Beijing, Changchun, Changzhou, Chongqing, Nanning, Shanghai Gebr. Heller Maschinenfabrik GmbH

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1 Sweden Slovakia France Värnamo Vráble Paris USA Switzerland Italy Spain Troy, MI Niederbüren Verona Barcelona, Santander RUSSia Yekaterinburg China Beijing, Changchun, Changzhou, Chongqing, Nanning, Shanghai Mexico Queretaro UK germany INDIa Brazil Belo Horizonte, Gravataí, Joinville, Sorocaba Redditch Goslar, Hattingen, Kirchheim, Nürnberg, Nürtingen, Saarbrücken, Salem Pune Some of the options shown are not included in the basic configuration. Design and scope of supply are subject to technical changes Gebr. Heller Maschinenfabrik GmbH Machining centres HELLER solution competence: Efficiency for your production. Worldwide. The H series 4-axis machining at its best

2 HELLER solutions: Knowing how it s done. HELLER out-facing head contents Machining of nickel base alloy Machining of stator housing Our quality promise: Made by HELler 4 H series: for high outputs 6 Machine concept: structure and basic construction 8 Machining units: highest precision 10 Tool management: comprehensive know-how for your tooling 14 Workpiece management: high precision and process stability 16 Machining of transmission cases Chip disposal: perfect solutions to suit your requirements 18 Operation: proven and perfected 20 Control: programming in the familiar system environment 21 Maintenance: optimising overall costs in next to no time 22 Energy efficiency: package offers providing maximum savings 23 Options: typical extra quality from HELLER 24 High-performance milling Machining of titanium Automation: solutions for increased efficiency 26 HELLER Services: ensuring maximum productivity 28 H series 3

3 H series F series C series Our quality promise Flexibly configurable 4-axis machining centres 5-axis production machines with or without pallet changer 5-axis mill/turning centres for complete machining made by A simple principle forms the foundation for the quality and precision of any HELLER solution: HELLER machines are produced on HELLER machines. HELler Our machining centres are manufactured within a global production network operated to HELLER s high quality standards. All components determining the reliability, precision and quality of a HELLER machine are developed and produced in-house. Wherever the daily availability of your HELLER machine is concerned, a high degree of vertical integration is paramount to us. That is why the Made by HELLER seal of approval is something you can rely on. 4 H series H series 5

4 H series for high outputs These compact and powerful machining centres are ideally suited for a wide range of parts and materials. From machining of individual parts through to high-volume production. From light-metal machining to heavy-duty cutting. Highly standardised series, but still configurable to individual requirements Models H 2000 to H provide pallet sizes of up to 1,000x1,000mm with a maximum loading capacity of 4,000kg per pallet Proven and perfected operation and costoptimised easy maintenance Basic scope of supply comprising technical added value Max. pallet loading capacity (kg) 4,000 2,000 1, H 2000 H 4000 H 4500 H 5000 H 6000 H 8000 H H H Machines designed for stable processes at adequate speeds that can be operated at full load even to the limit Chip disposal for highly productive applications is configurable in accordance with customer requirements from a wide range of options Pallets (mm x mm) 400 x x x x x x 800 1,000 x 1,000 1,000 x 1,000 1,000 x 1,000 X (mm) ,000 1,250 1,600 2,000 2,400 Y (mm) ,000 1,200 1,400 1,400 1,600 Z (mm) ,300 1,100 1,300 1,300 1,600 V (m 3 ) H series H series 7

5 Machine Concept Structure and basic construction 9 Weight compensation 9 Weight compensation 7 Tool changer 4 Column 2 H H Tool changer 4 Column 5 Machining unit H 4000 H 4500 H H Machining unit H 5000 H H Pallet changer 1 NC rotary feed table 8 Linear guideways 1 NC rotary feed table 8 Linear guideways 6 Pallet changer 3 Machine Bed 3 Machine Bed Every machine from HELLER is constructed from main components developed using FEA techniques, including a machine bed providing optimised rigidity and a column with reduced masses for high dynamics. At the same time, the vibration-optimised machine structure provides an optimal surface finish of the workpiece and extended tool life. 1 H : NC rotary feed table moves in Z axis direction, driven by two ball screws H : NC rotary feed table moves in Z axis direction, driven by one central ball screw For all sizes: optimal force flow and thermo- symmetrical design 2 H : free chip fall below the tool spindle H : optimal chip disposal through use of 3 spiral conveyors 3 Highly robust cast-iron machine bed carries X and Z axis 4 X axis designed as cast-iron column 5 Powerful and precise spindle units in the Y axis. Equipped with spindle growth compensation as standard 6 Pallet changer: highly precise even at high load 7 Tool changer: fast and precise also with high tool weights and moments of weight 8 Use of high-precision linear guideways and absolute encoded measuring systems (glass measuring scales, encoders) 9 Pneumatic weight compensation provides high dynamics 8 H series H series 9

