Spindle Setting Analyzer PPC Curve Ver Program Manual Serial by sanmelody


          PPC Curve
           Ver 14.4

Spindle Setting Analyzer
      PPC Curve
        Ver 14.4

    Program Manual

    Serial Number #
      Password :
         February 2011

        E-mail Contact

         SpinTech, Inc.
      Gresham Oregon USA

                                       PPC Curve
                                        Ver 14.4

     o Major changes
1.   About PPC Curve Analysis
2.   Menu
3.   LOGIN
4.   DAQ Data Acquisition
     4.1. DAQ Preparation
         4.1.1. Cable connection
         4.1.2. Green switch Setting
         4.1.3. Spindle Speed Setting
         4.1.4. Push Pull Force Setting (DAQ Loading Range)
         4.1.5. 3 Points Displacement sensors Zero Adjustment
         4.1.6. Load Cell Zero Adjustment
         4.1.7. Data File Name
     4.2. Data Acquisition
     4.3. List of Warning for DAQ and Analysis programs
     4.4. Renew of ‘PPC in file’ in case of Warning 4
     4.5. Good and Warning data Examples of DAQ
5.   Analysis Program
     5.1. Analysis
         5.1.1. Bearing Setting Analysis for Fixed Arrangement
         5.1.2. Local Stiffness Analysis
       Example of Preload Spindle Analysis
       Example of Zero Preload Spindle Analysis
         5.1.3. Spring or Hydraulic Preload Analysis
         5.1.4. DT Analysis
     5.2. Load Compensation
     5.3. Simulation
         5.3.1. End Play Simulation
         5.3.2. Preload Simulation
     5.4. Remote Analysis
6.   PPC Curve Generation
     6.1. Automatic generation by DAQ program
     6.2. Generation by PPC Curve Generation program
7.   Data Recording
     7.1. Analysis Screen Record
     7.2. Data File Transfer to EXCEL
     7.3. SpinTech PG file
8.   Error Message Trouble Shooting

                                   PPC Curve
                                    Ver 14.4

   o Major Changes in Ver14.4

          i. PPC Curve Optimization program:
New version program generates wide range of PPC curves. It is optimized fit best
with the actual data by increasing the number of data base pattern. The PPC
Curve generation is based on three sources, Measurement of spindle
characteristic, DATA Base in the program and Input information for the
application. Program will generate it automatically just after spindle
measurement. It will take for 5 minutes or more. Program can generate PPC Curve
spindles with preload as well as end play condition. This eliminates the need
preparing a dummy spindle with end play which was the base of Master Curve

         ii. Introduction of Temperature recoding.
The new program will allow temperature input manually and automatically
(Option) recording room temperature and housing temperature. This will
provide the preload vs. temperature characteristic of the spindle in quantitative

        iii. Upgrade of DAQ and Analysis Warning system.
The program is upgraded for the warning guide line utilizing the local stiffness
analysis result. This will provide better guide line for heavy preload DATA.
Good data provide repeatable good analysis. The Warning system allows identifying
the source of error at the time of DAQ.

        iv. Remote Technical service.
Analysis program include option for Remote Analysis Button. This will send the
data to SpinTech for further details review and comments. (Annual Technical
Service is required.)

        v. PPC load monitoring during DAQ program.
Indicator Back panel change the color when the load is over PPC load.
Green:       100%-110% of PPC Load
Light Green: 110%-120% of PPC Load
Red:         Over 120%

         vi. 3 Point Zero Adjustment
3 point zero adjustment is easier with large screen indicators and spring nut

                                     PPC Curve
                                      Ver 14.4

1. About PPC Curve Analysis

PPC Curve:
PPC Curve is a hypothetic curve representing a spindle characteristic of zero
endplay and zero preload condition in axial direction. The program generates it
automatically after DAQ. It is generated based on three sources, Measurement of
spindle characteristic, DATA Base in the program and Input information for the
application. The program analyzes preload amount by measuring distance between
the data spots and the PPC Curve at a PPC Load. PPC Curve is displayed on
screen as blue line. Measured DATA spots are shown in red dots.

