UniForce 7000C

Machine no.:

2024-5006

Travels:

X = 3000 mm
Y = 2100 mm
Z = 1500 mm

Control:

SIEMENS 840D sl OPERATE

Construction year:

2017

X-travel

8000 mm -> extension to 10000 mm

Y-travel

3100 mm

Z-travel

1800 mm

Control

SIEMENS 840D sl OPERATE

 

Basic machine UniForce 7000C

 

 Travels of the machine

Machine column horizontal-longitudinal                      X = 8.000 mm

 

Spindle stock slide vertical                                          Y = 3.100 mm

 

Spindle headstock horizontal-cross                            Z = 1.800 mm

 

Machine bed X-axis

Basis for a fast and secure movement of the machine column in X-direction is our machine bed in flat bed design. A distance of 1.400 mm between the linear guides (RUE 65) grant highest accuracy.

Inside positioned energy chain, as well as rack and pinion drive ensure production security for decades.

Electrically driven X-axis using two synchronized motors.

 

Machine Column Y-Axis

The machine column is of a compact, buckling-restistant welded construction. The guides on the column are combined sliding and roller guides with hardened flat bearings. The guides are protected against swarfs and water by means of telescope covers.

 

Headstock slide

GGG 60 cast iron design with hydraulic counterweight, guided on the column with screwed and hardened slide ways. Long guidings lea to the machine column and the spindle stock and grant highest force transmissions at a constant quality. In order to avoid a tilting of the column, the Y and Z Axis are arranged as close as possible.

 

Headstock Z-Axis

Cast iron design made of GGG 60 with two opposed anti-friction guideways.The headstock incorporates the C-Axis, which can be continuously swivelled, with integrated interface for media connection.

This is prerequisite for automatic changing of different milling heads:

       Axis speed 20 rpm

       Continuous swivelling range from 0° to 360°

       Axial clamping torque 20.000 Nm

       Axial torque 800 Nm at 100% ED (duty ratio)

       Indexing accuracy 6 sec

 

SHW-DuoDrive

Electro-mechanical control unit using 2 vertical ball screws with separate drives, measurement systems and CNC axes to ensure a long-lasting, accurate, co-planar and low-maintenance movement of the headstock.

 

Drive System

Individually operating digital feed drives with AC motors ensure a high-precision processing with a constant torque, feed and rapid feed continuously variable from:

Y- and Z-axis:               2 to 24.000 mm/min.

X-axis                           2 to 36.000 mm/min

Acceleration in all axes 2 m/s²

 

Measurement System

Direct contactless measuring with linear measurement systems for a high precision machining.

 

Main Drive

Frequency controlled liquid cooled AC motor. Due to direct power transmission WITHOUT gears additional heating and wear is avoided.

       75 kW drive power at 100 % duty, 100 kW at 40 % duty

       Torque: 1.360 Nm at 100 % duty, 1.820 Nm at 40 % duty

       Speed range 10 – 5.000 rpm

According to performance diagram of main drive, no. E 741.0475.225

 

Travelling Platform

Travelling platform moving in the X-direction, with built-in CNC control. The elevating platform is mounted on the machine column and adjustable in height.

The vertical displacement is 1.500 mm. With the machine at standstill, the elevating platform can be extended horizontally by 1.000 mm.

 

Electrical Equipment

Electrical equipment according to EN60204, VGB 4 for 400/230V (±10%) 3-phase, 50 Hz, Fuse 250 A slow.

Control voltage 24 V, total connected load ca. 120 kVA, 190 A.

The separate electrical cabinet comprises the control devices for main spindle and feed drives, as well as free programmable control units and the switches for additional devices.

Protection category of the electrical cabinet, feed drives and fan of the main drive is IP54. Protection category of the main drive IP55. Machine and cabinet are connected with connectors. All cables are in the cable duct for which the customer has to take care, according to the machine layout.

 

Air Condition System Electrical Cabinet

Mounted on cabinet doors. Bicameral system. No exchange of internal air with external air. Automatic temperature reduction of internal air thru an evaporator. At the same time dehumidification of the internal air.

