KNECHT A 95 User manual

Operating Instructions
Grinding Machine for Sickle-shaped and Circular Knives
Status 08.2023 Version 2.2 | Translation
A 95

3
A95 Grinding Machine for Sickle-shaped and Circular Knives
Manufacturer
KNECHT Maschinenbau GmbH
Witschwender Straße 26
88368 Bergatreute
Germany
Phone [phone]
Fax [phone]
[email protected]
www.knecht.eu
Documents for machine operator
Operating Instructions
Date of issue of the operating instructions
August 31, 2023
Copyright
These operating instructions as well as the operating documents remain the copyright property of KNECHT
Maschinenbau GmbH. They are supplied only to customers and operators of our products and belong to
the machine.
Without our express permission, these documents may neither be duplicated nor made accessible to third
parties, in particular competitor companies.
Operating Instructions

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1. Important notes 8
1.1 Preface to the operating instructions 8
1.2 Warnings and symbols in the operating instructions 8
1.3 Warning and mandatory signs and their meaning 9
1.3.1 Warning and mandatory signs on / in the grinding machine 9
1.4 Rating plate and machine serial number 10
1.5 Figure and position numbers in the operating instructions 10
2. Safety 11
2.1 Basic safety instructions 11
2.1.1 Observe notes in the operating instructions 11
2.1.2 Obligation on the part of the operator 11
2.1.3 Obligation on the part of the personnel 11
2.1.4 Hazards involved in handling the grinding machine 11
2.1.5 Malfunctions 12
2.2 Intended use 12
2.3 Warranty and liability 12
2.4 Safety regulations 13
2.4.1 Organizational measures 13
2.4.2 Protective equipment 13
2.4.3 Informal safety measures 13
2.4.4 Selection and qualification of personnel 13
2.4.5 Machine control system 14
2.4.6 Safety measures in normal operation 14
2.4.7 Hazards due to electrical power sources 14
2.4.8 Particular hazard areas 15
2.4.9 Servicing (maintenance, repair) and fault rectification 15
2.4.10 Structural alterations to the grinding machine 15
2.4.11 Cleaning the grinding machine 15
2.4.12 Lubricants/ oils and greases 15
2.4.13 Relocation of the grinding machine 15
3. Description 17
3.1 Intended use 17
3.2 Technical specifications 17
3.3 Functional description 18
3.4 Description of assemblies 19
3.4.1 Grinding unit 20
3.4.2 Axes 20
3.4.3 Laser measuring device and serration unit (optional) 21
3.4.4 Coolant pump 21
3.4.5 Flow monitor 21
3.4.6 Pneumatics 22
3.4.7 Switching the grinding machine on/ off 22
Table of Contents

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3.4.8 Control panel 23
3.4.9 Structure of the user interface (main screen) 24
4. Transport 26
4.1 Transport aids 26
4.2 Transport damage 26
4.3 Transport to another installation site 26
5. Installation 27
5.1 Selection of qualified personnel 27
5.2 Installation site 27
5.3 Supply connections 27
5.4 Settings 27
5.5 Initial start-up of the grinding machine 28
6. Commissioning 29
7. Operation 31
7.1 Switch on the grinding machine 31
7.2 Grinding sickle-shaped knives 31
7.2.1 Loading the grinding program 31
7.2.2 Clamping the sickle-shaped knife 33
7.2.3 Grinding the sickle-shaped knife 37
7.2.4 Polishing sickle-shaped knife (optional) 37
7.3 Serrating/ re-serrating sickle-shaped knives 38
7.3.1 Loading the grinding program 38
7.3.2 Measuring the profiling wheel 39
7.3.3 Clamping the sickle-shaped knife 40
7.3.4 Serrating/ re-serrating sickle-shaped knife 44
7.3.5 Polishing serrated sickle-shaped knife 44
7.4 Grinding circular knives 45
7.4.1 Loading the grinding program 45
7.4.2 Clamping the circular knife 46
7.4.3 Grinding the circular knife 49
7.4.4 Polishing the circular knife (optional) 50
7.5 Serrating/ re-serrating circular knives 51
7.5.1 Loading the grinding program 51
7.5.2 Measuring the profiling wheel 52
7.5.3 Clamping the circular knife 53
7.5.4 Serrating/ re-serrating circular knife 56
7.5.5 Polishing serrated circular knife 57
Table of Contents

