Functional check list_c7466 FORM 008

MACHINE Type:

机床型号:

SR1000 + TR25P CUSTOMER:

用户:

CATERPILLAR

PRODUCTION NUMBER :

生产编号:

c.7466

*I n 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”

Table A: MACHINE FUNCTIONALITY

1.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 actua l 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

configuration

9.Table center position: che the position in according to the lay out configuration

Report in the colum n ‘’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 VERIFICATION

1.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

contract

3.Standard cycles: check the standard cycles of the NC, drill, deep drill, tapping, boring with

spindle orientation

4.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 CHANGE

1.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.Tool’s 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 measur ement 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 UP

1.Pick-up functionality: verify the scope of supply and the assembly of the pick-up

2.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.

https://www.360docs.net/doc/dc5067533.html,bination between attachment loadin/unloading and tools: verify that the tool is

unloaded before unload the attachment.

4.Rolling shutter and sliding door: verify the functionality in maual and automatic mode of

the rolling shutter, eventual peripheral doors and Pick up translation.

5.Safety switches on the Pick-up: verify the functionality of the safety switches on the Pick-

up.

Table F/1: TOOL RACK

1.Tools loading/unloading from the rack on the pick-up: functionality loading/unloading,

automatic tool change to the machine spindle and eventual attachment head.

Table G: ATTACHMENT HEADS

Tables G/1 –G/4 refere to milling attachtment heads, such as TS TU TTL. Tables G/5 – G/7 refer to TW UT and accessories for milling and boring.

As description the following point are refered to the TW, because is the one that have all the test forseen for the other attachments.

1.Functional Test: verify the attachment head general functionality, in terms of number of

maximum rotation speed, attachment indexing or axes positioning

2.Tool change: if required verify the functionality of the automatic tool change, verify also

the manual tool change.

3.Coolant: if foreseen in scope of supply, test the coolant system. If it is not possible to use

4.Tapping with/without encoder: verify the functionality of the tapping cycles, in terms of

rotations and eventual tool retrieve.

5.Attachment length, centering and compensation functioning: up load the attachment

heads quotes ( different axes quotes component) to the cinematic managing part program.

Using the ball tool verify that the position of the tool loaded on the machine spindle is the same achieved from same tool loaded on the attachment head (attachment properly NC

compensated). Then verify that the same position is achieved also after attachment head

axes rotations.

https://www.360docs.net/doc/dc5067533.html,ling test: perform roughing and finishing test milling test.

IMPORTANT: indicating in ‘’NOTE’’ machining parameters, tools specifications and

machining power.

7.Heavy tools indexing/movement: test the functionaliy of indexing and movement of the

attachment head loaded with heavy tools.

(35 Kg, if different indicate the actual tool weight in ‘’NOTE’’).

8. 5 axes machining: only for TW heads, verify the TRASFON function. Using the ball tool

verify the continuos movement ACCURACY. Machining a test piece using 5 axis movement

i.e.

Table H: COOLANT SYSTEM

1.System Functionality: verify the completeness of supply and feature. Test the I/O signals,

poumps rotations and liquid levels. The test is performed by electrician and machine

operator.

2.Pressure and flowing: Check system pressures and flow capacities according to the

contract specifications.

3.Recovery coolant system functionality: verify the coolant flows corractly from the machine

to the recovery tank in the foundatution (no fluid stagnacy) along the recovery

trenches.Test the functionality of the recovery nim max cicles.

Table I: EMERGENCY RESTORATION

1.Tool change restoration: during the automantic tool change interrupt the cycle giving a

RESET. From both, the main control pannel and the manual control pannel, re-establish the system. Verfy the movement fron the ATC to the chain with automatic cycle.

2.Attachment change restoration: during the automantic attachment change interrupt the

cycle giving a RESET. From both, the main control pannel, re-establish the system. Repeat

the test also for the rotation.

3.Change Pallet restoration: during the automantic pallet change interrupt the cycle giving a

RESET. From the manual control pannel, re-establish the system.

Table J: CHIP CONVEYOR

1.Dimensional check: check the chip conveyor dimension according to the contract

specification.

2.Functionality test: test the chip unloaded and loaded (without/with chips) conveyor

functionality in both direction.

