okuma america corporation productivity proposal 11-27-12 m560-v (12k) w-thinc proposal page 1 of 21...

Revision: 11-27-12 M560-V (12K) w-THINC Proposal of 21

Okuma America Corporation

Productivity Proposal

GGEENNOOSS MM556600--VV ((1122KK))

Vertical Machining Center with

.

Applicable Model and Versions:

M560-V with OSP-P200 THINC control system

Standard Specification

Spindle Taper NT40 Big Plus

Spindle rpm 50 - 12,000

Spindle Horsepower (Max/Continuous) 30/25 HP

Tool changer - Number of Pockets 32 Tools

OKUMA Thermal Technology TAS-S and TAS-C


GENOS M560-V Introduction

The OKUMA GENOS M560-V CNC is the vanguard of the proven Okuma vertical machining centers. The M560-V adopts a powerful new double column structure to offer the most machining in the least floor space. The latest innovations in thermal countermeasures have been incorporated to offer the best performance available today. The OKUMA M560-V is equipped with a high speed; high power 40 Taper 12,000 rpm spindle with a 30/25 HP VAC liquid cooled integral motor. This model incorporates a high-speed 32-position automatic tool changer and 1574ipm (X/Y) rapid traverse, resulting in a powerful production capability. Control is by Okuma's own patented OSP THINC with Hi-Content control system which includes the patented OSP absolute position encoders which do not require a zero return.

A thumbnail of the M560-V Standard Specification:

Travels: X: 41.34” Y: 22.05” Z: 18.11 OSP-P200M THINC control system

T-slot table: 51.18” x 22.05” Okuma control, motors, encoders and drives

12,000 rpm, 30/25 HP integral motor spindle – standard

15” LCD w 3D color animation

CAT 40 Big Plus 40 V-flange specification

40GB Hard Disk – 512 MB DDR

Spindle jacket cooling system MACMAN machine utilization monitoring

Oil air mist spindle bearing lubrication Thermal Active Stabilizer technologies TAS-S and TAS-C standard.

1,575 IPM, rapid feed X, Y. ( .6, .65 G) 8 Sets of external m codes

Z-axis rapid & max. feed-rate: 1,259 IPM

MACMAN machine utilization monitoring

32 tool ATC magazine 1.2 sec. T-T; 3.2 sec. C-C*

60 gal roll-away twin 0.5 hp coolant syst. Twin chip channel (insulated) with coil

conveyors. See Control P200M Proposal for control

features and specification. Preparation for 1,000 psi coolant

through spindle

Okuma Care, 24-7 support + 2 year warranty. First year parts and labor, second year parts.*

*See warranty statement for details.

The M560-V continues Okuma’s fundamental commitment to total system engineering of its machine tools. This means ALL Okuma design and manufacture of machine, motors, drives and controls and including the industry leading Okuma Care (24-7) support program. This level of integration and support is an Okuma Trademark. Your single source. Thank you for considering Okuma products.


CONSTRUCTION

M560-V Orientation

FAST FACTS ABOUT M-V Compact footprint - service at front and rear Install the machines closer side to side Double column rigidity - less overhang Total enclosure every model Thermal deviation countermeasures Symmetrical design Insulated chip channels Insulated cross rail Center mounted screws and ball nut Heat generation clear of machine No hydraulic unit Spindle motor re-circulating cooling - new design Bearing jacket re-circulating cooling Oil mist lubrication spindle bearings - new design TAS-C and TAS-S standard (thermal technology) Faster axes at higher G force Cast in ball screw brackets Heavier X and Y guideways Service at front and sides Easy access ATC - faster ATC Centralized grease lubrication Rear chip ejection - ATC shutter included as standard Okuma THINC Control System


CAPACITY MAXIMIZING FLEXIBILITY AND SPEED

Work Range Okuma has one of the largest work envelopes in its class. This provides the flexibility to handle a wide range of work-pieces. Axis Travel Inch Metric

X-Axis Ram saddle L/R 41.34 in. 1050 mm

Y-Axis Table - Front / Rear 22.05 in. 560 mm

Z-Axis Ram Head U/D 18.11 in. 460 mm

Table Capacity

Table size 51.18” x 22.05” 1300 x 560mm

Max. table load 1980 lb. 900 kg Spindle nose to table top 5.91” 24.02” 150 610 mm

Floor to table top 31.50” 800 mm

Axis Orientation

GENOS M560-V work range


Spindle Head bearing support - rigidity & finish

Dual oil jacket for motor and bearings - thermal stability.