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7.6 Positioning the polishing unit (optional) 58
7.7 Changing the front/rear grinding wheels 59
7.7.1 Intermediate flange for ceramic grinding wheels 60
7.8 Changing the profiling wheel (optional) 61
7.9 Dressing ceramic grinding wheels front/rear 63
8. Control 65
8.1 Settings 65
8.2 Serrating (re-serrating) 66
8.3 Axes manual operation 69
8.4 Grinding data 71
8.4.1 Data 72
8.4.2 Data – Contour 72
8.4.3 Data – Serration 73
8.4.4 Data – Change position 74
8.4.5 Data – Abrasives 74
8.4.6 Steps – Step 1 74
8.4.7 Feeds – Feed 1 – Steps – Step 1 75
8.5 Manual functions 76
8.5.1 General 76
8.5.2 Grinding disk front 77
8.5.3 Grinding disk rear 77
8.5.4 Serrating unit 78
8.5.5 Polishing unit 78
8.6 Message texts 79
8.7 Options 79
8.8 Knife contour 80
8.8.1 Axial run-out 81
8.8.2 Contour deviation 81
8.9 Knife selection 82
8.10 Setting up an Internet connection 83
9. Care and maintenance 84
9.1 Coolant 84
9.1.1 Coolant additive 84
9.2 Cleaning 84
9.2.1 Cleaning agent and lubricant table 85
9.3 Maintenance plan (one-shift operation) 85
9.4 Lubrication points 86
9.4.1 Lubricating the grinding wheel slide 86
9.4.2 Lubricating the angle adjustment slide 86
9.4.3 Lubricating the serration unit (optional) 87
9.4.4 Lubricating the polishing unit (optional) 87
9.4.5 Lubricating the cross slide 88
Table of Contents

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Table of Contents
10. Disassembly and disposal 89
10.1 Disassembly 89
10.2 Disposal 89
11. Service, spare parts and accessories 90
11.1 Postal address 90
11.2 Service 90
11.3 Wear and spare parts 90
11.4 Accessories 91
11.4.1 Abrasives used etc. 91
11.4.2 Abrasives used etc. for serrating unit and polishing unit 91
12. Appendix 93
12.1 EU Declaration of Conformity 93

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1.1 Preface to the operating instructions
These operating instructions are intended to make it easy to learn how to use the grinding
machine for sickle-shaped and circular knives, hereafter referred to as the grinding machine,
and to properly utilize its features.
These operating instructions contain important notes on how to operate the grinding machine
safely, properly and efficiently. Observing these instructions helps to avoid hazards, reduce repair
costs and downtimes, and to increase the reliability and service life of the grinding machine.
The operating instructions must always be stored in the location that the grinding machine is
used.
The operating instructions must be read and applied by every person tasked with working with
the grinding machine, e.g.:
• transport, installation, commissioning
• operation, including error rectification during operation, as well as
• servicing (maintenance, repair).
Recognized technical standards for safe and professional work must be observed in addition to
these operating instructions and the binding accident prevention regulations applicable in the
country of use and at the place of use.
1.2 Warnings and symbols in the operating instructions
The operating instructions use the following symbols/designations that must be followed:
The hazard triangle with the signal word “CAUTION” serves as a work
safety notice for all work for which there is a risk of personal injury or
death.
In these cases, work should be done with special attention and care.
ATTENTION ”ATTENTION” is written in places where special attention must be paid to
prevent damage or destruction of the grinding machine or its surroundings.
NOTE ”NOTICE” refers to user tips and especially useful informations.
1. Important notes
CAUTION

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1.3 Warning and mandatory signs and their meaning
1.3.1 Warning and mandatory signs on/in the grinding machine
The following warnings and mandatory signs have been affixed on/in the grinding machine:
CAUTION! DANGEROUS ELECTRICAL VOLTAGE
(Warning sign on the control cabinet)
The grinding machine carries life-threatening voltage when it is
connected to the power supply.
Voltage-carrying device parts may only be opened by authorized
personnel.
The grinding machine must be separated from the mains supply
before carrying out servicing, maintenance and repair work on it.
CAUTION! RISK OF INJURY DUE TO ABRASIVE PARTICLES
(Mandatory sign on the slide of the Z-axis)
Dressing the grinding wheel gives rise to abrasive particles that
can get into the eyes.
Wearing eye protection is mandatory when carrying out such
work.
CAUTION! RISK OF INJURY FROM KNIFE
(Mandatory sign on the slide of the Z-axis)
Working with the grinding machine involves grinding knives that
could cause serious cut injuries due to their sharpness.
Protective gloves must be worn when clamping and releasing
knives.
Caution when transporting knives. Use the protective equipment
provided by the knife manufacturer. Protective gloves and safety
shoes must be worn.
1. Important notes

