HELLER Machines. Made to work. · Machines The new F series Setting standards in 5 axis HELLER...
Transcript of HELLER Machines. Made to work. · Machines The new F series Setting standards in 5 axis HELLER...
Machines
The new F seriesSetting standards in 5 axis
HELLER Machines. Made to work.www.heller-machinetools.com
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HELLER Machining Centres
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Contents
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FP 2000/4000 Efficient, universal, highly-productive 14
Control The choice is yours 16
CAD/CAM integrationFrom idea to finished product 17
Tool management Fast, precise, flexible 18
HELLER ServicesThere for you throughout every phase 20
HELLER locationsWe are here for you. Worldwide. 22
FP 2000/4000The production machine 12
FT 2000/4000 Enhanced space and precision 10
5-axis competence in HELLER quality 3
Innovative spindle technology Process stability times three 6
FT 2000/4000The workshop machine 8
The new F series Machine concept 4
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HELLER – for good reasons
Your investment in a new machining centre has to pay off. To
make your production future-proof, you need reliability, precision
and high productivity. We are here to help you.
Our answer: the new F series.
5-axis machining centres designed to offer more than their
competitors.
A plus in sturdy engineering:
HELLER is synonymous with milling and with high-quality
machining since 1894. The F series embodies our complete
know-how gained from the development of the 5-axis MCH-C
series and its predecessors. The F series is a safe investment:
it offers productivity and precision from the very first minute.
A plus in process experience:
Our extensive process experience forms the basis for this 5-axis
machine series allowing you to respond swiftly and flexibly to
changing machining tasks, whilst ensuring maximum output and
optimum quality.
A plus in productivity:
Highest productivity in continuous operation – that is what the F
series has been designed for: the FT type for ergonomic table
loading, the FP type with pallet changer for compatibility with all
HELLER automation systems, 5-sided and simultaneous 5-axis
machining, robust machine design, powerful spindles.
A plus in flexibility:
Cutting costs through complete machining – the F series provides
the response to this trend in the machine tool industry. Being able
to perform as many tasks as possible with the same machine
provides flexibility now and in the future.
A plus in availability:
The F series was specifically designed for robust processes. This
means: not chasing after peak values but providing adequate
speeds, proven components, truthful characteristics. What are the
benefits to you? A machining centre with staying power offering
unparalleled opportunities.
A plus in service:
The HELLER service concept is designed to accompany you from
process design, machine installation through to the purchase of
new equipment and to ensure constant productivity. What is so
special about it? We are wherever you are. All it takes is a phone
call.
Optimised life cycle costs:
The running costs of a machine over its complete lifecycle are easy
to calculate from the cost of investment and the cost of operation.
Keeping these costs at a minimum, without compromising on the
quality and reliability of the machine, is the quintessence of what
we do. This is exactly what we have achieved with the innovative
manufacturing concept offered by the F series. The savings are
directly passed on to you.
5-axis machining: milling from solid material. Aluminium housing component (machine industry).
