Colibri Sander BOH 80 2.1 D 60 User's Manual
Contents
1. t o Brushes Press Vs Length 1 2 Pe bar 0 8 0 6 0 4 0 2 0 o E N o 2b Pc 0 2 e 06 bar Pc Brushes Pressure mm Lc Brushes Length Brushes Wear Vs Length 19 Wy Mm 17 15 6 11 16 21 26 1 X mm We 3 45 e 06x 4 5 Mm W Brushes Wear mm X Brushes Length Brushes Wear Vs Pressure 0 02 04 06 0 8 1 1 2 Pc bar We 17 24 P 1 5 Mm W Brushes Wear bar Pc Brushes Pressure Brushes Lifetime Vs Length 2800 Ly hr 2400 2000 1600 1200 800 10 14 18 22 1000 d a 3 45 e 06x 4 5 L 2045 45 In b 4230 57 mm b Final Length mm a Primery Length mm X Brushes Length hr L Brushes Life Time Condition Initial Pressure 0 9bar 28mm 20 Raw Materials Data The Spindle is made from the following materials Stainless steel SAE 303 SAE 2316 Brass SAE 40 Copper Polymers Delerin SAE303 SAE2316 BRASSSAE40 COPPER Cu 0 15 034 Cu 066 09 8 10 Ni O53 Hardness HB 0 296 proof stress N mm2 0 196 proof stress N mm2 Tensile strength N mm2 500 750 Elongation L 5d min 35 Core strength N mm2 900 1100 Modulus o2. 45 55 0 01 um lower then 15 C lower then 0 1 ppm MO bar 72 5 psi 1 3 5 lpm 20 25 oC within 1 oC 10 35 um 10 35 um 1 um 1 um 0 3 um 0 3 um 14 N um N um 60 N 100 N A um 6 7 Kg 6 5E 5 Kg m2 70 db a 1 0 03 gmm corresponding bar 1 25 m 199 m 8 15 m 2500 hr 38 14 2 84 28 8 54 Es 0 055 F 0 043 S 0 417 3 6 S 16 487 Sa 10 06 L 71 54 L 91 84 Es Es Sr Sr Sa Sa Lr Lr La La FI FI SI SI MECHANICAL COEFFICIENT Air Flow Coefficient 43 e 290 VP Vsp 60 Krpm Water Flow Coefficient 0 9 1 4 In Pw Pw 4 bar Still Air Cooling Efficiency Water Flow Cooling Still Air Cooling 60 Krpm 280 e 0017 Vsp Air Flow Cooling Efficiency Water Flow Cooling Air Flow Cooling 60Krpm 82 3 9 0007 Vsp Thermal Behavior Coefficient T T J Tm 100 Shaft Extension Coefficient 0 236 Tm 5 426 1 Q Tm 100 c Radial Stiffness Coefficient 13 642 In Ps 7 956 Ps 6 Axial Stiffness Coefficient 6 425 In Ps 1 454 Ps 6 Radial Load Coefficient 64 39 In Ps 43 832 Ps 6 Axial Load Coefficient 67 664 In Ps 29 4 Ps 6 Mechanical Friction Coefficient 6 5 10 3 Vsp2 1 V 60 Krpm Stiffness amp Load Coefficient 7 10 4 4 Sr Sa 3 Lr La
3. Flow LPM a 0 9 B 1 4 Fim 0 9 1 4 In Pw 05 1 15 2 25 3 35 4 45 5 Pw bar 4 Pw bar Water Pressure FIh LPH Water Flow in L H FIm LPM Water Flow in 3 CONDITION 1 Water Temperature 18 C 20 2 Room Temperature 22 C 24 C 3 No Rotation 1 0 Fim LPM 0 05 1 15 2 25 3 35 4 45 5 Pw bar 44 Motors Temperature Vs Rotation Speed amp Cooling System 150 9 100 E 50 0 0 10 20 30 40 50 60 7 0 Temp C Motor temperature Vsp Krpm Speed rotation CONDITION 1 General 2 Still air cooling 4 Water flow cooling No tool holder wheel mount Including sensor 3 Air flow cooling Air Flow 40 LPM Water Temperature 12 Water Pressure 5 bar Ambient Temperature 22 24 Air Pressure 5 bar Cooling Water Flow 3 2 LPM Temp Measurement termistor Motor Temperature Vs Water Pressure The Spindle Thermal Behavior 100 89 S o amp 80 60 e 50 60 E 40 7 40 30 20 9 m 29 is s 03 dd 0 10 20 40 50 60 70 80 90 VSP Krpm Tm C Ts 15 92 e 00191 P ibar P 3bar P3 5bar Tf 215 487 e 0 018 1 Tz22 Ppy P e 15 Tr 17 58 e 9015 Tm Vsp Krpm Speed rotation Tm C Motor temperature Pw
4. 28 THERMISTOR Thermistor is the generic name given to thermally sensitive resistors Negative temperature coefficient thermistor is generally called as thermistor Thermistor is a semi conducting ceramic resistor produced by sintering the materials at high temperature and made mainly from metal oxide Depending on the manufacturing method and the structure there are many shapes and characteristics for various purposes such as temperature measurement temperature compensation etc Temp2 C Rst2 KO 2 40 Temp2 95 512 23 47 In Rst Temp1 Rst2 KO 0 70 Temp1 110 139 28 929 In Rst Rst2 Temp 10 80 Rst2 58 189 0276 Rst1 KO Temp 0 180 Rst1 48 881 Rst Thermistor resistant as function at temperature Temp Electric motor temperature 203GT 1 TEMPERATURE VS RESISTANCE CHA s soe uro ow Resistance 20kQ at 29 C SH Resistance Tolerance 3 B Value 4282K at 25 85 B Value Tolerance 25 Temp C Rmax ko Rst Rmin ko Tolerance 50 2144 1901 1683 1 6 41 6 40 1011 909 0 816 9 1 5 1 5 30 496 9 453 2 413 0 14 14 20 256 1 236 6 218 4 1 3 1 3 10 137 2 28 3 119 9 1 2 1 2 0 76 43 72 32 68 37 1 0 1 1 10 44 16 42 24 40 36 0 9 40 9 20 26 36 25 47 24 58 0 7 40 8 30 16 37 5 82 15 27 0 8 0 8 40 10 55 0 10 9 663 1 0 1 1 50 6 971 6 620 6 280 1 3 1 3 60 4 717 4 444 4 182 1 6 1 6 70 3
5. Volt watt Hp Nm rpm Amp Amp 76 PC PC 11 Brushless DC Motor Maximum Continuous Stall Torque Tc is the amount of torque produce at zero speed which results in a 100 C rise in temperature Generally the highest operation temperature that should be allowed is 150 C and is a combination of the ambient temperature and the temperature rise for a given operating condition Maximum rated Torque Tr is the amount of torque that the motor can produce without demagnetizing the rotor The torque is only available for short durations Also it may not be possible to produce the Maximum rater torque because of limitations of voltage and current see peak torque Motor Constant Ky is the rations of the peak torque to the square root of the input power at stall which 25 C ambient temperature The ratio is useful during the initial selection of a motor since it indicated the ability of the motor to convert electrical power into torque Te Peak Torque VPp Peal Input Power Or Ky Torque Constant Ry Terminal Resistance Electrical Time Constant tr is the ration of inductance Ly IN henries to the resistance Ry IN ohms This is the inductance and resistance as measured across any two phases in a delta or wye configuration Lu Ru Mechanical Time Constant tm is the time required to reach 62 3 of the motor maximum speed after the application of constant DC voltage trough the commutation
