is moving Only when the STOP button is pressed does the move ment abort after which X is reset to the stop position 2 XP 0 so values for depth ar...

Page 69: ...want the undercut to be longer than the automatic has calculated you can switch to ZP and simply increase the length Before the start of the cut the number of passes is shown again which can be changed quickly with the knob as usual Example A bolt end has been turned and is 30 mm long A thread is to be cut with 0 97mm thread depth We set the depth of the undercut to XP 1 50mm The length is then ca...

Page 70: ...you enter the parameter menu Exit the menu by pressing the HIGH key or LEFT X Ap Finish Depth of the last finishing pass in mm Finish feed rate Speed of the finishing pass either as a percentage of the feed rate set or if it continues to exceed 100 also in discrete values in mm revolution The roughing pass is then carried out at the feed rate set in the mode the last finishing pass at the speed se...

Page 71: ...he thread groove is hit again and again Important As long as the thread is not finished you should not go over the permitted 1200 rpm on the main spindle otherwise the position can get lost Basically you shouldn t exagger ate the speed and should rather drive slower then the necessary starting distance is shorter Before each start you can select the number of passes and the depth of infeed as in t...

Page 72: ...s is the same method that one learns as a lathe operator by tilting the top slide in order to be able to then feed it at an angle It is absolutely necessary to enter the flank angle in the parameter menu The modified flank infeed is an extension It cuts on both sides but very little on the right side This leads to better surfaces and good chip control but is worse on weak machines than method no 2...

Page 73: ...X axis is not moved but must be moved manually 2 ZP 0 XP 0 so a length and a thread depth are specified After the START signal the controller first displays all the data for the individual passes in an overview and then starts again after a new start command Here you can also abort at any time by pressing the STOP buttons The return travel always takes place in X slightly above the zero point beca...

Page 74: ...mm Ÿ Poor surfaces possible on the right side Ÿ Good chip control Ÿ Reduced cutting forces less vibration Ÿ Uneven tool wear only one side Ÿ Uniform cut depths Ÿ Preferred to use Ÿ High surface quality Ÿ Good chip control Ÿ Reduced cutting forces less vibration Ÿ Uniform tool wear Ÿ Long service life Ÿ Uniform cut depths Ÿ Only possible with backlash free threaded spindle on the Z axis recirculati...

Page 75: ... X then to Z ZP Thread length XP the thread depth ap F the thread pitch ATTENTION X is ALWAYS in the removal direction in this case X is towards the operator This is the other direction than with the external thread To zero the X axis always approach the oper ator and then set it to 0 this is the only way to ensure that the backlash is taken into account The procedure is otherwise the same as with...

Page 76: ...S in the graphic above The longer the higher the feedrate and the higher the spindle speed the longer the path will be If the zero point is set in this mode directly at the workpiece edge the first threads become very narrow and only at the end of the acceleration path does the thread pitch correspond to the set nominal feedrate value F The first thread pitch is then set at the end of the accelera...

Page 77: ...ate mode but there are several ways to turn a left hand thread 1 Turn the turning steel around and let the spindle turn clockwise Then you can turn the external left hand thread in the external thread mode 2 Use an internal thread turning tool and place the opposite end of the workpiece Then you use the internal thread mode to turn an external left hand thread when the spindle is turning clockwise...

Page 78: ... the spindle and end the cycle Then the cutting edge in Z is exactly right 1 Set the ELS in the parameter menu for external threads to Radial infeed 2 Set the correct thread pitch 3 Place the thread chisel in Z on the zero point 4 Set the thread length ZP set XP to 0 5 Now position the lathe tool in the X direction slightly above the existing surface so that no material is removed when moving 6 No...

Page 79: ...read This way it can be accepted immediately If the cone ratio is set to 1 0 no cone is defined anything greater than 1 0 creates a tapered thread 1 0 is preset after a restart The cone modes also have this parameter so that for taper threads you can first turn a cone with e g 1 16 and then directly afterwards the suitable thread The parameter cone ratio re mains the same as it was set in one of t...

Page 80: ...menu The setting is Tool Corner Radius Due to the Tool Corner Radius compensation the X axis travels slightly beyond XP Even in the Z direction a small excess of the ZP path can occur An important prerequisite for turning cones is a precisely measured backlash of the X axis set in the control system This can be measured with a dial gauge and must then be entered in the settings A cone is defined b...

