Machining Centers in Portal and Gantry Design

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Pierce Marsh
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Headquarters: Dörries Scharmann Technologie GmbH Hugo-Junkers-Straße 12-32 D-41236 Mönchengladbach-Rheydt Tel. +49/2166/454-0 Fax +49/2166/454-300 www.ds-technologie.de www.starragheckert.

de Products: Dörries Vertical Turning Lathes Vertical Turning Centers Droop+Rein Portal Machining Centers High Machining Centers Scharmann Horizontal Machining Centers Boring Mills Berthiez Vertical

1 Headquarters: Dörries Scharmann Technologie GmbH Hugo-Junkers-Straße D Mönchengladbach-Rheydt Tel. +49/2166/454-0 Fax +49/2166/ Products: Dörries Vertical Turning Lathes Vertical Turning Centers Droop+Rein Portal Machining Centers High Machining Centers Scharmann Horizontal Machining Centers Boring Mills Berthiez Vertical Turning Machines Vertical Grinding Machines Ecospeed 5-Axes High Performance Machining Centers Service Sites, Subsidiaries and Service Centers: Dörries Scharmann Technologie GmbH Product line Droop+Rein Hofkamp 2, D Bielefeld Tel. +49/521/5804-0, Fax +49/521/ Dörries Scharmann Technologie Service Center GmbH & Co. KG Am Sülzenbrückener Weg 14, D Ichtershausen Tel. +49/36202/77980, Fax +49/36202/ Dörries Scharmann Technologie GmbH Service Center South Wannetal 47b, D Lindau Tel. +49/2166/ , Fax +49/2166/ DST / StarragHeckert (Shanghai) Company Ltd. Room , Tower 1, German Centre 88 KeYuan Road, Pudong, Shanghai, PR China Tel. +86/21/ , Fax +86/21/ sh_office@starragheckert.com DST / StarragHeckert Company Ltd. Beijing Branch Room 1, Asia Hotel office building, No. 8 Xingzhong Xijie Gongti Bei Road, Beijing, PR China Tel. +86/10/ , Fax +86/10/ bj_office@starragheckert.com Dörries Scharmann Technologie GmbH Moscow Office ul. Tverskaya 16/2, Gebäude 1, 7. Etage, RUS Moskau Tel. +7/495/ , Fax +7/495/ DS Technology (USA) Inc. StarragHeckert Inc. North American Headquarters Skyport Business Park, 2379 Progress Drive Hebron, Kentucky Tel. +1/859/ , Fax +1/859/ ussales@starragheckert DS Technology (UK) Ltd. 43/45 Phoenix Park, Avenue Close, Nechells Birmingham B7 4NU, United Kingdom Tel. +44/121/ , Fax +44/121/ info@ds-technology.co.uk Berthiez SAS 5, rue Barrouin, F St. Etienne Cédex 1 Tel. +33/4/ , Fax +33/4/ sales@berthiez.fr E - low Machining Centers in Portal and Gantry Design Droop+Rein

TFM Multifunctional Portal Machining Center Droop+Rein offers high productivity and versatility with their TFM series of Portal Machining Centers.

solution. The modular design allows 4 different table configurations, 3 different tool maga zines and 3 different CNC controls.

1,250 mm Use of standard modules out of the product lines TFS and FOGS Spindle exchange (gear driven spindle/motor spindle) 2,0-5,500 mm 2,750 mm 1,250 mm depending on table length Higher dynamics

Z-drive Rapid traverse/feed 30/30 m/min 30/30 m/min Piston shaft fixed at cross rail 110 20/20 m/min 2 Z-ram Cross slide Fork Type Head Spindle cartridge TFM C-version/continuous controlled