 

Lubrication

Guideways and ball screws                 Central impulse lubrication

Spindle                                                 Permanent grease lubrication

Milling head                                          Oil-air lubrication

Rack and pinion drive                          Grease lubrication

 

Oil Cooler

Cooling aggregate for stabilization of operating temperature of the head stock resulting in an increased production accuracy during machining.

 

Other Connections

Compressed air 6 bar, (filter pressure controller with manometer and water separator at the machine, connector G 1″ ).

 

Telediagnosis

For a fast diagnosis and rectification of errors.

Prerequisite is provisioning the machine with a network connection or a SIM card (UMTS).

 

CNC Control Siemens 840D

CNC system Siemens 840D sl (see separate description).

Central control panel, swivel mounted. Carrier of this panel mounted in operator’s platform.

 

 

Handheld Terminal HT8

The mobile SINUMERIK Handheld Terminal HT 8 combines in one unit the functions of an operator panel and a machine control panel, thus offering the possibility to completely operate and monitor the machine. The terminal HT 8 is used either in addition with the main control panel or as an auxiliary control panel. The touch pen with strap is included in the delivery and allows an easy handling of the touch screen, even if wearing gloves.

       Mobility in operating and monitoring

       Fully graphical 7.5‘‘ TFT color display

       Easy handling by touch screen, membrane key and touch pen

       Emergency stop and 2 approval keys for left- and right-handers
  (2 channels)

       Solid, compact and ergonomic design

       With hand wheel function

 

Radio-Controlled Handwheel

Functioning:

Button keys:      Keys for selection of axes

                          Keys for the direction +/-

                          Key for pre-set of feed rates

                          Keys with machine functions

                          Spindle ON/OFF

                          2 affirmation keys

                          Emergency stop

 

Encoder:                       1 encoder for a continuous moving of the axes.

Display:                         2-lines LCD-Display for axes position.

2 Potentiometers:         for an infinitely variable control of feed rate and spindle.

 

Siemens MDynamics

Software package Siemens MDynamics, for 3- and 5-axes machining in connection with a machine axis optimisation.

Exact surface machining, precision in contour guide combined with short processing times. These are the factors influencing significantly the quality and productivity in the manufacturing. This is exactly where SINUMERIK MDynamics comes into play:

Perfect surfaces by means of a new, intelligent motion guide – Advanced Surface an optimized NC data compressor, fast adaption to work piece, tool and program handling, optimum machining through a flexible programming. All of this enabling economic machining and flawless surfaces with the SINUMERIK package – perfectly customized for any industry.

Scope of supplyng:

       Advanced surface

       User memory on User-CF-Card

       Spline interpolation

       Transmit and circumference transformation

       Automatic measuring cycles

       3D-Simulation – drawing

       Identification of remaining material

       Machining package 5 axis

       3D tool radius correction

 

Control Mode 3

Additional Control mode 3 according to attached description.

 

AUTOMATIC UNIVERSAL MILLING HEAD

IN ORTHOGONAL DESIGNE

WITH CONTINUOUS POSITIONING A-AXIS

– Liqud cooled milling head

– GGG 60 cast design

– Milling head, A-axis: continuous positioning range of ±120°

– Axis speed 20 rpm

– Clamping torque 16 000 Nm

– Tangential moment of axis 812 Nm at 100% duty ratio

– Indexing accuracy ±3 arcseconds

– The positions can be programmed, as well as positioned and processed

  with the CNC control unit

– Repeat accuracy at spindle nose ± 0.002 mm

– Tool taper SK 50 BIG-PLUS

– The milling spindle is equipped with a hydro-mechanical tool clamping system

– Tool clamping force 20 kN

– Internal coolant supply form AD

– External coolant supply via shower ring

 

Technical data UniForce 6/7/8 according to  E 730.1396.15Technical data PowerForce 8 according to E 730.1396.16

 

