X = 2000 mm
Y = 1300 mm
Z = 1300 mm
SIEMENS 840D sl OPERATE
SIEMENS 840D sl OPERATE
Basic machine UniSpeed 2000
BASIC CONFIGURATION OF THE MACHINE
Machine column horizontal-longitudinal X = 2.000 mm
Spindle stock slide vertical Y = 1.300 mm
Spindle headstock horizontal-cross Z = 1.300 mm
HYBRID FRAME X-AXIS
The hybrid frame is designed as torsion-resistant welded steel construction with mineral filling. Extensive foundation works are unnecessary. Due to the inherently rigid structure the hybrid frame serves as the basis for all other machine components.
At the rear of the base frame 3 hardened compact guides in gantry design connect the X axis to the machine column. This kind of construction grants high precision and rigidity during travel and ensures a dynamic and vibration-damped run of the machine column along the X axis.
The inner space with all-side steep walls is leading to a central opening. The interface of the machine table is positioned on top and accessible all around. This allows an ideal removal of chips and coolant in the central chip conveyor.
CENTRAL CHIP CONVEYOR
The slat-band chain conveyor is located in longitudinal direction (X axis) under the central opening of the hybrid frame. The spacious loading width provides optimum chip and coolant removal.
– Loading width mm 900
– Ejection height mm 1.140
– Ejection to the left
MACHINE STAND Y-AXIS
The column is a distortion-free welded construction. In longitudinal direction (X axis) 3 compact linear guides connect the machine column with the hybrid frame. Two additional linear guides, arranged vertically on the machine column, host the headstock slide with headstock (Y axis). Large-scale guide rail distances grant the transmission of high cutting capacities at a constant quality. A lamella curtain (vertical blinds) protects the column against chips and coolant water in direction of the working area.
HEADSTOCK SLIDE AND HEADSTOCK
The head stock slide and the headstock are GGG 60 cast iron constructions. In vertical direction (Y axis) the head stock slide is connected with the machine column by means of 2 compact linear guides.
The headstock disposes of two horizontally placed linear guides. Guides with holding strips (keepers) are guiding the headstock in the headstock slide.
In order to avoid a tilting of the headstock column, the Y and Z axes are arranged as closely as possible to each other. The large-scale guide rail distances grant highest transmissions of cutting capacities at a constant quality.
Digital feed drives for the X-, Y- and Z axes permit working at a high contour precision with constant torque. Feed and rapid feed range.
– Feed / rapid feed in all the axes: 2-30.000 mm/min
– Acceleration values in all the axes 2 m/s²
– Drive of the X axis by means of a ball screw Ø80 mm
– Drive of the Y axis by means of a ball screw Ø63 mm
in connection with an hydraulic counterweight
– Drive of the Z axis by means of a ball screw Ø63 mm
For a precise move of the three main axes, exclusively direct, absolute linear measuring systems of Heidenhain are used.
The work space is completely closed to the outside. Two opposed angled sliding doors with large inspection windows are mounted in front. The large opening width offers an ideal accessibility for loading by crane. Another door with large window for the personnel is mounted on the hybrid frame. It allows the operator to directly view the process and to enter the work space if required. The floor inside the work space consists of a coarse mesh and anti-slip protective grid for best possible chip flow. The rear area in direction machine column is completely closed by means of a lamella curtain/vertical blinds, in which the tool change flap is integrated. Two lights mounted in the roof ensure a good illumination of the work space. An additional light for a good illumination of the operator platform is installed outside on top of the access door.
– Opening width of the doors for UniSpeed 2000 mm 2.240
– Opening width of the doors for UniSpeed 3000 mm 2.900
DESIGN VIEWING WINDOW SAFETY GLASS
The sight window in the front side prismatic sliding door and lateral operator’s access door are executed with safety glass. The side oriented to the working area (glass) offers, compared to screens made of polycarbonate, a greater durability against influence due to coolant emulsions and chips.
WORKSTATION / COMFORT PACKAGE (RIGHT)
The workstation on the right side offers much more than standard functionality of a platform. It combines ergonomics and functionality – it is a plus for the operator. The bench seat gives him the chance to program at the panel and to monitor the machining process in an ergonomic and comfortable position. For paperwork or minor assembly work he has a workbench at his disposal which offers additional storage space in the lower shelves. Drawings can be fixed at an integrated board – tools find their place in three laterally arranged storage locations. Sockets are available for external units. A Bluetooth radio with USB and speakers is also integrated. Summing up: this unit is a smart working station perfectly suited for the requirements of the operator.
VISIPORT / VIEWING WINDOW
Rotating machine window mounted on the window next to the control unit (Operator’s side).
SIGNAL LAMP 3-COLOUR INTEGRATED
The signal lamp – a LED light band – is homogenously integrated into the right side of the machine cover.
