Instructions for Setting Up The Etamic CMZ32 Air Gaging
Contents
1. BAD if ANY of its measured values fall outside the upper amp lower tolerance limits 3 You ll have to set the tolerance for Taper a amp Straightness a based on the specific application That is the value entered will be based on what measured value do you want the system to reject and tag a part BAD when a part s taper and straightness is beyond a certain limit 4 Even if you decide you do not want to enable a specific comp Straightness for example you MUST still have a valid value entered in these locations ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 17 6 11 10 Setting up the Etamic CMZ32 Air Gage System iii Tool Compensation Screen Refer to the Measurement Tool Compensation Configuration picture below The Output Type parameter This parameter should be set to DISABLED on all measurement variables except for the Average Bores Size Taper and Straightness These have to be set to Socket otherwise the CMZ32 will not send the appropriate comp to the SV machine EXCEPTION Some SV machines may have the Straightness comp set to DISABLE This was due to the fact that at the time the machine was being tuned it was found that there wasn t a need to enable the automatic Stroke Length adjustment Straightness comp The UCL amp LCL parameters You ll need to adjust the UCL amp LCL for Average Diameter a Tap2. Open as read only Figure I 13 Restore browser Scroll down until you get to the gage backup folder C Program Files Sunnen Products SUNNEN1 Gage Backup NOTE The default file name of the gage backup archive is the same as the name of the current project folder refer to 1 Step in section Project Window above and also the section above referring to the Backup button In the examples we have been using throughout this document our project folder has been Gage Projects such that the default file name of the backup archive is Gage Projects zip Select the backup file from the Gage Backup folder and then press the Open button The following window will appear on the screen asking what part of the archive to open Project Restore Options Restore Into f The current projects folder Another existing projects folder A new projects folder Cancel Figure I 14 Restore options The current project folder Selecting this option will restore the archive to the currently selected projects folder Another existing projects folder This option is used to select a different existing project folder to restore the archive into A new projects folder This option is used to create a new project folder to restore the archive into it NOTE By default the first option The current projects folder should be selected It is highly recommended that this be the option of cho
3. 6 16 built date 090808 or later KKK NOTIE THE DATA IS ENTERED EITHER IN UNITS OF INCHES in OR METRIC mm THE UNITS SELECTED IS DETERMINED BY WHAT IS CHECKED IN THE GENERAL SETTINGS PAGE LOCATED IN THE PROJECT MENU Example The Nominal value for M042 Average Diameter b under the Master tab is entered as 0 393937 The data entered is in inches such that the Units Project General Settings selected in the General Settings page is English inch Project Name Sunnen Post Process Units z English inch X 4 Parts 1 Masters 1 Serial Output COM Port Disabled Value Type FAILURE TO DO FOLLOW THESE INSTRUCTIONS PROPERLY MAY RESULT IN CAUSING THE CMZ TO INCORRECTLY SET THE PART STATUS AS GOOD OR BAD ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 15 6 11 10 Setting up the Etamic CMZ32 Air Gage System To Find CMZ82 version Go to Help at top of screen and select About CMZ32 CMZ3 Part Picture Display Gage Status Fie Mode Diagnostics View Window Maas CMZ32 Etamic Movomatic Copyright 2002 7006 Users Guide Version 4 6 0 Build 053107 Network ID 24 015 001 OF NOTE Only those measurement variables M001 M300 required for the particular SV machine should be enabled gt Those being used need to have their Active parameter set to YES gt Those not us
4. CMZ32 Air Gaging System ver 1 000 20 6 11 10 Setting up the Etamic CMZ32 Air Gage System NOTE 1 Normally we have the Upper Control Limit UCL for the Average Diameter a set very high so we do not make unnecessary negative bore size adjustments That is it is preferred that the abrasive naturally wear down rather then make a bore size comp to reduce the bore size Of course when you do this the trade off is you ll need to decide how much greater from the nominal size you are willing to have the bore honed to before the system must generate a negative bore comp 2 Set the Lower Control Limit LCL for the Average Diameter a to a value that will allow the system to make a positive bore size comp early enough before honing too small of a diameter Remember that the Spindle Column is honing a part at the same time that the gaging system is measuring a part such that any comps that the gage system generates will be too late for the existing part being honed 3 The parameters should be set such that the stones on the honing tool are allowed to wear normally without any need to make additional positive bore comps and at the same time not too high so we do not have to make any negative bore comps The actual graph shown on the Tool Comp Monitor screen should look Saw Tooth as shown in Figure VI 7 below Note in Figure VI 6 below that the comps for Straightness a has been disabled Output Type Di
5. Files35unnen Productes 5UNNENT Gage Froject Browse EPan men REUNEN Gag Fea Bore HO Barrel Class2 cmz Project Groups Popete Groups stele Hi c aaa HD Barrel Class Enter project file name Sunnon Post haces 1 5pindle New Paste Save As gt PAG A As a x M Do not display in project mode Modified 16 OctO 06 30 4M Project No 1 Back Up Restore New Project Select Close Figure I 7 New project file name Press the OK button after completing the project file name The CMZ32 will generate a completely new project file The name given to the file will be displayed in the Projects window Refer to Figure I 8 below The new project name is New Project and the new file name for this project is New_project cmz Projects Projects Folder File Marne C AProgram Files Sunnen Products 5UNNENT4Gage Project Browse new project cmz Project Groups Projects HO Barrel Class4 HO Barrel Class1 0 HO Barrel Class11 HO Barrel Clase Sunnen Post Process Sunnen Post Process 3 Spindle Sunnen Post Process 3 Spindle 10mm the Hew Button Sunnen Post 3 Hee 11 mimi Sunnen Po z curl DO05mm Limen Post Process Spindle a New Project created using New Delete Cut Paste Save As gt Do not display in project mode Modified NEVER Project No 18 Back Up Restore New Project Select Close Figure I 8 New project created NOTE This method o
6. Projects window 2 A new project can be created using the Save As or New buttons 3 A project file can be restored from an existing backup file ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 2 6 11 10 Setting up the Etamic CMZ32 Air Gage System a Select an Existing Project An existing project can be selected by highlighting a project name listed in the Projects window Sometimes there are more projects then can be displayed in the Projects window Use the Scroll key or the Up amp Down Arrow buttons located in the lower right corner of the Projects window to see all the projects The example below shows the Sunnen Post Process 3 Spindle 10mm project file selected Note that the name of the actual project file is shown in the File Name window NOTE 1 To change the project name Click on the text in the Project Name Edit Box located at the bottom center of the Projects window 2 Not all of the characters of the file name are displayed in the window If you click on the file name as shown below an edit box will appear enabling you to edit the full file name Normally the file name is the same as the project name 3 The date and time of the last changes done to the project along with the project number is displayed below the list of projects names Projects Projects Folder or File Mame E Program Files Sunnen Products SUNNENT SGage Project Browse CS
