Palletisation...
in mould tool manufacturing
? Experience always shows that measures to reduce the idle times of your machines are significantly more worthwhile than chasing seconds in the actual machining process. The solution is a stable and exact reference system. This lets you preset away from the machine and then set up the machine with minimum idle time. Quickly and precisely!
! Fitting the machines with the same reference system means that electrodes and workpieces can be moved between the machines without subsequent alignment and checking – One Minute Set-up.
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Conventional setting-up
Job 4
Job 3
Job 2
Job 1
Machining time
Idle time One manned shift – eight hours
Job 6
Job 5
Job 4
Job 3
Job 2
Job 1
Pallet system
One manned shift – eight hours
Higher productivity, calculation example: Conventional setting-up
Pallet system
8
8
-4
-0.5
=4
=7.5
x5
x5
= 20
=37.5
Working time per day Setting-up time per day (hours) Spindle time per day Working days per week Spindle time per day
Faster payback, calculation example: Hourly invoicing (€) Spindle time / week (hours) Revenue / week (€) Capital cost of machine (€) Capital cost pallet system (€) Total capital outlay (€) Paybacktime (weeks)
A reference system minimises setup times
!
Conventional setting-up
Pallet system
50
50
x30
x37.5
=1 500
=1 875
150 000
150 000
0
+10 000
=150 000
=160 000
100
85
Big earnings are within your reach
The machine generates revenue when its spindle is turning – and only then.
Every minute that can be converted from internal to external setting time increases the spindle time of the machine and with it the productivity of the business.
Work smarter, not harder.
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System 3Rs reference system … gives extreme flexibility … is user-friendly
… reduces setting-up times ... links all your machines together … ensures precision and quality … is suitable for automatic changing with System 3R’s automation program.
A reference system with unique properties
Modern production is based on the use of a single reference system throughout the production process. But developing a reference system that meets today’s requirements calls for ample knowhow and experience. System 3R offers many unique features, such as: • chucks with fixed references and holders with movable references • all references integrated into the same workpiece and plane • ability to handle high forces, moments, impacts, dirt, vibration, corrosive environments, without adverse effect on performance.
Z
Y
X
The result
System 3R lets you move tool and workpieces between machines while maintaining an accuracy of 1 µm, without time-consuming resetting.
Suited to your operations
Our pallet systems can handle workpieces measuring a few centimetres and workpieces weighing several tonnes with equal ease. In addition, our systems are suitable for old and new machines of practically every type and make – die-sinking and EDM machine, grinders, presses, high-speed milling machines, lathes and measuring machines.
Dynafix
Macro & MacroMagnum
350
Macro MacroJunior
40
250
150 40
100 kg
50 kg
1 kg
40
250 kg
150
150
250
250
350
Note: For every pallet system there is a “recommended” maximum workpiece size. However, this should only be regarded as a guide, since the size of the workpiece relative to the pallet depends above all on the material and the type of machining.
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350
MacroCombi
The MacroCombi chucks accept two completely different types of electrode holder. Both Macro with its immovable stability and precision, and MacroJunior with its highly economical holders. The limitations are few, the possibilities many. The smart chucks can be installed in both old and new machines without software changes, thanks to the air logic (patent applied for) of the chucks, with servo and differential valves.
Spindle chuck MacroCombi
• Clamping force – 5000 N • Fixed index positions 4x90° • Required air pressure, pneumatic chuck – 6±1 bar • Recommended tightening torque, manual chuck – 4 Nm
Pallet sizes – MacroJunior Drawbar – Macro
• Ø25 and Ø30 mm Pallet sizes – Macro
Drawbar – MacroJunior
• 54x54, 70x70, Ø75 and Ø116
Pallet/reference element/ holder - Macro Workpiece
For further information, ask for the separate brochure T-2292-E ”MacroJunior & MacroCombi – reference systems for mould tool manufacturing”
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Macro
Among users world wide, the Macro system is a byword for precision. And with good reason, since very single Macro product is thoroughly checked before it is dispatched. But precision can be graded too. The Macro products are therefore “classified” in terms of accuracy, material and life – but always with full compatibility – as Standard, High Performance and Nano. Even so, it’s worth remembering that the accuracy of a system is determined by the product with the lowest classification. •
Workpiece/ electrode
Repetition accuracy: MacroNano – within 0.001 mm MacroHighPerformance – within 0.0015 mm MacroStandard – within 0.002 mm
Macro pallet/ holder
• Locking force – 6000 N • Fixed index positions 4x90°
Drawbar
• Required air pressure, pneumatic chuck – 6±1 bar • Recommended tightening torque, manual chuck – 4 Nm
Table chuck
• Recommended max workpiece weight – 50 kg.
Pallet sizes – Macro • 54x54, 70x70, Ø75 and Ø116 mm
For further information, ask for the separate brochure T-2286-E ”Macro – reference systems for mould tool manufacturing”
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MacroMagnum
Workpiece/ electrode
MacroMagnum is larger variant of the patented Macro system. The high clamping force and the position of the reference surfaces far away from the chuck centre mean that MacroMagnum can provide “Macro class” stability and accuracy, even in applications with high machining forces. The double references of the chucks mean that in addition to the MacroMagnum pallets, the extensive range of Macro pallets can also be fixed to MacroMagnum.
