FLECKENSTEIN Werkzeugmaschinen GmbH - Stockist for used machines

turning diameter . mm︱turning length 1.000 mm︱control SINUMERIK 840 C ︱swing over bed 550 mm︱swing diameter over bed slide 480 mm︱cross movement. (x-axis) 405 mm︱longitudinal traverse (z-axis) 1.099 mm︱tool turret 8 ︱tool adaptor VDI 50 ︱driven tools no ︱spindle headstock ︱size spindle head 8 ︱diameter front bearing 150 mm︱spindle bore 103 mm︱chucking diameter 315 mm︱max. power on 50% ED 53 kW︱max. torque 780 Nm︱spindle speed 30-3.000 min-1︱feeds: ︱cross slide (x-axis) 10.000 mm/min︱

---

Equipment & accessories CNC lathe for turning of chuck parts Pivoting control panel Pressing oil full clamping cylinder make FORKARDT Hydraulic system make Hydrokraft switch cabinet with cooling unit and temperature controller, make RITTAL Chip conveyor with tank capacity 325l, ejection right 1 pc. 3-jaw power chuck Oil mist extraction Coolant system with tank capacity 600l, pump pressure Pmax = 5.5 bar, flow rate Q = 60l/min, pump capacity P = 1.1 kW Execution as chuck machine without tailstock Operating hours: 43956h | spindle hours: 14525

turning diameter 450 mm︱turning length 3.000 mm︱control SINUMERIK 840 D powerline ︱swing diam. over bed 700 mm︱swing diam. over X-carriage 600 mm︱main spindle ︱integrated spindle motor with C-axis ︱position 0,01 °︱spindle nose DIN 55026 type A size 8 ︱spindle bore 100 mm︱bearing diameter 150 mm︱max. power ED 40 % 95 kW︱torque max. (40 %) 800 Nm︱spindle speed 0-3.100 min-1︱tool magazine ︱number of tools 40 ︱max. tool diameter 100 mm︱max. tool length 350 mm︱total power requirement kW︱weight of the machine ca. t︱

---

Equipment, Accessories all drives in digital-servo-technology coolant system with coolant tank 450 liter, feed pump 5 bar/50l/min, high pressure pump 50 bar, band filter 2 chip-conveyor dust exhausting automatic doors

turning diameter - mm︱turning length - mm︱control SINUMERIK 840 D ︱swing over bed 1.000 mm︱swing diameter over face slide 650 mm︱Distance between centres 4.000 mm︱movement cross slide 680 mm︱bed width 750 mm︱lathe tool cross section h x w 40 x 40 mm︱main spindle : ︱spindle diameter in front bearing 360 mm︱spindle bore 200 mm︱power 60/100% ED 52/37 kW︱max. torque on the spindle 6.000 ︱turning speed range 3,55-910 U/min︱feed power X 100% ED 20.000 N︱feed power Z 100% ED 30.000 N︱rapid traverse X-axis 3 m/min︱rapid traverse Z-axis 6 m/min︱diameter of quill 160 mm︱

---

accessories - full cover closed at the top - preparation for extraction system - 4-fold tool turret manufacturer SAUTER - boring bar holder mounted on cross slide - hydraulical clampable tailstock - 2 piece steady‘s, Ø 80 – 450 + Ø 440 – 800 mm - 2 piece chip conveyor longitudinal – ejection right - workroom doors automatically operated - power chuck equipment without chuck - coolant equipment with paper band filter - control SINUMERIK 840 D incl. roughing - Machine will be delivered without chuck

bore capacity in steel (diameter) 150 mm︱x-travel 4.000 mm︱y-travel 3.000 mm︱z-travel 2.500 mm︱w-travel 900 mm︱B-axis rotary movement table 360 Grad︱b-axis, positioning accuracy 360.000 x 0,001 °︱Machining unit - ︱fixed spindle nosing, length 280 mm︱shortest distance, spindle nose to mid of table -162/+88 mm︱lowest position above table surface 0 mm︱tool taper DIN 69871 ISO 50 BIG PLUS ︱power 55 kW︱max. torque at the spindle 2.917 Nm︱spindle speed, steppless adjustable 5-3.000 min-1︱Nc rotary table - ︱surface area 2.000 x 2.500 mm︱Max. Rotation speed 1,5 min-1︱max. load 25.000 kg︱width of T-slots 28 mm︱

