Nakanishi NR50 -5100 ATC RS User manual

OPERATION MANUAL
NR50 - 5100 ATC RS
Automatic Tool Replacement Spindle
Thank you for purchasing Automatic Tool Replacement Spindle " NR50 - 5100 ATC RS ". This Spindle is designed
for suited for PCB drilling. The E3000 CONTROLLER, Brushless Motor and Air Line Kit are required to drive this
Spindle. Read this and all the associated component Operation Manuals carefully before use. Always keep this
Operation Manual in a place where a user can referred to for reference at any time.
001
2. BASIC PACKAGE
Table.1Packing List Contents
NR50-5100 ATC RS・・1pc. Collet chuck ȭ3.175mm
(CHR - 3.175 RS) ・・1pc.*
Bar Wrench (K - 236)・・1pc.
Wrench (9 x 11)・・1pc. Wrench (12 x 14)・・1pc. Air Hose with Filter
(ȭ6mm x 2m)・・1pc.
Inspection Card・・1pc. Operation Manual・・1set
When opening the package, check if it includes all items listed in " Table.1 Packing List Contents ".
In the event of any shortage, please contact either NAKANISHI (see the " 4. CONTACT US " section) or your local dealer.
* The Collet chuck is attached to the Spindle.
Company Name
Business Hours
U.S. Toll Free No.
Telephone No.
Fax No.
Web Address
:
Industrial Div.
: 8:30am to 17:00pm (CST)
(closed Saturday, Sunday and Public Holidays)
: 800-585-4675
: 847-843-7664
: 847-843-7622
: www.nskamericacorp.com
Contact UsContact Us
For U.S. Market
Company Name
Business Hours
Telephone No.
Web Address
:
: 8:00am to 17:00pm
(closed Saturday, Sunday and Public Holidays)
: [phone]
: [email protected]
For Other Markets
4. CONTACT US
For your safety and convenience when purchasing our products, we welcome your questions.
If you have any questions about operation, maintenance and repair of the product, please contact us.
3. WARRANTY
We provide a limited warranty for our products. We will repair or replace the products if the cause of failure is due
to the following manufactures defects. Please contact us or your local distributor for details.
①Defect in manufacturing.
②Any shortage of components in the package.
③Where damaged components are found when initially opening the package.
(This shall not apply if the damage was caused by the negligence of a customer.)
11
9
12
14
᳨ᰝᡂ⦼⾲
Inspection Card
5. FEATURES
① The tools can be replaced automatically by putting ON - OFF the air.
② The Spindle housing is made from precision ground, hardened, stainless steel (SUS) with an outside diameter
of ȭ50mm.
③ The Collet chuck size is ȭ 3.0mm,
ȭ
3.175mm,
ȭ
4.0mm,
ȭ
6.0mm,
ȭ
6.35mm.
6 - 2 Outside View
0
-0.01
ȭ10.6 ȭ13.6 ȭ29.6
ȭ50
End of Spindle Area
(128.5)
(9.5) 106 (13)
(5.2)
12.5
ȭ20.5
ྲྀᢅㄝ󰩣᭩
OPERATION MANUAL
Fig. 1
8. CONNECTION OF AIR HOSE AND AIR SUPPLY
①Connect the provided ȭ6mm Air Hose with Filter and 3-way valve to Air Inlet Joint shown in Fig. 3.
②Supply clean air from air compressor through air filter or air dryer to the 3-way valve at the set air pressure :
from 0.55 - 0.6MPa.
・Please purchase the recommended commercially available air inlet fitting for the air inlet joint.
recommended air inlet SMC is KQ2S04-M5N.
ȭ6mm to ȭ4mm tubing reducer
SMC is KQ2H04-06A.
・When installing the collet chuck clamp / unclamp fittings, thoroughly read the instructions before connecting.
(Fig. 4)
Fig. 3
Fig. 4
〈When using the rear air inlet joint〉
Air Inlet
Exhaust Air
Air Inlet Joint
ȭ6mm Air Hose with Filter
3-way valve
Air Inlet
Exhaust Air
Reducer (ȭ6mm -ȭ4mm Adaptor)
ȭ4mm Air Hose
Air Inlet Joint
ȭ6mm Air Hose with Filter
3-way valve
1. CAUTIONS FOR HANDLING AND OPERATION
■Read these warnings and cautions carefully and only use in the manner intended.
