Operating manual
RM-A
Original operating manual
date
11-2011
author
jmu
version
001
firmware version
1.49
articles
6531011 �
Contents
1
Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2
Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1
Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2
Examples of improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3
Risks arising from improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4
Protective clothing and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5
Risks arising from the emission of toxic dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1
Description of menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2
Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3
Router module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4
HF motor spindle 4040 DC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5
Changing the motor spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.6
Motor spindle power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.7
Adjusting the extraction strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.8
Setting the motor spindle as the tool for the module . . . . . . . . . . . . . . . . . . . . . . 27
3.9
Initialisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.10
Making material-dependent settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.11
Carry out a test cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4
Cleaning and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2
Cleaning the motor spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3
Lubricating the lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4
Running-in specifications for HF motor spindle 4040 DC-SZ. . . . . . . . . . . . . . . . 37
5
Surface compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1
Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2
Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3
Carrying out the measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4
Switch surface compensation on/off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6
Basic principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1
Router description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2
Groove cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4
Multipass/finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5
Routing behaviour of the cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1
2
6.6
Formulae . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.7
Force analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.8
Tips and tricks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Product description
Introduction
1
Product description
1.1
Introduction
The router module (RM-A) is designed to be used with 1000 W Zünd motor spindles for cutting operations such as drilling and routing. The router option also includes a boom with a converter and an
optional extractor in addition to the router module.
Note!
For more information about the motor spindle, please see the manufacturer's
documentation.
CSA certification
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
The motor spindle, power supply and drive controller are CSA tested and certified.
3
Product description
Introduction
1.1.1
4
Router module
1
Extractor
3
Slider for setting extraction strength
2
Motor spindle
4
Motor spindle holder
Product description
Introduction
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
1.1.2
HF motor spindle 4040 DC-SZ
1
Collet
3
Sealing air connector
2
Collet holder
4
Converter connection
5
Product description
Introduction
1.1.3
6
Boom, converter
1
Converter
4
LEDs
2
On/off switch
5
Module mount
3
Connector pipe for extractor
Product description
Introduction
1.1.4
Controls on the control panel
1
1.1.5
Adjusting wheel motor spindle speed
setting
2
Converter standby key
Technical information
Module
Name
Weight
Measurement Unit
3.9 kg
HF motor spindle 4040 DC-SZ
Name
Motor type
BLDC
Operating voltage
45 Volts
Torque
17 Ncm
Peak power
Max. rotational speed
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
Measurement Unit
Max. current
1000 Watts
50000 min-1
16 A
7
Product description
Introduction
Name
Measurement Unit
Weight
2.9 kg
Direction of rotation
Left
Protection class/type
III / IP 54
Collets
1.5 - 6.35 mm
Compressed air
Name
Air pressure
Air flow
Measurement Unit
0.6 - 0.8 MPa
40 l/min
Technical requirements for extractor
Name
Min. flow volume
8
Measurement Unit
3800 l/min
Safety regulations
Proper use
2
Safety regulations
Note!
These safety requirements and notes only represent module-specific supplements to
the Safety Requirements chapter in the operating instructions
This chapter
•
defines the intended use of the module;
•
contains tool-specific safety precautions and instructions;
•
provides information on the protective equipment required for work and maintenance
Special operational and situation-specific safety requirements are listed in the relevant processing
steps in subsequent chapters of this manual.
2.1
Proper use
Using the module for its intended use is a basic prerequisite for safe operation.
The equipment delivered with the module determines its possible uses.
The router module is primarily designed to be used with 1000 W Zünd motor spindles. Proper use is
therefore limited to machining operations such as the drilling and routing of solid materials using a
suitable router.
Any other use or any use outside of this scope constitutes improper use. The user bears sole liability
for any damage arising as a result of improper use.
The module is deemed to be used properly under the following conditions:
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
2.2
•
All nationally imposed safety regulations are complied with,
•
The safety instructions listed in this manual are complied with,
•
The operating conditions are adhered to and the prescribed materials are used.
