My Company Name

PO Number:

Functional Specification

And

Operations Manual

For

Customer Name

Machine Make and Type

Model Number
Serial Number
Mfg. Date

Project Type

CONFIDENTIAL DOCUMENT
PROPRIETARY NOTICE

The information contained on all pages of this document consists of technical information which is confidential and proprietary to
My Company Name.. This information is furnished in confidence with the understanding that it may not be reproduced or used in
whole or in part, for any purpose other than evaluation of this document and the recipient agrees to return the proposal to My
Company Name upon request.

Confidential Page 1
3/23/2021
Table of Contents
Table of Contents_______________________________________________________________________________2
Revision History________________________________________________________________________________3
Customer Signoff_______________________________________________________________________________3
Purpose______________________________________________________________________________________4
System Characteristics_____________________________________________________________________4
Machine description:______________________________________________________________________________4
Machine Control Update:__________________________________________________________________________4
Automatic Grinding Cycle___________________________________________________________________5
Four Grinding Phases in an Automatic Cycle:__________________________________________________________5
Coarse Phase____________________________________________________________________________________5
Fine Phase______________________________________________________________________________________5
Sparkout_______________________________________________________________________________________5
Taper Phase_____________________________________________________________________________________5
Automatic Approach:_____________________________________________________________________________5
Sequence of Operation (Automatic Grind Cycle):_______________________________________________________6
Headstock Reversal:______________________________________________________________________________6
Roll Tracking:___________________________________________________________________________________7
Manual Grinding Operation_________________________________________________________________7
Sequence of Operation (Manual Grind Operation):______________________________________________________7
Pausing and Automatic or Manual Grinding Operation____________________________________8
Automatic Pause Sequence............................................................................................................... 8
Automatic Pause Resume Sequence................................................................................................. 8
Manual Pause Sequence................................................................................................................... 8
Manual Pause Resume Sequence..................................................................................................... 8
Operating Modes____________________________________________________________________________8
Handwheel:_____________________________________________________________________________________8
Joystick:_______________________________________________________________________________________9
Initial Setup_________________________________________________________________________________9
HMI Screens_________________________________________________________________________________9
Manual .............................................................................................................................................. 9
Auto .............................................................................................................................................. 9
Setup .............................................................................................................................................. 9
Roll Geometry______________________________________________________________________________10
Calculations..................................................................................................................................... 10
Setup Menu Items_________________________________________________________________________12

03/23/21 Page 2
Revision History

1 January 24, 2008 Initial document creation

Customer Signoff
Signing this document indicates that the functional specification has been accepted by the customer. Accepting this specification
also indicates that the functionality has been established for runoff, and that any changes from here on will be considered out of
scope.

Date Project Manager

1

03/23/21 Page 3
Purpose

The purpose of this document is to define the required operation and configuration of the Roll Grinder once
retrofitted.

System Characteristics

Machine description:

The Roll Grinder is a production grinder used for grinding “Work” and “Backup” rolls for the customer’s
production facility. The machine has two axes. The X-Axis (Infeed Axis) is the axis which causes the
Grinding Wheel to move into and away from the work piece. The Z-Axis (Traverse Axis) is the axis which
causes the Grinding Wheel to move side-to-side parallel to the work piece.

In addition to the two axes described above, the Roll Grinder has a Grinding Wheel and a Headstock. The
speed and direction of both the Grinding Wheel and Headstock will be controlled by new machine control.

Machine Control Update:

The control update of the Roll Grinder will accomplish 5 things:

1. Increase uptime due to the updated control system.

2. Machine improved functionality
3. Operator ease of use- Operator controls are designed for ease of use
4. Maintainability- Maintenance will have a single point to access drive and CNC/PLC system
(Ethernet network)
5. Established a functional specification that will become the operators manual once the project is
completed

03/23/21 Page 4
Automatic Grinding Cycle

Four Grinding Phases in an Automatic Cycle:

Coarse Phase -- Traverse and Feed until at the Fine Feed Position. The coarse phase is the initial
part of the grinding cycle. This phase is where material is removed from the
touch-off point down to where the Fine Feed Amount of material is left on the
roll. For example, if the operator inputs a “Feed Setpoint (Fd Setpoint)” value of
0.0500 and a “Fine Feed Amount (F Feed Amt)” of 0.0100, the coarse phase
would feed the X-Axis down from the touch-off point a total of 0.0400 toward the
work piece. The infeed will occur at both ends of the traverse stroke in the
increment set in the setup parameters. Infeed and Traverse Feed Rates for this
phase are set by the operator in the setup parameters for the Coarse Phase.
Fine Phase -- Traverse and Feed until at the “Feed Setpoint (Fd Setpoint)” Position. The fine
phase is the middle part of the grinding cycle. This phase is where material is
removed from the “Fine Feed Amount (F Feed Amt)” down to the “Feed Setpoint
(Fd Setpoint)”. Using the example above, the Fine Phase would remove 0.0100
amount of material from the roll. The infeed will occur at both ends of the
traverse stroke in the increment set in the setup parameters. Infeed and Traverse
Feed Rates for this phase are set by the operator in the setup parameters for the
Fine Phase.
Sparkout -- Continue traverse motion back and forth at the end of the Fine Phase with no
infeed (X-Axis) motion. The sparkout phase ends when the number of sparkout
passes is reached or the amount of sparkout time has elapsed. The type of
sparkout cycle desired and the number of passes or amount of time is set by the
operator in the setup parameters for the Sparkout Phase.
Taper Phase -- This cycle will be added as an optional phase. There must be a way for the
operator to disable or bypass this phase. The function of this phase is to grind the
tapers on the end of the roll after the Sparkout phase is complete. Setup
parameters will have to be added to accommodate this phase.

Automatic Approach:

If the operator selects “Automatic Approach” in the setup parameters the wheel will make an
automatic approach to the roll when a cycle is initiated. During the automatic approach the
Grinding Wheel moves slowly toward the roll and senses when the wheel touches the roll. The
control knows when the wheel touches the roll by monitoring the Grinding Wheel Load. When the
wheel touches the roll the X-Axis position is set to zero and the Coarse Phase is initiated. The
Traverse (Z-Axis) motion is active while the automatic approach is in process. The Traverse (Z-
Axis) is moved during “Automatic Approach” to keep the wheel from marking the roll when it
touches.

Sequence of Operation (Automatic Grind Cycle):

Following is the sequence of operation for a three phase automatic grinding cycle:
03/23/21 Page 5
  The operator sets all necessary setup parameters for each phase of the grinding cycle.
 The operator loads roll into the machine.

 The operator presses the Cycle Start button.

 The Grinding Wheel, Headstock, and Coolant pump are all started if they have not been
started previously by the operator.

 The machine waits for the Grinding Wheel and Headstock “At Speed” signal.

 If Auto Approach is selected, the Z-Axis moves to the nearest Z-Axis Reversal Position and
the X-Axis begins feeding toward the roll.

 If Auto Approach is not selected, the Z-Axis moves to the nearest Z-Axis Reversal Position.

 The Z-Axis begins moving back and forth between the Headstock and Tailstock Z-Axis
Reversal Positions. An incremental infeed occurs at each reversal position until the Infeed
(X-Axis) reaches the Fine Position. If “Speed Sweep” is enabled the Grinding Wheel and/or
Headstock speeds will vary by the value set in the setup parameters. When the Infeed (X-
Axis) reaches the Fine Position, the cycle changes to the Fine Phase.

 The Z-Axis continues moving back and forth between the reversal positions at the speeds set
in the setup parameters for the Fine Feed Phase. When the Infeed (X-Axis) reaches the
Setpoint Position, the cycle changes to the Sparkout Phase.

 The Z-Axis continues moving back and forth between the reversal positions at the speeds set
in the setup parameters for the Sparkout Phase. The Sparkout Phase is complete when the
number of sparkout passes have been completed or the sparkout time has elapsed.

 The Grinding Wheel Retracts and the Z-Axis stops. If Speed Sweep is enabled the speed
varying stops and the Grinding Wheel and Headstock maintain a constant RPM.

Headstock Reversal:

The headstock is capable of reversing. It is desirable to reverse the direction for fine finishing of
the roll. When Headstock Reversal is selected for a cycle, the following sequence is executed:
 The Infeed (X-Axis) retracts away from the roll.