■These warnings and cautions are intended to avoid potential hazards that could result in personal injury to the
operator or damage to the device. These are classified as follows in accordance with the seriousness of the risk.
Class Degree of Risk
WARNING A safety hazard could result in bodily injury or damage to the device if
the safety instructions are not properly followed.
CAUTION A hazard that could result in light or moderate bodily injury or damage
to the device if the safety instructions are not followed.
WARNING
①This Spindle is not a hand tool. It is designed to be used on CNC machines or special purpose
machines.
②Do not touch the cutting tool while it is running. It is very dangerous.
③Wear safety glasses, dust mask, and use a protective cover around the Spindle whenever the
Spindle is rotating.
④Never connect, disconnect or touch the Power Cord Plug or Motor Cord Plug with wet hands.
This may cause an electric shock.
⑤Never operate or handle the brushless motor and Spindle until you have thoroughly read the
Operation Manuals and safe operation has been confirmed.
1)To prevent injuries / damages, check the brushless motor, Spindle and cutting tool for
proper installation, before operating the brushless motor and Spindle.
2)Before disconnecting the brushless motor and Spindle, always turn the control power off
and turn the compressed air supply to the CONTROLLER off. Then it is safe to remove the
brushless motor and Spindle.
⑥When installing a Spindle to a fixed base, make sure the fixed base is grounded in order to
avoid the risk of an electric shock.
⑦When installing a tool, tighten the collet chuck correctly and check again the collet chuck
before use. Do not over-tighten the collet chuck. This may cause damage to the Spindle.
⑧Do not open and close the collet chuck while the brushless motor is runing.
⑨Do not use bent, broken, chipped, out of round or sub-standard tools, as this may cause them
to shatter or explode. Tools with fractures or a bent shank will cause injury to the operator.
When using a new tool, rotate it in a low speed and increase speed gradually for safety.
⑩Do not exceed the maximum recommended allowable tool speed. For your safety, use speeds
below the maximum allowable speed.
⑪Do not apply excessive force. This may cause tool slippage, tool damage, injury to the operator
or loss of concentricity and precision.
CAUTION
①Do not drop or hit this Spindle, as shock can damage to the internal components.
②Do not connect this Spindle to the reduction gear. This may cause collet chuck breakage by
overload.
③Be sure to clean the collet chuck, the inside of the Spindle before replacing the tool. If ground
particles or metal chips stick to the inside of Spindle or the collet chuck, damage to the collet
chuck or Spindle can occur due to the loss of precision.
④When cleaning a Spindle, stop the brushless motor and remove debris with a soft brush or a
cloth. Do not blow air into the End of Spindle Area (refer to section " 6 - 2 Outside View " ) with
compressed air as foreign particles or cutting debris may get into the ball bearing.
⑤Always clean the tool shank before installing the tool in the Spindle.
⑥ When sizing the correct collet chuck size to the tool shank diameter, a tolerance of +0 〜
-
0.01mm
is strongly recommended.
A tool shank within the +0 〜
-
0.1mm range is mountable, however,
this may cause poor concentricity and or insufficient tool shank gripping force.
⑦Select suitable products or tools for all applications. Do not exceed the capabilities of the
Spindle or tools.
⑧Do not stop the brushless motor and Spindle while coolant spray is being applied to the
cutting tool. Removing the air pressure from the brushless motor and Spindle causes a loss of
purging, allowing the brushless motor and Spindle to ingest coolant. This will cause damage to
the brushless motor and Spindle.
⑨Carefully direct coolant spray to the tool. Do not spray directly on the Spindle body. If large
amount splay directly on the Spindle, it may cause excess load of the motor rotation with loss
of durability to the Spindle.
⑩Stop working immediately when abnormal rotation or unusual vibration are observed.
Immediately, please check the content of section " 14. TROUBLESHOOTING".
⑪Always check if the tool, collet chuck, connection hose and supply air / oil hose for damaged
before and after operating.
⑫If the collet chuck show signs of wear or damage, replace it before a malfunction or additional
damage occurs.
⑬After installation, repair, initial operation, or long periods of non operation, please refer to
section " 12. BREAK-IN PROCEDURE " detailed in Table. 2. When checking the spindle, no
vibration or unusual sound should be observed during rotation.
⑭Do not disassemble, modify or attempt to repair this Spindle. Additional damage will occur
to the internal components. Service must be performed by NSK NAKANISHI or an authorized
service center.
