flex process flex solution flex...

Flex Process Flex Solut ion Flex Product ion

Flex Process Flex Solut ion Flex Product ionM a c h i n i n g - C e n t e r s - M a n u f a c t u r i n g

2Flex Process Flex Solut ion Flex Product ion

M a c h i n i n g - C e n t e r s - M a n u f a c t u r i n g

Horizontal head - Milling-Reaming HSK 100

Solutions for high productivity

4 and 5-axis range for Milling-Reaming & Milling-Turning-Grinding

Electrospindles with torque from:

300 - 600 - 1000 Nm

Speed from:6.000 - 18.000 Rpm

Square pallets:630x630 mm630x800 mm800x800 mm

1000x1000 mm

Circular pallets diameter:800 mm

1000 mm1250 mm



3

4 and 5-axis range for Milling-Reaming & Milling-Turning-Grinding

A range of electrospindles, Tilting heads and tables for milling, reaming, turning and grinding completes the “Flex Process” proposal.

Tilting head Milling - Reaming HSK 100 Multitasking Capto C8




Excellence of milling, turning and grinding performance - Productivity increase – Complete machining of complex components in one single set-up – Availability of electrospindles with large speed range and high power and torque – The high performance allows for high chipping with any type of mate-rial – C-AXIS – Electrospindle in milling and tool-holder in turning – The con-

Unequalled productivity performance

4-5 axis Milling-Reaming – HSK 100

Mt(Nm)1000

500

615

1000

ELECTROSPINDLE CURVES 6000 1/MIN HSK-A100

3000 6000 n (1/min)

60

75

S6-40%

S6-40%

S1

S1

0 0

P(Kw)

Milling

Technical features MILLING-REAMING MULTITASKING Tank 1600 Tank 1300 / 1600Spindle speed rpm 6.000 - 8.000 -12.000 - 18.000 8.000 -12.000Spindle torque (S6-40%) Nm 388 / 1.000 388Turning-Milling Table speed rpm 30 250 / 210Turning-Milling Table torque (S1) Nm 1.540 1.540 / 3.500

Multi - tasking



5

version from milling to turning is made by means of the HIRTH-tooth-coupling that makes the spindle and the frame integral, eliminating load from bearings.

The selection of Capto taper guarantees extreme accuracy, rigidity and large modularity.

5-axis Milling-Turning-Grinding Capto C8

Mt(Nm)388

298

10

1280 5000 10000 12000 n (1/min)

20

40

52

S6-40%

S6-40%

S1

S1

0 0

P(Kw)

ELECTROSPINDLE CURVES 12000 1/MIN HSK-A100

Technical features MILLING-REAMING MULTITASKING Tank 1600 Tank 1300 / 1600Spindle speed rpm 6.000 - 8.000 -12.000 - 18.000 8.000 -12.000Spindle torque (S6-40%) Nm 388 / 1.000 388Turning-Milling Table speed rpm 30 250 / 210Turning-Milling Table torque (S1) Nm 1.540 1.540 / 3.500

Turning

Multi - tasking




1

High productivity – Component machining with minimum time in production

5-axis solutions – The extreme accuracy and rigidity guarantee complete machining in one single set-up with minimum cycle-time



7

2 3

4 5

6

[1] Indexed head: Step 1 degree 380 Nm electrospindle.[2] Continuous Head: Torque – 1.000 Nm electrospindle.[3] Continuous head: Torque – 380 Nm electrospindle.[4-5] Column roughing and finishing in one single set-up. [6] A400M undercarriage superfinishing (dimensions: 1250 x 1200 x 500 mm) -extreme accuracy in the central boring length = 1250 mm - concentricity 0.025 (obtained with tilting head).

High productivity – Component machining with minimum time in production

5-axis solutions – The extreme accuracy and rigidity guarantee complete machining in one single set-up with minimum cycle-time




X=1300/1600 Z=1300

Y=11

00

Automation proposal

Productivity: Productive autonomy tailored to requirements



9

9359

6632

A

T

1

2

E

3

13739

1800

11939

22212

3

T

1

2

A

E

T

1

2

E

A

13056

7574

A

E

3

2

1

5

T

4

13574

6836

E

A

2T

5

MP10

MP18

Automation proposal

Productivity: Productive autonomy tailored to requirements

TWO-PALLETS

FMS




1

Productivity increase with innovative Automation Components

Unmanned production



11

3 4

7

5

8

2

9

6 [1] Tool-changer with bufferIncrease of productivity – Better flexible management – Guarantee of a new tool every 10 sec (includingtaper washing and tool integrity).[2] Tool-magazine with large-sized toolsTool length = 700 mm[3] High density single and mirror tool-magazine Reduced lay-out dimension – Flexible management of magazine lay-out - High capacity up to 1.000 tools[4] Simple or double fork shuttlePrearranged for euro-pallets - Reduction of overall floor lay-out - Simplified installation - Possibility to use larger fixtures.[5] Multiple presetting with 5 tools[6] System with pallet-changing directly from the shuttle[7] Direct pallet-changerReduction of overall floor lay- out – Possibility to use larger fixtures.[8] 2-positions-pallet-changer for square and round pallets Increase of productivity and autonomy.[9] Mirror magazine, Super-tool, Tool-room

