Turn / Mill Center
S-191 LINEAR
The complete solution Machining of high precision complex parts from bar or blank Modular concept utilizing up to 3 spindles and 7 axis
S-191 The complete solution Innovative concept Complete machining of complex parts without secondaries operations at reduced cycle times 5-axis simultaneous interpolation
Turn / Mill The swiveling “B“ axis tool spindle and synchronous mill/turn options at the main and sub-spindle provides unique capability for complex parts requiring 6-side machining in all materials.
S-191 Machining Example A small sampling of complex parts and difficult materials typical of the medical, aerospace, dental,automotive, jewelry, connectors and fitting industries. Innovation: The BUMOTEC S-191 brings innovative machining technology to a compact high performance platform characterized by:
Acceleration of 1.1 G 50 meters /min. Linear drives 30‘000 rpm in 1.5 sec. 0 to 90‘ in 0.35 sec. up to 7 axis and 3 spindles HSK40 60 tools High precision Digital technology 5 axis simultaneously stability Surface finish reduced cycle times Flexibility
2
3
S-191 A Modular Concept Offering Up To 7 Axis: Choose the S-191 machine configuration from a selection of modular options that best fits your present or future machining needs.
Clamping Options An excellent selection of interchangeable main spindle clamping options for working from bar or blank.
A Counter Spindle Part Clamping A variety of quick change, sub-spindle part clamping options mount to the fully powered counter spindle allowing maximum flexibility for additional back and side working machining. Some systems are interchangeable.
W
Swiveling Counter Spindle: A fully powered, retractable counter spindle moves to and from a horizontal or vertical position allowing full turning and milling capacity Power: 7.5 Kw Torque: 28 Nm
Retaking Unit Part Clamping: A variety of quick change clamping fixture options are available for the retaking unit including special fixturing designed for your specific application.
Main Spindle and C Axis Direct drive spindle 32 or 42 mm bar capacity Power: 7.5 Kw Torque: 28 Nm Max. speed: 5500 rpm
red CNC axis orange Automatic movement violet Adjustable movement
4
High Precision Locking and Location A Hirth coupling insures a perfect radial and axial location for the swiveling counter spindle.
Fixed Table Option 500 x 300 mm tooling area allowing single or multiple fixturing. An optional C axis fixture for the table is available.
W‘
Swiveling Retaking Unit When a fully powered counter turning spindle is not desired, the retractable retaking unit provides another backside machining option for complexs parts.
5
S-191 Ultra Modern Milling and Turning Technology Higher precision and repeatability Better surface finish
Faster cycle times Reduced Maintenance
Interpolation 1/100 micron resolution on linear scales provides a new level of precision interpolation Below: ball bar protocol
Linear Motor Drive Option for the Z and Y axis Linear motor slides provide a step up in production speed, quality and stability while eliminating maintenance.
Ball Screw vs. Linear Motor Considerations
ISO 230-4 Déviations Circulaires
Comparison Criteria
Linear Motor Drive
Ball Screw Drive
YZ 360 test 2 Instrument: BallbarQC10
Acceleration Speed
Up to 1.2G Only limited by linear guides & measuring systems None
Up to 0.8G limited by mechanical components Limited by mechanical components
Machine: BUMOTEC S-191 LINEAR Opérateur: gachoudb Date: 2007-Août-29 11:15:39
Wear Reliability Components
Very high
High,particullary while fast movements High
No mechanical coupling Necessary zero over lifetime
Ball screw, nut, coupling, drive etc. Necessary while fast movements Minimal but increase with wear
Déviations Circulaires (SAH) Valeur 1.4 µm Paramètres du test Rayon 50.0000mm Fréquence d'échantillonnage 41.667Hz Vitesse d'avance 500.0mm/min Type de passe SAH Plan de mesure YZ position de mesure Angle de début 270° Angle de fin 270° Angle de dépassement 180°
2µm
Passe 2
2.0 µm/div
6% Win 80% 70%
82%
90%
The Additional Advantage of Speed • Reduction of bi-times • Better dynamics and finishes at higher speeds
100%
100%
94%
A Reduction in Cycle Times Cycle time comparison between ball screw and linear drives while producing a watch band link with diamond setting preparation.
100%
18% Win
Cooling Backlash
Exceptional Surface Quality All the benefits the S-191‘s advanced electronic and mechanical component technology combine to provide the highest level of surface quality. Shown: High quality watch band link with diamond setting preparation.
Hig wi h acc torqth line elera ue ar tio dri an n ve d s
40%
10%
Ball screw
20%
Cycle time Linear drive
30%
Machining time reduction
High jerk High smoothing
Ball screw
50%
Speed
Machining time (G1) Linear drive
60%
Temperature Control An advanced water circulation cooling system insures a constant temperature providing exceptional stability,precision and elimination of warm-up cycle and times.