Green = production, orange = setting, red = fault
According to EN 60204 VBG 4 for 400/230V (±10%) 3 phases, 50 cycles, fuse 160 A slow. Control voltage 24 V, total power approx. 80 kVA, 125 A.The separate control cabinet contains the electronic drive units for main and feed motors, the programmable interface for control and the switch gears for additional equipment. Protective system of control cabinet and feed motors IP 54. Cable installed in cable duct provided on site as per foundation 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.
– Guideways and ball screws Central impulse lubrication
– Milling head Oil streaks lubrication
(Standard Hirth coupling)
Oil air lubrication
(in connection with continuous C axis)
Grease lubrication of the A and the C axis
(for HSC head)
– Milling spindle Permanent grease lubrication
– Motor spindle Oil lubrication
Compressed air 6 bar, connector G 1″.
The paintwork is carried out in RAL colors, DD textured paint, silky gloss, oil – and sodium-free.
RAL 7016 (anthracite grey):
Milling head; head stock; socket of hybrid frame; angled sliding doors with door guidance; frame ToolTower; parts of sheet covering ToolTower; movable part of the tool changer transfer unit; pressure accumulator; Chip conveyor; coolant unit
RAL 7004 (signal grey):
Machine column; head stock carrier; hybrid frame; covering hybrid frame; interior metal sheets, parts of covering ToolTower; work station; upright part of the transfer unit
RAL 7035 (light grey):
Electric cabinet; Cooler electric cabinet; cooling unit
Further color accents in a green-yellow shade (RAL 100 80 60) are provided on different machine components.
For a fast diagnosis and rectification of errors.
Prerequisite is provisioning the machine with a network connection or a SIM card (UMTS).
1 SET OF LEVELING UNITS / FIXATORS
For alignment and adjustment of the machine, inclusive of foundation bolts (without grout).
Frequency controlled liquid cooled AC motor. Direct power transmission to the milling head, no intervening gearing.
– 32 kW drive power at 100 % duty
– 44 kW drive power at 40 % duty
Torque in relation to the speed variant chosen.
MAIN DRIVE UP to 6.000 rpm
– Speed range 10 – to max. 6.000 rpm
– Torque 637 Nm at 100 % duty
– Torque 875 Nm at 40 % duty
– According to performance diagram no. E 741.0532.186
TOOL HOLDER HSK 100-A
Unless explicitly specified with deviating tool holder, all relevant machine components (milling head, tool changer, magazine) are adapted to tool holder type HSK 100-A.
The tool clamping force at the milling head is 45 kN.
AUTOMATIC UNIVERSAL MILLING HEAD
IN ORTHOGONAL DESIGN
– Liquid cooled milling head
– Cast design GGG 60
– Automatic rotation of axes
– Swivel range of milling head adapter (C- axis) degree wise ± 180°
– Swivel range of milling head (A-axis) degree wise ± 180°
– Indexing of axes via Hirth-coupling with a dividing accuracy of ±3 sec
– 64.800 full degree positions can be programmed via the CNC-control
– Milling head in semi-shell design, easy to maintain
– Hardly any interference contour due to the compact design and the
media supply located completely inside
– Tool taper according selected version
– The milling spindle is equipped with a hydro mechanical tool clamping system
– Internal coolant supply
– External coolant supply via spray ring
– Drive via frequency controlled, liquid cooled main drive motor
– Speed range according selected speed range of main drive
Technical data as per diagram E 745.1343.03
MILLING HEAD INTERFACE 3-POINT / HIRTH
The orthogonal / universal milling head is equipped with a crown gear nozzle ring with integrated 3-point-support. This enables a later fitting of tools (for example an angular milling head). In such a case the tool has to be adjusted on site to the interface of the orthogonal head. This is not part of the scope of supply.
CONTROL SIEMENS 840D sl OPERATE
CNC system Siemens 840D sl (see separate description)
Central control panel swivel-mounted at the right side of the machine.
SIEMENS OPERATING HANDSET HT2
– Emergency OFF – Key switch for on/off
– Double spaced display – Override with 12 settings
– 20 Assignment keys – Electronic hand wheel
– 20 LED in the keys – Cable
SCAFFOLDING STATION WITH MOTORISED TURNING FUNCTION
The basic stationary set-up place will be additionally equipped with a rotary axis. After unlocking it will be possible to turn the pallet motorically. This allows an access of 360° degree to the pallet.
This option does not fulfil any requirement regarding the run-out accuracy and run-out of table surface (with pallet clamped).