2 TFM Multifunctional Portal Machining Center Droop+Rein offers high productivity and versatility with their TFM series of Portal Machining Centers. If the demand is for five-sided-machining, short tool exchange times, five-axis-contouring or the combination of turning and milling applications, the TFM series offers a productive machine tool solution. The modular design allows 4 different table configurations, 3 different tool maga zines and 3 different CNC controls. Integrated Fork Type Head with exchangeable spindle (gear driven spindle/motor spindle) (100% DC) 30 kw 600 Nm different technical data on demand RAM unit D30 5,000 rpm High flexibility travel of 1,250 mm Use of standard modules out of the product lines TFS and FOGS Spindle exchange (gear driven spindle/motor spindle) 2,0-5,500 mm 2,750 mm 1,250 mm depending on table length Higher dynamics Double spindle drive for Integration of two hollow drive shafts Elimination of hydraulic weight compensation Fall prevention device fixed at Z-ram Integrated Fork Type Head / / - 10 Z-drive Rapid traverse/feed 30/30 m/min 30/30 m/min Piston shaft fixed at cross rail /20 m/min 2 Z-ram Cross slide Fork Type Head Spindle cartridge TFM C-version/continuous controlled Five-axis-machining TFM P-version/positioned 3+2-axis-machining 10 B C = ±200 M = 8,000 /12,000 Nm clamping moment 3,600 /min M = 8,000 /12,000 Nm clamping moment 3,600 /min M = 12,000 Nm clamping moment M = 20,000 Nm clamping moment Spindles (changeable) Gear driven spindle Motor spindle Portal Machining Center with fixed cross rail Compact design Different table configurations, pallet change Five-side-machining Five-axis-machining (C-version) or 3+2-axis-machining (P-version) Complete machining ful roughing Highly dynamic and highly accurate finish machining Integrated Fork Type Head for exchangeable spindles Gear driven spindle Motor spindles 30 kw 600 Nm 5,000 rpm SK50 / HSK-A kw 48 Nm 18,000 rpm High geometrical accuracy and surface quality Reduction of bench rework Reduction of total production time Three different CNC controls Automatic spindle exchange Automatic tool change Tool measuring, part probing, etc. 3

TFS RAM unit D (100% DC) kw 1,100/1,800 Nm Portal Machining Center Ongoing customer demands for a more flexible uni ver sal machine design resulted in the creation of the TFS series.

3 TFS RAM unit D (100% DC) kw 1,100/1,800 Nm Portal Machining Center Ongoing customer demands for a more flexible uni ver sal machine design resulted in the creation of the TFS series. These are of portal configuration with a fixed cross rail. The TFS series offers customers in many industry sectors, e.g. Tool and Die Industry, Aerospace Industry and General Engineering, an economical and powerful solution for five-sided or five-axis-machining requirements and even for combined turning applica tions. TFS offers a variety of options like automatically exchangeable s, tables in different designs and practical solutions for the peripherals. Table dimensions Length Width 6,000 rpm 3,000-6,000 mm 2,200/2,500/3,000 mm 4,000-7,000 mm 3,200/3,500/4,000 mm 1,500 mm positioned (P-version) Rapid traverse/feed 30/30 m/min Long table version 30/ m/min 30/ m/min ± ± positioned (P-version) TFS RAM unit D Milling heads (examples) Vertical Angular Fork Type Head Z-ram Spindles Gear driven spindle Motor spindle P-version C-version Main drive kw Nm 1,800 1,800 1, Gearbox, 2-stages (1,800 Nm) Clamping M = 20,000 Nm P-version Positioned 0.001, clamped, M=20,000 Nm C-version Continuous controlled/clamped, M=8,000/ 20,000 Nm Max. speed Throat rpm mm 4,000/6, /550 4,000/6, /550 5, , Tool pick-up SK50 / HSK-A100 TFS C-version/continuous controlled TFS P-version/positioned SK50 / HSK-A100 Five-axis-machining 3+2-axis-machining SK50 / HSK-A100 M=8,000 /12,000 Nm clamping moment ; M=12,000 Nm clamping moment RAM unit D with integrated Positioned and clamped, P-version Continuous controlled, C-version Automatic exchange of milling units Automatic tool change Alternative table configurations Wide range of milling attachments Wide range of peripheral units Tool measuring, part probing, etc 4 5

T/TF Portal Machining Center RAM unit R50/R60/R75 (100% DC) 50/60/75 kw 2,0/4,000/5,500 Nm Droop+Rein Portal Machining Center series T/TF is designed for heavy duty machining applications in the

Five-side- and five-axis-machining with powerful s Our system includes spindle extensions, various angular s for indexing or controlled application.

traverse/feed 20/30 m/min TF T 20/30 m/min Building on the strength, high accuracy and performance capacity of the basic machines, DST offers a comprehensive system of innovative automation stages.

