2000 Series Centerless Grinder Operating Manual

 

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Introduction

This manual is designed to give the operator a working understanding of how to operate your new CNC Centerless Grinder. The control is designed to simplify the operation of your Centerless Grinders high-end features. We have elected not to use g-codes to manipulate the servo axis. Instead, we use the combination of a simplified data entry routine with a graphic interface that the operator will find extremely easy to use.

Each page contains items that are used specifically for the function of the individual screen like starting and stopping motors, changing cycle modes, entering new feedrates and positions, etc.

There are other items that are used globally. This means that the same items are found on all of the pages. Primarily they are the machine state, cycle time, and date and time at the top of the screen, the axis position, cycle status, current feedrate, and wheel speed on the right side of the screen.

Operator Panel Overview

The following is a description of the Operator Panel and it's functional devices. The numbered balloons point to the object.

centerless_grinder_interface.png

  1. Computer HMI. Consists of screens designed to control the machine functions and feedback information on the machine state.
  2. Emergency Stop Button. Used to stop process and motors in the event of an emergency, by turning off all active output logic.
  3. Cycle Start Button. Used to initiate an automatic cycle and confirm actions.
  4. Feedhold Button. Used to pause an automatic cycle in place.
  5. Cycle Stop Button. Used to stop an automatic cycle in place.
  6. Reset Button. Used to clear or reset machine faults and enable system servo motors.
  7. Rapid Speed Control Buttons. Used to change the speed the machine moves during rapid moves.
  8. Feedrate Override Knob. Used to change the speed the machine moves during feed moves.
  9. Spindle Control Buttons. Used to start and stop the wheel and change the speed override value.
  10. Programmable Function Buttons. Used to customize the control.
  11. Jog Control Buttons. Used to manually jog servo axes while the machine is not in a cycle.
  12. Jog Speed Knob. Used to control the speed during manual jog moves.

    Control Overview

    The control supports an In-Feed cycle for plunge grinding and a Thru-Feed cycle for bar grinding.  It also supports Grind Wheel and Regulating Wheel Dressing (Truing) with up to 2 coordinated axes each. 

    overview.png

    Screen Navigation

    Easily navigate the 5 pages of the screen using the tab menu at the bottom of the screen.  The control will seamlessly switch operating modes following the active page and update the Axis Position group to only show the relevant axes for that operation.

    2k_Centerless_Screen_nav.png

    1. Status
      • Status - Displays any current messages (Home All Pressed, Cycle Start Pressed, etc.)
      • State - Displays the current state of the machine (Run, Feed Hold, etc)
      • Cycle Time - Displays how long the GCode has been running
      • Date - Date and time of the timezone of the control
    2. Operation Pages
      • In-Feed Cycle Page
        2k_Centerless_Screen_In-Feed.png
      • Thru-Feed Cycle Page
        2k_Centerless_Screen_Thru-Feed.png
      • Grind Wheel - Setup and Dressing Page
        2k_Centerless_Screen_GrindWheel.png
      • Regulating Wheel - Setup and Dressing Page
        2k_Centerless_Screen_RegWheel.png
      • Service
        • Maintenance and Support
          2k_Centerless_Screen_Service_Maint.png
        • Dashboard
          2k_Centerless_Screen_Dashboard.png
        • Machine I/O
          2k_Centerless_Screen_Service_IO.png
        • Grinder Settings
          2k_Centerless_Screen_Service_GrinderSettings.png
        • Program
          2k_Centerless_Screen_Service_Program.png
    3. Operation Display
      • Axis Position Display
      • Cycle Status
      • Feedrate Display
      • Grind Wheel Display
      • Regulating Wheel Display
    4. Grinder Dashboard
      • Configurable Dashboard with Widgets for machine auxiliaries (Hydraulics, Mist Collectors etc.)
    5. Side Bar Dashboard
      • Configurable Dashboard with Widgets for productivity

    In-Feed Cycle

    The In-Feed Grinding cycle begins at the Load Position and rapids to the start of the Coarse grind and continues through Medium and Fine with optional Feedrates and pauses until it reaches the Finish Position and pauses to spark-out.  Then rapids to the Retract Position and completes the cycle at the Load Position

