The World of Products and Services

HELLER Solutions 2012 / 2013HELLER Solutions 2012 / 2013

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HELLER Machining Centres Flexible Manufacturing Systems HELLER Services

Metal cutting companies around the world benefit from HELLER‘s comprehensive solution competence. Based on our many years of experience we develop customised manufacturing solutions tai-lored to the specific needs of our customers. Our comprehensive range of machines and services provides the foundation for these solutions. For a wide range of workpieces and materials. From machining of individual parts through to high-volume production. From light-metal machining through to heavy-duty cutting.

HELLER Solutions. Knowing how it’s done.

02 HELLER Solutions

The H series4-axis horizontal machining

The H series is based on a robust, highly standardised machine concept. Proven components, adequate speeds and a wide range of standard equipment guarantee an excellent price-performance ratio, whilst optional extensions provide a high degree of flexi-bility.

Series H 2000SK 40 / HSK-A 63 / BT 40

H 4000SK 40 / HSK-A 63 / BT 40

H 5000SK 50 / HSK-A 100 / BT 50

H 6000SK 50 / HSK-A 100 / BT 50

Working range (X/Y/Z) 630 x 630 x 630 mm 800 x 800 x 800 mm 800 x 800 x 800 mm 1,000 x 1,000 x 1,000 mm

Pallet size 400 x 500 mm 500 x 630 mm 630 x 630mm 630 x 630 mm

Max. workpiece height 850 mm 1,000 mm 1,000 mm 1,200 mm

Max. loading capacity 800 kg | 500 kg 1,400 kg | 800 kg 1,400 kg | 1,000 kg 1,400 kg | 1,000 kg

Chip-to-chip time (VDI) 2.8 s | 2.3 s 3.0 s | 2.5 s 4.0 s | 3.6 s 4.2 s | 3.8 s

Rapid traverse 60 m/min | 90 m/min 60 m/min | 90 m/min 50 m/min | 60 m/min 50 m/min | 60 m/min

Acceleration 8 m/s2 | 10 m/s2 8 m/s2 5 m/s2 | 7 m/s2 5 m/s2 | 7 m/s2

Spindle unit (ED S6 – 40 %) 10,000 rpm · 38 kW · 242 Nm | 16,000 rpm · 40 kW · 95 Nm 24,000 rpm · 25 kW · 40 Nm

8,000 rpm · 43 kW · 822 Nm | 6,000 rpm · 60 kW · 2.292 Nm12,500 rpm · 52 kW · 166 Nm | 12,500 rpm · 52 kW · 500 Nm

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Technical data

HELLER Machining Centres

PRODUCTIVE

Series MCH 350SK 50 / HSK-A 100

MCH 400SK 50 / HSK-A 100

MCH 450SK 50 / HSK-A 100

MCH 460SK 50 / HSK-A 100

Working range (X/Y/Z) 1,250 x 1,000 x 1,000 mm 1,400 x 1,000 x 1,250mm 1,600 x 1,200 x 1,250mm 2,000 x 1,400 x 1,250 mm

Pallet size 800 x 800 mm 800 x 800 mm 800 x 1,000 mm 800 x 1,000 mm

Max. workpiece height 1,200 mm 1,450 mm 1,450 mm 1,450 mm

Max. loading capacity 1,250 kg 2,500 kg | 4,000 kg 2,500 kg | 4,000 kg 2,500 kg | 4,000 kg

Chip-to-chip time (VDI) 4.7 s (Dynamic package: 4.5 s) 5.4 s 5.7 s 6.1 s

Rapid traverse 50 m/min 40 m/min 40 m/min 40 m/min

Acceleration 4 m/s2 4 m/s2 4 m/s2 4 m/s2

Spindle unit (ED S6 – 40%) 6,000 rpm · 43 kW · 822 Nm | 12,500 rpm · 72 kW · 460 Nm | 6,000 rpm · 60 kW · 1,145 Nm

PRODUCTIVETechnical data

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The MCH seriesUniversal high-performance machining

The proven machines from the MCH series are true allrounders delivering top-notch performance for the machining of heavy workpieces. Whether used for highly productive or flexible manu-facturing, the MCH machining centres provide great versatility. Loading of the setting station via overhead gantry or directly onto the rotary table as well as conventional FMS linkage are possible. Excellent accessibility to all assemblies, units and optio-nal equipment plus perfect coolant and chip management ensure optimum machine operation.

HELLER Machining Centres

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The F seriesSetting standards in 5 axis

With the F series, HELLER now offers two completely different types of 5-axis machining centres. Our FP models are production-oriented machines equipped with a typical pallet changer that can be fully integrated into standard pallet automation systems. Now, for the first time, HELLER also offers a classic workshop machine for manual table loading with model FT.

Series FP 2000SK 40 / HSK-A 63 / BT 40

FP 4000SK 40 / HSK-A 63 / BT 40

FT 4000SK 40 / HSK-A 63 / BT 40

Working range (X/Y/Z) 630 x 630 x 830 mm 800 x 800 x 1,000 mm 800 x 800 x 1,000 mm

Pallet size 400 x 500 mm 500 x 630 mm Ø 720 mm

Max. workpiece height 850 mm 1,000 mm 1,500 mm

Max. loading capacity 800 kg 1,400 kg 1,400 kg

Chip-to-chip time (VDI) 3.5 s 3.7 s 3.7 s

Rapid traverse 60 m/min 60 m/min 60 m/min

Acceleration 6 m/s2 6 m/s2 6 m/s2

Spindle unit (ED S6 – 40%) PCU 63: 10,000 rpm · 44 kW · 242 Nm | PCT 63: 10,000 rpm · 46 kW · 116 Nm | SCU/SCT 63: 16,000 rpm · 40 kW · 80 Nm

