KOMflex precision spindle Operating instructions head cuttingtools.ceratizit.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Contents 1 Introduction ....................................................................................................................................... 1 Purpose of this document .......................................................................................................... 1 Obligations and liability .............................................................................................................
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Manually configuring the basic settings .................................................................................. 17 Mounting.................................................................................................................................. 18 8 7.4.1 Tool mounting .................................................................................................................. 18 7.4.
KOMflex precision spindle head 1 Operating instructions Introduction Purpose of this document These operating instructions are designed to familiarise users of the KOMflex precision spindle head with the following: • • • • Working principles Operation Safety information Maintenance Obligations and liability • • • • • • An understanding of the fundamental safety information and safety regulations is a basic prerequisite for safe handling and trouble-free operation of the KOMflex precision spindle hea
KOMflex precision spindle head 2 Operating instructions V1.1 31.03.2021 Safety information Operating personnel Components must only be operated by trained personnel who are familiar with the working principles, operation and safety devices of the KOMflex precision spindle head. Note Always keep the operating instructions with the KOMflex precision spindle head. The instructions must always be to hand.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 EC Declaration of Conformity cuttingtools.ceratizit.
KOMflex precision spindle head cuttingtools.ceratizit.com Classification: Öffentlich Operating instructions V1.1 31.03.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Radio Approval Japan: R 202LSJ048 “This device has been granted a designation number by Ministry of Internal Affairs and Communications under „Ordinance concerning Technical Regulations Conformity Certification etc. of Specified Radio Equipment (特定無線設備の技術基準適合証明等に 関する規則)“ Article 2-1-19.
KOMflex precision spindle head 3 Operating instructions V1.1 31.03.2021 Glossary KOMflex adjustment range The KOMflex can be adjusted between -0.25 mm and +0.25 mm in relation to the central position of the slide. Centre position definition The centre position (CP) is the central position of the slide (zero point).
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Reinitialisation During reinitialisation, the KOMflex precision spindle head is reverted to its initial state. This means that the KOMflex travels to the VIP and the radius wear in the tool table is reset to 0. (See section 8.3) cuttingtools.ceratizit.
KOMflex precision spindle head 4 Operating instructions V1.1 31.03.2021 System overview The KOMET KOMflex compensation system consists of the following components: • • • • • • KOMET KOMflex with BLUM wireless unit BLUM RC66 receiver BLUM IF20 interface BLUM EM3x extension module BLUM software Any measuring unit, e.g. measuring probe The automatic KOMflex compensation system enables process-secure boring of holes and pins on a machine tool.
KOMflex precision spindle head 5 Operating instructions V1.1 31.03.2021 Description of the RC66 wireless receiver The RC66 is a compact wireless receiver with BRC technology which is suitable for all Blum measuring devices and the KOMflex with wireless transmission. It enables wireless communication between the measuring devices/the precision spindle head and the NC control. Data is transferred to the NC control via the IF20 interface.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Pairing mode The MODE LED (1a) flashes white continuously in pairing mode. The TX and RX LED (1d, 1e) indicate that data is being transferred. Once a KOMflex has been successfully taught-in, the BATTERY and the STATUS LED (1b, 1c) flash green. If pairing fails, due to timeout or a problem with the data transfer or an incorrect device type, for example, then the BATTERY and STATUS LED (1b, 1c) flash red.
KOMflex precision spindle head 6 Operating instructions V1.1 31.03.2021 Description of the KOMflex precision spindle head The automatic precision spindle head communicates with the BLUM RC66 wireless interface and forms a closed-loop operation (process, measure, correct, process) in conjunction with any measuring unit. Therefore, the KOMflex enables automatic diameter correction for precision holes.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 KOMflex system description ① ABS 50 adapter ② Combined tool interface ABS 32 / dia. 16 mm / teeth ③ Slide ④ Inner and outer coolant supply ⑤ Battery compartment WAF2.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Description of the KOMflex modes The KOMflex can be operated in manual or automatic mode. Both modes Manual adjustment with magnetic pen and Automatic adjustment via NC cycle are covered in more detail below. 6.4.1 Manual adjustment with magnetic pen To operate the KOMflex in manual mode, for example on the presetting equipment, the precision spindle head must be in standby mode (all KOMflex LEDs off).
