GiieI<eI

Prdzisions-Schleif masch inen

Service lnstructions
Grinding Machine GOckel

Machine-Type: RB3
Serial No.: 2234

Gustav G6ckel Maschinenfabrik GmbH ; 64293 Darmstadt

 Service instruction for RB3
Ser.No.:2234
Prizrsions-schleliraschinon
Paqe 'l of 76
 Service instruclion for RB3
Ser.No.; 2234
Prdzislons-Schtsifmdchinen
2of76
 Operating lnstructions 0

Pr5zisims-S.hlelrmaschinsn
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0 Safetv lnstructions

0.1 Warninqs and Svmbols

The following designations and symbols are used for particularly important items in the
operating instructions:

Hazard
lnformation to prevent injury and extensive property damage,

Caution
lnformation on damage prevention.

Note
lnformation requiring particular attention.
0.2 lntended Use
o.2.1
This machine has been constructed according to the state-of-the-art and recognized
technical safety regulations. Nevertheless its use c€n present hazards for life and limb ofthe
user and third parties as well as damage lo the machine and other property.
0.2.2
This machine should be operated only in a.technically perfect state for the intended
application observing all safety regulations and being aware of all hazards! Eliminate
malfunctions which could affect the safety immediately.
o.2.3
This machine is intended exclusively for grinding. Any other use or any use going beyond
this application is not intended. The manufacturer/supplier cannot assume any liability for
damage resulling from such operalion. The user carries the sole risk.
o.2.4
Use as intended also includes observing the operaling instructions and maintenance ofthe
inspection and repair instructions.
 Operating lnstructions 0

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4 ol76

0.3 Oroanizational Measures

0.3.1
Always keep operating instructions where they are readily available at the location where
the machine is used!
0.3.2
ln addition to the operating instructions observe and inslruct employees to observe all
general, legal and other obligatory regulations regarding accident prevention and
environmental protection!
Such responsibilities may include items such as handling dangerous substances or
provision oflwearing personnel protective equipment.
0.3.3
Personnel assigned to activities involving the machine must read the operating instructions,
particularly the chapter with safety instructions before starting work. After starting work it is
loo late. This applies particularly for personnel who work on the machine only occasionally
for set-up, maintenance, etc.
0.3.4
Check at least occasionally to ensure that the personnel are safety conscious and aware of
hazards and observe the operating instructions!
0.3.5
Use personal protective equipmenl to the extent necessary or required by regulations!
0.3.6
Observe all safety and hazard instructions regarding the machine!
0.3.7
ln the event of any changes to the machine or its operating characleristics relevant for
safety stop the machine immediately and reporl the malfunction to the responsible point!
0.3.8
Do not make any changes, modifications or attachments to the machine which could affect
the safety without approval by the supplier!
0.3.9
Replacement parts must meet the technical requirements specified by the manufacturer.
This is always ensured when genuine replacement parts used.
0.3.10
Do nol make any changes to the programming (software) on programmable control
systems!
0.3.11
Appropriate workshop equipment is absolutely necessary to perform any type of repair.
 Operating lnstructions 0

Prerslons-Schleilm.schihen
Paoe 5 of 76

0.4 Personnel Selection and Qualifications

0.4.'l
Work on or with the machine should be accomplished only by responsible personnel.
0.4.2
Use only trained or instructed personnel, clearly establish responsibilities of personnelfor
operation, set-up, maintenance, repairs!
0.4.3
Ensure that only assigned personnel work on the machine!
o.4.4
Allow personnel being trained, instructed or in the scope of a general course of training work
on the machine only under continuous supervision of an experienced person!
0.4.5
Work on the machine electrical equipment should be accomplished only by trained
electrician or by persons with on-the-job training under the supervision and control of a
trained electrician according to electro-technical regulations.
0.4.6
Allow only personnelwith special knowledge and experience with hydraulic systems to work
on the hydraulic equipment!
0.5 Safetv Notes on Certain Operatinq Phases
0.5.1
Avoid all types of work which is not safe!
o.5.2
Take measures lo ensure that the machine is operated only in a safe and properly
functioning state!
Operate machine when all safety equipment and safety related devices such as detachable
guards, emergency OFF devices, ailoustic insulation, evacuation equipment, is present and
operating properly!
0.5.3
Check machine or externally recognizable damage and defects at least once each shift!
Report any changes which have occurred (including operating characleristics) to the
responsible point immediately! Shut down and secure machine immediately if necessary!
0.5.4
ln the event of malfunctions shut down and secure the machine immediately! Have
malfunctions eliminated immediately!
0.5.5
Observe all switch-on and switch-off operations and indicators according to operating
instructions!
0.5.6
Before switching on/starting up machine ensure that no one can be endangered as the
machine starts running!
 Operating lnstructions 0

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0.5.7
Do not switch or remove the evacuation and ventilation equipment when the machine is
running!
0.5.8
Maintain all adjustment, maintenance and inspection work and intervals including
replacement of parts/equipment as specifled in operating instructions! Have such work
performed only by trained personnel.
0.5.9
lnform operating personnel before starting any type of special work or repair work!
Designate supervisor!
0.5.10
When performing any type of work involving operalion, production adaptation, conversion or
adjustment of the machine and its safety equipment including inspection, mainlenance and
repair, perform switch-on and switch-off operations according to operating instructions and
observe notes for maintenance work!
0.5.11
When performing maintenance work secure wide area as required!
0.5.12
lf the machine is completely shut off for maintenance and repair work ensure that it is
secured against unintended switch-on:
. Lock main control device and/or aftach warning sign to main switch

0.5.'13
During overhead assembly work use climbing aids and working platforms provided for this
purpose or other safety equipment. Do not use machine parts as climbing aids! When
performing maintenance work at great heights wear proteclive devices against falling!
0.5.14
Check all hydraulic oil lines for leakage, loose connections, chafed points and damage!
Eliminate defects immediatelyl
0.5.15
During maintenance and repair work always tighten loosened threaded connections!
0.5.16
lf it is necessary to remove safety equipment for setting up, maintenance or repair, reinstall
and check the safety equipment immediately afrer completing the maintenance and repair
work.
0.5.17
Ensure that service products and auxiliary materials as well as replacements parts are
disposed of safely in such a manner that they cannot pollute the environment!
 Operating lnstructions
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Paoe 7 of 76

0.6 Notes on Special Tvoes of Hazards

0.6.1
Use only original fuses with specified current rating! ln the event of malfunctions switch off
the power suppiy to the machine immediately!
0.6.2
Have work on the electrical system or operating equipment performed only by a trained
eleclrician or person with on-the-job training under the control and supervision of a trained
electrician according to electro-technical regulations.
0.6.3
Switch off power to machine and system parts on which inspection, maintenance and repair
work is being performed, if so prescribed. First check to ensure that the power is shut off to
the parts, then ground and short circuit and insulate adjacent parts still under power!
0.6.4
ChecUinspect the electrical equipment on the machine at regular intervals. Eliminate
defects such as loose connections or burned cable immediately.
0.6.5
When it is necessary to work on parts under power, always have a second person ready to
actuate the emergency off of main switch in an emergency. Cordon off working area with
red/white safety chain and warning sign. Use only electrically insulated tools!
0.6.6
When working on high voltage assemblies after switching off the voltage connect the supply
cable to ground and short circuit components such as capacitors with a grounding rod.
0.6.7
Have work on the hydraulic equipment performed only by personnel with special knowledge
and experience with hydraulic systems!
0.6.8
Check all leads, hoses and threaded flttings regularly for leakage and externally
recognizable damage! Eliminate damage immediately! Oil spraying out can lead to injury
and bumsl
0.6.9
Relieve pressure on pressure lines to be opened before starting repair work.
0.6.10
Work on the electrical system, including lamp replacement, may only be carried out with the
machine switched off when disconnected!
0.6.11
Protective devices and covers must be kept closed.
During visual inspection during the grinding process, safety goggles must be worn.
 Operating lnstructions 0

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o.6.12
The rear area of the machine may only be used by authorized and trained personnel
to be entered. Before doing so, make sure that the machine is in rest position.

0.6.'13 Caution
The magnetic table generates magnetic fields

0.6.14 Caution
For carriers of pacemakers or prostheses or implants, a safety distance of 2 meters should
be maintained.
 Operating lnstructions RB3
Giicfra;,
Pdizisions SchleilmMhlnen
1

1.1-.1.4
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l SET-UP

1.1 Acceptance
After the machine anives check the delivery immediately for transport damage. lf any
damage is noted report it immediately to the shipping company.
Check for completeness of the delivery using the delivery slip.
1.2 Transoort

Caution
Have machine transoorted onlv bv oualified oersonnel trained for this ouroose!
Ensure that the machine is not subjected to any jolts or concussions.
se cables (not chains) for transport to avoid damage to the machine.

A Caution
Selecl cables with sufficient suooortino caoacitv.
1.3 Transport Procedure
Slide 250 x 1500 mm long steel rods ('l) through transport openings (2). The adjustrnent
screws are removed at two openings so that the transport rods will not make contact there.
Hook in cables (3) and secure.
Support cables (3) with shims (4) to prevent contact with the machine housing.
When lifted carefully the machine should hang vertically.
Giicfall Operating lnstructions RB3 1

1.1-.1.4
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1,4 SET-UP
For setting up the machine a special foundation is not required, a rigid concrele floor is
suflicient. However, we do recommend fastening the machine with lag screws or expanding
anchors, The machine base is provided with 4 mounting holes and 4 alignment bolts. The
machine should be positioned on 4 steel plates (see figure).
Before setting up ensure that the pressure plates (1) in the area of the foundation openings
make good contact. lf necessary smooth foundation.
Suspend the machine above the foundation and screw the lag bolts (2) into the mounting
holes from the below with nuts and washers. Then lower the machine so that an approx. 40
mm wide gap remains between the foundation and machine. The pressure plates (1) can
then be positioned below the machine (pressure plates, lag bolts and expanding anchors
are not included with the machine; they are available as special accessories).

