KENT KGS-1020M User manual

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CONTENTS
A). Transit And Unpacking
Packing Diagram
B). Choice Of Site 2
C). Installation
(1). Power Consupmtion
(2). Foundation
(3). Contour And Nomenclature 4
(4). Cleaning Up The Machine
(5). Mounting The Table S
(6). Levelling The Machine 6
(7). Table Size And Grinding Capacity 6
(8). Lubrication Instruction
(9). Circuit Diagram & Connection Diagram
The Electric Wiring Diagram of KGSIO2O 10
(lO).Balancing The Grinding Wheel ii
D). Specifications 14
E). Putting The Maching Into Operation
(1).
Wiring Of Power Source 14
(2). Control Panel & Description 15
(3). Operation
a. Before Operation 1 ()
[1 b. Operation 1 6
F). General Comments Of Grinding I 7
G). Wheel Inspection I 7
H). Dressing The Wheel And Correct Treatment Of
Dressing Diamond i
I). Storage Of Grinding Wheel 20
J). Selection Of Suitable Grinding Wheels 20
~ K). Wheel Be Recommended 22
L). Choice Of The Grinding Condition 22
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M). Use Of The Optional Attachment
(a). Parallel Dressing Attachment 24
(b). Angle Forming Attachment 24
(c). Sine Bar 26
(d). Radius Forming Attachment 26
(e). Coolant System 29
(1). Common Cases In Side Grinding
(g). Right Angle Grinding 3 1
N). Complete Knock Down Drawing & Parts Lists 32
0). Electrical Parts List 48
P). Trouble Shooting 49
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THIS MACHINE IIAS BEEN FULLY TESTED, AT)JUSTED ANI)
INSPECTED FOR CORRECT ALIGNMENT AND OPERATION
PRIOR TO S~{IPMENT, TN TRANSIT OR INSTALLATION, PLEASE
ENSURE THAT THE MACHINE IS NOT BUMPED WHEN BEING
ROLLED OR . SET DOWN TO AVOID ANY FAILURE.
A). TRANSIT AND UNPACKING
I. Machine weight: Net
Gross
2. To avoid damaging the machine
and unpacking.
3. Loosen the fixing screws before
4. Packing Diagram
I. Machine
2. Standard Accessories
3. Coolant Tank
4. Table and Splash Guard
5. Blancing Base
1•.
1:
[
I 730Kg
1480Kg
or paint, please pay more attention when transit
lifting machine, then remove the sk itt—board.
.1.
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B). CHOICE OF SITE
The output of the machine and the degree of accuracy of thc components produced
depend to a very special on the correct choice of site for the crcction of the machine.
The grinding machine should be handled just as careful!)’ as a jigborcr. A fler all
extreme precision is demanded of both types of machine.
Grinding machine are often found between milling, shaping. dri lug and even
slotting machine, without any thought of the consequences of such planning. In such
cases, it is impossible to achieve good surface finishes, as the vibrations from the inillin,~
machine or jerks from the reversal of the shaper stroke, etc. arc transmitted to he
grinding machine. Chatter marks can be found on the ground surface. which arc (lie fl
these extraneous influences.
Unsàlid floor is unsuitable for taking the machine as it rcsuits in dicioriinn ot he
machine bed.
Floor plan:
EZLTL~~__
_.r~~~~ *~
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C). INSTALLATION
(I). Power Consumption
i\’lachine
( oulant
EleMag Chuck
lotal
(2). Foundation
a. Dimension
b. 1)se the levelling pads and screws
* Screw the levelling screws (1105, nut M20) on Ibe machine base a’~
figure shown. For easy levelling and more steady of the machine. make
levelling screw as deep as possible.
* Lay down the machine slowly to let screws fall into the center hole of
Levelling pads (10~7).
* Levelling the machine.
I.
1..
