☞ This is the 7435th article published by Metal Processing (mw1950pub).
How to Become a Machine Tool Maintenance Expert?
Share the key points of basic maintenance skills, explain the techniques for disassembling and assembling electromechanical components in detail, gather market-leading system maintenance examples, and provide innovative advanced instances of CNC machine maintenance.
Beginners learn theory and use experience, intermediate learners borrow cases and use methods, and comprehensive learners implement transformation and design, achieving a step-by-step self-learning growth from “theoretical armament → practical training → innovative enhancement”.
Includes Videos:
2 DVDs with video explanations for more intuitive learning; share the key points of maintenance skills; detail practical techniques for disassembling and assembling electromechanical components; gather highlights of market-leading system maintenance examples; analyze innovative advanced instances of CNC machine maintenance.
This book is based on three modular maintenance methods—electrical signal deduction method, working medium flow direction method, and mechanical action coupling method—illustrating typical fault cases of modern CNC machines and comprehensive electromechanical application examples, quickly eliminating electrical faults in CNC systems, spindle drives, servo drives, and auxiliary devices (hydraulic, lubrication, cooling, chip removal, tool changing), as well as mechanical faults in spindle components, feeding components, and auxiliary devices, rapidly growing into a maintenance expert for CNC machines!
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This book is divided into 6 chapters. Chapter 1 covers safety operations and maintenance key points for CNC machines, Chapter 2 covers practical operations of tools and measuring instruments for CNC maintenance, Chapter 3 covers practical operations of instruments and meters for CNC maintenance, Chapter 4 covers practical disassembly and assembly of electromechanical components in CNC machines, Chapter 5 provides detailed analysis of typical cases in CNC machine maintenance, and Chapter 6 offers a comprehensive application explanation for advanced maintenance engineers.
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Contents:
Preface
Chapter 1 Safety Operations and Maintenance Key Points for CNC Machines 1
1.1 Safety Operation Key Points for Maintenance Fitters 1
1.2 Safety Operation Key Points for Maintenance Electricians 4
1.3 Four-Step Completion Method Operation Key Points 4
1.4 Key Points for Implementing Diagnostic Analysis Methods 5
1.5 Emergency Rescue Operation Key Points for Electric Shock on Site 13
Chapter 2 Practical Operations of Tools and Measuring Instruments for CNC Maintenance 18
2.1 Detailed Practical Operations of Steel Rulers, Calipers, and Feeler Gauges 18
2.1.1 Illustrated Correct Use of Steel Ruler Length Measurement 18
2.1.2 Common Errors in Adjusting and Measuring with Calipers 18
2.1.3 Techniques for Measuring Machine Joint Surface Gaps with Feeler Gauges 20
2.2 Detailed Practical Operations of Vernier Calipers 21
2.2.1 Measurement Techniques and Reading for Five Types of Vernier Calipers 21
2.2.2 Measurement and Marking Key Points for Vernier Height Gauges 26
2.2.3 Techniques for Measuring Step Depth with Vernier Depth Gauges 27
2.2.4 Techniques for Measuring Part Tooth Thickness with Vernier Calipers 28
2.3 Detailed Practical Operations of Micrometers 29
2.3.1 Reading and Measurement Techniques for External Micrometers 29
2.3.2 Measurement Operation Key Points for Lever Micrometers 32
2.3.3 Techniques for Measuring Hole Diameters with Two-Point Internal Micrometers 34
2.3.4 Techniques for Measuring Internal Dimensions with Three Types of Internal Micrometers 34
2.3.5 Correct Measurement Techniques for Three-Jaw Internal Micrometers 35
2.3.6 Detailed Analysis of Measuring Standard Length with Public Line Micrometers 35
2.3.7 Detailed Analysis of Checking Thread Middle Diameter with Odd Groove Micrometers 38
2.3.8 Usage Techniques for Electronic Depth Micrometers 40
2.4 Detailed Practical Operations of Gauge Blocks and Their Accessories 41
2.4.1 Structure and Operation Key Points of Gauge Blocks (Length) 41
2.4.2 Selection Techniques for Complete Gauge Blocks and Their Accessories 42
