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IN OPTION
DECO 20a
DECO 26a 0018 & 0020
300556 en
ATTENTION !
TORNOS SA
CH2740 MOUTIER
http://www.tornos.ch
300556 en 01/07
TABLE OF CONTENTS
1.
GENERALITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1
1.2
ADDRESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
1.4
2.
2.1
2.2
2.3
3.
3.1
3.2
3.2.1
(595798)
3.2.2
(306057)
3.3
LIVE GUIDEBUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
3.3.1
10
3.3.2
14
3.3.3
16
3.4
GUIDEBUSH DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
300556 en 01/07
3.4.1
21
3.4.2
25
4.
CONNECTION TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
4.1
31
4.2
33
4.3
35
4.4
35
5.
5.1
5.2
5.2.1
5.2.2
5.3
5.3.1
5.3.2
5.4
5.4.1
5.5
10
5.5.1
10
5.5.2
16
5.5.3
17
5.6
MECHANICAL LOCKING FOR PICKOFF SPINDLE DECO 26A, FUNCTION 0940 225 . . . .
19
5.6.1
19
300556 en 01/07
5.6.2
22
5.6.3
23
6.
6.1
6.1.1
6.1.2
6.2
6.2.1
6.2.2
6.3
6.4
10
6.5
18
6.5.1
18
6.5.2
21
6.6
25
6.7
RADIAL POLYGONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
6.7.1
(306071)
27
6.8
GENERATING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
6.8.1
31
6.9
35
6.9.1
(306101)
35
6.9.2
41
6.9.3
42
300556 en 01/07
6.9.4
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
6.10
50
6.10.1
50
6.10.2
52
6.10.3
55
6.11
57
6.11.1
57
6.11.2
59
6.11.3
59
6.11.4
60
6.12
63
6.13
65
6.13.1
65
7.
7.1
7.2
7.3
10
7.4
12
7.5
17
8.
8.1
8.1.1
8.1.2
8.2
300556 en 01/07
8.2.1
8.2.2
8.2.3
8.3
8.3.1
8.3.2
8.4
8.4.1
8.4.2
8.4.3
8.5
PNEUMATIC EXTRACTOR + GRIPPER CLEANING SYSTEM WITH OIL 20 / 20A 4104 223
8.5.1
(306282) Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.2
10
8.6
11
8.6.1
(306128) Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
8.6.2
15
8.7
16
8.7.1
16
8.7.2
19
8.7.3
19
8.8
23
8.8.1
23
8.8.2
27
8.8.3
27
300556 en 01/07
8.9
30
8.9.1
30
8.10
33
8.10.1
33
8.10.2
37
8.11
42
8.11.1
42
8.11.2
Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
8.11.3
48
8.11.4
48
8.11.5
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
8.12
57
8.12.1
57
8.12.2
60
8.12.3
65
8.12.4
69
8.12.5
71
8.12.6
74
8.13
76
8.14
77
8.14.1
80
8.14.2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
300556 en 01/07
9.
9.1
9.1.1
(216174) Minisensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.2
9.1.3
9.2
9.2.1
9.2.2
9.2.3
9.2.4
9.3
11
9.4
12
9.5
15
9.6
17
9.6.1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
9.6.2
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
9.6.3
17
9.6.4
18
9.7
20
10.
10.1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.1
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.2
300556 en 01/07
10.1.3
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.4
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.3
10.3.1
10.3.2
10.3.3
10.3.4
10.4
10.4.1
10.4.2
10.5
10.5.1
10.5.2
10.5.3
10.6
10
10.6.1
10
10.6.2
10
10.6.3
10
10.6.4
11
300556 en 01/07
10
10.7
12
10.7.1
12
10.7.2
12
10.7.3
12
10.8
13
10.8.1
14
10.8.2
14
10.8.3
14
10.8.4
15
10.9
15
10.9.1
17
10.9.2
17
10.9.3
17
10.10
19
10.11
20
20
20
11.
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
11.1
INDEX: OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
300556 en 01/07
11
>>>
300556 en 01/07
12
1.
GENERALITIES
1.2
ADDRESSES
TORNOS S.A.
1.1
GENERAL INFORMATION
Rue Industrielle 1 1 1
CH2740 MOUTIER / SUISSE
E08400 GRANOLLERS
Tel. (34) 93 846 59 43
Fax (34) 93 849 66 00
Karlsruher Str. 38
D75179 PFORZHEIM
TORNOS TECHNOLOGIES
IBERICA
TORNOS TECHNOLOGIES
ITALIA SRL
Via CESARE PAVESE 21
20090 OPERA/MI
Tel + 39 02 57 68 15 01
Fax + 39 02 57 68 15 230
contact@tornos.it
TORNOS TECHNOLOGIES
FRANCE
TORNOS TECHNOLOGIES
US CORPORATION
STPIERRE EN FAUCIGNY
F74807 LA ROCHE
S / FORON CEDEX
Tl. 04 50 038 333
Fax 04 50 038 907
TORNOS TECHNOLOGIES UK Ltd
Tornos House
Whitwick Business Park Coalville
Leicestershire
LE67 4JQ
Tel. 01530 513100
Fax 01 530 814212
TORNOS SHANGHAI
REPRESENTATIVE OFFICE
Tower B, Office 512513
Far East International Plaza
No. 319 Xianxia Road
CNSHANGHAI 200335
Tel. +86 2162351235
Fax +86 2162351938
300556 en 01/07
Chap. 1.2 /1
1.3
Warning !
Read the instruction before operating the machine.
Should the user disregard the instructions of this manual, TORNOS SA
declines any liability whatsoever.
Danger !
indicates a direct danger of death or serious injury.
Warning !
indicates an object or action which may cause death or serious
injury.
Caution !
indicates an object or action which may cause injury or serious
damage.
. Attention !
indicates incorrect actions or such that may cause damage.
1.4
Prohibition !
indicates an action or operation prohibited because of evident or
alleged hazards.
. Attention !
Certain maintenance works are absolutely necessary to ensure good
operation of the machine. They are given in the MAINTENANCE
SCHEDULE on the machine
(or see Instructions: OPERATION-MAINTENANCE).
. Attention !
TORNOS SA disclaims all responsibility for any modifications carried
out by the customer to the machine, and to its related equipment and
software, without agreement ratified by TORNOS SA.
Info :
Gives information or comment related to safety.
Note :
Gives information unrelated to safety
300556 en 01/07
Chap. 1.4 /2
2.
2.1
COMPONENTS
Item
1010
1020
1030
Description
Chip pan
Splash guard
Outside guard
Data
130 l
1020
Notes
Dismounting
Emptying
Attention!
Do not operate the machine unless Guards 1020 and 1030 are in
place.
300556 en 01/07
Chap. 2.1 /1
2.2
Item
010
1010
1020
1030
Feature
Volume:
Holes to connect
accessories / options:
Data
220 l
140 l
(non-operational level)
1x
G 3/4
2x
G 2
010
Maintenance Interval:
Action
1010
Notes
Checking
1020
1030
306195
ASSOCIATED EQUIPMENT FOR OIL TANK
The oil tank is provided with two G2 holes for connecting:
Item
Description
Additional tanks,
Cutting oil cooler
300556 en 01/07
Chap. 2.2 /2
2.3
You can easily adapt the containers to suit your specific requirements.
Notes
300556 en 01/07
Chap. 2.3 /3
>>>
300556 en 01/07
Chap. 2.3 /4
3.
3.1
060
070
080
110
1010
COMPONENTS
Items
010
020
030
040
050
Description
Notched nut
Key
Bush holder collet
Collet sleeve
Tie
EQUIPMENT
The following equipment can be selected as and when required:
Items
(306057)
Description
Guidebush coolant system
020
080
070
1010
010
060
040
030
306043f2
300556 en 01/07
050
Chap. 3.1 /1
306043f1
300556 en 01/07
Chap. 3.1 /2
OPERATION
The guidebush ensures precise guidance very close to the tool.
OD [mm]
To be ordered specially
ID [mm]
20
Bar capacity
[mm]
OD [mm]
ID [mm]
round 20
hex 18
on flats
1010
Identif. No.
16
Meister
1357
28
20
hex 18
Neukomm
18.001
square 15
040
Collet sleeve
40
030
050
Tie
060
Pipe key
070
Setting tool
48
M25 x 1
28
40
40
TB 481354
TB 481356
48
24
40
TB 481484
M24 x 1
TB 481452
TB 481357
TB 481452
Note: For constraints concerning the guidebushes, see: determination of remnant length, see instructions 300412.
300556 en 01/07
TB 481354
TB 481483
TB 481357
TB 481355
Meister
1357
24
round 20
on flats
Identif. No.
round 16
square 15
Bar capacity
[mm]
Chap. 3.1 /3
DISASSEMBLY
What to do?
Notes
PRIOR CONDITIONS:
What to do?
Notes
DISASSEMBLY
ASSEMBLY
Screws 110.
ATTENTION!
PRIOR CONDITIONS:
PRIOR CONDITIONS:
What to do?
Notes
What to do?
Notes
DISASSEMBLY
DISASSEMBLY
Unscrew Nut 010.
ASSEMBLY
ASSEMBLY
300556 en 01/07
Chap. 3.1 /4
3.2
APPLICATION
This item is used in:
Item
1010
1020
1030
1040
1050
designation
199223
DECO 20 / 20a
1010
1020
Designation
Collet
Collet sleeve
Collet nut
Pipe key
Pipe key lever
1030
1040
1050
595798
300556 en 01/07
Chap. 3.2.1 /5
DESCRIPTION
TECHNICAL DATA
Type
Bar
Collet
Guidebush
CNC
Notes
........ for front end
adjusted guidebushes
CNC 25
25
5.68 7.36
CNC 30
30
7.37 10.45
CNC 35
35
10.46
14.07
CNC 35
35
14.08
15.57
CNC 35
35
15.58
18.10
CNC 40
40
18.11 ........
CNC 50
50
. Caution!
DISASSEMBLY
INSTALLATION
What to do?
What to do?
Notes
Attention!
Check the headstock carriage
travel...
See:
300556 en 01/07
Notes
For belt changing, see (306027)
Guidebush Drive later in this
chapter or in the index.
OPERATION DESCRIPTION
Bar guidance is by carbide rollers driven by the rotation of the bar.
The guidebush must only be used for bar diameters corresponding to the
dimension indicated on cover No. 21.
Bar play is adjusted in the same way as for a conventional guidebush, i.e. by
turning the nut No.29 at the rear of the guidebush.
GUIDEBUSH CHANGE
What to do?
DISASSEMBLY
Undo collet nut 1030.
ASSEMBLY
For capacities greater than 26 mm (32 mm), front endadjusted bushes are
recommended.
300556 en 01/07
Notes
Chap. 3.2.1 /7
COMPONENTS
170
Item
010
100
140
170
Data
10 microns
max. 10 bars
Designation
Filter support
Filter
Joint
Joint
140
010
306057b
300556 en 01/07
306057a
Chap. 3.2.2 /8
OPERATION DESCRIPTION
This system provides regular lubrication between the guidebush collet and
bar so as to reduce the risks of jamming.
The coolant flowrate can be adjusted before filtration.
. Caution!
Remove the cutting oil conduit from the vertical support before using
coolantfree guidebushes. Mishandling of the control valve could flood
the bush bearings.
INSTALLATION
What to do?
Notes
CLEANING OF FILTER
See also, in the instructions OPERATION / MAINTENANCE:
Vertical support (306005)
FREQUENCY:
What to do?
300556 en 01/07
Notes
Remove and unscrew the Joint
170
Chap. 3.2.2 /9
3.3
LIVE GUIDEBUSHES
APPLICATION
This item is used in:
Designation
199223
DECO 20 / 20a
(306027)
199225
DECO 26 / 26a
(306113)
COMPONENTS
Item
20
40
170
180
1010
1020
Rotation speed
Guidebush collet
Description
max.
Shaft 34 mm
Data
10000 min1
Dunner B227
Meister 227 T
Neukomm 227
Bar capacity
round 26 mm
hex 22 mm
square
18 mm
Angular alignment
adjustment
Length
Overall
148 mm
Jdimension
120 mm
Designation
Spindle
Tie
Oring (To be fitted with the compressed air supply only)
Tie lock screws
Guidebush 34 mm shaft collet
Key
300556 en 01/07
306156f1
300556 en 01/07
OPERATION DESCRIPTION
>>>
The drawback collet ensures precise guidance very close to the tool.
The spindle is supported by two bearing, each consisting of obliquecontact
highprecision ball bearings pregreased for life.
The drive, without backlash, is provided by a timing belt.
Alignment of the guidebush collet is guaranteed by a key.
The guidebush must be protected by compressed air supply:
DECO 20a / 26a: guidebush pressure (3060208)
see the index in instructions 300571
What to do?
Notes
ASSEMBLY
Remove Plug G1/4 located above
the rear of the guidebush bore
DISASSEMBLY
Remove the nozzle and hose
Block the holes
300556 en 01/07
DISASSEMBLY
COLLET CHANGE
PRIOR CONDITIONS:
Drive belt removed. (306027)
What to do?
PRIOR CONDITIONS:
Notes
What to do?
Notes
DISASSEMBLY
INSTALLATION
PRIOR CONDITIONS:
Guidebush Drive installed. (306027)
Compressed air supply fitted (306021)
What to do?
Notes
. Caution!
Check the headstock carriage
travel
Make sure the guidebush air supply is connected.
STANDARD REPAIR
To avoid collisions of the headstock spindle with the guidebush.
See instruction 300412 chap. 3.4
300556 en 01/07
What to do?
Notes
STANDARD REPAIR.
