Nakanishi NR50 -5100 ATC User manual

Automatic Tool Replacement Spindle
NR50 - 5100 ATC
OPERATION MANUAL
Thank you for purchasing Automatic Tool Replacement Spindle " NR50-5100 ATC ". 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.
■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.
1. CAUTIONS FOR HANDLING AND OPERATION
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
①The 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 Spindle and brushless motor until you have thoroughly read the
Operation Manuals and safe operation has been confirmed.
1)To prevent injuries / damages, check the Spindle, brushless motor and cutting tool for
proper installation, before operating the Spindle and brushless motor.
2) Before disconnecting the Spindle and brushless motor, always turn the control power off
and turn the compressed air supply to the CONTROLLER off. Then it is safe to remove the
Spindle and brushless motor.
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 correctly and check again the collet before use. Do
not over-tighten the collet. This may cause damage to the spindle.
⑧Do not open and close the collet while the brushless motor is running.
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 redutcion gear. This may cause collet breakage by overload.
③Be sure to clean the collet, the inside of the spindle before replacing the tool. If ground
particles or metal chips stick to the inside of spindle or the collet, damage to the collet 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 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 supply cooling air for motor during operation of the machine.
Removing the air pressure from the Motor / Spindle causes a loss of purging, allowing the
Motor / Spindle to ingest coolant. This will cause damage to the Motor / 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 " 15. TROUBLESHOOTING ".
⑪Always check if the tool, collet, connection hose and supply air hose for damaged before and
after operating.
⑫If the collet 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 " 13. 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.
2. BASIC PACKAGE
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.
Table. 1Packing List Contents
NR50 - 5100 ATC・・1pc. Collet φ3.175mm
(CHR - 3.175)・・1pc.*
(For U.S. market φ3.175mm
(CHR - 3.175))
Bar Wrench (K - 236)・・1pc.
Wrench (9 x 11), (12 x 14)
・・Each 1pc.
Air Hose with Filter
(φ6mm x 2m)・・1pc.
Inspection Card・・1pc.
Operation Manual・・1set
φD
φD
φD
検査成績表
Inspection Card
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取扱説明書
OPERATION MANUAL
* The collet is attached to the Spindle.
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.)
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.
Company Name
Business Hours
U.S. Toll Free No.
Telephone No.
Fax No.
Website
:
Industrial Div.
: 8:00 to 17:00 (CST)
(closed Saturday, Sunday and Public Holidays)
: [phone]
: [phone]
: [phone]
: www.nskamericacorp.com
Contact UsContact Us
For U.S. Market
Company Name
Business Hours
Telephone No.
e-mail
:
: 8:00 to 17:00 (JST)
(closed Saturday, Sunday and Public Holidays)
: [phone]
: [email protected]
For Other Markets
5. FEATURES
① The tools can be replaced automatically by putting ON - OFF the air.
②The Spindle housing is made from precision ground, hardened, stainless steel (SUS) with an outside diameter
of
φ
50mm.
③
The collet size is φ 2.0mm,
φ
3.0mm,
φ
3.175mm,
φ
4.0mm,
φ
6.0mm,
φ
6.35mm.
6 - 1 Specifications
Model NR50 - 5100 ATC
Maximum Motor Rotation Speed 50,000min-1 (rpm)
Spindle Accuracy Less than 1μm
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 φ2.0mm
: PC board (ex. Glass Epoxy Resin)
: Less than 1.6mm
: Less than 3,000mm / min
Weight 1,370g
Noise Level at 1m distance Less than 70dB (A)
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.
6 - 2 Outside View
5 1
（9.55）
（128.6）
106
12.5
End of Spindle Area
（13）
φ20.5
φ20.9
φ15.8
φ10.6
φ50
-0.01
0
Fig. 1
7. CONNECTION OF THE SPINDLE TO THE BRUSHLESS MOTOR
CAUTION
Make sure your hands and all interlocking parts of the Spindle and brushless motor are clean
before connecting the Spindle to the brushless motor. This is critical in preventing contaminants
from entering the Spindle or brushless motor.
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).
Tighten
Collet chuck
Loosen
9
11
12
14
Spindie
φD
φD
φD
Air Inlet Joint φ6Hose with filter 3-way valve
Air Inlet
Exhaust Air
（clamping area）
70
17
Reducer(φ6-φ4 Adaptor)
φ4 Hose
Air Inlet Joint φ6Hose with filter 3-way valve
Air Inlet
Exhaust Air
27
Turn
Tighten
Transmission Clutch
Fig. 2
8. CONNECTION OF AIR HOSE AND AIR SUPPLY
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.
①Connect the provided φ6mm 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 (79.8 - 87psi).
Air Inlet Joint
φ6mm Air Hose with Filte
Dry Air Air Supply
(Supply Side)
3-way valve
Air Release
Fig. 3
〈When using the rear air inlet joint〉
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.
・Please purchase the recommended commercially available air inlet fitting for the air inlet joint.
Recommended air inlet SMC is KQS04
- M5.
φ6mm to φ4mm tubing reducer
SMC is KQH04 - 06.
・When installing the collet clamp / unclamp fittings, thoroughly read the instructions before connecting.