Examples of improper use
•
Operating the motor spindle outside of the module
•
Use of unsuitable routers
•
Use of router shafts not manufactured according to DIN-ISO standards
•
Use of unauthorised speeds for the motor spindles being used
•
Improper or non-intended use
•
Incorrect installation of the motor spindle
•
Incorrect mounting of the router
•
Incompatible router shaft and collet sizes
9
Safety regulations
Risks arising from improper use
2.3
2.4
•
Infrequent cleaning of motor spindle
•
Insufficient collet holding force due to wear or dirt
•
Failure to use the extractor
•
Failure to use personal protective equipment
•
Non-observance of maintenance instructions
•
Non-adherence to safety requirements
•
Failure to react to signs of wear and damage
Risks arising from improper use
•
Snapping of router shafts
•
Tool unintentionally slipping out of the collet
•
Breakage/cracking of the router
•
Damage to the vacuum plates as a result of incorrect settings (routing set too deep)
•
Damage to the motor spindle if operated without extraction
•
Personal injury if routing is carried out without extraction and toxic dust is present
•
Personal injury if routing is carried out without personal protective equipment
Protective clothing and equipment
When operating, cleaning or maintaining the equipment, wear close-fitting clothing and personal protective equipment suited to the task at hand.
Personal protective equipment comprises:
•
Work clothing
•
Safety goggles
•
Protective gloves where injury is possible due to:
•
–
burns
–
sharp or pointed objects
Ear protection if the continuous sound pressure level is over 85 db(A)
Note!
You are personally responsible for:
10
•
using the required personal protective equipment;
•
cleaning and maintaining the equipment on a regular basis;
•
replacing damaged and unusable items of protective equipment in good time.
Safety regulations
Risks arising from the emission of toxic dust
2.5
Risks arising from the emission of toxic dust
Warning!
Risk of poisoning from the emission of toxic dust
Processing different materials can lead to the creation of toxic dust with significant
risk to health.
•
Obtain information about the toxicity of the material to be processed from the manufacturer
•
Use a suitable extraction unit or take other appropriate action accordingly
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
The employer is responsible for making sure that all national regulations concerning the maximum
permissible dust concentration at work are adhered to. When handling hazardous types of dust, all
local safety regulations as well as the manufacturer's instructions must be observed. When routing
or cutting hazardous materials always use dust extractors with special dust filters designed for this
purpose. As an optional accessory, Zünd offers extraction systems which comply with the following
requirements:
•
the extraction of hazardous dusts with MAK values of up to 0.1 mg/m3 and of wood dusts conforming to dust class M.
•
The extraction of dusts conforming to dust class H.
11
Safety regulations
Risks arising from the emission of toxic dust
12
Operation
Description of menu
3
Operation
3.1
Description of menu
The examples in the following guide assume that the module is being used in slot 1.
Name
Menu
Setting/function
Change module
1-5-1
Changing module
Tool type
1-1-1-1
Assign the tool to module 1
Router converter
1-1-1-3-1-1
Assigning the converter
Define Z init pos
1-1-1-2-1
Setting the zero point
Up Z pos
1-1-1-2-3
Set the up Z pos (above the material)
Down Z pos
1-1-1-2-4
Set the cutting depth
Z-offset
1-1-1-2-6
Correction value for down Z pos
Test cut
1-1-1-2-5
Carry out a test cut
Define init height
1-1-1-2-7
Setting the extractor position
Offset
1-1-1-3-5-3
Set the upper extractor position
Up XY tool
1-1-1-3-2-1
Speed in upper position
Down XY tool
1-1-1-3-2-2
Speed in lower position
Lift Z
1-1-1-3-2-3
Lifting speed
Lower Z
1-1-1-3-2-4
Lowering speed
Up X&Y
1-1-1-3-3-1
Acceleration in upper position
Down X&Y
1-1-1-3-3-2
Acceleration in lower position
Increase RPM
3-2-1-2
Increase RPM
Decrease RPM
3-2-1-3
Decrease RPM
Switch on router
3-2-1-4
Switch on router
EasyDrive on/off
3-2-1-6
Turning the converter on/off
3-2-3-1
Switch the extractor on/off
Initialisation
Speed and acceleration
Operation of router 1
Extractor
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
Switch the extractor
on/off
13
Operation
Converter
3.2
Converter
3.2.1
Turning the converter on/off
1
•
3.2.2
Main switch on/off
Switch the router converter on/off using the main switch.
