Broderik Engineering UK Limited Unit B, Buxton Rd Leek, Staffordshire ST13 6EJ

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1 CNC Single Columns Vertical Turret Lathe with C axis and ATC We never produce the cheapest machine, but the high class & reliable machine Price of standard machine CK5116M, Siemens 828D ATC: 6 turning tools & 24 stations milling tools Full guard and cooling system Heidenhain linear scale for X/Z axis Option: 1, Fanuc 0i TD 1, Features Technical Configuration The machine is designed and built to meet modern machining requirements with high speed cutting tools and carbide cutters on workpieces of ferrous, non-ferrous and other materials. 1

2 Functions: 1. I.D.& O.D. cylindrical turning 2. End-facing 3. I.D.& O.D. cone turning 4. Grooving (Note: The right bottom two functions are available with its CNC counterpart models only.) Basing on its super rigid structure, big machining capacities, heavy table load capacity, stable structure and high machining efficiency, the machine has a wide application in, power generation heavy electrics hydro / steam turbine generators foundry, casting, metallurgy pump / valve industries ship building, heavy engineering, etc 1.1 This series machine is suitable for finely and roughly turning cylinder and inner hole, inner and outer taper, surfacing, curving of the ferrous, grooving, drilling, threading and grinding, nonferrous metal and some kinds of non-metal materials with carbide and porcelain tools. 1.2 When the head is in high-speed movement, head in horizontal direction, and vertical rapid movement speed can be 10m/min. 1.3 The main drive adopts AC spindle servomotor with two steps. The high-speed rotating workpiece are balanced in static or dynamic pattern. Transmission gears with 5 grade precision are specially grounded to implement high efficient transmission, lower noise and smooth running in high speed turning. 1.4.Feed system is driven by AC servomotor which is connected with ballscrew by flexible couple to implement clearance-free transmission and high precision turning. 1.5 The columns, whose thermal symmetric construction, is calculated by finite element method, stand on table base. Effective vibration-insulated method is adopted to ensure high rigidity and strong anti-vibration ability. 1.6 The table is thermal-symmetric construction. The spindle is centered by high-precision double-row short cylindrical roller bearing whose radial clearance can be adjusted. With large high-precision thrust ball bearing on axial direction as rolling guideway, and oil 2

3 temperature cooling device, the table has high swivelling precision, larger load ability and smaller deformation. 1.7.Linear dual-direction roller guideway is applied to ensure high effective transmission and good precision reliability in heads and ram feed movement. 1.8 Chip conveyer and half-closed guide are also equipped by costumers' requirement. 1.9 On customers' requirement, the followings can be supplied tool magazine, tool setting device, boring & milling, table indexing and feed, grounding cooling device and wholeloop control, etc. 2, Specification ITEM Unit CK5116M Worktable diameter. mm 1400 Max. swing diameter mm 1600 Max. cutting diameter mm 1600 Worktable Max. workpiece height mm 1400 Max. worktable load kg 8000 Max. output torque of worktable N.m Worktable speed turning rpm Indexing & milling rpm Travel of X axis mm Travel Travel of Z axis mm 1000 Vertical travel of crossbeam mm 800 Rapid travel speed of X axis mm/min Rapid travel speed of Z axis mm/min 6000 Feed speed of X/Z axis mm/rev

4 Tool capacity set 24 (milling tool) or 6 (turning tool) Tool magazine Tool shank BT50 Max. tool weight kg 20 Total tool weight of tool magazine kg 360 ATC tool changing time sec 30 Milling head speed rpm Milling head Live spindle motor KW 28 Max. output torque N.m 800 Machine overall Coolant tank L 700 Machine size (LXWXH) m 6.7x3.3x5.6 3, Machine Body The big casting of this machine is made by resin casting which has been treated by oscillation long aging times in order to avoid the inner stress. The smaller casting has been treated by high temperatures. All the steel parts are thermal refining. Guideway of cross rail made by roll and slide complex way, and treated by spreadable quench. The ram of vertical toolpost has made by spherical graphite cast iron. The slide parts on guideway are turcite style which could insure the precision and maintain cycle much longer. Also the automatic centralized lubrication is used on the cross rail and slide parts. 4

