INT100,200,300,400mk4 In s t al a llla att iio on p ro oc c ed e du u re r e an a nd d ac cu urr a ac cy y s he h ee ett
This procedure for when you install INTmk4 machine. And after follow step by step on this procedure, you will get all accuracy sheet and parameter sheet in the last 2 pages. Print this sheet and keep it in the machine cabinet and send another copy to office for record.
This procedure for both Metric and Inch system, However However some of point in this procedure require to use u se Metric only because of avoid confusion. Each sheet give you a for input value and a for output. Please read carefully each caution.
R o u g h L e v el el
Orig inal Param eter inch Chuck Width(SP face to Chuck face)
BA2
TR1
Z-axis distance (work center to Home)
66535 0.00001inch
Correc tion of center rotation on B-axis (X-direction: from Home)
BA61
TR1
28 1.0um
X-coordinate of the sensor’s reference point
BA97 BA97
TR1 TR2
*Please input "inch" or "mm"
BA19
TR1
264961 0.00001inch
Correction of center rotation on B-axis (Z-direc tion: from Mill SP fac e)
BA62
TR1
586674 0.00001inch
Z-coordinate of the sensor’s reference point
-1314391 0.00001inch 0 0.00001inch
BA99 BA99
TR1 TR2
-1476157 0.00001inch 0 0.00001inch
Offset amount (X) during automatic tool setting value calculation
BA109
TR2
0 0.00001inch
Height axis rotational center offset of the first rotary axis(Tool tip point control)
K124
1490152 0.1um
Z-axis stroke for tip position memory(TEACH function)
L5
1704666 0.00001inch
Second zero-point coordinating value
M5
X1
4550 0.1um
M5
Y
-803900 0.1um
90600 0.1um 28490 0.1um 39194 0.1um
M16 M16
Y X2
14711 0.1um 0 0.1um
Zero-point shift amount
M16 M16 M16
X1 Z1 Z2
W-AXIS REVISION (X-AXIS REV.)
RS11
W-AXIS REVISION (Yt-AXIS REV.)
0 0.1um
W-AXIS REVISION (X2-AXIS REV.)
RS13
0 0.1um
Y-AXIS REVISION(B=90°)
0 0.1um
Y-AXIS REVISION(B=180° )
RS16
RS12
0 0.1um
RS15
0 0.1um
F i n a l Z -a x i s L e v e l
Pitch: Twist:
When bubble move to HD2 side "-", HD1 side "+". When bubble move to Magazine side "-", Operater side "+". Level HD1 MID HD2 Pitch -0.005 0 0 Twist -0.005 -0.005 0
mm/M mm/M
Level Pitch Twist
mm/M mm/M
Tolerance HD1 +/- 0.02 +/- 0.01
MID +/- 0.01 +/- 0.005
HD2 0 0
Final W-axis L evel
Pitch: Twist:
When bubble move to HD2 side "-", HD1 side "+". When bubble move to Magazine side "-", Operater side "+". Level HD1 MID HD2 Pitch -0.01 -0.005 0 Twist +0.005 0 0
mm/M mm/M
Level Pitch Twist
mm/M mm/M
Tolerance HD1 +/- 0.02 +/- 0.01
MID +/- 0.01 +/- 0.005
HD2 0 0
S p i n d l e T a p er n e s s C h e c k This form useable both for inch and metric. *If you got result with "-" which means B-side is smaller than A-side Do not use harder material on this test, you will get different result. (aluminium or brass is OK.) Also do not deep cut, it will get different result. Headstock Check inch *Please input "inch" or "mm" A= 1.7826 inch B=
1.7826 inch
C=
6.1 inch
C B
A
0.0000 /
10
inch
0.0000 /
10
inch
0.0000 /
10
inch
Tailstock Check A=
0 inch
B=
0 inch
C=
1 inch
C B
A
B
A
Headstock #2 Check
C
A=
1.9665 inch
B=
1.9665 inch
C=
6 inch
Tolerance
B-side smaller than A-side / -0.0003 10 inch
T r an s f e r P o s i t i o n C h e c k This form useable both for inch and metric. After SP Taper check, leave cutting material in 2nd SP and grab indicater in 1st SP. Indicator inch *Please input "inch" or "mm" Reading Indicator 0.0001 inch Tolerance 0.0004 inch You have a procedure in Japanese website as you see in berrow, however useally when you install new machine you do not need this process to make machine straight.
to m ake this con dition with Level adjustm ent.
