Loading ePaper
UPF-5 ULTRA PRECISION MILLING MACHINE IN THE BLACK FOREST, TECHNOLOGY HAS A LONG TRADITION.
PRECISION IS OUR EXCELLENCE. 02
Lehmann Präzision GmbH, a manufacturer of precision machinery in the Black Forest, combines traditional and modern tech- nology. The company emerged from a traditional manufacturing enterprise for precision mechanics. This manufacture continues to be an important mainstay. Today, the company is among the leading suppliers of complex precision assemblies for different sectors of industry and of high-precision machine tools. These are used for a variety of applications, amongst others in the watchmaking industry or in the optical industry. 03
UPF-5 With the newly developed 5-axes CNC ultra precision milling machine (UPF-5), we are setting new standard with regard to precision and repeat accuracy. The machining of precision parts in the µ-range can be easily accomplished. Both the construction of the machines and the components used are of high quality and thus form the basis for their repeat accuracy and process reliability. The machine is geared to a multiple shifts production. It is quick and easy to retool and is thus also well suited for the production of small batch sizes. Important criteria for the quality of this machine: - The machine construction from natural hard stone - The use of precision spindles - The thermal stabilisation of guides and spindle - The use of the latest control and regulation technology from Heidenhain The modular design permits an optimum customisation, backed by various enhancement options. Thus, the processing of special materials such as glass or ceramics can also be ensured. 04
TECHNICAL DATA Working range Travel x-axis Travel y-axis Travel z-axis Rapid traverse, linear (x-y-z) Acceleration, linear (x-y-z) Feed force, linear (x-y) Feed force, linear (z) Repeat accuracy Positioning accuracy, linear Position measuring system Pivoting angle b-axis Rotation angle c-axis Clamping surface on c-axis Table loading capacity Tool spindle (ball bearing mounted) Size Speed range Power rating Nominal torque Tool holder 500 mm 370 mm 450 mm 30 m/min 10 m/s² 1,500 N 2,000 N <1 µm <1 µm/100 mm absolute, resolution 0.005 µm ±135° unrestricted Ø 150 mm 20 kg (can be adapted to application) Ø 120 mm 24,000 – 75,000 rpm 10 kW S1 1.3 Nm HSK-E 25/32 Zero point clamping system Depending on the application, various zero point clamping systems can be used. Controller Heidenhain Dimensions Height Width Depth Weight Connection data Connection voltage TNC 640 3,180 mm 2,000 mm 3,280 mm approx. 6,000 kg without options, loading robot, mounting parts and workpieces 400/230 V/50 Hz Compressed air connection 6 bar Circularity test x/y-axis 1 graduation mark = 1 µm Clamping examples 05
DIMENSIONS 06
WORKING RANGES Working range in 3-axes operation Working range in 5-axes operation Working range in 5-axes operation Placement of 3 clampings in 5-axes operation A workpiece that has been machined on all six sides leaves the machine after each machining operation. 07
FEATURES HARD STONE STRUCTURE All precision machines by Lehmann are mounted on a sub- structure of natural hard stone. Apart from the massive base plate, the UPF-5 is equipped with a yoke-shaped mounting bracket for the x/z-axis. Natural hard stone is absolutely free of distortion, has a low thermal expansion coefficient and excellent vibration damp- ing properties. These properties contribute to the high repeat accuracy of machining operations and lead to an outstand- ing surface quality of the workpieces. 1490 2 1 9 1 1 5 0 0 Ra 6,3 geschliffen Ra0,8 X = -0,1 -0,3 Rohmaße: Fertigmaße: Änderungsindex: $aet1 Werkstoff: Oberfläche: $aei1 $aed1 $aeu1 Granitblock kpl. UPF 4-5 gez.: 09.05.2016 Jessin Banoune gep.: 08.09.2016 id Maßstab: Blatt von 1:10 3 3 Zeichnungsnummer : Infra-Nummer : Z0025939 Identnr: Z0025939_2 (347) Allgemeintoleranz ISO 2768 - f H ≤6 ≤30 ≤120 ≤400 ≤1000 fein ±0,05 ±0,10 ±0,15 ±0,20 ±0,30 4181042,93 g Dichte: Gewicht: Volumen: Fläche: 40mm Werkstückkanten DIN ISO 13715 Oberflächenangaben DIN EN ISO 1302 Form- und Lagetolerierung DIN ISO 1101 Fertigung und Lieferung nach Hausnorm L01 Weitergabe sowie Vervielfältigung dieses Dokumentes, Verwendung und Mitteilung sind verboten, soweit nicht ausdrücklich gestattet. Zuwiederhandlung verpflichtet zu Schadenersatz. Alle Rechte für den Fall der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten. ® LEHM ANN präzision Lehmann Präzision GmbH Weilerstr. 