ProfiMill – Portal Milling Machines

02 | Tradition
03 | Concept
04 | Technology
Milling machine, 1953
Tradition and Innovation
Building portal milling machines has a long tradition at
WaldrichSiegen, with its roots dating back to 1951. In 1961,
WaldrichSiegen entered into a joint venture with Ingersoll
USA, thus making a quantum leap towards the manufacture of high-performance portal milling machines so far not
known in Europe.
The milling tools available on the market at that time did
not meet the high requirements of these new generation
milling machines. Therefore, a new and modern company
for the production of suitable high-performance milling
tools was built as a Greenfield project in Burbach,Germany,
WaldrichSiegen’s present location.
Soon thereafter, WaldrichSiegen introduced the use of fully
hydrostatic guideways on milling machines, which led to
a further pioneering development in the manufacture of
heavy-duty, high-performance machine tools.
With this new technology it became possible to perform
even heavy-duty cutting operations on WaldrichSiegen portal milling machines on almost friction-free guideways with
unlimited lifetime. We supplied more than 400 machines of
this type to customers around the world.
Based on WaldrichSiegen’s wealth of experience, we have
considerably enhanced our proven milling machine concept, attaching special importance to:
§
significant increase of performance and torque as
compared to all other concepts currently available on the global market
§
reduction of complexities with the aim to provide
efficient and economic solutions
§
increase of availability while reducing maintenance and repair cost
§
development of a modern machine enclosure of
functional, minimalist design, reflecting our Corporate Design
ProfiMill | Concept 03
Standards & Modules
Machine Structure
WaldrichSiegen offers a clear-cut, modular machine program with three machine sizes, covering a complete spectrum of configurations
§
torque up to 10.000 Nm
§
table length up to 12.000 mm, larger tables in
double-table design
§
ram travel between 1.500 and 4.000 mm
§
integrated rotary tables
§
tool changer (chain) with 40/60/80 pockets
§
tool changer (rack) with 80 to 480 pockets
All major machine components are made of high-quality
cast iron and are machined in-house at WaldrichSiegen to
maintain the highest precision and quality. The fully hydrostatic design in all machine axes guarantees nearly unlimited lifetime, zero backlash, highest static and dynamic
stiffness as well as maximum table load.
ProfiMill series
Size 1
Size 2
Size 3
Clearance
width
2-4m
2,5 - 5 m
4 - > 10 m
Clearance
height
1,5 - 3 m
1,5 - 5 m
2 - > 10 m
Milling power
50/65 kW
70 / 80 kW
80 / 100 / 120 kW
Design
table
table & gantry
table & gantry
WaldrichSiegen hydrostatic worm drives or master-/slave/
rack drives ensures high dynamic stiffness of the table
drives and for the column drives (for gantry-type machines).
Preloaded ball screws guarantee for highly precise positioning of the adjustable cross rail. Electrically preloaded
master-/slave drives for Y-movement of the milling unit
provide for high dynamics as well as for excellent positioning accuracy. Physically induced minimal deflections of
the system are compensated by applying compensation
curves to the portal and cross rail guideways.
Controlled vertical and horizontal heal clearance provides
for optimum cutting performance and excellent surface
qualities.
04 ProfiMill | Technology
Masterhead Concept – up to 120 kW at the Tool
Masterhead concepts for milling attachments have been
in use for quite some time. Traditionally, large heavy-duty
machines had rams with integrated main spindle and tool
taper interface, allowing the tool to be mounted directly
into the ram. WaldrichSiegen is the first manufacturer,
who consequently further developed the Masterhead
concept for machines with highest power and torque: the
“spindle” is reduced to a simple drive shaft, with substantial advantages:
§
limitation of speed to an technologically reasonable
extent allows for large bearing diameters as well as
grease lubrication at drives shafts and numerous milling attachments
§
no temperature increase and thus no geometrical
distortion within the ram
§
long service life of bearings supporting the drive shaft
§
slip rings or rotary transmissions for liquid media are
not required
§
low noise level due to low speeds in the power train
§
exchangeable milling attachments for highest
performance
§
improved overall efficiency
§
increased availability
§
decreased maintenance cost
All milling attachments are adapted through the Masterhead interface. For high speeds, a universal milling head
with exchangeable motor spindle can be adapted. Thus,
all required spindle speeds are available. All milling attachments can be equipped with life-time grease lubrication.
Additional cooling and lubrication circuits are not required.
Also, the number of media transfers at the Masterhead
interface can be reduced. The result is a reduction of
downtime and an improvement of overall machine availability and maintenance cost. The Masterhead interface is
provided with four self-locking clamping elements with a
high clamping power of 120 kN at relatively low hydraulic
pressure of 80 bar.
ProfiMill | Technology 05
Drive Concepts
The machines of the ProfiMill series are equipped with a
motor gear box with an ideal speed-torque characteristic.
The 2-step planetary gear unit is integrated into the ram.
Water and oil cooling provides for best possible thermal
behaviour of the unit.
Located in the upper part of the ram, the motor gear box
is accommodated in a so-called media transfer plate. Due
to its special design, the media transfer plate prevents any
potential heat transmission into the ram.
The media transfer plate serves as distribution block for
all media, which are forwarded through hoses to the ram’s
Masterhead interface, thus providing for:
§ minimum installation efforts and cost
§
no leakages
§
minimum maintenance efforts
Speed-torque diagram for ram – 600 x 600 mm
06 ProfiMill | Technology
Hydrostatic Guideways and Drives
WaldrichSiegen has continuously further developed
hydrostatic worm drives and guideways for heavyduty cutting processes. We have gained excellent expertise in both the engineering and the production
of hydrostatic worms and racks. The dynamic stiffness of all elements has been extremely enhanced.