Danger
With oositioninq the pressure olates alwavs suoport the bed additionallv:
PINCHING HAZARD !
Then screw out the adjustmenl screws (3) approx. 5 mm downward and lower the machine
onto the pressure plates.
Roughly align the grinding bed with the adjustment screws and adjustment levels. Then lill
the holes in the foundation and allow to harden.

t"%
I

An adjustrnent level with scale increments of 0.02 mm/m, length 300 mm is required for
aligning the machine. Adjust the machine with the adjustment screws (3) and countemuts
(4). Use the surface on the lateral support in fror{ of the part spindle as the alignment
surface.
Arrest the machine in ihe exact position with the lag screws (2). Ensure that the machine is
not under tension. .
 Operating lnstructions RB3 2

Prazisions-schlelfm.schinen
2.1-2.3
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2 Start-Uo

2.1 Cleaninq
After provisional set-up clean the machine. All unpainted parts are coated with a corrosion
proteciion grease. Remove this grease with naphtha or other grease solvent. Then oil the
parts lightly.

Caution !
Observe handlino instructions for cleanino aoent.
2.2 Electrical Connection
The machine is complelely wired. At the rear of the machine please connect the main power
wires to the plug.

Note !
Ground machine bed. For this purpose use ground screw located on machine bed. The
ground lead should have a cross-section of at least 16 mm".

Caution !
Have machine connected onlv bv technicallv qualified oersonnel trained for this puroose.
2.3 Coolino Water
Fill the cooling water basin with water up to max. 50 mm below the edge of the basin. Add a
suitable water-soluble grinding agent according to instructions.

Caution !

Use onlv qrindino aqents allowed accordino lo local reoulations.

 Operating lnstructions RB3 3
3.1
Paae 12 of 76

3.1 Clamoino Workoieces

Disc-shaped workpieces can be clamped on the machine. The workpiece spindle has an
intemaltaper l\4K4 (1) in which the clamping mandrill (2) is inserted.
3.1.1 Assemblv and Disassemblv of the Clamoinq Mandrill
Assemblv:
o Switch pneumatic clamping to "release"
. Clean inner taper ('l) and claming mandrill (2). Do not oil!
. lnsert clamping mandrill (2) tightly into inner taper (1 ) paying attention to the zero
marking on the tool spindle and clamping mandrill.
. Screw clamping bolt (3) into connecting rod (4). The clamping screw can be
screwed in to different depths depending on the thickness of the parts to be
clamped.

Note
Observe minimum screw-in deoth of 10 mm
 Operating lnstructions RB3 3
3.1
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Disassemblv:
. Switch pneumatic clamping to "release".
. Unscrew clamping bolt (3).
. Screw hex. head bolt with machined section (5) into one of the threaded holes in
the clamping mandrill (2) until it releases from the inner taper (1).

4
 Operating lnstructions RB3 3
Prbzasio.s-Schlellnaschinen
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3.'1.2 Clampino the Workoieces
To clamp the workpieces (6) centering discs (7) and clamping caps (8) to fit the work
pieces are supplied as special accessories:
. Position matching centering discs (7) (larger centering discs are screwed down).
. Position workpiece (6).
. Position clamping cap (8).
. Switch pneumatic clamping to "clamp".

Danger !
When actuating the pneumatic clamping hold the clamping cap on the outside and ensure
thai it makes good contact.
Danger of pinching
It may be necessary to adjust the clamping bolt (3) slightly. For this purpose release lhe
pneumatic clamp.

Note
ObseNe minimum screw-in deoth of 10 mm.

I
3
 Operating lnstructions RB3 3
Prazisions-S.hlelfmaschinon
3.3
P 15 of 76

3.3 Workpiece Spindle Adiustment

3.3.1 Pivotino
The workpiece spindle can be pivoted for grinding bezzels and flat surfaces during
circumferential grinding.
To pivot loosen the hex. nut (2) and pivot the work headstock (1) by hand. The required
angle can be read off on the scale (3).

A *o,"
Retiohten hex. nut (2).
AdcrcI
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Operating lnstructions RB3 3
3.3
e16of76
3.3.2 Movino
The work head stock (1) can be fastened in 4 positions for grinding work pieces with
highly differing sizes.
. Clean surface of longitudinal support (4) and oil lightly.
. Unscrew plugs in longitudinal support for fastening holes
. Unscrew the 4 plugs (5) in the base of the work head stock.
. Move work head stock (1) and retighten.
. Replug mounting holes not used with plugs.

a *or"
After moving the work head stock it may be necessary to readjust the zero position
(angle) with the aid of a clamping pin or dial gauge.
3.3.3 Adiustino blade orindino
For grinding with circumferential grinding wheels and cup wheels for inner bezzles
(bottom blade) adjust the center of the grinding spindle and the workpiece spindle to the
same height (see Chapter 3.2 for adjustment). When grinding the bezzles ensure that the
inner edge of the grinding wheel cuts cleanly over the full width of lhe bezzle.

INCORRECT CORRECT
To grind the outer bezzle (upper blade) adjust the middle ofthe grinding spindle 75 mm
lower than the middle of the wodeiece spindle (see Chapter 3.2 for adjustment).

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 Operating lnstructions RB3 3
3.4
Priizisions-S.hl6if naschlnen
P 17 ol76

3.4 Cup Grindino

Cup wheels are used for cup grinding. The cup grinding program must be selected in the
main menu (see Chapter 3.6).
ln this mode the grinding downfeed (downfeed axis) is accomplished with the Z-axis
(longitudinal support with work piece head-stock).
ihe X-axis (lateral support with grinding spindle) is located at a stationary position.
 Operating lnstructions RB3 3

Prazisions-Schlelfmaschin.n
3.5
Pa e 18 of 76

3.5 Circumferential Grindino (Circumferential Grindino Proqram)

Straight grinding wheels are used for circumferential grinding. The circumferential grinding
program musl be selected in the main menu (see Chapter 3.6).
ln this mode the grinding downfeed (downfeed axis) is accomplished by the X-axis (lateral
support with grinding spindle).
The Z-axis (longitudinal support with work piece spindle) is the oscillating axis.
When grinding work pieces with different diameters (e.9. upper blade) and pivoted work
piece spindle, different oscillating positions are required: The parameter " Z-Osc. corr " in
the menu " Gen " is present for this purpose. Simple offset ofthe oscillation posilion is
possible in both directions with the aid ofthis parameter.
Example:
o Set parameter " Z-Osc. corr " to zero.
.Attach largest work piece and teach in oscillation position (see chapter 3.6)
lf the next work piece is smaller, the two oscillating positions will have to offset in the minus
direction by approximately the difference in the radius depending on the angle set. This
parameler can be changed before starting a new semi-automatic or automatic cycle without
changing the operating mode.

Caution
Before enterino or teachino in new oscillatino oarameters alwavs set the parameter " Z-Osc.
corr " menu " Gen ' to zero,
 Operating lnstructions RB3 3
3.6
P.li26lons-Schl.ilmaschinen
Sheet 19 of 76

3.6 Switchinq Functions

[" SIEMENS SIMA'IC Pl.l'IEL

Gdckel Mas.filn€ntab.lk
D{4293 Darmltedt

mtT-il rn l]l I r;r

lrlolcl!l t -HEI
::::::: t l L-J
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[o/ t'rlttrEM- r E
Etr]trEEffiE

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 Operating lnstructions RB3 3
3.6
P.hzis ons-Schleiimaschinei
Sheet 20 of 76

3.6.1 General
The following operaling instructions describe operation of the RB3 machine using the
built-in grinding controller as well as supplementary information required for overall
understanding of the machine operation.
3.6.2 Operatino Notes
All communication with the machine is handled over the grinding controller.
The seftings for the individual axes are displayed and the grinding variables can be
entered.
All entries can be made in clear text using easily understandable menus.
The menu displays can be changed with the function keys F1 or F4 when arrows (<< or
>>) are located above the keys.
The ESC key serves to exit the menu.
Posilion the cursor (dash) on the desired value with the aid of the anow key to edit the
grinding variables.
To change the text for a variable (e.9. Yes or No), move the cursor to the text to be
changed and press the'ENTER' key, the textfield goes invert. The desired funclion can
then be selected with the anow keys, then press'ENTER" again, the textfield comes
back from inverl and the variable is setted. Numerical variables can be changed on the
number Pad.
 Operating lnstructions RB3
Giir;Ia;l
PrdzisioB-schreilrnaschinen
3
3.6
Sheet 21 of 76

3.6.3 Switching On
First, switch on the system with the main switch. After a short time, a number of
messages appear indicating that the SPS and control panel are switching on. These
messages can be ignored.
The basic display is shown on the control panel

SIEMENS S]MATIC HMI

The control voltage can then be switched on with key 1.6.

