Title SERVICE MANUAL - 4 Tool Turret for RLX

Issue: 1 Date: 10/07/19

Applies to: ¾” Turret: XYZ Part Number: 17110 (RLX355 and RLX1630)
1” Turret: XYZ Part Number: 17111 (all RLX Lathes)

1 Description
1.1 Overview
The 4-tool turret consists of a pneumatically operated, automatic tool changer for the RLX, CNC lathes.

The turret uses a 3 piece, Hirth coupling to provide accurate and rigid clamping of the turret in the 4
tool positions.

The turret is fully integrated into the RLX control so that tools can be changed manually in DRO mode,
or automatically during programme RUN.

The turret is mounted on the cross slide, in place of the manual, tool post.

1.2 Specifications:
• Maximum no of tools: 4
• Size of tooling:
o ¾” model: 20mm square section tooling
o 1” model: 25mm square section tooling
• Indexing time: 2.5s
• Operating air pressure: 80 to 90psi
• Indexing accuracy: ±6 arc secs
• Indexing repeatability: ±2 arc secs
• Parallelism (Tool mounting surface to turret base): 55µm
• Centreline Height tolerance: +55µm/-130µm

Notes:

• Since tools fitted to any particular turret are always setup in the RLX control, repeatability is the
important figure; accuracy this small can be ignored.
• These figures are static and do not take into account any movement of the turret (or, indeed the
cross slide) induced by cutting forces. However, these effects are small and, certainly for
finishing cuts, can be ignored.
• These figures do not include any deflection of the tool/tool holder.
• The centreline height tolerance is the value achieved by XYZ when first installing a new turret
onto a machine (shims are used to match the machine centreline to the turret).

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1.3 RLX Interface
The turret is connected to the computer module for operational commands and feedback.

1.3.1 Inputs into RLX control

1. IN - AIR PRESSure: Connected to an air pressure switch which monitors the incoming air
pressure. Set to be closed when pressure exceeds 60psi. Turret cannot be operated if this
switch is open.
2. IN - TURRET: Comprising
a. Clamped input:
i. Input from clamp proximity switch.
ii. Sense: Input active (input LED on) when turret is clamped/locked to prevent
movement from cutting forces.
b. In Position input:
i. input from position monitoring proximity switch.
ii. Sense: Input active (input LED on) when the turret is in any one of the four
cutting positions.

1.3.2 Outputs from RLX control

1. OUT- TURRET-INDX: 24VDC signal to operate the air valve controlling the indexing cylinder.
Causes the indexing cylinder to extend.
2. OUT-TURRET UNCLMP: 24VDC signal to operate the air valve controlling the Hirth coupling.
Causes the turret coupling to be unlocked.

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1.4 Operation
1.4.1 Turret Initialization Sequence
1. Upon power up, the RLX control checks the three inputs:
a. Air Pressure - to determine if the air pressure is high enough (above 60 PSI) to keep the
turret properly clamped.
b. In Position – to determine if the turret is in one of the four cutting positions.
c. Unclamped – to determine if the turret coupling is closed, and the turret is locked in
position.
2. If all three inputs are OK, the software prompts the operator to enter the current turret
location. Software will automatically keep track of the turret location from this point forward,
until the machine power is turned off.
3. If air pressure is input OK, but the other two inputs are not OK, the software assumes that the
turret is located somewhere in-between stations. The software turns ON the “Open Coupling”
output, to unclamp the turret, and prompts the operator to turn the turret anticlockwise slowly
by hand. The control monitors the position input during the manual rotation. As soon as the In-
Position input turns ON, the software turns Off “Open Coupling” solenoid output, which causes
the coupling to clamp the turret. Assuming the clamp closed sensor and in position sensor are
both correct, the software assumes that the turret is in one of the four turret locations and
prompts the operator to enter the current turret location. At this point, turret is ready for
normal operation. The condition outlined here may occur during initial turret installation, when
the turret is rotated to allow access to the mounting screws, or if the lathe power/air pressure
has been interrupted in the middle of the turret index, or if the turret has crashed into
something.
4. All other input combinations are treated as a fault and the turret cannot be operated. For
information on fault finding, see section 2.

