1
Dicing Spindle Manual V5.0
Content
Illustration
Page 1
Page Contents and illustration numbers
Page 2
Introduction to air bearings, spindle mounting
Fig 1
Page 3
Dicing Spindle general specifications
Fig 2
Page 4
GA of spindle, key parts
Fig 3
Page 5
Labyrinth seal
Fig 4
Page 6
Unpacking spindle from box
Fig 5
Page 7
Spindle test sheet (certificate of conformance)
Fig 6
Page 8
Driver connection
Fig 7
Page 9
Air supply/Filter set and elements
Fig 8
Page 10 Air supply continued
Page 11 Water supply
Page 12 Water-Air supply specification chart
Fig 9
Page 13 Contact brush setup
Fig 10
Page 14 Changing contact brush (with springs) B03862
Fig 11
Page 15 Changing contact brush (without springs)B06301
Fig 12
Page 16 Mounting Hubless blades
Fig 13
Page 17 Opening Hubless flanges
Fig 14
Page 18 Mounting Hubbed blades
Fig 16
Page 19 Graphs for Speed-Torque-Power
Fig 16/17
Page 20 Graphs for Speed-Vibration
Fig 18
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
2
Introduction
Loadpoint Bearings is the leading manufacturer of Dicing Spindles supplying all
original equipment manufacturers in the world with products that have become
accepted as industry standards.
A range of spindles to suit all types of dicing machine is available. These include flange mounted, gantry mounted and round
bodied cantilevered spindle styles. Spindles may also be customised to meet individual requirements.
The spindles cover a full range of blade diameters from 50 mm (2 in) up to and including 101 mm (4 in). For 50 mm diameter
blades, spindles have a maximum speed of 80 000 rpm and 1.2 kW of available power. Larger spindles for 101 mm blade
diameters have a maximum speed of 40 000 rpm and develop 3.0 kW of power. DC brushless motors are fitted as standard to
achieve maximum operating torque over a wide range of speeds. This makes the spindles suitable for cutting a variety of
materials ranging from silicon through to quartz. AC motors can also be fitted to spindles to meet customer drive specifications.
Spindles are fully water cooled to minimise thermal growth. They are also designed and constructed for maximum durability.
All spindle designs have been proven in heavy duty dicing applications.
Loadpoint Bearings can also fit electrical brushes for touch sensing circuits and supply balanced wheel mounts and spacers.
AC and DC drives specially matched to dicing spindle applications are available from Loadpoint Ltd.
s
Rear Flange Mounting
Surface Mounting
Fig 1
Sleeve Mounting (Gantry)
Types of Spindle
Mounting
Heavy Duty
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
3
Figure 2
General Specifications (consult drawings for more details)
Part Number
Mounting
Length (mm)
Wafer/Substrate Size (mm)
Body Diameter (mm)
D03423/
1
D03423/
3
D05890/
1
D05890/
3
D06671/
1
D06671/
3
D05716/
1
D05716/
3
Gantry
Gantry
R.Flange
R.Flange
R.Flange
R.Flange
F. flange
F.Flange
319
319
347
347
407
407
267
293
200-300
200-300
150-200
150-200
200-300
200-300
200-300
200-300
76
76
80
80
80
80
80
80
Blade Diameter (mm)
50-76
50-76
50-76
50-76
50-76
50-76
50-76
50-76
RPM (max)
60.000
60.000
60.000
60.000
60.000
60.000
60.000
60.000
Motor Type
Motor Power (KW)
Continuos Torque (Nm)
Axial Load (KG Max)
DC
1.2
0.4
14
DC
2.4
0.8
14
DC
1.2
0.4
15
DC
2.4
0.8
15
DC
1.2
0.4
15
DC
2.4
0.8
15
DC
1.2
0.4
15
DC
2.4
0.8
15
Radial Load (KG Max)
14
14
13
13
13
13
13
13
Axial Stiffness (KG/µ)
1.2
1.2
0.9
0.9
0.9
0.9
0.9
0.9
Radial Stiffness (KG/µ)
1.2
1.2
1.3
1.3
1.3
1.3
1.3
1.3
Wheelmount Runout (µ)
<1
<1
<1
<1
<1
<1
<1
<1
Shaftlock (optional)
Yes
Yes
No
No
No
No
Yes
Yes
D03604
D07058
D1001/4
D04136
D04137
D04283-4
Mounting
Body
Body
Body
Body
Body
Body
Length (mm)
406
462
346
412
442
346
Part Number
Wafer/Substrate Size (mm)
150-200
200-250
100-150
100-150
150-200
100-150
Body Diameter (mm)
75
110
82
82
82
82
Blade Diameter (mm)
80-100
125-150
50-76
50-76
50-76
50-76
RPM (max)
Motor Type
Motor Power (KW)
30,000
DC
3.5
30,000
DC
2.5
40,000
AC
1.0
40,000
AC
1.0
40,000
AC
1.0
40,000
AC
2.2
Continuos Torque (Nm)
2.1
1.5
0.2-0.25
0.2-0.25
0.2-0.25
0.25-0.4
Axial Load (KG Max)
110
70
18
18
18
15
Radial Load (KG Max)
50
40
8
8
8
8
Axial Stiffness (KG/µ)
3.6
3.0
0.8
0.8
0.8
0.8
Radial Stiffness (KG/µ)
2.0
1.8
0.7
0.7
0.7
0.7
Wheelmount Runout (µ)
Shaftlock (optional)
<1
No
<1
No
<1
No
<1
No
<1
No
<1
No
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
4
Figure 3, illustration of dicing spindle parts and layout
How an Air Bearing Spindle Works
The principle of an air bearing has been established for over 50 years. Compressed air flows to a reservoir surrounding
the bearing, from which the air passes through small holes called jets and into a narrow gap between the bore of the
bearing and the outside of the shaft.
