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INSTRUCTION MANUAL

6.2.2.3.3.3. DRILLING, COLLARING AND TRIMMING COMBINATION TOOLS (DCT)

TULEE UUSI KUVA KUN SAAN OHJELMAN

Tool number

Identification number of the tool

Tool Status

N/A

Tool size

Nominal tool size, stamped on the tool

Tool rotation

angle

Tool rotation

angle S1

Tool rotation

angle S2

Drilling tool

diameter

Drilling tool

length

Length of tool from cone

bottom to the drill end

Drilling tool

cutter length

Length from the cutter

insert to the drill end.

Summary of Contents for S-80

Page 1: ...INSTRUCTION MANUAL COLLARING MACHINE S 80...

Page 2: ...to elaborate this instruction book with the greatest possible care and attention The accuracy of the in formation has been carefully checked during the preparation of the manual Should any subsequent...

Page 3: ...2 5 2 Layout of the S 80 Collaring machine 13 5 3 Installation of the light curtains optional equipment 15 5 4 Connection of the machine to the sources of energy 16 5 4 1 Connection to the electricity...

Page 4: ...57 6 7 Control tower signal lights 59 7 Operation of the S 80 machine 60 7 1 Machine general setup 60 7 1 1 Collaring tool setup 60 7 3 Tool magazine 62 8 Maintenance 63 8 1 Clamping device maintenan...

Page 5: ...use NOTE Read all the instructions for the entire operation sequence before proceeding with the installation operation or maintenance of the machine 1 2 SYMBOLS FOR WARNING AND DANGER USED IN THIS MA...

Page 6: ...during the process relating to the collar Don t put your hands on the tube line under the machine or in the end of the machine during process Mind the rotating tool Warning Moving parts Be extremely c...

Page 7: ...apacity of the machine Before removing or mounting a collaring head or a clamp the electric current supply must be disconnected by pushing the power OFF O button in the front panel Disconnect power be...

Page 8: ...equirements All this to guarantee that the T DRILL S 80 unit is reliable even in heavy duty industrial use 3 2 THE PURPOSE OF THE MACHINE The S 80 unit is designed for extrusion of collars to straight...

Page 9: ...2 2 1 Machine main frame 2 MFT Manual Feed Table Optional equipment 3 Clamping unit 4 Moving frame slide set and frame 5 Spindle 6 Tube support 7 Covers and doors 8 Front cover 9 Chip shield 10 Warnin...

Page 10: ...oring Tool in position sensors Chip cover for tool magazine 3 5 AXIS DIRECTIONS OF THE MACHINE Y Y Z Z X X Main movements X axis Stroke 85 85mm Speed max 10 m min 166 mm s Holding brake 40kN lin force...

Page 11: ...ck or with a crane and lifting chains 1 2 Lifting the S 80 machine 1 Use a fork truck drive the forks through the machine frame holes ensure that the forks go all the way through the machine frame to...

Page 12: ...Anchor bolt and leveling bolts Floor plate fixing Use chemical anchor bolts M16 W rth W VD or equivalent Anchor bolt holes 18 Secure with M16 nuts Alignment of the machine Check the horizontal straigh...

Page 13: ...80 COLLARING MACHINE 1 2 3 4 2611 1700 2100 600 5225 4711 R1000 1100 1000 1000 1000 2569 2393 1000 Space requirement for operation and maintenance of the machine 1 Door opening areas 2 Display reach...

Page 14: ...INSTRUCTION MANUAL 14 3279 2613 2569 2238 1015 3321...

Page 15: ...80 5 3 INSTALLATION OF THE LIGHT CURTAINS OPTIONAL EQUIPMENT The light curtains are installed according to layout For further information See Datalogic Slim instruction manual enclosed 1 Light curtai...

Page 16: ...ve fatally dangerous voltage a aDANGER Only a qualified and authorized person is allowed to carry out the connection of the S 80 unit to the mains The terminals for connection of the external supply c...

