Knowledge Basetag:www.t2k.net,2008:/support/kb/12008-09-24T22:47:19ZT2K Support Knowledge BaseMovable Type 3.35IMTS 2008tag:www.t2k.net,2008:/support/kb//1.132008-09-15T22:41:02Z2008-09-24T22:47:19ZT2K exhibited at the IMTS 2008 at McCormick Place's Lakeside Hall in Chicago from September 8-13. The show was a great success with many inquiries regarding both our spin window systems, and the new ZeroClamp zero point clamping system from...
sales@t2k.net.]]>
Explanation of Parts in Typical Retrofit Unit Ordertag:www.t2k.net,2008:/support/kb//1.142008-02-27T01:06:26Z2008-09-26T21:13:26ZThe typical Visiport® retrofit installation to a new or existing machine tool consists of specifying 4-6 discrete parts, and evaluating optional connection fittings, disc coating, and the machine tool window itself. Discrete parts required for complete installation 1. Visiport® Base...
The typical Visiport® retrofit installation to a new or existing machine tool consists of specifying 4-6 discrete parts, and evaluating optional connection fittings, disc coating, and the machine tool window itself.
Discrete parts required for complete installation
1. Visiport® Base System
Includes Base Unit, Standard Mounting Plate Assembly, Bulkhead Assembly.
2. Conduit
Goes between "Installation Point" on window and "Bulkhead Point" on sheet metal.
Required not just to exit the conductors from cabin, but also to aspirate the Visiport.
Aspiration required to prevent fogging and overcome any disc pumping action.
Comes standard with matched length (conduit+8" prox.) of 2-conductor wire harness.
Sold in unit lengths, i.e., 1.5-m takes 2.0-m price point.
3. Fitting
Attaches conduit to Visiport base (and bulkhead assembly).
Priced as 1 part (T2K supplies 2nd matched fitting for Bulkhead Assembly end).
4. Power Cable
Goes between "Bulkhead Point" and "Power Supply Point".
Robotics-grade 3 conductor (2+ground) cabling.
Sold in unit lengths, i.e., 1.5-m takes 2.0-m price point.
Also sold in legacy 10-m length (Code P or P/N 220A7015).
5. Power Supply [option]
Required if machine does not have 5 amps, 24VDC to dedicate to unit.
Visiport® consumes only 200mA under no-load conditions.
When used with high-pressure coolant, Visiport® draws up to 4.8 amps.
T2K power supply is UL508 compliant with UL/TÜV/CE approvals.
Alternately, customer may supply own fully-regulated 120W power supply.
6. Installation Vacuum Pump [option]
One-time purchase for installers of Visiport & DiscAir systems (reusable).
Used to quickly and completely adhere standard VHB adhesive to substrate.
Helps installer identify color-shift in adhesive that had 'made' to substrate.
Comes with 4-40 & M4 thread adapters for T2K Mounting Plates/Bases.
Additional options and installation evaluation steps:
Optional Connection Fittings
When considering the necessary parts to make connections between the "Installation Point" and "Bulkhead Point", and between the "Bulkhead Point" and the "Power Supply Point" span distances, there are 90° Strain Reliefs and Adapters available for the Terminal Box bulkhead assembly that allow you to modify the plane that the Conduit and Power Cable will drape in, to allow for smooth opening of doors and windows to which the Visiport® system is installed. Please refer to the price sheet for price and part number details.
DLC
Diamond-like carbon (DLC) coating is an option for the glass disc supplied with the Base Unit. The few atoms deep layer provides exceptional scratch resistance and lubricity to the regular chemically strengthened glass used. This coating is popular with aerospace machining operations, but it sufficiently costly that T2K advises customers to evaluate the standard disc's life under operating conditions prior to making the 2X cost to 5X plus wear calculation. Please note that the coating does not impart any additional impact resistance to projectiles, as the coating is only several atoms thick.
Machine Tool Window Evaluation
Finally, there are several issues regarding the condition of the machine tool window that must be considered by the Visiport® installer in order to ensure a successful installation. The window must not be so scratched as to prevent proper viewing through the window. The Visiport® does not replace the existing window, it augments the window that is already there. Merely installing a Visiport® system over a scratched up window will not provide the desired visibility.
