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1 I-HTC-120 Control MANUAL for SUNNEN TUBE HONING MACHINES HTC SERIES Version: VC-40 50/ VCSC11 30, V -6.43/44b File: CME-V643 Date: 15 March, 2006 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THE HTB-TUBE-HONING-MACHINE. SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD SAINT LOUIS, MO 63143, U.S.A. PHONE: SUNNEN AG Fabrikstrasse ENNETAACH SWITZERLAND PHONE:

2 Table of Contents 1 INTRODUCTION OPERATING PANEL START-UP MODE THE DISPLAY NUMERIC INPUT WINDOW (EDITING WINDOW) MULTI-EDIT INPUT WINDOW ACCESS CODE INPUT WINDOW ERROR MESSAGE INFORMATION WINDOW SELECTION FROM A LIST DOWN LOAD THE MACHINE AND PART PARAMETERS MAIN SCREEN INITIALIZING MANUAL FUNCTIONS BASIC MENU DWELL TIME AT THE START AUTOMATIC ON /OFF START / STOP PAUSE INTERLOCK RELEASE / LOCK SPINDLE BRAKE ACTIVATE / (OPTIONAL SERVO SPINDLE: SPINDLE JOG) OIL PUMP (MAGNETIC SEPARATOR) SUB-ROUTINE CODE INPUT FOR BACKGROUND PARAMETERS SUB-ROUTINE START CORRECTIONS END CORRECTIONS OSCILLATIONS DISTANCE PERFORMANCE VALUES SPEED HONING TOOL CALIBRATION WORKPIECE SET-UP WORKPIECE SET-UP SET-UP PAGE 1: NEW WORKPIECE SET-UP PAGE 2: CHOOSE A WORKPIECE SET-UP PAGE 3: DIAMETER AND TOOLING SET-UP PAGE 2: (OPTIONAL SERVO SPINDLE) DIAMETER AND TOOLING HONING TOOL SET-UP PAGE 3: START AND END POSITION SET-UP PAGE 4: SIZING METHOD AND SPARK OUT Combinations for Sizing Method SET-UP PAGE 3: SELECTION OF THE HONING PROCESS Normal honing Corrected honing Parameter Normal and Corrected Honing Preload Power Feed only during Pull-Stroke SET-UP PAGE 6: SAVE OF WORKING PARAMETERS SET-UP PAGE 7: SAVE OF WORKING PARAMETERS ON A FILE SET-UP PAGE 8: DELETE OF WORKING PARAMETERS OPTIONALS (OPTIONAL) TAPER HONING Edit of a Taper REMOTE HONING CYCLE Set-up for the Remote Honing Cycle

3 9.3 TWO STAGE TOOLS (DOUBLE STAGE) Set-Up for two Stage honing...45 KEY REFERENCE CHARD...47 HTC SET UP PARAMETERS V

4 1 Introduction -3- This document describes the operation of the honing machine HTC. For the daily use, this document is not intended because of the fact, that the control is almost self-explaining. After a short introduction, almost everybody is able to start the machine without this manual. However, we recommend, that everybody read this manual in order to get more background information and to get to know the special functions, which may be of great help for the daily use. Operation of the machine can generally be done via the touch screen, which means that a function may be started by touching the corresponding key on the screen. All the function may also be started with the keyboard. The number of hardware keys is limited. 1.1 Operating Panel See the picture of the panel below. The most important elements are marked for easy identification Graphic 1: Operating Panel 1 LCD (Color) with Touch-Screen 2 Manual Feed Switch 3 Keys for manual Stroke movement left / right 4 Acknowledge key 5 SAFETY / EMERGENCY STOP 6 Key to acknowledge the SAFETY STOP 7 RETURN or ENTER key 8 Function key

5 1.2 Start-up mode -4- When the machine is first started, the complete hardware is automatically initialized. In a normal case, also called warm-start procedure is completed, which means that all parameters are set according to what they were prior to having switched OFF the machine. In case new software is installed, a cold start has to be used which allows setting of all parameters to pre-selected values. 2 The Display For the operation of the system, a ten key keyboard with some control functions is available. The menu functions can be selected with the keys below the display, directly on the screen. A selected function is marked on the screen by the inverse symbol (dark background, highlighted symbol). In normal case, the operation is via the touch screen (menu keys). Some of the functions require input of values, which are then entered with the keyboard, being acknowledged with the control key. Such parameters mostly appear in groups. A so-called menu level always contains 10 soft keys. As soon as it is requested to exit from one level into the next higher, the tenth key (at the very right) allows to exit the menu. See such an example below. Prior to mentioning the individual functions, some general inputs and displays are explained all of them regularly used in the complete program. 2.1 Numeric Input Window (Editing Window) By a numeric input we understand changing a value or to re-enter a value completely by a row of numbers. A parameter can be set directly to the desired value. If a function is selected requiring entering values, a window with all values to be changed is clearly shown. The editing window may look like shown below: At the very top of the window, the title is shown in large letters. The individual parameters are listed below each other. From left to right: parameter name, the actual value in the so-called input field and finally the valid unit (i.e. meter, inch). The cursor is in the input field of the first parameter. Parameters marked with the cursor can be changed only. Exit of the window with ESC or by touching the screen! Graphic 4: Parameter Window

6 -5- Keys for numeric Enters: In order to change parameters which contain a listing i.e. YES or NO. The value is stored and the cursor moves into the next input field of the next parameter. Only the one number is deleted, marked with the cursor and not the complete value. Exit the actual parameter window. Should it be required to change additional parameters, the window is opened automatically. If it is the last or only window, automatic exit from the function with automatic storage of the parameter. ATTENTION: Please note that the changed value is accepted by the control only, if the acknowledged with the ENTER key! Flash up / down allows to scroll from one parameter to the next up or down. If a value is changed it is not stored, and the previous value remains valid. Move the cursor left / right within the input field from one digit to the next.

