Operating Display SCREENS

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1 I-VSS-610B Operating Display SCREENS for SUNNEN VERTICAL SINGLE STROKE HONING MACHINE SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE ST. LOUIS, MO 63143, U.S.A. PHONE:

2 GENERAL INFORMATION Sunnen equipment has been designed and engineered for a wide variety of parts within capacity and limitation of equipment. With proper care and maintenance this equipment will give years of service. READ FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE OPERATING THIS EQUIPMENT. IMPORTANT: Read any supplemental instructions BEFORE installing this equipment. These supplemental instructions give you important information to assist you with planning and installation of your Sunnen equipment. Sunnen Technical Service Department is available to provide telephone assistance for installation, programming, & troubleshooting of your Sunnen equipment. All support is available during normal business hours, 8:00 AM to 4:30 PM Central Time. Emergency breakdown support is available on a 24 hour / 7 day basis. Review all literature provided with your Sunnen equipment. This literature provides valuable information for proper installation, operation, and maintenance of your equipment. Troubleshooting information can also be found within Instructions. If you cannot find what you need, call for technical support. Where applicable, programming information for your Sunnen equipment is also included. Most answers can be found in literature packaged with your equipment. Help us help you. When ordering parts, requesting information, or technical assistance about your equipment, please have following information available: Have ALL MANUALS on hand. Customer Services Representative or Technician will refer to it. Have Model Number and Serial Number printed on your equipment Specification Nameplate. Where Applicable: Have Drive model and all nameplate data. Motor type, brand, and all nameplate data. For Troubleshooting, additional information may be required: Power distribution information (type - delta, wye, power factor correction; other major switching devices used, voltage fluctuations) Installation Wiring (separation of power & control wire; wire type/class used, distance between drive and motor, grounding). Use of any optional devices/equipment between Drive & motor (output chokes, etc.). For fast service on your orders call: Sunnen Automotive Customer Service toll free at: Sunnen Industrial Customer Service toll free at: Customers outside USA, contact your local authorized Sunnen Distributor. Additional information available at: or sunnen@sunnen.com NOTE: Sunnen reserves right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle 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 time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify discrepancy with Sunnen before proceeding.

3 TABLE OF CONTENTS! Column Initialization... 4! Main Menu... 5! Setup Menu... 6! System Utilities... 10! Save Setup... 11! Check Parts... 12! Engineering Menu... 13! Run Menu ! Run Menu ! Run Screen... 16! Machine Parameters... 17! Machine Fault List... 18! Skip Honing Cycle... 19! Additional Setup Menu... 20! Warning Windows... 21! Maintenance Reminders PAGE NOTE: This manual was written for a VSS-64. VSS-64 has a six station table with one, four head, Single Stroke Honing Column. Screens for different machine configurations will be slightly different. 3

4 COLUMN INITIALIZATION When VSS is powered up, it does not know home position of carriage. Pressing palm buttons will move carriage to home position. From that point on, as long as power remains on, VSS will know carriage positions. CAUTION: It is important that machine be in a safe state before proceeding. VSS requires guard doors to be closed before it allows this motion. Press PALM BUTTONS to HOME machine and continue to Main Menu. (Go to Page 5.) 4

5 MAIN MENU Function Keys F1 Setup Menu: For entering and editing setups. F2 System Utilities: To alter special machine functions, including saving or retrieving setups. F3 Run Menu: This function is available after the machine has been setup. The two numbers located above the Run Menu Function Key display the version of the software that is running and the date that it was written. 5

OPT. 1 OPT. 2 SETUP MENU This screen presents options to enter a new setup and edit the current set up. The highlighted Palm Button Function is set to Column Up or Column Down.

