TECHNICAL OFFER OF THE PRODUCT. Horizontal boring mill WH(Q) 105 CNC

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1 TECHNICAL OFFER OF THE PRODUCT Horizontal boring mill WH(Q) 105 CNC From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 1

2 1. FEATURES OF THE PRODUCT 1.1 The WH 105 CNC table type, live spindle, fixed column horizontal boring mill as the CNC model of the company complements the whole TOS VARNSDORF product line on its lightest end. The machine has inherited some of the subassemblies and design features, including the technological equipment, from the advanced generation of the advanced CNC borers of TOS VARNSDORF a.s. At the same time it offers greater travels and power on spindle than its closest type relative, the WH 10 CNC. It is a perfect choice machine offering an excellent manufacture quality with all the attributes of a universal CNC horizontal borer. The machine, including its standard equipment and peripherals etc., is intended for broadly universal chip removal machining of non-rotational parts of smaller size and weight particularly of cast iron, cast steel and steel, employing the most sophisticated part-programs. Items of special and/or peripheral equipment are optionally available to broaden operational capacity of the machine or to aid to its smooth operation. 1.2 Basic concept of the machine The machine is of the classical longitudinal setup with fixed column fitted upon a rigid longitudinal bed. Along the bed travels the longitudinal slide (Z-axis) with the transverse guideways on its top. Along these travels the saddle crosswise (X-axis) bearing the machine's indexing table (B-axis). The headstock travels vertically (Y-axis) along the column. The headstock contains all the spindle bearings and the spindle driving mechanisms (C-axis) as well as the ones for the longitudinal travel of the live spindle (W-axis). The tool clamping system is also there. Various items of standard or optional equipment such as spindle leading support, facing or milling heads etc., may be mounted on the headstock face - see the separate technical presentations of the individual devices. The equipment such as angle plates etc., may optionally be used on the clamping surface of the table - see the separate technical presentations of the individual devices. From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 2

3 2. MAIN OPTIONS OF THE MACHINE 2.1 Options with respect to a tool carrier (headstock) - headstock N is suitable especially for power machining. Max. speed is suitable for finishing operations - headstock R option with higher spindle speed is suitable especially for the precision power machining of high cutting speed - headstock R4 option with max. spindle speed of R.P.M. 2.2 Options with respect to a design automatic tool change (ATC) - WH 105 CNC basic design - WHQ 105 CNC machine design equipped with automatic tool change (ATC) 2.3 Options with respect to a control system - HEIDENHAIN itnc 530 control system - Sinumerik 840D control system After the prior discussion with machine tool manufacturer, the machine can be also supplied with another type of control system (FANUC 30i/31i etc.) 3. BASIC TECHNICAL DATA 3.1 Headstock Headstock type N R R4 Spindle diameter mm Spindle taper ISO 50 / ISO 50 BIG+ without ATC ČSN DIN 2080 Taper standards available ČSN ČSN with or DIN A without AVN BT 50 MAS CAT B Spindle speed range R.P.M. 10 2, , ,000 Main motor power, rated (continuous load operation S1) kw Main motor power max. (operation S6-60% of the load time) kw Spindle revs, rated R.P.M Spindle torque, rated (S1) Nm 1, Spindle torque max. (S6-60%) Nm 1,462 1,148 1,148 Spindle stroke W mm 630 Note: Machine with headstock R4 - this execution is necessary to be equipped compressor cooling system OLAER or SCHIMPKE. From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 3

4 3.2 Column 3.3 Table 3.4 Feeds Headstock vertical travel Y mm 1,250; 1,600 Min. distance of the spindle axis above table mm 0 Workpiece weight max. kg Table clamping surface mm 1,400 x 1,400; 1,400 x 1,600 T-slots on the table - dimension mm 22H8 - pitch mm number 9 Table centering hole diameter mm 100H6 Table longitudinal travel Z mm 1,250 Table transverse travel X mm 1,800 Feed range X, Y, Z, W mm/min 5 5,000 Rapid traverse X, Y, Z mm/min 10,000 W mm/min 8,000 B 1/min 2 Min. programmable positioning increment - X, Y, Z, W mm 0,001 - B grad 0,001 - C grad 0,1 Max. feed forces - X, Y kn 15 - Z, W kn 20 Clamping strength for B axis on R =0,5 m kn Automatic tool change (ATC) Number of pockets in stationary magazine 40; 60; 80; 120 Pitch of pockets in magazine mm 130 Tool dia max - with fully loaded magazine mm with free neighboring places mm 320 Dia max. of a special flat tool mm 390 (600) Tool length max mm 500 Tool weight max kg 25 Total weight of tools in magazine kg Imbalance of tools in magazine max kg 150 Tool change time (tool tool) sec Supplementary data Hydraulic circuits operational pressure MPa 8,1 8,8 Compressed air source output requirements From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 4