After switching on the control voltage, the lubrication pump runs momentarily to lubricate
the syslem.
A lamp test is then performed and all key lamps should come on for approx. 1s.
The machine is then ready for operation.
The control voltage can be swilched back on with key 1.5.
When the control voltage is switched off, the power to the drives is switched of so that
lhey cannot develop any lorque.
 Operating lnstructions RB3 3
3.6
PrAzblons-Schleihaschinen
Sheet 22 of 76

3.6.4 GRINDING CONTROLLER Kev Assionments

This chapter describes the key tunclions ofthe grinding controller. A detailed description
of the individual operating modes is given in the subsequent chapters.
Key F1 Move to Reference Point
When the basic display with the Gdckel logo appears on the grinding controller
monilor, the reference point mode can be selected by pressing key F1 (see Chapter
3.6.7).
Key F2 Automatic Mode, Circumferential Grinding Wheel
When the basic display with the Gdckel logo appears on the grinding controller
monitor, the Automatic mode for circumferential grinding can be selected wilh the key
F2. This is only possible after switching on the control voltage and completion of
referencing (see Chapter 3.6.8.'l ).
Key F3 Automatic Mode, Cup Vvheel
When the basic display with the G6ckel logo appears, on the grinding controller
monitor, the Automatic mode with cup wheel can be selected by pressing key F3. This
is only possible after switching on the control voltage and completion of referencing
(see Chapter 3.6.8.2).
Key F4 Manual Mode
When the basic display with the Gdckel logo appears, on the grinding controller
monitor, the Manual mode with cup wheel can be selected by pressing key F3, This is
only possible after switching on the control voltage and completion of referencing (see
Chapter 3.6.6).
Key K1 Workpiece Motor
The workpiece drive can be switched on after lhe chuck has clamped by pressing key
K1. lf the workpiece drive is already switched on, it can be switched back off by
pressing key K1 again.
A green LED next to this function key signals that this function is switched on.
The direction of rotation of the drive (left-hand or right-hand) cah be changed with a
variable in the Automatic mode. ln lhe Manual mode, the machine tums in the same
direction as set in the cup wheel grinding program (see Chapter 3.6.8.2).
Key K2 Chuck
The chuck can be switched on by pressing key K2 and switched back off by pressing
key K2 again. When the workpiece motor is switched on, the switch-off function is
disabled.
A green LED next to this function key indicates when this function is swilched on.
Key K3 Coolant Pump
The coolant pump the exhaust (special equipment)can be switched on by presSing key
K3 and switched back on again by pressing key K3 again.
A green LED next to this function key indicates when this function is switched on,
Adclef
Prlzi3ion$S.hleilmsschinen
Operating lnstructions RB3 3
3.6
Sheet 23 of 76

Key K4 Grinding Spindle

The grinding spindle can be switched on manually by pressing key K4. lf the grinding
spindle is switched on, it can be switched back off by pressing key K4 again.
A green LED next to this function key indicates when this function is switched on.
The direction of rotation of the drive (left-hand or right-hand) can be changed wilh a
variable in the Automatic mode. ln the Manual mode, the machine turns in the same
direction as set in the cup wheel grinding program (see Chapter 3.6.8.2)
 Operating lnstructions RB3 3
3.6
PrdzisionB-schlellnaschinen
Sheet 24 of 76

3.6.5 CONTROLS outside the GRINDING CONTROLLER

Key 1.1 Emergency Off Key
This key serves for switching off the output stage of the machine in the event of
hazards.
All drive units are stopped and must be switched back on after eliminating the
malfunction.
Override Switch 1.2
Setting the axis speed to 0 - 120olo of the set speed.
Handwheel 1.3
With the handwheel 'l.3 it is possible to move the selected axis corresponding to the
motion of the handwheel.
Key 1.4 Handwheel On
Pressing this key switches on handwheel 1.3. This is indicated by an integrated light.
Key '1.5 Control Voltage OFF
Serves for operative switch-off of the output stage.
Key 1.6 Control Voltage ON
The output stage of the machine can be activated with this key. This function is
indicated by an indicator light.
Key 1.7 Direclion of Motion +
When this key is activated, the selected axis moves in the positive direction in the
Manual mode.
Key 'l .8 High Speed
Press this key simultaneously with the corresponding motion key ('1.7 o|Lg) to move
the axis manually at high speed.
Key 1.9 Direction of l\,lotion -
When this key is activated, the selected axis moves in the negative direction in the
Manual mode.
Key 1.'10 Z Axis Active
Pressing this key activates the Z axis for the l\4anual modes (MANUAL and TEACH-
lN). Selection of the Z axis is signaled by the inlegrated light illuminating continuously.
Key 1.1'l X Axis Active
Pressing this key activates the X axis for the Manual modes (MANUAL and TEACH-
lN). Selection of the X axis is signaled by the integrated light illuminating continuously.
Key 1.12 Cleanpump
The cleanpump can be switched on by pressing key '1.12 and switched back off
by pressing key 1.12 again.
A lamp indicates when this function is switched on.
 Operating lnstructions RB3 3
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Prazisions-Scnleihaschin6
Sheet 25 of 76

Key'1.'13 Continue Program

ln the Automatic mode, the program moves on to the next step when this key is
actuated. Pressing this key has no efect for the functions Move to downfeed position
and Move to park position.
Key 1.14 Program OFF
When this key is pressed, the automalic cycle in progress is terminated. The downfeed
and oscillating axis moves to the park position and all assemblies are switched off.
Key '1.'15 Program ON
When no error message is indicaled on the control panel, a grinding cycle can be
started with this key.
This key flashes when the workpiece is clamped and the cycle has not yet been
started. lt illuminates continuously when a cycle is in progress.
Foot Swilch 2.1 Terminate program
When this foot switch is actuated, any automatic cycle in progress is terminated. The
downfeed and oscillating axis moves to the park position and all assemblies are
switched off .
When this foot switch is actuated outside of the grinding sequence, the workpiece is
released.
When lhe workpiece motor is prcgrammed to continue running at the end of the
program, it can be switched off by pressing the foot switch.
Foot Switch 2.2 Clamped Workpiece
The workpiece can be clamped with this footswitch.
 Operating lnstructions RB3 3
Giir;ra;,
Pr$zi.ioB-S.hroilrraschine.
3.6
Sheet 26 of 76

3.6.6 l\4anual Mode

The following menu appears when the Manual mode is selected.

iffii srMATrc IiMr

:. vtoto . vqq x :
M:.. @@@ Re GM: @@O@ Re
OO1-t/ inc

MD

ln lhe Manual mode, lhe Z or X axis can be moved manually. For this purpose, select
the axis to be moved with the keys '1.10 or 1.1'1. The selected key illuminates. The axis
can then be moved with the direction keys + and - (1 .9 and 1 .7).
The motion rate for the axes can be increased by simultaneously pressing the high speed
override key'1.8. The speeds for the Jog mode as well as High speed can be changed in
the machine data menu.
Moreover, it is possible to move lhe axes with the electronic handwheel. For this purpose,
select the handwheel by pressing key 1.4. This key illuminates when the handwheel is
selected. Then, turn the handwheel in the appropriate direction. The axis is moved
according to the value entered under "Hw:" each lime the handwheel is moved one mark
(increment).
Example: Hw: 1U/inc- per handwheel rotation 0.1 mm
Hw: 1op/inc- per handwheel rotation 1.0 mm
GM: This variable is the speed fer the grinding wheel.
R/L: This variable sets the turning direction of the grinding motor.
WM: This variable is the speed for the workpiece spindle.
R/L: This variable sets the turning direction of the workpiece motor.
A&Ief
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Operating lnstructions RB3 3
3.6
Sheet 27 of 76

3.6.7 Referencinq
The following menu appears when referencing is selected.

SIMATIC HMI
* Re f,e'r: e hde; 1p6i n;t1S *,*
,@@@@ A@@mm
'. OOO@ . @@@rnm

,-z

The specific axes can be referenced by pressing keys Fl and F2. For this purpose, the
axes move to the reference swilches located in the vicinity of the positive limit switch. At
the reference switch, the direction of rotation is reversed and the reference point for the
sensor is found after moving away from the reference switch, After finding this reference
point, the defined reference value is set in lhe machine data.
This operation is always required when the machine has been switched off. Presence of
the reference point is indicaled by an "R" following the setting displayed for the
corresponding axes.
Automatic operation cannot be selected before referencing has been completed,
Citclc;l;
P--.r"-;.-s"-;rdi'*-ffi
Operating lnstructions RB3 3
3.6
Sheet 28 of 76

3.6.8. Automatic Proorams

ln the Automatic mode, the individual axes are moved according to the selected
processing program.
It is possible to complete an entire grinding cycle or discontinue the cycle in progress.
Moreover, lhe grinding variables can be entered in this mode.
Before starting the automatic cycle it is necessary that the machine be moved to all
reference points.
ln the cup wheel grinding program, the Z axis is downfed while the X axis is moved to its
downfeed position.
ln the circumferential grinding program, the X axis is downfed and the Z axis oscillates.
The grinding sequence can be slarled by pressing key 1.15 ,"Program ON"
Some program steps can be terminated with the 'Continue program" key 1 .13.
The grinding cycle in progress can be terminated at any time by pressing the key 1.14
,"PROGRAM OFF' or foot switch 2.1 "TERMINATE PROGRAM". Moreover, the grinding
cycle is discontinued when a major malfunction occurs.
 Operating lnstructions RB3 3
3.6
PrlzlsloB-Schlsllma3chino.
Sheet 29 of 76

