Perfectly suited for 5-side machining - matec
Perfectly suited for 5-side machining - matec
Perfectly suited for 5-side machining - matec
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Editorial<br />
Hall 9 Booth C 67<br />
Erich Unger, Managing Director<br />
<strong>matec</strong> Maschinenbau GmbH<br />
www.<strong>matec</strong>.de<br />
<strong>matec</strong>-30 HVC - perfectly <strong>suited</strong> <strong>for</strong> 5-<strong>side</strong> <strong>machining</strong> of tall and heavy parts<br />
Spacious working area with perfect chip-flow<br />
Machines Processes Applications Ed. 4/2011<br />
<strong>matec</strong> maschines<br />
Flexible, highly precise, with perfect solutions <strong>for</strong> automation<br />
The tool and mould making sector is visiting the Euromold in Frankfurt at the end of the<br />
month, to learn about interesting innovations <strong>for</strong> their production. <strong>matec</strong> has redesigned the<br />
proven machine concept of the <strong>matec</strong>-30 HVC. The HVC is a <strong>machining</strong> center, which is<br />
ideally <strong>suited</strong> <strong>for</strong> 5-<strong>side</strong> <strong>machining</strong> of tall and heavy parts. Find an interesting report on the<br />
<strong>matec</strong>-40 P in this issue - a machine of the gantry series, which was designed <strong>for</strong> the requirements<br />
of tool and mould making.<br />
A hot topic today is the cost pressure in production. In order to counter this, we and our<br />
partners have worked on solutions <strong>for</strong> the automation of our machines, which help reduce<br />
costs by time-saving, lightly-manned production. In this issue of the <strong>matec</strong>-News we show<br />
you a wide variety of automation - there are special solutions <strong>for</strong> each machine series.<br />
And as usual, our machine concepts show their outstanding features: Get inspired!<br />
Cordially<br />
Erich Unger<br />
Special features<br />
1-axis CNC swivel head<br />
± 105° <strong>for</strong> 5-<strong>side</strong> <strong>machining</strong><br />
Free-standing CNC rotary table<br />
swing diameter max. 940 mm<br />
Long Z-axis <strong>for</strong> the <strong>machining</strong><br />
of tall workpieces<br />
Specifications <strong>matec</strong>-30 HVC<br />
Working area X 1,500 mm<br />
Working area Y 800 mm<br />
Working area Z 800/1,100 mm<br />
Spindle SK 40 (HSK-A 63)<br />
Speed 9,000-42,000 rpm<br />
Power 16 (30) kW - 40% DC<br />
Torque, max. 100 (91) Nm - 40 % DC<br />
Rapid feed 30/(48/80 with linear drive) m/min<br />
Tool magazine 36 (48 up to 128) pcs<br />
Content<br />
We show this<br />
machine at<br />
the Euromold<br />
in Frankfurt<br />
p. 1 Euromold exhibit <strong>matec</strong>-30 HVC<br />
pp. 2-3 Series P and PP<br />
pp. 4-5 Series HV and HVU<br />
pp. 6-7 Customer report <strong>matec</strong>-40 P<br />
p. 8 On <strong>matec</strong>/fairs<br />
pp. 9-16 Special: Automation
2<br />
Highest precision and flexible traveling paths<br />
Machines<br />
<strong>matec</strong>-30 HV <strong>matec</strong>-40 HV<br />
<strong>matec</strong>-50 HVU<br />
On this <strong>matec</strong>-30 HV prototypes <strong>for</strong> nearly all car manufacturers worldwide are manufactured.<br />
The machine is equipped with a swivel head <strong>for</strong> vertical and horizontal <strong>machining</strong> and with an<br />
integrated rotary table.<br />
Working area with intgrated rotary table and fixed machine table<br />
Your our plus: plus: extra ex extra xtra pr premium<br />
t tools<br />
You Yoou<br />
know the KOMET GROUP UP as a premium pr premium<br />
tools<br />
manufacturer manufacturer<br />
and you know w about the ideas behind<br />
our solutions. Now discover an unparalleled extra<br />
which offers<br />
you permanent and sustainable advantages.<br />
<strong>matec</strong>-30 HV with rotary table, diameter 1,300 mm<br />
HV- and HVU -<br />
<strong>matec</strong>-50 HV, traveling path of 4,000 mm in the X-axis, integrated rotary table,<br />
diameter 1,250 mm, <strong>for</strong> the <strong>machining</strong> of parts with a diameter of max. 1,500 mm.<br />
The swivel head ± 105° allows the complete <strong>machining</strong> in one clamping.<br />
We W e call it TOOLS+IDEAS: advanced services, ervices, unique<br />
technical hnical support support and and practical practical specialist specialist list seminars.<br />
seminars.<br />
For r more mor more<br />
in<strong>for</strong>mation see<br />
www.kometgroup.com www.kometgr<br />
etgroup.com<br />
www.kometgroup.com<br />
.kometgroup.com<br />
www
<strong>for</strong> the tool and mould making sector<br />
series - ideal <strong>for</strong> small and medium-sized parts<br />
The traveling column series has been conceived<br />