Converter - Activating standby mode
Caution!
Risk of injury.
Activate the standby mode on the converter before working on the motor spindle.
The standby mode of the converter is activated using the standby key on the control panel/via the
cutter menu. In standby mode, the power supply for the router converter is turned off. Activate standby mode before working on the router.
Standby key
Menu
EasyDrive on 3-2-1-6
EasyDrive off 3-2-1-6
14
Action
Switch on converter/activate standby mode
Operation
Converter
Status display
Status
Converter switched on
Converter in standby mode
3.2.3
Assigning the converter
Before you begin
Make sure that the following requirements are fulfilled:
•
The on/off switch on the converter is set to 'On'
•
The routing spindle is inserted into the module
•
The routing spindle is installed and selected in the menu as a tool
G3 cutters are designed for operation with two router converters. If two router converters are attached
to the cutter, the active routing spindle must be assigned to one of the two converters.
A Converter Select 1-1-1-3-1-1 .
B Use the navigation keys
to select the converter:
Result
Selection
Function
Converter 1
Converter 1 is connected to the current tool and is allocated to this
Converter 2
Converter 2 is connected to the current tool and is allocated to this
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
C Select OK to confirm
15
Operation
Converter
3.2.4
Status display
1
3.2.5
Operating LED
2
Warning/error LED
Indicator colours for LEDs
Meaning
Green
Operating
Yellow
Warning/error, please contact your service partner.
Setting motor spindle speed
The motor spindle speed is set in the menu. During routing, the speed can be changed either via the
menu or via the speed setting on the control panel.
Speed setting
Menu
Action
Increase RPM 3-2-1-2
Increase RPM
Decrease RPM 3-2-1-3
Decrease RPM
16
Operation
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
Router module
3.3
Router module
3.3.1
Module mount
1
Locking mechanism
2
Mounting ledge
3
Electrical connection
17
Operation
Router module
3.3.2
Inserting a module
A Changing a module 1-5-1 must be selected. The module carriage moves to the control panel.
B Place the module on the mounting ledge
C Tilt the module backwards onto the module carriage
D Lower the module until it stops
E Use an Allen key to fix the module in place
Results
The module is now mounted on the module carriage and is located by the software.
Rectifying problems
The module cannot be lowered.
•
18
Loosen the module locking mechanism before inserting the module.
Operation
Router module
3.3.3
Remove the module
A Change module 1-5-1 must be selected. The module carriage moves to the control panel.
B Use an Allen key to unlock the module
C Lift the module
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
D Remove the module
19
Operation
Router module
3.3.4
Storing the module
If it is not being used, store the module in the module mount. Attach the extraction hose to the mount.
1
20
Module mount
2
Holder for extraction hose
Operation
HF motor spindle 4040 DC
3.4
HF motor spindle 4040 DC
Caution!
Risk of injury due to motor spindle.
Switch the converter off before working on the motor spindle.
Caution!
Risk of damage to the motor spindle
3.4.1
•
When putting the motor spindle down, avoid kinking the cables/hoses.
•
If the clamping nut is not firmly tightened, the router may come loose.
•
If the clamping nut is secured too tightly, the clamping nut or the shaft may be damaged.
•
Do not operate the spindle without the collet or router inserted.
