Tongtai Machine & Tool Co., Ltd.

Transcription

1 Trust & Technology Horizontal Machining Center HB-8II Tongtai Machine & Tool Co., Ltd. Headquarters No.3, Luke 3rd Rd., Luzhu Dist., Kaohsiung City 811, Taiwan TEL FA Taoyuan Branch Taichung Branch Japan Branch Europe Branch Romania Branch Malaysia Branch Vietnam Branch Thailand Branch Indonesia ffice TEL TEL TEL TEL TEL TEL TEL TEL TEL FA FA FA FA FA FA FA FA China peration Center Shuzhou Tong-yu Machine & Tool Co., Ltd. No. Huahong Rd., Economic Development Zone of Wujiang, Suzhou City, Jiangsu Province, China TEL FA Wuhan Branch Chongqing Branch Guandong Branch Tianjin Branch Shanghai ffice Shenyang ffice TEL TEL TEL TEL TEL TEL FA FA FA FA FA FA Affiliates Honor Seiki Co., Ltd. Asia Pacific Elite Corp. Quick-Tech Machinery Co., Ltd PCI-SCEMM - rue Copernic ANGER Machining GmbH TEL : FA : TEL : FA : TEL : FA : TEL : FA : TEL : FA : HB-8II 1.9/4

2 1 HB-8II Horizontal Machining Center HB-8II Horizontal Machining Center HB-8II High efficiency machining Human-machine interface is applied on HB-8II through excellent industrial machine design. Significant non-machining time is saved for high production efficiency. High torque powerful spindle 1, rpm built-in spindle (standard) is with /3 kw motor power and ceramic bearings, that gives high torque performance up to 4 Nm. The spindle is suitable for aluminum alloy, cast iron and steel machining. Alternative option, spindle with gear box, has 1461 Nm powerful torque for cast iron, forging, and tough materials. HB-8II is widely used in automobile industries, construction equipment, agriculture machinery and general-purpose machining. Main Specifications Spindle 1, rpm Build-in spindle 6, rpm High torque spindle with gearbox CNTENT 3 Machining capability / Machining accuracy Main structure 7 Maintenance 8 Peripheral accessories 1 peration 1 Intelligent system & friendly human-machine interface 13 Flexible manufacturing system 14 Tongtai-Technical application center (T-TAC) 1 Diagrams 17 Standard/optional accessories 18 Specifications Three axes B axis rotary table ATC Rapid traverse m/min /Y/Z axis travel 1,4/1,/1,3 /Y/Z axis acceleration/deceleration.4/.6/.4 G /Y/Z axis LM 6/ / High rigidity roller guide way /Y/Z High precision ballscrew Ø Three axes linear scale (ptional) Gear coupling type 1 rotary table NC.1 rotary table (ptional) Separable type tool pots High speed cam type tool changing device

3 3 3 HB-8II Horizontal Machining Center HB-8II Horizontal Machining Cent Machining capability / Machining accuracy Trial cut data with 1, rpm Built-in spindle HB-8II Accuracy performance End mill Ø3 Material S4C Depth/Width 3/1 Spindle speed 44 rpm Feed rate /min Chip removal rate 114 cm 3 /min FCD 3/1 48 rpm 36 /min 143 cm 3 /min Face mill Ø1 Material S4C Depth/Width 4/1 Spindle speed 86 rpm Feed rate 88 /min Chip removal rate 31 cm 3 /min FCD 7/1 86 rpm 88 /min 61 cm 3 /min B Ø18 Ø C 4.9 C A D 11 Ø4 Ø43 D.. A 1 A Ø17 Ø4 3 //. B B A B 8 3 A-A ( 1 : ) 3 Three axes accuracy Test standard : IS Material : A661 Test standard : VDI3441 Unit : Unit : µm Test items Test accuracy Positioning accuracy Repeatability accuracy 1 Cylindricity. axis 7 3 Perpendicularity. Y axis 7 3 Machining accuracy Linear scale (ptional) Linear scale is able to compensate the positioning error, repeatability error, and ball screw pitch error, which are caused by the temperature changing. The positioning accuracy achieves ±3 µm with compensation of linear scales Parallelism Straightness Angular accuracy Angular accuracy Position accuracy Concentricity Z axis axis Y axis Z axis 7 Positioning accuracy with linear scale The above data is measured in-house. The test result may not be obtained due to differences cutting conditions and environment conditions. 3 Repeatability accuracy with linear scale