PPC Load:
PPC stands for Push Pull Constant. It should be set out side of preload range.
PPC load is initially selected depend on the measured data range. Once it is
stored in file, it is used for all of same model. The “PPC in file” is displayed on
DAQ screen. The DAQ loading range should be 110% ±10% of “PPC in file”.

2. Menu
A black arrow appears on left upper corner of screen when SpinTech program
                             The arrow is black when program is running.
                             It is white when the program stops.
                             Click white arrow to start program.

                              Click Stop button to stop program.

                              Select 0 for English or 1 for Japanese before Log In.

                                    PPC Curve
                                     Ver 14.4

Serial number: Marked on a label of the control box.
Password: Supplied with the program matched with the serial number and can not
be changed.
Model Name: Enter a test name or model name of the spindle. All DATA and
Master is filed under the file name. Different spindle application required different
file name. Less than 16 letters including space.
For existing file name, use pull down menu in the file list.
Bearing Series: Select bearing series used on the spindle.
Ball Material: Select ball material steel or ceramic of the bearing. Steel only for
Tapered Roller Bearing.
Application: Select spindle application for machining center or not.
Nose Bearing: Select nose bearing arrangement, single row or double rows.
Setting Bearing: Select rear bearing arrangement, Fixed Position or Spring Preload.
Brg Bore Size: Enter bearing bore size mm.
Contact Angle: Enter Angular contact bearing angle in degree ( °).

Max Speed rpm: Enter maximum spindle speed in rpm.

After entering all information, click OK. If there is one or more information missing,
login is not accepted.

                                   PPC Curve
                                    Ver 14.4

4. DAQ Data Acquisition
   4.1. DAQ Preparation
       4.1.1. Cable Connection
                                         To run DAQ, it is necessary connect
                                         control box and PC matching with the
                                         serial number. Following messages would
                                         show up on screen if it these are not
                                         connected to run DAQ.

       4.1.2. Green Switch Setting

Preparation of DAQ: Setting five green switch buttons.
   • Screen Cleaner: Click the button to clean up the graph.
   • Disp Sensor: When displacement sensor is mounted spindle front face,
      keep switch to green. If you measure from rear side of spindle, switch the
      direction of the sensor by changing it to rear/yellow.
   • Fixed or Sprig: When measuring preload for fixed position bearing
      arrangement spindle, keep this switch to green, If the spindle is spring or
      hydraulic preload, turn this switch to Spring/yellow
   • Zero Adjust
      Switch from DAQ (green) to Zero Adj (Yellow) for 3 point sensors initial
      zero setting..
   • Temperature
      Default is Manual (Green), Switch to Yellow when Temperature sensors
      are added to the system.

                                   PPC Curve
                                    Ver 14.4
       4.1.3. Spindle Speed Setting
We recommend spindle of about 1000rpm for high speed spindle 8,000rpm. If
spindle would rise a temperature during the measurement, change it lower speed
which would require more time to measurement complete. .
       4.1.4. Push Pull force setting. (DAQ Loading range)
    • New model: DAQ loading guide line. Use 6 times of anticipated preload for
       the spindle. For example when max preload is expected 500N, Push Pull
       force (DAQ loading range ) should be more than 3,000N.
    • Push Pull force for DAQ should be 110% ±of “PPC in file” value displayed
       on DAQ screen.
    • If the DAQ loading range is out side of guideline, analysis program will
       display warning messages and blinking red on analysis result. For high
       preload data, “PPC required” is shown. Since analyzed preload is not
       accurate, the PPC required is not accurate as well. It is a guide line for
       trail to establish new PPC.
Indicator Back panel changes the color when the load is over PPC in file load.
Green:          100%-110% of PPC Load
Light Green: 110%-120% of PPC Load
Red:            Over 120%

       4.1.5. 3 Point Displacement Sensor Zero Adjustment
                               Click “Zero Adjust” switch to make it yellow.

