TBT ML700 Series Manuel utilisateur

General

Erstelldatum: 03.02.2012 Version: 1_0 File: 106582_1

ML700 - 1 - 22 000 / 106582 –11 27.03.2012 Inh. 1

Contents

1General..........................................................................................................................1

1.1 Introduction....................................................................................................................2

1.1.1 Structure of the operating instructions ...........................................................................2

1.1.2 General notes ................................................................................................................4

1.2 Safety.............................................................................................................................6

1.2.1 General safety instructions.............................................................................................6

1.2.2 Intended application.....................................................................................................11

1.2.3 General hazard potential with this machine .................................................................11

1.2.4 Definitions....................................................................................................................15

1.2.5 Other precautionary measures.....................................................................................16

1.2.6 Requirements imposed on the user/operator...............................................................17

1.2.6.1 Requirements for safety devices..................................................................................18

1.2.7 Personal protective equipment.....................................................................................19

1.2.8 Safety during repair and maintenance .........................................................................20

1.2.9 Safety during tool change and set-up ..........................................................................21

1.2.10 Behaviour in an emergency .........................................................................................21

1.2.11 Danger zones...............................................................................................................22

1.3 Technical Specifications: .............................................................................................24

1.3.1 Description of the system.............................................................................................24

1.3.1.1 Basic machine..............................................................................................................24

1.3.1.2 Coolant system............................................................................................................26

General

Erstelldatum: 03.02.2012 Version: 1_0 File: 106582_1

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1.3.2 Machine diagram .........................................................................................................27

1.3.2.1 Machine identification ..................................................................................................28

1.4 Technical data..............................................................................................................29

1.4.1.1 Deep-hole drilling machine...........................................................................................29

1.4.1.2 Electrical system..........................................................................................................30

1.4.1.3 Machine drive (deep-hole drilling/conventional)...........................................................31

1.4.1.4 Workpiece clamping.....................................................................................................36

1.4.1.5 Coolant system............................................................................................................40

1.5 Drilling technique BTA .................................................................................................45

1.5.1 Principle of the BTA drilling technique .........................................................................45

1.5.2 Cutting speed...............................................................................................................46

1.5.3 Programmed feed rate.................................................................................................47

1.5.4 Coolant lubricant pressure - flow rate .........................................................................48

1.5.5 Drilling tool...................................................................................................................49

1.6 Drilling procedure.........................................................................................................50

1.6.1 Principle of single-lip drilling method (ELB)..................................................................51

1.6.2 Cutting rate ..................................................................................................................52

1.6.3 Feed speed..................................................................................................................53

1.6.4 Cooling lubricant pressure and flow rate......................................................................54

1.6.4.1 Standard application ....................................................................................................55

1.6.4.2 Comparison table Deep-hole drilling oil / emulsion......................................................57

1.6.5 Drilling tool...................................................................................................................58

1.6.5.1 Tool length (ELB).........................................................................................................58

1.6.5.2 Tool regrinding.............................................................................................................59

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1.6.6 Utilisation of standard accessories...............................................................................64

1.6.6.1 Submersion method.....................................................................................................64

1.6.6.2 Seal housing method ...................................................................................................65

1.6.7 General remarks with regard to bottle boring...............................................................66

General

Preparation date: 03.02.2012 Version: 1_0 File: 106582_1

ML700 - 1 - 22 000 / 106582 –11 27.03.2012 1

1 General

This chapter is subdivided into three sections:

Introduction: Chapter 1.1

Structure of the operating instructions, general notes

Safety: Chapter 1.2

Safety instructions, hazard potential

Technical Specifications: Chapter 1.3

Short description, machine diagram, technical data, drilling procedure

General

Preparation date: 03.02.2012 Version: 1_0 File: 106582_1

ML700 - 1 - 22 000 / 106582 –11 27.03.2012 2

1.1 Introduction

1.1.1 Structure of the operating instructions

The present operating instructions manual is intended for different groups of persons thus

consisting of separate chapters. You find the structure of the documentation and an over-

view of the chapters in the table of contents below. Additionally, each chapter begins with

its own table of contents. Each sheet of the documentation has its own sheet number at

the right bottom of the page. The first number (1-digit) refers to the chapter, the second

(max. 3-digit) is the running sheet number of the chapter.