4 HB-8II Horizontal Machining Center HB-8II Horizontal Machining Center 6 Main structure High rigidity structure Spindle Travel Standard spindle /Y/Z axis 1,4/1,/1, Rapid traverse /Y/Z axis m/min Three axes adopt high /Y/Z roller guide way Column adopts double-wall and syetrical structure Ø1 ceramic bearings are adopted in 1, rpm high torque built-in spindle. Cooling fluid circulation outside of spindle cartridge to maintain bearing temperature. Also, compressed air is led into motor chamber to cool motor. 4 Nm torque given by rpm is suitable for heavy duty mahcining, like cast iron and forging materials. Acceleration/deceleration /Y/Z axis.4/.6/.4 G Y-Axis Working area 1,3 -Axis 1 Max. speed 1, rpm 1 1, Z-Axis Spindle motor 3/ kw utput torque 4/3/38 Nm (%ED/1 min./cont.) Acceleration time. sec ( 1, rpm) 1.1 sec ( 4, rpm) Min. distance from spindle nose to table center 1 Min. distance from spindle center to table surface 1 Max. workpiece size Through the finite element analysis (FEA), structure design enables to keep high rigidity and stability in high speed motion. T-shape bed and strong column transfer and absorb vibrations to maintain excellent face machining. High torque spindle with gear box High precision gears are used in spindle to supply high transmission efficiency. The two step gear box can generates more than 1,4 Nm torque at rpm, it is specially suitable for hard materials and heavy duty works. Max. speed 6, rpm Spindle motor /18. kw utput torque 1,/883 Nm (3 min. S3, 6%/Cont.)

5 7 HB-8II Horizontal Machining Center HB-8II Horizontal Machining Center 8 Main structure peration B axis rotary table High precision positioning cones with hydraulic locking design, generating 18 tons of clamping force to ensure the table stability during machining. Full-circle hydraulic braking system (NC.1 index table) HB series adopts a full-circle hydraulic braking system. The full-circle surface is synchronously locked by hydraulic force. Clamping on large full-circle face, B axis has good rigidity and durability for heavy duty machining. The step up platform are provided at front side machine and operating panel side for operation assisatance. 4 Braking force Braking force 47~7 98~1,13 1,39 69~89 Unit : Max. table load 9 indexing time of 1 rotary table (Std.) 9 indexing time of.1 rotary table (pt.) 1,8 kg.4 sec 1.6 sec ATC With transparent window and wide tool magazine door design, friendly operating distance and height is convenient for operators. Pallet clamping force Braking torque 18, kgf 8 kg-m Automatic tool changer : Equipped with Japanese made cam type ATC. 61 APC 6 APC dynamic rigidity is strengthened by new hydraulic driven design and optimized PLC setting, APC indexing time is significantly reduced with max. loading condition. Ø Ø6 Maximum tool size for automatic tool changing Pallet changing time 17 sec 1 sec (Previous model) Air FRL unit and lubricant unit are centralized together for daily maintenance easily. 1,3 T to T C to C Tool capacity.4 sec 4. sec 6 pc (Std.) 9/1 pc (pt.) Spacious area facilitates loading, unloading and jig & fixture operations.

6 9 HB-8II Horizontal Machining Center HB-8II Horizontal Machining Center 1 Peripheral accessories Hydraulic and pneumatic supply for jig & fixture (pt.) Rearward type chip conveyor (Std.) 1. Suspended arm type supply Totally 6 ports are provided on each side and the maximum hydraulic pressure allowed is bar.. Hydraulic supply under pallet Quick couplers are used for hydraulic supply under pallet. There is no limitation for B axis rotating. According to different materials and chip size, Tongtai provides various chip conveyors for the best chip disposal. Suitable Non-suitable Steel Cast iron Aluminum/Non-ferrous metal Long/ Specification Curl chips Hinge type Scraper type Magnetic scraper type Drum type Integrated type Short chips Powder chips Short chips Long/ Curl chips Short chips Powder chips Coolant tank capacity 8 L(8% full) Short chips : Chips shorter than 6 or ball type chips smaller than Ø4. Curl long chips : Chips length is longer than short ones. Tool magazine side tool breakage detector (pt.) Tool breakage condition can be detected on standby tool for saving cycle time. Coolant Through Spindle C.T.S. increases the efficiency of chip flow and extends the tool life by cooling the cutting point. Discharge pressure : /4/7 bar (./4./7. MPa) Filtering accuracy : 4 µm Interior tool measuring device (pt.) Tool length and diameter can be measured by this function, it is well installed at working table side to avoid interference of tool and work piece. Shower coolant system (Std.) Assisted stair (Std.) ~1 Shower coolant continuously flush out chips during machining to save time of cleaning. The assisted stairs on loading / unloading side and operating panel side platforms are adjustable according to operator s stature. This friendly design makes operators more comfortable.