3.6.8.1 Circumferential Grindinq

During circumferential grinding, the steps listed in the table are performed in the
sequence given:
. Park Dosition X before Z
. Tool correction ON
. I\4oves to downfeeed Dosition Z before X
. Start Z axis oscilalinq motion
. Handwheel active (semiautomatic onlv !!)
. Rough grinding downfeed program
Downfeed is accomplished at the end positions
. Fine grinding downfeed program
Downfeed is accomplished at the end positions
. Soarkino out with strokes
. Stop oscillatinq motion
. Automatic tool correction Yes Automatic tool correction, no
Automatic tool conection No automatic tool correction
. Tool correctaon OFF
. Park position X before Z

This automatic sequence is accomplished with wheel '1' or '2' first, depending on the
selection in the variable wheels'1'. '2' ot'1+2'.
The program sequence shown in the table applies for one wheel. When wheel 1+2 is
selected, the sequence is repeated with the parameters for the 2no wheel after
completing lhe cycle wilh the first wheel.
With the excepton ofthe approach for the downfeed position and the park position, the
program steps can now be terminated with lhe "CONTINUE PROGMM" key'1.'13.
The park positions are moved to as absolute positions and are not subject to the tool
correction ??. This is visible on the grinding controller, because the actual value
display switches over to the park positions during the approach operation- The position
of the X axis in relation to the center of the grinding wheel is then displayed.
ln the semi-automatic mode, the axes first move to their downfeed position, Then the
handwheel is released to allow sparking in. This mode is always advantageous when
the workpieces have differenl dimensions as is the case for regrinding.
ln the full automatic mode, the Z axis goes to rough grinding immediately upon
reaching the downfeed position. This mode is practicai only when all pieces to be
ground have the same dimensions.
The teach-in mode provides a practical possibility for input ofthe parameters. Here, it
is possible to move the axis in the Manual mode and store the positions in the
parameters by pressing a button (Chapter 3.6.8.1.4)
 Operating lnstructions RB3 3
@ircle7
Priizlslons-S.hleilmaschine.
3.6
Sheet 30 of 76

3.6.8.1.1 Details on Circumferential Grindino Prooram

The following menu appears when circumferential grinding is selected.
rl|lAq SIMATIC HMI

ooo . aaa z . ooo .

: A . OOO

Page 'l

tHFlXl*E sLMAIrc rrMr

@@@ . @O@ Z: O@@ . OO@

Page 2

The spark-out strokes to be performed are indicated in lhe "Spark out" step where
an underscore is located at the bottom right, next to the arrows ">>".
The actual value is displayed for X: and Z:. lf a program has not been started, the
uncorrected position for the X axis is given here. The tool correction is taken into
consideration only after moving to the grinding position as shown in the table above.

Page 1:

It is possible lo go to the general parameter settings for both Wheels by pressing key
F1.
To display the menu for wheel 1, press key F2
To display the menu for wheel 2, press key F3
Press key F4 to go to Page 2

Page 2i
Press key F1 lo go to Page 1

Press key F2 lo activate the Teach-ln function (Chapter 3.6.8.1.4).

Pres key F3lo select or deselect the fully automatic mode. After successful
selection, the text'Full automatic" or 'Semiaulomatic' appears on the display.
Press key F4 to go to Page 1

When the ESC key is pressed, it is possible to quit the circumferential grinding
program when its cycle is not in progress.
 Operating lnstructions RB3 3
Gdcraif
Prbz sions-Schreitmaschinen
3.6
Sheet 31 of 76

3.6.8. 1.2 General Parameters

reiffiHF srMATrc HMr

:; C,oFr ''t@@@@nm
eels: " L+2
: @Opl1nc

Z-Osc.corr.: ls the offset for the reversal point. This parameter is added to both
oscillating positions.

Caution
Caution is required when teaching in new workpieces.
When teaching in the oscillating positions, this parameter
is not taken into consideration. This can result in 'undesired"
reversal points in the grinding operation
It is always necessary to set this parameter to "zero'for new
workpieces.

Wheels: Here, it is possible to set whether the parameters for the 1"t or 2nd
wheel are to be processed. When 1+2 is set, both parameter
records are completed one afrer the other. (2 grinding programs)
Hw: lndicate the evaluation for the handwheel motion. This parameter
is significant only in lhe Semi-automatic mode. The handwheel
is released to allow sparking in only after the approach in the
Semiautomatic mode
Example: Hw: ltlinc- per handwheel rotalion 0.1 mm
Hw: 'lou/inc-per handwheel rotation .1.0 mm
Glddel
PrdzBloB-Schleilmaschinen
Operating lnstructions RB3 3
3.6
Sheet 32 of 76

l{trffi srMATrc HMI

bg grind: @A@ rpm
bg sp . ouL.@@@ rpm
direct.: right

speed: lndicates the speed of the workpiece motor

sparkout: lndicatesthe speed ofthe workpiece motor by sparkout
direct.: lndicates the rotation of rotation of the workpiece motor

srMATrc HMr
ncl tj iwhie e:I,:: r]-ght :

arkpos: @@@.@@@mm
- -Pa:r'kp:os '. O@O . O@O mm

Grind.wheel: lndicate the direction of rotation of the grinding wheel

X-Parkpos: ls the park position to which lhe X axis moves at the beginning and
end of each grinding cycle. This position is entered as an absolute
value without tool correction.
Z-Parkpos: ls the park position to which the Z axis moves al the beginning and
end of each grinding cycle
 Operating lnstructions RB3 3
Gldc/ce7
Prh2is ons-Sch eilmaschinen
3.6
Sheet 33 of 76

UnEilm stMAlc HMI

or RbD, : 'W2:: ' ' No
'. O@ . AOOmm

Auto Approach Wheel 2 :Here it is possible to swilch in Auio Approach Wheel2

Auto Approach Handwheel ON : Here it is possible to switch in Auto Approach

with Handwheel on .

Safety : Distance between Workpiece and ApproachMheelposition.

Caution
Both wheels must be measured with the exact diameter and stored
at W1&W2 before set up a work-piece with Tech ln
Otherwise, a mllision hazard exits.

ftrnmffi srMATrc HMr

5Ut:6. loif

Auto Off: lndicates whether or not the workpiece motor is to continue

to run at lhe end of the grinding cycle.
@6M
PrAzlslm.+.t dftm.chinM
Operating lnstructions RB3 3
3.6
Sheet 34 of 76

3.6.8.1.3 Parameters. Wheel 'l and Wheel 2

SIEMENS SIMATIC HMI

gr . :@@@ .@@@mm
,::, ,, :,: ,O . O@Omm

SIEMENS SIMATIC HMI

Rough gr.: ls the path to be lraveled with rough grinding impulses

lmpulse: ls the value ofthe downfeed impulse at the reversal point for the Z axis
 operatins lnstructions RB3
AdCIel I
3
3.6
Prdzisions-S.hleilmaschincn
Sheet 35 of 76

srErvrENs SIMATIC HMI

ne :gr . :, O@O.@@@mm
1s: O . O@Omm

{(,, , ,,..,.,Wheie:L ,1

slEtvtENs SIMATIC HMI

thd1; gr;;..;;1 OOO . @OOrnrn: ::
15; ir r , @.@@@wn

Fine gr.: ls the path to be traveled with rough grinding impulses

lmpulse: ls the value of the downfeed impulse at the reversal point for the Z axis
 Operating lnstructions RB3
Giicfc;,
PrAzisioB-schreilrnaschinen
3
3.6
Sheet 36 of 76

StEMENS SIMATIC HMI

\rhf . poS ' O@@ .
Osc . pos 1- : OOO .
Osc. gos2. O@O.

SIMATIC HMI
!:DOWnf .: pbS: , @OO.@@O
l,-Oscz:- pod l ;, O@O . @@@
,-Oscz ,.pos2: @@@ . @@@

Downf. Pos: ls the grinding position to which the X axis moves.

Z-Osc .pos1: ls a reversing point for the Z axis. lt makes no difference
whether or not this parameter is grealer than " Z-Oscz.pos2".
This posilion is also used for approaching. At this position,
the Z axis waits for the X axis before starting to oscillate.
Z-Osc.pos2: ls a reversal point for the Z axis. ll makes no difference
whether or noi this parameter is grealer than " Z-Oscz.pos1".
 Operating lnstructions RB3
AAcIc;I
PrdzisionB-schlermaschinsn
3.6
Sheet 37 of 76

stEMEits SIMATIC HMI

akout St noke l

WheeIl 1

SIEMETUS SIMATIC HMI

oo

Spark-out Stroke: ls the number of strokes the Z axis performs during

sparking out. The strokes are counted upon reaching oscillating
position 2 in each case.
 Operating lnstructions RB3
Cdcrcll
Frl.isioneschlelfmaschin6n
3
3.6
Sheet 38 of 76

SIMATIC HMI
1 Diam. : @@@.@@@mm
. cor r auto: No
.corF/cu'kI.:@.@@@mm

SIMATIC HMI
Dl am. '. OO@ . @@Omm
:.Coir au,to: No
. corr /cU,k,l . : @ . O@Omm

wlivv2.: ls the diameter ofthe specific grinding wheel.

