QC YK7380 Vertical CNC Profile/Form Gear Grinding Machine

 The QC American #YK7380 is a world-class, high-precision external form grinding machine with 800mm (32”) capacity utilized for all manner of gears with face widths up to 550,0mm  (22”).   The  #7380 Features  on-board wheel  dressing, a  PC-Based NUM  Axium  Power 1050 Total  Numerical  Control  conversational  control  system, on-board inspection measurement  with printing capability and a  large, flexible grinding area.   The  #7380 can compete  with the  best  form  grinding machines available on the market today in speed and accuracy.   A somewhat close cousin to the venerable #7332 and #7340 series horizontal machines, the #7380 is a vertically oriented entry-level machine with a flexible rotary table configuration suitable for a wide  variety of  different  workpieces  and any number of  workholding systems.  Starting with a clean sheet of paper, QC has enhanced the proven vertical form gear grinder design approach with a  simple  and rugged, yet  accurate  approach made  to world standards  using the  best  available  components.   With a  20KW  (27 HP) grinding spindle, hydrostatic ways and enclosures designed to be loaded via overhead cranes, there are just shy of 100 #7380’s operating around the world as you read this.  

 The working principle of this machine is form grinding.   The profile of the grinding wheel  is  modified via  on an on-board wheel  dressing system  and software  package designed with a graphical interface to simplify complex profiling requirements.    
Main Characteristics
·   Compact machine design featuring a ribbed, one-piece cast iron bed.
·   Column, carriage and workpiece table utilize a constant flow hydrostatic  guideway system.
·   Ergonomic  design  with  complete  machine  access  from the  ground  floor  and through a well designed and completely lit enclosure.
·   Flexible  workholding area to accommodate  all  manner  of customer  workpieces up to 1200,0mm in height (47.24”).
·   The on-board automatic dressing cycle of the grinding wheel improves the  uptime  and  efficiency of this  machine  tool.    Using customized  QC  Software with a conversational format, profiles of the grinding wheel are easily modified.
·   NUM (Swiss Made – USA Serviced) 1050H PC Based CNC control with  eight (8) axes of control.
·   Integrated  Schmitt Industries  (SBS  –  USA) dynamic  grinding wheel  balancing system for greater control of the grinding and dressing process.
·   The  special  Human  Machine  Interface  (HMI) was  developed  by QC  according to the  working characteristics  of North  American  gear  processing.   Based  on  a conversational  programming protocol,
programming is  simplified  by entering work  piece  parameters  and  relevant technical parameters as called out by the operator. 
 1.    Base Machine
1.1   Assembly Groups
·   Machine  Base  of  a ribbed cast  iron design;  carries  the  column,  rotary table and outer column. Installation on leveling/vibration isolation pads.
·   Column made of cast iron with constant flow hydrostatic guide ways. Radial infeed using precision ball screw, powered directly by an AC servo motor.
·   Rotary table  with constant  flow  hydrostatic  bearing. Driven  by AC servo motor through backlash free worm wheel.
·   Stroke  slide  with constant  flow  hydrostatic  guide  ways. Stroke  motion through precision ball screw, powered directly by an AC servo motor.
·   Grinding slide with tangential movement using precision ball screw, powered directly by an AC servo motor.
·   Grinding spindle is a direct drive high-speed spindle.
·   CNC dressing device  is a stationary unit  for dressing grinding wheels  with dressing spindle  and diamond dressing wheels.   The  dressing paths  are generated by the vertical and the tangential grinding slide movement.
 ·   Outer  column    for clamping pinions  between centers. Tailstock height
adjusted through a screw and nut assembly.
 
1.2   Electrical Equipment
1.2.1   Power Supply
Operating voltage is 460/480 Volt/3Phase/60Hz.
 
1.2.2   Operator  Interface  Features:  NUM  Power  1050
Axium CNC Control
·   Operator station with TFT color flat screen and control panel in front of the control cabinet. Integrated keyboard with a team of horizontal and vertical soft keys.
·   Hand-held operating panel for more convenient set-up of the machine.
·   The  machining program  uses  standard CNC conversational  programming language  fully developed by QC, and the  interface  program  uses  NUM standard MMI TOOL software.
·   Swiss-owned NUM is serviced out of Naperville, IL.   QC American provides front-line service regardless.
Control Interface Features
·   Windows XP Professional Operating System
·   586MB Pentium processor
·   30GB hard drive
·   128M RAM
·   56K modem
·   Two USB Ports for archiving user and machine data.
·   3.5” floppy drive.
·   Parallel interface for connecting a printer.
·   Serial interface for common use.
·   Ethernet interface. 
Service Functions
·   Integrated modem  and ethernet  ports  for remote  diagnostics  connection between QC computers.
·   Graphical display of processing data.
1.0     Software for PC Based NUM Axium Power 1050H Control
This QC Developed software package enables the user to generate, edit and optimize grinding programs and analyze processing data on the PC on the machine or a remote PC. The software interface is identical with the machine control menu and may even be used for rudimentary training purposes. 
·   Gear  parameters  calculation  module  –  Input and  storage  of workpiece  data.    This  module  consists  of  a  conversational  interface  for geometrical  parameter  data  entry, technical  parameters  and measuring parameters  to facilitate  computing of  standard gears, gears  with addendum  modification, modified spur (helical) cylindrical gears.   Basic work piece data is recorded  into a database for later editing or processing.

