AMADA DV-1 CCD Automatic Profile Grinder
(optional 5 & 7 Axis model)
Projector Screen Size 12″ LCD (CCD Range 0.5 x 0.4mm) Magnification Optical 10x, Monitor 350x Lighting System Tapering Lighting 150W Working Surface Ø115mm Rotary Table Distance from Table to Focus Point 200mm Maximum Loading 20kg X Axis Travel 300mm Y Axis Travel 250mm Z Axis Travel 80mm Linear Jog Feed XY: 2,000mm/min
Position Detection XY Axis: Full Closed Loop
Z Axis: Semi Closed Loop
Rotary B Axis Travel 360 Degrees Rotary B Axis Position Detection Full Closed Loop Spindle Speed 2,000 – 20,000 RPM Reciprocation Stroke 80mm Reciprocation Speed 30 – 400 / min CNC Controller FANUC 180I-MB
Productivity Made Easy
CNC Rotary Table Allows Four-Sided Grinding for Maximum Efficiency — With a CNC rotary table as standard equipment, the DVI is capable of full periphery processing with one chucking. Multiple wheel operations for roughing all sides of the work-piece can be completed—completely unattended—before
changing the wheel for finishing.
Automation that Drives Accuracy
The implementation of CCD camera systems puts the DV1 in a new class of grinding technology.
Automatic measurement of workpiece form with automatic re-grinding ensures repeatable precision.
- The DV1 can process ultra-small workpieces below an angle of 0.04″ (1 mm), which is difficult to measure with a projector. In addition, the edge compensation function ensures consistency of inspection.
- Measurement data can be output, providing documented part qualification.
- Grinding wheel form measurement can be performed. Automated CCD camera measurement eliminates subjective manual inspection, dramatically reducing variations in processing quality.
Fully Automated Part Production with Articulated Robot and Stocker
Through automatic wheel changing, rough and finish operations are seamless and can be conducted completely unattended. The ATC spindle automatically clamps the necessary wheels to fully process workpieces, unattended. Measurement software for flat (1A1) grinding wheels automatically qualifies the wheel width/position, and an integrated rotary dresser provides peripheral, side, and corner radius dressing in flat wheels for semi-finish operations. Rough plunge cycles speed throughput.
Precision in Part Processing
An ultra-hard work-piece 0.1″ (2.5 mm) thick is precision-ground to within 1μm. Test piece is five steps of 10μm, as pictured, with grinding, measurement and compensated re-grind. A work surface finish of Rz0.16μm is achieved, showcasing the DV1’s ability to produce “light” surface finishes.
The custom software on the DV1 is designed for maximum productivity.
Image-Based Teach and Playback — Image-based teach and playback software can create programs visually using monitor images of digital profiles, providing digital accuracy instead of projector-and-chart methods. Additionally, using digital profiles enables automatic measurement of the workpiece profile by measuring the CCD camera image of the workpiece against the actual digital image. Image teaching provides an actual, wheel based profile by capturing digital images of the wheel profile. Then the wheel image is used to “teach” the wheel path against the digital workpiece profile. Actual teaching is done by manipulating the handle.
Automatic Workpiece Form Measurement/ Compensation Processing — After the grind operation is finished, the standard position is confirmed and measurements are made to determine the deviation from the standard. This is done automatically—no operator intervention or programming is required. At the time of measurement, multiple points are simultaneously inspected and large deviations from the standard are disregarded. The measured image area is as small as 0.019″ (0.5 mm). In order to measure areas less than 1μm, the number of pixels and dots is set.
Grinding Wheel Position and Shape Measurement — The on-board dresser unit re-trues the leading edge radius of the grinding wheel. The shape of the grinding wheel is plunged into the dummy workpiece fixtured to the table. Through the dummy, the profile of the grindstone radius is measured at multiple points, and determined by CCM calculations. Taking measurements at multiple points minimizes errors. This procedure automatically qualifies both the wheel radius and wheel position, greatly facilitating the setup process.