Technical Description Machine

NBH 5NBH 5NBH 5NBH 5

Technical Description Machine

Translation based on Original Documentation

AD.0102.9724-GB 05.06.2013

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Table of contentsTable of contentsTable of contentsTable of contents

MAG IAS GmbH 3

Table of contentsTable of contentsTable of contentsTable of contents

1111 Technical dataTechnical dataTechnical dataTechnical data 5555

1.1 NBH 5 5

1.2 Operating data of the control 10

1.3 Ambient and operating conditions 11

1.4 Cassette magazine (Option) 12

1.5 Torque support (Option) 12

2222 Construction principleConstruction principleConstruction principleConstruction principle 13131313

2.1 Machine base 13

2.2 Machine column 14

2.3 Spindle housing with motor spindle 15

2.4 Torque support (Option) 15

2.5 Table sub-assembly indexing table 360 x 1 ° 17

2.6 Table sub-assembly NC table (option) 17

2.7 Fastems loading station (optional) 18

2.8 Profile linear guides 18

2.9 Pallet changer 19

2.10 Workpiece loading place 20

2.11 Clamping hydraulic 6-fold (option) 20

2.12 Cam-controlled tool changer 21

2.13 Tool disc magazine 40 locations 21

2.14 Manual loading, Disk magazine, 40 places (Option) 23

2.15 Cassette magazine (Option) 23

2.15.1 Console 23

2.15.2 Tool magazine 25

2.15.3 Tool manipulator 26

2.15.4 Tool gripper 27

2.15.5 Tool drawer 28

Table of contentsTable of contentsTable of contentsTable of contents

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine

4 MAG IAS GmbH

2.15.6 Tool changer 28

2.15.7 Simple drill breakage monitoring cassette magazine (Option) 29

2.16 Tool length measurement / Broken drill check (option) 30

2.17 Broken tool check MSC (option) for tool disc magazine

with 40 locations 31

2.18 Balluff tool identification (Option) 32

2.19 Lubrication 32

2.20 Central Lubrication 32

2.21 Work area 33

2.22 Self-sufficient working area suction unit (Option) 33

2.23 Coolant system with built-in chip conveyor 35

2.24 Cooling water recooling unit (Option) 35

2.25 Hydraulic unit 35

2.26 Heating and cooling unit for the motor spindle 36

2.27 Electrical equipment 36

2.28 Digital drive engineering 36

2.29 Control system 38

2.30 Direct path measuring system 38

2.31 Switch cabinet 40

2.32 Operation 40

3333 Safety devicesSafety devicesSafety devicesSafety devices 41414141

3.1 EMERGENCY STOP - push-button 41

3.2 Position of EMERGENCY STOP - push-button 42

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Technical dataTechnical dataTechnical dataTechnical data NBH 5 1111

MAG IAS GmbH 5

1111 Technical dataTechnical dataTechnical dataTechnical data 1.11.11.11.1 NBH 5NBH 5NBH 5NBH 5

ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue

X-axis Y-axis Z-axis

mm 700 630 700

Workpiece contour max. Height x Width in mm 750 x 700

Distance to the centre of the table... Spindle nose in Z

mm 100 (SK 40)

Distance to the centre of the table... Spindle nose in Z

mm 100 (HSK-A 63)

Distance to the top edge of the table... Spindle nose in Y

mm 85


Distance coded in the guide rail profile Type of measurement direct

Positioning inaccuracy A according to DIN ISO

230-2

mm 0.007


Clamping surface of pallet DIN 55201, Form A2 Length x Width in mm 500 x 500

Transport load of each pallet approx. kg 500

Height of fixture mm 750

Pallet change time according to VDI 2852 approx. seconds 7

Centre of mass mm ≤ 400 mm above the centre of the pallet

Working area Working area Working area Working area

Position measuring systemPosition measuring systemPosition measuring systemPosition measuring system

PalletPalletPalletPallet

Rotary table, HirthRotary table, HirthRotary table, HirthRotary table, Hirth----gearing gearing gearing gearing (Standard)(Standard)(Standard)(Standard)

1111 Technical dataTechnical dataTechnical dataTechnical data NBH 5


6 MAG IAS GmbH


Rotary table indexing Degrees 360 x 1

Part accuracy Arc second 6

Tangential torque Nm 10 000

Tilting moment Nm 8 000


smallest increment Degrees 0.001

Positioning inaccuracy A according to ISO 230-2 Degrees 0.004

Tangential torque Nm 4000

Tilting moment Nm 8000


Max. fixture diameter mm 700

Max. fixture height mm 1000

Max. fixture weight kg 500

Max. pallet weight kg 150

Max. travel time single seconds 10

Motor details:

Speed 1/min max. 1300

Performance KW 0.37

Mains current A 1.3

Converter A 1.6


Tool holder, standard according to DIN 69871-A 40

SK 40

Tool holding fixture, Option 1 accord. to ISO 12164 (DIN 69893-HSK-A)

HSK-A 63

Tool holder, option 2 accord. to ASME B5.50 (ANSI)

ASME 40

Tool holder, option 3 acc. to JIS B 6339 (BT) BT 40

Diameter in the front bearing mm 80

Driving power 100% ED / 40% ED kW 13/18

Speed range - standard 1/min 10000

NCNCNCNC----rotary table (Orotary table (Orotary table (Orotary table (Option)ption)ption)ption)

Transfer station Fastems Transfer station Fastems Transfer station Fastems Transfer station Fastems

(Option)(Option)(Option)(Option)

Work spindleWork spindleWork spindleWork spindle


MAG IAS GmbH 7


Speed range, option 1/min 15000

Torque 100% ED / 40% ED max. Nm 202 (standard) 111 (option)


Feed rate setting range X, Y, Z axes mm/min 1 - 50000

Feed force X-, Y-, Z-axis, 40 % ED approx. N 5 000

Rapid traverse rate X, Y, Z axes m/min 50

Rapid traverse, rotary table 1/min 30

Acceleration approx. m/s2 7

Ball screw spindle (pitch) Ø mm 40 (20)


Tool disc magazine 40 locations (standard) max. number 40

Rack-type magazine (option) max. number 134

Tool loading and unloading position Number via the spindle

Maximum tilting moment on the tool referred to the centre of the grab groove.

Nm 8

Tool diameter / max. tool diameter

mm 80 / 150

Tool length max. mm 350

Tool weight max. kg 10

Tool changing time (tools up to 10 kg) approx. seconds 2.5 - 4.5

Cut-to-cut time / VDI 2852 (tools of max. 10 kg)

approx. seconds 4


Pneumatic pressure bar 4.5

Extension of tool change time due to the test procedure of the tool.

s 2.2

Accuracy of measurement in the spindle (at constant spindle temperature)

mm ± 0.05

Feed rate/Feed force/Rapid Feed rate/Feed force/Rapid Feed rate/Feed force/Rapid Feed rate/Feed force/Rapid traversetraversetraversetraverse

Tool magazineTool magazineTool magazineTool magazine

Tool lengths measurement Tool lengths measurement Tool lengths measurement Tool lengths measurement (option)(option)(option)(option)

1111 Technical dataTechnical dataTechnical dataTechnical data NBH 5


8 MAG IAS GmbH


Accuracy of measurement in tool disc (drill fracture)

mm ± 1

Minimal drill diameter to be measured mm 3

Diameter: Deflecting plate mm 20

Weight - whole unit kg 45

Max. tool length to be measured mm 350

Min. tool length to be measured mm 45


Operating voltage, three-phase alternating current; frequency

V; Hz 400; 50

Control voltage; frequency V; Hz 230 / 50; 24 DC

Connected load kVA 27

Fuse protection A 80


Compressed air

Supply pressure bar 5 - 7

Consumption Standard m3/h approx. 16

Filter mesh size µ and mg/m³ 5 µ and 5 mg/m³

Pressure dew point Degree Celsius + 3

Oil content mg/m3 < 1

Electrical systemElectrical systemElectrical systemElectrical system

Pneumatic systemPneumatic systemPneumatic systemPneumatic system(air quality in compliance with ISO 8573(air quality in compliance with ISO 8573(air quality in compliance with ISO 8573(air quality in compliance with ISO 8573----1, class 4/4/3)1, class 4/4/3)1, class 4/4/3)1, class 4/4/3)


MAG IAS GmbH 9


Operating pressure bar 75


Capacity - container min./max. depending on version

approx. l 300 - 600

Delivery rate of the pump „Tools outside" 3 bar

l/min 230

Delivery rate of the a pump „Tools inside“ 40 bar

l/min 23


Space requirement of the basic machine, L x W x H

approx. m 4 x 3 x 3

Weight approx. kg 12500

Height 1 155 mm

Standard, on the side

We reserve the right to make changes.