The drawback collet ensures precise guidance very close to the tool.
APPLICATION
199223
OPERATION
Designation
DECO 20 / 20a
COMPONENTS
Items
20
40
170
180
1010
1020
Description
Spindle
Tie
Oring (To be fitted with the compressed air supply only)
Tie lock screws
Guidebush 28 mm shaft collet
Key
TECHNICAL DATA
Description
Rotation speed
Guidebush collet
Bar capacity
Angular alignment
adjustment
Guidebush length
(Shaft 28 mm)
round
hex
square
Data
0 10000 min1
Meister No.1357
Neukomm 18.001
20 mm
18 mm
15 mm
EQUIPMENT
The following equipment can be selected as and when required:
Items
Description
(306027)
Guidebush drive
The following specifc tooling can be used
481452
Setting tool
CHECKS/MAINTENANCE
What to do?
Tension of guidebush drive belt.
Notes
See: checking of tension.
If necessary:
see adjustment of tension by the
offcenter roller,
see Belt Change.
If necessary:
STANDARD REPAIR.
Chap. 3.3.2 /14
306158f1
300556 en 01/07
APPLICATION
This item is used in:
Description
Designation
199225
DECO 26 / 26a
Rotation speed:
Guidebush collet:
42 mm shaft
Data
8000 min1
Meister 229 T
Neukomm MR 32
(28.001)
Bar capacity:
COMPONENTS
Item
010
020
080
205
220
230
1010
1020
Designation
Threaded tube
Spindle
Tie
Tie lock screws
Guidebush fastening screws
Oring
Key
Guidebush collet 229T
300556 en 01/07
round
32 mm
hex
27 mm
square
22 mm
Anguglar alignment
adjustment:
Guidebush length:
Overall
152.5 mm
Jdimension
160 mm
306112f1
300556 en 01/07
306112f2
300556 en 01/07
What to do?
DESCRIPTION
Synchronous live guidebush holder, for drawntype adjusted guidebush,
requiring a drive device.
EQUIPMENT
Guidebush 26 mm drive
Designation
306113
Notes
INSTALLATION
PRIOR CONDITIONS:
Guidebush drive installed. (306027)
Compressed aire supply fitted (306208)
What to do?
OPERATION DESCRIPTION
The drawback collet ensures precise guidance very close to the tool.
Notes
Guidebush drive
. Caution!
Check the headstock carriage
travel to avoid collisions
between headstock and
guidebush.
DECO 26a: See: (306208) Guidebush pressure, in the index of your Instructions 300581.
DISASSEMBLY
PRIOR CONDITIONS:
Drive belt removed (306113)
300556 en 01/07
COLLET CHANGE
PRIOR CONDITIONS:
STANDARD REPAIR
What to do?
Notes
What to do?
Remove the guidebush
Disassembly (306112)
DISASSEMBLY
Notes
INSTALLATION (306112)
ASSEMBLY
Fit a new Collet 1020
300556 en 01/07
3.4
GUIDEBUSH DRIVE
3.4.1 (306027) Guidebush drive for DECO 20a function 0270 223
APPLICATION
This item is used in:
OPERATION
Designation
199223
DECO 20 / 20a
The live guidebush has synchronous drive with the main spindle by means of
a preloaded profiled shaft and transmission by timing belt without backlash.
The angular orientation of the guidebush can be adjusted with Wheel 050
EQUIPMENT
The following specific tooling can be selected as and when required:
Items
(305042)
Description
Grease pump, see under greasing
TECHNICAL DATA
Description
Linearbearing shaft
THK
Rotation speed
Spindle/drive ratio
max.
300556 en 01/07
Data
LBF25 (order ref.
drawing 562057)
8000 min1
i = 1.25 : 1
306027f1
300556 en 01/07
306027f2
300556 en 01/07
COMPONENTS
Items
030
040
050
060
090
100
120
420
450
Description
Housing
Linearbearing shaft
Notched pulley
Housing
Expanding roller
Notched pulley
Excentric
Timing belt (main spindle)
Timing belt (guidebush)
Notes
Notes
ADJUSTMENT
Carry out the angular alignment
with pulley 100.
MANUAL GREASING
FREQUENCY:
PRIOR CONDITIONS:
What to do?
Move the headstock carriage (Z1)
to the rear position...
300556 en 01/07
Notes
...so as to establish communication
of the grease supply holes
between the spindle and nut.
...until it comes out on the side of
the nut
3.4.2 (306113) Guidebush Drive for DECO 26a function 0270 225
>>>
APPLICATION
This item is used in:
Designation
199225
DECO 26 / 26a
COMPONENTS
Item
040
050
060
090
340
370
Designation
Linear bearing shaft
Expanding roller
Notched pulley
Notched pulley
Timing belt (guidebush)
Timing belt (main spindle)
300556 en 01/07
306113f1
300556 en 01/07
306113f2
300556 en 01/07
TECHNICAL DATA
Rotation speed
Shaft
Description
Maxi
THK
EQUIPMENT
Data
6400 min1
LBF25
(as per drawing
562057)
i=
1.25 : 1
OPERATION DESCRIPTION
DISASSEMBLY
What to do?
Notes
INSTALLATION
What to do?
Remove the guards.
What to do?
Notes
What to do?
4 Screws 240.
Notes
ADJUSTMENT
Carry out the alignment with Pulley
060.
Loosen the screws of the Clamping Ring 310.
300556 en 01/07
MANUAL GREASING
FREQUENCY:
Halfyearly or every 1000 hours maximum
PRIOR CONDITIONS:
Pump filled,
see (305042) in the index,
Instructions 300581
What to do?
Pump the new grease through the
Nipple 330...
What to do?
DISASSEMBLY
Loosen Screw 260...
Notes
Notes
300556 en 01/07
4.1
4.
CONNECTION TUBE
. Caution !
The telescope tubing applies for Main Spindle (306094) only.
COMPONENTS
Item
Description
OPERATION
020
support
The telescope tubing helps protect, guide and insert the bar and pusher. It is
located between the barguide and the spindle. Its advantages are :
050
080
Bracket
300556 en 01/07
Pos. no.
030
120
110
100
090
CAPACITY
tube A int. dia.
Pos. no.
dia 34
060
dia 26
130
dia 21
140
dia 17
140
dia 12
140
Chap. 4.1 /1
306106f1
300556 en 01/07
Chap. 4.1 /2
4.2
CAPACITY CHANGE
STARTING CONDITION:
Steps
COMPONENTS
Item
Description
020
support
040
050
Bracket
DISASSEMBLY
Remove the fixed tube B.
ASSEMBLY
Pos. no.
080
090
100
CAPACITY
tube A int. dia.
Pos. no.
dia 12
060
dia 17
110
dia 26
070
It is fit by a pin.
TROUBLESHOOTING
Problems
The bar sticks in the tube
300556 en 01/07
What to do
Replace the tubes
Chap. 4.2 /3
306235f1
300556 en 01/07
Chap. 4.2 /4
4.3
. Caution !
The telescope tubing applies for Main Spindle (306380) only.
Item
020
040
080
Pos. no.
070
090
100
110
120
COMPONENTS
Description
Flange
Flange
Flange
CAPACITY
tube A int. dia.
Pos. no.
dia 26
050
dia 21
130
dia 17
140
dia 12
150
dia 8,5
150
300556 en 01/07
4.4
Item
020
040
060
Pos. no.
080
090
100
140
COMPONENTS
Description
Flange
Flange
Flange
CAPACITY
tube A int. dia.
Pos. no.
dia 26
070
dia 17
110
dia 12
120
dia 22
130
Chap. 4.4 /5
306140f1
300556 en 01/07
Chap. 4.4 /6
B
A
306234f1
300556 en 01/07
Chap. 4.4 /7
>>>
300556 en 01/07
Chap. 4.4 /8
5.
5.1
TECHNICAL DATA
Headstock
Spring washer:
Ring
(DECO 20 / 20a
Headstock (306004):
Description
Nominal rating
Data
700daN
5.5mm
COMPONENTS
Item
010
020
030
100
110
120
1010
1020
Designation
Ring 5.5 mm
Rod
Screwed sleeve
Nut
Schnoor washers
Roller bearing
Spring bushing
Elastic ring
300556 en 01/07
DESCRIPTION OF OPERATION
The tooling supplied can be used for mounting the spring washers in the
headstock so as to change the latters chucking characteristics.
The spring washers supplied allow soft clamping in order to guarantee perfect
operation when using extendednose collets for clamping small diameter
parts.
Chap. 5.1 /1
1010
1020
306064f1
300556 en 01/07
Chap. 5.1 /2
What to do?
ASSEMBLY
Fit Spring Washers 110 and the
ring in the spindle.
DISASSEMBLY
What to do?
Notes
... until Screwed Sleeve 030 presses against Spring Bushing 1010
Distance approx. 0.5 mm
Notes
300556 en 01/07
Chap. 5.1 /3
5.2
COMPONENTS
Item
010
020
030
040
Designation
199223
DECO 20 / 20a
Designation
Nose nut
Collet sleeve
Screwed key
Compression spring
TECHNICAL DATA
Collet:
Collet sleeve F20 for
collet F20
Bar capacity:
306042f1
300556 en 01/07
Description
SCHAUBLIN
Data
Type F20 No.76201
Round
Hex.
Square
16 mm
14 mm
11 mm
Chap. 5.2.1 /4
APPLICATION
This item is used in:
Item
010
020
030
040
Designation
199223
DECO 20 / 20a
Designation
Nose nut
Collet sleeve
Screwed key
Compression spring
TECHNICAL DATA
Collet:
Collet sleeve F30 for
collets F30
Bar capacity:
Description
SCHAUBLIN
Data
Type F30 No.76101
Round
Hex.
Square
25.4 mm
22 mm
18 mm
306077f1
300556 en 01/07
Chap. 5.2.2 /5
5.3
COMPONENTS
Item
010
020
030
040
Designation
199225
DECO 26 / 26a
306094
Headstock
Designation
Collet sleeve
Nose nut
Screwed key
Compression spring
TECHNICAL DATA
Description
Data
Round
Hex.
Square
1.50 to 20.5 mm
17 mm
15 mm
306119f1
300556 en 01/07
Chap. 5.3.1 /6
APPLICATION
This item is used in:
Item
010
020
030
040
Designation
199225
DECO 26 / 26a
Designation
Nose nut (F30)
Collet sleeve
Screwed key
Compression spring
TECHNICAL DATA
Collet
Collet sleeve F30 for
collets F30
Bar capacity:
Description
SCHAUBLIN
Data
Type F30 No 76101
Round
Hex.
Square
4 to 26 mm
22 mm
18 mm
306104f1
300556 en 01/07
Chap. 5.3.2 /7
5.4
OPERATION DESCRIPTION
Collet opening takes place at full pressure (6 bars).
The pressure is set with the collet closed. The pressure pushes the collet
spring out of the spindle collet.
APPLICATION
INSTALLATION
DECO 20 / 20a
199225
DECO 26 / 26a
COMPONENTS
Item
120
140
150
Designation
Pressure reducing valve
Air escape valve
Pressure gauge
What to do?
Notes
PRESSURE SETTING
PRIOR CONDITIONS: Install the headstock
What to do?
. Caution!
The spindle collet is likely to fail to open if the set pressure exceeds the
max. permitted value for a particular spindle type.
300556 en 01/07
Notes
Chap. 5.4.1 /8
306031f1
300556 en 01/07
Chap. 5.4.1 /9
5.5
DECO 20 / 20a
306004
ASSEMBLY TOOLING
Item
010
020
240
280
Designation
Rod
Screwed sleeve
Nut
Roller bearing
COMPONENTS
Item
030
040
050
060
070
080
090
100
200
220
230
250
260
Designation
Notched disk
Mounting plate
Lock
Cover
Cylinder
Guard
Rear spindlespring bushing, with bores
Support
Screrwed sealing plug
Disk fastening screw
Cylinder fastening screw
Lockingmechanism fastening screw
Raised head screw
300556 en 01/07
306122f2
306122f1
300556 en 01/07
DESCRIPTION
OPERATION
The spindle locking system is an option that can be mounted on the main and
pickoff headstocks.
TECHNICAL DATA
Description
24 divisions
Positioning accuracy
0.1 degrees
Locking torque
40 Nm
The standard notched disk comprises 24 divisions, i.e. one division every 15
degrees.
To reduce backlash as much as possible, the disk notches and locking pin are
slanted.
. Caution!
To guarantee correct operation of the system, the installation
instructions must be striclty followed.
. When changing over from the main to the pickoff spindle, reverse the
Screwed Sealing Plug 200.
300556 en 01/07
DISASSEMBLY
What to do?
Notes
(Use assembly tooling 010, 020, 240 and 280 delivered with the option.)
What to do?
DISASSEMBLY
Take down Guard 080.
Notes
ASSEMBLY
What to do?
Replace Bushing 90.
... completely.
300556 en 01/07
What to do?
Notes
What to do?
Notes
300556 en 01/07
Notes
By approx. 3 bars.
6 bars
300556 en 01/07
Line 5:
1. Position the spindle at the appropriate degree by using the function Mx19
Q..
3. Set the compressed air lock by using the functions M831 or M841.
Line 7/10: Mandatory timeout of 0.5 sec. to allow the lock to be correctly set.
Note : The spindles servo bushing is required to prevent any stress force on
the motor if the drive pulley has not been correctly adjusted. If this stress force
should be too high, it could trigger a NC alarm.
