2000 Series Centerless Grinder Setup Manual

Below is the standard setup for any 2000 series centerless Grinder:

 

Axis Setup

Axes Directions

  • Grind Dress - Moving toward the wheel is negative. 

Comp Directions

  • Grind Dress
    • Comp In should make the dresser move toward the wheel the next time you cycle the dress cycle. When you press Comp In, the machine doesn't move. It only updates the grind dress offset which causes the Y axis value to increment.
    • Comp Out should make the dresser move away from the wheel the next time you cycle the dress cycle. When you press Comp Out, the machine doesn't move. It only updates the grind dress offset which causes the Y axis value to decrement.

 

Basic IO Setup

Outputs

Apollo III Output Name

Function (Also description IO in Mach4)

Configuration in Mach4

Mach4 Signal Assignment 

Y0

Y0CR - Lube

 

Output0

Y1

Y1CR - Unused

 

Output1

Y2

Y2CR - Hydraulic Pump

PMC with time delay after enable turns off

Output2

Y3 

Y3CR - Grind Wheel Contactor (if applicable)

MM plugin - Grind wheel On

Output3

Y4

Y4CR - Reg Wheel Contactor (if applicable)

MM plugin - Reg wheel On

Output4

Y5

Y5CR - Coolant Pump

Config-> coolant

Coolant

Y6

Y6CR - Grind Wheel Coolant

MM plugin - lube - on with spindle

Output6

Y7

Y7CR - Unused

 

Output7

 

Inputs

Apollo III Input Name

Function (Also description IO in Mach4)

Active Low

Configuration in Mach4

Mach4 Signal Assignment

X0

Drive Fault - Do Not Use

Low Active

GMS - disable

Input0

X1

X1 - Lower Slide Home     motor 5 home

X2

X2 - Lower Slide Limit     motor 5 limit - +

X3

X3 - Upper Slide Limit      Input3

X4

      Input4

X5

      Input5

X6

      Input6

X7

      Input7

X8

X8 - Main Coolant Flow Okay

 

GMS - disable

Input8

X9

X9 - Hydraulic Pressure Okay

 

GMS - warning if hydraulics on (Output# 10) for 5 seconds

Input9

X10

      Input10

X11

      Input11

X12

X12 - Air Pressure Low

 

GMS - disable

Input12

X13

X13 - Way Lube Pressure Low

 

GMS - disable

Input13

X14

X14 - Way Lube Level Low

 

GMS - warning

Input14

X15

X15 - Overloads Okay

 

GMS - disable

Input15

 

 

 

Advanced IO Setup with PLC

Outputs

PLC Output Name

Function (Also description IO in Mach4)

Safety Relay

Configuration in Mach4

Mach4 Signal Assignment 

Q00.0

7202M - Hydraulic Pump

 

MM plugin - hydraulics 

Output# 10

Q00.1

7203M - Coolant Pump

 

Config-> coolant???

Coolant

Q00.2

Q00.2 - Grind Wheel Motor Contactor (Optional)

 

MM plugin - Grind wheel if used

Output# 12

Q00.3

Q00.3 - Reg Wheel Forward

 

MM plugin - Reg wheel on

Output# 13

Q00.4

Q00.4 - Reg Wheel Enable

 

PMC -> enable (add delay so it will enable correctly)

Output# 14

Q00.5

Q00.5 - Work Light (Above Safety Circuit)

Above

MM plugin - Work light

Output# 15

Q00.6

Q00.6 - Unused (Above Safety Circuit)

Above

 

Output# 16

Q00.7

Q00.7- Unused (Above Safety Circuit)

 

Above

 

Output# 17

Q01.0

Q01.0- Unused (Above Safety Circuit)

 

Above

 

Output# 18

Q01.1

Q01.1- Unused (Above Safety Circuit)

Above

 

Output# 19

 

 

 

 

 

Q08.0

7501CR - Lube

 

