Pragati BTP-63 Manuel utilisateur

BI-DIRECTIONAL

TOOL TURRETSTOOL TURRETS

TOOL TURRETS

INSTRUCTION MANUAL

JUNE 2003

BTP-63 BTP-80 BTP-100 BTP-125

vvv

INDEX

Page

1. Principle of working. 4

2. Instructions for fitment on the machine. 6

3. Fitment of tool disc on the turret. 6

4. Operation of coolant system. 7

5. Details of electrical connections. 8

6. Electrical motor wiring diagram. 9

7. Electricalsignals. 10

8. Handcranking. 11

9. Lubrication. 11

10. Turret control flow chart. 12

11. Requirements of turret control. 13

12. Adjustment of rotary encoder. 14

13. Adjustment of proximity switch. 15

14. Replacement of the proximity switch 15

15. Assemblydrawings. 16

16. Instructions for opening of gearbox. 21

17. Instructions for assembly. 22

18. Adjustment of Ringfeder Clamps 26

19. List of spare parts. 28

20. Faults and corrective actions. 31

BI-DIRECTIONAL TOOL TURRETS

1. Principle of Working :

Threepieceface gearcouplingis thebasicelement usedforindexing. Couplingdesignallows thetooldisc to

be indexed without lifting. It also ensures high repeat positioning accuracy as well as rigidity.

3phase electrictorque motordrives the camshaft througha systemof gears.‘Cam shaft’drives the‘follower

shaft’in a non-uniform manner, similarto that of ‘Geneva’ mechanism. Cam shaft is alsogeared to the ‘drum

cam’ which controls clamping and release of the coupling.

Initial 90° (approximate) movement of cam shaft does not transfer any rotary movement to follower shaft.

However,thedrumcamrotatesthrough30°,whichmovementreleasestheclampingforceandpullsthesliding

couplingoutofengagement.Further180°(approx.)movementofcamshaftindexesthefollowershaftthrough

90°,which inturn, indexesthe turretby 30° or45° dependingon gearratio. Duringthis movement,drum cam

profilekeepstheslidingcouplingindis-engagedposition.Inthefinal90°movementofthecamshaft,thefollower

shaftremainsstationary.Thedrumcampullstheslidingcouplingintoengagementandappliesclampingforce

through disc spring. One revolution of cam shaft completes one indexing cycle of declamp-index-clamp.

Absolutepositionencodergivesfeed-backoftheturretposition.Proximityswitchinspectstheclampedposition

of the turret.

FIG 1.1

BI-DIRECTIONAL TOOL TURRET

1. Cam Shaft 2. Follower Shaft 3. Drum Cam 4. Fixed Coupling

5. Indexing Coupling 6. Sliding Coupling 7. Disc Spring 8. Torque Motor

9. Proximity Switch 10. Encoder

Diagrambelowgives relativepositionsof mechanicalelementsand electricalsignalsduring onerevolution

of the cam shaft.

CAM ANGLE

MOTOR

TURRET

CLAMP

SWITCH

BIT 1

BIT 2

BIT 4

BIT 8

STROBE

PARITY

ENCODER

POSITION

COUPLING

TEETH

DRUM CAM

PROFILE

PARRALLEL

INDEX

DRIVE

O˚ 35˚ 9O˚ 18O˚ 27O˚ 325˚ 36O˚

FIG 1.2

BI-DIRECTIONAL TOOL TURRETS

2. Fitment on the machine :

Seatingsurfaceofthemachineshouldbeflattoensureproper

contactwiththeturretbase.Machinesurfaceshouldbeeither

scraped or surface-ground.

Turret should be aligned by dialing surface of the indexing

flange.Clampingboltsshouldbetightenedafteraligningthe

seating surface, square to the lathe axis.

Clampingboltsshouldusemachinewashersofextrathickness

(min.5 mm) to ensure proper clamping.

DowelPinsarenotrecommendedforensuringthealignment

of turret. It is preferable to allow the turret to slip in the event

of an accidental shock or overload. This slipping absorbs

some of the energy of the shock and reduces the possible

damage. Turret can again be brought back to alignment by

dialing a reference surface on the tool disc.

There is one more reason for avoiding the dowel pin. Acci-

dentalcollisionsarenotun-commoninthefieldofCNClathes.

In the event of a collision, dowel pins can get sheared or

damaged.Itisadifficulttasktoremovesuchdowelpins,and

to fit new ones. New dowels may involve enlarging the

damagedholebydrillingandreaming.Thisisdifficulttodoat

the customer's place. This is a difficult operation to be done on site, and is most likely to be less than perfect.

