Rotary Axis Unit for MDX-40 ZCL-40 User's Manual Thank you very much for purchasing this product. ➢ To ensure correct and safe usage with a full understanding of this product's performance, please be sure to read through this manual completely and store it in a safe location. ➢ Unauthorized copying or transferral, in whole or in part, of this manual is prohibited. ➢ The contents of this operation manual and the specifications of this product are subject to change without notice.
Contents To Ensure Safe Use ..................................................................................................................... 2 Chapter 1 Introduction ........................................................................................................................ 5 1-1 About This Manual ................................................................................................................................................. 6 1-2 About This Machine .........................
To Ensure Safe Use Improper handling or operation of this machine may result in injury or damage to property. Points which must be observed to prevent such injury or damage are described as follows. About WARNING and WARNING CAUTION Notices Used for instructions intended to alert the user to the risk of death or severe injury should the unit be used improperly. Used for instructions intended to alert the user to the risk of injury or material damage should the unit be used improperly.
To Ensure Safe Use Danger of electrical short, shock, electrocution, or fire WARNING In the event of an abnormal state (such as smoke or sparks, odor or burning or unusual noise), immediately unplug the power cord. Failure to do so may result in fire, electrical shock, or electrocution. Immediately disconnect the power cord and contact your Roland DG Corp. service center. Important Notes on Cutting CAUTION Do not touch the tip of the cutting tool with your fingers. Doing so may result in injury.
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Chapter 1 Introduction 5
1-1 About This Manual This document is the user's manual for the ZCL-40 (rotary axis unit). It describes how to install the rotary axis unit, and how to carry out cutting using the unit. For information on operations such as how to switch the power on and off, how to start the operation-panel screen, and how to start and stop cutting, read the user's manual for the cutting machine.
1-2 About This Machine What You Can Do with This Machine This is a rotary axis unit compatible with the MDX-40. By adding an axis of rotation (A axis) to the MDX-40, it makes it possible to perform four-axis machining operations such as multiple-surface cutting.
1-2 About This Machine Part Names and Functions Rotary axis unit Chuck-tightening knob Workpiece chuck This is a vise-type workpiece chuck. You turn the chuck-tightening knob to secure the workpiece in place. Angle-adjustment dial This changes the angle of the rotary axis unit. Each tick of the scale corresponds to 15 degrees of tilt. Live center This supports the loaded workpiece. Adjuster lock Core-support adjuster Angle-fixing control This keeps the rotary axis unit immobile at the set angle.
Chapter 2 Preparation 9
2-1 Included Items The following items are included with the machine. Make sure they are all present and accounted for.
2-2 Installing the Rotary Axis Unit Installing the Rotary Axis Unit CAUTION Before you carry out this operation, switch off the power to the cutting machine. Failing to do so may result in sudden movement of the cutting machine, causing the hands or fingers to become caught and resulting in injury. CAUTION When installing the rotary axis unit, be careful not to let it drop or fall. Doing so may result in injury. Procedure ➊ If a tool is installed, then remove it.
2-2 Installing the Rotary Axis Unit Connecting the Connector Attach to the expansion connector on the cutting machine. Expansion connector Attach it securely, so that it will not come loose. Rotary axis unit connector Installing the Z-origin Sensor Install the Z-origin sensor.
2-3 Setting the Y-axis Origin Point for the Center of Rotation Setting the Y-axis Origin Point CAUTION Do not touch the tip of the live center and center drill with your fingers. Doing so may result in injury. To perform cutting using the rotary axis unit, you need to set the Y-axis origin point at the center of rotation. Be sure to make this setting whenever you install or reinstall the rotary axis unit.
2-3 Setting the Y-axis Origin Point for the Center of Rotation 2. Use the live center to secure the sensor. ➊ 2. Turn the handle to extend the end about 5 mm. Mount the live center on the core support. 1. Loosen About 5 mm 3. Insert Core support Live center ➋ Loosen the core-support retaining lever. Move the core support and bring the live center into contact with the small Y-origin sensor. Line up the center hole of sensor and the tip of the live center and install.
2-3 Setting the Y-axis Origin Point for the Center of Rotation ➎ Pass here Run the sensor cable from the back to a location over the table. Insert the sensor cable into the hole on the back of the sensor. Insert Sensor cable 3. Install the Y-origin detection pin. ➊ Collet Insert the Y-origin detection pin into the collet. Y-origin detection pin About 30 mm ➋ Insert the collet and tool from underneath. While supporting the pin to keep if from falling, turn the collet to secure it in place.
2-3 Setting the Y-axis Origin Point for the Center of Rotation 4. Use the operation-panel screen for make the setting for the Y-axis origin point. ➊ Close the front cover. Press the VIEW button to make the VIEW light go out. ➋ Use the operation panel screen to select [Set the Y origin at the center of rotation]. Select [Start Detection]. ➌ Click [Continue]. The Y-origin detection pin automatically makes contact with the sensor. ➍ When the screen appears, open the front cover.
