Hardinge B161A DD200 Direct-Drive Rotary Table User Manual
Contents
1. Hardinge Inc 20122. Safety Recommendations 4 7 eter betreten e Deere ded ae X ER rne DM e esu EY Eae Nr EE TAN POR VE Eg cua 3 Introduction lP Basic BI re ubIo pP 7 1 2 Standard Spindle Clamp 2 22 reote eR Rene a a E ura cide debacle aR 7 l 3 High Stiffness Overall System cesses e e nemememeh heme mem ene 8 L4 Machinable Part Sizer sis cient ette It EE EU REA CREE FE E OR UR SER EE ERE ENTRA ERU 8 EONENI U OCDE 10 l Motor Thermostat sre eee fon ced nee E RR ER ERA Edere exe A ETE II 7 Specifications preesse ti oire theta eee R er ene ee DEP SP ra dee ER E RATEALE o EEA S a E LS Dimensions 5 oe Hee RE beta ter He EE E A ERE be Reps ter SEE Ie enge 12 2 Setup 2 General Setup siss toe eR RR RR ARES ES ER LR MH Re ERA ba FRA UR E Mode aga ERE ERNRRDR Adr 13 2 2 Use of Collets Sure Grip Expanding Collets Sure Grip 3 Jaw Power Chucks and Face Plates c 16 23 DD200 Collet Closer Optional esses eee neneneeeeeeenenseeeeeeenenseeee seen sees 16 2 4 Removing the DD200 Collet Closer sssee HH n memes emen ee 17 2 Use of Collets with the Hardinge Collet Closer esee 17 2 6 TOoling Locatioris as er Shae Sea pele Pee REA neos SERE e erre eoa chile a eea 19 3 Routine Maintenance 3 1 Use of Oil and Water Soluble Coolants csse I meme e eee 20 3 2 Clean po 2r ter ra etes eue eae Sones dy buses stows ARR Ree e E DAE REPE EE 20 3 3 Collet Key Replace
3. www shophardinge com Part No BA 0009500 0161 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A 3 Routine Maintenance 3 1 Use of Oil and Water Soluble Coolants For the use of oil and water soluble coolants the following guidelines should be observed e DO NOT SUBMERGE THE UNIT IN COOLANTS To the extent possible direct the coolant lines to the workpiece as opposed to directly upon the spindle seal area Avoid high pressure coolant applications where the pressure is above 200 psi Some machining centers provide flood coolant at enormous rates so that the head is practically submerged Throttle the flow back to appropriately match the application e Inspect the cables and gaskets regularly for cuts or swelling Damage must be repaired immediately 3 2 Clean Up At the end of the workday or shift it is important to clean the rotary table indexer The head should be free of any chips or grime Clean with a chip brush and apply a coat of rust preventative Do not use an air gun around front or rear seals Chips may damage the seals if blown in with an air gun 3 3 Collet Key Replacement Remove the set screw in the collet key access hole located on the spindle and then remove the old collet key from the face of the spindle with a 3mm Allen wrench Replace the collet key with Hardinge P N CJ 000028416C only using pipe sealant or thread Loctite 242 when installing Screw the collet key into the spindle until it begins t
4. area free from chips and coolant where air can circulate freely Do not let chips pile up over the motor enclosure as this would prevent proper cooling 4 Connect the DD200 Rotary Table Indexer using one of the techniques as described in the Hardinge servo control or Hardinge 4th axis manual which will be included with the mechanical unit 5 If adding a rotary table indexer to a Hardinge mill using a remote CNC cable or as a true 4th axis refer to the instructions in the Hardinge 4th axis manual or call your Hardinge service representative 6 If using the Hardinge servo control secure it in its required placement Do not cover any surface of the control as it will quickly overheat Do not place the unit on top of other hot electronic controls Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaARDINgE DD200 Rotary Table Indexer User Manual B 161A a The DD200 is wired directly to the Hardinge servo control For control box placement and cable routing the cable will need to be disconnected and reconnected according to the instructions in the Hardinge Servo control manual CAUTION Never connect or disconnect these cables with the power on Instant failure will result b Connect the AC line cord to a 120V AC grounded receptacle The cord is a three wire ground type and the ground must be connected Power