ANGLE MILLING HEAD FOR HEAD CHANGING SYSTEM

– Execution                                                                                90°

– Housing made of steel

– Length (NC-Measure)                                        mm      900

– Plunging depth                                                mm      500

– Interfering contour at pluging depth (l x h)         mm      ca. 220 x 350

  (without tool)

– Speed                                                             rpm      2.500

– Ratio                                                               i           1:1

– Spindle torque 100% duty cycle at 30 min         Nm       600

– Spindle torque 50% duty cycle at 30 min           Nm       800

– Tool taper                                                                    SK 50 BIG-PLUS

– Automatic tool clamping

– Internal coolant supply

– External coolant supply via spray ring

 

Excentric horizontal milling head

in SingleTorque design

– Length (NC dimension)                                                 mm      900

Effective plunging length at Dia of housing                   mm      600

– Dia of housing                                                 mmØ    210

– C-axis offset                                                    mm      100

– Maximum spindle speed                                              rpm      4.000

– Maximum spindle torque according to data sheet

– Transmission ratio  (SingleTorque)                                i           1:1

– Tool taper SK50 BIG-PLUS

– Automatic hydro-mechanical tool clamping system, holding force 20 kN

– Automatic tool change via ATC only with UniForce 6C/7C/8C

  and PowerForce 8C

– Automatic tool change via pick-up station (optional)

– Internal coolant supply, form AD

– External coolant supply via spray ring

 

Technical data for PowerSpeed 5C/6C according to E 745.1468.52

Technical data for UniForce 6C/7C/8C according to E 730.1396.52

Technical data for PowerForce 8C according to E 730.1396.58

 

Other changing heads on request.

 

MILLING HEAD INTERFACE 4-POINT / HIRTH

The orthogonal milling head is equipped with a crown gear nozzle ring with integrated 4 point support. This enables a later fitting of tools (as for example angle head). In case of a later fitting the tool has to adjusted on site to the interface of the orthogonal head. This is not part of the scope of supply

 

HEAD CHANGING MAGAZINE

Welded construction.For an automatic changing of milling heads. Superposed arrangement of storage shelfs. All-around protection against swarfs. Automatic opening of protection system for changing milling heads. Storage of the milling heads only without tool.

 

EXTRA CHARGE X= 10.000mm

Extra charge 8.000m to 10.000mm

 

CLAMPING PLATE DIN 876/1

Clamping plate including alignment elements with T-Slots 22 H 12, DIN 650, T-Slot distance 250mm, clamping area Accuracy Level 2, DIN 876.

 

Sizes:

Length in 1.000 mm steps.

Width in     500 mm steps

 

Special sizes are available on request.

 

SEMICIRCULAR CUT-OUT

Extra charge for each semi-circular section in the clamping field, to insert a rotary table.

 

PREPARATION TURNBUCKLE INTEGRATION

In the design of the machine, the turnbuckle is taken into account for mounting on the clamping plate at a later point in time. Electrical components in the control cabinet and the supply up to the plate field are also prepared.

 

The defined position of the turnbuckle on the platen must be determined in accordance with the machine installation plan when the order is placed.

 

The reversible clamp itself is not included in this offer and will be offered separately if required.

 

ROTARY TABLE D=2.000mm

CNC – ROTARY TABLE

with large size bearing

 

– Clamping surface                                                         mmØ    2.000

– T-slots parallel in table top                                   mm   22 H12 DIN 650

– 2 center slots, lengthwise / cross                         mm   22 H7, 10 deep

– Slot distance                                                      mm   250

– Center bush, hardened                                        mmØ 100 H7

– Run-out of center bush                                       mm   0,010

– Run-out of table surface Ø1.600 mm (without load)        mm      0,025

– Mechanical dividing accuracy via                         sec±  2,5

  direct absolute measuring system

– Speed                                                                rpm   5

– Tilting moment                                                    Nm    100.000

– Tangential moment clamped                                Nm    55.000

– Tangential moment in circular milling mode           Nm    16.200

– Table load (centric)                                             kg      15.000

 

SHUTTLE MACHINING

Separation of the machine’s work area in three work areas, (left, right and both together). With removable separating wall and fixed located work areas. (The position of the removable separating wall is fixed.) The individual CNC work piece programs are as signed to the work area and can be machined in flexible sequence.The safety interlock between the work areas is provided by an electrical door interlock. A perfect option to provide for part loading, parallel to machining in the other work area.