1017
0 I 7
.1.2 l\ w
U (X3K’.v
2 353Kw
‘ci
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(3) Contour and Nomenclature
Hand Wheel
(Longitudinal
Spindle Motor
S ~J. 11(11 e 11011 5-; rig
Table
Snddl E’
ll~r iid When 1
(Lower Vertical)
lIii 11(1 Wh n
( (r o~~; fe ~~cI )
(;() 1 ii Hi ii
Bed
Coo
Sys
When I (rin rd
Un nding Wheel
S p I ;i Ii ii ;i r d
i1 ectri c (‘onLro I
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(4). Cleaning Up the Machine
This machine has been packed with anti-dust grease bcibrc shipping out. so
for better operation and lubrication effect, please clcan UI) the follo~ving two
point before moving the three-axis travel:
1. Elevation slide way.
2. Saddle “V” groove.
(5). Mounting The Table
The machine is dcspatched completed with the exception of table. Sc) as to
protect the harden and ground slideways from demage during shipmcnt. When
installed, moui~ting the table as following procedures:
a. Wind the wire rope on the “Drum “3 cycles as figure shown, tighten dig the
wire and fix it temporarily.
Right End
Left End
/ttlj clsL i ci~
It
b. Put the steel ball retàii-~ers right in the middle of slidcways.
c. Lift up the table and plate it on the steel ball retainers. To prevent slideways
from damaging, j3~ease handle with care.
d. Fix the wire rope on the fixed stand.
e. The wire will loose after long use, and will cause.tahle move unsmoothly. In
this case please adjust the adjusting bolt the right end till its in tightening
condition.
f. The quantity of steel ball
The front retainer has 22 steel balls.
The back retainer has 23 steel balls.
This machine has 45 steel balls all.
I. x e
SL~ccid
I,
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(6). Levelling the machine
As following procedures:
a), Use longitudinal hahdwheel to let table at left end position. Levelling the
machine by a Spirit Level in longitudinal and latitudinal dircction.(Fig. A)
b). U.se loj~gitudinal handwheel to let table at right end position. l..evclling he
machine in longitudinal and latitudinal dircction.(Fig. U)
c). Use crossfecd handwheel to let table at front end position, levelling lie
machine by a Spirit Level in longitudinal and latitudinal direction. (Fig (‘)
d). Use crossfeed handwhecl to let table at rear end position. I.cvclling. the
machine in longitudinal and latitudinal direction. (Fig. I))
(7). Table size and grinding capacity
C
L.
I.
I
I.
255
14
24
.6.
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a
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ti). Lubrication instruction
Reliability of the machine and economic running are ensured only by the correct
ch~ce of lubricant for the individual lubricating points.
I). Lubrication pump: Manual lubrication pump module.
2). Lubricant: SAE3O, Lubrication oil of BP. ESSO, MOBIL. or SHELL.
3). Lubricant tank: I liters.
4). Lubricating points: Crossf~ed leadscrew
Machine bed NV” groove
Vertical leadscrew
Elevation slideways
Model: AJB-IT
Model: AJB-5T
Machinery Product~~td.
Lubrication flow chart
5). Oil distributor: No.1 —9
No.10—14
Manufacturer: Nanjing Bijur
.8.
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TC
SPINDLE
COOLANT
MOTOR MOTOR
2.2KW
90W
8.
6A
0. 591.
KGS1O2OM—1
ELECTRICAL
DRAWING
3’\.,220V
440V
60HZ
Li
QS
Li0 L20
~
L30
L30J
FE01
FU1
c5A)
u1~
—‘.
LZJ
—
V
Vii
~
W
r~i
Wil
-
. .
-
FU2
I
(~)
2~.
00
FRi
3
P8.2
K.M1
FRi
~.
6A(220V)
4.
97A(440V)
A Y
W202V2
W2U2V2
UI
Vi
WI
Ui
Vi
WI
220—240V
440—480V
-.
KM2
[~
FR2
(1.
~2A)
~4r~ ~
~
xSi
I
Ix~
SRi
~
5j
SB2
&-
ss:~:
HL()
ELL(I~J
SB5E-
KM2
9
KM2
—
‘—.—
.—.
—
%_.___
.——
——
—..—
..--
—.
.-.
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Description:
SB 1: Emergency push button
XD1: Indicator of power source
SB2: Push butt9n “OFF~ of Spindle motor
SB3: Push button “ON” of spindle motor
SB4: Push button “OFF” coolant or dust-collector power source
SB5: Push button “ON” of coolant or dust-colleC~Or power source
3-phase Tr.: Transformer to change local voltage to 220v
TC: Transformer for..~4v control circuit
CT2.CZ2: Socket for.illuminator
CT1.CZ~: So~ket..for coolant or dust-collector
Ml: Magnetic. contactor for spindle motor
M2: Magneti~COntactOr for coolant or du~t-~colleetOr
Fit: Fuse
FRI: Overload relay of Mi
FR2: Overload relay of M2
(9). T3lan~ing the grinding wheel
Efficient balancing is essential to eliminate unnecessary and additional sIrcSsS
in the wheel. It is also- unavoidable to obtain high quality results. Grinding
accuracy and surface finish as well life of grinding wheel, wheel spindle and
bearings depend to some considerable extent on careful balancing. Static
balancing will frequently sufficed for this purpose.
