GEMINI CNC Gantry Style Plate Fabrication Center for Drilling, Tapping, Milling, Marking and Thermal Cutting

Standard tECHniCal FEaturES•Twinbeamboxconstructionforminimumdeflectionwhenmachining•FanucCNCcontrolsforproductiveoperationalreliabilityandworldwide servicesupport•LowbacklashhardenedandgroundhelicalrackontheX&Y&Uaxes•Simplefloormountedinstallationwithouttheneedforspecialfoundations

•Minimalfootprint(upto60%lessthanothersolutions)•Highspeedmillinganddrillingwith6,000RPMspindlespeedsandautomatictoolchanger

•Integratedautomaticplateclampingrequiresnosetupandeliminatesvibrationtoachievehighratesofproductivity

andtoollife•Precisionlaserforplatereferencingeliminatestheneedtosquareplatespriortoprocessing

•SecondaryXaxisincreasesproductivityandpermitsmillingwithouttheneedtopositionthegantry

•Toolchangingoccurswhiletheplateremainsclampedforprecisiontapping,countersinking,boringandmilling

•Helicalmillingforlargerholeswithlowcosttooling•Facemillingforbearingsurfacesinconstruction/machineapplicationsandcolumnsinstructuralsteelfabrication

•200,260or400ampplasmasystems•Abilitytokeepmultipleremnantsonthetableeliminatesthematerialhandlingandneedtoreturnandretrievethemfromstock

•Cuttinglengthsfrom5-30m/20-100ft.•Air/mistorliquiddrillcoolant

OptiOnal FEaturES•CNCbevelplasmaheadforweldpreparations•Multipleoxy-fueltorches•Optionaltoolmonitoring•Downdraftorwatertables•Platemarkingandlayout“scribing” withpatentpendingtechnology•Pinmarkingforlowstressapplications•Markingwithplasma•Maximumplatewidthsof8’(2,540mm), 10’(3,100mm)and11’9”(3,600mm)•Chipvacuumevacuationsystems•Magnetictableforstand-alonemilling operations

CNC Gantry Style Plate Fabrication Center for Drilling, Tapping, Milling, Marking and Thermal Cutting

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Plasma torch with laser height sensing

Automatic tool changer with up to 24 tools per drill head (depending on the model)

Thecompleteplateworkingsolutionforfabricatorsandmanufacturersofallsizes.TheGeminihandlesfromlighttoheavyplateforthermalcutting,marking,milling,drilling,tapping,bevelingandmoreallononesystemwithunprecedentedaccuracy.Thisachievesthelowestcostduetoitsminimalfloorspace,lowcapitalinvestmentandproductivity.

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CuttinGThe Gemini’s mobile gantry design allows for a greaterrange of plate sizes and thicknesses without concernfor the plate weight and material handling due to thesimultaneousprocessingandloading/unloading.Suppliedwith plasma and optional oxy-fuel torches, theGeminicancutplatesfrom3/16”(5mm)to12”(305mm)insteelandfrom3/16”(5mm)to1-1/2”(40mm)instainless,brassandaluminum.Machine positioning accuracy of .004” (.1 mm) ensuresqualitypartsforbetterfitupandlessweldingtime.Forheavyplatework,theGeminicanbesuppliedwithuptothreeoxy-fueltorchesforaccuratestrippingormultiplepartcutting

MarKinG and SCriBinGFabrication and bending lines can be indicated with ascribingtoolorplasmamarking.Identificationmarksandpartnumbersfor fabricationcanbeaddedwith thescribing tool, plasmamarkerorapinmarker.Deeper marking suitable for viewing after painting orgalvanizingcanbeperformedwithscribing.Center locations for thepositioningandweldingofpartswith reference points are produced with our “patentpending”scribingtool.

The Gemini can be equipped with different optionalHypertherm plasma torches and with plate nestingsoftware package to maximize material utilization withefficientpartnesting.FanucCNChardwareisprovidedwithahumaninterfaceusingFicepPegasosoftware.

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Nesting CNC Fanuc control

Hypertherm control panel

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EdGE BEvEllinGThe Gemini can make weld preps either by milling orplasma beveling. For precision bevels, milling is moreaccurateandJgroovebevelscanalsobeachieved.Forvariablebevels,largepartsandKpreps,plasmabevelingisthemosteconomicalprocess.Forenhancedefficiencyin welding, J preps and thickness reduction can beperformedwithmillingtools.

FaCE and SlOt MillinGOnmachinepartsandmanystructuraldetailitems,slottedholes,milled bearingmating surfaces, etc. are required.Traditionally these operations were performed on largemachining centers or boring machines after fabrication.TheaccuracyoftheGeminiinbothcuttingandmachiningmeans thatmanyof theseoperationscanbeperformedonthestockplate,thuseliminatingtheexpense,handlingcost,floorspaceand lead-timeofsecondaryoperations.For fabrication the milling of weld prep surfaces candrasticallyreduceweldingcosts.