TURNING TABLE WITH PALETT CHUCKING STATION 8t
The clamping surface is a turn / mill table with direct drive. Apart from this table the control system of the machine is equipped with a comprehensive cycle package for turning operations. Furthermore the Orthogonal milling head is equipped with an interface for turning, a technology patented for SHW, enabling with its 3-point-suport / Hirth coupling the adaption of turning tool holders and other front attachments
CNC – TURNING TABLE
with large size bearing, direct drive and integrated pallet clamping station
– Clamping surface to load a pallet Ø1.600 mm – Ø 2.000 mm
– Repeating accuracy of pallet clamping mm 0,015
– Run-out of center bush with clamped pallet mm± 0,025
– Run-out of table surface at Ø 1.600 mm with clamped mm± 0,030
– Mechanical dividing accuracy via direct, absolute sec± 4
– Speed milling rpm 20
– Speed turning rpm 250
(including repeating accuracy errors)
– Torque Nm 3.000
– Tilting moment Nm 60.000
– Reduced tilting moment for turning operations
starting with 30 rpm Nm 3.000
– Tangential moment clamped Nm 26.000
– Table load for milling / pallet with work piece (centric) kg 8.000
– Table load for turning / pallet with work piece (centric) kg 6.000
up to 150 rpm
– Table load for turning / pallet with work piece (centric) kg 4.000
up to 250 rpm
– Max. clearance of components
– UniSpeed 2000 mm 2.300
– UniSpeed 3000 mm 2.400
For work pieces with a diameter larger than 1.600 mm the maximum speed decreases to 240rpm, lager than 2.100 mm the maximum speed decreases to 210rpm.
INTEGRATED BALANCING MEASURING DEVICE
By means of a special accelerometer mounted securely at the base of the rotary table, any vibrations found, are registered. An electronic balancing system then informs the operator of the required counterweight, together with the angle and diameter where this weight is needed. The operator has the possibility to adjust the given data and make further calculations.
Balancing quality according to DIN ISO 1940 for machine tool parts and tools: Dependent upon complexity G 6,3 > G3 is possible on the machine.
DOUBLE PALLET CHANGER
The Twin Pallet Changer is situated in front of the machine. In connection with a table, equipped with a pallet clamping station (separate position) integrated in the machine, alternatively two pallets (separate position) can be supplied to the machine.
Essentially consisting of:
– Pallet transfer station
– Shifting table with storage places
– Cover for the loading station
The pallet transfer unit bridges the distance between machine table and shifting table and carries out the transport of the pallet. For this the transfer unit is equipped with roller bars on which the pallet, by means of an integrated chain unit and a carrier bolt, is moved.
The shifting table has a linear axis arranged in a 90° position to the pallet transfer unit. On this linear axis there are two non-rotating tables with stationary roller bars. The deposit places are provided with a pallet locking mechanism. The linear axis positions the relevant storage place aligned with the pallet transfer unit, in order to start the pallet transfer.
The cover of the loading station includes a platform with integrated coolant trip pan which covers the complete area in front of the machine. By means of a pump the collected coolant is returned directly into the chip conveyor. Laterally the platform is surrounded by a fence. For free access to setting work, the front side is provided with a light barrier. In connection with the pallet changer the doors are electrically powered.
PALETTE Ø1.600 mm T-SLOTS PARALLEL
– Clamping surface mmØ 1.600
– 8 x T slots, parallel in table top mm 22 H12 – DIN 650
– 2 x Setting slots longitudinal / cross mm 22 H7, 10 depth
– Slot distance mm 160
– Center bush, hardened mmØ 50 H7
– Repeat accuracy of pallet clamping mm 0,015
– Run out of center bush with clamped pallet mm± 0,025
(including error of repeating accuracy)
– Run out of table surface at Ø 1.600 mm with mm± 0,030
clamped pallet (without load)
– Pallet weight kg appr. 2.300
– Table load according to table unit with pallet clamping station
ToolTower AUTOMATIC TOOL CHANGER
The ATC ToolTower is located on the right side behind the machine. In this ToolTower the tools are stored on several levels in circularly arranged storage places. The multi-axis handling unit, which carries out the tool transport, is placed in the center. Loading and unloading of tools takes place at a lock. The tool change position is at the right end of the X travel. The tool change itself is carried out via a digitally controlled linear unit and a change-over unit with cam mechanism. Protection of tool taper after every tool change with air pressure.
– No. of tools in the ToolTower pcs. 102
– Max. tool dia. with full magazine mm 125
– Max. tool dia. with free neighboring pockets mm 250
– Max. tool length mm 500
– Max. tool weight kg 30
– Max. tool torque Nm 40
– Actual tool change time sec appr. 7
– Spindle position during tool change vertical
– Fixed location coding
COOLING AGENCY 950 l
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 regulation via the machine control.
Pump capacity: 32 l/min at maximum 20 bar
Coolant tank: 950 l
Filter accuracy: < 50 µm
Other pumps and tank arrangements at request.
COOLING MATERIAL PUMP 40 bar / 32 l/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. 40 bar at 32 l/min
AIR THRU SPINDLE
Switchable between coolant and air thru spindle.
WASHING GUN IN WORKROOM
Spray gun with separate pump, connected with the container of the coolant installation. The spray gun is equipped with a flexible hose, 10 m long, and an automatic hose reel.
Pump Capacity: 70 l/min at max. 2 bar
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.
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.
PROBE RMP 60
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: RMP 60
According to safety regulations, the rear machine zone hast o be protected. For this purpose a safety switch is made available. The protection will be effected by customer (fence + door). Installation of the switch by SHW. As an option, the complete protection is available through SHW.
Access behind the machine is only possible when machine is switched-off.