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1.4 Rating plate and machine serial number
The rating plate (1-1) is located on the left side of
the machine.
The machine serial number (1-2) is located on
the rating plate (1-1) and at the front left at the
machine.
1.5 Figure and position numbers in the operating instructions
If the text refers to a component of the machine that is shown in a figure, the figure and position
number is given in brackets.
Example: (6-1/1) means picture number 6-1, position 1.
Open safety doors.
Adjust the coolant hose (6-1/1) as shown in the figure. The
distance to the rear grinding wheel (6-1/2) and front grind-
ing wheel (6-1/3) should be approx. 5 mm. The coolant
hose must not touch the grinding wheels.
1. Important notes
Figure 1-1 Rating plate
Figure 1-2 Machine serial number
Figure 6-1 Adjusting the coolant hose
1
1
2
3

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2.1 Basic safety instructions
2.1.1 Observe notes in the operating instructions
The basic prerequisite for the safe handling and uninterrupted operation of this grinding machine
is knowledge of the basic safety instructions and regulations.
• These operating instructions contain important notes on how to operate the grinding machine
safely.
• All persons carrying out work on the grinding machine must follow these operating instructions,
in particular the safety notices.
• In addition, the rules and regulations regarding accident prevention at the place of use are to be
observed.
2.1.2 Obligation on the part of the operator
The operator is obliged to allow only those persons to work on the grinding machine, who
• are familiar with the occupational safety and accident prevention regulations and have received
instruction in handling the grinding machine,
• have read and understood the operating instructions, in particular the section entitled “Safety”
and the warning notes, and have provided signed confirmation of this.
The safety-awareness of the personnel at work will be monitored at regular intervals.
2.1.3 Obligation on the part of the personnel
All personnel working on the grinding machine shall be obliged, before starting work, to
• observe basic occupational safety and accident prevention regulations,
• read the operating instructions, particularly the section entitled “Safety” and the warning notes,
and provide signed confirmation that they have understood them.
2.1.4 Hazards involved in handling the grinding machine
The grinding machine has been built to the latest technological standards and the recognized
rules of technical safety. In spite of this, its use poses inherent risks which could result in bodily
harm or even death of the user or third persons, or damage to the grinding machine or other
property.
The grinding machine may be used only:
• for its intended purpose
• in a safe and secure condition.
2. Safety

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2. Safety
Malfunctions that may impair safety are to be eliminated immediately.
2.1.5 Malfunctions
If safety-relevant malfunctions occur with the grinding machine, or if the processing behavior
indicates that such malfunctions may have occurred, the grinding machine must be stopped
immediately and until such time as the malfunction has been found and eliminated.
Allow only authorized trained personnel to eliminate the malfunctions.
2.2 Intended use
The grinding machine is intended exclusively for grinding and serrating circular and sickle-shaped
knives. Before working on a knife, it must first be checked whether the knife fits on the knife
mounting plate. Only then may the knife be clamped onto the knife mounting plate.
Any other use or use beyond this is not considered as intended. KNECHT Maschinenbau GmbH is
not liable for any damage resulting from this. The risk is borne solely by the user.
Intended use also includes observing all instructions in the operating manual.
ATTENTION Improper use of the grinding machine exists,
for example, if:
• knives are ground without a knife
mounting plate.
• fixtures are not properly attached.
2.3 Warranty and liability
Warranty and liability claims in case of personal injury or property damage are excluded if such
damage is attributable to one or more of the following causes:
• improper use of the grinding machine,
• improper transport, commissioning, operation, and maintenance of the grinding machine,
• operating the grinding machine with defective safety devices, or using improperly attached or
malfunctioning safety and protective equipment,
• failure to observe the instructions with regard to transportation, commissioning, operation,
maintenance and repair of the grinding machine,
• unauthorized structural alterations to the grinding machine,