Productivity increase with innovative Automation Components




com

plia

nce

[µm

/N]

10

10-2

Errore A

6/2 3

Correzione CNZ-0 µm Z-150 µm

5/2 205/2 19

-25,0

-20,0

5/2 21 5/2 22

-15,0

-10,0

5/2 23 6/2 0 6/2 26/2 1Tempo (h)

6/2 56/2 4 6/2 6 6/2 7 6/2 8

Derive termiche testa tilting

15,0

5,0

-5,0

0,0

10,0

20,0

micron25,0

ISO 230-2 1997 Analysis Plot-Lineare Traguardo (Millimetri)

200-5

0 50

-4

-3

-2

100 150 350250 300

1

-1

0

3

2

5

4

Accuracy and Repeatability

Reversal B : 0.36Accuracy A+: 2.06Accuracy A-: 2.02Accuracy A: 2.09

MeanDev.M: 0.33Sys.Dev.E: 0.52Repeat. R+: 1.94Repeat. R-: 1.65

Macchina: CLOCK TANK TH Nr. di Serie:1683.07Data:17:12 Feb 05 2007Asse: B

Axes’ nanometric management in order to minimize the side skid during the high speed direction changing and the oscillation on edges.

High dynamic accuracy: 5 microns

Direct measuring of linear and circular axes precision.Direct measuring of compensation due to thermal variation.

Virtual manufacturing SAFE PROCESS – ANTI-COLLISION – POWER CONTROLMACHINING STRESSES CONTROL

Advanced Active Dynamics for damped and stable process Advanced optionsincrease the power exploitation range and the process stability.

Innovative solutions for extreme performance

Immediate productivity with innovative solutions

Time (h)

Mic

ron



13

THERMOSYMMETRYESTREME ACCURACY

EXTREME RIGIDITY

Innovative solutions for extreme performance

Direct Baricentric Drive

Cell supervisorPRODUCTION - PLANNING - SCHEDULING – P.P. NETWORK - NETWORK – CUSTOMERS’ SUPPORT – GUIDED MAINTENANCE




Errore A

6/2 3

Correzione CNZ-0 µm Z-150 µm

5/2 205/2 19

-25,0

-20,0

5/2 21 5/2 22

-15,0

-10,0

5/2 23 6/2 0 6/2 26/2 1Tempo (h)

6/2 56/2 4 6/2 6 6/2 7 6/2 8

Derive termiche testa tilting

15,0

5,0

-5,0

0,0

10,0

20,0

micron25,0

Time (h)

micron

Accuracy

Automatic compensation with direct control of the thermal deformation

Safe production with unaltered accuracy in time

Extreme accuracy of X, Y and Z linear axes (μm)


-5-600

-4

-3

-2

-1

-400 -200 0 200 400 600

1

0

2

4

3

5



Macchina: CLOCK TANK THNr. di Serie:1683.07Data:13:54 Feb 05 2007Asse: X


Direct measuring of X, Y and Z linear axes

Thermosymmetry – Insula-tion of hot parts – Machin-ing and stabilization refined process of every machin-ing phase – Highly accu-rate geometry guaranteed by more than 200 hours of scraping – All sliding parts

Extremely rigid structure and components

ISO 230-2 ISO 230-2

A Accuracy of positioning

Repeatability

Mean reversal value

Systematic positional deviation

Mean positional deviation

X 1200

Measurement of the axes in millimetres Measurement of the axes in millimetres

E

M

R

R

B

3,1

1,7

1,5

2,3

2,6

0,1

Y1300

3,8

1,9

1,2

2,6

2,4

0,1

Z1300

3,3

1,3

1,1

2,8

2,4

0,1



15

Accuracy

The nanometric management, the commands’ extreme sensitivity and the accurate execution of the assembly allow to get an exceptional circularity.

Extreme accuracy of A and B circular axes (sec)


200-5

0 50

-4

-3

-2

100 150 350250 300

1

-1

0

3

2

5

4




Macchina: CLOCK TANK TH Nr. di Serie:1683.07Data:17:12 Feb 05 2007Asse: B

Direct measuring of A and B circular axes

are semi-finished, finished and scraped. Accurate and continuous controls with electronic level, optical col-limator and laser guarantee a correct manufacturing process and the machine fi-nal calibration.

