Palletisation - in mould tool manufacturing

Palletisation...

in mould tool manufacturing

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Fitting the machines with the same reference system means that electrodes and workpieces can be moved between the machines without subsequent alignment and checking – One Minute Set-up.

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!

Experience always shows that measures to reduce the idle times of your machines are significantly more worthwhile than chasing seconds in the actual machining process.

The solution is a stable and exact reference system. This lets you preset away from the machine and then set up the machine with minimum idle time. Quickly and precisely!

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Conventional setting-up Pallet system

Hourly invoicing (€) 50 50

Spindle time / week (hours) x30 x37.5

Revenue / week (€) =1 500 =1 875

Capital cost of machine (€) 150 000 150 000

Capital cost pallet system (€) 0 +10 000

Total capital outlay (€) =150 000 =160 000

Paybacktime (weeks) 100 85

Job

1

Machining time

Idle time

Conventional setting-up

One manned shift – eight hours

Job

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Job

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Job

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Job

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Pallet system

One manned shift – eight hoursJo

b 2

Job

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Job

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Job

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Faster payback, calculation example:

A reference system minimises setup timesEvery minute that can be converted from internal to external setting time increases the spindle time of the machine and with it the productivity of the business.

Big earnings are within your reach The machine generates revenue when its spindle is turning – and only then.

Work smarter, not harder.

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Conventional setting-up Pallet system

Working time per day 8 8

Setting-up time per day (hours) -4 -0.5

Spindle time per day =4 =7.5

Working days per week x5 x5

Spindle time per day = 20 =37.5

Higher productivity, calculation example:

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ZY

X

250 kg

100 kg50

kg1 kg

System 3Rs reference system

… gives extreme flexibility

… is user-friendly

… reduces setting-up times

... links all your machines together

… ensures precision and quality

… is suitable for automatic changing with System 3R’s automation program.

Suited to your operationsOur pallet systems can handle workpieces measuring a few centimetres and workpieces weighing several tonnes with equal ease. In addition, our systems are suitable for old and new machines of practically every type and make – die-sinking and EDM machine, grinders, presses, high-speed milling machines, lathes and measuring machines.

350350

350

250250150

150

15040

40

40

MacroJunior

Macro

Macro & MacroMagnum

Dynafix

Note:For every pallet system there is a “recommended” maximum workpiece size. However, this should only be regarded as a guide, since the size of the workpiece relative to the pallet depends above all on the material and the type of machining.

A reference system with unique propertiesModern production is based on the use of a single reference system throughout the production process. But developing a reference system that meets today’s requirements calls for ample knowhow and experience. System 3R offers many unique features, such as:• chucks with fixed references and holders with movable references• all references integrated into the same workpiece and plane• ability to handle high forces, moments, impacts, dirt, vibration, corrosive environments, without adverse effect on performance.

The resultSystem 3R lets you move tool and workpieces between machines while maintaining an accuracy of 1 µm, without time-consuming resetting.

250

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• Clamping force – 5000 N

• Fixed index positions 4x90°

• Required air pressure, pneumatic chuck – 6±1 bar

• Recommended tightening torque, manual chuck – 4 Nm

MacroCombiThe MacroCombi chucks accept two completely different types of electrode holder. Both Macro with its immovable stability and precision, and MacroJunior with its highly economical holders. The limitations are few, the possibilities many.

The smart chucks can be installed in both old and new machines without software changes, thanks to the air logic (patent applied for) of the chucks, with servo and differential valves.

For further information, ask for the separate brochure T-2292-E ”MacroJunior & MacroCombi – reference systems for mould tool manufacturing”

Pallet sizes – MacroJunior

• Ø25 and Ø30 mm

Pallet sizes – Macro

• 54x54, 70x70, Ø75 and Ø116

Drawbar – Macro

Spindle chuckMacroCombi

Drawbar – MacroJunior

Pallet/reference element/holder - Macro

Workpiece

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MacroAmong users world wide, the Macro system is a byword for precision. And with good reason, since very single Macro product is thoroughly checked before it is dispatched. But precision can be graded too. The Macro products are therefore “classified” in terms of accuracy, material and life – but always with full compatibility – as Standard, High Performance and Nano. Even so, it’s worth remembering that the accuracy of a system is determined by the product with the lowest classification.

• Repetition accuracy: MacroNano – within 0.001 mm MacroHighPerformance – within 0.0015 mm MacroStandard – within 0.002 mm

• Locking force – 6000 N



• Recommended tightening torque, manual chuck – 4 Nm

• Recommended max workpiece weight – 50 kg.

For further information, ask for the separate brochure T-2286-E ”Macro – reference systems for mould tool manufacturing”


• 54x54, 70x70, Ø75 and Ø116 mm

Drawbar

Macro pallet/holder

Workpiece/ electrode

Table chuck

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MacroMagnumMacroMagnum is larger variant of the patented Macro system. The high clamping force and the position of the reference surfaces far away from the chuck centre mean that MacroMagnum can provide “Macro class” stability and accuracy, even in applications with high machining forces.

