Technology to fascinate you: Wire Eroding System PA20

Transcription

1 Technology to fascinate you: Wire Eroding System Official Supplier of BMW Sauber F1 Team The Mitsubishi Electric business area FA Mechatronics EDM was awarded the Global Market Leadership Award 2005 by Frost & Sullivan, for their market-leading position in the eroding systems business. DIN EN ISO 9001:2000 Zertifikat: MITSUBISHI ELECTRIC EUROPE B.V. German Branch FA-Mechatronics EDM Gothaer Str Ratingen Phone (0) Fax: (0) edm.sales@meg.mee.com Specifications subject to change without notice. E

2 Highest precision Productivity Flexibility Efficiency Guaranteed future Exceeding your expectations precisely Mitsubishi Electric has once again taken a decisive step pushing forward the boundaries of eroding technology. With a guaranteed precision of ± 2 µm Mitsubishi's sets new standards of performance to give you technical advantage over your competition. In conjunction with the newly developed digital fine smoothing generator, for the finest surface finish, the also offers premium manufacturing quality. The flexible design of this high precision eroding system enables you to process a wide range of workpieces at a very high erosion rate. Furthermore, it can significantly increase your productivity and machining efficiency. Precision as a standard Material: Cutting height: 50 mm Wire electrode: 0.25 mm brass Surface quality: Ra 0.13 mm Processing time: 1 hour 24 minutes Production precision Material: Cutting height: 1.0 mm x 10 (pack) Wire electrode: 0.10 mm brass Precision: ± mm Surface quality: Ra 0.18 mm Processing time: 1 hour 26 minutes Ultimate precision Material: Carbide G30 Cutting height: 40 mm Wire electrode: 0.15 mm brass Surface quality: Ra 0.10 µm Processing time: 2 hours 12 minutes Perfect precision Material: Cutting height: 50 mm and 20 mm Wire electrode: 0.20 mm brass Surface quality: Ra 0.15 µm Processing time: 1 hour 34 minutes (stamp), 52 minutes (die) Manufacturer: Marquardt GmbH 2 3

3 Air conditioned encapsulation Direct shaft drives Easy maintenance High reliability An intelligent, well thought-out concept All elements of the machine design have been manufactured from high quality materials and tested extensively for strength and durability. The machine structure, which is completely temperature stabilised by means of an integrated cooling system, guarantees the highest precision over long periods. This is further supported by direct AC drives, re-circulating ball screw and nut resolution of 0.05 µm. In addition the spindle is positioned exactly in the centre of the load in order to ensure "soft" axis movement. A central oil lubrication system, working tank and sealing system made of stainless steel and a patented self-cleaning system are only a few of the maintenance reducing features of the machine. Thermal encapsulation A thermally tight encapsulation in conjunction with active cooling systems, avoids a loss of precision caused by thermal fluctuation. Cooler Filter unit Cast steel machine design This classic concept guarantees a long service life and the solid machine construction easily handles heavy workpieces. Direct drive and generously dimensioned spindles Non-slip clutches, double distance closed loop measuring systems and intelligent distribution of dynamic loads ensure long-lasting precision. 4 5

4 AT system for fastest wire threading Freely accessible working table User-friendliness Telecontrol Telecontact Everything is easier with good ergonomics The way the reduces manual machine activities to a minimum will astound you. The ergonomic design concept not only facilitates daily work, it also contributes to economic operation. An example of this is the extraordinary accessibility to the working table provided by a generous swinging hood in conjunction with the automatic vertical sliding door. In addition, the automatic wire threading system (AT), as well as the maintenance-friendly design of the tank sealing system also contribute to efficient operation. Further highlights are the optional features for remote control, maintenance and diagnosis by means of Telecontact and Telecontrol. Last but not least, the is Ready for Automation. Threaded in 10 seconds: the AT System. The combination of a new measuring sensor and a fast retract function gives you the highest reliability and ultimate speed, even for smallest starting holes. Telecontrol Teleservice Operator Telecontact Telecontact Telecontact Operator 2 Maintenance Telecontrol: Remote control via PC. Telecontrol provides remote monitoring and remote control of the machine from any site. System optimisation for running processes is also possible with this service. Operator 1 6 7

5 64-BIT CNC control system 3D graphic function Expert system Real time monitoring Optimisation tools The intelligent control system The Mitsubishi 64 BIT CNC control system leaves nothing to be desired. In spite of its complex function, it can be operated quickly and intuitively thanks to its clear menus and graphic images. The Graphic Check function allows you to perform a simulation of your program in 2D or 3D mode, before or during the processing. The expert system E.S.P.E.R. automatically determines the correct generator setting from your data. The Machining Monitor shows the current processing status for monitoring purposes. Furthermore, various evaluation and optimisation programs interactively support you during the determination of the optimal and most economic machine settings. This means: you can work with a workshop oriented control system. 3D graphic function Reliable graphic program check using the improved graphic and surface display. The speed of the graphic program check is faster than conventional systems. Programming The Graphic User Interface (GUI) makes the easy to operate, even for beginners. The operating and programming screens correspond to PC standards. Expert system E.S.P.E.R. The Easy Simple to Program by Expert system, combined with the 64-BIT CNC control system, complete the automatic adaptation and generator setting according to your process-specific data. Hybrid Pack Software This program helps you to achieve optimal machine settings for individual processes. 8 9