6. 3 6 Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed person under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations 4 Safety instructions governing standard operation 4 1 4 2 4 3 4 4 4 5 Avoid any operational mode that might be prejudicial to safety Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state Operate the machine only if all protective and safety oriented devices such as removable safety devices emergency shut off equipment sound proofing elements and exhausts are in place and fully functional Check the machine at least once per working shift for obvious damaged and defects Report any changes including changes in the machine s working behavior to the competent person immediately If necessary stop the machine immediately and lock it In the event of malfunction stop the machine immediately and lock it Have any defects rectified immediately During start up and shutdown procedures always watch the indicators in accordance with the operating instructions Before starting up or setting the machine in motion make sure
7. For each winding specified the product of peak current Ip and nominal torque sensitivity kr gives Tp unless the maximum rated torque Tg is reached Peak Current lp is the rated current used to obtain the nominal peak torque from the motor with nominal torque sensitivity lp is generally the design voltage divided by the terminal resistance Ry Torque Sensitivity is the ratio of the developed torque to the applied current for a specific winding is related to the BEMF constant Kg No load Speed Siy is the theoretical no load speed of the motor with the design voltage applied BEMF Constant is the ration of voltage generated in the winding to the speed of the rotor is proportional to Kr Terminal Resistance Ry is the winding resistance measured between any two leads of the winding in either a delta or wye configuration at 25 Terminal Inductance Ly is the winding inductance measured between any two leads of the winding in either a delta or wye configuration at 25 12 Pw W 1 sensors Higher motor temperatures can easily be accommodated with different materials 80 60 40 20 0 Torque amp Power Vs Rotation Speed 200 800 400 0 20 40 60 80 Vsp Krpm Vsp Krpm Rotation Speed T Nm Spindle Torque Pw w Nominal power 0 05 0 1 0 20 40 60 80 Vsp krpm Conditions 1 Temp Rise less then
8. Motor Temperature Vs Water Pressure The Spindle Thermal Behavior Shaft Extension Vs Thermistor Resistance Shaft Extension Vs Motor Temp Radial Stiffness Vs Air Pressure Axial Stiffness Vs Air Pressure Radial Load Capacity Vs Air Pressure Axial Load Capacity Vs Air Pressure No Load Deceleration Mechanical Friction Losses Voltage Constant BEMF Current Vs Rotation Speed Torque Vs Current Power Vs Current amp Rotation Speed Vibration Amplitude Vs Rotation Speed Vibration Speed Vs Rotation Speed w Noise Level a b C d e ff Raw Materials Data Spindle Modes Spindle Balancing Electrical System Electrical Connections Thermistor 203GT 1 Adapter for Power Cable and Signal Cable Remote Control Description of a Spindle Testing Cooling Water Sealing amp Flow Test Circuit Flow Test Circuit Sensor Pressure Tuning Motor temperature Vs Rotation Speed amp Water Temperature Torque Vs Air Pressure Load Vs Axis Length amp Air Pressure Torque Vs Air Pressure 8 b Load Vs Length amp Air Pressure Brushes Pressure Vs Length d Brushes Wear Vs Pressure e Brushes Wear Vs Length Brushes Lifetime Vs Length 2T Failure Cause Prevention 28 Appendix FUNDAMENTAL SAFETY INSTRUCTIONS 1 Basic operation and designated use of the machine 1 1 1 2 1 3 The machine has been built in accordance with state of the art standar
9. 100 C 2 Continuous operation at a load point 3 The curves assume a 25 ambient environment 4 No external loads Continuous Duty Speed Torque Curves for 100 C Temperature Rise The continuous duty speed torque curves provide a guide to the operational capability of the motors Continuous operation at a load point on or under the curve limits the temperature rise of the motor to 100 C Although the duration of acceleration or deceleration periods should be checked the RMS speed and torque combination should also lie on or under the continuous duty curve The curves assume a 25 C ambient environment Higher ambient temperatures will generally decrease the continuous duty capability of a motor The continuous duty capability of the motor may be increased However for most application the practical maximum motor temperature is 150 C with Hall effect EMOTEQ U K Ltd Final Velocity Vs Torque Acceleration Time amp External Inertia _ 4 2 V Krom J1 5 10 kg m 9 12 15 18 21 24 27 t sec J3 25 10 0 03 06 0 9 12 1 5 18 21 24 t Rec t sec Decelerations time V Krpm Speed T Nm Torque J kg m External Inertia 80 60 40 20 0 J2 25 10 kg m V Krpm 0 05 1 15 2 25 3 35 4 1 5 7 2 v Krom 4 5 10 kg m 0 03 06 09
10. 262 3 050 2 849 1 9 1 9 80 2 303 2 138 1 982 2 2 2 2 90 1 656 1 527 1 407 2 5 2 6 00 1 212 1 111 1 016 2 8 2 9 10 0 9013 0 8209 0 7469 3 2 3 3 20 0 6802 0 6160 0 5573 3 6 3 7 30 0 5203 0 4686 0 4217 3 9 4 0 40 0 4033 0 3613 0 3234 4 3 4 5 50 0 3163 0 2820 0 2511 4 7 4 9 60 0 2509 0 2226 0 1973 5 2 5 3 70 0 2011 0 1777 0 1568 5 6 5 8 80 0 1629 0 1432 0 1258 6 1 6 3 90 0 1331 0 1166 0 1020 6 5 6 8 200 0 1097 0 09573 0 08345 7 0 7 3 210 0 09122 0 07929 0 06885 1 5 7 8 220 0 07644 0 06620 0 05728 81 48 4 230 0 06453 0 05570 0 04803 8 6 49 0 240 0 05489 0 04722 0 04058 9 2 49 6 250 0 04700 0 04030 0 03452 9 8 410 2 29 ADAPTOR FOR POWER CABLE AND SIGNAL CABLE CABLE MOUNTING RS 403 904 f i CONNECTOR O TYPE 15 PIN MALE 224 c 6 18 9101112131415 Bode A x FH d 00090909909 V WV JY bl X DRIVER SIDE E o N 4 X X b 4 SPINDLE SIUE N 124578101 CONNECTOR AS 649 922 CONNECTOR O TYPE 15 PIN FEMALE 4 G AX o o0 0 REMOTE CONTROL 678921345 CONNECTOR O TYPE 9 PIN FEMALE TES 25 way Lontrol of the driver SPINDLE S o l o L 1 zZ IL Ls a Ly e CE Uh Z ul p 2 C gt LJ id 3 gt J x ce c3 CE CI CE t t 1 CA 4