<strong>for</strong> single-part and series production. Stability,<br />
precision and high speed are characteristics of<br />
these machines.<br />
Outstanding features of the HV machines are<br />
long traverse paths, horizontally and vertically<br />
swiveling machine spindles and an easy mounting<br />
of clamping units.<br />
A swivel head <strong>for</strong> 5-<strong>side</strong> horizontal and vertical<br />
<strong>machining</strong> as well as <strong>for</strong> 3D <strong>machining</strong> is characteristic<br />
<strong>for</strong> the HV series. These machines are also<br />
available in different configurations.<br />
<strong>matec</strong>-30 HV with zero-point clamping system<br />
For the tool and mould making sector the<br />
<strong>matec</strong>-30 HVK, the <strong>matec</strong>-30 HVE, and the<br />
<strong>matec</strong>-30 HVC are the best choice. Direct<br />
drives in swivel head and rotary table bring<br />
a plus in dynamics in 5-<strong>side</strong> and 3D <strong>machining</strong>.<br />
For more in<strong>for</strong>mation on our machines please see www.<strong>matec</strong>.de<br />
Specifications <strong>matec</strong>-30 HV<br />
Working area X 6,000 mm<br />
Working area Y 800 mm<br />
Working area Z 1,100 mm<br />
Spindle HSK-A 63<br />
Motor spindle speed 12,000 rpm<br />
Power 30 kW -40% DC<br />
Torque, max. 190 Nm - 40 % DC<br />
Rapid feed with linear drive X-axis 80 / Y- and Z-axis 48 m/min<br />
Tool magazine 48 pcs<br />
Specifications <strong>matec</strong>-40 HV<br />
Working area X 2,000-12,000 mm<br />
Working area Y 800 mm<br />
Working area Z 800/1,100 mm<br />
Spindle SK 50 / HSK-A 100<br />
Motor spindle speed 8,000 rpm<br />
Power 44 (68) kW - 20% DC<br />
Torque, max. 350 (460) Nm - 20 % DC<br />
Rapid feed 30/ (48/80 with linear drive) m/min<br />
Tool magazine 40 (60 up to 200) pcs<br />
Specifications <strong>matec</strong>-50 HVU<br />
Working area X 4,000 mm<br />
Working area Y 1,400 mm<br />
Working area Z 1,800 mm<br />
Spindle HSK-A 100<br />
Motor spindle speed 8,000 rpm<br />
Power 45 kW - 40% DC<br />
Torque, max. 520 Nm - 40 % DC<br />
Rapid feed X- / Y- and Z-axis 30 m/min<br />
Tool magazine 40 pcs<br />
<strong>matec</strong>-30 HVC <strong>matec</strong>-30 HVK <strong>matec</strong>-30 HVE<br />
<strong>matec</strong>-30 HVU<br />
<strong>matec</strong>-30 HVU, universal milling head<br />
Marposs has developed the Mida line of products<br />
to per<strong>for</strong>m part inspections, tool setting and machine<br />
monitoring applications on machine tools.<br />
System components are designed to withstand the<br />
harshest conditions in the machine environment, at the<br />
same time assuring the highest measuring precision.<br />
Mida system features various signal transmission<br />
options, enabling Marposs to supply the best application<br />
<strong>for</strong> all measuring requirements on machine tools.<br />
<strong>matec</strong>-30 HVK, rotary table with direct drive and face-plate<br />
<strong>matec</strong>-30 HVK with rotary table, diameter 630 mm<br />
MARPOSS offers a complete product line <strong>for</strong> verification on machine tools<br />
01<br />
02<br />
03<br />
Marposs GmbH • Mercedesstr. 10 • D-71384 Weinstadt<br />
Tel. +49(0)7151/2054-0 • Fax +49(0)7151/2054-150<br />
www.marposs.com<br />
Image 1:<br />
Mida Laser non contact<br />
tool setting system <strong>for</strong> tool<br />
checking an identification<br />
Image 2:<br />
Mida WRS Radio<br />
Frequency Transmission<br />
touch probe system <strong>for</strong><br />
worldwide use<br />
Image 3:<br />
Mida TBD non-contact tool<br />
breakage detector<br />
3
4<br />
<strong>matec</strong>-40 P with<br />
2-axis swivel head<br />
<strong>matec</strong>-50 P with<br />
2-axis swivel head<br />
Machines<br />
<strong>matec</strong>-30 PP with<br />
pallet changer<br />
Long traverse paths <strong>for</strong> voluminous work parts<br />
<strong>matec</strong>-30 PP with pallet changer<br />
A power of 30 kW and a spindle speed of up to 18,000 rpm,<br />
traveling paths of 10,000 x 3,500 x 1,500 mm and a gantry<br />
clearance of 1,300 mm allow the <strong>machining</strong> of very large<br />
parts as well as high-speed cutting.<br />
Kälte-Wärme-<br />
Versorgungstechnik<br />
GmbH<br />
Cooling units<br />
Cabinet coolers<br />
Cooling tunnels<br />
Temperature controls<br />
Heat exchangers<br />
<strong>matec</strong>-50 P with 2-axis swivel head<br />
<strong>matec</strong>-40 P with a power of 44 kW and spindle speed 12,000<br />
rpm. Traveling paths: 6,000 x 4,000 x 1,500 mm.<br />
<strong>matec</strong>-50 P, <strong>machining</strong> Frei<strong>for</strong>mflächenfräsen<br />
of aluminium<br />
Free-surface <strong>machining</strong><br />
cool ��� �����<br />