6 Process optimisation Surface qualities of up to Ra 0.1 µm Geometric fidelity of up to 2 µm Machining results to re-define the concept of quality The latest generator technology combined with precise mechanical engineering ensures ultimate workpiece quality. This opens up processing capabilities to support developments in micro technology, e. g. in the optical and medical industries. The newly developed fine smoothing generator allows the complete monitoring of the process in the spark gap as well as the optimisation of the generator settings in shortest cycles. This results in the finest and most homogenous surface structures. Furthermore, Orbit-Master, SL-Control, and many more process-optimising control functions ensure the highest amount of reproducible precision. Digital FS Generator: The newly developed fine smoothing generator allows a surface finish of up to 0.1 µm Ra. It can also be used when applied to automation systems. Material: Cutting height: 30 mm Wire electrode: 0.25 mm brass Precision: ± mm Surface quality: Ra 0.12 µm Processing time: 3 hours 28 minutes Workpiece height and surface quality [µmra] 0,25 0,20 Surface quality 0,15 0, Workpiece height in mm Orbit-Master continuously controls the conditions in the spark gap and allows geometrical reliability of the workpiece independent from corner geometries. Material: ASP23 Cutting height: 25 mm Wire electrode: 0.07 mm brass Surface quality: Ra 0.10 µm Processing time: 1 hour 36 minutes Orbit-Master has been developed to obtain a uniform gap for the electric discharge, independent from the corner shape. This function decreases the amount of faults of the radial shape and allows for an improvement in the overall accuracy of the workpieces. Sample processing Wire electrode ø 0.2 mm MS Workpiece , 60 mm Processing time 1 hour 47 minutes 0 0 A:5mm B:4mm 1 0 SL-Control ensures the best geometry of the eroding surface even when machining stepped workpieces. 7 µm 3 µm Material: SKD11 Cutting height: mm Wire electrode: 0.20 mm brass Surface quality: Ra 0.26 µm Processing time: 57 minutes Conventionally: Contour deviation at the step: -3 µm to +7 µm 2 µm 1 µm 7,0 µm SL-Control: Contour deviation at the step: +2 µm or less -7,0 µm The HL and LC circuits guarantee the achievement of true-shape surfaces. This helps to even make dovetail geometries fit perfectly. Material: Cutting height: 100 mm Wire electrode: 0.20 mm brass Precision: ± mm Surface quality: Ra 0.16 µm Processing time: 1 hour 47 minutes per workpiece 10 11

7 295 Ultimate machine accuracy Best surface qualities Universal and flexible A system to perform Even finer structures, even better surfaces the high precision eroding system helps you to achieve these important market requirements. You can rely on the proven, long-life quality of Mitsubishi as it satisfies the highest demands with a robust machine design paired with high-tech components. Machine innovations include the digital drive system, the intelligent 64 BIT CNC control system as well as the newly developed temperature stabilisation system and the liquid level monitoring system. This is why the is ready to help you gain greater productivity. Travel paths and workpiece dimensions in mm y = z = 300 x = Overall dimensions of the machine in mm Possible wire diameters from ø 0,3 mm to ø 0,05 mm 12 13

8 Technical data Layout plans Machine Machine Filter unit Model Travel path (X/Y/Z) mm 500 x 350 x 300 Travel path (U/V) mm ± 21 x ±21 Conic angle (for workpiece height) 10 (100 mm) Max. workpiece dimensions (W x D X H) mm 1050 x 800 x 295 Max. workpiece weight kg 1500 Table dimensions (W x D) mm 780 x 630 Possible wire diameters mm 0,05 0,3 Wire reel reception kg 10 Automatic water jet threading Max. advance (X/Y) mm/min 1300 Overall dimensions (W x D x H) mm 2210 x 2873 x 2150 Weight of the machine kg 3500 Tank capacity l 750 Filter fineness µm 2 Filter elements 2 Temperature control Dielectric cooler Overall dimensions (W x D x H) mm 880 x 2070 x 1565 Weight unfilled kg kg Wire station 1090 Generator / control Generator Control Model Power unit of transistor-controlled pulse generator Generator cabinet completely tight Cooling method Indirect air cooling Max. working current A 50 Dimensions 550 x 600 x 1650 Weight kg 240 Input interfaces Keyboard, floppy disk 3,5", RS232C, Ethernet Colour monitor 10,4" TFT LCD type Control system CNC, closed loop Min. instruction step µm X, Y, Z, U, V..1/0.1 µm Min. axis resolution µm 0,05 Max. instruction value mm ± 99999,999 Lateral view Footprint Front view Working table Wire collector box x 50 = M8 Equipment Model Equipment Wire station 20 kg Thin wire device (0,05 mm) Fine smoothing unit Digital FS B axis Automation Robot Automation Handling Ethernet interface Teleservice Telecontrol Telecontact kg Wire supply unit 230 Machine 2630 Generator Filter unit and cooler Control (Screen) x 50 = Travel path Travel path All indications in mm The dimensions may vary according to equipment. = standard = retrofittable options Model Overall power consumption [KVA] 13,5 Overall weight of the installation kg