* Value in brackets with max. pallet load

Hydraulic systemHydraulic systemHydraulic systemHydraulic system

Coolant systemCoolant systemCoolant systemCoolant system

Machine installationMachine installationMachine installationMachine installation

Chip ejector Chip ejector Chip ejector Chip ejector

1111 Technical dataTechnical dataTechnical dataTechnical data Operating data of the control


10 MAG IAS GmbH

1.21.21.21.2 Operating data of the controlOperating data of the controlOperating data of the controlOperating data of the control

Value Value Value Value

Humidity, humidity class according to DIN Humidity, humidity class according to DIN Humidity, humidity class according to DIN Humidity, humidity class according to DIN 40040400404004040040

F

Air pressureAir pressureAir pressureAir pressure 860 to 1080 hPa

Protection againstProtection againstProtection againstProtection against accidental contact, accidental contact, accidental contact, accidental contact,

protection class according to DIN VDE 0160protection class according to DIN VDE 0160protection class according to DIN VDE 0160protection class according to DIN VDE 0160

I

Protection class according to DIN 40050Protection class according to DIN 40050Protection class according to DIN 40050Protection class according to DIN 40050

� Front side operating panel IP 54

� Rear side operating panel IP 00

� Front side machine control panel IP 54

� Rear side machine control panel IP 00

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Technical dataTechnical dataTechnical dataTechnical data Ambient and operating conditions 1111

MAG IAS GmbH 11

1.31.31.31.3 Ambient and operating conditionsAmbient and operating conditionsAmbient and operating conditionsAmbient and operating conditions

Mains connection 400 VAC ± 10%

Frequency 50 Hz

± 1% permanent ± 2% short time

Phase sequence L1-L2-L3 (clockwise rotating field)

Type of network TN-C

Control circuit 24 V DC

Connected load 27 kVA

Total rated current 59 A

Fuse protection 80 A

Lighting and power outlet circuit 230 V AC, 50 Hz, Connection after the main switch

Voltage for solenoid valves, clutches and electric brakes

24 V DC

Voltage for inputs and outputs 24 V DC

Pneumatic system (supply pressure) (air quality in compliance with ISO 8573-1, class 4/4/3)

5 - 7 bar

Filter mesh size 5 µ and 5 mg/m³

Hydraulic system (operating pressure)

75 bar

Further ambient conditions acc. to EN 60204-1: 2006, paragraph 4.4

The machine is designed for industrial networks in compliance with limiting value class A according to EN 50370-1.

1111 Technical dataTechnical dataTechnical dataTechnical data Cassette magazine (Option)


12 MAG IAS GmbH

1.41.41.41.4 Cassette magazine (Option)Cassette magazine (Option)Cassette magazine (Option)Cassette magazine (Option)

Number of tool places: 134

Number of tool places drawer: 4

Tool diameter standard 80 mm

Tool diameter max. 150 mm

Tool length max. 350 mm

Tool tilting moment max. 8 Nm

Tool weight max. 10 kg

Tool cone SK 40, HSK 63; ANSI 40, BT 40

1.51.51.51.5 Torque support (Option)Torque support (Option)Torque support (Option)Torque support (Option)

Max. tool diameter 150 mm

Max. tool length 350 mm

Max. tool tilting moment 8 Nm

Max. tool weight 10 kg

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Machine base 2222

MAG IAS GmbH 13

2222 Construction principleConstruction principleConstruction principleConstruction principle

2.12.12.12.1 Machine baseMachine baseMachine baseMachine base

The machine base is designed as a heavy, intrinsically rigid and optimally

ribbed cast structure. The undivided T-bed of the machine basic body is fixed on the floor with a three-point support with vibration-damped mounting elements.

Two particularly large spiral chip conveyors integrated in the Z-axis of the cast body ensure optimised chip removal from the work area.

Hardened and ground profile guides with backlash-free pretensioned roller

slides serve as guides for the traverse units of the X and Z axes.

2222 Construction principleConstruction principleConstruction principleConstruction principle Machine column


14 MAG IAS GmbH

2.22.22.22.2 Machine columnMachine columnMachine columnMachine column

The strong, optimally ribbed cast iron machining module with built-in Y-axis is designed as a closed column.

With its thermostable, symmetrical structure, it serves to guide the spindle housing in the Y-axis via hardened and ground profile guides with backlash-free pretensioned roller slides.

The guides are lubricated via lubricating units upstream of the guide carriage.

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Spindle housing with motor spindle 2222

MAG IAS GmbH 15

2.32.32.32.3 Spindle housing with motor spindle Spindle housing with motor spindle Spindle housing with motor spindle Spindle housing with motor spindle

The spindle housing is a compact cast housing. It is easy to support the motor spindle and fasten the spindle nut of the Y-axis ball screw.

Therefore, if necessary, these sub-assemblies can be replaced very quickly. Alternatively, motor spindles with different characteristic curves and speeds are also available.

After a grease distribution run in the manufacturer's factory, the motor spindle can be operated immediately as a complete unit, i.e. long running-in

periods are not necessary. The motor spindle shaft has 3-fold bearings; combined with the thick-walled housing body, this makes the spindle highly rigid.

The motor spindle is cooled with water for thermal stabilisation.

Irrespective of the shape of the shaft taper of the toolholder, the tool is

always driven positively, which ensures the best possible torque transmission. Clamping is carried out with a spring clamping assembly. A pneumatic releasing function is used to release and eject. The clamping state is monitored with inductive proximity switches.