2.5 Detailed Practical Operations of Indicating Instruments 43
2.5.1 Detailed Analysis of Correct Measurement Techniques for Dial Indicators 43
2.5.2 Detailed Analysis of Measurement Techniques for Lever Indicators 47
2.5.3 Measurement and Maintenance Techniques for Internal Dial Indicators 50
2.6 Detailed Practical Operations of Angle Measuring Instruments 52
2.6.1 Reading and Measurement Techniques for Universal Angle Gauges 52
2.6.2 The Role of Center Gauges 55
2.7 Detailed Practical Operations of Level Instruments 56
2.7.1 Key Points for Measuring Levelness with Strip Levels 57
2.7.2 Reading and Measurement Techniques for Frame Levels 57
2.7.3 Correct Usage Key Points for Coincidence Levels 60
2.7.4 Detailed Analysis of Measurement Techniques for Electronic Levels 61
Chapter 3 Practical Operations of Instruments and Meters for CNC Maintenance 63
3.1 Detailed Practical Operations of Two Types of Multimeters 63
3.1.1 Measurement Techniques for Analog Multimeters 63
3.1.2 Measurement Techniques for Digital Multimeters 67
3.2 Measurement Techniques for AC/DC Current with Clamp Meters 69
3.3 Selection and Usage Techniques for Two Types of Insulation Resistance Meters 71
3.4 Measurement Operation Techniques for Three Types of Ground Resistance Meters 76
3.5 Detailed Practical Operations of Oscilloscopes and Probes 82
3.5.1 Selection Techniques for Oscilloscope Probes 82
3.5.2 Detailed Practical Operations of Oscilloscope Measurements 87
3.5.3 Selection and Maintenance Techniques for Oscilloscopes 92
Chapter 4 Practical Disassembly and Assembly of Electromechanical Components in CNC Machines 96
4.1 Disassembly and Assembly of Spindle Parts 96
4.1.1 Key Points for Disassembling Spindle Parts 96
4.1.2 Techniques for Assembling Spindle Parts 98
4.2 Knowing Axial Movement and Backlash of Screw Assemblies 104
4.2.1 Measurement and Adjustment of Axial Movement of Screw Assemblies 104
4.2.2 Measurement and Adjustment of Backlash in Screw Assemblies 104
4.3 Key Points for Component Mapping and Drawings during Maintenance 106
4.4 Detailed Analysis of Disassembly and Assembly of FANUC CNC System Hardware 109
4.4.1 Key Points for Component Replacement and Data Ghosting 109
4.4.2 Techniques for Replacing Axis Control Cards 112
4.4.3 Techniques for Replacing Storage Cards 113
4.4.4 Techniques for Replacing System Motherboards 114
4.4.5 Techniques for Replacing System Batteries 115
4.4.6 Techniques for Replacing System Fans 115
4.5 Detailed Analysis of Disassembly and Assembly of SINUMERIK CNC System Hardware 117
4.5.1 Techniques for Replacing NCU Modules in 840D Systems 117
4.5.2 Techniques for Replacing PCU Components in 840D Systems 120
4.5.3 Techniques for Replacing Machine Panel Knobs and Switches 123
4.6 Detailed Analysis of Disassembly and Assembly of LGMazak CNC System Hardware 124
4.6.1 Detailed Explanation of Motherboard Replacement and Data Ghosting 124
4.6.2 Techniques for Replacing Cooling Fans in NC Systems 130
4.6.3 Techniques for Replacing LCD Screens 130
4.7 Detailed Explanation of Replacing Encoders in Mazak Systems 131
4.8 Detailed Explanation of Installing the 4th Axis in VTC Models 133
4.9 Detailed Explanation of Setting the Origin for Mazak Tool Towers/Stores 137
4.10 Detailed Explanation of On-Site Assembly and Adjustment of Entire Units 141
Chapter 5 Detailed Analysis of Typical Cases in CNC Machine Maintenance 145
5.1 Detailed Analysis of FANUC Series Machine Maintenance Cases 145
5.1.1 FANUC 0i-TB Horizontal Lathe Irregular Knife Jamming Causing Workpiece Scrapping 145
5.1.2 FANUC 0i-TD Vertical Lathe Level Switch Fault Leading to 2050 Alarm 147
5.1.3 FANUC 0i-TD Horizontal Lathe Hydraulic Tailstock Clamping Failure 147
5.1.4 FANUC 0i Vertical Lathe Spindle Precise Stop Solving Drop Material Interference Issues 154
5.1.5 FANUC Horizontal Lathe External Thread Cutting Issues and Solutions 158
5.1.6 FANUC 0i Series Machine Reference Point Irregular Drift Handling 161
5.1.7 FANUC 0i-TC Grinding Machine Alarms ER32 and ER97 after Power On 167
5.1.8 FANUC 0i-MC Machining Center Abnormal Cutting Fluid Supply 169
5.1.9 FANUC 0i Mate TD Shaving Machine CNC System Restarting and Alarming 172
5.1.10 FANUC 0i Mate MD Gear Hobbing Machine Reference Point Failure Leading to Collision 175