5 - pressure MPa 0,6 - volume 1/sec 18 Voltage / frequency of power supply V / Hz 3 x 400 / 50, 3 x 400 /60 Control voltage V = 24 Total power consumption kva 52 Noise level "A" at the operator site max db (A) 80 Climatic resistance standard Total machine weight kg 17, DESIGN FEAUTURES OF MACHINE UNITS 4.1 The machine frame The machine frame is designed in the sense with a fixed column, traveling spindle and cross traveling spindle and cross traveling rotary table. The main machine frame components including the traveling ones are made of optimally dimensioned castings of gray iron. 4.2 The headstock The headstock contains all the spindle bearings and the spindle driving mechanisms (C-axis) as well as the ones for the longitudinal travel of the live spindle (W-axis). The tool clamping system is also there. Various items of standard or optional equipment such as spindle guiding support, facing or milling head etc., may be mounted on the headstock face. Precise spindle type, preloaded, multiple setup ball bearings have been used for the spindle. The spindle is driven via two sets of gears changed over with hydraulic actuated shifters. The headstock weight is compensated for by a counterweight moving inside the hollow of the column. 4.3 Guideways of movable groups Guiding or bearings as the case may be of the traveling CNC controlled axes are designed as: - combined type, with set up clearance, employing linear roller pads in combination with antifriction plastic lined slideways - guideways of the longitudinal slide - sliding type, with set up clearance between the ways and the anti-friction plastic lined counter ways - headstock and table saddle ways - combined type, with set up clearance between the ways and the anti-friction plastic lined counter-ways, combining circular slideways and an anti-friction bearing - rotary table guiding and pivoting - sliding type, with minimum running clearance - the slide fit of the workspindle within the quill (both hardened). The main guideways are reinforced with hardened steel plates. The B axis is hydro-mechanically clamped while in standstill. The X, Y, Z, W (spindle stroke) - axes are locked by an AC digital servo-drive in a closed position bond after reaching its final position. The guideways and the driving mechanisms, bearings etc., of the machine traveling axes are consistently covered to be protected against dirt particles from the workshop environment. From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 5

6 4.4 Feed drives and clamping The feed drive mechanics at all the CNC coordinates has been designed as backlash-free and preloaded, consisting of: - ballscrew and nut - longitudinal slide, table saddle, headstock and spindle travels - ring gear and pinion - the rotary table. 4.5 Lubrication of the machine Lubrication of the main traveling axes as well as other mechanisms of the machine has been designed as: - permanent, with grease charge - the main bearings, feed drive mechanisms of the traveling axes - automatic, autonomous, thermally stabilized oil circulation system - the spindle drive mechanisms - automatic, redundancy oil distributing system with metering valves supplied from a central lube unit - the guideways. 4.6 Operation of the machine The majority of the control elements are centralized on the main control panel (operator console) situated at the operator's site. The panel consists of the screen, CNC keyboard and PLC keyboard and may also be extended by an auxiliary handheld panel for the machine or ATC manual mode control. Work lights are placed upon the headstock above the spindle. Hydraulic power for the machine and its peripheral devices or optional equipment is supplied from the central Hydraulic Power Pack (HPP). Air-hydraulic power for the machine require external supplier of compressed air (the machine is consequently equipped with air-conditioning components and function controls. 4.7 Control systems The machine is fully CNC controlled in 4 axes (X, Y, Z & W). The rotary table is CNC positioned (B-axis). To provide for a higher accuracy at the four basic positions the table has been equipped with a 4x90 optical readout. The spindle rotation is also CNC positioned (Caxis). All the CNC controlled axes are as a standard powered by AC digital servo-drives of Siemens. The spindle is also driven by an AC digital converter of the same supplier. The machine is controlled by a sophisticated CNC control the features and peripherals of which are relevant to the applied type (e.g. HEIDENHAIN itnc 530, SIEMENS SINUMERIK 840D). 4.8 Encoders Measuring systems of the CNC axes: - linear axes X, Y, Z - direct measuring using sealed electro-optical scales of HEIDENHAIN - linear axis W - indirect measuring using electro-optical rotary encoder of HEIDENHAIN - rotary axis B - direct measuring using electro-optical rotary encoder of HEIDENHAIN - rotary axis C - indirect measuring using electro-optical rotary encoder of HEIDENHAIN. From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 6