7 Multi-Edit Input Window There are input windows, which allow a number of parameters to be changed at the same time on the touch screen. The input procedure is always the same way. In a normal case, the numbers can be edited direct (without keyboard), leaving however open the option of the keyboard, which however is more complicated, but for the case of a touch screen failure. In such a window various elements may appear, all of them listed below. Element Picture Description Vertical and Horizontal roll beam Function key Setting of any desired value. Min / max are pre-set. If set to the actual value, a window appears which allows to directly enter the number. Depending on the parameter, it is possible to set the min or max direct by touching the relevant value. Key that starts a function if pressed. Behind this key, other keys may be hidden. There are in general the elements, which may appear in the multi edit window. Some further explanations now about operation without the touch. As shown below, a key has a white frame. The key becomes active if the Enter key is pressed. To activate the desired key you may use the key to move to the next or with - to the one before. Graphic 5: Multi-Edit Input or ESC-Taste on Key Board In this example means that the window is closed, and all the changes are re-set. The key makes all changes to be accepted. Make sure that all changes are activated immediately after editing - should you have changed the speed, the machine will immediately adapt. The input windows described above, are mostly used to change machine settings.

8 Access Code Input Window In order to protect some important parameters, an access code must be entered. 2.4 Error message Even the most modern machine may run into trouble that is why we have to explain how to trouble shoot. In case of an error, the window below is opened. Graphic 6: Error Message The error message window contains all the information, to find the point of trouble. The top line describes the group to which the error is related and in brackets the error number. With help of the group and the number, the error is clearly identified. The lines in the center describe the error in more detail. Should the error be caused by a hardware failure, relation is made to the electric diagram, which then allows identifying the trouble-causing element. The lowest line then explains how to resolve the error. Such a window appears in case of an error and may disappear if the error is resolved or when the error is acknowledged RETURN. In case an error is acknowledged not being resolved, the window opens again! The machine stores the last 100 errors in a list, which is available at any time. There are errors that do not influence the production and the machine works normal. Should the error however be serious enough, the machine automatically stops or completes the move in progress. A special error is the Emergency Stop. This stop may trigger manually or automatically by the machine. The error remains active until the Emergency Stop button is re-set and must be acknowledged with the hardware key. The Emergency Stop relays is then also "reset" to

9 its normal condition. The machine may trigger an Emergency Stop in case an axis override switch is activated or in case the safety cover is opened during operation Information Window In some of the program parts it may happen that an information window appears in case of a wrong data input. The window then may contain text up to 10 lines explaining the cause in more detail. The window below shows such a window as an example. Graphic 7: Information Window The last line explains how to exit from the inf. window - with ESC or by touching the screen! Should the last line be missing, it is a message that disappears automatically after completion of the function! 2.6 Selection from a List The honing machine also offers the possibility to store all the data, which were ever used. All these data are entered into a list and may be recalled at any time. A data file is delivered with each honing tool, containing all parameters. If a tool is selected for operation, the relating tool data can be recalled from the list. A selection window appears, showing all the data stored and which then can be selected. The window below shows an example of a workpiece. The workpiece displayed inverse is the active workpiece or the one to be selected. The selection must be completed with ENTER. User the cursor up or down to select the workpiece in the list. Should you not want to select a new workpiece, exit by using EXIT or ESC. Graphic 8: Selection Window

10 2.7 Down load the Machine and Part Parameters -9- Instruction how to down load the machine and part parameters 1. Machine must be in the Manual Mode 2. Insert Floppy Disk (3,5 ) into Floppy Drive in the Main Electrical Enclosure. 3. Push Key (F10) 4. Push Key (F3) 5. Push Key (F9) 6. Push Key ALL PARAM (F5) Now all Parameters will be stored onto the Floppy Disk. 7. Remove Floppy Disk from Floppy Drive.

11 3 Main Screen -10- The main screen appears as soon as the machine is fully operational. All the parameters necessary for production are shown on a display as below Graphic 9: Basic Screen The main screen is divided into 8 major sections. 1 Title The title contains the actual date at the left the actual time at the right side In the center of the screen, the workpiece and the honing tool are displayed. 2 Display of most important production data in words. 6 different production values can be displayed, which can be selected by the user of the machine. The following parameters are available: 1. Tool position in reference to the workpiece in millimeter or inch. 2. Power of the Spindle performance in %. 3. Honing time. Depending on the brake condition the actual honing time or the remaining honing time. 4. Stroke speed in mm/min or y/min 5. Cycles of strokes. In case of regular honing the number of strokes and in case of spark erosion the number of remaining strokes. 6. Tool expansion position in reference to machine home position in millimeter (mm) or in inches. 3 Display of the actual honing performance and honing position within the coordinate system. Depending on the configuration of the machine, the display may adjust its display. The green line (lower line) displays the preset nominal value, the purple line (upper line) represents the max performance (border) in case it is defined. The red line finally represents the error performance.