6 Machining units highest Precision Economic Cutting 100 High Power Cutting 50 Power Speed Cutting 100 Speed Cutting 63 Spindle units Made by HELLER are key components determining the performance of a machining centre, including its capacity, accuracy, quality and precision. Guide slides cast from one piece provide high process stability Robust construction of spindle neck interface to the guide slide Dynamically stiff, short overall design of the spindle units and sophisticated water cooling of the spindle neck provide high precision The spindle cooling is always equipped with a precision cooling unit to provide maximum thermal stability. Additionally, spindle growth compensation is standard Extraction of internal coolant from the spindle provides fast chip-to-chip times, a clean work area and clean tools HELLER zero-spindle system provides proven solution for main spindle replacement options Multihead location with and without additional clamping for selected spindle units Heller out-facing head as a fully featured axis integrated into the NC control for contouring and face turning operations 10 H series H series 11

7 Machining units Well set up for the most demanding tasks Machining centre HSC 40/63 (High Speed Cutting) SC 40/63 (Speed Cutting) PC 40/63 (Power Cutting) SC 50/100 (Speed Cutting) EC 50/100 (Economic Cutting) PSC 50/100 (Power Speed Cutting) PC 50/100 (Power Cutting) EPC 50/100 (Enforced Power Cutting) HPC 50/100 (High Power Cutting) H 2000 H 4000 H 4500 H 5000 H 6000 H 8000 H H H Technical data Speed range rpm 5 24, , , , , , , , ,000 Torque 1) Nm ,146 2,292 Power 1) kw Spindle taper SK/HSK/BT /63/ 40/63/40 40/63/40 50/100/50 50/100/50 50/100/50 50/100/50 50/100/50 50/100/50 HELLER out-facing head HELLER multihead location HELLER multihead location with additional clamping Standard not available Option 1) At duty cycle S6 40% 12 H series H series 13

8 Tool management Comprehensive know-how for your tooling Chain-type magazine 1 Chain-type magazine with tool holders arranged on both sides of a double chain for optimal traversing dynamics Compact build providing high tool packing density Rack-type magazine 2 Rack-type magazine with highly dynamic loader for tool provisioning Optimal operating strategy provides short loading times Tool changer Perfect interplay of tool changer and chain-type or rack-type magazine. For short chip-to-chip times and provisioning of the follow-on tool parallel to machining 3 Traverse attachment acting as a link between chain-type magazine and tool changer provides precise positioning of tools for tool change at all times. On rack-type magazines this function is provided by the loader Options Fast tool breakage monitoring for effective process control Selected magazines for tool loading parallel to machining Tool shank cleaning Tool coding Measuring probe using wireless or infrared technology Magazine Chain-type magazine Rack-type magazine C 54 C 80 C 160 C 240 C 50 C 100 C 150 R 409 R 265 R 425 H 2000 H 4000 H 4500 H 5000 H 6000 H 8000 H H H Spindle taper (SK / HSK / BT) 40/63/40 40/63/40 40/63/40 40/63/40 50/100/50 50/100/50 50/100/50 /63/ 50/100/ 50/100/ Tool 1) (mm) Ø 160/Ø 72 Ø 160/Ø 72 Ø 160/Ø 72 Ø 160/Ø 72 Ø 280/Ø 112 Ø 280/Ø 112 Ø 280/Ø 112 Ø 188/Ø 72 Ø 280/Ø 72 Ø 280/Ø 72 Bridge-mounted tool (mm) Ø 260 x 160 Ø 260 x 160 Ø 260 x 160 Ø 260 x 160 Ø 460 x 280 Ø 460 x 280 Ø 460 x 280 Ø 300 x 188 Ø 485 x 280 Ø 485 x 280 Length (mm) 450 4) 450 4) 450 4) 450 4) /(800) 5) ) Weight (kg) (35) 25 (35)/35 25 (35) (35) 25 (35) Moment of weight 2) (Nm) (50) 25 (35)/50 30 (50) (50) 30 (50) HZP loading 3) /incl. incl. incl. incl. incl. 1) adjacent places free / all places occupied 2) referring to tool gripper groove 3) HZP= parallel to machining 4) observe limited tool length for H ) for model H 8000 and larger Standard Option not available ( ) optional values 2 3 H series 15