Onthe otherhand, it isperfectly possibleto usethe turret andtool discwithout theuse of dowels.The friction

joint can easily take up normal cutting loads, including occasional over loads.

Pragati turrets, therefore, do not have a provision of dowelling the body to the base.

TOOL

DISK

3. Fitment of Tool Disc on Turret Flange :

Tool disc is to be fitted on the indexing flange with the help of

clampingbolts,andmachinewashers.Discshouldbeangularly

adjustedwithintheclearanceoftheboltholes,togetthecorrect

centre height of the tool. It should then be firmly clamped by

tighteningthebolts.Dowelpinsforensuringthepositionarenot

recommendedfor the reasons explained earlier.

However,dowelpincanbeusedforthepurposeofalignment,but

itisrecommendedtoremovethepinafterclampingthetooldisc

inposition.Thereisaprovisionofsoftareasontheindexingflange

to facilitate drilling and reaming for dowel pins.

Boltholesinthetooldiscshouldbeofextralargesizetoallowfor

angularadjustment.Extrathickmachinewashersshouldbeused

to ensure proper clamping.

TURRET

BODY

FLAT

SEATING

SURFACE

(SCRAPEDOR

GROUND)

EXTRATHICK

WASHERS

OVERSIZE

BOLTHOLE

EXTRA

THICK

WASHERS

FIG 3.1

FIG 2.1

BI-DIRECTIONAL TOOL TURRETS

Turrethastwoalternativepositionsfortheconnectionofcoolantpipe.Coolantpassesthroughthedrilledhole

inthebodyandentersthepassageinthecoolantring(01&24).Thisringhasspringloadedcoolantvalve.Valve

button(130)continuouslypressesagainstcoolantflange(26)fittedonindexingflange.Coolantringaswellas

coolantflange haveprovision forangular adjustment.Coolant flange shouldbe adjustedto alignthe ‘O’rings

(37)withcoolantpassagesontooldisc.Coolantringshouldthenbeadjustedtoalignthecoolantvalvewiththe

proper hole on the coolant flange (ref. 4.1). There are 2 valve positions on the coolant ring. Only one of the

positionsistobechosenasfunctional,andshouldbefittedwiththespringloadedvalvebutton(130).Theother

valve positions should be blocked by plug (136).

Thisdesignensuresthatthecoolantisconnectedonlytotheworkingtoolposition.Coolantflowautomatically

stopsduringthe indexingmovement, as thecoolant flangeclosesthe openingofthe valvebutton.

Coolant passage through the turret body, coolant ring and the valve has been designed to provide as little

resistancetocoolantflowaspossible.However,thepathislongandnarrow,withanumberofbendsintheflow

passage.Furthermore, coolant hasto pass throughdrilled passagesin the tooldisc, before reachingthe tool

point. It might therefore be necessary to employ high pressure coolant pump, to ensure sufficient flow at tool

point. Coolant passages in tool turret can withstand a maximum pressure of 6 bar.

4.1 Procedure for adjustment of coolant ring :

Coolantringholdsontotheindexingflange(27),becauseofthefrictionofwiperseals.Itistherefore,notpossible

toadjusttheangularpositionofcoolantringbyhand.Followingprocedureistobefollowedforthisadjustment.

*Loosenclamps(140).Movethecoolantringalongwithindexingflangebyhandcranking(Ref.section8,page

11) to required position. Tighten clamps (140).

INDEXING

FLANGE(27)

CLAMPSFOR

COOLANTFLANGE

(137)

COOLANTFLANGECLAMPED

TOINDEXING FLANGE (26)

CLAMPFOR

COOLANTRING

(140)

COOLANTVALVE

ADJUSTMENTRANGE COOLANTVALVE ALTERNATE

POSITION AVAILABLE ON

OPPOSITE SIDE.

COOLANTENTRYPOSITION

AVAILABLE ON OPPOSITE SIDE.

20°

4. Operation of Coolant system :

FIG 4.1

COOLANT

RING(24)

4.2 Replacement of Valve Button ( fig. 4.2 ) :

Valvebutton(130)rubsagainstthecoolantflangeduring

indexing,andisliabletowear.Provisionhasbeenmade

toreplacethebutton,withoutremovingthetooldiscfrom

theturret.

Forreplacement,loosen theclamp (140)and move the

coolantringtobringthevalveinasuitablepositiontoget

access to the plug (134).

Removetheplug,thespringandthevalvebutton.Replace

withanewbutton,andplacebackthespringandtheplug.

Coolantringshouldthenbeshiftedbackandclampedin

originalposition.