Benzstrasse 2 � ������� ������������ � ����� ��� ��� ����������� � ��� ��� ��� ������������ � ����� ����������������� � ����������������<br />
Apparatebau<br />
GmbH & Co. KG<br />
Chip conveyors<br />
Filtration units<br />
Magnetic cylinders<br />
Tank construction<br />
Special plants<br />
The gantry
<strong>for</strong> the tool and mould making sector<br />
series – high stability and a milling per<strong>for</strong>mance above average<br />
The gantry machines <strong>matec</strong>-30P (taper SK 40/HSK-A 63),<br />
<strong>matec</strong>-40 P and 50 P (taper SK50/HSK-A 100), as well as<br />
the gantry machines <strong>matec</strong>-30 PP and 40 PP, were designed<br />
<strong>for</strong> single-part and series production of large and heavy work<br />
parts <strong>for</strong> tool and mould making, mechanical engineering,<br />
and structural steel engineering. Main range of application<br />
is the <strong>machining</strong> of 3D-shapes in steel and aluminium, plates,<br />
welding, and steel construction.<br />
The gantry construction guarantees good accessibility from<br />
all <strong>side</strong>s if space is limited. The application of either a swivel<br />
head (± 90°) or a 2-axis CNC motor spindle milling head<br />
permits multilateral <strong>machining</strong>. A rich variety of spindle speed<br />
and spindle power options <strong>for</strong> all materials is available.<br />
Specifications <strong>matec</strong>-30 PP/40 PP<br />
Working area X 3,000 mm<br />
Working area Y 3,200 mm<br />
Working area Z 1,300 (1,500) mm<br />
Gantry clearance height 30 PP 1,300 / 40 PP 1,500 mm<br />
Gantry clearance width 4,000 mm<br />
Pallet size 2,000 x 2,000 mm<br />
Spindle SK50 (HSK-A 100)<br />
Speed 9,000/12,000/15,000/18,000/24,000/42,000 rpm<br />
Power 30 PP 16 (30) / 40 PP 26 kW - 40% DC<br />
Torque, max. 30 PP 100 (190) / 40 PP 340 Nm - 40 % DC<br />
Rapid feed 30 m/min<br />
Tool magazine up to 250 pcs<br />
Subject to technical changes<br />
Standard specifications<br />
Gantry design with fixed machine table<br />
Traverse path in X-axis from 3,000 to 15,000 mm<br />
Traverse path in Y-axis from 1,600 to 5,000 mm<br />
Traverse path in Z-axis from 800 to 2,300 mm<br />
Pre-stressed roller guides in all axes<br />
Drive system in X-axis with ballscrews on both <strong>side</strong>s<br />
Rapid feed rate with digital AC servo motor<br />
Digital main spindle drive<br />
Motor spindle, speed 9,000 rpm<br />
Orientated spindle stop<br />
Tool magazine travelling in X-axis<br />
Tool position coding variable<br />
CHANGE!<br />
– The modular Quick Change Pallet System<br />
Patented Clamping Technology allows <strong>for</strong>ces up to 40000 N (9000 lbf)<br />
Fixing via short taper ensures a repeat accuracy of < 0.0002“ (0.005 mm)<br />
Largest modular system <strong>for</strong> standard clamping devices with more than 500 combinations possible<br />
Completely sealed and maintenance-free system<br />
EUROMOLD 2011 HALL 8/BOOTH C70<br />
EXCEPTIONAL PRECISION FROM THE COMPETENCE LEADER FOR CLAMPING TECHNOLOGY AND GRIPPING SYSTEMS.<br />
For more in<strong>for</strong>mation on our machines please see www.<strong>matec</strong>.de<br />
Specifications <strong>matec</strong>-40 P<br />
Working area X 3,000-20,000 mm<br />
Working area Y 2,500-4,000 mm<br />
Working area Z 1,300-1,500 mm<br />
Gantry clearance height 1,150-1,350 mm<br />
Gantry clearance width 2,800-3,800 mm<br />
Machine table width 1,600-3,600 mm<br />
Spindle SK50 (HSK-A 100 )<br />
Speed 8,000 rpm<br />
Power 33 kW - 40% DC<br />
Torque, max. 382 Nm - 40 % DC<br />
Rapid feed 30 m/min<br />
Tool magazine<br />
Subject to technical changes<br />
40 (up to 200) pcs<br />
Specifications <strong>matec</strong>-50 P<br />
Working area X 4,000-50,000 mm<br />
Working area Y 5,000 mm<br />
Working area Z 1,100 (1,500) mm<br />
Gantry clearance height 2,270 (3,070) mm<br />
Gantry clearance width 4,000 mm<br />
Machine table width 3,000 mm<br />
Spindle SK 50 (HSK-A 100)<br />
Speed 9,000 rpm<br />
Power 60 kW - 40% DC<br />
Torque, max. 575 Nm - 40 % DC<br />
Rapid feed 30 m/min<br />
Tool magazine<br />
Subject to technical changes<br />
18 (up to 200) pcs<br />
Tool life control<br />
Sister tool managing<br />
Automatic lag compensation in order<br />
to provide high speed milling of contours<br />
Chip conveyor on both <strong>side</strong>s along the X-axis<br />
Coolant system (CTS)<br />
Machine cladding (without roof), CE norm<br />
Control panel with all necessary operating devices<br />
Controls:<br />
Rexroth IndraMotion MTX<br />
Heidenhain iTNC 530<br />
Siemens 840D<br />
www.schunk.com/vero-s/en<br />
Machining of voluminous parts on <strong>matec</strong>-50 P<br />
<strong>matec</strong>-50 P with traveling operator plat<strong>for</strong>m<br />
Tool and mould making<br />
<strong>matec</strong>-40 P, X=10,000 mm<br />
5
6<br />