During tool change, air is blown over the tool taper and the conical seat of the spindle (cleaning function).

The external supply of cooling lubricant to the cutting area is carried out via adjustable spray nozzles on the outer ring of the motor spindle.

Optionally, you can also select inner cooling lubricant supply through the spindles.

As the motor spindle is designed with a built-in labyrinth seal and sealing air

in the spindle body, cooling lubricant, oil and dirt cannot enter the spindle.

2.42.42.42.4 Torque support (Option)Torque support (Option)Torque support (Option)Torque support (Option)

The torque support is used for support when working with drill heads.

It support does not have any media transfer point (air or coolant).

The torque support is mounted on the motor spindle in such a way that no cleaning air is required at the cutting point.

2222 Construction principleConstruction principleConstruction principleConstruction principle Torque support (Option)


16 MAG IAS GmbH

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Table sub-assembly indexing table 360 x 1 2222

MAG IAS GmbH 17

2.52.52.52.5 Table subTable subTable subTable sub----assembly indexing table 360 x assembly indexing table 360 x assembly indexing table 360 x assembly indexing table 360 x 1 °1 °1 °1 °

The table housing has a massive cast structure. The table module consists of a table slide which can travel in the Z-axis and a rotary table which is built in the table slide and executes rotation in the B-axis.

The leadscrew runs in axial-radial bearings on the drive end and in radial bearings on the opposite side.

The basic version of the machine features a rotary table with 360x1°

indexing. The smallest increment is 1 degree. The rotary table is accurately locked with Hirth gearing on hardened gear rings.

The pallet is clamped hydraulically. During this procedure, the pallet is firmly fixed to the surface of the rotary table with four clamping cones.

Sealing air prevents ingress of coolant and dirt.

2.62.62.62.6 Table subTable subTable subTable sub----assembly NC table (option)assembly NC table (option)assembly NC table (option)assembly NC table (option)

The table housing has a cast structure. The table has a built-in direct path measuring system (RON encoder) with an indexing accuracy of 0.001

degrees. The table is clamped with a hydraulic clamping ring. Rotation is carried out with an NC drive.

2222 Construction principleConstruction principleConstruction principleConstruction principle Fastems loading station (optional)


18 MAG IAS GmbH

2.72.72.72.7 Fastems loading station (optional)Fastems loading station (optional)Fastems loading station (optional)Fastems loading station (optional)

With the Fastems loading station the customer has the ability to load the

workpiece with pallet and fixture using a Fastems rack. The fixture transports pallets with a fixture in and out of the machine to a position in front of the machine. In this position in front the Fastems manipulator can retrieve the pallet.

2.82.82.82.8 Profile linear guidesProfile linear guidesProfile linear guidesProfile linear guides

Linear guides are used for all main axes as supporting and longitudinal slides. Each axis has four backlash-free, pre-stressed carriages with cylindrical roller bearing elements and they are used in combination with the hardened and ground profiled guide rails.

This design ensures extremely high rigidity and vibration damping. These

profiled guides feature very good running smoothness and high positioning accuracy combined with low wear and with this, long useful life.

Guide rail covers towards the work area protect the linear profiled guides from pollution in all axes.

A central lubrication system ensures independent lubrication of the linear

guides. The carriages are sealed by lip seal.

Glass linear scales serve as position measuring system which, in connection with the used digital control system an the used drives, provides high-precise positioning of the axes.

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Pallet changer 2222

MAG IAS GmbH 19

2.92.92.92.9 Pallet changer Pallet changer Pallet changer Pallet changer

The pallet change-over unit consists of a hydraulically driven 180°- swivel changer. The lifting and rotating movements of the changer are carried out

by a separate hydraulic system. With this, the swivel changer is on a slide component, which is lifted from set-up station to the top of the table unit before carrying out the rotational movement for changing the pallets.

2222 Construction principleConstruction principleConstruction principleConstruction principle Workpiece loading place


20 MAG IAS GmbH

2.102.102.102.10 Workpiece loading placeWorkpiece loading placeWorkpiece loading placeWorkpiece loading place

The workpiece loading station is designed as turnable reception for the pallets. With this, the 4 x 90 degrees indexing of the rotary plate allows the

workpiece on the pallet to be set-up easily, simultaneously to the machining of the workpiece. The position of the rotary plate is monitored by an inductive proximity switch.

2.112.112.112.11 Clamping hydraulic 6Clamping hydraulic 6Clamping hydraulic 6Clamping hydraulic 6----fold (option)fold (option)fold (option)fold (option)

The goal of 6-fold clamping hydraulics is to achieve a uniform arrangement of connections which meets the requirements of most customers. This is achieved by defining a standard procedure for clamping workpieces.

