Lesson 1Overview of a CNC milling centre: spindle, axes, table, tool changer, enclosure, and conveyor integrationThis section introduces the CNC milling centre as an integrated system, relating the spindle, axes, table, automatic tool changer, enclosure, and conveyors. It highlights component interactions, operational workflows, and fundamental inspection procedures essential for effective maintenance.
Major structural groups and castingsSpindle, axes, and table relationshipsTool changer location and motion pathsEnclosure, doors, and chip containmentConveyor routing and chip dischargeWalkaround inspection and baseline checksLesson 2Lubrication and coolant systems: central lubrication pumps, lines, nozzles, coolant filtration, tramp oil and sump managementThis section delineates lubrication and coolant systems, encompassing pumps, metering devices, lines, nozzles, filtration, and sump maintenance. It connects fluid condition to precision, component longevity, and adherence to environmental regulations.
Central lube pumps and metering unitsWay lube distribution lines and leaksCoolant nozzles, flow, and chip evacuationFiltration, screens, and bag filtersTramp oil removal and concentration testsSump cleaning, disposal, and recordkeepingLesson 3Conveyor and peripheral integration: automatic part handling, sensors, motorised rollers, timing, and safety guardsThis section scrutinises conveyors and peripheral devices for chip and part handling. It addresses motors, sensors, timing, guarding, and integration with CNC logic to guarantee reliable, safe, and low-maintenance functionality.
Chip conveyor types and drive optionsPart handling devices and escapementsConveyor sensors, jams, and level switchesTiming with CNC cycles and M-codesSafety guards, interlocks, and signagePreventive cleaning and wear inspectionLesson 4Linear motion and axis components: ball screws, linear guides, encoders, backlash and preload conceptsThis section elaborates on axis mechanics, incorporating ball screws, linear guides, and encoders. It introduces backlash, preload, and alignment principles, illustrating their influence on accuracy, rigidity, and the enduring reliability of the machine.
Axis kinematic chain and load pathsBall screw construction and support bearingsLinear guide types, sizing, and lubricationEncoder mounting, resolution, and feedbackBacklash measurement and compensationPreload, rigidity, and thermal growth effectsLesson 5Automatic tool changer (ATC) and magazine mechanics: grippers, selectors, sensors, diagnosticsThis section expounds on ATC and magazine construction, including grippers, carousels, sensors, and drives. It covers alignment, tool data management, diagnostics, and preventive maintenance to preclude misloads and collisions.
ATC layouts: carousel, chain, drum typesGrippers, pots, and tool retention checksMagazine indexing drives and home referenceTool presence, position, and orientation sensorsATC change sequence and interlocksCommon ATC faults and diagnostic routinesLesson 6Detailed spindle and drive system components: bearings, motor types (servo/variable frequency), belts, couplingsThis section concentrates on spindle and drive components, such as bearings, motors, belts, and couplings. It clarifies speed control, vibration origins, lubrication requirements, and maintenance practices to prolong spindle lifespan.
Spindle cartridge layout and cooling pathsBearing types, preload, and failure modesServo and induction spindle motor optionsBelts, pulleys, and tension adjustmentCouplings, keys, and alignment checksVibration, noise, and temperature monitoringLesson 7Sensors and safety subsystems: limit/home switches, interlocks, E-stops, vibration and temperature sensorsThis section encompasses sensors and safety subsystems, including limit and home switches, door interlocks, emergency stops, and condition sensors. It underscores testing, wiring inspections, and documentation to uphold safe operations.
Limit and home switch placementDoor and guard interlock principlesEmergency stop circuits and reset testsVibration and temperature monitoring usesSafety relays, circuits, and standardsPeriodic safety inspection proceduresLesson 8Electrical and control subsystems: power distribution, drives, servo amplifiers, PLC, CNC controller, HMIs and IO mappingThis section addresses electrical power distribution, servo drives, amplifiers, PLC, CNC controller, HMI, and I/O mapping. It correlates schematics with actual hardware, stressing troubleshooting, earthing, and safe measurement protocols.
Main power distribution and protectionServo drives, amplifiers, and motor cablesPLC roles, I/O modules, and field wiringCNC controller architecture and parametersHMI screens, alarms, and diagnosticsI/O mapping, signal tracing, and testing
