Otto Bilz and HFS3000-49 Wireless Machine Tapping Control System User Manual Manual

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Document ID	142483
Application ID	G4Y2d+OAhbGeJ4OHfMWQuA==
Document Description	Manual
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Document Type	User Manual
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Date Submitted	2001-03-30 00:00:00
Date Available	2001-03-30 00:00:00
Creation Date	2001-01-25 11:09:30
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Document Lastmod	2001-03-27 13:16:36
Document Title	Manual
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BA140.1 I
k GmbH & Co
Eln Unternehmen dcr LEITZ METALWORKING TECHNOLOGY GROUP
Notes to the FCC authority
to oDerate the equipment
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions:
(l)This device may not cause harmful interference, and
(2)thi.s device must accept any interference received, including interference that
may cause undesired operation.
Caution:
Changes or modifications not expressly approved by the party responsible for
compliance could void the user’s authority to operate the equipment.
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy
and, if not installed and used in accordance with the instructions, may cause
harmful interference to radio communications. However, there is no guarantee
that interference will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and receiver.
Connect the equipment into an outlet on a circuit different fi-om that to which
the receiver is connected.
Consult the dealer or an experienced radio/TV technician for help.
IIZ Werkzeugfabrik
,bank
GmbH & Co . Ust-IdNr
Telefon
Personlich
Essllngen
DE 145355716 . Hand®ister Essllngen
+ 49 (0) 711 3 48 01-O - T&fax
haftende Gesellschafterln
Bilz GmbH
BLZ 611 400 71 Kto 8 264 780. Baden
a N HRA 313 . VogeisangstraRe
8 . 73760 Ostfildern
+ 49 (0) 711 3 48 12 56 . C-mall anfo@btlz de . Homepage
. Handelsreglster
Wurttemberglsche
Esslingen
Bank Aalen,
a N HRB 1759 .
. Postfach 1155 .
73747 Ostflldern
http iiwww bllr de
Geschaftsfuhrer
Rwner
BLZ 600 200 30 Kto 8 960 902 800 . Deutsche
BIIZ
Michael Voss
Bank Esslingen
BLZ 611
700 76 Kto 102 012
BA140.11
Ein Unternehmen
dcr Lirll~Z METALWORI 40
Hz
mA
VA
mAh
°C
dBm
dB
50 Ohm
IP54
Height
98
3.9
Length
340
13.4
mm
inch
2.4 kg
5.3 pound
Page 9
01/22/2001
BA140.11
4.5 Remote Control of Receiver by Programmable Logic Control
4.5.1 Wiring explanations
R1, R2
R1.1
R2.1
E1, E2, E3
A1, A2, A3
VS
GND
REL1, REL2
REL4
Relay
Normally closed contact of relay R1, controlled by one of the PLC outputs
Main contact of relay R2, controlled by one of the PLC outputs
Inputs of PLC
Outputs of PLC
Voltage supply, up to 230 V
Ground wire of voltage supply
Normally closed contacts of the relays inside the receiver
Main contact of REL4 relay inside the receiver
4.5.2 Status schedule of relaycontacts
REL1
B.-CHECK
closed
Contact
REL2
ALARM
closed
REL4
POWER ON
open
No power supply
Power supply switched on and:
no signal received so far
closed
closed
closed
signal is just being received
open
open
closed
signal was received
closed
open
closed
reset when just no signal is being received
closed
closed
closed
The receiver is memorizing the reception of a signal until reset by front panel button or by reset input on
remote control connection, respectively.
4.5.3 Wiring Diagram of HF Receiver
SCHÉMA DE CÂBLAGE POUR TÉLÉCOMMANDE
Wiring diagram for remote operation
POSTERÉCEPTEUR HF
HF-Receiver
COMMANDE
PROGRAMMABLE
(SPS)
programable logic control
(PLC)
REL1
B.-CHECK
E1
REL4
POWER ON
E2
E3
VS
REL2
ALARM
COM
ENTRÉES SPS
PLC-inputs
SOURCE DE TENSION
Voltage source
GND
Masse / Ground
SORTIES SPS
PLC-outputs
RESET
GND
HFREL
A1
10
A2
PONT OU R1.1
wire bridge or R1.1
A3
R1.1
R2.1
Page 10
01/22/2001
BA140.11
4.5.4 Realisation of Remote Control Operation
• Wire receiver according to wiring diagram of chapter 4.5.3.
• PLC supervises inputs E1, E2, E3.