    2k_Centerless_Screen_In-Feed.png

    In-Feed Cycle Parameters

    Position Parameters

    Position_Parameters.png

    • Retract Position: The position the slide will move to at the end of the cycle to drop or eject the part.  When the Retract Position is not needed set the make it equal the Load Position.
    • Load Position: This is the first and last slide position in the cycle.
    • Finish Position: This is the final grind position and the position that Fine, Medium and Coarse grind amounts are referenced from.  The Finish Position can be set to a diameter or 0 depending on the setup.
    Cycle Parameters

    2k_Centerless_Screen_In-Feed_Cycle_Parameters.png

    • Coarse Grind
      • Coarse Grind Amount: The amount to be removed at the Coarse Feedrate
      • Coarse Feedrate: The Feedrate used during Coarse grind
      • T1: Optional Delay at the end of the Coarse grind
    • Medium Grind
      • Medium Grind Amount: The amount to be removed at the Medium Feedrate
      • Medium Feedrate: The Feedrate used during Medium grind
      • T2: Optional Delay at the end of the Medium grind
    • Fine Grind
      • Fine Grind Amount: The amount to be removed at the Fine Feedrate
      • Fine Feedrate: The Feedrate used during Fine grind
      • T3: Optional Delay at the end of the Fine grind, sometimes referred to as Sparkout Time
    • Retract Delay
      • T4: Optional Delay at the Retract position to allow the part to drop between the Regulating Wheel and Grinding Wheel
    • Load Delay
      • T5: Optional Delay at the end of the cycle.  This is normally used along with Cycle Repeat to allow time to load the next part.
    In-Feed Comp

    Comp is used to adjust the part diameter.   For more info see Compensation.

    For info on Grind Position calibration see Grind Position Calibration

    Cycle Start button is used to start the In-Feed cycle.

    At any point Cycle Stop or Retract buttons will cause the slide to Rapid to the Retract Position.

    Thru-Feed Cycle

    Thru-Feed Grinding will rapid the slide to the Grind Position and stay there. 

    2k_Centerless_Screen_Thru-Feed.png

    Thru-Feed Cycle Position Parameters
    • Retract Position: The position the slide will move to when Cycle Stop or Retract are used.
    • Finish Position: This is the position the slide will move to when the cycle is ran.
    Thru-Feed Comp

    When the slide is at the Grind Position and Comp offset is applied the slide will move back to the Grind Position.  When the slide is at any other position than the Grind Position the slide will apply the offset without any movement.  For more info see Compensation.

    For info on Grind Position calibration see Grind Position Calibration

    Cycle Start button is used to start the Thru-Feed cycle.

    At any point Cycle Stop or Retract buttons will cause the slide to Rapid to the Retract Position.

    Grind Wheel

    The Grind Wheel Page is where the Grind Wheel parameters and dress parameters are configured.  Depending on the enabled options of the machine some of these parameters will be hidden. 

    Grind_Wheel_Data.png

    Use the following figure for Grind Wheel dimensions and clearances

    Grind Wheel Parameter Descriptions

    • Diameter: The current wheel diameter.  The dressing cycle automatically updates the wheel diameter.  When a new wheel is mounted on the machine this parameter should be updated. 
    • Minimum Diameter: When the wheel is dressed to this diameter the control will not allow any more dress cycles to complete.  The operator will get a alarm messages stating that the wheel is to small.
    • Width: The current width of the wheel, used in the straight dressing cycles.
    • Minimum Width: When the wheel is side dressed to this width the control will not allow any more dress cycles to complete.  The operator will get a alarm messages stating that the wheel is to narrow.
    • Clearance Circumference: This is used in the dress cycle, the diamond will rapid to this clearance position and then switch to a feedrate move before touching the wheel.
    • Clearance Front Side: This is used in the dress cycle, the diamond will rapid to this clearance position and then switch to a feedrate move before touching the wheel.
    • Clearance Back Side: This is used in the dress cycle, the diamond will rapid to this clearance position and then switch to a feedrate move before touching the wheel.
    • Max Wheel RPM: Max RPM the wheel can be commanded to run.  Check the wheel specs and keep this number under it.
    • Wheel SFM: The commanded Surface Feet Per Minute or (SFM).  There are buttons just below that set the mode, RPM Mode or SFM Mode.
    • Wheel RPM: The commanded Rotations Per Minute or (RPM).  There are buttons just below that set the mode, RPM Mode or SFM Mode.
    • Wheel Speed Mode: RPM Mode or SFM Mode switch the command source between Wheel RPM and Wheel SFM modes.

