Spirit Versatility

Versatility in ED die sinking

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4AGIETRON

impa SPIRIT ing 21.03ok 29.3.2006 10:33 Pagina 2

Agietron Spirit 2, 3 and 4 are ED die-sinking machines for fast set-up, simple operation and

reliable ED machining.

The Agie EDM know-how of decades is to be found in every Agietron Spirit. In the mechanism,

in the control, in the generator. Made in Switzerland.

Agietron Spirit machines can be employed universally. From simple to demanding machining

jobs. Agietron Spirit machines in sizes 2, 3 and 4 offer a large number of functions and appli-

ances for this, making these ED die-sinking machines unique in their class.

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Small drill holesWith the FD (Fine Drill) variant forAgietron Spirit 2, small drill holescan be made with small electrodetubes in addition to normal ED die-sinking applications.

High removal rateWith new generator technologieswhich, by means of the intelligentinteraction of various functions,achieve removal rates that are aboveaverage in all application sectors.

Great application spectrumWith four controllable and program-mable axes, a comprehensive choiceof technologies as well as high ther-mostability, the whole range ED diesinking applications, from simple re-pair jobs to complex multicavities,can be coped with using the AgietronSpirit 2, 3 and 4.

Simple data inputThe operator is guided through theprogram by self-explanatory sym-bols. Minimum data about the work-piece and electrode suffice for thecontrol unit to generate the optimalEDM technology.

Short set-up timesWith manual control, automaticmeasuring cycles as well as good ac-cessibility to the working area, EDMjobs can be started in the shortesttime. Clamp, measure, ED machine –Agietron Spirit machines do not re-quire any special prior knowledge ofED die sinking.

Lowest power consumptionWith just 3.8 kW per hour, all AgietronSpirit ED die-sinking machines con-sume approx. 75% below the averagepower consumption of competingmachines.

Highlightsfor versatile ED die sinking

AGIETRON

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Ra 0.2 µm Ra 0.2 µm Ra 0.2 µm

4 10 15-62

Ø 0.1 mm

2000 kg1000 kg

400 630185

750

1100

370

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200 kg

Y 250

X 300

Z 250

X 550

Y 400

Z 350

X 700

Y 500

Z 400

25 kg 80 kg80 kg

650 960

255Workplace

dimensions

Workplaceweight

Axes travel paths

Electrode weight

Smallest roughness

Electrode magazine

Fine Drill


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The generatorfor exceptional results

The Agietron Spirit 2, 3 and 4 EDdie-sinking machines are equippedwith the APG Spirit generator whichhas the lowest power consumptionof all comparable ED die-sinkingmachines. It sets new quality andperformance standards with patent-ed Hyperspark technologies. Duringall roughing and finishing machiningjobs using copper or graphite elec-trodes, electrode wear is reduced.Productivity is exceptional duringstandard applications and, even inthe case of deep and narrow cavitieswith poor flushing conditions, astriking improvement in the removalresult is achieved with the electrodewear remaining the same:

To top results fastWith the comprehensive technologydatabase, quality results can beachieved straight away in the case ofstandard applications, blades, as wellwith sharp-pointed electrodes, as theEDM technology is optimally matchedto the application and generatedspecifically for the job.

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Intensified removalWith isogeometric impulses, thegenerator increases the removal perimpulse with the same electrodewear, the same spark gap, the samesurface roughness and a constantcrater geometry. As a result, the re-moval rate rises strikingly, especiallyin the case of pre-machined work-pieces, reducing the white coating onthe ED machined workpiece.

Intelligent lift-off movementsWith dynamic acceleration of thegenerator's timer function, the lift-offmovements are adaptively controlled.ED machining becomes faster andthe surface quality is optimised.

Low wearWith a fine tuning of low currents andinternal voltages, the electrode wearis kept low even in the case of highremoval rates.

Controlled process With ACC (Adaptive Current Control)and ACO (Adaptive Current Optimisa-tion), new, perfected algorithms havebeen implemented which react fasterand carry out the EDM process reli-ably, even with a higher removal rate,thus increasing productivity.

