komet komtronic® u-axis system · 5 500 000 500 000 500 000 1500 1000 500 0 6 8 10 1 l1 x 115 x 1...

KOMET KomTronic® U-Axis systemEconomic turning contours on the machining centre when working with a stationary workpiece

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KOMET KomTronic® U-Axis systemReplaces separate machining on a lathe

Benefits for you:

Lower investment costs- Useofstandardinsteadof specialmachines- Reductioninnumberoftools- Noneedforclampingdevices forfinishmachiningonturning machines

Reduced unit costs- Completemachiningonone machine.- Reductioninmachining andthroughputtimes- Savingsontoolchanges- Replacementoftimeconsuming circularmachiningoperations-Reducedholdingtimes-Highcuttingcapacity

Lower operating costs- Completemachiningonone machinewithouttheworkpiece beingrotated- Minimumpowerconsumption becauseofU-Axissystems

Machining examples

Grooving Turningvalveseats

Bearingseat TierodBorewithcoolantpassages

Undercuttingdifferentialhousing

Contourturning,externalandinternalcontourturning

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Tool-changeable NC axes for machining centres:

ThefreelyprogrammableKomTronic®U-Axissystemmakeanycontourandturningoperationspossibleonnon-rotationallysymmetricalparts.Combinedwithcustom-madefronttoolsandtheopti-mumselectionofinserts,contoursinboresandexternalmachiningoperationscanbesuccessfullycarriedout.Thisallowsaconsiderablereductioninproductiontimes,withbettersurfacequalityandgreateraccuracyofform.Furthersavingsintimeandcostscanalsobeachievedbyreducingthenumberoftoolspreviouslyrequired-forexample,circularmillingacomplexinternalcontourwithvariousformmillingtools.Thesavinginformmillingtoolsandtoolchangesthisachievesalsoreducesproductiontimeandproductioncosts.

Greatly reduced processing times and higher precision

KomTronic®U-Axissystemsessentiallyconsistofonecompactfacingheadwithsingleslidethatisdrivenbyaservomotorandthreadedspindle.Thepowersuppliedtotheelectronicsandthedriveistransmittedcontact-freeandinductivelytotheU-Axissystem.Similarly,thedataisexchangedinductivelywiththeU-Axissystem.Aso-calledstatorismountedonthespindleside.Itissegment-shaped, which permits the U-Axis tools tobechangedinandoutautomatically.Thering-shapedinductivetransmissionunitontheU-axissideensuresproperdataandenergyexchangeineveryangularposi-tion.Thankstothefreelyprogrammablecuttingedgethat is dynamically adjustable during machining, themechatronicU-Axissystemsareautomaticallychange-ableNC-axes.ProgrammingiscarriedoutintheusualNCprogramminglanguagewithallitsfunctionsandisintegratedintothemachinecontrolsystem.

Wearealsopleasedtoanswerquestionsviae-mailatKomTronic@kometgroup.com.

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UAS-125-Z-12

UAS-125-Z-12

L1 L2

E11 10050 UAS-1�5-HSK6�-E-Z-1�-1a HSK6� 166 ��

E16 10080 UAS-1�5-SK�0-E-Z-1�-1a SK�0 159 �5

E16 10090 UAS-1�5-CAT�0-E-Z-1�-1a CAT�0 159 �5

E16 10100 UAS-1�5-BT�0-E-Z-1�-1a BT�0 166 ��

L1

x1�

5 �0

66

�6

�500

�000

�500

�000

�500

�000

1500

1000

500

0 1 � � � 5 6

�×

L�

Max. stroke/spindle speed diagram

Technical data

spin

dle

sp

eed

[m

in–1

]

+/– stroke [mm]

•U-Axistool1�mmstrokewithtoothedtoolconnection

•externaldiameter:1�5mm

•weight:7,6kg(withHSK6�)

•max.feed:�00mm/min

•max.spindlespeed:10�0–�000min–1,dependingonslideposition(seestroke/spindlespeeddiagram)

•withinternalcoolant:�0bar

KOMET KomTronic® U-Axis systemThe u-axis for tool changing

Order No. Article Connection

Radi

als

trok

e

Cuttingedgeposition

Seepage18formoreapplicationdetails!