---

Moveable control panel Movable control panel with motorised transverse and hydraulic vertical movement. Vertical travel 2,000 mm, transverse travel 1,000 mm. Enclosure Complete enclosure (without roof) of the machine working area, height 3,500 mm. The chip conveyor is located between machine bed and column, ejection left. The cabin is equipped with two sliding doors at the front of the table (each with an opening of 2,000 mm for a total opening of 4,000 mm) and two doors at the rear (one on the left and one on the right of the upright). All doors are monitored by door limit switches. Numerical control SINUMERIK 840 D Solution Line - NCU 730.2 Basic, CNC user memory with 3Mbyte - PCU 50.3 with: Intel Pentium M Mobile 2 GHz/1Gbyte Hard disk 40 GB Integrated graphics 2D/3D Operating system Windows XP ProEmbSys 2 Ethernet 10/100 Mbit/s 4 USB 2.0 1 PROFIBUS/MPI interface Operator interface HMI advanced Control panel with color display 15", 1024x768 pixel Manual control panel with visualization of the values Mod. HT 2 Option DNC Coolant equipment Internal high-pressure cooling by the tool with paper filter and adjustment by potentiometer. Device for transferring the coolant for the NC milling head. - External coolant supply 28l/min - 4 bar - Internal coolant supply 28l/min - 40 bar - Tank capacity 1.200 l The flow rate can be adjusted by means of a potentiometer or JOG keys. Technical features and standard equipment CASTEL RED is a transverse travelling column boring machine with a table that can be moved in longitudinal direction. The CASTEL RED offers, like all horizontal FPT machines, practical advantages such as - Maximum flexibility thanks to the wide range of available accessories. - Easier operator access to the working area. - Better chip disposal. Machine structure: stability and accuracy - The structure of CASTEL is made of an electro-welded steel structure and integrates the upright and the cross slide in a single element. Between the four symmetrical vertical guideways, the spindle unit moves vertically. - The column achieves the necessary rigidity to ensure accuracy and alignment and to prevent deformation during heavy roughing operations. The special symmetrical structure has a high vibration damping capacity and ensures high thermal stability. - The column bed, which can be moved in a transverse direction, is made of an electro-welded steel structure. It is provided with hardened and ground guideways of large dimensions. The three guideways ensure high rigidity and accuracy. - The longitudinally movable stator bed consists of an electro-welded steel construction. The feed is on two linear guides, which enable a prompt, dynamic response and ensure high positioning accuracy. - The rotary slide table base is made of cast iron, computer designed, therefore optimally dimensioned and appropriately ribbed to ensure maximum rigidity. - The structural dimensioning, positioning and the shape of the ribbing were determined by FEM calculations. All components were tested statically and dynamically according to the qualification plan. All components are stabilized after rough machining to avoid internal tensions. - The milling head is integrated into the structure of the vertical guideways to increase resistance to deflection. - The table and machine anchoring has been designed to ensure perfect rigidity, accuracy and lasting stability of the machine geometry. Guide ways - The guideways and the base surfaces of the stand, stand and table beds are hardened and ground. The slideways are dimensioned to achieve maximum stability and accuracy. - The Y- and Z-axes are moved on preloaded roller slides, the X-axis is moved on linear guides and preloaded roller slides. This allows fast dynamic response and ensures high positioning accuracy. Axis shifting - The machine axes are moved by means of ground and hardened precision ball screws with preloaded ball screw nuts to minimize play and to achieve low friction when positioning on all axes. - The axis movement is by brushless AC drives. - The standard axis designation is: X = longitudinal travel, Y = vertical travel, Z = transverse travel (column); W = drilling spindle Weight balancing system - The hydraulic counterbalance system on the milling head reduces inertia effects to a minimum, resulting in good positioning accuracy and smooth contouring Milling head (spindle holder head) - The head is made of stabilized Meehanite cast GB/300 and moves within the stand on 4 guideways. The adjustment system used provides accuracy and rigidity for any type of application. Spindle motor - The AC Brushless SIEMENS spindle drive (55 kW) is continuously variable with a two-stage ZF gearbox Spindle - ISO 50 BIG PLUS spindle mount with automatic tool clamping. The axis of the drilling spindle is 900 mm and the diameter is 150 mm. The surface is completely nitrided. - The use of self-lubricating bushes (with oil backflow) and the forced circulation of the oil in the areas of high heat generation ensure maximum thermal stability. Cooling and lubrication system - The cooling system cools the oil circulating around the spindle, the bearings and the gearbox for thermal stability of the head and spindle. - This effective cooling system of the bearings allows 3000 rpm (option) - PLC control of the drilling spindle temperature. This system allows better control of the powerful cooling system and compensation of thermal expansion. Coolant system for the tool - Coolant system for the tool with 1,200 litre coolant tank, pump with 4 bar pressure, delivery rate 28 litres/min. Steel telescopic covers - Steel telescopic covers for horizontal, transverse and vertical guideways to prevent water and chips from entering.

bore capacity in steel (diameter) 130 mm︱x-travel 3.100 mm︱y-travel 1.800 mm︱z-travel 2.000 mm︱w-travel 800 ︱connected load 50 kVA︱Working Spindle - ︱boring quill diameter 130 mm︱spindle taper DIN 69871 ISO 50 ︱spindle power 37 kW︱transmission ratio 2 ︱Torque Gear range II 2360/590 Nm︱turning speed range 4 - 2.500 U/min︱clamping table - ︱max. workpiece weight 10.000 kg︱surface area 1.600 x 2.000 mm︱ 9 28H8 ︱resolution of measuring system 0,001 °︱tool changer - ︱drum magazine 40-fach ︱