5-axis competence
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Die neue Baureihe FThe new F series
The new F series: machine concept
Strong basis for high cutting capacity Bed manufactured from epoxy resin concrete: 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
Optimised resilience and thermo-symmetry
Quick chip evacuation for higher precision Z axis with concertina cover below the spindle prevents
contaminants from leaving the work area
Steep and extremely smooth chip chutes
Free chip fall from rotary table
Clean work area due to integrated flushing nozzles
Easy to clean due to good accessibility to work area
Customised coolant treatment Mesh-type filter system
Paperband filter system
Vacuum rotation filter system
Flexible installation Installation without anchoring
Quick installation, easy relocation
No separate foundation required
Low operating costs
Production precision down to the micron Absolute encoded, direct measuring systems
High-resolution rotary encoder
YRT bearing with integrated measuring system
Precise dynamics Proven axis kinematics of the tool: X, Y, C and A
Workpiece provides 2 axis: Z, B
Linear axes covered with tried and tested concertina covers
FT type: the workshop machine
FP type: the production machine
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Das MaschinenkonzeptMachine concept
Ease of operation you can feel Effective safety guarding
Optimum access to the work area for workpiece loading
Linear guided, smooth opening doors provide optimum access
for loading operations
Single-handed philosophy: short-stroke doors can be opened
with one hand
Lowered loading sill at knee height
Operating panel at the setting station with integrated flush/air
guns
Easy to connect to all common HELLER automation systems (FP)
Control Programming in the familiar system environment
SIEMENS Sinumerik 840D sl or HEIDENHAIN iTNC 530
Flexibility of choice according to individual requirements: with
automation for high-volume output or for manual loading in the
workshop
High processing power and easy operation
Complete integration into the CAD/CAM process chain
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The new F series
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Spindle technology
Innovative spindle technology:process stability times three
High performance cutting with Power
Cutting Universal PCU 63
C swivel range from +15° to –195°
High torque due to powerful 1PH8 motor
Robust housing in cast iron
HELLER zero-spindle system
Media supply directly through the spindle
Suitable for dry machining
State-of-the-art RMP wireless measuring
probe
Benefits:
Transmission provides extreme rigidity
and damping
1 : 1 gear train
HSK, SK and BT spindle taper
High cutting capacity
Perfectly suited for cast iron, steel and
titanium
Speed cutting with Speed Cutting
Universal SCU 63
Benefits:
Swivel motor spindle with energy and
media supply through the centre of the
swivel head
HSK, SK and BT spindle taper
High speed: 16,000 1/min
High chip removal rate
Swivel head geometry designed for opti-
mum stability
Speed cutting with Speed Cutting
Tilt SCT 63
A axis swivel range +30°, up to –120°
below centre axis
Robust housing in cast iron
Motor spindle mounted in fork head with
bearings
Energy and media supplied through the
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
Suitable for dry machining
Benefits:
For machining up to a +30° angle below
centre axis
Clearly arranged cutting geometry
High speed: 16,000 1/min
High chip removal rate
The F series with swivel head The F series with fork head
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The workshop machine: FT 2000/4000 for table loading
Sample workpiece Formula One racing car (aluminium) Integral component (aluminium)
Entry into HELLER 5-axis machining
Classic workshop machine for manual loading
Flexible, powerful, highly precise
Outstanding accessibility: F series for table loading (FT)
For a wide range of parts and materials produced in low
volumes
For frequently changing tasks and prototype construction
Combination of highest cutting capacity and optimum surface
finish on the market
Tool provides 5th axis via HELLER swivel or fork head
Storage capacity for up to 240 tools in chain-type magazine or
409 tools in rack-type magazine
Unparalleled ease of access to work area through three-part
work area door
Table with large clamping surface, optionally with hardened
surface
Glass mould with cooling holes (cast iron)
FT 2000/4000
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Technical data FT 2000 FT 4000
Work area X = 630 mm X = 800 mm
Y = 630 mm Y = 800 mm
Z = 830 mm Z = 1,000 mm
Table size Ø 720 mm
Workpiece Ø x height max. 1,000 mm x 1,300 mm 1,200 mm x 1,500 mm
Max. workpiece weight 800 kg 1,400 kg
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 350 mm 160 mm x 450 mm
Tool Ø x length (rack) 188 mm x 350 mm 188 mm x 450 mm
Spindle tapers SK 40 / HSK 63 / BT 40
Spindles** PCU 63: 10,000 1/min, 44 kW, 242 Nm
SCU/SCT 63: 16,000 1/min, 40 kW, 80 Nm
* Limitations see technical data** S6 – 40% duty cycle
The workshop machine
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FT 2000/4000
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Workpiece management
Safety and ease of operation have a crucial impact on
the availability of a machine. Faster and more efficient
operation minimises operating errors and risk of failure.
With the F series you can profit from our application
experience day in and day out.
Well-designed workpiece management allows you to machine
workpieces with a wide range of geometries and weights whilst
ensuring high process stability and perfect machining precision.