Changing the collet
1
Collet holder
3
Ring spanner
2
Collet
4
Open-ended spanner
Removing the collet
A Hold the collet holder in place using an open-ended spanner
B Undo the collet using a ring spanner
C Turn the collet to remove it from the collet holder
Inserting the collet
A Turn the collet to insert it into the collet holder
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
B Hold the collet holder in place using an open-ended spanner
C Tighten the collet using a ring spanner
21
Operation
HF motor spindle 4040 DC
3.4.2
Changing the router
a
Routing depth as per manufacturer's
instructions
1
Collet holder
b
7 mm
2
Collet
c
Router shaft
3
Ring spanner
s
Chip channel outlet
4
Open-ended spanner
Removing the router
A Hold the collet holder in place using an open-ended spanner and use a ring spanner to undo the
collet
B Remove the router from the collet
22
Operation
Changing the motor spindle
Inserting the router
Note!
•
Use only balanced routers.
•
Ensure that the router shaft matches the collet diameter.
A Clean the collet holder, collet and router shaft (see chapter Cleaning the motor spindle)
B Insert the router shaft into the collet. Be aware that the required clamping depth may vary depending on the material thickness and the router. In general, the router should be inserted into the collet
as far as the router channel outlet(s)!
C Hold the collet holder in place using an open-ended spanner and use a ring spanner to tighten the
collet.
3.5
Changing the motor spindle
Caution!
Risk of injury due to motor spindle.
Before working on the motor spindle, turn the on/off switch on the converter to 'Off'.
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
Caution!
Risk of damage to the motor spindle
•
When inserting/removing the motor spindle, avoid contact with the router or the motor
spindle holder.
•
When inserting the motor spindle, ensure that the arrowheads are aligned (Inserting the
motor spindle, item B).
•
When putting the motor spindle down, avoid kinking the cables/hoses.
23
Operation
Changing the motor spindle
3.5.1
Inserting the motor spindle
Fig. 1: Inserting the motor spindle
A Insert the motor spindle
B Turn the motor spindle until the arrowheads are aligned
C Tighten the fastening screw by turning it clockwise
Results
The motor spindle is inserted and fixed in place.
24
Operation
Changing the motor spindle
3.5.2
Removing the motor spindle
A Turn the fastening screw anticlockwise
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
B Remove the motor spindle
25
Operation
Motor spindle power supply
3.6
3.6.1
Motor spindle power supply
1
Extraction hose
3
Fastening screw
2
Connection cable
4
Sealing air hose
Connecting the motor spindle
A Insert the extraction hose
B Insert the connection cable. Tighten the fastening screw by turning it clockwise.
C Insert the sealing air hose
3.6.2
Disconnect the motor spindle
A Disconnect the sealing air hose
B Loosen the fastening screw by turning it anticlockwise. Disconnect the connection cable.
C Disconnect the extraction hose
26
Operation
Adjusting the extraction strength
3.7
Adjusting the extraction strength
The extraction strength can be set using the slider. The extraction strength has been set correctly if
the extractor removes waste but not the material that has been cut out.
3.8
1
Slider
B
A
Extraction strength - high
Extraction strength - low
Setting the motor spindle as the tool for the module
Refer to the "Tool handling" chapter of the operating instructions.
3.9
Initialisation
Warning!
Risk of injury during tool initialisation!
The light barriers are not active during manual initialisation.
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
3.9.1
•
Do not touch the operating area of the tool during initialisation.
•
Define the zero point with automatic initialisation.
Introduction
•
The following activities are required for successful initialisation:
27
Operation
Initialisation
•
Defining the zero point (manual/automatic*)
•
Setting the up Z position
•
Setting the extractor position
•
Carrying out a test cut
•
Correcting the cutting depth using the Z-offset function if necessary
Make sure that the following requirements are fulfilled:
3.9.2
•
The machine is in the 'STOPPED' operating status.
•
The motor spindle has been mounted and assigned to the module.
Setting the zero point
A Define Z init pos Select 1-1-1-2-1 .
B Use the travel keys to lower the router until it is on the base
C Select OK to confirm
3.9.3
Setting the up Z position
Note!