5.1.11 FANUC 0i-MD Gear Hobbing Machine SV0411 and SV0436 Alarms 177
5.1.12 FANUC AC Servo Motor Structure and Fault Handling 180
5.1.13 FANUC Intelligent Robot Stacking Alarm and Zero Reset 184
5.1.14 Elimination and Optimization Control of “S” Marks in Type B Axle Grinding 186
5.1.15 Faults and Quick Diagnosis of CNC Machine Handheld Pulse Generators 189
5.2 Detailed Analysis of Siemens Series Machine Maintenance Cases 199
5.2.1 SINUMERIK 802D Boring and Milling Machine Hydraulic Oil Temperature Rise Causing Y Axis Vibration 199
5.2.2 SINUMERIK 802Dsl Gear Hobbing Machine Reference Point X Axis Not Moving 201
5.2.3 SINUMERIK 840D Grinding Machine X Axis Severe Vibration Causing Product Wrinkles 202
5.2.4 SINUMERIK 840D System Profile Monitoring 25050 Alarm 205
5.2.5 Oerlikon Gear Cutting Machine SINUMERIK 840Dpl System Loading Failure 207
5.2.6 Oerlikon B27 Grinding Center Blade Clamping Unit Abnormal Alarm 210
5.2.7 Oerlikon Gear Cutting Machine Rittal Cooling Device Refrigerant Leakage 211
5.2.8 SIMODRIVE 611D Power Module Diagnostics and Fault Elimination 214
5.2.9 SIMODRIVE 611D Power Module Monitoring and Fault Detection 217
5.2.10 SINAMICS S120 Drive Optimization and Fault Elimination 218
5.3 Detailed Analysis of Flexible Manufacturing Line Maintenance Cases 226
5.3.1 Step7 PLC Variable Table Modification for Arm Robot Positioning 226
5.3.2 Arm Robot Frequently Damaging Machine Door in Flexible Manufacturing Line 229
5.3.3 Flexible Manufacturing Line Automatic Operation Loop Interruption Abnormal Exit 232
5.3.4 FANUC 0i-TD Vertical Lathe Frequent Stops in Flexible Manufacturing Line 232
5.3.5 Intelligent Robot Unloading Occasionally Overlapping in Flexible Manufacturing Line 234
5.4 LGMazak QT Series Lathe Electric Grease Pump Low-Pressure Alarm 238
5.5 Omron PLC Short Circuit Causing Hydraulic Pump Start-Stop 244
5.6 Failure Analysis and Corrective Measures for Spindle Rolling Bearings 247
5.7 Analysis and Handling of Abnormal Operation of Single Machine Chip Removal Devices 259
5.8 Common Faults and Handling Measures of Linear Grating Detection Devices 264
5.9 Switching Between Multi-Line Proximity Switches and Two-Line Proximity Switches 267
Chapter 6 Detailed Explanation of Comprehensive Applications for Advanced Maintenance Engineers 271
6.1 Troubleshooting Unstable Processing Dimensions in CNC Machines 271
6.2 Shielding and Activation of Linear Grating Scales 274
6.3 Modification of Imported Forming CNC Grinding Machine Trimming Mechanism 277
6.4 Design of Drill and Tap Fixtures for Bevel Gears 282
6.5 FANUC System Macro Program Protection Password Operations 287
6.5.1 CNC Parameter Setting Program Protection Password 287
6.5.2 Macrohelper Obtaining Protection Password 288
6.5.3 Window Function Compiling Ladder Diagrams to Obtain Protection Password 290
6.6 Open FANUC System Disk Data Ghosting 295
6.7 FANUC 0i-TD Horizontal Lathe Robot Intelligent Expansion 300
6.8 SINUMERIK 802Dsl Gear Hobbing Machine Robot Intelligent Expansion 309
6.9 Mazak Machine Hard Disk Data Backup and Recovery 317
Appendix Abbreviations 321
References 325
Related Books:
This book consists of 6 chapters, mainly introducing the composition and characteristics of CNC machines, key technologies for modifying CNC machine control systems, servo systems, auxiliary control systems, hydraulic systems, and mechanical structures, common issues and precautions in CNC machine modification, focusing on the debugging knowledge for applications using Siemens 840D/840Dsl/802D/828D and FANUC 0i control systems, sharing 40 on-site debugging experiences of CNC machines, and explaining 20 classic CNC machine modification case analyses, summarizing the core technology content discussed in previous chapters to deepen readers’ understanding.
This book emphasizes materials focused on new Siemens and FANUC CNC systems, distilling the scattered content from various manufacturers’ manuals, with debugging and technical modification application examples sourced from engineering practice. This book is a practical, accessible, and advanced resource suitable for designers, maintenance personnel, engineering debugging personnel in CNC system applications, as well as engineering technicians with a certain electrical technology foundation.
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