Versions differing from the standard version are treated as special cases. Standardisation applies to the loading table side, the allocation of valves and the layout of lines up to the pallet.

The distribution of lines from the pallet and the connection to the cylinders for clamping the fixture are not standardised. The distribution is customer-

specific as it depends on the fixture and, therefore, on the parts to be manufactured.

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Cam-controlled tool changer 2222

MAG IAS GmbH 21

2.122.122.122.12 CamCamCamCam----controlled tool changercontrolled tool changercontrolled tool changercontrolled tool changer

The mechanical MTC tool changer with gripper arm and tool lock manufactured by Messrs. Miksch is designed for tool change between the

tool magazine and a machine spindle.

This tool changer is a cam-controlled device for converting uniform rotary motion of the input shaft into a logical sequence of non-uniform, linear and rotational movements of the output shaft on which the gripper arm is seated. With its simple design, the generation of movements by the mechanical system consisting of cam plate and output link, and reliable control during

the entire work sequence, this product offers the following special features: high precision; high speed; smooth movements; low-vibration, noiseless movements; wide range of applications; small dimensions.

Tool lockTool lockTool lockTool lock

On the gripper arm, tools can be mechanically locked in the gripper clamps. This lock is activated in these MTC tool changers after the tool is lifted out by approx. 0.4 mm to 0.6 mm from the moved-in position. From this point onwards, the tools are locked.

2.132.132.132.13 Tool disc magazine 40 locations Tool disc magazine 40 locations Tool disc magazine 40 locations Tool disc magazine 40 locations

The tool magazine is designed as a disc and can hold maximum 40 tools. This allows tools to be removed quickly from the disc and placed directly in the motor spindle and vice versa with the pick-up procedure.

For tool change, the disc is positioned and then moved linearly with hydraulic means so that tools can be moved from and into the spindle. Tools

2222 Construction principleConstruction principleConstruction principleConstruction principle Tool disc magazine 40 locations


22 MAG IAS GmbH

are clamped mechanically with fixing clamps at the required location in the tool disc.

A tool support can be provided at fixed locations for oversized tools.

Optionally, the machine can be equipped with various tool magazine sizes (tool sizes).

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Manual loading, Disk magazine, 40 places (Option) 2222

MAG IAS GmbH 23

2.142.142.142.14 Manual loading, Disk maManual loading, Disk maManual loading, Disk maManual loading, Disk magazine, 40 places gazine, 40 places gazine, 40 places gazine, 40 places (Option)(Option)(Option)(Option)

Manual loading and unloading of tools during production on the machine. The production run of the machine is not interrupted.

An interruption occurs only when the tool is changed in the machine.

2.152.152.152.15 Cassette magazine (Option)Cassette magazine (Option)Cassette magazine (Option)Cassette magazine (Option)

The cassette magazine is an independent unit with built-in tool changer. The

following elements are mounted on a consoleconsoleconsoleconsole:

� the tool magazine, � the tool manipulator, � a tool drawer and � the tool changer.

2.15.12.15.12.15.12.15.1 ConsoleConsoleConsoleConsole

The console serves as the base for the entire cassette magazine. It is screwed to the side of the machine bed. As the machine tool stands on three

points, the cassette magazine is supported only on one point. This point is spring-supported (pneumatic cushioning) to ensure that the machine geometry is not affected.

2222 Construction principleConstruction principleConstruction principleConstruction principle Cassette magazine (Option)


24 MAG IAS GmbH

1 Console

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Cassette magazine (Option) 2222

MAG IAS GmbH 25

2.15.22.15.22.15.22.15.2 Tool magazineTool magazineTool magazineTool magazine

The tool magazine has 134 permanent tool locations.

The tools are suspended in tool cassettes (bent sheet part), i.e. the tool

taper is on top. They are held in place by tool clamps whose shape differs depending on the tool taper.

These tool clamps determine the positioning accuracy of the tools.

NOTENOTENOTENOTE

Inaccurate tool positions in case of laser and water jet cutting Inaccurate tool positions in case of laser and water jet cutting Inaccurate tool positions in case of laser and water jet cutting Inaccurate tool positions in case of laser and water jet cutting

The structure changes due to applied heat.

1 Tool clamp



26 MAG IAS GmbH

2.15.32.15.32.15.32.15.3 Tool manipulatTool manipulatTool manipulatTool manipulatorororor

This device consists of an area gantry which can be moved in X1 and Z1 and with this, the whole area of the tool magazine can be reached.

The movements are started via a toothed belt. The drives consist of an AC motor with gear unit.

