Functional check list_c7466 008.docx

Functional test for machine tool機床功能性檢查CODEPR 10.03 All. 4Rev. 1Pag. 18 of 1814/01/2020MACHINE Type: 機床型號:SR1000 + TR25PCUSTOMER:用戶:CATERPILLARPRODUCTION NUMBER :生產(chǎn)編號: c.7466VERIFICATION TYPE檢驗內(nèi)容 RESULT結(jié)果PAMAINST.安裝AMACHINE FUNCTIONALITY:機床功能性:PAMAFunct. Time功能時間(hour, 時)INST.安裝1Main control panel functionality主控制面板功能2Axes travel lenght and limit switch各軸的行程和限位開關(guān)3Axes rapid speed各軸快速移動的速度4Gear change Functionality and gear speed齒輪變速功能和齒輪速度5 Auxiliary PAMA panels functionalityPAMA輔助面板的功能6Ropes elongation cycle (OP_ROPES)鋼絲繩伸長周期 (OP_ROPES)7RAM & Borinbar travelling noise (Qualitative check)滑枕&鏜桿移動噪音（定性檢查）8Axes zero reference point position (Installation only)各軸零參考點位置 (只安裝)9Table center position (Installation only)工作臺中心位置 (只安裝)BNC type SINUMERIK 840D FUNCTIONALITY VERIFICATION:西門子840D功能 檢驗:PAMAINST.安裝1Check the activation of all the option request in the contract檢查合同中描述的所有選件能否激活2“M” functions (PAMA and standard)M功能（標準的和帕馬的） 3Standard cycles標準循環(huán)4Tapping without encoder不帶編碼器攻絲5Tapping witht encoder only CNC SIEMENS 用編碼器CNC西門子攻絲6Standard cycles for RENISHAWRENISHAW的標準循環(huán)7Part-program management子程序管理8mm/inch conversion 公英制的轉(zhuǎn)換 C/1TABLE VERIFICATION, Type: TR25P（3000x2000) 工作臺檢驗，型號：TR25P（3000x2000) PAMAINST.安裝1Functionality, axes travel, axes travel feed功能，軸的移動，軸移動速度 2Positioning 4x90 with index pin4x90分度銷定位3Loading Test荷載測試4M31=105, M31=106 Interference areaM31=105, M31=106干預(yù)區(qū)C/2TABLE VERIFICATION, Type: T（.x.) 工作臺檢驗，型號：T（.x.) PAMAINST.安裝1Functionality, axes travel, axes travel feed功能，軸的移動，軸移動速度 N.P.2Positioning 4x90 with index pin4x90分度銷定位N.P.3Loading Test荷載測試N.P.4M31=105, M31=106 Interference areaM31=105, M31=106干預(yù)區(qū)N.P.DPALLET CHANGER VERIFICATION, Type: TR 25P (3000x2000)托盤交換檢驗, 型號：TR25P(3000x2000) PAMAINST.安裝1Pallet changer functionality托盤交換功能2Assignation of a part-program to a pallet指派一零件程序到一托盤3Enclosure sliding door movement護罩滑動門的移動ETOOL CHANGER VERIFICATION, Type: CU145 R100換刀檢驗, 型號：CU145 R100PAMAFunct. Time功能時間(hour, 時)INST.安裝1Automatic tool change on spindle主軸上自動換刀2Manual tool change手動換刀3Tool magazine functionality刀庫功能4Tools pre-selection functionality刀具預(yù)選功能5Tools data loading/unloading from NCNC刀具裝卸數(shù)據(jù)6Wear tools unloading卸載磨損刀具7Automatic activation/deactivation of the cutting edge刀刃自動激活/撤銷8Tool changer time “VDI”刀具交換時間“VDI”9Tool changer time from pocket to spindle從刀套到主軸的換刀時間10Breack tool monitoring sitems 損壞刀具監(jiān)控11Tool data writing function BALLUF “BALLUF”刀具數(shù)據(jù)讀寫功能12Tool measurement function “BLUM”“BLUM”刀具測量功能13Adaptative monitoring function自適應(yīng)監(jiān)控功能 14Check twin tool, type 檢查雙刀, 型號 15Tool life monitoring刀具壽命監(jiān)控 16Automatic tool change with heavy tools重型刀具的自動刀具交換FPICK-UP VERIFICATION, Type: 3+1附件架檢驗, 型號：3+1PAMAINST.安裝1Pick-Up functionality附件架的功能2Attachments loading/unloading附件的裝載和卸載3Combination between attachment loading/unloading and tools附件裝卸和刀具裝卸聯(lián)合4Rolling shutter and sliding door卷鏈門和滑動門5Safety switches on the pick-up附件架上的安全開關(guān)F/1TOOLS RACK, Type:框架式刀庫, 型號：PAMAINST.安裝1Tools loading/unloading from the rack on the pick-up附件架上框架式刀庫的刀具裝載和卸載N.P.G/1ATTACHMENTS VERIFICATION, Type:TS. 附件頭檢驗, 型號：TS.PAMAFunct. Time功能時間(hour, 時)INST.安裝1Functional test功能測試N.P.2Tool change(automatic)自動換刀N.P.3Coolant M7, M8, M9冷卻水功能測試 N.P.4Tapping with encoder帶編碼器攻絲 N.P.5Tapping without encoder不帶編碼器攻絲 N.P.6Attachment length, centering and compensation functioning附件長度，中心偏差和補償功能N.P.7Milling test銑削試驗N.P.8Axes positioning with heavy tools ( 35 Kg )*帶重型刀具（35Kg）* 時各軸的定位N.P.9Manual tool change手動換刀N.P.10Speed and power limitation轉(zhuǎn)速和功率限制N.P.G/2ATTACHMENTS VERIFICATION, Type:TS. 附件頭檢驗, 型號：TS.PAMAFunct. Time功能時間(hour, 時)INST.安裝1Functional test功能測試N.P.2Tool change(automatic)自動換刀N.P.3Coolant M7, M8, M9冷卻水功能測試 N.P.4Tapping with encoder帶編碼器攻絲 N.P.5Tapping without encoder不帶編碼器攻絲 N.P.6Attachment length, centering and compensation functioning附件長度，中心偏差和補償功能N.P.7Milling test銑削試驗N.P.8Axes positioning with heavy tools ( 35 Kg )*帶重型刀具（35Kg）* 時各軸的定位N.P.9Manual tool change手動換刀N.P.10Speed and power limitation轉(zhuǎn)速和功率限制N.P.G/3ATTACHMENTS VERIFICATION, Type: TTL. 