Contents 9. Installation spindle monitoring VG-4 2

CTM Installation manual chapter 9 19/11/04 ARTIS GmbH page: 1

Installation spindle monitoring VG-4

Contents

9. Installation spindle monitoring VG-4 . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Registration of mechanical oscillations and acceleration . . . . . . . . . . . . . . . . . . . . . . . . 2

Oscillation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mouniting the acceleration sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Using switchboard SB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Switch position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

EMC compatible installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power supply VG-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Control signal on VG4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Coll1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Coll2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ToolChange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

RapidFeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CTM control signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Stipulating the monitoring channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Monitoring on the CTM card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Sub-menu "Parameter 1". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Sub-menu "Parameter 2". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Break1 [F2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

V-peak / overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

A-peak / overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Break2 [F3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wear [F4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

max. Integral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Missing [F5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

min. Integral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Parameter [F6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Sensorp. [F7] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Oscillation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Oscillation Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Filter band. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Sub-menue "Parameter 3" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Monitoring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Bearing damage - Spindle wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Spindle statistic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Go to spindle statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Imbalanced tool / chips in spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Monitoring in VG-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Collisions intolerably high acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Collision table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Display collision table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Sensor VA-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Sensor VA-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Sensor VA-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

VG-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Dimension Switchbox SB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

9. Installation spindle monitoring VG-4

Introduction

Registration of mechanical oscillations and acceleration

The state of machines and plant can be evaluated by registering the mechanical oscillations.

According to the corresponding directives issued in VDI-2056, DIN 45666 and ISO 10816-1,

this is based on acceleration and effective oscillation speed. This variable is derived from the

acceleration and also depends on the oscillation frequency.

Oscillation speed

The oscillation speed is stated in [mm/2]

The following statuses can be monitored:

1. Imbalance, oscillations

2. Bearing damage

3. Imbalance from chips in the spindle

4. Imbalance from indexible insert breakage during milling

5. Imbalance by non-balanced tools

Acceleration

Acceleration is stated in [g]

1[g] = 9.81 [m/s²]

The following statuses can be monitored:

6. Intolerably high acceleration

There are two quick-acting switching outputs on VG-4 for this

monitoring function (Coll1/Coll2 – reaction time < 1 ms).

Mounting the acceleration sensor

The sensors should be fitted so that they are close to the front fixed

bearings. To prevent any distorted measurements, the sensor must

not be fitted close to any other technical devices, e.g. hydraulic or

pneumatic leads. It should be mounted in a radial position, i.e. the

threaded axis for the sensor should be fitted vertically (90°) to the

monitored bearing axis. The thread must be at least 6 mm deep. The

surface quality must be at least RZ25, i.e. normally ground surfaces

are sufficient. Other sensors are to be fitted for monitoring other

bearing pairs (e.g. loose bearings). Use a medium strength screw fix-

ing agent for the threads during installation (e.g. Loctite 243). Before

installation, apply a thin coat of grease to the contact surface of the

sensor.


page: 2 ARTIS GmbH CTM Installation manual chapter 9 19/11/04

Imbalance

Sensor

Monitoring moduleVG-4

Process monitoringCTM

Channel 1 Channel 2

VG-4®

®

Computer integrated

Tool and Machine Monitoring

manufactured byGermany

ARTIS

®

Computer integrated

Tool and Machine Monitoring

manufactured byGermany

ARTIS

Monitoring moduleVG-4

Process monitoringCTM

Channel 1 Channel 2

VG-4®


Monitoring

The monitoring and oscillation controller VG-4 is used together with the CTM card. It is a fixed

installed monitoring device for permanent monitoring of machines.

The limit values are set and parameters adjusted on the CTM card. A collision table and spin-

dle statistics are also saved on the CTM card. VG-4 is responsible for monitoring acceleration

and issuing the alarms for stopping the machine quickly.

Processes which are not critical from a point of view of time, e.g. detecting imbalance or bear-

ing damage, are monitored on the CTM card.

Typical use

Tool monitoring and machine status monitoring of the feed axes by evaluation of the digital

controller data (DTA procedure) and monitoring the spindle for detecting imbalance and bear-

ing damage by the acceleration sensor.