Ceramic angular contact ceramic ball bearings

70 mm bearing ID

Oil-air mist bearing lubrication - life - stability

Spring clamping – electro pump release

CAPACITY MAXIMIZING FLEXIBILITY AND SPEED

Power and Torque Main Spindle Drive

The M560-V utilizes a 30 HP VAC motor-spindle drive system. The unique Okuma spindle drive accurately controls input commands and continuously monitors actual performance.

The wide range spindle motor develops 29.5 HP at 4,000 rpm, 20.1 HP at 720 rpm and a maximum torque of 146 foot/pounds is available from 50 to 720 rpm.

The spindle design allows the flexibility of feeds and speeds needed to cut work-pieces of steel, aluminum, stainless steel, high-temperature alloys and exotic Materials. The spindle motor design produces less vibration and power loss at the tool tip yielding excellent surface finish and impressive metal removal rates.

Axis Thrust

X, Y and Z-axis

The X, Y and Z axes are driven by Okuma brushless motors and servo drives. Ample Z-axis thrust is critical for drilling, boring and plunge milling operations especially tools with indexable inserts.

The M560-V has allowable thrust as follows: X-axis: 1323 lbf, Y-axis: 1323 lbf, Z-axis: 1784 lbf,

Dual spindle sleeve, symmetrical cooling


CAPACITY BALANCED SYSTEMS – CONSISTENT PERFORMANCE

ATC and Tooling capacity

32-Tool Magazine

The M560-V tool changer is simple, reliable and extremely productive. The standard tool changer has a capacity of 32 tools, held in a cast iron carousel magazine. Rotation of the tool magazine is powered by an Okuma servomotor, with position monitored and controlled by an Okuma absolute encoder. This design eliminates sub-arm and its mechanism, stepping motors, and clutches. Spindle orientation for tool change is accomplished by the Okuma spindle drive and magnetic pulse generator on the spindle unit, which accurately orients and holds the spindle in position. Big Plus tooling capability enables additional tooling rigidity provided by tool face to spindle nose contact. Standard Cat 40 tools can also be used as required. Automatic Tool Changer

The simple, reliable Okuma M560-V tool changer provides an impressive tool change time of 1.2 seconds T-T (tool to tool) 3.2 C-C (chip to chip)*. Using the standard CAT V-flange, it will handle tools weighing up to 17.6 pounds, 3.54 inches in diameter with tools adjacent, and up to 11.81 inches in length. Larger tools, up to 4.92 inches in diameter, can be handled if adjacent stations are open.

32 tool ATC magazine

Tool capacities

Maximum tool sizes

Boring bar offset See op maintenance manual for further details regarding tools

With tools adjacent

No tools adjacent

Okuma PREX motor


Machine without covers

T-slot table

The powerful bed construction which supports the rigid table.

RIGIDITY & CONSTRUCTION ROBUST SYSTEMS SUPPORT SHORT CYCLES

Machine Construction Design and Construction

There are eight main components of the M560-V vertical machining center.

Bed (w/twin column) Table Crossrail ATC Ram saddle CNC Systems Spindle head

Materials

These components are produced from high tensile strength (40,000#) alloyed cast iron which is carefully stress relieved. The bed casting is designed with reinforcing ribs for increased stability and load carrying capacity. The column utilizes a reinforced box construction to increase stiffness, resist vibration and minimize deflection during high thrust loads. Saddle & Table Support

The machine saddle is designed to provide full support of the machine table in the Y axis movement. Good machine design and fitting allows for exact perpendicularity of the spindle head. The machine table, holding the work piece, is supported by the fixed saddle and bed and is capable of supporting full table load while holding alignment Extra width in the saddle design prevents the table from overhanging the bed. The column and bed are joined at the column flange to produce alignment bed, column, & saddle tolerances of 0.00020” or better in full travel of the X, Y, and Z axis.