3.Efficienty test: verify the correct chips flow, in particular close to corners.

Tabella K: MACHINING TEST

1.NAS Test: perform the NAS test according to the relative Test Book.

2.Power Test: perform the POWER TEST test according to the relative Test Book, avoiding

3.Surface Finishing test: perform the FINISHINGTEST test according to the relative Test Book.

4.Work piece machining: when foreseen in the contract perform the test according to the

given specifcation.

5.Dimensional check: when foreseen in the contract che the dimension of the special

working piece.

6.Other required test: if foreseen in the contract perform the required test.

Tabella L: BLOCK SEARCH VERIFICATION

1.Block search WITHOUT attachment: 3 modality of calculation for SIEMENS 840D.

Restart the research punctual part-program in both condition with rigth tool and wrong

tool. In case of wrong tool the machine have to change to the right one and restart

correctly.

2.Block search WITH attachment: 3 modality of calculation for SIEMENS 840D.

As per the above case, research with wrong tool, wrong attachment, wrong attachment

orientation. For each case, the NC have to inform the machine operator about the wrong

condition and re-enable the system at part program condition in order to carry out the part program

3.Different NC: in case the NC implemented on the machine is different, check the procedure

of block research, test the restart functionality after a fault condition.

Tabella M: FUNCTIONAL TEST WITH AUTOMATIC CYCLE

1.Functional test with AUTOMATIC cycle: the machine runs an outomatic cycle which

performs all the main NC and machine features, without operator supervison.

In particular the part program required has to: move the machine axes in rapid feedrate

and machining feedrate, at max/min spindle rotation speed, perform the standard cicles,

tool change, chang speed gears. Perform also automatic attachment and pallets change

( this test will be performed at PAMA’s facilities if are accomplished all the safety

condition).

The machine have to run the part program for at least 24h witout any interruption.

In the charter ‘’NOTE’’, indicate in detail comments regarding possible problems and solutions, peculiarities, comments and other related to above

tests.

The check list is signed and dated by the testing operator.

The Check list needs to be completely performed both at PAMA’s and

Customer’s facilities.

表格A: 机床功能

1.检查主控面板的功能，尤其是键盘，屏幕，插头，网络和其他存在的设备。注意合同

中指出的任何特殊要求（其他插头，特殊标准的插头）

2.各轴行程长度和限位开关：检验各轴实际行程长度是否符合合同要求。

3.各轴快速移动的速度：检验各轴实际移动的快速速度是否符合合同要求，用手动和自

动模式‘’G00-G01’’.检验。

4.齿轮变换和速度：检验齿轮数‘’M41 –M42-M43’’，实际旋转速度，检查自动齿轮变换

‘’M40’’，检查实际变换数是否与零件程序给定的一致。上述所有测试需要在两个方向

同时进行‘’M3’’ ‘’M4’’。检查机床和附件头的最大旋转速度。

5.辅助面板：对于主控面板，检查是否正确装配，功能以及最终具体的合同要求。

辅助面板有：工作台面板，附件架面板，刀库面板，刀具交换和托盘回收面板。

6.钢丝绳伸长：‘’OP_ROPES’’,检查钢丝绳自动伸长测量的功能

7.滑枕&镗杆移动噪音：评估噪音质量水平以及镗杆和滑枕在主轴最大旋转速度时移动

每100 mm产生的震动。

8.各轴零参考点位置：根据平面图配置检查位置。

9.工作台中心位置：根据平面图配置检查位置。

在立柱”功能时间 (时)”报告启动阶段(M.I.S)机床工作的时数。

表格B: 西门子840D功能性检查

1.按照合同:检查客户最终的特殊要求，检验它们的功能。

2.M功能：检验所有标准的M功能以及合同要求的特殊功能。

3.标准循环：检查NC的标准循环，钻，深度钻，攻丝，主轴回转镗。

4.不带编码器攻丝：检验零件程序及其功能（西门子840D 循环84）

5.带编码器攻丝：检验零件程序及其功能。检查自动循环过程中的停止检索选项（西门

子840D 循环84）

6.‘’RENISHAW’’标准循环：检查测量循环，JOG模式的掩蔽循环，循环AUTO结果页面。

测试主调整循环，参考系统移动原点，标准点和形状测量。

启动，包括Renishaw工具调试和调整，感应器装在机床上。检验感应器的开关功能，使用M50, M51以及L100和L101。

7.零件程序管理：检查NC程序功能：编辑，保存和移动删除。

8.公制/英制转换：如需要，检查转换按钮，测试相关的循环(i.e. L106, L120, L140, 附件

影像 )。该测试需要在同时具有英制和公制时进行。

表格C1/C2: 工作台检验型号T….. (… x …..)