From here the pressurised air runs continuously along the shaft until it escapes to atmosphere at each end of the bearing. When a radial load is applied to the shaft the pressure distribution automatically changes to resist the force.
The General Design of a Loadpoint Air Bearing Dicing Spindle.
FIG 3. (above) shows a typical Loadpoint dicing spindle design. The various parts of the spindle have been labelled to
help aid identification.
The only wearing part of a Loadpoint air bearing dicing spindle is the shaft earthing brushes (if fitted).
If continuous and planned maintenance is carried out a Loadpoint air bearing spindle should give many years of trouble
free service.
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
5
Figure 4, Flinger/Labyrinth Seal
This is a very important feature to ensure that cutting water and contamination cannot get
inside the spindle from the wheelmount area. This improves spindle reliability in hostile cutting environments. This is a standard feature in all dicing spindles, the rotating seal is blue in
colour and easy to identify. The redline indicates the air exhaust out of the spindle, and the
blue lines represent the cutting water trying to get inside the spindle.
The rotating flinger/seal prevents the water entering the spindle.
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
6
Figure 5
Unpacking spindle
Remove and inspect test sheet and check results comply to specification
Check all parts/accessories are in box and remove spindle careful without touching the shaft. Water and air fittings are supplied, please do not use PTFE tape on air fitting, as the small particles
can get inside the small air gap and cause damage.
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
7
Figure 6
spindle test certificate, every spindle has a 22 point test.
CUSTOMER.:
SPINDLE TYPE.:
Dicing
CUSTOMER PART NO.:
SPINDLE SERIAL NO.:
SPECIFICATION REVISION.:
SHAFT NO.:
OUTLINE DRAWING NO.:
SPECIFICATION
UNIT
(METRIC)
See Drawing
PASS
80 or less @ 5.5 bar
l/min
3 Cooling Water Flow
1.6 @ 2.0 bar
l/min
4 Wheelmount Location Diameter
19.050/19.047
mm
5 Wheelmount Runout radial
1.0 or less
um
6 Wheelmount Runout axial
1.0 or less
um
See Procedure
PASS
INSPECTION
1 Etching Check
2 Air Flow
7 Hall Sensor Check
8 Spindle Rotation Direction
D05716/3
TEST RESULT
CW or ACW
9 Maximum Spindle Speed
60,000
RPM
10 Radial Load at Shaft Nose (Static)
13
kg
11 Radial Stiffness at Shaft Nose (Static)
0.9
kg/um
12 Axial Load (Push)
15
kg
13 Axial Stiffness
0.9
kg/um
70 or less
db
14 Noise at 60,000 RPM
15 Maximum Vibration (Spindle Front)
15 Maximum Vibration (Spindle Rear)
0.25 or less to 50,000
RPM
1.0 or less to 50,000
RPM
mm/s
mm/s
16 Run Test
6 Hours
PASS
17 Brush to Brush Resistance Check
30 (max)
Ohm
18 Brush to Body Resistance Check
1,000,000 (min)
Ohm
19 Parts with Spindle
Check Parts List
20 Shaft lock tested
500 times
Yes/No
21 Blade nut supplied
B05979/5897
Yes/No
22 Blade Change Tool
B06001
Yes
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
8
Figure 7
Connecting Drive.
Loadpoint supply Sieb Meyer SD2S drivers configured to run dicng spindles. There are a range of powers available to suit different motor powers. All connections to spindle are the same and all cables are provided with the
spindles.
