Thanks to it s rugged mechanical structure it can perform highly demanding jobs with an unrivalled quality/price ratio.

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1 ROBOFORM 23P/53P

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3 Introduction The ROBOFORM 23P/53P, the fruit of CHARMILLES world experience in EDM, is not only amazingly flexible, making it possible to cover numerous applications, but also offers exceptional reliability and ease of use. Thanks to it s rugged mechanical structure it can perform highly demanding jobs with an unrivalled quality/price ratio. Equipped with an efficient and well proven generator, the ROBOFORM 23P/53P are the ideal partner for carrying out demanding applications. The Machines _Repeatability of machining ensuring the production of high quality of the parts produced. _Multi-task CNC for increased productivity. _Expert Systems for optimum perfomance. 3

4 The Machines Rigid and compact The use of cast iron and the short C frame design ensure static and dynamic rigidity of the mechanical structure. The cross-table, fitted with linear glass scales, guarantees the positioning accuracy. The ergonomics of the machine have been designed to provide the most favorable ratio between the floor space area and the work surface area. _Linear glass scales on all axes _Crossed table for accurate positioning _Centralized lubrication _Easy accessibility ROBOFORM 23P Front door ROBOFORM 53P Front & Side door _Workpieces weight 440 lbs 1760 lbs _Work tank dimensions 37 x x in 47.2 x 31.5 x 19.7 in _XYZ Travels 13.8 x 9.8 x 9.8 in 23.6 x 15.7 x 15.7 in 4

5 C axis A rugged C axis delivers high positioning precision (0.001 ) regardless of electrode weight (up to 100 lbs) and full machine current. Completely intergrated, the C axis is easily extended to increase X and Y travels when machining very large parts. 3µm 110 lbs 3.94 in 6.6 lbs 7.87 in 2.2 lbs Servo-control tolerance during machining is ± 3µm The significant inertia of the C-axis allows to offset electrodes while maintaining utmost precision 1 CNC order MOV X10; 2 Position reached? yes STOP no 3 4 Checking the position (linear glass scale) Movement of the axis (encoder motor) Closed loop servo-control Positioning measurements are done by means of linear glass scales fixed directly onto the X, Y and Z axes of the ROBOFORM 23P/53P, thus eliminating errors that may arise when the screw thread becomes worn or too hot. Furthermore, before delivery, every ROBOFORM 23P/53P are rigorously checked by means of a laser in order to guarantee the best possible accuracy. Linear Tool Changer LTC Designed to be economical but efficient, the fully integrated Linear Tool Changer is ideal for less complex applications requiring few electrodes or involving longer cuts. ROBOFORM 23P: 4 positions ROBOFORM 53P: 6 positions 5

6 Generator A «success story» More than generators of this type are in operation worldwide, proof that its success is no coincidence. With this generator the ROBOFORM 23P/53P can provide outstanding performances for a wide variety of applications. It guarantees repetitiveness, surface homogeneity and precision. In cases where there is a particular need for power in roughing, the generator can supply up to 128 Amperes (optional) so as to attain high rates of material removal. While fast machining is ensured, the geometric details of the electrodes are preserved. _Toolbox _Rear light of vehicle 36