5 microns

ISO 230-2ISO 230-2

A

A150

E

M

R

R

B

2,2

1,5

0,7

1,1

1,1

- 0,3

B360

2,1

0,5

0,3

1,9

1,7

0,1

Accuracy of positioning

Repeatability

Mean reversal value

Systematic positionaldeviation

Mean positional deviation

Measurement of the axes in degreeMeasurement of the axes in degree




Multitasking

The new frontier of the flexible process

Operator Multi-Function Control Panel



17

The new frontier of the flexible process“Milling – Reaming – Turning – Grinding” is emphasized by “jfmx”, mCm Manufacturing execution System that guarantees the production system management, control and integration. With the MCM PLC, the new generation Siemens 840D CNC becomes a powerful, simple and safe production system.

Multitasking

Auxiliary video for machine secondary functions- High brightness 15” video, embedded PC and touch-screen hand-box- “Machining area direct display” function by means of one or several sealed cameras with

screen wiper, vertical and horizontal flexible orientation, x 40 zoom and autofocus. The internal working-area can be visualized even in the most hidden corners, i.e. the component side at the opposite side of the operator window

- By means of the x 40 zoom, it is possible to visualize the tool enlarged close-up shots in order to make any possible tool visual control easier during the machining operations, without getting into the machine

- Image available on-line, with fair frame speed- On-line camera drive with possibility to remote-control the flexible orientation and the zoom- “On-line handbook” function: possibility to visualize more than 100 pages of the machine

Use and Maintenance manual and, at the same time, use the CNC, in order to have a better interaction between the diagnostic messages (on main video) and the manual pages (on auxiliary video)

- Use of the Cell Supervisor as a “Remote terminal”, with visualization of the cell situations through the operating situations’ synoptic tables

- Long-term “Data Logger” to record external parameters such as ambient temperature feelers, with related visualization functions, diagrams, etc...

CNC main video for machine primary functions- High brightness 15” video, embedded PC and operator hand-box with Qwerty key-board- Allows for simple, comfortable and intuitive use of the machine functions- Direct commands through ergonomic knobs and keys for instantaneous and immediate

interventions of the operator on the machining parameters- Access and visualization with “window technique” of the operations related to the machining

process- Execution of the set-up procedures and machine restarting after breakdowns and direct

diagnostics on machine components with “jig-structured” uncoded synoptic tables- Application softwares from “Solution Provider” sub-suppliers for the Power Monitor, Tool

Monitor or Tool Balancing management- Dimensional measuring software applications by means of probes (3D measure inspects) and

related data handling.




OFF LINE

ON LINE

Machining simulation

Accelerometer monitoring

• Collision check• Toolpath review• Cutting parameters

• Collision detection• Tool unbalancing warning

Triaxial accelerometer

Protect the process with machine simulation and monitoring

Safe process

Loading unit and machine monitoring• Stock balancing control on

Loading Unit• Dynamic control system of

Piece balancing in machine during the process.

• Machining simulation• Accelerometer monitoring• Loading unit and machine monitoring • Spindle power and machine axes torque control• Reporting of alarms



19

OFF LINE

ON LINESpindle power and machine axes torque control

Reporting of alarms

• Spindle power absorption limit• Axes engines torque control

CNCconsole

• Alarms detailed reports with causes and duration data

Protect the process with machine simulation and monitoring

Safe process

Loading unit and machine monitoring

• Machining simulation• Accelerometer monitoring• Loading unit and machine monitoring • Spindle power and machine axes torque control• Reporting of alarms




jFMX Information Technology Enabling Intelligent Manufacturing

ERPEnterprise Resource PlanningProduction Planning

jLoader applicationgenerates automatically, every day, a production plan so to:• Respect the due dates;• Exploit the unmanned work shifts;• Prepare, in advance, tool and fixture data for jFMX.

Production Management and Efficiency Analysis

Production Execution

jFMX• coordinates flexible automation;• automatically activates planned tasks, considering: - availability of needed resources; - urgency of each work; with the goal to fully exploit production systems.

Plant Monitoring

jFMX• registers and shows, in real time, the status of production

resources (machines, shuttles, load stations, tools, fixtures).

Efficiency Analysis and Data Export

The jReport module• creates, automatically, efficiency reports for a time period;• registers and classifies inefficiency causes.It is easy to navigate inside reports like in a web page, to print and to export data towards other information systems.

Production GANTT



21


Resources Management and Process Control

Production Resources Management

jFMX• traces resources availability status;• manages safely the data flow from and to the production cell,

using also RFIDs (Radio Frequency Identification) linked to resources.

Dynamic Machining Cycles

The NetPP (Network Part Program) module• manages the process cycle like a network of machining

working steps, linked by precedence relations;• makes easier error identification inside the machining

program;• automatically decides the execution sequence that minimizes

toolchanges and tool travelling time;• restarts automatically the cycle, after an abort, from the

interrupted working step.