0
Machining time
0%
XX
X XX
X
X
The chart provides an example of tolerance stability in an automatic production cycle prior to and after an 8 hour production stop.
19
15
13
11
07
X
05
03
XX
09 09
03
02
01
117
115
111
22 113
109
107
103
21 105
101
99
95
20 97
93
91
87
X
19 89
85
83
79
18 81
77
75
71
17 73
69
67
63
16 65
61
59
55
15 57
53
51
47
14 49
45
43
39
13 41
37
35
31
12 33
29
27
23
11 25
21
19
10 17
15
13
11
07
X
05
XX
X
08 01
XX
07
X
XXX
10 17
3µm
XX
X X
XX
08.00 Start production
06
XX
XX
XX XXX
127
X XXXX
24 129
X XX
05
XXX
XXX XXX
125
X XX
123
XXX X
119
XX
23 121
XX X
XXX
09 09
hour
6
X XX
03
piece nr.
8h Stand Still
X XX
08 01
Ø 7.013
7.018 7.017 7.016 7.015 7.014 7.013 7.012 7.011 7.010 7.009 7.008
24.00 Stop
04
08.00 Start production
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S-191 The Tool Spindle
Fanuc CNC
High speed with high torque High rigidity
The S-191 utilizes the latest generation Fanuc control Easy to operate
Ultra Dynamic B Axis
BUMOTEC SA
Swiveling B Axis The tool spindle is mounted on a rotary B axis controlled by a 226 Nm torque motor. The combination provides: • Zero backlash • Rapid acceleration (0 to 90‘ in 0.35 sec.) • Higher precision • Zero wear over lifetime • Improved surface finish while
CNC Functions A wide range of CNC functions are integrated into CNC package to increase complex machining capabilities. Below: Functions examples:
S-191
TOOLS TYPE 01 02
Milling Turning
16 17
Turning Milling
31 32 33
GEOME R 0.0000 0.0000 0.0000
WEAR L 0.0000 0.0000 0.0000
WEAR R 0.0000 0.0000 0.0000
OFFSET TURNING 03 Milling 18 TOOL Turning GEOME L 125.0000 125.0000 125.0000
01.0 01.1 01.2
OFFSET TURNING TOOL 02.0 02.1 02.2 02.3 02.4 02.5 02.6 02.7 02.8 02.9 02.10 02.11 02.12 02.13 02.14 02.15
B 0 0 90 90 90 90 0 0 90 90
Geome X Geome V 3.0000 1.0000 -3.0000 -1.0000 125.0000 1.0000 125.0000 -1.0000 125.0000 1.0000 125.0000 -1.0000 3.0000 1.0000 -3.0000 -1.0000 125.0000 1.0000 125.0000 -1.0000 3.0000 1.0000 -3.0000 -1.0000 3.0000 1.0000 -3.0000 -1.0000 3.0000 1.0000 -3.0000 -1.0000
No Tool No Tool No Tool HEMIS R 0.0000 0.0000 0.0000
Geome Z Geome R 125.0000 40.0000 125.0000 40.0000 -3.0000 40.0000 3.0000 40.0000 -3.0000 40.0000 3.0000 40.0000 125.0000 40.0000 125.0000 40.0000 -3.0000 40.0000 3.0000 40.0000 125.0000 40.0000 125.0000 40.0000 125.0000 40.0000 125.0000 40.0000 125.0000 40.0000 125.0000 40.0000
High Pressure Coolant The tool spindle is designed to facilitate optional rough tool coolant up to 80 bars.
B Axis and Tool Spindle Cooling Temperature controlled water circulation guarantees precision and stability in daily production.
READ
PUNCH
OFFSET
COPY
TOOLS TYPE
No Tool No Tool No Tool
RPM 0 0 0
Geome O 0.0000 180.0000 0.0000 180.0000 0.0000 180.0000 0.0000 180.0000 0.0000 180.0000 0.0000 180.0000 0.0000 180.0000 0.0000 180.0000
MDI **** *** *** GEONO MILLING TURNING METRY SEARCH
46 47 48
T 2 3 3 4 2 3 1 2 4 3 2 3 2 3 2 3
P 1 1 1 P 1 1 1 1 2 2 2 2 3 3 1 1 2 2 3 3
21:45:11 INPUT
TOOL
MAC MACHINE X1 0.0000 Y1 0.0000 Z1 0.0000 PROB PROBE X1 -1 -190.5329 Y1 75.9082 Z1 1 115.6666
PATH 1
User Friendly Bumotec has developed numerous routines helping reduce set-up and programming times. Simple functions assist you in all phases of set-up. Particular emphasis is placed on tool management for mill / turn machining.