7 11 HB-8II Horizontal Machining Center HB-8II Horizontal Machining Center 1 Tongtai Intelligence Manufacturing System Flexible Manufacturing System (FMS) Considering productivity improvement, better machining precision, operating facilitation, as well as protection and maintenance assistance, TIMS includes four management functions: production management, intelligent monitoring, tool management, and workpiece management. These provide customers a comprehensive intelligence manufacturing system and a friendly human-machine interface. Production management APC Production management Cutting Load Monitoring The spindle and feeding axis motor loads are able to be monitored from the operation panel directly. The tool number is also shown during machining. APC Information The operator is able to assign the program codes of A/B pallet in the operating interface directly and the system will call the corresponding programs of workpiece automatically. Tool management Tool management Tool Usage Time Tracking Record the information of last machining date, time, and accumulated machining time in each tool. Tool Compensation When the machining process needs tool length compensation, the operator is able to key in the compensation data for the tools. Flexible Manufacturing System (FMS) means a reasonable, flexible and versatile machining system including machine itself, auto moving system, and software which can integrate both. Main application is suitable for products of low volume and high variety, in detail will include the machining unit, storage unit, logistic handling unit, accessory unit and control unit. First four units are hardware of flexible manufacturing system. The control unit will integrate each hardware, control the info flow between each unit and make the whole system flexible, reasonable and compactable. Container Stacker Crane It allows temporary storage of machined parts and It assists workpiece movement from storage area finished goods. The basic storage capacity is 1 to loading area, loading area to machining station, sets and possible to expand to sets maximum. or between the stations. Machine Alarm Messages Record Alarm messages will be recorded in detail during machine processing. Tool Life Management Display the tool life information and reminds the operator to check workpiece before tool life almost approaching its maximum. Troubleshooting and Maintenance Support Graphical display interface assists operators to understand detail alert and warning information. Tool verload Protection Display the information tool loads, spindle loads, machining time, abnormal data, and overload value of tools. When overload value reached, system will shut down the machine and show the alarm message. Intelligent monitoring PLC Intelligent monitoring Motor Load Monitoring Monitoring and retrieving the motor load data during machining from the operation panel. In addition, according to the setting values, the system will show the alarm messages or shut down the machine. Machining Adaptive Control Monitoring the spindle loads and the system enables automatic feeding adjustment to protect tools and ensure machining efficiency. Crush Protection With the real-time detection of servo loads during feeding, the electrical brake is activated when a crash happens to minimize the damage. Workpiece management Workpiece management Workpiece positioning The CCD camera is used to monitor the characteristics of workpiece, and then the system will calculate and compensate program coordinates for increasing machining precision. Loading/unloading station Raw material and finished workpiece can be loaded and unloaded at this station. ne loading/unloading station is standard and the second one is available. Based on following four conditions to decide the priority of handling sequence, first in first out, optimization route, machine intelligence judgments and manual priority sequence adjust. perator can control the raw material input, adjust priority sequence, and check workpiece history record. When one single machine is down, other machine can still work properly. Manufacturing Management System, MMS All control information of FMS can be set in this system. Moreover, it can combine with a monitoring module for collecting the production information and feedback. Item Workpiece storage system MMS Number of machine Number of stacker cranes Max. loading capacity of stacker crane(kg) Number of containers Storage number of pallet Number of loading/unloading station Minimum limited machining time CC1 control system MMS-(Machine status monitoring) MMS-1(Remote monitoring service) Specification 1 1, 1() 1 () 1 () 4.(1) 1 option option 1 ()

8 13 HB-8II Horizontal Machining Center HB-8II Horizontal Machining Center 14 Tongtai- Technical Application Center Interference diagram The purpose of T-TAC is to take care of customer s machining solution actively. Based on the outstanding technical applications, Tongtai is able and willing to provide advanced machining technologies, machining solutions as well as trial tests to its customers and ensures them excellent experiences in machine operation, maintenance convenience and machine availabity. After-sales technical service Solution planning Customize machine development Ø6 1 Trial tests Response rapidly & Innovation process & Technology development Delivery instruction Customer demands Machining test & Ensure quality Ø1,3 13,ST Staff training Counication and experience sharing with customers and partners Solution offering Issue diagnosis & 7 1,4 TTAL SLUTIN PRVIDER TSP 7 T-TAC technical and machining solutions Solutions Product manufacture test Contents Through the manufacturing progress and jig & fixture plans, Tongtai s skilledstaff will manufacture the first piece for understanding the client s corresponding demands. 8 Ø1,3 Ø1,3 Machining technologies By introducing innovative technologies and adding the extra functions, T-TAC is available to provide the brand-new solutions. Machine technology ur technical staff will test current problems, which clients have, in the same machine model for processing problem diagnosis and providing possible solutions. Furthermore, our skilled staff is able to provide the services at the client s factory. Ø81 Ø6 1,ST 1,4 1,ST Training Technology exhibits T-TAC is open to train current clients, potential customers, agents, teachers/students, and employees and to strengthen their abilities. T-TAC is also an excellent platform to launch new products/technologies by cooperation with software/hardware suppliers. With presentation of highly reliable products/technologies, it s possible to provide higher efficiency and availability solutions than existing ones. Ø ,4ST 1,3ST 1 1 Unit :