Example: 2-spindle machining centre


X2

Y2

Z2

X1

Y1

Z1

S1

Profibus or Interbus

NC/PLC

CTM card

Measurement converter

VG-4

acceleration sensor

VA-1 or VA-2

S2

Installation

Electrical wiring:

Please refer to the CTM installation manual for the following additional information:

- Installation CTM card: chapter 1

- Installation Profibus cable: chapter 1

- Installation sensor bus cable: chapter 1

- Profibus interface chapter 3



+ +++A A B B

Sensor 1

Channel 1 Channel 2

Sensor 2- RS485 - PowerS

hie

ld

Sh

ield

- -- -

1

30

30

2

29

29

3

28

28

4

27

27

5

26

26

6

25

25

7

24

24

8

23

9

22

10

21

11

20

12

19

13

18

18

14

17

17

15

16

16

VG-4

alarm output

channel 1

alarm output

channel 2

24V DCsupply

sensor2e.g. VA-1 or VA-2

sensor1e.g. VA-1 or VA-2

e.g. spindle 1 e.g. spindle 2

Gn

d-

bla

ck

AR

TIS

sen

so

rb

us

Coll1

These signals only have to be wired formonitoring of unacceptably highacceleration (collision monitoring).

These signals are not necessary forbearing and imbalance monitoring.The necessary control signals for thesetypes of monitoring have to be providedon the CTM card. Coll2Coll1 Coll2

TC TC

To

olC

ha

ng

e

To

olC

ha

ng

e

Ra

pid

Fe

ed

Ra

pid

Fe

ed

Re

se

t

Re

se

t

RF RFRes. Res.

channel 1 - sensor 1 channel 2 - sensor 2

PLC

Pro

fib

us

DP

min. Ø 0,75 mm2

Apply earthing clip(machine gnd)

Apply earthing clip(machine gnd)

wh

ite

wh

ite

bro

wn

bro

wn

bla

ck

bla

ck

A - geen

B - red

Do not shorten the cable! Do not shorten the cable!

Sensor cable5 m or 15 m long

Sensor cable5 m or 15 m long

Process monitoring CTM

Final resistanceDIP switch ON

Use

ea

rth

ing

clip

so

nb

oth

sid

es!

Fin

alre

sis

tan

ce

R=

22

0O

hm

/¼

W


Using switchboard SB1

The connection of sensors to the VG-4

and to the CTM card is a stationary fea-

ture. Switchbox SB1 offers the possibil-

ity of switching the sensor signals to a

BNC socket. External devices can be

connected to the BNC sockets. Simul-

taneous analysis of the signals by the

VG-4 and at the BNC socket is not

possible.

Electrical connection

Cut the sensor cable. Use the free cable end as connection lead between switchbox SB1 and

VG-4.

Use the ground clips shown in the circuit diagram. Carefully strip the cable shield for the

ground clips.

Switch position

The sensor signal is changed over by the corresponding flip switch.

Monitoring

Normal position: the sensor signal is switched through to VG-4

Test

The sensor signal is switched through to the BNC socket, where an external device can be

connected up. Monitoring with VG-4 and the CTM card is inactivated when the switch is in this

position.


apply earth clip(machine-gnd)

+ +

Sensor 1 Sensor 2

Sh

ield

Sh

ield

wh

ite

wh

ite

bro

wn

bro

wn

bla

ck

bla

ck

- -

30

30

29

29

28

28

18

18

17

17

16

16

VG-4SB1

Sensor 1

Sensor 2

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ite

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ield

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ield

Sensor (1) Sensor (2)VG4 (1) VG4 (2)

1 12 24 45 56 633

®

SB1 Switchbox

Sensor 1 Sensor 2

Test

Monitoring

Sensor1 Sensor2VG4 Ch.1 VG4 Ch.2connection for

external devices

Channel 1 Channel 2

®

VG-4

EMC compatible installation

Apply the ARTIS sensor bus cable to machine ground on both sides, the sensor cable on one

side.

To do so, carefully strip the PUR insulation of the cable and wind round with at least 2 layers of

copper foil. Remove any coats of paint or similar at the point where the ground clips are fitted.

In theory it possible for one or two VA-1 or VA-2 sensors or other suitable acceleration sensors

to be connected to VG-4, e.g. for spindle 1 and spindle 2 in one machine. But to avoid potential

problems, VG-4 should always only be used for one machine!

Power supply VG-4

• Terminal 22, 21 = +24 VDC

• Terminal 20, 19 = Gnd 24V

• 18-36 V/DC, 500 mA

Control signal on VG4

These control signals are required for collision monitoring.

Range

• high Pegel: 14-28V DC

• low Pegel: 0 - 5V DC

Coll1

• Terminal 2, 1 and 4, 3

• Alarm display limit value exceeded acceleration channel 1

• Open coll 5-24 VDC, 150 mW / reaction time < 1 ms (for RL

= 1k )

• low active: Open Collector open = alarm

Coll2

• Terminal 13, 12 and 15, 14

• Alarm display limit value exceeded acceleration channel 1

• Open coll 5-24 VDC, 150 mW / reaction time < 1 ms (for RL

= 1k )

• low active: Open Collector open = alarm

ToolChange

• Terminal 5 for channel 1


• Starts collision monitoring in "ToolChange" mode

• Activation only necessary if strong signal differences for acceleration registered between nor-

mal operation of the machine and tool change.

