Spindle Setting Analyzer. PPC Curve Ver Program Manual. Serial Number # Password :

Transcription

1 Spindle Setting Analyzer Program Manual Serial Number # Password : February Contact Tsuneyoshi@spindlesetting.com SpinTech, Inc. Gresham Oregon USA 1

2 o Major changes 1. About Analysis 2. Menu 3. LOGIN 4. DAQ Data Acquisition 4.1. DAQ Preparation Cable connection Green switch Setting Spindle Speed Setting Push Pull Force Setting (DAQ Loading Range) Points Displacement sensors Zero Adjustment Load Cell Zero Adjustment Data File Name 4.2. Data Acquisition 4.3. List of Warning for DAQ and Analysis programs 4.4. Renew of PPC in file in case of Warning Good and Warning data Examples of DAQ 5. Analysis Program 5.1. Analysis Bearing Setting Analysis for Fixed Arrangement Local Stiffness Analysis Example of Preload Spindle Analysis Example of Zero Preload Spindle Analysis Spring or Hydraulic Preload Analysis DT Analysis 5.2. Load Compensation 5.3. Simulation End Play Simulation Preload Simulation 5.4. Remote Analysis 6. Generation 6.1. Automatic generation by DAQ program 6.2. Generation by Generation program 7. Data Recording 7.1. Analysis Screen Record 7.2. Data File Transfer to EXCEL 7.3. SpinTech PG file 8. Error Message Trouble Shooting 2

3 o Major Changes in Ver14.4 i. Optimization program: New version program generates wide range of PPC curves. It is optimized fit best with the actual data by increasing the number of data base pattern. The PPC Curve generation is based on three sources, Measurement of spindle characteristic, DATA Base in the program and Input information for the application. Program will generate it automatically just after spindle measurement. It will take for 5 minutes or more. Program can generate spindles with preload as well as end play condition. This eliminates the need preparing a dummy spindle with end play which was the base of Master Curve method. ii. Introduction of Temperature recoding. The new program will allow temperature input manually and automatically (Option) recording room temperature and housing temperature. This will provide the preload vs. temperature characteristic of the spindle in quantitative manner. iii. Upgrade of DAQ and Analysis Warning system. The program is upgraded for the warning guide line utilizing the local stiffness analysis result. This will provide better guide line for heavy preload DATA. Good data provide repeatable good analysis. The Warning system allows identifying the source of error at the time of DAQ. iv. Remote Technical service. Analysis program include option for Remote Analysis Button. This will send the data to SpinTech for further details review and comments. (Annual Technical Service is required.) v. PPC load monitoring during DAQ program. Indicator Back panel change the color when the load is over PPC load. Green: 100%-110% of PPC Load Light Green: 110%-120% of PPC Load Red: Over 120% vi. 3 Point Zero Adjustment 3 point zero adjustment is easier with large screen indicators and spring nut adjustment.. 3

4 1. About Analysis : is a hypothetic curve representing a spindle characteristic of zero endplay and zero preload condition in axial direction. The program generates it automatically after DAQ. It is generated based on three sources, Measurement of spindle characteristic, DATA Base in the program and Input information for the application. The program analyzes preload amount by measuring distance between the data spots and the at a PPC Load. is displayed on screen as blue line. Measured DATA spots are shown in red dots. PPC Load: PPC stands for Push Pull Constant. It should be set out side of preload range. PPC load is initially selected depend on the measured data range. Once it is stored in file, it is used for all of same model. The PPC in file is displayed on DAQ screen. The DAQ loading range should be 110% ±10% of PPC in file. 2. Menu A black arrow appears on left upper corner of screen when SpinTech program starts. The arrow is black when program is running. It is white when the program stops. Click white arrow to start program. Click Stop button to stop program. Select 0 for English or 1 for Japanese before Log In. 4

5 3. LOGIN SpinTech Serial number: Marked on a label of the control box. Password: Supplied with the program matched with the serial number and can not be changed. Model Name: Enter a test name or model name of the spindle. All DATA and Master is filed under the file name. Different spindle application required different file name. Less than 16 letters including space. For existing file name, use pull down menu in the file list. Bearing Series: Select bearing series used on the spindle. Ball Material: Select ball material steel or ceramic of the bearing. Steel only for Tapered Roller Bearing. Application: Select spindle application for machining center or not. Nose Bearing: Select nose bearing arrangement, single row or double rows. Setting Bearing: Select rear bearing arrangement, Fixed Position or Spring Preload. Brg Bore Size: Enter bearing bore size mm. Contact Angle: Enter Angular contact bearing angle in degree ( ). Max Speed rpm: Enter maximum spindle speed in rpm. After entering all information, click OK. If there is one or more information missing, login is not accepted. 5