View of table showing protective covers and chip

channel [opt. auto tool length offset]

2-cam ATC, powered by OSP servo

Cross rail, ram head saddle and spindle head

CONSTRUCTION ROBUST SYSTEMS SUPPORT SHORT CYCLES

Crossrail, Saddle & Spindle Symmetrical dual column construction

Robust power train provides for long term reliability

Heat deviation eliminated from crossrail

Symmetrical box structure offers balanced expansion

Insulated cross rail keeps heat away

Low moment of guideway construction

Cast-in ballscrew brackets - rigidity

1575/1259 ipm rapid X,Y/Z

Quiet operation 72dB at operator station*

* at the operator station under full rpm and full rapid test conditions.

Table

Inch T-Slot

Table dimension: 51.18” x 22.05”

Maximum table load: 1,980 lbs.

Robust power train provides for long term reliability

Suitable for powered fixture applications

2 – cam ATC

NC Servo driven system

High power and reliability drive

ATC – step tracking by encoder

Magazine position tracking by encoder

Robust construction assures durabilty

17.6 Lb. Tool x 11.81 inches x 3.54 in.

4.92 in large Tool – no adjacent tools)

1.2 Seconds T-T, 3.2 C-C, enabled by servo + CAM*

New design eliminates the sub-arm design

Low maintenance, long grease interval. Cycle times are incremental and under nominal conditions


M560-V “Cast-in” ballscrew brackets offer the highest rigidity

RIGIDITY & CONSTRUCTION ROBUST SYSTEMS SUPPORT SHORT CYCLES

Axis Drives Ball Screws

Powerful, robust high precision ball-screws generate sideway movement to all three axes of the M560-V. The ball screws are based on unique Okuma designs and exacting performance standards. They are directly coupled to special Okuma axis drive servomotors. Contrary to commercial drive systems, the custom Okuma servomotors precisely match the electrical and mechanical prerequisites of the M560-V performance requirements. An essential element in the drive system is the unique Okuma absolute position digital feedback encoder connected directly to the shaft of each Okuma servo drive motor. The Ballscrews are precision mounted on the exact center of any controlled axis and are preloaded at the end of the ball screw opposite the drive system. The precision ball screws are supported by a twin set of thrust bearings mounted in ball screw support brackets at each end of the ball screw. Preload is set during machine construction by careful hand sizing and fitting. Once set, the preload is maintained by a twin set of ball screw mounting brackets supporting both ends of the screw. The ball screw mounting is designed for both tension and compression for thermal compensation and control of ball screw growth.

Ball Screws X Y Z Diameter in (mm) 1.57 (40) 1.57 (40) 1.57 (40) Pitch In (mm) .79 (20) .79 (20) .63 (16) Allowable thrust lbf (N) 1,323 (5,880) 1,323 (5,880) 1,784 (7,840)


Okuma dual-supported ballscrew Mass centered ball screws. (Typ )

Okuma HSR NR NRS

Vertical Stiffness

100 % 200% 140%

Horizontal Stiffness

100 % 70% 140%

Guideway illustration

45

CONSTRUCTION ROBUST SYSTEMS SUPPORT SHORT CYCLES

Ball Screws Powerful, robust high precision ballscrews generate slideway movement to all three axes of the OKUMA M560-V. The ball screws are based on unique Okuma designs and exacting performance standards. They are directly coupled to special Okuma axis drive servomotors. Contrary to commercial drive systems, the custom Okuma servomotors precisely match the electrical and mechanical prerequisites of the M560-V performance requirements. An essential element in the drive system is the unique Okuma absolute position digital feedback encoder connected directly to the shaft of each Okuma servo drive motor. Preload is set during machine construction by careful hand sizing and fitting. Once set, the preload is maintained by a twin set of ball screw mounting brackets supporting both ends of the screw.

Guide ways

Centrally Lubricated oversize NRS type linear guideways are employed on X, Y and Z-axes. The class is selected as one size above that indicated by manufactures design specification. The NRS designation is a guideway design with greater uniform stiffness than competing designs.

