ECOSPEED Series. Headquarters:

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1 Headquarters: Dörries Scharmann Technologie GmbH Hugo-Junkers-Straße D Mönchengladbach-Rheydt Tel. +49/2166/454-0 Fax +49/2166/ Products: Dörries Vertical Turning Lathes Vertical Turning Centers Droop+Rein Portal Machining Centers High Speed Machining Centers Scharmann Horizontal Machining Centers Boring Mills Berthiez Vertical Turning Machines Vertical Grinding Machines Ecospeed 5-Axes High Performance Machining Centers Service Sites, Subsidiaries and Service Centers: Dörries Scharmann Technologie GmbH Product line Droop+Rein Hofkamp 2, D Bielefeld Tel. +49/521/5804-0, Fax +49/521/ Dörries Scharmann Technologie Service Center GmbH & Co. KG Am Sülzenbrückener Weg 14, D Ichtershausen Tel. +49/36202/77980, Fax +49/36202/ Dörries Scharmann Technologie GmbH Service Center South Wannetal 47b, D Lindau Tel. +49/2166/ , Fax +49/2166/ Dörries Scharmann Technologie GmbH Beijing Office Room 704, Kun Tai Building, No. 10 Chao Wai Da Jie, Chaoyang District, Beijing, PR China Tel. +86/10/ , Fax +86/10/ Dörries Scharmann Technologie GmbH Moscow Office ul. Tverskaya 16/2, Building 1, 7. Floor, RUS Moscow Tel. +7/495/ , Fax +7/495/ DS Technology (USA), Inc Palace Drive, Cincinnati, OH 45249, USA Tel. +1/513/ , Fax +1/513/ DS Technology (UK) Ltd. 43/45 Phoenix Park, Avenue Close, Nechells, Birmingham B7 4NU, United Kingdom Tel. +44/121/ , Fax +44/121/ Berthiez SAS 5, rue Barrouin, F St. Etienne Cédex 1 Tel. +33/4/ , Fax +33/4/ sales@berthiez.fr ,500 E ECOSPEED Series 5-Axes High Performance Machining Centers

2 Is it your business? C-Frame Wing Rib Spar A-shape Frame Stringer 2

3 Is this your cycle time? Total Cycle Time (2 set-ups) 8 hours, 42 minutes C-Frame Material Aluminium Length / Width / Thickness Billet weight Part weight 5,800 x 1,600 x 100 1, Total Cycle Time (3 set-ups) 19 hours, 26 minutes Wing Rib Material Aluminium Length / Width / Thickness Billet weight Part weight 5,563 x 1,669 x 190 4, Total Cycle Time (2 cycles) 4 hours, 15 minutes Spar Material Aluminium Length / Width / Thickness Billet weight Part weight 6,200 x 350 x Total Cycle Time (2 set-ups) 27 minutes A-shape Frame Material Aluminium Length / Width / Thickness Billet weight Part weight 900 x 900 x Average Cycle Time (2 set ups in one cycle) less than 12 min/m, 12 min/39.4 in Stringer Material Aluminium 3 Stringer length 2,000 30,000

4 Cost per part Cost at what price Optimised Productivity ECOSPEED Series Down the years, Dörries Scharmann Technologie GmbH (DST) has established itself as a proven partner for the aerospace industry. In 1998 DST was challenged with the development of a machine tool concept to achieve the lowest cost per part at an optimum level of investment for monolithic aluminium aircraft parts. This resulted in the innovative and highly efficient ECOSPEED machine series. With the horizontally orientated, parallel kinematic Sprint Z3 machining head at its core, the ECOSPEED series sets the benchmark in its field. Since market introduction in 1999, more than 50 machining centers employing ECOSPEED technology have been installed at many major aerospace manufacturers world wide and are producing a wide variety of different components in different sizes. The ECOSPEED series offers the most advanced technology for machining aluminium aerostructure parts that will ensure future competitiveness for your business. Best reliability and performance installed with ECOSPEED technology with improvement over the years. Optimum DST ECOSPEED product series Contents Sprint Z3 DST s highly dynamic, parallel kinematic head concept. Page 6 Investment costs ECOSPEED Travelling column machining center with vertical table for large parts. ECOSPEED F Fixed column machining center with vertical table for medium sized parts up to 8 m in length Low cost machines Over-engineered machines ECOSPEED F HT Fixed column machining center with horizontal table for small parts up to 1.25 m in length. ECOLINER Travelling column machining center for stringer parts Technical data and details