 

AUTOMATIC TOOL CHANGER

Tools in Magazine                                                           70

Maximal Tool Diameter with full magazine                        mm      125

Maximal Tool Diameter with free neighbour pocket           mm      250

Maximal tool length                                                        mm      500

Maximal tool weight                                                        kg       25

Maximal Tool moment                                                     Nm      40

Tool taper                                                                      SK 50 DIN 69871

Tool change time                                                sec.      10 (approx)

Spindle position when changing tool                               horizontal

Fixed location coding

 

Blowing out of tool taper with compressed air after each tool change

 

EXTENSION 70 TO 120 TOOLS

The meander-shaped magazine of the UniForce 6 with 120 places is attached to the UniForce 7C.

 

Maximum loading capacity approx. 2,000 kg

 

WIDTHENING THE WORKING LENGTHS TO 700 mm

The maximum tool length of 500 mm will be extended to 700 mm. The given limits of maximum weight and load torque continue to be valid.

 

SPINDLE VERSION 400 mm STEPLESS A-AXIS

Longer execution of the milling spindle for automatic universal milling heads in orthogonal design with continuous A-axis. In this case the NC distance from A-Axis to the spindle was increased from 230 mm to 400 mm and additionally the spindle has 7 bearing points instead of 5, what is resulting in a positively longer live and a higher stability of the milling spindle.

 

Differing execution of the orthogonal milling head as per drawing E 730.1396.99

 

COOLANT THRU SPINDLE

Coolant system for coolant supply switchable at will from external coolant (spray ring) to internal coolant supply (IK), including a compact filter unit for coolant cleaning.

 

Frequency controlled high pressure pump with steplessly variable pressure control via the machine control.

 

Pump capacity:     32 l/min at maximum 20 bar

Coolant tank:         500 l

Filter accuracy:      < 50 µm

 

Other pumps and tank arrangements at request.

 

COOLANT PUMP 70 bar / 30l/min

Coolant system for coolant supply switchable at will from external coolant to internal coolant supply.

Frequency controlled high pressure pump with steplessly variable pressure and quantity control via potentiometer in the control panel. The standard pump (32l/min 20bar) is replaced.

 

Pump capacity:     max. 70 bar at 30 l/min

 

BIGGER COOLANT TANK

Capacity: 2000 l

 

Tanks with a volume of 1 000 litres and more require a separate protection bin, according to the Federal Water Act. (Relevant local rules and regulations have to be checked by the customer). The separate protection bin is not included in this option.

 

 

SAFETY BOTTOM 2.000 l

Safety bin for coolant system with a tank capacity of 2.000 l. Volume- and leakage sensor inclusive.

 

AIR THRU SPINDLE

Switchable between coolant and air thru spindle.

 

2 WASH GUNS IN THE WORKROOM

Two spray guns with one separate pump, connected with the container of the coolant  installation. The spray guns are equipped with a flexible hose, 10 m long, and an automatic hose reel.

Pump Capacity:              70 l/min at max. 2 bar

 

The position should be determined in the machine layout.

 

OILSKIMMER

The oilskimmer is integrated in the coolant.

 

REFRIGERATION DRYER SMC

The refrigerant dryer is connected upstream of the compressed air supply line of the machine.

 

Make: SMC

 

SHW UniScan

3D Crash and Vibration overload recognition

SHW UniSc@n provides a real time crash recognition in all axes. This is possible with a 3D acceleration sensor with a reaction time of less than a millisecond. An identified collision leads straight to a machine stop, thus reducing significantly consequential damages. A further function provides warning limits with regard to vibration overload. Potential damages due to excessive use of the machine are prevented.

