Machining Centres HELLER solution competence: Efficiency for your production. Worldwide. Setting standards in 5 axis www.heller.biz The F series Some of the options shown are not included in the basic configuration. Design and scope of supply are subject to technical changes. © 08. 2012 Gebr. Heller Maschinenfabrik GmbH Content 5-axis competence 5-axis competence in HELLER quality 5-axis competence in HELLER quality 3 The F Series: Machine concept 4 Your investment in a new machining centre has to pay off. A plus in flexibility: To make your production future-proof, you need reliability, Cutting costs through complete machining – the F series provides precision and high productivity. We are here to help you. the response to this trend in the machine tool industry. Being able to perform as many tasks as possible with the same machine Innovative spindle technology: Process stability times three The workshop machine: FT 4000 for table loading The production machine: FP 200 / 4000 with pallet changer Control: The choice is yours CAD/CAM integration: From idea to finished product Tool management: Fast, precise, flexible 6 Our answer: the new F series. 5-axis machining centres designed to offer more than their competitors. 8 12 provides flexibility now and in the future. A plus in availability: The F series was specifically designed for robust processes. This A plus in sturdy engineering: means: not chasing after peak values but providing adequate HELLER has been synonymous with milling and high-quality speeds, proven components, truthful characteristics. What are the machining since 1894. The F series embodies our complete benefits to you? A machining centre with staying power offering know-how gained from the development of the 5-axis MCH-C unparalleled opportunities. series and its predecessors. The F series is a safe investment: 16 17 1 8 it offers productivity and precision from the very first minute. A plus in service: The HELLER service concept is designed to accompany you from A plus in process experience: process design, machine installation through to the purchase of Our extensive process experience forms the basis for this 5-axis new equipment and to ensure constant productivity. What is so machine series allowing you to respond swiftly and flexibly to special about it? We are wherever you are. All it takes is a phone changing machining tasks, whilst ensuring maximum output and call. optimum quality. Optimised life cycle costs: HELLER services: Availability and maximum performance20 At a glance: HELLER Machining Centres 22 A plus in productivity: The running costs of a machine over its complete lifecycle are Highest productivity in continuous operation – that is what the easy to calculate from the cost of investment and the cost of F series has been designed for: the FT type for ergonomic table operation. Keeping these costs at a minimum, without compro- loading, the FP type with pallet changer for compatibility with mising on the quality and reliability of the machine, is the quint all HELLER automation systems, 5-sided and simultaneous 5-axis essence of what we do. This is exactly what we have achieved machining, robust machine design, powerful spindles. with the innovative manufacturing concept offered by the F series. The savings are directly passed on to you. 2 The F series sets the standards in 5-axis machining providing productivity and precision from the very first minute. 3 F Series The machining concept The F Series: machine concept Strong basis for high cutting capacity Customised coolant treatment Bed manufactured from epoxy resin concrete: Paperband filter system Proven axis kinematics of the tool: X, Y, C and A Programming in the familiar system environment Vacuum rotation filter system Workpiece provides 2 axes: Z, B Siemens SINUMERIK 840D sl or Heidenhain iTNC 530 Linear axes covered with tried and tested concertina covers Flexibility of choice according to individual requirements: efficient damping of machine movements, reduced emissions, optimised overall weight Steel column with optimised topology in Y axis with minimal deflection Statically and dynamically optimised by means of structural mechanics simulation Optimised feedback control Precise dynamics Flexible installation with automation for high-volume output or for manual loading Installation without anchoring Ease of operation you can feel Quick installation, easy relocation Effective safety guarding High processing power and easy operation No separate foundation required Optimum access to the work area for workpiece loading Complete integration into the CAD/CAM process chain Low operating costs Linear guided, smooth opening doors provide optimum Optimised resilience and thermo-symmetry Production precision down to the micron Single-handed philosophy: short-stroke doors can be opened Absolute encoded, direct measuring systems Z axis with concertina cover below the spindle prevents High-resolution rotary encoder Lowered loading sill at knee height YRT bearing with integrated measuring system Operating panel at the setting station with integrated Steep and extremely smooth chip chutes Free chip fall from rotary table in the workshop access for loading