6 OPT. 1 OPT. 2 SETUP MENU This screen presents options to enter a new setup and edit the current set up. The highlighted Palm Button Function is set to Column Up or Column Down. Pressing the +/- key will change the direction. The column will move in the direction of the Palm Button Function when both buttons are pressed. Function Keys F1 Main Menu: Return to Main Menu. F2 Additional Information: This function is available available at Rapid Feed Rate. Once Available it will be ON from Final Diameter through Maximum Spindle Load. F2 Accept Position: This function is available when editing Top of Bore through Index Position. F3 Recommended Position: This function is available when editing Rapid Stop through Index Position. This screen begins setup process by asking for workpiece specifications. This information will be found on workpiece blueprint or by measuring workpieces. You cannot proceed to next step until all these parameters have been entered. With Single Stroke Honing Tools, Feed Rate means linear speed of tool into workpiece bore. Units are millimeters (or inches) of linear travel per minute. Final Diameter - Input desired bore size to be achieved by tool in the final spindle. Bore Length - When entering bore length, be sure to exclude length of any countersinks or counterbores. Abrasive Length - Because there are a wide variety of tools available, including some specials, the Machine does not have abrasive length data. This must be measured for particular tool being used. Spindle Speed - The Machine recommends a spindle speed based on the final diameter. This value can be edited. Speed can be reduced, but a common mistake is to slow spindle down for safety without changing any other parameter. When spindle is slowed and feed rate is unchanged, torque load on tool increases and actually makes a crash of tool or fixture more likely. If spindle is slowed significantly, feed rate should be reduced by same percentage. 6

SETUP MENU (cont d) Rapid Feed Rate - This is the rate at which tools will travel downward as they approach bores. Default is maximum 6350 mm/min (250 in/min).

7 SETUP MENU (cont d) Rapid Feed Rate - This is the rate at which tools will travel downward as they approach bores. Default is maximum 6350 mm/min (250 in/min). This can be edited to a slower value if experience with application has shown that a slower approach improves reliability of tool entering bore. However, slowing this rate will adversely affect cycle time. Honing Feed Rate - Because there are a wide variety of tools available, including some specials, the Machine does not recommend a honing feed rate. If you are unsure what feed rate to enter, start with a slow value, such as 250 mm/min (10 in/min). Increase this rate only after observing honing performance. Reverse Feed Rate - This value defaults to maximum of 6350 mm/min (250 in/min). For most applications, tool withdrawal from bore should be as fast as possible to keep cycle time to a minimum. In some rare applications, there may be a benefit to slowing reverse rate. Maximum Spindle Load - When this value is 100%, full spindle motor torque will be available for honing. If this value is reduced the Machine will limit spindle motor torque. When spindle load limit is reached the Machine will shut down. Because there are a wide variety of tools available, including some specials, the Machine defaults to 100% spindle load limit. If small tools and or delicate fixtures are being used, this value should be reduced. If long running jobs have a history of tool breakage or fixture failure under load, it is recommended that spindle load limit be reduced so that worn out tools can be replaced when warning appears without having a costly tool failure in-process. (NOTE: When a column has multiple spindles, spindle load displayed on screen is for all spindles combined. If you intend to monitor spindle load over time as an indication of tool wear, then tools should be replaced in sets so that spindle load display is a reliable indicator of tool condition.) Coolant - OFF / ON. Use this feature to set the coolant lines. 7

8 SETUP MENU (cont d) Some of setup process requires interaction with various machine movements. It is important to read and follow all instructions that are displayed on screen. The positions can be entered three different ways. The first way is to press enter and then type the desired position. The second is to move the column to the desired position and press F2. This will place the current column position in the highlighted selection. The last is to press F3. This will place the recommended value in the highlighted selection. NOTE: This setup screen assumes that workpiece fixtures have already been installed on the Machine. If they have not, it will be necessary to install them first. Top of Bore - For this position move carriage down as instructed until bottom of abrasive is aligned with top of bore. When this position is entered the Machine will know at all times the location of workpiece relative to tool. Note: Every time the top of bore is changed, the system will recommend new values for the Rapid Stop, Spindle Start, Reverse Feed, Spindle Stop and Index Position. Rapid Stop Position - This is position where rapid feeding of tool will stop and slower honing feed rate will begin. To protect tool, recommended position is where bottom of abrasive is aligned with top of bore. Spindle Start Position - This is where spindle rotation will start. Recommended position is same as rapid stop position. If honing feed rate is relatively fast it may be wise to have spindle start somewhat before rapid stop position. Reverse Feed Position - This is bottom of stroke, where tool will reverse its motion. The Machine calculates an optimum reversal point based on bore length and length of abrasive that was entered. (Recommended position is where length of abrasive, still engaged with bottom of bore, is equivalent to one bore diameter.) A different position should be entered only after experience shows recommended position to be a problem. Spindle Stop Position - Recommendation is to have spindle stop on withdrawal at same location it started when it was entering tool. A different position may be selected if desired. Index Position - This is position where tool will stay while index table moves workpieces to next station. The Machine recommends a position near the top (19 mm /.75 ) because this position depends on height of fixtures being used and length of any pilot that might be on tool. Make sure that index position is high enough to safely clear all workpieces and fixtures as they index under tools. Current Position The columns current position. 8