7. Seqi0 Seqil Seqi2 Seqi3 Seqi4 Seqi5 Seqi6 Seqi7 Seqis ETE Level3 Level4 Level5 Mid Level6 Level7 Level Level9 Bot SEQIO SEQ11 SEQI2 SEQI3 SEQI4 SEQI5 SEQIB SEQI7 SEQIS FO VO VO VO VO O VO VO VO Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled 00020 00020 00020 00020 00020 00020 00020 00020 00020 T2 T2 T2 T2 T2 T2 T2 T2 T2 00000 00000 00000 00000 00000 00000 00000 00000 00000 Diameter Ref a 01 01 01 01 01 01 01 01 01 Measurement1 a 01 Measurement 2 a 01 M004 Measurement3a 01 M005 Measurement 4 a M006 Measurement 5 a V Require mastering every 100 parts or 0 minutes Wam 0 parts prior Report GRR Peri Ne La rai To enable this feature The Require mastering every check box must be checked A value of how many parts that have to be gaged before requiring mastering must be entered In the example below the CMZ32 is setup so it will set a flag showing that it has to be re mastered after gaging 100 parts i Require mastering every 100 parts or minutes Warn OD parts prior Previous Next List NOTE For multi column machines the first gage column meeting these requirements will cause all other gage columns to be re mastered also ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 9 6 11 10 Setting up the Etamic CMZ32 Air Gage System IV Setup i Input Devices From the Project M
8. These values are Factory Set and are recommended settings but can be changed Refer to the SV manual for setting up the CMZ32 ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 26 6 11 10 Setting up the Etamic CMZ32 Air Gage System TUNING PARAMETERS in the CMZ32 PROJECT Menu GAGE MASTER GAGE RING AXIS MEASURMENT SCREEN F6 Upper Lower NOMINAL CERTIFIED Nominal M1 Offset Approach Approach SIZE DIFFERENCE see note 1 see note 2 Ca am amore o Tl wan wanes o wan omones HONG Tuning Parameter Worksheet CMZ32 Measurement Screen F6 in Project Menu ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 2 6 11 10 Setting up the Etamic CMZ32 Air Gage System TUNING PARAMETERS in the CMZ32 PROJECT Menu MASTER GAGE RING GAGE AXIS COMPENSATION SCREEN F9 Output Max Max Comp NOMINAL CERTIFIED bi P ter Target com Cum Inc Stray CB FCB SCB Skip SIZE DIFFERENCE yp 4 P Comp Y He 6 6 3 3 5 49 6 STRAGHTNESS corn lo loo of te STRAGHTNESS sour o loo t 2 s28 lona lolal lila LU TAPER coer lo oor orratetmueos soro lo ooo ly 828 se lola ly LU TAPER soe lo oor ly orratctmueos soe lo Jowl ly SIZE se loco lll lobol luho e ISV113A Setting up the CMZ32 Air Gaging System ver 1_000 28 6 11 10 S
9. be done in two places on the screen Rename the file name shown in the File Name box located in the upper right corner of the screen Rename the file name in the same manner to the second file listed shown on the bottom middle of the screen Select which file you want loaded in the CMZ To do this highlight the file name and then press the Select button to load that setup ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 23 6 11 10 Setting up the Etamic CMZ32 Air Gage System In this example we will rename it to Sunnen Post Process 3 Spindle 11 0005mm Projects Projects Folder File Name C AProgram Files Sunnen Products SUNMENTSGage Project Browse Copy of Sunnen PP 3 Spindle Project Groups Projects HO Barrel Class HO Barrel Class6 HO Barrel Class9 HO Barrel Class10 HO Barrel Class11 HO Barrel Class12 Sunnen Post Process Sunnen Post Process 3 Spindle Sunnen Post Process 3 Spindle 10mm Sunnen Post Process 3 Spindle 11mm Hew Delete Cut Paste Save As gt New Delete Cut Paste 8 T Do not display in project mode Modified 13 dar 08 01 23 PM IN Back Up Restore Copy of Sunnen Post Process 3 Spindle 11mm Select Close E Figure VI 8 Example of copying an existing setup Projects Projects Folder File Name CAProgram Files Sunnen Products 3S5UNNEN1 4G age Project Browse Sunnen PP 3 Spindle Project Groups Projects HO Barrel Class HO Barrel
10. button is used to copy an existing project The new project can then be renamed using the File amp Project Name Edit boxes as explained in a Selecting an Existing Project above The default name of the new project file is the same as the old project name but copied with the text Copy of appended to the front of the old project name For example Say an operator needed to create a project file for an 11mm part The only project file he presently has is for a 10mm part The only difference between the two parts is the bore diameter Everything else like tolerance and control limits are the same He could create a whole new project file using the New button however this would require a lot of work going through all of the parameters in the CMZ32 screens An easier and much faster method would be to copy the 10mm project to another file name and then edit the nominal size parameter in the new project To do this the operator would first highlight the 10mm project name In this example the project name is Sunnen Post Process 3 Spindle 10mm The user would then press the Save As button after highlighting the project name A new project Copy of Sunnen Post Process 3 Spindle 10mm is created and listed in the Projects window as shown in the figure below The user can then use the project Name Edit Box as explained above to rename the default project name to whatever they wish it to be NOTE Th
11. your equipment Troubleshooting information can also be found within the 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 the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available o Have ALL MANUALS on hand The Customer Services Representative or Technician will refer to it o Have Model Number and Serial Number printed on your equipment Specification Nameplate O Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required 0 Power distribution information type delta wye power factor correction other major switching devices used voltage fluctuations O Installation Wiring separation of power 8 control wire wire type class used distance between drive and motor grounding O Use of any optional devices equipment between the Drive amp motor output chokes etc For fast service on your orders call O Sunnen Automotive Customer Service toll free at 1 800 772 2878 O Sunnen Industrial Customer Service toll free at 1 800 325 3670 0 Customers outside the USA contact your local authorized Sunnen Distributor O Additional information available at h
12. 0 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 D 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 14 0000000 0 0001000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 000000 0 0000000 0 0000000 0 0000000 0 0010000 0 1200000 0 0000000 0 0000000 0 0000000 0 0000000 0 0010000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 21 0 0000000 0 0000000 6 11 10 Setting up the Etamic CMZ32 Air Gage System iv Examples 1 Properly tuned system Example of a properly tuned Gaging System controlling the bores size diameter on Spindle Column A Each White dot represents a measured part Each purple dot represents a sub group A sub group may represent 1 or more parts This can be 1 2 or 3 depending on when the previous comp was made In this example the sub group is 2 refer to section above explaining the parameters in the Tool Compensation screen The tolerance was set to 0 000200 The Upper Control Limit was set to 0 000160 The Lower Control L