6 4. DAQ Data Acquisition 4.1. DAQ Preparation Cable Connection To run DAQ, it is necessary connect control box and PC matching with the serial number. Following messages would show up on screen if it these are not connected to run DAQ Green Switch Setting Preparation of DAQ: Setting five green switch buttons. Screen Cleaner: Click the button to clean up the graph. Disp Sensor: When displacement sensor is mounted spindle front face, keep switch to green. If you measure from rear side of spindle, switch the direction of the sensor by changing it to rear/yellow. Fixed or Sprig: When measuring preload for fixed position bearing arrangement spindle, keep this switch to green, If the spindle is spring or hydraulic preload, turn this switch to Spring/yellow Zero Adjust Switch from DAQ (green) to Zero Adj (Yellow) for 3 point sensors initial zero setting.. Temperature Default is Manual (Green), Switch to Yellow when Temperature sensors are added to the system. 6

7 Spindle Speed Setting We recommend spindle of about 1000rpm for high speed spindle 8,000rpm. If spindle would rise a temperature during the measurement, change it lower speed which would require more time to measurement complete Push Pull force setting. (DAQ Loading range) New model: DAQ loading guide line. Use 6 times of anticipated preload for the spindle. For example when max preload is expected 500N, Push Pull force (DAQ loading range ) should be more than 3,000N. Push Pull force for DAQ should be 110% ±of PPC in file value displayed on DAQ screen. If the DAQ loading range is out side of guideline, analysis program will display warning messages and blinking red on analysis result. For high preload data, PPC required is shown. Since analyzed preload is not accurate, the PPC required is not accurate as well. It is a guide line for trail to establish new PPC. Indicator Back panel changes the color when the load is over PPC in file load. Green: 100%-110% of PPC Load Light Green: 110%-120% of PPC Load Red: Over 120% Point Displacement Sensor Zero Adjustment Click Zero Adjust switch to make it yellow. Click START then three indicator show up on the screen. Adjust all three displacement sensor zero position within ±0.1mm. When it is adjusted Indicator will change color from Red to green. Make all indicators to green. Click EXIT and restart DAQ from Main menu Load Cell Zero Adjustment Click START button and adjust Load Cell Zero Adjustment dial on right upper corner in DAQ Screen. It is not necessary to adjust exact zero while program will make adjustment automatically. 7

8 Data File Name. After Start button clicked on DAQ screen, Spindle Model name is shown up as the file name entered at the Log In program. This file name links with model information for DAQ and Analysis programs. Pick up a data file and/or modify it while it will over write with new data. It requires an extension of.lvm at the end of the file name DAQ Data Acquisition Spindle need to be rotated to measure the accurate spindle displacement under the axial force. The recommended spindle speed is 1000rpm. It can be above 1000rpm to reduce the measuring time. It can be 500rpm or less to reduce the spindle temperature change if required. DAQ starts by clicking START and operate the push pull jack handle. Monitoring the screen, rotate the handle to push (or pull) side first to achieve the maximum load then reverse the rotation to achieve maximum of pull load and return to zero load. After completing one cycle of the push load and pull load, click ANALYSIS for the analysis result. 8

9 4.3. List of Warning for DAQ and Analysis programs Warning messages and red blinking will appear on screen when the measured data is not appropriate for accurate analysis. Warning Number Contents Impact of Analysis result 1 Measurement force is less than PPC in file Larger difference, larger analysis error. 2 Poor data point. Large Error Short Measuring Time 3 DATA Scatter Unstable Sensor or Poor Spindles Alignment Larger Scatter, larger error. 4 Important PPC in file and DATA range is not enough compared with the preload of spindle. 5 PPC required exceed capacity of AS-SC-40 (5,000N). Large error. DAQ again for new PPC and DATA.. Only for AS-SC-40 6 DATA irregular Can not make analysis. 7 Insufficient DATA Skip Analysis (for Zero Adjustment) 8 Measurement force is over 120% of PPC in file. Larger difference over 120%, larger error Renew of PPC in file in case of Warning 4 DAQ again with the force as PPC required value. If PPC file exist, change Model name at the time of Login or delete the old data locate at C;\SpinTech PG\. To keep old PPC in file, log in with different model name for new PPC in file. One model, One PPC in file 9

10 4.5. Good and Warning Data Examples Good Data Example Warning 1: DAQ loading range is less than PPC in file 10

11 Warning 2: Need more data points Warning 3: Large Scatter Unstable sensor 11

12 Warning 3 Scatter Poor Alignment Warning 4: -Important- PPC and data is not sufficient. 12

13 Warning 8: DAQ Load exceed 120% of PPC in file 13

14 5. Analysis Program 5.1. Analysis Bearing Setting Analysis for Fixed Arrangement Select the PPC file from pull down menu. All of PPC data filed in the C drive/spintech PG/PPC Curve holder are shown in the menu. Select data Blue line is the PPC Curve for the spindle. This curve represents the spindle character at zero endplay and zero preload. This curve also simulates the setting when value of a preload or endplay is type in the simulation input area. Red dots are measured data spots of the spindle. Green line is an analysis curve of the spindle character simulated from the PPC curve with the preload setting result Stiffness Analysis Spindle Axial stiffness Analysis result is shown in graph display. Vertical axis is Axial load N and horizontal axis is stiffness N/um. The curve indicates the change of stiffness at different load. This would be strong tool to evaluate the spindle characteristics. 14

