Scharmann ECOFORCE Horizontal machining centers

Size: px
Start display at page:

Download "Scharmann ECOFORCE Horizontal machining centers"

Transcription

1 Engineering precisely what you value Scharmann Scharmann ECOFORCE Horizontal machining centers

2 02 Scharmann ECOFORCE Innovative and high-performing Scharmann ECOFORCE machines stand for innovative horizontal machining center solutions focussing on productivity, availability and quality. Based on a modular concept, each machine is tailored to the customer s individual needs. As a multifunctional all-rounder the range of Scharmann ECOFORCE horizontal machining centers offers a comprehensive program of different headstocks and head attachment units. It is constructed in bifurcated column design, combining decades of engineering experience and applications expertise. To ensure our own high quality standards we manufacture the key components of the machines ourselves, including the main spindles, the gears, the attachment heads and the tables. Equipped with a comprehensive range of technology, the Scharmann ECOFORCE can be adapted to cope with almost any machining task. Energy efficiency All proprietary machine tool series implement several ways of making efficient use of energy. Savings of over 20% are already being achieved. The measures taken affect the drive systems, the hydraulics, cooling system, mechanics, coolant and compressed air systems.

3 Scharmann ECOFORCE 03

4 04 Scharmann ECOFORCE Technology Our goal: a machine that can do almost everything! We supply customised machine tool solutions based on standardised machine tool components. This is the only way to ensure the best possible configuration for the application in hand. Fittings to the machine tool are adapted to the customer concerned and to the machining requirements. Our customers can select from a comprehensive range of technology. This is a significant advantage particularly with very complex workpieces. The following solutions are just some of those available for an extremely wide range of machining tasks: Traversable spindle Facing head Angled milling head with a wide range of shapes and dimensions Fork-type milling head Support bearing Attachment head Actuating and deep hole bore tool in automatic handling Speeder spindle We can also create special solutions to meet every single requirement. Only this approach can guarantee maximum productivity.

5 Scharmann ECOFORCE 05

6 06 Scharmann ECOFORCE Technology Headstock with traversable spindle (W axis) The Scharmann ECOFORCE is equipped with a cast headstock mounting a traversable spindle. The spindle has a diameter of 150 mm and a stroke (in the W axis) of 800 mm. The spindle and the milling sleeve are lapped and precision fitted to each other, enabling excellent run out to be achieved, even at long spindle extension. This means that shorter tools can be employed, allowing higher cutting forces and reducing the need for expensive, special tools. Accessibility for internal machining operations is also improved, and a higher degree of precision can be attained. The W axis is designed as a full NC axis with direct measuring system. As an option, the headstock can be configured to include a stable interface for mounting a wide range of head attachments. These are automatically mounted to the headstock thru a pick-up type head exchanging unit. The water-cooled spindle drive in conjunction with anti-friction and oil-air lubricated spindle bearing arrangement ensure maximum reliability. The 2-stage gearbox is equipped with a combined oil cooling and lubrication system. An axial thermal growth compensation system for the spindle can be selected as an option. The benefits: Optimised thermal behaviour 2-stage gearbox for an optimized speed-performance characteristic High torque rating in continuous duty cycle (S1 mode) Compact design Wide track of guideways High spindle rigidity Excellent traversable spindle run out Automatic exchange of head attachments with high repeatability Axial thermal growth compensation Standard tool interfaces: HSK-A 100 according to DIN SK 50 according to ISO CAT 50 / ASME.B 50 (other systems on request)

7 Scharmann ECOFORCE 07

8 08 Scharmann ECOFORCE Technology Column (Y axis), column bed (Z axis) and table bed (X axis) These amply dimensioned fabricated main components are combined with precision compact roller guideways to ensure the consistently high accuracy of the base machine. The design of the fabrications has been optimised to suit the respective Y axis travel and the table size respectively. The precision machined datum surfaces and pre-loading of the guideway elements result in high rigidity, constant dampening and excellent straightness of the axes. Column The bifurcated column design ensures the symmetrical guidance of the headstock along the Y axis. The twin ball screw axis drives and roller guideways provide the high rigidity of column assembly as carrier of the headstock. The benefits: High thermal positional accuracy of the spindle as the basis for high precision indexing machining Symmetrical transmission of axial loads, thereby avoiding torsion to the column Optimised stiffness-to-moving mass ratio Wide track of guideways

9 Scharmann ECOFORCE 09 Column bed (Z axis) table bed (X axis) The column bed / table bed form the basis for highly accurate movement and guidance of the machine column and the machine table.

10 10 Scharmann ECOFORCE Technology Machine table A range of four table sizes (HT2 HT5) is available. In conjunction with high load capacity of the precision anti-friction table bearing, the design of NC-tables ensure high machining performance and high geometric accuracy of the workpiece. The table configuration offer high tipping and tangential moments. As a core competence, all table groups are manufactured in house. The benefits: High stiffness of the supporting guideways Wide track of guideways Very good axial and radial run out Rotary axis (B axis) with constantly high accuracy Constant high holding moment of the rotary axis (B axis) Excellent positioning accuracy of the rotary axis (B axis) High payload capacity Maintenance-friendly design

11 Scharmann ECOFORCE 11

12 12 Scharmann ECOFORCE Technology Palletisation In addition to the basic version with a fixed machine table for direct workpiece loading, the machine is also available in a pallet changing configuration. This configuration can be equipped with two, three or four pallets as a stand-alone machine, or connected to a high volume pallet-handling system in a flexible manufacturing system (FMS). This latter option enables the automation of different machine types form the Starrag Group product range. The benefits: High precision Low-wear design Expandable into a FMS Cell without modification of the pallet changing devices Uninterrupted operation Operation in lights-out respective low-manpower shifts