The grinding wheel together with be wheel flange is Fitted to balancing arbor
and this assembly is then placed on two accurate parallel knife edges of the
wheel balancing base, and balancing can be effected as following: (sec
Fig.2).
Level
-Wheel
Flange
cing
r
s~’ Fig;1~~
F i g ~
F’ig.3
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* The wheel balancing base must b~ levelled {Fig. I)
* Allow the, wheel to oscillate to find the cen~er of gravity which is then marked
“S, with chalk (Fig. 3)
* Apply the first balancing weighl “0” opposite to this point ‘S’ and screw it up.
It can not be moved again (Fig. 4)
* Place two correction weight “K” anywhere around the pcriphcry, hut at equal
distance “a” from weight “0” (Fig. 5)
* Turn the wheel through ~O at a timeand see ii it is balance. If not. the
Correction weight . “K’ must be moved until the wheel is in balance in any
Position (Fig. 6)
* Aflet balancing, the wheel must be given a test run of at least live milittles at
full working speed before being used or startii~g re-balance
After being balanced for the first time, the wheel must be mounted on the ~rindint~
spindle of the machine and dressed. This can be done with the parallel dresser on the
spindle carrier or with one fitted on the table. When dressing the wheel from the
table, the table must be locked longitudinally and then cross-traversed with handwhec!.
The wheel must be dressed until it runs dead true. The grinding finish is improved, if any
out-of-truth in the side walls of the wheel is also removed.
After this first balancing, the wheel must be removed from the spindle again and then
carefully re-dressed. After being fitted to the spindle again re-dressed, it is ready for
use.
As wear can leads to unbalance, the wheel should be re-checked and if necessary.
rebalanced.
Grinding wheel absorbs humidity and coolant, it is therefore advisable not to shart
coolant supply_when the wheel is stationary, otherwise the wheel will absorb liquid on one
Fig .4
Fig.5 Fig.6
12.
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side only and will then be out of balance. If the wheel is allowed to stand for any length
of time coolant will collect at the lowest point. Unbalance will also be generated if the
wheel is not allowed to idle after operation. Idling is essential to throw-off coolant by
centrifugal force.
Prior to place the flange-mounted grinding wheel to the spindle, flange bore atid
spindle taper must be absolutely clean, and the wheel is pushed by hand onto the spindle
~±aper. Subsequently, tighten wheel flange securely with fixed bolt or nut. (Fig. 7) -
~.To release wheel flai~g~ from spindle taper with extractor. (Fig. 8)
Fixed nut . E~tractor
* If various material have to be ground, so that the wheel has to be changed frequently.
it is more advantageous to shange the wheel complete with flange. It would involve
unnecessary loss of time and wheel waste to remove the wheel from its iriounting every
time and re-balance and re-dress it.
A
13
F~ g .7
Fig .8
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D). SPECIFICATIONS
Size of working table 25OmmX5lOmm
(10~• X2C)
Table traverse>.
Longitudinal traverse 620z-~im(24.4
Cross traverse 2~0min(l I
Distance from spindle axis to table surface 70-530mm
(2.76”-21)
Spindle vertica! traverse : 460mm(18
Wheel size 200mm X 25mm X 32 mm
8X1”Xl.25
Spindle motor 6OHi.
3420r/min
Overall dimension (LxWxl-P 50~20 mm>~ 1925mm
((~5 X5<L1~ X75.X
E). Putting The Machine Into Operation
(1). WiringCof power source
Be
sure that the wire connection is same as your powcr ~ourcc before power
“ON” the machine.
Attention: Following motors must be wired in accordance with power source
voltage.
I. Spindle motor.
2. Coolant or dust-collector motor (Optional accessoty)
14.
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1:
(2). Control panel & Description
SBI: Emergency push button
XDI: Indicator of power source
SB2: Push button “OFF” of spindle motor
SB3: Push button “ON” of spindle motor
SB4: Push button “OFF” of coolant power source
SB5: Push button ‘ON” of coolant power source
CZ2: Socket for illuminator
CZI: Socket for coolant
[Q~ ~ ~)E~5~
o 0
C7.2
O 0
[ :
i:
1:
L
1_.