5. before installation USE CAUTION around exposed mechanisms and tooling especially when setting up Be careful of sharp edges on tools DON T USE worn or defective hand tools Use the proper size and type for the job being performed USE ONLY a soft faced hammer on tooling and fixtures DON T USE worn or broken tooling on machine MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools INSPECT ALL CHUCKING DEVICES daily to make certain that they are in good operating condition Replace any defective chuck before operating the machine USE MAXIMUM ALLOWABLE gripping pressure on the chuck Consider weight shape and balance of the workpiece DON T EXCEED the rated capacity of the equipment DON T LEAVE the equipment unattended while it is operating DON T CLEAN the equipment with an air hose KEEP TOTE PANS a safe distance from the machine Don t overfill the tote pans DON T LET STOCK project past the back end of the collet closer or equipment spindle without being adequately covered and properly supported UNLESS OTHERWISE NOTED all operating and maintenance procedures are to be performed by one person To avoid injury to yourself and others be sure that all personnel are clear of the equipment when opening or closing the coolant guard door and any access covers FORYOUR PROTECTION WORK SAFELY DON T OPERATE THE EQUIPMENT with damaged or worn electrical cables VERIFY that the electrical cables are not restrained
6. or pinched during full travel movement of the machine Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A Introduction 1 1 Basic Description The Hardinge DD200 Direct Drive Rotary Table Indexer is ideal for rapid and accurate positioning of medium sized parts in machining operations such as milling drilling tapping contouring and spiral milling The DD200 is a rigid high accuracy programmable rotary positioning device The mechanical indexing head holds the workpiece and is controlled by either a machine control as a true 4th axis or by the Hardinge All Digital Servo Control Positioning of the workpiece is accomplished by using the appropriate position preparatory feedrate and M codes just like a regular axis For use as a true 4th axis see the 4th axis manual and for use with the Hardinge servo control see the servo control manual It can be mounted in the horizontal position or in some cases vertically for face and end working applications A collet closer cannot be used when mounted with the spindle in the vertical position The rotary table indexer also has a spindle clamp to help assist the motor for off axis drilling and milling applications while maintaining a fixed position Advantages of the 16C DD200 Rotary Table Indexer e No Backlash High Res
7. tight to the spindle and tighten the chuck mounting bolts to the proper torque indicated in your chuck installation manual Use the collet closer drawtube to adjust the chuck for proper stroke required for ID and OD gripping Since the A2 5 spindle nose is such a tight tapered fit a face plate or 3 jaw chuck may be difficult to remove from the spindle even after the bolts are removed If this happens support the face plate or 3 jaw chuck with a hoist and lightly strike the outside diameter of the face plate or 3 jaw chuck with a piece of brass a plastic hammer or a rubber hammer so that nothing is damaged Note A hoist may be required to mount a 3 jaw chuck depending on the size of the chuck 2 3 DD200 Collet Closer Optional The DD200 collet closer has a 1 687 42 8mm through hole design with pneumatic open and close The through hole can be DD200 Collet Closer used for through spindle coolant or for holding long parts The FORCE CHART pneumatic closer has 625 15 87mm of stroke which allows the use of power chucks With the collet closer installed the unit 2 cannot be mounted in the vertical position The air pressure can psi Ibs be adjusted to achieve different drawbar forces out of the collet closer as shown in the chart NOTE Do not supply the collet closer with more than 100 psi of air pressure Part No BA 0009500 0161 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 4
8. 65 536 counts per rev This can be further interpolated by the subsequent electronics Dependant upon the control system used the DD200 system encoder can yield a resolution of up to 16 777 216 counts per revolution I 2 Standard Spindle Clamp The Hardinge DD200 comes with a fail safe spindle clamp that is standard from the factory This clamp allows the spin dle to handle cutting forces equal to 275 ft Ib 373 Nm allowing for greater cutting forces in the non contouring mode of operation The unit contains a pressure sensor that will prevent indexing in the event that air pressure drops below 85 psi to the clamp so that damage is prevented Air is supplied to the clamp through the cable conduit and is either connected to the back of the servo control box or machine air supply in the machine canopy wireway When equipped with the Hardinge servo control the clamp can be controlled automatically so that the clamp is engaged when the Ro tary Table Indexer arrives at its programmed destination or it can be controlled with G codes For ease of use a C will appear on the display of the control whenever the clamp is engaged There is a potential for a drop in air pressure if the air line supplying the Rotary Table Indexer is also supplying something else with air If you receive a low pressure alarm the first thing you should check is the air pressure supplied to the Rotary Table Indexer Please note that even a momentary drop in air pressure can create