    Grind Wheel Diamond Setup

    2k_Centerless_Screen_GrindWheel.png

    1. Using the Jog buttons or MPG, Jog the GD (X) axis so the diamond is just touching the front side of the wheel.
    2. Press the yellow Teach button for X.
    3. Using the Jog buttons or MPG, Jog the GD (Y) axis so the diamond is just touching the circumference of the wheel.
    4. Press the yellow Teach button for Y.

    Y Diamond Comp

    Diamond Comp can be used at anytime and during a dress cycle to move the diamond in closer to the wheel.  Sometimes the wheel will wears a lot between dress cycles, and this can be use to reduce the number of dress passes.  For more information see Compensation.

    Y_Diamond_Comp.png

    Dress Cycles

    The control supports two dress cycles for the wheels, Standard Dress and New Wheel Dress.  Both of these cycles are very similar and allow you to store two sets of parameters, one for normal production (Standard Dressing) and one set of parameters for shaping a wheel (New Wheel Dress). 

    Use the following table to compare the dress cycles:

    Dress Cycle Features Standard Dress New Wheel Dress
    Dress Rate Yes

    Yes

    Dress Passes Yes

    Yes

    Dress Amount Yes

    Yes

    Spark-Out Passes (Free Passes) Yes

    No

    Changing the profile of the wheel No Yes

    Standard Dress

    The Standard Dress is the default dress cycle and would be used after the wheel has been shaped and is ready for production.  Standard Dress will use whatever profile was selected on the New Wheel Dress page. 

    2k_Centerless_Screen_Standard_Dress.png

    Standard Dress Parameters
    • Dress Rate: The feedrate the diamond will travel across the wheel.
    • Dress Passes: The number of passes the diamond will make across the wheel.
    • Dress Amount: The amount mount of wheel to remove per pass.  The amount is in radius of the wheel so 0.001 will change the wheel diameter by 0.002.
    • Spark-Out Rate: The feedrate the diamond will travel across the wheel during the Spark-Out Pass or Free Pass.
    • Spark-Out Passes: The number of passes the diamond will make across the wheel without in-feeding the diamond into the wheel.  Sometimes this type of pass is called a Free Pass.
    • In-Feed Parts Per Pass: This is only used in the In-Feed Cycle and will cause the control to automatically call a dress cycle after the number of cycles is greater than the value in this parameter.  A value of 0 disables this feature. 

    New Wheel Dress

    The New Wheel Dress is the cycle used to create the profile in the wheel and to rough the wheel into shape.

    2k_Centerless_Screen_New_Wheel_Dress.png

    New Wheel Dress Parameters
    • Dress Rate: The feedrate the diamond will travel across the wheel.
    • Dress Passes: The number of passes the diamond will make across the wheel.
    • Dress Amount: The amount mount of wheel to remove per pass.  The amount is in radius of the wheel so 0.001 will change the wheel diameter by 0.002.
    • Custom Profile: When the Custom Profile is off the dress profile will be a straight profile and use the Grind Wheel Parameters to make the profile.  When Custom Profile is on there will be a subroutine with a profile that the diamond will follow.

    Cycle Start button is used to start the Dress cycle.

    Wheel Profiles

    The control supports Straight Profile and Custom Profile.  The straight profile uses the data from the Grind Wheel Parameters and the custom profile uses the Grind Wheel Profile Dressing dialog to draw any custom profile.  To switch between the straight and custom profiles turn the Custom Profile on or off.

    New Wheel Dress - Straight Profile

    When the Custom Profile is off the dress profile will be a straight profile and use the Grind Wheel Parameters to make the profile.

    New_Wheel_Dress_Stright_Profile.png

    New Wheel Dress - Custom Profile

    When the Custom Profile is on the the dress cycle will use the Subroutine that is created with the profile number.

    New_Wheel_Custom_Profile.png

    Custom Profile

    Profile Number shows the selected Profile to use. To change the profile press Open.
    There are 3 buttons for creating opening and editing the custom profiles. 

