讲义参考案例教案03002en us

1、Operating InstructionsQishuyan LocomotiveCNMachine No.B4979Original Operating Instructions 03-002en-US417962AKLINGELNBERG P 250Gear Measuring CenterLegal NoticeKlingelnberg GmbH Peterstraße 4542499 Hückeswagen, Germany Phone:Fax:infoKlingelnberg AG Binzmühlestrasse 171CH-8050 Zür

2、ich, Switzerland Phone: +41 44-278 78 79Fax: +41 44-273 15 56District Court of Cologne HRB 37950 VAT ID no.: DE 184637081Tax number: 221/5749/01252KLINGELNBERG P 25003-002en-US417962A© 2011 Klingelnberg AG.This documentation is the copyrighted by Klingelnberg AG. It contains technical informati

3、on that may not be copied in whole or in part, published, or used without permission or redistributed to others for commercial purposes.CHAPTER OVERVIEW1SAFETY REGULATIONS2MACHINE DESCRIPTION3TECHNICAL DATA4PACKING AND TRANSPORT5SETUP AND INSTALLATION6CONTROLS AND INDICATORS7COMMISSIONING8OPERATION9

4、TROUBLESHOOTING10SERVICE AND MAINTENANCE11REPAIRS12DECOMMISSIONING AND STORAGE13DISPOSAL14INFORMATION417962A03-002en-USKLINGELNBERG P 2503KAPITELÜBERSICHTChapter OverviewPageIntroductionStructure and Meaning of Labels Product SafetyProduct-Specific Hazards Information in Case

5、of EmergencyOrganizational Measures and91114162122nel HierarchyProduct Description EquipmentSafety and Monitoring Equipment273443.73.8Range of Application Measurement Uncertainty Dimensions and Weights Setup Location Requirements StorageEmissions Operating FluidsUtility R

6、equirements5354556166666664.4IntroductionPacking the Machine PackingUnpacking717273744KLINGELNBERG P 25003-002-en-US417962A4Packing and Transport693Technical Data512Machine Description251Safety Regulations7CHAPTER OVERVIEW4.54.6Interim StorageTransport747SetupAnchoring in the Fou

7、ndation Installation81828Conventions in This Manual Main Machine Breaker Indicator LightsOverview of the Controls Moving the AxesLimit Switches1031041051061161177.17.2Commissioning by KlingelnbergInitial Commissioning1211IntroductionTurning On and Powering Up t

8、he Machine Powering Down the MachineGraphical User Interface SetupOperating Functions1251271281291341509.1Messages159417962A03-002en-USKLINGELNBERG P 25059Troubleshooting1578Operation1237Commissioning1196Controls and Indicators1015Setup and Installation79KAPITELÜBERSICHT10.4Introduc

9、tion Maintenance Schedule Maintenance TasksMoving the Axes16316616818011.111.2IntroductionReplacing Parts183185IntroductionDecommissioning Storag113.213.313.413.5Introduction Operating Fluids Machine AssembliesDisassembling Machine AssembliesNotifying the Manufacturer and Au

10、thorities19719819819920Conventions in This Manual ContactsIndex2052062116KLINGELNBERG P 25003-002-en-US417962A14Information20313Disposal19512Decommissioning and Storage18711Repair18110Maintenance1611SAFETY REGULATIONSCONTENTSPAGE....21

11、...31.6.4IntroductionStructure and Meaning of LabelsSafety Instructions Further NoticesSymbols Used in This ManualProduct SafetyBasic PremiseNon-Observance of Safety Regulations Basic Safety InstructionsSafety and Monitoring EquipmentProduct-Specific HazardsHazard Labels on

12、 the Machine Electrical Hazard Zones Mechanical Hazard Zones Pneumatic Hazard ZonesInformation in Case of Emergency Organizational Measures and91111121314141415151617181920212222222424nel HierarchyResponsibilities and Qualification Requirements Target GroupsDuty to Perform Maintenance, Service and R