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 6.4.2 Automatic adjustment via NC cycle Successful teach-in of the precision spindle head is the prerequisite for automatic operation of the KOMflex, see section 8.2.4. In standby mode (all KOMflex LEDs off), "Automatic adjustment" mode can be activated via the computerised numerical control (CNC). In this state, the precision spindle head indicates the key statuses via flashing LEDs. An overview of the statuses is given below.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Emergency shutdown If the KOMflex is in an active state, but does not receive any commands from the interface IF20, the head is deactivated after a timeout of 5 minutes and goes into standby mode. Possible scenarios in which an emergency shutdown may occur • Switch-off command does not reach the KOMflex, e.g. problems with radio connection • The emergency stop or reset of the NC is activated.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Indicating the basic settings Once the insulation pad has been removed/the batteries have been inserted, the basic settings are indicated. The magnetic pen is not needed for this. Once the basic settings have been indicated, the precision spindle head goes into standby mode.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Manually configuring the basic settings The basic settings can be changed in this mode. Note The magnetic pen is needed to operate the KOMflex in this section. 1. Remove the batteries. 2. After 30 seconds, re-insert the batteries in the battery compartment. Pay attention to the battery polarity. Refit the battery compartment lid. 3. The basic settings are indicated (indication phase). 4.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Mounting 7.4.1 Tool mounting When fitting the tools, the indexable insert must point in the direction of the cutting edge shown on the base body. The permitted maximum RPM is nper. = 8000 RPM. The permitted RPMs depend on the tool used (mass & type). The RPMs must be adjusted in line with the machining process and its conditions.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 7.4.4 Coolant The precision spindle head has a thro' coolant supply. Usage of the central coolant supply is mandatory and ensures optimal chip formation and chip removal. The coolant pressure must not fall below the minimum level of 5 bar. An increase in coolant pressure to 10-20 bar improves the machining process and should therefore be the aim. The maximum coolant pressure is 30 bar.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 8 Commissioning the KOMflex Presetting equipment Before the KOMflex precision spindle head can be taught-in with the IF20 and therefore initialised, the VIP must be approached in manual mode, on the presetting equipment for example. This step always needs to be carried out if: • • • KOMflex is being commissioned for the first time. A new machining process (new VIP) is taking place. A new tool is being used.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 There are three ways of defining the VIP on the presetting equipment: ① Trial cut ② Without trial cut ③ Offset trial cut No correction through offset; value for the trial cut is included in VIP. Target diameter of the cutting edge corresponds to the position of the VIP. The VIP position is corrected by means of offsets via the R-parameter in the Global User Definition (GUD) on the Siemens CNC.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Use of the KOMflex on the machine 8.2.1 Overview of the product range Range Description Reference BKF_USERPARATABn Subprogram for defining the customer program Section 8.2.2 BKF_CONTROLLER Subprogram for NC ←→ IF20 communication BKF_CHECKIN Program for teaching-in the KOMflex Section 8.2.4 BKF_CORRECTION Program for automatic correction of the KOMflex Section 8.2.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 The KOMflex tool data can also be defined in more detail in the BKF_USERPARATABn subprogram. The following table gives further information about the most important parameters. Definition of the tool data Parameter Meaning _BKF_TOOLNAME • "NAME", if a tool name is needed. • "NUMBER", if a tool number is needed.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 8.2.3 Parameter overview when calling up programs If no call parameters are transferred in the program calls, the parameters in the BKF_USERPARATAB1.SPF program are effective. Parameter Explanation KFID ID number with which teach-in was carried out for the KOMflex. Up to 16 KOMflex can be taught-in with an RC66. |1| <= KFID <= |16| The teach-in process can be skipped for an already taught-in KOMflex with negative KFID.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 8.2.4 Teaching in the KOMflex In this phase, a non-taught-in KOMflex can be taught-in in IF20 or an already taught-in KOMflex can be initialised. This means that the position of the head at the moment of teach-in is saved. If the precision spindle head used has already been taught-in on the machine and pairing is not to take place again, then this step can be skipped. This cycle takes place in automatic mode.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 4. Switch KOMflex on • The precision spindle head is automatically switched on after initial teach-in of a new KOMflex or initialisation of an already taught-in KOMflex. 5. Set VIP • VIP 1 is set in the program. • Optional: VIP 2 is used in the program as the monitoring value for detecting manual intervention. 6. Approach VIP • VIP is approached. 7.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 8.2.6 Manually switching off The KOMflex can be manually switched off with the BKF_OUT () program. Range: BKF_OUT (KFID) Parameter • KFID KOMflex ID number: 0 - 16 If the KFID = 0, the switch-off signal is sent to all KOMflex. Reinitialisation of the KOMflex During reinitialisation, the KOMflex can move back to its original position, set during teach-in (position for a trial cut).