9. 68 5946 www shophardinge com 15 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A 9 M6 BOLTS ADAPTER Msc gi ANTI ROTATION PLATE Us BRACKET 4 M6 BOLTS 2 4 Removing the DD200 Collet Closer Air collet closers fitted at the factory are not intended to be removed However if servicing is required the following instructions can be used to remove the collet closer First remove all workholding from the unit spindle Disconnect the air to the closer and cycle valve to relieve internal pressure Then remove the four M6 bolts on the back of the bolster that hold the sheet metal anti rotation bracket in place Remove the nine M6 bolts that go through the collet closer body which hold the closer to the unit Stick a brass rod down the center of the spindle from the front of the unit and locate the end of the brass rod on the end of the collet closer drawtube Lightly tap the end of the brass rod while moving it around the face of the drawtube until the closer is fully disengaged from the adapter plate at which time it can be removed from the unit A second person may be required to support the closer while this is being done Once removed from the unit the closer piston will be visible Be sure not to allow any chips or debris to get in the piston area of the collet closer If access to the rear of the DD200 is needed remove the four M6 bolts that hold the adapter plate to the spindle and carefully remove the adapte
10. AS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A Setup and Operation for the Hardinge DD200 Direct Drive Rotary Table Indexer Original U S A Instructions Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 RS HaARDINgE DD200 Rotary Table Indexer User Manual B 161A Thank you for purchasing a Hardinge DD200 Direct Drive Rotary Table Indexer This User s Manual is provided to assist you with setup procedures and to familiarize you with the features specifications and maintenance recommendations of your unit The mechanical indexing head can be maintained by the customer with proper cleaning and maintenance Any necessary repairs required during the warranty period will be made at Hardinge Inc or by a factory authorized representative For best workholding results with this rotary table Hardinge recommends Hardinge brand collets 6C workholding products step chucks and expanding collets Hardinge Inc One Hardinge Drive Elmira New York 14902 1507 U S A p 800 843 8801 or 607 378 4022 p 800 468 5946 Canada f 607 734 3886 F E Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A Table of Contents
11. J 12 24 311 001 4 025 E 12 63 320 9 gt Optional mounting plate required when placing unit on its back J gt 4 101 6 0003 4 0076 9 37 238 1826 463 9 Forward 8 89 479 7 Back Part No BA 0009500 0161 RS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A 2 Set Up 2 General Setup Fill out the warranty information by visiting www hardinge com rotarywarranty on the internet Jen s P E MG 1 ec of 2 Place the rotary table indexer on the machine Route the cable from the head so that it avoids tool changers and table edges Cable slack must be provided for your machine s movements If the cable is cut the motor or feed back system could fail prematurely Replace a damaged cable immediately Secure the rotary table indexer to the machine s T slot table as shown upright or on its back A special mounting plate will be needed to mount the unit on its back T nut packages are available for purchase for various T slot tables Kit includes 2 T nuts 2 bolts and 2 flat washers Check to verify that all clearances are satisfied in full machine axis movements and that there is no possibility of a collision NOTE End user is responsible for properly routing cable Hardinge accepts no responsibility for damages in cabling resulting from improper installation 3 Place the rotary table indexer in an