5 4. CNC system Fanuc 0i TD/Siemens 828D/840D, total 4 axis are controlled by CNC, 3 axis could be interlocked at the same time, the function of Siemens 840D: 1. Controlled axes (6 Axes) 2. Simultaneous controllable axes (4 Axes) mm Least input incre 4. Machine Lock 5. Emergency stop 6. Backlash compensation 7. Stored pitch error compensation 8. Automatic operation (memory) 9. DNC operation 10. MDI operation 11. Program number search 12. Sequence number search 13. Dry run 14. Single block 15. JOG feed 16. Manual reference position return 17. Manual handle feed 18. Incremental feed x1,x10,x Position G Linear interpolation G Circular interpolation G02 G Dwell 23. Skip function G Reference position return G Reference position return check G nd reference position return 27. Rapid traverse rate G00 5

6 28. Rapid traverse override Fo,25,50,100% 29. Automatic acceleration/deceleration 30. Feedrate override 31. Override cancel 32. Optional block skip 33. Program number O4-digit 34. Sequence number N5-digit Siemens Drive 35. G90 Absolute/G91 incremental programming 36. Decimal point input 37. Plane selection G17,G18,G Manual absolute on/off 39. Sub program call: 4 folds nested 40. Canned cycles for drilling 41. Circular interpolation by R programming 42. Miscellaneous function lock 43. Spindle speed override 44. Spindle orientation 45. T code 46. Tool offset memory 47. Tool length compensation 48. Registered programs 49. Part program editing 50. Program protect signal 51. Status display 52. Current position display 53. Program display 54. Parameter setting and display 55. Self-diagnosis function 56. Alarm display 57. Alarm history display 6

7 58. Operation history display 59. Run hour and parts count display 60. Actual cutting feedrate display 61. Servo setting screen 62. Chinese display 63. Data protection key 3 types 64. Setting and display unit 10.4 colorful 65. RS232-C interface 66. Interlock 67. Custom macro B 68. Miscellaneous function 69. Input power supply 220Vac 50Hz 70. Program restart 71. Manual handle interruption 72. Programmable data input 73. Scaling 74. Tool offset By manual and program input, following functions could be executed: 1, Turning and milling inner/external cylinder, end surface, steps, grooving and end surface constant speed cutting. 2, Turning and milling inner/external circular cone or surface of revolution by line or circular arc interpolation. 3, Turning and milling straight thread, taper thread and plane thread by feed per revolution. 4, Pitch compensation of ball screw in two moving direction of tool post, could be stored and error compensated automatically. 5, Pitch compensation of ball screw in vertical moving direction of ram, could be stored and error compensated automatically. 6, Tool nose radius compensation 7, Program graphic function for program testing and adjusting. 8, Failure self-diagnosis function. 7

8 9, Reference offset for work piece position compensation. Work piece coordinate setting. Absolute and increasing dimension switching. 10, Using milling head, thread tapping or boring by feed per revolution or minute. 11, Using turning function, thread cutting by feed per revolution or minute. 5, Worktable base Worktable base is under worktable, it s the base of the machine, on the surface of base has annular hydro-static guideway, they are near the center hole of worktable. There are two drive systems inside the worktable base: One gear ring is for turning, one gear ring is for indexing. Between the two gear rings have one clutch, to make the indexing system empty when the turning system is working, and the same to make the turning system empty when the indexing system is working. The servo indexing system is aside of the worktable base. The servo system is used by AC servo motor and Europe gear box with anti-backlash. The HEIDENHAIN encoder is in the center of worktable could test the position of worktable for indexing. At the same time, with the help of HEIDENHAIN circle grating ruler under the worktable to make the C axis indexing in closed-loop control. To work with HEIDENHAIN circle grating ruler, worktable could be high accuracy indexing by CNC controlled in 360º without limitation. 6. C axis structure under worktable Double Fanuc servo motors connect with two speed gear box which supply worktable big torque and fast response characteristic. During C axis indexing, one servo motor working in main driving and another working in slave driving condition, to eliminate backlash when rotary direction changing. The two Fanuc servo motors get the feedback from Heidenhain encoder to make the positioning for the worktable. 8