• When not operated (mains supply connected), inputs E1, E2, E3 are connected to VS.
Input
Function
Source of signal at receiver
E1
B.-CHECK
Output 1
E2
Mains
Output 3
E3
ALARM
Output 2
Output
A1, A2
Function
Reset of receiver
Action
Bridge between receiver’s inputs
8 and 10 is being opened
A2, A3
HF reception suppressed
Bridge between receiver’s inputs
9 and 10 is being closed
After a malfunction signal and the necessary steps, the machine control cancels the signal. For that purpose PLC
will activate the contact R1.1 for a short moment (> .1 sec).
4.5.5 Actions at alarm
Program step K
Error signal at
input E3?
yes
Retract the unit,
release all chucks
no
Error signal at
input E1?
yes
Battery
monitoring
alarm
Compress each tool
in succession
no
Alarm of
collision detection
yes
Error signal at
input E1?
no
Sight ring is shifted
Replace battery
of this tool
Check tool and workpiece
replace if necessary
Reset
HFE 3002 / HFE 3004
Reset
HFE 3002 / HFE 3004
Shift sight rings
to zero position
Shift sight rings
to zero position
Program step K+1
During this actions at alarm, the bridge
between pins 9 and 10 of the HARTING
socket must be open.
Page 11
01/22/2001
BA140.11
5 The HF Receiver ”HFC 70”
The use of the HF receiver ”HFC 70” is of help to easily identify a chuck having caused battery monitoring
alarm.
Such chuck can be identified by making contact to the transmitting antenna (yellow ring) of the chuck by the
”HFC 70” antenna.
antenna
battery
check
LED indication
ON
ON button
HFC70
Operating elements of the hand-held receiver
• ON button:
Hand held receiver is switched on as long as ON button is being pushed.
• Indication of signal level (by LED):
The level of the signal received by the stub antenna is being shown by LED row. A distinct deflection will be
seen only after the antenna bar has nearly touched the antenna ring on the chuck.
• Battery check:
A red LED in the left corner of the LED row is determined to show operating readiness:
fully charged battery:
when pushing ON button: LED lights up for a short moment
weak battery:
when pushing ON button: LED doesn’t light up
The battery is of standard 9 V bloc type.
Page 12
01/22/2001
BA140.11
6 Installation
6.1 General Information
The HF receiver is protected against interference pulses. Normally adjacent electrical motors, transformers, controls, radios etc. will not cause alarm signals. On the operating frequency, interference signals must not exceed
the maximum level of -93 dBm.
The field strength of the HF signal transmitted by the chucks stays below the permitted upper limit, and thus
interference with other radio services and other electronic equipment are prevented.
We recommend that BILZ HF Equipment on adjacent machines is operated on different channels to avoid
mutual interference.
6.2 Assembly
HF Quick Change Tapping Chucks
The insertion of HF Quick Change Tapping Chucks into the spindle is simple and follows the same principle as
standard chucks. However, avoid damaging the yellow isolation of the antenna ring which neither must be completely screened by metallic items.
Receiver antennae
2 (HFE 3002) or 4 (HFE 3004), respectively, antennae can be connected to the HF receivers. The positioning of
the antennae should be as close as possible to the chucks, however far enough away from metallic parts (minimum distance 30 cm), to avoid weakening of the HF reception field.
The ideal length of the antenna bar is one quarter of the wavelength, as a rule the antenna is abt. 1.1 m long (HFA
0). However, if lack of space prevents the use of such antenna, a shorter one (HFA 2) can be used.
The antenna cable (RG58U) should be as short as possible; the maximum length between each antenna and the
receiver is 25 m. Please handle the antenna cable with care, do not pull nor bend it!
Level output on the front panel of HF receiver
To make installation easier and to evaluate the strength of a signal received, the receivers are equipped with a
level output which can be connected to standard voltmeters.
Digital voltmeters must not be used, as they cannot react quickly enough to the transmitter’s pulsed
signals.
To evaluate the level of a signal received by a certain antenna, only this one is to be connected to the receiver. All other antennae are to be disconnected from the receiver so far.
The voltage at the level output is increasing depending on the level of the signal received.
The following standard values should be considered for new transmitter batteries:
• Voltage < 1 V: weak signal received, improve antenna positioning.
• Voltage > 2 V: good signal received.
