Functional check list_c7466 008.docx

Functional test for machine tool机床功能性检查CODEPR 10.03 All. 4Rev. 1Pag. 18 of 1814/01/2020MACHINE Type: 机床型号:SR1000 + TR25PCUSTOMER:用户:CATERPILLARPRODUCTION NUMBER :生产编号: c.7466VERIFICATION TYPE检验内容 RESULT结果PAMAINST.安装AMACHINE FUNCTIONALITY:机床功能性:PAMAFunct. Time功能时间(hour, 时)INST.安装1Main control panel functionality主控制面板功能2Axes travel lenght and limit switch各轴的行程和限位开关3Axes rapid speed各轴快速移动的速度4Gear change Functionality and gear speed齿轮变速功能和齿轮速度5 Auxiliary PAMA panels functionalityPAMA辅助面板的功能6Ropes elongation cycle (OP_ROPES)钢丝绳伸长周期 (OP_ROPES)7RAM & Borinbar travelling noise (Qualitative check)滑枕&镗杆移动噪音（定性检查）8Axes zero reference point position (Installation only)各轴零参考点位置 (只安装)9Table center position (Installation only)工作台中心位置 (只安装)BNC type SINUMERIK 840D FUNCTIONALITY VERIFICATION:西门子840D功能 检验:PAMAINST.安装1Check the activation of all the option request in the contract检查合同中描述的所有选件能否激活2“M” functions (PAMA and standard)M功能（标准的和帕马的） 3Standard cycles标准循环4Tapping without encoder不带编码器攻丝5Tapping witht encoder only CNC SIEMENS 用编码器CNC西门子攻丝6Standard cycles for RENISHAWRENISHAW的标准循环7Part-program management子程序管理8mm/inch conversion 公英制的转换 C/1TABLE VERIFICATION, Type: TR25P（3000x2000) 工作台检验，型号：TR25P（3000x2000) PAMAINST.安装1Functionality, axes travel, axes travel feed功能，轴的移动，轴移动速度 2Positioning 4x90 with index pin4x90分度销定位3Loading Test荷载测试4M31=105, M31=106 Interference areaM31=105, M31=106干预区C/2TABLE VERIFICATION, Type: T（.x.) 工作台检验，型号：T（.x.) PAMAINST.安装1Functionality, axes travel, axes travel feed功能，轴的移动，轴移动速度 N.P.2Positioning 4x90 with index pin4x90分度销定位N.P.3Loading Test荷载测试N.P.4M31=105, M31=106 Interference areaM31=105, M31=106干预区N.P.DPALLET CHANGER VERIFICATION, Type: TR 25P (3000x2000)托盘交换检验, 型号：TR25P(3000x2000) PAMAINST.安装1Pallet changer functionality托盘交换功能2Assignation of a part-program to a pallet指派一零件程序到一托盘3Enclosure sliding door movement护罩滑动门的移动ETOOL CHANGER VERIFICATION, Type: CU145 R100换刀检验, 型号：CU145 R100PAMAFunct. Time功能时间(hour, 时)INST.安装1Automatic tool change on spindle主轴上自动换刀2Manual tool change手动换刀3Tool magazine functionality刀库功能4Tools pre-selection functionality刀具预选功能5Tools data loading/unloading from NCNC刀具装卸数据6Wear tools unloading卸载磨损刀具7Automatic activation/deactivation of the cutting edge刀刃自动激活/撤销8Tool changer time “VDI”刀具交换时间“VDI”9Tool changer time from pocket to spindle从刀套到主轴的换刀时间10Breack tool monitoring sitems 损坏刀具监控11Tool data writing function BALLUF “BALLUF”刀具数据读写功能12Tool measurement function “BLUM”“BLUM”刀具测量功能13Adaptative monitoring function自适应监控功能 14Check twin tool, type 检查双刀, 型号 15Tool life monitoring刀具寿命监控 16Automatic tool change with heavy tools重型刀具的自动刀具交换FPICK-UP VERIFICATION, Type: 3+1附件架检验, 型号：3+1PAMAINST.安装1Pick-Up functionality附件架的功能2Attachments loading/unloading附件的装载和卸载3Combination between attachment loading/unloading and tools附件装卸和刀具装卸联合4Rolling shutter and sliding door卷链门和滑动门5Safety switches on the pick-up附件架上的安全开关F/1TOOLS RACK, Type:框架式刀库, 型号：PAMAINST.安装1Tools loading/unloading from the rack on the pick-up附件架上框架式刀库的刀具装载和卸载N.P.G/1ATTACHMENTS VERIFICATION, Type:TS. 附件头检验, 型号：TS.PAMAFunct. Time功能时间(hour, 时)INST.安装1Functional test功能测试N.P.2Tool change(automatic)自动换刀N.P.3Coolant M7, M8, M9冷却水功能测试 N.P.4Tapping with encoder带编码器攻丝 N.P.5Tapping without encoder不带编码器攻丝 N.P.6Attachment length, centering and compensation functioning附件长度，中心偏差和补偿功能N.P.7Milling test铣削试验N.P.8Axes positioning with heavy tools ( 35 Kg )*带重型刀具（35Kg）* 时各轴的定位N.P.9Manual tool change手动换刀N.P.10Speed and power limitation转速和功率限制N.P.G/2ATTACHMENTS VERIFICATION, Type:TS. 附件头检验, 型号：TS.PAMAFunct. Time功能时间(hour, 时)INST.