Virtual Prove-out

The One-click Simulation module• integrates jFMX with state-of-the art CNC machine simulators;• prepares data for the automatic start of simulations;• collects and reports to the user the programming errors and

the machining time evaluation.

Quality Control

The jQuality module:• associates to the pieces one control card with: - measurements to do and related tolerances; - frequency of measurements;• shows control instructions to the operator of the unload station;• collects results for quality reports.

Tools, fixtures, stock and finished pieces, programs

Simulator





Alarms

Maintenance and Reliability

Maintenance Management

The jMaintenance module• plans preventive maintenance operations;• shows on-line the technical

documentation;• registers executed interventions.

Remote Assistance

The remote connection to jFMX allows users to benefit from:• technical support for using the system;• remote diagnosis of breakdowns and assistance for their resolution;• SMS warning on the mobile phone in case of alarms on the plant.

Reliability Analysis

The jAlarm module• registers alarms and machine stops;• creates reports and classifies alarms events.

Rapid Diagnosis

The Beyond Training module• shows a map of the status

of machine components;• makes easier and direct

breakdowns identification;• contextually links the

technical documentation.



23


jTerm jConsole

Wi-fi

PC

PC

password

Robustness, Usability, Integration

Robustness

jFMX hardware• industrial pc;• Pentium M processor;• 1GByte RAM;• double HD of 3.5” and 40GByte (RAID 1);• Debian Linux operating system, optimised by MCM;• UPS (Uninterruptible Power Supply) system;• jNode-HA (High Availability) with 2 PCs and 4 HDs in mirroring for multi-machines plants.

Usability

• web-browser user interface;• simple navigation among the production/process data;• rapid identification of status of resources (in/out of production, in alarm).

Integration

• wired and/or wireless connection of jFMX to the enterprise network;

• protected access to jFMX from the other PCs of the network.

jNode

Enterprise network

MACHINING CENTERS MANUFACTURINGMCM CANADA2311- 29th Ave. LAVAL WEST, QCH7R 3L4 CANADAPhone ++1 (450) 627 1414 Fax ++1 (450) 627 7336E-mail: [email protected]

MCM FRANCE SarlF-91600 Savigny sur Orge6 Av. du GariglianoTel. ++33 1-69-21-21-00Fax ++33 1-69-24-10-34E-mail: [email protected]

MCM SpaI-29020 Vigolzone (PC)Viale F. e G. Celaschi, 19Tel. ++39 0523 879901Fax ++39 0523 879130 E-mail: [email protected] http: www.mcmspa.it

MCM VERTRIEBS GmbH DEUTSCHLANDD-65189 Wiesbaden Humboldstraße, 13Tel. ++49 611-372747 Fax ++49 611-372745E-mail: [email protected]

MCM USA Inc.34525 Melinz Parkway, Suite 208-CEastlake, OH 44095 - U.S.A.Phone ++1 (440) 9181415Fax ++1 (440) 9180776Toll free 877 MCM 5999

MULTITASKING

TANK X-Axis Y-Axis Z-Axis Dimension A Dimension B Dimension C Fixture D Fixure H Milling pallet Turning pallet TANK 4 AXIS Version 1 1300 1010 1100 1400 1150 630x800-800x800

TANK 4 AXIS Version 2 1300 1300 1300 1400 1300 630x800-800x800-1000x1000

TANK 4 AXIS Version 3 1800 1400 1600 1800 1400 630x800-800x800-1000x1000

TANK 5 AXIS Version 1 1300 1100 1300 370 820 440 1200 1150 630x800-800x800 D=800 D=1000 D=1250

TANK 5 AXIS Version 2 1300 1200 1350 370 920 675 1300 1150 630x800-800x800-1000x1000 D=800 D=1000 D=1250

TANK 5 AXIS Version 3 1300 1400 1400 370.5 1119.5 440 1400 1150 630x800-800x800 D=800 D=1000 D=1250

TANK 5 AXIS Version 4 1600 1200 1600 400 890 560 1750 1300 630x800-800x800-1000x1000 D=1000 D=1250 D=1400

Rapid feeds m/min 60 Axes thrust daN 3.000 Rotation speed rpm 14.000/8.000/6.000 Wheel/rack type toolmagazine capacity n. 95/999 Max. tool length mm 600 Chip-to-chip tool changing time s 6 Max. “barycentric” tool diameter mm 340/500 Max. load on pallet (1300) kg 1.500/2.000 Max. load on pallet (1600) kg 2.000/3.000

4-axis TANK5-axis TANK

90

80

C

BA

10

90

Z-Axis Stroke Z-Axis Stroke

Fixture D. Fixture D.

Y-Ax

is S

trok

e

Fixt

ure

Hei

ght

Y-Ax

is S

trok

e

flex process flex solution flex...

Documents