TEK4 6g FHD GXL EDM system February 2018

Transcription

1 Specification and Quotation TEK4 6g FHD GXL FAST HOLE DRILL EDM 5 AXIS CNC EDM with tool changer TECHNICAL DESCRIPTION Originator- Jan van Egmond 20-February-2018 TEK4 Limited UK England 1 TEK4

2 Overview- Key features Key features; 5 Axis 915mm (36 ) electrodes Up to 458mm (18 ) Electrode guide holders Extra large travel X,Y,Z 1000,800,800 mm Advanced Break Through detection + Pre break through detection Shaped hole EDM ing In built probing system with advanced cycles Probe machine check with auto set of datum s 6 point nest probing cycles Electrode datum probing bore and software cycles De-ionised water plant included Fully enclosed machine 5g Pendant panel Electrically operated dial indicator Water and air wash guns Sliding access steps Industrialised PC with solid state hard drive- Electrode guide holders with inbuilt specific flushing Advanced EDM generator with 500 process programs Dedicated technology developed specifically for the Gas Turbine industry Monitoring of clamping on both table and head Erowa chucks Long life high pressure rotary coupling Geared spindle head drive Electrical crash detection on the tooling Heat exchanger fitted to Dielectric plant ready for connection to a chilled water supply (or chiller- (chiller not supplied)) Dielectric tank capacity is 250 litres (55 gallons) 2 TEK4

3 Machine This machine is based on using a new HAAS machine fitted with a 5 axis Haas CNC control system. The machine is of robust construction and utilizes linear bearings with ball screws driven by brushless high response servo motors. The machine is fitted with a robust tilt turn table, in the centre of the rotary table is a Erowa chuck allowing for quick change over of fixtures. The materials used are corrosive resistant or protected to allow the use of deionised water dielectric. The rotary axis are so configured to allow the component to be positioned on the centre line of both axis, this reduces the distance traveled in the linear axis and has the effect of increasing machine capacity. The machine is enclosed in a fully CE purpose designed machine enclosure with access via a horizontally sliding door, the enclosure will have internal illumination. Additionally there will be a Erowa chuck mounted on the EDM head which will carry the electrode guide and allow quick change over between hole sizes. Strokes X axis 1000mm Y axis 800mm Z axis 800mm A axis 360 (+/- 180) B axis 360 Continous EDM stoke 915mm Accuracies Linear axis 20 microns accuracy Linear axis 10 microns repeatability Rotary axis 25 arc seconds accuracy Rotary axis 13 arc seconds repeatability Auto tool changer 10 Guide tool holders 14 Electrode holders Maximum Part and fixture weight 113kg 3 TEK4

4 Control CNC The CNC control System is a Haas CNC, this control is highly flexible and easy to use. The screen, keyboard, push buttons and hand wheel are mounted in a pendant unit that can pivot to allow easy operation of the machine. With its triple, 32-bit Processors this system uses three high-speed Motorola processors allowing servo loop calculations to be performed 4,000 times per second for each of five motors, and providing up to 1,000 blocks per second of program execution speed. Battery-powered static RAM is dedicated exclusively to program storage. Options of up to 16 MB are available for handling large files or archiving jobs on the machine. Unlike a PC s dynamic RAM, which only retains memory while power is turned on, battery-powered static RAM retains changes instantly and permanently. In addition to RAM program storage, other storage options available include floppy disk, Ethernet connectivity and hard disk storage of up to 20 GB. All Haas controls also come standard with a high-contrast, colour TFT LCD display. Memory size 1Mb expandable to 16Mb USB Interface Macro Programming Ethernet Interface 4 TEK4