Page 17: ...ted Kl mpin liikenopeus Tehdasasetus l s d Takuu p ttyy Clamping speed Factory setting Warranty expires if adjusted Kl mhastighet Fabriksinst llning Garantin l per ut om den justeras NOTE The planetar...

Page 18: ...ol panel is lit red and the start screen opens to the display 6 1 2 CLAMP REMOTE CONTROL CB3 1 2 3 Clamp remote control 1 Manual control ON OFF 2 Clamps close 3 Clamps open The remote control is for p...

Page 19: ...work cycle is on 4 MAN 0 AUTO 5 Enter the safety area request button Request to enter safety area A controlled stopping of the machine to next step of the program 6 Reset safety curtain button Reset...

Page 20: ...INSTRUCTION MANUAL 20 6 2 DESCRIPTION OF THE USER INTERFACE SCREENS 6 2 1 START UP SCREEN When the power is switched ON the start screen opens to the display Tap the display to enter...

Page 21: ...l appear to this screen When there are active alarms the button flashes red 6 2 2 4 8 Stop the S 80 PLC The PLC closed and the Windows system stays on Restart the PLC program from the Windows menu on...

Page 22: ...values are set in machine settings 2 Tube length feed table information 3 Tube diameter The actual diameter of the tube to be collared 4 Tube wall thickness 5 Milling tool number 6 Drilling tool numb...

Page 23: ...degrees With MFT manual tube support just for notes Diameter Diameter of the collar or a round hole The elliptic pilot hole is defined automatically by the size of the collar Height The height of the...

Page 24: ...Automatic screen 6 2 2 2 3 5 Tap to enter Settings screen 6 2 2 3 6 Tap to enter Alarms screen All alarms will appear to this screen 6 2 2 4 7 Tap to enter Users screen Manage user information 6 2 2...

Page 25: ...k cycle with this amount of stages is done For example Function 30 tells that is has 3 stages and the first work cycle is done as described in the table Function 12 tells that it has 1 stage and the f...

Page 26: ...llipse 12 Collaring 13 Trimming 14 Drilling 15 Cleaning 20 Milling Collaring 21 Milling Cleaning 22 Collaring Trimming 23 Collaring Cleaning 24 Trimming Cleaning 25 Drilling Cleaning 30 Milling Collar...

Page 27: ...ve movement 3 Jog movement and buttons move the axis in steps jog 4 Cylinders Tap button to activate movement function Clamp cylinder open close Chuck lift cylinder open close the tool gripper Chuck l...

Page 28: ...ANUAL 28 S 80 axis list Axis name Movement function 10 c Cover of the tool magazine Y Y Z Z X X 20 x Sideways direction 20 y Depth direction 20 z Up down direction 30 S1 S 80 inner spindle 30 S2 S 80...

Page 29: ...be found on Tool settings screen Tool fasten for fastening the tool Automatic function Tool release for returning the tool Automatic function See 7 1 1 Collaring tool setup 4 Tube handling Clamp Faste...

Page 30: ...processes of the machine Milling collaring trimming and drilling 6 2 2 3 2 3 Tool settings All tool settings 6 2 2 3 3 4 Tool magazine Tool magazine holder and position settings 6 2 2 3 4 5 Positions...

Page 31: ...tification number of tool in the machine 3 Tube offset The position of the collar can be adjusted according to zero point of the spindle if the collar is not on the correct position on the tube 4 Trim...

Page 32: ...om the list activate line and it will turn red The number fields on the picture are editable the edited value is transferred to the chosen process list The values can be edited also on the selected pr...

Page 33: ...hanges are done Milling process settings has all required information to make a pilot hole For pilot hole measures see pilot hole table Check the milling instructions for tool size always use a correc...

Page 34: ...to open Drilling collaring and trimming combination tool settings screen 1 2 3 4 1 Tool identification list Select the tool to manage from the list activate line and it will turn red 2 Select button T...

Page 35: ...the tool 2 Tool Status N A 3 Pin diameter The milling pin diameter 6 or 8 mm are typically used 4 Tool length Length of the tool cone seam to end of milling pin 5 Cutter length Length of the cutting a...