1.托盘交换功能：检查所有功能，V轴和B轴‘’F’’功能下移动和快速进给。

2.4x90定位：用分度销定位（如在供货范围内）,检查销的安装，并测试相关的零件程

序循环。

3.荷载测试：根据工作台的技术规范承载工作台，测试定位功能和轴校正。

表格D: 托盘交换

1.主轴上自动换刀：检查机床主轴自动换刀循环。

2.刀库功能：检查链条回转或刀架轴移动，ATC轴移动包括旋转，缩回，移动，倒转和

松开刀具销子管理。

3.护罩滑动门移动：检查滑动门的功能和安全设备。

表格E: 换刀

1.主轴上自动换刀：检查机床主轴自动换刀循环。

2.手动换刀：检查机床主轴手动换刀循环。

3.刀库功能：测试刀库功能，如刀链旋转，刀架轴移动，ATC轴移动及回转，缩回，倒

转和松开刀具销子管理。

4.刀具预选功能：ATC上载时测试刀具预选循环功能(i.e. T91), 检查中间记忆。

5.NC刀具数据装卸：主轴装载一个刀具后，检查补偿刀具数据是否自动装载到NC.

6.磨损刀具卸载：测试刀库控制面板的磨损刀具卸载管理。检查开门操作，用踏板卸载

和当地模式区

7.刀刃自动激活/取消：检查刀具装卸工程中刀刃的正确管理。NC应管理相关的刀具刀

刃，卸刀时（非取消时）需要在清单上标注出。

8.换刀装置‘’VDI’’:如合同要求，请参考VDI条例。

9.从刀位到主轴的换刀时间：如有要求，检查从刀位到主轴的实际换刀时间是否符合规

范。

10.破损刀具监测系统：检查激光感应系统装配（通常在刀架上）和其功能。检查破损刀

具的阻止功能和其他相关的合同规范。

11.刀具数据读写功能‘’BALLUF’’:检查测量系统( BILZ, BaLLUF 或其他)的装配是否符合平

面图规范。检查功能。

12.刀具测量功能‘’BLUM’’:如有要求，检查机床上测量系统的装配(BLUM 或其他)检查标

准测量循环，尺寸和一般功能。测量已知尺寸的刀具并与所得结果比较。

13.自适应监控功能：检查循环PO_ADOM e OP_ADOFF, 与控制开关开启和关闭有关。用

一测试件检查控制功能。当达到最大报警等级，机床停止轴进给，2秒钟之后，主轴

旋转停止，机床进入NC停止状态，表示测试成功完成。

14.检查双刀：检查刀具禁止情况下的NC刀具管理。比如出现刀具寿命结束，刀具破损

或其他故障时，NC必须禁止特定刀具。如有召回，NC应管理刀库中下个相同的刀具，尽管已被禁止。如果没有相同的刀具出现，NC应停止零件程序执行，并使机床处于

NC停止状态。

15.刀具寿命监控：一旦监控中的刀具寿命已到（根据加工的时间和工件数），NC禁止

目标刀具，一旦从刀库中卸载，只有在刀具寿命预设后才能被召回。

16.重型刀具自动换刀：测试机床主轴上自动换刀循环，标准重型刀具的重量为35kg。

如与35kg不同，重型刀具的实际重量在‘’备注’’中显示。

表格F: 附件架

1.附件架功能：检查供货范围和附件架的装配。

2.附件装/卸：检查循环装/卸,L140(附件编号)，交换不同附件。注意在装卸任何附件前，

检查各轴和主轴的位置和附件头分度是否相互一致，是否符合抓取位置。

3.附件装卸和刀具联合：检查卸载附件前刀具是否已卸载。

4.卷帘门和滑动门：检查卷帘门，外围门和抓取变换在手动和自动模式下的功能，

5.附件架上的安全开关：检查附件架上安全开关的功能。

表格F1: 刀架

1.从附件架机架上装卸刀具：装卸功能，机床主轴和附件头上的自动换刀。

表格G: 附件头

表格G/1 –G/4是关于附件铣头：如TS TU TTL。表格G/5 – G/7是关于TW UT和镗铣头。