•

RapidFeed



• Starts collision monitoring in "RapidFeed" mode.

Reset

• Deletes the collision alarms

CTM control signals

• Control signals for monitoring on the CTM card e.g. monitoring for spindle wear, imbalance

chips in the spindle, etc.

• See CTM installation manual chapter 3




Stipulating the monitoring channels

• VG-4 can be operated as 1- or 2-channel device.

• Corresponding monitoring channels must be allocated for VG4 on the CTM card.

• See CTM installation manual chapter 1 and chapter 3.

Sensor calibration

• Every VA-1 oscillation sensor is calibrated

• A corresponding calibration factor (Cal.Fact) is fitted to the end of the sensor cable.

• This value has to be entered.

Procedure

1. Read off the "Cal.Fact" value at the end of the VA-1 cable.

2. Go to the CTM-Visu interface

3. Required user level: "Service"

4. Go to the menu "System F5" – "Settings" – "Sensor settings".

5. Use the TAB key to go to the "Start calibration" field and confirm with ENTER –

press OK.

6. Use the cursor keys to go to the corresponding entry in the field "Adjustment"

7. Use the PageDown or PageUp key to enter the read off value

8. Use the TAB key to go to the field "End calibration" and confirm with ENTER.


Monitoring on the CTM card

All setting parameters are accessible in the menu "Param. [F4]" - "Extended Mode".

CTMViSu parameter menu:

Sub-menu "Parameter 1"

see CTM user manual

Sub-menu "Parameter 2"

Break1 [F2]

for type "oscillation speed":

V-peak / overload

• monitoring of the oscillation speed

• surpassed limit generates "breakage" alarm

for type "acceleration":

A-peak / overload

• monitoring of acceleration

• surpassed limit generates "breakage" alarm

• note: acceleration is also monitored in VG-4

Break2 [F3]

• only available when the parameter "step monitoring" is set to "absolute"

• monitoring of the lower level for V-peak or A-peak

• description see CTM user manual chapter 2

• value below limit generates "breakage" alarm




Wear [F4]

max. Integral

• monitoring of the signal surface (integral)

• learned signal surface used 100% as basis for the max. integral limit

• surpassed limit generates "wear" alarm

Missing [F5]

min. Integral

• monitoring of the signal surface (integral)

• learned signal surface used 100% as basis for the min. integral limit

• value below limit generates "missing" alarm

Parameter [F6]

see CTM user manual

Sensorp. [F7]

Type

Selection of signal type:

Oscillation speed

e.g. for monitoring imbalance, bearing damage, chips in the spindle

Acceleration

e.g. for monitoring intolerably high acceleration

Note: acceleration is also monitored in VG-4

Oscillation Velocity

• Selection of scaling for oszillation velocity

• only available in versions “Oszillation Velocity”

Filter band

• only for type "oscillation speed"

• signal filtering

- normal band = standard setting

- broad band = for monitoring wide speed ranges

- high band = for monitoring high speed ranges and filtering slow oscillations

caused by the machine (faults)

Sub-menue "Parameter 3"

see CTM user manual


Monitoring examples

Bearing damage - Spindle wear

It is important that the initial conditions are always identical.

Monitoring only under constant initial conditions:

• The entire machine must be warm

• System conditions

• Test program with identical variations in time

• Balanced tools (master tool) must be used

• Spindle position

:

If the monitored value is to be saved in the spindle statistics, then set the signal "spindle moni-

toring" before monitoring. (see chapter 3)

1. For a new spindle, activate the Learning function.

CAUTION: after this the Learning function should not be activated any more!!

2. Adapting the sensor parameters under "Sensorp. [F7]":

- Type : select "oscillation speed"

- Oscillation speed : select a suitable measuring range e.g. 20 mm/s

- Filter band : select "normal band"

- Oscilloscope : select "off"

3. Change to a balanced master tool.

4. Accelerate the spindle which is still warm from operating to a defined speed in a defined

position.

5. Once the speed has been reached, activate the signal "spindle monitoring" and then also

the signal "feed active".

6. Let the monitoring function run for a defined period of time (e.g. 5 s).

7. Adjusting the monitoring parameters:

- V peak : adjust a corresponding limit

- max. integral : adjust a corresponding limit

The limit value refers to the learnt integral (signal surface).

Recommended setting:

Spindle monitoring

V-Peak = 0,2 .. 0,3 Typical value

V-Peak = 0,5 Advance warning limit

V-Peak = 0,8 Preliminary damage already exists, repair must be planned

V-Peak ≥ 1,1 Spindle damage, repair necessary




Spindle statistic

When the signal "spindle monitoring" is set, the "max. integral" value is saved in the spindle

statistics.