13. 000000 0 000000 0000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 Tol Type Flier Upper Tol Upper Approach Lower Approach Lower Tol Master Upper Master Lower 0 000040 0 000040 0 000040 0 000040 0 000040 0 000040 0 000040 0 000040 0 000040 0 000040 0 000000 Figure VI 3 Example of the Measurement Configuration screen ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 16 6 11 10 Setting up the Etamic CMZ32 Air Gage System The Nominal parameter must be set to the nominal value of the MEAN Master Gaging Ring This parameter is usually set to the same value as the associated Spindle Column final diameter For example if Spindle Column B is configured so its final size is 0 472008 11 989mm then the Nominal parameter for Gage Column b would also be set to 0 472008 The MEAN Master Gaging Ring is the ring installed on the Gage Column Auto Zero Bracket and is used when Zeroing the Gage Column Note that the actual size of the MEAN Master Gaging Ring may not be the exact same size as the nominal size entered in the Nominal parameter This difference is noted on the rings Certification letter shipped with every SV machine incorporating an Air Gage Column The difference must be set in the M1 Offset parameter In the example below the Measurement Configuration screen s
14. 32 User guide for more information Projects Projects Folder File Name C Program Files Sunnen Producte SUNNEN Gage Project Browse Sunnen PP 1 Spindle cmz Project Groups Projects HO Barrel Classi HO Barrel Clase4 HO Barrel Class10 HO Barrel Claze11 HO Barrel Clase12 Sunnen Post Process Sunnen Post Process 3 Spindle Sunnen Post Process 3 5pindle 10mm Sunnen Post Process 3 Spindle 17mm Sunnen Post Process 3 Spindle 177 0005mm New Delete Cut Paste Save As gt New Delete Cut Paste Save As Do not display in project mode Modified 12 Feb 08 01 05 PM Project No 17 Back Up Restore Sunnen Post Process 1 5pindle Select Close Figure I 3 Project Window 1 Step Use the Browse button to point to the current project folder Make sure that the Project Folders window is pointing to the correct folder on the hard drive All CMZ32 project files are saved to the following folder C Program Files Sunnen Products SUNNEN1 Gage Projects This is the text that you should see in the Project Folder window refer to figure above 2 4 Step Select a Project Group from the Project Groups window Normally there will only be one project to select from The default project is Sunnen1 Project Group 3 4 Step Select a Project file This can be done in one of three ways 1 An existing project can be selected from the list of projects shown in the
15. 4 0000 59 64 196860 5 0000 one 14 2875 _ 15 16 5 1594 3764 14 6844 5 5563 15 0000 61 64 59531 1982 150813 31 82 236220 60000 sawa 15 4781 1 4 6 3500 5 8 15 8750 63 64 6 7469 16 0000 FORMULAS MULTIPLY TO GET MULTIPLY TO GET INCHES in FEET ft MILLIMETERS mm METERS m MILLIMETERS mm METERS m INCHES in FEET ft UK SUNNEN PRODUCTS LTD Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 www sunnen co u e mail hemel sunnen co uk SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SWITZERLAND SUNNEN AG 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 Phone 41 71 649 33 33 www sunnen ch e mail info sunnen ch IG ny CHINA SHANGHAI SUNNEN MECHANICAL Co LTD Phone 86 21 5 813 3322 Fax 86 21 5 813 2299 UNWNEN www sunnensh com e mail sales sunnensh com os ITALIA S R L a Slop a ABALA hen fie Se ae maan En mena sunnenialiaesin Phone 314 781 2100 Fax 314 781 2268 U S A Toll Free Sales and Service 1 800 325 3670 International Division Fax 314 781 6128 Fax 41 71 649 34 34 FRANCE SUNNEN SAS Phone 33 01 69 30 0000 Fax 33 01 69 301111 www sunnen
16. 5unnen PP 3 Spindle 10mm cmz PE Project ene Projects HD Barrel Class H Barrel Clase4 HD Barrel Class10 HD Barrel Class11 HD Barrel Class 2 Sunnen Post Process Semen Fost Process 3 Spindle i Conner PrP rces Genade ttm Project name edit box Sunnen Post Process 3 Spindle 11 0005mm Sunnen Post Process 1 5pindle Hew Ng Save As al gt Delete Paste Save As v Dona display i in project mode CL _ _____ Madi Modified Jedi 08 11 42 4M Project No 14 Back Up Restore Garren Post Process 7 Spinde 10r Post Process 3 Spindle 10mm J Select Close Figure I 4 Selecting an existing project File name edit box Press the Select button to activate the project file highlighted in the Projects window The file selected will be displayed in the top horizontal tool bar in the System Menu Figure I 5 below shows how the CMZ32 tool bar displays that project file 14 Sunnen Post Process 3 Spindle 10mm file is selected oe CMZ32 File Mode Diagnostics Tools wiew Help EP Suen PP 3 Spindle 10mm emz Current Project File Being Used Figure I 5 Displaying the current project loaded in the CMZ ISV113A Setting up the CMZ32 Air Gaging System ver 1_000 3 6 11 10 Setting up the Etamic CMZ32 Air Gage System b New Project A new project can be generated using either the New or Save As buttons 4 Save As Button The Save As
17. ATA IN THE 1 HALF ARE ALL ENTERED IN UNITS OF INCHES THE DATA IN THE 2 HALF ARE ALL ENTERED IN UNITS OF MM THE VALUES IN THE LAST 6 GROUPS MUST MIRROR THE 1 6 GROUPS THAT IS THEY ARE SET TO THE SAME VALUE BUT ARE ENTERED IN UNITS OF INCHES IN THE 1 6 GROUPS AND IN UNITS OF MM IN THE 2ND M001 in M151 mm M002 in M152 mm M149 in M259 mm M150 in M300 mm EVERY VAULE IN THE LAST 6 GROUPS MUST BE SET TO THE SAME VALUE AS ITS MATCHING MEASUREMENT VARIABLE IN THE 1 GROUP Example The Nominal value for M042 Average Diameter b under the Master tab is entered in units are in inches as 0 393937 The equivalent metric measurement variable would be M192 The Nominal value for M192 would be entered in units are in mm as 10 006 I WARNING The Units selection on the Project General Settings Project Name Sunnen Post Process page MUST ALWAYS have English inch selected Units English inch gt Parts 1 Masters fo Serial Output DO NOT CHANGE THIS SETTING O ER Type Value FAILURE TO DO FOLLOW THESE INSTRUCTIONS PROPERLY MAY RESULT IN CAUSING THE CMZ TO INCORRECTLY SET THE PART STATUS AS GOOD OR BAD ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 14 6 11 10 Setting up the Etamic CMZ32 Air Gage System Measurement Screen Setup using CMZ32 version 4 6 16 KKK For CMZ32 version 4
18. Class8 HO Barrel Claz23 HO Barrel Class10 HO Barrel Class71 HO Barrel Clase12 Sunnen Post Process Sunnen Post Process 3 Spindle Sunnen Post Process 3 Spindle 10mm Sunnen Post Process 3 Spindle 11mm Hew aste Save As gt New Delete Cut Paste Save As Do not display in project mode Modified 13 Mar08 01 23 PM Project No 16 Back Up Restore Sunnen Post Process 3 Spindle 11_0005rmrm Figure VI 9 Example of renaming the newly copied setup 2 The 2nd step would be to edit the Measurement Parameters You would then proceed to edit this new setup with the changes That is the Nominal parameter now becomes 11 0005 mm 11 0000 0 0005 The M1 Offse parameter now needs to be edited to offset the change we just made to the Nominal parameter Such that M1 Offse is now 0 0006 mm 0 0001 mm 0 0005 mm ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 24 6 11 10 Setting up the Etamic CMZ32 Air Gage System VII Gaging i Selecting the CMZ setup file There are various methods to select a setup file 1 Accessing from the System Menu The setup files can be selected by going to the System menu Refer to the instructions above under Setting up a Offset on Nominal Size Ze Using the Top Menu key Select the CMZ setup file from one of the other menus Example Press the button between GAGE and Part 1 of 5 buttons located on the top left side of t
19. I SV 113A NS 4 A SUNNEN Instructions for Setting Up The Etamic CMZ32 Air Gaging System for SUNNEN VERTICAL HONING SYSTEMS Models SV1000 SV1005 SV1010 amp SV1015 SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST LOUIS MO 63143 U S A e PHONE 314 781 2100 Setting up the Etamic CMZ32 Air Gage System GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp 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
