Broderik Engineering UK Limitedbroderikeng.co.uk/CNC VTL with C axis.pdfBroderik Engineering UK...

Broderik Engineering UK Limited Unit B,

Buxton Rd

Leek,

Staffordshire

ST13 6EJ

VAT Reg No:187 5356 66 Company No: 9025444

1

CNC Single Columns Vertical Turret Lathe with C axis and ATC

We never produce the cheapest machine, but the high class & reliable machine

Price of standard machine

CK5116M,

Siemens 828D

ATC: 6 turning tools & 24 stations milling tools

Full guard and cooling system

Heidenhain linear scale for X/Z axis

Option:

1, Fanuc 0i TD

Technical Configuration

1, Features

The machine is designed and built to meet modern machining requirements with high speed

cutting tools and carbide cutters on workpieces of ferrous, non-ferrous and other materials.


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


2

Functions: 1. I.D.& O.D. cylindrical turning 2. End-facing 3. I.D.& O.D. cone

turning 4. Grooving

(Note: The right bottom two functions are available with its CNC counterpart models only.)

Basing on its super rigid structure, big machining capacities, heavy table load capacity,

stable structure and high machining efficiency, the machine has a wide application in,

○ power generation ○ heavy electrics

○ hydro / steam turbine generators ○ pump / valve industries

○ foundry, casting, metallurgy ○ ship building, heavy engineering, etc

1.1 This series machine is suitable for finely and roughly turning cylinder and inner hole, inner

and outer taper, surfacing, curving of the ferrous, grooving, drilling, threading and grinding,

nonferrous metal and some kinds of non-metal materials with carbide and porcelain tools.

1.2 When the head is in high-speed movement, head in horizontal direction, and vertical

rapid movement speed can be 10m/min.

1.3 The main drive adopts AC spindle servomotor with two steps. The high-speed rotating

workpiece are balanced in static or dynamic pattern. Transmission gears with 5 grade

precision are specially grounded to implement high efficient transmission, lower noise and

smooth running in high speed turning.

1.4 .Feed system is driven by AC servomotor which is connected with ballscrew by flexible

couple to implement clearance-free transmission and high precision turning.

1.5 The columns, whose thermal symmetric construction, is calculated by finite element

method, stand on table base. Effective vibration-insulated method is adopted to ensure

high rigidity and strong anti-vibration ability.

1.6 The table is thermal-symmetric construction. The spindle is centered by high-precision

double-row short cylindrical roller bearing whose radial clearance can be adjusted. With

large high-precision thrust ball bearing on axial direction as rolling guideway, and oil


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


3

temperature cooling device, the table has high swivelling precision, larger load ability and

smaller deformation.

1.7 .Linear dual-direction roller guideway is applied to ensure high effective transmission

and good precision reliability in heads and ram feed movement.

1.8 Chip conveyer and half-closed guide are also equipped by costumers' requirement.

1.9 On customers' requirement, the followings can be supplied tool magazine, tool setting

device, boring & milling, table indexing and feed, grounding cooling device and whole-

loop control, etc.

2, Specification

ITEM Unit CK5116M

Worktable

Worktable diameter. mm 1400

Max. swing diameter mm 1600

Max. cutting diameter mm 1600

Max. workpiece height mm 1400

Max. worktable load kg 8000

Max. output torque of worktable N.m 16000

Worktable speed

turning rpm 1-315

Indexing & milling rpm 0.0032-3.2

Travel

Travel of X axis mm -20-1200

Travel of Z axis mm 1000

Vertical travel of crossbeam mm 800

Rapid travel speed of X axis mm/min 10000

Rapid travel speed of Z axis mm/min 6000

Feed speed of X/Z axis mm/rev 0.01-50


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


4

Tool magazine

Tool capacity set 24 (milling tool) or 6

(turning tool)

Tool shank BT50

Max. tool weight kg 20

Total tool weight of tool magazine kg 360

ATC tool changing time sec 30

Milling head

Milling head speed rpm 1-2000

Live spindle motor KW 28

Max. output torque N.m 800

Machine overall

Coolant tank L 700

Machine size (LXWXH) m 6.7x3.3x5.6

3, Machine Body

The big casting of this machine is made by resin casting which has been treated by

oscillation long aging times in order to avoid the inner stress. The smaller casting has

been treated by high temperatures. All the steel parts are thermal refining. Guideway of

cross rail made by roll and slide complex way, and treated by spreadable quench. The

ram of vertical toolpost has made by spherical

graphite cast iron. The slide parts on guideway

are turcite style which could insure the precision

and maintain cycle much longer. Also the

automatic centralized lubrication is used on the

cross rail and slide parts.