12. RDING is in place and that all doors to the primary machine are closed and secured DON T OPEN GUARD DOORS of the primary machine while any machine component is in motion MAKE SURE chucks closers fixture plates and all other spindle mounted workholding devices are properly mounted and secured before starting the unit or the machine MAKE CERTAIN all tools are securely clamped in position before starting the unit or the machine REMOVE ANY LOOSE PARTS OR TOOLS left on the unit or the machine or in the work area before operating the equipment Always check the machine and work area for loose tools and parts especially after work has been com pleted by maintenance personnel REMOVE CHUCK WRENCHES before starting the unit or the machine BEFORE PRESSING THE CYCLE START PUSH BUTTON make certain that proper functions are programmed and that all controls are set in the desired modes KNOW WHERE ALL stop push buttons are located in case of an emergency MAKE CERTAIN that all guards are in good condition and are functioning properly before operating the equipment INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condition and are functioning properly before the cycle is started CHECK THE POSITION of any load unload automation before pressing the Cycle Start push button CHECK SETUP TOOLING AND SECURITY OF THE WORKPIECE if the machine has been OFF for any length of time DRY CYCLE a new setup to check for programmin
13. RRANTY The Hardinge DD200 Rotary Table Indexer is provided with a one year warranty against any defects in material and workmanship 1 6 Motor Thermostat The motor is equipped with a thermostat that monitors the internal temperature in the motor windings The thermostat is set to open at 85 degrees C This is done to restrict the electrical components inside the unit 1 7 Specifications Spindle Clamping Torque ft Ib INm Runout Max TIR Backlash arc sec Maximum RPM Rotational speed degrees sec Spindle Nose Collets Horizontal Spindle Height inch Indexing Accuracy arc sec Repeatability arc sec Resolution arc sec Max Rotation Step 4th axis degree Motor Rare Earth Permanent Magnet Torque Motor Maximum Peak Torque ft Ib Nm Continuous Torque Air Cooled ft Ib Nm Continuous Torque Liquid Cooled ft Ib Nm Operating Specifications Duty Cycle Operating Temperature max ambient Power Rating Oil Requirements Clamp Air Requirements psi bar Collet Closer Air Requirements psi bar Weight Rotary Indexer Ib kg Control Ib kg Workholding Collets round max capacity in mm Collets Hex max capacity in mm Collets Square max capacity in mm 275 373 0 0002 0 175 with Servo Control 120 volt single phase 350 with Servo Control 220 volt single phase 250 as 4th Axis with 20 amp Fanuc Drive Amplifier 0 001 to 2100 with Servo Control 0 001 to 1500 as Fanuc 4 Axis A2 5 16C Standar
14. am to rotate the spindle clockwise or counterclockwise with step sizes from 00 to 9999 99 degrees Using G83 amp G84 continuous rotation is allowed Contact Hardinge for maximum speeds based on duty cycle ABSOLUTE OR INCREMENTAL PROGRAMMING With Hardinge Servo Control Up to 1000 different steps can be stored in memory and each step can be repeated looped 999 times RS 232 INTERFACE With Hardinge Servo Control For computer control of sending and receiving programs and controlling indexer via the CNC control of host machine capable of RS 232 communication RESOLUTION Standard resolution of 001 degrees SIMPLE EDITING With Hardinge Servo Control Edit a program by simply writing over existing steps or inserting or deleting a step or several steps with automatic program step renumbering SUBROUTINES With Hardinge Servo Control Allows repeated sequences up to 999 times saving programming time and memory space VARIABLE FEED RATES Variable from 001 deg sec to 2100 deg sec with Hardinge Servo Control up to 1500 deg sec as true 4th axis Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A ZERO RETURN With Hardinge Servo Control An automatic home position can be programmed to return the spindle to its original starting position from any point ONE YEAR WA
15. an alarm situation Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaARDINgE DD200 Rotary Table Indexer User Manual B 161A CAUTION Never attempt to defeat the clamp protection logic as this may result in an opportunity for the system to rotate when the clamp is engaged This will cause an overload fault and repeated attempts to operate in this manner may damage the clamp The clamp requires a minimum of 85psi with a maximum of 00psi of OF DRY FILTERED AIR to fully release the spindle and must be supplied to the unit even if the clamp is not going to be used 1 3 High Stiffness Overall System The DD200 is inherently stiff due to its construction with the robust housing and cross roller bearing design coupled with a heavy duty cylindrical roller bearing Furthermore the direct drive motor offers a level of servo stiffness for the spindle that is superior to geared systems due to the elimination of gear backlash and other system compliances The high servo gains supported by the high resolution encoder make a powerful combination for heavy contouring applications 1 4 Machinable Part Size The DD200 Rotary Table Indexer is designed with a 1 6C spindle seat similar to the lathe spindle that Hardinge is noted for The Hardinge DD200 has been designed for those parts that can be conveniently gripped in any of the 1 6C gripping sys