Eggert CNC-Technik GmbH<br />
The right machine concept <strong>for</strong> high added value<br />
It merely took job shopper Eggert CNC-Technik eleven years to grow<br />
from two to 46 employees. A lot of things have changed in these years of<br />
dynamic growth, but one thing has remained the same: <strong>matec</strong> <strong>machining</strong><br />
centers are the heart of the metal <strong>machining</strong> department of the company.<br />
In the year 2000, at the age of 32, Jochen Eggert dared to start up his own business.<br />
His experiences as an employee <strong>for</strong> packing machines manufacturer Paltec and<br />
two years working <strong>for</strong> <strong>matec</strong> had made him sure: in the region there was a need <strong>for</strong><br />
mechanical <strong>machining</strong> of parts, which the existing job shoppers could not fulfil. For that<br />
reason, Jochen Eggert founded the Eggert CNC-Technik GmbH eleven years ago –<br />
with one single machine, a <strong>matec</strong>-30 HV.<br />
Machining capacities and added value must correspond<br />
The dynamic growth of his company was based on a simple strategy, the owner<br />
knows: „The most important thing was to start with a machine, which could on the one<br />
hand manage the <strong>machining</strong> capacities, and on the other hand provide a high added<br />
value. <strong>matec</strong> Managing Director Erich Unger gave the advice to order a <strong>matec</strong>-30 HV<br />
<strong>machining</strong> center, with traveling paths in X of 4,000 mm.“ Today the innovative entrepreneur<br />
is glad to have put the emphasis on the <strong>machining</strong> of large parts right from the<br />
beginning. That way hard work, ability and order income were acompanied by a<br />
good margin, which enabled further growth. Jochen Eggert remarks: „In most cases<br />
our customers have provided the impetus <strong>for</strong> investing in a new machine. By and by<br />
the orders <strong>for</strong> large parts were followed by requests <strong>for</strong> the <strong>machining</strong> of small parts,<br />
so we had to purchase another HV machine quickly.“ And this is how it went <strong>for</strong> a couple<br />
of years, so almost every year a new <strong>matec</strong> maching center was purchased.<br />
Nevertheless Eggert still couldn’t meet all requirements: „The more our clientele grew,<br />
the more requests we had <strong>for</strong> the <strong>machining</strong> of parts in sizes, which we couldn’t do<br />
even on our largest machine.”<br />
Investing in a gantry machine with traveling path in X of 10,000 mm<br />
By and by Eggert came to the decision to round up his <strong>machining</strong> per<strong>for</strong>mance by a<br />
much bigger <strong>machining</strong> center. Unger still remembers the discussions he had with the<br />
young entrepreneur Eggert: „When I discuss an investment with a customers, I am not<br />
simply selling a machine. I want all <strong>matec</strong> customers to benefit from my experience in<br />
the market. That is the reason why I said over and over again, Jochen, if you want to<br />
earn money, you have to invest in a gantry machine.“ After more detailed consultations<br />
with Erich Unger, Eggert settled <strong>for</strong> a gantry <strong>machining</strong> center <strong>matec</strong>-40 P with<br />
traveling path in Y of 10,000 mm. Unger is conviced, that this is a further investment<br />
which will pay off nicely : „Today Eggert CNC-Technik is the only job-shopper within a<br />
Industrial<br />
Our customers<br />
radius of 50 kilometers who owns a machine with a table length of 10 meters. Such a<br />
unique selling point pays off in orders and margins.“<br />
Customer and supplier, a constellation which is profitable <strong>for</strong> both parties<br />
The investment of such a lot of money, was not easily decided on by the young company.<br />
The commitment of <strong>matec</strong> founder Unger, to make use of one third of the machine’s<br />
capacity by placing orders <strong>for</strong> <strong>matec</strong>-parts, quite helped. Meanwhile the 40 P<br />
produces in three shifts. Be<strong>side</strong>s housings, machine bases and columns <strong>for</strong> <strong>matec</strong>, a<br />
great variety of parts are manufactured. Customers are found in sectors such as construction<br />
machinery to general engineering or special machinery.<br />
Eleven <strong>matec</strong> machines are currently at work <strong>for</strong> Eggert. 46 employees supervise<br />
the production of parts in two and three shifts. Company owner Jochen Eggert sees<br />
potential <strong>for</strong> further growth. The very first <strong>matec</strong>, a <strong>matec</strong>-30 HV, is till running in<br />
two and three shifts.