You need
T r an s f e r P o s i t i o n C h e c k This form useable both for inch and metric. After SP Taper check, leave cutting material in 2nd SP and grab indicater in 1st SP. Indicator inch *Please input "inch" or "mm" Reading Indicator 0.0001 inch Tolerance 0.0004 inch You have a procedure in Japanese website as you see in berrow, however useally when you install new machine you do not need this process to make machine straight.
to m ake this con dition with Level adjustm ent.
You need
T u r r e t S t r a ig h t n e s s This form useable both for inch and metric. inch *Please input "inch" or "mm" Test Bar Length: 7 inch Specify to + and - direction.
1,Y
-0.0005 inch
0
2,X
-0.0003 inch
0
B=0
B=180
0
6,Y
0.0005 inch
0
5,X
0.0007 inch
B=90 0
0
-0.0007
1,Y 2,X 3,Z 4,Y 5,X 6,Y
-0.0003 -0.0002 -0.0004 -0.0001 0.0004 0.0003
inch/4inch inch/4inch inch/4inch inch/4inch inch/4inch inch/4inch
-0.0001 inch
Indicate from HD1 for B=0 and 90.
Indicate from HD2 for B=180.
3,Z
4,Y
0.0004
/
Tolerance +/-
4
inch
B-axis rotation center B A61,BA 62,K124 This form useable both for inch and metric. inch
T= Test bar Length D/2= Test bar Diameter X= Distance of X move Z= Distance of X move BA61=(Xx25.4)-(Zx254)/2x1000 BA62=(X+Z)/2x100000 BA62 Data before change BA61 Data before change K124 Data before change BA61= Metric
Different between OLD and NEW
BA62=Inch or Metric
Different between OLD and NEW
New BA61= Metric New BA62=Inch or Metric New K124= Metric
*Ex: When you want to input "inch" value, please input "inch" if not "mm".
Data 7.874228 0.984426 9.548198 9.486078 788.924 951713.8 951766 0.00001inch 1000 1.0um 2417485 0.1um
Test Bar
Mill SP
T= 7.874228 inch D= 1.968852 inch
#1
#2
Machine pos. Z= -10.21627 inch Distance move Z=
Machine pos. Z= 6.15961 inch 9.48608
#1
#2
789 1.0um -52.2 0.00001inch 1789 1.0um 951714 0.00001inch 2417353 0.00001inch
* When you check this test, you need to find highest point on the testbar by moving Y-axis. And after found the
B-axis rotation center B A61,BA 62,K124 This form useable both for inch and metric. inch
T= Test bar Length D/2= Test bar Diameter X= Distance of X move Z= Distance of X move BA61=(Xx25.4)-(Zx254)/2x1000 BA62=(X+Z)/2x100000 BA62 Data before change BA61 Data before change K124 Data before change BA61= Metric
Different between OLD and NEW
BA62=Inch or Metric
Different between OLD and NEW
New BA61= Metric New BA62=Inch or Metric New K124= Metric
*Ex: When you want to input "inch" value, please input "inch" if not "mm".
Data 7.874228 0.984426 9.548198 9.486078 788.924 951713.8 951766 0.00001inch 1000 1.0um 2417485 0.1um
Test Bar
Mill SP
T= 7.874228 inch D= 1.968852 inch
#1
#2
Machine pos. Z= -10.21627 inch Distance move Z=
Machine pos. Z= 6.15961 inch 9.48608
#1
#2
Machine pos. X(D)= -37.9883 inch X/2(r)= -18.99415 Distance move + L X=
Machine pos. X= -5.1123 inch X/2= -2.55615 9.5482
789 1.0um -52.2 0.00001inch 1789 1.0um 951714 0.00001inch 2417353 0.00001inch
* When you check this test, you need to find highest point on the testbar by moving Y-axis. And after found the position do not move Y-axis until check tip of testbar.