---

Equipment. • CNC-control HEIDENHAIN iTNC 530 • tool changer 40-fold • coolant tank with pump • chip conveyor • basic equipment tool holder

x-travel 2.500 mm︱y-travel 1.500 mm︱z-travel 1.200 mm︱Control HEIDENHAIN iTNC 530 ︱integrated NC-rotary table - ︱surface area 1.600 x 1.400 mm︱T-slots 22 H10 mm︱max. workpiece weight 15.000 kg︱Bearing AD 1.095 mm︱Pitch Accuracy 2,5 sec︱Feeds - ︱X-, Y- and Z-axis, stepless 2 - 15.000 mm/min︱max. feed force X-Y-Z-axis 24.000 N︱rapid in X/Y/Z 25 m/min︱working spindle wirh automatic milling head - ︱AC-main drive with gear box - ︱capacity at 100% load 30 kW︱transmission ratio 3 ︱turning speed range - stepless 0 - 4.000 U/min︱Max. torque 1.460 Nm︱

---

Chip conveyor • Chip conveyor No. 1 installed between machine column and work piece table • Chip conveyor No. 2 installed in front of the work piece table • Cross conveyor on the left side of the machine for reducing the machine length • Discharge high ca. 1.250 mm • Integrated coolant tank with lifting pump Guides, drive and measuring system • All axis drives with digital servomotors SIEMENS • Direct measuring system for X-, Y- and Z-axis HEIDENHAIN • X-, Y- and Z-axis with INA high-precision linear guides for maximum precision and dynamics • Precision ball screws in all axis with with pretension nut´s Coolant equipment • Cooling through spindle including paper band filter • Clean water tank ca. 500 l, • Normal coolant supply 50 l/min 5 bar • High pressure pump 20 bar • Internal coolant through spindle centre taper DIN 69871 Form AD • Clamping bolt DIN 69872 Form A equipment • Autom. Milling head 2,5° positioning • Gear-box 3-fold • Cooling unit for gear-box • 3-D-Compensation for thermal extension of the milling unit • Spindle drive 30 kW, SIEMENS • X-, Y- and Z-axis with INA high-precision linear guides • Direct measuring system for X-, Y- and Z-axis HEIDENHAIN • Precision ball screws in all axis with pretension nut´s • NC-Rotary-Table 1.600 x 1.400 mm –enhanced- • Radio touch probe manufacturer M&H, RWP 38.41 incl. autom. measuring cycles • CNC-Control HEIDENHAIN iTNC 530 with digital drive control • Electronical handwheel HR 410 • Autom. Tool changer 40-fold • Coolant equipment with external coolant circuits and internal coolant through spindle • 3 pc. Chip conveyor • Ca. working hours: Main switch ON: 13.300h, Machine ON: 16.300 h, Operating: 5.500 h

x-travel 2200 mm︱y-travel 3500 mm︱z-travel 1500 mm︱Control HEIDENHAIN iTNC 530 HSCI ︱clamping table 3500 x 2100 mm︱T-slots 22 ︱max. load 1000 kg/m2︱feed X/Y/Z axis 5-65.000 mm/min︱rapid traverse X/Y/Z axis 65.000 mm/min︱speeding up max. 3,5 m/sec2︱fork milling head no. 4, torque motor drives : ︱A-axis (spindel swivel axis) . ︱swivel angle 220 +/-110 °︱swivel torque (simultaneous) 500 Nm︱holding force (clamped) 3000 Nm︱speed 360 °/sec︱axis acceleration 800 °/sec2︱direct measuring system - distance coded . ︱C-axis (milling head rotation axis) . ︱swivel angle 550 +/-275 °︱