⑮When using this Spindle for mass production, please consider the purchase of an additional
Spindle to be used as a back-up in case of emergency.
Collet chuck (CHR- □□ RS)
ȭ
3.0mm,
ȭ
3.175mm,
ȭ
4.0mm,
ȭ
6.0mm,
ȭ
6.35mm
<Option>
7. CONNECTION OF THE SPINDLE TO THE BRUSHLESS MOTOR
Fig. 2
Align the thread on the front end of the
brushless motor and the rear of the
Spindle, and turn the Spindle clockwise.
If the drive shaft of the brushless motor
does not engage properly to the drive
dog on the Spindle, it may only turn
aprroximately two threads before stopping.
DO NOT FORCE THEM TOGETHER.
Loosen the Spindle from the brushless
motor, rotate the Spindle shaft by hand
then re-try. The drive shaft and the drive
dog must be fully engaged. When fully
engaged, secure the brushless motor and
Spindle using the provided 27mm wrench
(Fig. 2).
27
Transmission Clutch
Turn
Tighten
CAUTION
Make sure your hands and all interlocking parts of the Spindle and brushless motor are clean
before connecting the brushless motor to the Spindle. This is critical in preventing contaminants
from entering the brushless motor or Spindle.
CAUTION
Securely connect the air hose to the brushless motor and air line kit to avoid accidental
disconnection and injury to the operator during use.
6 - 1 Specifications
Model NR50 - 5100 ATC RS
Maximum Motor Rotation Speed 50,000min-1 (rpm)
Spindle Accuracy Less than 1m
Applicable Motor
* This Spindle can not use the reduction gear .
EM-3060, EM-3060J/EM-3060J-2M, EM-3030J/EM-3030J-2M
Milling Capacity
(Cutting or Milling PC boards with an end mill.)
End Mill Size
Work
Thickess
F
: Less than ȭ2.0mm
: PC board (ex. Glass Epoxy Resin)
: Less than 1.6mm
: Less than 3,000mm / min
Weight 1,370g
6. SPECIFICATIONS AND DIMENSIONS
* You may need to lower feed rate (mm / min) depending on the shape of tools being used or the thickness of
work. Always check the milling condition before working.
CAUTION
・The rear air inlet port is closed with an M5 screw before shipment. When changing the air inlet
port location, remove the M5 screw to install an air inlet joint.
・Use any one of the two air inlet port. Be sure to close the unused air inlet port with the removed
M5 screw.
・After installing the fitting, supply air and confirm that there is no air leakage, then proceed with
the installation.
OM-K0668E

10. REPLACING THE COLLET CHUCK
①Stop the coolant air of motor.
②Supply air pressure : from 0.55 - 0.6MPa to Air Inlet Joint to keep the collet chuck opened.
Do not take off the tool when the air pressure is supplied.
③Place the provided wrench 12mm on the wrench hook of the spindle shaft, and tighten the Spindle.
④Place the provided wrench 9mm on the collet chuck and turn it counterclockwise to loosen the collet chuck.
And take off the collet chuck with the tool from the spindle shaft.
⑤Remove the tool from another collet chuck.
⑥Insert the tool into another collet chuck and turn it
clockwise to be attached on the spindle shaft.
⑦Tight it lightly with the provided wrench 12mm and wrench 9mm. (Specified tightening torque : 1.0 N・m).
⑧Exhaust the air through 3-way valve.
⑨After the chuck is replaced, supply the coolant air of motor to the motor.
Fig. 6
Tighten
Collet chuck Loosen
Tool
12
14
11
9
Spindie Shaft
11. INSTALLATION OF THE SPINDLE
①When mounting a Spindle, refer to the Clamping Area
etched on the Spindle (Fig. 7).
Fig. 7
(Clamping area)
70
17
CLAMPING AREA
③How to fabricate the Split Type Holder
（1）Rough bore the inside diameter of the
Split Type Holder.
（2）Cut a slit. (Ex. Slit 2mm) wide.
（3）Tighten the Screw for Removal and
Force Open the Slit Area.
（4）Insert a spacer (Ex. thickness = 2mm)
into the Slit Area.
（5）Loosen the Screw for Removal, and
tighten the fastening bolt with its
specified torque.
（6）Finish the Split Type Holder so that
the inside diameter of the Split Type
Holder is ȭ50 with its tolerance range
from
-
0.01mm to
-
0.015mm, and its
roundness and cylindricity of less than
5m.