DST s knowledge and application of machining techno logy hold the key to your success. Our success depends on the success of our customers.

4 T/TF Portal Machining Center RAM unit R50/R60/R75 (100% DC) 50/60/75 kw 2,0/4,000/5,500 Nm Droop+Rein Portal Machining Center series T/TF is designed for heavy duty machining applications in the Aircraft-, Tool and Die- and Automotive Industry as well as General Engineering. Five-side- and five-axis-machining with powerful s Our system includes spindle extensions, various angular s for indexing or controlled application. Table dimensions Length Width 4,000 rpm 3,000-6,000 mm 2,200/2,500/3,000/3,500/4,000 mm 4,000-7,000 mm 3,000-5,000 mm 1,500 mm W-axis 1,000-3,000 mm x 360 ± 180 indexed (I-version) Rapid traverse/feed 20/30 m/min TF T 20/30 m/min Building on the strength, high accuracy and performance capacity of the basic machines, DST offers a comprehensive system of innovative automation stages. Nowhere are DST s strengths and experience more apparent than when complex and new machining concepts are required. DST s knowledge and application of machining techno logy hold the key to your success. Our success depends on the success of our customers. Therefore we have a long term investment in developing and optimizing systems and processes that allow our customers to achieve shorter production times; without compromise to cost and quality. Advantages RAM unit Thermosymmetry All heat sources are thermosymmetrical arranged to the RAM slide cross section Hydrostatic bearing (,, ) Highest precision Coaxial assembly Motor, drive and bearing Any heat generated by the guideways is eliminated by temperature controlled lubrication oil. Internal heat sources are controlled by cooling circuits. Motor Gear unit Milling heads W-axis I-axis Vertical milling head 50/60/75 2,0/4,000/ 5,500 4,000 Angular milling head 50/60/75 2,0/4,000/ 5,500 2,500 15/20 m/min 4/4 m/min Fork Type Head /50/60 1,100/1,500/ 2,0 6,000/5,000/4,000 positioned/continuous controlled indexed (I-version) Fork Type Head with motor spindle ,000 kw Nm rpm T/TF assembly Hydrostatic guidance Measuring system Table Support slideway Gear rod X Attachment Tool pick-up SK50 /60 HSK-A100 /125 HSK-B125 /160 Bed Electrical preloaded drive Hydrostatic Hydrostatic guideways in all linear axes Thermosymmetrical RAM design Integrated Digital drives High rigidity and damping Automatic head exchange Automatic tool change Alternative table configurations Wide range of milling attachments Wide range of peripheral devices 6 7

G/GF Portal Machining Centers in Gantry Design RAM unit R50/R60/R75/H100 (100% DC) 50/60/75/100 kw 2,0/4,000/5,500/8,000 Nm 4,000/2,500 rpm Platefield dimension Length from 8,000 mm + 1,000 mm steps

and unwieldy components, without involving their weight as factor for the machining result. This eliminates the lack in dynamic through table of workpiece influence.

W-axis 20/20 m/min 15/20 m/min 4/4 m/min NC controlled I-axis indexed (I-Version) The well known s of type T/TF are also available for the portal machining centers in gantry design.