9 SETUP Use following procedure for installation of Single Stroke Honing Tools. 1. Roughly adjust tool size. Tool is adjusted by either a screw on end of tool or, if a small diameter tool is used, with a Sunnen Sleeve Adjusting Tool. Diameter of tool can be roughly gauged with a micrometer. Or take a workpiece that is completed from previous operation, and slide tool into its bore. As a crude starting point no less than 50% of abrasive section should be able to slide into bore. If less than 50% enters bore (tool too large) then tool must be adjusted to a smaller diameter. This cannot be done with adjustment screw. Sleeve diameter can only be reduced by pressing sleeve down arbor. If tool sleeve slides completely into workpiece bore (tool too small) then adjust tool to expand it slightly. NOTE: It is much easier to expand tools than to reduce their diameter. When making rough adjustment it is better to err on side of a diameter that is too small. 2. Install tool into spindle. Continue to step 3 if optional tool holder is used. 3. Install tool and holder into spindle 4. If tool holder is a floating tool holder or rigid type tool installation is complete. 5. If tool holder is the optional adjustable spindle nose, then tool runout must be adjusted. 6. Attach Sunnen runout indicator to spindle housing and adjust it so that indicator points will contact tool shank. For best results, spread points as far away from each other as possible and place indicating point as close to abrasive sleeve as possible. 7. Turn Runout Knob on indicator counterclockwise until it stops. Then turn knob clockwise one turn. 8. Loosen Indicator Clamp Knob and rotate indicator assembly on its post until Reference Gage Point comes in contact with tool arbor. Then tighten Clamp Knob. 9. Turn Runout Knob counterclockwise, toward conical symbol, until it stops. This brings reference point and indicating point in contact with arbor for measuring conical runout. 10. Rotate spindle by hand, taking note of location of highest reading. 11. Adjust for conical runout by loosening lettered setscrew closest to high reading on indicator. Tighten lettered setscrew on opposite side. 12. Repeat steps 10 and 11 until conical runout is 0.03 mm ( in) or less. 13. Turn Runout Knob clockwise toward parallel symbol until it stops. This keeps Reference Gage Point from contacting arbor so that parallel runout can be measured. 14. Rotate spindle by hand, taking note of location of highest reading. 15. Adjust for parallel runout by loosening numbered setscrew closest to high reading on indicator. Tighten numbered setscrew on opposite side. 16. Repeat steps 14 and 15 until parallel runout is 0.03 mm ( in) or less. 17. Recheck conical runout, if it is not still 0.03 mm ( in) or less then repeat steps

SYSTEM UTILITIES Some of setup process requires interaction with various machine movements. It is important to read and follow all instructions that are displayed on screen.

10 SYSTEM UTILITIES Some of setup process requires interaction with various machine movements. It is important to read and follow all instructions that are displayed on screen. Save/Retrieve Setup - Select and press ENTER. (Go to Page 11). Units Inch / mm. Coolant OFF / ON. MAINTENANCE REMINDER OFF / ON. Every 10 column hours a message will appear to check the coolant level and concentration. Every 30 hours a message will appear to check the level of oil in the gear case. Turning this function off will prevent these messages from popping up RESET MACHINE This is used to clear current setup. Serial Port Transfers This is used to update the machine s software from an external PC. A qualified technician should only perform this function. Language Used to select the current language. Function Keys F1 Main Menu: Return to Main Menu. F2 Check Parts: To enter a mode where each workpiece on index table can be brought to load station for checking bore. This is periodically necessary on multiple spindle machines to see if all tools are honing workpieces straight and to correct size for that operation. F3 Engineering Menu. 10