                                 Click “START” then three indicator show up on
                                 the screen.
                                 Adjust all three displacement sensor zero
                                 position within ±0.1mm. When it is adjusted
                                 Indicator will change color from Red to green.
                                 Make all indicators to green.
                                 Click “EXIT” and restart DAQ from Main menu.

       4.1.6. Load Cell Zero Adjustment
                      Click START button and adjust Load Cell Zero Adjustment
                      dial on right upper corner in DAQ Screen.
                      It is not necessary to adjust exact zero while program will
                      make adjustment automatically.

                                     PPC Curve
                                      Ver 14.4

        4.1.7. Data File Name.
After Start button clicked on DAQ screen, Spindle Model name is shown up as the
file name entered at the Log In program. This file name links with model
information for DAQ and Analysis programs. Pick up a data file and/or modify it
while it will over write with new data. It requires an extension of “.lvm” at the end
of the file name.

   4.2. DAQ Data Acquisition
            Spindle need to be rotated to measure the accurate spindle
            displacement under the axial force. The recommended spindle speed
            is 1000rpm. It can be above 1000rpm to reduce the measuring time.
            It can be 500rpm or less to reduce the spindle temperature change if
            required. DAQ starts by clicking “START” and operate the push pull
            jack handle. Monitoring the screen, rotate the handle to push (or
            pull) side first to achieve the maximum load then reverse the rotation
            to achieve maximum of pull load and return to zero load. After
            completing one cycle of the push load and pull load, click
            “ANALYSIS” for the analysis result.

                                   PPC Curve
                                    Ver 14.4

   4.3. List of Warning for DAQ and Analysis programs

Warning messages and red blinking will appear on screen when the measured data
is not appropriate for accurate analysis.

Warning Number                  Contents                 Impact of Analysis result
       1          Measurement force is less than        Larger difference, larger
                  “PPC in file”                         analysis error.
       2          Poor data point.                      Large Error
                  Short Measuring Time
       3          DATA Scatter                          Larger Scatter, larger
                  Unstable Sensor or                    error.
                  Poor Spindles Alignment
  4 Important     PPC in file and DATA range is not     Large error.
                  enough compared with the preload      DAQ again for new PPC
                  of spindle.                           and DATA..
       5          PPC required exceed capacity of       Only for AS-SC-40
                  AS-SC-40 (5,000N).
       6          DATA irregular                        Can not make analysis.
       7          Insufficient DATA                     Skip Analysis
                  (for Zero Adjustment)
       8          Measurement force is over 120% of     Larger difference over
                  “PPC in file”.                        120%, larger error.

   4.4. Renew of “PPC in file” in case of Warning 4

   •   DAQ again with the force as “PPC required” value.
   •   If PPC file exist, change Model name at the time of Login or delete the old
       PPC Curve data locate at C;\SpinTech PG\PPC Curve.
   •   To keep old “PPC in file”, log in with different model name for new “PPC
       in file”. One model, One PPC in file

                              PPC Curve
                               Ver 14.4

4.5. Good and Warning Data Examples
    4.5.1. Good Data Example

   4.5.2. Warning 1: DAQ loading range is less than “PPC in file”

                           PPC Curve
                            Ver 14.4

4.5.3. Warning 2: Need more data points

4.5.4. Warning 3: Large Scatter Unstable sensor

                            PPC Curve
                             Ver 14.4

4.5.5. Warning 3 Scatter Poor Alignment

4.5.6. Warning 4: -Important- PPC and data is not sufficient.

                          PPC Curve
                           Ver 14.4

4.5.7. Warning 8: DAQ Load exceed 120% of “PPC in file”

                                   PPC Curve
                                    Ver 14.4

5. Analysis Program
   5.1. Analysis
       5.1.1. Bearing Setting Analysis for Fixed Arrangement

                                                           Select the PPC file from
                                                           pull down menu. All of
                                                           PPC data filed in the C
                                                           drive/SpinTech PG/PPC
                                                           Curve holder are shown
                                                           in the menu. Select data
                                                           Blue line is the PPC
                                                           Curve for the spindle.
                                                           This curve represents
                                                           the spindle character at
zero endplay and zero preload. This curve also simulates the setting when value of
a preload or endplay is type in the simulation input area.
Red dots are measured data spots of the spindle.
Green line is an analysis curve of the spindle character simulated from the PPC
curve with the preload setting result.