20. T INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE REVENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F O B Buyer s destination shipments SPC will not be liable for any settlement claims for obvious and or concealed shipping damages The customer bears the responsibility to unpack all shipments immediately and inspect for damage When obvious and or concealed damage is found the customer must immediately notify the carrier s agent to make an inspection and file a claim The customer should retain the shipping container and packing material SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you as user and licensee Licensee and Sunnen Products Company SPC with respect to preprogrammed software Software provided by SPC for use on SPC Equipment By using the Software you as Licensee agree to become bound by the terms of this Agreement In consideration of payment of the license fee License Fee which is part of the price evid
21. This Warranty does not apply to the following o Normal maintenance items subject to wear and tear belts fuses filters etc o Damages resulting from but not limited to gt Shipment to the customer for items delivered to customer or customer s agent F O B Shipping Point gt Incorrect installation including improper lifting dropping and or placement gt Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops gt Incorrect air supply volume and or pressure and or contaminated air supply Electromagnetic or radio frequency interference from surrounding equipment EMI RFI gt Storm lightning flood or fire damage gt Failure to perform regular maintenance as outlined in SPC manuals gt Improper machine setup or operation causing a crash to occur gt Misapplication of the equipment gt Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration gt Incorrect software installation and or misuse gt Non authorized customer installed electronics and or software gt Customer modifications to SPC software THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND EXPRESS OR IMPLIED WHETHER AS TO MERCHANTABLLITY FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER SPC IS NOT RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS SPC SHALL NOT BE LIABLE FOR DIREC
22. This means that the actual Stroke Position Comp from the CMZ to the SV machine will change by 0 001 for every 0 000001 of error in the bore s taper but in the opposite direction of the error That is the Center of Stroke will be moved down a little more the next cycle based from the last center of stroke position when the CMZ determines that the bore is getting too small on the bottom or too big on the top of the bore The Center of Stroke will be moved up a less more then the last position it was at when the CMZ determines that the bore is getting too small on top or too big on the bottom of the bore 3 Straightness a gt This should be set to 0 001 Such that the Output Value 1000 Comp Value This means that the actual Stroke Length Comp from the CMZ to the SV machine will change by 0 001 for every 0 000001 of error in the bore s straightness but in the opposite direction of the error That is the amount that the Stroker Axis will stroke up amp down during the next cycle will decrease a little more then the last cycle when the CMZ determines that the bore is getting too small in the middle or too big on the ends The length of the stroke will increase a less more then the last cycle when the CMZ determines that the bore is getting too big in the middle or too small on the ends ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 19 6 11 10 Setting up the Etamic CMZ32 Air Gage Sys
23. _ Incremental Incremental _ Incremental Incremental Incremental _ Incremental Incremental _ Incremental 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 O 0000000 O D000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0001600 0 0001200 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 50 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000400 0 0000400 0 0001200 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 50 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 _0 0000000 0 0000000 0 0000000 0 0000000 0 0002000 0 2000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 000000
24. alue Output Value Correction Error Skip Count Reject Count Est Status AVENE IE DEUI H LILI NULL NI ies Taper a 0 00000 0 00000 0 00000 0 00000 0 00000 0 1 0 0 NA Average Diz 0 00001 0 00000 0 00000 0 00000 0 00000 0 1 0 0 NA Taperb 0 00000 0 00000 0 00000 0 00000 0 00000 0 1 0 0 NA Average Die 0 00001 0 00000 0 00000 0 00000 0 00000 0 1 010 NA Taper c 0 00000 0 00000 0 00000 0 00000 0 00000 OM 0 0 N A Figure VI 1 NOTE Press Diagnostic in the upper left corner of the CMZ screen and select the Tool Comp Monitor option to bring up the Tool Comp Monitor window bo Fie Mode View Window Fault Log Network Monitor SPC Alarms Monitor Tool Comp Monitor Temp Comp Monitor hi Shift Register a i Last Cycle Status Measurement Status All adjustments will either be from the Measurement or Compensation CMZ screens Both are selectable from the CMZ Project menu shown below Chis Fie Mode Diagnoses Tocs Wew Hep ETAMIC MOVOMATIC CMZ J Ng F gt F12Pro ompensation F11 Project Summar nput Donic f 3 it gc Figure VI 2 ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 13 6 11 10 Setting up the Etamic CMZ32 Air Gage System ii Measurement Screen 1 Measurement Screen Setup using CMZ32 version 4 6 0 For CMZ32 version 4 6 0 built date 053107 HII WARNING IHH THE 12 GROUPS ARE DIVED INTO 2 SECTIONS 6 GROUPS EACH THE D
25. bility for consequential or accidental damages and to the extent this is true the above limitations may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement ISV113A Setting up the CMZ32 Air Gaging System ver 1_000 ill 06 11 10 Setting up the Etamic CMZ32 Air Gage System NOTE These instructions are to be used when using CMZ32 version 4 6 0 Build date 5 31 07 Only a qualified Operator should attempt to backup amp restore setup files Pictures of various screens in this manual are taken from version 1 2 3 0 There may be some variation from the actual screens shown on the SV machine Failure to follow these steps correctly may damage the machine ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 IV 06 11 10 Setting up the Etamic CMZ32 Air Gage System L MANAGING PROJECT FILES AA ATAT 1 Bes OVS UE TNA VION AA AA AA AA AA AA AAP APA 1 la POT NOON AA AGA ANA AA AA 2 a Selectan BIS UMS PEO AA 3 D NWP O AA APA 4 Backup amp Restore a Project c seesieriekinei isseire NG ieden E Erei aeei EEEE EE ETENEE EEN E EEEE Eiin 6 PBA Bang ki O LA Hal CAPE AA AA 8 L MAE Vy OW cada scrtacance tastcaciteaeiciccrsnsusetieccssecentasassvsshcacnssasaneesapvasaatcanesctautestineicessssdenseinsid ca
26. e SV machine must be generated before the CMZ32 can be used To do this the user must go to the Project Window in the System menu to setup a project folder amp project file s System Menu Press the lt 1 gt SYSTEM key to get into the CMZ32 System Menu NOTE All communication between the CMZ32 and the SV software will be halted while the user is in the System Menu A warning message will appear on the screen warning you that communication with i 6 x EN AP SUNNEN Warung Entering System Mode wil shed off 1 0 Devices j mark bo Contre D ta Status oi aw pev ure Figure I 1 Warning message when switching from Gage Menu to System Menu From the System Menu screen press the lt F3 gt PROJECT FILES key to enter the Project Window CM737 Na Moda Dukgreritoee Tooke View Map 1 ystem 2 Diagnostics 4 ETAMIC 5 M 6 M 7 S 8 roject age MOVOMATIC Figure I 2 System Menu ISV113A Setting up the CMZ32 Air Gaging System ver 1_000 1 6 11 10 Setting up the Etamic CMZ32 Air Gage System 1 Project Window Use the lt F3 gt PROJECT FILES key from the System Menu to get to the Projects Window refer to Figure I 3 below From here the user can manage the CMZ32 setup files such as recovering a previously saved CMZ32 setup using the Restore button or to save the existing CMZ32 setup using the Back Up button Refer to the keywords Project Files in the CMZ