operations Quick chip evacuation for higher precision contaminants from leaving the work area Control with one hand flush/air guns Easy to connect to all common HELLER automation systems (FP) Clean work area due to integrated flushing nozzles Easy to clean due to good accessibility to work area 4 5 F Series Spindle technology Innovative spindle technology: process stability times three The F series with swivel head The F series with fork head Swivel range from +15° to –195° Axis swivel range +30°, High torque due to powerful 1PH8 motor up to –120° below centre axis Robust housing in cast iron Robust housing in cast iron HELLER zero-spindle system Motor spindle mounted in fork head Media supply directly through the spindle with bearings Suitable for dry machining Energy and media supplied through the State-of-the-art RMP wireless measuring probe outside of the fork head New cooling system provides reduced thermal growth in the machine and highest workpiece precision Media supply directly through the spindle High performance cutting with Power Speed cutting with Speed Cutting Speed cutting with Speed Cutting Cutting Universal PCU 63 Universal SCU 63 Tilt SCT 63 The benefits to you: The benefits to you: The benefits to you: Transmission provides Swivel motor spindle with Suitable for dry machining energy and media supply For machining up to a +30° through the centre of the angle below centre axis extreme rigidity and damping 1 : 1 gear train HSK, SK and BT spindle taper swivel head HSK, SK and BT spindle taper Perfectly suited for cast iron, High speed: 16,000 rpm High speed: 16,000 rpm High chip removal rate High cutting capacity with steel and titanium Swivel head geometry de signed for optimum stability 6 The F series provides four spindle variants offering flexibility for any machining task whilst ensuring highest precision and performance. Clearly arranged cutting High cutting capacity geometry PCT High chip removal rate 7 FT 4000 The workshop machine The workshop machine: FT 4000 for table loading Outstanding accessibility: F series for table loading (FT) Profile: Application: Facts: Entry into HELLER 5-axis For frequently changing tasks Tool provides 5th axis via Technical data machining Classic workshop machine for manual loading Flexible, powerful, highly and prototype construction HELLER swivel or fork head Combination of highest Storage capacity for up to cutting capacity and class- 240 tools in chain-type leading surface finish magazine or 409 tools in precise rack-type magazine For a wide range of parts and Unparalleled ease of access to materials produced in low work area through three-part volumes work area door Table with large clamping surface, optionally with hardened surface Model FT 4000 Working range X = 800 mm Y = 800 mm (SCT 900) Z = 1,000 mm Table size Ø 720 Workpiece Ø x height max. Max. workpiece weight Chip-to-chip time Rapid traverse 1,020 mm x 1,500 mm 1,400 kg 3.7 s 60 m/min Acceleration 6 m/s² Tool Ø x length (chain) Tool Ø x length (rack) Spindle tapers Spindles* 160 mm x 450 mm 188 mm x 450 mm SK 40 / HSK-A 63 / BT 40 PCU/PCT 63: 10,000 rpm, 44/46 kW, 242/116 Nm SCU/SCT 63: 16,000 rpm, 40 kW, 80 Nm * S6 – 40% duty cycle Sample workpiece Formula 1 racing car (aluminium) 8 Integral component (aluminium) Glass mould with cooling bores (cast iron) 9 FT 4000 The workshop machine FT: enhanced space, user-friendly ergonomics and precision Safety and ease of operation have a crucial impact on FT for manual table loading the availability of a machine. Faster and more efficient Optimum access to the work area operation minimises operating errors and risk of failure. Quick and easy handling of workpieces With the F series you can profit from our application Exceptionally well suited for workshop operation experience day in and day out. Ideally suited, e.g. for tool and die manufacturers with frequently changing tasks and small batch sizes Well-designed workpiece management allows you to machine workpieces with a wide range of geometries and weights whilst Robust rotary table for high workpiece weights ensuring high process stability and perfect machining precision. Maximum speed: 30 rpm (F 2000/4000) The loading concept of the F series is based on the experience Workpiece support plate in optional design (slots, threads) gained from the H series. The result is impressive: more space, Hydraulic workpiece clamping (optional: 5-point services less chip accumulating surfaces, higher precision able to take workpiece weights up to 1,400 kg. interface with 60 or 200 bars oil pressure or 200 bars with proportional technology) Ball screw drive arranged in the centre Hydraulic supply via bored holes in support plates Component maintenance can be performed from outside the work area 10 Convenient manual loading of the FT is guaranteed enabling you to benefit from our application experience every day. 11 FP 2000/4000 The production machine The production machine: FP 2000/4000 with pallet changer Highest productivity: F series with pallet changer (FP) Profile: Application: Facts: State-of-the-art 5-axis Prepared for unmanned Cutting capacity for a wide Technical data production machine with pallet changer Designed for highest