Secondly, the windows installed into machine tools are of two types, namely polycarbonate plastic or a multi-layer machine tool safety window composed of a glass layer on the wet side of the window for scratch resistance to chip activity together with a polycarbonate plastic layer for impact resistance, either with an edge seal or metal frame for containment and mounting. Machine tool safety windows that meet clarity requirements can be easily cleaned up to allow very successful bonding of the VHB adhesive that is used in the standard VHB Mounting plate.
Polycarbonate windows are another story, in that chip activity and oil contamination are typically such that the window found on a machine tool in use cannot be cleaned sufficiently to accommodate bonding of the VHB adhesive. While 3M's VHB adhesive is tremendously strong, it needs to bond to the window substrate rather than to a thin film of oil on the surface of the substrate, and due to the wetting action of modern metalworking fluids, together with the scratches and pitting common to chip activity, a used window must be considered contaminated and should thus be replaced at the same time a Visiport® installation is done.
As a customer service, T2K can easily provide you with a replacement polycarbonate window of any given size and thickness, with or without a hole pattern, and can also provide premounting of the VHB Mounting plate in a specified location to speed the installation process. Given the necessary dimensions, T2K can also provide custom aftermarket machine tool safety windows from SEGE, the world's leading manufacturer, with full CE Mark impact class requirements, at an extremely competitive cost.
With machine tool windows having been classified as a wear item in some countries that should be periodically replaced to prevent metalworking fluid embrittlement over time, T2K would strongly recommend that customers consider replacing any machine tool windows that are blind, cracked, severely pitted, or over 5 years old. Research has found that over 8-10 years, some polycarbonate windows had as little as 10-15% of their original impact strength, due to the exposure to metalworking fluids, and that it was impossible to visually determine which windows had been embrittled simply by visual inspection. The ease of replacing these windows, and the ease of maintaining you Visiport® installation on your machine tool window, should help to improve operator safety and productivity at the same time. Please contact T2K for more information.
Flex Conduits, Venting & Air Flowtag:www.t2k.net,2007:/support/kb//1.122007-06-08T00:45:23Z2007-06-08T00:46:27ZInternal Visiport Venting Visiport's patented design incorporates the ability to vent ambient or "clean" air from outside the machine cabin to prevent internal fogging of the Visiport. The most common method of providing this air flow is throught the use...
Internal Visiport Venting
Visiport's patented design incorporates the ability to vent ambient or "clean" air from outside the machine cabin to prevent internal fogging of the Visiport. The most common method of providing this air flow is throught the use of flex conduit, which is a steel wire braid over a PTFE (teflon) tubing material. With the new B-type units, T2K also provides PUR (polyurethane) tubing as an alternative conduit material. [Shown as PUN on parts list and price sheets]
Venting and Air Flow
Improper installation of the flex conduit can block air flow to the unit. This can allow the Visiport spin window to fog up and can possibly lead to electrical and/or mechanical malfunctions.
Improper restriction of air flow can be caused by (a) over-tightening the fittings, (b) accidentally putting a crimp in the flex tubing, or (c) inappropriate placement of silicone sealant during installations. Please note that adequate air flow to the unit through installed flex conduit is necessary for the unit to function properly. The flex conduit protects the wiring harness between the Visiport unit and the external bulkhead assembly the on/off switch and/or motor electronics, but it is air flow that is the primary purpose behind the use of the flex conduit, PUN tubing, and STK-Steel Tubing Kit (for discontinued Visiport VP210, VP215 and VP220 models) sold with the product.
Custom OEM Wiring Harness / Tubing Designs
Customers incorporating their own tubing scheme to route the wiring harness between the Visiport and the external bulkhead assembly or the machine tool's electrical cabinet should note that it is extremely important to ensure adequate air flow is accommodated in their custom tubing designs.
If aesthetics or integration concerns demand a customized routing scheme, air flow considerations cannot be overemphasized. Due to the necessity to prevent fogging and internal moisture problems that may cause premature product failure, T2K can easily supply flex conduit for new or currently in service Visiport units. In addition, T2K is happy to provide technical support to customers who require custom installations. Contact T2K for details.]]>
Powering Visiport Spin Windowstag:www.t2k.net,2007:/support/kb//1.112007-06-08T00:40:43Z2007-06-08T00:45:12ZElectrical Hookups Final connection to a machine power supply must be made only to fully regulated 24±1 Volt D.C. auxiliary power connections, which is the same supply that drives the machine hydraulics and most proximity and interlock circuitry. Some customers...