11. 55 60 Vsp Krpm 17 Noise Level db 69 2 68 2 67 66 65 64 63 200 250 300 350 400 Distance cm Lp 100 3 6 7 In D 0 44 e 0993 PIn Vsp Vsp rpm Kotation Speed N dB Noise Level D cm Length from Spindle Motor Temperature Vs Rotation Speed amp Water Temperature 120 100 80 60 40 20 Tw 0 457 28 1 0 82 T e 915 v C Tm Motor Temperature C Tw Water Temperature Krpm Vsp Rotation speed Vsp 760 Vsp 50 Vsp 40 Vsp 30 Vsp 20 Vsp 10 Vsp 80 Vsp 60 Vsp 40 Vsp 20 18 Moment Vs Air Pressure 9 8 7 6 5 4 3 2 1 0 0 2 4 6 8 bar 10 Nm M Axial Moment bar Ps Spindle Air Presuure Load Vs Axis Length amp Air Press zZ d N L4 Axial Load bar Ps Spindle Air Press mm a Length From the Axies Moment Vs Air Pressure 1 6 1 4 M Nm 1 2 1 0 8 0 6 0 4 0 2 0 2 4 M In Ps 0 7 Nm M Radial Moment bar Ps Spindle Air Press 8 Pg bar Ps 7 130 Ps 6 a mm Ps 5 Load Vs Length amp Air Pressure 21 00 E 75 50 25 0 15 45 75 105 135 a mm Ps z5 Ps 6 lt 7 L 100 10 In Ps 7 a N L Radial Load bar Ps Spindle Air Press mm a Length Form Spindle s End
12. following order sensor signal power 1 Testing Seal Of Coolant System Using air manometer at zero rpm measure that air pressure is declining as a time function 2 Testing Engine Coolant Flow Testing coolant flow to engine lpm with air manometer At zero rpm 3 Air Flow For Bearing Testing airflow to spindle lpm with air flow meter At zero rpm 4 Air Flow In Rear Ventilation Testing airflow in rear ventilation Ipm with air flow meter At zero rpm 5 Engine Coils Resistance Testing engine coil resistance At zero rpm 6 Thermistor Resistance Testing Thermistor resistance At zero rpm 7 Deceleration Testing deceleration time from 40Krpm to 10Krpm 8 Sensors Checking Air Pressure Testing air pressure with an air manometer At zero rpm 9 Sensors Testing Resistance And Sensor Disconnection Testing resistance of brush to brush At zero rpm 10 Vibrations Analyze vibrations instrument 11 Noises Testing spindle noise with a noise meter 12 Current Testing engine current in 3 phases Will show a chart of current Vs rotation speed 13 Voltage Testing voltage at engine entrance in 3 phases 14 Thermal Control Of Spindle Reading the temperature in 3 points on the spindle including motor thermistor The thermistor is a resistor that changes according to temperature change 15 Continues Running Continuous running at maximum speed allowed for 48 hours during which parameters such as speed current voltage
13. of a rigid rotor and has a tendency to bend or distort due to centrifugal and unbalance forces High speed flexible shaft balance correction low speed balance correction low speed rotating centerline mass centreline High speed flexible shaft effect at high speed initial unbalance Correcting Unbalance In Situ Requirements In situ balancing is best Unbalance is primary problem In situ balancing is not always Access to add remove weight possible Ability to start stop machine at will Balance Tolerances ISO 1940 1 has also been adopted by Manufacturers recommendation BS 6861 Part 1 British Standards International standards ISO 1940 1 ANSI S 2 19 1975 American National Standards Institute VDI 2060 German Standards 24 ISO Rotor Classifications GO 4 Spindles precision grinders Gyroscopes G1 Small special purpose electrical rotors drives G2 5 Gas steam turbines Turbo compressors machine tool drives Small and special purpose electric rotors G6 3 Fans Pump impellers general electric rotos centrifuge drums general machinery parts Balance Tolerances ISO 1940 1 MCD e m x 1000 9549 x G 2 60 Where G Balance quality grade n Max rotor seryice speed Uper gmm e per W Uper gmm 9549 yw n Where G Balance quality grade W Weight of Rotor in kilograms n Max rotor service speed in RPM Symmetrical Rotors Correction Plan
14. system or equipment may only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such electrician and in accordance with the applicable electrical engineering rules 6 3 If provided for in the regulations the power supply to parts of machine on which inspection maintenance and repair work has to be carried out must be cut off Before starting any work check the de energized parts for the presents of power and ground or short circuit in addition to insulating adjacent live parts and elements 6 4 The electrical equipment of machine is to be inspected and checked at regular intervals Defects such as loose connectors or scorched cable must be rectified immediately 6 5 Necessary work on live parts and elements must be carried out only in the presence of a second whom can cut off the power supply in case of danger by actuating the emergency shut off or main power switch Secure the working area with a red and white safety tape and a warning sign Use insulated tools only 6 6 Check all lines hose and screwed connections regularly for leaks and obvious damage Repair damage immediately 6 7 Depress all system sections and pressure pipes to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work 6 8 Compressed air lines must be laid and fitted promptly Ensure the no connections are interchanged The fittings length
15. temperature etc will be displayed and monitored in large time intervals according to need The test will be based on a sample 31 COOLING WATER SEALING amp FLOW TEST CIRCUIT C electric valve E air flow meter water inlet m F pressure meter AIA shuttle Jes D electric valve Iv water outlet in x di out O J valve N 7 7 e air inlet A electric valve FLOW TEST CIRCUIT H 1 manual pressure spindle air n regulator pressure main pressure G electric valve gt J SPINDLE rl e A j NO ns SENSOR PRESSURE TUNING vel air outlet B electric valve outlet air flow ALK lh ZT air outlet 32 FAILURE CAUSE PREVENTION Failure Cause Prevention The shaft doesn t There is dirt or oil in Check the air pressure and air rotate freely bearing gap cleaner according to spec Low air pressure Air bearings are damaged after crash conditions Air pressure must be 5 Bar Return the spindle to the manufacturer for repair The spindle getting warm Low water flow High temperature of income coolant water Friction in the bearings Motor failure Driver failure Machine control failure Water flow 3 5 lpm Water temperature 25C max Return the spindle