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


5

4. CNC system

Fanuc 0i TD/Siemens 828D/840D, total 4 axis are controlled by CNC, 3 axis could be

interlocked at the same time, the function of Siemens 840D:

1. Controlled axes (6 Axes)

2. Simultaneous controllable axes (4 Axes)

3. 0.001mm Least input incre

4. Machine Lock

5. Emergency stop

6. Backlash compensation

7. Stored pitch error compensation

8. Automatic operation (memory)

9. DNC operation

10. MDI operation

11. Program number search

12. Sequence number search

13. Dry run

14. Single block

15. JOG feed

16. Manual reference position return

17. Manual handle feed

18. Incremental feed x1,x10,x100

19. Position G00

20. Linear interpolation G01

21. Circular interpolation G02、G03

22. Dwell

23. Skip function G31

24. Reference position return G28

25. Reference position return check G27

26. 2nd reference position return

27. Rapid traverse rate G00


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


6

28. Rapid traverse override Fo,25,50,100%

29. Automatic

acceleration/deceleration

30. Feedrate override

31. Override cancel

32. Optional block skip

33. Program number O4-digit

34. Sequence number N5-digit Siemens Drive

35. G90 Absolute/G91 incremental programming

36. Decimal point input

37. Plane selection G17,G18,G19

38. Manual absolute on/off

39. Sub program call: 4 folds nested

40. Canned cycles for drilling

41. Circular interpolation by R programming

42. Miscellaneous function lock

43. Spindle speed override

44. Spindle orientation

45. T code

46. Tool offset memory

47. Tool length compensation

48. Registered programs

49. Part program editing

50. Program protect signal

51. Status display

52. Current position display

53. Program display

54. Parameter setting and display

55. Self-diagnosis function

56. Alarm display

57. Alarm history display


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


7

58. Operation history display

59. Run hour and parts count display

60. Actual cutting feedrate display

61. Servo setting screen

62. Chinese display

63. Data protection key 3 types

64. Setting and display unit 10.4”colorful

65. RS232-C interface

66. Interlock

67. Custom macro B

68. Miscellaneous function

69. Input power supply 220Vac 50Hz

70. Program restart

71. Manual handle interruption

72. Programmable data input

73. Scaling

74. Tool offset

By manual and program input, following functions could be executed:

1, Turning and milling inner/external cylinder, end surface, steps, grooving and end surface

constant speed cutting.

2, Turning and milling inner/external circular cone or surface of revolution by line or circular

arc interpolation.

3, Turning and milling straight thread, taper thread and plane thread by feed per revolution.

4, Pitch compensation of ball screw in two moving direction of tool post, could be stored and

error compensated automatically.

5, Pitch compensation of ball screw in vertical moving direction of ram, could be stored and

error compensated automatically.

6, Tool nose radius compensation

7, Program graphic function for program testing and adjusting.

8, Failure self-diagnosis function.


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


8

9, Reference offset for work piece position compensation. Work piece coordinate setting.

Absolute and increasing dimension switching.

10, Using milling head, thread tapping or boring by feed per revolution or minute.

11, Using turning function, thread cutting by feed per revolution or minute.

5, Worktable base

Worktable base is under worktable, it’s the

base of the machine, on the surface of

base has annular hydro-static guideway,

they are near the center hole of worktable.

There are two drive systems inside the

worktable base: One gear ring is for

turning, one gear ring is for indexing. Between the two gear rings have one clutch, to make

the indexing system empty when the turning system is working, and the same to make the

turning system empty when the indexing system is working.

The servo indexing system is aside of the worktable base. The servo system is used by AC

servo motor and Europe gear box with anti-backlash. The HEIDENHAIN encoder is in the

center of worktable could test the position of worktable for indexing.

At the same time, with the help of HEIDENHAIN circle grating ruler under the worktable to

make the C axis indexing in closed-loop control. To work with HEIDENHAIN circle grating

ruler, worktable could be high accuracy indexing by CNC controlled in 360º without

limitation.

6. C axis structure under worktable

Double Fanuc servo motors connect with two speed gear box which supply worktable big

torque and fast response characteristic. During C axis indexing, one servo motor working in

main driving and another working in slave driving condition, to eliminate backlash when

rotary direction changing. The two Fanuc servo motors get the feedback from Heidenhain

encoder to make the positioning for the worktable.


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


9

7. Toolpost （Z axis, live spindle, ram）

The ram is square type in front of ram, the material of

ram Forging steel, it has manual square turret. The

turrets could be uses for turning cutting. The X axis

and Z axis of this ram both has Fagor liner grating

scale(option), which could make the machine closed

loop and guarantee the high accuracy of machine.