16. d 16C 6 000 0 001 3 2 077 9999 99 or Continuous Using G83 or G84 in the Hardinge Servo Control 118 160 2 27 37 2 56 76 2 100 at full speed 104 F 40 C Varies 3 No Oil 85min 00max 5 8min 6 9max dry air 100 6 9 Minimum dry air 240 109 9 54 4 34 15 s 41 27 1 3 32 35 71 19 64 28 97 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 DD200 Rotary Table Indexer User Manual B 161A BS HaRDINgE FlexC Collet Systems Style D 3 Jaw Chucks diameter Slotted Face Plate diameter Collet Stops part positioning 1 8 Dimensions DD200 Rotary Table Indexer Step Chucks max capacity in mm Sure Grip Expanding Collets in mm Fixture Plate Collet Style diameter Fixture Plate Spindle Mount diameter up to 6 152 40 27 16 65 00 5 6 and 8 1 8 4 3 17 101 60 63 5 161 92 5 4 139 7 87 5 225 42 87 5 225 42 10 254 00 YES 3 will vary according to motor requirements of the 4th axis interface I 13 20 335 3 13 63 346 30 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com continuous torque available 24 7 365 days 2 from standard GE Fanuc H104 amplifier 10 00 aA E 254 0 us 279 4 Y n IIa 1 6 152 4
17. entative Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A Inertia vs Weight vs Required Torque to Spin Part AXIS OF ROTATION Example A Example B Material Steel Material Steel Weight 5 3 Ibs 2 4 kg Weight 2 5 Ibs I 1 kg Inertia about axis of Rotation 2 7 Ib in Inertia about axis of Rotation 17 8 Ib in 0 0008 kg m 0 008 kg m Torque required to hold Balanced Part in position N A Torque required to hold Unbalanced Part Balanced in position 7 5 in lbs 0 85 Nm Example A is a balanced part which is approximately twice as heavy as Example B which is an unbalanced part Notice that since Example A is balanced the torque required to hold the part in position is negligible and its moment of inertia is very low Since Example B is unbalanced its moment of inertia is about 10 times larger than Example A even though it weighs about half as much Note that torque is required to hold Example B in position Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A 1 5 Features RIGID DESIGN Precision cross roller bearing coupled with a tapered bore cylindrical roller bearing will
18. g errors MAKE CERTAIN that you are clear of any pinch point created by moving slides before starting the machine DON T OPERATE any equipment while any part of the body is in the proximity of a potentially hazardous area DON T REMOVE CHIPS with hands Use a hook or similar device and make certain that all machine movements have ceased BE CAREFUL of sharp edges when handling a newly machined workpiece DON T REMOVE OR LOAD a workpiece while any part of the equipment is in motion DON T OPERATE ANY EQUIPMENT while wearing rings watches jewelry loose clothing neckties or long hair not contained by a net or shop cap DON T ADJUST tooling or coolant hoses while the equipment is running DON T LEAVE tools work pieces or other loose items where they can come in contact with a moving component of the equipment DON T CHECK finishes or dimensions of workpiece near running spindle or moving slides DON T JOG SPINDLE in either direction when checking threads with a thread gage DON T ATTEMPT to brake or slow the equipment with hands or any makeshift device Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaARDINgE DD200 Rotary Table Indexer User Manual B 161A Safety Recommendations continued ANY ATTACHMENT TOOL OR MACHINE MODIFICATION not obtained from Hardinge Inc must be reviewed by a qualified safety engineer
19. is 120VAC The power service must supply a minimum of 15 amps continuously Conduit wire must be 2 gauge or larger and fused for at least 20 amps If an extension cord is to be used use a three wire ground type and the ground line must be connected Avoid outlets that have large electric motors connected to them Use only heavy duty 12 gauge extension cords capable of 20 amp load Do not exceed a length of 30 feet Permanent installations should be hard wired or installed with locking plugs Semi Fourth Axis Connect the remote interface cable See separate Hardinge Servo Control manual Connect 85psi minimum 00psi maximum of dry filtered air to the quick disconnect fitting on the back of the control box or in the machine wireway This will supply air to the air purge on the nose cap as well as to the spindle clamp CAUTION Never attempt to operate the DD200 without the 85psi minimum lO0psi maximum of dry filtered air connected to the air fitting or mechanical damage will occur QUICK DISCONNECT FITTINGS Back of DD200 without Collet Closer Back of DD200 with Collet Closer 10 Connect air to the quick disconnect fitting on the back of the rotary table if unit is equipped with a pneumatic collet closer Connect air to the quick disconnect fitting on the cable side of the rotary table indexer if unit is not equipped with a pneumatic collet closer Save the packing materials in case you need to ship the unit At the end of the w