Electrical Hookups
Final connection to a machine power supply must be made only to fully regulated 24±1 Volt D.C. auxiliary power connections, which is the same supply that drives the machine hydraulics and most proximity and interlock circuitry.
Some customers mistakenly feel that hooking up to the tool changer power supply, for instance, will extend the spin window's operational life because it is not running constantly. This actually hinders operation because the brushless DC motors can take from 3 to 30 seconds (depending on Visiport model generation) to ramp up to full speed with power interruptions. With heavy coolant spray, this will affect visibility.
In addition, power interruptions of this type will shorten the life of the electronics. The load on the motor from heavy coolant spray on the unit during its ramp up to full RPM's may trigger the unit's overload protection, which turns the unit off to prevent damage to the motor and electronics. T2K spin windows are engineered for continuous duty operation, and are designed to be on whenever the machine tool is on and producing chips.
Please be aware that failure to hook up the power supply as required will void the warranty on the unit.
Power Supplies From T2K
In order to provide a matched power supply of the appropriate type for customer and distributors, T2K offers the 100 Watt PS24-100 (Visiport VP220A Series and before) and the 120 Watt PS24-10 (Visiport VP220.B5 and VP220.C Series) power supplies as optional equipment with every new unit purchase. Fully enclosed, compliant to UL-508, DIN-rail or enclosure mountable, these power supplies ensure adequate amperage for each installed Visiport at all times of machine operation. T2K also offers a slimline version of the 120 Watt power supply (PS24-120S).
Contact T2K for pricing and availability.]]>
"Siliconized" Machine Windowstag:www.t2k.net,2007:/support/kb//1.102007-06-08T00:35:14Z2007-06-08T00:40:30ZT2K has been informed by a number of customers that scratch resistant "siliconized" machine window are offered as a replacement option for machine windows surfaces which become badly damaged due to chip activity. Bonding Visiport or DiscAir spin window systems...
1) Material Compatability Issues
The 3M VHB+ material used on all mounting systems for Visiport and DiscAir products is based on an acrylic carrier closed-cell foam. A window material with a silicone-based coating is fundamentally compatible only with other silicone products. While the edge sealing material T2K supplied is compatible, the VHB+ material, being acrylic based, is not. As such, bonding is somewhat compromised in theory.
Based on our testing, however, any T2K spin window bonded according to the instructions laid out in the Installation documents will bond adequately well, as the area required for bonding is many times greater than that required to hold the unit onto the substrate. (Keep in mind that the secondary purpose of the bondset is as a gasket.) The installation instructions are available for download from each Visiport product page and supplied with the product.
2) Poor Cost-Benefit Ratio
As we hear it from the customers actually buying these products, the cost factor is much higher than for the simple, plain optical grade polycarbonate commonly used in the industry. If, however, the point is to increase the life of the window in a machine tool application, then this money is by and large wasted as the extra life provided by the siliconized surface is only marginally longer than for polycarbonate without it.
Truly, if you have a machining application that has sufficient chip activity that the ability to look through the polycarbonate window is destroyed, then you would be far better served either installing a Visiport and allowing the rest of the polycarbonate window's view area to degrade as before, or replacing the polycarbonate window with a safety window incorporating a glass surface on the inside of the machine to resist the chip activity of your application. The use of either window type, of course, does not impact your ability to bond the Visiport on, although a better bond is achieved in practice with glass due to the difference in surface energy this material provides.
3) Downtime and Availability
When the time comes to replace the window, either due to chip activity affecting visibility, metalworking fluid replacement guidelines (which at two years is no different than standard polycarbonate), cracking, or damage due to tool impact, a siliconized window may or may not be available from your OEM as quickly as standard polycarbonate. Certainly it will be more expensive.
T2K can provide you with either a new mounting plate or offer our factory rebonding service to replace the bondset from directly mounted spin windows. With our factory pre-mount service, we can send your Visiport clean, refurbished, and mounted so that you can minimize the downtime switching the old window for new.