sectors + applications<br />
in different industrial sectors and all over the world<br />
Enormously versatile: <strong>matec</strong>-40 P machines a wide variety of different materials. Customers can be found in machine tool business, the general<br />
engineering sector, or in agricultural and construction machinery. The traveling operator plat<strong>for</strong>m provides <strong>for</strong> a good control of the <strong>machining</strong> steps.<br />
Highest precision in the <strong>machining</strong> of guideways<br />
The cooperation between supplier and customer is profitable <strong>for</strong> both parties: „The precision,<br />
that Jochen Eggert reaches, <strong>for</strong> example, in the <strong>machining</strong> of guideways, is really<br />
astonishing.“ Unger points to the machine base, which is ready <strong>for</strong> <strong>machining</strong> on the 40 P:<br />
„In the case of this machine base with guideways of a length of 3,000 mm, the deviation<br />
across the total length of the base amounts to only one hundredth mm. That is really firstclass.“<br />
Linear drives <strong>for</strong> rapid feeds up to 80 m/min in the X-axis<br />
Be<strong>side</strong>s the precision, Eggert appreciates the flexibility of the 40 P. „We have machined<br />
parts on this machine with a length of more than 8 meters and a weight of 18 tons.<br />
Whether you believe it or not - the biggest challenge in those cases was, to get the parts<br />
onto the machine. The <strong>machining</strong> itself was not problematic at all. But parts of these dimensions<br />
are not daily routine. In most cases we machine several parts clamped in a row, or<br />
mount a part, while a second one is being machined.“ The tool magazine with 2 x 40<br />
tools is placed safely and space-savingly in the traveling column, which means that all<br />
<strong>machining</strong> procedures can be done with no problem in a tool change time of only 4,5<br />
seconds and a chip-to-chip-time of less than 10 seconds. Optionally a tool magazine with<br />
up to 200 tool pockets is available. With a tool length of 4,600 mm in the standard version,<br />
and a maximum tool weight of 25 kg, plus a power of 33 kW at 40 % DC and a<br />
torque of 382 Nm at 40 % DC, almost all <strong>machining</strong> tasks can be per<strong>for</strong>med.<br />
Powerful spindle with 8,000 rpm<br />
Most important <strong>for</strong> Eggert is the possibility to machine different materials on the machine.<br />
For the <strong>machining</strong> of aluminium on the <strong>matec</strong>-40 P, he can use a spindle with a speed of<br />
8,000 rpm. „Our competitors are limited to 400 rpm“, says Eggert. Another important<br />
aspect <strong>for</strong> his decision to buy even more <strong>matec</strong> machines in the future, is the good aftersales<br />
service. The short distance to the machine builder in Köngen near Stuttgart means<br />
that support is available at any time, whenever it is needed. In times, when the majority of<br />
the <strong>machining</strong> centers is working in two or three shifts, this is a decisive factor.<br />
We grow with our customers<br />
According to Unger’s experience, the success story of Eggert CNC-Technik is no single<br />
case „Almost all the companies, that put their trust in <strong>matec</strong> as a supplier, have developed<br />
economically. The majority of them are still dedicated customers. And we have grown with<br />
our customers.“<br />
The original version of this article was published in MAV Ed. March 2011 · Author: Holger Röhr<br />
Erich Unger and Jochen Eggert agree: the <strong>matec</strong>-40 P is quite the right machine<br />
<strong>for</strong> the range of parts, which the Eggert GmbH is currently producing - and<br />
there is more in it <strong>for</strong> future requirements<br />
Work-parts up to a length of 8 m and a weight of up to 18 tons can be machined<br />
on the <strong>matec</strong>-40 P<br />
7
8<br />
EMO 2011 A successful fair <strong>for</strong> the machine tool sector<br />
Welcome to the Euromold in Frankfurt<br />
Fairs 2012<br />
Nortec<br />
January, 25-28<br />
METAV, Düsseldorf<br />
February, 28 - March, 3<br />
AMB, Stuttgart<br />
September, 18-22<br />
Euromold, Frankfurt<br />
November, 27-30<br />
Fairs On <strong>matec</strong><br />
29.11.-02.12.2011<br />
Hall 9 Booth C 67<br />
Our exhibit:<br />
<strong>matec</strong>-30 HVC<br />
We are looking <strong>for</strong>ward<br />
to your visit!