1:
0
15.
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(3). Operation [
a). Before operation
It’s only after the following instructions have been fully complied with that
the machine can be started:
I. Ch’oics of a location free from vibration.
2. Clean up the machine of those anti-rust oil and grease.
3. Installation and levelling of the machine.
4. Lubrication of the machine according to lubrication instruction.
5. Checking the spindle (wheel) rotation direction, must be in clockwise. Please
take off the wheel prior to start spindle or it will cause danger if it rotates
- in counter-clockwise
b). Operation
I). Power ON & OFF
1. XD I indicator will lights when clectric control box is ready.
2. SBI is for emergency stop.
2~ Coolant system (Optional accessory)
1. Press SB5 to start coolant pump.
2. Adjust valve to get suitable coolant flow.
16.
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F) General Comments of Grinding
The grinding results obtained depend to a very degree on the
choice Of the correct grinding wheel and suitable operation.
(1) Stock removal efficiency
For intensive stock removal a coarse grain (about 30-36) should
be used. The wheel is dressed by passing the diamond over
quickly so that the Surface of the wheel is roughened and bites
well.
(2) Surface finish required
• If fine finish isto be produced, a finer grain wheel is required
(40-80). Thé.~~diamond in this case is passed slowlyove~r the
wheel so a~•.to break up the grain.
(3) Distortion 6f the workpiece
If the workpiece shows too much distortion when being ground,
this means that the stock removal was too great and the
longitudinal and cross movements of the table was too slow,
or the grinding wheel in ‘clogged”.
(4) Undesirable burns and grinding cracks
If. burn marks and grinding cracks appear, this means that the
wheel is too hard, or the wheel “clogged”.
G) Wheel Inspection
It is absolutely essential to comply fully with following safety
rules.
These are intended to protect the operator abainst danger.
Wheel inspection and fitting:
Prior to fitting any grinding wheel, it should always be tested.
Sounding the wheel .is a generally accepted test method.
The wheel should be suspended from a mandrel secured to its
bore and should then be lightly sounded with a wooden hammer.
Even wheelswith hair cracks not visible with the bare eye will
produce a distorted note in comparis6n with perfect wheel
where the sound is clear. Defective grinding wheel must not
• be used.
• ..~•~There. ~o. pieces of paper washer~n bøth faces of wheel and serve
as plastic packings between wheel and mo.unting flange.The packing
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washer must not be removed, when mounting the wheel should
s”.ide onto the ‘flange easily by hand without the need for force.
Wheel’ flange must be absolutely clean especially on the
• clamping and location surface, in the spindle bore and thread.
‘H). Dressir~g The Wheel And Correèt Treatment Of Dressing Diamond
i Th~ diamond is inserts in the dressing device. The sleëVë’ of
‘the. device is arranged at an angle of about 50, so that, when
the diamond
loses its keenness, it can be turned in the sleeve,
along with its holder, thus ensuring that there is always a sharp
dia-mondedge.~.avai1able
Various de~grees of roughness can be produced in the ground
com-ponent
by varying the s~peed at which •the diamond is
passed over the grinding wheel.
If’thére is only about 0.2mm to 0.3mm stock removal, it is
advisable• to roughen the grindingwheel. This is done by feeding
the diamond in about 0.03mm and turning the handwheel
rapiUky, so-that the dressing diamond moves quickly over the
wheel. This make’s the wheel bite well and the stock remova]
is good.
If the component is to. .be finish ground to size with the same
grinding wheel, the wheel must be dressed again, this time
slowly, in twO or three passes, with the diamond fed in
onlyabout 0.01mm.
Freouent light ‘dressing is better for the life of the grinding
• wheel ~.nd the diamond than a heavy cut.
• When dressing,: ‘the diamond should always be cooled, if possible,
but ‘sudden cooling is ‘dangerous, as it can lead to the diamond
being split.
‘As the diamond is very brittle because of its extraordinary
hardness ‘and being sensitive to even the slightest knock,
naturally ‘cracks easily. .
~When dressing, ‘begin in the center, as the edges are usually
• worn down further... If dressing i~ be,gun ‘at the worn edges~
• ‘ there is danger of the higher pressur~n the centei~ overstressing
the diamond ‘and :shattering it. .
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