PRODUCTIVE UNIVERSALTechnical data

HELLER Machining Centres

PRODUCTIVE

Series MCH 280 CSK 50 / HSK-A 100

MCH 350 CSK 50 / HSK-A 100

MCH 450 CSK 50 / HSK-A 100

Working range (X/Y/Z) 1,000 x 1,000 x 1,100 mm 1,250 x 1,000 x 1,300 mm 1,600 x 1,200 x 1,700 mm

Pallet size 630 x 630 mm 800 x 800 mm 800 x 1,000 mm

Max. workpiece height 1,000 mm 1,200 mm 1,450 mm

Max. loading capacity 800 kg 1,250 kg 2,500 kg / 4,000 kg

Chip-to-chip time (VDI) 6.8 s 7.1 s 8.2 s

Rapid traverse 50 m/min 50 m/min 40 m/min

Acceleration 4 m/s2 4 m/s2 4 m/s2

Spindle unit (ED S6 – 40%) 6,000 rpm (8,000 rpm) · 43 kW · 822 Nm

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The MCH-C series:Flexible 5-axis heavy-duty cutting

For three models of the MCH range HELLER offers an optional compact machining unit with C-axis. The C-unit enables 5-axis and 5-sided machining at a freely selectable machining angle. This machining unit features a CNC controlled rotary axis at a 45° angle below the spindle axis with an accuracy of 360,000 x 0.001°. The MCH-C series comprises universal production machi-nes offering a high performance potential for customers with a wide spectrum of different machining requirements.

PRODUCTIVETechnical data

HELLER Maschining Centres

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The C seriesCombined Processing

The 5th axis provided by the tool makes the C series the perfect solution for 5-axis machining but also for turning operations. Horizontal and vertical turning with B and C axis allows to gene-rate precise outer and inner contours. The HSK-T spindle taper provides high precision and repeatability for tool positioning. Options comprise a version with direct manual loading onto the table of the machine (CT) or with integrated pallet changer (CP) and hydraulic clamping.

PRODUCTIVE UNIVERSAL

Series CP 2000HSK-T 63

CP 4000 HSK-T 63

CT 4000HSK-T 63

Working range (X/Y/Z) 630 x 630 x 830 mm 800 x 800 x 1,000 mm 800 x 800 x 1,000 mm

Pallet size 400 x 500 mm 500 x 630 mm Ø 720 mm

Rotational speed* 500 rpm 500 rpm 500 rpm

Max. workpiece height 850 mm 1,000 mm 1,500 mm

Max. loading capacity 800 kg 1,400 kg 1,400 kg

Chip-to-chip time (VDI) 3.5 s 3.7 s 3.7 s

Rapid traverse 60 m/min 60 m/min 60 m/min

Acceleration 6 m/s2 6 m/s2 6 m/s2

Spindle unit (ED S6 – 40%) PCU 63: 10,000 rpm · 44 kW · 242 Nm | SCU/SCT 63: 16,000 rpm · 34 kW · 68 Nm

PRODUCTIVE UNIVERSALTechnical data

HELLER Machining Centres

*Higher data on request

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Scalable manufacturing systemsin modular design

HELLER MC series: Versatile productivity

For automotive light-duty applications, HELLER provides the MC machining modules from the Module Line range with direct loading. The standard versions are equipped with 4 axes. A 5th axis provided by the tool is available as an option. The compact machines in modular design are scalable and can be linked to a fully automated manufacturing system at any time.As the perfect supplement HELLER is offering a special auto- motive version of the 4-axis machining centres from the H series with pallet changer.

Technologies for crankshaft and camshaft machining

With a unique know-how of the complete process chain HELLER is also offering solutions for the flexible production of crankshafts and camshafts. The machines from the RFK, DRZ and RFN series allow to combine different technologies to enable perfect internal and external milling or chasing operations – in accordance with customer requirements either as stand-alone solution or linked manufacturing system.

HELLER Manufacturing Systems

Supplements to the MC series:Process modules and special solutions

For automotive heavy-duty machining, the range of MC machines is complemented by additional models (e.g. machines with direct loading, head changer systems or process modules for special tasks). When maximum productivity is required, HELLER‘s TRS 4000 provides a powerful special solution for high-volume production. Thanks to our recent co-operation with WENZLER, we are now able to offer machining centres from the VKM range for the machining of structural parts.

HELLER ServicesFor highest productivity and

availability

The availability and sustained performance of the machines and systems is guaranteed by HELLER Services. With a range of services to match your maintenance philosophy we are catering to your needs throughout the complete lifecycle of your machines and production systems.From commissioning and the reliable supply of spare and wear parts, remote diagnostics and condition monitoring, customised maintenance and servicing agreements, training of your opera-ting and maintenance staff through to machine relocations, rebuilds, overhauls and retrofitting we offer you a partnership to

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last throughout the entire service life of your manufacturing systems. A tight-knit network of service bases ensures short response times and extensive, personal support on site around the globe. With our Total Productive Services HELLER is offering service packages helping you to achieve sustainable productivity beyond the warranty period and at predictable costs.For this, HELLER provides a complete range of services to ensure long-term cost-effective operation of advanced machining centres incorporated in efficient manufacturing solutions. Available worldwide, offering unrivalled performance.

18 HELLER Contacts

Contact

HELLER worldwide

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INDIAPune

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Tel.: +49 7022 77-0Fax: +49 7022 77-5000info@heller.biz

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HELLER solution competence: Efficiency for your production. Worldwide.

Design and scope of supply are subject to technical changes. © 09.2012 Gebr. Heller Maschinenfabrik GmbH