Line
1
2
3
4
5
6
7
8
9
10
Spindle S1
M103 S0
G4 X
M119 Q0
G4 X
M800 P1=1700
M831
G4 X0.5
Machining
M832
G4 X0.5
300556 en 01/07
Counterspindle S4
M403 S0
G4 X
M419 Q0
G4 X
M800 P1=1703
M841
G4 X0.5
Machining
M842
G4 X0.5
>>>
APPLICATION
This item is used in:
Designation
199224
DECO 10
199223
DECO 20a
306122
199225
DECO 26a
306139
OPERATION
Electrovalve 020 controls locking pin advance.
AirFlow Regulator 010 reduces the advance rate of the locking pin
AirFlow Regulator 050 reduces the retraction rate of the locking pin.
300556 en 01/07
306125
300556 en 01/07
5.6
MECHANICAL LOCKING FOR PICKOFF SPINDLE DECO 26a, function 0940 225
DESCRIPTION
The spindle locking system is an option that can be mounted only on the pick
off spindle.
APPLICATION
DECO 26a
306107
Pickoff spindle
TECHNICAL DATA
Description
Notched disk
32 divisions
Data
Allows angles of 90 /
180 degrees)
Positioning accuracy
0.1 degrees
Locking torque
40 Nm
OPERATION
The NC positions the spindle.
For orientedspindle locking, an airactuated locking pin fixes the spindle
position by means of a notched disk fitted at the rear of the spindle.
During spindle locking/unlocking, the electric spindle control is switched off.
For orientedspindle unlocking, a spring retracts the locking pin.
306219f1b
300556 en 01/07
The standard notched disk has 32 divisions, i.e. one division every 11.25
degrees.
306219f1
300556 en 01/07
COMPONENTS
Item
020
030
040
Designation
Cover
Lock
Cylinder
Notes
...see disassembly of the pickoff
spindle in the Machine Equipment
book 300579.
... using the 2 Screws 240.
Do not tighten.
. Caution!
See Manipulation Manual
300553 chap.6.7 page 11;
concerning alignment of Spindle
Find approximately the soft anguS4.
lar position of Spindle S4 and take
this as the new reference.
(Spindle alignment S4.B = ...offset
S4)
Check that the locking mechanism
is approximately facing a notch.
Activate the locking mechanism...
300556 en 01/07
Line 5:
1. Position the spindle at the appropriate degree by using the function Mx19
Q..
3. Set the compressed air lock by using the functions M831 or M841.
Line 7/10: Mandatory timeout of 0.5 sec. to allow the lock to be correctly set.
Note : The spindles servo bushing is required to prevent any stress force on
the motor if the drive pulley has not been correctly adjusted. If this stress force
should be too high, it could trigger a NC alarm.
Line
1
2
3
4
5
6
7
8
9
10
Spindle S1
M103 S0
G4 X
M119 Q0
G4 X
M800 P1=1700
M831
G4 X0.5
Machining
M832
G4 X0.5
300556 en 01/07
Counterspindle S4
M403 S0
G4 X
M419 Q0
G4 X
M800 P1=1703
M841
G4 X0.5
Machining
M842
G4 X0.5
DECO 13a
199225
DECO 26a
306219
199228
DECO 13bi
199229
DECO 13b
OPERATION
010 Electrovalve 010 controls the locking pin advance.
AirFlow Regulator 040 reduces the advance rate of the locking pin
AirFlow Regulator 030 reduces the retraction rate of the locking pin.
307560f1
300556 en 01/07
Notes
Dismounting :
Clean the insides of the spindle
nose.
Loosen the clamping screw 140 of
the thrust tube
4 turns minimum
306107f1
300556 en 01/07
6.
Some mainwork options presented in this chapter are used on machine tooling
systems other than X1-Y1 or X2-Y2.
The other systems that can accommodate these options are specified in the
paragraphs below under the toolholder geometrics or as tool stations other
than T11 to T15 or T21 to T25 (i.e. combs).
6.1
199223
DECO 20 / 20a
199225
DECO 26 / 26a
DECO 20 / 20a
199225
DECO 26 / 26a
300556 en 01/07
Chap. 6.1.2 /1
6.2
APPLICATION
This item is used in:
Name
199223
DECO 20 / 20a
199225
DECO 26 / 26a
Capacity:
Geometrics
Mainwork:
Description
Borehole
Data
2 x Diameter 16 H6
X1; X2
Y1; Y2
117.5
+ 10 mm / 10 mm
050 mm
(infinitely variable)
Z1
COMPONENTS
Item
030
040
100
110
130
140
160
Name
Spacing rod
Spacing screw
Spacing nut
Coolant plug
Fastening screws
Securing screws for spacing
Tool clamping screws
Shaft:
Front face
Rear face
127.5 mm
64.5 mm
OPERATION
The bores allow for a modular userfriendly application of standard or other
tooling.
The toolholder has a hole for the supply of cutting oil. Unscrew plug 110 and
fit a coolant tube suitable for the application.
The tool is clamped in the tool holder with four clamping screws 160.
The length of the tool holder can be varied by up to 40 mm by unscrewing the
two securing screws 140.
300556 en 01/07
Chap. 6.2.1 /2
306067f1
300556 en 01/07
Chap. 6.2.1 /3
TOOLHOLDER CHANGE
PRIOR CONDITIONS:
Action
Notes
DISASSEMBLY
Unscrew the 4 fastening screws
130
Take down the toolholder
Block the coolant inlet
If required
ASSEMBLY
Fit the other toolholder in position
. Caution!
Application possible, but depending on how part disposal manipulator is
adjusted for part removal from guidebush, conflicting geometrics can
occur with the toolholder in T11 to T13.
Machine equipped with pickoff spindle: Application possible but not
in positions T11, T12, T21 and T22.
X4 > Y1 and X4 > Y2 must be respected at all times.
300556 en 01/07
. Caution!
if the diameter of the extension head exceeds 20 mm, the tool line
is exceeded, so conflicting geometrics may occur.
The length of the extension head must not exceed 15 mm, so as to
ensure the tool ratings (setting range, maximum drilling depth).
Chap. 6.2.1 /4
APPLICATION
This item is used in:
199223
Name
Machine version
DECO 0001
Use
Modular application possible
DECO 20 / 20a
DECO 0003
T11... T15
T21... T25
T13... T15
T23... T25
COMPONENTS
Item
030
040
100
110
130
140
160
Name
Spacing rod
Spacing screw
Spacing nut
Coolant plug
Fastening screws
Securing screws for spacing
Tool clamping screws
Preferably:
T15 > T14 > T13
T25 > T24 > T23
TECHNICAL DATA
Capacity:
Geometrics
Mainwork:
Shaft:
300556 en 01/07
Description
Borehole
Data
Diameter 25 H7
X1; X2
Y1; Y2
Z1
127.5
0
0100 mm
(infinitely variable)
Front face
Rear face
145.5 mm
64.5 mm
Chap. 6.2.2 /5
306068
300556 en 01/07
Chap. 6.2.2 /6
OPERATION
TOOLHOLDER CHANGE
PRIOR CONDITIONS:
Action
Notes
DISASSEMBLY
Unscrew the 4 fastening screws
130
Take down the toolholder
Block the coolant inlet
If required
ASSEMBLY
. Caution!
The bulk of this tool protrudes beyond the tool line,
so it can preclude the simultaneous use of the two tool systems if used
on both.
Machine with frontwork unit: Application absolutely impossible
because of unavoidable conflicting geometrics.
Machine with pickoff spindle: Use of the part disposal manipulator is
impossible with the tool mounted in positions T11, T12, T13, T21 and
T22.
300556 en 01/07
Note:
The length of the extension head must not exceed 40 mm in order to
guarantee the tool ratings (setting range, maximum drilling depth).
Chap. 6.2.2 /7
6.3
DECO 20 / 20a
199225
DECO 26 / 26a
COMPONENTS
Item
Description
GENERAL DATA
Feature
Notes
Montage:
Data
All the positions according to the tools
300556 en 01/07
Chap. 6.3 /8
306286f1
300556 en 01/07
Chap. 6.3 /9
6.4
This device makes it possible to increase the number of tools available on the
barrel by installing two revolving units on the comb 1. This motor drive system
complements the S2 motor drive system already installed as original equipment on comb 2.
An INFRANOR axis motor is mounted on one plate of the X1/Y1 comb. This
motor is used to rotate spindles into position T11 or T12 or even both at the
same time.
Set 306231, sheet 2/2, describes the various rotation options. Driving positions
T11 and T12 together requires the use of the positioning belt 140, type
32/T5/750DL.
In order to avoid overheating of the motor, it is vital to stop it from rotating when
it is not required (unventilated motor).
LOCATION
This component is used in:
Name
199223
DECO 20 / 20a
199225
DECO 26 / 26a
Ref. mark
20
40
70
120
130
140
160
200
LOCATION OF COMPONENTS
Name
Insulating plate
Axis of tensioner
Motor pulley
Roller
Double timing belt 32/T5/750DL
Double timing belt 32/T5/620DL
Bed plate (set of 2 plates) Ref. no. 472194
Ball bearing 60012RZ
521946f1
521946f2
521947f1
. Caution!
Limitations:
no synchronisation with other motor drive systems,
no tapping possible,
requires at least version TB DECO 5.07 PACK11 software and PMC
V036.
No precise alignment between mainwork gangs 1 and 2 for
simultaneous drillings. The bore/drill tools between the mainwork gangs
1 and 2 are therefore not in the same geometrics (example : position
alignment T12 and T22). An alignment requires adding bed plates under
the bore tools. The bed plates can be planed according to the gaps read
on the machine between the mainwork gangs 1 and 2.
The bed plate is identified under the number 472194 and is planed to a
thickness of 2 mm +/ 0.02. (see drawing 306231f1 below)
300556 en 01/07
GENERAL CHARACTERISTICS OF S2
Components
Description
Characteristics
Max. number of motor
2
driven positions:
Functions: M
Clockwise rotation
Counter
clockwise rotation
Start/stop
Right rotation =
M603
Left rotation =
M604
Fitting positions:
T11 and T12
Drilling diameter:
(mild steel)
6 mm
Positions T13, T14 and T15 are free for turning tools; when this motor
drive system is not in use, positions T11 to T25 can receive turning toolholders.
Revolving attachments
(crossdrills)
Option1600
which can be fitted:
Stop rotation
Maximum drive power:
Tightness index:
Available torque:
Stop =
M605
1.25 kW
IP65
4 Nm ED 100%
2 Nm ED 50 %
ESX25
300556 en 01/07
5002000 min1
5000 min1
. Caution !
Check the direction of rotation before starting the program in
AUTO mode.
Application and limitations
Transverse drilling/milling (end cutter, 2 sizes) on bar.
No machining with slot cutters and 3 size cutters (disk cutters).
Incompatibility with NSK spindles, options 2000 and 2100, which cannot
be fitted onto this X1/Y1 comb. NSK spindles can still be fitted onto X3/Y3
tool systems and counteroperation.
The powered spindle is pressurized at 0.6 bars, which prevents oil from entering the spindles motor.
306231f3
300556 en 01/07
306231f1
300556 en 01/07
306231f2
300556 en 01/07
521946f1
300556 en 01/07
521946f2
300556 en 01/07
521947f1
300556 en 01/07
6.5
DECO 20 / 20a
199225
DECO 26 / 26a
Item
50
60
70
120
130
160
170
1010
Name
Front flange
Rear flange
Holding ring
Bearing
Bearing
Coolant nozzle
Fastening screw
Flats
1010
306159f1
300556 en 01/07
DESCRIPTION
Use
Mainwork:
Frontwork gang
Modular fitting of
from 1 to 4 tools
T22 to T25
Frontwork:
Modular fitting of
from 1 to 4 tools
T31 to T34
Axial backwork:
T41 to T44
Modular fitting of
from 1 to 3 tools
T51 to T53
Radial backwork:
X3
0 mm
(Y3)
25 mm
Z3
187.5 mm
X4
127.5 mm
Y4
0 mm
Z4
25 or 45 mm
OPERATION DESCRIPTION
TECHNICAL DATA
Description
Data
Capacity
ESX25
ET 25
Slitting saw dia.
1 to 16 mm
M3.5 to M10 (M12)
max. 50 mm
Height setting
2 positions possible
20 mm max.
Rotational speed
max. 8000 m1
Geometrics
Mainwork gang
X2
127.5 mm
Y2
0 mm
Z1
25 or 45 mm
300556 en 01/07
The spindle is driven by a notched pulley, screwed and secured at the rear end
of the spindle.
Toolholder
The toolholder has a cutting oil supply (spout) for standard use
(geometry height 25 mm)
The toolholder has no oil supply when used in milling position
(geometry height 45 mm)
The toolholder must be blocked by holding the spindle over flats 1010 for
unscrewing the nut ESX.
The toolholder can assume 2 different height settings 20 mm apart by being
turned upsidedown.
>>>
TOOLHOLDER CHANGE
PRIOR CONDITIONS:
Drive belt removed or slackened:
S2 mainwork (306035)
S3 frontwork (306011)
S5 radial backwork (306036)
S5 axial backwork (306099)
Action
Notes
DISASSEMBLY
Unscrew the 4 fastening screws
Take down the toolholder
If required
300556 en 01/07
6.5.2 (306086) 63mmOD milling spindle for ESX 25 collet, function 1650
APPLICATION
This item is used in:
Name
199223
DECO 20 / 20a
199225
DECO 26 / 26a
COMPONENTS
Item
020
030
100
110
160
170
1010
1020
Name
Spindle
Notched pulley
Spindle locking screw (fixed spindle)
Fastening screw
Spindle nut EX 25 M M30x1
Coolant spout
Flats
Compressed air hole
306086f2
300556 en 01/07
306086f1
300556 en 01/07
DESCRIPTION
TECHNICAL DATA
Description
Data
ESX25
ET 25
Slitting saw dia.