2-3 Setting the Y-axis Origin Point for the Center of Rotation ➏ Open the front cover. Turn the core-support retaining lever to move the core support Core support Core-support retaining lever ➐ Detach the sensor cable and the small Y-origin sensor. 5. Install the large Y-origin sensor. ➊ 1. Loosen 2. Turn Loosen the adjuster lock. Turn the core-support adjuster to extend the end about 5 mm. About 5 mm Core-support adjuster Adjuster lock ➋ Install the large Y-origin sensor on the workpiece chuck.
2-3 Setting the Y-axis Origin Point for the Center of Rotation ➌ Move the core support and bring the live center into contact with the large Y-origin sensor. Tighten the core-support retaining lever. Line up the center hole of sensor and the tip of the live center and install. Core support Core-support retaining lever 2. Tighten completely 1. Turn ➍ Turn the core-support adjuster half a turn. Tighten the adjuster lock completely. Make sure to fasten the sensor securely.
2-3 Setting the Y-axis Origin Point for the Center of Rotation 6. Use the operation-panel screen for make the setting for the Y-axis origin point. ➊ Click [Continue]. The Y-origin detection pin automatically makes contact with the sensor. ➋ When the screen appears, open the front cover. Rotate the spindle half a turn. Spindle Spindle ➌ Close the front cover. Click [Continue].
2-3 Setting the Y-axis Origin Point for the Center of Rotation ➎ ➏ Detach the sensor cable and the large Y-origin sensor. Z-origin sensor ➐ Insert the sensor cable into the Z-origin sensor. Close the front cover. Click [Continue]. The Y-origin detection pin automatically makes contact with the Z-origin sensor.
2-3 Setting the Y-axis Origin Point for the Center of Rotation 7. Detach the Y-origin detection pin, collet, live center. ➊ Open the front cover. ➋ Large wrench (included with the cutting machine) ➌ Detach the Y-origin detection pin, and collet. Small wrench (included with the cutting machine) 2. Turn 1. Loosen 3. Detach Loosen the adjuster lock. Turn the core-support adjuster all the way, then detach the live center.
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Chapter 3 Operation 23
3-1 Getting Ready for Cutting Using the Rotary Axis Dimensions of Workpieces Installable and Start Location Dimensions of Workpieces Installable Example : Loading a Square Block A workpiece that fits within the range of a 42.5 mm radius from the center of the rotary axis by 135 mm long can be loaded. The figure shows the maximum size when loading a workpiece that is 40 mm thick. Workpiece Workpiece Objects that fit within the range of a 42.
3-2 Loading a Workpiece Loading a Workpiece Less Than 120 mm in Length The mounting method varies according to the length of the workpiece you're loading. When you're loading a workpiece measuring less than 120 mm, follow the steps below. 1. Entering the length of the workpiece at the operation panel screen. ➊ Click [Workpiece Length]. ➋ Enter the length of the mounted workpiece. Click [OK]. 2. Carry out the preparations for securing the workpiece in place. ➊ Close the front cover.
3-2 Loading a Workpiece ➍ 2. Turn the handle to extend the end about 5 mm. Mount the center drill on the core support. 1. Loosen About 5 mm 3. Insert Core support Center drill ➎ Loosen the core-support retaining lever. Move the core support and bring the tip of the center drill into contact with the workpiece. Core-support retaining lever ➏ Tighten the core-support retaining lever.
3-2 Loading a Workpiece 3. Drill a hole for retaining the workpiece. ➊ At the operation-panel screen, click [Workpiece Drilling]. ➋ Click [Rotate]. The rotary axis starts to turn. ➌ Turn the core-support adjuster slowly to drill the hole by center drill. Cut in about 3 mm from the blade tip. Core-support adjuster ➍ Click [Stop]. The rotation stops. ➎ Click [Close].
3-2 Loading a Workpiece ➏ Loosen the core-support retaining lever to move the core support. Core support Core-support retaining lever ➐ Center drill Turn the core-support adjuster all the way, then detach the center drill.
3-2 Loading a Workpiece 4. Use the live center to secure the workpiece in place. ➊ 2. Turn the handle to extend the end about 5 mm. Mount the live center on the core support. 1. Loosen About 5 mm 3. Insert Core support Live center ➋ Loosen the core-support retaining lever. Move the core support and bring the live center into contact with the workpiece. Core-support Core-support retaining lever ➌ Tighten the core-support retaining lever. Core-support retaining lever ➍ 2.
3-2 Loading a Workpiece Loading a Workpiece 120 mm or Longer in Length When you're loading a workpiece measuring 120 mm or longer, follow the steps below. 1. Entering the length of the workpiece at the operation panel screen. ➊ Click [Workpiece Length]. ➋ Enter the length of the mounted workpiece. Click [OK]. 2. Carry out the preparations for securing the workpiece in place. ➊ Close the front cover. Press the VIEW button to make the VIEW light go out.
3-2 Loading a Workpiece ➍ Secure the workpiece in place on the workpiece chuck. Fasten the workpiece securely, so that it will not fall. Workpiece chuck Workpiece ➎ Loosen the core-support retaining lever. Move the core support and bring the tip of the center drill into contact with the workpiece.