 

Machine diagnosis:

A further function of the SHW UniSc@n is a machine diagnosis which gives direct indications as to the condition of the machine. Consequently a condition-based maintenance is possible, thus avoiding unexpected downtimes and helping to achieve a higher machine uptime.

 

SUCTION PUMP WITH CASE

Pump for a manual insertion into the pump sump of the foundation.

The pump sump has to be impervious to fluids! The extracted liquid is to be lead into a separate bin (it should not be sucked in the coolant tank of the machine).

 

SAFETY WINDOWS

Strength 18mm for Travelling Operators Platform.

 

3-SIDE SPLASH GUARD WALLS

Made of varnished sheet steel, 2 mm thick. Standard height 2400 mm (option: 2.900 mm). For better observation of the working area these walls are equipped with inspection windows (Polycarbonate 6 mm). The main guiding of the sliding doors- strong and flexible longitudinal arms – is arranged in the upper part of the walls. Several maintenance free roller bearings grant their smooth movement. All doors are equipped with adjustable hydraulic dampers and positive stops. At the bottom the sliding doors are guided via dirt resistant rails with semicircular profile. These doors are mounted on a base plate with integrated liquid run backs, which is adjusted, fixed and sealed on the foundation.

 

ELECTRIC DOOR DRIVE

The 2 x 2 sliding door elements of the three-side protection are electrically driven. Control is either via buttons on the door handle or on the control panel. They can also be opened at the customer’s request after the program has ended.

 

SPLASH GUARD WALLS

Applicable for rear and lateral machine area. Grid with frame, mounted on suitable supports.One element composed of support and fence element.Height 140 cm / width 150 cm

 

SAFETY ACCESS STANDARD VERSION

Following the safety regulations, the rear machining area must be safeguarded by a security door.

 

By activating the key “Movement Start” / STOP” on the control panel and “Movement Stop” at the safety entrance, the machine can be stopped and the area behind the machine can be entered. After access to the operators platform the machine can be re-started via the key “Movement Start”. When leaving the area behind the machine through the safety door, the machine can be re-started via a key switch at the door “Movement Start”.

 

SAFETY ACCESS EXTENDED VERSION

Following the safety regulations, the rear machining area must be safeguarded by a security door.

 

There is no machine stop with the advanced version of the safety access. The machine is reduced to a max. rapid speed of 5 m/min via the key “Movement Start / Stop”  ” on the control panel and “Movement Stop” at the safety entrance and the area behind the machine can be entered. After access to the operators platform the machine can be re-started via the key “Movement Start”. When leaving the area behind the machine through the safety door, the machine can be re-started  to its programmed speed via a key switch “Movement Start” at the door.

 

Possible danger areas at the machine as well as the rear range of the machine pit are secured in X direction.

 

PERFORMANCE AND GRATING X= 10.000 mm

Inlet plates:

Metal sheet covering for the return of chips and coolant mounted in longitudinal machine direction fixed towards the chip conveyor on both sides. Made from 2 mm sheet metal, unpainted. A metal tray of 2 mm unpainted steel sheet is additionally installed in a channel system around the rotary table and clamping plate. Aprons  of 22 mm unpainted sheet metal are mounted around the clamping plate..

 

Grids / anti-slip plates:

Longitudinal grids are fixed above the chip conveyor in X direction. Grid frames made from flat steel and step bars made from grooved, galvanized construction steel. Additional grid frames around rotary table and clamping plate. Grids mounted on hollow profile consoles. The cover plates in the sector of media channels are made from 3mm anti-slip plates.

                                     

SHW-Werkzeugmaschinen GmbH clearly point out that an absolute leak tightness cannot be given due to the complex design and ease of dismantling of this kind of metal sheet covering.

 

SEALING AIR

As to all linear axes of machines, the glass scales are pressurized in order to reduce the residual risk of dirt and soiling to a minimum.