For additional information, contact T2K.]]>
Chip Activity & Abrasiontag:www.t2k.net,2007:/support/kb//1.92007-06-08T00:29:35Z2007-06-08T00:30:33ZAbrasion Specific Limitations The Visiport product warranty states that abrasion to the spin disc is not covered by the limited warranty. For customers having an application where spin disc assemblies are replaced often due to chip activity, T2K sells a...
Abrasion Specific Limitations
The Visiport product warranty states that abrasion to the spin disc is not covered by the limited warranty.
For customers having an application where spin disc assemblies are replaced often due to chip activity, T2K sells a DLC (diamond-like carbon) coated version of the spin disc. This part is for applications with higher than average chip velocity or aluminum material ablation problems, e.g. high velocity aerospace machining.
Even though the spin disc is available with a DLC coating, please note that the same exeption for wear in the limited warranty exists with respect to this part.
For more information, pricing, and availability of DLC coated disc assemblies for your application, please contact T2K.
Part Numbers:
220B500, Disc Assembly [for 220.B models]
220B500DLC, DLC Disc Assembly [DLC version of 220B500]
220500, Disc Assembly [for models 210, 215, 220, 215-A, 220-A]
220500DLC, DLC Disc Assembly [DLC version of 220500]
150500, Disc Assembly [for model 150 - no DLC version]
180B500, Disc Assembly [for 180.B models]
180B500DLC, DLC Disc Assembly [DLC version of 180B500]]]>
Disc Assembly Weartag:www.t2k.net,2007:/support/kb//1.82007-06-08T00:28:01Z2007-06-08T00:29:17ZAll spin windows operate on the same basic concept, i.e., that a spinning disc catches the metalworking fluid and chips and spins them off to keep the viewing area clear at all times. Wear Factors: Depending on the type of...
Wear Factors:
Depending on the type of material being machined, and the aggressiveness of the machining being done on a given piece of equipment, and the distance between the work are and the spin window, as well as a number of other factors, a glass spin disc will begin to lose it clarity and viewability over time.
This is due not only to the scratches and abrasion from chips, but also due to the surface interaction of evaporating metalworking fluids and the chemically-strengthened float glass itself. This is especially so in environments where calcium salts are used to prevent the foaming of coolant.
Finally, there are unintended influences such as tool breakage and projectiles such as inserts that will instantly degrade you viewing experience.
With such a large number of variables involved, there is no way for T2K to predict how long a spin disc will last in your particular application. Some aggressive applications, such a ceramic machining, will cause the spin disc to lose its clarity quickly, whereas other end customers have machined parts for nearly ten years and never replaced the disc assembly.
Replacement:
While we can make no prediction as to how long your disc assembly will last, T2K has designed the product to make the replacement of the disc assembly literally a two minute process, once you have acquired the appropriate replacement part. While we would recommend that all end user sites have at least one spare disc in stock to overcome broken discs due to tool failures, T2K tries to maintain stock of all models of Visiport and DiscAir spin windows available for same-day shipment. For details, contact T2K.]]>
Is the Spin Disk safe?tag:www.t2k.net,2007:/support/kb//1.72007-06-08T00:26:44Z2007-06-08T00:27:51ZAvoiding Contact with the Spin Disc Visiport spin window systems are rugged and safe. There have been no reports of accidents involving any spin window system we know in their 15 year history. As with any product, Spin Windows must...
T2K recommends that to avoid any possibility that hair or clothing could become entangled in a rotating spin disc, however, that the Visiport be switched off to avoid any such incidental contact. ]]>
Effect of Poorly Maintained Coolantstag:www.t2k.net,2007:/support/kb//1.62007-06-08T00:20:00Z2007-06-08T00:26:26ZBonding failures have occasionally occurred where customers have used synthetic or semi-synthetic cutting fluids at extremely low pH levels. A known problem with such coolants is their tendency to become caustic if not maintained carefully, allowing them to attack the...
Bonding failures have occasionally occurred where customers have used synthetic or semi-synthetic cutting fluids at extremely low pH levels. A known problem with such coolants is their tendency to become caustic if not maintained carefully, allowing them to attack the interface between the Visiport aluminum base and the bonding material.
After simulating such conditions with low pH metalworking fluids, it seems that bonding failures of this type are due more to the fact that the caustic metalworking fluid has eaten the aluminum away from underneath the seal junction than from a failure of the sealing material itself.