<strong>matec</strong>-30 PP - gantry machine with pallet changer<br />
The highlights:<br />
� 2-axis CNC swivel head <strong>for</strong> 5-axis simultaneous <strong>machining</strong><br />
� C-axis (rotary axis) ± 180°/B-axis (swivel axis) ± 95°<br />
� New tool magazine with 250 tool pockets<br />
Machines<br />
Special: Automation<br />
� Large Z-axis up to 1500 mm<br />
� Rigid gantry bridge<br />
� Pallet changer<br />
The right automation saves production time and brings economic efficiency<br />
In modern production these are very decisive factors. High cost pressure on the market makes automation even more important. State-of-the-art<br />
solutions bring flexibility even in single part production. Manufacturing with less manpower reduces unit costs - a lot of companies follow this route<br />
today.<br />
<strong>matec</strong> has the right automation <strong>for</strong> every machine series. Usually the customer orders a <strong>matec</strong> machine together with an automation, especially if<br />
series production and a high productivity are demanded. In this case standard systems are customized to the machine. More complex solutions are<br />
designed and manufactured by <strong>matec</strong>.<br />
A pallet changer as automation is advantageous in every machine series, especially in the<br />
<strong>machining</strong> of voluminous and heavy parts and in complete <strong>machining</strong> in one clamping and<br />
long <strong>machining</strong> time.<br />
9
10<br />
� 1-axis CNC swivel head <strong>for</strong> 5-<strong>side</strong> <strong>machining</strong> ± 105°<br />
� Free-standing CNC rotary table swing diameter max. 940 mm<br />
� Automation with pallet magazine and robot<br />
Machines<br />
Swiss manufacturer of packaging machines relies on <strong>matec</strong>-30 HV and 30 HVC with robot cell<br />
� Long Z-axis up to 1100 mm<br />
� Tool magazine with 210 pockets
+ Solutions<br />
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Special: Automation<br />
For more in<strong>for</strong>mation on our machines please see www.<strong>matec</strong>.de<br />
Perfect automation: pallet magazine, robot loading unit, devices, and clamping systems<br />
<strong>matec</strong>-40 HV pallet loading system and additional<br />
circular tool magazine with 200 tool pockets<br />
Being able to produce seven days a week in three shifts - fully automated and flexible down to the<br />
single piece - this vision of a Swiss manufacturer of packaging machines was to be made a reality.<br />
In the approach to a solution a <strong>matec</strong>-30 HVC was found, equipped with 5 simultaneous axes,<br />
complemented by an automation. Swiss <strong>matec</strong> representative SMI had designed a concept which<br />
consisted of a customized version of a standard machine plus an automation adapted to the<br />
manufacturing. This concept covered 80 % of the cubic parts and the demands <strong>for</strong> flexible batch<br />
sizes.<br />
The manufacturing cell consists of a <strong>matec</strong>-30 HVC, a Fanuc robot with load capacity of 210 kg, a<br />
pallet magazine <strong>for</strong> pallets of the sizes 400 x 400, 500 x 500, 500 x 800 and 600 x 800 mm,<br />
a loading station <strong>for</strong> pallets and tools, and a magazine of 210 HSK 63 tools with transfer station,<br />
plus 48 tools deposited in<strong>side</strong> the machine.<br />
The pallet magazine allows a random storage of various pallet sizes. The <strong>matec</strong>-30 HVC has traverse<br />
paths in X/Y/Z of 1,500 x 800 x 1,100 mm, a B-axis ± 105°, a C-axis 360°, and is equipped<br />
with an integrated rotary table which is offset from the center in X/Y-direction, with diameter<br />
630 mm. The offset provides <strong>for</strong> an extra large interference diameter. A Unilock zero-point clamping<br />
system clamps pallets, stationary chucks, multiple clamping devices and tombstones. The<br />
smaller pallets are made of steel and are covered with mineral casting, in order to achieve a<br />
weight reduction, high rigidness and minimum vibration. The larger pallets are made of aluminium.<br />
The customer is satisfied: „Our vision of a 24 hour production has almost come true. Based on<br />
168 hours in a week, we are significantly above 100 hours of effective spindle time.“<br />
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11
12<br />
Machines<br />
<strong>matec</strong>-30 HVK - <strong>machining</strong> center and automation from one source <strong>for</strong> a perfect interaction<br />
The <strong>matec</strong>-30 HVK is the perfect solution <strong>for</strong> complex <strong>machining</strong> tasks in 3D and in 5-<strong>side</strong> <strong>machining</strong>.<br />
Shown above is a combination of pallets and robot automation. Also available as milling/turning center!<br />
� Traverse paths X=1,300/Y=600/Z=800 mm<br />
� Integrated rotary table, diameter 630 mm with swing diameter 940 mm<br />
� Direct drive in rotary table (A-axis) and swivel head (B-axis)<br />
<strong>matec</strong>-30 HV as robot cell with 128 additional tools<br />