1 Drive motor X1 5 Tool changer

2 Y1 axis 6 Tool gripper 3 Toothed belt X1 7 Tool cassette 4 X1-axis

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction prConstruction prConstruction prConstruction principleincipleincipleinciple Cassette magazine (Option) 2222

MAG IAS GmbH 27

2.15.42.15.42.15.42.15.4 Tool gripperTool gripperTool gripperTool gripper

A Y1 slide is mounted on the X1 axis. This slide is moved up and down via a pneumatic cylinder (1). The pneumatic cylinder (1) has built-in magnetic field

sensors for position monitoring.

The tool gripper (choice of SK40, BT40, HSK63 or ANSI40) is located in the Y1 slide. The tool gripper can be swivelled about 90 degrees. The hydraulic cylinder has built-in magnetic field sensors for position monitoring. Swivelling can be performed during the Y1 lifting movement or while the Z1 and X1 axes travel. Upward swivelling is damped by a shock absorber.

Tools are held via a pneumatic tool clamping cylinder. They are clamped with spring force and released pneumatically.

Depending on the taper design, a suitable taper cleaning device is mounted.

1 Pneumatic cylinder 3 Hydraulic swivel cylinder 2 Z1 axis 4 Tool clamping cylinder



28 MAG IAS GmbH

2.15.52.15.52.15.52.15.5 Tool drawerTool drawerTool drawerTool drawer

The tool drawer is used for tool change in parallel to the machining operation.

4 tools can be placed in it.

Suitable electrical and mechanical safety devices ensure that the operator cannot enter the danger zone of the tool manipulator when the drawer is pulled out.

2.15.62.15.62.15.62.15.6 Tool changerTool changerTool changerTool changer

The mechanic tool changer is a cam-controlled unit which transfers the uniformly rotating movement of the drive shaft into a stroke and a rotating movement of the output shaft.

There is a grab arm on the output shaft. The grab arm has a cushion clamp for locking the tools which is locked by the stroke of the grab arm.

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Cassette magazine (Option) 2222

MAG IAS GmbH 29

1 Grab arm 2 Cushion clamp

2.15.72.15.72.15.72.15.7 Simple drill breakage monitoring cassette Simple drill breakage monitoring cassette Simple drill breakage monitoring cassette Simple drill breakage monitoring cassette magazine (Option)magazine (Option)magazine (Option)magazine (Option)

The tools are checked tool breakage before they are put into the corresponding cassette.

2222 Construction principleConstruction principleConstruction principleConstruction principle Tool length measurement / Broken drill check (option)


30 MAG IAS GmbH

2.162.162.162.16 Tool length measurement / BrokeTool length measurement / BrokeTool length measurement / BrokeTool length measurement / Broken drill n drill n drill n drill check (option)check (option)check (option)check (option)

The correct functioning of the tool length measurement / broken drill check can only be guaranteed for a diameter of > or = 3 mm.

The standard setting is not suitable for PKD-tools.

With this, a broken drill check can be carried out outside the working area.

The minimum checked length is 67 mm before the front face of the spindle.

The unit consists of a pneumatic cylinder for driving and a guide with

integrated measuring system for measurement. This measured value is processed in the control unit and is compared with the setpoint value.

A surrounding hood protects the unit from coolant and chips.

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Broken tool check MSC (option) for tool disc magazine with 40

locations 2222

MAG IAS GmbH 31

2.172.172.172.17 Broken tool check MSC (option) for tool Broken tool check MSC (option) for tool Broken tool check MSC (option) for tool Broken tool check MSC (option) for tool disc magazine with 40 locationsdisc magazine with 40 locationsdisc magazine with 40 locationsdisc magazine with 40 locations

With this option, a drill breakage test can be performed outside the work area. The minimum test length is 67 mm before the front edge of the spindle.

The unit consists of a pneumatic cylinder for driving and a guide with built-in measuring system for recording measured values. These measured values

are processed in the control and compared to the desired values. A hood surrounding the unit provides optimal protection against coolant and chips.

2222 Construction principleConstruction principleConstruction principleConstruction principle Balluff tool identification (Option)


32 MAG IAS GmbH

2.182.182.182.18 Balluff tool identification (Option)Balluff tool identification (Option)Balluff tool identification (Option)Balluff tool identification (Option)

This tool identification system is used to read and write tool data on a data carrier on the tool.

2.192.192.192.19 LubricationLubricationLubricationLubrication

The goal of lubrication systems is to keep the machine in a maintenance-free state as far as possible. For this reason, grease lubrication systems

have been provided for motor spindle, ball screws and profile guide. They guarantee efficient lubrication with long maintenance intervals.

The 360 x 1° indexing table and the NC table are lubricated with oil.

2.202.202.202.20 Central LubricationCentral LubricationCentral LubricationCentral Lubrication

The automatic centralised lubrication system supplies lubricating oil to the slide guides of the X, Y and Z axes and all the recirculating ball screws in intervals.

