SURFACE FX SPM1 MANUAL

SURFACE FXINC.139 RYERSON RD. LINCOLN PARK,N.J.07035 201-522-9038
1
SURFACE FX SPM-1 /SPM-1C
POLISHING MACHINE MANUAL

2
Table of contents
Introduction 3
Capacity 4
Slurry 4
Loading & Unloading 4
Programmablecontrolfeatures 5
Safety 5
External Supply Requirements 7
Installation 8
Operation 8
Operation II 8
Cleaning 10
Maintenance 11
Troubleshooting 15
Screen Shotdescriptions 17
Parts List P
PLC Ladder Diagram 18

3
Introduction
Introduction to the Surface FxModelSPM-1/SPM-1C SphericalPolishing Machine
The SPM1 SphericalPolishing Machine wasdesigned specifically for the
biomedicalindustry to polish femoralcap headsand other sphericalparts to
within a 0.1 micron finish. Although sphericaltruing is a by-product of the
operation, an out–of round condition willnot be corrected. The basic purpose of
the machine is to bring a fine polish to the product. Operationstake place on three
axes, two rotary, (supplied by variable speed controlled spindles) and one pivoting
axis.
Spindle speeds are definable from 10 revolutionsper minute up to a maximum of
300 revolutionsper minute. The pivot action is performed using a regulated
pneumatic cylinder with flow valves. These flow valves controlthe pivot speed,
and are preset from manufacture and only need adjustmentduring maintenance
procedures.
Overall controlis performed using a DirectLogic PLC (Programmable Logic
Controller) coupled with a touchscreen interface with variable time and speed
constantsto meet customers’ requirements.
The offsetadjustmentallows for variouspartoffset diameters (as defined in
capacity). Offsetis performed by using the offsetarm located on the righthand
side of the machine with a calibration scale matched. The offset arm is connected
to the offset plates via rack and pinion for smooth and accurate positioning.
Cycle time is programmable (in minutes) from 1 minute through 13 minutes.
Elapsed time is displayed during operation and iscontrolled via the PLC internal
clock.

4
Capacity
The capacity of the SPM-1 modelsfor femoralcapsrangesfrom a minimum
diameter of 12 mm to a maximum of 85mm, with an offset range of 28mm.
Slurry/ Polishing Media
Distribution of the slurry is performed using a six cartridge peristaltic pump. Slurry
drip rate is controlled in the program by way of the drip rate % input.
*Slurry removalis performed using a stainless steel hopper mounted below the
work area asa recovery tank. Slurryand water flow downinto the tank and
accumulate. A two stage diaphragm pump istriggered every 5 machining cycles
by a pneumatic solenoid valve, purging to an externalstorage container provided
by the end user.
The slurry pump is controlled by a d.c drive unit located in the electrical enclosure.
*Optional
Part Loading & Unloading
The machine comesstandard with one step push button loading and unloading.
Selection of the spindle to load or unload is performed from the touchscreen in the
load/unload menu. With the operator windowopen, and the partunclamp button
pressed, the partwill be unclamped from the spindle selected. When the button is
released, the arbor willclamp again. The unit is designed to defaultto a clamped
condition in the event of a power failure, or other condition to protectthe parts
mounted on the spindles.

5
Programmable Control Features
The SPM-1C machine hasupgradesincorporated which have been developed over
sixteen yearsof operations, improving uptime and lowering maintenance costs.
A touch screen is integrated into the PLC to display machine functions, and
eliminate rotary switcheswhich are prone to failure in harsh conditions.
The result is a display which is weatherproof with allfunctions (status display and
inputs for speeds, time cycles, and maintenance features).
Status lights are outfitted on the machine to allow visual recognition of the
machine processstatus.
Safety
Safety Proceduresfor the SPM-1
The Surface FxSPM-1 wascreated and designed using 24voltd.c. controlvoltages,
and a single 110voltGFCI outlet circuit for externalinspection equipment(2amp
max). Interlocksare installed on all access points to protectboth operatorsand
maintenance personnelfrom accidentalexposure to risk. All motionsare
pneumatically controlled, and will relax in a safe position should power be
interrupted, or interlock triggering.
The following guideline must be adhered to for continued safe operations:
 A clean, low impedance groundmustbe connected to the machine and
supply ground (bussground).
 Shutthe machine down, and disconnectpower priorto performing
maintenance if guardswill be removed, or when reaching into machine
beyond normaloperation.
 Do not attempt to bypassinterlocks, (door interlocks, main disconnect)
which may presentan unsafe operating condition.

6
Safety, cont’d
 Do not reach into any mechanicalcomponentssuch asbelts pulleysetc.
while power is on.
 Do not operate or maintain any componentif machine power ison, or air
supply is connected.
 Wear safety glasses and gloves during alloperations, and maintenance
proceduresto reduce chance of eye, or hand injury thatmay presentitself.
Although this machine wasdesigned with total safety in mind, it is the
responsibility of the purchaser to comply with safety guidelinesset forth above.