and pallet magazine. Pallet dimensions 500 x 500 mm<br />
Our service:<br />
<strong>matec</strong>-50 HV with pallet loading system and additional circular magazine with 240<br />
tool pockets. Pallet dimensions 800 x 800 mm, loading capacity 1.5 tons<br />
The medium-sized company HINZ has 45 employees in two<br />
locations and manufactures machine parts with a piece weight<br />
of up to 50 tons. We deliver best quality - from thermal cutting<br />
to finished and coated parts - everything from one source!<br />
� Thermal cutting<br />
� Welding<br />
� Thermal stress relief<br />
� Sandblasting<br />
� Priming/Coating<br />
� CNC Machining Learn more about us: www.hinz-maschinenbauteile.de<br />
Our plants<br />
Plant 1<br />
Daimlerstr. 3-5<br />
D-71254 Ditzingen-<br />
Schöckingen<br />
Phone 07156/9555-0<br />
Fax 07156/9555-11<br />
Plant 2<br />
Langwiesenstr. 14<br />
D-74363 Güglingen-<br />
Frauenzimmern<br />
Phone 07135/97405-0<br />
Fax 07135/97405-25
+ Solutions Special: Automation<br />
Examples <strong>for</strong> automation with gantry loader and robot<br />
The traveling column series is<br />
highly flexible and has a great<br />
variety of traverse paths. Heavyweight<br />
parts in small to mediumsized<br />
batches can be machined.<br />
The automation depends<br />
on the <strong>machining</strong> task. A gantry<br />
loader is more expensive than a<br />
robot, but it can transport longer<br />
and heavier parts. The<br />
gantry loader (3 or 4 axes) has<br />
a linear movement, which is<br />
ideal <strong>for</strong> long distances. The<br />
gantry loader can load linked<br />
machines quite easily, a robot<br />
can’t. Due to its joints (practically<br />
6 and more axes) the<br />
robot is the most flexible.<br />
We have the right solution <strong>for</strong> every automation task. And <strong>for</strong> yours!<br />
Magazining and loading of chucks by gantry loader Robot loading of drawer magazines<br />
precision boring<br />
from 0.4 to 3,255 mm diameter.<br />
As the first and only tooling company Wohlhaupter offers digital precision boring<br />
tools from 0.4 to 3,255 mm diameter. Your advantages: simple tool adjustment<br />
thanks to integrated digital display, direct opto-electronic traverse<br />
measurement with �-accurate dimension correction and a feeding<br />
accuracy of 0.002 mm in diameter. For fewer scrap parts and<br />
increased productivity. A new dimension in precision boring.<br />
For more in<strong>for</strong>mation on our machines please see www.<strong>matec</strong>.de<br />
Challenge us:<br />
www.wohlhaupter.com<br />
13
14<br />
Machines<br />
<strong>matec</strong>-30 HVTH - Complete solution with bar feeder, saw unit and NC gripper<br />
Workpart <strong>machining</strong> on the main spindle Workpart transfer into the opposed spindle<br />
<strong>matec</strong>-30 HVTH is a <strong>machining</strong> center with a rotary table and opposed spindle <strong>for</strong> complete <strong>machining</strong> (front and back <strong>side</strong>s) of workparts from a bar in singlepart<br />
or series production with a loading and unloading automation unit. The range of <strong>for</strong>ms machined on <strong>matec</strong>-30 HVTH extends from profiles, round material,<br />
square and rectangular cross-sections up to diagonals of 120 mm. Optionallly with 2-axes saw unit to crosscut the part from the bar. Bar loader and unloading<br />
automation unit provide manless operation <strong>for</strong> a certain length of time. For small and medium-sized batches <strong>machining</strong> from the bar is the perfect solution - as<br />
well as <strong>for</strong> single-part production.<br />
W.KÖNIG GmbH > apparatus engineering OSTRING 13<br />
> shaping of sheet<br />
> powder coating<br />
D-73269 HOCHDORF<br />
Fon 07153 / 98 60 - 0<br />
Fax 07153 / 98 60 29<br />
Special features<br />
Lathe spindles A8 or A11<br />
Automation unit with roboter or<br />
NC-gripper / discharge belt<br />
U-axis with opposed spindle<br />
Bar feeder<br />
info@koenig-online.net<br />
www.koenig-online.net
+ Solutions<br />
Bar feeder, saw unit and NC gripper - economic and efficient automation<br />
<strong>matec</strong>-30 HV with bar feeder and saw unit <strong>for</strong> <strong>machining</strong> from the bar<br />
A <strong>machining</strong> center automates itself!<br />
Pendulum <strong>machining</strong>. Workpiece handling by means of an NC gripper, loaded from<br />
the tool magazine. Working area on the left <strong>side</strong>: Raw parts/finished parts<br />
Working area on the right <strong>side</strong>: <strong>machining</strong><br />
FIRSTCLASS MACHINING<br />
The automatic loading and unloading of lathes and <strong>machining</strong><br />
centres garanties top results <strong>for</strong> the cycle times.<br />
� ILS-RBK 100/160 Automatic short bar loader<br />
Material lengths: 1,200/1,600 + 2,200 mm<br />
� ILS-MUK Multi universal automatic short bar loader<br />
Material lengths: 1,200/1,600 mm<br />
� ecoPROFI/PROFImat Multichannel loading magazine<br />
Material lengths: 3,000 to 6,000 (10,000) mm<br />