Page 81: ... quick access to useful settings It can be reached by navigating down with the DOWN key If you change from Feed ZP XP further down you enter the parameter menu Exit the menu by pressing the UP key or LEFT Tool Corner Radius The radius of the cutting edge very important for correct radius com pensation X Ap Finish Depth of the last finishing pass in mm Finish feed rate Speed of the finishing pass e...

Page 82: ...ere again in the direction of the removal i e towards the operator X is away from the operator An important prerequisite for turning cones is a precisely measured backlash of the X axis set in the control system This can be measured with a dial gauge and should then be entered in the settings A cone is defined by 2 diameters D1 D2 and the length L The controller expects two specifications ZP This ...

Page 83: ... If you change from Feed ZP XP further down you enter the parameter menu Exit the menu by pressing the UP key or LEFT Tool Corner Radius The radius of the cutting edge very important for correct radius com pensation X Ap Finish Depth of the last finishing pass in mm Finish feed rate Speed of the finishing pass either as a percentage of the feed rate set or if it continues to exceed 100 also in dis...

Page 84: ...rner Radius in mm accessible via parameter menu Correctly set backlash on both axes Limitations in dimensions None Maximum speed 3000 rpm The speed can be freely changed during the cut A stop can be made at any time by pressing the STOP button In all radius cycles the following parameters are available in the parameter menu The parameter menu allows quick access to useful settings It can be reache...

Page 85: ...und insert Pr cutting radius 1 Tool is moved beyond XP by the amount of the cutting radius 2 Tool then stands deeper than XP 3 Z is delivered contour is traversed 4 The movement ends beyond ZP by the amount of the cutting radius 5 Then the reset to 0 0 or to the set derivative position takes place With small cutting radii the distance that must be travelled further is therefore small but it must b...

Page 86: ...xis The depth you just cut is still in XP Use the JOG key to move the X Axis to the depth you just cut It will stop there after reaching the point There you can zero the X Axis to have the exakt point of the material surface 3 Then return to the end of the material and zero the Z axis there Always drive from right to left to compensate for the backlash 4 Then set the desired values for ZP and XP a...

Page 87: ...ation the exact route is shown below Pr cutting radius 1 Tool is moved to XP 2 Tool is being moved to the left by the Tool Corner Radius PR into the materialContour is being traversed 3 The traverse ends at ZP the tool then stands beyond 0 by the amount of the cutting radius 4 Then the reset to 0 0 or to the set resting position takes place The radius is defined here by the values ZP and XP Circul...

Page 88: ... zero the X Axis to have the exakt point of the material surface 3 Then return to the end of the material and zero the Z axis there Always drive from right to left to compensate for the backlash 4 Then set the desired values for ZP and XP and start Before starting the process you can se lect the number of passes and the cutting depth per pass The depth is displayed converted to the radius and corr...

Page 89: ...dure is shown below for clarification with a round insert Pr cutting radius 1 Tool is moved beyond ZP by the amount of the cutting radius 2 The tool then stands lower than ZP 3 Contour is traversed 4 The travel ends by the amount of the cutting radius further beyond XP 5 Then the reset to 0 0 or to the set resting position takes place With small cutting radii the distance that must be travelled fu...

Page 90: ...will stop there after reaching the point There you can zero the X Axis to have the exakt point of the material surface 3 Then return to the end of the material and zero the Z axis there Always drive from right to left to compensate for the backlash 4 Then set the desired values for ZP and XP and start Before starting the process you can se lect the number of passes and the cutting depth per pass T...

Page 91: ...on the exact route is shown below Pr cutting radius 1 Tool is moved to ZP 2 Tool is being moved forward by the Tool Corner Radius PR into the material 3 Contour is being cut 4 The traverse ends at XP the tool is then still in the Z direction by the amount of the cutting radius beyond 0 5 Then the axes move to 0 0 or to the resting position The radius is defined here by the values ZP and XP Circula...

Page 92: ...n zero the X Axis to have the exakt point of the material surface 3 Then return to the end of the material and zero the Z axis there Always drive from right to left to compensate for the backlash 4 Then set the desired values for ZP and XP and start Before starting the process you can se lect the number of passes and the cutting depth per pass The depth is displayed converted to the radius and cor...

Page 93: ...her wise a paragraph may appear at the bottom of the groove In addition the cutting radius of the insert must be set correctly in the parameter menu The entries in this mode indicate the diameter of the groove in the Z direction and the depth in the X direction Circular grooves are cut by making the diameter in Z equal 2 XT so to speak diameter 2xRadius Elliptical grooves will appear if you make t...

