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　　SHD 系列动力刀塔 使用说明书 温岭市三和数控机床设备有限公司 A 三和数控 目 录 1 安全注意事项 1.1 图标说明 ··············································································································3 1.2 使用规范 ··············································································································3 1.3 操作技术要求 ···································································································· 3 1.4 产品特征及注意事项 ························································································· 3 1.5 责任承担 ··············································································································4 2 产品描述 2.1 零件名称 ··········································································································· 5 2.2 技术参数 ··········································································································· 6 2.3 允许载荷 ··········································································································· 7 3 装配与安装 3.1 刀塔驱动电机 ···································································································· 7 3.2 驱动电机 ······································································································· 8 3.3 刀塔润滑 ··········································································································· 9 4 刀塔启动 4.1 刀塔驱动电机 ··································································································· 9 4.2 齿轮箱电机 ······································································································· 10 4.3 液压系统 ········································································································· 11 5 操作 5.1 动力刀座与其他刀座 ························································································ 13 5.2 可能出现的故障及补救措施 ············································································· 14 6 电气安装- 6.1 相关电气规格说明································································································· 14 6.2 注意事项··············································································································· 15 6.3 安装环境条件········································································································ 15 6.4 安装方向与空间及示意图······················································································ 16 6.5 断路器与保险丝建议规格······················································································ 16 6.6 外围装置接线图···································································································· 17 6.7 驱动器连接器与端子····························································································· 