Page 36: ...ter changing the settings 1 Tool number Identification number of the tool 2 Tool status N A 3 Tool size Nominal tool size stamped on the tool 4 Tool rotation angle 5 Tool rotation angle S1 6 Tool rota...

Page 37: ...ength 11 Collaring tool number of pins 12 Trimming tool diameter The midst diameter of the cutter blade path see picture 13 Trimming tool length 14 Trimming tool cutter width The width of the cutting...

Page 38: ...fication number of the tool 2 Tool Status N A 3 Tool size Nominal tool size stamped on the tool 4 Tool rotation angle 5 Tool rotation angle S1 6 Tool rotation angle S2 7 Drilling tool diameter 8 Drill...

Page 39: ...f tool from cone bottom to pin ends with pins fully out 14 Collaring tool number of pins A counting parameter for the program 15 Trimming tool diameter The midst diameter of the cutter insert path see...

Page 40: ...tap numeric field to open keypad 3 Servo motor axis list Choose axis to move check position from the pull down menu 4 Moving to a certain position Actual position field shows the current position and...

Page 41: ...opy paste all positions Activate a line from field 1 tap Copy to copy all field 2 information Activate another line from field one and tap Paste to paste all information to field 2 of the activated li...

Page 42: ...target 5 Jog movement and buttons move the axis in steps jog 6 Set actual position for selected axis For setting of the actual position one selected or all axis after a successful positioning Set sets...

Page 43: ...e around it 1 Manageable parameter values Values to adjust tap numeric field to open keypad 2 Servo motor axis list Choose axis to move check position from the pull down menu 3 Save Tap Save after cha...

Page 44: ...2 2 3 7 REFERENCES T Drill service only Required only when mechanical parts are changed 1 2 T Drill Service only Choose axis to move check position from the pull down menu About tools 6 5 5 Reference...

Page 45: ...1 Alarm information area 2 Acknowledge only selected alarm line 3 Acknowledge all alarm lines Non active alarms 4 Scroll alarms 6 2 2 5 USERS MANAGEMENT Tap desired function Set button to open pop up...

Page 46: ...STRUCTION MANUAL 46 6 2 2 6 COUNTERS SCREEN 1 2 3 1 2 3 Check all counters to follow the machine events 6 2 2 7 I O DATA SCREEN The I O screens show the actual inputs and outputs Helps with troublesho...

Page 47: ...g the last workpiece is removed and a new workpiece can be placed to the clamps and a new work cycle can be started When the light curtain has been interrupted during the tool change or the EMERGENCY...

Page 48: ...oil container with lubricant Use only lubricants recommended by T Drill 2 Point the lubrication nozzle so that the mist spray reaches the collaring area The quantity of lubricant is determined by mean...

Page 49: ...illing pin Open the pin tightening nut 7 with the special tool loosen the nut to release the pin from the spring collet 6 Change pin and tighten nut Adjust the pin height measure with a vernier calipe...

Page 50: ...INSTRUCTION MANUAL 50 6 5 2 COLLARING TRIMMING TOOL 1 2 3 4 5 6 7 1 Retention knob 2 Tool holder cone 3 Tool cover adjuster disc 4 Drive wheel 5 Cone 6 Drill core 7 Forming pins...

Page 51: ...e 2 Positioning peg 3 Drive key stopper 4 Dial Tool holder cone drill core angle difference S1 axis 5 Dial Drive wheel drill core angle difference S2 axis 6 Collaring tool The tool axis angles affect...

Page 52: ...hat the zero lines are on the operator side drive key stopper Rotate tool against the stopper and tighten to place wit positioning peg Tightened peg will prevent rotating The zero line 1 of the device...

Page 53: ...up angles of the tool are S1 90 xx S2 90 yy 90 0 180 270 NOTE Only positive angle values are allowed Angles are measured clockwise from the 0 point The values are written to the 6 2 2 3 3 Tool setting...

Page 54: ...l Settings 34 5560486 Adapter head 19 5560477 Adapter head 25 5560480 Adapter head 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 Drilling collaring tool parts 1 Cone retention knob is fixed to the con...