The loading concept of the F series is based on the experience
gained from the H series. The result is impressive: more space, less
chip accumulating surfaces, higher precision able to take
work piece weights up to 1,400 kg.
FT for manual table loading
Optimum access to the work area
Quick and easy handling of workpieces
Exceptionally well suited for workshop operation
Ideally suited, e.g. for tool and die manufacturers with
frequently changing tasks and small batch sizes
Robust rotary table for high workpiece weights
Maximum speed: 30 min-1 (F 2000/4000)
Workpiece support plate in optional design (slots, threads)
Hydraulic workpiece clamping (optional: 5-point services
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
FT: enhanced space, user-friendly ergonomics and precision
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FP 2000/4000
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The production machine:FP 2000/4000 with pallet changer
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Highest productivity: F series with pallet changer (FP)
For machining of large workloads
Prepared for unmanned operation using pallet and
workpiece automation
Flexible for short-term job changes
Perfect for production-oriented users with high output
High cutting capacity for a wide range of tasks from
5-sided machining through to machining of complex
free-form geometries
Simple and cost-effective pallet automation solutions
Fully compatible with HELLER H series
State-of-the-art 5-axis production machine
with pallet changer
Designed for highest availability and productivity
Hydraulic housing (cast iron, plastic) Aerospace valve housing (titanium) Housing component from mould and die making (aluminium)
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The production machine
Technical data FP 2000 FP 4000
Work area X = 630 mm X = 800 mm
Y = 630 mm Y = 800 mm
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
Max. workpiece weight 800 (600)* kg 1,400 (1,000)* kg
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 350 mm 160 mm x 450 mm
Tool Ø x length (rack) 188 mm x 350 mm 188 mm x 450 mm
Spindle tapers SK 40 / HSK 63 / BT 40
Spindles** PCU 63: 10,000 1/min, 44 kW, 242 Nm
SCU/SCT 63: 16,000 1/min, 40 kW, 80 Nm
* Limitations see technical data** S6 – 40% duty cycle
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FP 2000/4000
PP Pallet pool PMB Basic pallet magazine
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FP with pallet changer
Compatible with horizontal machining centres from HELLER H
series and combines with pallet pools with 6 pallets per
machine, pallet handling via turntable
Integration into various pallet magazine systems:
PMB: basic design with 10 to 24 pallets per machine, handling
via stacker crane
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
HELLER machining centres are synonymous with productivity.
They provide precise and reliable operation over many
years even under constant load. We expect the same from
our automation solutions: maximisation of productive time
and throughput, increase of production and flexibility in
terms of modifications. From swift and easy manual loading
to the setting station through to a fully integrated flexible
manufacturing system – the F series is ready for any solution.
FP: efficient, universal, highly-productive
Automation
WRS Robot with trolley system
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The new F series
Control:the choice is yours
The new F series is equally suited for machining of individual
parts in tool and die manufacturing and the requirements
of high-volume production using 5-axis machining.
SIEMENS Sinumerik 840D slfor high output with automation
Highly precise control of speed and acceleration
Highly adaptable for precision and surface finishes
Exceptionally well suited for machining of sculptured surfaces
Graphical cycle support
Remote diagnostics via ePS
HEIDENHAIN iTNC530for manual operation in the workshop
Highly precise control of speed and acceleration
Highly adaptable for precision and surface finishes
Short block processing time of 0.5 ms
Free contour programming
DCM – dynamic collision monitoring
User-friendly setup functions
Simply choose the type of control that suits your
requirements best: SIEMENS or HEIDENHAIN.
Workpiece and pallet management
Clearly arranged graphical and tabular visualisation of pallets
and programs
Easy allocation of NC programs
Preparation of pallet data for pending jobs
Clearly arranged display of machining status
Tool management
Extensive tool tables
Cutting data tables for automatic calculation of spindle speed
and feed from workpiece-specific data
Replacement tool strategy
Monitoring of tool life and usage
Tool loading during spindle operation and in automatic mode
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Control
CAD/CAM integration:from idea to finished product
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.