27. e actual file name of the new project is also defaulted with the same text as that used for the project name It is strongly suggested that the user use the File Name Edit Box to rename the file name of the project to match that of the project name as explained above in Select an Existing project Projects Projects Folder File Marne C AProgram Files45Sunnen ProductssSUNNENT Gage Project Browse Copy of Sunnen PP 3 Spindle Project Groups Projects HO Barrel Class4 HD Barrel Class10 HD Barrel Class 1 HD Barrel Class12 Sunnen Post Process Sunnen Post Process 3 Spindle Sunnen Post Process 3 Spindle 10mm Sunnen Post Process 3 Spindle 11mm Sunnen Post Process 3 Spindle 11 0005mm New Project created using the Save As Button New Delete Cut Paste Save As gt Do not display in project mode Modified 15 Apr 08 11 42 AM Project Mo 1 Back Up Restore Copy of Sunnen Post Process 3 Spindle 10mm Select Close Figure I 6 New project using the Save As feature ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 4 6 11 10 Setting up the Etamic CMZ32 Air Gage System 5 New Button Use the New button to create a completely new project An edit box will appear on the screen displaying the default project name as shown in Figure I 7 below You can use this default name or create you own by typing in a project name m Frojects Falder pa File Name IC Program
28. e value of Coefficient 1 if the measured difference is greater then the difference found in the certification sheets For example The air gaging system was designed with the following pneumatic formula Pneumatic formula 7 8 G 75 B7 0 Coefficient value As shown the portion of the pneumatic formula representing the coefficient value is G 75 The actual number that should be entered under Coefficients 1 is 075 75 10 The Minimum Master Ring Gage measured 9 991mm The Maximum Master Gage Ring measured at 10 007mm The Minimum Master Ring Gage certification equaled 9 992mm The Maximum Master Gage Ring certification equaled 10 008mm The measured difference is less then the difference shown in the certification sheets such that the Coefficient 1 or Gain parameter should be slightly increased We started with 0 075 so we should increase to 0 076 or 0 077 and repeat the procedure until we are within the tolerance of the type of Master Ring Gage Refer to the CMZ help file for more details press the lt F1 gt key in any of the CMZ32 menus ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 10 6 11 10 Setting up the Etamic CMZ32 Air Gage System Diagnostics Input Devices From the Diagnostic Menu use the lt F2 gt Inout Devices button to view all connected input devices This feature is used to monitor the raw data coming from the TPE 99 air to electronic transducer Ideally
29. ed Mastered Mastering passed NOTE The lt F6 gt Zero Master Refs button may need to be pressed if a gage column fails to master This WILL occur any time the SAVE button is pressed while in the Measurement Configuration screen in the Project Menu ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 8 6 11 10 Setting up the Etamic CMZ32 Air Gage System III Auto Re Mastering The CMZ32 can be setup such that the system will require to be mastered after so many parts have been gaged This is done from the Part Master page in the PROJECT menu i Part Master Menu Press the x25 MASTER key to get into the CMZ32 Projects Menu Fis kinda Dage Tonk View Haii uy Gunnar POT Spiga sce System Project a EJ dw a E g Hi ETAMIC MOVOMATIC diz la g j oe ii Go jE zl 2 ln cp O w C 2 G 5 18 ia f et Shutdown Close Fido RT input Devices F4 PanvMaster F5 Pan Picture FE Measurements From the Project Menu screen press the lt F4 gt PART MASTER key to enter the Part Configuration window The bottom left corner of the Part Configuration window provides a means for setting up the CMZ32 to automatically require re mastering after gaging x amount of parts E Part Configuration PART 01 IV Active Label Gage Status Select Part aaa KK VB BV 8 8 88 8 8 Select Sequence 1 CO Seq01 Seq02 Seq03 Seqdd Seq05 Seq06 Seq07 Seqd8 Seqd9
30. ed must be set to NO gt Use the lt gt key to change the state from YES to NO gt Use the lt gt key to change the state from NO to YES NOTE 1 By default all the measurement variables should already be set to their proper states 2 Not all measurement variables in a single group may be used active Some of these have their Nickname set to Spare and are reserved for future use 3 By default the CMZ is setup to take a maximum of 9 of the possible 15 measurements The unused measurements 10 15 are reserved for future use BB Measurement Configuration All Formula Limit Master Display Flags Serial Network Active Nickname M001 ES Diameter Ref a M002 YES Measurement 1a M003 YES Measurement 2 a M004 YES Measurement 3a M005 YES Measurement 4 a M006 YES Measurement 5 a MOO YES Measurement 6 a M008 YES Measurement a M009 3 YES Measurement 6 a Measurement 9 a Measurement 10 a Measurement 11 a Measurement 12 a Measurement 13 a Measurement 14 a Measurement 15 a M017 YES Average Diameter a M018 YES Tapera NG Spare Spare straightness a Spare Spare Spare Spare 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000000 0 000000 0000000 0 000000 0000000 0 000000 0 000200 0 000160 0 000000 0 000000 0 000160 0 000000 0 000000 0 000000 0 000000 Bilateral Bilate
31. eeds to be adjusted The ICB parameter Tells the CMZ how many parts it needs to measure before it is allowed to make the initial comp the very first comp after resetting the CMZ controls This should be set to 1 The FCB parameter This tells the CMZ how many parts it must measure before generating a comp once the part falls outside the Upper Lower Control Limits and after a ICB type comp was made This should be set to 2 The SCB parameter This tells the CMZ how many parts must be measured while inside the Upper Lower Control Limits That is the CMZ makes a Running Average using this number of parts You can think it as a number of parts in a Sub Group This parameter is normally set to 3 but can be changed Too small a number and you risk the Gaging System Output Control to oscillate responding to quickly to changes Too high a number and you risk the Gaging System Output to fall behind responding too slowly to changes The Skip parameter This value lets the CMZ know how many parts are between the gage and spindle column For example the Spindle Column will be honing a part at the SAME time that the Gage Column is measuring a part The CMZ will need to know that the next part 1 part did NOT have the comp that the CMZ just generated based on the part it had just measured This parameter MUST be set to 1 on all normal SV machines ISV113A Setting up the
32. een included for use at the machine when an ESD safe workstation is not available You are now properly grounded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sensitive devices make sure you GROUND ISOLATE NEUTRALIZE ISV113A Setting up the CMZ32 Air Gaging System ver 1_000 li 06 11 10 Setting up the Etamic CMZ32 Air Gage System SUNNEN LIMITED PRODUCT WARRANTY Sunnen Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace or refund the purchase price with respect to parts that prove to be defective as defined above Any equipment or tooling which is found to be defective from improper use will be returned at the customer s cost or repaired if possible at customer s request Customer shall be charged current rates for all such repair Prior to returning any SPC product an authorization RMA and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer Warranty Limitations and Exclusions
33. enced by your receipt Receipt SPC grants to you as Licensee a non exclusive right without right to sub license to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subsequent copies or updates in any media The Software and all accompanying written materials are covered by copyrights owned by SPC If supplied on removable media floppy disk you as Licensee may copy the Software only for back up purposes or you may request that SPC copy the Software for you for the same purposes All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement The Software and accompanying written materials including the user s manual if any are provided in an as is condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose even if SPC has been advised of this purpose SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct indirect consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use It is recognized that some states do not allow the exclusion or limitation of lia