PARAMETERS
Function TCP, G43.4 H_; TCP function (tool center point for 5 axis machining) controls the movement at the tool center point to follow the programmed path even if the tool axis direction changes. Machining path Programmed path
Tool axis I, J, K Tool length H
BUMOTEC SA
Q
Function G43.5 I_J_K_H_Q_; The function provides facility to program an angle on the B axis.
H
S-191
PREFERENCES WARNING WARNING
! !
CYCLE DOOR OPENED BARRE FEEDER ON
CLAMPING BY RESET KEY TOOLSSPINDLE LOADER1 IN MANUAL SPINDLE MOVE2THE TOOL CLAMPING RESET KEY KEY RIGHT TO THE BY STORE
NO NO NO NO
KEY LEFT MOVE THELOADER TOOL TO THE ARM PARAMETERS TOOL
Acceleration / De-acceleration BUMOTEC High dynamics translate Speed acceleration de-acceleration to superior acceleration 30 000 1515 msec and de-acceleration resul25 000 1780 msec ting in faster cycle times. 20 000 15 000 460 msec
10 000 5000
608 msec
95 msec
143 msec
Lubrication The tool spindle bearings area is injected via an air/ oil lubrication system supporting high speed and long life.
Fixed Tool Lock A superior locking system insures the perfect positioning for fixed tools (turning) operations eliminating load on the ball bearings. Tools may Sealing be indexed in 45 degree A pressurized labyrinth seal increments. keeps contaminates out.
KEY UP MOVE THE TOOL JAWS UP LOADING KEY DOWN UNLOADING MOVE THE TOOL JAWS DOWN 1 2 1.0000 3.0000 W2 ANGLE AT TOOL STORE 120.0000 3.0000 W2 ANGLE AT CLEANING -40.0000 3.0000 W2 ANGLE AT SPINDLE
All machine setting points are incorporated into the control eliminating dedicated machine information entry particularity valuable for shops utilizing multiple, identical machines.
CENTRE POINTS X Y Z X Y Z X Y Z X Z
0.0140 0.0000 0.0000 62.8536 0.0000 -62.7628 0.0140 0.0000 0.0000 -0.0384 62.8012 0.0000 0.0000 0.0000 0.0000 0.0000
X Y Z X Y Z X Y Z X Z
-104.6318 0.2667 159.8536 -167.4086 0.2667 222.6842 -104.6318 0.2367 159.8536 -0.0289 62.8037 0.0000 0.0000 0.0000 0.0000 0.0000
X Y Z X Y Z X Y Z X Z
0.0000 0.0000 0.0000 62.8536 0.0000 327.2372 0.0140 0.0000 390.0000 -0.0384 62.8012 0.0000 0.0000 0.0000 0.0000 0.0000
FRONTAL TURNING FRONTAL TURNING FRONTAL TURNING SIDE TURNING SIDE TURNING SIDE TURNING MILLING MILLING MILLING DEPORT-IN DEPORT-IN
0 0 600 msec 2000
4000
6000
MDI **** *** *** GEONO MILLING TURNING METRY SEARCH
READ
PUNCH
OFFSET
COPY
TOOLS TYPE
21:45:11 INPUT
TOOL
Function G41.2 D; G42.2 D C5 axis tool radius compensation This negates the need for recalculation of the tool path in the CAM module during tool replacement thus increasing productivity.
R
Tool Path Programmed Path
Tool interferences detection Tool path interferences are detected even with tool size bigger than programmed path Bigger tool radius.
PATH 1 PARAMETERS
Tool path with small dia tool Programmed Path.
Torque Maximum torque at low rpm‘s provides optimum conditions for both small and large diameter tools.
kW/ Nm
6
5 kW 6 Nm
5
Comparison of machining between conventional type and Nano interpolation
4
High Speed and Long Life Hybrid ball bearings facilitate high speed, rigidity and life time.
3 2 1 0 0
8
8000 Rpm
20 000
30 000
Conventional 1µm = 1000nm
Nano-Interpolation 1nm
Nano Interpolation The movement commands are calculated by nanometer (1/100 micron) before being passed onto the precision digital servo system. Even though the program may only be generated at micron resolution, nano interpolation enables the tool path to be very tightly controlled thereby achieving the highest quality surface finish with an associated increase in feed rate.
Workpiece Setting Error Compensation The workpiece setting error is detected through measuring cycles that determine the setting error and automatically correct the error prior to initiating the standard part program.
Y
Y‘
X‘ X
9
S-191 Accessoires
100
to on
tu
SK 40
SK 40
H
H
SK 40 H
epi ec e
rn
ut rc fo
E1 6 H
H
400
100
400
115
191
°
Floorplan
Parts Conveyor A conveyor belt provides part evacuation from the machining zone.
ca 62 83
270 2489
100
126 310
Swiveling Retaking Unit 100
100
3084
400
400
115
°
170 400
324
270
310
ca 62
10 70.09
10
3077 610
30°
100
620
with counter spindle
2015
R 580
2377
Automation Numerous automatic loading / unloading are available to meet your application needs.