7 Job Preparation Cone 1 Cone 2 tangeantiel Multicavity Module Squar 1 Squar 2 Spher Expan Helic Squar 1 Squar 2 Spher Expan Helic angl 2 isogap isogap 3D ORB 3D ORB 3D Vect C Vect Down Easy programming on PC (SPS) Compatible with all CHARMILLES machines, the innovative Sinker Programming System (SPS) boosts performance and productivity. With shortened cycle times and a 100% use of generator capabilities, SPS lets you tap the full potential of your ROBOFORM machine regardless of job complexity. It guides operators through a number of menu-driven screens for job sequencing without the risk of error. Cone 1 Cone 2 Cavity Module Cone 1 Cone 2 Cone 1 Cone 2 Squar 1 Squar 2 Squar 1 Squar 2 Spher angl 2 tangeantiel Squar 1 Squar 2 Spher Expan Helic Squar 1 Squar 2 Spher Expan Helic Squar 1 Squar 2 Spher Expan Helic Cone 1 Cone 2 Squar 1 Squar 2 Spher Expan Helic angl 2 isogap isogap 3D DOWN ANGUL EXPAN HELIC ORB 3D ORB 3D Vect C Vect Down angul angul 1 1 angl angl 2 2 Cone Cone 1 1 isogap isogap Cone Cone 2 2 isogap isogap 3D Squar 3D Squar 1 1 Squar Squar 2 2 Cone Spher 1 Spher Cone Expan 2 Expan Helic Helic Squar 1 Squar angul 2 1 Spher angl 2 Expan isogap Helic Cone 1 Cone 2 Squar 1 Squar 2 Spher complete Expan Helic range of automatic tangeantiel angl 2 isogap isogap 3D isogap 3D tangeantiel Vect C Vect Down ORB 3D ORB 3D Vect C Vect Dow VECT CONE CONE SPHERE Cone 1 Cone 2 Machining cycles In a constant endeavor to fulfill users needs as well as possible, CHARMILLES has developed a machining cycles to enable the ROBOFORM 23P/53P to cover a vast gamut of applications. The easy programming of these ORB 3D ORB 3D Vect angl C 2 Vect angl 2 Spher tangeantiel Expan isogap 3D Squar 1 Squar tangeantiel 2 isogap Helic ORB 3D ORB 3D Vect C Vect Down Vect Vect C C Vect Vect Down Down tangeantiel angul 1 angl angl 2 2 isogap isogap ORB 3D isogap isogap ORB 3D 3D angul 3D 1 tangeantiel angl 2 isogap cycles makes isogap 3D the operator s tangeantiel task a angl Vect 2 C Vect isogap Down isogap 3D tangeantiel model of simplicity. SQUAR SQUAR 3D ORB ORB 3D ISOGAP ISOGAP 3D isog ORB 3D 3D ORB 3D 3D Vect C C Vect Down Down ORB ORB 3D 3D Vect C Vect Down ORB ORB Vect Vect Vect Vect ORB 3D ORB 3D C Down Very efficient measuring cycles CORNER angul 1 EXTERNAL CENTER INTERNAL CENTER The workpieces and electrodes are measured by means of automatic modules. Thanks to the measuring accuracy of ± 0.002mm, the geometric dimensions of the parts produced can be checked directly on the machine before they are removed. EDGE 1 EDGE 2 In addition the ROBOFORM 23P/53P are equipped with functions for automatically measuring the tool offsets along all four axes X, Y, Z, and C. Hence the exact position of the cavity being machined is guaranteed whatever the offsets of the electrode. 7

8 Performance With a powerful generator and the latest innovations in EDM technologies, CHARMILLES delivers job repeatability, surface finish quality and unattended machining for top performance in a wide variety of applications. POWER CONTROL EXPERT Checks each spark to ensure a perfect quality of surface finish. It also allows to determine in real time the intensity of machining discharge as the electrode s surface increases. SPAC A Charmilles exclusive. Allows to eliminate any short circuit by applying a specific discharge during a fraction of a second. No longer slowed down due to short circuits, machining continues at full speed and without interruption, thus improving productivity. PILOT-EXPERT 3 Guarantees top performance while taking into account machining conditions at all times. It provides for unattended machining and delivers perfect job reproducibility. Power V Time SPAC A 1 (µs) cm² Depth 2 (µs) Depth Temps d'impulsion (µs) When the job involves challenging geometry, PCE determines ideal machining current based on the electrode s active surface. 1. Drop in machining voltage due to a CC. 2. Elimination of the CC by applying a specific current discharge. Convetional System Pilot Expert 8