34. entical to A except that the final size is different by a small amount say only 0 0005mm This may be done when an operator wishes to have a group of parts honed at various sizes to match a set of plungers that have been segregated into groups of classes each class differing only slightly in bore size from the next One way to achieve this is to adjust the Nominal value set in the Measurement screen to this difference in bore size Then make the same adjustment to the M1 Offse value but in the opposite direction That is if you add a difference to the Nominal then subtract the same amount to the value in the M1 Offsef parameter Example Suppose you had a setup in the CMZ32 called Sunnen Post Process 3 Spindle 11mm The Nominal size was set to 0 4330696 11 0000 mm and the M1 Offset parameter was set to 0 000004 0 0001 mm You want to hone some parts exactly like this setup however you need the bore to be 0 0000197 0 0005 mm larger 1 The first thing to do would be to copy the existing setup and then rename it v v v v v Go to the System Menu Press the lt F3 gt Project Files key From the Projects window shown below highlight the setup you want to copy Press the Save As button in the Projects window The new file will automatically be named the same as the copied file but with a prefix Edit the name of the file NOTE This must
35. enu use the lt F3 gt Inout Devices button to configure offsets coefficients and limits for Input Devices as they apply to a CMZ32 Project Coefficient 1 Coefficient2 Upper Range Lower Range Upper Master Lower M o 001s000 0 0015000 0 0010000 NO 0 0015000 0 0015000 0 0010000 0 0010000 NO 0 0015000 0 0015000 0 0010000 0 0010000 NO The column labeled Coefficients 1 is used to tweak the full range of the actual output That is it allows a means for the operator to adjust the output during calibration of the selected input device The full range output of the device should be calibrated using a set of certified Maximum amp Minimum Master Gage Rings The initial value of Coefficient 1 or Gain should be equal to the coefficient portion of the pneumatic formula divided by 10 This number should then be adjusted to correct the value of the input device To do this first measure the Maximum Master Gage Ring Measure the Minimum Master Gage Ring and then take the difference of these two Next take the difference of the actual inside bore diameters of the Minimum amp Maximum Master Gage Rings that is recorded in their respective certification sheets The difference in the certification diameters should equal the difference measured earlier Increase the value of Coefficient 1 if the measured difference is less then the difference found in the certification sheets Decrease th
36. er a and Straightness a to the values specific to your application The Upper Control Limit sets the threshold when a negative adjustment is required to reduce whatever comp that particular limit is linked to The Lower Control Limit sets the threshold when a positive adjustment is required to reduce whatever comp that particular limit is linked to gt Program the Upper Approach amp Lower Approach limits on the Measurement screen to the same value you set the UCL amp LCL to on the Tool Compensation screen refer to the last section above The Target parameter Used to set how much above or below the nominal value you want the gaging system to aim for Normally this is only used for the Average Diameter a comp In the picture below you can see that the gaging system was setup so the bore size comp would try to reach 0 000040 1um above the nominal bore size This is usually set to a value such that any positive bore size comp will attempt to get the next size a little higher then normal but still below the LCL The Max Comp parameter This should not be set higher then the upper lower tolerance set in the Measurement screen The Max Cum Comp parameter This should be set to 0 ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 18 6 11 10 Setting up the Etamic CMZ32 Air Gage System The Comp Inc parameter This is used to boo
37. etting up the Etamic CMZ32 Air Gage System STRAIGHTNESS __ SIZE _ TAPER _ CMZ32 WORKSHEET GRAPH Gage Column ah NOTE The UCL and Upper Approach Limit NEL L ANA UPPE IP PPOaACH Limit 7 7 7 parameters must have the SAME VALUE UCL Upper Approach Limit UCL gt LCL C D LCL Lower Approach Limit NOTE The LCL and Lower Approach Limit parameters must have the same value 29 6 11 10 ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART Z I Z O O MILLIMETER ERAcTION DECIMAL MILLIMETER FRACTION DECIMAL LU 003937 01000 9 32 7 1438 2182 007874 02000 19 64 7 5406 gt oman 03000 sne 7 9375 43164 03969 8 0000 11 16 015748 04000 21 64 8 3344 45 64 LU 019685 sooo 1182 8 7313 023622 0 5000 9 0000 2832 027559 07000 23 64 9 1281 47164 07938 38 9 5250 081496 0 8000 25 64 9 9219 sa U 035433 0 9000 10 0000 4964 039370 1 0000 13 82 103188 25182 1 1906 2764 107156 15875 11 0000 51 64 1 9844 716 11 1125 186 078740 20000 29 64 11 5094 23813 1582 11 9063 saba 27781 12 0000 27 32 on 11810 30000 3164 12 3031 55 64 31750 2 12 7000 3 5719 13 0000 7 8 3 9688 33 64 13 0969 57 64 157480 40000 1782 134938 4 3656 __35 64 13 8906 2082 47625 1
38. f generating a new project file will cause the CMZ32 to clear or default many of its parameters requiring the user to review the settings of all the CMZ parameters Such that it is recommended that this method only be used when it is really necessary ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 5 6 11 10 Setting up the Etamic CMZ32 Air Gage System C Backup amp Restore a Project A project folder can be saved and later retrieved using the Backup and Restore buttons 6 Backup Button The following window is displayed when the Backup button is pressed This allows individual group or all existing project groups to be saved and archived Back Up Projects All Project Groups Archives all projects in all groups All Project Groups C Selected Project Group Sel ected Pr oject Gr oup Sf Archives a specific selected project group Cancel Selected Project only Archives a specific selected project Figure I 9 Backup types NOTE By default the first option All Project Groups is selected It is highly recommended that this be the option of choice A browser window will appear after pressing the OK button Scroll down until you get to the gage backup folder C Program Files Sunnen Products SUNNEN1 Gage Backup The default file name of the gage backup Eman archive is the same as the name of the current project folder refer to 1 Step in sec
39. fr e mail info sunnen fr RUSSIA SUNNEN RUS 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 user verify discrepancy with Sunnen before proceeding Phone 7 495 258 43 43 Fax 7 495 258 91 75 www sunnen ru e mail sunnen sunnen russia ru CZECH REPUBLIC SUNNEN S R O Phone 420 383 376 317 Fax 420 383 376 316 www sunnen cz e mail sunnen sunnen cz POLAND SUNNEN POLSKA SP Z 0 0 Phone 48 22 814 34 29 Fax 48 22 814 34 28 Email sunnen sunnen pl http www sunnen com e mail sunnen sunnen com www sunnen pl PRINTED IN U S A 1006 COPYRIGHT SUNNEN PRODUCTS COMPANY 2010 ALL RIGHTS RESERVED