Protectionclass:IP67

Operatingmodes:fullNCaxisforinterpolation

TogetherwithKOMETfronttoolingandKOMETinserts,theKomTronic®U-Axissystemopensupmachiningpossibilitieswhichuntilnowwouldhavebeenunthinkableonamachiningcentre.

Guideholes

It‘s not possible to use the system UAS-125-Z-12 and UAS-115-Z-22 together in the same machine!

5

�500

�000

�500

�000

�500

�000

1500

1000

500

0 � � 6 8 10 1�

L1

x11

5

x1�

7

UAS-115-Z-22

L1 L2

E21 20010 UAS-115-HSK6�-E-Z-��-� HSK6� 178 ��

E21 22010 UAS-115-SK�0-E-Z-��-� SK�0 171 �5

E21 24010 UAS-115-CAT�0-E-Z-��-� CAT�0 171 �5

E21 26010 UAS-115-BT�0-E-Z-��-� BT�0 178 ��

�6

UAS-115-Z-22

1111

6×�0

L�

Technical data

•U-Axistool��mmstrokewithtoothedtoolconnection

•externaldiameter:115mm

•weight:6,�kg(withHSK6�)


•max.spindlespeed:750–�000min–1,dependingonslideposition(seestroke/spindlespeeddiagram)








spin

dle

sp

eed

[m

in–1

]

+/– stroke [mm]


Radi

als

trok

e

Cuttingedgeposition

Guideholes

Rota

ting

dia.

159

It‘s not possible to use the system UAS-115-Z-22 and UAS-125-Z-12 together in the same machine!

6

�500

�000

�500

�000

�500

�000

1500

1000

500

0 � � 6 8 10 1�

L1

x16

0

x1�

7

UAS-160-Z-22

L1 L2

E21 31010 UAS-160-HSK100-E-Z-��-1 HSK100 �0�,5 �5

E21 33010 UAS-160-SK50-E-Z-��-1 SK50 19�,5 �5

E21 35010 UAS-160-CAT50-E-Z-��-1 CAT50 19�,5 �5

E21 37010 UAS-160-BT50-E-Z-��-1 BT50 �11,5 5�

�6

UAS-160-Z-22

1111

6×�0

L�

Technical data

•U-Axistool��mmstrokewithtoothedtoolconnection


•weight:1�,�kg(withHSK100)










spin

dle

sp

eed

[m

in–1

]

+/– stroke [mm]


Radi

als

trok

e

Cuttingedgeposition

Guideholes

7

�500

�000

�500

�000

�500

�000

1500

1000

500

0 5 10 15 �0 �5

UAS-160-Z-50

L1 L2

E21 31020 UAS-160-HSK100-E-Z-50-1 HSK100 �17,5 �5

E21 33020 UAS-160-SK50-E-Z-50-1 SK50 �07,5 �5

E21 35020 UAS-160-CAT50-E-Z-50-1 CAT50 �07,5 �5

E21 37020 UAS-160-BT50-E-Z-50-1 BT50 ��5,5 5�

x16

0

x19

8

�6

UAS-160-Z-50

�5�5

10°

8×�0

L�

L1

Technical data

•U-Axistool50mmstrokewithtoothedtoolconnection


•weight:1�,�kg(withHSK100)





Rota

ting

dia.

��8

Patentsappliedfor.

Workpiecescanbecompletelymachinedwithhighprecisionandcycletimesavingsutilisingtheseoptionsforturning,undercutting,chamferingandgenerationofNCcontrolledcontours.




+/– stroke [mm]

spin

dle

sp

eed

[m

in–1

]



Radi

als

trok

e

Cuttingedgeposition

Guideholes

8

KOMET KomTronic® U-Axis systemMachining examples

Machining:turninganinsideradiusCuttingspeed vc=80m/minFeed f =0,1mm/rev.Cuttingwidth 1stcut ap=1,5mm �ndcut ap=0,�mmRadialstroke10mm

Workpiece: differential housing

Benefitsforyou:

•Flexibility

•Savesonexpensiveblanking

•Replacesseparatemachiningona latheandthuseliminatestheneed foraclampingdevice

•Increaseinquality

Machining:rearplaningCuttingspeed vc=80m/minFeed f =0,1�mm/rev.Cuttingwidth ap=0,�mmRadialstroke1�,5mm

9

�5

x1�

x�1


Workpiece: control block

Machining:turninganinsidetaper

Benefitsforyou:•Replacesseparatemachining

onalatheandthuseliminatestheneedforaclampingdevice

•Reducedproductiontimes•Increaseinquality

ThematerialInconell6�5wasappliedtoataperedholeandmachinedin�cuts.