9 1 HB-8II Horizontal Machining Center HB-8II Horizontal Machining Center 16 Pallet Spindle output and torque chart 8 4 1, rpm Build-in spindle (Low-winding) (High-winding) Horsepower [kw] Torque [N.m] Horsepower [kw] Torque [N.m] Nm 3Nm 39 Nm S3, % kw S, 1 min 1 kw S1 Cont Spindle speed (rpm) 1 kw 118 Nm 1 84 Nm 17 6, rpm High torque spindle with gearbox (Low-winding) (High-winding) Nm 1 11 Nm 3 kw S, 3 min kw S1 Cont Spindle speed (rpm) Horsepower [kw] Nm 171Nm 91 Nm 3 kw S3, % kw 3 min 18. kw Cont Spindle speed (rpm) Torque [N.m] 17.7 kw 14.8 kw Nm 136 Nm 4 Nm Nm 17 Nm Horsepower [kw] kw S3, % kw 3 min 18. kw Cont Spindle speed (rpm) Torque [N.m] 17.7 kw 14.8 kw Pull stud (coolant through spindle A type) Tool shank MAS BT Machine dimensions Unit : M4xP Ø17 7 Ø1, ST:1,3 Ø38 Ø6 7 4 R Ø Ø3 3,87 3,689 1, 1,3 791 ST:1, Unit : 61

10 17 HB-8II Horizontal Machining Center HB-8II Horizontal Machining Center 18 Standard/optional accessories Specifications Standard ptional Spindle B axis Tool shank 1, rpm Build-in spindle 6, rpm High torque spindle with gearbox Hirth coupling 1 rotary table NC.1 index table (Rotary encolder in B axis is available) BT HSK-A1 Item Travel Specification axis Y axis Z axis Spindle nose to table center Unit HB-8II 1,4 1, 1,3 1-1,4 Angle of BT pull stud DIN CAT MAS47 BTIII(9 ) MAS47 BTII(6 ) MAS47 BTI(4 ) Pallet Spindle center to table surface Table height from floor Pallet size Max. load kg 1-1,3 1, ,8 Coolant through spindle pump Tool capacity bar 3 bar 7 bar 6 pc 9 pc 1 pc Spindle Pallet face Min. Indexing increment Spindle speed Spindle shift Spindle taper degree rpm step M16 4 holes 1 (pt..1 ) 1, Two steps by electric 7/4 Taper No. Cooling system Automatic pallet changer Interior chip disposal Chip conveyer Spindle cooling system Hydraulic temperature control system Coolant temperature control system Air conditioner for electrical cabinet Two pallets 8PPL system FMS (flexible manufacture system) Two chip augers Scraper type conveyor Magnetic scraper type conveyor Hinge type conveyor Feed ATC Bearing diameter Rapid traverse Cutting feedrate Tool shank Pull stud Tool capacity Max. tool diameter Max. tool diameter (w/o adjacent tool) Max. tool length m/min /min degree pc Ø1 1-, BT 9(MAS-PT) 6 Ø1 Ø 61 Lubrication system Three axes linear scale Jig & fixture hydraulic/ pneumatic supply Tool measuring system Drum type conveyor Integrated type conveyor General lubricant system LHL integrated lubrication system µm resolution 3 µm resolution Suspended arm type supply, 6 holes on each side (Maximum hydraulic pressure bar) Table type, 6 holes on APC side (Maximum hydraulic pressure bar) Tool breakage detector (Installed on tool magazine side to detect tool breakage) Renishaw TS-7R touch sensor (Installed in the interior of the machine for measuring tool length, tool breakage and tool diameter) APC Required electricity Max. tool weight Tool selection system Number of pallets Pallet changing system Required electricity Required voltage Current frequency Pneumatic source Air supply kg kva v hz mpa liter/min Fixed type Rotary type 6 - ±1% or 6 ±1%. 4 Controller FANUC 31i-M Capacity Hydraulic tank liter 3 ther accessories FANUC i-m Workpiece measuring system Machining air blow Air gun Coolant gun Machine size Lubricant tank Coolant tank Width x Depth x Height Weight liter liter kg 8 4,3 x 8,83 x 3,87, il skier il mist collector Specifications may be changed without prior notice