27 D-78739 Hardt www.lehmann-praezision.de A1 DIN ISO 5456-2 Format NC SWIVELLING ROTARY TABLE The high precision swivel and rotary axis is driven with zero backlash high-end torque motors and is equipped with an automatic hydro-pneumatic spindle clamping. The axes are thus driven directly without gearbox. The b-axis is equipped with a coun- ter bearing. Different zero point clamping systems can be mounted on the c-axis, such as the pneu- matically actuated EROWA PowerChuck P-clamping chuck in extra flat design, as shown in the illustration. 8 1 0 2 . 9 0 4 0 . : m a t k c u r d e g GUIDES All axes of the machine are manufactured in-house and are equipped with high-precision M- and V-rail guides or profile rail guides, which are pretensioned back- lash-free. The machine is driven with ball screws and servo motors. A high positioning and repeat accuracy is ensured by absolute position measuring systems with a resolution of 0.005 µm. Because of this design con- figuration of the axes, it is possible to drive the machine with increased acceleration values and to considerably increase productivity. The temperature of the bearing points of the ball screws and the guide rails is controlled with an accuracy of ±0.1 K by means of a water circuit to minimise the thermal growth of the components and the surrounding construction. 08
FEATURES TOOL SPINDLE Different standard spindle types are offered depending on the application. Lehmann has developed both ball bearing and air bearing spindles. All spindles are designed for serial production. On account of their design, all spindles exhibit a high degree of concentricity due to the particular stiffness of the bearings, thus ensuring a highly precise machining of the workpieces. The spindles are integrated in the machines’ cooling circuit, thus preventing an uncontrolled change in length. This has a positive effect on tool life, repeatability and thus surface quality. THERMAL STABILISATION In all places where heat can arise on the machine, the temperature is controlled with an accuracy of ±0.1 K by means of a cooling circuit. On the one hand, this applies to the tool spindle, where a growth in z-direction is prevented. On the other hand, it applies to the bearing points of the ball screws and the guides. This prevents a heating of the axes and their substructure. The machine thus has a very high temperature stability. 09
FEATURES TOOL CHANGER The tool changer is installed behind the machine. It can be equipped with up to three magazine discs. Special features: - The double gripper for a fast tool change - Programming and operation, which both take place via a 7” touch panel - The protective equipment with access opening for loading the magazine discs Number of positions per disc Max. tool length with 1 disc Max. tool length with 2 discs Max. tool length with 3 discs Change time HSK 25 75 HSK 32 50 350 mm 180 mm 95 mm approx. 6 s 10
CONTROLLER The machine is controlled by a Heidenhain TNC 640. The entire drive system (motors, controllers, measuring systems) is also made up of Heidenhain components. The TNC 640 is equipped with an optimised motion control short batch processing time and special control strategies. This enables high machining speeds at highest possible contour accuracy, which is of particular im- portance for machining 3D-contours. In addition, the controller is characterised by: - Programming in Heidenhain plain text, with smarT.NC or according to DIN/ISO - The USB and Ethernet interfaces for the transmission of programs from external programming stations - Automatic calculation of cutting data - The electronic handwheel All display and control elements are arranged on an ergonomically designed, height-adjustable control desk: - The large 19” TFT colour flat screen with softkey selection buttons - The control panel with full keypad and touch pad Access to password-protected data is possi- ble via electronic keys that are programmed according to the user level and are passed on to the employees. MAINTENANCE, SERVICE All components that need to be accessible for machine maintenance (pneumatic system, central lubrication, etc.) are mounted on the outside of the machine in a clearly laid out, easy to maintain manner and are protected by a pane. Remote access to the controller for diagnostic and maintenance purposes is prepared. 11