TaperedsealforhighcoolantpressureCuttingspeed vc=�0m/min

Feed f=0,08mm/rev.

1stcut ap=�,5mm

�ndcut ap=0,5mm

Cuttingspeed vc=150m/minFeed f =0,08mm/rev.Taperangle a =9,5°–0,05°

Material: Castaluminum

Workpiece: wheelmount

Machining:reversetapermachining

Benefitsforyou:•Completemachiningononemachine•Replacesseparatemachiningonalatheandthus

eliminatestheneedforaclampingdevice•Reducedprocessingtimes•Increaseinquality

10


Workpiece: bearing plate

Machining:turningabearingplate

Benefitsforyou:

•Reducedprocessingtime•Reducedtoolchangetime•Reducedtoolcosts•Completemachining•Flexibility•Higherprecisionandprocessreliability

Material��CrMo�Variablediameter


Machining:completemachiningononemachining/millingcentre

Benefitsforyou:

•Reducedproductiontime•Reducedtoolcosts•Flexibility•Increaseinquality

Material��CrMo�


Machining:turninganoutercontour

Benefitsforyou:

•Completemachiningononemachiningcentre

•Replacesseparatemachiningonalatheandthuseliminatestheneedforaclampingdevice

•Reducedproductiontimes

•Increaseinquality

Material:Inconel

11

5,6 �,6

�±0,�

R0,5

R1

Ra0,8

x10

,0

1,5°±0,1°


Workpiece: Brake caliper

Machining:reamingandrecessinginoneoperation

Benefitsforyou:

•Completemachiningonone machine•Reducedprocessingtime•Reducedtoolcosts•Reducedadditionalcosts•Flexibility•Increaseinquality

Material:GGG50

Reaming: Cuttingspeed vc=1�0m/min Feed f =0,15mm/rev.Grooving: Cuttingspeed vc=100m/min Feed f =0,06mm/rev.

Workpiece: joint plate

Machining:tapermachiningwithradiuscontour

Benefitsforyou:

•Reducedprocessingtime•Reducedtoolcosts•Reducedproductiontime•Higherqualityandprocessreliability

Material:Titan

Cuttingspeed vc=50m/minFeed f =0,05mm/rev.

1�


Workpiece: hydraulic cylinder

Machining:springingvalvesBoringinnercontoursandrecesseswith�U-axissystems

Benefitsforyou:

•Reducedprocessingtimes•Reducedtoolchangetimes•Reducedtoolcosts•Reducedadditionalcosts•Flexibility

Material:X1�CrMoS17

Feedf =0,1–0,15mm/rev.Spindlespeedn=�000min–1

Workpiece: cylinder head

Machining:centralboreofthecylinderheadsofadieselengine

Benefitsforyou:

•Increasedprecisionandprocessreliability•Replacescircularmillingoperations•Timesavingof80%

Material:GGG50

Ø66,6+0,15mm

Cuttingspeedvc=1�0m/minFeedf =0,1mm/rev.Cuttingwidthap=0,65mm

Mac

hining

direc

tion

1�

Benefits for you:

• Time saving

• Saving on tools

• Increase in quality

• Automatic wear compensation

• No holding times

Complete machining in a closed process chainTurning and measuring on the machining centre

• Complete machining: turning on a milling machine, no switching to a turning machine, thus eliminating the need for a clamping unit

• Reduction in number of tools, no special forming tools

• Higher quality

• Precision measuring with direct measuring using a barrel gauge or calliper

• Automatic test cut possible

1�

X d1 X d2 L L1

P80 23030 ABS��N �� ,5

P80 24030 ABS�0N �0 �7 �7,5

P80 25030 ABS50N 50 �� 8

P81 21010 x16 �5,8 �6,5 �7

P81 21020 x�0 �0 51,5 ��

P81 21030 x�5 �8 76 6�

P81 21040 x�� 5� 76 6�

L1

ABS

-NL1

Xd1

Xd2

LL

KOMET KomTronic® U-Axis systemModular systems: modular tool holders

Thefronttoolcanbemounteddirectlyontotheslide.Thefollowingadaptorsareavailablewhenusingstandardtools(othersavailableonrequest):

Order No.

