Put through its paces

Transcription

1 Put through its paces MULTIGRIND CA Machine Check in fertigung magazine werkzeug extra Januar/Februar 2011 B 30523, Einzelpreis 15,- Sonderausgabe Branchenreport GDX-Schnittstelle Auf Herz + Nieren Kühlschmierstoffe: Holpriger Start in Schleifmaschine Multi- Wasser statt Öl? 6 neues Zeitalter 14 grind CA von Haas 60 The Haas Newsletter. The latest news from the world of grinding werkstück Put through its paces The Multigrind CA grinding machine from Haas Schwerpunkt: GDX-Schnittstelle Titelbild und Beitrag Seite 12 momentum no. 4 March 2011

2 PUT THROUGH ITS PACES Machine Check The CA machine for Haas is mainly used to grind tools. When combined with a wide variety of different available components, it can also be used for high-quality grinding jobs on workpieces from the fields of medical and automotive technology. Photos: Haas MULTITALENTED WITH A KICK The Multigrind CA grinding machine from Haas: at Haas, grinding technology is defined by the interaction of system components whose functions are finely tuned to one another and that together form a grinding cube with an optimized design. The CA machine, as a smaller offshoot of the CB machine, exhibits the same rigidity, precision, and dynamics as its predecessor. And when it comes to the machine s level of automation, functionality, and accessibility, it in fact offers additional benefits. R egardless of whether the user is grinding tools or using functional parts from the fields of medical engineering and automotive manufacturing, with the CA machine from Haas the user can adjust the machine s design to perfectly match their specific needs. Machine Design The machine s components are assembled for the customer in the Haas Machine Configuration Program, and the data generated is then used throughout the rest of the workflow to check on the availability of parts, to order parts, to provide information about delivery times, for parts lists, and to calculate prices. This dataset forms the basis for the scope of all further work. The machine s design, the various components, all supply lines, and the electrical appliances are all available as a CAD dataset. When it comes to the CA machine s design, the base of the machine is completely seamless. This means that the middle section of the base and the support assembly for the Y and Z axes are cast from a mineral composite with an epoxy content of about five percent into one cube. The machine s rigidity and precision are achieved through the central placement of the axes, the minimization of protrusions, and calculation of the dimensions of the cast composite cube using FEM (fi- 60 fertigung January/February 2011

3 PUT THROUGH ITS PACES Machine Check Robots with their own Fanuc controllers are used for automated workpiece loading. The Multigrind CA is a compact machine with an attractive design. The operator pendant is swivel-mounted, and the height of the keyboard can be adjusted for the perfect viewing and ergonomics. The Comprehensive Machine Check: Results You can view the complete list at Maximum points available Haas Multigrind CA points scored Initial startup Time until first job Confirmation of processing quality Axis measurement Operator training Ease of maintenance Accessibility for maintenance purposes Accessibility in case of malfunctions Time needed to exchange main spindle Time needed to exchange feeder components Automatic monitoring features Automation Startup / initializing Operating / loading Effort required to load workpieces / transport parts Controls Controls / ease of use Collision inspections Ease of retooling Loading table flexibility Setup effort Multiple loading / mixing models Service Availability of service personnel Spare parts inventory / spare parts manufacture Part drawings archive; online availability Service agreements TCO Analysis of cost drivers available Assessment and figures: downtime / repair time CIP by machine supplier in the event of a malfunction alert Contractual terms Warranty period Payment terms Fixed TCO process Total fertigung January/February

4 The CA machine comes standard with a 12 kw spindle that rotates at 8,000 rpm (or 18,000 rpm) and two grinding wheel ends. A high-frequency spindle that rotates at 70,000 rpm can also be attached to the front flange. At a glance Multigrind CA Grinding Machine from Haas Strengths: Multifunctional X axis A rigid machine Attractive overall design High-precision basic geometry Good accessibility Numerous available modules (2,500 total) Own software for NC and PLC Flexible tool changer Numerous preprogrammed grinding cycles Structurally well-designed and flexible coolant Dedicated service team unit Intelligently designed mineral-composite machine body The implementation of a database for service Weaknesses: Expertise in spindle manufacturing analyses is missing in the area where the two connect; as a result, the entire Z axis does not need to move when rotating the spindle. This design significantly enhances the dynamics of the grinding spindle. Haas manufactures the grinding spindles used in the CA machine itself, and they are directly powered and finely balanced. The standard version comes equipped with an HSK-50-E tool holder. If both ends of the main spindle are to be loaded with tools, the tools are mounted using a taper. Before being installed, all spindles must unnite element method). The guides for the linear axes (X, Y), which are embedded in the composite, are aligned using a high-precision template and then connected to the base with an adhesive thus further enhancing the machine s level of precision. The Z slide carriage is located directly in the center of the machine, which means that its kinematics and kinetics are perfect for the grinding process. The CA machine s Z axis has also been redesigned. Here, the integrated C axis is only pivotmounted to the bolted-on main spindle dergo a 24-hour endurance test. Haas also offers a high-frequency spindle that rotates at 70,000 rpm as an optional accessory. This spindle is held up by the main spindle housing and is decoupled to reduce vibrations. The CA s machine table is highly flexible thanks to the built-on X axis and the integrated A axis. A total of 15 different variations of the table are available; so when it comes to length, tailstock design, grinding between tips and steady rests, and grinding longer tools, no customer need will go unfulfilled. Facts and Figures: Machine Data Haas Multigrind CA Workspace (mm) Machine table (mm) 1, C axis, angle of rotation 300 A axis 1,000 rpm; optional: 2,600 rpm Height of centers 175 mm Tool holder for working spindle HSK 50E Spindle option: 1 spindle end 8,000 rpm; 11.5 kw (100%); 14.4 kw (40%) Spindle option: 1 spindle end 18,000 rpm 11 kw (100%); 12 KW (40%) 2 spindle ends mounted taper mm; 8,000 rpm; 11.5 KW (100%); 14 KW (40%) A axis tool holder SK 50; HSK 50/63/80 optional Tool changer (number of tools) 8 up to Ø 250; 16 up to Ø 100; 13 up to Ø 250; 27 up to Ø 100 Time to change tools 10 seconds without grinding wheel guard Controller Siemens 840 D sl (Haas software for grinding cycles) Footprint (mm) 2,621 2,400 3,200 Weight 8.5 metric tons Base price: about 210,000 euros without optional equipment The heart of the grinding machine is the grinding spindle: it is symmetrically fitted in the grinding cube. The vibration-cushioned mineral-composite base, the embedded guides, and the machine s wellengineered kinematics lend the machine precision and process reliability. 62 fertigung January/February 2011