T.corr auto: lndicates whether or not the grinding wheel diameter is to
be corrected automatically at the end of each grinding cycle.
T.corr/cycl .: ls the quantity subtracted from the wheel radius at the
end of each grinding cycle. The diameter ofthe wheel is
therefore reduced by two times the value T,con/cycl.
Example:

At the end of the cycle for wheel 1 (park position between wheel I and wheel 2),
the value diam. '199,994 mm is indicated for W1.
At the end of the entire cycle, diam. 199,994 mm is displayed for W1 and
199,996 mm for W2.
 Operating Instructions RB3 3
A6cIc;,
Prlzisiom-Schlellmaschinen
3.6
Sheet 39 of 76

SIEM ENS SIMATIC HMI

ind.m.:.'@@@Ornl:s
OsC2:;::, : o@@omm/:m'tn
Spa r k ,: OOOOmrfit rnin

SIMATIC HMI

O@@Amm/min
OA@Omm/m:-n

Grind m. The circumferential speed of the grinding wheel is displayed

here.
v*60 mln
The speed can be calculated from: n =
n [min'1]; v [m/s]; d [m].

The speed increases as lhe wheel becomes smaller due to

consumption. However, the circumferential speed remains the
same.
z Oscz.,: ls the speed ofthe Z axis for oscillation
z Spark: ls the speed of the Z axis during sparking out.
 Operating lnstructions RB3 3
Giir;re;,
P*izhioB-S.hroilrnaschine.
3.6
Sheet 40 of 76

3.6.8.1.4 Teach-ln Mode for Circumferential Grindinq Proqram

ln the Teach-ln mode, the axes can be moved in the same manner as in the Manual
mode and the positions slored in the parameters by pressing key (F2).
The cursor must be positioned on the parameter to be entered. This can be set with
the anow keys. Scrolling in the menu is possible with the function keys F1 and F4.
The mode can be exited with ESC.
All positions displayed for the X axis except for the park position are subject to tool
correction.

. pos . O@@ . @@@mm

t. pos:@@@.O@Omm

Downf. Pos: ls the grinding position to which the X axis moves. This
parameter can also be entered directly (Chapter 3.8.'1.3)
 Operating lnstructions RB3
Glitcfel
Prdzislons-S.hlsilm.rchinsn
3
3.6
Sheet 41 of 76

SIEMCNS SIMATIC I]MI

L,: @@@ . @OOmm

, 2: " @@O . @O@mrn

'Teaic,h

'. @@O . @O@ Whee,l2

,.,1,:, ,OO@.@@@mm
. 2-. @O@ . @OOmm

Oscz. 1: ls the 1st oscillating position for the Z axis. lt makes no difference
which ofthe two positions Oscz. 1 or 2 is greater.
Oscz. 2: ls the 2nd oscillating position for the Z axis. lt makes no difference
which of the two posilions Oscz. '1 or 2 is greater.

Caution
When teaching in a new workpiece, it is necessary to set the
parameter for the oscillating conection to zero in the general menu.
Otherwise, a collision hazard exits.
 Operating lnstructions RB3 3
3.6
FrAzlsloB.Schlsif maschine.
Sheet 42 of 76

3.6.8.2 Cuo Wheel Grindinq

During cup wheel grinding, the steps listed in the table are performed in the sequence
indicated.
. Move to park position Z before X
. Tool correction ON
. Move to downfeed position X before Z
. Release handwheel (Semiautomatic mode onlv !!l)
. Rough grinding
Downfeed is accomDlished after oauses
. Fine grinding
Downfeed is accomplished after pauses
. Soarkino out via time
. Autom. tool correction: Yes Autom. tool correction: No
Automatic tool corection No tool correction
. Tool correction OFF
. Move to Dark oosition Z before X

The park positions moved to are absolute values. This means that the tool correction
for the Z axis is not taken into consideration and is not indicated on the control panel.
This is indicated in the two program steps in the table above before and after moving
to the park positions. An example is given further on under the description ofthe
parameters.
ln the Semiautomatic mode, the axes firsl move lo lheir downfeed posilion. Then the
handwheel is released to allow sparking in. This mode is always advantageous when
the workpieces have different dimensions as is the case for regrinding.
ln the full Automatic mode, the Z axis goes to rough grinding immediately after
reaching the downfeed position. This mode is practical only when all workpieces to be
ground have the same dimensions.
The Teach-ln mode provides a practical method of entering the parameters. For this
purpose, the axes are moved in the Manual mode and the posilions can then be stored
for the parameters by pressing a key (Chapter 3.6.8.2.3)
 operating lnstructions RB3 J
Adde, I 3.6
PrlitrhioBs.hreitmaschine.
Sheet 43 of 76

3.6.8.2.1 Details of Cup Wheel Grindino Proqram

The following menu appears when the cup wheel grinding program is selected

'. O@@ . @OO Z: @@@ .

' Teach Mode

The menu for setting the parameters for the cup wheel grinding program can be
called by pressing key F'l.
Pressing key F2 calls the Teach-ln functions (Chapter 3.6.8.2.3).
Pressing key F3 selects or deselects the "Fully automatic' mode. After successful
selection, the text "Fullautomatic" or "Semi-automatic' appears on the display".
Press the ESC key to quit the cup wheel grinding program when a cycle is not in
progress.
During sparking out, the remaining time for sparking oui before moving to the park
positions is indicated in the parameter field in addition to the mode (F3).
The slep just completed is indicated in clear text at the margin in the 3d line. Here,
"Parkpos" is for moving to the park position.

3.6.8.2.2 Cuo Wheel Grindino Prooram Parameters:

SIEMEITIS SIMATIC HMI

gr : @@@.@O@mm
'. O
O@@mm
: OOO,

P FRFM .

Roughgr.: ls the distance to be traveled with the rough grinding impulses

lmpulse; .Value for one downfeed impulse
Pause: Pause between two downfeed impulses
Adc/cl,
PrAzBlds-Schleitma.chihon
Operating lnstructions RB3
3.6
3

Sheet 44 of 76

lne gr. : @OO .@@@mrr

mpuls. O.@OOm
@ . @@Amm
ause. @@Os

Fine gr.: ls the distance to be traveled with the fine grinding impulses.
lmpulse: Value for one downfeed impulse
Pause: Pause between two downfeed impulses

ryflfffi srMATrc HMr

,rParkp,o,s,|" @@@ . OOOmml
kpos: @@@.@@Omm

Z-Parkpos: ls lhe park position to which the Z axis moves at the beginning and
end of each grinding cycle. This position is entered with absolute
values and without lool correction. This position can also be
taught in (Chapter 3.6.8.2).
X-Parkpos: ls the park position to whi6h the X axis moves at ihe beginning and
end of each grinding cycle. This position can also be taught in.
(Chapter 3.6.8.2).
@6der
Prdzisions-schleirmaschin€n
Operating lnstructions RB3 3
3.6
Sheet 45 of 76

StEtvtENs SIMATIC HMI

ownf - pos:
r--' O@O.
Osc. posl: @O@.
Osc . pos2'. @@O .

DF.Pos: ls the grinding position to which the Z axis moves. This

parameters can also be taught in. (Chapter 3.6.8.2)
X Osc. posl: ls the 1* oscillating position for the X axis. lt makes no difference
which ofthe two positions Oscz. 1 or 2 is greater.
x Osc. pos2: ls the 2nd oscillating position for the X axis. lt makes no difference
which of the two positions Oscz. 'l or 2 is greater.

SIEMENS SIMATIC HMI

.i,hd..mo,t6'r@@@@ :,.rpm
iM, direct. right
Oscz. : @O@@ mm/min

Grind motor :ls the speed of the grinding motor.

Grind motor :ls the direction of rotation of the grinding motor
X Oscz.: ls the oscillating speed of X-Axis
Gdde,
;;EEiffi;ffi;
Operating lnstructions RB3 3
3.6
Sheet 46 of 76

SIEMENS SIMATIC HMI

bg spa.ou@OO rpm
direction: nlght

WM speed: lndicates the speed ofthe workpiece motor

Wl\4 sparkout lndicates the speed of the workpiece motor by sparkout
WM direct.: lndicales ihe rotation of rotaiion of the workpiece motor

SIEMENS SIMATIC HMI

: ', @@p/,,i,nC
ou,t,:,,, ,, OOOs
sp a .,ou:t: :: @ O 0 Ornmlrnln

CUP
::

Hw: lndicate the evaluation for lhe handwheel motion. This parameter
is significant only in the Semi-automatic mode. The handwheel
is released to allow sparking in only after the approach in the
Semiautomatic mode
Example: Hw: 1plinc- per handwheel rotation 0.1 mm
Hw: 1op/inc-per handwheel rotation.1.0 mm
Spark out: Timebase for programstep spark-oui.
X spa.out: Speed from the X-Axis by programstep spark-out
C&Ial,
Pra2isions-Schleilnaschinen
Operating lnstructions RB3 3
3.6
Sheet 47 of 76

SIEMENS SIMATIC HMI

. cor r comp :@@ . @@@mm
.corr auto.: No
.corrlcgk1..@.@@@mm

'ennnM.

T.corr comp: lndicates the entire iool correclion effective on the Z axis
To delete the tool correction, enter 0.000 mm for this
parameter.
T.corr auto.: lndicates whether or not the tool conection is to be changed
automatically at the end of each cycle.
T. corr/cycl. : ls the quantity to be added to the total tool correction
"T.corr comp" at the end of each grinding cycle
Example:

ln this example, 0.005 mm is added to the total conection at the end of each
grinding cycle so that the reading is then 1.005 mm.
During the next approach, the Z axis is then located 0.005 mm further in the
negative direction than previously. The park positions are not affected by this
parameter. These positions are absolute.

