Nakanishi NR40 -5100 ATC User manual

1. CAUTIONS FOR HANDLING AND OPERATION
Automatic Tool Replacement Spindle
OPERATION MANUAL OM-K0457E 003
Thank you for purchasing the Automatic Tool Replacement Spindle " NR40 - 5100 ATC ". 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 classied 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.
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
Spindle・・1pc. Collet ȭ3.175mm
(CHB - 3.175)・・1pc.*
(For U.S. market ȭ3.175mm
(CHB - 3.175))
Bar Wrench (K - 236)・・1pc.
Wrench (6.1 x 8), (9 x 11)
・・1pc. Each.
Air Hose with Filter
(ȭ6mm x 2m)・・1pc.
Inspection Card・・1pc.
Operation Manual・・1set
᳨ᰝᡂ⦼⾲
Inspection Card
ྲྀᢅㄝ󰩣᭩
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.
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.
e-mail Address
:
: 8:00am to 17:00pm
(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, stainless steel (SUS) with outside diameter of ȭ40mm.
③
The collet size is ȭ 2.0mm,
ȭ
3.0mm,
ȭ
3.175mm,
ȭ
4.0mm.
6 - 1 Specications
Model NR40 - 5100 ATC
Maximum Motor Rotation Speed 50,000min-1 (rpm)
Spindle Accuracy Within 2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
Noise Level at 1m distance Less than 70 dB (A)
Weight 740g
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.
Collet (CHB- □□ )
ȭ
2.0mm,
ȭ
3.0mm,
ȭ
3.175mm,
ȭ
4.0mm
<Option>
6 - 2 Outside View
Fig. 1
ȭ24
ȭ20.5
ȭ10.8
ȭ6.9
10
3
882(13)
(6.1)
(109.1)
End of Spindle Area
ȭ40 0
-0.01
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).
27
Transmission Clutch
Tighten
Turn
Fig. 2
9. CHANGING THE TOOL
CAUTION
WARNING
Do not open and close the collet while the brushless motor is running.
・
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.
8. CONNECTION OF AIR HOSE AND AIR SUPPLY
Securely connect the air hose to the brushless motor and air line kit to avoid accidental
disconnection and injury to the operator during use.
CAUTION
① Connect the provided ȭ6mm Air
Hose
with lter and 3-way valve to
Air Inlet Joint shown in Fig. 3.
②Supply clean air from air
compressor through air lter or air
dryer to the 3-way valve at the set
air pressure : from 0.55 - 0.6MPa
(79.8 - 87psi).
Air Inlet Joint
3-way valve
Air Release
Dry Air Air Supply
(Supply Side)
ȭ6mm Air Hose with Filter
Fig. 3
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 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 will be closed and the tool can be xed.
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 conrmed.
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 xed base, make sure the xed 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 insufcient 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 supplied cooling air to the brushless motor during operation of the machine.
Removing the air pressure from the brushless motor causes a loss of purging, allowing the
Spindle to ingest coolant and debris. This will cause damage to the Spindle.
⑨Carefully direct coolant spray directly on the tool. Do not spray directly on the Spindle body.
If large amount spray directly on the Spindle, it may cause excess load of the Spindle 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, 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 " 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.
RECOMMENDATIONS
Please set the cutting tools to minimize the overhang amount. 13mm is the maximum amount of
overhang to maintain high accuracy and safety.
NR40 - 5100 ATC
Temperature Humidity Atmospheric Pressure
Operation Environment 0 - 40°C MAX.75% (No condensation) 800 - 1,060hPa
Transportation and Storage
Environment -10 - 50°C 10 - 85% 500 - 1,060hPa

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.
Contents are subject to change without notice.
10. REPLACING THE COLLET
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 9mm on the wrench hook of
the spindle shaft, and tighten the Spindle.
④Place the provided wrench 6.1mm 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 9mm and
wrench 6.1mm (Specied 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.
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.
Tool
Collet
Loosen
Tighten
Spindle Shaft
11
9
6.1
8
Fig. 4
11. INSTALLATION OF THE SPINDLE
WARNING
When installing a Spindle to a xed base, make sure the xed 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 xture.
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. 5). (Clamping Area)
15 55
CLAMPING AREA
②When installing a Spindle to the holder, recommended installation method is shown Fig. 6. Refer to " ③How to
fabricate the Split Type Holder ". If this is not possible, install as shown in Fig. 7.
Fig. 5
Fastening Bolt Fastening Bolt Fastening Bolt
Slit of Bushing
Slit
Spacer
Bushing with Slit
Split Type Holder
Fig. 6 Fig. 8Fig. 7
CAUTION
Do not allow set screws to come directly in contact
with the Spindle body as shown in Fig. 8, 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. 9)
Bearing
Fastening Bolt
Deformation
Damage of internal
Components
Fig. 9
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 specied torque.
(6)
Finish the Split Type Holder so that the inside diameter of the Split Type Holder is ȭ40 with its tolerans
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 Fastening Bolt
Slit
Front View Side View
Screw for Removal
Screw for Removal
Spacer
Fastening Bolt
Fig. 10
CAUTION
・How to conrm 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 nal 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 specications.
Please carefully check the Spindle's specications against the requirements of your
equipment and verify suitability and safety of the Holder prior to initial use.
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.
Table. 2
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.
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 specied 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. 11. 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, 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.
13
Fig. 11
14. TROUBLESHOOTING
If a problem or concern occurs, please check the following prior to consulting your dealer.
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 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 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 hose.
Low air pressure. Check and adjusting the air circuit.
Error connection of the air circuit.
2015.07.20 003
Refer to the brushless motor and the E3000 CONTROLLER Operation Manuals.