Naturally, caution should be exercised when using coolant susceptible to such pH balance problems. In addition to damaging the Visiport installed in such applications, it seems highly likely that significant and costly machine tool component failures would be an eventual outcome from this type of situation. Coolant types based on water soluble mineral or natural oils would seem to be preferable under these conditions, and are eminently compatible with Visiport installations.
The edge sealant provided with the system is intended to be applied during installation. This material is an oil-resistant silicone formulation that is used to protect the VHB bonding material at its interface with the substrate of the machine tool window from migration of the dyes used in most metalworking fluids. These dyes can leach into the VHB material over time, which presents an aesthetic rather than functional issue.
The edge sealant is not sufficient to prevent or protect against the effects of metalworking fluids that are not maintained to proper pH.
For more information, please contact T2K.
Ceramic Machining Applicationstag:www.t2k.net,2007:/support/kb//1.52007-06-08T00:16:38Z2007-06-08T00:19:08ZMachining abrasive materials, such as ceramics, will cause the spin disc to take on a sandblasted appearance over time, impairing vision. The spin disc is made from chemically strengthened float glass, but this nor any other available treatment, including the...
Machining abrasive materials, such as ceramics, will cause the spin disc to take on a sandblasted appearance over time, impairing vision. The spin disc is made from chemically strengthened float glass, but this nor any other available treatment, including the DLC (diamond-like carbon) coating available for high speed aluminum maching, will prevent the effect of sandblasting the glass surface.
It should be noted however, that some customers have purchased the Visiport and DiscAir system precisely for the cost saving and vision maintainability over traditional machine tool windows. (One customer purchased 10 replacement discs together with his Visiport for just such a ceramic machining application.) The OEM-supplied window will become permanently sandblasted unless replaced, just as the Visiport spin disc.
The difference is that replacing the spin disc is an inexpensive operation requiring two minutes of down time. Replacement of the machine tool window is far more expensive and often requires many hours of down time to tear down and replace the machine tool window.
The customer is invited to decide the cost-benefit ratio for abrasive machining applications, and to contact T2K for more information and pricing.
Cast Iron Machiningtag:www.t2k.net,2007:/support/kb//1.42007-06-08T00:14:34Z2007-06-08T00:16:25ZPotential Problems One problem encountered (but not necessarily limited to) machining is the collection of small particles in and around the outer seal ring of the Visiport or DiscAir disc assembly. High speed machining under certain conditions will also produce...
Potential Problems
One problem encountered (but not necessarily limited to) machining is the collection of small particles in and around the outer seal ring of the Visiport or DiscAir disc assembly. High speed machining under certain conditions will also produce small chips which may collect around the seal ring.
Cast iron machining applications also produce small chips and dust that can interfere with proper spin window function without adequate maintenance. Gradual buildup occurs whereby material is deposited between the seal ring and the base. If this buildup is not flushed away or deflected with adequate guarding, the resulting interference can cause noise, disc wobble, slowing of disc rotation, and ultimately stall the spin disc.
The Visiport 220.B5 models were designed with this problem in mind, and have a new and improved forward-facing seal labyrinth which minimizes the ability of small chips and swarf to enter between the spin disc and the base.
Maintenance & Cleaning
Extended operation without cleaning of a spin window with internal contamination from buildup of small chips and dust will lead to motor failure. All spin windows are designed to operate with adequate coolant and are not suited to dry or near-dry machining applications.
To remedy this situation, carefully remove the disc by following the installation instructions. Clean the seal ring and spin window base, reassemble and restart the spin window. To prevent significant chip buildup, planning and attention to adequate coolant delivery to the interface between the disc assembly and the base of the unit should be undertaken.
Though this problem affects only a small percentage of installations, T2K has worked to find mitigating solutions suitable to address these applications. In addition to evaluating an upgrade to one of the new Visiport 220.B5 models, the next section addresses several alternative solutions that T2K, distributors, and customers have used to overcome difficult chip applications.
Present Solutions
Addressing the problem of small sized chips entering the labyrinth seal requires evaluating the type of machine, type of coolant, amount of coolant, coolant pressure, intended location of spin window, type of material being machined, and whether small chips or particles might accumulate in the area designated for spin window installation due to the typical trajectory of chips leaving the work area.