MM plugin - lube - on with machine enabled; event

Output# 20

Q08.1

7502CR - Grind Wheel Coolant

 

MM plugin - Grind wheel coolant

Output# 21

Q08.2

7503CR - Reg Dresser Coolant

 

MM plugin - reg wheel coolant

Output# 22

Q08.3

7504CR - Grind Dresser Coolant

 

MM plugin - grind dresser coolant

Output# 23

Q08.4

7506CR - Grind Wheel Lube

 

PMC -> enable

Output# 24

Q08.5

7507CR - Main Air

 

PMC -> enable

Output# 25

Q08.6

7508CR - Unused

 

 

Output# 26

Q08.7

7509CR - Unused

 

 

Output# 27

 

 

 

 

 

Q09.0

7511CR - Grind Dresser Front

 

MM Plugin - centerless

Output# 28

Q09.1

7512CR - Grind Dresser Back

 

MM Plugin - centerless

Output# 29

Q09.2

7513CR - Grind Dresser Diamond

 

MM Plugin - centerless

Output# 30

Q09.3

7514CR - Reg Dresser Front

 

MM Plugin - centerless

Output# 31

Q09.4

7516CR - Reg Dresser Back

 

MM Plugin - centerless

Output# 32

Q09.5

7517CR - Reg Dresser Diamond

 

MM Plugin - centerless

Output# 33

Q09.6

7518CR - Unused

 

 

Output# 34

Q09.7

7519CR - Unused

 

 

Output# 35

 

Inputs

PLC Input Name

Function (Also description IO in Mach4)

Active Low

Configuration in Mach4

Mach4 Signal Assignment 

MachMotinoModbusDevice

I00.0

I00.0 - E-Stop Okay

Low Active

GMS - disable if off for 2 seconds after machine neable

Input #10

Input0

I00.1

I00.1 - Overloads Okay

 

GMS - disable

Input #11

Input1

I00.2

I00.2 - Air Pressure Low

 

GMS - disable

Input #12

Input2

I00.3

I00.3 - Way Lube Pressure Low

 

GMS - disable

Input #13

Input3

I00.4

I00.4 - Way Lube Level Low

 

GMS - warning

Input #14

Input4

I00.5

I00.5 - Coolant Filter Dirty

 

GMS - disable

Input #15

Input5

I00.6

I00.6 - Hydraulic Filter Dirty

 

GMS - disable

Input #16

Input6

I00.7

I00.7 - Grind Wheel Hydraulic Filter Dirty

 

GMS - disable

Input #17

Input7

I01.0

I01.0 - Coolant Flow Okay

 

GMS - disable

Input #18

Input8

I01.1

I01.1 - Hydraulic Pressure Okay / Bearing at Pressure

 

GMS - warning if hydraulics on (Output# 10) for 5 seconds

Input #19

Input9

I01.2

I01.2 - Reg Wheel Axis Drive Fault

 

GMS - disable

Input #20

Input10

I01.3

I01.3 - Unused

 

 

 

Input #21

Input11

I01.4

I01.4 - Unused

 

 

Input #22

Input12

I01.5

I01.5 - Unused

 

 

Input #23

Input13

 

 

 

 

 

 

I08.0

I08.0 - Grind Dresser Front

 

MM Plugin - centerless

Input #24

Input16

I08.1

I08.1 - Grind Dresser Back

 

MM Plugin - centerless

Input #25

Input17

I08.2

I08.2 - Reg Dresser Front

 

MM Plugin - centerless

Input #26

Input18

I08.3

I08.3 - Reg Dresser Back

 

MM Plugin - centerless

Input #27

Input19

I08.4

I08.4 - Wheel Guard

 

 

GMS - warning

 

Input #28

Input20

I08.5

I08.5 - Wheel Balancer Fault

 

GMS - disable

 

Input #29

Input21

I08.6

I08.6 - Unused

 

 

Input #30

Input22

I08.7

I08.7 - Unused

 