9 Sparking Whatever the challenge, CHARMILLES delivers the right spark solution available through menu-driven programming. As illustrated on these pages, each machine supports a variety of specific mouldmaking applications regardless of complexity or difficulty. Solution for injection point Each mould has at least one injection point. This type of machining requires a 3D cycle and a strategy adapted to evolving electrode surfaces. The calculated geometric data necessary to describe the electrode movement is automatic, based on workshop drawings. Subgate application with 3D machining cycle Surface homogeneity A uniform texture of the injected part is directly linked to the quality of surface finish. To respond to the need for a perfect surface finish of the mould, CHARMILLES has developed a Surface technology designed to meet the most stringent criteria of surface homogeneity. GPS Mould R (mm) Factor Machining depth (mm) Micromachining Especially when electrode dimensions are reduced, surface finish and wear become decisive factors in terms of performance. To address the needs of the connectics and micromachining sectors in particular, CHARMILLES has developed a dedicated module designed to reduce electrode wear by up to 30% and to offer unequalled surface finish. Fibre-optic connector 9

10 Technical specifications 2500 mm 825 mm 2700 mm 1950 mm 3170 mm 1670 mm 825 mm 2500 mm 1260 mm 2480 mm 10

11 ROBOFORM 23P ROBOFORM 53P Machine Machine dimensions (width x depth x height) in 49.6 x 65.7 x x 98.4 x Machine weight lbs Machines Safety and Health Directive 89/392/EEC 89/392/EEC Electromagnetic Compatibility Directive 89/336/EEC 89/336/EEC Axes X, Y and Z XYZ travels in 13.8 x 9.8 x x 15.7 x 15.7 XYZ measuring device Linear glass scales Linear glass scales Measuring resolution µm 0,5 0,5 Machining head Max. electrode weight (without C axis) lbs Min./max. chuck-to-table distance in 7.3/ /23.1 Machining table Max.workpiece dimensions (W x D x H) in 29.1 x 17.7 x x 31.5 x 19.7 Max. workpiece weight lbs Table dimensions (W x D) in 24.8 x x 23.6 Number of slots 4 5 Dimensions of slots in Space between slots in Worktank Min./max. dielectric level in 5.5/ /17.7 Inside dimensions (width x depth x height) in 37 x x x 31.5 x 19.7 Width of front door in /21.6 Dielectric system Filter cartridges 2 (paper) 6 (paper) Capacity of dielectric reservoir gal Heat exchanger Standard Standard Generator Type of generator ISOPULSE ISOPULSE Standard machining current (Option) A 32 (64) 64 (128) Optimum surface finish CH 0/Ra 0.1 µm CH 0/Ra 0.1 µm Available technology Copper/Steel - Graphite/Steel Copper/Steel - Graphite/Steel Copper-tungsten/Carbide Copper-tungsten/Carbide Copper-tungsten/Steel Copper-tungsten/Steel Copper/Copper Copper/Copper Numerical control Colour graphics screen CRT 14 colour CRT 14 colour Remote control Standard Standard Type of disk drive 3.5 DOS 3.5 DOS DNC1 + DNC3 communication interface RS-232C RS-232C Measuring cycles Standard Standard Axes controlled X, Y, Z and C X, Y, Z and C EXPERT SYSTEMS Pilot-Expert 3 Pilot-Expert 3 Power Control Expert Power Control Expert Program-Expert Program-Expert SPAC System of protection against System of protection against short circuits short circuits Electrical supply Three-phase input voltage V or 400 Main network frequency Hz 50 or or 60 Main options C axis lbs Max. electrode weight 55 Max. electrode weight 25 Linear tool changer 4 positions 6 positions Additional generator module A

12 Contact Charmilles Technologies SA rue du Pré-de-la-Fontaine Meyrin 1, Geneva/Switzerland Tel. +41 (0) Fax +41 (0) Agie Charmilles Group /07.06/US The technical data and illustrations are not binding. They are not warranted characteristics and are subject to change. Please consult the General Sales Conditions of Charmilles Technologies SA.