16. to the manufacturer for repair Return the spindle to the manufacturer for repair Return the driver to the manufacturer for repair Return the control unit to the manufacturer for repair Spindle shaft rotated too slowly with the same adjustment of speed control unit Motor failure Friction in the bearings Control unit failure Driver failure Return the spindle to the manufacturer for repair Return the spindle to the manufacturer for repair Return the control unit to the manufacturer for repair Return the driver to the manufacturer for repair High vibration level The shaft s balancing has changed Balance of wheel mount was changed There is dirt on air cover area of the shaft Check that spindle shaft is not damaged Change the wheel mount Clean the air cover area of the shaft from dirt The shaft rotates freely but the spindle does not turn vibrates or turns too quickly Motor failure Electrical connections problem see above Return the spindle to the manufacturer Check electrical connections The shaft rotates freely but after starting it vibrates Incorrectly connected phases Connect phases according to diagram Spindle shaft s speed is sharply increased immediately after starting and in this case it s impossible to adjust it Incorrectly connected phases Connect phases according to diagram The shaft rotates freely but the spindle does no
17. 12 15 18 21 24 27 3 t sec 1 2 13 Peak Torque 2 0 302 N m Continuous Stall Torque 3 0 192 N m RMS Torque 13 Air Flow Vs Air Pressure 50 Inlet Air Flow 1 21 864 5 40 22 bar Inlet Air Pressure 30 Fai LPM Inlet Air Flow zd 20 Sensor Ventilation Air Flow 0 241 P jn 8 471 0 Pai bar Inlet Air Pressure 0 0 5 1 1 5 2 25 3 3 5 4 4 5 5 Fbv LPM Air Flow in Sensor Ventilation Pai bar Outlet Air Flow CONDITION 0 198 PAI 1 Ambient Temperature 22 C 24 C Fyo 5 75 2 No Rotation 3 Inlet pipe diameter D 4 mm bar Inlet Air Pressure 4 Inlet pipe length L 1500 mm Fao LPM Air Flow in spindle exit 5 No tool holder 6 Including brushes CONDITION 7 Air outlet ventilated 1 Pipe diameter at checking point D 4 mm 8 Flowting Point 2 bar 2 Pipe length at checking point L 1000 mm Inlet Air Flow Vs Rotation Speed 43 42 0 Fu 43 e 0 0013 5 Vsp Krpm Rotation Speed x Fai LPM Inlet Air Flow 139 38 CONDITION 37 1 Ambient Temperature 22 C 24 5 15 25 35 45 55 65 75 2 Ambient Humidity 6096 3 Including sensor brushes Vsp Krpm 4 Entry pressure Pal 5 bar Water Flow Vs Water Pressure 240 Flowzo p In Pressure Flow LPH o 56 p 83 Flh 56 83 In Pw co eo Fih LPH S o
18. 127 braal Tol 4272 4 0238 1304 Fax 4972 4 9 58 0061 E mail s www colibrispind los com
19. COLIBRI AIR BEARING SPINDLES THE ADVANTAGE OF FLOATING Manual Book BOH 80 2 1 D 60 High stability Contamination free process Revolutionary compact design High speed rotation COLIBRI The miniature Colibri hummingbird hovers motionless in the alr its brilliant wings beating with the highest frequency of any type of bird Colibri Spindles s patent pending technology floats a high speed shaft in an exceptionally compact air bearing to provide unsurpassed spindle performance MFLOATING MHIGH SPEED BCOMPACT BSMART THE ADVANTAGE OF FLOATING I Q Charactersitics In most respects aerostatic bearings are ideally suited for use in high speed machines Their low friction provides high mechanical efficiency and minimizes bearing heating problems They are quiet and smooth running and do not add to sound and vibration levels of the machine in the way that high speed ball bearing do Q Applications One of the most important fields of application of aerostatic bearings is undoubtedly on machine tools where the range of machine tool application is very wide Q Advantages Almost all of the benefits result from three properties of aerostatic bearings low friction precise axis definition and the absence of wear In comparison with spindles with ball or roller bearings the lower level of vibration of aerostatic bearings is an important advantage This is particularly true in relation to the production of g
20. E T 23 12 24 13 25 49 Q Q Q 0 Q T ese ug ML 228 Hanc 2868 ee aa S UM aro C C le EDT 410K dy GEB Eg i e ES es m X A F a is u Nh T cil DIGI TA aes E VULTMETER REMOTE CONTROL LaL 30 DESCRIPTION OF A SPINDLE TESTING Introduction After connecting the spindle to the computerized testing system air electricity control etc it will automatically perform a series of tests record the results send notice when the test fails and stop in case of danger At the end of each test a detailed report is received including diagrams e You can change the numeric definitions for the operating process e Results recording will be continuous and written in data format In case of a failure data will be recorded for the propose of repairing the defects faults As well as reference and proposals for improving e When a test will fail a window will open with the name of the test blinking A test report will be produced at the end of the test e On the screen there will be a display of the test progress a graphic display and a analogy of digital display Connecting The Spindle To The Testing System Identify the spindle serial number bar code etc Connect inlet and outlet water tubes do the same with air tube Connect ventilation tube Connect pressure measuring sensors tube rather then a screw Connect cables in the
21. SI 0 417 10 Size Constants Maximum Rated Torque Maximum Continuous Stall Torque Temp Rise 100 Motor Constant Electrical Time Constant Mechanical Time Constant Angular Acceleration theoretical Thermal Resistance Maximum Cogging Torque Viscous Damping Hysteresis Drag Torque Rotor Inertia Frameless No of Poles Winding Constants Design Voltage Peak Torque Torque Sensitivity Peak Current No Load Speed Voltage Constant Terminal Resistance Terminal Inductance RMS Torque Performance Performance 25 C D esign Voltage Continuous Power Output Torque Speed Iphases dc link Efficiency Temperature Rise Ambient temperature Cooling Mechanical Lamination Material No of phases Phase Connection Parallel path Turns Coil Wire Gage AWG Lead wire Gage AWG 4 r2 2 13 Tc 0 30 Km 0 03 0 46 Tm 800000 TPR 20 65 Tf 9 180E 03 Fi 2 1 038bE 07 Th 2 481E 04 Jm 2 2 596E 06 P 6 Vp 150 Tp 2 13 Kt 0 02 Ip 120 Snl 8500 Kb 0 02 Rm 0 36 bm 0 17 Vp 150 Power 1200 1 6 0 2 60000 12 4 8 75 92 70 25 Water cooling C49 3 DELTA 21 27 24 ELECTRICAL MOTOR SPECIFICATION Nm Nm Nm Aw msec msec rad sec C watt Nm Nm rpm Nm Kg m Volt Nm Nm Amp Amp rad sec v rad sec Ohm mH