Additional Antennae
If, despite optimal antenna positioning, the signal level remains too low (metal parts and/or coolant may affect
transmission fields), additional antenna rings combined with rods can improve the radiation of signals from the
chuck group. These are special items to be designed for each individual case. For any further advice we will be
gladly at your disposal.
Page 13
01/22/2001
BA140.11
6.2.1 Front mounting of receiver in the switchboard
157
bracket set
GT/33-650
Ident-Nr. 43927844
consisting of:
one bracket for
each side
86
96
267
ALARM
POWER
B.-CHECK
RESET
detail of front panel
insertion depth of receiver,
including plug abt. 310 mm
LEVEL
HF-RECEIVER
4,5
68
all dimensions in mm!
81
retaining screws M4
not included in our supply
R7
151
179
6.2.2 Mounting of receiver with sliding blocks for handle and feet slots
sliding block for handle slot
sliding block for feet slots
The sliding blocks (extruded aluminium, alodine) provide an optional means of attachment for the receiver case.
The blocks are inserted in the lateral slots of the case or in place of the feet.
Line drawing of the attachment points
sliding block for handle slot
Notes:
sliding block for feet slots
-all distances in mm
-centre distance between the two feet slots: 83.4 mm.
Page 14
01/22/2001
6.2.3 BILZ Antennae
∅17
HFA 2
∅5
λ /4
ca. 283
HFA 0
∅ 13
antenna base,
not included
in our supply
max. 3
antenna base,
not included
in our supply
∅ 12
washer
serrated lock washer
washer
max. 5
SW 17
SW 17
SW 14
to coaxial socket
of receiver
all dimensions in mm
∅5
∅5
to coaxial socket
of receiver
all dimensions in mm
BA140.11
Page 15
01/22/2001
cable,
5 meters
cable,
5 meters
BA140.11
7 Maintenance
7.1 Quarterly Maintenance
1. Sight inspection of antenna and its accessories:
a. damages, dirt, moisture
b. screwed connections of the antenna cable and loose plug connections of the remote control indicator.
Protocol:
Date:
Name:
1st yearly quarter
2nd yearly quarter.
3rd yearly quarter
4th yearly quarter
2. Quick change adaptors type WESN
Dismantle adaptors’ safety clutches, clean everything and refill with grease Molykote Pate G, readjust
torque according to operating instructions and table BA 102. For cold-forming of threads increase torque values by 50 % to the values shown in tapping torque tables.
Protocol:
Date:
Name:
1st yearly quarter
2nd yearly quarter
3rd yearly quarter
4th yearly quarter
Page 16
01/22/2001
BA140.11
7.2 Semi-annual Maintenance
HFS 3100:
Check of transmitter batteries:
Fully charged battery
Chuck compressed:
Yellow ”B.-CHECK” LED flashes
in 1 sec. rhythm.
Chuck released:
Yellow ”B.-CHECK” LED flashes
in 1 sec. rhythm till follow-up time
of transmitter has run out, after
which indication ends.
Remedial actions:
No action required!
All chucks are to be compressed in turn
Weak battery
Chuck compressed:
Yellow ”B.-CHECK” LED flashes
in 1 sec. rhythm.
Chuck released:
Yellow ”B.-CHECK” LED flashes
in 1 sec. rhythm till follow-up time
of transmitter has run out, after
which it flashes in .5 sec. rhythm
(battery monitoring alarm).
Remedial actions:
Replace battery!
Empty battery
Chuck compressed:
Yellow ”B.-CHECK” LED doesn’t
light up.
Chuck released:
Yellow ”B.-CHECK” LED doesn’t
light up.
Remedial actions:
Replace battery!
HFS 3000: Remove battery block as per 3.2.2 and test voltage by battery tester: minimum 3.0 V.
Protocol:
Date:
Name:
1st half of the year
2nd half of the year
Page 17
01/22/2001
BA140.11
8 Annex
8.1 Frequency Table
Channel
No.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Frequ.
MHz
Channel
No.
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Frequ.
MHz
72,000
70,040
70,120
70,200
70,280
70,360
70,440
70,520
70,600
70,680
70,760
70,840
70,920
71,000
71,080
71,160
71,240
71,320
71,400
71,480
71,560
71,640
71,720
71,800
71,880
71,960
w/o quartz
70,000
70,080
70,160
70,240
70,320
70,400
70,480
70,560
70,640
70,720
70,800
70,880
70,960
71,040
71,120
71,200
71,280
71,360
71,440
71,520
71,600
71,680
71,760
71,840
71,920
Channel
No.