The hydrostatic guideway principle was also applied to the
guideways of the ram. The square-shaped ram is completely
hydrostatically guided and thus achieves highest stiffness
combined with unsurpassed damping characteristics.
Up to 4 individual hydrostatic guideways with pump
per pocket systems on WaldrichSiegen tables allow for
loads of up to 40 tons per meter of table length, corresponding to workpiece weights of up to 500 tons.
The portals of the gantry machines are also equipped with hydrostatic guideways and worms. The Y-axis (saddle on cross
rail) is driven by an electrically pre-loaded master-/slave drive.
Hydrostatic worm
ProfiMill | Technology 07
Customized Solutions
Especially with regard to larger machines, the gantry design offers advantages due to considerably reduced space
requirements. State-of-the-art control concepts with master-/slave drives assure smooth and accurate movement
of all axes. The WaldrichSiegen hydrostatic worm drive
for portals or tables assures highest static and dynamic
stiffness.
production purposes, are the basis for WaldrichSiegen’s
competence in specifying and designing these machines
to be tailor-made for our customers’ applications. In this
context, the later economically efficient use of the equipment is an important criterion.
The high level of modularity of the ProfiMill concept allows
for optimized adaption of the machine to individual requirements of customers’ workpieces and installation sites.
Modular design of the individual modules:
§
clearance width: in steps of 500 mm
§
rotary tables: in steps of 500 mm
§
clearance heights: in steps of 500 mm
§
ram travel: in steps of 500 mm
§
table length: in steps of 1,000 mm
§
milling power: 50 to 120 kW
§
tool changer: 40 to 480 pockets
The long-term experience with milling machines, those installed at our customers’ sites and those we use for our own
Turbine housing
08 ProfiMill | Technology
Attachment Changer
The diversified range of different workpieces requires a
large number of optional attachments. Depending on the
application, the required attachments are automatically
exchanged via an attachment changer.
The changing carriage moves on a guideway system. The
exact positioning of the changing carriage relative to the
ram is carried out via a servo drive. The transparent cover
of the changing unit does not only protect the Masterhead interfaces from contamination, but at the same time
emphasizes the consistency of this machine concept’s
design elements. The attachments are accessible for inspection and maintenance during machine operation.
Universal fork head with electro spindle
ProfiMill | Technology 09
Tool Changers
In case only a small number of tools is required, a chain
type tool changer is used (40 to 120 pockets). The chain
type changer is installed at the side of a portal column.
A gripper system is handling the tool changing process.
If a larger number of tools is required, a rack type tool
changer is available (80 to 480 pockets), which provides
for optimized utilization of storage space. Tools with a maximum weight of 75 kg, a maximum length of 500 mm and
a diameter of 360 mm can be stored. Individual pockets
for special tools can be provided for. Other tool changing
systems are available upon request.
A separate tool loading station allows to prepare the magazine with new tools for the next workpiece to be machined
parallel to the production process. The WaldrichSiegen tool management system operates independently from the machine control and is characterized by
§
optimized utilization of storage space including collision check
§
monitoring of storage capacity
§
tool life time control
§
additional data interfaces to external devices (e.g. CAM system, tool presetting, machine control via Ethernet)
§
optional data input devices: barcode scanner or
identification chip, serial interface
Tool changer with manipulator, spindle positions infinitely variable between 0 to 90°
Tool magazine and manipulator
10 ProfiMill | Technology
High Availability
Controls
Centralized transfer blocks for different required media
reduce the maintenance-intensive hose connections to a
minimum. Easily accessible valves, pumps, pressure and
temperature switches as well as terminal boxes facilitate
fast and easy access to all necessary maintenance units.
A centralized locking system ensures easy opening of the
cover of the milling unit in a minimum of time, thus reducing maintenance times.
The ProfiMill machines are available with Siemens 840D sl
control or, as an option, with Fanuc 30i control especially
for the Japanese and the US market.
With the Masterhead concept main spindle, tool taper and
pre-loaded bearings within the ram are no longer required
and potential failure sources are thus eliminated.
Operator panels and operator platforms are designed
precisely to our customers’ requests.
These are only a few examples reflecting the importance
we attached to user-friendliness and easy maintenance
when designing the ProfiMill series.
As for machines equipped with Siemens 840D sl, these
are also provided with the Siemens-Sinamics drive concept. Digital interfaces with “drive-cliq” function allow for
simple configuration and diagnostics.
ProfiMill | Technology 11
Machine Design & Enclosures
State-of-the-art machine concepts must comply with the
applicable safety regulations, must operate at low noise
levels and must be ergonomically designed. Last but not
least, these machines should also address the operator
on an emotional level. The machines of the ProfiMill series fulfil these requirements in each and every respect. To
achieve this, WaldrichSiegen had to do quite some pioneer
work.
The machines’ color concept reflects the rules of our corporate design, its new shapes and contours provide the
machine with a functional elegance and the transparent
enclosure allows for optimum view into all working areas.
If applicable, safety standards require a full enclosure of the
machine, this is realized with a glass enclosure concept.
Frameless sandwich glass elements were required to pass
extensive safety testing procedures before they were admitted for use with our ProfiMill machines. Standardized
elements in different configurations and shapes allow the
machines to be adapted to local conditions in an economical way.
Standard glass element as sliding door with position-controlled drive
Ident. No. MILL-2014/05-EN
Subject to change
WaldrichSiegen Werkzeugmaschinen GmbH · Daimlerstraße 24 · 57299 Burbach · Germany
T: +49 (0) 2736 493-02 · F: +49 (0) 2736 493-559 · waldrich-siegen.de