7 4.9 Automatic tool change It consists of a chain magazine, manipulator travel on the frame and the manipulator itself provided with a turning two-armed lever. The search for the relevant tool is designed on the basis of coded beds in the magazine Power supply units Power supply units, switchgear, safety and protective elements and other electrical devices are housed within a separate compact electric cabinet. Component selection for each machine is individual, subject to the national regulations relevant to the destination country The machine covers In its standard design, the machine without tool cooling or with the external CHZ cooling is not particularly enclosed with covers. Referring to the safety-at-work regulations, we would like to point out that a residual risk of flying chips and cooling/ cutting fluid spray and take necessary measure for mitigation of such risks (e.g. restrictions of personal access, passive protective measures against flying chips, etc.) If the machine is equipped with the cooling through the spindle centerline, it is necessary to adopt for the machine some of the below shown methods of fitting it with covers the manufacturer consider this a strictly compulsory measure (owing to the character of machining, it is suitable to apply this even for the machines with the external tool cooling systems): The most common (recommended) design Protective covers for the working space (traveling cage marked as KVR). The cage travels on the table skids and delineates the protected space round the table. The cage is opened in the direction to the machine, while its wall facing the workshop is equipped with a manually operated door; the cab has not any roof. The walls are fitted with look holes made of clear polycarbonate. The cabs are standardized and extended by the size of the Y coordinate and internal space diameter for turning the work-piece. Before placing the order finally, it is advisable to consult an optimum size of the cab with the dealer. Even in this case, there still remains a residual risk of possible/partial flying of chips and fluid over the cab edges and the customer must take this possibility into account. A variable arrangement of the covers enabling easier handling of work-pieces If the covers on the front side of the machine make the work-piece handling operations difficult, then in such special cases it is possible to use mobile/movable protective partitions keeping the flying chip away. During transporting and clamping the parts, it is possible to move the wheeled partitions aside. During machining operations, they must be placed back to the dangerous sectors. Even in this case, the customer should be aware of the risk of flying of chips and fluid over the edges or through spaces between the partitions. Such arrangement of covers is neither compact nor permanently installed, and therefore the residual risk is higher. For this reason, the customer will be responsible for the layout of sufficient number of partitions in order to minimize the risk. This solution requires enclosing the whole space with a protective fence. Also, this does not constitute any obstacle against spilling of the fluid over the workshop floor. From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 7

8 A compact and technically advanced design of covers The enclosure of the whole X Group (marked as the C cover) stands on the floor around the whole X coordinate space (incl. the bed). It is particularly suitable in cases, where the work-piece size does not allow the use of the traveling cab. A manually operated door is place on the enclosure front side (with blocking). There will be a residual danger of partial flying of chips and fluid over the enclosure edges and the customer must take this possibility into account. 5. MACHINE ACCURACY AND TESTING 5.1 Geometric accuracy of the machine The machine geometric accuracy is certified by the document called "Machine Acceptance Chart", defined according to the ISO The test is performed at the producer during final inspection, the protocol is attached to the machine and the test is being repeated at the machine handing over to the customer. 5.2 Accuracy in positioning of individual machine parts As regards the mechanical and electronic aspects, the machine is adjusted in a manner to achieve a high positioning accuracy (repeated accuracy 12 μm). If the customer requires a certificate of positioning accuracy in separate axes, then the request for laser measurements, either at the manufacturer s or customer s plant, should be included in the contract. The positioning accuracy will be then expressed in typical values according to VDI/DGQ 3441 Standard. 5.3 Working accuracy of the machine Is being tested at the producer during the final inspection by machining the testing workpiece NASA. Test result is documented in the protocol which is internal document of the producer. The test is not being performed at the customer unless specified in purchase agreement otherwise Other tests during the final inspection - testing of proper function of all parts of the machine at the idle run - testing of electrical equipment of the machine - checking of conformity of technical parameters, production execution and completeness of the product with the delivery specification. 6. SAFETY AND HEALTH PROTECTION 6.1 This is to confirm that the machine structure and its production execution comply with the generally valid norms related to the work safety and hygiene thus ensuring the safe control of the machine. The machine can be delivered also according to the special safety regulation 6.2 A special attention must be paid to the compliance with the EU Directives, which is From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 8