15

SINUMERIK8�0C

SIEMENSSINUMERIK8�0D

SINUMERIK8�0Disl

Fanuc15i/16i/18i/�1i/150i/160i/180i/�10iFANUC

Fanuc�0i/�1i/��i/�00i/�10i/�10is/��0i

HeidenhainTNC��6/TNC��0

HEIDENHAINHeidenhainiTNC5�0

MillPlus

INDRAMATMTC-�00V18INDRAMAT

INDRAMATMTX

G0U15

G1Z0

G1U1�.5Z-0.5

G1Z-6

G1U1�

G1U1�.75Z-6.�5

G1Z-17

G1U1�.5

G1Z-�5

G�Z-��.18U9.9E1�.5

G1Z-��U1�

G0U9.75

G0Z10

Integration of theKomTronic® U-Axis system into different machine control systems

Nothing new for programming ...

cornerbreak

step

cornerbreak

step

radius

angle

Control system Manufacturer

16

115/��0V��0W

KOMET®

��V0,5A

NC:analogue

axismodule

PLC:11E�A

NCANCAdaptation

Machine manufacturer

Power pack 48V

Line:encodervalue(KOMET)

Line:±10Vspeedcommand(KOMET)

fromthemachine

In electrical cabinet

On machine / spindle

Statorwithstatorlinex8,�mm,max.length5m

Bus line(KOMET)x8,�mm

fromthemachine

48 V connection line(KOMET)x11,1mm

1. PLC connection 11inputsand�outputsarerequiredonthePLC. �M-commandsarerequiredforselectingU-Axisfunctions.

2. Nominal value requirement ±10VnominalspeedvaluefromanalogueaxismoduleofNCcontroltotheKOMETNCA.

3. Incremental actual position value ThecurrentpositionistransmittedfromtheKOMETNCAtotheanalogueaxis

modulefortheNCcontrol.Thefollowingsignalformsareavailable •TTLlevel(5V)inacc.withRS��,interpolated,squaresignalform •1Vpp(1Vpeaktopeak),sinesignalform •11µApp(11µApeaktopeak),sinesignalform

The KomTronic® U-Axis system does not need a power unit on the NC control.

PLCinterface

KOMET KomTronic® UAS-1�5Schematic system overview

Modulator

U-Axis

17

115/��0V��0W

KOMET®

��V0,5A

KOMET KomTronic® UAS-160Schematic system overview

NC:analogue

axismodule

PLC:11E�A

NCANCAdaptation

Machine manufacturer

Power pack 24V

Line:encodervalue(KOMET)

Line:±10Vspeedcommand(KOMET)

fromthemachine

In electrical cabinet

On machine / spindle

Statorwithstatorlinex8,�mm,fixedlength�m

Bus line(KOMET)x6,5mm

24 V connection line(KOMET)x11,1mm

1. PLC connection 11inputsand�outputsarerequiredonthePLC. �M-commandsarerequiredforselectingU-Axisfunctions.

2. Nominal value requirement ±10VnominalspeedvaluefromanalogueaxismoduleofNCcontroltotheKOMETNCA.

3. Incremental actual position value ThecurrentpositionistransmittedfromtheKOMETNCAtotheanalogueaxis

modulefortheNCcontrol.Thefollowingsignalformsareavailable •TTLlevel(5V)inacc.withRS��,interpolated,squaresignalform •1Vpp(1Vpeaktopeak),sinesignalform •11µApp(11µApeaktopeak),sinesignalform

The KomTronic® U-Axis system does not need a power unit on the NC control.