(Fig. 4)
Tighten
Collet chuck
Loosen
9
11
12
14
Spindie
φD
φD
φD
（clamping area）
70
17
Air Inlet Joint
φ4mm Air Hose
φ4mm Air Hose
Dry Air Air Supply
(Supply Side)
3-way valve
Air Release
φ6mm Air Hose with Filter
Reducer (φ6mm -φ4mm Adaptor)
Fig. 4
Collet (CHR - □□ )
φ
2.0mm,
φ
3.0mm,
φ
3.175mm,
φ
4.0mm,
φ
6.0mm,
φ
6.35mm
<Option>
Temperature Humidity Atmospheric Pressure
Operation Environment 0 - 40°C MAX.75%
(No condensation)
700 - 1,060hPa
Transportation and Storage Environment -10 - + 50°C 10 - 85% 500 - 1,060hPa
OM-K0537E 006
OM-K0537E006_スピンドル NR50-5100 ATC 取説 英_230124.indd 1OM-K0537E006_スピンドル NR50-5100 ATC 取説 英_230124.indd 1 2023/01/24 9:31:582023/01/24 9:31:58

16. 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.
9. CHANGING THE TOOL
WARNING
Do not open and close the collet while the brushless motor is running.
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 is not closed.
・Do not open and close the collet before the tool is not installed. Because this will cause damage
to the collet 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.
①Stop the motor. (Or check if the motor is stopped)
②Supply air pressure : from 0.55 - 0.6MPa (79.8 - 87psi) to Air Inlet Joint through 3-way valve. Then, the collet
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 will be closed and the tool can be fixed.
10. REPLACING THE COLLET
CAUTION
Collet will be worn and torn if it will be opened and colsed about 5,000 - 10,000 times. Replace it
with the new collet at this time.
①Stop the coolant air of motor.
②Supply air pressure : from 0.55 - 0.6MPa (79.8 - 87psi) to Air Inlet Joint to keep the collet opened.
Do not take off the tool when the air pressure is supplied
③Place the provided wrench 14mm on the wrench hook of the spindle shaft, and tighten the Spindle.
④Place the provided wrench 9mm on the collet and turn it counterclockwise to loosen the collet. And take off the
collet with the tool from the spindle shaft.
⑤Remove the tool from another collet.
⑥Insert the tool into another collet and turn it clockwise
to be attached on the spindle shaft.
⑦Tight it lightly with the provided wrench 14mm and
wrench 9mm (Specified tightening torque : 1.0 N・m).
⑧Exhaust the air through 3-way valve.
⑨After the collet is replaced, supply the coolant air of
motor to the motor.
11
14
9
12
Tighten
Loosen
Tool
Collet
Spindie Shaft
Fig. 5
12. INSTALLATION OF THE SPINDLE
11. ADJUSTMENT OF " TOOL MOUNTING DEPTH "
WARNING
When installing a Spindle to a fixed base, make sure the fixed base is grounded in order to avoid
the 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, damage 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.
①When mounting a Spindle, refer to the Clamping Area etched on the
Spindle (Fig. 7).
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.
φD
φD
φD
17
CLAMPING AREA
(Clamping Area)
70
Fig. 7
Bushing with Slit
Fastening Bolt Fastening Bolt
Slit of Bushing
Split Type Holder
Slit
Spacer
Fastening Bolt
Fig. 8 Fig. 10Fig. 9
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)
Bearing
Damage of internal
Components
Deformation
Fastening Bolt
Fig. 11
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
φ
50 with its tolerance range from
- 0.01mm
to
- 0.015mm, and its roundness and
cylindricity of less than 5µm.
(7) When inserting the Spindle loosen the
Fastening Bolt, and tighten the Screw for
Removal, widening the Slit Area.
Fastening Bolt
Spacer
Screw for Removal
Fastening Bolt
Fastening Bolt
Screw for Removal
Side View
Front View
Slit
Fig. 12
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
Spindles 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.
13. BREAK-IN PROCEDURE
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
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. CAUTIONS WHEN USING GRINDSTONES AND TOOLS
CAUTION
3.14 x Diameter (mm) x Rotation Speed (min-1) (rpm)
1,000 x 60
Surface Speed (m / s) =
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 clean. If contaminants are left in the collet or collet 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.
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.
φD
φD
φD
13
Fig. 13
15. TROUBLESHOOTING
Trouble Cause Inspection / Corrective Action
Spindle does not rotate
or rotate smoothly.
The Spindle 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 bearing, 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 Spindle ball bearings have been
damaged.
Tool slippage. Collet is not correctly installed. Check and clean the collet. Reinstall the collet .
The collet is worn. Replace the collet.
High run-out. The tool is bent. Change the tool.
Collet is not correctly installed. Secure the collet correctly.
The collet is worn. Replace the collet.
Inside of the Spindle is worn. Replace the spindle shaft.
(Return to NAKANISHI dealer service.)
Contaminants inside the collet or the
Spindle.
Clean the collet and the inside of the taper and
Spindle.
The Spindle ball bearings have 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.
If a problem or concern occurs, please check the following prior to consulting your dealer.
Refer to Brushless Motor and E3000 CONTROLLER Operation Manuals.
Please make the stopper by your own to adjust " Tool Mounting Depth "
Utilize the screw M4 x 0.7ℓ10 in the spindle in consideration for " Dimension φA " to fit for tool shank diameter and
the required adjust length (L) refer to Fig 6.
Note 1: The depth to the stopper mounting position is a reference dimension. If you need an accurate depth,
check the actual measurement.
Note 2: Make a φ1.5 through hole in the stopper for air purging.
Without a through hole, air cannot be purged when replacing tools, and dust may enter the collet,
resulting in poor runout accuracy.
（26.4）※
φA
φ6.55
L
M4x0.7
10
Stopper
φ1.5 through hole
（For air purge）
Fig. 6
OM-K0537E006_スピンドル NR50-5100 ATC 取説 英_230124.indd 2OM-K0537E006_スピンドル NR50-5100 ATC 取説 英_230124.indd 2 2023/01/24 9:31:592023/01/24 9:31:59