Automatic continuous grease lubrication Substantial sealing and way protection

offer precision over a long period Wear by friction is negligible Design life span of 10 years 1575 ipm rapid traverse rates for X & Y. 1259 ipm

for Z. Excellent positioning and repeatability

Note: See additional axis drive data in section 2 – (Specifications)


ACCURACY & REPEATABILITY MAXIMIZING LONG TERM QUALITY

X, Y and Z axis Accuracy The rigid machine structure coupled with a high response positioning system provides the following machine performance: Positioning accuracy of +/-0.00016" ( 0.004 mm) for all three axes, full stroke. Repeatability of 0.000060". ( 0.0015 mm) with ball screw pitch error compensation employed These positioning guarantees are based laser measurements of a single, uni-directional, rapid traverse move of the slide to a programmed position along the X, Y, and Z Axis of 3.94”. For repeatability inspection each Axis is moved 3.94” from the starting position, for repeatability tests. This measurement is repeated seven and the difference between the largest result and the smallest result is the repeatability of X, Y, and Z axes.

Geometry Inspection Laser alignments and positioning accuracy checks are among the over 200 quality tests performed on every M560-V. Lead screw and backlash compensations are measured during final inspection and maintained in the Okuma OSP THINC control to insure and guarantee the above stated accuracy definitions. Inspection data sheets accompany each machine tool showing target data and actual data of 35 machine geometry inspections.


Centralized grease station

Guideway and ball screw grease

Typical X, Y and Z

Self-contained tool unclamp Electric pump cylinder

. Motor and spindle Spindle oil air mist cooling unit (8k min-1)

Pneumatic Panel

FLUID SYSTEMS MAXIMIZING LONG TERM VALUE

Machine Lubrication

Long interval maintenance

The M560-V is lubricated with a manual lubrication system. The ATC, all ballscrews and all linear guides are lubricated by the system. The two lubrication manifolds are centrally located for convenience, where the entire machine can be serviced.

The M560-V is a manually lubricated machine, grease lubrication need occur only after every 200 hours. No tramp oil separator is required since there is no oil contaminating the coolant, there are no moving parts in the less complex system and the grease has a higher resistance to viscosity breakdown due to temperature increases.

Machine System Lubrication

X,Y, Z ball screw / nut Central system - grease

Guidways Central system – grease

ATC mechanisms Central system - grease Gear box - oil

Main spindle bearings Oil-air mist lubrication

Ball screw bearings Sealed

No hydraulic unit Reduced energy consumption Reduced heat generation – better accuracy

Clean environment Specialized Hydraulic fixtures may require discrete power unit(s)

Cooling Systems Main spindle bearing housing – re-circulating oil

Main motor spindle housing cooling – re-circulating oil

Spindle bearings – oil air mist

Main electrical control enclosure – heat exchanger

Heat generating units mounted for good convection flow

Pneumatic Machine applications:

Supply required: 71 psi, 500 NL. Spindle bearing oil - air mist

ATC air blow

Chip air blow at spindle

ATC shutter


Roll-away coolant system and chip tank

Chip channels to rear of machine

Insulated twin chip gutters – to rear tank

5 coolant nozzles at spindle

Front view with optional lift-up chip conveyor and bucket

Coolant tank shown

With optional side lift-up chip conveyor

FLUID SYSTEMS MAXIMIZING LONG TERM VALUE

Chips and Coolant Basic Coolant Supply 60 gallon (230 litres) Roll away reservoir and chip recovery tank with settling partitions and screen filtering (A lift up chip conveyor is optional) Chip channels Seamless channels to rear – Machine front is clear

Slanted way covers and APC casting apron shed chips to flush channels which send chips to the rear.

Chips, tanks, conveyors and coolant

Included as standard twin coil system to rear of machine.

Spindle nozzle coolant 0.33 Hp pump and 6 gal (22-26 liter) / min.

5 adjustable nozzles surrounding the spindle Optional rear chip conveyor available

For machining operations where large quantities of chips are produced, an optional lift and drop chip conveyor is appropriate. Several types are available selectable based on material application.

Available through spindle options: Through spindle coolant 215 psi Through spindle coolant 1000 psi Interface and coupling for 1000 psi included as standard


GUARDING AND ENCLOSURE

Easy Access

The operating area of the machine is totally enclosed and has a low friction sliding front door with observation window. Construction permits easy entry for workpiece loading/unloading and easy access to the tooling.