（7）When inserting the Spindle loosen the
Fastening Bolt, and tighten the Screw
for Removal, widening the Slit Area.
Fastening Bolt
Screw for Removal
Fastening Bolt
Slit
Front View Side View
Screw for Removal
Spacer
Fastening Bolt
Fig. 12
12. BREAK-IN PROCEDURE
During transportation, storage or installation, the grease inside the bearings will settle. If the Spindle is suddenly run
at high-speed, the grease will be ejected from the bearings, causing excessive heat that will cause bearing damage.
After installation, repair, initial operation, or long periods of non operation, please follow the break-in procedure
detailed in Table. 2.
14. TROUBLESHOOTING
If a problem or concern occur, please check the following items prior to consulting your dealer.
15. DISPOSAL OF THE SPINDLE
When disposal of a Spindle is necessary, follow the instructions from your local government agency for proper
disposal of industrial components.
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2015.12.04 002 י
9. CHANGING THE TOOL
①Stop the motor (Or check if the motor is stopped).
②Supply air pressure: from 0.55 - 0.6MPa to Air Inlet Joint through 3-way valve. Then, the chuck will be opened.
At the same time, the tool is pushed out by the air exhaust for the coolant of motor. So, need the tool holder
not to be damaged to the tool.
③Replace the tool.
④Exhaust the air through 3-way valve. The collet chuck will be closed and the tool can be fixed.
WARNING
Do not open and close the collet chuck while the brushless motor is runing.
CAUTION
・When the air is supplied to the inlet joint of the Spindle, the tool will be pushed out by exhausting
the coolant air of brushless motor from the edge of Spindle. Be careful not to be damaged to the
tool or be injured.
・Use the air on-off valve through which the air can be exhausted. Do not use 2 way valve, because
the 2 way valve is not echausted and the collet chuck is not closed.
・Do not open and close the collet chuck before the tool is not installed. Because this will cause
damage to the collet chuck or loss of precision.
RECOMMENDATION
Please set the cutting tools to minimize the overhang amount. 13mm is the maximum amount of
overhang to maintain high accuracy and safety.
WARNING
Whenever connecting a Spindle to a brushless motor, or when installing a spindle to a fixed base,
ensure that the fixed base is grounded in order to avoid risk of an electric shock.
CAUTION
・When installing a Spindle, do not hit, drop or cause shock to the Spindle. This may cause
damage to internal components and result in malfunctions.
・When mounting the Spindle, be sure to secure within Clamping area etched on the Spindle O.D.
If the Spindle is installed incorrectly, amage to the internal components is possible.
・Cautions when tightening the securing bolts on to a Split Type Holder
Do not over-tighten the bolt. This will cause damage to Spindle's precision.
Tighten the bolt until the Spindle body can not be rotated by hand within the fixture.
Extreme tightening is not necessary or recommended.
Apply working force and check that the Spindle is tight before using.
CAUTION
Do not allow set screws to come directly in contact
with the Spindle body as shown in Fig. 10, as this
will result in damage to the Spindle housing and
internal components.
When installing, never clamp directly over the
bearings, as this will result in bearing damage.
(Refer to Fig. 11)
Fig. 11
Bearing
Fastening Bolt
Deformation
Damage of internal
Components
CAUTION
・How to confirm the correct tightening or clamping of the Spindles in the holder
Measure the current value of the CONTROLLER's power cord by the clamp meter.
Fasten the holder so that the increase in the no-load current value (during rotation at the
maximum rotation speed) with the Spindle fastened is 10mA (for type 200V / 230V) or less,
compared to the no-load current value (during rotation at the maximum rotation speed) without
fastening the Spindle. Do not over-tighten the Fastening Bolt. It may damage Spindle's precision
and shorten the life of the bearings.
・The final responsibility for ensuring holder's safety for use in a given application is left to the
designer of the equipment in which NAKANISHI's Spindle is installed.
NAKANISHI offers Spindle with a wide variety of capabilities and specifications.
Please carefully check the Spindle's specifications against the requirements of your equipment
and verify suitability and safety of the Holder prior to initial use.