Auto Off: lndicales whether or not the workpiece molor is lo continue

to run at the end of the grinding cycle.
 Operating lnstruclions RB3
Gl6c/e,
PrdzisioB-s.hlellma*hinen
3
3.6
Sheet 48 of 76

3.6.8.2.3 Teach-ln Prooram for Cuo Wheel Grindinq Proqram

ln the Teachin mode, the axes can be moved in the same manner as in the Manual
mode and the positions stored in the parameters by pressing key (F2).
The cursor must be positioned on the parameter to be entered. This can be set with
the arrow keys.
All positions displayed for the Z axis except for the park position are subject to tool
correclion.

SIMATIC HMI
'.@@@.OOO X:OOO.@OO
D,F , P,os ..' , ,@O@ . @@@rnm

<{ Teach
Z DF. Pos: ls the grinding position to which the Z axis moves. This parameter
can also be entered directly (Chapter 3.6.8.2.2)

ls the '1=' oscillating position for the X axis. lt makes no difference

which of the two positions Oscz. I or 2 is greater.
ls the 2nd oscillating position for lhe X axis. lt makes no difference
which of the two positions Oscz. I or 2 is greater.
 Operating lnstructions RB3
@6cre,
Prersld!-s.t.ll a..hi.6n
3
3.6
Sheet 49 of 76

SIEMENS SIMAIIC HMI

:., OOO,,'Xl,OO@ . OOO'
@OO .
i Parkpos - ,OOA .OOOmm
I Parkpos . @@@.@@@mm

Z-Parkpos: ls the park position to which the Z axis moves at the beginning and
end of each grinding cycle. This position is entered with absolute
values and without lool correction. This position can also be
taught in (Chapter 3.6.8.2.2).
X-Parkpos: ls the park position to which lhe X axis moves al the beginning and
end of each grinding cycle. This position can also be taught in.
(Chapter 3.6.8.2.2).
 Operating lnstructions RB3
Gdclal,
Prlzi3ions-Schleilrnaschinen
3
3.6
Sheet 50 of 76

3.6.9 Machine Data

The speeds for the Automatic programs and for the Manual mode can be defined in this
menu. All parameters for the axis modules can be changed in the menus for the axes.
users only have access to the levels with the machine data for the automatic programs
and the Manual mode (Page 1). The other menus (Page 2) require entry of a password.

SIEMEN'S SIMATIC HMI

Maschi ne Data

Pagel

iffi SIMATIC HMI

,ne

Z X
Page2

Pagel
Pressing F1 changes the display to the general parameters.
Pressing F2 changes to the display for the parameters for circumferential grinding
Pressing F3 changes to the display for the parameters for cup wheel grinding
Pressing F4 changes the display to Page 2

Page 2
Pressing F1 changes the display to Page 1

Pressing F2 calls the display for the Z axis parameter

Pressing F3 calls the display for lhe X axis paiameters
Pressing F4 calls the display for ihe system parameters in the Siemens menu

The menu can be exited with ESC.

G&rcl
PrAzlrloB-Schlefnaschin.;
Operating lnstructions RB3 3
3.6
Sheet 51 of 76

3.6.9.1 General Machine Data

STEMENS SIMATIC HMI

lC .pause:
V: ,@@@O,mrnlm]-n
V: @@O@ mmlmr n

Lubric.pause: This is the pause between two lubricating operations by the lubricating
pump
Jog V: ls the Jog speed in the Manual mode. This is active for both axes.
Rapid V: ls the rapid speed in the Manual mode which can be achieved by pressing
the high speed override (key '1.8). This parameter is also effective for both
axes.
 Operating lnstructions RB3
GldcIeI
Pr?izisions-Schleilmaschinen
3
3.6
Sheet 52 of 76

3.6.9.2 Machine Data for Cup Wheel

StEtvtENs SIMATIC HMI

'. AOAOmmlm1n
-Rap1d: O@@Ontm/rnin

X-Rapid: ls the high speed for the X axis.

This is used for moving to the park positions, for example,
Z-Rapid: ls the high speed for the Z axis.
This is used for moving to the park positions, for example.

stEtttENs SIMATIC HMI

Dowhf:eed Speled
: @@@@ mm/min

Zl ls the speed at which the downfeed impulses are execuled

I srMATrc HMt
Parkposlitioh
:,@OOO . @@@rnm: ::

:[email protected]@mm

X: ls the park position for the X axis

Z: ls the park position for the z axis
Odclel
PrlzisioB-schleilmaschinen
Operating lnstructions RB3 3
3.6
Sheet 53 of 76

SIEi,IEJVS SIMATIC HMI

a fter measu r i ng
: O . O@Omm

Security distance after measuring (option) means they way between

workpiece and grindhead after programstep measuring.

3.6.9.3 lvlachine Data for Circumferential Grindinq

SIMATIC HMI
Vma'x : @A'm/ s
d. @@@@mm/min
-Rbpi:d: @O@O'nmlrn,in

MD PER

GM Vmax: Here, it is possible to defne the maximum circumferential speed for the
grinding wheels which can entered in the circumferential grinding menu.
This serves as a safety feature, because the corundum wheels are not
approved for lhe high speeds which can be achieved with the RB3.
This value does not limit the current value in the cirtumferential
grinding menu. Only new entries are checked and refused where
applicable.
X-Rapid: ls the high speed for the X axis.
This is used for moving to the park positions, for example.
Z-Rapid: ls the high speed for ihe Z axis.
This is used for moving to the park positions, for example.
GibIa;I
P16zisioB-schreithaschihon
Operating lnstructions RB3 3
3.6
Sheet 54 of 76

STEMENS SIMATIC HMI

Wl: @@@@mml mj. n

W2: @@@omm/ min

xwl: ls the speed at which the downfeed impulses are execuled for wheel '1.

x w2: ls the speed at which the downfeed impulses are execuled for whee 2.

Security distance after measuring (option) means they way between

workpiece and grindhead after programslep measuring.
 Operating lnstructions RB3 3
3.6
P16zisions-schreilnaschinen
Sheet 55 of 76

3.6.9.4 Machine Data forZ and X

Caution
It is necessary to be careiul when changing the machine data in the axis module
menu. Basic settings for the machine are contained in this data. ebalgCsshggblbe
made onlv bv technicallv oualified and trained personnel!
Access to the machine data menu for the axis modules is possible only when the
control voltage is switched off. After selecting one of the axis data menus, you are
requested to enter a password. The axis menu can be accessed only affer entry.

SIEMEXS SIMATIC HMI

Parameter: @@@O
Wert: @@@@@@@@Hex
@@@@@@@@@@Dez

BMRXX X
REFID WRITE EPROM

SIEMETUS SIMATIC HMI

Parameter: @O@@
Wert: O@@@@@@@Hex
@@@@@@@@@@ Dez
BMFXX Z
REFID WR]TE EPROM

Parameter: Parameter number to be displayed or changed.

ls the value for the parameter in the hexadecimal system.
This is advantageous because some parameters are hexadecimal
or binary.
Val.oec: ls the value of the parameter in the decimal system
 Operating lnstructions RB3 3
3.6
PrAzBloB.schtsifmaschinen
Sheet 56 of 76

To change a parameter, enter lhe parameter number whose value is to be changed in

"Parametef. The value of the parameter then appears in the field Val.Hex or Val.Dec.
After changing the value in Val.H€, or Val.o€c, the value can be taken over with ENT.
The axis module can lhen be stored in the "Eprom" with the key F4. As long as the
operation is running, the word Eprom flashes in the Controller. The flashing stops
when the entire parameter record has been stored.
 Operating lnstructions RB3
Ciir;Iel,
PrgzkioB-schreilrnaschinen
3
3.6
Sheet 57 of 76

3.6.10 Error Displav

lf a malfunction occurs on the machine, it is indicated in clear text on the control panel
and the ! LED illuminates. An enor message describes the cunent menu text and remains
on the display until it has been acknowledged by pressing the ACK key. After eliminating
the malfunction, the ! LED on the controller extinguishes. lf the error message is still
present, the LED remains illuminated. To display the message again, change to the
message level. This can be accomplished by pressing the ESC key in the Start display.
Press the ENTER key to return to the control level.

All possible error messages are listed below:

11Q1
0002 6Q1, 7Q'1, 00'11 HWLSX-
CB Cool., Cleanpump X-Axis
or Paperbandfil. Hardware LS-

0003 cB 13Q1 0012 HW LS X+

No OiL or X-Axis
Circuit Breaker Hardware LS+
Lubrication '13Q1
OO13 HW LS Z-
0004 581 Z-Axis
No Air Hardware LS-
or preasure to low
0014 HW LS Z+
0005 4G1 Z-Axis
Error X-Achse l\4odul Hardware LS+
Code:
OO15 BTB 2A1
0006 scl Disturbance
Error Z-Achse Modul Converter 2A1
Code: Grindingmotor

0007 SW LS X- 0016 rdy 5A1

X-Axis Disturbance
Software LS- Converter 5A1
Toolmotor
OOOS SW LS X+
X-Axis
Software LS+

OOO9 SW LS Z.
Z-Axis
Software LS-

OO1O SW LS Z+
Z-Axis
Software LS+
 operating lnstructions RB3 3
A fj,e, I 3.6
P162isions-Schlellhaschinen
Blatt 58 von 76

Notes
 A6cfe,
Pdzision.-S.hlelthaschinen
Operating lnstructions RB3 4
4.1
Paqe 59 of 76

4. Grindinq

4.1 Grindino Wheel

Shape:
Cup wheels and straight wheels. Max. dia. 200 mm, bore dia.50,8 mm.
Tvoe:
Corundum, CBN and diamond wheels can be used on the machine. The grain size.
hardness and binding agent depends on the material to be ground as well as on lhe
required removal and surface quality.
The following rules apply for selection ofthe grinding tools:
. The harder the material the softer the grinding.
. For soft metals (brass and copper), which tend to smear, keep grinding wheels as
soft and coarse as possible.
. At the same binding agent hardness grinding wheels with fine grain have a harder
effect lhan grinding wheels with coarse grain.
. For intenupted surfaces use harder grinding wheels than for smooth surfaces.
. Generally a soft grinding wheel is preferable to a hard grinding wheel in spite of
ils higher wear, due to the higher performance and lower power requirement.
However, it should not be selected too soft in order to limit wear to a minimum.