PLCinterface

Modulator

U-Axis

18

KOMET KomTronic® U-Axis systemInstallation support by KOMET

Note:Thetechnicalnotesprovidedintheapplicationdetailsdependontheenvironmentalandapplicationconditions(suchasmachine,environmentaltemperature,lubrication/coolantusedanddesiredmachiningresults):thesearebasedonproperapplicationconditions,useandcompliancewiththespindlespeedlimitsgivenforthetools.

InordertoensurethattheKomTronic®U-Axissystemiscorrectlyincorporatedintothemachineandisabletocarryouttherequiredfunctions,thecustomermustprovideclarificationandcomplywiththenecessaryrequirements:

1.Fittingthestatorfornon-contactpoweranddatatransmissiontothe KomTronic®U-Axissystem.Careshouldbetakentoensurethatnoconflict

occurs with other parts of the machine, the tool changer or similar units.KOMET’sobligationsdonotincludeprovisionoftheadaptorelementforthestatorunit.

�.ThecustomerwillsupplytheinputsandoutputsrequiredfortheKomTronic®U-Axissystemonthemachineside.TheanalogueaxisunitrequiredforoperationwiththeU-Axismustbeprovidedandconfiguredforthemachinecontrolsystembythecustomer.

�.Thecustomermustcarryoutthenecessarysoftwareadjustmentsforthemachinesequencecontrolbeforetheinstallation.

�.Function clarification: Process requirements must be met with reference tomachineandprocessingconcept.Forexamplecycletimesandmachiningdatamustbeclarified.Thetoolchangermustbedesignedforthetoolweightandthetoolmustfitintothetoolmagazine.

KOMET will provide the necessary assistance for clarification of the tasks as stated.

19

Fax to +49(0)7143.373-577E-Mail: [email protected]

ThisorderissubjecttotheconditionsofsupplyandpaymentfortheKOMETGROUPGmbHandtotheinstallationandcommissioningrequirementsforKomTronicproducts.

Requirements for successful project planning for KomTronic® u-axis systems:BeforedetailedclarificationofthemachiningtaskthefollowingquestionsonthemachineandNCcontrolsystemneedtobeansweredpositively.

1. Questions relating to machine•CantheNCcontrolbefittedwithananalogueservointerface?

•Isthemachinemanufacturerpreparedtoadaptthemachine?Thecustomernormallyneedstoaskmachinemanufacturertoadaptthemachine.Therewillbeadditionalcostsfortheworkcarriedoutbythemachinemanufacturer.Dependingontheageofmachineswhicharealreadyinstalled,machinemanufacturersmaynotbepreparedtocarrythisout.ThePTPmethodisavailableforsimplefeedmovements.Inthiscasenoanalogueservointerfacewillberequired.

•Stator:istheresufficientspaceonthespindletofitthis?Checkcablelengthlimit�mor5m.Cantoolsbeautomaticallychangedwithoutcollidingwiththestator?Statorholdermustbeprovidedbythecustomer/

machinemanufacturer.

•Automatictoolchanger:isthechangeoverweightsufficient?NormallyforHSK100/ISO50–machines�5kgnoproblem.ForHSK6�/ISO�0machinesthechangeoverweightissometimesnotsufficient.Forsomeapplicationsthechangeoverspeedneedstobereduced.

Doesthetoolfitintothemagazine?Normallyadjacentspacesneedtobekeptfree.

2. Questions relating to part being machined•Isthestrokesufficientfortheoperation?

Rangeofparts?Ifpartsofdifferentsixesaretobemachined,willthestrokebesufficientforalltheparts?

•Maximumspindlespeed?OnKomTronic®toolchangesystemswithasingleslide,thespeedmustbereducedastheslideisextended.Ruleofthumbforspindlespeed:�500/√stroke.Seestroke–spindlespeeddiagramfortoolheads.

•Permissibletoolweightandlength?Nofiguresdefinedasyet.Thesewillbecalculatedbyourengineersortrialdepartment.

Machine

Spindleconnection: Controlsystem:

Manufacturer: Controltype:

Type: ControlNo.:

MachineNo.: Yearofmachineconstruction:

Max.changeweight:: Maximumpermissibletoollength?:

Parts to be machined

Surfacequalityrequired: Cpkvalue:

Tolerances: Stroke:

Cycletime: Affectingcycletime?