5 Well-proven head concept Sprint Z3 The parallel kinematic concept Three parallel linear axis drives are mounted radially equispaced in a barrel-shaped headstock. The spindle platform is connected to each drive by means of rigid levers with a simple pivot at one end, and a ball joint at the other end. A high performance motor spindle is mounted to the spindle platform. The headstock is mounted horizontally and moves vertically inside the column. This arrangement offers minimum movable mass resulting in unprecedented dynamic characteristics. When all three axes are moved equally and simultaneously, the spindle is moved in a straight line in Z-direction. If the three axes move differentially, the spindle platform will be tilted in the A/B-planes. Synchronized motion of the three Z axes allows the spindle to describe any path within a spherical cone of ± 40 degrees. Working area Cubic working area through linear motion of X-, Y- and Z-axis. - Conical working envelope with ± 40 degrees of angular freedom. Acceleration / deceleration in all axes Rotation range Axis speed Acceleration A-/B-axis conical work envelope A-/B-axis conical work envelope A-/B-axis Z-axis ± 40 max. 80 /. 685 / ² 1 g ( m / 2 ) Advantages Motor spindle in cartridge design Linear ball screw drives with directly connected servomotors No slip rings or rotary couplings required Standard components are used No counter balance for Y-axis required 6 7

6 ECOSPEED Highlights Since its introduction in 1999, the ECOSPEED machine with travelling column and its unique Sprint Z3 parallel kinematic head concept, has revolutionized high performance machining of large-sized aluminium structural aerospace parts, and rendered traditional multi-spindle profilers almost obsolete in this field of application. Now, based on the experience of over a decade of round-the-clock operation, DST has proven that the ECOSPEED is the most productive solution in its class on the machine market, capable of drastically reducing production costs and time for large-scale manufacturing of structural aircraft parts. At the same time, machining accuracy and surface finish have been considerably improved. Advantages Ergonomic horizontal part loading/unloading Pallet changer for uninterrupted operation Highly dynamic 5-axis simultaneous machining High acceleration / deceleration in all axes Very high material removal rate with direct disposal via chip conveyor Extremely high accuracy Excellent surface quality Dramatic increase in productivity, virtually eliminating surface polishing Highest crash safety Advantageous price-performance ratio 8 9

7 ECOSPEED F Highlights ECOSPEED F was developed from the ECOSPEED travelling column machine to provide an even more dynamic machine solution for medium sized structural aircraft parts. This was achieved by placing the unique Sprint Z3 parallel kinematic headstock into a fixed column, thereby reducing the moveable mass at the tool. This arrangement provides the best preconditions for the most precise and fastest aluminium cutting process in structural aerospace machining today. Advantages Ergonomic horizontal part loading / unloading Twin pallet changer for uninterrupted operation High acceleration / deceleration in all axes Highly dynamic 5-axis simultaneous machining Highest jerk characteristics Highest material removal rate with vertical chip fall Extremely high accuracy Excellent surface finish quality Dramatic increase in productivity, virtually eliminating surface polishing Highest crash safety Advantageous price-performance ratio 10 11

8 ECOSPEED F HT Highlights Thanks to modern 3D CAD systems, designers are now able to exploit the physical strength properties of typical aerospace materials by selecting ever more complex geometric shapes, which in turn have lead to a large increase in 5-axis machining content. The ECOSPEED F HT is the highly dynamic, high performance and extremely productive solution to the very demanding machining tasks for small to medium sized parts resulting from this development. As the name implies, the ECOSPEED F was developed one step further to combine the fixed column concept with a horizontal table group. Since the table group includes a NC-controlled continuous Bt-axis, the ECOSPEED F HT can boast 6-axis capability. Advantages Rotary pallet changer for uninterrupted operation Highly dynamic 5-axis simultaneous machining High acceleration / deceleration in all axes Highest jerk characteristics Very high metal removal rate Extremely high accuracy Excellent surface finish quality Dramatic increase in productivity, virtually eliminating of surface polishing Highest crash safety Outstanding price-performance ratio 12 13