Go to spindle statistics

• Required user level "Service"

• Go to menu "System [F5]" – "settings" – "sensor settings"

• Select the menu point "Spindle statistics"

• Select the required spindle (corresponds to the CTM monitoring channel)

• The spindle statistics are shown.

• Press the left/right or TAB key to show the individual values:

- max. integral (achieved value)

- date/time

• Show an excerpt from the statistics:

1. Press key F5 "Select left edge" and use the left/right key to choose the left edge.

2. Press key F5 "Select right edge" and use the left/right key to choose the right edge.

3. Press ENTER

4. Press the F5 key repeatedly to show the full range again.

• Print the statistics: press F7.


Imbalanced tool / chips in spindle

1. Activate the Learning function for the corresponding tool.

Caution: The Learning function should not be activated any more after this!

Note: The signal must learn once with a balanced tool.

2. Adapting the sensor parameters under sensorp. [F7]:

- Type : select "oscillation speed"

- Oscillation speed : select a suitable measuring range e.g. 20 mm/s

- Filter band : select "normal band"

- Oscilloscope : select "off"

3. Change new tool

4. Enter program no., T-no., machining no.

5. Accelerate spindle in a defined position to a defined speed

6. Once the speed is reached, activate the signal "feed active"

7. Let the monitoring function run for a defined period of time (e.g. 3s)

8. Adapting the monitoring parameters:

- V-peak : adjust a corresponding limit

- max. integral : adjust a corresponding limit

The limit value refers to the learnt integral (signal surface).




Monitoring in VG-4

Collisions intolerably high acceleration

• Monitoring in VG-4

• Alarm message through COLL output at VG-4

• Limit values are set via the CTMViSu user interface

• Activate the signal “RapidFeed

• TIP: in most cases the signal can stay on permanently

• Only activate the signal “ToolChange” when higher accelerations occur in tool change situa-

tions than in normal operation of the machine

Adjust limits and measuring ranges:

• Required user level “Service”

• Go to the menu “System [F5]” – “Settings” – “Sensor settings”

• Go to menu point “Sensor parameter”

• Adjust the scaling and the collision limits for the individual statuses

- Operate = OP

- Rapid feed = RF

- Tool change = TC


OP

TC

Feed activ

Tool Change

Rapid Feed

RF

Rapid Feed Rapid Feed Rapid FeedMachiningToolchange

Limits in VG-4:

Signals at VG-4:

Signals via Profibus:(e.g. for monitoring imbalance)

Collision table

The last 100 collision alarms are saved.

Display collision table

• Required user level “Service”

• Go to the menu “System [F5]” – “Settings” – “Sensor settings”

• Go to menu point “Collision table”

• The collision table is shown




Technical data

Sensor VA-1

Sensitivity: 100 [mV/g]

Housing: CrNi Steel

Weight: 100 [g]

Protection: IP67, coolant-resistant

Cable: coolant-resistant, 15m

do not lengthen or shorten!

Dimension

Sensor VA-1

Sensor VA-2

The sensor must be

fitted using a

medium-strength

screw securing agent

(e.g. Loctite “blue”)

VG-4

Weight: 380 g

Temperature: 0 - 70 °C

Protection: IP20

Dimensions: 75 x 100 x 110 mm

top hat rail (mounting rail)

optional: wall-mounting

Power supply: 24V /DC (18 - 36 V)

Measuring signal input: 2 x VA-1 Sensor

Measuring signal output: ARTIS Sensorbus ASB an CTM card

Switching signals: 24V/DC ( Rapid Feed, TC, Reset )

Switching output: 4 x open collector for collision alarm

reaction time < 1 ms

max. 150mW / 18-36VDC


18

15

35

17,5

12

12

R17,5

cheese head screw M5x15 DIN912 cable: Ø 6,2 x 15m (standard)

M5

18

,2

21

,8

cable L=15 mØ 4 mm

cable L=15 mØ 4 mm

8,1

18

,2

29

,9

SW

7

14,9

Æ

14,9Æ

VA-2-S

with threading

VA-2-SO

without threading

Dimension Switchbox SB1



Test

Normal operation

SB1 Switchbox

®

Sensor 1 Sensor 2

Sensor 1 VG-4 Ch.1 Sensor 2 VG-4 Ch.2

86mm [3.386"]

2 fastening bores for M4 (Ø 4.7 mm) 98mm [3.858"] 48 [1.890]

36

[1.4

17

]

83

[3.2

68

]

64

[2.5

20

]

Contents 9. Installation spindle monitoring VG-4 2

Documents

Transcript of Contents 9. Installation spindle monitoring VG-4 2