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The new F series
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Tool management
What do you require in terms of tool management from a
5-axis machining centre made by HELLER? You might wish
to utilise your existing stock of tools, use a wide range of
tools and large tool geometries; you require a flexible
solution that will meet your production requirements in
the most efficient way. At the same time, tool loading times
and downtimes as well as idle times should be minimised.
No problem: the new F series can provide all of this.
Tool changer
Motor arranged outside of coolant and chip area
Optimised accessibility for belt tensioning.
Torsionally stiff housing due to enclosed design
(only assembly openings)
Easy exchange of motors on the ZT1 axis due to use
of elastomer coupling
Chain-type tool magazine
Chain-type tool magazine with 54, 80, 160 or 240
storage places
Max. tool diameter: 160 mm
Max. tool lengths: 350 mm on F 2000, 450 mm on F 4000
Max. chain speed: 32 m/min
Tool axis moves along the chain path
Optimised tool provisioning time
Magazine only fixed to console
Tool loading parallel to machining
Rack-type tool magazine
409 magazine places
Max. tool diameter: 188 mm
Max. tool lengths: 350 mm on F 2000, 450 mm on F 4000
Reduced space requirements due to double-sided arrangement
Magazine access
Loader axes with NC technology
Leakproof floor pan, no leakage of coolant or lubricant
Manually operated rotary station, optional: automatic rotary
station
HSK, SK and BT spindle tapers
Proven basic structure: tools aligned in Z direction, storage and
r etrieval unit moves in X, Y and Z direction
Short tool selection path
Compact, space-saving layout
Tool management:fast, precise, flexible
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HELLER Services: there for you throughout every phase
The new F series
The purchase of a machining centre is much more than an investment into a new generation of machines: it starts with
project planning and goes beyond efficient spare parts service. The HELLER service concept accompanies and supports
you throughout the complete lifecycle of your machine. Our focus is clear: constant availability of your machines. We are
committed to achieve this.
Practical training for practical application
Training for operators, programmers and maintenance staff
On-site training
Troubleshooting workshops
Training
Customer and project-specific training courses
Comprehensive training for turnkey projects
E-mail support for programmers
Higher performance for your machine
Conversions
Retrofits
Modernisations
Engineering
Machine and system-specific diagnostics modules
Machine upgrades and additional peripheral equipment
Optimum machining and processes
Technology and process consulting
Production support and training
Equipment selection and specification
Part changeover
Tool optimisation
Process optimisation
NC program development and optimisation
Customer-specific detailed developments
Close to you wherever you are
Commissioning
Fault rectification
On-site repairs
HELLER ServiceLine
Preventative teleservice
Maintenance
Full service
Decommissioning and re-installations
Here for you around the clock
HELLER original spare parts
HELLER original wear parts
HELLER original parts packages
HELLER service kits
Availability of HELLER original parts for your machines
Attractive financing
for new and used machines
Attractive financing for new and used machines
New machinery financing
Used machinery financing
Project financing
Machinery insurance
Proven services at cost-effective prices
Repairs
Sub-assembly overhauls
Factory overhauls and retrofits
Buy-back of your used HELLER machine
Sale of used HELLER machines, fully or partially
factory-overhauled
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Service concept
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HELLER worldwide
HELLER locations:We are here for you. Worldwide.