•
If the cutting base is defined as the zero point, the value for the Up Z pos setting must be
greater than the material thickness.
The Up Z pos setting determines the position of the tool when raised.
28
Operation
Initialisation
Up Z position = zero point + Up Z pos
1
Zero point
a
Material
4
Up Z pos
A Up Z pos Select 1-1-1-2-3 .
B Enter a value
C Select OK to confirm
3.9.4
Setting the down Z position
Note!
If the cutting base is defined as the zero point, the value for the Down Z pos setting
must be set to zero. Entering a positive value will damage the cutting base.
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
The Down Z pos setting defines the position of the tool when lowered. When a zero point is defined,
the value for the Down Z pos is automatically set to zero.
29
Operation
Initialisation
To improve quality, routing can be carried out in several stages (Multipass).
Fig. 2: Setting the down Z position
1
Zero point
a
Material
2
Down Z pos
A Select Down Z pos .
B Enter a value:
a
If routing is through the entire material (Setting the down Z position, item A), the value is automatically
set to 0.
b
If routing is only part way through the material (Setting the down Z position, item B), the value is set
to e.g. -5 mm
(material thickness 10 mm - cutting depth 5 mm)
C Select OK to confirm
30
Operation
Initialisation
3.9.5
Setting the Z-offset
Value for the correction of the cutting depth (Down Z pos) ±1.5 mm. When a zero point is defined, the
value for the Z-offset is automatically set to zero.
A Z-offset Select 1-1-1-2-6 .
B Enter a value
C Select OK to confirm
3.9.6
Checking the router positions
jmu, 11-2011, 001, 1.49, 6531011 � , RM-A
After initialisation, three router positions are possible.
Item
Position
Description
A
Park position
Moves to the highest position on the
Z-axis
B
Up Z pos
Zero point + Up Z pos
C
Down Z pos
Zero point + Down Z pos + Z-offset
Key
Signal
31
Operation
Initialisation
3.9.7
Setting the extractor position
Extractor position during routing.
A Use the keys SHIFT+
to raise the router into the park position
B Define init height Select 1-1-1-2-7 .
C Use the travel keys to lower the extractor until the brush is on the material
D Select OK to confirm
Setting the upper extractor position (offset)
32
Operation
Making material-dependent settings
1
Upper extractor position (offset)
2
Upper router position
3
Small pieces of material
This setting defines the extractor position during breaks in routing, and between the end of a routing
process (A) and the start of the next routing process (D)
The router remains in the material while the extractor is being raised (B). Afterwards, the router rises
(C). This prevents small pieces of material being removed by the extractor.
Setting the upper extractor position (offset)
A Offset Select 1-1-1-3-5-3 .
B Enter a value
C Select OK to confirm
3.10
Making material-dependent settings
The speed and acceleration settings are dependent on the material.
You can find recommended settings on the Zünd homepage or by contacting your Zünd partner.
3.11
Carry out a test cut
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Make sure that the following requirements are fulfilled:
•
The machine is in the OFFLINE operating status.
•
The router has been initialised
•
The extractor has been initialised
•
Material-dependent settings have been made
•
Module RM-A is the active module
•
The on/off switch on the extractor is set to 'On'
•
The extractor has been switched on using the menu
•
The converter on/off switch is switched on
•
The converter is activated (menu/standby key)
•
The base and material are present
•
The vacuum (fixing) is switched on
33
Operation
Carry out a test cut
3.11.1
Procedure
Caution!
Risk of injury due to chips
Always use your personal protective equipment when routing.
A Select test cut .
B Select the router test from the list
C Select OK to confirm
3.11.2
Inspecting the test cut
A Inspect the results of the test cut and adjust the settings if necessary
B Check the extraction and adjust the settings if necessary
Results
If the routing depth is set correctly, the router will leave a slight trace in the base.
34
Cleaning and maintenance
Maintenance schedule
4
Cleaning and maintenance
Caution!