The first option is to ensure that the spin window is mounted where it can do the operator the most good for viewing rather than where it might receive the highest chip volume. Sometimes spin windows have been mounted in an awkward location for the operator to see simply because the installer knew that location received the worst swarf on the window. Relocation of the window to where the operator could see porperly also bypassed the worst area of fluid and chip impact on the window.
Add additional coolant delivery nozzles as may be required to flush chips from the window and any other areas of the machine tool where chip buildup could lead to more serious maintenance issues for the spin window system.
Add guarding above the spin window to deflect the majority of chips from landing of the top 120 degrees of the circumference of the spin window. The distance of such auxiliary guarding should be close enough to prevent the majority of chips from being able to land on the top of the unit, but not so close as to cause a binding problem, especially if the application or machining operations undertaken can include stringy chips that may potentially become lodged between the spin window and the auxiliary guard.]]>
Options for Purchasing T2K productstag:www.t2k.net,2007:/support/kb//1.32007-06-07T23:02:48Z2007-06-08T00:11:03ZT2K Spin Window products are available from several sources: 1) As an OEM accessory provided by a number of machine tool builders. We frequently hear from folks that "they" should make this kind of product standard on every machine tool....
sales@t2k.net or support@t2k.net, depending on your request.
International callers can reach us at +001 (425) 558-0200 by telephone, or +001 (425) 558-0700 by fax.
As always, thank you for your support for Visiport and DiscAir spin window systems from T2K.]]>
Launch of revised T2K.NET websitetag:www.t2k.net,2007:/support/kb//1.22007-06-06T22:29:09Z2007-06-07T23:00:52ZJust like high school, it seems to have taken forever to "graduate" to our new site. But it's up and running. We are sure that there are many glitches we haven't fixed yet, but there are only a couple of...
sales@t2k.net.
If we actually get one, we'll send you a T2K baseball hat. Stylish and bound to provoke
"What the heck is Visiport?"
questions most everywhere your wear it!
Don't be shy about letting us know about anything else you find. Our goal is to help you find what you are looking for quickly and easily. Thanks for your support of T2K and the Visiport and DiscAir product lines!
]]>
Non-Standard Mounting Optionstag:www.t2k.net,2007:/support/kb//1.12007-06-06T22:28:18Z2007-06-07T22:22:24ZThe Visiport and Discair product lines have been offered with 3M VHB adhesives as standard since their inception. 3M VHB (very high bond) adhesives have a number of advantages that have made it a good choice for most installations: 1....
The Visiport and Discair product lines have been offered with 3M VHB adhesives as standard since their inception. 3M VHB (very high bond) adhesives have a number of advantages that have made it a good choice for most installations:
1. Excellent bonding to clean glass and polycarbonate window substrates.
2. Conformance to surfaces nearly 1-mm out of flatness.
3. High resistance to water soluble coolants at correct pH.
4. Excellent vibration resistance characteristics.
There are applications, however, for which users have expressed a desire for bonding and application alternatives. Two other options are available:
1. E-Type Mounting Plate Assembly.
Bonding of Visiport VP220.B5 models with two-component urethane adhesive and a special VHB bondset. First the unit is bonded in the standard recommended fashion, i.e., using a vacuum pump to create a good seal with the VHB portion of the Mounting Plate Assembly. After this step is complete, a two-component urethane is injected into special cells in the bondset until they are filled. A supplied expansion tube captured excess urethane during curing. Once cured the injection tubing is removed, and the Visiport is bolted to the mounting plate as in standard V-Type installation using the six nylon coated screws. An E-Type mounting can be ordered using Model Order Code Suffix E, e.g., VP220.B5.E.
2. D-Type mounting. A bolt-on style of mounting for use with polycarbonate
Field installation using this method are only possible with polycarbonate (PC) windows. A bolt-hole pattern to accommodate 6 each 4-40 mounting screws must be drilled into the PC window in the desired mounting location. From the outside of the window, screws of the appropriate length are then theaded into the units mounting holes on the inside of the window, capturing a thin metal washer on the outside.Sealing is accomplished by capturing an o-ring between the inside surface of the PC window and the Visiport unit in a machined gland. A D-Type mounting can be ordered using Model Order Code Suffix D, e.g., VP220.B5.D.
If your application requires the use of non-standard mounting methods, please contact us. We can help you determine which one of the possible mounting methods is best suited to your application.