machining center for mass production parts machining nx-series
TRANSCRIPT
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Machining Center for Machining Center for Mass Production Parts Mass Production Parts
MachiningMachining【【 NXNX--SeriesSeries 】】
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Voices from Automotive Voices from Automotive Parts Production SitesParts Production Sites
• Machines are too big for the workpiece sizes. Palm-sized workpieces are currently processed on a machine which is over 1000mm in width.
• Workpiece life is getting shorter, and lines are now often changed. However, lines based on specialized machines are often inflexible, more expensive and take a long time to convert.
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LineLine--up for Mass up for Mass Production LinesProduction Lines
680 mm 955 mm 1,550 mm
NX2000 SERIES NX3000 SERIES NX4000 SERIES
NXH2000 SERIES
NXV2000 SERIES
NXT2000 SERIES
NXH3000 SERIES
NXV3000 SERIES
NXH4000 SERIESHorizontal MC
Vertical MC
Turning Center
Horizontal MC
Vertical MC
Horizontal MC
Pallet Size
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Target WorkpiecesTarget Workpieces
Φ140×100 mm Φ400×400 mm Φ700×700 mm
NX2000 SERIES NX3000 SERIES NX4000 SERIES
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NXNX Series DesignSeries DesignModular concept with unified size Modular concept with unified size
955 mm
955 mm
1,000 mm
NXH3000 DCGHorizontal MC
NXV3000 DCGVertical MC
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NX2000 Axis Configuration• By making heaviest axis the vertical axis,
machine is stabilized and vibration reducedColumn
fixed
Y-axis saddle vertical motion
X-axis saddle side-to-side motion
Z-axis spindle head front-to-back motion
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Flexibility by Removing one axis
or
from 3 axis to 2 axis moving unit
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Reconfigurable Capability
Vertical Bed Vertical Spindle
3AX Column
VMC
2AX Table
VMC/5AX
Turning Spindle
VT
Horizontal Bed Horizontal Spindle
HMC
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Flexible Changes to Flexible Changes to Production Line LayoutProduction Line Layout
ReconfigurReconfigurationation
Meets changes in production amountby changing the number of machines in the line
Meets changesin workpieces by changing the line formation
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Unlike conventional machines, DCGTM quickly eliminates vibration during positioning. Rotational vibration, which occurs at all acceleration start points, is reduced to an amount equal to the distance between the drive point and the center of gravity. This prevents the deterioration of the machined surface.
Without DCG
With DCG
Residual vibration after positioning
Pushing moving parts at the center of gravity with twin ball screws
Box-in-Box Constructionfor compact design
DD CC GGDriven at the Center of GravityDriven at the Center of Gravity
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High PrecisionHigh PrecisionRoundness Thermal DistortionWith S5000, F1000and diameter 40mm,roundness is 2.9μm
Less than ½ that ofconventionalmachines
(Material: A5052)
Because it is small, rigidity is increased, allowing high precision.
Because it is light, it is very responsive, so its contouringaccuracy is good.
Because the moving parts are light, there is almost no vibration.
Because energy consumption is low, little heat is generated.Thermal expansion is small.
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Accessibility to WorkpiecesAccessibility to Workpieces
Gantry LoaderGantry Loader
Work ConveyorWork ConveyorRobotRobot
• Spindle 3-axis travel→Simple fixture layout, etc.• Workpieces can be transferred from right, left,
top or front
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Small is an advantageSmall is an advantageIdeal functions and size for small workpieces.Ideal functions and size for small workpieces.
A small machine has big advantages.
HighPrecision
HighSpeed
HighEfficiency
2,610 mm
2,300 mm 3,755 mm
2,500 mm
955 mm3,000 mm
NX3000 floor size comparisonWith the NH4000 DCG horizontal MC
NX3000 Series→Work Size Max.Φ400NX2000 Series→Work Size Max.Φ140
-- NXH3000DCG NXH3000DCG --
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Chip DisposalChip Disposal
There is excellent access to the table. Parts which need daily maintenance are gathered at the front and rear.
Chips do not accumulate behind the protector because they are discharged by pit or conveyor to the front or rear.
Chip chuter directly below the table
Center trough conveyor Side disposalchip conveyor
Operability, Operability, MaintenanceMaintenance
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NX2000 Series NX2000 Series ExamplesExamples
16.7m
Workpiece travel distance is 30% less than previous models
Workpiece transfer shuttle
Workpiece stocker
1313--Second Piston LineSecond Piston Line
Total 11 NX2000 Machines
Horizontal MC → 4Vertical MC → 4Vertical Lathe → 3
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Productivity per floor spaceProductivity per floor space→→40% UP40% UP
4.6m
7.2m
2.9m
6.8m
NX2000 NX2000 SeriesSeries ExamplesExamples
1 robot can transfer workpieces between 6 machinesNX LinePrevious models
Robot
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New Model New Model PickPick--up Turnup Turn【【NPNP】】
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・CompactCompact・Small floor space: Space-savingproduction line・Low: good visibility over factory
・Improving speedImproving speed・Reduced feed acceleration time constant・Reduced spindle acceleration time・Reduced tool indexing time
・Improving flexibility of systems・Construct line transfer systems
Development Aim/ConceptDevelopment Aim/Concept
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2807
1550
2350
1700
※
※
Red frame・Red figures: Mori
Seiki machine
Machine volume 85% of competitor’smachineFloor space 97% of competitor’smachine
Cover-line height
55% of competitor’smachine
※
Compact Compact Competitor’s
machine
Mori Seiki
Competitor’s machine
The height which allows the operator to see the next lineThe height which allows the operator to see the next line
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CharacteristicsCharacteristics
Gun drill
High-output spindle (30/22kW) 1.6sec/5000min-1
Turning gang type turret (12 tools)
Workpiece loading pathWe are also preparing a turret with a built-in motor
Z-axis slideway42m/min
The aim is to improve cutting
・
High-speed X-axis feed110m/min
1G
Because the moving parts (spindle) have a low center of gravity,Because the moving parts (spindle) have a low center of gravity,there is little vibration during highthere is little vibration during high--speed feedspeed feed
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StandStand--AloneAlone TypeType
Gun drill
Spindle (15/11kW)
8-station Built-in turret
X-direction feed
Workpiece loading path
Acceleration 1.0GSpindle-core cooling
Slideway
X-direction
Z方向 Z-axis direction
Rear-ejection conveyor
X- axis stroke
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Robot TransferRobot Transfer
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9200
800
120020002035 (competitors)
9375 (competitors)
Appearance (Line Spec.)Appearance (Line Spec.)
Red figures: Mori SeikiRed figures: Mori Seiki
15501550
22002200
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Started development on August 4, 2005
Design model September 28, 2005
Test machine basic model October 31, 2005
Mock-up model December 7, 2005
Test machine No.1 February 3, 2006
Mass production machine completed on April 21, 2006
6 Months From the Start of Development 6 Months From the Start of Development to Completion of Test Machineto Completion of Test Machine
Evaluation period: 2.5 months 4 test machines were made.
8 meetings with the customer until the design completion (3 months)Initial model
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