       5.1.2. Stiffness Analysis

                                               Spindle Axial stiffness Analysis
                                               result is shown in graph display.
                                               Vertical axis is Axial load N and
                                               horizontal axis is stiffness N/um.
                                               The curve indicates the change of
                                               stiffness at different load. This
                                               would be strong tool to evaluate
                                               the spindle characteristics.

                        PPC Curve
                         Ver 14.4   Example of Preloaded Spindle Analysis   Example of Zero preload Spindle Analysis

                                     PPC Curve
                                      Ver 14.4

       5.1.3. Spring Preload Analysis
                                               When data is taken from spring or
                                               hydraulic preloaded spindle, master
                                               is not required for the analysis.
                                               Switch to Spring/yellow button and
                                               click START. Preload amount is
                                               analyzed as the intersection point
                                               of spring deflection curve and
                                               bearing deflection curve. If the
                                               spring stiffness is larger than 50 %
                                               of nose bearing stiffness, it is
automatically analyzed as the “Fixed position” spindle.

       5.1.4. DT Step Analysis
                                                        In case of 2 Rows bearing
                                                        arrangement, there is a case
                                                        that zero zone area has a
                                                        stiffness slope while analysis
                                                        indicates end play. This could
                                                        happen because of DT error
                                                        of stacked bearings. Program
                                                        will automatically detect the
                                                        possible DT error and report
the amount of zero zone and stiffness at zero zone which correspond to single
row’s stiffness.
    5.2. Load Compensation.
In case of vertical spindle, a spindle self weight causes the bias load on
measurement. When the spindle is setting endplay, program adjusts automatically
the amount of the load for the analysis. For the preloaded spindle, spindle weight
can be manually input.

                                PPC Curve
                                 Ver 14.4

5.3. Simulation
The master curve/Blue line simulates the setting typed in the simulation
column. To switch the simulation from endplay to preload or reverse, input
zero and run to show up the input column.
    5.3.1. End play simulation
                                                Type a value in End Play
                                                column and click START.
                                                Example shows 0.015mm
                                                endplay simulation in blue line
                                                while red spots indicates
                                                measured data of spindle
                                                deflection. The analysis result
                                                is -0.0005mm Preload.

   5.3.2. Preload Simulation
                                                Type value in the preload
                                                column and click START. The
                                                example shows 500N preload
                                                simulation in blue line. The
                                                red dots are measured data
                                                spots and the green line is
                                                analyzed curve.

                                                  Next example shows
                                                  preloaded spindle data and
                                                  500N targeted preload
                                                  Current spindle setting is
                                                  252 N preload or -0.0164mm
                                                  dimensional preload.
                                                  Spacer Adjustment amount
                                                  to achieve the target
                                                  preload is calculated as

                                  PPC Curve
                                   Ver 14.4

   5.4. Remote Analysis Services (Annual Technical Service required.)
SpinTech Expert provides “Remote Analysis Services” to evaluate the Test
method, Test Result, DATA and Analysis.

To use this service, connect PC to internet and Click “Remote” Button ON at
the right upper corner of “Analysis” Screen.

When Analysis complete, click Yes on popup message show up on screen.

Enter return e-mail address and your message, questions in the column.
The SpinTech engineer comments will be e-mailed normally within a day.