Predictive planetary EDMWith PLS (Predictive Learning Sys-tem), the EDM conditions duringorbital movements are continuallystored and analysed. With every oscil-lation, the process of planetary EDMis then optimised step by step.Cavities are thus shaped exactly andquickly.


Manual centring of electrodes With Jog Erosion, electrodes can becentred into already existing tools.The EDM direction is to move alongthe main axis and the electrode iscentred manually with the other ax-es. A visual check of the EDMprocess then permits a perfect align-ment of the electrode to the work-piece. A brilliant further benefit forall Agietron Spirit models.

Agie MoldFix

Low power consumptionWith a maximum of 3.8 kW per hour,Agietron Sprit 2, 3 and 4 have thelowest power consumption. Com-pared with competing machines, thesavings amount to over 75%. An evermore important factor with rising en-ergy costs.

Performance-enhancing modulesWith the optimal 32 A power unit,higher EDM performances areachieved than with comparable com-peting machines. The finishing mod-ule strikingly shortens the time takenfor finishing. And with an optimisedSF module in the high frequencyrange, results are achieved when finefinishing lying far below the surfacequalities of finishing.

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The control system of Agietron Spirit2, 3 and 4 is based on Microsoft Win-dows and offers the same function-ality as on your PC at home. The operator is guided purposefullythrough all the data input steps nec-essary for the machining, includingthe measuring cycles page. The sys-tem automatically corrects the work-piece, machining and electrode posi-tion. Various machining strategiescan be selected by a mouse click:

Controlled ED machiningWith windows, that can be called upat any time, the program that hasbeen input, complete with all themovement sequences, can bechecked. Even during ED machiningthe current state of the process canbe viewed and optimised if required.

Clear structuresWith an interactive, graphics-aideddialogue, even complex movementsequences in a three-dimensionalarea become routine. The screenpages are clearly and distinctly struc-tured, and functions can be quicklyselected. There are various operatorlanguages available.

External planningWith Agie Spirit PC, the planning anddata input for an EDM job can becarried out on a PC. The operatingsurface is absolutely identical to theAgietron Spirit 2.

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The controlfor short planning and set-up times

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Automatic

Erosion

Programm

Job Creation

Automatic

Erosion

Programm

Automatic

Erosion

Programm

Erosion

Process

Diagnostic

Automatic measuring cyclesWith the touch probe, electrode andworkpiece positions are recorded bycorner touching, precise edge touch-ing with the X, Y and Z-axis, internalcentring and external centring.Agietron Spirit 2 then automaticallyadjusts the machining program bycorrecting the workpiece location andelectrode position in accordance withthe measurement data.

Rapid target definitionThe machining target is defined witha few intuitive inputs and with self-explanatory icons. By selecting andclicking, the positioning, measuringcycles, machining targets and strate-gies are specified and implemented.The system recognises missing inputs,and operating hints can be called upat any time.

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Measuring cycles

A Corner touching

B Precise edge touching

with X, Y and Z-axis

C Internal centring

D External centring

E Electrode alignement

F Angular position of workpiece

C

D

XY

B

FE

C

A

D

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Variant for increasing productivityThe Agietron Spirit size 4 can be exclu-sively retrofitted with an electrodechanger for 28 electrodes with a stan-dard clamping chuck or for 56 elec-trodes with a combination clampingchuck. In this way, the productivity andflexibility can be strikingly improved.

Thanks to their compact type of con-struction, Agietron Spirit 2, 3 and 4require little floor space. The bal-ance of these ED die-sinking ma-chines' thermal and mechanical sta-bility is shown by the exactly posi-tioned and precisely shaped cavitiesin the workpiece. An integrated C-axis as well as an electrode maga-zine make all the Agietron Spiritmodels into a profitable manufactur-ing centre:

Rapid commissioningThe Agietron Spirit 2, 3 and 4 readyfor operation with just a few connec-tions. The ED die-sinking machinesare delivered complete as a wholeand can be transported to their loca-tion by fork-lift truck.