5 G/GF Portal Machining Centers in Gantry Design RAM unit R50/R60/R75/H100 (100% DC) 50/60/75/100 kw 2,0/4,000/5,500/8,000 Nm 4,000/2,500 rpm Platefield dimension Length from 8,000 mm + 1,000 mm steps Width 3,000-7,000 mm / 1,000 mm steps from 9,000 mm + 1,000 mm steps 5,000-9,000 mm / 1,000 mm steps GF G The essential advantage of the gantry design is to work optimally on big, heavy and unwieldy components, without involving their weight as factor for the machining result. This eliminates the lack in dynamic through table of workpiece influence. Rapid traverse W-axis 1,500/2,000/3,000 mm 1,000-6,000 mm x 360 ± /20 m/min indexed (I-Version) Milling heads for type T/TF and G/GF Drive by main motor of RAM unit Ship diesel manufacturing W-axis 20/20 m/min 15/20 m/min 4/4 m/min NC controlled I-axis indexed (I-Version) The well known s of type T/TF are also available for the portal machining centers in gantry design. Gantry type machining center Bracket Y-drive Z-drive Z-Ram Cross slide Traverse W-drive Cross rail Area machining Landing gear manufacturing Column The G/GF series is especially developed for high and unwieldy components. At the same time it shows the advantages of type T/TF. Platefield dimension X-drive 3+2-axis-machining (Hirth-gearing) (I-version) five-axismachining (C-version) Bed Contour machining 8 9

FOGS 3,800-15,800 mm High Machining Center Due to innovative machining technology, the FOGS provides a new dimension in high speed milling.

Superior surface accuracy is achieved by using efficient cutting tools.

environment Proven design with well tested components provided for the smooth operation of a totally automated system using: Fully automatic pallet change Completely automatic tool change with up to

6 FOGS 3,800-15,800 mm High Machining Center Due to innovative machining technology, the FOGS provides a new dimension in high speed milling. The Droop+Rein concept is a quantum leap in technological development considering time and quality: The amount of manual work associated with traditional machining is reduced to a minimum. Superior surface accuracy is achieved by using efficient cutting tools. Rapid traverse/feed 2,500-7,000 mm 1,500/2,000 mm x 360 ± 180 ± / m/min + 1,000 mm steps indexed (I-version) indexed (I-version) / m/min 30/ m/min Superior competence from the machine to the environment Proven design with well tested components provided for the smooth operation of a totally automated system using: Fully automatic pallet change Completely automatic tool change with up to 320 tools Tool length and diameter measuring and compensation Automatically exchangeable motor spindles The combination of machines, CNC controls, tools, motor spindles and pallet changing units results in efficient, process-oriented systems. FOGS with pallet changer and table dimension of 15 m x 4.5 m Assembly X-drive Rack Rail Double pinion drive electrically preloaded Preloaded linear recirculating roller bearing Foundation tray Bellows Measuring system X-bed Fixator wedges Acceleration of axes Motor milling spindles Linear axes Rotational axes (100% DC) Tool pick-up , m/s 2 7,200 /s , , ,000 kw Nm rpm HSK-A100 Innovative machine and technology concept Workpiece carrier as fixed floorplate Tool executes all movements Acceleration of constant masses independent from the workpiece sizes and weight Fastest effective feed rates Integrated Fork Type Head for integrated motor milling spindle Reduced operator times lead to highest profitability Automated peripheral functions Tool change Video control Tool measuring, part probing, etc. Spindle change Pallet change 10 11

FOGS D RAM unit D (100% DC) kw High Machining Center 1,800 Nm 6,000 rpm 3,800-15,800 mm 2,500-7,000 mm + 1,000 mm steps 1,500/2,000 mm positioned (P-version) 110 Rapid travers /feed /

8,000 /20,000 Nm clamping moment; 3,600 /min Acceleration of axes Linear axes Rotational axes max. 3.2 m/s 2 max.