1 to 16 mm
M3.5 to M10 (M12)
max. 63 mm
Height setting:
2 positions possible
26.5 mm maximum
Rotational speed:
Capacity:
Use
Mainwork:
Modular fitting of
from 1 to 4 tools
T22 to T25
Frontwork:
Modular fitting of
from 1 to 4 tools
T31 to T34
Axial backwork:
Action
Radial backwork:
Action
Conflict possible
with the pickoff
spindle
Geometrics
Mainwork:
Frontwork:
X2
127.5 mm
Y2
0 mm
Z1
25 or 51.5 mm
X3
0 mm
(Y3)
25 mm
Z3
187.5 mm
300556 en 01/07
OPERATION DESCRIPTION
TOOLHOLDER CHANGE
PRIOR CONDITIONS:
S2 mainwork (306035)
S3 frontwork (306011)
The spindle is driven by a notched pulley, screwed and secured at the rear end
of the spindle.
Toolholder:
Action
Notes
DISASSEMBLY
If required
If required
300556 en 01/07
6.6
DECO 20 / 20a
199225
DECO 26 / 26a
GENERAL DATA
Feature
Notes
Data
Max. torque :
2 Nm
Max. speed :
Capacity :
ESX 11
Max. dia. 8 mm
Mounting on :
occupies 2 positions
occupies 2 positions
. Caution !
This device is approved by Tornos under the following conditions :
utilization only in positions T22T23 and T12T13.
Tornos disclaims any responsibility for damage to the machine caused
by the operation of the indicated device
This device is warranted and serviced by its manufacturer.
300556 en 01/07
306284f1
300556 en 01/07
6.7
RADIAL POLYGONING
TECHNICAL DATA
DECO 20 / 20a
199225
DECO 26 / 26a
Mounting stations:
Data
Preferably T25
. Caution!
In T25, this unit must be used at a cutting
angle of 26.56 degrees in X and Y axes).
For a live tool, only one tool station is
required to cut in X2 & Y2 with the big
80mm cutter.
300556 en 01/07
Mounting stations:
2 tool mounting
stations required
machining in X is
possible
Cutting angle:
T25
Y2 / X2 = 1/2
(26.56 degrees)
Milling cutter:
80 mm
Rotational speed:
max. 8000
Transmission ratio
1:1
ID 16 mm H6
min1
(Cutter)
OPERATION DESCRIPTION
CUTTER CHANGE
PRIOR CONDITIONS:
Transmission is by a pair of bevel gears and a timing belt without backlash. The
bearings are pregreased for life.
Action
Notes
DISASSEMBLY
COMPONENTS
Item
010
020
310
Name
Cutter fastening screw
Driving pinion
Fastening screw
Allen key: s = 5 mm
300556 en 01/07
Allen key: s = 5 mm
306071f1
300556 en 01/07
Gomtrie standard
Action
Notes
DISASSEMBLY
Remove the 4 screws 340
Remove bearing 060
GREASING
see instruction
OPERATION / MAINTENANCE
Pinion or bevel gear greasing
DECO 20a: 300571
DECO 26a: 300581
ASSEMBLY
Fit bearing 060
Screw in and tighten the 4 screws
340
Appel polygoneur
306071f3
300556 en 01/07
6.8
GENERATING UNIT
DECO 20 / 20a
199225
DECO 26 / 26a
DESCRIPTION
Generating milling unit for cutting of longitudinal profiles.
. Caution!
This unit can be mounted only in T25. and precludes modular
application in T24 of any other tooling with the exception of
ESX 25 drilling spindle (306038) which can be fitted in T24 if the
angular setting of the generating unit does not exceed 5 degrees.
.
The unit occupies more than one tool station.
The unit does not have its own cutting oil connection (spout).
The unit must not revolve without a cutter, as this may cause the
driving key to fly off.
See also instruction 300195: DIRECTIONS FOR USE OF
WATERMISCIBLE CUTTING FLUIDS
306083f2
300556 en 01/07
306083f1
300556 en 01/07
COMPONENTS
TECHNICAL DATA
Angular setting:
Rotational speed:
Torque:
Description
Data
+/ 5 degrees
max.
8000 min1
optimum:
transmissible
7 Nm
ID
Total length
Max. diameter
Key
13 mm
25 mm
32 mm
DIN 138 (section 3 x
3 mm)
+/ 10 degrees
Tooling
Cutters:
Spacer rings:
Stack height:
DIN 2084 B
dia. 13 / 22
i.e. cutter + spacer rings
32 mm (e.g. 25 + 2 +
5)
Name
Toothed wheel
Pivoted gear casing
Sleeve
Casing
Steady
Steady fastening screws
Gear casing locking screws
Fastening screws
Cutter fixing screws
Sleeve fixing screws
Angular setting screw
OPERATION DESCRIPTION
The cutting type is continuous cutting by master cutter.
It is used for producing very long splined shafts, and gears of very diverse profiles.
The speed ratio between the spindle ( S1 ) and cutter ( S2 ) is equal to the
number of female splines to be cut, the cutter speed being lower.
Geometrics
T25
Item
010
040
060
070
090
340
350
360
330.1
330.2
365
X2 cutter axis
105.5 mm
X2 space factor
127.5 mm
The angular setting of the cutter must be suitable for correct splining.
For straight splines, the inclination of the cutter is given by its helix angle.
The bearings of the unit can be protected by compressed air at the hole (for
example when using emulsions).
Before using compressed air, transfer plug 475 into the threaded hole below
cover 050 of the unit (leakage drain hole in a standard version machine).
300556 en 01/07
Note:
This milling cutter is designed to cater for a very precise gear profile
(diameter, number of teeth).
This same cutter is not suitable for teeth cutting of different
characteristics.
Notes
Action
DISASSEMBLY
Remove the 2 screws 350
Take down casing 070
Remove the 4 screws 330.2 from
the sleeve
Take down sleeve 060
Notes
GREASING
Carry out the greasing of the bevel
gears
ASSEMBLY
Mount sleeve 060
Fit and tighten the 4 screws 330.2
fastening the
sleeve
LOCTITE 243
300556 en 01/07
6.9
050
Name
450
199223
DECO 20
199225
DECO 26
150
080
COMPONENTS
Item
040
050
080
150
450
Name
Baseplate
Orientable gearbox
Toolholding flange
Cover plate
Gearbox screw
306101f2
OPERATION
The toolholder spindle, mounted on preloaded ball bearings, can be inclined
to avoid nicking during the cutting of threads.
The movement is transmitted by bevel gears and a timing belt without backlash.
The ball bearings are greased for life.
. Caution!
This attachment:
occupies more than one tool station.
does not have its own cutting oil connection (spout)
is not designed to operate with watermiscible cutting fluids
(emulsion)
306101f1
300556 en 01/07
Note:
Fitting of this attachment onto the machine requires a modification to a
guard as per item 200 in whirling attachment assembly drawing
306101f1.
The guard is fitted ex works for delivery of the attachment mounted on
the machine.
This guard must be modified by the user in the event of the attachment
being mounted at a later date.
The modification is shown graphically in drawing 562770f1.
A borehole of diameter 16.5mm is required for fitting the bulkhead
stuffing box for the coolant piping.
562770f1
300556 en 01/07
ANTICOLLISION GEOMETRICS
For normal use: See travel limitations
X1 + X2 > 0
X1 + X2 > 25
Action
Notes
ANGLE SETTING
Loosen the 2 screws of gearbox
450
Set the inclination
Bar capacity:
Angular setting:
Rotational speed:
Transmissible torque:
max.
Belt:
Tools
Presettable cutter holder:
Geometry:
Data
10 mm
+/ 15 degrees
8000 min1
5.63 Nm at 8000 min1
6.30 Nm at 4000 min1
472088
X2 mill. cutter axis 118.5
X2 space require- 153
ment
300556 en 01/07
>>>
Action
Notes
DISASSEMBLY
Remove closing plate 150 fixed by
the 4 screws 490.
Remove flange 140 and then
remove the belt
2 screws 510
ASSEMBLY
Mount box 120
Fit and tighten the 4 screws 420
used for fixing box 120.
Fit clamping sleeve 580 and pinion
130.
2 screws 510
306101f3
300556 en 01/07
Info :
Station T25
Info :
Option 1900
Feature
Option :
Dimensions :
see drawing
Ident. No.:
Tornos
Note :
472088
Data
Cover with positioning mark (r).
1910
Thread whirling head for machining an external
thread with 3 cutters outer 15 mm, thickness
4 mm, borehole 5 mm.
Use for 510 mm (offset of the front face of
the cutter in relation to the reference line of the
work 9.5 mm).
r
c
300556 en 01/07
Feature
Data
Option :
1920
Dimensions :
Ident. No.:
Tornos
570504
Notes
21.5mm
Tighten the flange
Flange
Fig. 1507
300556 en 01/07
Notes
c
g
g
g
c
Unloosen the ring (b) to completely release the tool from the spinner.
Install the tool on the spinner
according to the mark (r).
Tighten the 3 conehead screws.
Reinstall the ring (b) against the
spinner.
r
b
6.9.4 Programming
Note:
The attachment is mounted in T25, but its bulk also occupies T24.
Thread types
The attachment cuts LH and RH threads. In both cases, refer to the table below
so as to use the correct programming parameters.
The 15 bar option (No. 307102, function 5250) is required for cutter
lubrication.
Retract the comb X2Y2 (indexing in T21 or T22) before catching the part
(to prevent the pickoff spindle from colliding with the whirler).
Geometries
Thread
ISO code
Rotation S1
ISO code
Rotation S2
Inclination of
head
right
C1+
M203
Upward
left
C1
M203
Downward
A single cutter holder head can be used on the attachment, i.e. function 1910
(472088).
Xaxis geometry
The centre of the whirling attachment is located at 118.5 mm from the reference
pin. The blades work on a diameter of 12 mm (6 on the radius) from the centre
of the attachment. Since the theoretical distance from the reference pin is
127.5 mm, the theoretical geometry in X is 6 mm.
Yaxis geometry
Swing axis of the head in line in relation to the axis of the blade centre.
Geometry in Y superfluous.
Zaxis geometry
Upward
See table:
Downward
1910
300556 en 01/07
Z
(Blade centre)
30
300556 en 01/07
PROGRAMMING
Programming of external whirling requires a new operation line comprising the
C1, X2 and Z1 axes.
The figure below shows the third operation line (C1axis) on which the whirling
operation will take place, together with the various operations required for
orientation of the attachment:
Op. 3:1
ISO code:
M203 S2600
M203 S2600
Op. 2:6
Indexing T25
ISO code: G1 X2=80 G100
G903 P1=25
Op. 2:7
2.
OP: 3:2
ISO code:
Note :
Rotation: Tornos = M203, Pibomulti = M204
300556 en 01/07
300556 en 01/07
Note:
dmean is calculated from the bar and the of the root of thread!
TECHNICAL DATA
Stock:
Working of cutters (geometry):
12 mm
Cutting speed:
98 m/min
n=
whirling attachment speed:
2600 rpm
fz = advance per tooth:
0.025 mm
z=
number of teeth:
3
Note:
The advance per tooth fz is derived from experience gained in whirling
and is usually between 0.02 and 0.05 mm. This advance can be
optimised so as to guarantee a good thread quality and good control of
blade wear.
1.
nC1
nC1
x dmean
0.031 x 3 x 2600
x 5.215
= 12 min1
300556 en 01/07
2.
Vf
= nc1 x 360
Vf
= 12 x 360 =
3.
tg
4320 /min
Lead
=
x dmean
2.75
=
x 4.46
Note:
dmean is calculated from the of the top of thread and of root of
thread!
In the light of this angle of inclination, it is easy to set the inclination of the
attachment by means of a graduated scale or comparator, by shifting the
Z3axis.
Example
Shift of Z3 by 20 mm, h = tg x 20 = 0.1962 x 20 = 3.925 mm
h
Z3
300556 en 01/07
DECO 20
199225
DECO 26
COMPONENTS
Item
010
100
110
120
1010
Name
Toolholder
Fastening screws
Tool clamping screw
Coolant spout
Multipurpose bore M10x1 for various fittings
306066f1
300556 en 01/07
TOOLHOLDER CHANGE
TECHNICAL DATA
PRIOR CONDITIONS:
Description
Capacity:
Bore
Data
30 H7
Use
Action
Notes
DISASSEMBLY
Unscrew the 4 fastening screws
Mainwork:
T11 to T15
T21 to T25
Frontwork:
T31 to T34
Axial backwork:
T41 to T44
Radial backwork:
T51 to T53
If required
ASSEMBLY
positioned by two locating pins
OPERATION DESCRIPTION
The toolholder has a cutting fluid supply from its own spout, but an M10x1 bore
is available to enable fitting to other lubrication systems if necessary.
Tool holding is by split clamping, preventing high local pressures and allowing
livetool spindles to be fitted.
The toolholder is to be fitted forward on the baseplate to make full use of the
coolant spout.
. Caution!
When the tool mounted in the 30mmID toolholder (306066) protrudes
beyond the rear of the latter, there is a likelihood of conflicting
geometrics with the protective shutters of the livetool spindle drives.