Small space requirement With the dielectric unit integrated intothe machine and the control unit withintegrated operating console connect-ed at the side, the Agietron Spirit 2, 3and 4 impress with their compacttype of construction which is mani-fested by their small floor space re-quirement.

Controlled dielectricHigh thermal stability is achievedwith a heavy duty dielectric/waterheat exchanger. A double tempera-ture check and monitoring of the levelof the dielectric give process reliabili-ty at all times.

Functional working areaWith electrode handling for 4 posi-tions (size 2), for 10 (size 3) or15/28/56 (size 4) and a large workingarea, that can be completely utilisedwith several clamped workpieces,Agietron Sprit machines are excel-lently suited for multiple machiningjobs. Pressure or suction flushing canbe used for an efficient EDM process.

Remote-controlled operationAll the set-up functions can be car-ried out with a handbox. The axespowered by a high-resolution dcservomotor can be quickly positionedwith the handbox, and it is even possi-ble to control ED machining manually.

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The mechanism for exact forms

AGIETRON

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11Conform safety With electromagnetic screening bycomplete encasing as well as furthermeasures relevant for safety, theAgietron Spirit 2, 3 and 4 comply withall applicable safety regulations.

Good accessibilityWith their swivelling door and largeworking area, Agietron Spirit can beconveniently loaded from the front.The outstanding feature of all the rel-evant components for service andmaintenance, such as changing thepaper filter cartridges, is their opti-mum accessibility.


Great variety of formsWith the combineduse of the programma-ble X, Y, Z and C-axes, thewhole range of ED die-sink-ing machining operations iscovered. From the simplecavity to the highly complexform in a three-dimensional area:Helical moulds. Spherical moulds.Toothed racks. Flat and 3D-paths.Jaw moulds. Undercuts, also com-bined with C-axis. Interlinked EDMsteps. Drill holes, also combined withC-axes. Multiple moulds, alsoarranged in circular form. Two andthree-dimensional vector widening.Circular widening. Distortion-freecavities with Equimode.

Escapestrategy

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Additional benefit for drill holesWith the FD (Fine Drill) variantexclusive to Agietron Sprit 2,small drill holes can be insert-ed using small electrode tubeswith diameters ≥ 0.10 mm,such as are required, for ex-ample, as starting holes in EDwire cutting. The rotation andalso the high-pressure pumpare program-controlled.

EQUIMODE for distortion-free 3D-geometries

Varied machining strategies With Agietron Spirit, not only areforms simply reproduced in the mate-rial, but planetary strategies can beactivated in addition, such as equidis-tant shaping with Agie Equimode, cir-cular widening, 2D or 3D-vector witha free choice of the number of cor-ners or programmable interlinking ofEDM movements, as well as pathcontrol.

Automatic implementation of interlinked EDM steps


Made in Switzerland

With its ultramodernproduction plant, Agiemanufactures all the

mechanical and elec-tronic components relevant for

the precision itself. A sturdy type ofmachine construction, large-dimen-sioned spindles and guides of the ax-es, an efficient CNC control, as wellas a fully digitised generator withpatented hyperspark EDM technolo-gies turn all Agietron Spirit machinesinto an investment in ED die sinkingmachines with a guaranteed future.The manufacturer's know-how ofdecades goes into every AgietronSpirit. In the mechanism, in the con-trol system, in the generator.

Certified qualityAgietron Spirit pass through exactlyprescribed checking and testing sta-tions and must ED machine a rangeof practice-related inspection pieces.The time taken for the complete certi-fication of each individual AgietronSpirit is thus far greater than what weneed for the actual assembly.

Construction of size 2With a sturdy C-frame made of fine-grained grey cast iron, the AgietronSpirit 2 is designed for smaller tomedium-sized workpiece sizes. TheC-axis is integrated into the workinghead of the Z-axis. Workpieces arepositioned µm exactly in X and Y di-rection with the cross table, thanks tohigh-precision spindles and guides.All 4 axes can be controlled synchro-nously.