22. U per 0 084 gmm TOTAL Permissible Unbalance Uper at C of 0 084 gmm TOTAL For Symmetrical Rotor 0 042 gmm Per Plane But this is NOT a Symmetrical Rotor Left plane radius 15mm Right plane radius 9 5 Permissible Unbalance Uper 0 084 gmm TOTAL Uper Left 0 084 x 65 0 055 gmm 0 0036 g 15 mm Uper Right 0 084 x 35 0 03 0 003 9 9 5 mm 26 ELECTRICAL SYSTEM Electricity Electrical flow for frequency converter Warranty will be granted only when using the original driver that we supplied The electricity connection is done with fittings Connect the cables according to their marks Power Cable marked power with a D type 15 pin plug Signal Cable marked signal with D type 9 pin plug plastic socket with 2 pins for thermistor Brushes cable marked brushes with a mini UHP inlet for connecting the spindle and 2 plastic pins for connecting the sensors The spindle has a unique sensor system built in using 2 brushes attached to the shaft by air pressure The coals wear out with time and their life span shortens The purpose of the brushes is to transfer the electricity from the control system through the shaft through the machine base back to the controller This system is able to perform calibration of the height shaft mili ict tra 2GvikcETY een 21 ELECTRICAL CONNECTIONS
23. and quality of the hoses must comply with the technical requirements 7 Mobile machinery and equipment 7 1 Cut off the external power supply of the machine even if only minor changes of place are envisage Properly reconnect the machine to the supply mains before restarting 7 2 For restarting process only in accordance with the operating instructions WARRANTY NOTICE We warrantee this spindle to be free of material and workshop defects This warrantee is conditional upon proper use in the applications of which this spindle is designed to Warrantee is void if damaged caused due to improper use installation negligence accident inadequate maintenance to the spindle or the machine in which it is installed This warrant is also void if customer did not follow the complete manual and caused damage In any case of damage failure analysis will be perform by Plasel to determine the cause of the failure Warrant is void if damaged caused by inadequate machine maintenance or improper use ex Leaky valves Z axis leakage wear contained air supply lower higher air presser inadequate vacuum using the spindle to work on material that is too hard drilling into anything other then the right material ona d I ATTENTION DAILY CHECK BEFORE OPERATING THE SPINDLE For first time installation look at Installing the spindle paragraph Check air supply 5 6 bar Check water supply 4 5 bar Check water supply 4 5 bar Check ventilati
24. ation Speed 30 Vf Volt Voltage between two phases 0 0 10 20 30 40 50 60 70 Vsp Krpm Current Vs Rotation Speed 3 E 1 5 Amp Current Phases 1 Vsp Krpm Rotation Speed 0 5 CONDITION 0 1 Driver BDH Hathaway 2 No external load 0 10 20 30 40 50 60 70 3 Including Sensor Brushes 4 No tool holder 5 Humidity 5096 6 Ambient temperature 22 24 C Torque Vs Current Vsp Krpm 1 5 1 T 0 018 I E lt 0 5 Kt 0 018 Nm Amp 0 T Nm Spindle Torque I Amp Current m 0 2 6 8 10 Amp 12 Kt Nm Amp lorque Sensitivity ower Vs Curren otation 5pee 1500 P 18 I Vsp 1200 Amp Current 900 Vsp Krpm Rotation Speed Pw W Power 600 V21Krpm V 22Krpm V 3Krpm 300 V 5Krpm 6 0 0 1 2 3 4 7 Amp ibration Amplitude Vs Rotation Spee 0 25 0 2 Var 0 056 In V 0 03 0 15 TR A 2d Vat um Vibration Amplitude Vsp Krpm Rotation Speed 0 05 0 CONDITION 1 Peek to Peek 0 5 10 15 20 25 30 35 40 45 50 55 60 Vsp Krpm Vibration Speed Vs Rotation Speed 1 2 2 E Vgg7 7 5 10 EM 4 5 10 Vsp 17 5 10 0 8 Vsp 30 Krpm E Vs 70 15 0 029 In V Im 0 4 Vsp 30 Krpm gt Vsf mm s Vibration Speed 0 Vsp Krpm Rotation Speed 0 5 10 15 20 25 30 35 40 45 50
25. bar Water Pressure Tf C Temperature in the front area Tm C Motor temperature Temperature the middle area Tr C Temperature in the rear area CONDITION 1 Driver BDH Hathaway CONDITION 2 Ambient Temperature 22 24 3 Ambient Humidity 6096 4 Temp Measurement termistor SEMITEC 203GT 1 1 No cooling 2 Ambient Temperature 22 24 3 Ambient Humidity 6096 4 Air Pressure in entrance 5 bar Shaft Extension Vs Thermistor Resistance Shaft Extension Vs Motor Temp 12 8 9 6 M x u m 4 NX 3 2 0 0 0 2 4 6 8 10 12 14 16 0 10 20 30 40 50 60 CONDITION R 9 Tn E 1 Ambient Temperature 22 24 C 2 End shaft extension 3 Reaction time for temperature stabilization AL 0 236 Tm 5 426 AL 16 442 e 0 14 Rmotor in shaft 5 min AL u Shaft extension R Q Termistor resistance Motor temperature 15 Radial Stiffness Vs Air Pressure 20 Sr 13 642 In Ps 7 956 Theoretical curves Sr N u se 8 4 Ps bar Spindle air pressure 0 Sr N u Radial Stittness CONDITION 0 1 2 3 4 5 6 d 8 1 No Rotation Ps bar 2 Distance Form The End of The Spindle 18mm Axial Stiffness Vs Air Pressure 15 40 Sa 6 425 In Ps 1 454 S Theoretical curves B 5 P