9 Workpiece management Pallet changer 1 Fork shape of the swivel traverse ensures force application for overall loads of up to 8t 2 Air nozzles at the swivel traverse remove chips Option for cleaning of functional surfaces of the rotary table and setting station with maintenance function High precision and process stability NC rotary feed table 3 Equipped with worm gear to provide optimal damping at high rigidity for demanding 4-axis operations Compact build allows high permissible tilting moments Rotary table clamping with oil-hydraulic diaphragm brake High tangential and circular milling torques 2 Rotary feed table positioning using direct path measurement with absolute rotary encoders 2 Blow air ensures clean pallet locations, pallet locking and coupling points of media transfer Pallet alignment by means of diamond-type dowel pin and indexing pin for consistent clamping and alignment Optionally with services interface option for hydraulic workpiece clamping with 60bars, 200bars or 200bars using proportional valve technology Workpiece setting station Friction-locked 4 x 90 indexing at the setting station with foot release 4 Optional automatic rotating setting station with automatic setting station doors 3 Optional pneumatic location check, unclamp/position check Services interface option for hydraulic workpiece clamping at the setting station with 60bars or 200bars 16 H series 1 4

10 Chip disposal Perfect solutions to suit your requirements Chip conveyor and coolant unit Extendable with scraper belt or hinge band conveyor depending on the requirements of the machining process Coolant units with paperband filter or vacuum rotation filter technology High pressure coolant supply, optionally with 50 or 70bars Internal coolant supply through the spindle with up to 7 pressure steps, programmable via NC program Coolant units with large reservoir volumes and high volume flows Optional additional coolant cooler for an increased level of process dependability by providing thermal stability Work area 1 H 2000 H 6000: free chip fall below the spindle and central chip conveyor for fast chip disposal and higher production rates H 8000 H 14000: use of 3 spiral conveyors provides optimal chip evacuation from the work area Perpetual self-cleaning effect of moving concertina covers through stainless steel blades Numerous flushing nozzles for wet machining included as standard to keep workpiece and work area clean Additional machine bed flushing Easy to clean due to good accessibility to work area Air and wash gun as standard Optional coolant extraction from the work area 1 18 H series H series 19

11 Operation Control Proven and perfected Programming in the familiar system environment Operation 1 Safe and comfortable operation ensures highest availability Optimal accessibility of operating stations With optional screen blow-off device at the main operating door Workpiece setting station 2 4 Short reach to stetting station centre for comfortable handling Automatic loading/unloading sequence provides high process dependability and short idle times Tool loading 3 Tool loading at the magazine while spindle is running Linear guideways provide smooth operation of setting station doors. Option: comfortable operator panel Ergonomic integration of the operating panel into the safety guards Linear guideways provide smooth operation of setting station doors Sinumerik 840D solution line and Fanuc 31i-B Increased operator convenience Operating modes 2 and 3 included in standard scope of supply Integrated pallet and program management User-guided setup functions / automatic return to home position Trust is good, control is better Practice-oriented functions HELLER IPM (Integrated Process Monitoring) for process, collision and tool breakage monitoring Comfortable programing with Heller technology cycles (drilling, milling, measuring) Tool breakage monitoring parallel to machining Job management/management of multiple clamping RDS remote diagnostics of the machine and coolant unit Alternative strategy (program continuation e.g. in case of tool breakage) CDS Condition Monitoring Tool requirements planning Technology package milling Automatic loading/unloading sequence 20 H series H series 21

12 Maintenance Energy efficiency Optimising overall costs in next to no time 1 Package offers providing maximum savings Energy efficiency made by HELLER Supply units and maintenance points are limited to a few locations to ensure quick and easy inspection and operation 2 The quick response times of the HELLER spare parts service helps to keep production downtimes in emergencies short 3 All function-relevant systems and components are installed within quick and easy reach Easily removable guard panels arranged for ease of maintenance provide access at the touch of a hand 4 The proven HELLER zero-spindle system provides quick replacement of the milling spindle HELLER BLUE Energy efficiency packages for energy savings of up to 30% At HELLER, the use of regenerative drive systems, servomotors with efficient utilisation of the overall speed range and power-reduced valves has been standard for years just as consistent use of methods for topology optimisation of structural components (e.g. beds and columns). These methods help to increase stiffness and to optimise masses of moving components. The new HELLER BLUE energy efficiency packages allow to unlock further potential independent of the manufacturing situation. The more universal and varied the machining task, the more important is adaptive (i.e. requirements-based) current consumption of peripheral equipment and main units in order to be able to optimise various operating points. HELLER BLUE basic Basic supply for all HELLER machines from the H, F and C series Use of IE2 motors with up to 5% lower power consumption Shut-down of individual consumers after a programmable time interval HELLER BLUE supply Requirements-based shut-down of consumer air Constant media and filter monitoring supports the smooth operation of your machine HELLER BLUE smartsupply Flexible deactivation/activation of all consumers In addition to BLUE supply, this option includes shut-off or sleep mode of further functional units, including cooler, pumps, lights, chip conveyor, seal air and other separate options HELLER BLUE coolant The use of a frequency converter allows to perfectly adapt the volume flow of the high-pressure coolant pump, and thus energy consumption, to the requirements of your machining task HELLER BLUE chill Flexible control instead of ON/OFF control As with the coolant pump, the central cooler can be controlled by means of a frequency converter in accordance with operating requirements In combination with a new type of compression technology this results in a significant reduction in power consumption HELLER BLUE hydraulics High pressure on demand Booster technology based on the principle of pressure amplification provides low-noise and energy-saving high pressure supply, whilst minimising heat input into the hydraulic system H series 23