Risk of injury due to motor spindle.
Before working on the motor spindle, turn the on/off switch on the converter to 'Off'.
Caution!
Risk of damage to the module
Never clean the module using ultrasound, a steam jet, compressed air, etc.
Never use cleaning products (cleaning spray, grease solvents, etc.) on the machine.
4.1
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4.2
Maintenance schedule
Interval
Activity
Daily
Cleaning the motor spindle
Daily
Removing material deposits from the module
Weekly
Cleaning the cover using a plastic cleaner
Monthly
Lubrication
Cleaning the motor spindle
35
Cleaning and maintenance
Lubricating the lubrication points
1
Brushes
2
Collet holder
3
Collet
A Use a brush to clean the collet holder
B Use a brush to clean the collet
C Lightly lubricate the collet thread
4.3
Lubricating the lubrication points
•
36
Name
Specification
Klüberoil®
4UH1
Lubricate the lubrication points with a drop of oil
Cleaning and maintenance
Running-in specifications for HF motor spindle 4040 DC-SZ
4.4
Running-in specifications for HF motor spindle 4040 DC-SZ
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Following extended storage periods/downtimes, the motor spindle must be run in according to the
manufacturer's running-in specifications. For further information, see the manufacturer's original operating manual.
37
Cleaning and maintenance
Running-in specifications for HF motor spindle 4040 DC-SZ
38
Surface compensation
Functional principle
5
Surface compensation
Note!
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5.1
•
The scanning of the surface is carried out mechanically. Do not use surface compensation
with pressure-sensitive materials!
•
The maximum height difference which can be detected within the area is ±4 mm.
•
The maximum height difference which can be detected between two scanning points is ±1
mm.
•
Ensure that the underside of the extractor is free from processing residue, in order to avoid
damage to the material being processed.
Functional principle
39
Surface compensation
Menu
1
Processing material
r
X/Y-axis grid (30 mm-1200 mm)
2
Corner point
a
Defined area – 12 mm
3
Scanning point
Surface compensation allows for precise routing depths. Uneven surfaces on the material being processed, which may be caused by the routing support, conveyor belt or table, are ascertained by the
extractor scanning the surface of the material to be processed.
Compensation of uneven surfaces during processing takes place relative to the Z zero point (initialisation). Optimal results are achieved if initialisation is performed inside the defined area.
5.2
5.3
Menu
Name
Menu
Setting/function
Start measurement
2-6-1
Start measurement process
Surface compens.
2-6-2
Switch surface compensation on/off
Show area
2-6-3
The module carriage leaves the defined area
Remeasure the area
2-6-4
Remeasure an already defined area using the same
grid
Area
2-6-5
Defined/not defined
Grid
2-6-6
Grid distance display
Carrying out the measurement
The measurement is carried out in three steps:
1) Definition of the area to be measured
2) Definition of the grid
3) Measurement of the area
5.3.1
Measurement
A Activate module (Shift + 1/2/3).
B Start measurement 2-6-1 must be selected.
C The area is defined as a rectangle. Move to the two diagonal corners of the rectangle.
D Enter the distance between the scanning points (grid).
E Start the measurement.
Results
The surface is scanned.
40
Surface compensation
Switch surface compensation on/off
5.4
Switch surface compensation on/off
Surface compensation is switched on automatically as soon as the measurement is performed.
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If the surface compensation is to be deactivated, it can be switched off in the Surface compens. menu
2-6-2 Shut down.
41
Surface compensation
Switch surface compensation on/off
42
Basic principles
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Router description
6
Basic principles
6.1
Router description
43
Basic principles
Router description
6.1.1
D
Shaft diameter. This measurement corresponds to the measurements of the collet.
L
Total length of router
d
Nominal diameter of the cutting edge
T
Length of cutting edge. This is the maximum possible routing depth. The longer the cutting
edge, the higher the risk of unwanted vibrations.
z
Number of cutting edges. The higher the number of cutting edges, the longer the router
holds in place and the higher the feed speed that can be used. Routers for wood, plastic
and MDF only have one cutting edge and a large chip space.