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• unauthorized modification, e.g. of the drive conditions (output and speed),
• failure to monitor machine parts that are subject to wear, and
• use of unapproved replacement and wear parts.
Use only original replacement and wear parts. If externally purchased parts are used, it is not
guaranteed that they have been designed and manufactured to meet the requirements in terms
of stress and safety.
2.4 Safety regulations
2.4.1 Organizational measures
Inspect all available safety devices regularly.
Observe prescribed intervals for recurring maintenance work or as specified in the operating
instructions!
2.4.2 Protective equipment
Before every commissioning of the grinding machine, ensure that all protective equipment is
properly mounted and in functional condition.
Protective equipment may be removed only after the grinding machine has stopped and has been
secured against accidental restart.
When attaching spare parts, the protective equipment must be attached by the operator as
stipulated.
2.4.3 Informal safety measures
The operating instructions must be permanently available at the place of use of the grinding
machine. In addition to the operating instructions, the generally applicable as well as locally
relevant accident prevention regulations must also be made available and observed.
All safety alert symbols and hazard warnings on the grinding machine must be complete and
clearly legible.
2.4.4 Selection and qualification of personnel
Only trained and instructed personnel may work on the grinding machine. Observe the legally
permitted minimum age!
The responsibilities of personnel with respect to commissioning, operation, maintenance, and
repair must be clearly specified.
2. Safety

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Personnel still undergoing training or instruction may only work on the grinding machine under
the permanent supervision of an experienced person!
2.4.5 Machine control system
Under no circumstances make program changes to the software. Parameters that the operator
can set himself are excluded from this (e.g. setting the number of cycles).
Only trained and instructed personnel are permitted to switch on and operate the machine.
2.4.6 Safety measures in normal operation
Do not operate the machine in any unsafe manner. Only operate the grinding machine if all the
safety devices are installed and fully functional.
At least once per shift (or per day), check the grinding machine for externally visible damage and
proper functioning of the safety devices.
Immediately report any changes present (including those of the operating behavior) to the respon-
sible office or person. If necessary, immediately shut down the grinding machine and secure it
against restart.
Before you switch on the grinding machine, ensure that no one can be injured by the start-up of
the machine.
In the event of a malfunction, immediately stop the grinding machine and secure it against re-
start. Rectify malfunctions immediately.
2.4.7 Hazards due to electrical power sources
The control cabinet must always be kept closed. Access is only permitted to authorized personnel.
Work on electrical systems or operating materials may only be performed by a qualified electrician,
in accordance with electrical regulations.
Defects, such as damaged cables, cable connections, etc. must be immediately rectified by an
authorized specialist.
The yellow power supply cable is electrically live even when the main
switch is turned off.
CAUTION
2. Safety

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2.4.8 Particular hazard areas
In the area of the grinding wheels, profiling wheel and polishing brushes, there is a risk of crush-
ing and of e.g. clothing, fingers and hair being drawn in. Suitable personal protective equipment
must be worn.
2.4.9 Servicing (maintenance, repair) and fault rectification
Maintenance work is to be carried out on schedule by trained personnel. Inform operating
personnel before beginning repair work. Designate a supervisor responsible for this.
For all service work, the grinding machine is to be disconnected from the current supply and
secured against accidental restart. Remove power plug. Secure repair area as necessary.
After completing maintenance work and rectifying any faults, install all safety devices and verify
that they are fully functional.
2.4.10 Structural alterations to the grinding machine
Do not make any changes, additions or conversions to the grinding machine without the approval
of the manufacturer. This also applies to the installation and setup of safety devices.
Any conversion work requires the written permission from KNECHT Maschinenbau GmbH.
Immediately replace machine parts that are not in perfect condition.
Use only original replacement and wear parts. If externally purchased parts are used, it is not
guaranteed that they have been designed and manufactured to meet the requirements in terms
of stress and safety.
2.4.11 Cleaning the grinding machine
Properly handle any cleaning agents and materials used and dispose of them in an environmentally-
friendly manner.
Dispose of the wear parts and replacement parts in a safe and environmentally-friendly manner.
2.4.12 Lubricants/oils and greases
When using oils and greases, follow the safety regulations applicable to the product. Comply with
the special regulations for the food areas
2.4.13 Relocation of the grinding machine
Disconnect the grinding machine from any external power supply, even in the event of a minor
change of location. Before restarting the grinding machine, connect it properly to the power
supply.
2. Safety

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2. Safety
For loading work, use only lifting equipment and load-bearing devices with sufficient lifting
capacity. Appoint a qualified instructor for the lifting operation.
No persons other than those designated for this work may be present in the loading and
installation area.
Only lift the grinding machine properly with lifting gear as specified in the operating instructions.
Only use a suitable transport vehicle with sufficient load-bearing capacity. Secure the load reliably.
Use suitable attachment points.
When restarting the machine, proceed only in accordance with the operating instructions.

