1 Control of IBAG-Periphery

1.1 Introductions

This manual is designed for programmers and designer who should set up an IBAG spindle.
It contents informations how control und supervision should be realised. It does not content any
informations about maintenance or using of the spindle unit. The programmer/designer has to
know the local laws and rules for using HSC-spindles and he is responsible to convert those
rules into the real application. It is machine-tool-builders obligation to make a risk-analysis for
the machine tool together with an IBAG-spindle and to realize the safety-modification
necessary. IBAG does not take any responsibility in case of damage or accidents caused by
wrong using of the spindle or of its periphery. In case of any question do not hesitate to contact
our service department.

1.2 Lubrication

This chapter is not important if your spindle has grease-lubrication (Option P).

1.2.1 Design of lubrication

The dosage-unit can be connected directly to the oil-system, if you have a single-spindle unit. If
there is more than one spindle running on the same lubrication-system, the lubrication has to be
switchable for every single spindle. Put valves between the oil- and the air tubes. After each
valve has to be put a pressure-switch to supervise the function of the valves. Make sure, the
valve you are going to use is allowed for the working-pressure. Sometimes are air-valves with
sep. pre-control necessary.

1.2.2 Control of lubrication-system (IBAG-Amolub)

Pre-lubrication

The lubrication should run for 2 [min] after switch-on of the machine to make sure, the oil has
reached the spindle oil-entry. The valves, if there are any in the oil- and air-tubes, has to be
switched on during pre-lubrication. Oil and air supplied to the spindle has to be switched at the
same time!!

Lubrication, if spindle is running

The spindle has to be lubricated, if the spindle is running. Switch the lubrication-system, oil- and
air valve on while the spindle is not in standstill.

Supervision of air pressure of lubrication

The air pressure is normally monitored at the air-filter-unit, or if there is a valve between air-unit
and spindle, after the valve. It is recommended generally to put the air-pressure-switch as close
as possible to the spindle. If there are feed-trough or other critical parts, the pressure-switch has
to be mounted after those components.

Shut off of lubrication after spindle stop

The lubrication has to be kept on for another 3 [min] after the spindle has been stopped (speed
zero). If the spindle has not been started during this time, the lubrication can be switched off.
The lubrication needs to be switched on immediately when the spindle has been started again.

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 Monitoring of oil-pressure of lubrication

The IBAG Amolub-system consist internal oil-pressure supervision. For single-spindle-

application is this supervision sufficient. Are there valves in the oil-tubes, an oil-pressure-switch
has to be mounted after the valve. If the oil-system is powered on, it delivers every 3 [min] a
lubrication impulse of approx. 7-12 [s]. The monitoring must be able to detect losses of
lubrication impulses. The pressure-switch should be set to approx. 18 [bar].

Supervision of lubrication-system

The IBAG Amolub-system does have internal pressure- and oil-level supervision. If this signal
disappears, the spindle has to be stopped immediately.

1.3 Supervision of cooling-system

The cooling-system must make sure, the spindle is supplied with cooling-water with a
temperature between 25 [C] and 28 [C]. There are normally flow-switch mounted in the return-
tube of the cooling-system, to be sure, the spindle is supplied with water. An additional
supervision for over temperature, set to 35 [C] is recommendable. Other supervision are
allowed, if they can make sure, the spindle is cooled enough.

1.4 Air-Conditioning of switch-cabinet

All electrical components, which are not mounted in the spindle, are built for an environment-
temperature between 15 and 40 [C]. Switch cabinet has to be cooled, if necessary.

1.5 Control of tool-changer

Tool-change is allowed in standstill only. Use the signal speed zero from the drive to make
sure, the spindle is in standstill. Make some additional delay of 1..2 [s] after getting the
frequency zero-command from an open-loop-converter to be sure, the spindle is really in
standstill. It is recommendable to interlock the tool-changer if the drive has tripped because
some drive do not provide the right signal if they have tripped. If the tool change is active, the
start-signal has to be locked to be sure, the spindle cannot be started.

Mount a 5/2-way or 4/2-way-valve to the TI/TO-tubes on pneumatic tool changer to switch them,
where the pressure-less tubes is ventilated.

The TI-connection on hydraulic tool changers (option H) can be pressured permanently with
6 [bar]. The tool can be released by hydraulic pressure. Youll find the necessary releasing-
pressure in the datasheet provided with the spindle. Make sure, that the oil can flow back into
the tank without any considerable resistance in the tubes, if the tool changer is not pressured.

Before you start the spindle the first time, make sure, the rotor shaft is rotating free without any
resistance. If something is making any resistance, please check the lines TI and TO again.

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1.6 ATC-Sensors

The ATC-sensors check the position of the drawbar.

PI TI TO NT --> Sensors in spindle

0 0 0 0 Undefined, maybe cable unplugged Start not allowed

1 0 1 0 Tool unclamped Start not allowed
x 0 1 1 Undefined, maybe short-circuit Start not allowed
0 1 0 0 Tool clamped Start allowed
0 x 0 1 No tool clamped Start not allowed,
Except for orientation
if n < 500 [1/min]
x 1 1 0 Undefined, maybe short-circuit or Start not allowed
Sensors disadjusted
x 1 1 1 Undefined, maybe short-circuit Start not allowed

x: can be 1 or 0

Remarks:

Those are the standard-signals of IBAG-spindles. On special-version, this signal can vary.
Details can be found in the instruction-manual to the spindle. During tool change, some
undefined conditions can appear. Wait approx. 1 [s] after operation before you check the ATC-
signals to avoid wrong alarm-messages. The signal TI should be delayed for approx. 0.2 [s]
before the spindle is started again, to avoid touching of tool changer-piston on the drawbar. An
add. safety can be installed if a pressure-switch is mounted into the hydraulic-line. The TO-
condition is fulfilled, if the sensor TO and the pressure-switch appear.

1.7 Air pressure-Switch Tool changer

The air pressure-switch for the tool changer is normally mounted on the filter-unit. Set point is
5.5 [bar], even on hydr. spindles.

1.8 Control of sealing-air (AS)

Switch on the sealing-air together with the machine. If the spindle is built in in over-head
position, the AS has to kept on a certain time after switch off of the machine, until no water or
dirt can go into the spindle.

1.9 Air-pressure-switch sealing air (AS)

Air-pressure-switch for the sealing-air is normally mounted on the filter-unit. If a different switch
already monitors a higher pressure, the pressure-switch for the sealing-air is not necessary
anymore.

1.10 Spindle-Start

Spindle-Start is allowed only, if all supervision signalise operation without fault and all safety-
devices are installed and working correctly. The ATC-signal has to be interlocked while the
spindle is running.

Info_Ansteuer_kompo / Ansteuerung Peripherie_e.doc 27.05.09 ; ms