13、epairs Duty to Report Faults and Damage417962A03-002-en-US KLINGELNBERG P 25071SAFETY REGULATIONS8KLINGELNBERG P 25003-002en-US417962A1SAFETY REGULATIONS1.1IntroductionPermitted activitiesThe following groups ofnel are permitted near the machine and theyshould only perform the activities described:&

14、#161; Operators may operate and clean the machine, provided that NO tools are required to do so.¡ Machine supervisors may maintain the machine and remain within themantire operating area.¡ When a part needs to be replaced, the necessary procedure should only beperformed by maintenancenel.A

15、ed and complete description of the functions and expertise of theindividual target groups can be found in the section entitled "Organizational, nel".417962A03-002-en-US KLINGELNBERG P 2509Before commissioning, operating, servicing, or repairing the machine, and make sure you thoroughly und

16、erstand the manufacturer's operating guidelines and these Operating Instructions.All instructions provided in this Operating Instructions document must be followed. These instructions are a basic prerequisite for ensuring safe operation of the machine and the safety ofnel.This also applies accor

17、dingly for the operating instructions of machine parts d by so-called third-partyrs, These are available in printedformat in the folder entitled "External documentation" or in electronic format on the documentation CD for this machine.Failure to observe these safety regulations can result

18、in severe injury or death.A printed copy of these Operating Instructions must be kept at the machine at all times. This also applies for operating instructions from third-partyrs, insofar as they are relevant for safety.1SAFETY REGULATIONSResidual risksOperation of this machine always entails residu

19、al risks due to improper conduct, including:¡ Alcohol consumption, abuse of prescription medications or recreational drugs¡ Carelessness, negligence¡ Improper useFailure to maintain an open line of sight and communication with people in the machine danger zone can result in additional

20、 residual risks. As a general rule, themachine is operated by 1.10KLINGELNBERG P 25003-002en-US417962AThe machine attendant must ensure that the machine danger zone is kept clear of alls at all times while the machine is in operation.1SAFETY REGULATIONS1.2Structure and Meaning of Labels1.2.1Safety I

21、nstructionsThe safety instructions are classified by signal words and a corresponding color. The following section explains the various safety instructions:Tab. 1Meaning of the safety labelsEach notice consists of 5 elements:Structure of the safety instructions417962A03-002-en-US KLINGELNBERG P 2501

22、1Fig. 1Safety instruction structureSignal wordAvoidance of dangerType and source of dangerDanger symbol Possible consequencesassociated with the dangerSafety instructionDescriptionDANGERDANGER: Indicates an immediate danger, which, if not avoided, will result in death or severe, permanent injury.xx!

23、xxxWARNING: Indicates a potentially hazardous situation, which, if not avoided, can result in death or severe, permanent injury.WARNINGxx!xxxCAUTIONCAUTION: Indicates a potentially hazardous situation, which, if not avoided, may result in slight or minor, non-permanent injury.xx!xxxNOTICENOTICE: Ind

24、icates a potentially damaging situation, which, if not avoided, may result in damage to themachine or a nearby object.xx!xxx1SAFETY REGULATIONS1.2.2Imperative noticeFurther NoticesAn imperative notice contains import can include the following:¡ Technical regulation¡ Important noticenformat

25、ion that is to be observed andGeneral noticeA general notice is a piece of information to improve understanding and can include the following:Background informationSpecific data12KLINGELNBERG P 25003-002en-US417962AA general notice may appear here.An imperative notice may appear here.1SAFETY REGULAT

26、IONS1.2.3Symbols Used in This ManualSymbols for prohibitions, hazards, and mandatory actions can appear both in this operating manual and on the machine itself.ProhibitionsHazardsMandatory actionsTab. 4Mandatory action symbols417962A03-002-en-US KLINGELNBERG P 25013Prohibited!No Forklifts/Industrial