9 compulsory for the machines operating in the EU member states (the CE Marking). The requirement for the compliance with the relevant EU Directives (the CE Marking) must be indicated in the order. The machine design for the CE requirements must contain the elements according to Chapters 4.11 and 6.3. For technical and safety reasons, it is advisable to apply such requirement even outside the EU member states. 6.3 In order to comply with these requirements, the machine must be equipped with the following safety elements: - protection of operators as well as the machine neighborhood against emissions of substances must be carried out by covers according to Chapter 4.11 observing also the residual risks. - protection against the access of unauthorized persons must be provided by a protective fence according to the dimensional sketch prepared by the supplier and approved by the customer; the agreed layout will be then binding. Any potential request for changes must be agreed by the supplier. - the machine itself and its control and safety logic circuits meet the requirements of the relevant EU Directives and it is not necessary to solve them individually in a non-standard way. 7. DELIVERY, COMMISSIONING AND USE OF THE MACHINE Information: Upon the purchase contract execution, the customer will be obligated to approve the machine dimensional drawing. Only this completed step represents the instruction for the commencement of the machine manufacture. 7.1 The machine is delivered partially dismantled; all the standard equipment is included. All the oil tanks and gearboxes including the coolant tank are empty and have to be filled up before the machine is commissioned. The technical documentation is a part of the delivery. 7.2 The machine is delivered with the final surface finish. The machine is being offered in 4 standard color specifications including equipment and accessories. This should be specified with machine contract in advance. 7.3 The conditions and procedure for the machine final acceptance act has to be agreed upon with the machine producer in advance. The acceptance procedure can be specified to article In order to reach the guaranteed product manufacture quality and geometric as well as operational accuracy the machine has to be placed upon the proper foundation and anchored as required by the producer. With respect to the warranty terms and conditions it is essential that the machine erection and its commissioning be performed either by the producer's own or by them authorized personnel. 7.5 The conditions and directions regarding the machine erection, its safe and effective operation, the rules and principles as how to operate the machine and the directions and conditions for maintenance and fault-fixing are to be found in the accompanying technical documentation. 7.6 User oriented training courses and technical support of an in advance agreed upon scope is also From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 9

10 available from the producer. 8. PACKING, TRANSPORT, KEEPING ON STOCK 8.1 The way as how the machine is made ready for transport and transport is subject to purchase agreement. Once the casings has been removed the machine components have to be adequately protected against undesirable weather conditions and any kind of damage. 8.2 Suggestions for manipulation with machine groups are stated in the ac-companying technical documentation. 9. ACCESSORIES 9.1 List of the standard equipment: - KM anchoring hardware kit - PVK spindle leading support (short) - pull studs for tool clamping - WH 105 CNC - 15 pcs - WHQ 105 CNC - according to number of tools in magazine - spindle taper brush - set of service and maintenance tools - consumable parts kit - accompanying technical documentation including operating manual. 9.2 List of the special equipment: - LD facing head - HPR 50 - vertical manual milling head (after the prior discussion with the manufacturer) - HUR 50 - hand universal milling head - CHZ tool cooling kit, conventional - CHOV through spindle tool cooling kit (10, 20, 30 bar) - workspace protective guards - safety features and elements for compliance with the CE regulations (fencing, protective guards etc., including the safety devices etc.,) - at the level and in the extent relevant to the particular model configuration and the end-user's needs - chip conveyor(s) - UK 500, UK clamping cube - UU 800, UU 950, UU 1120, UU clamping angles - additional pull stud kits - basic set of clamping and measuring tools - compressor cooler for the headstock lube circuit (oil fridge) The optional equipment according to the above list - for details see the separate technical presentations of the individual devices. From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 10

11 9.3 Optional Accessories The machine, after prior agreement with the manufacturer, may be equipped with additional devices and/or process accessories. From 19th series of WH(Q) 105 CNC / 02/2012 / T. Jägr - Marketing Dep. Sheets: 11 / Sheet: 11

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