Page 94: ...an take some time with large contours this is noticeable at paus es which the control inserts before the infeed The cut is made gently in several passes the number and depth can be easily selected before the cut Principle of cutting The rough contour is cut in n steps The cutter will dive into the material and move to the left The image below shows how this is done After roughing it will cut the f...

Page 95: ... roughen quickly and finish slowly to save time X Offset Defines the offset of the contour into or out of the material Groove offset for deep or flat grooves Normally grooves are always cut by XT into the material If the groove is to be deeper or flatter the contour can be shifted With X Offset in the parameter menu you find a setting for a shift of the contour in X direction Both negative and pos...

Page 96: ...Zeroing is done as follows Possible grooves 94 ...

Page 97: ...er the desired drilling depth ZP The feed rate is given in mm rev Pressing the START button starts the process pressing the STOP button stops it entries made in XP are ignored the X axis does not move in this mode Available parameters in the parameter menu Depth of cut The infeed per pass in mm Retract depth Either total retraction where the hole is completely retracted from the drilled hole after...

Page 98: ...This mode works with both stationary and rotating spindles so it is also possible to use it for making keyslots when the spindle is left stationary You can also specify a path in X with XP After starting you can specify the number and depth of infeeds as in the other modes If XP is less than 0 here the X axis will be advanced at each pass This allows automatic grinding or grooving The latter howev...

Page 99: ... the angle to 0 in this mode 2 Switch to thread mode and cut the first thread 3 Switch back to angle mode and manually rotate the chuck to the desired angle This would be 180 for a 2 course thread 120 for a 3 course thread and so on Then set the angle to 0 4 Return to thread mode and cut again you will see that the new track is next to the first one 5 Repeat for all gears If the thread does not fi...

Page 100: ...th face turning the face side This gives you the surface exactly on X0 and Z0 as well as two machined surfaces on which you can measure exactly Drive from waiting position to 0 After each function the ELS sets the axes to the set waiting position If this is not equal to 0 the axes are at a value above 0 If you would like to move an axis to 0 set the end position to 0 and move to it from the right ...

Page 101: ...rily halve the number of encoder pulses to double the feed rate Of course you have to take the change into account Also at settings drive of Z axis can be reversed temporarily e g to turn right side Of course you have to keep in mind that the Z axis then moves exactly the other way round than usual even when moving manually Moving the X axis manually in gear mode In gear mode the X axis can be dea...

Page 102: ...on again 7 The software is now loading you hear a clicking sound and LEDs 2 and 3 flash alternately If everything works fine the controller switches to the newly loaded program after approx 8 seconds If an error occurs you will hear several tones The number of tones indicates the error 1 Invalid card type 2 Invalid Bootdate 3 Read error 4 Cluster not found card defective 5 Wrong program 6 Wrong CP...

Page 103: ...r die Gewindelänge Um die verwendet man den Parameter Kegelverhältnis üblicherweise ist das auch beim Gewinde ange gleich übernehmen Steht das Kegelverhältnis auf 1 0 ist kein Kegel definiert alles größer als 1 0 erzeugt e 1 0 ist nach einem Neustart voreingestellt Passend dazu haben die Kegel Modi auch diesen Parameter so dass man für Kegelgewinde ers 1 16 drehen kann und dann direkt danach das p...

Page 104: ... mounting On the back there is a retaining bracket for wall mounting In addition a wall bracket is avail able that can be adjusted in all axes and mounted with screws How to adjust and fasten the control optimally 102 ...

Page 105: ...ing 1200 rpm Smallest step size 0 01mm way in Z und X Axis Smallest possible thread pitch 0 001mm Max manual feed rate 4800 mm min 1 Motor outputs 2 Screw and RJ45 Digital inputs 4 screw Digital outputs 4 12V max 300mA Encoder inputs 1 Screw or RJ45 Maximum feed rate ca 20 mm rev 1 1 Depending on encoder and motor setting 4 5 6 7 8 168 00 103 70 43 50 12 90 8 78 103 ...

Page 106: ... aluminium case can be recycled much easier when separated from the electronic parts Dispose the electronic parts in the ap ropriate disposal services Of course you can also dispose it completely Contact us Manufacturer is Rocketronics de Dipl Ing FH Louis Schreyer Hugo Grotius Str 18 27404 Zeven GERMANY Tel 04281 50 79 78 2 Mo Fr 14 18 Uhr Email info rocketronics de USt IdNr DE813546414 WEEE Reg ...

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Rocketronics ELS 4 Basic, Operating Instructions Manual

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