40. he Gage menu This will bring up a window listing all of the CMZ setups Highlight the file and press the Select key to load the file MZ32 Part Picture Display Gage Status File Mode Diagnostics View Window Help F16 Sunnen FF 3 Spindle 11_0005mm c mz Part Snecificatians Projects Projects x 8 Reset I O Q Print O Shutdown SC4 Close ce roe toe rauts g Project Groups Projects HD Barrel Class D Barrel Class11 D Barrel Class1 2 LI Sunnen Post Process 3 Spindle Sunnen Post Process 3 Spindle 10mm Sunnen Post Process 3 Spindle 11mm bk ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 25 6 11 10 Setting up the Etamic CMZ32 Air Gage System VIII Appendix i CMZ32 Worksheet Use the following worksheets to organize how the various parameters are to be entered in the CMZ32 NOTE 1 The Upper Approach setting must be the same exact value entered for the UCL 2 The Lower Approach setting must be the same exact value entered for the LCL 3 These setting highlighted in RED are factory set and MUST NOT BE CHANGED 4 The setting for Target size should initially be set to zero when first starting Refer to the SV manual for setting up the CMZ32 5 Asa Rule of Thumb the Max Comp should not be set greater then the absolute value of the lower Tolerance Max Comp lt ABS TOL 6
41. hows that the nominal value of the MEAN Master Gaging Ring is 0 472008 The M1 Offse is set to 0 000020 which means that the actual value of the MEAN master Gaging Ring is 0 472028 0 472008 0 000020 Measurement Configuration Formula Limits Master Display Flags Serial Network Active Nickname _s Master Ref M1 Offset M2 Offset M3 Offset Nominal M001 YES DiameterRefa 001 0 000020 0 000000 0 000000 0 472008 M002 YES Measurement 1 a 000 0 000000 0 000000 0 000000 01000000 Figure VI 4 You ll need to make sure that the Upper Tol amp Lower Tol are set to the parts tolerance These two parameters determine the RED zone in the gage graphs Program the Upper Approach amp Lower Approach limits to the same value you set the UCL amp LCL to on the Tool Compensation screen refer to next section below The actual values set in these parameters are sent to the SV machine They determine the YELLOW amp GREEN regions of the Gage Bar Graph displayed on the SV E Gage a Single Bar Graph Sele D 439638 Figure VI 5 Example of Gage Column a Bar Graph displayed in the Run Menu 0 432599 0 432520 0 432461 0 432402 1 You must set all the values mentioned above for Diameter ref a Measurement 7 a thru Measurement 9 a and Average Diameter a 2 Apart is set to
42. ice ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 7 6 11 10 Setting up the Etamic CMZ32 Air Gage System Il Mastering i Master Window Press the lt 5 gt MASTER key to get into the CMZ32 Master Menu Use the lt F2 gt Start End function key to master ALL attached gage systems Oisjleyed Whee any Gage Codon it Foui Dy the CNS ro Need Masang NOTE This Function will only work if the Sunnen1 application is not running or if the Sunnen1 application is in a specific state in its Gage Diagnostic menu as explained in the Sunnen SV Gage operating Display Screens manual Station 1 Deme Nia A Station 2 3 Station 2 BA a LP AA PA PAA AA AA maa maang i 4 i 3 Staton J BAG sialon d F ere 3 He Tit es M After mastering the CMZ32 reports the status of the process for each gage column The status is shown in the horizontal status bar for each gage column The first column in the status bar correspond to the gage a d the second column displays the reading the CMZ32 took during mastering The third column is a bar graph representing the transducer signal at the time the mastering was done and the last column is the actual status The status can either be No Status Problems with the gage column caused the mastering to fail Failed Mastering failed MST Verified Mastering was checked and found OK gage column was not re master
43. imit was set to 0 000040 As you can see from the graph the machine honed the first 36 parts no only within tolerance but also within the Bore Size Control Limits A positive bore comp was generated by the CMZ when it detected that the average diameter of part 37 fell below the Lower Control Limit The CMZ then ignored the next part 38 the SKIP parameter because it was honed at the same time the last part 37 was gaged The 38 amp 39 part made up the next subgroup which is denoted by the next purple dot on the graph In fact in this example the gaging system only made 3 positive bore comp during the first 100 parts After measuring the 37 73 and 97 parts The 3 vertical lines on the graph below represents when the bore size comps were generated by the CMZ After each positive bore comp the machine was able to hone the next part back within the control limits The graph also shows that the stones were allowed to wear down naturally eliminating the need for any negative comps This gives the graph that Saw tooth effect mentioned above Figure VI 7 ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 22 6 11 10 Setting up the Etamic CMZ32 Air Gage System pa Setting up a Offset on Nominal Size Some machines require a means to hone at multiple sizes That is a machine may be setup in such a way that setup A has the final size at x yy mm and then have another setup B almost id
44. in what will need to be done on the CMZ to tune the gage control system It is strongly suggested that the machine first hone with all gage columns working but with all comps disabled When you first begin have the machine hone and gage the parts while you monitor the status of the comps that the CMZ makes this will be explained in more detail below As long as the overall comp control is enabled on the SV side Enable Automatic Adjustments in the System Settings menu the CMZ will continuously monitor the honed parts and generate the necessary adjustments comp to the SV machine The individual comps made by the CMZ32 can be seen and monitored on various CMZ screens i e the Diagnostic Tool Comp Monitor window and the Scatter Chart graph Refer to the Sunnen SV Gage Operating Display Screens manual for more information regarding enabling and disabling comps Note How to monitor comps Disable the individual comps in the Setup menu This will cause the machine to ignore all comps coming from the CMZ However you can see what comps are made from the CMZ if you look on the Tool Comp Monitor window ISV113A Setting up the CMZ32 Air Gaging System ver 1_000 12 6 11 10 Setting up the Etamic CMZ32 Air Gage System An example of the Diagnostic Tool Comp Monitor window is shown in the picture below BB Tool Comp Monitor M017 Average Diameter a Gaged Values Running Average Nickname Offset Target Comp V
45. ral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral Bilateral 0 0 O 0 0 O O 0 O 0 0 O o O 0 O 0 0 0 O 0 O 0 0 O Insert Delete 0 000160 0 000160 0 000160 0 000160 0 000160 0 000160 0 000160 0 000160 0 000160 0 000160 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000160 0 000120 0 000000 0 000000 0 000120 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000040 0 000120 0 000000 0 000000 0 000120 0 000000 0 000000 0 000000 0 000000 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000200 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000200 0 000160 0 000000 0 000000 0 000160 0 000000 0 000000 0 000000 0 000000 0 000060 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 O 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000060 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0 000000 0000000 0 000000 0 000000 0 000000 O 000000 0 000000 0
46. sabled You may or may not want this comp enabled for your specific application Refer to the notes above for Output Type E Measurement Tool Compensation Configuration E Tool Compensation Temperature Compensation Surface Finish Compensation Meas Nickname Output Type Output Mode UCL LCL Target Max Comp Max Cum Comp Comp Incr Stray ICB FCB SCB M001 Diameter Refa Disabled Incremental 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 0 0000000 Skip Measurement 1a Measurement 2a 1 Measurement 3 a Measurement 4 a Measurement 5 a Measurement 6 a Measurement 7 a Measurement 6 a Measurement 9a Measurement 10 a Measurement 11 a Measurement 12 a Measurement 13 a Measurement 14 a Measurement 15 a Average Diameter a Taper a Spare Spare Straightness a Disabled Disabled Spare Spare Spare Spare Figure VI 6 Measurement Tool Compensation Configuration screen Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Socket Socket Disabled Disabled Disabled Disabled Disabled Incremental Incremental Incremental __ Incremental Incremental _ Incremental Incremental _ Incremental __ Incremental _ Incremental Incremental _ Incremental Incremental _ Incremental Incremental Incremental _