The double references of the chucks mean that in addition to the MacroMagnum pallets, the extensive range of Macro pallets can also be fixed to MacroMagnum.

• Repetition accuracy – within 0.002 mm

• Locking force – 16 000 N



• Recommended tightening torque manual chuck – Macro-pallet 5 Nm

• Recommended tightening torque manual chuck – MacroMagnum-pallet 12 Nm

MacroMagnum pallet/ reference element

Table chuck

Workpiece/electrode

Drawbar

For further information, ask for the separate brochure T-2289-E ”MacroMagnum – reference systems for mould tool manufacturing”


• 54x54, 70x70, Ø75 and Ø116 mm

Pallet sizes – MacroMagnum

• Ø142 mm, Ø156 mm and 240x240 mm

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DynafixDynafix permits machining with optimal cutting data, without sacrificing accuracy and quality. The easy-to-handle aluminium pallets have reference elements of high-alloy steel with directly measurable Z-references.

Locking mechanism with built-in soft-landing function protects the references and simplifies handling in applications involving heavy workpieces. In addition, automatic air-blast cleaning of the Z-references and peripheral sealing make Dynafix a practical and user-friendly reference system which minimises setting-up times, increases machine capacity and provides a basis for automated production.

• Repetition accuracy – within 0.002 mm

• Locking force – 60 000 N



For further information, ask for the separate brochure T-2291-E ”Dynafix – reference systems for mould tool manufacturing”

Pallet sizes – Dynafix

• 280x280 and 400x400 mm

Dynafix palletholder


Table chuck

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MaxiAn especially robust, uncomplicated and user-friendly system for larger and heavier electrodes and workpieces. The chucks are of the fishtail type with three references for rapid mounting of the accessories with a single two-handed operation.

Chuck adapters – with Maxi as the basic mounting on the machine table – also give access to the Mini, MacroJunior and Macro systems.

• Repetition accuracy within 0.01 mm.

• Recommended maximum weight 500 kg.

Chuck

Holder/pallet

The Mini ”original”The ancestor of the reference systems! The introduction of the Mini system in the early 1970s created the basis for efficient electrode production and spark-erosion machining.

The Mini system is a “Reverse Reference System”, in which the chuck adapts itself to the electrode holder, which is why all electrode holders must be exactly alike – in diameter, roundness, straightness and hardness – to meet the accuracy requirements.

Even today, the Mini system is probably the most widespread reference system in the world.

• Clamping force – 4000 N

Workpiece/electrode

Mini holder/handle Ø20 mm

Chuck

For further information, ask for the separate brochure T-2295-E ”Mini – reference systems for mould tool manufacturing”

For further information, ask for the separate brochure T-2294-E ”Maxi – reference systems for mould tool manufacturing”

Pallet sizes – Maxi

• 150x150 and 150x90 mm

Sizes

Workpieces/electrodes of various sizes are mounted directly on Ø20 mm handles.


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Wire EDM machining with a Macrochuck

… is suitable for automatic changing

... links all your machines together

With a Macrochuckas basic equipment on the machine table, you can interconnect all your machines to create a single system. Move the workpiece from the wire EDM machine to the grinding machine or the die-sinking machine without subsequent alignment – quickly and precisely.

If you choose a pneumatic Macro chuck, you can operate round-the-clock production if you wish.

• Z-references with automatic air-blast cleaning• X and Y references of cemented carbide• Repetition accuracy 0.002 mm• Turbo locking – enhanced clamping force

Pre-set in three axeswith System 3Rs levelling adapter. This can be done with an accuracy of thousandths of a millimetre!

The simple, directly measurable references of the levelling adapter mean that presetting can be done on an ordinary surface plate, using one of System 3R’s presetting stones.

Preset away from the machine. Lift the preset “package” into place – levelling adapter, holder and workpiece – fix with a few simple manual operations and start the machine. Simple, quick and precise.

For further information, ask for the separate catalogue T-2159-E "Reference system for wire EDM machining"

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Make your dreams come true … boost productivityOnce you have started to use our reference system it is easy to add automatic handling of tools and workpieces. This allows you to utilise your machines round the clock with minimal manual supervision.One or more production cells can be equipped with computerised inspection, giving each tool and workpiece a unique identity. All information about the production process, NC programs etc., is stored in a central database. This makes it very easy to plan and control production.The next step is to upgrade the computer system to a complete production planning system with pricing, materials, delivery dates, ISO documentation and much more. Simple and user-friendly.

All in the same system, from the same supplier – System 3R!