11 SAVE SETUP Use Up/Down Arrows to select setup number/name. Key in new setup. Press any key to return to System Utilities. Function Keys F1 To Load Selected Setup. F2 To Save Selected Setup. F3 To Delete Selected Setup. 11

12 CHECK PART SIZES When there are multiple honing spindles it is essential to periodically check bore sizes being produced by each tool. This screen allows you to index table and check bore size of any or every workpiece on table. It is essential you check only one workpiece at a time and that you replace that work piece in fixture it came from. Likewise, index table must be returned to position you started from so that workpieces that are not complete will go back to where they had been in process. NOTE: Movement of the highlighted station on diagram may seem confusing, as if index table is moving backwards. However, look at wording on diagram. It will say something like Workpiece at Load station 1 is from station [x]. Therefore, the highlighted station is showing you where workpiece that is now at station 1 came from before indexing table. Function Keys F1 System Utilities: To alter special machine functions. 12

13 ENGINEERING MENU With this screen you have entered Diagnostic Mode. In this mode you can independently actuate a variety of machine functions and view state of inputs and outputs of machine control system. This is helpful for diagnosing or repairing machine problems. NOTE: Because machine functions can be actuated independently, great care should be taken when in Engineering Menu. Fixtures or tools can be damaged. Before leaving the Engineering Menu, it is a good practice to return machine to same state it was in before entering. Clear Cycle Count Press ENTER to clear current cycle count. Check For Coolant Faults The system will not check for coolant faults if this is set to NO. Allow Skip Honing The system will not allow skip honing if this is set to NO. Index Table Allowed This will be set to NO when a setup is entered in the machine. Spindle Speed This is the speed that the spindle will rotate at while the selector switch is held up. Press ENTER to edit value. Current Position The current column position. The column can be moved up and down by changing the Palm Button Function to Column Up or Down and then pressing the Palm Buttons. Machine Function Function Keys F1 System Utilities: To alter special machine functions. F2 Machine Parameters: To alter machine parameters. 13

14 RUN SCREEN - 1 (New Setup) This screen only appears when a new setup is entered. Press 1 to index table at the start of the first cycle. Press 2 to hone the parts without indexing the table. 14

15 RUN SCREEN - 2 (Ready to Run Screen) The machine is ready to run. Press the Palm Button to start the cycle. Function Keys F1 Main Menu: Return to Main Menu. F2 Coolant ON/OFF: Turn coolant flow on to set coolant nozzles for optimum workpiece and tool cooling. F3 Skip Honing: Allow operator to skip honing cycle. Visible only when feature is turned ON. 15

RUN SCREEN The bar graph shows the current carriage position and spindle load. NOTE: The selector switch will increase or decrease the highlighted selection up to 25% of the current value.

16 RUN SCREEN The bar graph shows the current carriage position and spindle load. NOTE: The selector switch will increase or decrease the highlighted selection up to 25% of the current value. Press the +/- key to select a different parameter to highlight. Spindle Speed The current Spindle Speed. Honing Feed Rate The current Feed Rate. Cycle Time - The current cycle time. Cycle Count The number of completed honing cycles. 16

MACHINE PARAMTERS Machine Type This is used to define the type of machine. Stations Per Index This defines the number of stations that move per index.

17 MACHINE PARAMTERS Machine Type This is used to define the type of machine. Stations Per Index This defines the number of stations that move per index. Pulses Per Index This defines the number of pulses that pass per index. Column Lower Limit Lower software limit. This can be used to protect fixturing. Column Setup Rate Rate column moves during a setup. Function Keys F1 Engineering Menu: F2 Error List: 17