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3. Description
3.1 Intended use
The A95 Grinding Machine for Sickle-shaped and Circular Knife automatically grinds sickle-
shaped knives, circular knives or similar cutting tools (hereinafter referred to as knives) up to a
radius of 600 mm.
Optionally, the knives can be measured for axial runout, serrated and the cutting edge be
polished.
3.2 Technical specifications
Height ������������������������������������������������������������ approx. 2280 mm
Width ������������������������������������������������������������� approx. 2255 mm
Depth ������������������������������������������������������������� approx. 1270 mm
Space requirement (WxDxH) �������������������������������������� 3500x2100x2300 mm
Weight ��������������������������������������������������������������� approx. 800 kg
Power supply* ������������������������������������������������������������� 3x 400 V
Mains frequency* ���������������������������������������������������������� 50/60 Hz
Power output* ���������������������������������������������������������������� 9 kW
Power consumption* ���������������������������������������������������������� 11 kW
Current consumption* ����������������������������������������������������������� 14 A
Back-up fuse* ������������������������������������������������������������������ 32 A
Control voltage* ������������������������������������������������������������� 24 V DC
Compressed air supply according ISO 8573-1:2010 [1:4:2] ���������������� 6.5 bar (50 l / min)
Measured A-weighted emission sound pressure level ����������������������������� 72 dB (A)
at the workplace LpA**
Grinding wheel speed front/rear ����������������������������������������� 0 -1000 1 / min
Grinding wheel front/rear ���������������������������������������������� d.100 x 60 x d.40
Speed profiling wheel (optional) �������������������������������������������� 2600 1/min
Profiling wheel (optional) ������������������������������������������������ d.200 x 5 x d.17
*) This information may change depending on the electrical power supply.
**) Two-digit sound emission value according to EN ISO 4871 (measurement uncertainty KpA. 3 dB (A)).
Emission sound pressure level according to EN ISO 11201. A sickle-shaped knife (type known from the
company KNECHT Maschinenbau GmbH) was ground.

2280 mm
2255 mm
1270 mm
2280 mm
2255 mm
1270 mm
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Figure 3-1 Dimensions in mm and centers of gravity (CoG) of the machine
3. Description
3.3 Functional description
With the A95 Grinding Machine for Sickle-shaped and Circular Knives, sickle-shaped and circular
cutting tools up to a radius of 600 mm can be ground and deburred automatically.
The knife is mounted on an individual knife mounting plate and machined fully automatically after
program start.
Optionally, these cutting tools can be initial-serrated and re-serrated on the A95. For this pur-
pose, the flatness of the knife is measured by a 2-D laser before serrating. During serrating, the
grinding machine compensates for the axial runout of the knife. As a result, uniform serration is
obtained over the entire outer contour of the cutting tool.
The serration is finally polished to a burr-free finish with a polishing unit.
With the “emergency stop” function, the grinding machine can be brought to an immediate
complete stop at any time.
SP SP

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3. Description
3.4 Description of assemblies
1 Serration unit and laser measuring unit (optional)
2 Front and rear grinding unit
3 Holding flange
4 Water tray
5 Adjustable machine feet
6 Polishing unit (optional)
7 Safety door
8 Control panel
1
8
2
5
4
3
Figure 3-2 General view of grinding machine
6 77

+–
+–
+
–
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3. Description
3.4.1 Grinding unit
1 Servomotor for grinding wheels
2 Coolant hose
3 Grinding wheel rear
4 Grinding angle display at rear (hidden)
5 Grinding wheel front
6 Grinding angle display front
3.4.2 Axes
1 X-axis
2 B-axis
3 Z-axis
Figure 3-3 Grinding unit
Figure 3-4 Axes
1
4
2
3
5
1
3
2
2
6
1

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Figure 3-5 Laser measuring unit and serration
unit
2
3
1
3.4.3 Laser measuring unit and serration unit (optional)
1 Serration unit
2 Laser scanner with blow-off device
3 Blow-off nozzle
3.4.4 Coolant pump
1 Coolant pump with cover
3.4.5 Flow monitor
1 Flow monitor
3. Description
Figure 3-6 Coolant pump
Figure 3-7 Flow monitor
1
1