---

Guides, drive and measuring systems - All linear axes with linear motors make SIEMENS - water-cooled - Both rotary axes of the milling head with torque motors - Direct measuring systems for X, Y and Z axes made by HEIDENHAIN - X-, Y- and Z-axis guidance by means of high-precision linear guides for highest precision and dynamics Chip conveyor - 1 pc. hinged belt chip conveyor installed in Y-direction in front of the machine table - Drop-off height approx. 1.100 mm Coolant equipment make KNOLL 450 S-2 - tank volume approx. ca. 950 l - Internal coolant supply max. 40 l/min 60 bar - External coolant supply max. 70 l/min 10 bar Equipment / Accessories - Highly dynamic Gantry-high-bed Portal Milling Machine in compact design Portal moving in X direction. - Machine bed in rigid cast iron, side walls, cross slide and portal as welded steel construction, walking beam in cast iron. - Foundationless installation of the machine. Due to the inherently rigid machine bed, only a standard industrial floor, approx. 300 mm thick, steel-reinforced, is sufficient for installation. A special foundation, however, is not required. The machine is installed and aligned by means of fixators with anchor bolts. - The linear axes (X,Y,Z) are equipped with water-cooled linear motors made by SIEMENS. The X-axis is designed as a GANTRY-axis. - The linear and rotary axes are equipped with direct measuring systems. - The Z-axis drive is supported by highly dynamic pneumatic cylinders (weight compensation). - The linear axes are equipped with a safety system which brakes and safely holds the axes in case of voltage loss. The linear axes are equipped with hardened and ground, backlash-free preloaded linear-guideways. - The guideways are protected by bellows. - All guideways as well as the counterbalance cylinders, which have to be lubricated with grease or oil, are equipped with catching systems so that excess lubricant is collected in a controlled manner and the workpieces cannot be contaminated. The workroom is closed all around. - A top cover prevents dust form escaping unhinderd from the work area and also limits the upward flight of chips. - The front part of the cover (loading side of the machine) can be manually unlocked or locked so that the machine can be loaded and unloaded by crane or forklift truck. - The working area is illuminated with fluorescent tubes (IP 54, protected against water jets and solid foreign bodies). - 2-axis simultaneous fork-milling-head No. 4, - high frequency milling spindle make FISCHER, 24.000 min-1, HSK 63 - CNC-control HEIDENHAIN iTNC 530 HSCI - Portable electronic hand wheel (radio) -68-fold tool changer -Compact coolant system make KNOLL -3-D radio probe make M&H, Type 20.41 MULTI -Laser tool control system HEIDENHAIN, Type TL Micro 300 -Emulsion mist exhausting system -Prepared for additional external exhausting system -Chip conveyor -Milling head mechanics overhauled -All bellows renewed -Roller Blinds overhauled -Change of milling spindle on 25.Oct.2018 at 9.911 spindle hours -Operating hours: control ON 38.595 h, Machine ON 32.535 h, Prog.Run 13.390 h, Spindle 13.466 h, Axes 13.230 h

x-travel 4.000 mm︱y-travel 3.000 mm︱z-travel 1.000 mm︱Control HEIDENHAIN iTNC 530 ︱max./ min. distance spindle nose / table 1.500/500 mm︱clamping table 4.500 x 2.000 mm︱T-slots 22 H8 mm︱distance between columns 2.500 mm︱feed rate X-axis 2-15.000 mm/min︱workpiece weight max. 10.000 kg︱feed rate Y- and Z-axis, stepless 2-12.000 mm/min︱torque of the drives 37 NM︱ball screws: - ︱longitudinal (X)-axis/pitch 63/12 mm︱Vertical (Z)-axis, diameter/pitch 63/10 ︱working spindle with automatic milling head UAD: - ︱capacity at 100% load 30 kW︱transmission ratio 2 ︱turning speed range - stepless 40-5.000 U/min︱max. torque 1.045 Nm︱

---

x-travel 3500 mm︱y-travel 1083 mm︱z-travel 1074 mm︱control HEIDENHAIN iTNC 530 HSCI ︱clamping table - ︱surface area 4.000 x 1.000 mm︱Thread bore with fitting - ︱Feeds - ︱X-, Y- and Z-axis, stepless 2 - 30.000 mm/min︱rapid travel x/y/z 30 m/min︱Max. feed force of axis 10.000 N︱2-axis Milling Head - ︱2-axis milling head TUB-E92 with power on - ︱Torque-Motors for 5-axis-simultaneos processing - ︱capacity at 100% load 29 kW︱Speed stepless 2- 30.000 ︱max. torque 92 Nm︱Max. torque 60 min-1︱tool taper HSK 62A-DIN 69893 ︱automatic tool changer ATC - ︱

---

Guides, drive and measuring systems • All axis drives with digital drives manufacturer HEIDENHAIN • Direct measuring systems for X,Y, and Z axis manufacturer HEIDENHAIN • X-, Y- and Z-axis guidance using high-precision linear guides for maximum precision and dynamics • Precision ball screw with preloaded nuts in X-, Y- and Z-axis Coolant Equipment with Chip conveyor • Coolant outlet, switchable from coolant to air, at the front of the milling head via manually swivelling nozzles • Internal coolant supply, switchable from coolant to air, through the spindle centre. • Tank volume approx. 1.000 l • Normal coolant supply 25l/min 5 bar • High pressure pump for internal cooling 20 l/min 50 bar • Coolant tank incl. Cartridge filter and paper-belt filter system • Hinged belt chip conveyor, discharge height approx. 750 mm Equipment • Machine bed, column and vertical saddle as welded steel construction, annealed with low tension • Milling slider as welded steel construction • Orthogonal milling head TUB-E92 with motor spindle, C- and A-axis drive via torque motors • Oil cooling unit for cooling the milling head • CNC thermal compensation • Spindle drive 29 kW • Spindle speed max. 18.000 min-1 • Axle drives by means of precision ball screws and digital servo motors • Touch probe system manufacturer BLUM, TC 63-30 with radio transmission and automatic measuring cycles • Milling head Measurement “Kinematics Opt” • Laser tool presetter BLUM - NT version mounted on machine table • CNC control HEIDENHAIN iTNC 530 HSCI incl. digital drive technology • Portable electronic handwheel HEIDENHAIN HR 520 with 3 m spiral cable • swivelling control panel for machine operation in front of the machine • Automatic tool changer with 30 magazine places, change position vertical • Coolant system with external shower rim and IKZ through the spindle • 1 chip conveyor in the working area, ejection right • Pretensioned linear guides in all axes • Precision ball screws in all axes • Hydraulic weight compensation in the vertical axis • Bellows cover of the X-axis • Milling slide above and below in the vertical axis with bellows covers with attached stainless steel lamellas closed • Work area enclosure closed on all sides. Back side of the work area with bellows cover with attached stainless steel lamellas closed. The manual sliding doors on the front of the machine can be opened and closed over the entire length of the table. Safety fencing for the back machine area with two secured access doors.