300556 en 01/07
DESCRIPTION
Name
199223
DECO 20 / 20a
199225
DECO 26 / 26a
TECHNICAL DATA
COMPONENTS
Item
Name
243247
010
Spindle NR3060S
243271
020
243246
030
Motor EM3060
243245
100
Description
Use:
Data
Mainwork:
Modular fitting on X1 Y1
T11 to T15
Frontwork:
T31 to T34
Axial backwork:
T41 to T44
Radial backwork:
Modular fitting
possible
T51 to T53
ASSOCIATED EQUIPMENT
The following items can be fitted as and when required:
Name
306066
30mmID toolholder
306442
Generator enclosure
300556 en 01/07
. Caution !
TORNOS accepts this attachment if the following points are observed:
Used in the positions and values indicated.
TORNOS disclaims any liability whatsoever in the event of damage to
the machine resulting from operation of the attachment mentioned.
The manufacturer provides warranty and service.
nut K265
Collet CHK
100
010
020
300556 en 01/07
TECHNICAL DATA
Couple [Nm]
. Caution!
With the speed reducer (increased torque), pay attention
to the machining performance and reliability on the spindle
Description
Data
Without reducer
500060000 min1
Output:
Motor
350 Watt
Nominal available
torque:
Without reducer
0.07 Nm
0.28 Nm
Spindle speed:
Torque
motor
Speed
MACHINING PERFORMANCE
. Caution!
This tool is not designed for removing large chip volumes.
Check the actual performance by means of practical tests.
Description
300556 en 01/07
Data
Advance / rev.:
= 0.01 x
Drilling capacity:
Without reducer
brass max.3 mm
Ck45 max.1.5 mm
100Cr6 max.1 mm
With reducer
brass max.4 mm
Ck45 max.2.5 mm
100Cr6 max.2 mm
INSTALLATION
Action
Notes
APPLICATION
Name
199223
DECO 20
199225
DECO 26
Notes
ASSEMBLY
Unscrew the motor spindle
Screw in the speed reducer
between the spindle and the motor.
COMPONENTS
Name
Casing
Cover
300556 en 01/07
306442f1
300556 en 01/07
010
243270
020
243271
030
Motor EM3060
243246
100
243245
100
020
Collet CH8
030
010
300556 en 01/07
TECHNICAL DATA
. Caution!
With the speed reducer (increased machining performance),
pay attention to the problem of reliability on the spindle.
See below Machining performance .
Description
Angle spindle:
DESCRIPTION
Torque rating:
Motor cooled by air and spindle delivered with a 1:4 speed reducer depending
on the working speed range.
Maximum 2 spindles per machine (see also 306070 in chapter 6.10.2)
reducer included
1 : 2.67
With 1:4 reducer
Without reducer
0.18 Nm
0.75 Nm
MACHINING PERFORMANCE
. Caution!
This tool is not designed for removing large chip volumes.
Check the actual performance by means of practical tests.
Couple [Nm]
Torque
Data
. Caution !
TORNOS accepts this attachment if the following points are observed:
Used in the positions and values indicated.
TORNOS disclaims any liability whatsoever in the event of damage to
the machine resulting from operation of the attachment mentioned.
The manufacturer provides warranty and service.
Speed
motor
300556 en 01/07
INSTALLATION
Notes
Generator enclosure
Action
Notes
ASSEMBLY
Unscrew the motor spindle
Screw in the speed reducer
between the spindle and the motor.
300556 en 01/07
DESCRIPTION
Modular design.
DECO 20 / 20a
Two toolholder stations may be required for the orientation device depending
on use and the inclination of the device.
199225
DECO 26 / 26a
COMPONENTS
Item
010
020
030
Name
Setting plate
Clamp
Spacer 24.5 mm
TECHNICAL DATA
Spacer thickness:
Description
Data
24.50 mm
2 parts 562422
Crossdrilling 0 to 90
Use
ASSOCIATED EQUIPMENT
Mainwork:
T11 to T15
Name
306066
30mm ID toolholder
306087
Generator enclosure
306080
HF slotting spindle
Frontwork:
2 tool stations
Front slotting
T31 to T34
Radial backwork:
Back drilling 0 to 90
T51 to T53
Optional
306041
15 bar pump
300556 en 01/07
306088f1
300556 en 01/07
306088f2
300556 en 01/07
DECO 20 / 20a
199225
DECO 26 / 26a
GENERAL DATA
Feature
Notes
Data
Mounting :
Max. power :
250 W
Max. speed :
80 000 rpm
Diameter / length :
25 / 120 mm
Collets :
ER 8 up / dia. 1 5 mm
300556 en 01/07
306288f1
300556 en 01/07
DECO 20 / 20a
199225
DECO 26 / 26a
306084f2
COMPONENTS
Item
030
040
050
200
250
Name
Setting screw
Claw 6 to 11 (No. 562311)
Claw 11 to 26 (No. 562312)
Locking screw
Compression spring
306084f1
300556 en 01/07
DESCRIPTION
Modular design.
Hydraulics unnecessary
Clawing force adjustable
Clamping compatible with all other types of guidebush
. Caution!
Clawretain the bar simultaneously with both Vclaws to avoid lateral
stresses on the guidebush of the machine.
Notes
DISASSEMBLY
SETTING
TECHNICAL DATA
Description
Data
Fitting: preferably
facing each other.
X1; X2
127.5 mm
Y1; Y2
0 mm
Z1
20 mm
Use
Mainwork gang:
Action
Geometrics
Mainwork gang:
OPERATION
Each tool system X1/Y1 and X2/Y2 comprises a claw instead of a toolholder.
The retaining action is provided by the approach into position of the X1 and X2
axes which, by soft contact (spring) lock the bar while the main spindle retreats.
300556 en 01/07
7.
7.1
DECO 20 / 20a
199225
DECO 26 / 26a
306081f2
300556 en 01/07
Chap. 7.1 /1
306081f1
300556 en 01/07
Chap. 7.1 /2
TECHNICAL DATA
COMPONENTS
Item
040
050
060
070
080
190
200
210
220
260
270
290
300
310
1010
Designation
Collet arbor
Spindle
Toothed wheel
Rod
Ring
Screwed sealing plug for compressedair hole
Spindle locking screw (stationary spindle)
Rear screw
Fastening screw
Collet nut M20 (M20x1)
Coolant nozzle
Compression springs
Coolant nozzle
Coolant nozzle
Flats
300556 en 01/07
Capacity:
Extension/compression stroke:
Height setting:
Rotation speed:
Geometry
Mainwork gang:
Frontwork gang:
Radial backwork:
Description
EX 16
Data
0.5 to 10 mm
ESX 16
1 to 10 mm
max.
2 positions possible
max.
30 mm
20 mm max.
X2
127.5 mm
Y2
0 mm
Z1
X3
25 ou 45 mm
0 mm
(Y3)
25 mm
Z3
X4
187.5 mm
127.5 mm
Y4
0 mm
Z4
25 or 45 mm
Chap. 7.1 /3
8000 min1
OPERATION DESCRIPTION
The differential spindle consists of a collet arbor that slides inside a spindle.
The toolholder has a cutting oil supply via its own spout.
To unscrew the ESX collet nut the spindle must be locked over Flats 1010.
The toolholder has 2 height setting positions, differeing by 20 mm, obtained by
reversal.
The bearings of the attachments can be protected by compressed air at the
hole.
(For example when using emulsions)
Note:
For short threads, in view of the 30 mm travel, it may be possible to
work without threading feed.
DESCRIPTION
Description
Utilization
Mainwork gang:
Frontwork gang:
Axial backwork:
Radial backwork:
300556 en 01/07
Data
Modular adaptations of
1 to 4 tools
Modular adaptations of
1 to 4 tools
Adaptation possible by
locking the spindles
Modular adaptations of
1 to 3 tools
Chap. 7.1 /4
T22 to T25
T31 to T34
T41 to T44
T51 to T53
TOOLHOLDER CHANGE
PRIOR CONDITIONS:
FREQUENCY:
S2 Mainwork gang
(306035)
S3 Frontwork gang
(306011)
Notes
DISASSEMBLY
What to do?
Notes
DISASSEMBLY
Remove Screw 210
If required
CLEANING
If required
. Caution!
Check the condition of the inside
surfaces
GREASING
ASSEMBLY
Make sure that Screws 190 & 200
do not jut out beyout the bearing
face.
Collet arbor
ASSEMBLY
Positioned by 2 locating pins
300556 en 01/07
Chap. 7.1 /5
7.2
APPLICATION
This item is used in:
Designation
Utilization
Mainwork gang:
199223
DECO 20 / 20a
Frontwork gang:
199225
DECO 26 / 26a
Axial backwork:
Radial backwork:
COMPONENTS
Item
020
110
130
Data
Modular adaptations
possible
Modular adaptations of
1 to 4 tools
Adaptation possible
from 1 to 4 tools
Modular adaptation
possible
T11 to T15
T22 to T25
T31 to T34
T41 to T44
T51 to T53
Designation
Toolholder shaft
Fastening screws
Coolant spout
. Caution!
A tool must not protrude at the back of a 20mmID toolholder, since this
may cause conflicting geometries with the protective shutters of the
livespindle drives.
306039f1
300556 en 01/07
Chap. 7.2 /6
306039f2
300556 en 01/07
Chap. 7.2 /7
TECHNICAL DATA
Capacity:
Description
ID
Front face
Data
Diameter 20 H6
Front/Rear locating
pins
37.5 mm / 97.5 mm
Rear face
97.5 mm / 37.5 mm
X2
127.5 mm
Y2
0 mm
Z1
25 mm
X3
0 mm / 0 mm
(Y3)
25 mm / 25 mm
Z3
187.5 mm / 187.5 mm
X4
25 mm / 25 mm
Y4
0 mm / 0 mm
Z4
187.5 mm / 187.5 mm
X4
127.5 mm
Y4
0 mm
Z4
25 mm
Geometry
Toolholder shaft:
Mainwork gang:
Frontwork gang:
Axial backwork:
Radial backwork:
OPERATION DESCRIPTION
300556 en 01/07
. Caution!
Make absolutely sure to check the toolholder Yaxis alignment when
remounting it from the front + middle pins to the rear + middle pins or
vice versa.
Chap. 7.2 /8
TOOLHOLDER CHANGEMENT
PRIOR CONDITIONS:
What to do?
Notes
Note:
The distance between the collet nose and the shaft diameter must be =
or < 40 mm to allow unhindered application on the X1Y1 and X2Y2
mainwork gangs.
DISASSEMBLY
Unscrew the 4 Fastening Screws
110
Take down the toolholder
If required
. Caution!
If the extension nut diameter is greater than 35 mm, it conflicts with the
locating pin of the machine.
ASSEMBLY
Place the toolholder in position
Screw in and tighten the 2 Fastening Screws 110
300556 en 01/07
Chap. 7.2 /9
7.3
DECO 20 / 20a
199225
DECO 26 / 26a
DESCRIPTION
See instruction OPERATION / MAINTENANCE
DECO 20a : 300571
Chapter 6
Chapter 6
300556 en 01/07
306040f1
306040f2
300556 en 01/07
7.4
DECO 20 / 20a
199225
DECO 26 / 26a
. Caution!
Do not admit the coolant unless the belt guard and protective shutters
are in place. Otherwise the motor and the bearings of the rollers can be
damaged or destroyed.
COMPONENTS
Item
030
050
100
110
360
370
S3 TECHNICAL DATA
Designation
Tensioning roller plate S3
Toothed axis of tensioning roller
Protective shuuter
Belt guard S3
Fastening screw
Tensioning roller screw
Drive
Rotation speed
Motorspindle ratio
Motor
Available torque
values (spindle)
Acceleration time
300556 en 01/07
Description
modular
Data
1 to 4 tools T31 to T34
0 6000 min1
100% / 15 min. 50%
ED
06000 min1
4.77 / 7.00 Nm
2.39 / 3.5 Nm
0.69 / 0.47 sec*
Exact characteristics depend on the live units and tooling fitted to the
machine.
306011f1
300556 en 01/07
300556 en 01/07
Torque 100%
300556 en 01/07
Temps [ s ]
The drive system limits the possibilities of machining at high speed (differential).
Given below are a few examples illustrating the scope of machining.
These are theoretical estimations, to be confirmed by practical tests, on
the basis of a half worn tool.
Tapping capacity
S3
03000 min1
6000 min1
Brass
M10
M8
9SMnPb36
M8
M5
Ck45
M6
M5
100 Cr 6
M6
M5
Couple [Nm]
Torque
Vitesse S3 [ min1 ]
Couple 100% ED
Couple 50% ED
Temps 100% ED
ps 50% ED
Temps
OPERATION DESCRIPTION
The drive, of asynchronous type, allows the use of live units for frontwork operations such as drilling, milling, etc...
What to do?
Notes
DISASSEMBLY
300556 en 01/07
7.5
DESCRIPTION
Live long type unit for ESX 25 collet.
Utilization
Frontwork gang:
Axial backwork:
Designation
199223
DECO 20 / 20a
199225
DECO 26 / 26a
Modular adaptations of 1
to 4 tools
T31 to T34
T41 to T44
ASSOCIATED EQUIPMENT
The following specific tooling can be used as and when required:
Designation
595816
OPERATION DESCRIPTION
The drilling unit is equipped with a spindle mounted on preloaded ball bearings
at the front and rear. The bearings are pregreased for life.
The spindle is driven by a notched belt screwed and secured at the rear end.
The toolholder has a cutting oil supply via its own spout during standard utilization (height geometrics 25 mm).
The toolholder has no builtin cutting oil supply for use in the milling position
(height geometrics 45 mm).
To unscrew the ESX collet nut the spindle must be locked over Flats 1010.
306164f2
The toolholder has two height setting positions, differing by 20 mm, obtained
by reversal.