 

Where available, encoders of rotary- / turning tables also are supplied with sealing air.

 

PROBE RMP 60 Q

3-dimensional, signal transmission via integrated radio wave transmitter. For automatic tool change or manual change. Suitable among others to determine part length and the zero points of the part in horizontal and vertical position.

(Depending the CNC control unit, further measurement applications are  possible) producer: Renishaw typ: RPM 60 Q

 

CHIP CONVEYOR OF THE BASIC MACHINE

Flap joint type conveyor

Width                                         mm         350

Height                                        mm      1.140

 

For servicing is installed in the discharge flap of the chip conveyor a reversing switch for right and left run, as well as an EMERGENCY STOP (control-independent)

 

Basic price for X = 8.000 mm

 

CHIP CONVEYOR OF THE BASIC MACHINE

Each further meter (up to X = 20.000 mm)

 

LEVELLING UNITS (FIXATOR)

One set of levelling units for alignment and adjustment of the machine. Levelling units including the foundation bolts (without grout).

 

DOUBLE DESIGNATION CONTROL CABINET

 

INCREASED ACCURACY UniForce 6/ UniForce 7

With the option of “Increased accuracy” the tolerance of the machine alignment is minimized and the values are certified by an attached acceptance protocol.

 

The higher accuracy during the machining depends a lot on the required machine dynamics. Due to the extension of the tool magazine (up to 180 tool’s) and there the resulting higher masses, the increased accuracy only can be granted if the feed rates are adapted to the specific work (for example when changing the direction). In addition, the measuring conditions as per acceptance protocol must be respected.

 

SIGNAL LAMP 4-COLOURED / MDE

The machine provides the following machine data via a network connection for the customer’s production data acquisition.

 

– Malfunction

– Production / program running (automatic mode)

– Ready for operation (equipped; interrupted automatic operation)

– setting-up

 

The respective states are additionally indicated optically by a signal lamp. The installation must be specified in the case of an order on the basis of the installation plan.

 

– red = fault

– orange = not assigned

– green = production / program running (automatic mode)

– blue = setup

– green / blue = ready for operation (prepared; interrupted automatic mode)

 

SPECIAL VARNISHING

Special painting according to customer’s specification (costumer has to write the specification on machine layout), but only within RAL-colour norm.

 

DD textured paint, silk gloss, oil and soda resistant.

 

3D MACHINE MODEL

Providing a 3D solid model of the machine in the format Step (.step).

 

CAMERA SYSTEM WITH MONITOR IN WORKING PLATFORM

The camera provides an additional better insight into the working range. The camera is installed underneath the ATC at the machine column. The housing is certified as per IP 65. Operation is via control panel, can be swivelled in 2 planes and has an 18-fold optical zoom. The monitor as well as the control panel is attached to the operation panel of the machine.

 

BALLUFF TOOL IDENTIFICATION / UP TO M

Tool data are stored in the code carrier in the tool holder. A writing/reading head is recording the data on the loading position of the tool magazine. The related evaluation unit in turn is linked to the control unit which directly transmits the tool data to the tool administration.

 

The data input onto the code carrier has to be carried out in advance through the tool presetting device (by the customer). Further on, while removing the tools from the magazine, tool data are written back to the code carrier.

 

Auswerteinheit:                BIS M System

Schreib/Lesekopf:                    BIS M System

Codeträger:                    BIS M 122-02/A

 

ENERGY-SAVING MODE

All the SHW machines are provided with a build-in energy-saving mode, setting the machines into standby according to pre-set time intervals. A large number of aggregates can be switched-off completely with the energy-saving mode (for example the coolant system, the swarf conveyor and the hydraulics) thus considerably reducing the power consumption to under 1kW.

 

EXTENSION WEEKEND SWITCHING

An additional pump enables the coolant to be circulated both in the tank and via the chip conveyor. This process can be triggered manually via the coolant system.

 

LED WORKROOM LIGHTING

To improve lightning of the working area a LED-spotlight is mounted at the machine column.



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