There is one Taiwan live spindle mounted inside ram

for drilling or milling (If ram travel over 2500mm will

use electro-spindle). This spindle is driven by Fanuc

motor 18.5/36KW servo motor to realize enough torque machining. Big output power of

milling head could meet most of requirement of heavy cutting and hard material. Various

special tools and head is more easy for multiple machining.

Additionally, customer could choose Taiwan-Gongyang manual right angle milling head or

Italy/German manual right angle milling head are as option. The ram’s four sides have the


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


10

turcite guideway around. The

guideway is made of alloy(Zinc,

Copper, aluminum) which

import from Germany, with

strong lubrication and wearless.

Inside the ram has the live

spindle which imported from Taiwan, all the bearings inside live spindle is NSK.

8. Hydraulic system

The main function of hydraulic system is, ram hydraulic balance, live spindle clamping or

releasing tools, hydraulic lock of worktable indexing lock. This hydraulic system have

automatic circle cooling and also have alarm for oil level, temperature, oil pipe choke, and

the Min. Working pressure. Also inside the

hydraulic oil tank has the temperature control

system and filter, to keep the machine

working more stable in any condition. All the

hydraulic parts like valves, pumps are from

Compass-Taiwan & USA.


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


11

9. Lubrication system

The lubrication for all the guideways and ballscrew on this machine is automatic way, set at

time and rationed feeding. The centralized lubrication is controlled by the CNC system. The

machine also has the waste oil collector, to avoid the lubrication oil mixed with hydraulic oil

and protect the environment.

10. Cooling system

The spindle and gearbox has constant temperature cooling system, to avoid the thermal

deformation and assure the accuracy and life of the machine.

The electric cabinet has air condition with temperature control for cooling the electric units

especially in hot weather.

Also depend on the working condition in customer’s side, if the weather is too hot, it’s

necessary to choose the oil fridge for hydraulic oil tank.(option)

11, Components we used on our

machine

No. Item Quantity

1 CNC Control system two years global guarantee Siemens 828D

2 Axis drive motor ( X/Z axes ) Siemens servo motor

3 Linear scale-closed loop Heidenhain-Germany

3 Electrical parts of cabinet ABB-France

4 Live spindle Taiwan-Taida

5 Bearing inside the live spindle NSK-Japan


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


12

6 Bearings on ballscrew NSK-Japan/INA-German

7 Ballscrew-cross rail & ram THK-Japan

8 Automatic lubrication system ISHAN-TAIWAN

9 Control panel station MECANO- Germany

10 Air condition for electric cabinet(Option) Leibo

11 Hydraulic parts Compass-Taiwan

12, Warranty and after sale service

1, Warranty period: one year after final installation, during the warranty period, all the daily

damage parts will be provided freely by the manufactory.

2, Out of warranty period, the factory will still supply the support for the whole life of the

machine, including technical advice, spare parts, labor, after sales service, and so on.

And the factory will just take the necessary cost.


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


13

13, C axis Machine in our workshop


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


14


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


15

14. Fullton VTL with C axis in customers’ side


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


16


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


17

15. Solution with guard


Buxton Rd

Leek,

Staffordshire

ST13 6EJ


18

19

16. Accuracy testing report

No. Testing item Testing Drawings Allowed Tolerance（mm） Actual Inspection(mm)

G1 Worktable planeness

Whole allowed tolerance ：0.034 （ concave ） Part

allowed tolerance： 0.01/300

G2 Worktable runout on

flat

0.014

20


G3 Worktable runout on radial

0.014

G4

Cross rail vertical traverese match the worktable rotary axes parallel: A is inside the flat which parallel cross rail

0.025/1000

21


G4

Cross rail vertical traverse match the worktable rotary axes parallel: B is inside the flat which be vertical cross rail

0.04/1000

G5 Vertical tool post moving match the parallel of worktable

0.02/1000

22

No. Testing item Testing Drawings Allowed Tolerance（mm） Actual

Inspection(mm)

G6

Vertical tool post moving to the parallel of worktable rotary axes A is inside the flat which parallel cross rail

0.02/1000

G6

Vertical tool post moving to the parallel of worktable rotary axes B is inside the flat which be vertical cross rail

0.04/1000

Broderik Engineering UK Limitedbroderikeng.co.uk/CNC VTL with C axis.pdfBroderik Engineering UK...

Documents

Transcript of Broderik Engineering UK Limitedbroderikeng.co.uk/CNC VTL with C axis.pdfBroderik Engineering UK...