Steps 1 2 3 4
Rotation Speed (min-1) (rpm) 15,000 30,000 40,000 50,000
Rotation Time（min）15 10 10 15
Items to Check
No Abnormal
Noises
The spindle housing temperature during
the break-in process should not exceed
20 degrees C (36 degrees F) above
ambient temperature. Should the spindle
exceed this limit, rest the spindle for at
least 20 minutes and re-start the break
in procedure from the beginning. If the
housing temperature rises again and
exceeds 20 degrees C (36 degrees F)
above ambient temperature, check the
spindle and motor for proper installation.
The spindle housing
temperature during
the break-in process
should not exceed
20 degrees C (36
degrees F) above
ambient temperature.
Table. 2
Trouble Cause Inspection/Corrective Action
Spindle does not rotate
or rotate smoothly.
The spindles ball bearings have
been damaged.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
The motor has been damaged. Replace the motor.
(Return to NAKANISHI dealer service.)
Overheating during
rotation.
Cutting debris has contaminated
the ball bearings, and the ball
bearings are damaged.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
Abnormal vibration or
noise during rotation.
The tool shank is bent. Replace the tool.
Cutting debris has contaminated
the ball bearing.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
The spindles ball bearings have
been damaged.
Tool slippage. Collet chuck is not correctly
installed.
Check and clean the collet chuck. Reinstall the
collet chuck.
The collet chuck is worn. Replace the collet chuck.
High run-out. The tool is bent. Change the tool.
Collet chuck is not correctly
installed.
Secure the collet chuck correctly.
The collet chuck is worn. Replace the collet chuck.
Inside of the Spindle is worn. Replace the Spindle shaft.
(Return to NAKANISHI dealer service.)
Contaminants inside the collet
chuck or the Spindle.
Clean the collet chuck and the inside of the
taper and Spindle.
The Spindle ball bearings has
been damaged.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
Check can not be opened
and closed.
Poor the air hose. Check all threaded joints and re-tighten if
necessary.
The air hose have been damaged. Replace the air hoses.
Low air pressure. Check and adjusting the air circuit.
Error connection of the air circuit.
Table. 3 Overhang and Speed
Overhang (mm) Max. Speed (min-1) (rpm)
20 N x 0.5
25 N x 0.3
50 N x 0.1
N=Max. Operating Speed with 13mm overhang. Fig. 13
13
13. CAUTIONS WHEN USING GRINDSTONES AND TOOLS
3.14 x Diameter (mm)x rotation speed (min-1) (rpm)
1,000 x 60
Surface Speed (m/s) =
CAUTION
The maximum surface speed or rpm is always specified for a grindstone. Do not exceed the
maximum speed with reference to the calculating chart below. Always follow the grindstone
manufacturer's recommendations.
①The proper surface speed for general grindstones is 10 - 30m/s.
②Do not exceed 13mm of overhang for mounted grindstones as shown in Fig. 13. If the overhang must
exceed 13mm, reduce the motor speed in accordance with Table. 3.
③Dress the grindstone prior to use.
④Do not use cutting tools with bent or broken shanks, cracks or excessive run-out.
⑤For grinding, the maximum depth of cut should not exceed 0.01mm radially or axially. Reciprocate the tool
several times after each pass to eliminate tool pressure.
⑥Always operate cutting tools within the allowable recommended speed of the cutting tools. Use of a cutting
tool outside of the allowable speed of the cutting tools could cause damage to the Spindle and injury to the
operator.
⑦Keep the cutting tool shank and collet chuck clean. If contaminants are left in the collet chuck or chuck nut,
excessive run-out will cause damage to the cutting tool and or Spindle.
⑧Do not strike or disassemble the Spindle.
⑨Please set the cutting tools to minimize the overhang amount. 13mm is the maximum amount of overhang to
maintain high accuracy and safety.
②When installing a Spindle to the holder, recommended installation method is shown Fig 8. Refer to " ③How to
fabricate the Split Type Holder ". If this is not possible, install as shown in Fig. 9.
Fig. 8
Fastening Bolt Fastening Bolt Fastening Bolt
Slit of Bushing
Slit
Spacer
Bushing with Slit
Split Type Holder
Fig. 9 Fig. 10
CAUTION
・Collet chuck will be worn and torn if it will be opened and colsed about 5,000 - 10,000 times.
Replace it with the new collet chuck at this time.
・Before replacing the collet chuck, ensure that the Bushings (3 pcs.) and the O-ring (1 pc.) are
properly and securely attached (Fig. 5). If any of these items are missing, install them before
replacing the collet chuck.
Fig. 5
O-ringBushing