availability and productivity for machining of large workloads operation using pallet and range of tasks from 5-sided workpiece automation machining through to Flexible for short-term job Model Working range machining of complex free- changes form geometries Perfect for production-oriented Simple and cost-effective users with high output pallet automation solutions Fully compatible with HELLER H series FP 2000 FP 4000 X = 630 mm X = 800 mm Y = 630 mm (SCT 730) Y = 800 mm (SCT 900) Z = 830 mm Z = 1,000 mm Pallet size 400 mm x 500 mm 500 mm x 630 mm Workpiece Ø x height max. 720 mm x 850 mm 900 mm x 1,000 mm 800 (600)* kg 1,400 (1,000)* kg Max. workpiece weight Chip-to-chip time* 3.5 s 3.7 s Rapid traverse 60 m/min Acceleration 6 m/s2 Tool Ø x length (chain) 160 mm x 410* mm 160 mm x 450 mm Tool Ø x length (rack) 188 mm x 410 mm 188 mm x 450 mm Spindle tapers Spindles** SK 40 / HSK-A 63 / BT 40 PCU/PCT 63: 10,000 rpm, 44/46 kW, 242/116 Nm SCU/SCT 63: 16,000 rpm, 40 kW, 80 Nm * Limitations see technical data **S6 – 40% duty cycle 3 Hydraulic housing (cast iron, plastic) 12 1 Aerospace valve housing (titanium) Housing component from mould and die making (aluminium) 13 FP 2000/4000 Automation FP: efficient, universal, highly-productive HELLER machining centres are synonymous with productivity. FP with pallet changer They provide precise and reliable operation over many Compatible with horizontal machining centres from years even under constant load. We expect the same from HELLER H series and combines with pallet pools with our automation solutions: maximisation of productive time 6 pallets per machine, pallet handling via turntable and throughput, increase of production and flexibility in Integration into various pallet magazine systems: terms of modifications. From swift and easy manual loading PMB: basic design with 10 to 24 pallets per machine, to the setting station through to a fully integrated flexible handling via stacker crane manufacturing system – the F series is ready for any solution. PME: extended version with 8 to 42 pallets per machine, handling via rotary fork PMF: flexible design from 16 pallets per machine, handling via telescopic fork Robot automation with standard robot cell or individual solutions 14 Fully automatic: the FP provides high productivity even under constant load. 15 F Series Control Control: the choice is yours The new F series is equally suited for machining of individual Simply choose the type of control that suits your require- parts in tool and die manufacturing and for the requirements ments best: Siemens or Heidenhain. of high-volume production using 5-axis machining. Heidenhain iTNC 530 Siemens SINUMERIK 840D sl CAD/CAM integration From idea to finished product For manual operation in the workshop For high output with automation Highly precise control of speed and acceleration Precise control of speed and acceleration Highly adaptable for precision and surface finishes Highly adaptable for precision and surface finishes Short block processing time of 0.5 ms Exceptionally well suited for machining of sculptured Free contour programming surfaces DCM – dynamic collision monitoring Graphical cycle support User-friendly setup functions Remote diagnostics via ePS Workpiece and pallet management Tool management Clearly arranged graphical and tabular visualisation Extensive tool tables of pallets and programs Easy allocation of NC programs Fast, highly precise machining without unnecessary correction loops – that is what is required of a 5-axis machining centre. Benefit from maximum flexibility by programming at the machine combined with innovative technology and machining cycles or use the existing CAD/CAM chain at your facilities. Be a master of your processes at any time with the F series. If you are dealing with frequently changing tasks or complex shapes, the machines provide the precision and efficiency you need. Cutting data tables for automatic calculation of spindle speed and feed from workpiece-specific data Preparation of pallet data for pending jobs Replacement tool strategy Clearly arranged display of machining status Monitoring of tool life and usage Tool loading during spindle operation and in automatic mode 16 17 F Series Control Tool management: fast, precise, flexible What do you require in terms of tool management from a Tool axis moves along the chain path 5-axis machining centre made by HELLER? You might wish Optimised tool provisioning time to utilise your existing stock of tools, use a wide range of Magazine only fixed to console tools and large tool geometries; you require a flexible solu- Tool loading parallel to machining tion that will meet your production requirements in the most efficient way. At the same time, tool loading times Rack-type tool magazine and downtimes as well as idle times should be minimised. 