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Instruction and maintenance manual

ENGLISH

ATTACHMENTS

This manual includes the following attachments:

a) Dimensional drawing

b) Installation chart

c) List of spare parts

15.1 Declaration of conformity

TECNOMAGNETE S.p.A. hereby declares that the
equipment is compliant with the main requirements
and any other applicable provision specified in di-
rectives:

2004/108/CE

and 2006/95/EC.

The EC declaration of conformity is available for ref-
erence at the following Web page:

http://www.tecnomagnete.com/engcecertificate.htm

To view the declaration of conformity, open the Web
page and click the name of the purchased product.

Содержание CUBOTEC Series

Страница 1: ...ls série rectification et fraisage ELEKTROPERMANENTE MAGNETSYSTEME AbteilungVerankerung vonWerkzeugmaschinen Serie Schleifen und Fräsen SISTEMAS MAGNÉTICOS ELECTROPERMANENTES División anclaje sobre máquinas herramienta serie rectificado y fresado ELEKTROPERMANENTA MAGNETSYSTEM Avdelning för fästanordningar till verktygsmaskiner serie för finslipning och fräsning Manuale uso e manutenzione Instruct...

Страница 2: ... 60 6 2 Preparation 60 6 3 Mechanical installation 60 6 4 Electrical connections 60 6 5 Useful technical information 61 7 ASSESSMENT OF RESIDUAL RISKS 61 Page 8 ORDINARY USE OF THE SYSTEM 62 8 1 Clamping force 62 8 2 Cutting force 62 8 3 Positioning the parts onto extensions 63 8 4 How to calculate the clamping force 65 8 5 Example of how to calculate the clamping force of a magnetic chuck 65 8 6 ...

Страница 3: ...xisting manual by providing the text explaining the use of the modified integrated com ponent along with a description of potential residual risks 1 1 Overview of the company TECNOMAGNETE started its activities in 1972 as manufacturer of permanent electro magnetic sys tems designed to ensure power flexibility and maxi mum safety Its state of the art technologies and the patents developed over the ...

Страница 4: ... operation described step by step Parts that require specific attention are highlighted with symbols Units of measure including decimal values have been indicated using the international system of units 1 5 Definition of symbols All information related to safety is highlighted in bold All warnings that draw the attention of operators on operations that may be hazardous in terms of safety or health...

Страница 5: ...ticular personnel must always wear indus trial shoes along with ear protection helmets and goggles if required All personnel should refrain from wearing loose clothing that could get tangled with moving com ponents 1 9 General safety precautions The instructions and recommendations provided below comply with current safety regulations and imply the obligation of complying with applicable provision...

Страница 6: ...ce with he instructions provided Use appropriate materials Comply with all the instructions provided Safely and firmly fix the system and all its parts Contact TECNOMAGNETE S p A in case of doubt to determine whether a specific opera tion is permitted The clamping of special materials other than those referred to in this manual must be preventively authorized in writing by the TECNOMAGNETE S p A 1...

Страница 7: ...o be lifted and handled with appropriate lifting equipment with charac teristics and capacity suitable for the weight to be handled Handling operations must always be performed very carefully in order to avoid potential impacts that could damage the system parts and prevent them from operating correctly When using fork lifters always verify that speed and inclinations are within recommended values...

Страница 8: ...ated by magnetic sys tems are evenly distributed along all contact sur faces in addition to having an intrinsic strength 2 The part that has to be machined is clamped only along the contact surface so that the remaining surfaces can be accessed by the tool The substantial difference in distribution of the clamping forces account for the greater perform ances offered by magnetic systems as compared...

Страница 9: ...If the part has a simple design it is sufficient to correctly position it on the northern and southern poles of the magnetic chuck The clamping force is proportional to 1 The square of the density of the magnetic flow present on the surface that is in contact with the part 2 The area of the part that is in contact with the magnetic chuck up to maximum saturation point Clamping force daN cm 2 Flow ...

Страница 10: ...apacity of absorbing magnetic flows An nealed materials provide higher performances Tem pered materials are unable to satisfactorily absorb the magnetic flow and tend to maintain a certain degree of magnetism even after the chuck has been disabled DEMAG to the point that it is sometimes difficult to detach the part from the magnetic chuck Residual or absorbed magnetism can be removed by using a de...

Страница 11: ... smaller thick ness values is inversely proportional to the ratio between the thickness S of the part and the theo retical magnetic clamping section L as described above Consequently the flow reduction factor Fr will be equivalent to Fr S L N S N S N S N S N S N S Figure A Figure B Figure C L C S L L 2 x C S 0 5 x C L 3 x C S 0 35 x C ...

Страница 12: ...erations the polarity of the magnet under the pole is inverted by the solenoid that surrounds it while on systems for grinding op erations the magnet is magnetized and demagnet ized by the solenoid In the circuit of systems for milling operations all north and south poles are alternated Consequently the crown or frame is neutral and is therefore called neutral crown On systems for grinding operati...