附件頭檢驗, 型號：TTL.PAMAFunct. Time功能時間(hour, 時)INST.安裝1Functional test功能測試N.P.2Tool change(automatic)自動換刀N.P.3Coolant M7, M8, M9冷卻水功能測試 N.P.4Tapping with encoder帶編碼器攻絲 N.P.5Tapping without encoder不帶編碼器攻絲 N.P.6Attachment length, centering and compensation functioning附件長度，中心偏差和補償功能N.P.7Milling test銑削試驗N.P.8Axes positioning with heavy tools ( 35 Kg )*帶重型刀具（35Kg）* 時各軸的定位N.P.9Manual tool change手動換刀N.P.10Speed and power limitation轉(zhuǎn)速和功率限制N.P.G/4ATTACHMENTS VERIFICATION, Type: TU30-144附件頭檢驗, 型號：TU30-144PAMAFunct. Time功能時間(hour, 時)INST.安裝1Functional test功能測試2Tool change(automatic)自動換刀3Coolant M7, M8, M9冷卻水功能測試 4Tapping with encoder帶編碼器攻絲 5Tapping without encoder不帶編碼器攻絲 6Attachment length, centering and compensation functioning附件長度，中心偏差和補償功能7Milling test銑削試驗8Axes positioning with heavy tools ( 35 Kg )*帶重型刀具（35Kg）* 時各軸的定位9Manual tool change手動換刀10Speed and power limitation轉(zhuǎn)速和功率限制G/5ATTACHMENTS VERIFICATION, Type: ADAPTER ISO 50/60附件檢驗, 型號：適配器IS050/60PAMAFunct. Time功能時間(hour, 時)INST.安裝1Tool change(automatic)自動換刀N.P.2Manual tool change手動換刀N.P.3Coolant M7, M8, M9冷卻水功能測試N.P.4Attachment length and compensation functioning附件長度和補償功能N.P.5Milling test銑削試驗N.P.G/6ATTACHMENTS VERIFICATION, Type: TW附件檢驗, 型號：TWPAMAFunct. Time功能時間(hour, 時)INST.安裝1Functional test功能測試N.P.2Tool change(automatic)自動換刀N.P.3Coolant M7, M8, M9冷卻水功能測試 N.P.4Tapping with encoder帶編碼器攻絲 N.P.5Tapping without encoder不帶編碼器攻絲 N.P.6Attachment length, centering and compensation functioning附件長度，中心偏差和補償功能N.P.7Milling test銑削試驗N.P.8Axes positioning with heavy tools ( 35 Kg )*帶重型刀具（35Kg）* 時各軸的定位N.P.9Manual tool change手動換刀N.P.10Speed and power limitation轉(zhuǎn)速和功率限制N.P.115 Axes function in continuous五軸連續(xù)功能N.P.G/7FACING HEAD VERIFICATION, Type: UT 平旋盤檢驗, 型號: UTPAMAFunct. Time功能時間(hour, 時)INST.安裝1Functional test.功能測試N.P.2Manual tool change手動換刀 N.P.3Automatic tool change自動換刀N.P.4Coolant M8, M9冷卻水功能測試N.P.5Attachment length and compensation functioning附件長度，中心偏差和補償功能N.P.6Machining test加工試驗N.P.7Speed limitation速度限制N.P.HCOOLANT SYSTEM, Type: 冷卻系統(tǒng), 型號：PAMAINST.安裝1System functioning系統(tǒng)功能2Pressure and flowing according with the contract按合同要求的壓力和流量3Coolant recovery system冷卻水回收系統(tǒng)IEMERGENCY RESTORATION緊急復(fù)位PAMAINST.安裝1 Tool change restoration刀具交換復(fù)位2Attachment change restoration附件交換復(fù)位3Pallet change restoration托盤交換復(fù)位JCHIPS CONVEYOR VERIFICATION鐵屑輸送器檢驗PAMAINST.安裝1Dimensional check (Installation)尺寸檢查 (安裝)2Functional test (Installation)功能試驗(安裝)3Efficiency test (Installation)效率測試 (安裝)KMACHINING TEST加工測試PAMAINST.安裝1NAS test加工NAS 2POWER test功率測試3Surface FINISHING test精銑平面測試4Work piece machining工件加工5Dimensional check of the work piece工件尺寸檢驗6Other required test, type:. 其它需要的測試, 種類:LBLOCK SEARCH VERIFICATION 分塊查找檢驗PAMAINST.安裝1Block search without attachment with 3 modality of calculation(only CNC SIEMENS)不帶附件的分塊查找，利用三種計算模式(僅西門子CNC)2Block search with attachment with 3 modality of calculation(only CNC SIEMENS)帶附件的分塊查找，利用三種計算模式(僅西門子CNC)3Block search with tool restoration帶刀具復(fù)位的分塊查找4Block search with pallet restoration帶托盤復(fù)位的分塊查找5 Block search for other NC其它NC的分塊查找MFUNCTIONAL TEST WITH AUTOMATIC CYCLE自動循環(huán)功能測試PAMAINST.安裝1Test in automatic execution for 24 hours consecutively連續(xù)24小時的機床自動運行*In the NOTE indicate the weight of the heavy tool if different than 35 Kg.*在備注 中顯示了重型刀具的重量，如果與35公斤不同. NOTE”“備注”最終結(jié)果說明Final Results LegendN.P. 不預(yù)期Not ForeseenN.E. 不執(zhí)行Not ExecutedN.I. 未安裝Not Installed O.K. 