For further information, ask for the separate brochures Automation, WorkPal Compact servo, WorkPartner, WorkMaster, Workmaster linear, Automation with 6-axis robot, WSM etc

Examples of applications: WorkMaster Linear, automation cell Full Rack magazine

Drain & Rinse Station

Washing Station

Multiple Load Station

Half Rack Magazine

WorkMaster Linear

Rail

Work Preparation Station

Rotary Magazine

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ASIA

Far East, China & IndiaSystem 3R Far East Pte.Ltd.6 Harper RoadLeong Huat Building, 01-01SINGAPORE SG-369 674tel +65-6289 4811fax +65-6289 3011e-mail: [email protected]

Shanghai Contact Office tel +86-21 6432 7927fax +86-21 6432 7928e-mail: [email protected]

Beijing Contact Officetel +86-10 8225 1632fax +86-10 8225 1635

Guangdong Contact Officetel +86-769 8162 0628fax +86-769 8162 0638

Malaysia Contact Officetel +60-03 7877 4785fax +60-03 7877 5948

Taiwan Regional Officetel +886-02 2278 3126fax +886-02 2278 3108

Japan & KoreaSystem 3R Japan CO., Ltd.Kaki Building2-5-22, Suido, Bunkyo-kuTOKYO JP-112-0005tel +81-03 5840-7383fax +81-03 5840-8723e-mail: [email protected]

Nagoya Regional Officetel +81-052 774 6250fax +81-052 774 6285

System 3R International ABSorterargatan 1, SE-162 50 VÄLLINGBYtel +46-08 620 20 00, fax +46-08 759 52 34, e-mail: [email protected], www.system3r.com

Combi, Delphin, Dynafix, Locx, LX, Macro, One Minute Set-Up, One System Partner, R2R, System 3R, VDP, WorkMaster, WorkPal, WorkPartner, WorkShopManager, 3HP, 3R, 3Ready-To-Run and 3Refix are registered trademarks of System 3R.

EUROPE

System 3R Europe GmbHWasserweg 19DE-64521, GROSS-GERAUtel +49 61 52 80 02 0fax +49 61 52 80 02 35e-mail: [email protected]

Chech Republic & SlovakiaSystem 3R CzechTiskarska 10/257CZ-108 28 PRAHA 10tel +420 234 054 224fax +420 234 054 225e-mail: [email protected]

France & PortugalSystem 3R France56 Boulevard de CourcerinLes Espaces Multiservices 15F-77183 CROISSY BEAUBURGtel +33-01 60 95 90 80fax +33-01 60 37 88 16e-mail: [email protected]

Germany & BeNeLuxSystem 3R DeutschlandWasserweg 19DE-64521, GROSS-GERAUtel +49 61 52 80 02 0fax +49 61 52 80 02 35e-mail: [email protected]

Italy & SpainSystem 3R ItaliaVia Ponchielli, 2/4IT-20063 CERNUSCO SUL NAVIGLIO (MI)tel +39 02 92 38 821fax +39 02 92 11 23 19e-mail: [email protected]

ScandinaviaSystem 3R NordicSorterargatan 1SE-162 50 VÄLLINGBYtel +46-08 620 20 00fax +46-08 759 52 34e-mail: [email protected]

Järfälla HärdverkstadElektronikhöjden 8SE-175 43 JÄRFÄLLAtel +46-08 580 125 50fax +46-08 580 126 55e-mail: [email protected]

Switzerland & AustriaSystem 3R Schweiz AGWilerstrasse 98CH-9230 FLAWILtel +41-071 394 13 50fax +41-071 394 13 60e-mail: [email protected]

TurkeySystem 3R TürkiyeAbdi Ipekci Cad. Ozel Idare Is Merk 150/209Bayrampasa 34030 ISTANBULtel +90-212 613 8062-8063fax +90-212 613 8069e-mail: [email protected]

United KingdomSystem 3R UKParadise WayWalsgrave Triangle Coventry, West MidlandsCV2 2ST, United Kingdomtel +44-02476 538653fax +44-02476 538695e-mail: [email protected]

AMERICAS

System 3R USA Inc.Headquarters & Technical Center915 Busse RoadELK GROVE VILLAGE, US-IL 60007tel +1 847 439 4888fax +1 847 439 5099e-mail: [email protected]

Canada & MImobile +1 519 870 8339fax +1 847 439 5099e-mail: [email protected]

AZ, CA, CO, ID, MT, NM, NV, OR, UT, WA, WY & Mexicomobile +1 714 299 4923fax +1 847 439 5099e-mail: [email protected]

IA, MN, ND, NE, SD & Western WImobile +1 612 963 6904fax +1 847 439 5099e-mail: [email protected]

AR, IN, KY, OH, TN, MO, KS, OK & Southern ILmoblie +1 317 694 7508fax +1 847 439 5099e-mail: [email protected]

AL, FL, GA, LA, MS, NC, SC & TXmobile +1 813 326 0125fax +1 847 439 5099e-mail: [email protected]

Nothern IL & Eastern WImobile +1 847 400 6073fax +1 847 439 5099e-mail: [email protected]

NJ, NY & PAmobile +1 201 248 3885fax +1 847 439 5099e-mail: [email protected]

CT, DC, DE, MA, MD, ME, NH, RI, VA, VT & WVmobile +1 201 214 7088fax +1 847 439 5099e-mail: [email protected]

For further information, see www.system3r.com

Palletisation - in mould tool manufacturing

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