A
Right-hand router
B
Left-hand router
Right-hand cutting
These routers are used as standard.
Advantages of right-hand cutting:
6.1.2
•
Chips are conveyed upwards to make room for following chips.
•
This prevents build-up on the cutting edge and generation of heat.
Left-hand cutting
When processing laminated panels, the surface must not be damaged. Left-hand router
Disadvantages of left-hand cutting:
44
•
Only thin panels can be processed.
Reason: Chips are forced downwards and block the outlet channel. With a large volume of
chips, the chips may slide between the panel and the routing support.
•
As the chip angle at the bottom is negative, it is either not possible to cut into the material or only
with great difficulty. The best option is to enter the panel from the outside.
Basic principles
Groove cutting
6.1.3
Router selection
Note!
To ensure the correct choice of router, follow the recommendations in the Zünd
accessories catalogue!
Use the largest possible router diameter. The thinner and longer a router is, the more easily it bends.
Although this cannot be seen by the naked eye, it impairs the dimensional stability and causes the
router to vibrate. In the worst case scenario, incorrect speed and feed values could even cause the
router to fracture. The weakest area on a router is the cutting part. This is where it bends most due
to the grooves which have been ground out.
6.2
Length of cutting edge
(max. routing depth)
T
In order to avoid vibrations and to be able to set the highest
possible speed, the routing depth T must be kept as small as
possible.
Router diameter
d
The router diameter chosen should be as large as possible.
Number of cutting edges
z
z=1: soft materials such as wood, MDF, plastics
z>1: tough materials such as aluminium, brass, etc.
Groove cutting
1 Feed
2 Direction of rotation of the router
3 Up-cut routing side
4 Down-cut routing side
The cutting edge of the router comes into contact with the material.
The cutting edge of the router runs against the material.
In the initial phase, the cutting edge grinds against the material.
Only when a certain thickness of chip is reached does the router
begin to cut.
•
The grinding during the initial phase generates heat and causes wear on
the router.
•
The smaller the feed selected, the longer the grinding process lasts.
•
Grinding takes place only on the up-cut routing side.
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As soon as the cutting edge has penetrated deeply enough into the
material, cutting with outflowing chips takes place.
45
Basic principles
When the cutting edge reaches the centre, the chip thickness is at
its maximum.
The cutting edge runs in the down-cut area. The chip thickness
decreases continuously.
The chip gets smaller.
The chip is removed.
6.3
6.3.1
Up-cut routing
In up-cut routing, the movement of the cutting edge is relative to the workpiece. When the cutting
edge enters the material, the chip thickness is zero and then increases continuously. In the initial
phase, the cutting edge grinds against the workpiece. This generates frictional heat and - with few
exceptions - a poor quality surface.
46
Basic principles
6.3.2
Down-cut routing
In down-cut routing, the chip thickness is at its maximum when the cutting edge first comes into contact with the material. The chip thickness decreases continuously until the cutting is finished. This produces - with few exceptions - a better quality surface.
Down-cut routing direction
1
Routing direction
5
Finishing path
2
Workpiece
6
Up-cut routing side
3
Vector
7
Down-cut routing side
4
Router force
The router direction should be chosen so that the finished workpiece is on the right-hand side in the
direction of travel. The right-hand side of the finished groove always has the better surface.
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In the first router passes, the track is generally corrected by at least 8% of the router diameter to the
left of the vector so that a dimensionally accurate contour can be produced in the finishing process.
47
Basic principles
Multipass/finishing
6.4
Multipass/finishing
The chip thickness (b) can be calculated from the feed speed and the router speed. If the feed speed
is doubled, the chip thickness doubles. However, doubling the chip thickness does not double the
router force.
If the chosen feed speed is too low, no actual cutting will take place and the cutting edge will just grind
against the groove instead. The frictional heat generated in this way heats the router and the material
so much that plastics will begin to melt during processing.