Chapter

Description

Group of persons

General

All persons which have to

carry out work on the

machine.

1.1

Introduction

–Explanation of the operating instructions

–General notes

–Warranty provisions

–Copyright

–Reservation of title

1.2

Safety

–Safety instructions for the machine handling

1.3

Technical Specifications:

–Description of functions

–Technical data

–Description of technology

–Tool regrinding

Installation

–Notes on the transport

–Notes on the foundation work

–Notes on the installation of the machine/machine com-

ponents

–Notes on the commissioning of the hydraulic, pneu-

matic and central lubrication systems

Transport personnel,

assembly personnel,

commissioning personnel

General

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ML700 - 1 - 22 000 / 106582 –11 27.03.2012 3

Chapter

Description

Group of persons

Description

–Mechanical assembly groups

–Coolant system

–Hydraulic system

–Pneumatic system

Operating personnel,

commissioning person-

nel,

service personnel

Operation and set-up

–Data relating to specific safety devices

–Data relating to the operation and control components

–Details on programming support

(machine screens, machine data, NC programs)

–Data relating to fault messages

–Data relating to the tool change

–Data relating to the set-up work

Operating personnel,

installation personnel,

programmers

Repair

–Safety instructions relating to repair work

–Data relating to the maintenance of mechanical, hy-

draulic, pneumatic and electrical assembly groups

–Inspections (preventive maintenance)

–Repair work

–Setting and adjustment work

–Disposal

Operating personnel,

commissioning person-

nel,

service personnel

This chapter is relevant only to the service and assembly

personnel and serves as support for troubleshooting,

commissioning and installation of individual assembly

groups.

General

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1.1.2 General notes

The operating instructions must be read and always kept available at the

machine.

We furnish no guarantee for the data and pictures contained in this docu-

mentation; they may be changed without any further notification. The fig-

ures may slightly differ from the actual construction state of the machine

which however should not impair your understanding.

In order to achieve the full performance and precision, the machine re-

quires not only proper operation but also care and maintenance.

Check your machine regularly and observe the specified maintenance in-

tervals. If necessary, make sure that our customer service checks the

machine; it is always at your disposal.

Service addresses:

Customer Service

Mr Klein, R.: ++49 7123 / 976-302

E-MAIL: [email protected]e

Mr Hadolt: ++49 7123 / 976-301

E-MAIL: M[email protected]

FAX: ++49 7123 / 976-300

Spare parts service

Mr Roszick: ++49 7123 / 976-131

E-MAIL: R.Rosz[email protected]

Mrs Dieterle: ++49 7123 / 976-130

E-MAIL: A.Di[email protected]

FAX: ++49 7123 / 976-139

If you have any queries, please specify the machine type, machine number

and the designation from this documentation together with the sheet num-

ber.

We can only provide the contractually agreed warranty for defects on the

machine when the instructions and regulations contained in the documen-

tation have been complied with and when no interventions and conver-

sions have been performed without prior consent of the manufacturer of

the product.

The guarantee period is generally 12 months as of the delivery date with

one-shift operation, if not otherwise agreed in writing.

The purchase contract remains always binding.

The warranty of the manufacturer does not extend to:

–Damage caused by non-compliance of the user with written instructions

by the manufacturer in relation to operation and maintenance of the

equipment.

–Damages caused by natural wear.

–Damages caused by force majeure.

–Damages caused by any type of operator errors or by improper use or

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operation of the plant or its parts.

–Damages caused by a third party.