1S
2S
3S
4S
5S
6S
7S
8S
9S
UK
Channel
No.
7 UK
8 UK
9 UK
10 UK
11 UK
12 UK
DK
Frequ.
MHz
w/o quartz
* 62,000
* 62,080
* 62,160
* 62,240
* 62,320
* 62,400
30,270
30,300
30,340
Channel
No.
1 DK
2 DK
3 DK
Frequ.
MHz
w/o quartz
32,275
32,300
32,325
USA
Frequ.
MHz
49,820
49,852
49,884
49,916
49,948
49,980
Channel
No.
1U
2U
3U
4U
5U
6U
Frequ.
MHz
49,830
49,860
49,890
49,815
49,845
49,875
8U
9U
10 U
11 U
12 U
13 U
14 U
15 U
16 U
17 U
18 U
19 U
20 U
72,030
72,090
72,150
72,210
72,270
72,330
72,390
72,450
72,510
72,570
72,630
72,690
72,750
USA
Channel
No.
21 U
22 U
23 U
24 U
25 U
26 U
27 U
28 U
29 U
30 U
31 U
32 U
33 U
34 U
35 U
36 U
37 U
38 U
39 U
40 U
Frequ.
MHz
72,810
72,870
72,930
72,990
72,060
72,120
72,180
72,240
72,300
72,360
72,420
72,480
72,540
72,600
72,660
72,720
72,780
72,840
72,900
72,960
Channel
No.
1A
2A
Frequ.
MHz
w/o quartz
40,665
40,695
* Only for replacement!
Page 18
01/22/2001
8.2 Homologations
For EC-Type Examination see separate file
BA140.10
HF Tapping Control Unit
System HF 3000
Check-list of HF Tapping Control Unit, system HF 3000
for HF alarm.
The HF Tapping Control Unit supervises tapping during machining process and
indicates arisen faults by alarm signal.
The HF receiver differentiates
between:
ALARM
POWER
B.-CHECK
RESET
1. Procedure alarm due to faults arisen during
tapping operation
2. Battery monitoring alarm due to battery voltage
fallen below limit value
LEVEL
HF-RECEIVER
Machine stop due to
procedure alarm
Machine stop due to
battery monitoring alarm
Red LED ALARM at the receiver lights
up, detector ring of the chuck displaced
Red ARARM and yellow LED BATTERY ALARM
at the receiver light up, detector ring of the chuck
not displaced.
Cause of malfunction:
Cause of malfunction:
Length compensation of chuck compressed due to:
a. released safety clutch by:
− worn out tap
− wrong torque setting in
adaptor
− cored hole too narrow
− cored hole not deep enough
− lack of coolant
Battery voltage below limit value.
b. missing cored hole
c. cored hole not chamfered
Such alarm may arise during machining process
as well as during non working time of the machine.
Recognition of the spindle having caused
battery monitoring alarm
The hand-held receiver HFC 70 helps to identify
the chuck having signalized the malfunction.
The chuck emitting alarm signal will be identified
by making contact to the chuck’s transmitting antenna
(yellow ring) by the „HFC 70“ antenna.
d. insufficient initial cutting pressure
by the chuck
Otto Bilz Werkzeugfabrik GmbH & Co
D-73760 Ostfildern (Nellingen)
Telefon (0711) 3 48 01-0
Telefax (0711) 3 48 12 56
BA140.10
HF-Tapping Control Unit
System HF 3000
Recognition of the spindle having caused
procedure alarm:
Malfunction signal is being indicated by
LED bar graph array.
Since at procedure alarm the length compensation of the chuck is always being
compressed, the detector ring of the chuck
is inevitably being displaced, thus allowing
to identify the chuck having signalized malfunction, even at multispindle operation.
antenna
After eliminating malfunction push back
detector ring into zero position and cancel
alarm signal by pushing reset button. Now
the machine is ready for operation again.
LED bar graph array
ON
HFC70
Battery monitoring alarm may also be
recognized without the use of HFC 70:
The chucks are to be compressed in
succession. The chuck having signalized
battery monitoring alarm will be recognized
by the fact, that the yellow LED of the
receiver discontinues to give light as long as
the chuck is being compressed.
HF Tool Supervising System
Layout Diagram
detector
ring
transmitter
antenna
radio link
detector
ring
Bilz-chuck
type WFLP-HF
or WFL-HF
Bilz-adaptor
type WESN/B
or WES/B
HF-receiver

---

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