300556 en 01/07
306164f1
300556 en 01/07
COMPONENTS
Item
10
20
70
130
140
160
200/210
1010
TOOLHOLDER CHANGE
Designation
Front flange
Rear flange
Holding ring
Coolant nozzle
Bearing
Bearing
Coolant nozzle
Flats
PRIOR CONDITIONS:
What to do?
DISASSEMBLY
Unscrew the 4 fastening screws
Take down the toolholder
Block the oil spout
TECHNICAL DATA
Description
Data
Capacity:
ESX 25
ET 25
Slitting saw dia.
1 to 16 mm
M3.5 to M10 (M12)
max. 50 mm
Height variation:
2 positions possible
20 mm max.
Rotation speed:
ASSEMBLY
Place the toolholder in position
Screw in and tighten the 4 fastening screws
Fit and tension the drive belt
Notes
If required
Geometry
Frontwork gang:
Axial backwork:
X3
0 mm
(Y3)
25 mm
Z3
187.5 mm
X4
Y4
Z4
0 mm
25 mm
187.5 mm
300556 en 01/07
>>>
300556 en 01/07
8.
8.1
8.2
DESCRIPTION
The front nut is built in two parts to make it easier to set the chucking force of
fragile parts.
Designation
Screwed key
Collet sleeve
Nose nut internal part
Nose nut external part
Compression spring
300556 en 01/07
306443f1
Chap. 8.2.1 /1
Designation
Compression spring
Screwed key
Collet sleeve
Nose nut internal part
Nose nut external part
306444f1
Designation
Screwed key
Collet sleeve
Nose nut external part
Nose nut internal part
Compression spring
300556 en 01/07
Chap. 8.2.3 /2
8.3
Item
10
20
30
100
COMPONENTS
Designation
Screwed key
Collet sleeve (F25)
Nose nut (F25)
Compression spring
OPERATION
Collet axial motion :
306242f1
Elements
TECHNICAL DATA
Description
Data
Collet:
Standard
F25 No 7664
Bar capacity:
Round :
Hex.:
Square :
1 20 mm
4 18 mm
4 15 mm
300556 en 01/07
Chap. 8.3.1 /3
Item
10
20
30
100
COMPONENTS
Designation
Screwed key
Collet sleeve (F30)
Nose nut (F30)
Compression spring
OPERATION
Collet axial motion :
Elements
TECHNICAL DATA
Description
Data
Collet:
Standard
F30 No 76101
Bar capacity:
Round :
Hex.:
Square :
3 26 mm
4 22 mm
5 18 mm
300556 en 01/07
306241f1
Chap. 8.3.2 /4
8.4
DESCRIPTION
The front nut is built in two parts to make it easier to set the chucking force of
fragile parts.
Designation
Screwed key
Collet sleeve
Nose nut external part
Nose nut internal part
Compression spring
306445f1
300556 en 01/07
Chap. 8.4.1 /5
Designation
Screwed key
Collet sleeve
Nose nut external part
Nose nut internal part
Compression spring
306446f1
Designation
Screwed key
Collet sleeve
Nose nut part external part
Nose nut part internal part
Compression spring
300416f1
300556 en 01/07
Chap. 8.4.3 /6
8.5
PNEUMATIC EXTRACTOR + GRIPPER CLEANING SYSTEM WITH OIL 20 / 20A 4104 223
OPERATING DESCRIPTION
Rotating extractor mounted in the pickoff spindle assembly with gripper cleaning system using cutting liquid to clean gripper.
LOCATION
Designation
199223
DECO 20 / 20a
306004
Pickoff spindle 20 mm
Item
010
020
030
040
Components
End stop
COMPONENTS DESIGNATION
Designation
Flange
Thrust tube
Extractor rod
Extractor tube
GENERAL DATA
Description
Adjustable
300556 en 01/07
. Caution !
The headstock tightening collet centers the extractor in the forward
position.
If the extractor starts rotating without this collet, strong vibrations may
damage the extractor.
Info :
To adjust the cleaning liquid flowrate see.
Extractor pneumatics 306282
Coolant valve 306217
Features
max. 200 mm
Chap. 8.5.1 /7
306282f1
300556 en 01/07
Chap. 8.5.1 /8
REMOVING EXTRACTOR
INITIAL CONDITION:
position
What to do?
Notes
DISMOUNTING
What to do?
Notes
Oil
Remove flange 10
Screw 320
Release thrustor
Screw 310
MOUNTING
Proceed by reversing order of dismounting steps
Sortir lextracteur
What to do?
Install the pickoff spindle thrust
tube
Notes
300556 en 01/07
Chap. 8.5.1 /9
LOCATION
This item is used in:
Designation
199223
DECO 20 / 20a
306282
Extractor
Item
30
40
80
COMPONENTS DESIGNATION
Designation
Tube
Electrodistributor
Flow limiter
306409f1
OPERATION
The distributor 40 controls the advance of the extractor.
The flow limiters 80 allow adjusting the speed of the extractors movements.
300556 en 01/07
8.6
DECO 26 / 26a
306107
. Caution
Activation of collet cleaning with cutting fluid while the spindle is rotating can cause seizure in rotating joint.
ASSOCIATED EQUIPMENT
Flushing valve accessory is compatible:
COMPONENTS
Item
030
150
1010
Description
Distribution body
Ejector rod
Collet flushing connection
Item
(306085)
TECHNICAL DATA
Component
Travel :
DESCRIPTION
Description
See Flushing Valve
Description
Standard
Data
200 mm
Rotating ejector mounted on the pickoff spindle, with possibility of system for
collet cleaning by cutting fluid.
The ejector can be used with collet capacities F37 and F30, but is incompatible with F25 and smaller ones.
300556 en 01/07
306128f1
300556 en 01/07
DESCRIPTION OF OPERATION
Notes
The ejector is fitted at the rear of the pickoff spindle.
Manually
Notes
Flushing fluid passes via the outside of the actuator to have a large crosssection to pass through, avoiding the need to have pressure to provide the flow
rate.
Activation of collet cleaning with cutting fluid while the spindle is rotating can
cause seizure of the rotating joint.
300556 en 01/07
Ejector activated
What to do ?
Notes
DISASSEMBLY
Push back ejector rod 150.
300556 en 01/07
DECO 26a
Ejector
OPERATION
The distributor controls the movements of the ejector as well as pneumatic
collet cleaning.
When the system is inactive, no pressure is exerted on the ejector, to avoid
excessive air consumption.
Flow rate limiters allow the speed of the ejectors movements to be adjusted,
as well as the flow rate of air for collet cleaning.
306221f1
Item
10
190
210
COMPONENTS
Description
Tube
Flow rate limiter
3channel electrodistributor
300556 en 01/07
8.7
DESCRIPTION OF OPERATION
APPLICATION
Description
199223
DECO 20 / 20a
306004
When the part is inserted into the collet (max. length 50 mm) it pushes back
the endpiece and compresses the spring.
DESCRIPTION
Rotating ejector mounted in the pickoff spindle with possibility for collet cleaning using the cutting fluid.
Can be used alone or with collet cleaning 306152.
The ejector can be used with collet capacities F30 and F25, but is incompatible with F20 and smaller sizes.
TECHNICAL DATA
Component
Travel :
Description
maxi
300556 en 01/07
Data
50 mm
306151f1
300556 en 01/07
COMPONENTS
Item
90100
30
220
Description
Endpieces
Tube
Spring
PRIOR CONDITIONS :
What to do ?
Notes
DISASSEMBLY
REMOVAL OF EJECTOR
What to do ?
As above
Notes
ASSEMBLY
INSTALLATION OF EJECTOR
What to do ?
Insert the ejector into the pickoff
spindle.
Notes
On back of pickoff spindle.
Center flange 40 with respect to
thrust tube
300556 en 01/07
APPLICATION
This item is used in:
Description
199223
DECO 20a
306004
199225
DECO 26a
306107
306218I1
DESCRIPTION
Device fitted inside the pickoff spindle to allow collet cleaning.
Mounted at the rear of the pickoff spindle.
Can be used alone or with ejector 306151.
Must be connected to coolant pump 306150 to guarantee sufficient cleaning
power.
300556 en 01/07
DESCRIPTION OF OPERATION
Description
Guard
Clamp
Cutting fluid inlet connector
Endpiece
PRIOR CONDITIONS :
What to do ?
Notes
What to do ?
Insert the tube with the clamp into
the pickoff spindle...
Notes
... on the back of the pickoff
spindle
... and tighten the 2 screws 210.
300556 en 01/07
306218f1
300556 en 01/07
Au combin ou aux
contreoprations
Am Stirnapparat
oder an RckWZsystem
On front tool system
or backwork system
A la contrepoupe
An Abgreifspindel
On pickoff spindle
Pompe 15 bars
15 barPumpe
15 bar pump
306150f2
300556 en 01/07
8.8
APPLICATION
This item is used in:
Description
199225
DECO 26 / 26a
306107
Component
Travel :
Description
maxi
Data
50 mm
DESCRIPTION OF OPERATION
DESCRIPTION
Rotating ejector mounted in the pickoff spindle with possibility for collet cleaning using the cutting fluid.
When the part is inserted into the collet (maximum length 50 mm) it pushes
back the endpiece and compresses the spring.
COMPONENTS
300556 en 01/07
Item
5070
90
210220
Description
Endpieces
Tube
Spring16daN or 6daN
306154f1
300556 en 01/07
EJECTOR REMOVAL
What to do ?
What to do ?
Notes
DISASSEMBLY
PRIOR CONDITIONS :
As above.
ASSEMBLY
Take out the locating ring 190,
then the retaining flange 10.
As above.
EJECTOR INSTALLATION
What to do ?
Fit the retaining flange 10, then the
locating ring 190 ...
Insert the ejector into the pickoff
spindle.
Notes
... on the back of the pickoff
spindle.
300556 en 01/07
>>>
What to do ?
Notes
DISASSEMBLY
Remove Seeger ring 150 and
adaptor flange 20.
Take out the spring.
ASSEMBLY
Insert the new spring
Refit adaptor flange 20 and
Seeger ring 150.
300556 en 01/07
APPLICATION
This item is used in:
Description
199223
DECO 20a
306004
Pickoff spindle 20 mm
199225
DECO 26a
306107
Pickoff spindle 26 mm
306218I1
300556 en 01/07
DESCRIPTION
What to do ?
Take off connector 20 with the
pipe.
DESCRIPTION OF OPERATION
The cutting fluid arrives at the pump on connector 20 via a flexible pipe.
COMPONENTS
Item
10
20
50
70
Description
Clamp
Cutting fluid inlet connector
Guard
Endpiece
300556 en 01/07
Notes
What to do ?
Notes
306220f1
300556 en 01/07
8.9
DECO 20a
199225
DECO 26a
DESCRIPTION OF OPERATION
This device allows the pickoff spindle collet to be cleaned via the inside of the
ejector.
The flushing valve is mounted on the 15 bar coolant pump.
The lubricating fluid is filtered upstream of the ejector or tube.
A pneumatic valve allows the lubricating fluid to be switched on and off.
An ejector (pushrod) with larger flowholes is provided to avoid restricting the
fluid flow.
See also:
COMPONENTS
Item
140
Description
Pneumatic ballvalve
300556 en 01/07
030
306217f1
300556 en 01/07
TECHNICAL DATA
Components
Pipes
Fluid
Description
Operating pressure
Maximum viscosity
REMOVAL
Data
max10 bars
28 mm2/s
PRIOR CONDITIONS :
What to do ?
Notes
4 screws 100
INSTALLATION
PRIOR CONDITIONS :
What to do ?
Fix the pneumatic valve to the protective cover of the pickoff spindle
carriage.
Notes
4 screws 100
300556 en 01/07
APPLICATION
This item is used in:
Description
199223
DECO 20
199225
DECO 26
Description
Toothed pin of tensioner roller
S5 tensioner plate
S5 belt guard
Fixing screw
Tensioner roller screw
Components
Drive
Rotation speed
Motor spindle ratio
Motor
Description
modular
03000 min1
8000 min1
08000 min1
P nominal P maxi
1,5
/ 2,25 kW
Data
1 to 3 tools T51 to T53
0 8000 min1
1
08000 min1
4,8 Nm
1,79 Nm
0,54 sec *
The exact values depend on the revolving devices ant the tooling the
machine is equipped with.
DESCRIPTION OF OPERATION
Asynchroous motor drive allows the use of live units to perform transverse
movements in backwork operations such as drilling and milling, etc...
Transmission is via a synchronous belt on toothed pionions with no backlash.
Adjustment of belt tension is by means of a single tensioner.
. Caution !
Do not switch on the machine flushing function without the guards in
place, as this could damage/destroy the motor and the bearings in the
rollers.
300556 en 01/07
306036f1
300556 en 01/07
Belt arrangement
300556 en 01/07
What to do ?
Notes
DISASSEMBLY
Time [s]
Torque [Nm]
Speed S5 [min1]
Torque 100 % ED
Max. Torque
Time 100 % ED
Min. Time
300556 en 01/07
036c
DESCRIPTION
Asynchronous drive for live units.
DECO 20
199225
DECO 26
Caution !
For safety reasons, do not operate the drive assembly without the
guards.
COMPONENTS
Item
040
090
190
410
470
Description
Toothed pin of tensioner roller
S5 tensioner plate
S5 belt guard
Fixing screw
Tensioner roller screw
300556 en 01/07
DESCRIPTION DE FONCTIONNEMENT
Asynchronous motor drive allows the use of live units to perform axial movements in backwork operations such as drilling and milling, etc...
Transmission is via a synchronous belt on toothed pinions with no backlash.
Adjustment of belt tension is by means of a single tensioner.