5 TEK4 TECH-Pulse EDM generator The EDM generator is a TEK4 Tech-Pulse EDM generator, this generator is a advanced system specifically designed for producing holes in aero engine and industrial gas turbine components. It has the ability to store up to 500 process parameter programmes, each programme is able to adjust the process parameter up to four times during the drilling of a single hole, these changes are triggered at different depth settings. A key feature of the Tech-Pulse generator is it process analysis capability, the process is graphed showing a depth against time thumb print, this Thumbprint can be stored and or printed out, developing new process parameters becomes very simple as the previous Thumb print is always displayed, thus as process changes are made it is easy to see whether they are above the previous graph (better) or below (worse). Key specification 50 Amps peak power 25 Amps mean power Up to 500 process programmes Shaped hole capability Programmable pulse shaping Data logging Process Thumb printing Break through detection Pre Break through detection On screen technology and help 5 TEK4

6 Probing System The machine is fitted with a Heidenhain probing system, this is mounted on a automatically extending probe arm which is activated by the CNC control. This probe is used in three main ways; 1 Machine check A four minute CNC probe cycle checks out the accuracy of all the 5 machine axis and also sets the zero datum points for all axis. This cycle enable the machine to be checked for geometrical accuracy on a daily basis and can be used to check for machine damage after a tooling crash. 2 Part set In built cycles in the control system enable the probe system to be used to find the Part, this is done using a 6 point probing routine (3-2-1-Plane-Line-Point), the advantages are; Fixturing becomes lower cost Multiple sets of datum s can be used with refixturing Parts cannot be miss loaded and machined Improved accuracy 3 Electrode set A special calibrated machined bore is probes and measured for position and diameter, each electrode tool as it is loaded is then contact sensed IN and the electrode is checked for diameter and position, a automatic tool offset is applied to the tool which compensates for any small positional error in the electrode position, this is especially useful when using long electrode guide holders. 6 TEK4

7 Dielectric System The dielectric system is housed in a stainless steel tank unit located under and to the rear of the machine. The system is a two tank system, with a clean and a dirty tank. A pump continually pumps fluid from the dirty tank through a high capacity filter (used on EDM wire cut machines), when the clean tank is full it can weir over back into the dirty tank. The system has the capability to pass the fluid through a iron exchange resin bed canister to deionise the water, this is controlled by a valve system which is also controlled by a resistivity sensor so that a controlled value of resistivity can be maintained. A high pressure pump delivers fluid at a programmed pressure to the EDM electrode through the rotary spindle unit. A Heat exchanger with fitting ready for connection to a chilled water supply or a free standing chiller unit (not supplied) is included in the system. Tank capacity is 250 litres (55 gallons) 7 TEK4

8 System Connectivity Machine Data Collection Machine Data Collection (MDC) lets you use Q and E commands to extract data from the control through the Ethernet port or the Wireless Networking option. Setting 143 both enables the feature and specifies the data port that the control uses to communicate. MDC is a software-based feature that requires an additional computer to request, interpret, and store data from the control. The remote computer can also set certain Macro variables. The Haas control uses a TCP server to communicate over networks. On the remote computer, you can use any terminal program that supports TCP; this example uses PuTTY. Up to (2) simultaneous connections are allowed. Output requested by one connection is sent to all connections. Data Collection Queries and Commands MDC Queries These commands are available: Command Definition Example Q100 Machine Serial Number?Q100 SERIAL NUMBER, Q101 Control Software Version?Q101 SOFTWARE VERSION, Q102 Machine Model Number?Q102 MODEL, CSMD-G2 Q104 Mode (LIST PROG, MDI, etc.)?q104 MODE, ZERO Q200 Tool Changes (total)?q200 TOOL CHANGES, 35 Q201 Tool Number in use?q201 USING TOOL, 4 Q300 Power-on Time (total)?q300 P.O. TIME, 06282:17:13 Q301 Motion Time (total)?q301 C.S. TIME, 00098:18:29 Q303 Last Cycle Time?Q303 LAST CYCLE, 00000:00:13 Q304 Previous Cycle Time?Q304 PREV CYCLE, 00000:00:01 Q402 M30 Parts Counter #1 (resettable at control)?q402 M30 #1, 380 Q403 M30 Parts Counter #2 (resettable at control)?q403 M30 #2, TEK4

