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
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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
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
Distance coded in the guide rail profile Type of measurement direct
Positioning inaccuracy A according to DIN ISO
230-2
mm 0.007
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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
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6 MAG IAS GmbH
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
Rotary table indexing Degrees 360 x 1
Part accuracy Arc second 6
Tangential torque Nm 10 000
Tilting moment Nm 8 000
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
smallest increment Degrees 0.001
Positioning inaccuracy A according to ISO 230-2 Degrees 0.004
Tangential torque Nm 4000
Tilting moment Nm 8000
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Technical dataTechnical dataTechnical dataTechnical data NBH 5 1111
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ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
Speed range, option 1/min 15000
Torque 100% ED / 40% ED max. Nm 202 (standard) 111 (option)
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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)
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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
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8 MAG IAS GmbH
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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)
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Technical dataTechnical dataTechnical dataTechnical data NBH 5 1111
MAG IAS GmbH 9
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
Operating pressure bar 75
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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
ComponentComponentComponentComponent UnitUnitUnitUnit ValueValueValueValue
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
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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
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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)
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine
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
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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
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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
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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)
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine
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
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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)
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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
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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
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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
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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
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine
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
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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)
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine
24 MAG IAS GmbH
1 Console
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine Construction principleConstruction principleConstruction principleConstruction principle Cassette magazine (Option) 2222
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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
2222 Construction principleConstruction principleConstruction principleConstruction principle Cassette magazine (Option)
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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
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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
2222 Construction principleConstruction principleConstruction principleConstruction principle Cassette magazine (Option)
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine
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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
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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)
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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
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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)
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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
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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)
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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
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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
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine
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.
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This is achieved due to a direct force transmission to the ball screws with star coupling.
2222 Construction principleConstruction principleConstruction principleConstruction principle Control system
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine
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.
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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
Technical Description MachineTechnical Description MachineTechnical Description MachineTechnical Description Machine
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
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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
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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