Page 55: ...laced to the jig the jig lugs will keep the tool in position when loosening or tightening the cone to the tool Tool cone jig 6560093 is used with all collaring tools to avoid leaving marks and scratch...

Page 56: ...jor repair like change of a servo motor which will affect the position of the parts 1 1 The fixed spindle reference position setting tool The tool references are defined using a reference arbor which...

Page 57: ...8 mm diameter bent tube and two different sets of collars to it The manual positioning device is equipped with a two stage positioning plate pin to hole and an angle and height adjustment to allow the...

Page 58: ...ce the tube to Tube holder 1 and to the clamp 9 close the clamp Adjust height for the collaring of the left end of the tube Pull knob 5 and adjust height the gas spring 4 will ease lifting Adjust corr...

Page 59: ...l light shows the state of the machine Red The machine has stopped because of a fault e g servo fault or main air pressure is too low emergency stop Red blinks if there is an active alarm Orange Manua...

Page 60: ...whole machine to check all axis movements 7 1 MACHINE GENERAL SETUP Check the following parameters before beginning to place or remove the collaring tool or starting to make a collar 1 Tube diameter 2...

Page 61: ...ining The tool axis angles affect the positioning of the tool The angles depend on how tightly the tool is tightened when assembled Measure the angle difference of the collaring tool axis and fill it...

Page 62: ...INSTRUCTION MANUAL 62 7 3 TOOL MAGAZINE See 6 5 2 1 Collaring tool measuring device 5560252 For instructions on program fields See 6 2 2 3 4 Tool magazine...

Page 63: ...store and guides from metal chips and debris Use a lint free cloth to clean machine surfaces Daily Check all tube fasteners tube size specific and tools before starting to operate the machine Daily Ch...

Page 64: ...k ball screw drives of X Y Z movements Vaseline Castrol Tribol GR 4747 220 2 HT or equivalent Service interval for 2 shift operation and 5 days week 3 months 100 hrs Ball screw drives of X Y Z movemen...

Page 65: ...or pneumatic cylinder 1 2 Open the locking screws of the toothed rack 2 3 Place a gauge tube to the MFT Adjust the clamps by the adjustment screw to grab the gauge tube Make sure to leave a stroke mar...

Page 66: ...wn the positioning peg very close to the surface of the reference setting point tool using manual screen functions Attach a small dial gauge with magnetic leg to the spindle axle and position the peg...

Page 67: ...e clamp center Remove tube specific clamps Attach a small dial gauge with magnetic leg to the spindle axle and position the gauge tip to clamping device horizontal surface Move the spindle slowly manu...

Page 68: ...e bench or similar to keep steady the tool is placed to the jaws as shown in the picture Place the tool to a vice bench with the cone facing downwards Tighten the tool to the vice by the cone bottom O...

Page 69: ...cover 3 clockwise as seen from the cone side until the pins are fully out The tool body may rotate along Remove the pins Place the tool on the table cone pointing downwards Put the new forming pins i...

Page 70: ...adily and smoothly Measure pin width 1 again with a slide caliper The collar size adjustment is recommended to measure from the first collar made with the tool The collaring pin max width can be adjus...

Page 71: ...the Tool cone jig which is fastened to a vice bench securely 8 3 DRILLING COLLARING TOOL MAINTENANCE 1 Top position stopper fixed to the cone 1 2 3 2 Set screw for tightening of the tool 3 Fixing surf...

Page 72: ...rming pins are completely retracted loosen both locking screws located in the cone 2 Rotate the cone in relation to the brake drum by means of the special adjustment tool A If a larger inner diameter...

Page 73: ...forming pins out 5 Insert new forming pins into the holes and put the pin lugs into the groove of the cone Rotate the cone counterclockwise to retract the forming pins into the head 6 Carry out the ad...

Page 74: ...a sign of insufficient lubrication Use of a dull bit must be avoided because a dull bit wears out very quickly and thus its life expectancy will be relatively short Where do we resharpen The bit is re...