Loadpoint Bearings can mail or email driver manuals.
The IO can be through serial RS port or through parallel data connections on the front panel.
All firmware and software parameters are pre-set in the driver ready for operation.
Consult Loadpoint for technical advice.
Range of drives available from 1KW-6KW
Drives can output to PC, speed, current, temperature in real time graph format
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
9
General Advice on Air Supplies and their Maintenance
The continued reliable performance of the spindle is dependent on its air supply.
The following is Loadpoint’s recommendations for the air supply equipment and maintenance
please also refer to FIG 8 below.
Figure 8 Air Filter Set
We recommend a 3 filter arrangement as shown in FIG 8 (above).
3 stage SMC pressure regulator set AW30-F03D.
Three element filters inside the
AF30P-060S (5micron).
AFM30P-060AS (0.3micron).
AFD30-F03D (0.01micron).
air set remove water, oil, gas and vapours
(prefilter for fluids, water, )
(coalescing filter to remove oil)
(active charcoal to remove oil vapour)
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
10
The first filter we recommend is a pre-filter and regulator. This filter should be a maximum 5 micron particle size. Finer filters can be used (1 micron particle size) though it is
important that any filter is maintained to stop clogging and therefore air starvation of the
spindle. We normally fit an auto drain 5 micron filter which has an indicator built into the
top. The indicator changes colour when the flow becomes low at which point the filter
cartridge should be changed. Please note that we do not recommend the use of ceramic
elements since they cause contamination if the elements are damaged in transit. The
pressure regulator should be fitted to maintain 80 p.s.i. (5.5 bar) line pressure.
The second filter is a 0.3micron oil coalescing filter with auto-drain. This filter removes oil
The final filter unit we recommend in sequence is an activated charcoal element
type to absorb any oil vapour in the air supply, (0.01micron) . If you suspect any oil vapour possibilities then this filter is mandatory since nothing will ruin the bearings quicker
than oil vapour condensing in the tiny air jets and so blocking the fine clearances in the
spindle.
Air supplies are ideally taken from an oil free compressor or a rotary screw type unit
with subsequent freeze drying into an expansion chamber. Air lines should ideally be
new to avoid any possibility of contamination. Air line fittings should not use sealing tape,
which can (if used carelessly) allow tape particles into the downstream air supply, which
could then block vital air jets.
A pressure sensitive electric switch should be fitted between the filters and the spindle to sense any reduction in air pressure due to partial filter blockage. The pressure
switch should be set to 70 p.s.i and linked to the spindles electrical drive system. If the
line pressure drops below 70 p.s.i, the spindle drive will then be automatically turned off.
This will protect the spindle by stopping its use on low air supply pressure. An audible or
visual signal is also valuable to alert the machine operator to a malfunction.
What is most important is that the air must be free of oil in both particle and vapour content.
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
11
Spindle Coolant Supply and Maintenance
Spindles are fitted with water cooling systems for one of two reasons, either to maintain
a constant, near ambient operating temperature for minimising thermal growth or in less
critical applications simply to remove excess heat that might damage the motor or reduce
bearing operating clearances.
All water cooled spindles have specified flow rates which should be strictly adhered to.
The recommended cooling system consists of a chiller, recirculating clean, distilled water
in a closed loop arrangement. The chiller, piping and fittings should all be manufactured
from non corrosive materials. Water inlet temperature to the spindle should be controlled
and maintained at 18 – 21 degrees Centigrade. Sensors for detecting the presence of
coolant are recommended and should be used to switch off the spindle drive in the event
of coolant loss.
Degradation of water quality over extended periods of operation can occur due to bacterial growth. This should be avoided as it may lead to a blockage of the coolant feed pipes
or porting within the spindle. The use of proprietary bacterial agents as instructed by
their manufacturers provides a satisfactory solution.
Wheelmount Removal
We do not advise the removal of the wheelmount at the customer’s premises. Removal of
the wheelmount will effect the spindle balance and therefore its performance may be
compromised.
Vibration.
If you are experiencing a deterioration in surface finish on the components or the spindle
is “buzzing”, this may be caused by the tooling fitted to the spindle. Before returning the
spindle for repair check that all tooling including wheel mounts and spacer sets are balanced.
Preventative Maintenance.
Routine maintenance is limited to changing the air filter elements at regular intervals as
recommended by the your machine supplier or filter supplier. This will ensure the air supply remains uncontaminated.
Service.