Страница 13: ...ITH PARALLEL POLES Series SGL PRL TFP1 TFP0 TPF MDS MAGNETIC CHUCKS WITH ROUND POLE Series RPC MILL TEC 4 1 Magnetic chucks with square poles 4 1 1 Series QX and SQ ST Models with a low density of poles that are particu larly suitable for medium and large magnetic chucks These models are constituted by magnetic sectors formed by islands of poles that produce a clamp ing force proportional to the d...

Страница 14: ...agnetic surfaces and can therefore be used to clamp parts with small and medium dimensions 4 1 3 Series QX and SQ HP These systems which can be configured in version ST or HD offer the power required to machine parts with discontinuous surfaces They are ideal to rough non machined or forged parts because of the com bination of a high clamping force and wide ranging magnetic field ...

Страница 15: ...izontal machining centers and FMS systems The system provides a supporting surface that can be fixed onto machine workbenches and a second surface to support parts with large dimen sions and weights 4 1 5 Series QX HN QXG and QG These systems have a square pole like models QX and SQ but are designed with a special technology that allows them to be used with high speed grinders and millers for the ...

Страница 16: ...gnetic chucks for grinding and milling operations based on the typical technologies of MILLERS and GRINDERS with poles arranged in a parallel config uration Even these chucks are specifically designed for the machining of parts like models SGL but re quire the integration of dedicated technologies when used for grinding operations 4 2 3 Series TFP1 Permanent electro magnetic systems for GRINDING o...

Страница 17: ...hese systems differ from model TFP1 be cause the magnetic surface is coated with a mix of steel resin 4 2 5 Series TPF Permanent electro magnetic systems for GRINDING operations specifically designed for high precision grinding These systems have the same character istics of model TFP1 but have a higher polar pitch that allows the machining of parts with a small thick ness ...

Страница 18: ...ich is also applied to EDM systems 4 3 Magnetic chucks with round poles 4 3 1 RPC Permanent electro magnetic systems for GRINDING operations specifically designed for high precision grinding of parts with medium dimensions and thick ness These systems can be fitted with a shapeable over plate fully coated in metal Poles are arranged in a circular configuration ...

Страница 19: ...Mobile extension Double fixed extension Fixed extension with stop Round mobile extension TECNOMAGNETE S p A is also able to supply on request special and custom accessories 5 2 Systems for grinding operations The system described in the manual comprises One or more magnetic chucks 5 2 1 Accessories for grinding To able to machine parts with shaped supporting surfaces it is possible to separately p...

Страница 20: ...with a miller fitted with a scraping insert or a grinder Customers who decide to install directly the magnetic system must specifically refer to the instructions provided in this manual If additional fixing holes are required always remember to drill them on the housing that encloses the magnetic circuit If necessary it is also possible to drill on these surfaces positioning and reference holes fo...

Страница 21: ...magnetization demag netization cycles over short intervals of time may increase the temperature of the magnetic chuck It is therefore advisable to run cycles only when nec essary The connection of the magnetic chuck to the power supply must be carried out by qualified personnel only Check the supply voltage and frequency 7 ASSESSMENT OF RESIDUAL RISKS In designing the chuck the manufacturer has ta...

Страница 22: ...ied by a tool includes a component that tends to slide the part being ma chined along the surface of the magnetic chuck PART TO MACHINE MAGNETIC CHUCK Width Depth The horizontal component is influenced by the ge ometry and direction of movement of the tool There fore the clamping force must necessarily be greater than the cutting force which is distributed in all di rections in order to guarantee ...

Страница 23: ...it is also possible to use fixed polar ex tensions as mechanical stops See Example 1 The magnetically clamped bar or fixed polar exten sions enable to use the system both as mechanical support and for magnetic clamping purposes Both systems are in fact able to conduct the magnetic flow Example 1 Example 2 MECHANICAL STOPS Tool movement 8 3 Positioning the parts onto extensions To be able to mill a...

Страница 24: ...g force is directly proportional to the surface in contact with the part to clamp and thus to the number of polar extensions The greater the number and the higher the clamp ing force Verify that the polar extensions are correctly po sitioned checking also the magnetic balancing number of poles with SOUTH polarity NORTH polarity In other words if it is not possible to use the whole surface of the p...

Страница 25: ...6 mm Type of material to machine C40 Model of magnetic chuck Magnetic chuck model For milling operations with square poles series QX or SQ ST and series QX or SQ HD Clamping force per cm2 6 kg cm2 see page 51 in paragraph 3 3 6 Chart for MILLERS Taking into consideration the information provided above the clamping force can be calculated by means of the following formula Total clamping force 6 kg ...

Страница 26: ...NOMAGNETE paragraph 5 1 1 These extensions can be used to automatically and consistently shim the sheets to machine with a quick and accurate procedure The correct use of these accessories and of the fixed polar extensions enable to obtain high levelness and parallelism tolerances even during the initial milling operation in addition to superior final finishes These accessories also en able too re...