    Grind Wheel Profile Dressing

    The Grind Wheel Profile Dressing is where you create your custom dress profile for the wheel.  The profile can be a mixture of lines and arcs.  There are four columns Type, X Position, Y Position and Radius showing the data for the given line or arc segment. The example below has profile number 2005 loaded.

    2k_Centerless_Screen_New_Profile.png

    Add Line Segment

    Use the Add button to add an new line or arc.  The new segment values will be copied from the previous segment.  Use the Type field to change between a line or clock wise (CW) and counter clock wise (CCW) arcs.  All positions can be modified at any time, click on a value and it will highlight to green to show it can be changed.

    Remove Line Segment

    Use the Remove button to remove any line segment.

    Profile Operations

    Open: Open a different dress profile
    Profile_Dressing_Open.png
    Add: Add new line segment to the dress profile
    Profile_Dressing_New_Segment.png
    Remove: Remove a line segment from the dress profile
    Profile_Dressing_Remove.png
    Save As: Save the profile with a new name
    Profile_Dressing_Save_As.png
    Save: Save the current profile
    Profile_Dressing_Save.png

    Regulating Wheel

    The Regulating Wheel Page is where the Regulating Wheel parameters and dress parameters are configured.  Depending on the enabled options of the machine some of these parameters will be hidden. 

    Regulating_Wheel_Data.png

    Use the following figure for Regulating Wheel dimensions and clearances

    Regulating Wheel Parameter Descriptions

    • Diameter: The current wheel diameter.  The dressing cycle automatically updates the wheel diameter.  When a new wheel is mounted on the machine this parameter should be updated. 
    • Minimum Diameter: When the wheel is dressed to this diameter the control will not allow any more dress cycles to complete.  The operator will get a alarm messages stating that the wheel is to small.
    • Width: The current width of the wheel, used in the straight dressing cycles.
    • Minimum Width: When the wheel is side dressed to this width the control will not allow any more dress cycles to complete.  The operator will get a alarm messages stating that the wheel is to narrow.
    • Clearance Circumference: This is used in the dress cycle, the diamond will rapid to this clearance position and then switch to a feedrate move before touching the wheel.
    • Clearance Front Side: This is used in the dress cycle, the diamond will rapid to this clearance position and then switch to a feedrate move before touching the wheel.
    • Clearance Back Side: This is used in the dress cycle, the diamond will rapid to this clearance position and then switch to a feedrate move before touching the wheel.
    • Max Wheel RPM: Max RPM the wheel can be commanded to run.  Check the wheel specs and keep this number under it.
    • Wheel SFM: The commanded Surface Feet Per Minute or (SFM).  There are buttons just below that set the mode, RPM Mode or SFM Mode.
    • Wheel RPM: The commanded Rotations Per Minute or (RPM).  There are buttons just below that set the mode, RPM Mode or SFM Mode.
    • Wheel Speed Mode: RPM Mode or SFM Mode switch the command source between Wheel RPM and Wheel SFM modes.

    Regulating Wheel Diamond Setup

    2k_Centerless_Screen_GrindWheel.png

    1. Using the Jog buttons or MPG, Jog the RD (Z) axis so the diamond is just touching the front side of the wheel.
    2. Press the yellow Teach button for Z.
    3. Using the Jog buttons or MPG, Jog the RD (A) axis so the diamond is just touching the circumference of the wheel.
    4. Press the yellow Teach button for A.

    Dress Cycles

    The control supports two dress cycles for the wheels, Standard Dress and New Wheel Dress.  Both of these cycles are very similar and allow you to store two sets of parameters, one for normal production (Standard Dressing) and one set of parameters for shaping a wheel (New Wheel Dress). 

    Use the following table to compare the dress cycles:

    Dress Cycle Features Standard Dress New Wheel Dress
    Dress Rate Yes

    Yes

    Dress Passes Yes

    Yes

    Dress Amount Yes

    Yes

    Spark-Out Passes (Free Passes) Yes

    No

    Changing the profile of the wheel No Yes

    Standard Dress

    The Standard Dress is the default dress cycle and would be used after the wheel has been shaped and is ready for production.  Standard Dress will use whatever profile was selected on the New Wheel Dress page. 