Check whether the grinding wheels supplies fullill the above requirements and observe
when purchasing new grinding wheels.
 Operating lnstructions RBs 4
Praz6 ons-Sch eilmaschinen
4.2
e60of76

4.2 Chanqino Grindinq Wheel

4.2.1 Chanqino onlv the qrindino wheel:
. Tum grinding wheelguard (1) to favorable position.
o Position 27 mm open-end wrench on wrench shaft (2).
. Unscrew machine screws (3) with 5 mm hex. screwdriver.
. Remove clamping flange (4).
. Replace grinding wheel.
.
Reassemble in opposite order.
4.2.2 Chanoino orindinq wheel mount:
. Turn grinding wheelguard (1) to favorable position.
o Position 27 mm open-end wrench on wrench shaft (2).
. Unscrew 8 mm machine screws (6) with hex. screwdriver (5). Press grinding
wheel mount (7) off of grinding spindle journal (8).
. Clean taper on grinding wheel mount (7) and grinding spindle journal (8).

A *o,"
!! Do not oil !!

. Position grinding wheel mount (7) and tighten with machine screw (6).

Caution
After changing grinding wheel move grindinq wheel quard (1) back to correct position.
 Operating lnstructions RB3 4
PrAzlslons-Schleihaschinon
4.3-4.4
P e 6'l von 76

4.3 Vibration comoensation

Smoolh running ofthe grinding wheel is important for good grinding results. Forthis reason,
balance new as well highly used grinding wheels. A balancing groove wilh balancing
weights is located in the grinding wheel mounts for balancing.
4.4 Dressino the orindino wheels
A dressing device (1) with 2 dressing tools (2 and 4) is attached to the workpiece headstock
(3) for dressing the grinding wheels.
4.4.1 Dressino corundum orindino wheels
Corundum grinding wheels (5) can be dressed with the dressing diamond (2).
To dress, set the workpiece headstock (3) to 0' and fly back or remove the lurning tool
(4). Move the grinding wheel (5) against the dressing diamond (2) with the Z and X-axis.
While dressing, downfeed at a rale of approx. 0.02 mm per stroke and cool with cooling
water.

Chanoino the dressino diamond

Unscrew old dressing diamond with 8 mm open-end wrench.
lnstall new diamond.

A *o,"
!l Clean taper. do not oil !!
 Operating lnstructions RB3 4
4.3-4.4
P*izisions-Schlellmaschinon
P 62 von 76

4.4.2 Dressino diamond and CBN qrindino wheels

Diamond and CBN grinding wheels (5) can be dressed with the dressing tool (4).
For dressing, set the workpiece headstock (3) to 0' and pull up the dressing tool (4) until
the dressing surface extends beyond the dressing diamond (2). Move the grinding wheel
(5) against the dressing tool (4) with the Z and X-axis.
For dressing, downfeed at a rate of 0.003 mm per stroke and cool with cooling water.
As a rule, only new grinding wheels are dressed in order to ensure perfect concentricity.

Caution
When dressino with workpiece attached. oav attention to possible collisions.
Gldcle,
Prezisions-Schleirmaschine.
Operating lnstructions RB3 4
4.5
e 63 von 76

4.5 Grindinq Soeed

The speed ofthe grinding spindle can be adjusted inlinitely on the control panel between
1000...3500 RPM.

Danger
When adiustino soeed observe max. permissible cuttino soeed for orindino wheel used.

Cutting speed [m/s]

RPM Diameter [mm
150 175 200
1000 7.4 9.2 10.s
1250 9.8 11.4 13.1
'1500 1't.8 13.7
17 50 13.7 't6.0 18.3
2000 15.7 18.3 20.9
2250 17.7 20.6
2500 19.6 22.9 26.2
2750 21.6 24.8
3000 27 .5 31.4
3250 25.5 29.8 34.0
3500 27.5 36.6
 Glirclel
Pdrulslons-Scht.ilm$chlnen
Maintenance lnstructions RB3 5
5.1
64 of 76

5. Maintenance

5.1 Grindinq soindle

The grinding spindle runs in precision self-aligning bearings and is provided with life-time
lubrication.
Mainlenance:
Clean drive motor (cooling ribs, fan)for grinding spindle when extremely dirty.
 Maintenance lnstructions RB3 5
5.2
Pr62blorc-Sch eilmaschinen
e65of76

5.2 Workoiece Spindle

The workpiece spindle runs in a precision rolling bearing. Drive is accomplished with a
toothed belt ('l). The bearings are permanently lubricated wiih grease.
!&!$e!3!ce!
. Clean drive motor (cooling fins) when heavy accumulations are present.
OiicIa;I
Prlizlslons-Schl.ilmaschlnen
Maintenance lnstructions RB3 5
5.3
66 of 76

5.3 Lonqitudinal Supoort

The longitudinal support runs in linear self-aligning guides and can be adjusted with a ball
thread drive. Both elements are lubricated automatically by the central lubrication.
Maintenance:
Check bellows (1) for damage.
Regularly clean surfaces (4) in front of work piece headstock.

A *o,"
Before lonoer pauses in work clean surface (2) and oil liohtlv.

RB3_5,3_1
GiiclaiI
[email protected]
Maintenance lnstructions RB3 5
5.4
P 67 ol76

5.4 Lateral Support

The lateral support runs in linear self-aligning guides and can be adjusted with a ball thread
drive. Both elements are lubricated automatically by the central lubrication.
Maintenance:
Check bellows for damage.
 Maintenance lnstructions RB3 5
5.6
Prizis ohs S.hleilmaschin.n
68 of 76

5.6 Coolinq water svstem

Water with a water soluble grinding agent is used for cooling during grinding. Change the
cooling water depending on the contamination.

Caution
Dispose of contaminated coolino water accordinq to applicable local reoulations.
Clean reservoir and lines thorouohlv.
Paoer strio filter (option)
The contaminated cooling water flows through the paper filter (1) running off of a roll in slrip
form. The paper filter (1) supported by a combination wire mesh strip (2) forms together with
the latter a deep filter recess which allows continuous flow of the cooling water. Deposit of
the contamination on the filter paper (1) clogs the filter causing the liquid level to rise. An
adjustable floai (3) controls transport of the paper filler (1) when the filter recess is full.
This ensures that the filter paper (1) is regenerated automatically depending on the quantity
of contamination.
Maintenance:
. lnsert new filter paper roll (4).
. Empty sludge box (5).

A *o,"
When the roll offilter paper (4) is used up, insert a new roll of filter paper
immediately, because the cooling water is no longer cleaned without filler paper (1).

9
AdcIeI
Priizisions-S.hlelfnaschinen
Mainlenance lnstructions RB3 5
5.7-5.9
P e69of76

5.7. Electrical Equipment

The switch cabinet is installed in the machine base. Maintenance is not required.
5.8 Cleanino
Clean the machine regularly. Flush grinding sludge deposits out of machine chamber.
Clean water drain opening from machine bed regularly lo prevenl back-ups.
Before longer pauses in work clean longiludinal support surface in front of work piece
headstock and oil lightly.
Clean the cooling ribs, cooling air inlets and fans on lhe motors from time to time.
Check the function ofthe paper strip filter regularly. Clean intake screen regularly. Replace
used paper rolls immediately with new rolls.
Magnetic lilter (special version):
Flush the intermediate chamber between the magnetic drum and housing regularly. Check
wiper plate regularly and readjust if required.
5.9 Lubrication
Lubricalion is limited to regularly checking the oil level in the central lubricalion tank.
See lubrication chart for all other lubrication points.
G&Ic;,
Pdzirions-S.hleilnschinen
Maintenance lnstructions RB3 5
5.12
70 of 76

5.12 Lubrication Chart

Oil/Grease Desiqnation Frequencv Quantity
Central lubrication 3 hours 12x
@ Guide way adjustrnent spindle automatic O.O3 cm3

Adjustment spindle bearing

5-10 drops/1000lair 0.045 liter
@ Work piece clamping automatic

List of lubricants and manufacturerc on next paoe = not on all machines

@
_@_ fl;;[;i,."",vs0,,*.,,u0""

* *
;: i De6ignotion of lubriconte l'lonufocturer
xruu". l n"tr l*'a
Symbols
o DIN 51502 DIN 5602 Ard lor l o* |
toide.ov ol CGLP D.gpnit Energol