9 Three-in-one (PROGRAM, Oxxxxx, STATUS,?Q500 PROGRAM, MDI, IDLE, Q500 PARTS, xxxxx PARTS, 380 Q600 Macro or system variable?q MACRO, 0.0 You can request the contents of any macro or system variable with the Q600 command; for example, Q600 xx Machine monitoring can also be easily carries out using Haas Connect which is a free service and easy to set up. 9 TEK4

10 Exported Data The following data will be exported and placed in an accessible folder on the system hard drive, this data will be accessible via the Ethernet connection. The file format will be in text file format (CSV) allowing it to be imported directly into programs such as Microsoft Excel. The system will create a new folder for each component processed, the file name for this folder will be the component serial number which can be entered in either through the key board or via a bar code scanner. The part specific folder will contain multiple files; A file containing the following; o CNC program name o Part serial number o CNC program number o EDM process program number o Date o Time o Start time o Overall cycle time o Machine ID o 6 point nest corrections o Tool offset correction Multiple files- one file for each hole drilled containing o Cycle time per hole o Hole number o Depth / Time EDM process graph o ON time o OFF time o Feed o Response o Voltage o Current o Fluid pressure o Breakthrough detection status and settings o Pump pressure o Water temperature o Water resistivity o Electrode water flow rate o Guide water flow rate o Block change depths will be recorded to at least 0.1mm resolution o Times will be recorded to a 1 second resolution These files are located on the EDM Generator SSD Hard drive and can be retrieved via the Ethernet connection or the manually via the USB port. 10 TEK4

11 11 TEK4

12 Documentation The following documentation will be supplied with the equipment, Ø Operator manual - 1 copy also supplied on CD Ø Maintenance manual - 1 copy also supplied on CD Ø Control manual - 1 copy also supplied on CD Ø Electrical Schematic drawing supplied on CD Ø Mechanical Assembly drawings- Supplied on CD Ø Parts list including expected consumable spare parts-supplied on CD Ø 3D model of MTL (Machine Tool Layout)-Supplied on CD Ø Backup software enables reload of machine software if necessary-supplied on CD 12 TEK4

13 Laser Ablation Option As an option the machine can be equipped with a laser ablation system for the removal of ceramic coating TBC. We use an IPG 100W HF fibre laser with 2 axis scanning. 13 TEK4

14 Tooling and Consumables Options Consumables TEK4 part TEK4 part Low Pressure Filter TEK High Pressure Filter TEK Resin TEK Cabinet Filter TEK Brush - Head Busbar TEK Brush Assembly - Table TEK Spindle Brush Kit TEK Spares 14 TEK4

15 Electrode Guide Red - through flush TEK Electrode Chuck Collet (TC) TEK Electrode Chuck Key (TC) TEK DI flow valve TEK DI water solenoid TEK Probe Stylus TEK Drive Belt Set TEK TEK TEK TEK TEK4

16 Axis Limit Switch (roller type) TEK Axis Motor (sigma1/sigma5) TEK Rotary Axis Cable Assembly TEK EDM Head Axis Motor TEK EDM Spindle Motor TEK Deublin Coupling TEK Spindle Bearing Upper TEK TEK4

17 Spindle Bearing Lower TEK Contact Braiding TEK EDM Generator PCB EDM200 TEK High Pressure Pump Seal Kit Flushing/High Pressure Valve TEK TEK Flexible coupling KK encoder TEK TEK4

18 Recommended Spares Package The following spares package is recommended to be held in stock by the end user. * Main EDM generator board * EDM servo motor * EDM spindle motor * Spare drive belt sets * High pressure spindle rotary coupling * Brush set for spindle, bus bar and rotary table * Solenoid valves 18 TEK4