9 ECOLINER Highlights A special development of the ECOSPEED travelling column machine with shorter Y-axis, the ECOLINER is specifically designed for machining aluminium profiles stringers of up to 30 m length from thin billet material or semi-finished tion. The machine concept uses the unique Sprint Z3 head concept in combination with the lowest moveable mass to achieve the best preconditions for high precision and fastest metal cutting processes. Advantages B B1 H1 H Raw part: T-tion Al-extrusion Stringer length Stringer width Stringer height Profile height Clamping area Waste material metal removal B H H1 B m appr. 90 % The machine is rounded off by a highly flexible, fully automatic fixture system which holds the stringer part in its raw and semi-finished condition in both set-ups for front and rear side machining, and also performs the intermediate transfer procedure. All variances of stringers can be produced on ECOLINER. Machining time is 12 minutes per meter. Highly dynamic 5-axis simultaneous machining High materal removal rate with vertical chip fall Extremely high accuracy Excellent surface finish quality Dramatic increase in productivity, eliminating surface polishing Highest crash safety Parts machined in both set-ups in one cycle 14 15

10 Features Spindle Features Jerk Spindel technology Spindle capacity, 100 % ED Spindle torque, max. Spindle speed, max. Constant power from Tool holder according to Spindel 1 Spindel Nm 46 30,000 rpm 30,000 13,800-30,000 rpm 16,500-30,000 HSK A 63/80 HSK A 63/80 Nm rpm rpm Example Endmill Ø 32 Spindle speed Number of teeth Chip load Width of cut Feed rate 24, rpm /tooth Feed-time-chart (s = 50 ) Tool clamping force 21 kn Spindel 1 Spindel 2 21 kn feed () jerk 10 m/s 3 jerk 20 m/s 3 jerk 50 m/s 3 jerk 70 m/s 3 jerk 100 m/s 3 jerk 200 m/s time (s) Others Power 60 Depth of cut Time / pass Number of passes Time / pocket Jerk 10 m/s 3 Saving 0 % Others m/s 3 21 % Flange size Ø B Taper size at gage line Ø A Others Spindle m/s 3 m/s % % Spindle m/s 3 76 % HSK Tool taper shanks Designation DIN HSK-A63 Ø A Taper size at gage line 48 Ø B Flange size 63 Tool clamping force 18 kn Conclusion Machines with low jerk capability have difficulties in reaching prograed feed rate. Jerk is the significent key to achieving true high performance pocket machining. Velocity Change of position over time -> m/s DIN HSK-F kn Acceleration Change of velocity over time Proportional to drive force in connection with the moved mass -> m/s² -> *m/s² = N DIN HSK-F80 DST Standard HSK A 63/ kn kn Jerk Change of acceleration over time Proportional to change of drive force in connection with the moved mass -> m/s³ -> *m/s³ = N/s 17

11 Five sides milling and drilling C-axis Speed C-axis Torque C-axis C-axis angle rpm Nm continuous Two systems are available for integrating angular milling and drilling heads into the machine to expand the range of machining possibilities. The first system includes a torque support with integrated air supply. Small angular drilling heads can be loaded into the spindle and then be positioned at the required angle through the M19 (spindle orientation) function. The selected position is maintained during machining by means of a pneumatically relieved brake. The angular drilling heads can be stored like standard tools in the tool magazine and handled by the automatic tool changer. This variant is available for all machine types. Right Angular Milling Head Speed Torque Power 15, rpm Nm Tool holder according to HSK A-63/80 The ond system entails the integration of a fully functional 6th NC-axis, - C-axis consisting of a torque motor installed around the spindle. This arrangement is capable of receiving not only the small angular drilling heads as described above but also permits the use of a more powerful angular milling head with automatic HSK-A63 /80 tool clamping system. The selected position is maintained during machining by means of the NC control. In combination with a suitably configured automatic tool changer and magazine, this feature permits tools be inserted into the milling head as well as into the spindle. The head enlarges the angular work space cone of the spindle by 90 degrees in all directions, thus offering unprecedented accessibility. This system can be implemented on ECOSPEED and ECOSPEED F machines. Right Angular Drilling Head, Example Speed Torque Power Clamping range 15, ,5-7 rpm Nm Comparison of working envelope Fork-type-heads DST ECOSPEED typical min. 200 only

12 Accessories Tool magazine Chain magazine Number of pockets Tool shank Tool length, max. Tool diameter, max. per tool location 40/60/ pockets HSK-A 63/80 Accessories Pallet handling systems Example of machine system arrangement Tool weight, max. 10 ECOSPEED F HT Chip to chip 7 Tool to tool 1,8 Double pallet shuttle load/unload station and buffer stores Pallet load/unload station Rack type magazine WERO ECOSPEED 2570 Number of pockets 129 pockets, min. Chip to chip 15,3 Tool shank HSK-A 63/80 Tool to tool 2,5 Tool length, max. Tool diameter, max. per tool location Tool weight, max ECOSPEED F Chip to chip Tool to tool 8 1,8 Pallet changer stand alone machine Pallet changer in tilt motion 20 21