max. wheel diameter 130 mm︱gear width - mm︱max. module 3 ︱min. module ︱table speed max. 1.000 min-1︱axial travel max. 350 mm︱milling head swivelling angle +/- 45 Grad︱milling head ︱power capacity 11,5 kW︱milling spindle speeds 4.000 U/min︱hob dia. - max. 100 mm︱electrical supply data ︱power requirement 48 kVA︱operating frequency 50 Hz︱control voltage 24 V DC︱control SIEMENS 840 D ︱total power requirement - kW︱weight of the machine ca. 9,5 t︱dimensions of the machine ca. 2,2 x 3,1 x 2,9 m︱

---

equipment • constructed for dry machining • hydraulic power unit • magnetic belt conveyor • exhausting unit make REVEN • heat exchanger for hydraulic oil temperature control system (without cooler unit) • counterholder with lowering equipment and vertical adjustability • swivelling ring loader with pickup unit (without conveyor belt) • deburring unit

max. wheel diameter 80 mm︱gear width 44 mm︱max. module 5 ︱min. module ︱Control SIEMENS 840 C ︱adjustment axis angle shaping sp. - wp table -0,5 - +0,5 °︱stroke range 250-1.500 DH/min︱centre distance table/shaping spindle -15 bis +170 mm︱max. stroke length 55 mm︱max. helix angle 45 ︱max. tool diameter 180 mm︱feeds: ︱feed rotation axis of workpiece (100 mm wp diam.) mm/min︱feed rotation axis of work piece (100 mm wp. diam. 10-15.700 mm/min︱feed center axis of machine column 1 - 3.750 mm/min︱ 23 kw︱voltage 400 V︱operating frequency 50 Hz︱control voltage 24 V DC︱total power requirement kW︱

---

equipment · stroke positioning adjustment controlled by CNC · stroke length adjustment mechanical-manually · machine is fixed to the ground with specific damping shoes (part of the delivery scope) · oil mist exhaust system · tailstock · shaping spindle and lift of shaping head equipped with hydrostatic bearing

grinding diameter max. 35 mm︱regulating wheel width 250 mm︱max. width of grinding wheel 250 mm︱Control SINUMERIK 840 D ︱max. grinding length while plunge grinding 245 mm︱grinding wheel diameter x width 450 x 250 mm︱regulating wheel diameter x width 250 x 250 mm︱grinding wheel power 15 kW︱Profiling of grinding wheel by diamond roll ︱Dynamic balancing unit DITTEL ︱workpiece handling ︱total power requirement kW︱weight of the machine ca. t︱dimensions of the machine ca. m︱