    2k_Centerless_Screen_Standard_Dress.png

    Standard Dress Parameters
    • Dress Rate: The feedrate the diamond will travel across the wheel.
    • Dress Passes: The number of passes the diamond will make across the wheel.
    • Dress Amount: The amount mount of wheel to remove per pass.  The amount is in radius of the wheel so 0.001 will change the wheel diameter by 0.002.
    • Spark-Out Rate: The feedrate the diamond will travel across the wheel during the Spark-Out Pass or Free Pass.
    • Spark-Out Passes: The number of passes the diamond will make across the wheel without in-feeding the diamond into the wheel.  Sometimes this type of pass is called a Free Pass.
    • In-Feed Parts Per Pass: This is only used in the In-Feed Cycle and will cause the control to automatically call a dress cycle after the number of cycles is greater than the value in this parameter.  A value of 0 disables this feature. 

    New Wheel Dress

    The New Wheel Dress is the cycle used to create the profile in the wheel and to rough the wheel into shape.

    2k_Centerless_Screen_New_Wheel_Dress.png

    New Wheel Dress Parameters
    • Dress Rate: The feedrate the diamond will travel across the wheel.
    • Dress Passes: The number of passes the diamond will make across the wheel.
    • Dress Amount: The amount mount of wheel to remove per pass.  The amount is in radius of the wheel so 0.001 will change the wheel diameter by 0.002.
    • Custom Profile: When the Custom Profile is off the dress profile will be a straight profile and use the Regulating Wheel Parameters to make the profile.  When Custom Profile is on there will be a subroutine with a profile that the diamond will follow.

    Cycle Start button is used to start the Dress cycle.

    Wheel Profiles

    The control supports Straight Profile and Custom Profile.  The straight profile uses the data from the Regulating Wheel Parameters and the custom profile uses the Regulating Wheel Profile Dressing dialog to draw any custom profile.  To switch between the straight and custom profiles turn the Custom Profile on or off.

    New Wheel Dress - Straight Profile

    When the Custom Profile is off the dress profile will be a straight profile and use the Regulating Wheel Parameters to make the profile.

    New_Wheel_Dress_Stright_Profile.png

    New Wheel Dress - Custom Profile

    When the Custom Profile is on the the dress cycle will use the Subroutine that is created with the profile number.

    Regulating_Wheel_Custom_Profile.png

    Custom Profile

    Profile Number shows the selected Profile to use. To change the profile press Open.
    There are 3 buttons for creating opening and editing the custom profiles. 

    Regulating Wheel Profile Dressing

    The Regulating Wheel Profile Dressing is where you create your custom dress profile for the wheel.  There are four columns Type, Z Position and A Position showing the data for the given line segment. The example below has profile number 3010 loaded.

    Regulating_Wheel_Profile_Dressing.png

    Add Line Segment

    Use the Add button to add an new line.  The new segment values will be copied from the previous segment.   All positions can be modified at any time, click on a value and it will highlight to green to show it can be changed.

    Remove Line Segment

    Use the Remove button to remove any line segment.

    Profile Operations

    Open: Open a different dress profile
    Profile_Dressing_Open.png
    Add: Add new line segment to the dress profile
    Profile_Dressing_New_Segment.png
    Remove: Remove a line segment from the dress profile
    Profile_Dressing_Remove.png
    Save As: Save the profile with a new name
    Profile_Dressing_Save_As.png
    Save: Save the current profile
    Profile_Dressing_Save.png

    Operations

    Running Grinding Cycle

    Before running parts on the control, be sure the following steps have happened after starting the control software:

    Dressing the Wheels

    Before dressing the wheels, be sure the following steps are complete:

    • Machine is homed.
    • Mount the wheels on their respective spindles.
    • Set the regulating wheel to the proper angel.
    • Follow the Grind Wheel Diamond Setup and the Regulating Wheel Diamond Setup.
    • Configure the dressing profiles for both the Grind Wheel and Regulating Wheel
    • Starting the cycle:
      • Grind Wheel Dress: Press "Cycle Start" while the Grind Wheel page is active.  Make sure to select between a Standard dress or a New Wheel dress.
      • Regulating Wheel Dress: Press "Cycle Start" while the Regulating Wheel page is active.  Make sure to select between a Standard dress or a New Wheel dress.

    Appendix

    Start-Up Sequence

    1. Apply power to the control
    2. Press the Reset button on the operator panel. The control will go through it's start-up sequence. Allow time for the computer to start up.
    3.  Start the Mach4 application from the shortcut on the desktop. Allow time for the system to initialize.
    4. Press Cycle Start when the control requests to Enable and Home the servo axes.