20. ment pesiin e beati eigo E ob ERR HRERP RIP ERE REA IEEE ERE edebat 20 4 One Year Limited Warranty esses eee heme hememes esee seme ses esse sess eene nenne 20 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A Safety Recommendations READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE OPERATING THIS UNIT Note Equipment refers to the rotary table indexer and or machine it is used with When this instruction book was printed the information given was current However since we are constantly improving the design of our products it is possible that the illustrations and descriptions may vary from the system WARNING Occupational Safety and Health Administration OSHA Hazard Communication Standard 1910 1200 effective May 25 1986 and various state employee right to know laws require that information regarding chemicals used with this equipment be supplied to you Refer to the applicable section of the Material Safety Data Sheets supplied with your unit when handling storing or disposing of chemicals HARDINGE SAFETY RECOMMENDATIONS Your Hardinge machine is designed and built for maximum ease and safety of operation However some previously accepted shop practices may not reflect current safety regulations and procedures and should be re examined to i
21. nsure compliance with the current safety and health standards Hardinge Inc recommends that all shop supervisors maintenance personnel and machine tool operators be advised of the importance of safe maintenance setup and operation of Hardinge built equipment Our recommendations are described below READ THESE SAFETY RECOMMENDATIONS BEFORE PROCEEDING ANY FURTHER ANYONE HAVING ACTIVE IMPLANTS pacemakers or having any other ferromagnetic prosthesis is not qualified to work with these kinds of devices or to approach them Keep at a safe distance from the motor READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation or maintenance of the equip ment Make certain that you understand all instructions DO NOT ALLOW the operation or repair of equipment by untrained personnel CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times When necessary wear respirator helmet gloves and ear muffs or plugs DON T OPERATE EQUIPMENT unless proper maintenance has been regularly performed and the equipment is known to be in good working order WARNING or INSTRUCTION TAGS are mounted on the unit for your safety and information Do not remove them or damage them DO NOT ALTER THE EQUIPMENT to bypass any interlock overload disconnect or other safety device DO NOT OPERATE EQUIPMENT if unusual or excessive heat noise smoke or vibration occurs Report an
22. o protrude into the inside diameter of the spindle and turn until the flat on the bottom of the key is parallel to the spindle centerline Place a new Hardinge collet into the spindle to test if key depth is adequate Remove collet and adjust key until a proper fit is achieved NOTE When using collet type workholding never run the spindle without the collet key having been properly installed Failure to do this may cause the collet to rotate in the spindle and possibly cause some level of damage 4 One Year Limited Warranty The Hardinge DD200 Direct Drive Rotary Table Indexer is provided with a one year warranty against any defects in material and workmanship Specific details of the warranty can be found in the Hardinge Terms and Conditions document associated with the purchase agreement Part No BA 0009500 0161 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com I9 Hardinge Inc One Hardinge Drive P O Box 1507 Elmira New York 14902 1507 USA USA 800 843 8801 Canada 800 468 5946 Fax 607 734 3886 To Order Online www shophardinge com Corporate Homepage www hardinge com E mail info shophardinge com Live Online Support www shophardinge com All specifications are subject to change without notice due to ongoing continuous improvement All marks indicated by and are trademarks of Hardinge Inc Instruction Manual B 161A Litho in USA