15 Example of Preloaded Spindle Analysis Example of Zero preload Spindle Analysis 15

16 Spring Preload Analysis When data is taken from spring or hydraulic preloaded spindle, master is not required for the analysis. Switch to Spring/yellow button and click START. Preload amount is analyzed as the intersection point of spring deflection curve and bearing deflection curve. If the spring stiffness is larger than 50 % of nose bearing stiffness, it is automatically analyzed as the Fixed position spindle DT Step Analysis In case of 2 Rows bearing arrangement, there is a case that zero zone area has a stiffness slope while analysis indicates end play. This could happen because of DT error of stacked bearings. Program will automatically detect the possible DT error and report the amount of zero zone and stiffness at zero zone which correspond to single row s stiffness Load Compensation. In case of vertical spindle, a spindle self weight causes the bias load on measurement. When the spindle is setting endplay, program adjusts automatically the amount of the load for the analysis. For the preloaded spindle, spindle weight can be manually input. 16

17 5.3. Simulation The master curve/blue line simulates the setting typed in the simulation column. To switch the simulation from endplay to preload or reverse, input zero and run to show up the input column End play simulation Type a value in End Play column and click START. Example shows 0.015mm endplay simulation in blue line while red spots indicates measured data of spindle deflection. The analysis result is mm Preload Preload Simulation Type value in the preload column and click START. The example shows 500N preload simulation in blue line. The red dots are measured data spots and the green line is analyzed curve. Next example shows preloaded spindle data and 500N targeted preload simulation. Current spindle setting is 252 N preload or mm dimensional preload. Spacer Adjustment amount to achieve the target preload is calculated as 0.009mm. 17

18 5.4. Remote Analysis Services (Annual Technical Service required.) SpinTech Expert provides Remote Analysis Services to evaluate the Test method, Test Result, DATA and Analysis. To use this service, connect PC to internet and Click Remote Button ON at the right upper corner of Analysis Screen. When Analysis complete, click Yes on popup message show up on screen. Enter return address and your message, questions in the column. The SpinTech engineer comments will be ed normally within a day. 18

19 6. Generation 6.1. Automated Generation by DAQ program. After the DAQ completed, and click the analysis, program will generate PPC Curve for the data if the model name is not filed yet. Program will analyze the data with existing PPC for the model name in the file already. is stored in a file C:\SpinTech PG\\(model name).lvm. Optimization Program will run for the PPC generation. This will take for 5 minutes or more. The screen has a blinking lamp of Analysis button during running of the PPC optimization program Generation by Generation program Login with the model name to be used Open generation program from Main menu Model name is shown at right top corner. Enter PPC file name in column below. Existing file name can not be used Select DATA file and click Start Red dots are data. Blue line is a new. The file locate in C;\SpinTech PG\PCC Curve\(New Model Name).lvm The new PPC in file with from data for the model can be used for Analysis program. 19

20 7. Data Recording 7.1. Screen Recording DAQ, ANALYSIS and MASTER generation screen can be print on a printer connected to the PC by clicking PRINT Button Convert DATA file to Excel sheet. Analysis program stores the analysis result of each test number, preload and setting in a file locates at C: SpinTech PG Result Data files. All data in the DATA file are tab separated data. It can be read by Excel program. 20

21 8. Error Message, Cause and Fix SpinTech Program Error Msg. Cause Fix Log In Some Info is Log In information is not Log in again and missing completed for new file complete input all name login information Log In Password is not Password is not match Input correct Correct. with Serial Number of password. control box. DAQ No Signal from There are 5 causes for Check next 5 steps DAQ Card. this msg. one by one till fixed. Please insert DAQ Card in PC. DAQ No Signal from 1) No Signal from DAQ Check insert of Card, DAQ Card. card flat cable connection Please insert and control box DAQ Card in PC. power. DAQ No Signal from 2) NI-DAQ6024E card is Use PC with OS of DAQ Card. not compatible with XP or Please insert Windows Vista DAQ Card in PC. DAQ No Signal from 3) No driver for the card Install it by following DAQ Card. It should be found at Windows new devices Please insert Control Panel/System/ wizards. It is included DAQ Card in PC. Hardware/Device Manager in SpinTech program /Data Acquisition CD. devices/ DAQCard-6024E 21

22 Program Error Msg. Cause Fix DAQ No Signal from 4) Other than NI-DAQmx Open Measurement DAQ Card. driver is assigned at and Automation Please insert Measurement and program. Right Click DAQ Card in PC. Automation program.. Devices and Interfaces to create new. Select NI- DAQmx Simulated Device/E Series DAQ/NI-DAQ-6024E. DAQ No Signal from 5) Devices name is wrong Right Click active DAQ Card. at Measurement & NI DAQCard- Please insert Automation. The name 6024E: Dev? and DAQ Card in PC. should be NI DAQCard- rename it to Dev1 6024E: Dev1 instead of Dev? DAQ Not enough Number of Sampling Data Click continue to sampling is less than expected. proceed with current number of sample. DAQ Connect Cable The identification signal Check power cable, and Power on from control box does not power on, and SN DAQ Control box match with input of Serial number on the control with same Serial Number. box. Number 22