---

Machine bed made of mineral casting - thermostable and vibration damping - Foundation area 3,200 x 2,000 mm - Coolant discharge height approx. 500 mm - integrated bed flushing - levelling elements - Recesses for transport - Elements for mounting the switch cabinet Cross slide systems on the grinding wheel side X-slide - for wear compensation of the grinding wheel and the infeed movement for grinding and for dressing (X1 axis) with recirculating roller guides - Adjustment by means of digital three-phase servomotor via ball screw drive - smallest infeed increment 0.1 µm - Equipment with glass scale Z-slide - arranged on the X-slide - for transverse movement of the grinding wheel during dressing (Z2 axis) with recirculating roller guides - Adjustment by means of digital three-phase servomotor via ball screw drive - smallest infeed increment 0.1 µm grinding wheel headstock - with integrated protective cover in cast steel design - attached to Z-slide - Mounting of a grinding spindle with bearings on both sides - 6° inclined grinding spindle - mounted on both sides in anti-friction bearings - suitable for 250 mm wide grinding wheels - long-life grease lubrication - Bore diameter of the grinding wheel 203.2 mm - Max. Speed 7.200 min-1 Drive grinding spindle - Main drive for grinding wheel circumferential speed 40....150 m/sec via three-phase main spindle motor 15 kW (water-cooled) Remark: Use of recooling system or use of an existing cooling circuit Coolant conditions: - Filter fineness 100 µm - Cold water flow 8 l/min - Cooling capacity 2750 W - Coolant inlet temperature <25°C - Cooling medium - water or low-viscosity oils Cross slide systems on the regulating wheel side X-slide - for wear compensation of the regulating wheel and the feed motion for dressing (X4 axis) with recirculating roller guides - Adjustment by means of digital three-phase servomotor via ball screw drive - smallest infeed increment 0.1 µm - Equipment with glass scale Z-slide - arranged on the X-slide - for transverse movement of the regulating wheel during dressing (Z3 axis) with recirculating roller guides - Adjustment by means of digital three-phase servomotor via ball screw drive - smallest infeed increment 0.1 µm bearing housings - with drive for control spindle - arranged on the Z-slide regulating wheel lowering - manual clamping - Adjustment via adjusting spindle - Maximum lowering -20 to +40 mm - Angle of inclination at maximum lowering +/- 5° Control Spindle - mounted on both sides in anti-friction bearings - suitable for 250 mm wide regulating wheels - long-life grease lubrication - Bore diameter of the disc 127 mm - Control spindle drive via three-phase servo motor 5 kW - Dressing speed max. 1,000 min-1 - Working speed max. 500 min-1 Diamond roller device (without diamand roller) - located in the centre of the machine on the working level Complete with: - Bearing for diamond roller mandrel - direction of rotation in the same and opposite direction - Spindle speed up to 9.000 min-1 - Speed and coolant flow monitoring - diamond roll mandrel - Drive via three-phase motor - swiveling -3°<->0°<->+3° -3°->0°<->+3° -3°->0°->+3°-+3° -3°->+3° - Clamping width up to 135 mm - Diamond profile roller diameter 95 mm - Diamond form roller diameter 125 mm - Diamond roll mandrel diameter 52 mm Dressing device for regulating wheel - suitable for holding standing dressing tool (M 14 x 1) - located in the centre of the machine on the working level Full protection of working area - for coolant mist shielding with electrical safety door monitoring - Safety glass windows - Connecting piece for external oil mist extraction system Electrical system with switch cabinet and control unit - Switch cabinet permanently attached to the machine - Grid feed in from above - Switch cabinet cooling via external service water cooling (not included in scope of delivery) - Operating voltage 400 V, 50 Hz CNC control: - CNC control SIEMENS SINUMERIK 840 D and inverter system SIMODRIVE 611 D - Control panel can be swivelled and attached to the control cabinet - second identical control panel on the rear side of the machine - Operating panel front OP010 with 10.4" TFT colour display - 19" Push Button Panel (PP012) and user-specific extensions of the PP012 - 3 spindles and 4 position-controlled servo axes with digital setpoint interface - Use of "Safety Integrated" with fail-safe modules (Profisafe) - Parameter selection, fault diagnosis and operator guidance through clear menu structure - Constant grinding and regulating wheel peripheral speed - Integrated hardware and software for remote diagnosis and teleservice - Connection via Ethernet Additional monitoring of complete machine Handset: - incl. function extension - Start/Stop Produce - Input correction of the grinding gap with confirmation - retreat - emergency stop - Move to home position - acknowledgement button - override switch - incl. 10 m cable - pluggable to main control unit Grinding wheel incision detection: - in conjunction with profile roller truing device consisting of - Electronics AE6000 incl. software for 4 sensors Function: - visual control with indication on the display - Cut recognition of the grinding wheel during dressing Dresser detection control wheel - in conjunction with dresser detection Grinding wheel consisting of - additional sensor Function: - visual control with indication on the display - Bleed detection of the regulating wheel during dressing Incision detection workpiece: - in conjunction with dresser detection Grinding wheel - 1 sensor Function: - visual control with indication on the display - Cut detection of the grinding wheel on the workpiece Dynamic balancing device DITTEL consisting of - 1 built-in balancer with integrated conless receiver - 1 control unit in control cabinet - 1 electronic display integrated in the control panel - 1 conless transmitter with speed sensor Fire extinguishing system BATEC - CO² fire extinguishing system completely installed (delivery without CO² bottle) - Interface to the machine control system - Detector for switching off machine function - controlled fire damper at the suction nozzle Preperation of external coolant system consisting of - electric main coolant valve mounted on the machine - Coolant return interface Coolant used so far: Oil Maximum temperature: 25 °C Temperature constancy: +/- 1 °C/h Quantity: 150 l/min Pressure: 3,5 bar filtration degree: 20 µm - Connection for a rinsing gun incl. holder for cleaning the interior of the machine - prepared for high pressure rinsing of the grinding wheel, operating pressure approx. 