7
Machine External Supply Requirements
The Surface FxSPM-1 Requiresthe following:
Electrical:
Voltage 208- 240 volts A/C
Amperage 20 Amps
Ground Low Impedance Building or System Buss
Pneumatic Supply:
Clean dry 60 – 100 P.S.I. @2CFM
Air supply must be run to machine to the right rear corner where the Pneumatic
regulator is located. Connection can be made via flexible hose, or hard plumbing.
The air regulator uses a ¼” NPT fitting. Customer must install a service disconnect
in line with pneumatic supply.
Rinse Water
Used at customersconvenience for rinsing parts, or machine cleaning.

8
Operation
Power on Sequence
 Verify main air pressure supply is set to 80 psi (located rear rightcorner of
machine).
 Turn main power switch to “ON” position (located on the electrical
enclosure cabineton the right side of the machine) verify that the display
comes up at the login screen.
 Release Emergency Stop button, and pressReset button for 2 seconds.
 Verify thatarborsand laps are properly selected and preparedfor operation
(See Maintenance section for Arbor installation and removal).
 Select the proper offsetasdetermined for the partsize and offset (The
offset arm is located on the rightside of the machine and has a graduated
scale above it).
 Arbor RPMand Lap RPM should be set in the program written for the
correspondingpartto be polished (Setting in program mode in “Screen
Functions” section).
 Load partonto Arbor (“PartLoading and Unloading”).
 Verify thatCycle time, Slurry %, Spindle RPMand Lap RPM are correctfor
the partto be polished (Program screen).
 Prime slurry pump ( if beginning of shift) using the “Maintenance”
screen(Setting in program mode in “Screen Functions” section).

9
Power on Sequence cont’d
 Wet down laps for first operation to preventfriction to partand lap pad
failure.
 Close Operator window
 Select “Auto Mode”
 Press the “Cycle Start” button on the frontpanel.
 Verify thatlap pressure regulator isset for approximately 45 PSI (regulator
is located on right side of machine).
 Verify spindles are rotating, and slurry isdripping at expected rates.
 Verify thatpivot is moving.
 When the Cycle end lamp flashes, the partsare completed.
At this point, the machine has been setup for partsrun in Auto Mode. All
additionalcycles of same partsizes will only require partchanging and “Cycle
Start”.

10
Machine Cleaning and Waste Removal
Waste is removed from the machine by a pneumatically powered
diaphragm pump,*in between cycles.
The machine stainless enclosure and interior surfacesshould be gently
washed down, or wiped down atthe end of shift.
NOTICE:
 WHEN MACHINEIS NOT RUNNING ALL SPINDLESTATIONS, ORIS
SPRAYED WITH WATER FOR CLEANING, THE SUPPLIED YELLOW
COVERS MUST BE COVERING THE OPEN LAP SPINDLELOCATIONS!
 AT END OF SHIFTOF DURING POWER OFF, LEAVE OPERATOR
DOOR/WINDOW OPEN TO REDUCE HUMIDITYLEVELS IN MACHINE.
 POLISHING ABRASIVEMAKES GOOD PARTS, BUT IS EXTREMELY BAD
FOR MECHANICAL COMPONENTS, AND MAY VOID WARRANTY
REPAIRS ON ASSOCIATED COMPONENTS IF NOT PROPERLY
FOLLOWED.
Monthly inspection of Slurry tank should be performed for buildupof
solidified Slurry, and removed if so by reducing with water, and agitating
while pumping outusing the “waste button” (located on frontoperator
panel).

11
Maintenance
Proper maintenance of the SPM-1 is as importantasproper operation.
Under normaloperating conditions, the machine willrequire inspection, and
maintenance to insure reliable operation.
o Daily Clean Arborsto preventbuildup of abrasives
o Daily Clean interior stainless enclosure
o Monthly inspection of Belts (Arbor and Lap)
o Monthly inspection of spindle pulleysfor possible slurry contamination
o Monthly grease Lap spindle housings(1 pump each with grease gun)
o Monthly inspect slurry tubing at pump headsfor flat spots, or clogging
o Annualinspection of gearboxesfor properlubrication level

12
Maintenance cont’d
Arbor removal:
 Open operator window
 Select spindle arbor to be removed
 Press “PartUnclamp” button on frontpaneland unscrew center wedge of
arbor with flat blade screwdriver
 Release button
 Using a wrench, unscrewarbor(standard threads, counter clockwise to
remove)
 To install reverse procedure
 Clamping adjustmentsare made by tightening or loosening the wedge
Pivot Cover Removal:
 Remove power from machine at disconnectswitch
 Open rear doorsof machine
 Verify no person is near the pivot ,or in the operator area
 On the slide and pivot solenoids, activate the manualoverride
 The slide and pivot will activate to a convenientposition for access
 Open fronthinged operator panel
 Remove operator windowcover (door interlock cable mustbe unscrewed)
 Remove cap nuts and seal washerson pivot cover
 Lift closest edge of cover, then slide cover towardsrear of the machine
while lifting cover off
 Reverse procedure to reinstall