001 M = 25,000 Nm clamping moment kw Nm rpm Vertical 1,800 4,000/6,000 SK 50 Angular 1,800 4,000/6,000 SK 50 Die manufacturing Fork Type Milling Head Pick-up of different milling spindles

from the workpiece sizes and weight Fastest effective feed rates Integrated Fork Type Head for integrated motor spindle Guaranteed high productivity due to reduced operator times

7 FOGS D RAM unit D (100% DC) kw High Machining Center 1,800 Nm 6,000 rpm 3,800-15,800 mm 2,500-7,000 mm + 1,000 mm steps 1,500/2,000 mm positioned (P-version) 110 Rapid travers /feed / m/min Adaptable Fork Type Milling Head FOGS D C-version Five-axis-machining 10 B C = ±200 / m/min 30/ m/min positioned (P-version) M = 8,000 /12,000 Nm clamping moment; 3,600 /min M = 8,000 /20,000 Nm clamping moment; 3,600 /min Acceleration of axes Linear axes Rotational axes max. 3.2 m/s 2 max. 7,200 /s 2 FOGS D P-version/positioned 3+2-axis-machining 12 Examples s Max. speed Tool pick-up M = 12,000 Nm clamping moment M = 25,000 Nm clamping moment kw Nm rpm Vertical 1,800 4,000/6,000 SK 50 Angular 1,800 4,000/6,000 SK 50 Die manufacturing Fork Type Milling Head Pick-up of different milling spindles Landing gear manufacturing Special Innovative machine and technology concept Workpiece carrier as fixed floorplate Tool executes all movements Acceleration of constant masses independent from the workpiece sizes and weight Fastest effective feed rates Integrated Fork Type Head for integrated motor spindle Guaranteed high productivity due to reduced operator times Automated periphery functions Tool change Video control Tool measuring, part probing, etc. Spindle change Pallet change Roughing and finishing operation on one machine Multifunctional applicable for a wide range of machining tasks: General engineering Tool and Die Industry Integration of turning tables (for turning operations) 13

Machine Assembly Periphery High flexibility Controls Focused on

different control units: Fidia X C 20 Heidenhain itnc 530 Siemens

variety of options like automatically exchangeable s, tables in

Due to this, Droop+Rein machining centers are suitable for

itnc 530 Siemens Sinumerik 8 D The s are moved into the change

The automatic adaption to the milling unit is followed by

Tool changing systems are designed for customers demands and the

According to the machining tasks required, we can supply chain-

Chain magazine Head changer Rack type magazine Tool-arena Pick-up

Master-slave-principal Electronically pre-loaded drive Double

Backlash elimination High stiffness High positioning accuracy

Rapid traverse Feed Rapid traverse Special Long table T Double

8 Machine Assembly Periphery High flexibility Controls Focused on the application of the machine it can be configured with three different control units: Fidia X C 20 Heidenhain itnc 530 Siemens Sinumerik 8 D Customers demands are met by selecting from a variety of options like automatically exchangeable s, tables in different designs and different CNC-controls. Due to this, Droop+Rein machining centers are suitable for applications in General Engineering and Tool and Die Industry or the Aerospace Industry. Milling head and tool changing systems Fidia X C 20 Heidenhain itnc 530 Siemens Sinumerik 8 D The s are moved into the change position. The automatic adaption to the milling unit is followed by automatic clamping and coupling of all supply systems. Tool changing systems are designed for customers demands and the degree of automation desired. According to the machining tasks required, we can supply chain- and rack-magazines and robot-supported systems. Chain magazine Head changer Rack type magazine Tool-arena Pick-up magazine Palletizing possibilities/ Automation competences 14 Master-slave-principal Electronically pre-loaded drive Double pinion, electronically pre-loaded by two drives Advantages Backlash elimination High stiffness High positioning accuracy Easy maintenance by reduced number of elements Plate magazine Rapid traverse Feed Rapid traverse Special Long table T Double table DT Turn table TT Pallet system PT Wide variety of peripheral devices Different control options Pick-up magazine Plate magazine Chain magazine with up to 120 tool places Rack type magazine with up to 320 tool places Milling head change and spindle change Tool measuring, part probing, etc. Pallets 15

High Speed and Portal Machining Centers

High Speed and Portal Machining Centers Technologie Dörries Droop + Rein Scharmann Berthiez High and Portal Machining Centers Droop + Rein 2 Portal Machining Centers aprogramme of outstanding performance T/TF In addition to the High Machining