Construction of sizes 3 and 4With their portal type of construction,Agietron Spirit 3 and 4 are suitablefor machining medium to large-sizedworkpieces. The machine framemade of mineral casting ensures anoptimal thermal behaviour, mechani-cal stability and absorption of vibra-tions. The portal travels in Y-directionalong two pre-stressed, closed guideswith ground recirculating ball spin-dles. The working head on the portalmakes the movements in X and Z-di-rection. The C-axis is integrated intothe electrode clamping system in theworking head.

Flexible working areaIn next to no time, the working areaof every Agietron Spirit can be en-larged to a maximum by dismantlingthe electrode magazines so that, de-pending on the model size, thelargest possible workpiece in eachcase can be machined.

Precise axis drivesWith high-resolution servomotors anda transductor for dynamically slidingmovements by all axes, an µm-exactpositioning is achieved with all Agi-etron Spirit models. The positioningspeed is 0.9 m/min.

Compact designA unit is formed in each case madeup of the machine and dielectric unit,and also the control and generator.Both are coupled together and aredelivered as one whole on a frame.All Agietron Spirit machines can thusbe manoeuvred with little effort and,thanks to their small floor space re-quirement, find their place even innarrow rooms. Commissioning couldnot be simpler with a total of just 4connections required.

The machine construction according to model size

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AGIETRON SPIRIT 2

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AGIETRON

Axes travels X/Y/Z axes 300 x 250 x 250 mm (11.8 x 9.85 x 9.85 in)Workpiece Max. use of working space Width x depth x height 630 x 400 x 185 mm (24.8 x 15.7 x 7.3 in)

Max. dimensions With integrated electrode magazine 500 x 400 x 185 mm (19.68 x 15.7 x 7.3 in)Max. weight 200 kg (141 lbs)

Electrode Max. weight With automatic chuck 25 kg (55 lbs)120 kg (265 lbs)

Table to quill distance Minimal / maximal 190 - 440 mm (7.5 - 17.4 in) [1]Work area

Worktank Bath level programmable 225 mm (8.85 in)Machine table Clamping surface Length x width 400 x 300 mm (15.7 x 11.8 in)

Clamping plate with hole pattern grid 50 mm (1.95 in) ■

Integrated C axis For positioning, rotation and helical erosion Rotation 0-40 RPMMax. working current Rotating / stationary 72 A / 72 AMax. electrode weight 25 kg (55 lbs)Quill equipment Integrated automatic chuck standard type ▲

Integrated electrode changer Electrodes magazine ▲ ELM 4 rightElectrode changer -Fingers For automatic chuck standard type ▲

Universal high performance generatorAGIE APG-SPIRIT “Advanced Power Generation” Type integratedProcess adaptation according to the degree of difficulty ACC/ACO automatic ■

Selection and automatic adaptation of the technology AEP (Automatic Erosion Programming) ■

Servo system for maximum ED machining efficiency AGIE APG Fuzzy ■

Accurate depht and homogeneus surface in fine finish UNIGAP automatic ■

Frontal and lateral compensation of undersize GAP automatic ■

Database for User-Technology User-Technology ■

Polarity Programmable ■

Performances Max. removal rate Vw mm3/min ◆ Copper / Steel at 72 A / 550 mm3/min ■

◆ Graphite / Steel at 72 A / 600 mm3/min ■

Best roughness ◆ Ra 0.2 µm (RMS 9.6 µin)Electroerosive polishing AGIEBRIL ■

Optional power stage 32A for best use with grafite electrodes ◆ Increase to 104A, removal rate Gr/Steel -Flushing Number of connection Tank / quill 3 / 1

Pressure, suction ■ 1Dielectric unit Integrated Charge volume 300 l (79.2 gal)Filtration Cartridge filters Canisters / cartridge filters 1 / 2