26. ds and recognized safety rules Nevertheless its use may constitute a risk to life and limb of the user and of the third parties or cause damage to the machine and to other material property The machine must only be used in technically perfect conditions in accordance with its designated use and the instructions set out in the operation manual Only safety conscious persons who are fully aware of the risks involved in operation the machine should operate it Any functional disorders especially those affecting the safety the safety of the machine should therefore be rectified immediately The machine is designed exclusively for drilling grinding and milling operations Using the machine for purposes other than those mentioned above is considered contrary to its designated use The manufacturer cannot be held liable for any damage resulting from such use The risk of such misuse lies entirely with the user Operating the machine within the limits of its designated use also involves observing the instructors set out in the operation manual and complying with the inspection and maintenance directives 2 Organizational measures 2 1 2 2 2 3 24 2 5 2 6 2 7 2 9 2 10 2 11 2 12 2 13 2 14 2 15 2 16 2 17 The operating instructions must always be at hand at the place of use of the machine In addition to the operating instructors observe and instruct the user in all other generally applicable legal and other mandat
27. e L Correction Plane R h1 hr d Rules for Symmetrical Rotors 1 Correction Planes are between bearings 2 Distance b is greater than 1 3 d 3 Correction plane are equidistant from the center of gravity Balance tolerance per Plane Uper 2 When correction planes are NOT equidistant from the center of gravity Uper Left Uper hR b Uper Right Uper hL b The Uper Left or Right should not be less than 30 or more then 70 Uper If they are then use the rules for narrow plane rotors 25 Applying ISO 1940 on Aerostatics Spindle GO 4 MCD e Service speed 80000 rpm Weight 700 grams Balance quality G0 4 MCD e 9549 G n MCD e 9549 x 0 4 80000 0 048 um So Permissible Unbalance U per 0 048 um x 0 7 kg So Permissible Unbalance U per 0 034 gmm TOTAL Permissible Unbalance Uper at C of G 0 034 gmm TOTAL For Symmetrical Rotor 0 017 gmm Per Plane But this is NOT a Symmetrical Rotor MCD e 35 65 4 Left plane radius 15 mm Right plane radius 9 5 Permissible Unbalance Uper 0 034 gmm TOTAL Uper Left 0 034 x 65 0 022 gmm 0 0015 g 15 mm Uper Right 0 034 x 3596 0 012 gmm 0 0013 g 9 5 mm Applying ISO 1940 on Aerostatics Spindle G1 Service speed 80000 rpm Weight 700 grams Balance quality G1 MCD e um 9549 G n MCD e um 9549 x 1 80000 7 0 12 um So Permissible Unbalance U per 0 12 um x 0 7 kg So Permissible Unbalance
28. e driver on and spin the spindle Start at low speed 5000 rpm for 5 minutes and slowly increase up to 60 Krpm Check for motor current at 5000 rpm less 0 5 Amp SPECIFICATION FOR HIGH SPEED AIR SPINDLE Rotation speed 2K 75K rom Air supply Pressure Flow rate Filtering Dew point Oil residue PCW Pure Clean Water pure H20 Coolant Water Pressure max Flow rate min Temperature Variation range Static run out of the rotor Radial direct max Thrust direct max Dynamic run out of the rotor Radial direct max Thrust direct max Radial direct Fluctuation between peaks Thrust direct Fluctuation between peaks Rigidity of the rotor Radial direct Thrust direct Load capacity Radial direct Thrust direct General Shaft Axial Extension Tm 40 oC Spindle Weight Rotor Inertia Noise level O up to 10 Krpm max Resistance between shaft amp frame Balance G0 4 ISO 1940 CE standard Floating Point Cables length Power cable Signal cable Brushes cable Brushes life time 30 40 Krpm Mechanical Coefficient Air Flow Coefficient Water Flow Coefficient Still Air Cooling Efficiently Air Flow Cooling Efficiently Shaft Extension Coefficient Mechanical Friction Coefficient Stiffness amp Load Coefficient Thermal Behavior Coefficient Radial Stiffness Coefficient Axial Stiffness Coefficient Radial Load Coefficient Axial Load Coefficient 5 7
29. ecured Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity Never work or stand under suspended loads For carrying out overhead assembly work always use specially designed or otherwise safety oriented ladders and working platforms Never use machine parts as a climbing aid Wear a safety harness when carrying out maintenance work at greater heights Keep all hardens steps handrails platforms landing and ladders from dirt Clean the machine especially connections and threaded unions of any trace of oil fuel or preservative before carrying out maintenance Never use aggressive detergents Use lint free cleaning rags Before cleaning the machine cove or tape all openings which for safety and functional rezones must be protected against water steam or detergent penetration Special care must be taken with electric motors and switchboard cabinets Always tighten any screwed connections that have been loosened during maintenance work Any safety devices removed for set up maintenance or repair purpose must be ratified and checked immediately upon completion of the maintenance work Ensure that all consumable and replaced parts are disposed safely and with minimum environmental impact 6 Warning of special dangers 6 1 Use only original fuses with the specified current rating Switch off the machine immediately if trouble occurs in the electrical systems 6 2 Work on the electrical
30. f elasticity 103 N mm2 Density kg dm3 Thermal conductivity W m K Electric resistivity Ohm mm2 m Specific heat capacity J kg K Mechanical properties PoC BRASS SAE 40 COPPER Cu Tensile strength N mm2 Elongation L 5d min Hardness HB Din 1 4305 Din 1 2316 X8CrNiS18 9 X36CrMo17 Z10CNF1809 Z35CD17 530300 THYROPLAST 2316 Typical properties ilver graphite Item Density Buik density g cm3 Tensile strength kg cm2 Hardness Pressure strength kg cm2 Specific resistivity m W m Flexural strength kg cm2 Flexural atrength Mpa Modle hardness kg cm2 Paripheral speed MAX m sec Elongation 96 Current density MAX A cm2 Hardness Abrasion mg less for 1000 revol 21 SPINDLE MODES i Length mm 0 10 20 S0 40 50 60 70 80 290 100 110 120 130 140 150 160 170 180 190 200 210 220 1 25 1 0 75 22 SPINDLE BALANCING Why is balancing important Force F generated by unbalance can be calculated from formula 9 0 001 x gmm x RPM 1000 r 9 0 001 x w x r x RPM 1000 where w Unbalance weight in grams Radius in millimetres Effects of Unbalance Reduced component life Bearings seals windings rotor bars foundations supports Impaired clearancs tolerances Component displacement Reactive misal