306099f1
300556 en 01/07
300556 en 01/07
306099f2
TECHNICAL DATA
Time [s]
Torque [Nm]
Components
Drive
Rotation speed
Motor spindle ratio
Motor
Description
modular
03000 min1
8000 min1
08000 min1
Pnominal Pmaxi
1,5
/ 2,2 kW
Data
1 to 4 tools T41 to T44
0 8000 min1
1
08000 min1
4,8 Nm
1,79 Nm
0,54 sec *
The exact values depend on the revolving devices and the tooling the
machine is equipped with.
Speed S5 [min1]
Continous torque
Intermittent torque
Continous time
Intermittent time
300556 en 01/07
>>>
What to do ?
Notes
DISASSEMBLY
Take off belt guard 190.
Belt arrangement.
300556 en 01/07
300556 en 01/07
306279f1
300556 en 01/07
306279f2
300556 en 01/07
. Warnings!
This device is installed in pos. T51. It also occupies pos. T52.
This device cancels pos. T41 and T42.
It is not designed for working with aqueous cutoff fluid (emulsion).
INCLINATION ADJUSTMENT
Steps
Notes
Setting
Unscrew the 2 guard screws
Adjust the inclination
Bar passage
GENERAL CHARACTERISTICS
5 to 15 mm (based on the
angle)
Angular adjustment
Rotation speed
Transmissible torque
max.
Belt
+/ 15
8000 min1
Steps
Frequency
Notes
Annually or every 3000 hours
Disassembly
Remove the cover plate 160,
secured by the 4 480 screws.
Remove flange 130 then the belt.
2 500 screws
300556 en 01/07
>>>
Assembly
Steps
Notes
2 500 screws
300556 en 01/07
306281f1
300556 en 01/07
Characteristics
Data
Dimensions:
Identification:
Tornos
Note:
306281
Data
4655
Thread whirling head for creating an exterior
thread using 3 blades
exterior diameter 15 mm, thickness 4 mm,
bore diameter 5 mm.
300556 en 01/07
Data
Function
4660
Dimensions:
Identification:
Tornos
570504
BLADE GRINDING
Steps
Notes
Position the blades at a dimension above 20 mm (grinding allowance based on blade wear).
21.5mm
flange
finished dimension after grinding
Fig. 1507
300556 en 01/07
Notes
tapered
head
r
b
c
g
g
g
c
300556 en 01/07
8.11.5 Programming
Note:
The device installed in position T51, it cancels positions T41 and T42.
a
a = 1.5 mm
Pivoting axis
. Warning!
Collision possible with operation.
Blade centre
X axis geometry
The centre of the thread whirling device is located 71 mm from the reference
pin..
The blades work on a diameter of 18 mm (9 mm radius) from the centre of the
device. Since the theoretical distance of the reference pin is 80 mm, the resulting theoretical geometry in x is 160 mm.
Y axis geometry
Pivoting axis of the head is aligned based on the blade centre axis.
Since this offset is relatively small, a correction on the Y axis is not indispensable..
If a correction is introduced, the calculation to be introduced in the geometry
is positive for a right thread, and negative for a left thread (see the drawing).
Calculate value Y:
Given:
formula:
300556 en 01/07
Z axis geometry
THEORETICAL GEOMETRIES TO INTRODUCE TO THE RIGHT
Y
Function
(Compensation
to calculate)
(Blade centre
4655
160
52
Function
(Compensation
to calculate)
(Blade centre
1910
160
52
Thread types
>>>
The device is used to create threads on the right and left. For the two cases
see the table below in order to use the correct program parameters.
Thread
ISO Code
Rotation S1
ISO Code
Rotation S2
Head
inclination
to the right
C4+
M500
Up
to the left
C4
M500
Down
Up
Down
300556 en 01/07
Programming
Programming the exterior thread whirling device requires creation of a new
operation line including the axes C4, X4 and Z4.
The figure below shows the third line of operations (Axis C4) where the thread
whirling operation is to be carried out, as well as the different operations
needed for positioning the device:
Op. 6:10
Code ISO:
Op. 7:1
Thread whirling
Code ISO
T51
M498
G4 X1
G1 Z4=30 X4=5,067 G100
(1st stroke
G1 Z4=1,2 X4=5,792 F1000 G94
G1 C4=606,84 Z4=3,857 X4=10,400 F5500 (F3000 (F3600
G1 C4=2844 Z4=22,5 F5500 (F3000 (F3600
G1 X4=13 F2000
G1 Z4=1,2
G1 C4=0 F70000 (F21000
(2nd stroke
G1 Z4=1,2 X4=3,892 F1000
G1 C4=606,84 Z4=3,857 X4=8,5 F5500 (F3000
G1 C4=2844 Z4=22,5 F5500 (F3000
G1 X4=13 F2000
G1 Z4=1,2
G1 C4=0 F70000 (F21000
Op. 6:9
Code ISO:
Index T51
G3 Z4=30 X4=5,067 Y4=0 G100 T51 R300
M403 S0
M405
300556 en 01/07
(3rd stroke
M503 S2700 (S1800
G4 X.2
G1 Z4=1,2 X4=3,492 F1000
G1 C4=606,84 Z4=3,857 X4=8,10 F3000 (F3000
G1 C4=2844 Z4=22,5 F3000 (F3000
G1 X4=13 F2000
G1 Z4=10
G1 Z4=30 F3000 (G100
G95
M499
Chap. 8.11.5 /53
300556 en 01/07
Technical data:
Material:
diameter of blade operation (geometry) :
Cutting speed:
n=
number or revolutions of the thread
fz = advance per tooth:
z=
number of teeth:
Note:
The advance per tooth fz is based on the experience in thread whirling. It is generally located in a range of 0.02 0.05 mm. This advance
may be optimised in order to ensure a good quality thread and a good
mastery of blade wear.
2.
Vf
= nC4 x 360
Vf
= 3,75 x 360 =
3.
tg =
1350 /min
Thread
x daverage
3
=
x 10,39
Based on the inclination angle, it is easy to adjust the device inclination used
the scale or a comparator with movement of axis Z4.
For example:
Movement of Z4 by 20 mm, h = tg x 20 = 0.2063 x 20 = 4.1262 mm
1.
nC4
x daverage
0.024 x 3 x 1700
nC4
x 10,39
= 3,75 min1
Z4
Note:
daverage is calculated taking into account the diameter of the bar and
the diameter of the bottom of the thread !
300556 en 01/07
DECO 20a
199225
DECO 26a
COMPONENTS
Item
010
020
030
040
050
060
070
440
Description
Actuator support
Flange 10
Fixing plate
Guide sight
Ejection rod 10
Ejection rod 6
Actuator support bracket
Ejection actuator
300556 en 01/07
TECHNICAL DATA
Components
Actuator travel:
Ejector rod 565002:
Ejector rod 565003:
Description
Data
750 mm
10 / 4
End thread M5
6 / 3
End thread M4
OPERATION
CHANGING OF CAPACITY
What to do ?
The actuator ejector rod allows parts to be pushed through the pickoff spindle
into T41.
DISASSEMBLY
The guide sight for the ejector rod allows 6 and 10 mm rods to be used.
The rods are hollow and allow matching to the endpiece for passage of air or
oil.
INSTALLATION
PRIOR CONDITIONS:
Notes
Notes
SETTING
Align the end of the rod on the line
of tools;...
ASSEMBLY
ASSEMBLY
Fit the subassembly. Insert,
tighten and lock the 2 screws 350.
In T41
300556 en 01/07
306226f1
300556 en 01/07
APPLICATION
Item
050
450
480
DECO 20a
199225
DECO 26a
Description
Recovery chute
Tipout actuator
Selection actuator
ASSOCIATED EQUIPMENT
The following accessories can be used together according to requirements:
Description
306226
306214
306229
306228
306136
306213I2
300556 en 01/07
306213f1
300556 en 01/07
TECHNICAL DATA
Components
Longitudinal travel:
Diameter of parts:
Max length outside
pickoff spindle:
Max length inside
pickoff spindle:
Description
>>>
Data
500 mm
7 32 mm
100 mm
700 mm
DESCRIPTION OF OPERATION
Operation is activated by pneumatic actuators.
The operation of the selection actuator is controlled by detectors.
Parts are collected behind the pickoff spindle in a recovery chute.
This chute moves back to take parts outside the perimeter of the machine.
Next, another actuator tips the parts onto an inclined plane.
Long parts tipper for DECO 20a et 26a:
300556 en 01/07
(see 306214)
306213f2
300556 en 01/07
306213f3
300556 en 01/07
306214I1
300556 en 01/07
306214I2
306214f1
300556 en 01/07
APPLICATION
ASSOCIATED EQUIPMENT
Description
Description
306226
199223
DECO 20a
306214
199225
DECO 26a
306229
306228
306136
COMPONENTS
Item
040
400
1010
1020
1030
Description
Inclined plane
Long parts frame
Parts access hatch
Maintenance access
M10 threaded holes for transport
REMOVAL
The long parts outlet (306213) remains fitted inside the tipping device
(306214).
What to do ?
DESCRIPTION
The aluminiumprofile frame, which receives parts through the pickoff spindle
is outside the machine perimeter.
TECHNICAL DATA
The following accessories can be used together according to requirements
Components
Description
Data
Overhang from
length
980 mm
machine:
width
780mm
Weight:
Weight:
300556 en 01/07
Notes
4 x M10 threads.
approx. 56kg
approx. 67kg
>>>
TRANSPORT
The long parts outlet (306213) remains mounted inside the tipper.
What to do ?
Notes
INSTALLATION
What to do ?
Notes
4 x M10 threads.
BY FACTORY
300556 en 01/07
DECO 20a
199225
DECO 26a
DESCRIPTION OF OPERATION
The electrodistributors control:
Ejection actuator
Position (306226)
Evacuation actuator
Position (306213)
Tipper actuator
Position (306213)
Flow rate limiters 050 and 060 serve for adjustment of the movement speeds
of the different components (speed adjusting itself to the outlet in both cases).
See also: Long parts kinematics (306213f2 and 306213f3)
COMPONENTS
Item
010
020
050
060
120
Description
Electrodistributor
Outlet valve
Flow limiters
Flow limiters
Outlet flow limiters
Note :
When diasassembling the long parts device, disconnect the 4 pipes
(180 and 190) fit 4 blanking plugs (150) in their place.
300556 en 01/07
306229f1
300556 en 01/07
Tipping actuator
Evacuation actuator
300556 en 01/07
Ejection actuator
Parts
Thrust tube
Identification
no.
Notes
20 ... 25,4
26 mm
562039
Basic machine
16 ... 20
21 mm
562023
11 ... 16
17 mm
562033
OPERATION
7,5 ... 11
12 mm
562034
Thrust tubes allow the part to be guided into the pickoff spindle and serve to
adjust the tightening travel of the pickoff spindle.
2 ... 7,5
8,5 mm
562035
Parts
Guide tube
Identification
no.
20 ... 25,4
26 mm
562253
16 ... 20
21 mm
562252
11 ... 16
17 mm
562251
7,5 ... 11
12 mm
562250
2 ... 7,5
8,5 mm
562249
APPLICATION
This item is used in:
Description
199223
DECO 20 / 20a
Note :
A thrust tube diameter 26 mm is the basic one supplied for the pickoff
spindle.
Guide tubes (nonrotating) allow the part to be guided beyond the pickoff
spindle.
. Caution !
In certain cases guidance closer to the diameter can be necessary or a
lower rotation speed must be chosen.
300556 en 01/07
Notes
>>>
Notes
COMPONENTS
Item
110
330
1040
50100
Description
Clamp
Locating pin
Thrust tubes
Guide tubes
300556 en 01/07
306228f1
300556 en 01/07
250
APPLICATION
20
DECO 26 / 26a
200 10
Parts
Thrust tubes
Identification no.
20 ... 25,4
26 mm
562643
16 ... 20
21 mm
562642
11 ... 16
17 mm
562641
7,5 ... 11
12 mm
562640
300556 en 01/07
306136f2
306136f1
300556 en 01/07
306274f1
300556 en 01/07
APPLICATION
T53
T52
T51
T53
T52
T51
Description
199223
DECO 20 / 20a
199225
DECO 26 / 26a
T44
T43
T42
T41
T44
T43
T42
T41
This device is approved by TORNOS, provided that the following points are
observed:
Use solely for backwork.
Possible fitting in T51 or T53, with restriction of use to the positions shown
in the following sketch:
300556 en 01/07
300556 en 01/07
mecnica de precisin
TECHNICAL DATA
Model
Weight
Size
Angular adjustment
Tool fixing
Tool
capacity
Speed
ratio
Max.
speed
Inlet
Outlet
Lubrication
P.021.00
001
2,8 Kg
44 x 70 x
230
From 0 to 90
Fixed positions every 15
Collet
ER11
0,5 to
7
1:1
8000
t/min.
right
right
lifetime
300556 en 01/07
These positions include the whole range from 0 to 90, at intevals of15.
7. Ready to go !
8.14.2Maintenance
0
15
30
45
60
75
90
No type of maintenance is necessary, given that the product leaves the factory
lubricated for life. Nevertheless, the care instructions must be observed, as
well as the way it is used, as is required for any precision tools.
If you want to do preventive maintenance:
Regrease using grease of type: Klber ISOFLEX NBU15.
Note :
For major servicing, contact MADAULA aftersales service.
300556 en 01/07
9.