                                   PPC Curve
                                    Ver 14.4

6. PPC Curve Generation

    6.1. Automated Generation by DAQ program.
After the DAQ completed, and click the “analysis”, program will generate PPC
Curve for the data if the model name is not filed yet. Program will analyze the
data with existing PPC for the model name in the file already. PPC Curve is
stored in a file C:\SpinTech PG\PPC Curve\(model name).lvm. PPC Curve
Optimization Program will run for the PPC generation. This will take for 5 minutes
or more. The screen has a blinking lamp of Analysis button during running of the
PPC optimization program.

   6.2. Generation by PPC Curve Generation program. .
       6.2.1. Login with the model name to be used.
       6.2.2. Open PPC Curve generation program from Main menu.
       6.2.3. Model name is shown at right top corner. Enter PPC file name in
             column below. Existing file name can not be used.
       6.2.4. Select DATA file and click Start.
       6.2.5. Red dots are data. Blue line is a new PPC Curve. The file locate in
             C;\SpinTech PG\PCC Curve\(New Model Name).lvm
       6.2.6. The new PPC in file with from data for the model can be used for
             Analysis program.

                                   PPC Curve
                                    Ver 14.4

7. Data Recording
   7.1. Screen Recording
DAQ, ANALYSIS and MASTER generation screen can be print on a printer
connected to the PC by clicking PRINT Button.
   7.2. Convert DATA file to Excel sheet.
Analysis program stores the analysis result of each test number, preload and
setting in a file locates at C:¥SpinTech PG¥Result.
   7.3. Data files.

All data in the DATA file are tab separated data. It can be read by Excel program.

                                  PPC Curve
                                   Ver 14.4
8. Error Message, Cause and Fix

Program   Error Msg.         Cause                       Fix
Log In    Some Info is       Log In information is not   Log in again and
          missing            completed for new file      complete input all
                             name                        login information
Log In    Password is not    Password is not match       Input correct
          Correct.           with Serial Number of       password.
                             control box.
DAQ       No Signal from     There are 5 causes for      Check next 5 steps
          DAQ Card.          this msg.                   one by one till fixed.
          Please insert
          DAQ Card in PC.
DAQ       No Signal from     1) No Signal from DAQ       Check insert of Card,
          DAQ Card.          card                        flat cable connection
          Please insert                                  and control box
          DAQ Card in PC.                                power.
DAQ       No Signal from     2) NI-DAQ6024E card is      Use PC with OS of
          DAQ Card.          not compatible with         XP or 2000.
          Please insert      Windows Vista
          DAQ Card in PC.
DAQ       No Signal from     3) No driver for the card   Install it by following
          DAQ Card.          It should be found at       Windows new devices
          Please insert      Control Panel/System/       wizards. It is included
          DAQ Card in PC.    Hardware/Device Manager in SpinTech program
                             /Data Acquisition           CD.
                             devices/ DAQCard-6024E

                                 PPC Curve
                                  Ver 14.4
Program   Error Msg.         Cause                        Fix
DAQ       No Signal from     4) Other than NI-DAQmx       Open Measurement
          DAQ Card.          driver is assigned at        and Automation
          Please insert      Measurement and              program. Right Click
          DAQ Card in PC.    Automation program. .        Devices and
                                                          Interfaces to create
                                                          new. Select NI-
                                                          DAQmx Simulated
                                                          Device/E Series
DAQ       No Signal from     5) Devices name is wrong     Right Click active
          DAQ Card.          at Measurement &             NI DAQCard-
          Please insert      Automation. The name         6024E:”Dev?” and
          DAQ Card in PC.    should be NI DAQCard-        rename it to Dev1
                             6024E:”Dev1”                 instead of Dev?
DAQ       Not enough         Number of Sampling Data      Click continue to
          sampling           is less than expected.       proceed with current
                                                          number of sample.
DAQ       Connect Cable      The identification signal    Check power cable,
          and Power on       from control box does not    power on, and SN
          DAQ Control box    match with input of Serial   number on the control
          with same Serial   Number.                      box.


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