OPTIONS All machines are basically of a modular design and can thus be customised to meet the respective application needs. The following options are offered: - Different tool spindles - Tool length measurement (tactile or contactless) - Camera system for control and measuring tasks - Electronic measuring probes systems - Cooling lubrication systems for emulsion or oil - Air purification system - Minimum quantity lubrication - Chip abstraction - Transparent window with air curtain - Automated workpiece storage and infeed - Different axis travels (special solution) - Chip conveyor (special solution) BALL BEARING TOOL SPINDLE The ball bearing tool spindle with rotary feedthrough for internal cooling of the tools and automatic tool change offers the following features: - A HSK 25 or HSK 32 tool clamping system. - Lubrication of the precision hybrid bearing with an oil-air mixture. - A sealing air barrier that prevents cooling lubricants or dirt from getting into the spindle during operation. This means that air continuously flows from an annular gap between shaft and housing. The air flow also prevents spent oil-air lubricant from escaping at the shaft gap. - Hollow shank taper cleaning with compressed air during tool change. AIR BEARING TOOL SPINDLE The air bearing spindle with automatic tool change offers the following features: - A HSK 25 tool clamping system. - A sealing air barrier that prevents cooling lubricants or dirt from getting into the spindle during operation. This means that air continuously flows from an annular gap between shaft and housing. - Hollow shank taper cleaning with compressed air during tool change. - An integrated balancing system for precision balancing the HSK tool holder including the tool in the spindle. The machine is able to achieve best surface qualities and high tool lives due to the high bearing stiffness, the con- centricity and the vibration-free run. As there is no bearing friction, the spindle is wear- and maintenance-free. 12
OPTIONS AUTOMATED WORKPIECE STORAGE AND INFEED WITH ROBOT SYSTEM The offered robot system can considerably optimise the production time. Automation of workpiece handling permits the time-consuming setup work to be performed parallel to the machine runtime. In addition, the use of an intelligent control system avoids organisational downtimes. This facilitates a rational, unmanned production in three shifts. The robot system is of modular design and can serve one or two machines. The workpieces are made available for machining on pallets inside a magazine. The pallets are loaded manually outside the robot system. Each pallet is provided with an identification chip and can therefore be located unambiguously in the magazine. As an option, magazine spaces can be designed as telescopic trays, the capacity of the magazine amounting to approx. 90 pallets (depending on pallet and workpiece size). For machining, the pallets are placed onto a zero point clamping system in the machine. After completion of workpiece machining, the pallets are placed back into the magazine. 13
OPTIONS TOOL PREPARATION SPACE At the tool preparation space, tools can be prepared for their use in the UPF-5. It comprises: - A hot air shrink fit device for changing the tools in the HSK tool holders. - A balancing spindle for balancing the HSK tool holders with mounted tools. Tools that have been balanced in this manner do not generate any vibrations, thus an excellent surface quality and a long tool life can be achieved. 14
OPTIONS CAMERA SYSTEM Camera systems can be used for various tasks: - Locating the workpieces and appropriate correction of the machine coordinate system. - Measuring and control tasks. Camera image for locating a duct with a cross-section of 0.25 x 0.25 mm in a glass body. Image detail 0.6 x 0.8 mm. 0.25 mm m m 5 2 . 0 WORKPIECE CLAMPING SYSTEMS To achieve an economic clamping of the workpieces, a wide range of workpiece clamping systems is available. By request, customised special designs are also available. MULTIPLE CLAMPING DEVICE ON TRIPLE MOUNTING SHANK CENTRE CLAMPING DEVICE ON ZERO POINT CLAMPING SYSTEM CENTRE CLAMPING DEVICE ON TRIPLE MOUNTING SHANK 15