18 MACHINE FAULT LIST Function Keys F1 Engineering Menu: 18

19 SKIP HONING CYCLE Function Keys F1 Run Screen: 19

20 ADDITIONAL SETUP MENU This screen presents additional setup options. Function Keys F1 Setup Menu: Return to Setup Menu. This screen asks for additional setup information regarding workpiece specifications. This information will be found on workpiece blueprint or by measuring workpieces. You cannot proceed to next step until all these parameters have been entered. Spindle Information Honing Rotation - Pressing ENTER will toggle spindle honing rotations between: Forward, Reverse, and Alternating. Return Rotation - Pressing ENTER will toggle spindle return rotations between: Same or Opposite of honing rotation. Stroke Information Additional Strokes - This allows increasing the numbers of current strokes by 1 to 10. Top of Stroke - This allows editing of current top of stroke position. Bottom of Stroke - This allows editing of current bottom of stroke position Stroking Rate - This allows editing of current stroke rate. Top of Bore - Refer ONLY. Rapid Stop Position - Refer ONLY. Reverse Feed Position - Refer ONLY. Index Position - Refer ONLY. 20

21 WARNING WINDOWS Please Wait for AC drives to power down - AC Drives have capacitors that must discharge. Release E-Stop and Close All Guards then Press Power On -- Make sure that all guard doors are closed and that both of two e-stop switches are released. (One on panel; one between finger buttons. Twist to release.) Machine will need to be placed at Index Position. Press Power On to Continue - The column must go to the index position. This will happen after power is turned on. E-Stop Warning - One or more of two E-Stop buttons has been depressed. Machine cannot continue until they are released. Guard Warning - The Guard Door is Open. Cycle Stop Warning - Cycle stop button was pressed during a cycle. Honing cycle was not completed. Spindle Torque Limit Warning - Spindle torque limit was reached. Coolant Flow Warning - Pressure switch detected low flow or no flow during honing cycle. Make sure coolant system is turned on and delivering flow to the Machine. Column Overtravel Warning - Spindle carriage has traveled to limits of its range. Index Table Fault - Index table either did not complete its move or it overran position where it should stop. Press Palm Button to Complete Index Table Movement - For some reason index table did not complete its motion. Pressing palm buttons again may allow it to complete its motion. Press Palm Button to move Column to Index Position - the Machine must move Spindle Carriage to Index Position before you can proceed. Column Drive Fault - Ball Screw Motor Drive has detected a problem. Communications Error - This happens when CPU is unable to communicate with the GPD515 Drive. This can happen when power is removed by a different Fault. MAINTENANCE REMINDERS Time Intervals 10 hrs - Check for proper coolant level and concentration. 30 hrs - Check Gear Case oil level. 200 hrs - Apply 2 pumps of Mobilith AW-3 Grease to Ball Nut. - Check oil level on the Index Table hrs - Drain and replace the oil in the Index Table hrs -Replace Ball Screw Drive Belt. - Drain and replace Gear Case oil - Check air gap on Ball Screw Brake. 21

22 Like any machinery, this equipment may be dangerous is used improperly. Be sure to read and follow instructions for operation of equipment. Sunnen reserves right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle 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 time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify discrepancy with Sunnen before proceeding. SUNNEN PRODUCTS COMPANY 7910 Manchester Ave. St. Louis, MO U.S.A. Phone: Fax: U.S.A. Toll-Free Sales and Service - Automotive: Industrial: International Division Fax: sunnen@sunnen.com 22 SUNNEN PRODUCTS LIMITED No. 1 Centro, Maxted Road Hemel Hempstead, Herts HP2 7EF England Phone: Fax: SUNNEN AG Fabrikstrasse Ennetaach-Erien, Switzerland Phone: Fax: SHANGHAI SUNNEN MECHANICAL CO., LTD. 889 Kang Qiao East Road, PuDong Shanghai , P.R. China Phone: Fax: SUNNEN ITALIA S.R.I. Via Stelvio 12/ Ospiate di Bollate (MI) Italy Phone: Fax:

techniques data file: #102 HONING SHORT BORES SUNNEN PRODUCTS CO MANCHESTER ROAD ST. LOUIS, MO U.S.A. PHONE:

SUNNEN H NING techniques data file: #102 HONING SHORT BORES SUNNEN PRODUCTS CO. 7910 MANCHESTER ROAD ST. LOUIS, MO 63143 U.S.A. PHONE: 314-781-2100 SUNNEN HONING TECHNIQUES TABLE OF CONTENTS SHORT BORES.................................................