The first automatic lubricating pulse will occur after the machine is switched on. All subsequent pulses will occur after a specified time interval. The default setting is 20 minutes.

If the oil level in the centralised lubrication system falls below a certain level, or if the pressure is insufficient for a lubrication pulse, an error message will appear on the control screen.

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Work area 2222

MAG IAS GmbH 33

2.212.212.212.21 Work areaWork areaWork areaWork area

A large inspection window made from safety glass on the operator's side provides for a good view on the cutting operation. Electrically locked hand

sliding doors allow the safe access to the large scaled working space and the loading position.

A special monitoring software allows the safe setting-up with open doors of the working space

The structural combination of door opening and roof lining offers excellent accessibility to the working space from the top. This reduces repair and

maintenance work clearly. A powerful lamp in the working space is included as standard equipment.

The optional rotational transparent sheet enables direct monitoring of the cutting operation also for maximum use of coolant without problems.

With this, straight set-up operations and test runs of new workpieces can be

performed more easily.

There is a working space shower available for improving the chip removal and the operator also can use a spray gun for optimizing the production process.

2.222.222.222.22 SelfSelfSelfSelf----sufficient working area suction unit sufficient working area suction unit sufficient working area suction unit sufficient working area suction unit (Option)(Option)(Option)(Option)

A self-supporting air suction system generates a slight vacuum. Due the vacuum, the cooling lubricant fume is extracted out of the working area.

Using a primary stage (preliminary separator, baffle plate) it is avoided that larger flying swarf and drops of cooling lubricant can get into the air suction system.

First, a rough filter retains the swarf which had not been deflected by the preliminary stage.

In a second stage, the air is brought into rotary motion (cyclone). With this, the particles and the cooling lubricant fume are pressed towards the walls and go back to the working area.

2222 Construction principleConstruction principleConstruction principleConstruction principle Self-sufficient working area suction unit (Option)


34 MAG IAS GmbH

In the final stage, the fine particles are filtered out by a one-way-deep filter to achieve the required MAK-value (legally required " maximum workplace concentration").

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Coolant system with built-in chip conveyor 2222

MAG IAS GmbH 35

2.232.232.232.23 Coolant system with builtCoolant system with builtCoolant system with builtCoolant system with built----in chip conveyin chip conveyin chip conveyin chip conveyorororor

The coolant system is integrated in the machine concept in such a way that it takes up very less space. We took special care to provide a large coolant

tank with a built-in pump for the cooling and flushing currents.

Spiral chip conveyors in the Z-axis carry chips to a scraper conveyor which carries them away laterally under the machine. The opening for chip ejection is located high above the floor so that standard chip buckets can be used without any problems.

The lifting pump pumps the cooling lubricant with fine particles to a self-

sufficient or central cooling lubricant filter system. Level sensors control the lifting pump and prevent overflowing if any faults occur.

Optionally, the pressure can be increased and the cooling lubricant can be filtered with a microfilter, depending on the type of machining.

2.242.242.242.24 Cooling water recooling unit (Option)Cooling water recooling unit (Option)Cooling water recooling unit (Option)Cooling water recooling unit (Option)

The air-cooled cooling water recooling unit is suitable for cooling fluid media (e.g. water, cooling brine). The device can be operated within a media temperature range of +5 °C to

+25 °C.

2.252.252.252.25 Hydraulic unitHydraulic unitHydraulic unitHydraulic unit

The hydraulic unit is designed as a central unit. It is easily accessible from

the outside for filling and monitoring purposes. It is a complete unit which includes all important hydraulic components.

An equalising reservoir filled with nitrogen ensures that there is a continuous supply of pressure in the system.

Optionally, the machine can be equipped with clamping hydraulics to enable

the use of automatic clamping devices.

2222 Construction principleConstruction principleConstruction principleConstruction principle Heating and cooling unit for the motor spindle


36 MAG IAS GmbH

2.262.262.262.26 Heating and cooling unit for tHeating and cooling unit for tHeating and cooling unit for tHeating and cooling unit for the motor he motor he motor he motor spindlespindlespindlespindle

A mixture of water and glycol is pumped out of a tank and through the cooling channels of the motor spindle by a circulation pump, absorbing the heat loss of the integral motor.

Then the heated medium flows through an air-water heat exchanger that discharges the heat loss to the environmental air.

2.272.272.272.27 Electrical equipmentElectrical equipmentElectrical equipmentElectrical equipment

The electrical system and the electronic system are both designed according to the applicable standards. The switch cabinet is located behind the machine bed. The machine is designed for TN-C-networks. If there is an other network available, it requires an isolation transformer. The installation

is carried out according to EN 60204, however there is no wire numbering.

The electrical equipment is designed for an ambient temperature between +5 and +40 °C (acc. to EN 60204).