Filter quality 3-5 µmFilter autonomy 40 h at 32 A

Cooling Cabinet with air cooling and dielectric with water / water heat exchanger ■

Cabinet with water / air and dielectric with water / water heat exchanger ▲

The versatility of the functions

◆ According to AGIE setting values■ Standard▲ Variant: not retrofittable● Option: at choice


AGIETRON SPIRIT 3 AGIETRON SPIRIT 4

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550 x 400 x 350 mm (21.7 x 15.7 x 13.8 in) 700 x 500 x 400 mm (27.6 x 19.7 x 15.7 in)960 x 650 x 255 mm (37.8 x 25.6 x 10 in) 1100 x 750 x 370 mm (43.3 x 29.5 x 14.5 in)760 x 450 x 255 mm (29.9 x 17.7 x 10 in) 920 x 550 x 370 mm (36.2 x 29.5 x 14.5 in)1000 kg (2200 lbs) 2000 kg (4409 lbs)50 kg (110 lbs) 80 kg (176 lbs)80 kg (176 lbs) 113 kg (250 lbs)170 - 520 mm (6.69 - 20.47 in) [1] 215 - 615 mm (8.5 - 24.2 in) [1]

295 mm (11.61 in) 410 mm (16.14 in)700 x 500 mm (27.55 x 19.68 in) 870 x 550 mm (34.25 x 21.65 in)■ ■

0-40 RPM 0-40 RPM72 A / 72 A 72 A / 72 A50 kg (110 lbs) 50 kg (110 lbs)▲ ▲

■ ELM 10 ■ ELM 15 (▲ ELM 22)- ▲ ELW 28 / 56▲ ▲

integrated integrated■ ■

■ ■

■ ■

■ ■

■ ■

■ ■

■ ■

■ ■

■ ■

0.2 µm (RMS 9.6 µin) 0.2 µm (RMS 9.6 µin)■ ■

● 1000 mm3/min (0.055 in3/min) ● 1000 mm3/min (0.055 in3/min)3 / 1 3 / 1■ 1 / 1 ■ 1 / 1500 l (132 gal) 840 l (221.9 gal)2 / 4 2 / 43-5 µm 3-5 µm40 h at 32 A 40 h at 32 A■ ■

▲ ▲

Operation and data inputRemote control for manual axes movement X/Y/Z/C and ■ JOGBOX with LCD Displaygeneral functions for work preparation Operator interface system Spirit 2 ■ 15” flat panel display, mouseControl unit integrated ■ CNC SPIRIT guided interactive inputOperating system ■ Windows / multitasking Operating mode ■ MultiprocessorCPU’s ■ Pentium for CNC and operator interfaceStorage capacity ■ 20 GB RAMServo controlled axes ■ X/Y/Z/C axesUnits of measurement ■ mm/inchCommand format ■ Absolute, incrementalModuls and functionsFine drill module ▲For Spirit 2 - Fine holes with electrodes from diam. 2 to 0.1 mmSmallest programmable step X/Y/Z/C axes ■ 0.001 mm / 0.001°Visualisation of erosion data ■ Graphics display with: power, stability, speed and depthProgram structure ■ Automatic Erosion Programing (AEP - guided)Pickup cycles for automatic determination of workpiece position and electrode ■ Intuitive programming with iconsReference definition and correction piece - electrode ■ Automatic savingOrbital movement in space for every application ■ Vector, circular, continuous spherical, vector 2D/3D, EQUIMODE,

continuous circular / sphericalModule for contouring ■ Geometry 3DPressure flushing and suction ■ ManualHelp functions, explanations with text and graphics ■ Manual integrated in the operating systemMachining simulation and positioning ■ Program check without erosionLanguages ■ English, DE, CN, CZ, DK, ES, FR, IT, KR, JP, NL, PL, PT, RUData storage media ■ USB; CD-ROM Interfaces for external peripheries ■ 1 x RS232C; 1 x Parallel; 1 x LAN; 2 x USB