17 6.8 电源接线方法········································································································ 18 6.9 马达·近接开关·编码器配线方式··········································································· 18 6.10 线材的选择 ······································································································· 18 6.11 CNI I/O 信号接线 ······························································································· 19 6.12 模式切换功能定义 ······························································································ 20 6.13 CNI I/O DI 的输入定义及 DO 输出的定义 ·························································· 21 1 三和数控 6.14 CN2 编码器信号接线 ······················································································· 21 6.15 异警一览表 ······································································································ 22 6.16 刀塔零点设置 ·································································································· 22 7 维修及保养 7.1 刀塔使用寿命 ··································································································22 7.2 保养周期 ········································································································· 22 7.3 刀盘排水 ··········································································································23 7.4 动力电机 ········································································································ 24 7.5 齿轮头 ······················· ···················································································· 24 7.6 刀盘 ················································································································ 26 7.7 接近开关 S8 S9 ····························································································· 29 7.8 冷却液分水阀组 ·························································································· 30 8 零件更换 ·················································································································· 31 附 录 液压系统图 HPD001································································································35 配线································································································36 刀塔控制线·························································································37 刀塔控制线·························································································38 刀塔控制线·························································································39 刀塔控制线·························································································40 功能图 SHDE001·····································································································41 功能图 SHDE002·····································································································42 刀塔原点设置流程图·································································································43 刀塔选刀控制流程图 ·······························································································44 2 三和数控 1． 