Axis travels within machining area
220 290
700
High Pressure Coolant The Hydro Fluid, high pressure coolant system provides: • Oil cooling • Automatic filtration down to 5 microns • Self-cleaning filters • High pressure up to 80 bars
Tool Magazine The standard tool magazine accommodates 30 tools with a 60 tool magazine optional. Tools can be loaded in any position as they always reintegrate into their initial position. Tool change time is 1.8 seconds.
1977
Bar Feeder A wide range of automatic bar feeders are available to meet your production needs and preferences.
Tool Holders A wide range of HSK tool holders is available for all machining applications.
30°
Paper Band Filtration An ideal filtration method for machining precious metals.
310
Workpiece Measuring Probe An ultra compact touch probe with wireless transmission provides a solution for workpiece inspection, part alignment and automatic offset updates during the cycle.
10 x1 0
of f
g lo n
Chip and Coolant Management Several chip and coolant system are available for all applications and materials.
SK 40
E1 6 SK 40
E2 5 SK 40 H
Tool Probe A Renishaw contact probe is available as a tool setting option. Cutting tools are measure on 3 axis which are automatically introduced into the CNC machine control. The system also allows broken tool detection.
ol
ou
12 x1 2
A wide range of accessories is available to extend the S-191 machine capability.
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Longitudinal travel Transversal Vertical Power / pushing force
S191F Mill X-Y-Z-W Ball scew
S191FL Mill X-W Ball scew X-Z linear drive
S191FT Mill / Turn X-Y-Z-W Ball scew
Acceleration
Z Y X Z Y X Z Y X X-Y-Z-W
400 mm 200 mm 410 mm 2.5 Kw / 550 daN 2.5 Kw / 550 daN 4.8 Kw / > 550 daN 40 m/min 40 m/min 40 m/min 8 m/s2 (0.8g)
Resolution
X-Y-Z-W
0.0001 mm
0.000 05 mm
C
7.5 Kw 22 / 28 Nm 90 000° /min (18 750°/s2) 4900 N at 6 bar 0.0001° / 0.001° ø 32 mm (option ø 42) F38 / W20 / Ottet / Mecatool (option F48)
43 000 N at 45bar
Max. speed
Main spindle Direct drive power Torque/max. torque Max. speed acceleration Clamping force Resolution / Precision Bar passage diameter Clamping types
7.2 Kw / 350 daN 2.5 Kw / 550 daN 4.8 Kw / 240 daN 2.5 Kw / 550 daN
7.2 Kw / 350 daN 4.8 Kw / 240 daN
50 m/min 50 m/min 50 m/min 10.4 m/s2 (1.1g)
50 m/min 50 m/min 50 m/min 10.4 m/s2 (1.1g)
Swivelling B axis tool spindle Power (direct drive) B Torque / Max. torque Max. speed Blocking torque Resolution / Precision Angular travel
4.3 Kw 119 / 226 Nm 5 sec) 36 000° / min (7500° / s2) (0 at 90° in 0.35 200 Nm 0.0001 degree / precision 0.001 degree e -25° / +120°
Tool spindle Power Torque max. Speed max. Tool holder clamping force Tool holder type Lubrication through center
5Kw 6 Nm from 0 to 8000 min-1 30 000 min-1 1000 N HSK-E-40 or HSK-A-40 80 bar (option)
Automatic tool changer Number of tools Tool changing time (chip to chip) Tool max. diameter Tool lenght max. Max tool weight
30 (option 60) HSK40 3.2 sec 40 mm (80 if side position is empty) 130 mm (from spindle nose) 1.2 kg
Counter operations Axis travel Power / pushing force Max. speed Power / direct drive Torque / max. torque RPM max. Deg./min. max. Clamping force Resolution / precision Clamping type
40 m/min 40 m/min 40 m/min 8 m/s2 (0.8g)
5500 min-1
X B
C
W
S191FTL Mill / Turn X-W Ball scew Y-Z linear drive
Z Y
A
W
310 mm 2.5 Kw / 550 daN 40 m/min (8.3 m/s2)
A
7.5 Kw 22 / 28 Nm 5500 min-1 90 000° /min (18 750°/s2) 8500 N (at 5 bar) 0.0001° / 0.001° F38 / W20 / Ottet / Mecatool / (option F48)
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Tel: +41 26 917 84 01 Fax: +41 26 917 81 18 admin@bumotec.ch www.bumotec.ch
Technical modifications reserved • printed in Switzerland • Issued November 07 • E 1500 • Marketing-Werbung-PR.ch
Technical data Type