23. olution Encoder Directly Mounted to Spindle LongLife with Low Maintenance e Optimal repeatability and positioning accuracy The DD200 is offered with a frameless wraparound rare earth permanent magnet torque motor that is manufactured ready to be cabled for a 200 or 400 volt machine and meets the most rigorous industry codes It has a horizontal spindle centerline of 6 00 152 4mm similar to the Hardinge 1 6C Rotary Table Indexer Cable connectors meet the IP 65 splash code that states that they can be sprayed with coolant Please note that the system cannot be submerged The spindle is hardened and ground for accuracy and has a special cross roller bearing coupled with a rigid cylindri cal roller bearing to support heavy cutting forces The system is designed with a series of appropriate sealing systems including a bearing seal to provide a longer bearing life and a front cap seal with air purge Positioning of the spindle is accomplished through a wraparound rare earth permanent magnet torque motor that requires no mechanical gears This type of motor requires no maintenance and will provide many years of smooth operating performance with zero backlash The system is fitted with a means of external liquid cooling of the motor to increase the continuous torque The high resolution encoder is mounted directly to the DD200 spindle to insure the highest available accuracy The main encoder ring has 16 384 lines which times 4 gives a native resolution of
24. orkday or shift it is important to clean the rotary table The rotary table indexer should be free of any chips or grime Clean with a chip brush and apply a coat of rust preventative CAUTION Do not use an air gun around the front or rear seals Chips may damage the seal if blown in with an air gun Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A NOTE Prior to powering on the unit read and understand the entire servo control or 4th axis manual 12 Initialization and homing of the unit is explained in the servo control and the 4th axis manuals 2 2 Use of Collets Sure Grip Expanding Collets Sure Grip 3 Jaw Power Chucks and Face Plates The unit accepts standard Hardinge 16C collets step chucks ID gripping collets chucks and face plates When inserting the collet align the keyway on the collet with the key inside the spindle Push the collet in and turn the collet closer drawbar clockwise until proper collet tightness is obtained Chucks and face plates utilize the A2 5 spindle nose on the Rotary Table Indexer Always make sure that the spindle and chuck or face plate are free of dirt and chips Align the chuck draw tube keyway with the spindle collet key and slide the chuck onto the spindle Turn the collet closer drawtube to engage the chuck Push the chuck
25. r plate CAUTION The DD200 Collet Closer relies on air i pressure to maintain clamping force and is released ADAPTER upon the removal of the air pressure j i PLATE 4 M6 BOLTS Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 DD200 Rotary Table Indexer User Manual B 161A BAS HaARDINgE COLLET 2 5 Use of Collets With the Hardinge Collet Closer NOTE All collets must be free from burrs and in good condition Collet Installation in the Collet Closer DRAWTUBE HANDLE 3 M6 BOLTS To install a collet first make sure that the closer is in the forward position Loosen the three M6 bolts on the back of the drawtube handle until they are fully disengaged from the closer piston These bolts will not fall out of the drawtube as there is a snap ring in the counter bore of each clearance hole Next align the collet keyway with the spindle key and insert the collet while turning the draw tube handle to engage the collet Turn the draw tube handle until the collet grips the part and then back off approximately 4 turn This will be a good starting point for fine tuning the grip range The collet should be adjusted with the drawtube handle as shown in the graphic above Once properly adjusted tighten up the three M6 bolts on the back of the handle to 10 ft lbs before actuating the closer CAUTION The DD200 Collet Clo
26. ser relies on air pressure to maintain clamping force and is released upon the removal of the air pressure Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A If the Collet is Sticking NOTE To prevent excessive wear and collet sticking make sure collets are in good condition and free from burrs A light coat of Molybdenum grease on the collet wear surfaces will extend the life of the spindle and or collet and help prevent sticking especially when operating dry Emergency collets are soft and are not recommended for long production runs These collets will stick after prolonged use 2 6 Tooling Locations The DD200 is equipped with tooling points on the underside of the unit in order to speed setups One of the most time consuming procedures in setup operations is aligning the head with the table On the mounting surfaces there are two 0 500 12 7mm bored holes on 4 000 101 6mm centers The holes on the bottom surface are parallel to the spindle within 0 001 0 025mm per 6 inches 152 4mm Locating buttons are bolted in the holes and used for alignment in the slots of the machine table This will give quick parallel alignment that will be adequate for most jobs Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946