 The Headstock slows down and reverses direction then begins to rotate at a slow speed to
allow the Headstock Rollers to re-engage the roll in the opposite direction.

 The Headstock accelerates to full programmed speed.

03/23/21 Page 6
  The Infeed (X-Axis) moves toward the roll stopping 0.0010 short of its previous position to
avoid hitting the roll and marking it.

Roll Tracking:

Customer Name would like to be able to track rolls with the new control. They would like to be
able to enter a “Roll Number” into the control when they set it up and upon completion of the grind
save the setup data and some operator measured data. The desired measured data is listed below:
 Roll Diameter
 Crown
 Micro-Finish
 Manual or Auto Cycle Taper Performed

Manual Grinding Operation

Sequence of Operation (Manual Grind Operation):

Following is the sequence of operation for a manual grind operation:

 The operator starts the X-Axis infeed by pressing the “Grind” button in “Manual”. This
starts the Infeed but performs no other actions.
 The operator can control the Traverse (Z-Axis) motion using the “Traverse” button and/or
the Joystick.
 The Infeed (-Axis) can be controlled using the Joystick, Handwheel, and/or the “Feed Step”
button.
 Manual Grind stops when the “Fd Setpoint” dimension is reached.
 If the Traverse (Z-Axis) is moving it does not stop. The operator will have to stop the
Traverse motion and move the machine to the “Park” position.

Note 1: The “Automatic Approach” feature is not available during manual grinding.

Note 2: The Manual Grinding Cycle uses the “Course Phase” setup parameters and the “Fd Setpoint”
stored in the control.

Pausing and Automatic or Manual Grinding Operation

While the automatic cycle is running or a manual grind is in process the operator can pause the process
by pressing the appropriate button. The “Cycle” button would be pressed if the machine is in an
automatic grind cycle or the “Grind” button would be pressed if the machine is in a manual grind cycle.

03/23/21 Page 7
 To resume after the pause, press either the “Cycle” button or the “Grind” button depending on which
process was paused.

Automatic Pause Sequence:

 Infeed (X-Axis) motion stopped.
 Grinding Wheel Retracts.
 Traverse (Z-Axis) Motion Stops.

Automatic Pause Resume Sequence:

 Traverse (Z-Axis) Motion Resumes.
 Grinding Wheel Returns to the roll stopping 0.0010 short of the paused position to prevent
bumping the roll and damaging the roll finish..
 Infeed (X-Axis) motion Resumes.

Manual Pause Sequence:

 Infeed (X-Axis) motion stopped.

Manual Pause Resume Sequence:

 Infeed (X-Axis) motion Resumes.

Operating Modes
Handwheel:
Manual Mode – When the machine is in Manual Mode the operator can select which axis
will be positioned using the Handwheel. The increment can also be selected
which will control how far the axis moves per click of the Handwheel.
Automatic Mode -- When the machine is in Automatic Mode the operator can only move the X-
Axis (Infeed) using the Handwheel. All input motion from the Handwheel
during Automatic Mode counts as motion toward the setpoint. It should be
noted that the operator uses the Handwheel in conjunction with the Joystick
to grind tapers on the end of the roll. The Traverse (Z-Axis) is jogged using
the Joystick while the Infeed (X-Axis) is moved in to grind the taper using
the Handwheel.

Joystick:
Manual Mode – When the machine is in Manual Mode the operator can move both axes
using the Joystick. The speed of this motion is set in the machine parameters.
Automatic Mode -- When the machine is in Automatic Mode the operator can only move the Z-
Axis (Traverse) using the Joystick. See the information above in the

03/23/21 Page 8
 Handwheel section to understand how the joystick and Handwheel are used
together in Automatic Mode to grind tapers on the end of a roll.

Initial Setup
Description: The operator must go through all the setup and cycle parameters to adjust the settings to
match the roll being prepared to be ground.