12 4 Actual tool position within the workpiece. In case the tool is outside the workpiece, a flash in the correct direction will make aware of the fact. Below the pipe, the actual start and End position are shown. Above are the necessary corrections. On the very right appears a sketch of the cutter in case it is activated. In case of optimized honing, the areas outside the tolerance are displayed Menu area, containing the function keys which can be operated directly on the screen or with the keys below. 6 Shows the Spindle Load setting. 7 Actual Action. Shows what the machine actually is doing. 8 Break Conditions RED Honing method GREEN Spark out BLUE MANUAL/AUTOMAT RED or GREEN Break Conditions: TIME, EXPANSION, PROBE (Zero Shut off) Honing method: NORMAL, CORRECTING, TAPER (and correcting) Spark out: SPARK OUT MANUAL/AUTOMAT: MANUELL, AUTOMAT

13 The main screen also contains some hidden keys. The picture below shows the hidden keys each with a direct function, to be called from any menu direct! Graphic 10: Operating Elements, Basic Picture (hidden Keys) 1. Workpiece set-up. 2. Performance parameters adjust 3. Start correction, dwell time at the start. 4. Speed. 5. End correction, dwell time at the end. 6. Spindle Load decreasing. 7. Spindle Load increasing The exact procedure for each of the above parameters can be found in the chapter to which is made reference.

14 4 Initializing -13- Prior to starting work, the machine must be initialized, because the machine does not know the location of the honing tool. The machine must be moved to the home position at the left machine side. At the home position is a limit switch, which is the zero point. A zero point override is not possible! When the Main Power switch starts the machine the Display shows the initializing Button. Graphic 11: Initializing Key

15 5 Manual Functions -14- The manual functions allow manual fees, as well as stone advance. These functions are used for set-up. In the manual function is the light barrier deactivated which is why this function must be acknowledged. The manual functions are only started with the hardware keys on the panel. and CARRIAGE LEFT: The for MANUAL STROKE KEY movement shows the direction of the movement and the ACKNOWLEDGE KEY overrides all safety functions, which are not necessary for this manual move (i.e. light barrier). Stroke to the left. If the machine is not initialized, the operator is made aware of. CARRIAGE RIGHT: Same as above but for movement to the right. and * EXPAND: The MANUAL FEED SWITCH allows expansion of the tool. If the switch is turned to the right, the tool starts expanding. * RETRACT: The MANUAL FEED SWITCH allows retraction of the tool. If the switch is turned to the left, the tool starts retractings. Table 1: Manual Function * NOTE: After Emergency-Stop sometimes the Tool can not released anymore, because of reduced feed force during the manual mode. Therefore first push one of the ACKNOWLEDGMENT KEY and then turn the MANUAL FEED SWITCH to the Retract position. CAUTION: By pushing the ACKNOWLEDGMENT KEY during feed retract or expand, the feed force can essentially increased. High Risk to damage the tool!

16 6 Basic Menu -15- As already mentioned above, the menus follow a strict priority order. The less a function is used, the further into the menu it is found. The basic menu contains all the functions, which are used for the daily operation of the machine. The machine operator mainly uses these functions together with the hidden keys on the main screen. The above basic menu is the one, which appears after the machine, is switched ON. Depending on the operation and the setting of the machine, a number of keys may change during the production cycle. 6.1 Dwell time at the Start Key: Function: Description: or Dwell time at the start activate /deactivate. It may happen that the start and end area of a workpiece is not honed enough, and that there is too much material left. The dwell time makes the tool to remove more material. The dwell time can be coordinated with simultaneous oscillation of the tool. Whether or not oscillation is active can be seen by the symbol yes ( ) or no ( ). The key allows making this function active or inactive.

17 AUTOMATIC ON /OFF Key: Function: or Change from Manual to Automatic or vice versa Description: This symbol stands for automatic (AUTOMAT). If this key is pressed, the machine will change from automatic to manual. If the operator changes from manual to automatic, the spindle will automatically move to the start position, from the program can be started. This symbol makes aware, that the machine is in automatic mode, with the spindle in start position and the machine being ready for operation. If the key is pressed, the mode will change from automatic to manual. If a manual move is made in this mode the mode will automatically change from AUTOMAT to MANUAL mode, because the spindle will then no longer be at the start position. If no function is executed for a certain time to be pre-set. The machine will automatically change to MANUAL with the positive effect, that the motors are not on constant power supply. When the next move is made, the system is reactivated. If the machine is in MANUAL mode, the two keys Start and Break are inactive. 6.2 START / STOP Key: Function: Description: Start / Stop of the honing process. This key is only active, if the machine is AUTOMATIC mode. Software Keys Hardware Keys Key is active Key is pressed The machine is in AUTOMATIC MODE, ready to be started. Cycle will start The honing cycle is in progress. Immediately the carriage moves to the start position and the spindle stops. Immediately the carriage moves to the start position and the spindle stops. Hardware Key only: Reset Counter by pressing for 2 sec.

18 6.4 PAUSE -17- Key: Function: Description: Honing process interrupts. This key becomes only active if the operation is in progress. The process can be interrupted, which means that the stroke is completed and the machine then stops in the start-position. If the key is pressed again, the honing process is continued. 6.5 INTERLOCK RELEASE / LOCK Key: Function: Description: The interlock is released / locked. If the key is inactive, the interlock is active. If the key is pressed, the interlock is released and the motor may be moved freely within a certain range. This function is necessary for a workpiece change. When the interlock is released, the tool support is automatically pulled forward in order not to drop the tool from the workpiece. The interlock becomes active automatically after a certain time or when the key is pressed again. The interlock is active only when the motor is latched at the correct position - the tool support then retracts automatically. 6.6 SPINDLE BRAKE ACTIVATE / (OPTIONAL SERVO SPINDLE: SPINDLE JOG) Key: or (OPTIONAL ) Function: Spindle brake ON / OFF / Spindle Jog Description: SPINDLE BRAKE ON / OFF: The spindle is stopped automatically when being switched OFF with a built in brake. The key allows activating or deactivating the function. If the symbol is inactive, the brake is active (not on power supply). During the honing process, the brake however is released and the symbol is shown as active. In the manual mode the brake can be operated with the key. The released brake becomes automatically active after a certain pre-set time. (OPTIONAL) SPINDLE JOG: The key allows to jog the spindle during the manual mode.