13
Removal of Lap belt:
 Remove pivot cover as outlined
 Loosen belt tensioner plate bolts (4)with a 3/16 Allen wrench (Tensioner is
located on lower rightof the slide unit)
 Remove serpentine belt (No componentsneed to be removed to change
belt)
 Inspectpulleys and spindles for free rotation
 Replace belt
 Tension plate againstbolt head using a large screwdriver for leverage
 Belt tension should be measured by ½” deflection midway between the
gearboxand tensioner
Removal of Arbor Belt:
 Open rear doors
 Loosen but do not remove tensioner hubslocated on left and right frame
verticals
 Remove belt
 Reverse operation to install (tensionerswill return proper tension)

14
Removal of Drawbars:
 Remove Arbors
 Power machine off
 Open rear doors
 Remove ejector cylinder bracketsand move away (leave tubing
attached)
 Pull drawbarsout
 InspectBelleville washersin drawbar cup for collapse, or over
compression (Replace if necessary)
 Reverse to re install

15
Troubleshooting
During machine operation, attimes it will be necessary to troubleshoot
operationalproblems, and determine causesof malfunctions.
The SPM1 hasbeen in service since 1999 with over 12 units Installed.
During this time, re-engineering and controlupgradeshave added to the
dependability of the unit.
The basic mechanicalfunction remainsthe same.
Most common items for troubleshooting are listed below.
Machinewill not power up: Possible Remedies:
 Is the main power switch on?
 Did anyone plug a device into
the outlet of the machine?
 Is the interior work lighton?
No response frompush buttons:
 Are access doorsclosed?
 Are status lights flashing?
 Is the Emergency Stop button
depressed?
R.P.M. is not displayed on display:
 Has the tachometer sensor
been disturbed?
 Doesthe display vary much?
Main disconnectfuses, Transformer
fuse (2amp), powersupply.
Faulty Button, Emergency Stop
depressed
Check gap on tachometer sensors
Test by waving metal shim in frontof
sensor, Replace switch.

16
Troubleshooting cont’d
During operation, a jumping sound
or vibration isfelt or heard:
 Are Lap and Arbor Belts
adjusted and in good
condition?
 Is there buildup of Slurry on
pulleys?
 Is the offset correct, and Lap
pressure below 60p.s.i. ?
During operation a squeaking noise
is heard:
 Are the Laps dry?
 Is the offset correct?
 Doesit happen withoutLap
pressure applied?
During operation, Lapsor Arborsdo
not rotate:
 Is the belt broken?
 Do drive units have a fault
alarm?
No Pivot motion during cycle:
 Is the piston stuck up/down?
 Is there air pressure to
machine?
 Did the piston move at all?
Possible Remedies:
Tension improper on belt, belt failure,
contamination, binding on spindle /
pulleys, bearing, improper offsetor
lap pressure settings
Dry Lap, Improper settings, bearing
issue
Belt failure, Binding, Drive failure,
Gearboxfailure.
Pivot switches need adjustment/
replacement, flow valves clogged, low
or no supply air pressure

17
Screen Shots, and Descriptions
Operator Panel:
 PartUnclamp: Pushing the button releases the part,
Releasing the button clampsthe part.
 Waste Pump: If option is installed, pushing the button
manually pumpsthe waste.
 Slurry Prime: Pushing the button manually operatesthe
slurry supply pump.
 Cycle Start: In auto mode pushing the button starts the
automatic cycle.
 Cycle Stop: In auto mode pushing the button stops the
automatic cycle.
 Reset: Resets the drives after Emergency Stop has
been released
 Emergency Stop: Pressing Stops all machine movement and
powersoff all motion control. Turn clockwise to release

18
Screen Shotscont’d
Login Screen:
(Touchscreen Display)
The Login screen is the first screen that appearson power up.
By touching the “Login” prompt, The “Access code “ screen will appear.
Defaultaccess code from Mfg. is “11111”

19
Screen Shotscont’d
Operation Selection Screen:
Load/Unload mode allowsyou to load and unload parts, when selected “Spindle
Select” screen appears.
Touching spindle # allowsyou to clamp/unclamp from“Unclamp” operator button
on Operator Panel.

20
Screen Shots cont’d
Program screen:
When the “Program” selection is made, the program screen is displayed.
Arbor speeds can be set, Lap speeds, Cycle time, and Slurry drip rate.
Cap and Cup should always default to Cap.

21
Auto Mode screen:
The “Auto Mode” screen displays programmed speeds and cycle times.
When “Cycle Start” on the operator panel is pressed, the “Actual” results will be
displayed.

22
Maintenance mode screen:
The Maintenance screen is intended for maintenance personnel to test operations
of the machine.
Functions include:
 Moving the slide forward/ Back
 Moving the pivot up/ down
 Jogging the spindles
 Jogging the slurry pump
A Login screen will appear prior to being able to view this screen.

SURFACE FX SPM1 MANUAL

Recommended

Recommended

More Related Content

What's hot

What's hot (10)

Viewers also liked

Viewers also liked (16)

Similar to SURFACE FX SPM1 MANUAL

Similar to SURFACE FX SPM1 MANUAL (20)

SURFACE FX SPM1 MANUAL