13 Scharmann ECOFORCE 13

14 14 Scharmann ECOFORCE Technology Tool magazine Economic machining demands innovative tool management. Several different tool magazine designs are available to fulfil the requirements of today s manufacturing requirements. In conjunction with appropriate tool gripper systems, tools can be automatically changed into the main spindle and head attachments. Chain magazine 60 / 80 / 100 / 120 locations Tool length up to 800 mm Tool diameter up to 500 mm Tool weight up to 40 kg

15 Scharmann ECOFORCE 15 Tower magazine Number of tools 180 / 270 / 360 / 450 Tool length up to 800 mm Tool diameter up to 500 mm Tool weight up to 50 kg Magazine loading during operation RTM robot tool magazine Number of tools 200+ Tool length up to 1000 mm Tool diameter up to 800 mm Max. tool weight In exchange 50 kg In single exchange 100 kg Including cone cleaning Tool breakage monitor Magazine loading during operation

16 16 Scharmann ECOFORCE Technology Pick-up magazine The machine can be equipped with a modular pick-up magazine for head attachments. This enables the automatic exchange of head attachment units, such as facing heads, angled milling heads, universal milling heads, support bearings and special-purpose contour and boring bars. Thus, the combination of head attachments and pick-up magazine offers a high degree of machining flexibility. Headstock Detail adapter interface

17 Headstock Interface for auxillary heads covered by protective shield Scharmann ECOFORCE 17

18 18 Scharmann ECOFORCE Technology Machining heads Facing head The facing head enables the performance of complete machining including turning, boring and milling operations on a single Scharmann ECOFORCE machine. Complex workpieces can therefore be produced in fewer set-ups and with a lower floorto-floor time. By reducing the number of set-ups, higher workpiece accuracy can be achieved. The NC-facing heads are available either as integrated units or as head attachments. These accommodate a turning diameter of up to 1,250 mm and speeds of up to 300 rpm. Drilling and milling operations are performed with the main traversable spindle at speed of up to 4,000 rpm. The facing head design includes an automatic counterbalancing system. Due to their robust design, facing heads are ideally suited to high performance, high precision machining of workpieces made from high tensile strength materials. Headstock with integrated facing head

19 Scharmann ECOFORCE 19 Interface for head attachment Angular milling head Speeder spindle Interchangeable facing head Attachment extension Facing head (external supplier) Boring bar (external supplier) 1-axis universal head

20 20 Scharmann ECOFORCE Technology Machine design with tower magazine

21 Machine design with RTM Scharmann ECOFORCE 21

22 22 Scharmann ECOFORCE Technology Technical data Concept Construction Guideway system Drive system Cast construction: Headstock and machine table Welded construction: Column, column bed and table bed Compact roller guideways Single/dual ball screw drive in X/Z axis Dual ball screw drive in Y axis Headstock with tail spindle Output Torque Speed Spindle Ø Spindle stroke (W axis) 45 2, , , , , , kw Nm rpm mm mm Basic data HT 2 HT 3 HT 4 HT 5 Table bed (X axis) 2,000 2,500 2,500 3,000 3,500 4,000 4,000 (4,500) mm mm Column group (Y axis) 1,600 3,500 mm Column bed (Z axis) 2,200 3,650 mm Table design Table top size Collision circle Ø Central loading 1,250 x 1,600 2,000 / 2,500 10,000 1,600 x 2,000 2,500 / 3,000 15,000 2,000 x 2,500 3,500 / 4,000 25,000 2,500 x 3,000 4,000 / (4,500) 40,000 mm mm kg Pallet design Pallet size Collision circle Ø Central loading 1,000 x 1,000 1,000 x 1,250 2,000 / 2,500 10,000 1,250 x 1,250 1,250 x 1,600 2,500 / 3,000 15,000 1,600 x 1,600 1,600 x 2,000 3,500 / 4,000 25,000* 2,000 x 2,000 2,000 x 2,500 4,000 / (4,500) 40,000* mm mm mm kg The technical data are guideline values that can be adapted or changed to meet customers individual needs. * Depends on the size of the pallet

23 Scharmann ECOFORCE 23

24 24 Scharmann ECOFORCE Application examples / machine references Machining gear components on wind turbines using a facing head Machining high precision machine components

25 Scharmann ECOFORCE 25 Machining large valves Machining a gear housing

26 26 Scharmann ECOFORCE Application examples / machine references Machining marine diesel engines with HSK 160 B tools

27 Machining components for the off-shore sector Scharmann ECOFORCE 27

28 28 Scharmann ECOFORCE Application examples / machine references Machining gear housing using universal swivel head Machining general engineering components

29 Machining compressor parts Scharmann ECOFORCE 29

30 30 Scharmann ECOFORCE Application examples / machine references Machining of compressor housing Machining of compressor housing

31 ECOFORCE 31 Machining of printing machine components Machining of packaging machine components Machining of packaging machine components

32 Engineering precisely what you value Scharmann Starrag AG Seebleichestrasse Rorschacherberg Switzerland P F info@starrag.com Starrag Technology GmbH Hugo-Junkers-Str Mönchengladbach-Rheydt Germany T F info@starrag.com blau-haus.net by Starrag, 01/2018 All data furnished in this catalog shall be considered contractually agreed only if confirmed by us separately in writing.