Machinepreparation:See“Requirementsforu-axisInstallations”and“Conditions”

n Enquiry Company

n OrderOrderNo.:

Address

Contact

Quantity required

Tel. Fax

Date Signature

www.kometgroup.com

KOMET GROUP GmbHZeppelinstraße 374354 BesigheimTel. +49(0)7143.373-0Fax +49(0)[email protected]

KOMET GROUP GmbHWerk Stuttgart-VaihingenRuppmannstraße 3270565 Stuttgart / VaihingenTel. +49(0)711.78891-0Fax +49(0)[email protected]

KOMET do Brasil Ltda.Rua Brasileira, 43907043-010 Guarulhos - São PauloTel. +55(0)11.2423-5502Fax +55(0)[email protected]

KOMET GROUPPrecision Tools (Taicang) Co., Ltd.(Headquarter Asia Pacific)No. 5 Schaeffler RoadTaicang, Jiangsu Province, 215400Tel. +86(0)512.535757-58Fax +86(0)[email protected]

KOMET S.à.r.l.46-48 Chemin de la Bruyère69574 Dardilly CEDEXTel. +33(0) 4 37 46 09 00Fax +33(0) 4 78 35 36 [email protected]

KOMET (UK) Ltd.Unit 4 Triton ParkBrownsover RoadSwift ValleyRugby, CV21 1SGTel. +44(0)1788.5797-89Fax +44(0)[email protected]

KOMET Precision Tools India Pvt. Ltd.121/B, Bommasandra Industrial AreaBANGALORE - 560 099Tel. +91-80-27834821Fax [email protected]

KOMET Utensili S.R.L.Via Massimo Gorki n. 1120098 S. Giuliano Mil.Tel. +39-02-98 40 28 1Fax +39-02-98 44 96 [email protected]

KOMET GROUP KK# 180-00061-22-2 Naka-cho Musashino-shiTokyo JapanGrand Preo Musashino 203 Tel. +81(0)422 50 0682Fax +81(0)422 50 [email protected]

KOMET de Mexico S. de R. L. de C.VAcceso „A“, No. 110Parque Industrial Jurica,76120,Queretaro,Qro.MexicoTel. +52-442 2-18-25-44Fax +52-442 [email protected]

KOMET GROUP GmbHWagramer Straße 1731220 WienTel. +43-1-2 59 22-04 +43-1-2 59 22-12Fax +43-1-2 59 22 [email protected]

KOMET-URPOL Sp.z.o.o.ul. Stoczniowców 247-200 Kędzierzyn-KoźleTel. +48-77-482 90 60Fax +48-77-406 10 [email protected]

KOMET DIHART AG Precision ToolsIndustriestrasse 24657 DullikenTel. +41(0)62.2854-200Fax +41(0)[email protected]

KOMET of America, Inc.2050 Mitchell Blvd.SchaumburgIL 60193-4544Tel. +1-8 47-9 23 / 84 00 +1-8 47-9 23 / 84 80Fax +1-8 00-8 65 / 66 [email protected]

Square Tools ABBox 917720039 MalmöTel. +46-40-49 28 40Fax +46-40-49 19 [email protected]

KOMET IBERICA TOOLS, S.L.Av. Corts Catalanes 9-11Planta baja, local 6B08173 SANT CUGAT DEL VALLESTel. +34-93-583.96.20Fax +34-93-583.96.12

KOMET GROUP GmbH ul. Spartakovskaya, 2V 420107, Kazan Tel. +7 843 5704345Fax +7 843 [email protected]

KOMET GROUP Precision ToolsKorea Co.,Ltd.#201, Lotte IT Castle-2, 550-1,Gasan-dong, Geumcheon-gu,Seoul, 153-768Tel. +82(0)2.2082-6300Fax +82(0)[email protected]

KOMET GROUP CZ s.r.o.Na Hůrce 1041/2,160 00 Praha 6Tel. +42(0)2 35 01 00 10Fax +42(0)2 35 31 18 [email protected]

399 01 932 30-3T-06/09 Printed in Germany · © 2009 KOMET GROUP GmbH · We reserve the right to make modifications.

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komet komtronic® u-axis system · 5 500 000 500 000 500 000 1500 1000 500 0 6 8 10 1 l1 x 115 x 1...

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