 

Input #31

Input23

I09.0

I09.0 - Grind Dresser Speed Low Push Button

 

MM Plugin - centerless

Input #32

Input24

I09.1

I09.1 - Grind Dresser Speed Medium Push Button

 

MM Plugin - centerless

Input #33

Input25

I09.2

I09.2 - Grind Dresser Speed High Push Button

 

MM Plugin - centerless

Input #34

Input26

I09.3

I09.3 - Grind Dresser Out Push Button

 

MM Plugin - centerless

Input #35

Input27

I09.4

I09.4 - Grind Dresser In Push Button

 

MM Plugin - centerless

Input #36

Input28

I09.5

I09.5 - Grind Dresser Front Push Button

 

MM Plugin - centerless

Input #37

Input29

I09.6

I09.6 - Grind Dresser Back Push Button

 

MM Plugin - centerless

Input #38

Input30

I09.7

I09.7 - Dresser Coolant Flow Okay

 

GMS - disable if coolant on for 5 sec

Input #39

Input31

 

Hydraulics

image-1597937105986.png

 

 

 

Regulating Wheel Setup

Siemens PLC Setup

Wire up the regulating wheel to Analog Output 0 or Analog Output 1 of the PLC as shown here: Siemens PLC - Wiring SM1234 Analog Card .

Set up the regulating wheel in MachMotion Parameters as shown:

image-1597866567202.png

 

Set Max Speed Range 0 to the max RPM. 

Command the regulating wheel to go max RPM for Speed Range 0 and use a tachometer to confirm it goes the correct speed. If it doesn't, calculate the new Regulating Wheel Max Speed Range 0 as follows:

Actual RPM / Commanded RPM * Range 0 = New Regulating Wheel Max Speed Range 0

 

Yaskawa Servo Reg Wheel Speed

This is for when using the X15-02-10 adapter board.

To change the accel and decel you must change these Yaskawa drive parameters:

Pn305 = acceleration

Pn306 = deceleration 

 

 

Grind Wheel Setup

V1000 Setup

Set Control Source to Auxiliary. You must restart Mach4 before proceeding after making this change.

Set the V1000 Auxiliary Control Max RPM to the max RPM you want the grind wheel to go. 

image-1589903000781.png

Next set the Grind Wheel Max Speed Range 0 to the same as the Auxiliary Control Max RPM. Configure the other parameters as follows:

Parameter Name Value Description
Grind Wheel Enabled Yes Enables the grind wheel.
Grind Wheel Input IO -> Yaskawa-V1000_0->Motor_At_Speed Tells the control when the grind wheel is up to speed.
Grind Wheel Output Speed Mode RPM Tells the grind wheel to send a RPM value to the V1000. 
Grind Wheel Output Speed Multiplier 1 Should always be 1. 
Grind Wheel Output IO -> Yaskawa-V1000_0_Auxiliary->FWD Tells the V1000 to start rotating
Grind Wheel Speed Register Register -> Yaskawa-V1000_0_Auxiliary->Command_RPM Tells the V1000 what speed to rotate at.

 

image-1589904685796.png

Now test the grinding wheel speed. Enter in a speed command and monitor the actual speed with a tachometer. Make sure your Max Wheel RPM is high enough to allow the commanded speed you want to command. 

image-1589903658254.png

If it isn't correct, calculate the new Max RPM as follows:

Actual RPM / Commanded RPM * V1000 Auxiliary Control Max RPM = New Max RPM. 

Now set the V1000 Auxiliary Control Max RPM and the Grind Wheel Max Speed Range 0 to the new Max RPM. 

Load Meter Setup

image-1597937060919.png

image-1597937042209.png

 

 

 

 

Auto Loader

  • To enable the Auto Loader, set the pound variable AutoLoaderEnabled in the gcode file to 1. Also, setup user button 6 to set the pound variable AutoLoaderEnableButton to 1 or 0 to activate it or turn it off.