1.4.2 Normal Operating Sequence

After the turret is initialized, it can be indexed to a new location in either DRO, or program
mode.
When a new turret location is required:
1. The control determines how many times it needs to index the turret to reach the new
location.
2. The control turns the turret unclamp solenoid output ON and waits for the clamped
input to turn OFF.
3. Then, it turns the index Cylinder solenoid valve output ON, (this extends the rack
cylinder), and after a preset delay, turns the index cylinder off to retract the cylinder. It
then waits for the “In-Position” input to turn OFF, and then ON again.
4. Once In-position is back ON, it turns the unclamp solenoid valve OFF, and waits for the
“Coupling Closed” input to turn ON.
5. The software checks if the turret has been indexed the correct number of times to reach
the desired location. If the desired location has been reached, the new tool location is
displayed on screen and the turret is ready to cut.
6. If the desired location has not been reached, software sequence steps 2-5 are repeated
until the desired location is reached.

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1.5 Mechanical Description
The SWI 4 tool turret assembly consists of the following, major parts:

• Base
o Fixed to lathe cross-slide
• Rotating turret, with 4 tool locations
• 3 piece Hirth Coupling
o Locates the turret in each of the four index positions in an accurate and repeatable
fashion,
o Pneumatically operated.
• Rack and pinion mechanism:
o Allows rotation of the turret using a simple, linear, pneumatic operating cylinder
• Ratchet/pawl mechanism:
o To control the turret index angle at 90°and allow reset of the linear operating
cylinder.
o Rotation is always in an anti-clockwise direction (when viewed from the top)

1.5.1 Three-piece Hirth Coupling mechanism

This is a critical part of the 4 tool turret. It has four teeth, and is designed to precisely locate and
rigidly clamp the turret assembly in place after each index, prior to cutting metal. The coupling
comprises three rings and a large diameter needle thrust bearing. The three rings are:

1. Outer Ring:
a. rigidly attached and pinned to the fixed, turret base.
b. Contains 4 castellations or teeth to define the four indexing angles.
c. The ring is installed with the teeth facing downwards
2. Index Ring:
a. Rigidly attached and pinned to the rotating tool turret.
b. Installed concentric inside, and level with, the outer ring
c. Matching castellations to the outer ring.
d. Includes a one-way clutch bearing to ensure the turret rotates only in one direction
(anti-clockwise)
3. Clamp/Lock Ring:
a. Contains 4 castellations facing upwards. The teeth are are sufficiently wide so as to
mate with those of both the outer and Index ring, so as to lock these two rings
together.
b. Moves axially by about 5mm to engage/disengage with the outer and Index rings.
c. The clamp ring also forms the (annular) piston of the pneumatic lock/unlock cylinder;
there is no separate operating cylinder.
d. The large diameter of thIs “piston” provides a large clamping force; about 4000N at
80 psi of operating pressure.
e. The coupling is also held closed by springs; ensuring the coupling remains clamped if
the air pressure fails (albeit at a much reduced clamping force; around 400N)

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 When the Clamp Ring is disengaged (coupling open), the Index Ring and so the tool turret, is free to
rotate relative to the outer ring (and the base). When the coupling is closed, the index ring is locked
to the outer ring, thus locking the turret to the base.

For turret rigidity, the Index Ring is axially preloaded against the Outer Ring between two needle
thrust bearings using a precision Locknut.

1.5.2 Rack and pinon mechanism

It is designed to index the turret, and to engage/disengage the ratchet pawl, which controls turret
over-rotation due to turret and tool inertia.

The gear rack movement is powered by a dia. 32mm x 50mm stroke air cylinder. The indexing cycle
begins by extending the gear rack air cylinder. At this time the coupling is still clamped to prevent

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 turret rotation. As the rack extends, it rotates the pinion gear and its hub, which is free to rotate
inside the Index Ring’s clutch bearing.