陽性結(jié)果 Positive Result No OK 見注意 SeeNotePAMA開始PAMA Start Up安裝開始Installation Start up日期:Date: 操作員:Operator: 日期:Date: 操作員:Operator: Table A: MACHINE FUNCTIONALITY1. Verify the functionality of main control pannel, inparticukar key board, screen, plugs, networks and any other equipment present. Pay attention to any specific requirement indicatet in the contract ( additional plugs, specific standards of plugs)2. Axis travel length and limit switch: verify the actual travel lengths with the contract specifications.3. Axes rapid speed: verify the actual Axes rapid speed with the contract specification, check it both in manual and automatic mode G00-G01.4. Gear change and speed: verify the number of gears, M41 M42-M43, the actual rotation speed, check the automatic grear change M40 verify the actual change turn number respect to the inposed on the part program. All the above mentioned test needs to be performed in both rataiting senses M3 M4. Verify the maximum rotation speed of the machine and attachment heads.5. Auxiliary panels: as for the main control panel, verify the correct assembly, functionality, and eventual specific contract specification.The auxiliary panel are : table panel, Pick-Up panel, Tool magazine panel, Tool Changer and Pallet recovery panel.6. Ropes elongation: OP_ROPES, verify the functionality of the automatic rope elongation measurement. (I.E. check quote in the part program)7. Ram & Boringbar travelling noise: evaluate on a quality level the noise and the vibration of the spindle every 100 mm of borinbar and ram travelling at the maximum spindle rotation speed.8. Axes Zero reference point position: check the position in according to the lay out configuration9. Table center position: che the position in according to the lay out configurationReport in the column Intermediate Functioning (hours) number of hours in which the machine has worked during the phase of Start Up (M.I.S).Table B:NC FUNCTIONALITY VERIFICATION1. Contractual options: verify eventual special customer requirement as per contract, verfing their implemtation and functionality.2. M function: verify all the standard M function along with the special function as per contract3. Standard cycles: check the standard cycles of the NC, drill, deep drill, tapping, boring with spindle orientation4. Tapping without encoder: verify the part program aswell as the functionality (For SIEMENS 840D CYCLE 84)5. Tapping with encorder: verify the part program aswell as the functionality of the same. Verify the option of retrieve in STOP during the automatic cycle ( (For SIEMENS 840D CYCLE 84)6. Standard cycles for RENISHAW: verify the measure cycles, the mask cycles for JOG mode, cycles AUTO result pages. Test the main Calibration cycles, origin of reference system movement, measurement of standard points and shapes.Start up, including the aligment of Renishaw tool, calibration, with sensor mounted on the machine. Verify the switch ON and OFF functions of the sensor , using M50 e M51 as well as L100 and L101.7. Part-program management: check the NC program functions: editing, save and move delate.8. mm/inch convertion: when required, verify the presence of the conversion buttons, test all related cycles (i.e. L106, L120, L140, attachments cinematic ). The test needs to be performed in both configurations mm and inch.Table C1/C2: TABLE type TH and TR VERIFICATION 1. Pallet change functionality: check all the functionality, movement in F function and rapid feed, for both axes V and B.2. Positioning 4x90: with index pin if included in the scope of supply, verify the pin mounting and test the related part program cycle.3. Loading test: load the table in according with the table technical specification, testing the positioning functionality as well as the axes calibration.Table D:PALLET CHANGE 1. Automatic tool change on spindle: verify the automatic toll change cycle on machine spindle 2. Tool Magazine functionality: check rotation of chain or movement of rack axes, ATC axes movement included rotations, extraction, shiftment, reversal and unlocking tool pin management.3. Enclosure sliding door movement: Check the functiolaty of the sliding door and safety equipments.Table E:TOOL CHANGE1. Automatic Tool change on spindle: test