9.1
Sensor travel
Minimum checkable
diameter
90
0,3 mm
070
020
APPLICATION
This item is used in:
060
Description
199223
199225
010
DECO 20
DECO 26
050
COMPONENTS
030
Item
010
020
030
040
050
060
070
Description
Minisensor
Pressuresensitive switch
Fixing studs
Clamping nut
Y connector
Coaxial tube
Additional sensor pins
040
030
216174a
DESCRIPTION
TECHNICAL DATA
Components
Operating pressure
Lenght of sensors
Description
mini
300556 en 01/07
Modular design.
Data
4 bar
40 mm et 60 mm
Chap. 9.1.1 /1
ASSEMBLY
What to do ?
Notes
010
DESCRIPTION OF OPERATION
Each time a tool is withdrawn, air is sent into the device via an air valve or an
electrodistributor.
The duration of this pneumatic supply is about 0.2 to 05. s.
060
b)
Chap. 9.1.1 /2
>>>
APPLICATION
This item is used in:
Description
199223
DECO 20
199225
DECO 26
COMPONENTS
Item
010
020
Description
Electrodistributor YVx for Minisensor
Air flow control valve
. Caution !
The Minisensor pneumatic supply pipe must be installed in such as
way that it avoids all contact with the different operating devices.
To avoid any premature deterioration, the Minisensor pneumatic
supply pipe must not be in contact with the chips
300556 en 01/07
Chap. 9.1.2 /3
305091
300556 en 01/07
Chap. 9.1.2 /4
DESCRIPTION OF OPERATION
INSTALLATION
PRIOR CONDITIONS:
What to do ?
Notes
This adjustment is made by the tool setter mainly for sensing a fragile part or
tool.
The speed must be set so that anything arriving at the work or tool being monitored does not break the latter by its impact.
300556 en 01/07
Chap. 9.1.2 /5
INSTALLATION
Description
199223
DECO 20
199225
DECO 26
COMPONENTS
Item
010
020
100
110
120
Notes
Description
Rod M6
Rod dia. 8
Nut M6
Clamping nut
Flat washer
. Caution!
When installing Minisensor adaptor parts, there is arisk of collision
with the different axes and tools of the machine !
Take care with chips which can become wedged in fixing studs and
bar.
300556 en 01/07
DESCRIPTION
These adaptation parts allow one or several MiniDetectors to be fixed.
By sliding the bars and moving the tightening nuts, the MiniDetector can be
positioned over a wide radius.
Chap. 9.1.3 /6
9.2
Execution
DECO 20 / 20a
199225
DECO 26 / 26a
TECHNICAL DATA
Oil cooling system, type KRO 45 DP KELVIN
Components
Cooling power
Maximum ambient temperature
Oil outlet temperature
Supploy voltage
Power input
Current rating
Pump flow
Type of oil
Regulation
Data
5,12 kW
32C
20C
400/460V 3 50/60 Hz
2,3 / 2,9 kW
4,9 A
25 l/min. max. 10 bar
Coolant oil
+/ 2C
300556 en 01/07
Coolant
Connection
Dimensions
Weight
Paint finish
Chap. 9.2 /7
12
9
1
2
4
5
3
6
Outlet
Inlet
7
Item
1
2
3
4
5
6
7
COMPONENTS
Description
Main switch
Electronic monitoring thermostat with display
General alarm lamp (red)
Compressor running lamp (green)
Voltage present lamp (white)
Oil pressure gauge
Hole for pump cooling
300556 en 01/07
8
9
10
11
12
13
14
15
16
Support feet
Lifting hooks
Condenser
Oillevel indicator
Oil tank filler plug
Oil outlet connection
Oil inlet connection
Mains supply
Tank drain faucet
Chap. 9.2 /8
300556 en 01/07
Chap. 9.2.4 /9
306165
300556 en 01/07
>>>
300556 en 01/07
9.3
APPLICATION
This item is used in:
Description
199223
DECO 20a
199225
DECO 26a
Components
Type of machine :
Bar travel :
Fluids used :
Description
Data
sliding headstock
up to 32 mm
70% whole oils
30% soluble oils
Caution !
For impeccable operation of the CHIP CONVEYORLATHE assembly
TORNOS have issued instructions with the characteristics & functions
required for the conveyorlathe interface. The instructions are entitled:
INTERFACE SPECIFICATIONS FOR CHIP CONVEYOR INSTALLATION
These specifications must be strictly complied with to avoid malfunctioning of the chip conveyor, which might be imputed to the lathe.
TORNOS declines any liability whatsoever, should a damage or accident be imputed to the conveyor, which do not conform to the said
specifications &/or standards in force.
300556 en 01/07
9.4
APPLICATION
This item is used in:
Description
199223
DECO 20a
199225
DECO 26a
DESCRIPTION
Components
Flow:
Motor:
Weight:
Filter mesh:
Noise:
Description
Normal
Centrifuge
Total (with support)
Data
850 m3/h
1,1 kW
22 kg
30kg
100% from 0,8 to 5
micron
70dBA
. Caution!
In spite of installation of a smoke extractor, the treatment system can
be insufficient when there is a heavy emissiion of smoke. The user
should follow the suppliers instructions strictly.
The oil mist extractor option does not include a smoke filter. This can be
installed later if required (see Filter for dry smoke on Filtermist).
. Caution!
1
300556 en 01/07
306277I1
COMPONENTS
ASSEMBLY
PRIOR CONDITIONS:
What to do ?
Notes
Comment:
Even though annual maintenance is carried out, certain production
conditions necessitate more frequent maintenance / replacement.
PRIOR CONDITIONS :
Description
Support plate fx3000 / fx5000
Support
Cylindrical plug 20 x 25 / M6
FILTERMIST FX 3000 M
MAINTENANCE
FREQUENCY:
Item
010
020
320
330
Note :
All spare parts can be ordered directly from LESTOPREX AG CH
8640 RAPPERSWIL SG
++ 41 +55 210 41 41
It is possibleto consult the nearest FILTERMIST agent
( http://www.filtermist.com / )
Notes
300556 en 01/07
306277f1
300556 en 01/07
9.5
APPLICATION
This item is used in:
Description
199223
DECO 20a
199225
DECO 26a
Components
Flow:
Description
FILTERMIST FX3000
+ smoke filter
FILTERMIST FX3000
alone
Filter mesh:
Data
m3/h
850 m3/h
99,95% de 0,01 1,3
microns
ASSEMBLY DISASSEMBLY
DESCRIPTION
PRIOR CONDITIONS :
Filter for dry smokes to be put on oil mist extractors of the type FX 3000 BM.
What to do ?
Notes
Filter also suitable for extractors that have motors fitted with a brake.
ASSEMBLY
OPERATION
DISASSEMBLY
The dry smoke filter is used during machining using a cutting oil. It is not
necessary when working with emulsion.
MAINTENANCE
. Caution !
In spite of the installation of a smoke extractor, the treatment system
can be insufficient when there is a heavy emission of smoke.
FREQUENCY:
Note :
Even though annual maintenance is carried out, certain production
conditions necessitate more frequent maintenance / replacement.
PRIOR CONDITIONS :
300556 en 01/07
100
306223I1
306223I2
300556 en 01/07
9.6
5480 => DECO 13b/13bi, DECO 13a 2260001 & DECO 13a 2260010
5482 => DECO 7a/10a DECO 20a/26a
9.6.1 Description
Danger !
Unauthorized manipulation of the machines fire protection system can
diminish the working capacity of the system and/or cause harm to persons and cause material damage.
9.6.2 Application
This equipment for protection against fire makes it possible to contain an outbreak of fire during machining of materials likely to cause risks of
inflammation, for example:
machining of titanium, magnesium,
machining of stainless steel,...
Warning!
All oil mist extraction systems or fume filters (options 5430 to 5434)
must without fail be equipped with a shuttingoff system compatible
with the fire prevention device (nonreturn valve or motor brake connected to the emergency stop of the machine, this being the
responsibility of the purchaser if installed by the latter).
TORNOS SA supplies compatible systems.
300556 en 01/07
Attention!
The fire prevention system is disabled while the doors are open.
If a fire breaks out during an operator intervention in the machining
area, the operator must move away immediately and shut the doors.
x
306244f1
300556 en 01/07
300556 en 01/07
9.7
>>>
APPLICATION
This item is used in:
Description
199223
DECO 20 / 20a
199225
DECO 26 / 26a
DESCRIPTION
Plate and duckboard for recovey of any liquides that can run outside the
machine cowling.
COMPONENTS
Item
010
020
Description
Oil recovey plate
Duckboard
300556 en 01/07
010
020
306230f1
300556 en 01/07
>>>
300556 en 01/07
10.
10.1.1Inputs
Each optional socket comprises 2 inputs
(for units such as sensors, pressostats, push buttons etc.)
DECO 20 / 20a
199225
DECO 26 / 26a
These units are connected to Terminal Box XT 800 on the back of the machine.
10.1 GENERAL
There are two optional sockets available on the machine. They enable the user
to operate, through the partprogram, functions other than M functions, such
as:
10.1.3Outputs
These units are connected to Terminal Box XT 800 on the back of the machine.
Message display.
300556 en 01/07
Chap. 10.1.4 /1
fig. 2701
300556 en 01/07
Chap. 10.1.4 /2
(Cabinet XT800)
Box cover
fig. 2702
300556 en 01/07
Chap. 10.1.4 /3
DO 1751=1:
DO 1752=1:
DO 1753=1:
DO 1755=1:
300556 en 01/07
DO 1757=1:
DO 1760=1:
Chap. 10.2.2 /4
Code M811:
Code M812:
Note:
Alarms class 1 and 3 change over to alarms class 4 after 10 minutes
and cut off the power to the machine.
DO 1761=1:
DO 1765=1:
Code M813:
Code M814:
DO1762=1:
DO1766=1:
300556 en 01/07
Chap. 10.2.4 /5
Option : K 23.1 = 1
DO 1770=1:
DO 1771=1:
DO 1772=1:
DO 1773=1:
DO 1775=1:
Note:
300556 en 01/07
DO 1776=1:
DO 1777=1:
DO 1780=1:
Chap. 10.3.2 /6
>>>
Note:
Alarms class 1 and 3 change over to alarms class 4 after 10 minutes
and cut off the power to the machine.
DO 1785=1:
Code M823:
Code M824:
DO 1782=1:
DO1786=1:
300556 en 01/07
Chap. 10.3.4 /7
Quantity
indicator
2
300556 en 01/07
Operating
time
Terminal
box
XT 800
Chap. 10.4.1 /8
When Input 1 of the optional socket goes over to 1 (24V) the program stops
at the end of table (alarm class 1).
Endofpart signal.
Terminal
box
XT 800
300556 en 01/07
40
Chap. 10.5.3 /9
When part is present the program stops immediately (alarm class 3).
M800 P1=1753 P2=1757
1753 = disables Input 2 which is not used
1757 = selects alarm class 3.
2
Terminal
box
XT 800
M811 D811=300
M812
When tool is absent (input at 0 when M815 enabled) 2012 ALARM CLASS
1 ON OPTIONAL SOCKET is displayed on the screen and the program stops
at the end of table.
When part is present (input at 1 when M815 enabled) 1013 ALARM CLASS
3 ON OPTIONAL SOCKET is displayed on the screen and the program stops
at the end of table.
300556 en 01/07
Output 1 optional
socket 1
M815
Sensor Movement
Time[ITP]
300556 en 01/07
M815
M811
M812
Terminal
box
XT 800
300556 en 01/07
893
If Input 1 of optional socket 2 is at 0 when M825 is enabled, the alarm 2011
MESSAGE ON OPTIONAL SOCKET is displayed on the screen. When this
message is displayed the operator must assume that the oil tank is empty.
300556 en 01/07
Terminal box
XT 800
40
40
Terminal
box XT 800
Bornier
XT 800
M811 D811=1000
M812
G04 X2
Dwell of 2 seconds.
Depends on the time needed for the piston
to return.
M825
Time [ITP]
300556 en 01/07
Terminal
box
XT 800
300556 en 01/07
40
Terminal
box
XT 800
40
Terminal box
XT 800
M812
G04 X2
Dwell of 2 seconds.
(Depends on the time needed for the piston
to reach the Piston forward sensor).
M815
M813 D813=16
M814
G04 X2
Dwell of 2 seconds.
(Depends on the time needed for the piston
to reach the Piston backward sensor).
M825
300556 en 01/07
>>>
2 sec.
Piston
backward check
Time [ITP]
300556 en 01/07
Flag 3
Flag 6
Flags 1 and 2:
Flag 7
Flags 3 and 4:
Flag 5:
Flag 5
Flag 1
Classe 0
3
1
In1
Flag 6, 7, and 8:
enabled.
Classe 1
Flag 2
2
In2
Out 1
Flag 8
Flag 4
Flag 9
Out 2
Classe 3
Flag 9:
Event 7
24 V= (2x)
0V (2x)
Gnd
300556 en 01/07
10.11.2
Enable/Disable Flags for Optional Socket Outputs
OR (gates 3 and 4)
AND (gates 5 to 9)
OUT
OUT
OUT
Flags
Socket 1
Socket 2
1763
1783
1765
1785
1764
1784
1766
1786
1765
1785
1763
1783
1766
1786
1764
1784
RR1
1761
1781
RR2
1762
1782
Set OUT 1
Set OUT 2
Reset OUT 1
10.11.1
Optional Socket Configuration Flags
Reset OUT 2
Flags
Socket 1
Socket 2
1750
1770
1751
1771
1752
1772
1753
1773
1754
1774
1755
1775
1756
1776
1757
1777
1760
1780
300556 en 01/07
11.
INDEX
300556 en 01/07
Chap. 11.1 /1
Chap. 11.1 /2
Chap. 11.1 /3
300556 en 01/07
Chap. 11.1 /4