SAFETY

Safety Features

The M560-V is equipped with a variety of safety devices to prevent accidents and injuries. However, it is strongly advised that operators use the machine carefully and not rely solely on these devices. Complete safety precautions are found in the operation manual.

Programmed soft limits are used to provide each axis with stroke end limits.

Limit switches on X, Y and Z-axes provide each axis with a hard-wired limit.

Extreme axis limits use rubber cushions for dampening the contact before motor overload

occurs.

Emergency stop push button, slide hold push button, and alarm indicator on operational panel.

Fluid levels are interlocked

Full enclosure guarding with standard access door interlock for complete chip and coolant

containment.

Operators sliding door with interlock and excellent work area lighting

Measured 72 dB level at the operator station under full rpm and full rapid test conditions.

Interlocked pallet load station for correct pallet orientation

ATC Magazine access door interlock

Warning / Alert signage

Safety Documentation


USA STANDARD SPECIFICATIONS MACHINE WEIGHTS AND MEASURES

TRAVEL INCH METRIC

X-axis travel (Ram saddle right/left) 41.34 in. 1050 mm

Y-axis travel (table traverse F/R) 22.05 in. 560 mm

Z-axis travel (spindle up/down) 18.11 in. 460 mm

Spindle nose to table upper surface - (T-slot) 5.91 - 24.02 in. 150 - 610 mm

TABLE

Table size 51.18 x 22.05 in. 1300 x 560 mm

Table top surface to floor height - T-slot 31.50 in 800 mm

Table load capacity – T-slot – USA std. 1980 lb 900 kg

SPINDLE INCH METRIC

Spindle speed range – USA Std. 50 – 12,000 rpm

Tapered bore NT40 (BIG PLUS)

Spindle diameter at front bearing 2.76 in 70 mm

Spindle bearing lubrication Oil air mist

Number of spindle speed ranges infinitely variable

M560-V Table and T-slot



ATC & MAGAZINE INCH METRIC

V-Flange and Taper CAT40 (BIG PLUS)

Pull stud CAT – Special

Tool magazine capacity - USA Standard 32 tools

Tool selection Random

Tool Change Times

Tool –Tool* 1.2 seconds

Chip – Chip* 3.2 seconds

Max Tool Diameter

Max. Tool diameter. with adjacent tools 3.54 in 90 mm

Max. Tool diameter. Without adjacent tools 4.92 in 125 mm

Max tool length 11.81 in 300 mm

Max tool weight 17.6 lb 8 kg

Magazine feed rate* Adjacent pot 0.7 sec

10 pots 3.0 sec * cycle times are incremental and under nominal conditions

FEED RATE

Rapid traverse rate: X,Y 1,574 ipm @ 0.6, .65G 40 meters / min. @ 0.6, .65G

Rapid traverse rate: Z 1,259 ipm @ 0.48G 32 meters / min. @ 0.48G

Max Cutting federate X, Y, Z axis 1,259 ipm 32 meters / min.