31. ighment Resonance Flexing of critical speed rotors Excessive vibration and noise Health safety considerations Poor product quality Diagnosing Unbalance Vibration frequency equals rotor speed Vibration predominantly RADIAL in direction Stable vibration phase measurement Vibration phase shifts in direct proportion to measurement direction Causes of unbalance Rotor not mass centred geometrically Machining casting inaccuracioes Fitting assembly tolerance inaccuracies Uneven mass distribution Windings commutator segments Blow holes inclusions in castings Component mismatch Keys keyways Causes of unbalance Service effects Thermal dimensional changes Stress relieving Uneven thermal growth Thermal displacement loosening of components Displacement settling of components Windings Impellers Fan side plates Deposit build up Erosion corrosion Rotor flexibility Forced whip critical speed deflection Induced by other forces Aerodynamic Hydraulic Electrical 23 Rigid Rotors Maximum operating speed below 70 of natural frequency or first critical speed Can be balanced at any speed Will remain in balance throughout speed range provided tolerance calculated to maximum service speed is achieved tolerance calculated to maximum service speed is achieved Balance corrections made in any two arbitrary correction planes Flexible rotor zm Y 3 Y Y Does not satisfy the definition
32. ignoring friction wind age and cross losses Tu JM Kr Kg Thermal Resistance TPR correlated winding temperature rise to the average power dissipated in the stator winding The published TPR assumes that a housed motor is mounted to an aluminum heat sink of specific damnations Additional cooling from forced air water jacketing or increased heat sinking decreases the motor Thermal Resistance allowing higher power output then the published date Viscous damping Fo gives an indication of the torque lost due to B E M F in the motor when the source impedance is zero Fo value can be represented as Fo Kr Maximum Cogging Torque Tr is principally the static friction torque felt as the motor is rotated as low speed The published value does not include the bearing friction of a housed motor Number of Poles Np is the number of permanent magnet poles of the rotor For the QB Series this is generally a total of six three north and three south Design Voltage Vp is the nominal voltage required to produce the peak torque when the rotor speed is zero and the winding temperature is 25 C as such Vp is the product of lp and at any temperature greater then 25 C the required voltage to produce peak torque increases due to the increase in winding resistance The design voltage is not a limit but a reference point for the date Peak Torque tp is the nominal value of developed torque with the rated current lp applied to the windings
33. on exits Check for free movement of the shaft The spindle must be securely clamped to the machine and clear from any distraction Check for electric connections and command community grounding Start the spindle General Description e eG o0 nm oo T INSTALLING THE SPINDLE Remove the spindle from its package Follow the machine s safety and installation instructions Clamp the spindle to the machine using 5 screws M6 or 1M UNF socked head minimal length 15 mm 20 Remove plugs from water air and brushes ventilation connections 5 Connect inlet air pipe 6 mm to AIR IN Al Connect outlet air pipe 25 mm to AIR OUT AO Connect inlet water pipe 28 mm to WATER IN WI Connect outlet water pipe 8 mm to WATER OUT WO Connect 4 mm pipe to brushes ventilation hole BV Remove black plastic nut from the end of the shaft Turn air supply on spin the shaft by hand and make sure that the shaft is rotating freely Check for air pressure 4 5 5 5 bar Check for airflow 35 55 lpm Connect signal cable to the driver Connect power cable to the driver Connect brushes cable to the spindle Open water pressure on to derivate water leaks Check for water pressure 4 5 bar Check for water flow 2 5 3 5 lpm Turn th
34. ood work piece geometry and surface finish and in ensuring long life of the cutting tool drill or grinding wheel Aerostatic bearings have been employed in machines driven by most types of electric motors and most types of turbines They have also been employed in a wide range of machine tool spindles driven by various types of belts and flexible couplings In all these cases the driving torque is evenly and smoothly applied excepting the case of driving by means of a belt the drive does not apply large loads to the bearings Aerostatic bearings are most successful when operating under these conditions They are much less likely to be successfully applied to machines with pulsating drives which impose large internal loads on the bearings CONTENTS 10 E Ra 3 2 YS wa unoc5oocoocscou Fundamental Safety Instructions Warranty notice Attention Daly Check Before starting the spindle System general description Installing the spindle Specification for High Speed Air Spindle Mechanical Constant Electrical Motor Specification Brushless DC Motor Diagrams Torque amp Power Vs Rotation Speed Final velocity Vs Torque amp Acceleration Time amp External Inertia Air Flow Vs Air Pressure Inlet Air Flow Vs Rotation Speed Water Flow Vs Water Pressure Motors Temperature Vs Rotation Speed amp Cooling System