47. sstihenciucesasexeneecussee 8 IHI AUTO BE MASTERING a AA AAKALA 9 Ms Part Master PAA i a a 9 ki AE 0g ki BE AA AA AA AA AA AP 10 ag Gd AA AA AA AA AA 10 Wa SILO DILA aka NALNG aaa GP pA NGA AA 11 E Taput By GA AA AA AA AA AA 11 VI TUNING THE AIR GAGE COMP CONTROL 1 eee a 12 i PUM FO QUCTION GANIYAN ANAKAN AA 12 NN Measure ment SCTCE ID AA AB AABANG E E a EEEa 14 1 Measurement Screen Setup using CMZ32 version 4 6 0 14 2 Measurement Screen Setup using CMZ32 version 4 6 16 22 15 iii Tool Compensation NERCEN 2A AGAIN NAN NAA 18 iv HCL O AA AA AA AA AA AP 22 ke Na NO OC I UI SS AA AA 22 2 Setting Up a Offset on Nominal SIZE sssrinin aanas N NEEE EEE AE EST eaa 23 VIL are ces ce eee eee AA AD 25 Cain dl ai Pd AA CMA setup file sapipi AA AA AA AA 25 Le Accessing from the System MCU ion cieonsazonccavenscisaaidasanweswencsutlaaguensanensnnesioasedutsonutdaseenssendiednanseuvagneorssiesanaaneannnss 25 2 Using the Top Menu CA AA 25 3 Using the lt F6 gt Select Project key nnooooosoooereeeeererrrererrersrressseessssesssssnssssssssssssssseosesseeeseeeeseerererrerrrereo 25 ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 v 06 11 10 Setting up the Etamic CMZ32 Air Gage System NOTE ISV113A Setting up the CMZ32 Air Gaging System ver 1_000 vi 06 11 10 i Setting up the Etamic CMZ32 Air Gage System Managing Project Files A project file much like the setup files used on th
48. st the comp value calculated by the CMZ before it is sent to the SV machine This is normally changed when the operator feels that the feed system or stroker in regards to Taper amp Straightness comps needs a little more or a little less adjustment then what the CMZ would have generated if this value is set to 1 NOTE This value is actually divided into the compensation value Comp Value generated by the CMZ before being sent out to the SV machine Such that the actual output comp Output Value from the CMZ to the SV is Output Value Comp Value Comp Inc Refer to the lt F9 gt Compensation screen in the Project Menu shown below and also the bottom of the Tool Comp Monitor window shown above Default settings 1 Average Diameter a gt This should be set to 1 0 Such that the Output Value 1 Comp Value This means that the actual Bore Size Comp from the CMZ to the SV machine will track the error in the bore size but in the opposite direction of the error That is the Feed Axis will expand a little more the next cycle based from the last final diameter when the CMZ determines that the bore is getting too small It will exoand a less amount then the last final diameter when the CMZ determines that the bore is getting too big 2 Tapera gt This should be set to 0 001 Such that the Output Value 1000 Comp Value
49. tem Examples of changing the default setting 1 Average Diameter a gt If the operator wanted to double the Bore Size comp value sent to the SV then the Comp Inc parameter would be set to 0 5 Output Value Comp Value Comp Inc Comp Value 0 5 Comp Value 2 2 Taper a gt If the operator wanted the Stroke Position to change by 0 002 for every 0 000001 of error in the bore s taper then the Comp Inc parameter would be set to 0 0005 Output Value Comp Value Comp Inc Comp Value 0 0005 Comp Value 2000 3 Straightness a gt If the operator wanted the Stroke Length to change by 0 0005 for every 0 000001 of error in the bore s straightness then the Comp Inc parameter would be set to 0 002 Output Value Comp Value Comp Inc Comp Value 0 002 Comp Value 500 The Stray parameter This is the maximum amount between two com values sent to the SV machine That is if the CMZ determines that the latest comp that it has generated is above this amount from the last comp given then it will abort the comp and not send it to the SV machine The CMZ uses this feature to ignore bogus or Stray readings like what may occur if a finished part was sent back through the SV machine The default on this may be 0 001 however every application is different so you may find that this settings n
50. the indicator on the bar graph should be GREEN and it should be near the middle of the graph Status Wednesday Ar F1 Help F2 Input Devices k F7 Spare F amp Spare O O m the inputs of the TPE 99 Example of the raw data fro COO Omi mi Dra aata f icii A lii i Ec vv ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 11 6 11 10 Setting up the Etamic CMZ32 Air Gage System VI Tuning the Air Gage Comp Control i Introduction This section explains how to program specific Tool Comp parameters in the CMZ32 These parameters affect how the CMZ32 controls the SV machine Describing and explaining each and every parameter is beyond the scope of this manual Refer to the CMZ help file for more details use the lt F1 gt key in any of the CMZ32 menus Some parameters may require adjustments or tuning Others should be set to one specific value and not changed The goal is to adjust the parameters on the CMZ side so the correct comps are generated and sent to the SV machine Both types are described in the following section NOTE Every application is going to be different so some of the CMZ parameters having to do with the comps will most likely have to be tweaked NOTE Refer to the Etamic lt F1 gt HELP feature on any question regarding any of the CMZ32 menus parameters functions etc The following is a brief discussion amp pointers to help expla
51. tion Project Window above In the examples we have been using throughout this document our project folder has been Eli ih Gage Projects such that the default file iE 5h i if Gage Projeds 3 H oa Tana Deeiacke cs name of the backup archive is gt Gage Projects zip Select backup destination Figure I 10 Backup browser The user will get a warning message if a file already exists with this same name o ci Program Files Sunnen Products SUNNEM1 Gage Backup Gage Projects ZIP exists 5g Do you want to oyerwrike ik Figure I 11 Overwrite Warning message Press the YES button to proceed and archive using the same file name NOTE You must rename the existing file if you wish not to over write the current archive The following message appears if the system successfully archived the project Projects Ll j Project Groups successfully backed up to C Program Files Sunnen Products SUNNEN1 Gage Backup Gage Projects ZIP Figure I 12 Backup complete message ISV113A Setting up the CMZ32 Air Gaging System ver 1 000 6 6 11 10 Setting up the Etamic CMZ32 Air Gage System Restore Button A project can be retrieved using the Restore button A browser window will appear after pressing the Restore button CMZ Project File Archives Look in E Gage Backup to E Cl cage Projects ZIF File name Files of lype CMZ Project File Archives zip x Cancel
52. ttp www sunnen com or e mail sunnen sunnen com NOTE 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 accessoriespreviously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy ofinformation arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when hanaling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges 3 Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work A Put on your wrist strap or foot grounding devices B Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of static charges C Make sure that your work surface is clean and clear of unnecessary materials particularly common plastics D Anti static bubble wrap has b
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