10 bar, (high pressure) pressure pump not included) Automatic warm-up of the basic machine The warm-up function shortens the starting phase of the grinding machine. Conditions for the machine is ready for warm-up: - Machine is in basic position - No emergency stop error message is pending - No retraction Error message is pending - Drives and control voltage are switched off - Compressed air is available The machine is started via software time switch with the following sequence: - Switch on control voltage - Switch on drives - Referencing of all NC axes - Switch on grinding wheel, regulating wheel and coolant. - Disable screen darkening Automation for loading and unloading rotor shafts Designed for maximum workpiece diameter 60 mm, maximum workpiece length 160 mm basic handling - external with usable table width 750 mm - NC axes for horizontal and vertical travel loading portal - base frame - 2 NC axes for horizontal and vertical movement Basic gripping device 1-fold mechanical - for attachment to the basic handling system - mechanical gripper basic device for radial gripping of the shafts - 1 pair of gripper fingers each for radial gripping adapted to previous workpieces - 1 delivery prism for 1 finished part, arranged below the horizontal axis infeed belt - prism cycle belt - Length approx. 800 mm - with substructure and support at belt end - Side and top guide for securing the workpiece position - single-track prismatic clockband - Belt with prismatic milling on the transport side for the exception of the workpieces - Sensoric position control and sensoric recognition of workpiece presence - Storage capacity for approx. 9 workpieces Converter, Feeder - with mechanical radial gripper - Converter with a pneumatic horizontal and vertical axis and integrated, displaceable intermediate stop module - 1 set of gripper fingers The converter can move to three different positions (infeed cycle belt, measuring point, intermediate deposit prism under the loader axis). Preparation for integration of a measuring point - Measuring point integration for pre-process length measurement and DMC - Integration of a measuring point to be mounted from the handling table Clip-on prism for measured workpiece blank - for depositing the measured raw part under the horizontal axis of the gantry loader in transfer position of the gripper Pneumatically driven drawer - is moved into the traverse path of the Horizotal axis if SPC is required - is equipped with a bowl to hold the workpieces NIO clockband - Length approx. 1,200 mm - with 2 workpiece tracks - 3-track conveyor belt for separate depositing of workpieces with the NIO features "DMC not read" and "length tolerance not met." - Each workpiece track is assigned a NIO marker. - with substructure and support at belt end - Side and top guide for securing the workpiece position - single-track prismatic clockband - Belt with prismatic milling on the transport side for holding the workpieces - Sensory position control and sensory recognition of workpiece presence - Storage capacity sufficient for approx. 16 workpieces - the NIO band can be clocked manually via a button Automatic central lubrication - Automatic lubrication of all guide axes via a central pump lubrication unit Other - Protective device (CE-compliant), window areas equipped with Makrolon, 2 large double-action Doors with EUCHNER safety switches - Pneumatic device with maintenance unit and soft start - Electrics at the Profibus Measurement control for rotor shafts consisting of: measuring device - one base plate each prepared for integration into the loader - Integration of 2 measuring systems in separate mechanical extensions - Version complete with maintenance unit, cylinders, valves and proximity switches - wired to Muhr CUbe67 - manual calibration of the measuring point by the operator Measuring electronics P7me with housing IP 54 - for measured value acquisition - with Profibus interface - Transfer of the measurement data to the machine control system - with software Length measuring system - required for actual measurement of the base "B" to the stop side - for integration in charging automation -2 Workpiece pre-feed prisms - horizontal slide unit (pneumatically adjustable) - Preparation for integration of a reader for DMC acquisition - mechanical device for rotation of the parts for DMC detection Measuring device "Rotor consisting of - Pre-process measuring device for length measurement before grinding operation - with horizontal workpiece support - with workpiece orientation - with one probe against mechanical reference - Connection to common measuring electronics with post-proc Equipment/accessories - Centerless external cylindrical grinding machine KRONOS S 250 for plunge-cut grinding (6°) - Dynamic balancing device make DITTEL - Grinding wheel holder with balancing weights - Stand for control spindle with portal bearings - Device for adjusting the height of the workpiece - Coolant main valve (electric) for connection to central coolant supply - machine light - Equipping the feed axis Z2 with glass scale - Equipping the feed axis Z3 with glass scale - Interface for a central coolant system - Interface for coolant return - Automation for loading and unloading rotor shafts - Extension of the control components integrated in the control cabinet - Electrical and mechanical interface for loading and unloading system - Interface for a DataMatrixCode reader - Electrical interface for measurement control (32 I/O) - Workpiece support holder for plunge grinding - Workpiece support for plunge grinding - Pneumatically actuated hold-down device - Needle nozzles for plunge grinding (depending on workpiece) - Adjustable stop for workpiece support holder - Additional monitoring of complete machine - second control panel at the rear of the machine - operating handset - Cut detection Grinding wheel - Bleed detection Control wheel - Cut Recognition Workpiece - grinding wheel flushing - Additional regulating wheel unit - fire extinguishing system - Extension of the switch cabinet cooling system - Cooling of the control point - Automatic warm-up The machine was connected to a central coolant supply (grinding oil), and is therefore supplied without its own coolant system. The cooling of the grinding motor as well as the switch cabinet was carried out by decentralised service water cooling and must be ensured by a new cold water unit if necessary.