DESIGN EXAMPLES 5-axes machine with robot system A machine with special equipment, suitable for machining glass and ceramics. It is among others equipped with: - An optical measuring system for aligning the workpieces. - Overpressure in the guides to prevent fine dirt from penetrating. - A cooling lubrication system with a centrifuge for separating the fine and highly abrasive glass particles. Technical data Travel x-axis Travel y-axis Travel z-axis B-axis C-axis Tool spindle Tool magazine Robot system 500 mm 370 mm 450 mm +/- 135° Unrestricted rotation angle Ball bearing spindle HSK 25/32 with internal coolant supply to the tools 2 discs with 75 tools each 90 pallet spaces 16
DESIGN EXAMPLES Two machines with robot system A flexible manufacturing cell consisting of 2x UPF and a robot system. The system produces complex parts unmanned in three shifts, even over the weekends. Technical data Travel x-axis Travel y-axis Travel z-axis Tool spindle Tool magazine Robot system 300 mm 300 mm 200 mm Air bearing spindle HFS 80 HSK 25 10 pallets with 20 tools each 90 pallet spaces 17
DESIGN EXAMPLES A machine with robot system A highly productive manufacturing cell consisting of 1x UPF and a robot system for unmanned production in three shifts. Technical data Travel x-axis Travel y-axis Travel z-axis Tool spindles Tool magazine Robot system 300 mm 300 mm 200 mm 1x air bearing spindle HFS 80 HSK 25, 1x air bearing spindle HFS 60 10 pallets with 20 tools each 90 pallet spaces 18
DESIGN EXAMPLES Reciprocating table machine with two y-axes and two workpiece clamping devices This machine type facilitates a workpiece change irrespective of the primary processing time. While machining is ongoing at one of the workpiece clamping devices, the workpiece on the other one can be changed outside the machining area. The workpiece can be changed manually or fully automatically. Technical data Travel x-axis Travel y-axes Travel z-axis Tool spindles 500 mm 2x 720 mm 150 mm 3x air bearing spindle HFS 80 HSK 25 One of the spindles can be replaced with a thread cutting unit 19
DESIGN EXAMPLES Machine with three z-axes The machine process three identical workpieces simultaneously. It is equipped with three spindles, each of which is mounted on its own z-axis. A special software also permits the consecutive numbering of workpieces. Technical data Travel x-axis Travel y-axis Travel z-axes Tool spindles 300 mm 300 mm 3x 150 mm 3x air bearing spindle HFS 60, each mounted on its own z-axis Workpiece clamping device 36 workpieces 20
DESIGN EXAMPLES Reciprocating table machine with two y-axes, two workpiece clamping devices and three z-axes Thanks to the system of the reciprocating table machine, workpieces can be changed irrespective of the primary processing time and in addition, three workpieces can be machined simultaneously on the other workpiece clamping device. Technical data Travel x-axis Travel y-axes Travel z-axes Tool spindles 660 mm 2x 300 mm 3x 150 mm 3x air bearing spindle HFS 80 HSK 25, each mounted on its own z-axis Workpiece clamping devices 2x 6 workpieces Tool change with automatic loader from a palletising system 21
DESIGN EXAMPLES Machine with three axes, two spindles and loading robot The machine is designed for high-quality engraving and milling work. A robot for the automatic loading of the workpiece clamping device from baskets facilitates unmanned production. Technical data Travel x-axis Travel y-axis Travel z-axis Tool spindles 300 mm 300 mm 150 mm 2x air bearing spindle HFS 60 Workpiece clamping device 6 workpieces 22
DESIGN EXAMPLES Machine with three axes and two spindles This machine type is among other things used for high-quality engraving work. A spare tool can be stored in the second spindle, thus doubling the unmanned production time. The machine is designed for machining in oil. Technical data Travel x-axis Travel y-axis Travel z-axis Tool spindles 300 mm 300 mm 150 mm 2x air bearing spindle HFS 60 Workpiece clamping device 6 workpieces 23
GERMANY Lehmann Präzision GmbH Weilerstraße 27 78739 Hardt Phone: +49 7422 95800 Fax: +49 7422 958020 vertrieb@lehmann-praezision.de www.lehmann-praezision.de SWITZERLAND Lehmann Präzisionstechnik GmbH Ruppertsmoosstrasse 25 8583 Donzhausen Phone: +41 71 570 5372 verkauf@lehmann-praezision.ch www.lehmann-praezision.ch