:D
o
,i
l-)
l-mLPl Reqrerte for DIN 51501
Visccity da6 IS0 VG 224 DIN 5lS1S
s 220 LS-EP 2 K 229 0ll No. 1 0t 1 ?20

tr HydrouIc oll HLP Energol ilobl

2 Requeeb for DIN 51524 HF 32 HLP 32 H32 DIT 24 ott 32

c Vi.cdrty dc6 IS0 VG 32 DIN 5l5P

6co ol CLP Degel Enrsol llobdgu
tcLPl
e
l-) R6+'..ts for DIN 51517
vr.c@ity cltrB IS0 vG 229 OlN 5l5l9
BG 2A 6R-XP 220 EP zzb 630 0t 220

t-
o Ged oil CLP 0"eol Energol Spoton ilobilgeor 0molo
.9 l-cLtl Re<r;eeta {or DIN St517 86 4m GR-XP 460 EP 160 631 oit 160 =E
!r3
n
2 l:ry1 VrEco6lly da! IS0 VG 4m DIN 5l5tg to
0r=
Llbricoths greo6. KP Encrgraooe Boooo^ Hoblux o=
/-\ for DIN 51825 EP2 EP2 CE
/z r\ Re<peete
rtct-croE6 2 DIN 5AA
t+tP 2 LS.EP 2 Greoeo R2
!T
!r- 15'

.e
E
A\
/oo
Lov viscoBily 9r€oo. G
Reqrgete for DIN
r{6l-croc6 m orN 5a€
:t !,
oo
xj
Geor oil PG 0.ed Synlheso tlobil
R6+]osl6 for DIN es 2n sG-XP 220 GH&220 Glygoylg 30 s 220
viBco6iry cro.. lso vG 2m DIN 5l5ls

Geo oi PG Desol Enersyn Hobrl Ttvelo

c Recp.ete for DIN 65 460 s6-xP 460 Glygoylo 88 s460
.9 VlEcoBity cloce ISD VG 160 DIN 51519

-f Lo, vlscostty 9€o.r G Fli€Bfelt. Hobll

Reqrsl.s lor DIN s 420 6lygoy16
n NlGl-chca 0E DIN 5l8ts G.e6e B0
.t
c
 Operating lnstructions RB3/RBs 6

Pr:izisions-S.hlellmas.hhsn
6.2
Pa 72 oI76

6.2 Pneumatic chart. workDiece clamDinq

tr
2 Preasure Pressure input max. '10 bar Oil capacity 0.045 Liter
adjuslment Operating range min / max. 2.5/5 bar Hydraulic oil DIN 51524 ISO VS 32
Tension Pulling force 200 daN at 3 bar Metering '1 drop /'10 strokes

rffitr
IL
J
L
E il

tri 'L Ja
Item o'tv Designation/Remarks Type Manufacture
,|
1 el. swilch-on valve 172 956 HEE-D-MtNt-24 Festo
2 1 Combination maintenance unit 185 804 FRC-1/8-D-MtN|-KB-A Festo
3 2 5/2-way valve 196 939 CPE14-Ml BH-sJ-1/8 Festo
4 2 Compressed air cylinder Gdckel

5 I Throttle silencer 10 351 GRE-'I/8 Festo

 Parts list RB3 7

PrAzlsloB-Schlsilma*hinen
7.1
Paoe 73 of 76

7.1 Tools and Accessories

Q1v. Desionation TvDe - Dimensions - Model
1 Square Allen wrench DSV3sB SW8 DIN 31 ,I2
1 ClamDino Din R2-26E'11
4 Pressure Dlate G70-26E2
'l Double open-end wrench sw 10/13 DtN 3110
1 Double open-end wrench sw 17119 DIN 3110
1 Double oDen-end wrench sw 24130 DtN 3110
I Hex. speed wrench SW 6 DIN 911
1 Hex. speed wrench SW 8 DIN 911
1 Hex. soeed wrench SW 14 DIN 911
 Parts List R83 7
7.2
Praizisions-Schlellmaschinon
e 74 von 76

7.2 Lateral SuoDort Parts

Q'tv. Desionation TvDe - Dimensions - Model
2 Roll quides R1845 203 4'l / 850mm
4 Roller carriaoe R1824 223 66
1 Ball screw RB3-13C2
1 Axial/radial bearinq ZARF 1762 TN
I Grooved nut AM17 M'17x1
I Deeo qrooved ball bearino 6203-2RS 1714Ox12
I Sorino oin couolino WK_FS 40 15F/t14Ft
I Three-phase, synchronous motor DS 45135-SRS-50
without qroove for Woodruff key Mn= 3.2 Nm: n=3000 rom
2 Round buffer 30'18 027-1 1MN60
2 Bellows RB3-'1283
1 Series position switch BES 816-B-03-PA-12-602-1 1

7.2 Replacement Parts. Lonqitudinal Support

Q'ty Desiqnation TvDe - Dimensions - Model
2 Roll ouides Rl845 203 41 / 970mm
4 Roller caniaqe R1824 223 66
I Ball screw RB3-13C2
1 Axial radial bearino ZARF 1762 TN
I Grooved nut AM17 lM17x1
I Deep qrooved ball bearinq 6203-2RS 1714Ox12
1 Sorinq web couolino WK-FS 40
1 Three-phase, synchronous motor DS 45135-SRS-50
without qroove for Woodruff kev Mo= 3,2 Nm; n=3000 rpm
2 Round buffer 3018 027-11MN60
1 Bellows RB3-1387
1 Series position switch BES 81 6-B-03-PA-1 2-602-'t 1

7.2 Grindinq Soindle Parts

Qtv. Desiqnation Tvoe - Dimensions - l\4odel
1 Motor spindle MSP 80.450-2,2 kW / 3000 rpm
Frequency regulation up to max. 6000
rDm
2 Clampinq lever with female thread GN300-92-M12-SW
 Parts List RB3 7
7.2
Piezislons-SchlellmaschinRn
Paqe 75 von 76

7.5 Parts for Tool Soindle / r,ro

Q'ty Desiqnation Tvoe/Dimensions
1 Radial shaft sealinq rino 50-65-8 BA-72NBR DtN 3760
1 Axial anoular ball bearino dia.40/75x34.2RS ZKLN 4075.2RS
1 Deeo-qrooved ball bearinq dia.40/68x'15 6008-2RS
1 Anqular ball bearinq dia.15l42x19 3302-2RS
1 Slotted nut N4'15x1 ZM 15
1 Slotted nut M35x1.5 ZMA 35/58
1 Toothed belt pulley with TL PL-72-8M-20 with hole, dia. 30H7
socket
I Toothed belt 720-8M-20
1 Toothed belt pulley with TL PL-22-aM-20 with hole dia.19H7
sockel
1 Three-phase motor 1LA7080-4M12i 230V / 50Hz
P= 0,55 kW; n= 1500 min-1
version 814lC120, size 80
1 Blade shaft RB3-15D8
1 Connectinq rod RB3-15E21
1 Piston RB3-15E22
1 O-rino '102x4 70NBR
2 O-rino 60x3 70NBR
I O-rinq 115x2,5 NBR70

7.2 Replacement Parts. Coolinq Water Device

Qlv Desiqnation Tvoe- Dimensions - Model
PaDer striD filter PFA '120-S

1 Three-phase motor 5 IK 4OGN-A

1 Planetarv oear 5 GN 180
I Chain transport belt
1 Paper lilter 71 cm/ 100 m vs 387 / 50
1 Float

1 lmmersion pumD TB63/270

1 lmmersion oumo r8251270
4 Hose Truflex 54.09 22l29mm
7 Hose clamp Nt.2 % 22-32mm
2 Ball cock R%
I Screw-in nipple %-R%"
() Counter piece R%'
() Round nozzle. I mm R%
 Parts List RB3 7
7.2
Prezisiom-Schlellnas.hinsn
e 76 von 76

7.2 Replacement part. central lubrication

o'ty Desiqnation TvDe - Dimensions - lvodel
^1 Compact unit tvKUl -KW2-'l 0004-230V
12 Meterinq unit 321 403 G4

7.2 Grindino Tool Parts

Q'tv. Desiqnation Tvoe- Dimensions - Model
1 Grindingwheelflange RB3-22E1 Single wheel flange 5'l
ClamDinq ranoe -32mm
2 Grindingwheelflange RB3-22E2 Double wheelflange 51
Clampinq ranqe -52mm
1 SDacer Dlate 51/80x4 RB3-22E3
1 Soacer Dlate 51/80x8 RB3-22E4
I Spacer plate 51/80x12 RB3-22E5
1 Soacer plate 5'l/80x16 RB3-22E6
1 Bolt R6-24E100
1 Threaded rinq R4-24E62

7.2 Reolacement Parts. Housinq

o'ty Desiqnation Tvoe - Dimensions- Model
2 Bellows RB3-2484
,|
Wioer RB3-24E6
2 Roller R5-24E249
1 Glass plate RB3-24E14
1 Bail handle GN 426.1-AL-20-200-SM
1 Slide oack with cover 2 FBW501'loRGUU +'13551
3 Door seal 209-O12O m lono
6 Profile hinqe 242-9001 with cover sleeve
3 Door lock GN 116-VDE-A5
,I1g-VDE-Al
I Door lock GN

7.2 Replacement Parts, Electrical Equipment

Q',ty Desionation Tvpe - Dimensions- Model
1 Foot button FAK-RT/KC,I1lI
1 Foot button FAK-SWKC11/I
1 Protected lamD 1 1 1 440 000-RL70CE-124124Vd9

7.2 Replacement Parts. Dressino Device

Q\Y Desiqnation Type - Dimensions - Model
1 Dressinq diamond MKo 0.5 carat
1 dressinq steel R5-27E63
1 clamDinq lever GN 300-45-M6-SW