The device described in this manual is a High Frequency Spindle, model Z33-D060.02 S2A, designed for high-speed machining. Its primary function is to provide precise and powerful rotational movement for various machining applications, particularly those requiring high rotational speeds. This specific model features a pneumatic direct change system for tools.
Function Description
The Z33-D060.02 S2A is a high-frequency spindle that converts electrical energy into mechanical rotational energy. It is designed to operate at high speeds, making it suitable for applications like cutting, drilling, engraving, and grinding. The spindle's performance is driven by a 3-phase asynchronous motor, which can operate at frequencies up to 1,000 Hz, achieving a maximum rated rotation speed of 60,000 rpm. The pneumatic direct change system allows for quick and efficient tool changes, enhancing productivity and operational flexibility. The spindle is designed to be integrated into a machine tool and requires a frequency converter for operation, which controls the spindle's speed and other parameters. Sealing air is used to protect the internal components, particularly the bearings, from contamination by dust and chips generated during machining.
Important Technical Specifications
Power Values (S1-100% and S6-60%):
- Rated Power: 0.18 kW (S1-100%), 0.24 kW (S6-60%)
- Torque: 0.036 Nm (S1-100%), 0.047 Nm (S6-60%)
- Voltage: 44 V (S1-100%), 46 V (S6-60%)
- Current: 5.5 A (S1-100%), 6.5 A (S6-60%)
Motor Data:
- Motor Technology: 3-phase asynchronous drive (no brushes or sensors)
- Frequency: 1,000 Hz
- Motor Poles (pairs): 1
- Rated Rotation Speed: 60,000 rpm
- Acceleration/Braking Value: 10,000 rpm per second (other values by consultation)
Characteristics:
- Motor Protection: PTC 100°C
- Housing: Aluminium
- Housing Diameter: 33 mm
- Cooling: Uncooled
- Heat Dissipation: Via the spindle holder
- Housing Temperature: < +45°C
- Ambient Temperature: +10°C ... +45°C
- Sealing Air: G 1/8"
- Protection Category: IP54 (sealing air turned on)
- ESD Protection: Yes
- Tool Change: Pneumatic direct change
- Collet Type: 5,1P-5°
- Clamping Range: 3.5 mm (1/8")
- Clockwise Rotation: Yes
- Coupler Plug: 7-pin plastic
- Weight: ~1.1 kg
- Inner Taper Run Out: < 1 µ
Dimensions:
The spindle has an overall length of 215.4 mm, with a main body diameter of 52 mm. The clamping range is 89 mm.
Air Purity Classes (ISO 8573-1):
- Solid Impurities: Class 3 (filter grade at least 5 µm for solids)
- Water Content: Class 4 (max. pressure dew point +3 °C)
- Total Oil Content: Class 3 (max. oil content 1 mg/m³)
Setting Values for Sealing Air:
- Lowest sealing air supply: Dry machining
- Medium sealing air supply: Machining with spray water
- Highest sealing air supply: Machining with hose water
- Pneumatic system for tool change: ≥ 6.0 bar
Usage Features
The Z33-D060.02 S2A spindle is designed for ease of use and high performance.
- Tool Change: The pneumatic direct change system allows for quick and efficient tool changes. To change a tool, the collet is opened pneumatically, the old tool is removed, and a new tool is inserted. The collet then closes, securing the new tool. This process is designed to be quick and straightforward.
- Direction of Rotation: The spindle clamping system is designed for clockwise rotation. Tools should only be used with the correct direction of rotation.
- Run-in Procedure: Before daily operation, the spindle should be run-in with a clamped tool (without machining) for approximately 2 minutes at 50% of the maximum permissible speed and then for 2 minutes at 80% of the maximum permissible speed. This ensures the spindle reaches its operating temperature and lubricates the bearings.
- Safety Instructions: The manual emphasizes several safety precautions, including the importance of wearing protective goggles during work, ensuring proper clamping of tools, and observing limits for speed and temperature. It also warns against operating the spindle without a clamped tool or if the clamping system is damaged.
- Permissible Materials: The spindle can be used for machining metals (such as alloys, cast metals, etc.), sintered materials, plastics, wood, graphite, stone (marble, etc.), paper and cardboard, circuit boards, and glass and ceramic.
- Cooling: The spindle is uncooled, with heat dissipation occurring via the spindle holder. Proper cooling of the spindle holder is crucial to maintain the spindle's temperature below +45°C.
- ESD Protection: The spindle is equipped with ESD protection, which is provided by creating an electrically conductive connection between the rotating shaft of the HF spindle and the motor housing.
Maintenance Features
Regular maintenance is crucial for the longevity and optimal performance of the Z33-D060.02 S2A spindle.
- Ball Bearings: The HF spindle bearings have lifetime grease lubrication and do not require maintenance. However, it is important not to lubricate the ball bearings or apply grease, oil, or cleaning agents to the openings of the HF spindle.
- Daily Cleaning: After each use, the inner taper of the HF spindle shaft and the inner taper of the collet must be cleaned to prevent contamination. A light greasy film should be applied to the taper of the collet after cleaning. Compressed air and ultrasonic cleaning should not be used on the HF spindle. Steam jets should also be avoided.
- Every Time the Clamping Device is Changed: The inner taper of the HF spindle shaft and the inner taper must be free of chips and contamination. The tool taper should be cleaned, and a light greasy film applied to the taper of the collet after cleaning. This improves the sliding movement and increases the clamping force of the collet.
- Storage: The HF spindle is not required for a prolonged period of time, it should be stored in a horizontal position, protected from moisture, dust, and other environmental influences. The storage temperature should be between +10°C and +45°C, with a relative humidity of < 50%.
- Monthly Maintenance: The shaft of the HF spindle should be turned at least ten times by hand every four weeks.
- Long Periods of Storage: For storage periods exceeding three months, the shaft of the HF spindle should be turned at least ten times by hand every three months. Additionally, the HF spindle should be put into operation with a tool inserted for approximately 10 minutes. The speed during this operation should not exceed 20% of the maximum permissible speed for the HF spindle.
- Maximum Storage Time: The maximum storage time for the spindle is 2 years.
- Service Partners: Only certified service partners are authorized to open and repair the HF spindle. Failure to comply with this voids any warranty claims and compensation claims for damages.
The manual also provides detailed troubleshooting guides for common issues such as the HF spindle not rotating, the HF spindle becoming hot, the HF spindle becoming loud, no automatic tool change, and the sensor not sending any signals. These guides help users identify the cause of problems and suggest appropriate actions, often referring to specific sections of the manual for detailed instructions.
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