27. support heavy cutting forces on medium or small parts HARDENED AND GROUND SPINDLE Typical of the accurate long life Hardinge lathe spindle WRAPAROUND RARE EARTH PERMANENT MAGNET TORQUE MOTOR For very precise high speed indexing with no backlash and high repeatability AUTOMATIC CIRCLE DIVISION With Hardinge Servo Control You can program a step that automatically divides a circle into any number of equal parts between 2 and 999 STOP FEED HOLD With Hardinge Servo Control You can use the STOP to feed hold spindle movement without losing position on restart INTERFACING With Hardinge Servo Control Most CNC mills can be interfaced quickly and easily by using a spare M function which provides a switch closer as a signal between your mill and the control The Hardinge servo control will provide a finish set of contacts to send a response back to the mill LINEAR amp SPIRAL MILLING With Hardinge Servo Control For semi fourth axis capability MEMORY With Hardinge Servo Control A nonvolatile memory retains your program even when power is turned OFF and remembers the current spindle position and step number when the Servo is stopped PROGRAM STORAGE With Hardinge Servo Control Store and recall up to fifty different programs USER PARAMETERS With Hardinge Servo Control Some of the parameters can be changed by the user to alter a few of the basic features of the servo control PROGRAMMING With Hardinge Servo Control Progr
28. tems that Hardinge is also noted for Typical parts are in the range of approximately 2 50 8mm in diameter and gen erally not longer than 6 152 4mm without the use of a tailstock It is typical to speak in terms of the L D ratio which is the length divided by the part diameter A 2 50 8mm diameter part 6 152 4mm long has an L D ratio of 3 1 Part pieces with larger L D ratios should be used with a tailstock up to a typical L D ratio of 6 1 Larger part sizes than those described above can be handled with additional support i e Tailstock Trunnion etc When talking about machinable part size inertia and torque play an important role Any part and fixture combination should not exceed the maximum inertia of 0 55 kg m This inertia should be calculated about the center of rotation of the DD200 because when a part s mass gets further from the center of rotation its inertia increases An unbalanced part should also not require a torque that exceeds the allowable torque of the motor shown in section 1 7 of this document A part weighing 5 Ibs at a distance of 6 inches from the center of the spindle would require 30 in Ibs or 2 5 ft lbs of torque to rotate See examples on the following page for light parts that have high inertia Note Larger inertial loads may require changing a few motor parameters to get the unit to run properly If assistance is needed in calculating inertia torque or changing parameters please contact your local Hardinge repres
29. y excessive or unusual vibration sounds smoke or heat as well as any damaged parts LIFTING AND HANDLING OF THE UNIT should be done with full knowledge of the unit weight and using proper procedures MAKE CERTAIN that the equipment is properly grounded Consult National Electric Code and all local codes REMOVE POWER from the unit by unplugging the power cord before attempting repair or maintenance Where Applicable DON T OPEN THE CONTROL BOX without consulting with Hardinge Where Applicable DON T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wet surface Where Applicable REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished Where Applicable Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BA 0009500 0161 BAS HaRDINgE DD200 Rotary Table Indexer User Manual B 161A Safety Recommendations continued ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before restarting the machine Where Applicable KEEP THE AREA AROUND THE MACHINE well lit and dry KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equipment HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustible material and keep chips clear of the work area DON T USE a toxic or flammable substance as a solvent cleaner or coolant MAKE CERTAIN THAT PROPER GUA
Download Pdf Manuals
Related Search