Страница 27: ...hing the part to ma chine 8 6 4 Machining cylindrical parts To be able to machine parts with a cylindrical shape or an irregular surface it is necessary to place the part directly onto the magnetic chuck and rest it onto the fixed polar extensions These extensions prevent the part from rolling off but also conduct the mag netic flow thus enhancing the clamping of the part Machine the part so that ...

Страница 28: ... SQ ST SQ HD SQ HP Plate dimensions 250x250x50 Material C40 Miller Ø 100 mm Number of inserts 7 Geometry 45 Feeding 1000 mm min Speed 600 rpm Machining depth 1 40 mm models ST 2 10 mm models HD 2 80 mm models HP Drawn plate part dimensions above 150 mm Flattening planar and parallel surfaces Mobile extensions QX and SQ ST SQ HD SQ HP Plate dimensions 400x400x50 Material C40 Miller Ø 100 mm Number ...

Страница 29: ...5 mm Number of inserts 3 Geometry 90 Feeding 1000 mm min Speed 1500 rpm Machining depth 10 00 mm Machining depth 5 00 mm models ST 10 00x8 00 mm models HD 10 00 mm models HP Forged plate part dimensions above 150 mm Full contouring in one step Fixed or mobile extensions QX and SQ ST SQ HD SQ HP Plate dimensions 250x250x50 Material C40 Miller Ø 100 mm Number of inserts 7 Geometry 45 Feeding 1000 mm...

Страница 30: ... part dimensions above 150 mm Drilling and reeving tapping Fixed polar extensions to lift the part Pre drill if the extension cannot be removed QX and SQ ST SQ HD SQ HP Plate dimensions 250x250x50 Material C40 Drill Ø 30 mm Number of inserts 2 Feeding 0 06 mm rev Speed 1500 rpm Forged plate part dimensions above 150 mm Drilling and blind tapping Not required QX and SQ ST SQ HD SQ HP Plate dimensio...

Страница 31: ... sections Figure 8 7A Flattening drilling and formation of imprints Figure 8 7B Facing of strappers and creation of key slots Figure 8 7G Profiling of blades and chiseling of sheets Figure 8 7H Profiling of multiple joined guides Figure 8 7C Surface roughing Figure 8 7D Tilting roughing release of stress and finishing of second surface ...

Страница 32: ...e per formed after disconnecting the system from the power supply and enabling the emergency but ton All personnel responsible for the operation maintenance and cleaning of the system shall have to thoroughly follow the safety instructions applicable to the country of installation Always wear safety gloves and shoes and any other type of PPE required including overalls that cover as much of the bo...

Страница 33: ... of the controller 9 6 Maintenance operations required every six months These operations which are based on a daily work ing shift of 8 10 hours and must be performed by qualified and skilled personnel include Disconnection of the discharge cables of the magnetic chucks from the connection boxes Measurement of the resistance and insulation val ues at 500 V Passing a steel sheet over the surface of...

Страница 34: ...ng To decommission the system disconnect it from the power supply place it out of service disassemble it from the tool machine and remove the controller and all mobile parts 12 2 Disposal The user is responsible for the demolition disman tling and disposal of the materials components that are part of the system Said operations shall have to be carried out in accordance with UE directives or with t...

Страница 35: ...ion of the warranty period This warranty does not cover Damages originating from ordinary wear resulting from the use of the system Faults caused by improper use or assembly Damages originating from the use of spare parts other than those recommended Damages caused by incrustation 13 2 Warranty invalidity The warranty shall not apply in the following cases If the customer fails to make the payment...

Страница 36: ... SPAIN Tel 34 943 376050 Fax 34 943 370509 dtc dtctecnologia com SWEDEN NORWAY DENMARK FINLAND BALTIC REPUBLICS TECNOMAGNETE AB 16 Gustafsvagen 63346 Eskilstuna SWEDEN Tel 46 016 132200 Fax 46 016 132210 info tecnomagnete se U S A CANADA MEXICO TECNOMAGNETE Inc 6655 Allar Drive Sterling Hts MI 48312 Tel 1 586 276 6001 Fax 1 586 276 6003 infousa tecnomagnete com BRAZIL COMASE Com e Prest de Serv Lt...

Страница 37: ...OMAGNETE S p A hereby declares that the equipment is compliant with the main requirements and any other applicable provision specified in di rectives 2004 108 CE and 2006 95 EC The EC declaration of conformity is available for ref erence at the following Web page http www tecnomagnete com engcecertificate htm To view the declaration of conformity open the Web page and click the name of the purchas...

Страница 38: ...FR TECNOMAGNETE S A R L 52 avenue Saint Exupéry 01200 Bellegarde sur Valserine Tel 33 450 560 600 Fax 33 450 560 610 US TECNOMAGNETE Inc 6655 Allar Drive Sterling Hts MI 48312 Tel 1 586 276 6001 Fax 1 586 276 6003 SG TECNOMAGNETE Singapore R O 101 Thomson Road 26 02 United Square Singapore 307591 Tel 65 6354 1300 Fax 65 6354 0250 DE TECNOMAGNETE GmbH Ohmstraße 4 D 63225 Langen Tel 49 6103 750 730 ...

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