Maintenance and repair of the spindles is not recommended. If required, the spindles
should be returned to Loadpoint Bearings for full survey and diagnosis. If possible any
relevant information regarding the reason for failure should be enclosed with the spinRegistered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
12
Figure 9, Services Quality and Specifications.
Description
Specification
Comments
Air Compressor:
Rotary Screw type, oil free.
Service annually
Air Quality:
<0.1PPM contamination (99.5%).
Air Regulator:
3 stage SMC pressure regulator set AW30-F03D.
Air Filters:
AF30P-060S (5micron).
See air filter inspection note below
AFM30P-060AS (0.3micron).
Mist separator
AFD30-F03D (0.01micron).
Micro mist separator
Min 5Bar (75PSI).
Protect spindle with pressure switch operating at 5Bar (75PSI)
Air Pressure:
Nom 5.5Bar (80PSI).
Max 6.0Bar (90PSI).
Air Reservoir:
10Litre, (near to equipment).
Prevents spindle failure due to sudden air loss
Air Humidity:
Air dew point -15ºC<
Use dessicant based air drier, for lowest dewpoint
Room Temp:
21-23ºC
To maintain spindle thermal stability and new condition
Coolant Water:
21-23ºC temp controlled (as room temp)
Spindle cooled with recirculating water to ensure
(motor and body)
Cutting Water:
thermal stability and performance to spec.
+2ºC higher than room temperature
To avoid internal spindle condensation
Do not distort spindle body during clamping.
Consult website for more information
(if applicable).
Spindle Clamping:
Spindle Connectors: Do not use PTFE tape on air fittings
Do not obstruct air exhaust
PTFE tape can get inside air spindle and cause seizure
Check spindle drawing for location of exhausts
Pipe exhaust away where necessary
Spindle Cleaning:
Always clean work area of spindle before
Keep air supply on during cleaning
machinery shut down.
If work area very dirty, leave air on 24 hours per day
This avoids contaminants entering spindles.
Air Filter Inspection:
Monthly
Signs of oil or water, shut down machinery and investigate cause
Replace filters and air pipes with new prior to running equipment
Carbon Brushes:
If applicable
Do not keep constant current through brushes
Pulse current during contact setup only
Balancing:
Rotating parts balance to G0.4 (1/1000gcm)
Use loadpoint bearings approved balanced parts only
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
13
Figure 10, Contact Setup, Carbon Brushes.
When blade does not touch chuck, no current flows
thro from chuck to brushes
Brushes
Brushes
0 volts
5 Volts applied to chuck
When blade touches the chuck as below, current
should flow from chuck to brushes, 10mA maximum.
5 volts 10mA max
Brushes
5 Volts applied to chuck
Note, the carbon brushes should only have voltage applied during contact setup. After contact setup
completed, all voltage should be removed from brushes. Please use a relay to isolate brushes from I/
O floating voltage.
It is recommended that during contact setup operation the spindle speed reduced to 15,000 rpm or
lower. This is to remove any chance of contact setup problems with brush bouncing or bad contact to
the shaft.
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
14
Figure 11….
Changing Brushes with spring attached, type B03862.
Unscrew Brush
Pull out
brush
Drop inDrop in
new new
brush brush
Screw in
to secure
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
15
Figure 12
Changing Brush type B06301, (no springs)
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
16
Figure 13, Mounting of Hubless Blades
Tool for mounting and
removing flange
Wheelmount
Push hubless flange up against wheelmount
Apply blue lock nut, clockwise for shaft
rotating anti-clockwise
Apply black lock nut, anticlockwise for
shaft rotating clockwise
Tool for tightening black or blue
locknut
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
17
Figure 14, Opening of Hubless Flange
Remove Hubless Flange from
Wheelmount
3 pin fixture for mounting
hubless flange
Locate 3 holes on rear of flange
to the 3 fixture pins
Remove separated flanges from fixture
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
18
Figure 15, Mounting of Hubbed Blades.
Hubbed Blade mounted on
wheelmount directly
Fit black nut anticlockwise thread, blue
nut clockwise thread
Blade tool for
mounting and
demounting
Universal tool
for black/blue
nut
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
19
Figure 16 Speed/Torque Graph, low power 1.2KW and high power 2.4KW spindles
Figure 17 Speed/Power Graph, low power 1.2KW and high power 2.4KW spindles
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]
20
Figure 18 Speed/Vibration Graph, low power 1.2KW and high power
Registered Office: Loadpoint Bearings Ltd, 67 Haviland Road, Ferndown Industrial Estate, Wimborne, Dorset, BH21 7PY United Kingdom.
Tel: +44 (0)1202 894447 Fax: +44(0)1202 871641
www.loadpoint-bearings.co.uk email [email protected]