1.功能测试：检查附件头基本功能，根据最大旋转速度，附件分度或各轴定位。

2.换刀：如有要求，检查自动换刀功能，另检查手动换刀功能。

3.冷却液：如在供货范围中可见，测试冷却系统。如果不能使用冷却液，用空气测试内

外系统的功能。

4.带/不带编码器攻丝：检查攻丝循环的功能，回转和最终刀具取回方面。

5.附件长度，定心和补偿功能：上传附件引用（不同轴引用组件）到影像管理零件程序。

使用球形刀具，查证机床主轴上装载的刀具的位置与附件头上装载的同一刀具的位置

一致（附件正确NC补偿）。然后检查附件头各轴旋转后获得相同的位置。

6.铣削测试：进行粗铣和精铣测试。

在“备注”中指出加工参数，刀具规格和加工功能。

7.重型刀具分度/移动：检查装有重型刀具附件头的分度和移动功能

(35 Kg, 如有不同，“备注”中有实际刀具重量)

8.5轴加工：只适合TW附件，检查TRASFON功能；使用球刀查证连续移动的正确性。

使用5轴移动加工测试件。

表格H: 冷却液系统

1.系统功能：检验冷却液供应的完整性和特征。测试I/O信号，泵旋转和液位。该测试

由电气人员和机床操作员一起完成。

2.压力和流量：根据合同规范，检查系统压力和流量。

3.冷却液回收系统功能：检查冷却液是否沿着回收槽从机床正确流向地基内的回收箱。表格I: 紧急复位

1.换刀复位：自动换刀过程中断，循环将复位。主控面板和手控面板重建系统。检查自

动循环下ATC到刀链之间的移动。

2.附件交换复位：附件自动交换过程中断，循环将复位。主控面板重建系统，重复旋转

测试。

3.托盘交换复位：自动托盘交换中断，循环将复位，手控面板重建系统。

表格J: 铁屑输送器

1.尺寸检查：检查铁屑输送器的尺寸是否符合合同规定。

2.功能测试：在两个方向测试输送器装卸铁屑功能（不带/带铁屑）

3.效率测试：检查铁屑的正确流量，尤其靠近角落。

表格K: 加工测试

1.NAS测试：根据有关的测试报告进行NAS件测试。

2.功率测试：根据有关的测试报告进行功率测试，避免因夹具问题迫使机床达到最大加

工功率。

3.表面精加工测试：根据有关的测试报告进行精加工测试。

4.工件加工：若合同有规定，根据给出的要求进行测试。

5.尺寸检查：若合同有规定，检查特殊工件的尺寸。

表格I: 检查分块查找

1.不带附件的分块查找: 西门子840D有3种计算模式。在带正确刀具和错误刀具两种

情况下重启搜索准时零件程序。如果刀具错误，机床应换为正确的刀具并正确重启。

2.带附件的分块查找: 西门子840D有3种计算模式。

根据上面的情况，搜索错误的刀具，错误的附件，错误的附件定位。对于每种情况，

NC应告知机床操作员错误的情况，并在零件程序条件下重启系统来完成零件程序。

3.不同NC: 如果机床使用的NC不同，检查分块查找程序，测试故障发生后的重启功能。表格M: 自动循环功能测试

1.自动循环功能测试：机床运行自动循环，能在无操作员监督的情况下完成所有主NC

和机床特征。

特别是零件程序要求：机床各轴以快速进给量和加工进给量移动，在最大/最小主轴

转速下，完成标准循环，刀具交换，齿轮变换。也可进行自动附件和托盘交换（该测

试在PAMA的设备上进行，如果完成所有的安全条件）

机床必须运行零件程序至少24小时不中断。

在“备注”表中，表明了可能出现的问题和解决方案，特征，意见和其他

关于以上测试的详细建议。

检查清单由测试操作员签字并记载日期。

PAMA设备和客户设备必须完全执行该检查清单。