HMI Screens
Manual -- GW Speed
GW Load
HS Speed
HS Load
HW Increment
Feed/Speed Indication
Axis Status
Axis Position – ABS, PROG, DTG
Error Messages
Setup Screen Select
Auto -- Cycle Status
Program Selection/Status
GW Speed
GW Load
HS Speed
HS Load
HW Increment
Feed/Speed Indication
Axis Status
Axis Position – ABS, PROG, DTG
Error Messages
Setup Screen Select

Setup -- There may be several Setup Screens. These screens will contain setup parameters
arranged in logical groupings so the operators will find it intuitive to set the Machine and
Grind parameters easily.
Example: Coarse Phase Parameters
Fine Phase Parameters
Sparkout Phase Parameters
Taper Phase Parameters
Grinding Wheel Parameters
Headstock Parameters
Roll Geometry -- Type of Roll
Roll Profile
03/23/21 Page 9
 Tapered Ends

Roll Geometry
Calculations -- Roll Geometry on the Naxos-Union Roll Grinder is controlled mechanically by a cam
on the back of the machine. However, the following information is required so we can
ensure that the control we use on the Naxos-Union Roll Grinder can also be used on
the next retrofit of the Herkules Roll Grinder.

Roll Geometry Calculations are critical to producing accurate “Work” and “Backup”
rolls. The customer must provide methods for calculating these roll geometries
specific to their application which can then be integrated into the new control.

Industry standards on Roll Geometry Calculations vary from application to

application. Over the years, it has been found that a 70 degree portion of a cosine
curve (the eccentric rotates +/- 70 degrees from the TDC position) most closely
approximates the desired theoretical catenary or parabolic crown shapes required to
compensate for roll deflections in the machine. With a CNC control, the crown
profiles can be virtually any shape, including empirical non-mathematical type plots.
But usually the process dictates a standard sinusoidal shape, like 70 degrees, since this
is what convention has established. Therefore, the roll grinder control and operator
input screen should be programmed to produce any of the truncated cosine curves
from say 30 degrees through 180 degrees. The chart below shows the crown curve
multipliers for these angles. A parameter for the “Cosine Angle” must be added to
the HMI.

03/23/21 Page 10
 The above chart represents the crown profile from the “HE” to the midpoint. The
motion during a grinding pass from the headstock end of the roll to the tailstock end of
the roll is a continuous stream of small line segments along the profile of the roll. The
length of the roll is calculated as the distance between the operator set points “HE”
(Headstock End) and “TE” (Tailstock End).

During a grind pass motion from the “HE” to the “TE” the machine passes through the midpoint of the roll.
The midpoint of the roll is the point exactly half way between the “HE” and “TE” set positions. At the
midpoint, the dimension which is one half the compensated crown height, will be seen in the display on the
screen in the position display of the Infeed (X-Axis).

Note: The “Crown Profile” may be generated using an axis other than the X-Axis. In many cases, the
actual profile may be generated using a Tilt-Axis. In the case of the Herkules Roll Grinder there are
two Tilt-Axes. These axes are the C-Axis and the F-Axis. When the functional specification for
that machine is developed it will be critical to determine which axis (or both) will be used to create
the “Crown Profile”.