安全注意事项 本产品符合最新技术标准和安全技术规范，但危险仍然可能存在。 1.1 图标说明 警告 表示可能导致重伤甚至死亡的危险状况 此符号表示一个潜在的危险情况，这可能导致严重的人员受伤甚至死亡或刀塔 相关部件的损坏。 在有标示此符号的事项进行操作时，一定要将安全列为第一考量。 警告 表示高压可能引起电击危险 所有电气系统的作业必须由专业技工或工程师来操作。 1.2 使用规范 在设备完好并遵守操作规范的情况下操作。 在安全情况下按照操作规范操作。 按照操作手册使用相对应的刀座/动力刀座规格尺寸； 使用保护盖将所有未使用的刀具夹紧装置密封。 1.3 操作技术要求 要求受过培训的专业人员，按照操作手册要求对刀塔进行操作。 警告 会有人员受伤或机器损坏的危险。 电气安装必须由电气工程师进行！必须定期对电气线 产品注意事项 操作时需使用 24V 直流电源。 操作前须知 关闭机器电源 刀塔减压 →液压控制图 ， 请见操作手册附录 警告 受伤的危险 启动时，刀盘可能会发生意外旋转。 遵循刀塔安装步骤，油管入口 A 必须先加压。 警告 受伤的危险 3 三和数控 在故障或撞车时，刀盘可能会发生意外旋转，务必注意，以免有人员受伤。 在刀塔维修、调整或手动转动之前，需降低刀塔液压。 警告 工作中的机械导致人员受伤的危险 电源及油压回路开启时 于施工场所所设立警告标志。 防止其他人员操作。 勿靠近运作中的机器部位，尤其是旋转中的刀具范围 注意 料件损坏的风险 为正确启动耦合装置，齿轮箱电机必须加以设定。 卸除所有刀座/动力刀座。 针对齿轮箱电机进行基本调整。 注意 料件损坏的风险。 动力刀座耦合装置可能严重损坏。 按照操作手册使用刀座/动力刀座。 注意 碎屑或赃物进入刀塔时可能导致功能性故障。 使用密封塞封住刀座相关开口和冷却液出口。 注意 在刀塔出现故障时，请勿尝试转动刀塔，以免导致刀塔其他零件受损。 应及时与本公司售后服务部门联系。 1.5 责任承担 本操作手册中包含的信息以印刷时为准，如有更改恕不另行通知。 对于一下情况，本公司不承担责任： ·未严格遵照操作手册的注意事项或指示 ·未按规范使用本产品 ·未能正确操作包括本产品及附件 ·对包括附件在内的本产品进行了非专业维修或保养 ·未经制造商同意私自对本产品进行改装或功能改造 ·未使用适当的刀盘和刀座 ·未使用原厂零配件 4 三和数控 2 产品描述 2.1 零件名称 1.刀盘 2.刀盘盖 3.刀盘出水盖 4.刀盘保护盖 5.密封塞 6.接近开关 S8、S9 7.液压接头 A 、B 8.接近开关 S8、S9 线.冷却液出水阀 5 三和数控 2.2 技术参数 项目 单位 尺寸及规格 BMT 刀塔 16 20 25 中心高 mm 80 100 125 刀塔工位数 N 12 12 12 容许转动惯量 Kgm 2.5 5 12 含刀盘、刀座及刀具 刀盘旋转 s 0.12 0.15 0.20 —包含加速和刹车时每分度 30°时间 —不包含加速和刹车制动时每一工步时间 s 0.07 0.09 0.13 油压刀盘松开/锁紧时间 s 0.12 0.13 0.21 容许分度频率 -1 20 16 12 （换刀角度中间值Φm=90°） Min 液压运转压力 bar 50±10% 刀塔作动油量 c ㎡ 30 45 45 刀塔夹紧和松开 冷却液工作压力 ①. bar 5 ～ 25 容许环境温度范围 ℃ +10 ～ +40 刀具转速 ② rpm 6000 5000 4000 刀具尺寸 BMT45 BMT55 BMT65 刀盘减速比（马达对刀盘） 1：54 1：72 1：72 刀具减速比（马达对刀具） 1：1 1：1 1：1 刀塔重量(不含刀具) kg 125 160 200 ①.为延长冷却液出水阀使用寿命，建议过滤冷却液≤100μm。 ②.此参数依据短时间操作，更高转速会导致温度升高及声响。 6 三和数控 2.3 容许载荷 单位 16 20 25 最大切向力 Fy x ds Nm 2000 4000 8000 最大倾斜扭力（推压） Fz1 x ds Nm 2800 5800 12000 最大倾斜扭力（抬升） Fz2 x ds Nm 2400 5500 10000 最大径向力 Fx N 15000 25000 38000 不平衡扭力 Nm 32 63 125 安全系数=1.5 3 装配与安装 供应条件  齿轮箱电机不包含在交货范围内。  部分联轴器装置及用于组装的垫片已安装在刀塔上；提供另一部分电机端联轴器装置。  刀盘与齿轮头已调整。  所有刀具夹持装置使用保护盖密封。  刀塔安装时需排除油管空气。  刀塔经过测试。 3.1 刀塔驱动电机 在进行任何操作前请先切断电源： 1 3 2 1.传动小齿轮 2.M5x16 （用于锁紧小齿轮） 3. 电机 重要提示 安装传动小齿轮。 7 三和数控 ◆对边锁紧螺丝（3 ）。 ◆锁紧扭力为 8.5 Nm 。 ◆安装装好小齿轮的电机并且锁紧固定螺丝（3 ）。 ◆转动到参考点。 拆卸电机 反安装顺序即可拆下电机。 3.2 齿轮箱电机 准备工作： 切断机器电源  将衬套（3 ）推至心轴底端。  将耦合装置（1）推到底并调整先前已安装的耦合装置。  交叉锁紧电机（2 ）。  将固定螺丝（4 ）锁到底并稍微锁紧。  将固定螺丝平均并交叉锁紧直到达到 8.5Nm 锁紧扭矩。 ◆ 装上弹性环(5) 直结式联轴器 ◆连接联轴器 ◆将动力驱动电机（2）与联接法兰固定 8 三和数控 3.3 刀塔润滑 重要提示 为达到最佳运作可靠性及使用寿命，建议使用中心润滑系统。 