    Homing Machine

    Most machines are configured with a Enable and Home dialog that will be shown on startup.

    Enable_and_Home_Dialog.png

    Press the Cycle Start button on the dialog or the Cycle Start button on the operator panel.  The machine will enable the servos and home to the switches.

    If for some reason this dialog is not shown you can manual enable the machine by pressing Reset and then navigate to the Service page.

    Centerless_Grinder_Homing.png

    Home each axis individually or press Home All to home all axes.

    Part Setup

    Part Setup can very from machine to machine, so this is a very general outline to part setup.  The following drawing is a setup with the work height above centerline.

    Artboard-1.png

     

    A Centerless grinder has three main components: a grinding wheel, a regulating wheel and a workblade.

    1. Select the blade of proper material, thickness and top angle.
    2. Clamp the workblade with the correct relationship of the part center height above the wheel’s centerline.
    3. Clamp the workrest to the lower slide.
    4. Mount the wheels on their respective spindles.
    5. Set the regulating wheel to the proper angel.
    6. Dress Regulating Wheel
    7. Dress Grinding Wheel
    8. Select the proper regulating wheel speed.
    9. Set the regulating wheel distance to the workblade.
    10. Entrance/exit guide alignment.

    Grind Position Calibration

    Part Calibration should be done after the Part Setup steps have been complete.

    Calibration
    1. Place a part on the Workblade and if needed start the Regulating Wheel and Grind Wheel.
    2. Using the Jog buttons or MPG, Jog the slide in so the part is just touching the Grind Wheel.
    3. Press the grey Edit Offsets button. When this is active the Edit Offsets button will change to yellow.
      Edit_Offsets_Button_Grey.png
    4. When Edit Mode is active the Position DROs will be editable and there will be Zero buttons next to the DROs.Edit_offsets_DRO.png
    5. Press the Zero button or click into the DRO and Input the desired position and press Enter.
      Zero_Button.png
    6. Press the yellow Edit Offsets button to lock the offsets.
      Edit_Offsets_Button.png

    Now the Grind Position should be calibrated.

    Use Compensation to make small adjustments to the Grind Position

    Compensation

    Compensation or Comp is used to adjust the slide offsets to maintain the part diameter as the wheel breaks down and wears.  It can also be used to adjust the diamonds closer to the wheel while dressing.  Comp acts differently depending on the grinding mode.  See the table below to see how Comp is applied.

    Grinding Mode Adjust slide offsets? Moves to position after adjustment?
    In-Feed Grinding Yes

    No

    Thru-Feed Grinding at Grind Position Yes Yes
    Thru-Feed Grinding not at Grind Position Yes No

    There are Comp buttons on the screen, and some machines have buttons on panels for applying Comp.  Coarse and Fine Comp buttons allow the operator to choose between two defined increment sizes.

    Comp_buttons.png

    Total Comp

    Total Comp is for the operator to track how much Comp as been applied.  Resting the Total Comp will only zero the Total Comp indicator.

    Configure Comp Amount

    Coarse and Fine Comp amounts are configurable on the Service / Grinder Settings page.

    Coarse_and_Fine_Comp.png

    Backlash Move

    When Comp is being applied and the slide is moving away from the grinding wheel the control can make an extra move to take up any loss of motion from backlash in the slide.  To enable this option open the Interface Config dialog from the Service page and search for Backlash.  Modify the following parameters.

    • Backlash Move Enabled: This enables and disables the Backlash move
    • Backlash Move Distance: This is the distance the slide will move when applying Comp

      MDI Programmed Movement

      To command a movement using the MDI feature, press the [MDI] button.

      2k_Centerless_Screen_MDI_Button.png

      Enter the desired gcode command into the field and press [Cycle Start] to execute the command(s). The up/down arrow buttons will scroll through the history of cycled commands. Click the [X] or the [MDI] button to close the MDI window.
      mdi_mill_example.png

      Warranty Information

      MachMotion warranty policy is subject to change. Updated information is available at our website:
      https://machmotion.com/warranty

       

      The MachMotion Team
      http://www.machmotion.com
      14518 County Road 7240, Newburg, MO 65550
      (573) 368-7399 • Fax (573) 341-2672