03/23/21 Page 11
 Setup Menu Items

Parameter Name Parameter Description

TS (-) Limit Tailstock Z-Axis Reversal Point
HS (+) Limit Headstock Reversal Point
Auto-Apprch Enable the Auto-Approach of the Roll for an Automatic Cycle
Fd Setpoint Feed Setpoint
F Feed Amt Fine Feed amount
  Distance from the Feed Setpoint Value at Which the Fine Phase
  of an Automatic Cycle Begins.
C Feed Mode Coarse Feed Mode
-- Tail Incremental Feed by the Coarse Feed Rate at the Tailstock
-- Head Incremental Feed by the Coarse Feed Rate at the Headstock
-- Ends Incremental Feed at Both Z-Axis Reversal Points
-- Time Incremental Feed by Coarse Feed Rate at Coarse Feed Time
-- Cont
(Continuous) Constant Feed Coarse Feed Rate per Minute
-- Amps Feed at Feed Rate per Minute if Current is Below Feed Amps
-- Plng (Plunge) Timed-Increment Feed With No Z-Axis Motion
-- Manl (Manual) No Automatic Feed
F Feed Mode Fine Feed Mode
-- Tail Incremental Feed by the Fine Feed Rate at the Tailstock
-- Head Incremental Feed by the Fine Feed Rate at the Headstock
-- Ends Incremental Feed at Both Z-Axis Reversal Points
-- Time Incremental Feed by Fine Feed Rate at Coarse Feed Time
-- Cont
(Continuous) Constant Feed Fine Feed Rate per Minute
-- Amps Feed at Feed Rate per Minute if Current is Below Feed Amps
-- Plng (Plunge) Timed-Increment Feed With No Z-Axis Motion
-- Manl (Manual) No Automatic Feed
C Feed Rate Coarse Feed Rate. The Size of one X-Axis Feed Step During the
  Coarse Phase.
F Feed Rate Fine Feed Rate. The Size of an X-Axis Feed Step During the Fine
  Phase of an Automatic Cycle. For Continuous Feed Mode, it is the
  Amount of Smooth X-Axis Movement per Minute.
C Feed Sec Coarse Feed Time. Seconds Between Feeds in Time, Plng Feed
F Feed Sec Fine Feed Time. Seconds Between Feeds in Time, Plng Feed
C Feed Amps Coarse Feed Amps (Minimum Wheel Current in Amps Feed)
F Feed Amps Fine Feed Amps (Minimum Wheel Current in Amps Feed)
C Wear Comp Coarse Phase Wheel Wear Compensation. In Millionths added
  Infeed per Minute.
F Wear Comp Fine Phase Wheel Wear Compensation. In Millionths added

03/23/21 Page 12
   Infeed per Minute.
C Trav Spd Coarse Traverse Speed. Z-Axis Speed During Coarse Phase.
F Trav Speed Fine Traverse Speed. Z-Axis Speed During Fine Phase.
Sprk Tr Spd Sparkout Traverse Speed. Z-Axis Speed During Sparkout Phase.
Spark Mode Sparkout Mode (Pass and Time)
Sprk Passes Sparkout Passes. Z-Axis Passes in the Sparkout Phase.
Sprk Minute Sparkout Time. Length of the Sparkout Phase in Minutes.
Coarse Phase  
-- Whl RPM Wheel Speed in RPM
-- Whl Swp Ena Wheel Sweep (Interval) ON or OFF
-- Whl Swp % Wheel Sweep Band in %
-- Whl Swp Sec Wheel Sweep Time in Seconds
-- HS RPM Headstock Speed in RPM
-- HS Swp Ena Headstock Sweep (Interval) ON or OFF
-- HS Swp % Headstock Sweep Band in %
-- HS Swp Sec Headstock Sweep Time in Seconds
Fine Phase  
-- Whl RPM Wheel Speed in RPM
-- Whl Swp Ena Wheel Sweep (Interval) ON or OFF
-- Whl Swp % Wheel Sweep Band in %
-- Whl Swp Sec Wheel Sweep Time in Seconds
-- HS RPM Headstock Speed in RPM
-- HS Swp Ena Headstock Sweep (Interval) ON or OFF
-- HS Swp % Headstock Sweep Band in %
-- HS Swp Sec Headstock Sweep Time in Seconds
Sparkout Phase  
-- Whl RPM Wheel Speed in RPM
-- Whl Swp Ena Wheel Sweep (Interval) ON or OFF
-- Whl Swp % Wheel Sweep Band in %
-- Whl Swp Sec Wheel Sweep Time in Seconds
-- HS RPM Headstock Speed in RPM
-- HS Swp Ena Headstock Sweep (Interval) ON or OFF
-- HS Swp % Headstock Sweep Band in %
-- HS Swp Sec Headstock Sweep Time in Seconds
Handwheel Handwheel Axis (X or Z)
Handwhl Res Handwheel Resolution
TS Dwell Tailstock Dwell (Pause in Seconds)
HS Dwell Headstock Dwell (Pause in Seconds)
FD Retract X-Axis Retract on Pause or End of a Cycle
Jog X Slow Slow X-Axis Jog Speed
Jog X Fast Fast X-Axis Jog Speed
Jog Z Slow Slow Z-Axis Jog Speed
03/23/21 Page 13
 Jog Z Fast Fast Z-Axis Jog Speed
Jog HS Headstock Jog Speed
Metric Selects English ("NO") or Metric ("YES") Units

03/23/21 Page 14