9 7. Toolpost (Z axis, live spindle, ram) The ram is square type in front of ram, the material of ram Forging steel, it has manual square turret. The turrets could be uses for turning cutting. The X axis and Z axis of this ram both has Fagor liner grating scale(option), which could make the machine closed loop and guarantee the high accuracy of machine. There is one Taiwan live spindle mounted inside ram for drilling or milling (If ram travel over 2500mm will use electro-spindle). This spindle is driven by Fanuc motor 18.5/36KW servo motor to realize enough torque machining. Big output power of milling head could meet most of requirement of heavy cutting and hard material. Various special tools and head is more easy for multiple machining. Additionally, customer could choose Taiwan-Gongyang manual right angle milling head or Italy/German manual right angle milling head are as option. The ram s four sides have the 9

10 turcite guideway around. The guideway is made of alloy(zinc, Copper, aluminum) which import from Germany, with strong lubrication and wearless. Inside the ram has the live spindle which imported from Taiwan, all the bearings inside live spindle is NSK. 8. Hydraulic system The main function of hydraulic system is, ram hydraulic balance, live spindle clamping or releasing tools, hydraulic lock of worktable indexing lock. This hydraulic system have automatic circle cooling and also have alarm for oil level, temperature, oil pipe choke, and the Min. Working pressure. Also inside the hydraulic oil tank has the temperature control system and filter, to keep the machine working more stable in any condition. All the hydraulic parts like valves, pumps are from Compass-Taiwan & USA. 10

11 9. Lubrication system The lubrication for all the guideways and ballscrew on this machine is automatic way, set at time and rationed feeding. The centralized lubrication is controlled by the CNC system. The machine also has the waste oil collector, to avoid the lubrication oil mixed with hydraulic oil and protect the environment. 10. Cooling system The spindle and gearbox has constant temperature cooling system, to avoid the thermal deformation and assure the accuracy and life of the machine. The electric cabinet has air condition with temperature control for cooling the electric units especially in hot weather. Also depend on the working condition in customer s side, if the weather is too hot, it s necessary to choose the oil fridge for hydraulic oil tank.(option) 11, Components we used on our machine No. Item Quantity 1 CNC Control system two years global guarantee Siemens 828D 2 Axis drive motor ( X/Z axes ) Siemens servo motor 3 Linear scale-closed loop Heidenhain-Germany 3 Electrical parts of cabinet ABB-France 4 Live spindle Taiwan-Taida 5 Bearing inside the live spindle NSK-Japan 11

12 6 Bearings on ballscrew NSK-Japan/INA-German 7 Ballscrew-cross rail & ram THK-Japan 8 Automatic lubrication system ISHAN-TAIWAN 9 Control panel station MECANO- Germany 10 Air condition for electric cabinet(option) Leibo 11 Hydraulic parts Compass-Taiwan 12, Warranty and after sale service 1, Warranty period: one year after final installation, during the warranty period, all the daily damage parts will be provided freely by the manufactory. 2, Out of warranty period, the factory will still supply the support for the whole life of the machine, including technical advice, spare parts, labor, after sales service, and so on. And the factory will just take the necessary cost. 12

13 13, C axis Machine in our workshop 13

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15 14. Fullton VTL with C axis in customers side 15

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17 15. Solution with guard 17

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19 16. Accuracy testing report No. Testing item Testing Drawings Allowed Tolerance(mm) Actual Inspection(mm) G1 Worktable planeness Whole allowed tolerance : ( concave ) Part allowed tolerance: 0.01/300 G2 Worktable runout on flat

20 No. Testing item Testing Drawings Allowed Tolerance(mm) Actual Inspection(mm) G3 Worktable runout on radial G4 Cross rail vertical traverese match the worktable rotary axes parallel: A is inside the flat which parallel cross rail 0.025/

21 No. Testing item Testing Drawings Allowed Tolerance(mm) Actual Inspection(mm) G4 Cross rail vertical traverse match the worktable rotary axes parallel: B is inside the flat which be vertical cross rail 0.04/1000 G5 Vertical tool post moving match the parallel of worktable 0.02/

22 No. Testing item Testing Drawings Allowed Tolerance(mm) Actual Inspection(mm) G6 Vertical tool post moving to the parallel of worktable rotary axes A is inside the flat which parallel cross rail 0.02/1000 G6 Vertical tool post moving to the parallel of worktable rotary axes B is inside the flat which be vertical cross rail 0.04/

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