2003 STUDER S31

X-axis grinding wheel conveyer/holder carriage

the Disassembly group

I study and apply new FANUC Alpha axis motor

Supply and replacement of ball bearing recirculation screws and thrust bearings

Supply and replacement of the front bellows X-axis

or Review of telescopic guards

or Check for geometric wear of X-axis bed guide and possible restoration

the guide rectification for X-axis carriage

or Replacement of tubes and lubrication dispensers for guide lubrication and ball screw

Supply and installation of a new absolute Heidenhain optical line

Supply and replacement of machine perimeter materials (cables, hoses, chain conveyors, micro-switches)

Reassembly and geometric and functional testing

Z axis workpiece holder table

the Disassembly group

I study and apply new FANUC Alpha axis motor

Supply and replacement of ball bearing recirculation screws and thrust bearings

or Review of telescopic guards

the Z-axis guide rail grinding

or Replacement of tubes and lubrication dispensers for guide lubrication and ball screw

Supply and installation of a new absolute Heidenhain optical line

Supply and replacement of machine perimeter materials (cables, hoses, chain conveyors, micro-switches)

Reassembly and geometric and functional testing

Chuck spindle turret indexing stops

the Disassembly group

I study and apply new FANUC Alpha axis motor

Supply and replacement of bearings, seals and commercial components present in the

group

Disassembly and cleaning of Hirth double-sheave gear

or Check wear status of Harmonic Drive reducer and replacement of internal lubricant

Supply and replacement of machine perimeter materials (cables, hoses, chain conveyors, micro-switches)

Reassembly and geometric and functional testing

Rotating C-axis head stock

the Disassembly group

I study and apply new FANUC Alpha axis motor

Supply and replacement of bearings, seals, belts and available commercial components

in the group

Supply and replacement of machine perimeter materials (cables, hoses, chain conveyors, micro-switches)

Reassembly and geometric and functional testing

Tailstock

the Disassembly group

Supply and replacement of bearings, seals and commercial components present in the

group

or Restoring the correct fit between the ram and the tailstock through chroming and grinding in

adaptation

or Counterbalance cup springs replacement

Roller cage replacement of the micrometric regulation correction device

taper

Supply and replacement of machine perimeter materials (cables, hoses, chain conveyors, micro-switches)

Reassembly and geometric and functional testing

External grinding spindle

and Disassembly of spindle and liquid-cooled motor

Supply and replacement of bearings, seals, belts and available commercial components

in groups

Dynamic balancing of mill motor + pulley

dynamic balancing of grinding spindles + pulley

Supply and replacement of machine perimeter materials (cables, hoses, chain conveyors, micro-switches)

Reassembly and geometric and functional testing

Tool grinding holder spindle (internal) (42,000 rpm)

and Spindle disassembly

Supply and replacement of bearings and commercial components present in the spindle

Dynamic balancing

Supply and replacement of machine edge materials

Reassembly and geometric and functional testing

Pneumatic plant

Provision and replacement of tubes, solenoid valves, pressure sensors, and control components and

necessary checks for the proper functioning of the machinery

Hydraulic system

Supply and replacement of pumps, filters, tubes, solenoid valves, pressure switches, and components of

commands and controls required for the proper operation of the machinery

Lubrication and cooling system

Supply and replacement of tubes, solenoid valves, flow switches, and control components and

necessary checks for the proper functioning of the machinery

Machine housing

or Full removal of the cowling

Replacement or repair of damaged panels

or Replacement of damaged sliding door carriages

Replacement of seals and polycarbonate panels on sliding doors

and Painting according to Your specifications

Reassembly

Electrical schematic design with Spac system, including:

Functional

Topographic

the Clamps

and machine-side connections

Parts List

Electrical Panel

General switch with fuses and external side or front operating device

Power circuits 400Vac, with individual magnetothermal protections of the lines of

power supply, with indication of intervention on PMC input

24VDC auxiliary circuits, with separation of the various circuits, individually protected with

automatic circuit breakers, with indication of intervention on PMC input

Preferred Schneider Electric material

Lighting 220V, with internal transformer

the service outlet protected by residual current device

the Cosmotec-Stulz air conditioner

LED column light with three sectors PATLITE

the connection of the machine edge to the terminal strip

the Axis Drive Group Fanuc Alpha iSV-HVB series with line filter for the

EMC compatibility

or a Fanuc 0iF-Plus CNC Unit

or I/O Modules Fanuc Terminal Type

Inverter for the management of grinding electromanders

Command Console

Video Panel Fanuc Panel iH-Pro:

 15-inch color LCD display

 capacitive touch screen

Fanuc MDI Keyboard Unit, QWERTY

Machine control panel with customized buttons for machine-specific functions,

override axes and spindle

the control panel diameter 22

IP65 portable button panel, with:

 5 m cable

 Quick connection to connector

 Shaft selector

 Increment selector

 Electronic flyer

Emergency stop button compliant with EN ISO 13850

Enable button, with axis stop management in Category 1 according to EN 60204-1

Electrical System

Provision and installation of all connection cables to sensors and actuators (all cables)

will be for mobile installation, anti-oil), including suitable fixing systems (tubes,

channel, fittings, etc.).

Supply and installation of auxiliary button panels (guards, tool changer, etc.)

Supply and installation of any terminal strip connection boxes

Safeties

or The operator safety measures will be managed using Fanuc's Dual Check Safety.

With this option, the safety input/output signals (emergencies, door limit switches,

Grinding wheel enablement), they are managed on two channels by two PLCs, with control logics

crossed.

In addition, the numerical control is capable of activating safety functions that meet the

Category 3 requirements as well as the Performance Level PL d according to DIN EN ISO 13849-

1 and Safety Integrity Level SIL 2 according to DIN EN 61508.

The planned functions are

Safe stop (SS1)

During the intervention of a supervision or an emergency, stop the actuations in

safe mode

Safe operating stop (SOS)

Monitor the drive systems in the stopped state. In this phase the drives are

fully operational and in position regulation. The function will be activated

with the opening of the operator door

Safe Limited Speed (SLS)

Monitoring of designable speed limit values, which are activated in particular with

use of the manual control panel with doors open

Safety I/O signals (DCS)

Interface to the process (door limit switch, emergency stop button, button

activation, powering of electromechanical moving devices), with

dual-channel connection, managed by two PMCs

With the door open it will be possible to command the axes at reduced speed, in JOG mode,

with action kept on the activation button of the portable control panel.

By releasing the button you will have a safe axis stop

The grinding wheel rotation will not be possible

Sipro F Software

the dedicated operating surface with: which allows implementing the work program,

through a sequence of cycles, selecting them from the available ones

(Dunk, Swaying, etc.).

Each cycle is accompanied by a series of geometric parameters (positions and magnitudes of

machining, and technological parameters (turning removal, wheel speed and workpiece holder)

For executing the program, there is the option to select which

sequences/processing to perform and which not to do.

There is a test and setup area, which allows carrying out the predispositions of the

machine for processing, like diamond dressing, grinding wheel shaping, dressing workpiece,

definition of levers.

In all these operations, the user is guided by graphics with the possibility of

self-learning of positions.

For the grinding profile, simple parametric profiles are available, manageable with the

simple parameter entry. Complex profile mole also possible,

configurable through an integrated graphical editor or by direct writing of the

ISO program or import of a profile in DXF format.

The application replaces the standard CN interface. For this reason, the following are available

display, setup and diagnostic pages, to ensure that all are present

the tools needed to use the machine, without having to access the interface

standard of numerical control, which can still be recalled, for use

machine generic or for system settings and general tuning of the

numerical control.

Commissioning

Commissioning of the CN and PLC with axis optimization, functional tests and trials

of processing.

Documentation

electrical schematic on paper support in A4 format

the USB Key contains:

Backup of CN and drive parameters

PLC Program

 PC hard disk image after commissioning, for quick recovery

 Electric schematic in printable format (PDF)

 Operator manual of machine-specific functions in PDF format

 Specific documentation of used components

 User manuals and programming Fanuc 0iF-Plus

Compliance and release of CE certification for the machinery

and the plant will be designed according to safety and ease of operation criteria; it will be

thus marked CE according to Machinery Directive 42/2006 and Low Voltage 95/2006.