安装1Functional test功能测试N.P.2Tool change(automatic)自动换刀N.P.3Coolant M7, M8, M9冷却水功能测试 N.P.4Tapping with encoder带编码器攻丝 N.P.5Tapping without encoder不带编码器攻丝 N.P.6Attachment length, centering and compensation functioning附件长度，中心偏差和补偿功能N.P.7Milling test铣削试验N.P.8Axes positioning with heavy tools ( 35 Kg )*带重型刀具（35Kg）* 时各轴的定位N.P.9Manual tool change手动换刀N.P.10Speed and power limitation转速和功率限制N.P.G/3ATTACHMENTS VERIFICATION, Type: TTL. 附件头检验, 型号：TTL.PAMAFunct. Time功能时间(hour, 时)INST.安装1Functional test功能测试N.P.2Tool change(automatic)自动换刀N.P.3Coolant M7, M8, M9冷却水功能测试 N.P.4Tapping with encoder带编码器攻丝 N.P.5Tapping without encoder不带编码器攻丝 N.P.6Attachment length, centering and compensation functioning附件长度，中心偏差和补偿功能N.P.7Milling test铣削试验N.P.8Axes positioning with heavy tools ( 35 Kg )*带重型刀具（35Kg）* 时各轴的定位N.P.9Manual tool change手动换刀N.P.10Speed and power limitation转速和功率限制N.P.G/4ATTACHMENTS VERIFICATION, Type: TU30-144附件头检验, 型号：TU30-144PAMAFunct. Time功能时间(hour, 时)INST.安装1Functional test功能测试2Tool change(automatic)自动换刀3Coolant M7, M8, M9冷却水功能测试 4Tapping with encoder带编码器攻丝 5Tapping without encoder不带编码器攻丝 6Attachment length, centering and compensation functioning附件长度，中心偏差和补偿功能7Milling test铣削试验8Axes positioning with heavy tools ( 35 Kg )*带重型刀具（35Kg）* 时各轴的定位9Manual tool change手动换刀10Speed and power limitation转速和功率限制G/5ATTACHMENTS VERIFICATION, Type: ADAPTER ISO 50/60附件检验, 型号：适配器IS050/60PAMAFunct. Time功能时间(hour, 时)INST.安装1Tool change(automatic)自动换刀N.P.2Manual tool change手动换刀N.P.3Coolant M7, M8, M9冷却水功能测试N.P.4Attachment length and compensation functioning附件长度和补偿功能N.P.5Milling test铣削试验N.P.G/6ATTACHMENTS VERIFICATION, Type: TW附件检验, 型号：TWPAMAFunct. Time功能时间(hour, 时)INST.安装1Functional test功能测试N.P.2Tool change(automatic)自动换刀N.P.3Coolant M7, M8, M9冷却水功能测试 N.P.4Tapping with encoder带编码器攻丝 N.P.5Tapping without encoder不带编码器攻丝 N.P.6Attachment length, centering and compensation functioning附件长度，中心偏差和补偿功能N.P.7Milling test铣削试验N.P.8Axes positioning with heavy tools ( 35 Kg )*带重型刀具（35Kg）* 时各轴的定位N.P.9Manual tool change手动换刀N.P.10Speed and power limitation转速和功率限制N.P.115 Axes function in continuous五轴连续功能N.P.G/7FACING HEAD VERIFICATION, Type: UT 平旋盘检验, 型号: UTPAMAFunct. Time功能时间(hour, 时)INST.安装1Functional test.功能测试N.P.2Manual tool change手动换刀 N.P.3Automatic tool change自动换刀N.P.4Coolant M8, M9冷却水功能测试N.P.5Attachment length and compensation functioning附件长度，中心偏差和补偿功能N.P.6Machining test加工试验N.P.7Speed limitation速度限制N.P.HCOOLANT SYSTEM, Type: 冷却系统, 型号：PAMAINST.安装1System functioning系统功能2Pressure and flowing according with the contract按合同要求的压力和流量3Coolant recovery system冷却水回收系统IEMERGENCY RESTORATION紧急复位PAMAINST.安装1 Tool change restoration刀具交换复位2Attachment change restoration附件交换复位3Pallet change restoration托盘交换复位JCHIPS CONVEYOR VERIFICATION铁屑输送器检验PAMAINST.安装1Dimensional check (Installation)尺寸检查 (安装)2Functional test (Installation)功能试验(安装)3Efficiency test (Installation)效率测试 (安装)KMACHINING TEST加工测试PAMAINST.安装1NAS test加工NAS 2POWER test功率测试3Surface FINISHING test精铣平面测试4Work piece machining工件加工5Dimensional check of the work piece工件尺寸检验6Other required test, type:. 其它需要的测试, 种类:LBLOCK SEARCH VERIFICATION 分块查找检验PAMAINST.安装1Block search without attachment with 3 modality of calculation(only CNC SIEMENS)不带附件的分块查找，利用三种计算模式(仅西门子CNC)2Block search with attachment with 3 modality of calculation(only CNC SIEMENS)带附件的分块查找，利用三种计算模式(仅西门子CNC)3Block search with tool restoration带刀具复位的分块查找4Block search with pallet restoration带托盘复位的分块查找5 Block search for other NC其它NC的分块查找MFUNCTIONAL TEST WITH AUTOMATIC CYCLE自动循环功能测试PAMAINST.安装1Test in automatic execution for 24 hours consecutively连续24小时的机床自动运行*In the NOTE indicate the weight of the heavy tool if different than 35 Kg.*在备注 中显示了重型刀具的重量，如果与35公斤不同. NOTE”“备注”最终结果说明Final Results LegendN.P. 不预期Not ForeseenN.E. 不执行Not ExecutedN.I. 未安装Not Installed O.K. 阳性结果 Positive Result No OK 见注意 SeeNotePAMA开始PAMA Start Up安装开始Installation Start up日期:Date: 操作员:Operator: 日期:Date: 操作员: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