MacroMagnum pallet/ reference element
• Repetition accuracy – within 0.002 mm • Locking force – 16 000 N • Fixed index positions 4x90°
Drawbar
• Required air pressure, pneumatic chuck – 6±1 bar • Recommended tightening torque manual chuck – Macro-pallet 5 Nm • Recommended tightening torque manual chuck – MacroMagnum-pallet 12 Nm
Pallet sizes – Macro • 54x54, 70x70, Ø75 and Ø116 mm
Pallet sizes – MacroMagnum • Ø142 mm, Ø156 mm and 240x240 mm
Table chuck
For further information, ask for the separate brochure T-2289-E ”MacroMagnum – reference systems for mould tool manufacturing”
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Dynafix
Dynafix permits machining with optimal cutting data, without sacrificing accuracy and quality. The easy-to-handle aluminium pallets have reference elements of high-alloy steel with directly measurable Z-references. Locking mechanism with built-in soft-landing function protects the references and simplifies handling in applications involving heavy workpieces. In addition, automatic air-blast cleaning of the Z-references and peripheral sealing make Dynafix a practical and user-friendly reference system which minimises setting-up times, increases machine capacity and provides a basis for automated production. • Repetition accuracy – within 0.002 mm • Locking force – 60 000 N • Fixed index positions 4x90° • Required air pressure, pneumatic chuck – 6±1 bar
Pallet sizes – Dynafix • 280x280 and 400x400 mm
Workpiece/ electrode
Dynafix pallet holder
Table chuck
For further information, ask for the separate brochure T-2291-E ”Dynafix – reference systems for mould tool manufacturing”
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Maxi
An especially robust, uncomplicated and user-friendly system for larger and heavier electrodes and workpieces. The chucks are of the fishtail type with three references for rapid mounting of the accessories with a single two-handed operation. Chuck adapters – with Maxi as the basic mounting on the machine table – also give access to the Mini, MacroJunior and Macro systems.
Chuck
Holder/pallet
• Repetition accuracy within 0.01 mm. • Recommended maximum weight 500 kg.
Pallet sizes – Maxi • 150x150 and 150x90 mm
For further information, ask for the separate brochure T-2294-E ”Maxi – reference systems for mould tool manufacturing”
The Mini ”original”
The ancestor of the reference systems! The introduction of the Mini system in the early 1970s created the basis for efficient electrode production and spark-erosion machining. The Mini system is a “Reverse Reference System”, in which the chuck adapts itself to the electrode holder, which is why all electrode holders must be exactly alike – in diameter, roundness, straightness and hardness – to meet the accuracy requirements. Even today, the Mini system is probably the most widespread reference system in the world.
Workpiece/ electrode
Mini holder/handle Ø20 mm
• Clamping force – 4000 N
Sizes Chuck
Workpieces/electrodes of various sizes are mounted directly on Ø20 mm handles.
For further information, ask for the separate brochure T-2295-E ”Mini – reference systems for mould tool manufacturing”
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Wire EDM machining with a Macrochuck … is suitable for automatic changing ... links all your machines together
With a Macrochuck
as basic equipment on the machine table, you can interconnect all your machines to create a single system. Move the workpiece from the wire EDM machine to the grinding machine or the die-sinking machine without subsequent alignment – quickly and precisely. If you choose a pneumatic Macro chuck, you can operate round-the-clock production if you wish. • Z-references with automatic air-blast cleaning • X and Y references of cemented carbide • Repetition accuracy 0.002 mm • Turbo locking – enhanced clamping force
Pre-set in three axes
with System 3Rs levelling adapter. This can be done with an accuracy of thousandths of a millimetre! The simple, directly measurable references of the levelling adapter mean that presetting can be done on an ordinary surface plate, using one of System 3R’s presetting stones. Preset away from the machine. Lift the preset “package” into place – levelling adapter, holder and workpiece – fix with a few simple manual operations and start the machine. Simple, quick and precise.
For further information, ask for the separate catalogue T-2159-E "Reference system for wire EDM machining"
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Make your dreams come true ‌ boost productivity
Once you have started to use our reference system it is easy to add automatic handling of tools and workpieces. This allows you to utilise your machines round the clock with minimal manual supervision. One or more production cells can be equipped with computerised inspection, giving each tool and workpiece a unique identity. All information about the production process, NC programs etc., is stored in a central database. This makes it very easy to plan and control production. The next step is to upgrade the computer system to a complete production planning system with pricing, materials, delivery dates, ISO documentation and much more. Simple and user-friendly. All in the same system, from the same supplier – System 3R!
Examples of applications: WorkMaster Linear, automation cell
Multiple Load Station
Full Rack magazine
Drain & Rinse Station Half Rack Magazine
Washing Station
Work Preparation Station Rail
Rotary Magazine
WorkMaster Linear
For further information, ask for the separate brochures Automation, WorkPal Compact servo, WorkPartner, WorkMaster, Workmaster linear, Automation with 6-axis robot, WSM etc
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System 3R International AB Sorterargatan 1, SE-162 50 VÄLLINGBY tel +46-08 620 20 00, fax +46-08 759 52 34, e-mail: info@system3r.com, www.system3r.com ASIA
EUROPE
AMERICAS
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System 3R Europe GmbH Wasserweg 19 DE-64521, GROSS-GERAU tel +49 61 52 80 02 0 fax +49 61 52 80 02 35 e-mail: info.eu@system3r.com
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Combi, Delphin, Dynafix, Locx, LX, Macro, One Minute Set-Up, One System Partner, R2R, System 3R, VDP, WorkMaster, WorkPal, WorkPartner, WorkShopManager, 3HP, 3R, 3Ready-To-Run and 3Refix are registered trademarks of System 3R.
T-2296-E 10.11 Subject to modifications • System 3R, a member of the Georg Fischer Group.
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