35. ory regulations relevant to accident prevention and environmental protection Those compulsory regulations may also deal with the handling of hazardous substances issuing and of wearing personal protective equipment The operations instructions must be supplemented by instructions covering the duties involved in supervising and notifying special organizations working sequences or the personal entrust with the work Personal entrust with the work on the machine must have read the operating instructions and in particular the chapter on safety before beginning work Reading the instructions after work is too late This applies especially to persons working only occasionally on the machine e g during setting up or maintenance Check whether personal is carrying out the work in compliance with the operation instructions and paying attention to risks and safety factors For reasons of security long hair must be tied back or otherwise secured garment must be close fitting and no jewelry such as ring may be worn Injury must result from being caught up in the machinery or from rings catching on moving parts Use protective equipment whenever required by the circumstances or by law Observe all safety instructions and wearing attached to the machine See to it that safety instructions and wearing attached to the machine are always complete and perfectly legible In the event of safety relevant modifications or changes in the behavior of the machine du
36. ring operation stop the machine immediately and report the malfunction to the competent person Never make any modifications additions or conversions which might affect safety without the suppliers approval This also applies to the installation and adjustments of safety devices and valves Spare parts may comply with the technical requirements specified by the manufacturer Spare parts from original equipment manufacturers can be rely to do so Never modify the software of programmable control systems Adhere to prescribe intervals or those specified in the operating instructions for routine checks and inspections For the execution of maintenance work tools and workshop equipment adapted to the task on hand are absolutely indispensable A portable fire extinguisher must be placed within immediate reach Observe all fire warning and fire fighting 3 Selection and qualification of personal basic responsibilities 3 1 3 2 3 3 3 4 Any work or and with the machine be executed by reliable personnel only Statutory minimum age limits must be observed Employ only trained or instructed stuff and set out clearly the individual responsibility of the personnel of operation set up maintenance and repair Make sure that only authorized personnel work on or with the machine Define the machine operators responsibilities giving the operator the authority to refuse instructions by third parties that are contrary to safety 3 5
37. s bar Spindle air pressure 0 Sa Axial Stittness CONDITION 0 1 2 3 4 5 6 7 8 1 No Rotation Ps bar Radial Load Capacity Vs Air Pressure 90 75 Lr 64 39 In Ps 43 832 60 Theoretical curves 45 zi Ps bar Spindle air pressure 30 Lr N Radial load capacity 15 2 Distance Form The of The Spindle 18mm 0 CONDITION 0 1 2 3 4 5 6 7 1 No Rotation Ps bar Axial Load Capacity Vs Air Pressure 125 _ 100 La 67 664 In Ps 9 4 Z 75 Theoretical curves 50 25 Ps bar Spindle air pressure 0 Axial load capacity 2 3 4 5 CONDITION 1 No Rotation U o o No Load Deceleration Vsp 62 7 e 0096 t t sec Deceleration time Vsp Krpm Speed in t time Vsp Krpm AON goo 00 000 CONDITION 0 1 Ambient temperature 22 C 2 Water cooling 0 4 8 12 16 20 24 28 32 3 No external mechanical load t sec 4 Air pressure at entrance 5 bar Mechanical Friction Losses 6 5 10 Vsp FL w Friction Loss Vsp Krpm Spinning Speed CONDITION 1 No external mechanical load 2 Ambient temperature 22 All PleSsule Val FI w aa o 0 10 20 30 40 50 60 0 Vsp Krpm Voltage Constant BEMF 150 120 Vr 1 854 Vs 5 90 60 Vsp Krpm Rot
38. t turn Incorrectly connected phases Hall sensors are incorrectly connected Connect phases according to diagram Connect Hall sensors correctly according to diagram 33 The shaft rotates in air bearings but not freely in this case air pressure is normal Air ventilation hole AO of spindle is closed by dirt or sealed or used small inlet pipe to air out or this pipe is damaged Air ventilation hole Air out of brushes sensor BV is closed by dirt or sealed or used small inlet pipe to air out or this pipe is damaged Check spindle s air outlet Check brushes ventilation Contact resistance of the sensor more Brushes are too short Electrical connections Replace the brushes Check electrical connections than 10 KO problem Short circuit There is conductive Clean the brushes area between the Carbon powder in the Check brushes ventilation brushes contact area of the Check the brushes cable brushes Short circuit in brushes cable 34 ul Through I5CAR s 56 distributors Colibri has a presence throughout the world Five strategically located offices provide direct support sales and service ia c LL c gt ea ui T tud o znenie IMC Group afficgs Colibri MN COLIBRI SPINDLES LTD HEADQUARTERS Lavon Industrial Park Bikat Bat Hakaram 25
39. that nobody is in risk Never switch off or remove suction and ventilation devices when the machine is in operation 5 Safety instructions governing special work in conjunction with utilization of the machine and maintenance and repair during operation disposal and consumable parts 5 1 5 2 5 3 5 4 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 Observe the adjustment maintenance and inspection activities and intervals set out in the operation instructions including information on the replacement if parts and equipment Skilled personnel may execute those activities only Brief operation personnel before beginning special operations and maintenance wok and appoint a person to supervise the activities If any work concerning the operation conversing or adjustment of the machine and its safety oriented devises or any work related to maintenance inspection and repair always observe the start up and shutdown procedures set out in the operating and the information on maintenance work Ensure that the maintenance area is adequately secured If the machine is completely shut down for maintenance and repair work it must be secured against inadvertent starting by Locking the principal control elements and or Attaching the warning signal sign to the main switch To avoid the risk of accidents individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and s
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