In order to be able to process thick panels, multiple passes must be performed.
Pass 1
Scrubbing
48
Pass 2
Scrubbing
Pass 3
Scrubbing
Pass 4
Finishing path
Pass
1, 2
The infeed depth (t) for each pass is predetermined by the router diameter and the
material.
Pass 3
The material is not completely cut through on the penultimate pass. A thin strip (s =
0.2-0.6 mm) is left, in order to maximise the effect of the vacuum.
Pass 4
The strip is cut and, in down-cut routing, the final finishing chip f = 8 - 15 % of the router
diameter is taken from the right of the router. In order for the workpiece to be released,
a cut is deliberately made in the base (u). The dimension u depends on the evenness of
the table. (u = 0.3 mm - 0.8 mm).
Basic principles
Routing behaviour of the cutter
6.5
Routing behaviour of the cutter
The X-/Y-axes of a cutter are not rigid, instead they react dynamically to force changes. In the event
of force changes, controller deviations occur, which will be corrected after a given time period. Controller deviations lead to geometry errors in the finished contour!
During routing, the reaction force (F) is always perpendicular to the track. At the start of a router pass
(router vector), the router is first moved to be at a right angle to the track, until the controller adjusts
the errors to zero. During braking, this force diminishes and the track error goes in the other direction.
The greater the acceleration that is chosen and the greater the router forces, the larger this track error
becomes. If a high level of dimensional stability is required, the resulting error must be eliminated by
a finishing pass with low acceleration .
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6.6
Formulae
Parameter
Unit
Comment
vc
Cutting speed
m/min
The cutting speed depends on the router and the
material.
n
Router speed
rpm
With high-speed cutting, the very high calculated
speed cannot usually be used, as the routers are not
balanced and begin to vibrate.
d
Router diameter
mm
v
Feed speed
mm/s
b
Chip width
mm
z
Number of cutting edges
49
Basic principles
Force analysis
Router speed
6.7
Cutting speed
Chip width
Feed speed
Force analysis
Note!
Please note the following basic principles!
•
The sharper the router, the smaller the router forces.
•
The tougher and harder the material, the greater the router forces.
•
The deeper the router is fed into the material, the greater the router forces. This relationship
is linear. This means that if the infeed is doubled, the router forces double.
The following example is intended to demonstrate that it is more cost-efficient to reduce the infeed (t)
and increase the feed speed and/or the chip width (b).
The diagram shows two force paths:
Infeed depth (t)
Unit
6 mm
3 mm
50
Basic principles
Tips and tricks
6.8
Tips and tricks
6.8.1
General
6.8.2
•
Compared to a new tool insert, a worn router can increase the required spindle power by around
30%.
•
The Zünd "Sealgrip routing support" is the most suitable routing support. With this support, the
greatest holding force can be achieved.
•
Energy costs can be massively reduced if the open area is covered and only the necessary
vacuum zones are switched on.
Aluminium
Some types of aluminium are very difficult to process in a metal-cutting procedure. Ensure that you
only use aluminium in what is known as "turning and drilling quality".
Aluminium has a very hard surface, almost as hard as diamond. Therefore, only about 0.1 mm-0.2
mm should be processed in the first pass. 0.25 mm to 1.0 mm should be fed in per pass afterwards,
depending on the type of aluminium.
6.8.3
Processing printed and laminated panels
Laminated and/or printed panels must not be damaged during processing.
Drill through the registration mark and turn the panel. Follow the procedure in accordance with the
processing file.
6.9
Troubleshooting
Problem
Directi
on of
rotatio
n
Feed
Accel
eratio
n
Set
depth
Numb
er of
cutting
edges
Build-up on the cutting edges
+
+
-
Poor removal of chips
+
-
-
-
Vibrations, shuddering
+/-
-
-
+
+
-
Poor surface quality
-
-
+ ... increase
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- ... reduce
51