 ·   Profile  computing module  for  grinding wheel  –  Profile  and  Lead
modification.  This  module  serves  to gather data  in order to generate  the correct  wheel  profile  through an editable  series  of  dressing cycles  using the on-board dressing wheel system.   Based on data entered about the workpiece and special  requirements  on gears  to be  machined;  including profile, lead modification and fillet curve parameters, the profile of the grinding wheel can be automatically computed to meet the task at hand.




 ·   Conversational  Control  Design.    The G code will be automatically created based on the gear processing and grinding parameters entered by the user.   In addition, the  customers  can even directly use  and upload straight  G  code  if desired.
·   Customer can add specific modifications to suit their applications.  
1.5 Axis Information
Eight (8) CNC Controlled-Axes
·   ‘X’-Axis.   Radial  (feed) movement  of  the  column.  Constant  Flow Hydrostatic Guideway.    AC Servo motor with precision ball screw.
·   ‘Z’-Axis.   Axial  (vertical)  movement  of  the  grinding stroke  slide.  Constant Flow Hydrostatic Guideway.    AC Servo motor with precision ball screw.
·   ‘Y’-Axis.   Tangential  (horizontal) movement  of  the  grinding slide. Schneeberger Needle Type Linear guideway.    AC Servo motor with precision ball screw.
·   ‘A’-Axis.   Rotary movement  of  grinding wheel  head for grinding helix angles.    Rotary positioning encoder – Heidenhain.
·   ‘C’-Axis.   Indexing and rotary movement  of  the  rotary table.    Constant Flow Hydrostatic Guideway.    Heidenhain +/-0,001mm Resolution.
·   ‘W’-Axis.   Dressing axis  of  grinding wheel.    Schneeberger Needle-Type Linear guideway.
·   ‘S1’-axis.    Rotation of grinding wheel.
·   ‘S2’-axis.   Rotation of diamond dressing wheel.
 
All CNC axes utilize closed-loop controls. The positioning feedback devices of each axis utilize HEIDENHAIN high precision encoders and scales.  

 

1.6   On-Board, Integrated Measuring System (Option)

The  machine  can  be equipped  with  a Renishaw  measuring  system on-board the  machine.  Including the #LP-2 measuring probe, cables, adapter card and a QC software integration module. It is very easy to connect with your printer through one of the USB ports on the control. You can store  or  print  measurement  reports  at  any  time.  Based  on  the  measuring  data,  the  on-board inspection system can draw out a diagram of profile, lead，pitch, cumulative pitch of gear tooth and print and/or store the measuring data to allow for analysis of the previous grind cycle’s effect on the workpiece. The program can automatically analyze and judge the measuring results, correct the machine parameters and the profile data of the grinding wheel.    
 
This  system  has  long  been  perfected  on  the  #YK7380  &  #YK73125  machines.   There  is  an electrically operated moveable arm carrying the measuring probe. The arm automatically rotates as the machine moves to the measuring position, which is located close to the grinding wheel.   See picture, on page 1.
 
2.0    Peripherals
 
2.1     Hydraulics/Lubrication
Complete hydraulic system for lubrication, clamping, and tailstock stroke.
2.2     Hydrostatic System
Complete constant flow hydrostatic system for ‘X’, ‘Z’ and ‘C’ Axes.
2.3    Coolant Filtration System
 The  coolant  filtration system  cleans  used coolant  using paper filtration media  and includes the following:
·   Temperature controlled for grinding fluid utilizing a chiller–type oil cooler.
·   Filter capacity=120L/min.  
·   Multiple  circuit  coolant  chilling  equipment:  With automatic  temperature regulation for cooling oil.
·   Oil mist recovery and electrostatic air filter system.
 
3.0     Standard Machine Accessories

 4.0     Machine Color
Machine and peripheral units: Blue
Doors: White
 4.1     P For controlled retreat of the machine into a safety parking position in case of a power
outage to protect workpiece and tools.ower-off Protection System 
 4.2     Operator Training at Customer Facility
Our program  is  designed to prepare  your operators  to begin operating the  machine directly before  or after final  acceptance  at  your facility.
5.0 Special Accessories (Options)


6.0 Machine Warranty
 A warranty period of 12 months on entire machine and accessories from time of final acceptance or 5,000 hours of use – whichever occurs first.    An extended warranty is available per further negotiation(s). 
7.0     Spare Parts Warranty
Spare  Parts  availability is  guaranteed for 10 years  from  the  date  of  machine commissioning with deliveries under current market conditions.