Tolerance When finished this test, try this test again and if you get a result with in 1~2um different(as much smaller), it is OK, because there has no specified tolerance.
These parameters offset the tip coordinates and the tool length on B-axis turn. The settings differ between BA61 and BA62. BA61：The machine end is offset with actual axes travels according to B -axis turn angle. BA62：The value is automatically calculated on tool length measurement, but without machineend offset.
X 1 ,Y t ,Z 1-a x i s H o m e P o s i o n A d j u s t m e n t This form useable both for inch and metric.
Integrex
100 inch
Machine Position X -44.1003 inch Y -0.0003 inch -44.09892 Tolerance
100mm = 4"
+/-
0.0008 inch
Current Parameter M16 X 50040 0.1um M16 Y 24410 0.1um
*Please input "100","200","300","400" *Please input "inch" or "mm" Target -44.10000 inch 0.00000 inch
New Parameter 50002 0.1um 24334 0.1um
*Find Center of Test Bar by Rotation"
INTE INTE INTE INTE
Gage Block
100 200 300 400
X-axis target mm Radias Diameter -390 -780 -560 -1120 -610 -1220 -610 -1220
inch Radias Diameter -15.35 -30.7 -22.05 -44.1 -24.02 -48.04 -24.02 -48.04
Machine Position Z -11.06797 inch Gage Block Length
Target -11.06556 inch
X 1 ,Y t ,Z 1-a x i s H o m e P o s i o n A d j u s t m e n t This form useable both for inch and metric.
Integrex
100 inch
Machine Position X -44.1003 inch Y -0.0003 inch -44.09892 Tolerance
100mm = 4"
+/-
0.0008 inch
Current Parameter M16 X 50040 0.1um M16 Y 24410 0.1um
*Please input "100","200","300","400" *Please input "inch" or "mm" Target -44.10000 inch 0.00000 inch
New Parameter 50002 0.1um 24334 0.1um
*Find Center of Test Bar by Rotation"
INTE INTE INTE INTE
100 200 300 400
X-axis target mm Radias Diameter -390 -780 -560 -1120 -610 -1220 -610 -1220
Gage Block Length
Gage Block
Chuck Width(BA2)
inch Radias Diameter -15.35 -30.7 -22.05 -44.1 -24.02 -48.04 -24.02 -48.04
Machine Position Target Z -11.06797 inch -11.06556 inch Gage Block Length 3 inch Chuck Width BA2 40551 0.0001inch Z-axis distance BA19 276378 0.0001inch Different between Turret face to Home position BA62 951714 0.00001inch
M16 L5
Current Parameter Z1 22797 0.1um
New Parameter 22185 0.1um 1406556 0.00001inch
*If machine has not standered KITAGAWA Chuck, You can not use this form unless you find correct Chuck width(BA2).
Y -a x i s C o m p a n s a t i o n This form useable both for inch and metric. Indicator inch *Please input "inch" or "mm" Find center and set indicater "0" from HD1. (If it is not make indicator "0" with home position, please check home position adjustment one more time.)
100mm = 4"
Move B-axis 90 degree touch same point which you setted indicater on B-axis 0 degree. And find highest point.
Indicate from front side and read "+/-" direction also. Reading Indicater 0 inch Current Parameter New Parameter RS15 225 -0.0006 225 0.1um *Max input value on this parameter +/-500.
100mm = 4"
S e le c t H D 2 s i d e o n s e l ec t s w i t c h . Attach indicator on HD2 with no movement on Y,B-axis. Indicate from front side and read "+/-" direction also. Reading Indicater Y 0.00005 inch Current Parameter New Parameter RS12 -474 0.1um -468 0.1um *Max input value on this parameter +/-1000. This parameter effecteve when you select HD2 side.
First set indicator "0" on backside of test bar.
100mm
Read indicator at front side. 100mm = 4"
Set again indicator setting "0" with both front and back side, Then move B=180 and check center with HD2. (ex: X=1120mm(44.1") Y=0mm(0")) Indicate from front side and read "+/-" direction also. Reading Indicater -0.008 inch Current Parameter New Parameter RS16 0 0.1um -2032 0.1um *Max input value on this parameter +/-500.