3-2 Loading a Workpiece 3. Drill a hole for retaining the workpiece. ➊ At the operation-panel screen, click [Workpiece Drilling]. ➋ Click [Rotate]. The rotary axis starts to turn. ➌ Turn the core-support adjuster slowly to drill the hole by center drill. Cut in about 3 mm from the blade tip. Core-support adjuster ➍ Click [Stop]. The rotation stops. ➎ 32 Chapter 3 Operation Click [Close].
3-2 Loading a Workpiece ➏ Loosen the core-support retaining lever to move the core support. Core-support Core-support retaining lever ➐ Detach the workpiece once. ➑ Turn the core-support adjuster all the way, then detach the center drill.
3-2 Loading a Workpiece 4. Use the live center to secure the workpiece in place. ➊ Mount the live center on the core support. 2. Turn the handle to extend the end about 5 mm. 1. Loosen About 5 mm 3. Insert Core support Live center ➋ Loading the workpiece. Core support Core-support retaining lever ➌ Loosen the core-support retaining lever. Move the core support and bring the live center into contact with the workpiece.
3-2 Loading a Workpiece ➎ 2. Tighten completely Adjuster lock 1. Turn Turn the core-support adjuster half a turn. Tighten the adjuster lock completely. Core-support adjuster Securing the Workpiece in Place After securing the workpiece in place using the live center, go to the operation-panel screen and rotate the A axis. If the workpiece and the live center turn together, the workpiece is fastened securely.
3-3 Installing a Tool and Setting the Cutting-start Location Installing a Tool CAUTION Do not touch the tip of the blade with your fingers. Doing so may result in injury. Installing a Tool Follow the instructions in the manual for the cutting machine to install a tool. Adjust the amount of tool extension to match the size of the workpiece and the cutting depth. Special care is needed, because the corners may easily strike the tool when rotating the A axis. Setting the Cutting-start Location 1.
3-3 Installing a Tool and Setting the Cutting-start Location 2. Make the setting for Z origin point. ➊ Make sure to insert the sensor cable to Z-origin sensor. ➋ ➌ Using the operation panel screen, select [Set the Z origin at the center of rotation]. Select [Start Detection]. Click [Continue]. The tool automatically makes contact with the sensor, and the Z-axis origin point is set. 3. Make the setting for A origin point.
3-4 Changing the Angle of Cutting ➊ If the cutter installed, detach it. ➋ Loosen the screws shown in the figure. Hexagonal wrench ➌ Large hexagonal driver (included with the cutting machine) ➍ Detach the screw shown in the figure. Pull the angle-fixing control. Turn to a position not lined up with the groove. Groove Angle-fixing control ➎ Scale Turn to align with the scale on the angle-adjustment dial. Each tick of the scale corresponds to 15 degrees of tilt.
3-4 Changing the Angle of Cutting ➏ Press the angle-fixing control. When it clicks into place, the rotary axis is secured in position. Angle-fixing control ➐ Tighten the screws shown in the figure.
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Chapter 4 Appendix 41
4-1 Maintenance Daily Care ➢ This machine is a precision device, and is sensitive to dust and dirt. Perform cleaning on a daily basis. ➢ Never use a solvent such as thinner or benzine. ➢ Clean cuttings carefully. ➢ To clean the cover, use a dry cloth to wipe it. ➢ Never attempt to oil or lubricate the machine. Replacing the Center Drill If the tip of the center drill becomes worn, change the orientation of the tip.
4-2 What to Do If The machine doesn't run. Is the rotary axis unit cable connected? Connect the rotary axis unit cable securely. Redo the setting the Y origin point at the center of rotation Setting the Y-axis origin at the center of the rotary axis. 1. Close the front cover. Press the VIEW button to make the VIEW light go out. The cutting results are not attractive. Has correction of the origin point for the rotary axis been performed? 2. Use the operation panel screen to select [To Y Center].
4-3 Specifications Main Unit Specifications ZCL-40 Maximum angle of rotation Loadable workpiece size* ±18x10 ˚ (± 5000 rotations) Workpiece thickness holdable by workpiece chuck Loadable workpiece weight Control methods Feed rate Mechanical resolution Rotary-axis tilt angle Dimensions 12 to 40 mm (1/2 to 1-5/8 in.) Weight Packed dimensions 6.2 Kg (13.7 lb) Packed weight Accessories 9 Kg (20 lb) 5 Items within the range of a 42.5 mm (1-11/16 in.
4-2 Specifications Rotary Axis Unit Schematic Unit : mm 90 90deg. rotation (in increments 15deg.) Handle 65 94 27.5 196.
4-2 Specifications Rotary Axis Unit Schematic (Top View) 152.5 285 305 270 286.5 17.5 44.5 216 356.5 Rotary Axis Unit Schematic (Front View) 135 (Maximum width) 65 129 40(Max.) 12(Min.
4-2 Specifications 152.5 (Center location) 305 (Y-axis stroke) Installed on the MDX-40 (Top View) 5 (Distance from clamp end face) 115.5 189.
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