19 Oil Pump (Magnetic Separator) Key: Function: Description: Oil pump ON / OFF The oil pump must be ON during the honing process. Should this not be the case, the operation cannot be started. In a normal case, the pump is automatically started at the beginning of the operation, and switched OFF at the end. In manual, mode, the pump can be started with the key. 6.8 Sub-routine 1 Key: Function: Sub-routine 1 Description: The key allows entering into a sub-routine, which contains most of the functions, which are accessible with a hidden key. 6.9 Code Input for Background Parameters Key: Function: Description: Code-input A code input window appears.

20 -19-7 Sub-routine 1 Key: Function: Sub-routine 1 Description: The key allows entering into a sub-routine, which contains most of the functions, which are accessible with a hidden key. The sub-routine 1 contains mainly all functions, which are accessible via the main screen in one menu. Key allows to exit and to return into the basic menu. 7.1 Start Corrections Key: Function: Description: Start Corrections and Dwell time at the start This function opens a multi edit window in which the dwell time at the start as well as the start corrections can be modified. Graphic 12: Correction of the Start or End Point

21 -20- Start correction If the operators finds the start or end point has to be correct, the point can be changed and is immediately active. Corrections may always be changed or reset to the previous value, because it does not have an effect on the actual start point. This key allows calculating the correction as the new start position. By pushing this Oscillation Key the distance will be active during dwelling. If not activated only Dwell Time is active. Time The dwell time may either be expected at the position, which most likely causes a bad looking surface, or it may be supported by additional oscillation. The honing tool oscillates at the desired position. Distance The programmed distance will be active when the Oscillation Key is activated. Stroke Interval The dwell becomes active after the programmed Number of interval. EXAMPLE: When programming an interval number of 5, then each 5th stroke the dwell will be active. When programming an interval number of 1, then each stroke will have a dwell. Exit with storing the changes. 7.2 End Corrections Key: Function: Description: End corrections and Dwell time at the end This function opens a multi edit window edit window in which the dwell time at the end as well as the end corrections can be modified.

22 Oscillations Distance Key: Function: Edit of the Oscillations distance. Description: The dwell time may either be expected at the position, which most likely causes a bad looking surface, or it may be supported by additional oscillation. Oscillation distance During the honing process it is possible to start an oscillation at any given point. The oscillation can be started manually with the keys and which both have to be pressed at the same time. The oscillation is not automatically supported in every honing procedure! This parameter now defines the distance of the oscillation. Depending on the axis feed, there is a minimal distance. If the Stroke is decreased, the oscillation distance may automatically be adjusted! 7.4 Performance Values Key: Function: Description: Edit performance values This function opens a multi edit window that allows modifying the performance parameters. Spindle Load Power limit Power error limit Performance with which the workpiece shall be honed. If this performance limit is reached, the honing tool will automatically retract. If the performance exceeds the pre-set limit, an error message is generated and the machine is stopped. Exit without storing the changes. Exit with storing the changes. Graphic 15: Performance Values

23 Speed Key: Function: Description: Edit feed stroke speeds. Push stroke speed and Pull stroke speed can be different Adjustment of the stroke speed. This function opens a multi edit window, which allows changing the speed. 7.6 Honing Tool Calibration Key: Function: Description: Calibration of the honing tool When the key is pressed, the multi edit window appears. Tool Wear Comp mm Graphic 16: Calibration of the Expansion Control

24 -23- Exp. Check On The control monitors the expansion, which means that when the min or max expansion is reached, the process is automatically aborted. Reset Expansion The actual expansion of the honing tool is set to zero (0). The values for min/max are automatically adjusted. (Energy will set to zero kw/h) Move ZERO Position The actual Zero Position of the Expansion honing tool can moved + or from existing Zero Position. NOTE: This Function should be used to increase or decrease the Final Diameter of the Workpiece. Max. Retraction Adjustment of the max retraction. This value is in relation to the zero point, which is set Reset Expansion. Max. Expansion Adjustment of the max expansion. This value is in relation to the zero point, which is set Reset Expansion. Stone Wear Compensation ON / OFF This Function allows activating or deactivating the Stone Wear Compensation. (see attached description) Stone Wear Compensation This Function allows Compensating the Stone Wear. (see attached description) Stone Wear Factor This Factor will be setet automatically during STONE WEAR COMP. Button is used. (see attached description) The Stone Wear Factor can be adjusted. Tool Wear Compensation This Function allows Compensating the Tool Wear after each honing cycle. Its only active when STONE WEAR COMP. Button is used. Exit with storing the changes. In order to calibrate a new tool, it is set to the min expansion followed Reset Expansion. After this, the value for max expansion must be set, after which the tool is calibrated. The desired expansion can now be set, which is defined as zero point (Reset Expansion). The min / max expansion values are automatically adapted. The same function is also applicable when a new workpiece is set-up.

25 -24- How to Set-Up Max. Retraction and Max. Expansion This is only Activated if EXPANSION CHECK is on SETUP: 1. Before installing the honing Tool retract the Tool by Hand counter clockwise until Maximum Retraction has reached, then move one turn back clockwise (For Safety!). 2. Connect the Tool to the Machine. 3. In the Window for SETTING FOR TOOL EXPANSION Switch On EXPANSION CHECK. 4. Set RESET EXPANSION to ZERO, and Enter 0.00 in the Window for SETTING FOR TOOL EXPANSION by the Horizontal roll beam for MAX. RETRACTION. 5. Prepare the Machine for running one Cycle. When Tool is Expanded to the Nominal Power stop the cycle and go into Window for SETTING FOR TOOL EXPANSION and Reset again EXPANSION to ZERO. 6. Measure the Stone Height and Enter the Double Value on the Window for SETTING FOR TOOL EXPANSION by the Horizontal roll beam for MAX. EXPANSION. 7. Now the maximal Retraction and the maximal Expansion is stetted for the used Tool. This is a absolute Position and will not change when ZERO Position is adjusted. NOTE: This Position is the only Value where is not stored into the Workpiece Parameters.