Also, as the rack extends, it pivots a link, which rotates a cam on the top of the unit. The cam
disengages the ratchet pawl from the ratchet. This will allow the Index Ring and turret to rotate on
the rack return stroke. Once the rack is fully extended, the coupling is unclamped.

Next, the gear rack cylinder retracts, rotating the Index Ring (and tool turret) 90°. As the rack
cylinder retracts it also rotates the pawl cam which allows the pawl to re-engage with the ratchet.
At the end of rotation, the pawl stops over-rotation of the turret.

Once rotation is completed, the In-Position sensor turns ON, and the Clamp Ring valve solenoid
turns OFF, causing the Clamp Ring to move up and lock the turret into the new position

1.5.3 Pawl and ratchet mechanism

it is designed to prevent turret’s inertia from overrunning the one-way clutch inside the Index Ring.
The cam mounted on the top of the unit is driven by the gear rack link mechanism shaft that goes
through the centre shaft. The cam causes the pawl to pivot out of the ratchet tooth, to allow turret
rotation. Shortly after the turret starts to rotate, the cam rotates back which allows the pawl return
spring to swing back into the ratchet catch area. At the end of the index cycle, the pawl engages
with the ratchet, thus stopping further turret rotation.

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1.6 4 Tool Turret Sensors:
Proximity sensors are used to feedback information to the RLX control about the turret position and clamp state
of the Hirth coupling.

Sensor Adjustment
1. In-Position sensor: Set to ~ 0.25mm from the bottom of the tool post part.
2. Coupling closed sensor: Set to ~ 0.25mm from clamp ring when in the unlocked position.

Notes on input sensors:

1. These are Normally Closed, NPN, 3-wire type proximity sensors (P+F: NBB0.8-4M25-E3)
2. Wiring at the Computer Module:

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 3. Wiring at the Turret connector:

4. An active input (input LED on) requires the sensor to sense no metal.
a. For the clamped input this is achieved by placing the sensor below the clamping ring
when in the clamped position.
b. For the in-position sensor, this is achieved by locating plastic plugs in the turret body at
each of the 4, tool positions.

1.7 Pneumatic Assembly (27470-1)

The pneumatic assembly comprises the following:
1. Input Tee: with PCL nipple for input air supply and Tee off for air ride tailstock (this is blanked off if not
required)
2. Pressure regulator, filter and water trap
3. Air pressure switch
4. Manifold assembly with:
a. Unclamp control valve
b. Door shut off valve and Index control valve (door shut off valve isolates air to the index valve
when the lathe main door is open - operated from door safety relay,K3).

The control valves and door shut-off valves are fitted with LED indicators which illuminate to indicate the
following states:

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 1. Unclamp control valve: Illuminated when the valve is in the position for coupling unclamp.
2. Door shut off valve: Illuminated when the valve is open (door shut).
3. Index control valve: Illuminated when the valve is in the position for index cylinder extend (start of
index cycle).

2 Troubleshooting Guide
2.1 Error – Insufficient Air Pressure
Most likely causes:
1. Compressed air supply is disconnected, or the workshop compressor is OFF
2. Misadjusted pressure regulator (see manual for proper setting)
3. Misadjusted, incorrectly wired, unplugged, or failed pressure switch.
4. Excessively contaminated filter element inside the pressure regulator,
5. Badly leaking air connections.

2.2 Coupling not Closed (on startup).

Most likely causes:
1. Turret is not in one of the (4) tool positions, it is stuck somewhere in-between (pressing tooth on tooth).
2. Operate the coupling in service code 521 and check the In-Position feedback in the HW tester and the
computer module input LED change state. if they do not change, the sensor may be incorrectly adjusted,
faulty, disconnected, or connector pins are not making contact.
3. See section 1.6 for more information on sensors and indicator LEDs.

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2.3 In-Position sensor not On when turret is in one of the 4 locked positions.
Most likely causes:
1. Open the coupling in service code 521 and check the Coupler Closed feedback in the HW tester and the
computer module input LED change state as the turret is slowly rotated by hand. If they do not change
state, at all or only at some stations, the sensor is set too far away from target or at the edge of
sensing/not sensing,
2. Alternatively, the sensor is damaged, disconnected, or connector pins are not making a good contact.
3. See section 1.6 for more information on sensors and indicator LEDs.