X 100mm = 4"
Indicate from Top side and read "+/-" direction also. Reading Indicater X 0.008 inch
Yt Y
Current Parameter New Parameter RS11 0 0.1um 2032 0.1um *Max input value on this parameter +/-1000. This parameter effecteve when you select HD2 side.
*Note: After changing "X"(RS11), Please check "Yt"(RS16) again until X and Yt are "0".
X 2 -a x i s H o m e P o s i t i o n This form useable both for inch and metric.
Integrex Machine
200 inch
*Please input "100","200","300","400" *Please input "inch" or "mm"
Call "T1" by MDI mode
M16
100 200 300 400
Machine Position X2 -10.2397 inch
Target -10.62000 inch
Current Parameter X2 8046 0.1um
New Parameter 56344 0.1um
X2-axis target mm inch Radias Diameter Radias Diameter -205 -410 -8.07 -16.14 -135 -270 -5.31 -10.62 -215 -430 -8.46 -16.92 -215 -430 -8.46 -16.92
S e l ec t H D 2 s i d e on s e l e c t s w i t c h . Call "T101" by MDI mode Machine Position X2 -10.236 inch
Target -10.62000 inch
Current Parameter New Parameter RS13 -100 0.1um -48868 0.1um *Max input value on this parameter +/-1000. This parameter effecteve when you select HD2 side. *Since Low er turret does not h as Y-axis, If you see different on Y-direction, you c an only adju st by s h im. However, usually new machin e does not required to gr ind shim because already adjustd at Factory. So if you need to adjust Y-direction on new m achine, you n eed to a djust by Level .
ATC Adjus tment This form useable both for inch and metric.
Machine
inch
*Please input "inch" or "mm"
Set ATC alignm ent tool
Magazine
Taper Shaft (3piece alignment tool)
Mill Spindle
t ZDirectio
Machine Position X1 -0.001177 inch Yt -3.65171 inch
Ring (3piece alignment tool)
Up/Dow n Directio
M5 M5
ATC Arm
Shaft (3piece alignment tool)
New Parameter X1 -149 0.1um Yt -927534 0.1um
T o o l e y e S en s o r A d j u s t m e n t This form useable both for inch and metric.
Machine
inch
*Please input "inch" or "mm"
All measuurment must be unclamp on Mill coupling
S e t B A 9 5 ,9 6 ,9 7 ,9 9 t o a l l " 0 " b e f o r e d o i n g t h i s t e s t . Orient 180 degree
#2
#1 Tool OD Orient 0 degree
#4
#3
Orient 180 degree
Orient 0 degree
Tool OD
Upper Turret BA95 34.96 inch
Original BA95
#1 #2
0.00001inc New BA95
-479.7816 inch -548.6806 inch 3393900 0.00001inch
BA96 #3 #4 Original BA96
0.00001inc New BA96
378.5863 inch 447.4895 inch 3394320 0.00001inch
P l ea s e s et B A 9 5,9 6 w i t h n e w n u m b e r b e f o r e g o i n t t o n e x t t es t . BA97 #1 #2 Original BA97 -1314391
NEW BA97
-479.9562 inch -514.7079 inch -49733205 0.00001inch
BA99 #3 #4 NEW BA99
378.6094 inch 413.5769 inch -39609315 0.00001inch
Lower Turret Gage bloc #5
3 inch -7.37902 inch
Target
13.38 inch
New BA97
Gage bloc #6 #7 New BA99
-49 0.00001inch
0.622 inch 14.56057 inch -12.05669 inch
Target
27.64 inch
0.00001inch -19.647975 27.64 20.3597 15.58331 -1558331
Ad jus ted Param eter Sheet Customer: Inspected by (Customer): Machine anchoreYes
Model: Title: No
Installer:
Factory Setting BA2 BA19 BA61 BA62 BA97 BA99 BA97 BA99 BA109
TR1 TR1 TR2 TR2 TR2
Serial: Date:
Current Setting 66535 264961 28 586674 -1314391 -1476157 0 0 0
0.00001inch 0.00001inch 1.0um 0.00001inch 0.00001inch 0.00001inch 0.00001inch 0.00001inch 0.00001inch
BA2 BA19 BA61 BA62 BA97 BA99 BA97 BA99 BA109
TR1 TR1 TR2 TR2 TR2
40551 0.00001inch 276378 0.00001inch 1789 1.0um 951714 0.00001inch ######## 0.00001inch ######## 0.00001inch -49 0.00001inch 0 0.00001inch 0.00001inch
K124
1490152 0.00001inch
K124
2417353 0.00001inch
L5
1704666 0.00001inch
L5
1406556 0.00001inch
M5 M5 M16 M16 M16 M16 M16 RS11 RS12 RS13 RS15 RS16
X1 Y X1 Y Z1 X2 Z2
4550 -803900 90600 14711 28490 0 39194
0.1um 0.1um 0.1um 0.1um 0.1um 0.1um 0.1um
M5 M5 M16 M16 M16 M16 M16
0 0 0 0 0
0.1um 0.1um 0.1um 0.1um 0.1um
RS11 RS12 RS13 RS15 RS16
X1 Y X1 Y Z1 X2 Z2
If you have any other parameters were changed, Please write down.