26 -25- How to work with Stone Wear Compensation (SWC) SETUP: 1. Switch the Break Conditions into TIME 2. Start Machine until the Spindle Load is reached, then Stop the Cycle. 3. Set RESET EXPANSION to ZERO (Energy will set to zero). 4. Measure the Diameter of the Workpiece and add the difference to the Final Diameter by MOVE ZERO POSITION (Example + 0.2mm) 5. Switch the Break Conditions into POSITION (Zero Shut off) 6. Start the Cycle with the same Workpiece until Cycle stops at Expansion Position Activate the STONE WEAR COMPENSATION with the Button 8. Measure the Workpiece again and add the difference (Stone Wear) to the Final Diameter by using STONE WEAR COMPENSATION Button. Now the Control calculate how much Stone Wear is to compensate for a several amount of Energy (mm/kwh). Compensation can also be adjusted direct in mm/kwh. 9. Install a new Workpiece. The Final Diameter should now reach after Cycle is stopped. If the measure of the Workpiece still shows a difference to the Final Diameter, correct it again with the STONE WEAR COMPENSATION Button. NOTE: Do not use the STONE WEAR COMPENSATION Button to increase the Final Diameter. New Set Up is needed (Point 1 8). NOTE: When not using the Stone Wear Compensation (SWC) switch off the Button.

27 Workpiece Set-up Key: Function: Description: Workpiece set-up. The key allows entering the function "workpiece set-up", about which further information are in Chapter 8. Workpiece Set-up. 8 Workpiece Set-up This chapter described the procedure to change the machine from one to another workpiece. The complete procedure is in the so-called teach-in method, which means that you manually move the machine to a certain point, which then is entered. A new workpiece contains 6 individual input pages in which always the corresponding parameters are set. The bottom of the page always remains the same and is therefore described only once. The bottom part is described and shown below.... These keys allow to directly entering one of the pages. The key of the actual page is always active and cannot be pressed. Exit from the function. All changes are stored! ATTENTION: All inputs are immediately stored and used for the honing process!

28 8.1 Set-up Page 1: New Workpiece -27- If an already used Workpiece has to made please go direct to Set-up Page 2 If a new Workpiece has to made please use the Key NEW. With the Key NEW the program loads a Workpiece Parameter with the Default Parameters (DEFAULT). Graphic 17: New Work Piece Key: After pressing the Key NEW a Windows comes up for to store the last used workpiece. After this the Windows showing on Graphic 17 comes up to choice the proper Tool.

29 8.2 Set-up Page 2: Choose a Workpiece -28- The first page contains all the parameters describing the shape of the workpiece. Graphic 18: Load stored Work Pieces Load: After choosing one of the products the parameters will be loaded and active. CAUTION: Before loading a new product, save the last used program otherwise all parameters gets lost when those are not saved.

30 8.3 Set-up Page 3: Diameter and Tooling -29- General adjustments of the production sequences. Setup spindle RPM Graphic 18: Diameter and Tooling setting This input is divided into two parts. The left is to set-op the Diameter of the Workpiece, and the right side all functions to modify the honing tool parameters. The diameter is used for production, must be entered and the recommended RPM have to stetted by the Gear Box. New honing tool Edit honing tool Delete honing tool A keyboard appears on the screen with which the name of the tool can be entered. A list with all the existing honing tools appears. Select the desired tool from the list. (Access Code necessary) A list with all the existing honing tools appears. Select the desired tool from the list to be deleted. The delete command must be confirmed and then exit with ESC. (Access Code necessary) These functions allow maintaining a databank with tools. Data of tools are available for repeated use at any time.

31 8.4 Set-up Page 2: (OPTIONAL SERVO SPINDLE) Diameter and Tooling -30- General adjustments of the production sequence. Setup spindle RPM Graphic 19: Diameter and Tooling setting This input is divided into two parts. The left is to set-op the Diameter of the Workpiece, and the right side all functions to modify the honing tool parameters. The diameter used for production, must be entered and the recommended RPM will be used to run the spindle speed. CAUTION: Do not use Spindle speed below 10 RPM! New honing tool Edit honing tool Delete honing tool A keyboard appears on the screen with which the name of the tool can be entered. (Access Code necessary) A list with all the existing honing tools appears. Select the desired tool from the list. (Access Code necessary) A list with all the existing honing tools appears. Select the desired tool from the list to be deleted. The delete command must be confirmed and then exit with ESC. (Access Code necessary) These functions allow maintaining a databank with tools. Data of tools are available for repeated use at any time.