grinding length 800 mm︱grinding width 600 mm︱workpiece height mm︱control ERGOMATIC ︱headstock: dist. table - spindle center 700 mm︱max. table load 800 kg︱Length movement of the table mm︱table clamping with additional space 1.200 x 600 mm︱table longitudinal travel 900 mm︱table speed 30-3.000/300-30.000 ︱adjustment of X-movement by soft key on control pa ︱guidance system pretensioned roller guide ︱table drive Servo-Motor with ball scr kW︱manual table adjustment via joystick on the contr ︱measuring system 0,001 mm rotatorisch ︱Y-axis - vertical adjustment of the grinding wheel ︱max. distance table to spindle centre 700 mm︱rapid traverse 3.750 m/min︱guidance system pretensioned roller guide ︱axis drive servo motor with ball scr ︱

---

BLOHM Grinding control ERGOMATIC Movable setup console in the middle of the machine: Electronic handwheels for conventional operation of the machine for axes Y and Z. Joy stick for the axes X and Z. Feed control per axis via potentiometer, also active during program run. Control panel on support arm on the right side of the machine: LC display, visible area 121 x 103 mm, with backlight Membrane keyboard with short-stroke keys for acknowledging recommended default values or for entry of freely selectable parameters with the following functions: - Loading position X and Z axis - Set or change reversing points during the program - Set zero points for Y and Z axis - Set safety position - Set grinding wheel data - Select dressing function Softkey for preselection measuring system metric / inch Info button for help texts and service instructions Display for operating hours and maintenance intervals Fixed programs for workshop-related, operator-friendly handling: - Reciprocating loops with automatic Y-feed - Longitudinal, circumferential and surface grinding with intermittent or continuous crossfeed and automatic Y positioning - Grinding wheel adjustment with handwheel or automatic - ECO loops with automatic Y positioning: 1st layer: plunge grinding "roughing" 2nd layer: Surface grinding "finishing" 3rd layer: surface grinding "fine finishing" Automatic Y positioning: 3 layers with dressing, 10 parameter sets for 10 delivery programs storable, allowance or finished dimension grinding preselectable. Dressing programs: - Straight dressing from the table with compensation by single diamond, foldable dressing unit. - face dressing with single diamond or foldable dressing unit. - Dressing with compensation by automatic straightening device. - Deep dressing with compensation by PEA-T100. Coolant cleaning equipment Coolant system with belt filter (tank capacity 1,400 l) consisting of: - Belt filter with a cleaning surface of 2.25 m² for a flow rate of 250 l / min - Supply pump 200 l / min, 4 bar - Additional pump for water trough flushing and rinsing gun - Cooling unit for coolant emulsion with max. 5% grinding concentrate - Power 4.9 kW (4,200 kcal / h), refrigerant CFC-free Equipment/Accessories - Basic machine with work enclosure closed at the top - Spindle drive 15 kW, frequency controlled - Manual balancing device MPM incl. Vibration sensor and speed sensor - Belt filter coolant cleaning system Tank capacity 1,400 liters - Pneumatically folding dressing unit - Electro-permanent magnetic clamping plate 800 x 600 mm, transverse pole pitch 4 mm, with 8-fold adhesion control - 2 pieces of grinding wheel flanges - 1 pc. balancing mandrel - Machine documentation incl. CE conformity declaration - Finish: RAL 5009 azure / RAL 9002 gray white Grinding spindle insert renewed 02-2016

current capacity 250 kVA︱workpiece dia. - mm︱cross cut max. - mm²︱Control SIEMENS S7 -CPU 317-PN/DP ︱Max. friction force 81 kN bei 100 bar︱Min. friction force 5,7 kN bei 7 bar︱Max. upsetting force 120 kN bei 148 bar︱Max. spindle speed 2.500 min-1︱Max. slide stroke 400 mm︱Spindle drive power 147 kW︱Electrical supply data - ︱Nominal voltage 400/50 V/Hz︱Total connected load 250 kVA︱Medium power requirement 50 kW︱Medium power 250 A︱Fuse 630 A slow︱Cable cross section 240 mm²︱total power requirement kW︱weight of the machine ca. t︱dimensions of the machine ca. m︱

---

measuring range X-axis 250 mm︱measuring range Y-axis 250 mm︱Table dimensions mm︱Control HYPERION H250 F3 ︱universal taper HGH-UZ ROD ︱rapid traverse 17.000 mm/min︱tool posts 1 x HSK 40 incl. clamping ︱tool posts 1 x SK 30 incl. clamping ︱Overall size 1400 x 900 x 1500 mm︱weight of the machine ca. 250 kg︱

---

Equipment · Industrial-PC with ZOLLER image processing-software „pilot 3.0“ · Machine terminal with TFT-colour flatscreen, keyboard and mouse · Label printer · Membrane keyboard · Pivotable CCD-reflected light camera · Software-CD “pilot 3.0” · Software-CD “Formatgenerator” to generate output format for electronic “pilot 2.0”