2.3.1 Using Hardware Tester to Test 4 Tool Turret

1. Use service code 521 to launch the hardware tester (HW). The RLX software will shut down at the HW tester
software wil start.
2. Press the CONNECT button in upper left hand corner. It may take 2 button presses. Make sure to wait 10 or
so seconds.
3. Press the drop down menu and select RLX Euro

4. Select the NC Ready and NC Ready 2 boxes.

5. Press the POWER RESET button on run panel (LED may not come on)
6. Scroll down to the button of the HW tester page.

The following section of the hardware tester allows you to manually command the turret. Under Turret Inputs,
the Clamp and Unclamp indicators will go on and off as the user opens and closes the coupling. The box on the
right side that says “Open Coupling” toggles the clamp and unclamp internal cylinder. You should see the
“Coupler Closed” box change accordingly.

The “In-Position indicator” on the right side tells the user when the turret is in position, which is any of the 4
spots.
When the coupling is open and the turret is not locked, the user can then press and hold the “Retract Cylinder”
button to initiate a turret index cycle.

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3 Field Replaceable Spare Parts
3.1 4 Tool Turret Assembly (27450)
Item OEM Part No. XYZ Pn
Post-Tool Holder ¾ & 1, 4 Tool Turret 27406 * TBD
Gear Rack-Index-4 Tool Turret 27417 * TBD
Bracket-Gear Rack-Index-4 Tool Turret 27416 * TBD
Rod Coupler-Self Aligning-M6 27361 * TBD
Link-Pawl Cam-Ratchet-4 Tool Turret 27431 * TBD
Pin-Link Drive-Ratchet-4Tool Turret 27434 * TBD
Bearing-Needle Roller-Thrust 27364 ** TBD
Washer-Needle Roller–Thrust .032 THK. 27364-1 ** TBD
Washer-Needle Roller–Thrust .126 THK 27364-2 ** TBD
Sensor Assembly (includes both sensors) 27457 TBD
Ratchet Pawl Mount Assembly 27452 TBD
Pawl Assembly. 27426 TBD
Bearing-Needle Roller 27359-1 TBD
Retaining Ring-EXT 27363-1 TBD
Retaining Ring-EXT-Low Clearance 27363 TBD
Ratchet –Turret Index – 4 Tool Turret 27419 TBD
Cam-Ratchet Pawl 27420 TBD
Spring-Extension 27362 TBD
Square Head Screw M12-1” 23873 TBD
Cover-Center Pin 27436 TBD
Shaft-Ratchet Cam-4 Tool Turret 27430 TBD
Sheet Metal-Cylinder Cover-Bottom 27440 TBD
Sheet Metal-Cylinder Cover-Top 27441 TBD
Cylinder-32mm bore 50 mm Stroke 27583-9 17428
Fitting-G1/8 to 4 mm Tube-90-Plastic 27016-7 TBD
Valve-One-Way Control 28531-1 17451
Fitting-G1/8 to 6mm Tube-Straight 28562 TBD
Valve-Flow Control-Inline-6mm tube 28071-3 14109
Notes:
* - These parts are the most likely to get damaged during severe turret crash.
** - All three parts must be shipped together as a set. The 27364 bearing must be filled with Kluber grease (or
equivalent) prior to installation.

3.2 Pneumatic assembly spare parts

Item OEM Part No. XYZ Pn
Valve-Solenoid 28561 17461
Module-Branch-Pressure Switch 28566 16426
Valve On/Off 28566-1 TBD
Air Regulator-Filter 28569 17462
Filter Cartridge, 5 µm 26579 TBD

4 Stripdown, Repair and Assembly Instructions

These Instructions are available to authorised Distributors and Service Agents on request.

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5 Drawings
1. 27450 – Turret Assembly
2. 27470-1 – Pneumatic assembly

These drawings are available to authorised Distributors and Service Agents on request.

6 Revision History
Issue By Date Description

1 PC 10/7/19 1st issue

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