Jog Feed Rate 0.04 – 1,259 ipm 1-32,000 mm

AXIS DRIVE

Ball Screw Diameter X, Y 1.57 in 40 mm

Ball Screw Pitch X, Y 0.787 in 20 mm

Ball Screw Diameter Z 1.57 in 40 mm

Ball Screw Pitch Z 0.629 in 16 mm

Available Axis Thrust

X 1323 lbf 5880 N

Y 1323 lbf 5880 N

Z 1784 lbf 7840 N

Screw Mounting Pre-tensioned

Drive Connection Direct Motor Coupling



MOTORS AND ELECTRICAL INCH METRIC

Main spindle drive motor

Power (10 Min. / cont.) 30/25hp 22/18.5 kW

Torque (10 min./ cont.) 146.2 / 107 lbf.ft 199 / 146 N-m

Axis Servos

X – axis brushless drive motor 5.3 hp 4 kW

Y – axis brushless drive motor 5.3 hp 4 kW

Z – axis brushless drive motor 5.3 hp 4 kW

ATC – servomotor 2.7 hp 2.0 kW

Electrical Supply AC 200 V +/- 10%, 50/60 Hz, 3 ph

COOLANT SYSTEMS

Coolant System (Max capacity) – USA Standard

Reservoir – Roll-away tank 60 gallons 230 liters

Flood pump power ( to nozzles) 0.33 hp 0.25 kW

Pump Volume 9 gal / min. 22/26 liters / min

Pump Pressure 30psi (est) MPa

Distribution 5 directional nozzles at spindle

OTHER FLUID SYSTEMS CAPACITY

Spindle Head Cooling Unit – FC2 3.96 gal 15 liters

ATC oil 2.1 gal 8 liters

Pneumatic required minimum pressure 70 psi 0.5 - 0.7 MPa

Oil Air spindle lube Unit - 0.53 gal 2.0 liters



ACCURACY INCH METRIC

Positioning

X , Y, Z – USA standard specification 0.00016 in 0.004 mm

Over full stroke – with ball screw pitch error compensation employed.

Repeatability – with ball screw pitch error comp

X , Y, Z 0.000059 in 0.0015 mm

CYCLE PERFORMANCE

Spindle Acceleration

rpm Acceleration seconds Deceleration seconds

0 > 1200 0.08 sec 0.08 sec

0 > 8000 1.32 sec 1.1 sec

Spindle Orientation 1200 rpm 0.31sec

8000 1.39 sec

Positioning X 400mm 0.73 Y 400mm 0.72

Z 400mm 0.88

ATC Time T-T 1.2 sec

C-C 3.2 sec

Magazine 10 pots

3.0 sec

OTHER INCH METRIC

Machine Height 108 in 2,746 mm

Floor Space 97 x 122 in 2,470 x 3,100 mm

Machine weight 16,000 lb. 7,300 kg


USA STANDARD SPECIFICATIONS

Floor Plan of M560-V showing Optional Chip Conveyor


USA STANDARD SPECIFICATION M560V (12K)

OOKKUUMMAA MM556600--VV CNC Vertical Machining Center With THINC Control System

Base Machine Price

1. M560-V with OSP P200M CNC Controller and USA standard specifications

Standard Specification - OAC USA Standard

1 Axis stroke, X1050, Y560, Z460mm 1 set

2 Main spindle, 12,000min-1 (199N-m) 1 set

3 Main spindle motor, 22/18.5kW 1 set

4 TAS-S 1 set

5 TAS-C 1 set

6 Spindle big plus 1 set

7 Tool shank CAT40U 1 set

8 Pull stud bolt CAT type CAT40U 1 set

9 32 ATC 1 set

10 In-machine chip conveyor, coil type 1 set

11 Chip conveyor (Concep 2000) interface - electrical only 1 set

12 Chip pan 1 set

13 Prep. For through spindle coolant, 7.0MPa (1,000 psi) 1 set

(including through spindle air blower)

14 External M-code 8 sets 1 set 15 Pull stud bolt CAT40 (through tool coolant type) 20 sets 16 IEC standard 1 set

17 Preparation for transformer 1 set

18 Manuals 1 set

19 OSP P200M 3D-E kit 1 set

20 Inch/metric switchable (1 set)

21 API (1 set)

22 Okuma standard color (door is Crystal silver ) 1 set


PROPOSAL SUPPLEMENT

M560-V Available Options.

Machine Options Control Options Prep for rotary table. Collision Avoidance Software (CAS)

Rotary table (model to be defined) Super Nurbs

Lift up chip conveyor – hinge type 5 Axis control spec

Lift up chip conveyor drum type (Mayfran) 5 axis machining

Through spindle coolant 217 psi Caron adaptive control

Through spindle coolant 1,00 psi Machining Navi Mg

Transformer One Touch IGF including real 3D

Chip air blow thru spindle I-MAP

Shower coolant Common Variables 1000 sets

Work wash gun Program branch

Tool breakage detection Program message function

Auto gauging by Renishaw Cylindrical side face machining

Auto door open close with light curtain Inverse feed function

3 D tool compensation

DNC Function (T3, B, DT)

Warm up function

External program selection

Robot Interface Type D

M560-V Not Available Options. Alternative spindle power or taper specifications Table options Alternative tool magazine sizes Abso scales High column Ball screw spec change

Shuttle type 2 APC

okuma america corporation productivity proposal 11-27-12 m560-v (12k) w-thinc proposal page 1 of 21...

Documents