–Damages caused by the use of the plant or its parts under altered con-

ditions (e.g. materials, workpieces, tools, clamping devices, operating

materials, cutting parameters, programmes, etc.), especially without

consultation of and written release by the manufacturer.

–Damages to be attributed to altered environmental conditions.

The contractor reserves unrestricted ownership to the goods delivered

pending payment in full of all liabilities from the business activities of the

purchaser.

The purchase contract remains always binding.

For this documentation, we reserve all rights for the data and drawings, in

particular the priority for patent applications. Without our prior consent, the

documents may not be copied or made accessible to third parties, neither

completely nor abridged.

Documents supplied in advance may not comply in any case with the state

of the machine as delivered because of possible updates and technical

modifications.

Please note the date of issue!

This documentation is not subject to an automatic updating service. The

scope corresponds to the state as accepted and delivered.

The following modifications were documented and automatically replaced:

–Retooling to other workpiece types

–Fluid adaptation (coolant/pneumatic system and hydraulic system)

–Electric circuit diagram adaptation

–Software adaptation

These modifications must be marked with a modification index and the

modification date.

Upon completion of the installation/assembly work an acceptance record

will be prepared/filled in (together with the plant operator).

The operator and the supplier will get one copy each.

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1.2 Safety

1.2.1 General safety instructions

This operating instructions manual contains important information prereq-

uisite for safe and efficient working with the machine. It should be kept

readily accessible in the vicinity of the machine.

Before installation and commissioning, carefully read and observe the op-

erating instructions.

The operating instructions manual does not contain any repair information.

Repairs should only be carried out by specialist personnel of the compe-

tent customer service.

All warning and prohibitive signs at the machine must always be observed.

Legible signs must be replaced.

Nonobservance of the safety instructions may endanger persons as well

as the environment and the machine.

Nonobservance results in the loss of all claims for damages.

This machine may only be operated by trained and qualified personnel.

Persons entrusted with transport, storage, operation or maintenance and

repair of the machine must be familiar with the contents of the operating

instructions manual. These instructions, particularly the safety instructions,

must be obeyed.

In addition to the operating instructions, observe the valid general, statu-

tory and other regulations for the prevention of accidents and for environ-

mental protection which are in force in the particular country.

The following safety instructions are marked by symbols and described by

signal words. The operating instructions describe the dangers. The expla-

nations of these symbols / signal words must be read with care in order to

learn their meaning and effect.

DANGER

This symbol/signal word indicates direct hazards that may cause death or

serious injury, if the operating and work instructions are not complied with

exactly and the hazards avoided.

WARNING

This symbol/signal word indicates hazards that cause serious injury. This

warning is shown next to work instructions or operating instructions, that

are to be complied with exactly, in order to avoid serious damage or de-

struction of the machine or its components.

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CAUTION

This symbol/signal word indicates hazards that cause light injuries. This

note is shown next to work instructions or operating instructions, that are to

be complied with exactly, in order to avoid damage to the machine or its

components.

NOTE

This symbol/signal word stands for technical requirements and important

information (tips), that must be specially complied with in order to prevent

any damage to property and the environment and to ensure a failure-free

operation.

DANGER

Risk of burns due to a hot surface

Tool, spindle and revolver may reach temperatures of more than 80 °C!

May cause burns in case of contact.

DANGER

Pressure vessel

Pressure relief prior to disassembly or maintenance work

Gas prefilling pressure:_____ bar (entered on the sign by hand)

Must only be filled with nitrogen.

DANGER

due to corrosive substances

DANGER

due to a suspended load

DANGER

due to oxidising substances

DANGER

due to explosion hazard substances

For scavenging and flushing the gearbox casings and the liquid tanks and

for cleaning the guideways and other machine parts. Do not use low-

boiling, combustible solvents such as naphtha, benzene or similar.

DANGER

dangerous voltage

–Danger to life due to electric shock

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