32 8.5 Honing Tool -31- As already described before, data of tools can be stored and are readily available at any time and allow quick changing from one workpiece to the other without long definition procedures! This chapter now describes the data to be entered to describe a honing tool. Abbreviation Description Unit Tool length Length of a tool mm or inch Expansion per revolution Distance which the tool expands during one revolution. mm/ RPM. Reverse gear direction Reverses Expansion direction YES/NO Return backlash Speed for backlash compensation Speed for manual moving The gear has some backlash and the tool may not completely go back to zero when changing from expand to retract. A certain distance must be entered. Tapered honing requires compensating a certain backlash. The compensation is done in this speed, which shall be selected as fast as possible. Speed to expand the tool in manual operating mode. RPM. mm/s or inch/s mm/s or inch/s Ramp for manual moving Ramp at the start for the advance motor. kstep/s^2 Speed for manual intervention 1. Normal Honing allows the expansion of the tool to be changed during the operation. 2. Speed to expand the tool until honing stones touches the bore, during the process. mm/s or inch/s Speed for automatic The speed to expand the during the process. mm/s or inch/s moving Ramp for automatic Ramp at the start for the advance motor kstep/s^2 moving Maximal stroke speed Maximal allowed stroke speed defined for the tool. m/min or y/min MANUAL: stroke force AUTOMAT: stroke force Power limit MANUAL: feed torque AUTOMAT: feed torque Maximal torque allowed for the stroke motor during Manual Mode. (Percentage of Full Stroke Power) Maximal torque allowed for the stroke motor during Automatic Mode. (Percentage of Full Stroke Power) Maximal performance allowed for the honing process. (Percentage of Full Load Spindle Power) Maximal Feed Torque allowed for the Tool during manual mode. (Percentage of Full Feed Torque) Maximal Feed Torque allowed for the Tool during automatic mode.(percentage of Full Feed Torque) % % % % % Table 3: Parameter Honing Tools

33 8.6 Set-up Page 3: Start and End Position -32- Graphic 20: Start / End, Steady Rest, and Withdraw Position setting This page is divided into 4 major parts. The first part in the upper left defines the start position of the workpiece. The second part in the upper right then defines the end position of the workpiece. The third part in the center left is used to select a taper bore (OPTIONAL). The fourth part in the center right is used to select and positioning of the steady rest. This information only appears in machines with a long stroke, which require the extensions to be supported. If the key is active, the steady rest is moved. If this key is pressed, the actual tool position is taken as the start position. The start position and the offset now shift by 0. If this key is pressed, the actual tool position is taken as the end position. This key allows calculating an offset directly in relation to the end value. If this key is pressed, the Steady Rest is actuated. The Numeric Windows shows on which position the Steady Rest starts. Only for Machines with Steady Rests.

34 By pushing the button the actual position of the carriage can by programmed as Tool-out position (WITHDRAW). Therefore the carriage has to move to the desired position by using the Keys carriage left/right for manual Stroke Movement. (Same as Start / End Position). 2. To activate this Option just push to the Withdraw Symbol. Two Ways are possible: A. WITH PARK BUSH: Park bush must be in front of the part. Set the WITHDRAW Position into the park bush. The very last stroke of the cycle ends into the park bush. Tool will stop outside of the bore PARK BUSH B. WITHOUT PARK BUSH: Set the WITHDRAW Position that the tool is still 10 to 20mm into the bore. After this it should be much easier to take out the tool without making scratches to the surface. Tool will stop inside of the bore CAUTION FLYING WITHDRAW With this Function the machine goes into the Park Bush on the fly! CAUTION: Only activate this Function with Park Bush or Steady Rest, otherwise it can cause personal injury or machine damage!

35 8.7 Set-up Page 4: Sizing Method and Spark out -34- Programming of the honing sequence. Sizing Method Graphic 21: Sizing Method and Spark out Combinations for Sizing Method Combination Description Symbol of Key Time The honing time is according to this pre-set time, after which the process is completed and the machine stopped. If the time is activated, the honing time will be accordingly. The honing time can be adjusted between 0.1 and 99.0 minutes. (Reset can be done with Hardware Stop Key) Expansion The honing process is completed when the expansion is reached (Zero Shut Off) at Zero (0.00). The machine will complete the stroke and will then be stopped. MAXIMUM TIME can be added, to limit the Process. Check by measuring Time and Check by measuring Expansion and Check by measuring Numbers of strokes The honing time will be continued until the measuring probe detects the diameter to be correct. The actual stroke is completed and the machine is then stopped. MAXIMUM TIME can be added, to limit the Process. At first, the honing time will be according to the pre-set time. After that, the measuring tracer is activated and the cycle is continued until the diameter is detected to be correct. The actual stroke is completed and the machine is then stopped. MAXIMUM TIME can be added, to limit the Process. At first, the honing process will last until the tool has reached the pre-set expansion. After that, the process is continued until the diameter is correct. The stroke is completed and the machine is then stopped. MAXIMUM TIME can be added, to limit the Process. At first, the honing process will last until the tool has reached the pre-set expansion. After that, the number of strokes will be processed than the machine stops. Retract after Stop: Shows how much the honing tool retracts after cycle stops. NOTE: Will not be activated when Cycle is manual interrupted. To all above combinations, the option "SPARK OUT" can be added! Spark out cycles 1 = Spark out cycles with expands the tool until Spark Out Power has reached. Spark out cycles 2 = Spark out cycles without expansion of the tool.