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Extension of the machine with further KOMflex To integrate a new KOMflex into the machine, the program must be extended with a new BKF_USERPARATABn, whereby n is the KOMflex ID. This allows the system to be extended with ease, without losing clarity. The machine can be extended with up to 16 KOMflex systems. KOMflex tool data NC cycles cuttingtools.ceratizit.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Changing the cutting edge With the KOMflex system, the maximum wear limit for internal or external machining can be specifically adapted to the customer application via the _BKF_WEAR_LIMIT parameter in the BKF_USERPARATABn subprogram (section 8.2.2). If one of these values is dropped below or is exceeded, the program is stopped and the error message "Error E7 – Out of tolerance" appears on the machine control.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Battery replacement The KOMflex's batteries must be checked when: • The status LED flashes red or lights up red. • The error message 1117 – warning battery: battery voltage in critical state – appears on the CNC control. 8.6.1 Changing the battery Recommended type: Type Saft Lithium LS14500 Tadiran SL-360 mAh 2600 2400 Nominal voltage 3.6 V 3.6 V Size AA AA 1. 2. 3. 4. 5. 6. 7. 8.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 8.6.2 Disposal of batteries The KOMflex precision head spindle must be disposed of in compliance with national and local regulations as part of the normal recycling process. Once it is no longer being used, statutory disposal regulations apply. In general, observe the following during disposal: Separate components for recycling into electronic waste, scrap iron, aluminium, plastic and battery.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 KOMflex errors in machine operation Code Value 1100 1 Timeout: Position could not be reached in the specified time. 1102 1 Absolute VIP could not be set: Index outside range. 2 Relative VIP could not be set: Index outside range. 3 "Go to VIP" requested with invalid index. 1103 1 Requested position is outside the limit: Position greater than maximum.
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 Code Value 1106 2 Plausibility error detected: Motor blocked. 3 Plausibility error detected: Motor overcurrent. 4 Plausibility error detected: Motion in opposite direction detected (positive direction of travel expected). 5 Plausibility error detected: Motion in opposite direction detected (negative direction of travel expected). 6 System is in an error state (battery empty for example).
KOMflex precision spindle head Operating instructions V1.1 31.03.2021 BLUM errors in machine operation In the event of an error, the error number is set, and an error message appears on the screen. The program must be interrupted with the RESET button, the cause of the error must be resolved, and the program must be restarted. In the event of messages (e.g. E7), the program processing is interrupted by "M0". The cycle can be continued with "Cycle start".
KOMflex precision spindle head E22 Operating instructions V1.1 31.03.2021 "Communication error" Description: Solution: Connection error between NC and IF20. Ensure that a connection is established between NC and IF20. Also check all the connecting elements between them. Correctly configure the network or the field bus. Error number Digits after point Description of error 22 .1 Timeout communication 22 .2 IF or EM not connected 22 .02010 Error RC66 timeout 22 .
KOMflex precision spindle head 9 Operating instructions V1.1 31.03.2021 KOMflex recycling – Our recycling service Our joint contribution to the environment - beyond the lifetime of the tool: We take back your used fine adjustment heads KOMflex and recondition them professionally. This saves you costs and effort for disposal.