Page 75: ...blade cutting inserts are triangular in shape and can be turned three times to use all edges To remove blade open fixing screw CSTB 2 5 When the trimming quality is not as desired the blades can be ei...

Page 76: ...oid overtightening The belt must be able to twist approximately 10 15 take a firm grip from the belt and twist it with your fingers the belt is too tight if it does not allow to twist Top belt E 1 Ope...

Page 77: ...structions for Zimm screwjacks and accessories refer to separate manual 8 6 OIL COLLECTORS Check the large chip tray and oil and debris collecting tray daily and empty when required The large chip tra...

Page 78: ...spindle side Lubricate with grease gun two strokes Service interval for 2 shift operation and 5 days week 1 month 3 Lubrication of the planetary gear and needle bearing There are 2 grease nipples only...

Page 79: ...t E All other bearings of the S 80 unit are sealed and lubricated for lifetime To perform the lubrication proceed as follows 1 Turn the main switch off 0 2 Lubricate the above mentioned parts especial...

Page 80: ...hine stops in the middle of the work cycle Emergency stop or the safety light curtain was interrupted in the middle of the work cycle Reset Emergency Stop and curtain and Do Homing A controlled machin...

Page 81: ...e sensor the locking piece must activate sensor Are collaring settings OK Check settings Are tool settings OK Check settings Tap Tool release on screen ALARM Tool release sequence cannot be started Ai...

Page 82: ...side 20 B2 0 Work piece sensor is activated 10 B4 Check work piece sensor there should be nothing pushing sensor The S1 and S2 axis are not in home start position 2 deg Do homing If the problem is not...

Page 83: ...sively the responsibility of the customer T DRILL must receive any such information in writing within 10 days after a defect having been noticed T DRILL S warranty shall be limited to the aforesaid gu...

Page 84: ...e 2 2 3500904 Fastening plate 2 3 9214010 Screw M8 x 25 8 8 DIN7984 8 4 9016007 Set screw M8 x 8 12 9 DIN913 4 5 4280104 Clamp holder pin 4 6 9018037 Parallel pin 6m6 x 32 DIN6325 4 7 9018219 Spring p...

Page 85: ...tion of the horizontal and vertical rows will show you the max wall thickness of the tube This value is not to be exceeded Example Run tube 12 collar 10 6 8 10 12 15 8 0 5 0 5 10 0 8 0 8 1 0 12 0 8 1...

Page 86: ...2 3 2 9 2 9 2 9 3 0 3 0 88 9 1 5 1 5 2 3 2 3 2 9 2 9 2 9 3 0 3 0 114 3 1 5 1 5 2 3 2 3 2 9 2 9 2 9 3 0 3 0 Grey base on table available Specma clamping tool sizes Max wall thickness S in millimetres...

Page 87: ...S 54 adapter tool drill mm 23 19 11 8 9 6 25 19 11 8 9 6 23 15 12 28 19 11 8 9 6 23 15 12 25 17 13 38 19 12 8 9 6 23 15 12 25 17 13 28 19 13 30 21 13 34 23 13 38 28 17 51 19 11 8 9 6 23 15 8 25 17 13...

Page 88: ...pipe O D mm Pilot hole a mm Pilot hole b mm S 54 adapter tool drill mm 63 5 19 11 8 9 6 23 15 12 25 17 13 28 19 13 30 21 13 34 23 13 38 28 17 51 39 25 63 5 52 28 76 1 19 9 6 23 25 28 30 34 38 51 63 5...

Page 89: ...0 13 34 21 17 38 28 17 51 37 29 63 5 50 32 Grey base on table available Specma clamping tool sizes This table is intended as a guide only The values depend on the pipe materials and wall thicknesses a...

Page 90: ...21 3 114 3 mm Run tube sizes 33 7 323 9 mm T 110 Heavy Duty Collaring Station Collar sizes 21 3 219 1 mm Run tube sizes 33 7 804 mm TEC 150 HD Flanging machines for both cold and hot forming Tube diam...

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