36 8.8 Set-up Page 3: Selection of the honing process -35- Selection of the honing process. Feed delay 0.2 sec Graphic 22: Selection of the Honing Process The machine knows two different processes in the basic version. A third optional process can be added and is the one for tapered workpiece. Only one process can be active. The window allows defining the parameters for the individual process Normal honing The method Normal Honing is the one method used most and in which the tool moves from one side of the workpiece the other. The machine constantly detects the actual performance and automatically adjusts the expansion of the tool according to the pre-set value. This cycle is repeated until the value is correct. If the border performance at one point exceeded, the tool is immediately retracted until the performance falls below the nominal value. See Parameter Normal and Corrected Honing

37 Corrected honing Corrected honing is the process in which the machine automatically detects the area(s), which need to be selectivetly honed. This method is time saving to the point honing Parameter Normal and Corrected Honing Abbreviation Description Unit Expand limit The expansion during one stroke can be limited with this parameter. mm When not required set the Expand Limit to 3,0mm. Feed delay Smoothing (Filter) Max. correction cycles Expansion delays when power goes below the green line. (Recommendation: 1 sec.) Used when the measurement of the power is irregular and noisy. Therefore the results can be mathematically damped. With this, inaccurate results will not have any effect on the Honing Process. The damping is figured in from 1 to 100 units. The greater this value, the smoother the results. (Recommandation: 15) If the nominal values are not reached after the pre-set number of strokes, the hone will be advanced to the next position that needs corrected. (Recommendation: 3) Table 2: Parameter for Corrected honing sec 1 1 The oscillation function and the dwell time are not supported during the Corrected honing operation.

38 -37- Graphic 23: Display for Correction Honing The highlighted areas in those parts, which were recorded during the measuring cycle. These areas are now specifically machined until corresponding with the nominal value. This honing function does not support the oscillation function, which means that both hardware keys are without function. There is also no dwell time, since this effect may occur automatically because of the areas out of tolerance. If the function "erosion" however is activated, all functions are completed, since this then may be considered as a normal honing process. During correction honing cycle is not possible to do any manual corrections, exept the followings. change to the next fault area by pushing this button interupt the actual correcting stroke and start with a new measuring stroke. The oscillation function and the dwell time are not supported during the Corrected honing operation.

39 Preload Power This Function can be used when Parts are honed with large deformations. Cycle will start with a decreased Load. This method will save the Stone Wear Feed only during Pull-Stroke This Function can be used when small Diameter Parts are honed. The expansion only is activated when the tool is in the pull stroke so the drive shaft cannot be bend. In addition to this function also a number of mm in the diameter can be programmed to retract the tool within the push-stroke. Some of the cone-expanded tools with long drive shafts will expand during on the push stroke. With this feature this symptom can be eliminated by activating the FEED ONLY DURING PULL-STROKE Button and programming a number of mm (0,02 0,05mm) to retract during the push-strokes. 8.9 Set-up Page 6: Save of Working Parameters Storage of the actual workpiece parameters. Graphic 24: Store the Work Parameters

40 8.10 Set-up Page 7: Save of Working Parameters on a file -39- Definition of a new workpiece. Graphic 25: Save of Working Parameters on a file Enter a name, which refers to the actual workpiece parameters. The name then appears on top of the screen. This is now the actual product. (max. 8 Digits)

41 8.11 Set-up Page 8: Delete of Working Parameters -40- Delete of Working Parameters. Graphic 26: Delete of Working Parameters Delete a workpiece no longer used.

42 9 OPTIONALS (Optional) Taper Honing This honing function allows conical (tapered) holes to be machined. It does not make a difference whether the hole is already conical or if it has to be made this way. The honing machine records the actual shape and does automatically calculate the process. The calculation may also be made "manually" by entering parameters according to the workpiece. In order to hone a conical workpiece, some additional information has to be entered Graphic 26: Parameter Input for Conical Honing The final shape must be defined at the beginning. The actual shape is always shown in the framed area (4). Procedure to enter the nominal shape: 1. Shows the cursor position to the start position 2. Diameter relative to Start position 3. Taper Angle 4. Area of taper bore 5. Edge points 6. Cursor 7. Position of Cursor 8. Diameter difference of Taper

43 -42- All nominal shape points are defined and some honing procedure parameters have to be set now. The parameters are found in the "picture" part. Please note that the machine divides the workpiece into sections. The example above shows the workpiece divided into four individual sections, which are individually honed Edit of a Taper ENTER A NEW POINT 1. In case a form is define (corner points already existing (3) they have to be deleted by multiple pressing the key until no further corner points remain. 2. Position of the cursor (6), with two options available: either with the roll beam below the display (7) or by the finger to the desired position directly on the screen (The "finger" method may require the exact position to be adjusted with the roll beam. 3. Input of the diameter. After the position, the diameter must be entered with the roll beam on the right, beside the display (8). Since the control always takes reference to the point at the left corner, the diameter must not be entered correctly, but distance between two points is important. 4. The cursor is at the correct place and the diameter is also defined. If the key is now pressed, a new edge point is entered (5), which is now marked with the actual position and with the actual diameter. 5. Repeat the points 2-4, until the shape of the workpiece is defined. 6. In case you want to delete an already defined point (5), position the cursor near the point and press the key. Always the next point is deleted. All values are now defined for conical honing and the menu can be closed. Prior to starting the machine, the honing tool must now be adjusted to the exact expansion at the starting point. The more accurate the adjustment, the faster the finish. The machine can then be re-started. Each individual area is now honed until it is within the tolerance. There is now abort condition, since the machine automatically decides when the shape is correct. Depending on the start shape, the sequence will be repeated a number of times. With the ( and ) key, the operator may move to the section before are after. The oscillation function and the dwell time are not supported. After the workpiece has reached the final shape, one more sequence is repeated (depending on the erosion ) incorporating the complete workpiece in one move. During this procedure, the direction can be changed manually with the manual key with the effect that a certain area may is machined more.

44 9.2 Remote Honing Cycle -43- With this Mode the machine can run in a fully automatic Remote Honing Cycle. To use the machine in this mode the machine has to be supplied with a loading and unloading robot and an automatic part-clamping fixture. The following Picture shows how to start the machine into the Remote Honing Cycle. Graphic 27: Main Screen for the Remote Honing Cycle By pushing the button the Remote Honing Cycle can be started. Therefore the following conditions has to be exist: 1. Signal from Loading Robot to must say that the part is loaded into part fixture. 2. Signal of part clamping fixture must say that the part is securely clamped.