注意 因不当的润滑剂造成物料损坏的风险  润滑剂不可以包含以下物质： 钠皂 聚乙二醇 复合皂 砂油（甲基、苯基） 膨润土 全氟聚醚 聚碳酸酯 聚苯醚油  若原润滑剂与中心润滑系统之润滑剂混合，应避免润滑剂产生不利的互相影响。 4 刀塔启动 4.1 刀塔驱动电机 重要提示 在刀塔电机故障/维修组装后，如果需要的话，刀塔的参考位置应重新定义。 警告 移动机器零件可能造成损坏的风险。 如果打开电源供应与油压线路进行调整操作  工作区域贴上警告标志  避免非专业人员进入；对控制面板进行防护  不要靠近运作中的机器零件，特别是刀具转动的区域 警告 物件损坏的风险 安装驱动电机达到正确的耦合  移开所有非动力刀座/动力刀座 9 三和数控 基本调整 1 、按油压松开键，松开刀塔； 2、设定运作位置 1，用手旋转刀塔刀盘至选定的 1 号刀位。 3、按油压锁紧键，锁紧刀塔，并确认刀塔锁紧到位。 4 、1 号位设置为零点位置，设定电机驱动器参数，并重新开机。 驱动至运作位置 1 4.2 驱动电机 事前准备  关闭刀塔电机和驱动电机 当进行此项操作时机床控制器的低电压件必须保持运作。  松开刀塔  用手将刀盘转动 15 度  锁紧刀塔  移开运作位置的防护盖  将动力刀座放置在刀盘运作位置，但是不要锁紧 基本调整 1. 用扳手转动动力刀座轴（动力输入轴）直到感觉到阻碍。 读出机床控制器上的刀座位置并记录为数值 1。 2. 然后往反方向转动动力刀座轴（动力输入轴）直到感觉到阻碍。 读出机床控制器上的刀座位置并记录为数值 2 。  移开动力刀座  松开刀塔 用手往反方向转动刀盘 30 度 10 三和数控 锁紧刀塔 将动力刀座放置运作位置但不要锁紧 3. 重复步骤 1 和 2，并且将个别的数值记录下来 4. 决定记录数值的平均值，并且输入机床控制器，当作驱动电机重新设定的参考位置 功能检查  安装动力刀座 →见 12 页  检查功能 →功能图 4.3 液压系统 供应状况  刀塔内有油路  关闭 A 处和 B 处油路的压力  刀塔排气  每条内部的油路至少会有一个排气孔  所有排气孔都有螺丝孔（E） 联结 重要提示 刀塔油路能进行正常的松开与锁紧运作，即便机床没有运转。 →刀塔手册附件，液压回路图 11 三和数控 →油压运作：技术资料，见第 6 页 重要提示 在安装与机床的油压管路时，空气会进入刀塔的油压系统。 安装与联结后：  小心的使用适当的排气方法，防止油喷出  进行刀塔的电气安装  开启刀塔电机的开关 →使刀盘在锁紧运作时能转至其位置  开启油压供应开关 警告 移动机器零件造成损坏的风险  工作区域贴上警告标志  避免非专业人员进入；对控制面板进行防护  不要靠近运作中的机器零件，特别是刀具转动的区域 排气 1. 调整油路压力：最大值，50bar 警告：请勿松开排气孔的螺丝 2. 松开排气孔螺丝（最多旋转 2 次），使油排出并且再次关闭排气螺丝孔，多次锁紧/松开刀 塔。多次重复整个过程。 3.完整的排气，油压管线必须从安装好的排气孔排放 →当油不带任何气泡从排气孔流出，油压管线气体完全被排放，  用同样的方法排放剩下的管路。 5 操作 5.1 动力刀座与其他刀座 1． 刀盘 ， 2 ．保护盖 ， 3 ． BMT 动力刀座界面 12 三和数控  松开刀塔  将刀盘顶端的位置转到水平  锁紧刀塔  松开固定螺丝并且移开保护盖  检查保护盖的 O 型密封圈并且将保护盖及孔塞放置安全的位置  清洁刀盘的非动力刀座/动力刀座安装面 请勿使用对着刀盘清理！ 仅使用布料清理 检查非动力刀座/动力刀座的 O 型密封圈，如有需要请更换 使用非动力刀座/动力刀座根据操作手册中的规格尺寸 界面 A C K E F L H BMT45 45 84 8 6 15 58 58 BMT55 55 104 10 8 15 64 64 BMT65 65 112 14 12 18 70 73 插入非动力刀座/动力刀座 刀座螺丝锁紧时，对照表格，使用扭力扳手锁上扭力 界面 刀座螺栓规格 所需扭力 BMT45 4×M8-8.8 25N·m BMT55 4×M10-8.8 49N·m BMT65 4×M12-8.8 86N·m 警告 屑片掉入与脏污可能会引起功能性故障  将备用的保护盖安装在空着的刀具孔位上。 固定螺栓用 8.8 级，使用力矩 22N.M 13 三和数控 5.2 可能发生的故障与维修 任何维修运作前  关掉机床  松开刀塔油压 故障 原因 维修 处理人员 不正确的中心高 使用者 刀塔锁紧时的碰撞 校正刀盘 刀盘无法转动到相对位置 →见 26 页 齿轮损坏 更换损坏部分 售服人员 刀盘无法转动 刀塔电机或控制零件损坏 见机床操作手册 刀塔齿轮轴对应位置错误 校正齿轮轴 售服人员 刀塔无法锁紧 检查接近开关 S8、S9， 使用者 接近开关 S8、S9 无法使用 如需要请重新安装或更换 →见 29 页 刀盘只能往一个方向旋转 刀塔电机或控制零件损坏 刀盘转至换刀位置时无法停 见机床的操作手册 止或是置换刀位置时发生强 刀塔电机或控制零件损坏 烈碰撞 漏油 密封圈损坏 更换损坏部分 售服人员 分水阀组损坏 更换损坏部分 无法转换分水阀 分水阀组/通道被塞住 吹分水阀组/通道 售服人员 分水阀移出刀盘和刀塔之间 分水阀组损坏 更换损坏部分 刀具驱动系统 齿轮损坏 更换损坏部分 售服人员 刀具无法转动 使用者 驱动电机损坏 更换损坏部分 →见 10 页 使用者 刀盘移位 校正刀盘 →见 26 页 刀盘与齿轮头发生碰撞 售服人员 齿轮头位置错误 校正齿轮头 →见 24 页 14 三和数控 6 电气安装 6.1 相关电气规格说明 电源供应：三相 220VAC。 电源容许变动范围：三相 170-255VAC。 电源频率容许变动范围：50/60Hz±5%。 伺服马达功率：750W。 额定电流/最大电流：4.8/14.6A。 额定扭距/最大扭距：2.39/7.16Nm。 额定转速/最高转速：3000/5000rpm 转子惯量：0.000108Kgm ²。 驱动器外观尺寸：H 高162XW宽 93XD深 191mm。 驱动器最小安装所需空间：H 高260XW宽 130XD深 310mm。 防水等级：驱动器 IP00（不防水），伺服马达 IP54（喷水防护）。 安装环境：室内（避免阳光直射）无腐蚀性雾气（避免油烟易燃性瓦斯尘埃）。 环境高度：海拔 1000M以下。 环境适度：90%RH 以下（不结露）。 运转环境温度：驱动器-10～45℃，伺服马达 0～40℃。 耐

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