13 Options Typical extra quality 3 FROm HELLER Fast tool breakage monitoring 2 Air nozzles at the swivel traverse, pallet location, pallet locking and coupling points of the media interface ensure highest process dependability 3 Tool cleaning function for chain-type and rack-type magazines on chain type with tool pocket flushing, on rack type with brush and flushing option 4 Measuring probe for wireless or infrared technology 5 5 HELLER multihead location, also with additional clamping for critical operations or tools 6 HELLER out-facing head for performing turning operations on a machining centre HELLER zero-spindle principle for quick replacement of the main spindle Spindle growth compensation as standard, for optimisation of manufacturing accuracy 1 6 H series 25

14 Automation Solutions FOR Increased EFFiciency The machining centres from the H series epitomise productivity: in addition to their high precision and efficiency they provide maximum reliability, even under constant load, and can be flexibly adapted to new tasks. The same is true for our automation solutions. They have been designed to optimise your production process and provide maximum added value. The results are maximised effective machining time, optimised throughput and increased production output. We provide automation solutions ideally geared to your requirements that are continually enhanced and refined. The resulting advantages in terms of cost savings and safety are passed on to you directly. 1 Manual supply via roller conveyor 2 Fully automatic loading via travelling robot 3 Pallet rack system 4 Pallet and tool automation system 5 Rotary pallet magazine 6 Semi-automatic loading using balancer Solutions range from simple pallet pools to pallet rack systems through to flexible robot cells for complete workpiece handling. 26 H series 5 6

15 HELLER Services Ensuring maximum Productivity In global competition, maximum productivity is considered the key to success in the metal cutting industry. Several aspects play a role in achieving this: in addition to the optimisation of the manufacturing processes, the most important aspects are the reduction of unscheduled downtimes and increasing machine availability. That is why HELLER machines and the services provided by HELLER Services go hand in hand. With a global presence, quick response times and qualified customer care HELLER Services ensures highest machine availability over many years. For you we are offering a comprehensive range of services: HELLER standard rebuild packages To increase the efficiency and productivity of your HELLER machines, HELLER is offering a wide range of standardised rebuild packages. With these packages HELLER is providing a fitting solution to your optimisation requirements, e.g. when adapting the machines for a new machining task. They cover the following areas: Machining unit Media supply Measuring probe Process optimisation Safety guards/machine frame Software/control Workpiece management Tool management Increase of energy efficiency HELLER retrofit renewed productivity To get existing equipment ready for new production tasks, we provide all relevant aspects of retrofitting: Condition check and disassembly Overhaul of the basic machine Overhaul of assemblies Retrofit of control Retrofit of control cabinet and replacement of cabling Replacement of covers and safety guards Acceptance at factory prior to delivery The result is a machine that is as good as new, providing an increased level of productivity and safety. The benefit to you: a retrofitted machine is backed by the same warranty, warranty regulations and service availability as a new machine. HELLER training The HELLER TrainingCenter offers numerous practice-oriented training courses, effectively qualifying your staff for working with a HELLER machine. For this purpose we provide basic and advanced courses in the following fields: Operation Programming Maintenance If required, HELLER Services can arrange customer-specific training also at your premises. The contents of these premium training courses are tailored to the specific requirements of your company and cover all specialist fields of HELLER (technology, control engineering and machine technology). HELLER TPS modular service packages For optimal support in maximising your productivity HELLER has developed the modular TPS (Total Productive Services) range of services. It comprises various service packages which integrate seamlessly into your production system always with due consideration of your maintenance strategy. You decide which one of the three packages is ideal for you: TPS Performance Package: Annual manufacturer inspection TPS Maintenance Package: Annual manufacturer maintenance TPS Full Service Package: All inclusive 28 H series H series 29

16 HELLER solutions: Knowing how it s done.