45 9.2.1 Set-up for the Remote Honing Cycle -44- The Set-up for the Remote Honing Cycle can be programmed in the window No. 3 for Start & End Position. The following Picture shows how to program the Tool-Out position for the Remote Honing Cycle: Graphic 28: Window for Tool-out programming By pushing the button the actual position of the carriage can by programmed as Tool-out position. Therefore the carriage has to move to the desired position by using the Keys carriage left/right for manual Stroke Movement. (Same as Start / End Position). When the Remote Cycle is finished the tool will move to this position. Now the part is free to unload and load with the robot.

46 9.3 Two Stage Tools (Double Stage) -45- With this method the machine is able to hone with a desired tool the roughing and the finishing operation in one operation. To use this feature a two stage Tooling (Double Stage) has to be used Set-Up for two Stage honing SETUP: 1. Make setup as a NEW normal workpiece. 2. After choosing a Tool with the Double Stage capability (GHTS) a symbol for Two Stage honing appears on the right side of the screen. The Symbol first appears in red color. The first and the second stage are not adjusted yet. 3. ON Stage, set Retract after stop to minimum 3 to 5 times of stock to remove. By changing from Stage to Stage, the Hone Head will automatically change the position to the position of Retract after stop from the Stage. 4. Start to hone the first stage ( Stage ). After finishing the first stage the symbol goes to green color. 5. Now move with the manual rapid feed switch to the position where the honing Head expansion should start before starting the second stage. 6. ON Stage, set Retract after stop to minimum 3 to 5 times of stock to remove. By changing from Stage to Stage, the Hone Head will automatically change the position to the position of Retract after stop from the Stage. 7. Start to hone the second stage. After finishing the second stage the symbol goes to green color. The symbol Stage goes to green color after using the second stage. 8. The positions of Stage and Stage are adjusted now. 9. Change Workpiece. 10. Insert the honing head into the next workpiece. When starting the next honing cycle the machine first change the position of the honing head from Stage to Stage. After changing the feed position the machine start the honing cycle of Stage. After finishing the Stage, the machine changes to Stage automatically.

47 NOTE: To adjust again the Expansion positions of Stage 1 and 2, just reload the same workpiece name again. (The symbol stays now in red color again) -46- NOTE: It is always possible to change between Stage 1 and 2 during the set-up mode. CAUTION: Make sure the Retract after stop Position is set-up bid enough; otherwise the Hone Head can damaged by changing between Stage 1 and Stage 2.

48 Key Reference Chard -47- F1 F2 F3 F4 F5 F6 F7 F8 F9 F Optional: Remote Honing Cycle 2. Automatic 3. Start 4. Stop Spindle Jog 7. Carriage Release 8. Oil 9. 2nd Menu 10. Background Parameters F1 F2 F3 F4 F5 F6 F7 F8 F9 F Start Correction 12. End Correction 13. Oscillation Distance 14. Performance Values 15. Stroke Speed 16. Honing Tool Calibration 17. Setup Menu Exit F1 F2 F3 F4 F5 F6 F7 F8 F9 F New Part, Tool Selection 22. Select saved Setups 23. Spindle Speed 24. Stoke Length 25. Sizing Method 26. Honing Method 27. Save Setup 28. Save Setup to a File Name 29. Delete 30. Exit

49 HTC Set Up Parameters V SELECT WORKPIECE Name: (Bore Length:) If WORKPIECE-File exists, check RPM on Gear Box SET UP TOOL Diameter: RPM: Tool: Stone: Guide: WORKPIECE SIZING METHOD : : : : Overstroke left: Overstroke right: Stroke Length: Steady Rest: Spindle Load: % Stroke Speed: Push m/min / Pull m/min Desired Honing Time: min Desired Strokes: Retract after stop: mm Spindle Load: % Stroke Speed: Push m/min / Pull m/min Maximal Honing Time: min Retract after stop: mm Spindle Load: % Stroke Speed: Push m/min / Pull m/min Measuring Speed: Push m/min / Pull m/min Maximal Honing Time: min Safety Distance for Measuring Head: mm Retract after stop: mm Spark Out Power: % Spark Out Speed: Push m/min / Pull m/min Spark Out Cycles 1: Spark Out RPM: Spark Out Cycles 2: HONING METHOD Expand Limit: Expand Delay: Smoothing: mm sec Detection Tolerance: % Max. Correcting Strokes: Preload Power: % Retract during Push Stroke: mm

50 NOTES -49-

51 NOTES -50-

52 SUNNEN reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that the user verify the discrepancy with Sunnen before proceeding. SUNNEN PRODUCTS COMPANY 7910 ManchesterRoad St. Louis, MO U.S.A. Phone: Fax: U.S.A. Toll-Free Sales and Service - Auto: Ind: International Division - Telex: SUNNEN PRODSTL SUNNEN PRODUCTS LIMITED No. 1 Centro, Maxted Road Hemel Hempstead, Herts HP2 7EF ENGLAND Phone: Fax: SUNNEN AG Fabrikstrasse Ennetaach-Erlen, Switzerland Phone: Fax: SHANGHAI SUNNEN MECHANICAL CO., LTD. 889 Kang Qiao East Road, PuDong Shanghai , P.R. China Phone: Fax: SUNNEN ITALIA S.R.L. Viale Stelvio 12/ Ospiate di Bollate (MI) Italy Phone: Fax: PRINTED IN U.S.A COPYRIGHT SUNNEN PRODUCTS COMPANY 2006, ALL RIGHTS RESERVED