13 Flexible Manufacturing Systems SINDI Life-cycle-costs DST System for Information and Diagnosis creates transparency and cuts costs Machine tools are complex systems and they must fulfil stringent requirements. Durable efficiency, maximum availability and the costs incurred are also significantly dependent on correct operation and maintenance. Modular system for constantly high productivity Knowing how, where and what: ECOSPEED series machines are equipped with coercially available standard guide way, drive and feedback system components, appropriately dimensioned to ensure long life cycles with calculable maintenance costs. The motor spindles are guaranteed for 5,000 operating hours (under S1 [100% DC] conditions). Due to their cartridge design and the simple media connections, spindle exchange can be performed within a few hours. Furthermore, DST s spindle refurbishment program ensures that equal replacement spindles are always available. DST Cell Controller Well proven and often implemented software solution specifically developed by DST Serves to automatically control flexible manufacturing cells with 1 or more machining centers, an automatic pallet transport system, any number of pallet buffer stations and component load/unload stations. Featuring the following standard functions: Administration and allocation of: Workplans NC-Programs Tasks Pallet routing and sequencing Optional extended functionality: Tool disposition Extended workplans Extended NC-Program administration Fixture Management Task planning and visualization Unattended operation mode Display of clamping sketches Connection to other process equipment (e.g. CMM, wash station, Tool-Presetters) Transmission of measurement data Reporting functions Data Back-Up-functions The cell controller is open for customization. Machine diagnosis On-line data connection Trip recorder Malfunction analysis with duration and frequency Monitoring through external computer Monitoring DST remote diagnosis Iediate rectification of faults Video monitoring MDE Documentation of availability Makes procedures transparent Provides safety Prevents downtimes Saves costs Fault diagnosis Direct access to machine documentation Diagnosis Dynamic maintenance and servicing Maintenance Fault messages through or SMS SMS Self-diagnostic systems ensure that maintenance personnel are always up-to-date on the condition of all machine elements, and in combination with preventative maintenance programs, guarantee very high machine availability. High quality machine tools will repay your investment thru: Highest productivity Highest availability High accuracy Calculable life cycle costs Long service life Whereas low quality machine tools mean: Low productivity Low availability Moderate accuracy Incalculable life cycle costs Short service life Total cost of ownership cost Others ECOSPEED time 22 Video Help 23

14 Technical data Pallet ECOSPEED F HT 1010 ECOSPEED F 2035 ECOSPEED F 2540 ECOSPEED F 2060 / 2560 ECOSPEED F 2080 / 2580 ECOSPEED from 2570 up to ECOLINER Length (X-axis) 1,000 3,500 4,000 6,000 8,000 7,000-20,000 Width (Y-axis) 1,000 2,000 2,500 2,000 / 2,500 2,000 / 2,500 2,000 / 2,300 / 2,500 Payload 1,000 3,000 4,000 5,000 6,000 Traverse X-axis 1,250 3,800 4,300 6,300 8,300 Pallet length (X-axis) +800 Up to 30,000 Y-axis 1,350 2,500 3,000 2,500 / 3,000 2,500 / 3,000 2,500 / 2,600 1,500 Z-axis (spindle horizontal pos.) Z-axis (spindle ± 40 ) in B-axis (table) = 360, continuous Additional information Pallet changing time *. Chip to chip time *. Acc / dec in X-axis m/. 2 m/. 2 m/ m/. 2 Acc / dec in Y-axis m/. 2 m/. 2 m/. 2 m/. 2 m/. 2 m/ m/. 2 Acc / dec in Z-axis m/. 2 m/. 2 m/. 2 m/. 2 m/. 2 m/ m/. 2 Acc / dec in A- and B-axis 685 / / / / / / / 2 Rapid traverse / feed in X-axis max. 65 Rapid traverse / feed in Y-axis Rapid traverse / feed in Z-axis Rapid traverse / feed in Bt-axis 30 rpm Tool magazine Chain type 40/60/80 pockets Rack type 129 pockets Rack type 129 pockets Rack type 129 pockets Rack type 129 pockets Rack type 125 pockets Rack type 125 pockets 24 Optional C-axis (spindle 90 ± 40 ) 360 continuous Right angular milling head Right angular drilling head * Values for Type 2570 The technical data are standard values which may require adjustment or change according to client or individual requirements. 25