409 magazine places No problem: the new F series can provide all of this! Max. tool diameter: 188 mm Max. tool lengths: 410 mm on F 2000, 450 mm on F 4000 Tool changer Reduced space requirements due to double-sided arrangement Motor arranged outside of coolant and chip area Magazine access Optimised accessibility for belt tensioning Loader axes with NC technology Torsionally stiff housing due to enclosed design Leakproof floor pan, no leakage of coolant or lubricant (only assembly openings) Easy exchange of motors on the ZT1 axis due to use of elastomer coupling Manually operated rotary station, optional: automatic rotary station HSK, SK and BT spindle tapers Proven basic structure: tools aligned in Z direction, Chain-type tool magazine storage and retrieval unit moves in X, Y and Z direction Max. tool diameter: 160 mm Short tool selection path Max. tool lengths: 350 mm on F 2000, 450 mm on F 4000 Compact, space-saving layout Chain-type tool magazine with 54, 80, 160 or 240 storage places Max. chain speed: 32 m/min 18 F series ensures short loading times, short downtimes and short idle times. 19 Services Services HELLER services: availability and maximum performance When you invest in a machining centre today, you expect to Relocation Service get a solution that delivers highest availability and maximum Complete relocation of your machining centres from one source performance. That is why HELLER services are practically Upgradable with production support on site inextricably linked to the machine. From remote service Planning, professional preparation for transport, equipment, commissioning and training through to predictive implementation and re-commissioning from one source maintenance and spare parts supply. HELLER provides a (HELLER and other brands) complete range of services to ensure long-term cost- effective operation of advanced high-tech machining Additional options: inspection by manufacturer, overhaul of main assemblies, training, acceptance centres incorporated in efficient manufacturing solutions. HELLER services are available around the globe offering Fast-response spare parts concept unrivalled performance. High availability of spare parts, flexible, global supply Supply of exchange parts (reconditioned spare parts with Global presence to serve our customers worldwide special savings) Transnational services Service kits (ready-made spare part packages) Global service standards in HELLER quality Fast response thanks to our own repair shop Customised service concepts for global players Standardised spindle repair Group-wide service agreements Designated contact person (responsible for communication, technical support and implementation of standards at subsidiaries) HELLER Academy for technical staff development Customer-specific or standardised training of your staff (at HELLER or at your premises) Training for operators, programmers and maintenance staff Service solutions and service standards (hands-on instruction on main assemblies) Industry-specific and customer-specific solutions Practice-oriented, modular training materials Upgrades to expand your machining centre’s task profile NC simulation tools for programming courses Efficient solutions providing higher availability and precision Cost reduction through standardised services (rebuilds, repairs, training, upgrades) Direct support via teleservice and service hotline Rapid troubleshooting via teleservice (RDS) Dedicated contact person on site Short response times and 24/7 standby service Predictive planning of maintenance measures (CDS) 20 HELLER services provide optimum availability of your machining centre ensuring maximum productivity. 21 Machining Centres At a glance: HELLER Machining Centres H series – 4-axis horizontal machining F series – setting standards in 5 axis High performance and precision from light-metal machining volumes, frequently changing tasks. Production centre FP: through to heavy-duty cutting. For varying batch sizes and a high-production capacity with 5-axis / 5-sided machining, flexible variable range of parts and materials. response to job changes. Work area: 630x630x630 mm3 – 1,000x1,000x1,000 mm3 Working area: 630x630x830 mm3 – 800x800x1,000 mm3 Spindle taper: SK 40 / HSK-A 63 / BT 40 · SK 50 / HSK-A 100 / BT 50 Spindle taper: SK40 / HSK-A 63 / BT 40 Spindles: 6,000 – 24,000 rpm / 25 – 60 kW / 40 – 2,292 Nm Spindles: 10,000 – 16,000 rpm / 40 – 46 kW / 80 – 242 Nm Workshop machine FT: wide range of parts and materials, low MCH series – universal high-performance machining C series – Combined Processing Superior machine dynamics, optimum positioning and circular with A and B axis and powerful 5-axis machining, future-proof High-torque flexible machining from heavy-duty cutting at accuracy, reduced idle times. Suitable for high chip removal rates productivity. 822 Nm through to finish machining at max. 8,000 rpm. as well as flexible production. Milling/turning centre for horizontal, vertical or tilted turning Work area: 630x630x830 mm3 – 800x800x1,000 mm3 MCH-C series – flexible 5-axis heavy-duty cutting High precision and outstanding machining quality. Work area: 1,250x1,000x1,000 mm³ – 2,000x1,400x1,250 mm³ Spindle taper: HSK-T 63 Work area: 1,000x1,000x1,100 mm3 – 1,600x1,200x1,700 mm3 Spindle taper: SK 50 / HSK-A 100 Spindles: 10,000 rpm / 44 kW / 242 Nm · 16,000 rpm / Spindle taper: SK 50 / HSK-A 100 Spindles: 6,000 – 12,500 rpm / 43 – 72 kW / 460 – 1,145 Nm 22 Made to work 34 kW / 68 Nm Spindles: 6,000 (8,000) rpm / 43 kW / 822 Nm 23
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