� SiMag Single-channel loading magazine<br />
Material lengths: 3,000 to 6,000 mm<br />
� ILS-REX 72/100 Unloading system<br />
Workpiece lengths: 500/800/1,200 mm<br />
�<br />
Special: Automation<br />
For more in<strong>for</strong>mation on our machines please see www.<strong>matec</strong>.de<br />
The easiest way to automate a machine is by means of an NC gripper<br />
in the tool magazine. It can per<strong>for</strong>m the loading and unloading, the<br />
axes of the machine acting as handling system<br />
The <strong>matec</strong>-30 HV shown on the left is used <strong>for</strong> the manufacturing of radial gear<br />
units of large engines. It is equipped with a rotary table with vertical face-plate<br />
<strong>for</strong> the <strong>machining</strong> in the first clamping. After the <strong>machining</strong> of the fifth <strong>side</strong><br />
the part is handed over to a second rotary table with jaw chuck or other clamping<br />
fixture with horizontal face-plate. It is located on a slide unit traveling up<br />
to 1,400 mm. Both tables rotate 360°. In combination with the swivel head, it<br />
is possible to machine up to 5 <strong>side</strong>s of a workpiece. The saw unit crosscuts the<br />
workpiece to the required size after transfering it over to the second <strong>machining</strong><br />
area. After the <strong>machining</strong> the NC gripper removes the part from the working<br />
area and deposits it on a discharge belt.<br />
Due to the bar feeder no clamping device is necessary <strong>for</strong> the <strong>machining</strong> of<br />
parts. Every kind of part within the diameter of the bar can be machined - up to<br />
diameter 120 mm and up to a length of 400 - 500 mm.<br />
NC gripper loading the part<br />
into the lathe spindle<br />
�<br />
�<br />
�<br />
NC gripper depositing the part<br />
�<br />
Kurt Breuning IRCO Maschinenbau GmbH<br />
PO Box 1134 • 71140 Steinenbronn • Germany<br />
Tel.: 0049 7157 52860<br />
technologie@breuning-irco.de • www.breuning-irco.de<br />
15
Swivel table series Solutions <strong>for</strong> automation<br />
Machines can be tailored <strong>for</strong> special purpose applications,<br />
e.g. multiface <strong>machining</strong> with additional tools and pallet storage<br />
Specifications of gantry loader Specifications of <strong>machining</strong> centers<br />
X=3,600 mm, Y=800 mm, Z=800 mm X=800 mm, Y=480 mm, Z=500 mm<br />
Traverse speed: 60 m/min 180° swivel table, 24 tools,<br />
Parts weight: 60 kg Rapid feed 30 m/min, speed 9,000 rpm, power 16 kW<br />
Sectors<br />
General suppliers<br />
Automobile suppliers<br />
Tool and mould industries<br />
Tanks and containers industry<br />
Aluminium <strong>machining</strong>/Foundry<br />
Machine and plant engineering<br />
Packing machines<br />
Solutions<br />
Electric and electronics industries<br />
Plastic processing industry<br />
Medical technology<br />
Metal-working industry<br />
Aerospace industry<br />
Automobille manufacture<br />
Impressum<br />
Published by: <strong>matec</strong> Maschinenbau GmbH · Wilhelm-Maier-Str. 3 · D-73257 Köngen<br />
Phone +49-(0)7024/98385-0 · Fax +49-(0)7024/98385-30 · E-Mail: sales@<strong>matec</strong>.de · www.<strong>matec</strong>.de<br />
Special: Automation<br />
For more in<strong>for</strong>mation on our machines please see www.<strong>matec</strong>.de<br />
The highly productive swivel table machines usually have<br />
a very short operating time in the <strong>machining</strong> of parts. Since<br />
loading procedure takes place every 3-4 minutes, automation<br />
by pallet changer is not the best choice. The mounting<br />
of the parts would take too much time. In addition the<br />
necessary device is an extra expense-factor.<br />
Complete <strong>machining</strong>, long <strong>machining</strong> time, or the <strong>machining</strong><br />
of voluminous and heavy workpieces make a pallet changer<br />
a good solution <strong>for</strong> swivel table machines.<br />
When chaining machines, gantry loaders or loading robots<br />
are usually chosen. In this case size and weight of the workpieces<br />
are determining factors.<br />
Flexible manufacturing cell<br />
consisting of:<br />
2 <strong>machining</strong> centers <strong>matec</strong>-30 S<br />
1 CNC gantry loader<br />
1 CNC position-fixing station<br />
optionally available with <strong>matec</strong>-30 SD<br />
Flexible manufacturing cell <strong>for</strong> series production<br />
Per<strong>for</strong>ming a certain <strong>machining</strong> task, the CNC gantry loader<br />
grips the rotationally symmetrical parts from a rolling<br />
belt and places them in the position-fixing unit to adjust.<br />
So, the parts are fixed in the machine load area by turns<br />
and swivelled into the <strong>machining</strong> area by a 180° swivel<br />
table.<br />
During the <strong>machining</strong> process in both centers the gantry<br />
loader discharges the finished parts from the machines<br />
and deposits them on the rolling belt.<br />
The whole production flow of the flexible manufacturing<br />
cell is controlled by the gantry loader.