SystemDimensions of the complete unit (w x d x h) 1850 x 2100 x 2360 mm 2800 x 2800 x 2690 mm 3000 x 3000 x 2865 mm

(72.8 x 82.7 x 92.9 in) (110.23 x 110.23 x 105.9 in) (118.1 x 118.1 x 112.79 in)Dimensions of the control cabinet (w x d x h) 760 x 520 x 1740 mm 760 x 520 x 1740 mm 760 x 520 x 1740 mm

(29.92 x 20.47 x 68.5 in) (29.92 x 20.47 x 68.5 in) (29.92 x 20.47 x 68.5 in)Distance floor / clamping level 1050 mm 914 mm 914 mm

(41.33 in) (35.98 in) (35.98 in)Net weight 1280 kg 3300 kg 4000 kg

(2822 lbs) (7276 lbs) (8819 lbs)Weight ready-to-run 1550 kg 3800 kg 4800 kg

(3417 lbs) (8378 lbs) (10582 lbs)Line power 4.7 kVA 4.7 kVA 4.7 kVALine voltage 3 x 400 V 3 x 400 V 3 x 400 VMains frequency 50/60 Hz 50/60 Hz 50/60 HzCompressed air 7 bar, 5 m3/h 7 bar, 5 m3/h 7 bar, 5 m3/hCooling capacity required 2-3 kW 2-6 kW 2-6 kW

2 3 4

Notes: [1] Depending on the clamping chuck, e.g. with System 3R Macro


Electro-erosion, also called EDM –Electric Discharge Machining, is ayoung technology. A little over 50years old. Just as young as Agie. Atechnology which has been decisivelyinfluenced and shaped by Agie in thistime. What is EDM? By using electri-cal discharge machining, conductivematerials of any hardness can bemachined with an accuracy of downto a thousandth millimetre, practical-ly without any mechanical effect. Thismakes EDM a key technology in themanufacture of demanding dies andblanking tools which are used forthe mass production of parts madeof plastic, metals and glass.Objects from our everydaylife: toothbrushes, mobilephones, PET bottles, comput-ers, cutlery, ski boots, ball-point pens, car components,toys, implants, instruments –the list could be continued atwill and proves impressivelythat EDM is a dynamic tech-nology with unlimited futurepotential.

PARTNER TO THE BEST

The address for over 50 years of ED machining

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Advice. Competent and experiencedsales engineers, who are quite nearto you, advise you all round the topicof electric discharge machining. Noquestions are left open.

Information. Agie updates its web sitewww.agie.com constantly, publishesinteresting customer applications inthe magazine “experience” and, evenafter the sale, informs about the latestproducts with brochures and flyers.

Caring. Agie has technical consult-ants deployed world-wide who imple-ment practice-oriented application,automation, hardware and softwaresolutions and also facilitate the entryinto ED machining.

Training. Agie prepares individual in-structions for every EDM system sothat productive EDM jobs can becommenced already shortly aftercommissioning.

Documentation. Agie supports theoperator effectively with practice-ori-ented documentation for use andmaintenance in printed and electronicform.

Hotline. Agie routinely solves approx.90% of all problems directly by phoneon the hotline open all round theclock.

Service. Agie ensures world-wide op-timal functioning and utilisation ofyour Agie EDM system with its contin-uously trained service technicians.

Readiness for delivery. Agie offers a24-hour service and maintains a largestore for fast deliveries with 97 per-cent availability of original spare andwearing parts, consumables and ad-ditional equipment.

Original parts. Agie guarantees thebest EDM results with its originalspare and wearing parts. All the ma-chining technologies and works de-tails are based on this.

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Agie Charmilles Group

AGIE SACH - 6616 LOSONETELEPHONE +41 (0)91 806 91 11TELEFAX +41 (0)91 806 92 [email protected]

All rights to changes reserved.

© AGIE. The machine design is registered, 1997.

500.029.578April 2006Printed in Switzerland.

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Spirit Versatility

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