5 PUT THROUGH ITS PACES Machine Check The A axis can rotate at 2,600 rpm and as such can be used for cylindrical grinding in conjunction with measurement control. The supply units, such as oil for lubrication, semifluid grease for the spindle, the cooling unit, and the machine s pneumatic and hydraulic systems, are all installed in a separate enclosure in an extremely orderly fashion. The systematic design of these units, as well as of the entire machine, can be seen quite clearly here. CAD datasets exist for every part of the machine. This can also be easily understood examining the way the electrical cabinet is set up. And one point of interest is the fact that the machine s electrical wiring is fed through conduits cast as part of the machine s mineral-composite body. This minimizes the effort needed to wire up the machine and also ensures that the machine s interior remains free of wire clutter. Tool Changer The full flexibility of the Multigrind CA machine is encompassed in the design and configuration of the tool changer. It is designed as a pick-up changer with two segmented wheels that operate independently of one another and can hold a maximum of up to 27 grinding wheels with a diameter of 100 mm. The mounting device for the grinding wheels HSK flanges is supported by the base frame using spring-steel packages. These absorb the shock when the grinding spindle latches on, and this increases the useful life of the main spindle as a result. If the operator s grinding duties My Opinion The machine is constructed to be rigid and precise, which are the two most important requirements for grinding. Thanks to the many different components available, the machine can be customized for every customer. The tool-changer and X axis are both extremely impressive components due to the multifunctional design possibilities they offer. Haas has come up with a unique and intelligent solution with the automated height-adjustable coolant unit. When examining the CA machine and also when walking through the factory halls, one repeatedly encounters ingenious solutions that document the manufacturer s expertise and inventiveness. Edwin Neugebauer The height-adjustable coolant unit is a patented solution from Haas. The spray nozzles adjust automatically to match the grinding wheel. require fewer grinding wheels, then a segment of the changer can also be used to store workpieces. The highlight of the tool changer is the Haas-patented cooling unit. Since the position of the cooling nozzles in relation to the grinding wheel has a significant effect on quality and grinding performance during the grinding process, the design and use of this unit both take on important functions. The coolant unit and corresponding grinding wheel guard can be removed from and mounted to the changer with the main spindle. When wheels are changed that have different contours, the motor-driven coolant nozzles automatically adjust their height to match the current wheel s contour. As a result of intelligent wiring within the unit and the unit s controller, the nozzles for the front and back chambers can be operated independently. This feature is a world s first, and it ensures that the grinding wheel is always supplied with the ideal amount of coolant. Controls When it comes to the machine s control unit, Haas uses the Siemens 840D solution line as its hardware platform. The NC and PLC software and the layout of the user interface were all developed internally by Haas and contain all the necessary features. DLLs (direct library links) are used to program the wide variety of different grinding cycles and to ensure that the structure of the workflow is designed in the optimum manner. Special grinding cycles are programmed by Haas even 3-D tracks that can be inserted into the grinding wheel using the dresser unit. Automation Out of all the CA and CB machines The tool changer is equipped with two segments and can accommodate various tools. It can also be used as a place to store workpieces. Haas has delivered, about 90 percent are equipped with an automatic tool changer and about 70 percent with automated workpiece loading. For loading, robotic solutions are used that are controlled independently from the machine and only communicate with it through interfaces. On the CA machine, these are located on the right side, and they are on the left side of the CB machine. Service / TCO The service department is comprised of a small, dedicated team of four that is always available; after-hours calls are forwarded to an emergency hotline. If necessary, personnel from the final assembly department can also be called upon. On-site service is offered within 24 hours. If the customer has a maintenance agreement, service can be provided even faster. Technical personnel are always available in the service department; this means customers are provided troubleshooting support over the phone or by modem from the very first step. All service operations are recorded in a PP system, which makes it possible to conduct life cycle and cost analyses. These are carried out manually; fixed, preprogrammed assessment algorithms have not been defined, however. The daily quality meeting directly covers malfunctions experienced by actual customers, and this backs up the statement: Two or three malfunctions cannot be allowed to happen one after the other. Edwin Neugebauer Haas Schleifmaschinen GmbH, Germany D Trossingen, Tel.: 07425/3371-0, g.schepers@multigrind.com fertigung January/February

6 We keep your world spinning* The Haas Newsletter. The latest news from the world of grinding * spinning like a grinding wheel At heart, we have always been inquisitive and love to experiment. And, our world has now been revolving around the wheel for more than 75 years. To be more precise, around grinding wheels the grinding wheels that are used in our precision grinding machines. Our company is based in a country whose engineers are noted for their innate drive for perfection and we happen to employ a fair number of them. It comes as little surprise then that our products are always ahead of the times. HAAS Schleifmaschinen GmbH Im Sandbruch Trossingen Telefon 07425/33710 Germany Grinding with Attitude!