27、 VehiclesNo Metal ImplantsNo PacemakersDo Not TouchNo AccessNo Magnetic CardsNo loose clothingTab. 2Prohibition symbolsCaution! General WarningCaution! Hot SurfaceCaution! Explosion HazardCaution! Hand InjuryCaution! Rotating GearsCaution! Electric ShockCaution! Laser BeamCaution! Suspended LoadCaut

28、ion!Caution!Crush HazardFiazardCaution!Caution!Sharp, PointedCompressed AirObjectsCaution!Strong Magnetic FieldTab. 3Hazard symbolsWear Ear and Eye!Wear Safety Gloves!Wear Eye!Wear Hard Hat!Documentation!1SAFETY REGULATIONS1.3Product Safety1.3.1Basic PremiseThis machine meets terally accepted techni

29、cal rules and standards anddemonstrates a high standard of operational reliability.However, if used improperly or for purposes for which it was not designed, this machine may pose a safety hazard to people and equipment.The standards and directives applied during design, production, and configuratio

30、n are listed in the EC Declaration of Conformity and the Manufacturer's Declaration.The use of technical productails hazards that cannot be eliminated by designResidual Hazardsfeatures or protective mechanisms. Such residual hazards are indicated in thisdocument.1.3.2Non-Observance of Safety Reg

31、ulationsKlingelnberg will not be held responsible for damage caused by non-observance of this operating manual.This applies in particular to damage due to:Use of the equipment for purposes other than those for which it was designed Improper operationIncorrect selection of materials for workpieces an

32、d toolsInadequate or missed maintenance and repair14KLINGELNBERG P 25003-002en-US417962AAlways observe the national safety regulations in force in the country in which the machinery is operated, as well as company safety regulations and accident prevention regulations!1SAFETY REGULATIONS1.3.3Basic S

33、afety InstructionsThe following basic safety instructions must be followed:¡ Only authorizeds may work on the machine.¡ The machine may only be operated when in perfect working order, in accordance with this Operating Manual.¡ Maintenance and repair work may only be carried out after

34、the machine has been shut down.¡ Protective equipment such as safe work clothing, eye, safety shoes,and earmust be worn at all times. The managing operator mustensure the proper protective equipment is worn bynel.1.3.4Safety and Monitoring EquipmentSafety equipment and monitoring equipment may

35、only be removed after the machine has been shut down and disconnected from the power supply. In particular, safety equipment and covers may only be removed by authorizeds and must be reinstalled prior to commissioning.For more information, refer to the chapter and section titled Machine Description

36、/ Safety and Monitoring Equipment. DANGERUnauthorized machine modifications!Death, severe bodily injury, and property damageXXNEVER disable safety equipment.NEVER carry out unauthorized modification or rebuilding of the machine.417962A03-002-en-US KLINGELNBERG P 250151SAFETY REGULATIONS1.4Product-Sp

37、ecific Hazards16KLINGELNBERG P 25003-002en-US417962AFig. 2Danger zones overviewPneumaticsMeasuring rangeArea of axis movementSwivel range of top center (optional)Electrical outlet beneath theMachine control cabinet operator control unit1SAFETY REGULATIONS1.4.1Hazard Labels on the Machine417962A03-00

38、2-en-US KLINGELNBERG P 25017Fig. 3Safety instructions on the machineChange probe only whenElectrical control cabinet machine is onLabel indicating potential risk of clothing becocaught or tangled in moving parts1SAFETY REGULATIONS1.4.2Electrical Hazard ZonesEven when the main breaker is turned off,

39、certain electrical components are still live. These components are identified by warning labels on the machine and in the electrical enclosure. The line from the power supply to the main breaker is also live.Live components!Contact will result in death by electric shock.XThe electrical control cabin

40、et may only be opened by qualified the proper training and authorization.The safety labels in the electrical control cabinet must be followed.nel withXXBefore perfor supply.electrical work, disconnect the machine from the power18KLINGELNBERG P 25003-002en-US417962AFig. 4Electrical danger zoneElectri