GERMANY
Gebr. Heller Maschinenfabrik GmbH
Gebrüder-Heller-Straße 15
72622 Nürtingen
Telephone +49 7022 77-0
Telefax +49 7022 77-5000
HELLER Services GmbH
Nürtingen
Gebrüder-Heller-Straße 15
72622 Nürtingen
Telephone +49 7022 77-0
Telefax +49 7022 77-1200
HELLER Services GmbH
Chemnitz
Sandstraße 116
09114 Chemnitz
Telephone +49 371 844949-0
Telefax +49 371 8449-2720
HELLER Services GmbH
Goslar
Vor dem Nordhees 12
38644 Goslar-Jerstedt
Telephone +49 5321 6834-0
Telefax +49 5321 6834-2199
HELLER Services GmbH
Hattingen
Hüttenstraße 45
45527 Hattingen
Telephone +49 2324 9245-0
Telefax +49 2324 9245-2399
HELLER Services GmbH
Saarbrücken
Neumühlerweg 75
66130 Saarbrücken-Güdingen
Telephone +49 681 88372-0
Telefax +49 681 88372-2044
HELLER Services GmbH
Kirchheim
Paracelsusstraße 3
73230 Kirchheim
Telephone +49 7021 80758-0
Telefax +49 7021 80758-2699
HELLER Services GmbH
Salem
In Oberwiesen 10
88682 Salem-Neufrach
Telephone +49 7553 91677-0
Telefax +49 7553 91677-2266
HELLER Services GmbH
Nürnberg
Vogelweiherstraße 33
Gebäude M4 – 2. Obergeschoss
90441 Nürnberg
Telephone +49 911 400896-0
Telefax +49 911 400896-2819
BRAZIL
HELLER Máquinas Operatrizes
Indústria e Comércio Ltda.
Rua Joaquim Machado, 250
Bairro Aparecidinha
Caixa Postal 126
18087-280 Sorocaba - São Paulo
Telephone +55 15 2103-3000
Telefax +55 15 2103-3032
CHINA
HELLER Machinery & Trading (Shanghai) Co., Ltd.
Section A1, Floor 3rd, No. 475, Fute (W.1) Road,
Shanghai Wai Gao Qiao Free-Trade Zone
200131 Shanghai
Telephone +86 21 58666188
Telefax +86 21 58682815
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HELLER worldwide
HELLER Machinery & Trading
(Shanghai) Co., Ltd.
Beijing Branch
Chaowai SOHO, Building D, Room 1203
6B Chaowai Street
Chaoyang District
100020 Beijing
Telephone +86 10 59003652
Telefax +86 10 59003752
FRANCE
HELLER Machines Outils SAS
Parc d‘Activités des trois Noyers
15, Avenue James de Rothschild
Ferrières-en-Brie
77614 Marne-La-Vallée Cedex 3
Telephone +33 1 60 94 20 70
Telefax +33 1 60 94 20 72
GREAT BRITAIN
HELLER Machine Tools Ltd.
Acanthus Road
Ravensbank Business Park
Redditch, Worcs. B98 9EX
Telephone +44 121 275-3300
Telefax +44 121 275-3380
ITALY
HELLER Italia Macchine Utensili S.r.l.
Via Galileo Galilei 6
37029 San Pietro in Cariano
Verona
Telephone +39 045 6838510
Telefax +39 045 6838530
MEXICO
HELLER Machine Tools de Mexico
S. de R.L. de C.V.
Cortazar No. 102 – Col. Hidalgo
C.P. 37329 Leon, Gto.
Telephone +1 248 288-5000
Telefax +1 248 288-9560
SLOVAKIA
HELLER Services s.r.o.
Hlavná 1409 / 48
95201 Vráble
Telephone +421 37776-8300
Telefax +421 37776-8309
SPAIN
HELLER Iberica Machine Tools, S.L.
Antic Cami de Caldes, 1 b
08480 L’Ametlla del Vallès
Barcelona
Telephone +34 93 8430209
Telefax +34 93 8430333
USA
HELLER Machine Tools L.P.
1225 Equity Drive
Troy, Michigan 48084
Telephone +1 248 288-5000
Telefax +1 248 288-9560
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Machines
Machines Services
Inside Competence.Our extensive know-how allows us to offer innovative and comprehensive
production solutions for powertrain, drivetrain and chassis components. Highly productive. For minimal piece-part costs.
Made to work.Application know-how and technological competence to cater for all production
requirements. With a new generation of machining centres offering a wide range of options in our proven quality.
Just closer to you.Individual services and custom-made service packages ensure optimum
productivity and highest availability of your machines. Anywhere in the world, on site and around the clock.
HELLER Machines. Made to work.www.heller-machinetools.com
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