GEMINI XD 36

GEMINI XD 36 - front

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J groove edge beveled for deep penetration and no back welding

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Parts drilled and marked

Thick parts drilled and cut

drillinG and tappinG

TheGemini’shighspeedmachiningspindleallowsextremelyproductivedrillingofholesfrom1/8”(3mm)to3.15”(80mm).Forlargerholesupto15,7”(400mm),theGeminicanmillholeswithexceptionalaccuracy(<0.004”(.1mm)toleranceondiameterandconcentricity).

Thehighspeedspindlepositioning (subXandYaxis)combinedwithwideareaclamping provides very high productivity for themost common hole sizes (18 –15/16”(22mm)diameterholesperminuteon4”(100mm)centers).

TheprecisionoftheGeminiprovidesunprecedentedaccuracyofbothholetoholeandholetoedgelocations.

Formanyapplications,tappedholesinthecomponentscanreducewelding,fittingandassembly time. For tapping, thedigital control systemprovideshighqualitythreadsontappedholesassmallas1/8”(3mm)forcableclips,etc.andupto15/16”(22mm)forstructuralbolts.

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HARDWARE & SOFTWARE

Pegaso is the new generation CNC for Ficepmachines. PC,CNC and PLC are integrated on a single board, to have themaximum reliability.Pegaso isbasedonfieldbus technology:CanBusandEtherCAT,withupto32axescontrolled.

TheCNCispositionedonamobilecontrolpanel,sotheoperatorcanhaveacompleteviewofthemachine.Themostof input/outputinterfacedevicesandbrushlessmotorsdrivesarelocatedonthemachine.

programming• Simplifieddatainputwithgraphicaldirectpreview• 3Dpieceview• Diameterprogrammingwithautomatictoolassignment• Linear,matrixandflangepatterns• Programmingwithmillimetersorinches(alsofractions)• Linearnesting

processing• Automatictoolassignment• Unitoffsetautomaticsumming• Automaticgroupingandorderingofoperations• Setupmodificationlinesgeneration• Rototraslationofexecutingprogramtofollowsheet

orientation

Execution• Automaticcyclestopfortoolsetupmodification• Probingcapabilitytoadjustprogramquotestoactual

materialposition• Automaticsoftwaretopreventmachineunitcollisions• Automaticsoftwaretopreventtoolcollisionsagainst

material• Toolmanagementwithoperatingparametersandtoollife

management• Messagesandalarmnotificationstotheoperatorusing

customerlanguagewithhistorylog• Graphicscreenstodisplaymachinepieceshandlingtables• Productiontimesrecording

pEGaSO SYStEM

pC characteristics• CPUAMDOntario1.6GHzDualCore• Ram2Gb• DiskCompactFlash8Gb• USB6HighSpeed2.0(oneonthefront)• LANEthernet10/100/100Mbit• KeyboardIndustrialPS2• DisplayLCDLedtechnology15“withtouchscreen• Industrialpanelwith42pushbuttons• Op.Sys.Windows7EmbeddedwithEWFfilter• Teleservicesoftwareforremotediagnostics

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CAPACITIES AND SPECIFICATIONS

HP25 HP32 HD36 XD36Material dataPlatethickness(min.) mm/inch 5(3/16") 5(3/16") 5(3/16") 10(3/8")Platethickness(max.) mm/inch 80(3") 80(3") 127(5") 305(12")

Platedimensions(min.) mm/inch 800x1250(32"x48")

800x1250(32"x48")

800x1250(32"x48")

800x1250(32"x48")

Platedimensions(max.) mm/inch 2540x24400(100"x80')

3100x24400(80')

3600x24400(141"x80'),(3200x24400

(126"x80'withbevel)

3600x24400(141"x80'),3200x24400

(126"x80'withbevel)

axesCNCinterpolatedaxes number 4 4 3or5(6or9) 3or5(6or9)CNCtotalaxes number 5 5 10(18) 10(20)Plasmatorches number 1 1 1(2) 1(2)Plasmabevel(option) 1 1 1(2) 1(2)Oxy-fuelcuttingoption(max.) mm/inch 100/4" 100/4" 127/5" 305/12"drilling unit(s)Verticaldrillheads number 1 1 1(2) 1(2)Toolsperdrillhead number 8 8 24 16SpindleRPM rpm 6000(8000) 6000(8000) 6000(7000) 4500(5000)Spindletaper ISO40 ISO40 ISO40 ISO50Spindlelubrication internal internal internal internalSpindleatS3rating kW/hp 11/15 11/15 26/35 58/78Holediameterdrilling(max.) mm 32(1.25") 32(1.25") 40(1.57") 80(3.15")Holediameterinterpolatedmilling(max.) mm 240(9.5") 240(9.5") 400(15.7") 400(15.7")

installationWorkinglevelheight mm/inch 650(25.6") 650(25.6") 700(271/2”) 700(271/2")

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