The machines comply with the EC Machinery Directive and have the the CE sign.

The machines can be equipped with a warning light for indicating the current

machine states, as well as with devices for remote diagnoses by modems.

2.282.282.282.28 Digital drive engineeringDigital drive engineeringDigital drive engineeringDigital drive engineering

Brushless, digitally controlled three-phase servo drives with a totally enclosed-type construction are used for the X, Y, Z and B axes. These drives offer high working and rapid speeds with consistently high positioning accuracy of the axes.

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Digital drive engineering 2222

MAG IAS GmbH 37

This is achieved due to a direct force transmission to the ball screws with star coupling.

2222 Construction principleConstruction principleConstruction principleConstruction principle Control system


38 MAG IAS GmbH

2.292.292.292.29 Control systemControl systemControl systemControl system

The high dynamics and the working speed of the machines make high demands on the CNC-control system and the machine drives. These

requirements are met by applying digital drive technologies and using a powerful CNC control.

The machine is equipped with new control systems of the companies Fanuc und Siemens. To achieve high performance and to offer a compact design, motors and machines are exactly matched to each other. Therefore, it is not possible, to use other motor or measurement systems.

The control system has the following special features:

� CNC controls of the upper performance class Thread cutting without equalizing chuck PLC-programming acc. to IEC 1131

Compensation of spindle lead error Tool management Monitoring of the tool life time Automatic sister tool management Workpiece counter

� Regenerative power supply module

� Digital motor spindle and drive control with bearing control and monitoring of the travel area Installation and evaluation of two measuring systems with mutual

monitoring; No reference switch

This results in an extremely high level of machine safety and so this leads inevitably to a higher availability of the machine and lower maintenance costs.

2.302.302.302.30 Direct path measuring systemDirect path measuring systemDirect path measuring systemDirect path measuring system

The distances in the machining axes (X-;Y-;Z-) and in the optional NC table are directly measured. Integrated measurement systems are used on the linear guidance systems in all main axes.

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Direct path measuring system 2222

MAG IAS GmbH 39

A hard magnetic, periodic N-S scale serves as material measure which is integrated in the profiled rail.

The signal generating sensors are installed on a carriage, one on each axis. Short referencing times reduce the ready-to-start time after the switching on enormously.

2222 ConstConstConstConstruction principleruction principleruction principleruction principle Switch cabinet


40 MAG IAS GmbH

2.312.312.312.31 Switch cabinetSwitch cabinetSwitch cabinetSwitch cabinet

The switch cabinet is installed on the rear of the machine base. Thus, electrical sub-assemblies and connecting elements can be accessed very

easily.

Thanks to a clear and standardised arrangement of electrical components inside the switch cabinet and on the machine, faults can be diagnosed and rectified very quickly. Standard switch cabinets conform to the IP 54 protection class.

2.322.322.322.32 OperationOperationOperationOperation

The machine is equipped with a specific control keyboard including TFT colour flat screen monitor where all standard functions are available.

The functions of the control panel of the pallet change-over unit are selected using key pad on the front of the protective unit.

Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Safety devicesSafety devicesSafety devicesSafety devices EMERGENCY STOP - push-button 3333

MAG IAS GmbH 41

3333 Safety devicesSafety devicesSafety devicesSafety devices 3.13.13.13.1 EMERGENCY STOP EMERGENCY STOP EMERGENCY STOP EMERGENCY STOP ---- push push push push----buttonbuttonbuttonbutton

There is an EMERGENC STOP switch for emergencies:

� if human life is in danger,

� if there is the risk of damaging the machine or the workpiece.

Red mushroom pushbutton, yellow used as contrasting colour.

The operation of the EMERGENCY STOP push-button causes the following reactions.

� All drives are stopped in a controlled way using the most possible braking torque.

For releasing, the EMERGENCY STOP push-button is turned to the left side.

Please find more information about restarting the machine after activating the EMERGENCY STOP pushbutton in Operating Sequences after EMERGENCY STOP.

AppeAppeAppeAppearancearancearancearance

FunctionFunctionFunctionFunction

ReleaseReleaseReleaseRelease

Restart after EMERGENCY Restart after EMERGENCY Restart after EMERGENCY Restart after EMERGENCY STOPSTOPSTOPSTOP

3333 Safety devicesSafety devicesSafety devicesSafety devices Position of EMERGENCY STOP - push-button


42 MAG IAS GmbH

3.23.23.23.2 PPPPosition of EMERGENCY STOP osition of EMERGENCY STOP osition of EMERGENCY STOP osition of EMERGENCY STOP ---- push push push push----buttonbuttonbuttonbutton

1 Control of EMERGENCY

SWITCHING STOP 2 EMERGENCY SWITCHING

STOP for loading position

Documents

Technical Description Machine