the automatic tool change cycle on the machine spindle.2. Manual tool change: test the manual tool change cycle on the machine spindle.3. Tool magazine functionality: test the functionality of the tool magazine in terms of chain rotation, rack axes movement, ATC axes movement along with rotations, extraction, reversal and unblocking tool pin management.4. Tools pre-selection functionality: test the functionality of the tool pre-selection cycle (i.e. T91), with ATC upload. Check also the intermediate memory.5. Tools data loading/unloding from NC: after having loaded a tool on the spindle, verify that the compensation tool data are automatically loaded on the NC.6. Wear tool unloading: test the management of the wear tool unloading from the tool magazione control panel. Verify the operations of opening door, unloading by pedal and local mode sector.7. Automatic activation/de-activation of the cutting edge: verify the coorect management of the cutting edge during the operation of tool loading and unloding. The NC have to manage the related toll cutting edge, which need to be noted on the list when the tool is unloded ( no delated).8. Tool changer VDI: if required by the contract, refer to the VDI regulations. 9. Tool change time from packet to spindle: if required, check the actual tool change time from pockect to spindle, in relation to the specification required.10. Breack tool monitoring sitems: verify assembly of the laser sensor system, usually on the rack, and his functionality. Check the inhibition function of the broken tool, and any other related contract specification.11. Tool data writing function BALLUF: verify the assembly of the meausuring system ( BILZ, BaLLUF or other) according to the lay out specification. Check the functionality.12. Tool measurement function BLUM: if required, verify the assembly of the measuring system on the machine, (BLUM or other) check the standard measuring cycles, dimension and general functionality. Measure known dimension tool and compare check the results obtained.13. Adaptative monitoring function: verify the cycle PO_ADOM e OP_ADOFF, related to the control switch ON and OFF. Check the functionality of the control on a test piece. The test is successfully performed when at the maximum alarm level, the machine stops the axes feed, then after 2 s also the spindle rotation stops and the machine is drawn to NC STOP status. 14. Check twin tools: verify NC tool managing in case of tool inhibition. Following an event like end of tool life, broken tool, or other type of failure, the NC needs to inhibit the specific tool. In case of recall NC have to manage the next identical tool ( twin ) in the tool magazione, charging it in spite of the inhibit one. If no twins are available the NC have to Stop the part-program execution and draw the machine in NC STOP status.15. Tool life monitoring: once the tool under monitoring expires is life ( in terms of time or number of pieces machined ), the NC inhibites the tool in object and once unloaded in the tool magazine it is not recalled until the tool life will be resetted.16. Automatic tool change with heavy tools: test the automatic tool change cycle on the machine spindle, the standard wheigth heavy tools is 35 kg. Indicate in the NOTE the actual weigth of the heavy tool if different respect 35 kg.Table F:PICK UP1. Pick-up functionality: verify the scope of supply and the assembly of the pick-up2. Attactments loading/unloding: verify the cycle loading/unloading, L140(attachment number), changing the different attachments. Pay attention before perform any attachment load /unload verify that the position of axes and spindle along with the attachments index are coherent respect each others and respect the pick up position. 3. Combination between attachment loadin/unloading and tools: verify that the tool is unloaded before unload the attachment.4. Rolling shutter and sliding door: verify the function