-149 -927534 50002 24334 22185 56344
0.1um 0.1um 0.1um 0.1um 0.1um 0.1um 0.1um
2032 -468 -48868 225 -2032
0.1um 0.1um 0.1um 0.1um 0.1um
In t eg r e x m k 4 A c c u r a c y F o r m Customer: Inspected by (Customer): Machine anchored: Yes
Model:
Serial: Title:
No
Installer:
Date:
Z1-axis Level
Check
Level Pitch Twist
HD1 -0.005 -0.005
MID 0 -0.005
HD2 0 0
mm/M mm/M
PASS PASS
Level Pitch Twist
HD1 -0.01 +0.005
MID -0.005 0
HD2 0 0
mm/M mm/M
PASS PASS
Level Pitch Twist
HD1 +/- 0.02 +/- 0.01
MID +/- 0.01 +/- 0.005
HD2 0 0
mm/M mm/M
W-axis Level
Tolerance
Spindle straightness test Check
Headstock Check
C B
A
A=
inch 1.7826 inch
B=
1.7826 inch
C=
6.1 inch 0.0000 /
PASS
10
inch
10
inch
Tailstock Check
C B
A B
A=
0 inch
B=
0 inch
C=
1 inch 0.0000 /
A C
Headstock #2 Check A=
1.9665 inch
B=
1.9665 inch
C=
6 inch 0.0000 /
10
inch
-0.0003
10
inch
Tolerance /
Transfer Position inch Reading Indicator 0.0001 inch
Check
PASS Tolerance 0.0004
inch
Turret straightness test Check
1,Y
6,Y
B=0
2,X
5,X
B=90 B=180
1,Y 2,X 3,Z 4,Y 5,X 6,Y
-0.0003 -0.0002 -0.0004 -0.0001 0.0004 0.0003
inch/4inch inch/4inch inch/4inch inch/4inch inch/4inch inch/4inch
Tolerance 3,Z
4,Y
+/- 0.0004
/
4
inch
PASS
Data Section 03/20/2007 release Ver1.0
Description
Info from
04/05/2007 Ver1.01
Tooleye Adjus tment
1, Drawing of #1,#2(B A97) and #3,#4(B A99) was opposite.
Darren Mi lls on(National training)
Adjusted Parameter Sheet
1, correct link to other sheet
Tac
04/30/2007 Ver1.02
B-axis Rotation Center(BA61,62) 1, "mm" mode does not works correctly for BA61
Brandon Church(AT Service)
05/29/2007 release Ver1.1 X1,Yt,Z1-axis Home position All sheet
1, Z1-axis Home position calculation was not correctly Adjusted printable setting for all sheet
Pierre Gendron(Canada service) Tac
07/13/2007 Ver1.11
X2,Z2-axis Home Position
INT400 X2 storke information(inch only) was wrong
Tac
09/11/2007 Ver.1.12
X2,Z2-axis Home Position
HD2 side Target number was not link correctlly
Tac
Y-axis compensation
On RS16 of indicator unit was always "mm", This should be Tac a changeable when choose a "inch" unit.
Tooleye Adjustment
Upper Turret BA97,BA99 calculation was not correct.
Tac