41、cal outlet beneath theControl cabinet operator control unitDANGER1SAFETY REGULATIONS1.4.3Mechanical Hazard ZonesSharp, pointed workpiece holder; heavy components!Risk of head injury or hand injury due to crushing or pinchingXWhen clam center hole.the workpiece, DO NOT use your hands to hold on to it

42、sXXSafeguard the workpiece from tip Use a crane to lift heavy components.or falling out.SetupManual clamof workpieces can result in crush injuries.In measuring mode, all function sequences in the machine are carried out in a controlled fashion. Intervention is possible only by pressing EMERGENCY STO

43、P to interrupt machine operation.Residual hazards are present due to moving axes and the automatic probe change rack.Measuring modeLoose clothing!Strangulation due to loose clothing becotangled in moving partsXXDo not wear loose clothing.Pull long hair up in a bun or pony tail and wear a hair net or

44、 cap.417962A03-002-en-US KLINGELNBERG P 25019Fig. 5Mechanical danger zoneArea of axis movementSwivel range of top center Measuring rangeCAUTIONCAUTION1SAFETY REGULATIONS1.4.4Pneumatic Hazard ZonesThe specified pressure settings must not be changed. The permissible pressure values can be found on sig

45、ns located next to each pneumatic element.Actuating the EMERGENCY STOP switch turns the pneumatic system off, butsealing air continues to bed. WARNINGPneumatic system under pressureEye injury due to compressed airXXDO NOT change the specified pressure settings.Before carrying out maintenance or serv

46、ice work, shut off the compressed air supply and depressurize the system.XAlways wear protective goggles when perfor system.work on the pneumatic20KLINGELNBERG P 25003-002en-US417962AFig. 6Pneumatic danger zonePneumatic system beneath the bellows1SAFETY REGULATIONS1.5EMERGENCY STOPbuttonInformation

47、in Case of EmergencyEMERGENCY STOP brings the machine to a stop immediately.In the event of an accident, administer first aid treatment and dial your local emergency number.al injuryReporting an emergency:.5.6.Who is making the call? What happened?When? Where?How many people are injured?Any o

48、ther danger present?417962A03-002-en-US KLINGELNBERG P 250211SAFETY REGULATIONS1.6Organizational Measures and Hierarchynel1.6.1Responsibilities and Qualification RequirementsWhen the machine is in operation, the responsibilities for each activity involved must be clearly defined and adhered to (see

49、Target groups chapter).The owner/operator must ensure that only qualified and that the accepted rules for on-the-job safety as work on the machine hered to. Likewise, onlyqualifieds should be allowed in the machine danger zone.1.6.2Target GroupsOwner/operatorMachine supervisorTab. 6Machine superviso

50、r target group22KLINGELNBERG P 25003-002en-US417962ARoles and ResponsibilitiesQualification Higher-rankingwith legal status who is responsible for the proper use of the machine according to its intended purpose and for the employ of authorizeds to work on the machine. Defines mandatory skills and au

51、thority to issue directives for the authorizednel involved in his operation. Training in business studies; carries out management duties Relevant experience in risk assessment andnel managementTab. 5Owner/operator target groupRoles and ResponsibilitiesQualification Performs matup and retooling Posse

52、sses relevant vocational training Troubleshoots machine faults; makes Has attended Klingelnberg training arrangements for repair workcourses and obtained Verifies correct operation of safety equipment Has the authority to access all areas of the machine environs Performs preventive maintenance and n

53、otifies repairnel as needed1SAFETY REGULATIONSMachine attendantRepairnelService technicianTab. 9Service technician target group417962A03-002-en-US KLINGELNBERG P 25023Function and CompetencyQualification Performs measurements Cleans the machine Has received job instruction training from the machine

54、supervisor or through Klingelnberg training coursesTab. 7Machine attendant target groupFunction and CompetencyQualification Comprises qualified, trained mechanical technicians and electricians Repairs malfunctions and defects Decommissions the machine Has the authority to access all areas of the machine environs Vocational training