134

136

FIG 4.2

130

5. Details of Electrical Connections

BI-DIRECTIONAL TOOL TURRET

1. Torque Motor 2. Proximity Switch 3. Absolute Encoder 4.Thermal Relay

BTP-100 : 1.9 KVA

BTP-80 : 1.6 KVA

BTP-63 : 1.2 KVA

BTP-125 : 2.3 KVA

PROXIMITYSWITCH

(TURRETCLAMPSIGNAL)

BI-DIRECTIONAL TOOL TURRETS

415/

380

220

110

BTP-125 3.2 6.3 8.0

BTP-100 2.6 4.5 7.4

BTP-80 2.3 3.9 6.3

BTP-63 1.6 3.0 5.0

BTP-50 1.3 2.6 3.3

VOLTAGEAC

MODEL

1. Unused electrical entry points to be properly plugged.

2. Electrical wiring should be brought in through water proof conduit connection. Wire braided hydraulic

hoses can serve as conduits. They also give excellent protection against damage by hot chips.

FIG 6.2 DETAILS OF ELECTRICAL TERMINALS

MOTORCURRENT(Amps)

USEFUSERATINGABOUT

THREETIMESMOTOR

CURRENT. MINIMUM6AFUSE

TO BE USED.

6. Electrical motor wiring details

TC MR SSR1 SSR2

MR 0V

24 VDC

MMM

Q4.0 Q4.1I3.1

OUTPUT

INPUT

PROGRAMABLE CONTROLLER (PLC)

MOTOR

FUSES

TORQUE MOTOR

FORWARD REVERSE SOLID STATE

RELAYS

THERMAL RELAY

130˚ C

NORMALLY CLOSED

415 VAC 2 A

SSR

415 VAC 25 A

FIG 6.1 WIRING DIAGRAM FOR MOTOR

BI-DIRECTIONAL TOOL TURRET

Following points should be noted while selecting control system for turret :

1. Direction of rotation of motor for shortest indexing time is to be decided by control system.

2. Indexing times of these turrets are short. It is necessary to select particularly fast PLC

(programmable logic controller) for the control of turret operations.

3. Referring to the signal diagram, value of T3 is particularly critical. Motor must come to a physical

haltwithinthistime.Otherwise,theturretwillgetde-clampedandtheproximityswitchsignalwillbe

lost.Followingmeasures aresuggested for stoppingthe motorinminimum possibletime.

a. Control should be capable of detecting the proximity switch signal within 3 to 6 ms.

b. Solid state relays should be incorporated in the motor circuit to ensure fastest possible dis-

connection.Regular contactors can beused for motor directionselection, followed by solidstate

relays, at least in two phases.

7. Electrical Signals

123456789101112

101010101010

011001100110

000111100001

000000011111

111111111111

110100110010

POSITION NUMBER

BIT 1

BIT 2

BIT 3

BIT 4

STROBE

PARITY

T1 T2 T3

ms ms ms

max

FAST

STD

FAST

STD

BTP-100

BTP-80

BTP-63

110 60 50

135 75 60

100 55 45

110 60 50

80 45 35

TABLE 1 ENCODER SIGNALS TABLE 2

CCW CW

TURRET

CLAMP

SWITCH 1

ENCODER

BIT 1

BIT 2

BIT 3

BIT 4

STROBE

PARITY

T1T2

aaaa

CAM ANGLE

MOTOR 1

O˚ 180˚ 360˚ 360˚

180˚

POSITION 4 POSITION 5

TURRET CLAMP

POSITION 3

START

T1 ms T2 ms

BTP-125 175 135

BTP-100 150 115

BTP-80 125 95

BTP-63 100 75

BTP-50 75 60

Turretcanbeindexedbycrankingtherotorofelectricmotorbyhand.Handcrankingisrequiredforinspecting

the setting of encoder and proximity switch. It is also necessary for inspecting the clamping function of disc

springs.

Procedure for hand cranking is as follows :

1. Disconnect 3 phase power supply to the motor.

2. Remove end cover (119) of motor. Hexagon head of motor shaft is now approachable.

3. Use a suitable cranked spanner to crank the motor.

4. After cranking, do not forget to place cover (119), back in position.

119 118 114

HEX.END

FIG 8.1

FIG 9.1

9. Lubrication :

Turretislubricatedbymediumviscositygearbox

oil.

Oilcanbefilledafterremovingthefillingplug(161)

as shown in the fig (9.1). A drain plug (160) has

been provided to drain out the oil, if so required.

Oil quantity required for different turret models is

listedbelow:

MODEL Oil Qty Lit.

BTP-125 1.75

BTP-100 1.25

BTP-80 1.00

BTP-63 0.75

BI-DIRECTIONAL TOOL TURRETS

DRAINPLUG

160

FILLINGPLUG

161

8. Hand cranking :

Ce manuel convient aux modèles suivants

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